Contractor DBS-100RC User manual

CONTRACOR GmbH
42329 Wuppertal
Germany
Art. 10301/10401
DBS-100RC
DBS-200RC
Abrasive Blasting Machines
USER MANUAL
Version 2.4
Sandstrahlmaschinen
BEDIENUNGSANLEITUNG
Version 2.4
Seite 26.
Аппараты
абразивоструйные
РУКОВОДСТВО
ПОЛЬЗОВАТЕЛЯ
Версия 2.4
стр. 50.
РУССКИЙ
DEUTSCHENGLISH

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CONTRACOR®Version 2.4
Contents
1. Safety 3
2. Package and description 4
3. Set-up, operation and shut-down 6
4. Abrasive blasting operations 8
5. Maintenance 10
6. Troubleshooting 12
7. General drawings 14
8. Instructions for Use Pressure Vessel of
Abrasive Blasting Machine CONTRACOR DBS 19
9. Warranty and warranty service regulations 24
ATTENTION!
READ AND FULLY UNDERSTAND THIS MANUAL BEFORE STARTING WORK.
THE FOLLOWING INFORMATION IS IMPORTANT FOR SAFETY AND HEALTH OF
OPERATOR AND PERSONNEL IN VICINITY.
ATTENTION!
BUYING THE MACHINE, PLEASE, REQUEST TO FILL IN THE GUARANTEE CARD
CORRECTLY!
FAILURE TO PRODUCE A FILLED-IN FORM WILL MAKE YOUR GUARANTEE
INVALID.

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CONTRACOR®DBS-RC Art. 10301/10401
1. Safety.
ATTENTION!
SAFETY MEASURES FOR ABRASIVE BLASTING.
1. You must wear protective equipment: a helmet with positive
air feed, breathing air lter, protection suit, leather gloves, and
special footwear.
2. Do not use worn or damaged equipment during operation.
3. Point the nozzle only at the area to be cleaned.
4. Use only dry well-sieved abrasive materials, appropriate for
abrasive blasting operations.
5. All personnel without protection equipment should be outside the
zone of blasting operations.
6. Before starting abrasive blasting operations you must:
— Ensure that hoses and ttings are not worn;
— Fix hose couplings with wire;
— Ensure that air is fed to the helmet;
— Ensure that pressurizing valve is in correct position;
— Ensure that the machine is in steady state position

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2. Package and description.

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CONTRACOR®DBS-RC Art. 10301/10401
Fig. 2.1.
1 — cover,
2 — screen,
3 — machine tank,
4 — RC hose TWINLINE,
5 — Remote control valve RCV,
6 — moisture and oil separator
CAF-1,
7 — abrasive blasting hose
UNIFLEX,
8 — operator helmet COMFORT,
9 — nozzle holder,
10 — nozzle,
11 — RC handle DMH,
12 — breathing air hose,
13 — breath air lter BAF-1,
14 — safety ball valve.
2.1. Package.
Table. 2.1.
Order code Model Description, package
10301 DBS-100RC Abrasive Blasting Machine, 100 L,
screen,
cover,
moisture and oil separator lter CAF-1,
remote control valve RCV,
remote control handle DMH,
abrasive ow control valve FSV,
twin hose in RC TWINLINE 20m,
tting set for RC hose.
10401 DBS-200RC Abrasive Blasting Machine, 200l,
screen, cover,
moisture and oil separator lter CAF-1,
remote control valve RCV,
remote control handle DMH,
abrasive ow control valve FSV,
RC twin hose TWINLINE 20m,
tting set for RC hose.
10970 RCV Remote control valve (5, Fig.2.1)
10940 DMH Remote control handle (11, Fig.2.1)
12103 TWINLINE Remote control twin hose, d=6mm, roll 40 m
(4, Fig.2.1)

