AirCom AST24 User manual

Instruction
manual
FEED PUMPS
AST24
mod. AST24
aircom.it
EN

AIRCOM®- 2022 - v. 1.0
AVAILABLE MODELS
mod. AST24
Double diaphragm pump with
flow rate of 24 l/min

EN
Index
WARNINGS!
Carefully read and follow all instructions and safety precautions
before using the product.
Instruction manual
MANUALS
Our manuals are available at aircom.it/en/support/manuals/
Or, by scanning the QR Code on this page.
Packing
Description
Technical features
Products and dimensions
Usage
Pipes connection
Start Work
Safety
Painting cycle
Pressure discharge
Maintenance
Cleaning
Filter replacement
Anomaly resolution
Scheduled maintenance
Spare parts and components
Disposal and Support
.04
.05
.06
.07
.08
.09
.10
.12
.13
.14
.15
.16
.17
.18
.19
.20
.26

PACKING
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The pump is packed in a cardboard box. All components supplied as
standard are placed in the same package.
The weight of the equipment plus the packaging is ~22 Kg.
STORAGE
During transport and storage, make sure that temperatures between -15°C
and 40°C or 50°C for short periods not exceeding 24 hours are not
exceeded, which could damage the unit itself.
If the unit is to be stored, make sure it is stored in places with humidity
between 30% and 80%.
PLATE DATA
On the front plate, the equipment bears the manufacturer's identification
plate and the 2006/42/CE STANDARDS compliance plate, also represented
below.
The plate must not, under any circumstances, be removed, even if the
equipment is resold. For any communication with the manufacturer, always
quote the serial number (shown on the plate itself). On the body of the
pump there are some pictograms indicating safety warnings which must be
carefully observed by anyone preparing to use the painting unit. Failure to
comply with the provisions relieves the manufacturer from any damage or
injury to people or things that could derive from it and makes the operator
himself solely responsible towards the competent bodies. Replace the
nameplate and any removed, damaged or illegible stickers.
OBBLIGO DI
IMPIEGO DI
OCCHIALI E
MASCHERINA
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The equipment dealt with in this manual is a low pressure painting unit
which allows the use of any type of water-based or solvent-based paint.
Characterized by considerable practicality, versatility and ease of use, the
AST24 employs a pneumatically operated double diaphragm pump unit. The
spray system (usually a manual or automatic airbrush is used), allows the
delivery of special paints, textured, embossed, multicolored. It is possible to
paint small and medium-sized items, and to use them in applications where
a high level of surface finish is required.
The modularity of the equipment allows you to purchase only the pump unit
and then customize it with a considerable number of accessories
(conventional or HVLP spray gun, pump trolley, gravity tank, wall fixing
system, suction systems, etc.) see drawing below:
Double air pressure
regulator group both at
the pump and at the
spray gun.
Rear main air inlet
cock with ¼” G fitting
Filter
Group to
regulate
pressure
Transport trolley
Pump
DESCRIPTION
EN

TECHNICAL FEATURES
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The painting unit uses a pneumatic system that can be fed at a pressure
between 2 and 8 bar (from 28 to 114 psi). Compressed air is used to
obtain the movement of the two paint pumping membranes. All gaskets
are of a special type with high quality and high resistance; the valves are
in stainless steel, the seats are in stainless steel.
FEATURE AST24
CAPACITY
PRESSURE RATIO
OPERATING PRESSURE
NOMINAL PRESSURE
DROP TANK
PREVALENCE
AIR OUTLET FITTING
PAINT INLET FITTING
NOZZLE
WEIGHT
SOUND PRESSURE LEVEL
PEAK VALUE
24 Lt/min. (6 gal/min)
1:1
1÷ 8 bar (28÷114 psi)
6÷ 8 bar (85÷114 psi)
5 Lt. (1,25 gal)
15 metri
¼”M
F 1/2”
0,5 –5,0
15 Kg. (33 lb.)
Laeq=68,70 dB (A)
99,7 dB
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The AST24 series painting units are designed for painting ferrous material in
general, wood, plastics, fabrics, leathers. The products that can be supplied
are: paints, textured, embossed, multicolour paints, solvents, inks, oils,
resins. For the use of the equipment with particular products, the approval of
the manufacturer must be obtained, and the adaptation of the technical
characteristics of the unit for the processing of such products.
Solvents such as trichloromethane and chloromethylene (dichloromethane)
can chemically react with the aluminum which makes up most of the pump,
leading to dangerous explosions. We advise you to always read the technical
data sheet of the product you intend to apply very carefully, avoiding the use
of materials that contain this type of solvent. Do not use regenerated
solvents (cleaning thinners), make sure they are free from acids (caused by
regeneration); these acids are responsible for the corrosion of the gun.
