Operation manual WIWA PHOENIX
Contents
1. Close the spray gun and apply the safety catch Hold the drain hose into container B and secure it against slipping Depressurize the pump by briefly opening the drain valve drain screw on the high pressure filter Result The unit is now ready for operation Phoenix_BAoDB_en_1210 jw Translation of the original operation manual Airless Start up 15 6 1 Equipment preparation Job Prepare the unit for operation Prerequisite Required L D 1 empty open container to receive the mix E ture of solvent and coatings material called container B below 1 container of the coatings material that is to be sprayed called container C below e 4 coatings MEGEN C Procedure 1 Connect the inbound compressed air line Picture 6 1 1 6 1 2 Close the air tap lock Turn the air pressure regulator control knob counterc lockwise until it turns freely Connect the inbound air line to the fitting on the air motor gt gt Picture 6 1 1 Picture 6 1 2 1 air tap lock 2 air pressure regulator 3 air connection Pressure check YIN Q Depressurize the system Place a filter element according to Chapter 9 3 into the high pressure filter VV Feed preparation Bleeding air from the unit Place the suction pipe into container C Funnel mounted versions Fill the coatings material into the funnel Hold the drain hose into container B and secure it against slippin2. Replace worn parts with new ones Procedure Hold the drain hose into container B Close the air tap lock for the pump To depressurize open the drain aaa Picture 9 3 1 1 Drain valve 1 spanner 2 Drain hose 2 Kappe 3 nut Picture 9 3 1 4 filter insert 5 Stehbolzen Picture 9 3 2 Removing the filter insert Picture 9 3 2 Unscrew the cap 2 with the spanner 1 Unscrew the nut 3 with a fork wrench gt Remove the filter insert 4 Clean the filter insert 4 with the appropriate solvent recommended by the coatings manufacturer Mounting the filter insert Mount the high pressure filter in reserve order Replace the o ring if material leaks between the main housing and the cap Instructions for both versions Before restarting the pump ensure that the unit is properly grounded 1 R corrosion resistant RS stainless versi ons Lightly grease all threads to ease assem bly disassembly Phoenix_BAoDB_en_1210 jw Filter insert selection The insert must gt correspond to the material being sprayed gt be compatible with the spray tip used The mesh should always be a little finer that the bore of the tip being used Filter insert Tip size mm from to M 200 white 0 23 009 M 150 red 0 23 009 0 33 013 M 100 black 0 33 013 0 38 015 M70 yellow 0 38 015 0 66 026 M50 orange 0 66 026 fd if working with heavily pigmente
3. for normal operation Chapter 6 for shutting down Chapter 7 found in the separate User s Handbook for the fluid heater If residue solvent in the fluid heaters becomes warm this can lead to an explosion causing Picture 8 2 2 both injury and property damage When using a fluid heater observe the 20 Translation of the original operation manual Airless 337 747 Phoenix_BAoDB_en_1210 jw Optional versions Operating pressure 2 the long way up to the fluid pressure regulator The fluid heater has a maximum operating pressure of 450 The drain valve at the high pressure filter and the bar 6525 psi low pressure versions 200 bar 2900 psi spray gun remain closed The max operating pressure of the airless pump may be 3 Clean the fluid pressure regulator close all drain rated higher than the fluid heater valves on the unit as well as the spray gun and In this event replace the pump s safety valve with a lower allow solvent to flow through the fluid pressure rated one regulator for a short time Determine the maximum inbound air pressure for the Close the fluid pressure regulator and open the airless pump being used drain valve at the high pressure filter Pump the remaining solvent out of the system 450 bar 6525 psi Pressure Ratio Max Inbound Air Pressure Operation instructions Before turning on the fluid heater the spray material must be circulated cold gt Set the pressure on the flui
4. new is too big Tip is worn too big Air motor is frozen runs too slow The viscosity of the coating is too high suction loss Suction assembly leakage spray jet fluctuates Bottom valve leaks pump only stops on the upwards stroke when the spray gun is closed Piston valve leaks pump only stops on the downwards stroke when the spray gun is closed Upper or lower packings leak wear Packings are worn Translation of the original operation manual Airless 10 Solution Open the air tap lock 2 Clean or replace the filter insert 3 Repair the air motor according to the spare parts list Contact 977 WA Customer Service if necessary 1 Clean the sieve 2 Replace the hose 3 Trigger the spray gun without tip Open the high pressure filter drain valve screw Lightly hit the bottom valve from the side hammer Remove the suction assembly and press on the ball from below using a peg or screwdriver until loose 4 Remove the bottom valve and clean the ball and seat thoroughly Replace 1 Increase the inbound air pressure with the regulator and check the diameter of the inbound air hose 2 Use a smaller tip or larger pump 3 Replace 4 f possible reduce the inbound air pressure If not already in use mount an air maintenance unit with oiler Fill the oiler with anti freeze Glysantine and set it according to the instruc tions in the User s Handbook Ave rage set
5. Combi units gt Aijr Combi finishing gun Order No 0632578 11 3 Machine card gt includin gt tip g This User s Handbook is valid only in connection with gt air and fluid hose NW 6 1 4 the following machine card The machine card includes all machine specifications and details which are important and relevant for safety exact designation and manufacturing data technical specification and limit values ge besiehend aus equipment and inspection certificate gt WIWA Airless spray gun details and order numbers for spare parts gt material hose NW 6 1 4 NW 4 1 8 machine features machine components and accesso ries supplied with spare parts number Hot Job units Spray Accessory Kit No 16 N R Order No 0642477 No 17 N R Order No 0642478 VVVVYV gt manifold Aijrless ti P Please pay attention that the machine card specifications are in accordance with the nameplate In case of any deviations or if the nameplate is missing we would ask you to advise us without delay pt Phoenix_BAoDB_en_1210 jw
6. do not correspond to the maximum pres sure created by the pump are quickly prone to rupture leading to serious injuries Fluid hoses must be rated to correspond to the maxi mum operating pressure of the unit with an appropri ate safety factor allowance No hoses may show signs of leaks kinks wear or blisters All hose connections must be tight W IVA Phoenix_BAoDB_en_1210 jw Safety 6 The maximum operating pressure stated by us 1 must correspond to all 47737A components and accessory items within the system i e pumps heaters hoses spray guns safety valves If the pressure ratings differ the lowest rated max pres sure becomes valid for the entire system Example Pump max 420 bar 6090 psi Fluid hose max 600 bar 8700 psi Spray gun max 500 bar 7250 psi The maximum allowable operation pressure for the entire system is 420 bar 6090 psi A Warning If used outdoors a lightning strike could lead to injury Never operate the unit outdoors during a thunderstorm a Warning It is possible for a static charge to occur due to the high flow speeds during the airless spraying procedure Static charges can lead to fire and explosions Always use an open container Never spray solvents or materials containing solvents into narrow necked cans or barrels with bung holes Ensure that the spray gun has contact with the contai ner walls when working with metal conta