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3. Set-up, operation and shut-down.
3.1. Preparation for operation.
For remote control system start up you should follow these instructions:
1. If necessary shorten the RC hose to the length of the used blasting hose.
2. Connect the ttings provided in the package with RC hose. Connect RC hose to
distant control handle DMH from one side and TWINLINE line of the blasting machine
from another side.
ATTENTION!
DO NOT TIGHTEN UNIONS TOO MUCH, IN PARTICULAR THE UNIONS OF RC
HANDLE. IT CAN DAMAGE SOME COMPONENTS AND CAUSE AN AIR LEAK.
3. Ensure that all connections are leak-proof.
4. Ensure that all connections on the RC valve and RC handle DMH are connected
properly, and according to the color. Transverse joint will make the system non-
operational.
5. Fix RC handle DMH to the blasting hose, using clamp bands right behind the nozzle
holder.
6. We recommend to connect a twin hose Twinline to the blasting hose using clamp
bands every 1.5 m.

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CONTRACOR®DBS-RC Art. 10301/10401
ATTENTION!
ALWAYS USE AN OIL-MOISTURE SEPARATOR WHEN USING REMOTE
CONTROL SYSTEM TO PREVENT WEAR ON RC VALVE.
BESIDES, AN OIL-MOISTURE SEPARATOR OPTIMIZES ABRASIVE BLASTING
OPERATIONS.
7. Ensure that compressor is positioned out of the abrasive blasting operations zone on
downwind side.
8. Start compressor and increase pressure and temperature up to operational values.
9. Open the ball valve at machine compressed air line (the handle of the open valve
should be parallel to the compressed air line).
10. Open the safety ball valve 14 (Fig.2.1).
11. Close metering valve FSV by setting adjusting handle in the central position.
12. Connect compressed air hose to hose coupling of the machine. Compressed air hose
diameter should be at least 1.25”. Lock hose coupling with a safety clip or wire.
13. Connect abrasive blasting hose to hose coupling of the machine. Lock hose coupling
with a safety clip or wire.
14. Fill the machine tank with abrasive.
15. Put protective equipment on.

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CONTRACOR®Version 2.4
4. Abrasive blasting operations.
4.1. Start up.
1. Check all connections from compressor to the nozzle to ensure that they are properly
xed (badly xed air hose of the compressor cause a serious damage).
2. Ensure that abrasive blasting machine is lled with abrasive.
3. Ensure that the necessary safety measures for you and others are observed:
— protective equipment is used,
— puried air is fed to the helmet.
4. Always check position of RC handle lever, which should be in the safety position with
the holder in vertical position
5. Feed compressed air to the machine intake.
ATTENTION!
MACHINE MAXIMUM OPERATING PRESSURE — 12 bar.
6. Close both ball valves at the RC valve.
7. Ensure that there is no leak in the system. Air should come ONLY out of the vent
under the RC handle lever.

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CONTRACOR®DBS-RC Art. 10301/10401
4.2. Abrasive blasting operations.
ATTENTION!
DURING A BREAK IN OPERATION ALWAYS OPEN SAFETY BALL VALVE 14 (Fig.
2.1) AT RC VALVE, OVER AGAINST THE BLUE LINE OF TWIN HOSE (TWINLINE).
RC HANDLE LEVER SHOULD BE NEVER FIXED IN OPERATION POSITION.
SUCH FIXING MAY CAUSE A SERIOUS INJURE.
1. Turn the holder on RC handle and press the lever (start up). The tank is pressurized.
Only compressed air is expelled from the nozzle.
2. Adjust metering valve FSV to provide optimal air-abrasive mixture. The general rule for
abrasive blasting operations: the less abrasive you use, the better.
3. To stop operation you should release the lever (the holder automatically returns to its
initial position).
4.3. Shut-down abrasive blasting operations.
1. Remove the remains of abrasive from the tank. To do this disconnect the nozzle and
point the hose into a suitable container for the abrasive remains. Turn the holder on
the RC handle and press the lever.
2. If upon completion of operation the machine is left outside you should cover it with
plastic lm to avoid ingress of moisture into the tank.
ATTENTION!
AT START UP AND SHUT DOWN ALWAYS CHECK FOR PRESENCE OF WATER
IN THE VALVE BY OPENING THE PLUG «R» (Fig. 7.3). IF A LARGE AMOUNT OF
WATER IS PRESENT, CHECK THE FILTER CAF-3.