PRODUCTS AND DIMENSIONS
960 mm
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Before using the paint pump, check that it has not suffered damage due
to transport or storage conditions.
Also check that all the optionals ordered and all the components supplied
as standard are contained in the packaging.
Always wear the prescribed PPE; gloves, mask, goggles, in compliance
with workplace safety regulations. As a first step, it is necessary to make
sure that the lines are able to correctly feed the pump, in compliance
with the safety standards.
The unit is supplied with a double pressure regulator, it is recommended
to supply with a pressure of 6÷8 bar Max.
It is recommended to use dry compressed air for best painting results.
The drawing indicates the connection points of the equipment to the
pneumatic network.
.08
USAGE
Manometer
Sprayer manometer
Pressure and air
pump regulator
Sprayer air
pressure regulator
Rear air inlet fitting
Adapter plate
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2
7
5 3
6
8
4
PIPES CONNECTION
1
The pump must be placed in an easily
accessible position but in such a way
that it does not hinder the operator and
that it is not exposed to jets of paint.
•Connect the twin hose to both the
pump and the gun. The twin tube is
of two colors; (WHITE) for product,
and (BLUE) for atomizing air.
Important: pay close attention to the
connection, as the fittings of the blue hose
are identical to the fittings of the white
hose.
Do not reverse the pipes. Connect the
product passage pipe (WHITE) to the
product delivery pipe connection (Pos. 1).
Connect the atomizing air hose (BLUE) to
the atomizing air connection (Pos. 3).
• Connect the air supply pipe (minimum
internal diameter of the pipe 8 mm) to
the pump air connection fitting (Pos. 4).
• Connect the suction pipe (tightening
tightly) to the paint suction pipe fitting
(Pos. 2). If you have a gravity tank,
screw the tank to the paint suction pipe
connection using the 90° extension
supplied with the tank.
• Connect the return pipe (tightening
tightly) to the connection of the return
cock (Pos. 5). If you have a gravity
tank, recirculation takes place through a
rilsan tube (to be screwed to the return
tap fitting) and a curved end to be
inserted into the hole in the tank lid
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START WORK
SUCTION SYSTEM
• All our pumps are tested with chemical water, therefore a light film of
oil is deposited in the product passages. When starting for the first
time, it is recommended to circulate the solvent in the pump before
starting work.
• Immerse the vacuum system in a container of solvent.
• Make sure that the return cock (Pos. 5) is open.
• Open the line cock. Turn the engine air regulator knob to the right
(Pos. 6). Adjust the pressure to two bars (28 psi).
The pump begins to draw solvent from the container through the dip
tube and puts it back into the container through the return tube,
washing the pump body.
• During the washing phase of the pump body, the supply air to the
gun must be closed. Turn the atomizing air pressure regulator
handwheel to the left (until the end of the stroke). Let the solvent
circulate for a few seconds.
• Close the return cock; the solvent is sent to the gun through the
delivery tube. Adjust the thrust pressure of the product to 1 bar by
turning the handwheel of the paint pressure regulator to the right (Pos.
7).
• Rest the spray gun on a container, pull the spray gun control lever,
letting the solvent flow out for a few moments, then release the control
lever.
• Open the return cock and lift the suction system from the solvent
container, the pump empties through the recirculation pipe. Shut off
the pump supply air as soon as the system has completely emptied.
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GRAVITY TANK SYSTEM
• Fill the tank with solvent and open the return valve.
• Feed the system by opening the line cock. Adjust the air pressure to 2
bar. The pump begins to suck in solvent and put it back into the tank
through the return tube.
• Close the return tap, the solvent is sent to the spray gun through the
delivery tube. Adjust the thrust pressure of the product to 1 bar by turning
the handwheel of the paint pressure regulator to the right).
• Rest the spray gun on a container, pull the spray gun control lever,
letting the solvent flow out for a few moments, then release the control
lever.
• Disconnect the metal end of the return tube from the tank and place it in
the solvent container. Open the return valve and let the gravity tank empty
completely. Once the operation has been completed, close the pump
supply air.
SAFETY OF LOW PRESSURE HOSES:
Pressurized material circulates in the pipes, pay close attention to breakages,
cuts or slight leaks, which can cause solvent absorption in the epidermis or
other serious physical injuries.
- Check the connections before activating the system.
- Do not bend the pipes near the fittings and do not use damaged pipes
or worn out.
- Do not try to repair any leaks.
- Pay close attention to the writing on the pipes.
- Never exceed the maximum pressure indicated by the manufacturer.
- The tube marked with the maximum pressure value must be used for the
product, the other for the gun supply air.
START WORK
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The painting MUST preferably take place in a special painting booth
equipped with a suction hood. Do not use the unit if the vacuum system is
not running. Wear protective gloves, goggles and a mask with filters for
breathing with activated carbon and clothing suitable for body protection.