7. downward picture 4 4 Pos 1 Picture 4 4 5 Check the release agent level gt Check the level of release agent picture 4 4 Pos 2 refer to Chapter 9 2 Result The unit is now ready for operation W WA Translation of the original operation manual Airless z Phoenix_BAoDB_en_1210 jw 5 1 First cleaning Job This machine was factory tested after assembly for perfect functioning with a test medium The entire system should be flushed with wash thinner before spray operation begins so that the material to be sprayed is not affected by the test medium Prerequisite Required 1 open container with cleaning material at least 5 liters 1 3 gal of wash thinner or sol vent called container A below cleaning material 1 empty open container for the mixture of cleaning material and test medium called container B below v ocedure Prepare the spray gun for operation Pr 1 Close and apply the safety catch gt Remove the tip from the spray gun Observe and follow the instructions found in the spray gun s User s Handbook N Prepare the solvent container Place the suction pipe with strainer into the A contai ner Funnel mounted versions Fill the funnel with solvent Start up 5 Clean the high pressure filter Hold the drain hose Picture 5 1 3 Pos 2 into the container B and secure against slipping gt Open the drain valve Picture 5 1
8. the case please acquire this data from the relevant manufacturer The material to be sprayed must be slowly but tho roughly stirred before beginning to work w v offers a broad selection of accesso 1 ries for the optimised preparation of spraying materials i e agitators in various sizes gt material pre heating containers in various sizes fluid hester If working with plural component materials the pot life must be observed To insure that the necessary volume of air is supplied the compressor capacity must comply with the air con sumption requirements of the pump The diameter of the air supply hoses must correspond to the connection on the pump 1 Set up the pump The pump must be set up securely on a level and solid surface Pay attention to the information covering the required floor space found in machin card Operating elements must be easily accessible gt Safety features must be easily accessible Installation and Assembly Wall mounted versions To fix the wall mount use M 12 screws class 8 8 Be sure to use anchoring devices in accordance with the nature of the wall being used Ensure that at least 10 cm 4 in free space is left between the suction elbow and the floor after mounting refer to the picture in Chapter 3 2 Mount accessories For transport purposes the following components were dismounted and packed in a separate carton 1 Spray hose Picture 4
9. 2 2 Airless spray gun Picture 4 3 3 Air regulator or maintenance unit depending upon version Attach these items according to Picture 4 2 4 3 Note The air maintenance unit is connected to the air inlet of the air motor Picture 4 2 Spray hose con nection on the high pressure filter Picture 4 3 Spray hose con nection to the spray gun Warning Material leaks at connections can lead to se rious injury of property damage Check all turnable parts nuts screws and hose connections and tighten them securely Check the permissible maximum air pressure for the spray hose spray gun and accessories It must be greater than or equal to the maximum operational pressure shown on the pump s nameplate or on the machine card 3 Ground the unit Warning Due to the high flow speed created by Airless equipment static charging can occur A static charge can lead to fires or explosion A static charge can lead to fires or explosion The pump and object to be coated must be grounded properly Only use conductive hoses Note WA spray hoses are conductive and compatible with 77 37A pumps 12 Translation of the original operation manual Airless WIA Phoenix_BAoDB_en_1210 jw Start up 5 4 Open the ventilation hole gt When being used for the first time the sealing plug is to be removed from the venti lation hole overflow The ventilation hole is located in the elbow with the openeing facing
10. 2 Set the maximum pressure gt Set the maximum allowable pressure by turning the Picture 5 1 1 Picture 5 1 2 air pressure regulator control knob clockwise Picture 1 air tap lock 5 1 1 4 5 1 2 2 air pressure regulator 3 air connection Observe the maximum allowable operating 1 pressure for all system components If the ratings vary the lowest pressure rating becomes the maximum allowable pressure for the entire system refer to the examble in 14 Translation of the original operation manual Airless 37 27A Phoenix_BAoDB_en_1210 jw Chapter 2 6 3 gt Check the safety valve Briefly raise the pressure approximately 10 above the maximum allowable inbound air pressure The safety valve must blow off Check the seal of the system components Check the seal of the following components Spray hose gt Spray gun High pressure filter gt Connections Pump out the remaining solvent in the system Turn the air pressure regulator control knob counterc lockwise until the pump only runs very slowly gt Remove the suction pipe from the container A Y VYY YVYYVY Funnel mounted versions gt Pump the solvent out of the funnel until it is empty Hold the spray gun into container B Disengage the safety catch and open the spray gun Pump any remaining solvent out of the system Turn the air pressure regulator control knob counterc lockwise until it turns freely Close the air tap lock
11. 3 Pos 1 Open the air tap lock Picture 5 1 1 5 1 2 Pos 1 Adjust the air pressure regulator Picture 5 1 1 5 1 2 Pos 2 until the pump runs slowly maxi mum 2 bar 30 psi Picture 5 1 3 High pressure filter with drain valve Allow solvent soiled with test medium to be pumped into container B for at least 10 seconds Close the drain valve Picture 5 1 3 Pos 1 max 2 bar 30 psi min 10 seconds 6 Clean the spray gun HY Hold the spray gun into container B i Recommended cleaning time V gt Spray fora minimum of 10 seconds against the inner wall of the container Ensure that the spray gun has contact with the container walls when working with metal containers max 2 bar 30 psi AD min 10 seconds max 5 min recommended 1 min Recommended cleaning time 3 Remove the filter insert Result esu Remove the filter insert from the high pressure filter in The unit is now completely clean accordance with chapter 9 3 Continue with the pressure check Chapter 5 2 4 Connect the compressed air line Picture 5 1 1 5 1 2 Close the air tap lock 5 2 Pressure check Turn the control knob on the air pressure regulator Job counter clockwise until it turns freely a can of all Connect the air supply line to the inbound air connec eck the seal of all system components tion l Procedure lt 0 1 Close the spray gun Close the spray gun and apply the safety catch
