Practical Guide
Elcometer 200 Drum Cover: safely mixing & transferring from 200-litre drums – how it works in daily practice
When coating materials settle inside the drum or draw in air during transfer, it costs time, material and patience. The Elcometer 200 drum cover is designed to keep product homogeneous inside a 200-litre drum and to transfer it in a controlled manner when required – optionally with agitator and transfer pump (KARA 40 or Hudson 60).
What you will confidently be able to do after this guide
- select the right variant (cover, agitator, KARA 40, Hudson 60)
- set pressure- and speed-based reference values (without “flying blind”)
- quickly resolve faults (weak motor, air bubbles, low delivery rate)
- plan maintenance so that downtime becomes less frequent
Product image: Elcometer 200 drum cover (example configuration)
Product overview: variants, applications, advantages
| Variant | Typical application | Everyday strengths |
|---|---|---|
| Cover (basic) | Covering, clean working, preparation for transfer | Stable fit on 200-litre drums, stainless-steel construction (product page/datasheet) |
| Cover + rotary agitator | Keeping pigments/particles suspended | Improved uniformity in the drum; adjustable speed |
| Cover + KARA 40 (double diaphragm) | Transfer/decanting – robust for many coating materials | 1:1 principle, free flow approx. 10 L/min as guideline; max. air inlet pressure 7 bar (reference/limit values) |
| Cover + Hudson 60 (piston, stainless steel) – long | Transfer with stainless-steel piston pump | Max. air & product pressure 7 bar; free flow approx. 10 L/min (60 cycles/min) as guideline |
| Combinations with agitator + pump | Homogenising + direct transfer (continuous process) | Consistent material quality during transfer – less rework |
Note: Values and figures in this table are practical reference/limit values from manufacturer documentation and may vary depending on medium, viscosity, hose length and setup.
KPI 01 (guideline)
~10 L/min
Free flow (KARA 40 or Hudson 60 – depending on cycles/setup)
KPI 02 (limit value)
up to 7 bar
Max. air inlet pressure / max. pressure (pump-dependent)
KPI 03 (guideline)
0–200 rpm
Agitator output speed (adjustable, material-dependent)
Practical tip:
If you see “fisheyes”, clouding or fluctuating film thicknesses: first check the interaction between viscosity and air pressure.
Too much air pressure with too little material can lead to an overly dry application – better to reduce pressure and adjust material flow/viscosity. (Guideline derived from manufacturer application notes.)
Recommended basic settings (guideline values from manufacturer documentation)
- Air quality: dry, filtered and lightly lubricated; ideally via filter/regulator/lubricator (recommended principle: purifier-regulator-lubricator). (Guideline/best practice)
- Agitator motor operating pressure: approx. 2–6 bar (within the specified working pressure). (Guideline/limit range, material-dependent)
- Agitator speed: as low as possible, as high as necessary – only enough to keep the product homogeneous (use speed regulator).
- Pump air inlet: up to 7 bar as maximum – in practice start with a moderate value and adjust for stable material flow. (Limit value + practical guideline)
- Safety/ATEX: consistently ground equipment, use antistatic hoses; hose lengths should be appropriate to maintain grounding continuity (manufacturer specifies e.g. max. 50 m for product hoses as a framework condition).
Important: These values are guideline/limit values. Final settings depend on viscosity, temperature, hose length, nozzles/application and desired finish.
Professional workflow (5–7 steps) – from drum to stable transfer
- Secure the workplace: good ventilation, no ignition sources; PPE (goggles/hearing protection/respiratory protection if required) according to medium.
- Establish grounding: connect cover/system/pump/hoses and surroundings reliably to ground; use antistatic hoses.
- Preparation & tightness: check fittings, hoses tight and suitable; clean before first operation (remove protective film/oil residues).
- Set air supply: supply filtered, regulated air; start with moderate pressure, then optimise step by step (material flow & finish).
- Mix/homogenise: slowly ramp up agitator speed until product remains stably homogeneous; avoid vibrations (drum cover vertical/level).
- Transfer: activate pump, observe material flow; if air bubbles appear, immediately check and tighten suction side/connections.
- Shutdown & cleaning: after job completion, clean thoroughly with suitable solvent – service life depends heavily on proper cleaning.
Troubleshooting: 4 typical problems – quickly resolved
1) Motor runs weakly
- Check and clean/replace silencer/filter element.
- Check pressure supply and set correctly (too little pressure = low performance).
- Reduce/optimise viscosity if the medium is too thick.
2) Motor stops suddenly
- Check air supply/regulating valve: is the air inlet really open?
- Check outlet silencer filter for clogging.
- If pressure does not match viscosity: carefully increase pressure or adjust medium.
3) Low delivery rate / fluctuating material flow
- Open/optimise air inlet regulator; check inlet pressure.
- Clean/replace product outlet hose if blocked.
- Suction hose: secure, tight and with suitable diameter (consider viscosity).
4) Air bubbles at outlet / product exiting air exhaust
- Tighten suction pipe/connections – even small leaks draw in air.
- Check diaphragm/seals; replace diaphragm if necessary.
- If the problem recurs: inspect sealing surfaces and tighten/replace correctly.
Maintenance: 5 points that measurably reduce downtime
- Clean after every use: use suitable solvent; always clean completely when changing colour/product.
- Check fittings & tightness: especially after cleaning/repairs – eliminate leaks early.
- Keep filters/mufflers clean: dirty filters significantly reduce speed/performance.
- Make lubrication routine: lightly grease threads/fittings; lightly oil moving parts after cleaning. If air supply is not lubricated: every ~100 hours add a few drops of light oil to the air line (guideline).
- No “wrong” greases: manufacturer note: do not use graphite greases; prefer original spare parts.
FAQ (practice-relevant)
1) Do I really have to ground the system – even if it’s “just” transfer?
Yes. Manufacturer documentation emphasises grounding/antistatic hoses to dissipate static electricity – otherwise there is a risk of sparking (fire/explosion), especially with solvent-based media.
2) What air pressures are a good starting point?
As a guideline, start within the permissible working range (agitator typically 2–6 bar; pumps up to 7 bar max.) and then adjust so that material flow remains stable without unnecessarily “pushing” the system.
3) Why does the pump draw in air bubbles even though there is enough material in the drum?
Most often it is due to leaks on the suction side (loose connections) or seals/diaphragms. Always check mechanically first before increasing pressure.
4) Why does the finish become dry/rough or the coating “grainy”?
This is often related to the ratio of air pressure ↔ material quantity ↔ viscosity. Too much air pressure with too little material can cause the medium to dry too early. Conversely, too much material at too little pressure can result in a thick/grainy layer – guideline: reduce pressure/adjust material flow & viscosity.
5) How can I extend service life most effectively?
Consistent cleaning after every use, clean air supply (filtered/dry/lightly lubricated) and regular lubrication/filter maintenance deliver the greatest practical benefit.
Select the right Elcometer 200 variant now
Want to order directly? Here are the matching variants – each as a standalone product link (max. 5 CTAs):
Conclusion
The Elcometer 200 drum cover is a practical solution when you need to ensure homogeneity in a 200-litre drum and transfer material in a controlled way – with modular variants consisting of cover, agitator and transfer pump. When grounding, air quality, cleaning and suitable guideline values are implemented consistently, the setup runs stably, reproducibly and with significantly fewer interruptions.
Status: Practical guide based on manufacturer documentation (guideline/limit values) and product information.
