Contractor DBS-25RC User manual

CONTRACOR GmbH
42329 Wuppertal
Germany
Art. 10510/10515
DBS-25RC
DBS-50RC
Abrasive Blasting Machines
USER MANUAL
Version 1.0
Sandstrahlmaschinen
BEDIENUNGSANLEITUNG
Version 1.0
Seite 23.
Аппараты
абразивоструйные
РУКОВОДСТВО
ПОЛЬЗОВАТЕЛЯ
Версия 1.0
стр. 43.
РУССКИЙ
DEUTSCHENGLISH

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CONTRACOR® DBS-25/50RC Art. 10510/10515
Contents
1. Safety 4
2. Package and description 5
3. Set-up, operation and shut-down 7
4. Abrasive blasting operations 9
5. Maintenance 11
6. Troubleshooting 12
7. General drawings 14
8. Instructions for Use Pressure Vessel of
Abrasive Blasting Machine CONTRACOR DBS 16
9. Warranty and warranty service regulations 21
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® Version 1.0
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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CONTRACOR® DBS-25/50RC Art. 10510/10515
2. Package and description.
Fig. 2.1.

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CONTRACOR® Version 1.0
Fig. 2.1.
1 — cover,
2 — screen,
3 — machine tank,
4 — RC hose TWINLINE,
5 — Remote control valve RCV-0,
6 — moisture and oil separator
CAF-0,
7 — abrasive blasting hose
ExtraBlast,
8 — operator helmet COMFORT,
9 — nozzle holder,
10 — nozzle,
11 — RC handle DMH,
12 — breathing air hose,
13 — breath air lter BAF
14 — safety ball valve.
2.1. Package.
Table. 2.1.
Order code Model Description, package
10510 DBS-25RC Abrasive Blasting Machine, 25 L,
screen,
cover,
moisture and oil separator lter CAF-0,
remote control valve RCV-0,
remote control handle DMH,
abrasive ow control valve FSV-0,
twin hose in RC TWINLINE 5m,
tting set for RC hose.
10515 DBS-50RC Abrasive Blasting Machine, 50l,
screen, cover,
moisture and oil separator lter CAF-0,
remote control valve RCV-0,
remote control handle DMH,
abrasive ow control valve FSV-0,
RC twin hose TWINLINE 5m,
tting set for RC hose.

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CONTRACOR® DBS-25/50RC Art. 10510/10515
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® Version 1.0
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-0 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 1/2”. 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® DBS-25/50RC Art. 10510/10515
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® Version 1.0
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-0 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-0.

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CONTRACOR® DBS-25/50RC Art. 10510/10515
5. Maintenance.
5.1. Machine maintenance.
Pop-up Valve and O-ring
replacement.
To replace the rubber pop-up
valve (2) and O-ring (1), loosen the
ring-seat (4) with а pin-wrench (5).
After having loosened the
ring-seat, remove the old O-ring by
using a nger, screwdriver, or similar
object, to work the O-ring out of the
retainer groove. Push the new O-ring
all the way through the port and then
t it into the groove. For the last few
millimeters pull up on the rubber
O-ring and allow it to “pop” into position. Finally, reassemble the machine in reverse order.
ATTENTION!
USE ONLY ABRASIVE MATERIALS, APPROPRIATE FOR ABRASIVE BLASTING
OPERATIONS.
NEVER USE WET UNSIFTED ABRASIVE MATERIALS.
5.2. Daily maintenance.
1. Check the control valve for water presence. If water is present, check the CAF-0 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.
3
5
4
1
2

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CONTRACOR® Version 1.0
5.3. 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.
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.

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CONTRACOR® DBS-25/50RC Art. 10510/10515
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.
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-0
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-0
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 1.0
7. General drawings.
7.1. Abrasive Blasting Machines DBS-25RC/DBS-50RC
Fig. 7.1. * DBS-25RC only

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CONTRACOR® DBS-25/50RC Art. 10510/10515
Pos.
#Order code Description Quantity
DBS-25RC DBS-50RC
1 10903 CFT-0 Sandblast coupling 1/2” 2 2
2 10521 Nipple 1/2” (MM) 8 8
3 10565 CAF-0 Moisture separator 1/2” 1 1
4 10535 RCV-0 Remote control valve 1/2”, complete 1 1
4.1 10536 Remote control valve RCV-0 1 1
4.2 10537 Connection kit for RCV-0 1 1
4.3 10538 Silencer for RCV-0 1 1
5 10522 Union with a cap nut, straight, 1/2”, (FM) 2 2
6 10523 Union with a cap nut, straight, 1/2”, (FF) 1 1
7 10524 T-piece, 90°, 1/2”, (FFF) 2 2
8 10525 Ball valve, 1/2”, (FM) 1 1
9 10526 Pipe 1/2” 90 mm for DBS-25RC 1 -
9 10527 Pipe 1/2” 190 mm for DBS-50RC - 1
10 10528 Elbow, 45°, 1/2” (ММ) 2 2
11 10529 Pipe 1/2” 160 mm for DBS-25RC 1 -
11 10530 Pipe 1/2” 230 mm for DBS-50RC - 1
12 10531 Pipe 1/2” 65 мм 1 1
13 10520 FSV-0 Abrasive metering valve 1/2” 1 1
14 10533 Blast vessel 25 litre, assembly 1 -
14 10534 Blast vessel 50 litre, assembly - 1
15 10540 Wheel for DBS-25RC 2 -
15 10541 Wheel for DBS-50RC - 2
16 10542 Screen for DBS-25RC 1 -
16 10543 Screen for DBS-50RC - 1
17 10544 Tank cover for DBS-25RC 1 -
17 10545 Tank cover for DBS-50RC - 1
18 10546 Pipe 1/2” 120 mm for DBS-25RC 1 -
18 10547 Pipe 1/2” 170 mm for DBS-50RC - 1
19 10548 Elbow, 90°, 1/2” (ММ) 2 2
20 10549 Pipe 1/2” 100 mm 1 1
21 10532 Guide 1 1
22 15315 Pop-up valve, rubber, fоr DBS-25 / DBS-50 / CBS-25 / CBS-50 1 1
23 15316 O-Ring, rubber, fоr DBS-25 / DBS-50 / CBS-25 / CBS-50 1 1
24 15317 Seat for pop-up ring, fоr DBS-25 / DBS-50 / CBS-25 / CBS-50 1 1
25 10550 Elbow, 90°, 1/2” (FM) 3 2
26 10551 Pipe 1/2” 60 mm for DBS-25RC 1 -
26 10552 Pipe 1/2” 70 mm for DBS-50RC - 1
27 10553 Еxtension 27 mm for DBS-25RC 1 -
27 10554 Еxtension 40 mm for DBS-50RC - 1