12. IIA fluid heater Picture 8 2 1 Pos 2 to an Airless pump to achieve a desired spray tempe rature Fluid heaters can also be used gt as additional heaters for long hose lengths for heating the atomizing air Air Combi spray method for heating the air entering the air motor minimizing icing WIWA Material Fluid Heater Optional versions In the Hot Spray process the material is circulated as follows The material is suctioned from the container into the spray pump and is then forced through the fluid heaters where it is warmed up Then it flows to the high pressure filter and further to the spray gun If the spray gun is not operated the backpressure regulator opens and the material flows back into the inlet of the spray pump Material container 6 Spray pump 1 L Fluid heater 2 Back pressure regulator 5 Circulation Spray gun closed High pressure filter 3 Ss Spray gun 4 Spraying Spray gun open Circulation makes it possible to maintain a constant tem perature even during breaks in spraying Observe the pot life of the material being 1 sprayed A very short pot life and long pauses in spraying can lead to blocked circulation return hoses Burn danger When using a fluid heater contact with the heated material or surfaces can lead to burns on the hands or arms Wear protective gloves Observe and follow all instructions for start up Chapter 5
13. WA Copyright ownership for this user manual remains with WIWA WILHELM WAGNER GmbH amp Co KG GewerbestraBe 1 3 35633 Lahnau Phone 49 0 6441 609 0 Fax 49 0 6441 609 50 E mail info wiwa de Internet www wiwa de This operating manual is solely intended for personnel involved in prepa ration operation and servicing It is prohibited to pass on this operating manual for reproduction utili sation or communication of its contents unless this has been explicitly permitted Infringements incur an obligation to pay damage compensati on All rights reserved in the event of registration of the patented design industrial design or registered design This operating manual only applies in conjunction with the machine card that was given to you with the user manual for your equipment Please check that the type plate data is identical with the information on the machine card Please notify us immediately if there are discrepancies if the user manual has been incorrectly compiled or if the type plate is missing WIVA Phoenix_BAoDB_en_1210 jw 11 11 1 11 2 11 3 Table of contents Contents Preface Table of contents Safety Description of symbols Warnings located on the pump Dangers arising from the equipment Applications for the pump Pump surroundings Sources of danger Operating staff Installation site Behavior in case of emergency Safety features Pump handling and auxiliary materials Transpo
14. WA or W WA Customer Service Replace the material pump packing sets refer to the spare parts list for the material pump Clean the release agent chamber Fill the chamber with clean release agent We suggest using W WA release agent part no 0163333 High pressure filter maintenance Clean the filter insert before every change of spray mate rial or daily at the latest Observe and follow the instructions found in Chapter 6 3 Change of material 9 3 High pressure filter Job Clean or replace the filter insert 1 1 after shutting down the unit daily 2 before every change of spray material 3 if the pump does not cycle although the spray gun is triggered without tip or the drain valve drain screw for the high pressure filter is opened Prerequisite Required are D An empty open container for the mixture of sol LJ ry vent spray material hereafter called container 1 spanner 1 open end wrench Warning If blockages occur residual pressure may still be in the system even after depressurizing Residual pressure can lead to serious injuries to the body or eyes Size 13 Before starting any work on the high pressure filter the pump must be turned off WIA Phoenix_BAoDB_en_1210 jw Maintenance Briefly trigger the spray gun To drain pressure open the drain valve screw on the high pressure filter Disassemble the high pressure filter very carefully
15. WA Customer service personnel trained by 77 IA Customer service After work is completed Check the proper function of all safety features Check the proper function of the entire unit Handling of auxiliary materials gt When handling auxillary materials such as paint solvent oil grease and other chemical substances comply with the safety and dosing instructions of the manufacturer and the generally applicable regulations Leftover solvents oils grease and other chemical substances must be collected according to the legal regulations for recycling and waste disposal The local official laws for the protection of waste water must be observed Translation of the original operation manual Airless 9 2 12 Transporting gt VVYV VV Y VY VY Pcture 2 12 1 10 Disconnect the unit from the main air supply and from any electrical outlets for accessory items even if the unit is only to me moved a short distance Empty the unit before transporting Be careful when using a hoist to load this equipment If using a hoist ensure that the weight capacity is not exceeded and that proper lifting attachments are employed Attach the hoist securely to the unit Never stand under or near the unit when it is suspen ded Serious injury could result Only use appropriate hoisting equipment with sufficient load capacity Secure the unit to the transporting vehicle in such a way that it can not slide or
16. WIWA because it works Operation manual WIWA PHOENIX O Airless TYPE O Air Combi O 6530 O 6552 O 11018 O 11032 Serial No O Hot Job Translation of original operation manual WIWA Phoenix Phoenix DBE en 02 12 jw Contents h a j Preface This User s Handbook must always be availa 1 ble to operating staff The operating authority of the equipment must ensure that a User s Handbook is available to the operator in a language which he unders tands Dear customer Thank you for your decision to purchase W WA equip ment In the User s Handbook you can find all information re quired for the proper handling of your W W A PHOENIX However for safe operation there are further essential details which you should adhere to Please read and observe the guidlines valid for your country In Germany the Richtlinien fur Flussigkeitsstrahler Guidelines for fluid sprayers published by Hauptverband der Gewerblichen Berufsgenossenschaften Industrial Employer s Liability Insurance Association are valid Manufacturer s notes and operating guidelines for coating and pumping materials should be observed at all times No method of operation should be exercised which impairs the safety of 7WA products and the operating person nel We wish you much success and excellent working results when appliying your W WA PHOENIX WIWA Wilhelm Wagner GmbH amp Co KG Copyright 2009 WI
17. We request immediate notification should there be any discrepancies or if the nameplate is missing Picture 2 2 1 Safety information This sign lists the most impor tant safety guidlines for opera ting this piece of equipment Please read this information carefully as well as adhering to all instructions located in this User s Handbook am a a ee ae manm cee oe am E a m mp mampan nemem mimm m e m a a i an mm am m oe ee Picture 2 2 2 T augna m e gt G D Sea Picture 2 2 2 2 3 Dangers arising from the equip ment This unit was designed and built in accordance with all safety aspects It corresponds with the present standards of technical regulations and current rules for accident prevention WIA Phoenix_BAoDB_en_1210 jw Safety It left the factory in perfect condition and warrants a high level of safety However the following dangers exist if operated incorrectly or used inappropriately risk of physical injury or death to the operator or third persons gt risk of damage to the unit and other property belonging to the owner risk of poor coating results All personnel involved in the starting operation and main tenance of the unit must read the following notes carefully and observe them We recommend that the managers responsible for the proper operation of the unit have this confirmed in writing It is a matter of their safety Additionally please pay atte
