Related Manuals for wiwa AIRLESS 270
Summary of Contents for wiwa AIRLESS 270
- Page 1 Operation Manual AIRLESS 270 Serial number ________________ Translation of the original operation manual Airless 270_DB_en_1403 •• 0550022 •• jw...
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Page 3: Table Of Contents
Contents 1 Foreword ..................7 2 Safety ..................8 2.1 Explanation of symbols............8 2.2 Safety notes................. 10 2.2.1 Operating pressure ............10 2.2.2 Risks caused by the spray jet ........11 2.2.3 Hazard from electrostatic charging ........ 11 2.2.4 Hazards from hot/cold surfaces ........12 2.2.5 Explosion protection ............ - Page 4 3 Equipment Description ............23 3.1 Intended use ................ 23 3.2 Equipment design ..............24 3.3 Optional expansion parts and accessories ......25 3.3.1 Spraying accessory kits ..........25 3.3.2 Material flow heater ............26 3.3.3 Agitator ................26 4 Transport, installation and assembly ........27 4.1 Transportation ..............
- Page 5 6 Maintenance ................40 6.1 Regular inspections ............. 41 6.2 Maintenance plan ..............41 6.3 Maintenance unit ..............42 6.3.1 Checking the water separator and cleaning the container ................ 43 6.4 High pressure pump ............43 6.4.1 Checking release agent for material residue ....43 6.4.2 Fill in release agent and check the fill level ....
- Page 6 This User Guide remains the copyright of WIWA Wilhelm Wagner GmbH & Co. KG. •• Gewerbestr. 1-3 •• 35633 Lahnau •• Germany Tel.: +49 6441 609-0 •• Fax.: +49 6441 609-50 •• E-mail: info@wiwa.de •• Internet: www.wiwa.de This operation manual is solely intended for personnel involved in prepara- tion, operation and servicing.
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Page 7: Foreword
Moreover the manufacturer’’s instructions and guidelines for coating or feeder materials must be respected at all times. However, if you have any questions, please do not hesitate to contact us. WIWA Wilhelm Wagner GmbH & Co. KG. hopes that you have excellent work results using your equipment... -
Page 8: Safety
Explanation of symbols Safety information warns you of potential risks of accidents and tells you the measures that are required to prevent accidents. In WIWA operation manuals, safety information is specially high- lighted and marked as follows: DANGER Indicates danger of accidents; if you ignore the safety notes,... - Page 9 Safety Indicates important information on correct use of the equipment. Ignoring it can result in damage to the equipment or in its vicinity. In the safety notes about the risk of accidents, different pictograms are shown after each hazard source - examples: General accident risk Risk of explosion from explosive atmosphere Risk of explosion from explosive substances...
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Page 10: Safety Notes
Safety Use a respiratory protection mask Highlights the order to use a respiratory protection mask to prevent your respiratory tract from being damaged by gases, fumes or dusts. Wear protective gloves Highlights the order to wear protective gloves with lower arm protection to protect against burn injuries caused by heated materials. -
Page 11: Risks Caused By The Spray Jet
Safety Material hoses and hose assemblies must comply with the maximum working pressure, including the required safety factor. Material hoses must be leak tight and free of kinks, signs of abrasion or bulges. Hose connections must be tight. 2.2.2 Risks caused by the spray jet WARNING The material is discharged from the spray gun under very high pressure. -
Page 12: Hazards From Hot/Cold Surfaces
Always use electrically conductive containers. Avoid contact between spray gun and container wall. Use only electrically conductive material hoses. All original material hoses from WIWA are conductive and perfectly adapted to our equipment. Use only electrically conductive accessories/accessory parts. WARNING... -
Page 13: Explosion Protection
Safety 2.2.5 Explosion protection WARNING Equipments and accessories designed without explosion protection must not be used in workshops that come under the explosion protection ordinance! Whether your equipment or accessories have explosion protection is indicated by the symbol on the type plate and/or on the enclosed ATEX declaration of conformity. -