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5. Maintenance.
5.1. Machine maintenance.
Pressurizing valve replacement.
Open the inspection door of the machine to get access to the pressurizing valve.
Screw out the guide tube with the valve inside. Install a new valve and screw the guide tube
back into its place.
Pressurizing valve ring replacement.
The ring is replaced trough the machine lling orice. Pull out the old ring, put a new
ring into the groove and press it heavily to correct position.
ATTENTION!
USE ONLY ABRASIVE MATERIALS, APPROPRIATE FOR ABRASIVE BLASTING
OPERATIONS.
NEVER USE WET UNSIFTED ABRASIVE MATERIALS.
5.2. Disassembling if remote control valve RCV.
1. Disconnect remote control Valve RCV from abrasive blasting machine.
2. Take the union from the top part of the control valve (pos. 17, Fig. 7.3.)
3. Remove the drain collector with the mufer assembly. The mufer can be
disassembled according to the component drawing. You should be careful adjusting
the mufer shell support during the reassembling.
4. Turn out the screws (pos.18) to remove the top cover (pos.4), purge diaphragm
(pos.9), purge cylinder body (pos.2) and bottom plate (pos.8). Be careful working with
the seals (pos.12).
5. To remove the purge cylinder and the piston (pos.6 и 7) you should hold the piston
rmly with a suitable tool (try to preserve aluminum ) and turn out the screw (pos.16).
After that you can inspect the O-rings and the seals.

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6. To remove the intake valve and the piston for inspection (pos.5 и 7) you should hold
the intake valve using the steel pin 5mm through the hole 1 1/4 ” from the side of
connection of the control valve with the machine. The pin is inserted in the hole in the
center of the intake valve. Loosen the screws (pos.16) and remove the piston and the
intake valve.
5.3. Assembling of RCV.
Assemble remote control valve RCV following the steps in section 5.2 in reverse order.
ATTENTION!
NEVER USE ANY WORN PARTS DURING ASSEMBLING.
THEY CAN DAMAGE THE CONTROL VALVE.
It is recommended to replace timely the parts marked with an asterisk (*) in the part
list, to avoid an excessive wear and damage of the control valve.
5.4. Daily maintenance.
1. Check the control valve for water presence. If water is present, check the CAF-3 lter
state.
2. Ensure that the rubber insert of the RC handle is in proper condition. If they look bad
or are worn, replace them, to avoid possible damage.
3. Ensure that hoses and ttings are not worn; and properly xed.
5.5. Monthly maintenance
(or after every 160 operation hours).
1. Ensure that the mufer and its pipe are in proper condition.
2. Ensure that there is no leak in all air connections.
3. Dismantle the control valve following the steps in section 5.2 and check all moving
parts. If they look worn, replace them, to avoid possible damage. Assemble the valve
and lubricate its moving parts with general purpose lube oil.

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6. Troubleshooting.
Choking.
If neither abrasive, nor air comes out of the nozzle, relieve pressure and depressurize
the machine, then ensure that the nozzle is not choked. If only air without any abrasive
comes out of the nozzle, fully open the metering valve, and then quickly close and open
again the lower ball valve of the line. If these actions do not help to relieve the pressure in
the machine, open the inspection door and ensure that there is no foreign matter in the
tank (stones, paper, etc.).
Abrasive surges.
During start-up of the machine abrasive surges are normal to a certain degree.
However id abrasive surges continue, you should stabilize the abrasive ow by quick closing
and opening of the line lower ball valve. Abrasive surges often result from elevated moisture
content in compressed air system. Installation of additional moisture and oil separator can
solve this problem.
Wet abrasive removal.
To remove wet abrasive from machine tank you should disconnect the blasting
hose and remove rubber gaskets at machine hose coupling. Then you must fully open the
metering valve and close the lower ball valve in the machine compressed air line. With such
valve conguration compressed air will only enter the machine tank and press wet abrasive
out of the tank.
6.1. RC system troubleshooting.
The following list of checks can be used for determining problems in case the RC
system does not function properly:
1. Study the instructions in this manual.
2. Visually check all air hoses and connections to ensure that there are no air leaks.
3. Ensure that the safety and drain valve are closed.