18. a soft adjustable spray jet with minimal overspray The Air Combi spray method is ideal for fine finishes and complex profiles with large or small surface areas Air Combi units are supplied with a dual pressure regulator for controlling the spray pressure and atomizing air Pictu re 8 1 3 8 1 5 The operation of Air Combi equipment is similar to opera ting standard Airless pumps Observe and follow all instructions for start up Chapter 5 for normal operation Chapter 6 for shutting down Chapter 7 located in the Air Combi Spray Gun User s Handbook Special instructions for the Air Combi spraying me thod Compressed air and fluid hose connection Connect the dual hose according to Picture 8 1 2 8 1 6 Compressed air hose blue to the dual pressure regulator and the spray gun with the safety applied Fluid hose black to the outbound connection on the high pressure filter and the spray gun with the safety applied Picture 8 1 4 1 air tap lock 2 air pressure regulator 3 air pressure connection 4 air pressure regulator for Atomizing air air pressure connection from Air Combi unit to spray gun 6 air pressure connection for additional units O1 1 connecting nipple for air pressure hose blue from spray gun to Air Combi unit 2 connecting nipple for material hose black from spray gun to Air Combi unit 3 lever for Atomizing air 2 Picture 8 1 6 Air Combi Spray Gu
19. ary materials Condensed water drain The collected condensation will be automatically drai ned by the drain valve Place the hose into an empty catch basin Check the reservoirs regularly for contamination and clean as necessary Notes to the oil reservoir water cutoff gt To remove reservoir Press release downwards Turn reservoir counter clockwise Montage Take care during assembly that the O ring is seated properly in the housing 24 Translation of the original operation manual Airless 3377 374 Phoenix_BAoDB_en_1210 jw Malfunctions and troubleshooting Fault The pump does not cycle whether the spray gun is triggered without tip or the drain valve screw is opened Pump cycles but no material reaches the tip Pump cycles but does not stop with the spray gun is closed Pump cycles evenly but the required ope rating pressure can not be reached Pump cycles unevenly different stroke speeds on the upward and downward strokes and the required spray pressure can not be reached Coatings material spills out of the air motor anti vaccum hole Phoenix_BAoDB_en_1210 jw ae a Possible Cause Air tap lock is closed High pressure filter is clogged Air motor is defect Suction sieve is clogged Suction hose is blocked Bottom valve ball does not rise stuck Bottom valve does not close Packing and or valve worn eS Air supply pressure is too low Tip
20. can be installed inside or outside of spray booths and spray rooms To avoid pollution an outside installation is preferable The dimensions and weight of the unit can be found in Chapter 11 1 Technical specifications The unit must have a fixed position and sufficient space to ensure safe operating Keep the area you are working in clean especially walkways Remove any spilled paint or solvent imme diately gt Ensure that sufficient ventilation is available to avoid any injuries or damage to equipment Always follow the handling instructions givin by the materials manufac turer Although there are no laws governing the low over spray airless spraying method dangerous solvent fumes and paint particles need to be suctioned and filtered out of the air Protect any neighboring objects against damage caused by possible overspray The operator of this equipment must ensure that the complete system is protected against lightening strikes Adhere closely to all relevant guidelines covering safety and or accident prevention 2 9 Leaks Behavior in case of emergency Warning If leaks occur in hoses or hose connections material is expelled under very high pressure This can result in very serious injuries to hands arms or eyes Never try to seal leaks with hands or by bining Never patch fluid hoses Should a leak occur the whole system is to be shut down and depressurized immediately Clos
21. d or fiber filled materials gt donot use a filter insert the standard suction sieve may need to be re placed with a sieve having a larger mesh size gt usea W V reversible tip 9 4 Maintenance unit or Regulator Clu ster 1 Setscrew for fog oiler 2 Filling screw 3 Slide 4 Oil container 5 Water separator 6 Drain valve 7 Hose Picture 9 4 1 Release agent and or anti freezing agent Check the air motor s release agent in the bowl of the air maintenance unit and refill if required gt High air humidity can cause icing of the motor Incase of icing only use pure anti freezing agent Translation of the original operation manual Airless 23 9 Maintenance Adjustment of the fog oiler on the air maintenance unit Let the air motor run slowly at an air inlet pressure of approx 4 bar gt Check the sight glass on the fog oiler to ensure that one drop of release agent is fed into the compressed air at every 10 15 double strokes of the air motor If this not the case the adjusting screw on the fog oiler has to be set accordingly gt Check the oil level in the reservoir daily The air maintenance unit may not be operated 1 without oil The maximum oil level is marked with a line around the reservoir To fill the reservoir remove the filler screw or remove the reservoir and fill directly Only use the release agents and anti freezing agent as indicated in Chapter Appendix Auxili
22. d pressure regulator so that the pump runs at a rate of 2 5 cycles per minute amp lowers pressure increases pressure Fluid inlet 3 8 NPT Fluid outlet 3 8 NPT Pressure gauge 1 8 NPT optional Specifications of backpressure regulator Max operating pressure 400 bar 5800 psi Pressure adjustment range 0 400 bar Operating temperature range 4 5 100 C Max output 13 31 min 3 5gal min Cleaning and depressurizing instructions Before flushing the fluid heater must be tur A ned off and cooled down For this reason turn the fluid heater off approx 10 minutes before the spray job is finished Clean and depressurize the unit 1 the short way up to the high pressure filter on the fluid heater and or to the spray gun The drain valve next to the fluid pressure regulator remains closed WIWAP Translation of the original operation manual Airless 7 7 2a Phoenix_BAoDB_en_1210 jw 9 1 Regular inspections According to the rules for the prevention of accidents Working with liquid jet systems BGR 500 chapter 2 36 the equipment must be checked and overhauled at regular intervals by a specialist W WA Service The equipment must be checked before the first start up after changes and repairs of equipment parts having an effect on safety gt after an interruption of operation of more than 6 months gt however at least every 12 months For equipment whic
