Boyens Backservice Spruhboy 04s Airless User manual

Instruction manual
Sprühboy 04s
Airless
Hotline:
In case of malfunction please call our Hotline-No:
Tel.: [phone] / 96 37 38
Fax.: [phone] / 96 37 35
Before starting operation carefully read
and adhere to this instruction manual
and the safety advice!
Edition: 10.12 Article-No.: 3371

2Contents
Sprühboy 04s - Airless Edition 10.12
1 General hints........................................... 3
2 Basic safety instructions....................... 4
2.1 Obligations and liability............................. 4
2.2 Safety symbols ......................................... 4
2.2.1 General danger symbol ............................ 4
2.2.2 Attention symbol....................................... 4
2.2.3 Hint symbol............................................... 4
2.3 Intended use............................................. 5
2.4 Improper use ............................................ 5
2.5 Informing safety measures....................... 5
2.6 Training the personnel.............................. 5
2.7 Safety measures during normal
operation................................................... 5
2.8 Danger from residual energy.................... 5
2.9 Cleaning, maintenance, repair and
remedy of faults........................................ 6
2.10 Modifications............................................. 6
2.11 Cleaning and disposing ............................ 6
3 Description of the implement................ 7
3.1 Implement diagram...................................7
3.2 Functional description .............................. 8
3.3 Identification ............................................. 9
3.4 Technical data .......................................... 9
3.5 Technical features .................................. 10
4 Putting into operation ..........................11
4.1 General requirements on the
compressed-air source........................... 12
4.2 Filling the stainless steel pressure
vessel ..................................................... 13
4.3 Fill the Sprühboy 04s with the required
agent pressure........................................ 14
4.4 Selecting and exchanging the
agent-nozzle ........................................... 15
4.5 The spraying procedure ......................... 16
5 Cleaning, maintenance and repair...... 17
5.1 Cleaning intervals................................... 18
5.2 Cleaning ................................................. 18
5.2.1 Spray gun and agent-hose ..................... 19
5.2.2 Entire implement..................................... 20
5.3 Cleaning the agent-nozzle...................... 21
5.4 Cleaning the mesch filter........................ 22
5.5 Hinged joint............................................. 23
5.6 Exchanging the seal kit ..........................24
6 Trouble shooting ..................................25
7 Spare part list........................................ 26
7.1 Spray gun ............................................... 26
7.2 Spare parts ............................................. 27
8 Guarantee..............................................29

General hints
3
Sprühboy 04s - Airless Edition 10.12
1 General hints
Identification data
Implement: Sprühboy 04s
Type: Airless
Serial number:
Year of construction:
Capacity:

The identification data are of
documentary value and may not be
changed or disguised.
Manufacturer
Name of company: boyens backservice GmbH
Street: Gildestraße 76-80
Town: D-49479 Ibbenbüren
Phone: [phone] / 96 37-0
Fax: [phone] / 96 37-16
http:// www.boyensbackservice.de
e-mail: [e-mail]
Spare parts ordering and after-sales service
Address as above
Phone: [phone] / 96 37-38
Fax: [phone] / 96 37-35
Documentary data
Version: Sprühboy 04s - Airless
Edition: 10.12
Purpose of this document
This instruction manual acquaints the operator of the
implement with:
•the way of function,
•the operation,
•the safety notes and
•the maintenance.
Operator personnel
This implement may only be operated, maintained
and repaired by persons, who are acquainted with
this and who have been informed about any
associated dangers.
Storing the instruction manual
Always keep this instruction manual with the
machine!
The instruction manual must always be at hand!
Transport and take-over
Always transport and store the implement upright.
The transport and storage temperature must be at
least +2°C and at most +50°C. The maximum
atmospheric humidity during storage may not exceed
90%.
Check the delivery immediately on receipt with the
aid of the shipping documents for:
•completeness and
•possible damage.
In case of damage in transit or loss, immediately
arrange for the damage to be recorded by the
forwarding agent for the purpose of asserting
compensation claims.
User evaluation
Dear reader,
Our operating instructions are updated at regular
intervals. Your improvement suggestions will help us
to continually make these instruction manual more
user friendly. Please send us your improvement
suggestions by fax or e-mail.
Copyright © 2012 by
boyens backservice GmbH
Gildestraße 76-80
D-49479 Ibbenbüren
Germany
All rights are reserved