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CONTRACOR® Version 1.0
8. Instructions for Use Pressure Vessel
of Abrasive Blasting Machine
CONTRACOR DBS.
8.1. Technical Parameters.
Vessel Type DBS – 25 - 10 DBS – 50 - 10
Manufacturing Date - -
Volume V (L) 25 50
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
28 10828 RC Ball valve, 1/4” 1 1
29 10940 DMH Remote control handle 1 1
30 - Remote control hose, mounted with ttings, 0,8 m 1 1
31 12105 Remote control hose, mounted with ttings, 5m 1 1
32 12401 FTL-M Fitting,1/4” (M) x hose end 6 mm, for Twinline RC hose 6 6
33 12402 FTL-F Fitting, 1/4” (F) x hose end 6 mm for Twinline RC-hose 2 2
34 50051 Hose clamp 10 - 16 mm 8 8

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CONTRACOR® DBS-25/50RC Art. 10510/10515
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.
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.

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CONTRACOR® Version 1.0
C. Start up Procedure.
4. If not stated otherwise in the instructions for the start up of the vessel, the control
valve must open in such a way that the pressure does not rise more than 5 bar per
minute and the temperature does not exceed the value stated for the start up of the
vessel. Avoid sudden changes in pressure or temperature as they can cause unfavou-
rable tension.
5. Always watch the vessel, valves and ttings during the start up of the system. If a
problem occurs, e.g. leaks or cracks, the vessel has to be closed down immediately.
6. During transport vessels must not be under pressure and they must not contain
media.
7. When the working pressure is built up, check the vessel and its attachments for
leaks.
D. Operation of the vessels.
8. The vessel must be closed down immediately,
— if cracks appear,
— if there is a leak in a connection that can be disassembled,
— if there is a safety-equipment failure or defect (e.g. clogging of the safety valve)
or a failure of the level meter etc.,
— when there is immediate danger of an accident or a problem if operation conti-
nue,
— if any other unusual phenomena occur during operation whose causes cannot
be found or eliminated,
— if a deformation on the vessel wall occurs,
— if the temperature exceeds the maximum working temperature,
— in all cases stated in the manual that advise the operator to do so.

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CONTRACOR® DBS-25/50RC Art. 10510/10515
8.5. Operating the Vessel.
1. Only persons meeting the following requirements are allowed to operate the vessel:
— The person is of age and able to do such work,
— The person knows the applying regulations and rules for the operation of the
vessel well, has been trained practically and has passed a corresponding exam
which is documented by a certicate.
A. Duties and responsibilities of the operator
2. The person appointed to operate the vessel is obliged to:
— know all facilities and equipment securing a safe operation, and their use, well
and be able to react appropriately in unusual circumstances to restore safety,
— report every problem, damage or unusual incidents, occurring during operation
of the vessel or its attachments, to his superior immediately and close down the
vessel if further operation could be dangerous,
— take part in checks and inspections of the vessel, so that he knows the conditi-
on of the vessel,
— check and test the equipment as recommended,
— document the operation according to the regulations,
B. Vessel Inspections and Tests
3. The vessels have to be subjected to the following tests and inspections:
— External inspection during operation,
— Inspection of interior,
— Leak test,
— Pressure test ,
The tests must be conducted according to the applying regulations for the use
of pressure equipment of the respective country that the vessel is used in.

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CONTRACOR® Version 1.0
C. Documentation of Inspections.
4. The results of the inspections and tests are recorded in an inspection log, lled in on
inspection cards or an inspection-certicate is written. The inspection log has to be
kept with the user and available during the whole period of use of the vessel.
8.6. Cleaning and Maintenance of Vessels.
1. The cleaning method and media have to be in such a way that they do not to damage
the walls of the vessel or endanger the workers.
2. The vessel must be cleaned inside and outside and it must be covered with a suitable
layer of paint that protects it from inuences of the operating media and external
inuences.
3. Only specially trained and experienced persons are allowed to work on the vessel and
the system components, including the safety equipment. They have to be appointed
with their names put down and they have to know the regulations in this eld of work.
8.7. Repair of Vessels.
It is not allowed to weld or work on the parts of the vessel that are subject to pressu-
re. Only authorized organizations are allowed to install or repair the vessels.