23. e the air tap lock to cut off the inbound air supply Hold the drain hose into an appropriate container and ensure that it can not slip Open the drain valve Replace the defective parts immediately or contact W WA Customer Service Injuries gt Should an injury occur i e spray jet cut or injection we recommend a doctor be called immediately Inform the doctor of the material sprayed e g paint and the solvent thinner Have the product data sheet at hand adress and telephone number of supplier or manufacturer name of material and material number gt Memorize where aid can be found 8 Translation of the original operation manual Airless Safety gt Memorize the local emergency phone numbers gt Become familier with the first aid measures Fires Read and and observe the instructions for fire alarm and escape routes put up in your factory Do not use any other extinguishing agents than those which are prescribed by the coatings manufacturer 2 10 Safety features This equipment is delivered with the following safety features Safety valve Picture 2 10 1 The safety valve prohibits the maxi mum allowable inbound air pressure from being exceeded If the inbound air pressure exceeds the maximum allowable value the safety valve will blow off Picture 2 10 1 A Warning The safety valve is factory mounted and sealed to the air motor To ensure safe operation gt Never rem
24. fall off When lifting or loading the unit do not transport any further items i e paint cans or pails along with it Any components or accessories that had to be remo ved for transport must be remounted by skilled and trained personnel before beginning operation 4 Atop the air motor s muffler there is a s v threaded hole for a lifting screw pic ture 2 12 1 The lifting screw allows secure lifting of the unit by means of a hoist and is available upon request Translation of the original operation manual Airless Phoenix_BAoDB_en_1210 jw Safety WIA Component description 3 Phoenix Airless cart version Positions 1 cart frame 2 air motor 3 air pressure regulator with air tap lock and compres sed air connection nipple vent hole high pressure filter material pump N OF Ff suction pipe with strainer Phoenix Hot Job unit 10cm Phoenix Air Combi cart version Phoenix Air Combi wall version WIWA Translation of the original operation manual Airless 7 7 n Phoenix_BAoDB_en_1210 jw 1 Airless unit 2 Airless spray gun 3 Paint container 4 Spray hose Picure 4 1 Job The unit is to be installed at the job site and prepared for operation Prerequisite The material to be worked with is prepared All materials to be sprayed should be marked with information on viscosity processing temperatures mixing proportions etc If this is not
25. g Open the drain valve on the high pressure filter Open the air tap lock Turn the air pressure regulator control knob clockwise until the pump slowly cycles As soon as coatings material comes out of the drain hose close the drain valve drain screw tightly Disengage the safety catch and trigger the spray gun Spray the remaining solvent in the unit into container B until only coatings material exits the gun Close the gun and apply the safety catch Y VY Y VVV Y v gt O Complete the pressure check described in Chapter 5 2 Place a filter element into the high pressure filter Translation of the original operation manual Airless Operation Clean the gun outlet with solvent and a brush Mount a spraying tip or a reversible guard with the appropriate tip 8 Observe and follow the instructions found in 1 the User s Handbook for the spray gun being used 5 Test of the seals and joints After long periods without use Increase the pressure on the compressed air regulator to the given maximum air inlet pressure gt Now inspect the joints on the parts which carry material for tightness Regulate working pressure with the air regulator Result The unit is now ready for coatings operation Begin spraying according to Chapter 6 2 6 2 Spray operation Disengage the safety catch and begin spraying Explosion Danger If the feed of material is interrupted during operation the unit can ru
26. ger is first pulled Release the trigger before ceasing arm movement V VYY y thin here thin layer to thick layer approx 30 40 cm wall i k wrong Picture 6 2 1 Picture 6 2 2 Pauses in work Apply the spray gun safety catch at any pause in work Picture 6 2 3 Im merse the tip in a contai ner of appropriate solvent This will avoid residue coatings material from hardening and blocking the tip opening Picture 6 2 3 Exchanging the spray tip Exchange the spray tip before it is worn Worn tips result in increased paint consumption and reduced spray coating quailty Phoenix_BAoDB_en_1210 jw 6 3 Change of material 1 Shut down the unit gt Complete all steps for shutting down the pump found in Chapter 7 2 Clean or replace the filter insert gt Clean the filter insert or replace it if it is damaged Place the cleaned or replacement filter insert into the high pressure filter according to Chapter 9 3 3 Clean the suction strainer Clean the suction strainer using the solvent recom mended by the manufacturer of the coating or replace it if necessary 4 Operation gt Complete all the steps found in Chapters 6 1 6 2 Operation Translation of the original operation manual Airless 17 Job The unit is to be cleaned and taken out of service after work is completed Prerequisite Required 1 open container with at least 5 liters 1 3 gal of clean
27. h has been taken out of operation the check can be postponed up to the next start up The results of the checks must be recorded in writing and kept until the next check The checking certificate or a copy of it must be available at the place where the equip ment is used 9 2 Maintenance plan Warning Dismantling the pump under pressure can lead to serious body and or eye injury Before perfoming any maintenance or repairs the pump must be turned off Depressurize the entire system Disassemble the high pressure filter fluid hoses and spray gun very carefully Cover the hose connections with a rag before dis mantling to avoid paint splashes gt gt gt gt Check the release agent amount Before every start up check the amount of release agent in the release agent chamber Picture 9 2 1 The release agent level must be at least half the sight glass Check regularly the release agent for discoloration caused by contact with the spray material The discoloration can be monitored by draining a small amount of release agent After checking add a corresponding amount of clean release agent to the chamber 22 Translation of the original operation manual Airless Maintenance 1 add release agent 2 air motor 3 drain release agent 4 5 material pump sight glass Picture 9 2 1 Heavy discoloration and material contermination These steps may only be perfomed by person 1 nel trained by W
28. iners A Danger of explosion Heated solvent can lead to an explosion within the pump This could result in serious injuries including loss of vi sion and property damage Always observe the flashpoint and ignition temperature for the solvent being used Turn off the fluid heater whenever the following work is performed on the pump Flushing Cleaning Pressure check Preparation for operation gt Shutting down amp Danger If being operated in closed rooms explosive atmospheres can be created This could lead to serious injuries and pro perty damage Smoking using open fires or other ignitable sources is prohibited in the entire area of operation Phoenix_BAoDB_en_1210 jw 2 7 Operating staff Authorised Operators People under the age of 16 should not operate this equip ment The management in charge of the operation of the machi ne must make the User s Handbook available to the ope rator and must make sure that he has read and unders tood it Only then may the system be put into operation We recommend the manager has this confirmed in writing The operator of the machine is obliged to report any changes in the machine which might affect its safety to the manager as he must ensure that the machine is functional The responsibilities for the different activities on the system must be laid down clearly and adhered to No unclear competences may remain as these could endan ger the safety of the