Page 14: Health Risks
Safety 2.2.6 Health risks CAUTION Depending on the materials being applied solvent vapours may be generated which could cause damage to health and objects. Always ensure sufficient aeration and ventilation at the work- place. Always ensure an air change rate of at least 5. Always observe the processing instructions issued by the material manufacturers. -
Page 15: Information Signs On The Equipment
Safety Information signs on the equipment Information signs attached to the equipment, like safety information (see Fig. 1), refer to possible danger areas and must be strictly observed. They must not be removed from the equipment. Damaged and illegible information signs must be replaced immediately. -
Page 16: Safety Valve
Safety The equipment is equipped with the following safety features: Safety valve Compressed air shut-off valve Ground cable Checklist on the depressurised equipment: Lead seal on the safety valve still intact? Safety valve free of external damage? Ground cable free of damage? Operability of compressed air shut-off valve correct? on the pressurised equipment: Function of safety valve correct? (function test see chapter... -
Page 17: Compressed Air Shut-Off Valve
Safety WARNING If the maximum permissible air inlet pressure is exceeded, components may burst. This may result in damage to persons and property. Never allow the equipment to run without a safety valve or with a defective one! If the safety valve needs to be replaced, you can find the corresponding order number on the equipment card. -
Page 18: Ground Cable
Safety 2.4.3 Ground cable The ground cable prevents the electrostatic charge of the equipment. The ground cable is already connected to the equipment when it is delivered (e.g. on the high pressure filter, the ground bar, etc.). Fig. 5: Ground cable Replace the ground cable immediately (order no.: 0659675) if it lost or damaged! Operating and maintenance personnel... -
Page 19: Authorized Operating Personnel
Safety behaviour. Trained personnel have been instructed by the equipment builder such that they are capable of carrying out maintenance and repair work on the system and recognising potential risks on their own initiative and of avoiding these risks. 2.5.3 Authorized operating personnel Activity Qualification... -
Page 20: Notes On Warranty
2.6.2 Spare parts Only use WIWA original spare parts when carrying out mainte- nance and repair work. Use of components which have not been manufactured or deliv- ered by WIWA renders any warranty null and void. -
Page 21: Accessories
Safety 2.6.3 Accessories Using original accessories from WIWA which are designed for the operating pressure ensures suitability for our equipments. If you use third-party accessories, they must be suitable for the equipment –– particularly with regard to the operating pressure, the electrical connection data and the connection sizes. -
Page 22: Leakages
Safety 2.7.2 Leakages WARNING In case of leakages material can escape under very high pressure and cause serious bodily injuries and material damage. Stop the equipment immediately and release the pressure. Re-tighten any screw fittings and replace defective compo- nents (only by trained personnel). Do not try to seal leaks on the connections and high pressure hoses with the hand or by wrapping fabric around them. -
Page 23: Equipment Description
The technical data of your equipment can be found on the attached equipment card or on the type plate. Intended use The WIWA Airless equipments are only suitable for airless spraying of coating and ancillary materials for surface treatment. Any other use is considered to be unintended. If you intend to... -
Page 24: Equipment Design
Equipment description Equipment design Fig. 7 Airless LM 270 (here on cart) Translation of the original operation manual Airless 270_BAoDB_en_1405 •• 0550022 •• jw... -
Page 25: Optional Expansion Parts And Accessories
The following section lists only some of the most common accesso- ries and expansion parts. The detailed accessory catalogue can be found at www.wiwa.de. More information and order numbers can also be obtained from an authorised WIWA dealer or the WIWA service department. -