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CONTRACOR®DBS-RC Art. 10301/10401
4. Check the RC handle for air leaks:
— when the key is not depressed, the air should come only out of the body vent.
— when the key is depressed no air should come out of the handle.
Problem Cause Solution
Air does not come out
of the vent in the RC
handle body.
Twinline hose is clogged or
pinched.
Disconnect the Twinline hose
and ensure that it is not
clogged.
Control valve RCV does
not open.
Safety drain valve is still
open.
Close the safety drain valve.
Air feed to abrasive
blasting machine is not
sufcient.
Dismantle the control valve, all
parts should rotate freely.
RC control valve RCV
does not close.
RC handle channels are
clogged.
Remove the key and clean it.
Incorrect connection of
TWINLINE hose.
Check connections and change
them if they are incorrect.
Control valve failure. Disassemble the valve and
ensure that it functions
properly.

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CONTRACOR®Version 2.4
7. General drawings.
7.1. Abrasive Blasting Machines
DBS-100RC/DBS-200RC
Fig. 7.1.
Pos.
#
Order
code Description Quantity
DBS-100RC DBS-200RC
1 10900 Hose coupling, CFT 2 2
210911 Nipple 1 1/4” (MM), rubberized 6 6
310930 Oil-Moisture separator, CAF-3 1 1

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CONTRACOR®DBS-RC Art. 10301/10401
410970 RC module with the mufer RCV 1 1
4.1 10971 Remote control valve 1 1
4.2 10972 Connection kit 1 1
4.3 10975 Silencer for RCV 1 1
510915 Union with a cap nut, straight , 1 1/4”, (FM) 3 2
610909 Elbow, 90°, 1 1/4” (FM) 1 1
710910 T-piece, 90°, 1 1/4”, (FFF) 1 1
810942 Ball valve, 1 1/4”, (MM) 1 1
910913 Union with a cap nut, straight , 1 1/4”, (FF) —1
10 10914 Pipe 1 1/4” —1
11 10916 Elbow, 45°, 1 1/4” (FF) 1 1
12 10918 Pipe 1 1/4”, (MM) 390 mm for DBS-100 1 —
10917 Pipe 1 1/4”, (MM) 475 mm for DBS-200 —1
13 10919 Elbow, 45°, 1 1/4” (FM) 1 1
14 10990 Y-piece, 45°, 1 1/4”, (FFF), rubberized 1 1
15 10921 Pipe 1 1/4”, (100mm), rubberized 1 1
16 10920 Metering gate valve, FSV 1 1
17 10994 Pipe 1”, (MM) 190 mm for DBS-100 1 —
10952 Pipe 1”, (MM) 260 mm for DBS-200 —1
18 10953 Elbow 90°, 1”, (FF) 1 1
19 10993 Pipe 1”, (M) 165 mm for DBS-100 1 —
10954 Pipe 1”, (M) 190 mm for DBS-200 —1
20 10955 Guide 1 1
21 10960 Pressurizing valve 1 1
22 10950 Pressurizing valve seat 1 1
23 10932 DBS tank service assembly, kit 1 1
24 10935 Screen 1—
10936 Screen — 1
25 10933 Tank cover 1 —
10934 Tank cover —1
27 10956 Elbow, 90°, 3/4” (MF) 2 2
28 10958 Pipe 3/4” 1 1
29 10957 Union with a cap nut, straight, 3/4” (FF) 1 1
31 10828 RC Ball valve, 1/4” 2 2
33 10922 Wheel 2 —
10923 Wheel — 2
34 10830 Extension for DBS-100 RC/RCS 1 —
10844 Extension for DBS-200 RC/RCS —1

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CONTRACOR®Version 2.4
7.2. RC handle DMH.
Order code — 10940.
Pos. # Order code Description Q-ty
1 10801 Handle body 1
210802 Lever 1
310803 Air collector 1
410804 Lever protection holder 1
5 10805 Gasket 1
610806 Rubber insert 1
710807 Reducing socket 1/4” x 1/8” (limited) 1
810808 Reducing socket 1/4” x 1/8” 1
910809 Spring 2
10 10810 Screw 5 x 40 2
11 10811 Screw 4 x 25 2
12 10812 Screw 4 x 10 4
13 10813 Check nut 2
Fig. 7.2.