29. ing material the solvent must corre spond to the coating material and be recom mended by the material manufacturer called container A below ba TR 1 empty open container for the solvent coating material mixture called container B below 1 material container called container C below coatings material C Procedure 1 Turn off and depressurize the unit Close the air tap lock Turn the air regulator control knob counterclockwise as far as possible The pressure gauge must read 0 bar psi Close the spray gun and apply the safety catch Hold the drain hose into container B and secure it against slipping Briefly open the drain valve on the high pressure filter to depressurize VV y 2 Tip dismount and clean Dismount the standard tip and clean it thoroughly We recommend storing the tip standard or 1 reversible in the solvent recommended by the coatings manufacturer This will avoid residu al paint from drying and clogging the tip Clean the high pressure pump Remove the suction pipe from container C Wipe residual paint on the suction pipe and strainer into the container Place the suction pipe with strainer into container A Funnel mounted version gt Pump the remaining material out of the funnel and or fill the material back into the original container Fill the funnel with solvent Open the air tap lock Slowly turn the air regulator control knob clockw
30. ise until 1 2 bar 15 30 psi operating pressure is reached Hold the drain hose into container B and secure it agianst slipping Open the drain valve on the high pressure filter until clean solvent exits the hose may gt Close the valve tightly Yy VY e Yy VY VY Hold the spray gun against the inner wall of container B Trigger the gun until clean solvent is emitted Be sure 18 Translation of the original operation manual Airless Shutting down to maintain contact with the inner wall of the container Close the spray gun and apply the safety catch Lift the unit out of container A Funnel mounted versions gt Pump solvent from the funnel until it is empty Again hold the drain hose into container B and secu re it agianst slipping gt Open the drain valve on the high pressure filter until the pump runs dry Turn the control knob counterclockwise until it turns freely The pressure must read 0 bar psi on the pres sure gauge VV To avoid unnecessary loss of material still in 1 the hose we recommend spraying the coating back into container C until solvent emerges from the gun If working with plural component materials the pot life must be observed All system com ponents that come into contact with the mixed material must be cleaned with the appropriate solvent within the pot life given by the coa tings manufactuerer Observe gt Warm temperatures reduce the pot life Allo
31. lth reasons it is very important to pay attention to this warning USE BREATHING PROTECTION For health reasons it is very important to pay attention to this warning WEAR PROTECTIVE GLOVES Wear protective gloves with lower arm protection to avoid burn injuries The warnings must be adhered to HEALTH DANGER This marks materials which are hazardous to your health Observation of this information is absolutely essential FIRST AID In case of injuries or accidents these instructions should be absolutely adhered to 4 Translation of the original operation manual Airless Safety 2 2 Warnings located on the pump Warning signs and symbols which have been placed on the unit are there to inform of possible dangers and must be observed Warning signs and symbols may not be removed Damaged and illegible warning signs and symbols are to be replaced immediately The following signs are located on the unit Pos 1 Picture 2 2 1 Ground warning on the high pressure filter TOTOLO VO YOO 100 GEG oost The propietor is required according to the German Ac cident Prevention Regulation Unfallverhutungsvorschrift BGR 500 chapter 2 25 to ensure that the machine is properly grounded Please observe our User s Handbook Pos 2 Picture 2 2 1 Nameplate on the cylinder of the material pump Please observe that the information located on the nameplate corresponds to data found on the machine card
32. mission should be obtained from the manufacturer as the guarantee is otherwise invalid The observation of technical documentation and the compli ance with specified operational maintenance and starting guidelines are manditory in accordance with the valid regulations 2 5 Pump surroundings Rebuilds and modifications For safety reasons it is not allowed to carry out rebuilds or changes without authorization Protective equipment may not be dismounted changed or neglected If using components which are not produced or delivered by W A warranty coverage is negated as well as liability The machine may only be operated within the prescribed limits and machine parameters Danger caused by accessories and spare parts If you use original attachments and original spare parts from W WA the compatability with our equipment is guaranteed It is however essential that the safety regu lations of the attachments and spare parts are observed You can find these safety regulations in the User s Hand book located with the spare parts lists If you use attachments and spare parts from another source A cannot guarantee the safety of the entire system In this case our guarantee does not cover any damage or injury caused by such attachments and spare parts 6 Translation of the original operation manual Airless Safety Emissions It is possible for solvent vapours to occur depending on the materials used Therefo
33. n 1 connecting nipple for material hose black from Air Combi unit to spray gun Picture 8 1 7 High Pressure Filter Pressure setting Atomizing air approx 3 5 bar 51 psi spray pressure Inbound air pressure pressure ratio Compressed air hose G14 61 4 blue ae gt The spray pressure should be 80 100bar 1160 1450 eee 1 4 SB S pe black NPSM NPSM Sista 8 42 Instructions for shutting down Observe the order of steps to cutting off the air supply 1 First cut off the supply of atomizing air using the corresponding control knob Picture 8 1 6 Pos 3 2 Now turn the operating pressure control knob coun terclockwise Picture 8 1 3 8 1 5 Pos 2 until it turns freely 2777777 Translation of the original operation manual Airless 19 Phoenix_BAoDB_en_1210 jw 3 Close the air tap lock Picture 8 1 3 8 1 5 Pos 1 The setting for the atomizing air on the Air 1 Combi unit does not need to be changed Adjusting the air pressure regulator Unlock Pull the control knob upwards Lock Push the control knob downward Instructions for cleaning the unit The fine atomization of solvent can create a health hazard Therefore the supply of atomizing air must be cut off during the flushing process 8 2 Hot Spray Airless unit Fluid heater High pressure filter Airless spray gun Fluid pressure regulator Paint container OoahkWN Picture 8 2 1 The Hot Spray method adds a