Page 26: Material Flow Heater
Equipment description 3.3.2 Material ow heater Material flow heaters can optionally be used as: Heaters for the spraying material Auxiliary heaters for long hoses Heating the spraying air for Air Combi spraying (see separate operating instructions) Heating the air for the air motor to prevent icing over Observe and follow the separate operating instructions of the material flow heater. -
Page 27: Transport, Installation And Assembly
Transport, installation and assembly 4 Transport, installation and assembly The equipment left the factory in flawless condition and was appro- priately packed for transportation. Check the equipment on receipt for any damage in transit and for completeness. Transportation Please follow these notes when transporting the equipment: Ensure sufficient load bearing capacity of lifting gear and lifting tackle when loading the equipment. -
Page 28: Installation Location
Transport, installation and assembly Installation location The equipment can be installed inside and outside spray booths. However, outdoor installation should be preferred in order to avoid contamination. WARNING If the equipment is used outside during a thunderstorm, a light- ning strike can cause a life-threatening situation for the operating personnel. -
Page 29: Assembly
Transport, installation and assembly Assembly WARNING If assembly work is carried out by people who have not been trained for this work, you endanger yourself and other people and impair the safety and reliability of the equipment. Electrical components must only be mounted by trained time- served electricians ––... -
Page 30: Assembling Spray Hose And Spray Gun
Only use conductive material hoses. All original material hoses from WIWA are conductive and perfectly adapted to our equipment. Connect the spraying hose to the material outlet on the high pressure filter (see Fig. -
Page 31: Grounding The Equipment
Transport, installation and assembly 4.3.3 Grounding the equipment WARNING The high flow velocities associated with the Airless spraying method may cause electrostatic charging. Static discharges can cause fire and explosion. Ensure that the equipment has been properly grounded out- side of explosive atmosphere areas! Also ground the object to be coated. -
Page 32: Operation
Operation 5 Operation The equipment must have been set up correctly and completely assembled. Do not start commissioning the equipment unless you have the specified protective equipment. For more details, refer to Chap- ter 2.5.4 Personal protective equipment on page 19. A sufficient quantity of the spraying material has to be available. -
Page 33: Spraying
Operation Spraying The following steps for commissioning have to be completed before spraying (see Chapter 5.1 Put the equipment into operation on page 32). Place the suction pipe into the spraying material. Open the compressed air shut-off valve. Regulate the air inlet pressure such that the pump runs slowly. Unlock the spray gun and operate it until clean spraying materi- al free from bubbles is emitted. -
Page 34: Adjusting The Spraying Pressure
Operation 5.2.1 Adjusting the spraying pressure Please observe the following information when adjusting the spray- ing pressure: Optimal spraying pressure is indicated by a uniform application of material with fading out peripheral zones. Operate the equipment only with 30-40 cm an air pressure as high as neces- sary, to achieve good atomisation at the recommended spraying dis-... -
Page 35: Flushing
Operation Move the spray gun with your arm thin thick thin layer layer layer and not with your wrist. Area to be coated Already move the spray gun be- fore pulling the trigger. That way, you will achieve perfect, soft and smooth overlapping of the spray jet and avoid excessively thick application of material at the be-... - Page 36 Operation WARNING Heating up cleaning agents can cause an explosion. This may result in serious injury to persons and damage to property. Before flushing the equipment, switch off the material flow heater (optional) and leave it to cool completely. You will need: ••...