The pneumatic diaphragm pump must only be used by competent and
trained personnel for its safe and correct use. Make sure that the
personnel assigned to use it have received adequate training and have
fully understood this user manual. To use the spray gun, COMPLY
STRICTLY with the prescriptions and safety criteria indicated below.
• Always work on the equipment protected by the prescribed PPE; gloves,
protective masks, breathing filters with activated carbon, clothing suitable
for body protection.
• The pump is used with paint products or solvents, bear in mind that
these are highly flammable, therefore use the system in well-ventilated
environments and avoid any action that could cause fires (example:
smoking, high temperature slag or shavings, sparks or any electrical
risk).
• CHECK the chemical compatibility of the products to be used from their
safety data sheets.
• The use of products containing organic solvents can cause poisoning
due to the emission of toxic vapours.
• DO NOT USE with food or medicines.
• DO NOT EXCEED the maximum operating pressures indicated (see
paragraph 2.3). BEFORE any disassembly, cleaning, maintenance and
reassembly operation RELEASE the pressure in the pipes
• Never point the paint gun at the human body or at animals.
• Do not modify or alter the equipment as supplied; in addition to being
able to cause malfunctions, or worse, even dangerous failures, you would
invalidate the guarantee.
SAFETY
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PAINTING CYCLE
Prepare the paint following the manufacturer's instructions. Immerse the
intake system (or fill the gravity tank) in the prepared paint.
Open the system supply air (Pos.4) open the return cock (Pos.5). Slowly
turn the handwheel of the engine air pressure regulator to the right until
the product comes out of the recirculation pipe, at the minimum operating
pressure of the machine. Close the return tap, the paint is pushed to the
spray gun filling the circuit. Adjust the paint thrust pressure to the spray
gun at 1 bar, using the paint pressure regulator handwheel (Pos. 7). Pull
the control lever and discharge the solvent contained in the paint tube.
Release the lever when paint appears.
Adjust the atomizing air pressure to the spray gun by turning the knob of
the atomizing air pressure regulator to the right
(pos. 8).
Adjust the pressure between 3 and 5 bar (42-70 psi).
Test the adjustments just made on a smooth surface. Depending on the
density of the paint used, the air pressure at the pump motor must be
modified. For fluid paints, the recommended pressure is between 3 – 4 bar.
When using dense paints, increase the air pressure to the pump motor (do
not exceed 8 bar). Use the fluid pressure regulator to dose the desired
amount of product. Said device works up to a max. operating pressure. of 3
Bar. Act on the fluid pressure regulator (7) to adjust the quantity of paint
dispensed.
END OF THE WORK SESSION
When the supply air to the system is removed, residual pressure remains
in the product passage pipes which can cause serious physical injury,
spraying large quantities of harmful substances on the body. First,
release the residual pressure
Remove air from the system.
Almost completely screw the handwheel to adjust the needle stroke of
the spray gun. Close the atomizing air of the gun by directing the jet into
the paint container.
Open the pump return cock.
Thoroughly clean the unit.
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PRESSURE DISCHARGE
When the supply air is removed, residual pressure remains in the product
passage pipes which can cause serious injury. First, release the residual
pressure:
• Remove air from the system.
• Screw the needle stroke regulating handwheel on the spray gun almost
completely.
• Close the atomizing air of the gun.
• Pull the control lever of the gun, directing the jet into the paint
container.
• Open the pump return cock.
• Without disconnecting the spray gun from the pump, clean the system:
• Lift the suction system out of the paint container and let it drain well. If
using the gravity tank, remove the return tube and place it in the paint
container.
• Regulate the supply air to the system at 1 bar and empty the paint from
the pump.
• Immerse the suction system in the solvent (or fill the gravity tank). Let
the solvent circulate inside the pump body for a few minutes.
• Close the return cock. The solvent arrives at the airbrush.
• Close the paint supply tap, pull the lever and discharge the paint into the
product can. Release the lever when the solvent appears.
• Pull the control lever discharging the solvent into the appropriate can,
through the airbrush for a few minutes. Open the return cock and close
the general supply air.
EMERGENCY SITUATIONS
FIRE: Use powder extinguishers, which must be located near the
equipment as required by LAW (Legislative Decree 81/08 safety in the
company) DO NOT USE WATER. Personnel must be trained to know how
to operate under such conditions.
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MAINTENANCE
Adequate maintenance is a decisive factor for a longer life of the equipment
in optimal operating and performance conditions, and ensures functional
safety over time. It is recommended to have the maintenance operations
carried out by trained personnel. Personnel must be provided with personal
protective equipment commonly used for similar operations, and follow the
safety procedures prescribed in the following chapter.