34. n dry The resulting friction can lead to an explosion that results in injuries and or property dama ge Therefore gt Do not allow the pump to cycle if the feed container is empty Do not allow the suction assembly to become plugged kinked or otherwise defect If no coatings material exits the gun shut the unit down immediately Set the operating pressure The optimal operating pressure is reached when coa ting applies evenly with graduated edges Only use as much pressure as is necessary to achieve a good spray pattern at a distance of approx 30 40 cm 12 16 in to the object being coated If the pressure is too high excessive material 1 consumption and spray fog will result If the pressure is too low fingering and un even coating thicknesses will result WIA Phoenix_BAoDB_en_1210 jw Operation Coating Finishing tips Hold the spray gun at a 90 angle to the surface being coated If held at a different angle the coverage will be uneven and spotted Picture 6 2 1 The sprayer s arm must move evenly back and forth An even speed must be maintained Move the spray gun parallel to the surface being coated Move the spray gun with the arm and not with the wrist Waving the spray gun will lead to uneven coating results Picture 6 2 2 Begin moving the spray gun before the trigger is pulled This ensures even smooth overlapping results and avoids higher coating builds when the trig
35. nal triggering of the spray gun Apply the safety catch on at any pause in spraying Picture 2 10 8 All safety devices must be checked Before commissioning the system Before beginning to work with the system After any modifications have been made to the unit After flushing or cleaning the system After any repair or maintenance work on the system Phoenix_BAoDB_en_1210 jw Checklist for checking the safety devices with the system depressurized Check to see whether the seal on the safety valve is damaged Check the safety valve for signs of damage Check the ground cable for damage Check the connctions for the ground cable on the unit and the conductive object it is connected to Check whether the air tap lock is functioning properly Check the spray gun safety catch to ensure it functons properly VV VYY If one of the safety devices is not functioning 1 properly or if any other malfunction is found the air supply to the unit must be cut off and the drain valve opened The unit may only be restarted once the pro blem has been solved and the system is func tioning perfectly again 2 11 Pump handling and auxiliary mate rials Adjusting servicing cleaning maintenance and repair of the unit Before starting any of the above gt Turn off the unit Depressurize the system Pay attention to residual pressure Repair work Maintenance work personnel trained by W
36. ntion to the following Please read and observe the guidlines valid for your country In Germany the Richtlinien fur Flussigkeitsstrahler Gui delines for liquid sprayers Published by Hauptverband der Gewerblichen Berufsge nossenschaften are valid We recommend adding a copy of all guidelines and acci dent prevention regulations into the User s Handbook Manufacturer s notes and operating guidelines for coating material and pumping material should be observed at all times In principle no method of working should be exercised which impairs the safety of 47737A products or the ope rating personnel 2 4 Applications for the pump Version ee ist ae OllsandFats o o Primers o deoe doe Spray filers o o Lacquers and varnisches gt oto Two component coatings J gt oto Hammerstone tt Zinebased paints tt Anti corrosion coatings ttt Micaceous coatings Poe foe foe Water soluble coatings o t o Water based lacquers gt gt Phoenix_BAoDB_en_1210 jw Dangerous chemical reactions can occur if closed or pressurized systems with aluminum or galvanized pump components come into contact with solvents such as 1 1 1 trichlorethylene or methylene chloride that contain halogenated chlorofluorocarbons CFC If such solvents or paints or lacqures that contain them are to be used we recommend contacting A Customer Service or the 37737A factory directly for further information Plea
37. onents have their own nameplate with separate markings according to ATEX The marking with the lowest rating for explosion protection becomes valid for the entire system If the intended application could lead to injury of personnel if this equipment malfunctions on sight precautions and preven tive measures must be implemented Marking If this equipment appears to be malfunctioning the unit must be shut down immediately and 77 3A Customer Service contacted as soon as possible Translation of the original operation manual Airless 5 It must be ensured that the pump is grounded separately or together with the equipment it is mounted to maximum resistance 10 Q picture 2 4 1 ground potential equalization Picture 2 4 1 Groun ding screw on the high pressure filter Equipment that is not rated as explosion proof may not be operated in areas requiring explosio proof protection Pneumatically driven Airless spraying equipment is not effected by this If however agitators heaters or other electrical accessories are used they must first be checked for their explosion proof rating Plugs for heaters agita tors etc may only be connected to sockets outside of the explosion proof area even if the unit itself is rated as explosion proof Other usage is not in line with regulations Before VA equipment is used for other purposes or with other materials and therefore not according to the regulations per
38. ove the safety valve gt Never change the safety valve setting New safety valves must correspond to the maximum all owable inbound air pressure and be sealed appropriately The part number and maximum allowable inbound air pressure can be found in the machine card for the unit Air tap lock Picture 2 10 2 2 10 6 WOOS The compressed air tap lock makes it possible to shut Air tap lock The compressed air tap lock makes it possible to shut down the unit immediately Picture 2 10 2 compressed regulator on Phoenix Airless 6530 and 11018 WIA Phoenix_BAoDB_en_1210 jw Safety Picture 2 10 4 compressed regulator on Phoenix Air Combi 6530 and 11018 Picture 2 10 3 compressed regulator on Phoenix Airless 6552 and 11032 and Hot Job units Picture 2 10 5 compressed regulator on Phoenix Air Combi 11032 Picture 2 10 6 compressed regulator on Phoenix Air Combi with additionally com pressed air supply Ground cable connection Picture 2 10 7 Due to the high flow speed created by Airless equipment static char ging can occur A static charge can lead to fires or explosion The unit must therefore always be grounded properly Factory delivered W WA Airless spraying equipment comes standared with a ground cable If lost or defective it must be replaced part no 0474487 Picture 2 10 7 Spray gun safety catch Picture 2 10 8 The spray gun safety catch is used to avoid unintentio
39. re please ensure the workplace is sufficiently ventilated in order to avoid damage to health and property Always observe the processing information given by the material manufacturer The sound pressure level of the equipment is below 85 db A The operator is responsible for compliance with the rules covering the prevention of accidents due to noise BGV B3 Therefore pay special attention to the environmental conditions at the site e g noise can be increased if the machine is installed in or on hollow bodies Exact specifications covering noise emissions are found in Chapter 11 1 Technical specifications 2 6 Sources of danger Always remember plural component systems operate at very high pressure levels and unauthorized usage could lead to life threatening injuries SS Ry Th warning Material exits the spray gun at very high pressure levels The spray jet can cut or be injected under the skin or eyes resulting in serious injuries gt Never point the spray gun towards yourself other people or other living creatures gt Never hold your finger or hand in front of the spray gun and never reach into the spray jet A Warnung Unintentional triggering of the spray gun can lead to injury or damage to property Always apply the spray gun safety catch regardless how short the pause in spraying is Before operation always check the function of the spray gun safety catch A Warnung Components that