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Page 37: Material Change
Operation Remove the nozzle from the spray gun. Observe and follow the notes in the user manuals for the spray gun. Remove the filter element from the high pressure filter (see Chapter 6.4.4 Cleaning the filter element on page 44). Remove the suction pipe from the material container. -
Page 38: Releasing Pressure
Operation Relieve pressure Close the compressed air shut-off valve. The equipment will vent automatically. To release pressure from the material as well, insert the drain hose into a container and open the drain valve. Operate the spray gun until all pressure has been released. Secure the spray gun. -
Page 39: Decommissioning
Operation Decommissioning If you want to decommission the system for a longer period of time, proceed as follows: Flush the equipment as described (see Chapter 5.3 Flushing on page 35). Do not drain the pump fully. Turn down the operating pressure fully (0 bar) as soon as clean solvent is emitted from the spray gun or the drain hose on the high pressure filter. -
Page 40: Maintenance
Maintenance and repair work on electrical components must only be carried out by trained electricians –– any other mainte- nance and repair work must be performed by WIWA custom- er service or by specially trained personnel. WARNING Sources of ignition may result from maintenance work (e.g. -
Page 41: Regular Inspections
Maintenance After completing the maintenance and repair work, check the function of all safety features and the correct functioning of the equipment. Regular inspections The has to be examined and serviced by an expert regularly: before initial commissioning, after the modification or repair of parts of the system, which could affect safety, after work breaks longer than 6 months, but at least every 12 months. -
Page 42: Maintenance Unit
Maintenance Maintenance unit The maintenance unit prevents condensation water and dirt parti- cles from entering the equipment. The maintenance unit is equipped with the following maintenance elements: Fig. 15 Maintenance elements No. Designation Compressed air shut-off valve with automatic venting function / EMERGENCY STOP Pressure gauge for displaying the air inlet pressure Compressed air plug coupling DN 7.2... -
Page 43: Checking The Water Separator And Cleaning The Container
In this case, have the pump packing replaced as soon as possible. After the examination, top up the amount of fresh release agent through the filler openings. We recommend using release agent from WIWA (order number 0163333). Translation of the original operation manual Airless 270_BAoDB_en_1405 •• 0550022 •• jw... -
Page 44: Fill In Release Agent And Check The Fill Level
Maintenance 6.4.2 Fill in release agent and check the ll level Before each start-up check the release agent level as far as possi- ble. Top up with release agent if necessary. The total filling capacity is approx. 120 ml. No. - Page 45 Maintenance Open the release ball valve (1) and quickly operate the gun to verify that the equipment is fully depressurised. Use the enclosed hook spanner to release the box nut (2) on the cap and remove the cap (3) of the high pressure filter.
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Page 46: Filter Elements For High Pressure Filters
Recommended operating materials Only user original operating materials from WIWA: Operating materials WIWA order number Release agent, yellow (0.5 l) ¹... -
Page 47: Special Tools
Maintenance Materials required for cleaning and repair work (see information in spare parts lists) The release agent and the pneumatic oil are available in large containers on request. Special tools The following special tools for maintenance and repair work are included with delivery: Hook spanner for opening the high pressure filter... -
Page 48: Rectification Of Faults
Rectification of faults Translation of the original operation manual Airless 270_BAoDB_en_1405 •• 0550022 •• jw... - Page 49 Rectification of faults Translation of the original operation manual Airless 270_BAoDB_en_1405 •• 0550022 •• jw...
- Page 50 Rectification of faults Translation of the original operation manual Airless 270_BAoDB_en_1405 •• 0550022 •• jw...
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Page 51: Technical Information
Technical information 8 Technical information Technical data Type 28088 Article No. 0659730 Pressure ratio 88 : 1 Max. free- ow output (l/min) Delivered volume per double stroke (ccm) Max. air inlet pressure (bar)/safety valve Max. permissible operating pressure (bar) Air consumption (I / DH) 14.77 Piston diameter of the air motor (mm) Piston stroke of the air motor (mm) -
Page 52: Equipment Card
The QR code is located at the front of the carriage (see Fig. 7) and contains a link which leads to the equipment support for your equip- ment type on the WIWA website. This provide more information on your equipment, e.g. electrics lists, repair instructions, etc. - Page 53 Technical information Scan the QR code with the camera of your mobile equipment (e.g. smartphone, tablet). You will need a QR code reader for decoding the QR code. This is available as an app. Translation of the original operation manual Airless 270_BAoDB_en_1405 ••...
- Page 54 Translation of the original operation manual Airless 270_BAoDB_en_1405 •• 0550022 •• jw...
- Page 55 Translation of the original operation manual Airless 270_BAoDB_en_1405 •• 0550022 •• jw...
- Page 56 WIWA Headquarters and production WIWA Wilhelm Wagner GmbH & Co. KG Robert Jansen WIWA Partnership USA WIWA LP Otto Dietrich WIWA Subsidiary China WIWA (Taicang) Co., Ltd. WIWA Middle East General Trading LLC Michel Laksander JK Tan QR-Code WWW.WIWA.DE...