To keep the AST24 system in perfect working order, it is necessary to clean
it at each end of work and periodically check the filters, fittings and coupled
hose, replacing them if worn or damaged. It is necessary to prevent paint
residues from drying inside the system, compromising the functionality of
the system itself.
PERFORM MAINTENANCE ONLY WITH THE PUMP STOPPED AND ISOLATED
FROM THE POWER SUPPLY.
To isolate the machine from the power supply, close the pump air connection
cock POS.4 and disconnect the general supply pipe.
The main warnings to adopt when performing maintenance on the machine
are:
• Disconnect the air supply before removing any part of the unit or making
any replacement of components.
• Do not wear rings, watches, chains, bracelets, etc. during maintenance
operations.
• Always use personal protective equipment (gloves, goggles, safety
shoes).
• Use only original spare parts.
• Do not use open flames, sharp points or pins for cleaning.
• Not smoking.
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CLEANING
The external surfaces of the unit must be cleaned at the end of each
working day or in any case at the end of each work. This allows you to
keep the unit in good condition. For external cleaning, the use of a soft
cloth soaked in thinner or a detergent solution is sufficient.
To ensure flawless operation of the equipment over time, the paint circuit
must be cleaned daily or in any case at the end of each job to prevent
product residues from drying inside the equipment. Cleaning must be
extended to the entire system, gun and hoses included. The entire
cleaning takes place without disassembling its components.
1. Lift the suction and recirculation pipes out of the product canister,
making them to drain.
2. Carry out the pressure relief procedure.
3. Immerse the tubes in a can containing clean solvent and let the
solvent circulate inside the pump for a few minutes, opening the supply
air (regulated at 2 bar) and the recirculation valve.
4. Close the circulation valve.
5. Release the lever safety catch and discharge the paint residues left in
the gun high pressure hose into the solvent can
(continue the operation until clean solvent appears).
6. Close the air supply, carefully open the recirculation valve and
discharge the cleaning solvent into the can. The recirculation cock must
remain open until the system is used again.
7. Clean the line filter by disassembling and washing it, paying particular
attention to the filter sieve and the gun.
8. Carefully clean the inside of the product passage gun head.
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FILTER REPLACEMENT
After about 100 hours of operation, it is necessary to clean or, if necessary,
replace the steel filtering element (sieve) of the filter. The efficiency of the
filter cartridge depends exclusively on the type of paint used. To replace it,
unscrew the cylinder (1) then remove the filter element (2), see figure
below.
Replace or clean the filter element, then reassemble everything.
Before opening the filter unit, release the pressure it contains by opening
the recirculation cock.
2- filter cartridge 1- filter body
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ANOMALY RESOLUTION
PROBLEMS POSSIBLE CAUSES SOLUTIONS
The pump doesn’t work No pressure inside
Check that there is pressure
in the supply air circuit, open
the air ball valve and the
pump pressure regulator.
• Press alternately the starter
buttons located on the sides
of the exchanger.
The pump running very well but
there is no paint to the spray
gun
No pressure in the
pump
• Check that there is pressure
in the supply air circuit, open
the air ball valve and the
pump pressure regulator.
• Check that the suction pipe
or the suction valves are not
blocked by hardened paint
residues.
The paint flow is insufficient
and does not vary by increasing
the supply pressure.
• Check that the suction
filter is not partially blocked.
• The paint has too high
viscosity.
• Spray gun nozzle hole
blocked by dry paint.
• Clean tube and filter.
• Dilute the paint according
to the manufacturer's
instructions.
• Clean tube and filter.
• Clean the nozzle needle
and cap without using
metal objects.
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SCHEDULED
MAINTENANCE
After about 100 hours of operation, it is necessary to clean or, if necessary,
replace the steel filtering element (sieve) of the filter. The efficiency of the
filter cartridge depends exclusively on the type of paint used. To replace it,
unscrew the cylinder (1) then remove the filter element (2), see figure
below.
Replace or clean the filter element, then reassemble everything.
Before opening the filter unit, release the pressure it contains by opening
the recirculation cock.
OPERATIONS FREQUENCE CONDITIONS
Daily Weekly Monthly* Half yearly *
Cleaning the complete unit
X
Operations to be performed with the
equipment stationary without carrying out
work activities
Check the hoses integrity
X
Check the ball valve working
X
Check the presence condensation
X
Check the clogging of the paint
filter
X
Operations to be performed with the
equipment stationary without carrying
out work activities
Check the clogging of the air filter
X
Check if the screws are fixed very well
X
Check pneumatic connection’s
X
Check pump membrane wear
X
Check pump shaft wear
X
(*) Operation to be performed just from trained and professional operators
EN

Spare parts
and components
FEED PUMPS
AST24
EN
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