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CONTRACOR®DBS-RC Art. 10301/10401
7.3. RC valve RCV.
Order code — 10970.
Fig. 7.3.

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CONTRACOR®Version 2.4
Pos. # Order code Description Q-ty
110814 Valve body 1
210815 Exhaust cylinder body 1
310816 Exhaust collector 1
410817 Top cover 1
510818 Inlet valve 1
610819 Exhaust cylinder 1
710820 Piston 1
810821 Bottom plane 1
910822 Diaphragm* 1
10 10823 Piston seal* 1
11 10824 O-ring* 1
12 10825 Packing * 1
13 10826 Brass hexagonal union 1/4” 1
14 10827 Brass hexagonal union 1/4” 1
15 10828 Ball valve 1/4” 1
16 10829 Piston screw 8 x 15 1
17 10830 Hexagonal union 3/4” 1
18 10831 Screw 8 x 25 1
19 10832 Silencer body 1
20 10833 Silencer top cover 1
21 10834 Silencer bottom plane 1
22 10835 Silencer body pin 5 x 215 1
23, 24 10836 Silencer insert and support 1
25 10838 Nut 1
26 10839 Through elbow 1
27 10840 Hexagonal union 3-4” 1
28 10841 Isolation valve (not shown) 1
29 10842 Plug 1/4” (not shown) 1
30 10843 O-ring* 1

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CONTRACOR®DBS-RC Art. 10301/10401
8. Instructions for Use Pressure Vessel
of Abrasive Blasting Machine
CONTRACOR DBS.
8.1. Technical Parameters.
Vessel Type DBS – 100 - 10 DBS – 200 - 10
Manufacturing Date 2007 2007
Volume V (L) 100 200
Calculated Pressure P (MPa) 1,0 1,0
Maximum Working Pres-
sure
PS (Bar) 10 10
Maximum Test Pressure PT (bar) 14,3 14,3
Minimal Operating Tempe-
rature
TSmin (°C) -10 -10
Maximum Operating Tem-
perature
TSmax (°C) 50 50
Corrosion charge c2 (mm) 0,5 0,5
Media air + abrasive ma-
terials
air + abrasive ma-
terials
Number of notify category 1433 1433
Danger Class III III
Module F F
8.2. Field of Application.
The pressure vessels are intended for use only with the media and within the parame-
ters stated in the table above. The use for any other purpose is not allowed.

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8.3. Set Up and Installation.
1. The vessels can be set up indoors or outdoors under a roof.
Safety-regulations and standards and re-regulations and standards, depending on
the media used, must be observed when choosing a place for setup. When set up
outdoors, the minimal and maximum working temperatures must be observed.
2. The vessels have to be installed in such a way that they and all ttings and parts are
accessible for inspections, tests, maintenance and cleaning, from the inside and the
outside.
The type plate has to be accessible and kept clean so that it is readable at all times.
3. The main body is based on supports, stands or feet suitable for the strain of the
pressure test. The vessel must be set up on foundations with a stability suitable for
the strain of the pressure test.
8.4. Setting the Vessel to Work.
A. Conditions for setting the vessel to work.
1. The vessel can be set to work, including test operation, if:
— its condition does not pose a danger to people and environment,
— the system and equipment is complete, tested and meets the requirements
according to the documentation and applying standards.
B. Procedure before start up of the machine
2. Before closing the vessel make sure that there is no foreign matter or object inside.
3. Make sure that all inspection doors and anges have the correct number of bolts,
that the bolts are inserted correctly in place and of the right length and tightened to
the correct torque.