40. rting Component description Installation and Assembly Start up First cleaning Pressure check Operation Equipment preparation Spray operaton Change of material Shutting down Optional versions Air Combi Hot Spray Maintenance Regular inspections Maintenance plan High pressure filter Maintenance unit or Regulator Cluster Malfunctions and troubleshooting Appendix Technical specifications Auxiliary materials Machine card Translation of the original operation manual Airless Page OOWMDAON DOA AHA b 12 14 14 14 NO 2 1 Description of symbols The signs and symbols used in this User s Handbook have the following meaning NOTE This marks a section of text which is especially re levant to safety Special attention should be paid to this section and the contents strictly observed SMOKING PROHIBITED This marks a situation in which a fire hazard arises through the use of flammable or explodable solid fluid or gaseous materials WARNING This marks a situation which could be dangerous If not observed death or very serious injuries could result DANGER OF EXPLOSION This marks a situation where there is danger of explosion Observation of this information is abso lutely essential ELECTRICAL VOLTAGE This marks a situation where there is a danger of explosion through an electostatic charge Observation of this information is absolutely esseniial USE EAR PLUGS For hea
41. se note that there are stainless steel Airless pumps that are designed for use with such materials Using this equipment in areas requiring explosion protection x Il 2G cT4 This equipment fulfills the explosion proof require ments found in the guideline 94 9 EC for the type of explosion equipment catagory and temperature class found on the nameplate This equipment is able to be installed in areas requiring Zone explosion protection Due to the possibility that ex plosive gases and overspray may be created this unit is to be considered as Group Il Equipment Catagory 2G The flash point for the materials being sprayed as well as the solvent being used must be above 200 C When operating this equipment the User s Handbook must be followed closely The required inspection and maintenance intervals must be adhered to strictly All information found on the unit s signs or plates must be adhered to and not exceeded Do not allow this unit to be overloaded It is the responsibility of the operator of this equipment to determine the explosion risk zone determination accor ding to EC regulation 94 9 EC Appendix Il Nr 2 1 2 3 in the area of usage in accordance with local regulatory authority guidelines Furthermore it is the responsibility of the operator on sight to check and ensure that the technical specifications and markings according to ATEX are compliant with local requirements Please observe that some comp
42. ting 1 drop every 10 cycles 1 Thin the coating Use a larger pump 2 Check the seal of all suction assembly connections and replace if necessary 3 Remove the bottom valve and clean the ball and seat thoroughly 4 Clean the ball and seat in the dual pi ston and replace if necessary 5 Replace Replace Note Do not close or block the anti vaccum hole 25 11 Appendix 11 1 Technical specifications Max free flow output in l min gal min O 65 1 7 6517 129 2 2 2 i 9 5 in l min 6 5 1 7 6 5 1 7 11 2 9 11 72 a6 i i 5 2 5 2 5 2 95 i Air motor stroke length in mm in 75 2 95 75 2 95 75 2 95 75 2 95 Air inlet inch G 3 8 G 3 8 G 3 8 G 3 8 material outlet inch 1 4 NPSM 1 4 NPT 1 4 NPT 1 4 NPT 1 4 NPT Hot Job Sound pressure level at the work place o At idle Lyay 4B Running with load Ly dB ee Accessories 11 2 Auxiliary materials Airless units Release agent Order No 0163333 gt Spray Accessory Kit ak No 10 RS Order No 0629957 Pneumatik oil 0 5 liter Order No 0632579 No 13 N R Onder No 0642474 Order No 0631567 No 14 N R Order No 0642475 Thread sealant 50 ml 1 7 Order No 000015 No 15 N R Order No 0642476 fl oz bestehend aus gt W WAD Kirless spray gun Grease acid free Order No 000025 gt material hose NW6 1 4 Materials required for maintenance and repairs Aijrless tip Air
43. users The operator must make sure that only authorised persons work on the machine He is responsible to third parties in the working vicinity of the system The operator of the equipment is obliged to repeat instruc tions about dangers and safety measures at regular inter vals at least once a year for young persons twice a year Personal protective equipment gt We callto your attention that the valid guidelines and re quirements in accordance with work surroundings mi ning closed areas etc must be absolutely adhered to The prescribed protective clothing must be worn at all times as solvent vapours and solvent splashes cannot be completely avoided gt sound pressure level of the equipment is below 85 db A Nevertheless appropriate noise protection means should be made available to the operating staff Although spraying fog is kept to a minimum when the correct pressure setting and proper method of operation are observed the operating painter should wear a protective breathing mask F when working with heated materials the outer surface of the pump can become hot Protective gloves must be worn at all times gt x Never use solvent or other materials which present a health hazard for cleaning skin Only suitable skin protective skin cleansing and skin care materials may be used 2 8 Installation site Translation of the original operation manual Airless 7 High pressure spray equipment
44. w the solvent to circulate for a while gt No paint residue may remain in the pump or high pressure filter Removing the filter insert Remove the element from the high pressure filter ac cording to the instructions found in Chapter 9 3 Wipe the inside of the high pressure filter completely clean Close the high pressure filter with only the nut moun ted inside without the filter element Y VY VJS If taken out of service for a long period Clean the unit as described Do not however completely empty the pump of sol vent As soon as clean solvent exits the spray gun and high pressure filter reduce the pressure to O bar psi Hold the spray gun against the inner wall of container B and tigger briefly To depressurize the high pressure filter Hold the drain hose securely into container B Briefly open the drain valve The solvent that is left in the material pump is to re main until the next time the pump is used gt When restarting the pump be sure to flush the system thoroughly VV VY VY WIA Phoenix_BAoDB_en_1210 jw Optional versions 8 1 Air Combi Air Combi unit Air Combi spray gun Paint container Spray hose Air hose ahwND With this method the material being sprayed is fed to the air assisted airless Air Combi spray gun under moderate pressure and pre atomized The fine atomization is achie ved by adding compressed air to the spray jet This results in
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