4Basic safety instructions
Sprühboy 04s - Airless Edition 10.12
2 Basic safety instructions
This instruction manual contains the most important
information for a safety conscious operation of this
implement.
2.1 Obligations and liability
Observe the information contained in the instruction
manual: A basic requirement for a safety conscious
handling and a trouble-free operation of this
implement is the knowledge of the basic safety hints
and safety advice. This instruction manual, especially
the safety hints, must be observed by all persons who
operate the implement. In addition, the rules and
regulations for the prevention of accidents applicable
at the place of application have to be observed.
Dangers when operating the implement:
The implement Sprühboy 04s has been designed
according to the state of the art and approved safety
regulations in accordance with good engineering
practices according to Article 3, paragraph 3 of the
Pressure Equipment Directive 97/23/EC.
Nevertheless dangers for the health and life of the
user or third parties or impairments to the implement
or other material assets may arise during its use.
The implement may only be used:
•for the intended use,
•in a perfect condition as far as safety is
concerned.
Faults which might affect safety must be remedied
immediately.
Guarantee and liability:
In principle, our "General conditions of sale and
delivery" are applicable". These have been available
to the user at the latest since conclusion of the
contract. Warranty and liability claims for personal
injury or damage to property shall be excluded if they
result from one or several of the following reasons:
•use contrary to the intended use of the implement,
•Improper mounting, commissioning, operating and
maintenance of the equipment,
•use of the implement with faulty safety equipment
or improperly fitted or inoperative safety devices
and guards,
•not adhering to the hints in the instruction manual
regarding transport, storage, assembly, putting to
operation, maintenance and setting up the
implement,
•unauthorised structural changes to the equipment,
•inadequate monitoring of implement wearing
parts,
•improper repair work,
•catastrophes caused by alien elements and acts
of god.
2.2 Safety symbols
In the instruction manual the following terms and
signs for dangers are used:
2.2.1 General danger symbol
This symbol indicates a direct danger for life and
health of persons. Not adhering to these hints will
cause severe danger for health up to injuries with
high danger to life.
2.2.2 Attention symbol

This symbol gives important hints for the appropriate
handling of the implement. Not adhering to these
hints may cause faults on the implement itself or in its
environment.
2.2.3 Hint symbol

This symbol offers you hints for operation and
especially useful information. They will help you to
make best use of all functions on your implement.

Basic safety instructions
5
Sprühboy 04s - Airless Edition 10.12
2.3 Intended use
The implement Sprühboy 04s has exclusively been
designed for the common use to decorate bakery
products with egg wash or glazing agents and to
greasing and spraying baking tins and baking trays.
Our equipment is suitable for all common egg wash
products and glazing agents. High-quality parting
waxes and non-resinous cutting and sliding oils are
used as baking parting agents. Spraying of other
agents, apart from air and water to clean the
implement, requires the prior explicit written
permission of Messrs. boyens backservice GmbH.
Any use beyond the one stipulated above shall be
considered use contrary to the intended use. The
manufacturer does not accept any liability for
personal injuries and damage to property resulting
from this. The operator himself carries the full risk for
this.
Intended use also means:
•observing all hints in the instruction manual and
•adhering to the inspection and maintenance work.
2.4 Improper use
Using the implement for other purposes than
stipulated above is prohibited. In case of improper
use, danger for human beings and animals may
result. Such improper using includes, e. g.:
•heating or spraying of, e. g. acids, lyes in
particular salt solution and solvent agents or
•other liquids, especially inflammable ones.
2.5 Informing safety measures
Always keep the instruction manual on the
implement. In addition to these instruction manual
make available and observe the generally and locally
applicable accident prevention and environmental
protection advice. Further more adhere to the general
health- and labour medical regulations and hygienic
precautions.
Keep all safety- and danger hints on the implement
readable and clean and exchange if necessary.
2.6 Training the personnel
Only trained and advised personnel may operate this
implement. The responsibility of the personnel must
be clearly determined for operating, conversion and
maintenance. Semi-skilled personnel may only
operate the implement under supervision of an
expert.
2.7 Safety measures during normal
operation
Only operate the implement with all guards fully
functioning. Check the implement for externally
noticeable damage at least once a day.
Never leave your implement unattended while the
implement is connected to a compressed-air system.
Protect the spray gun during spraying pauses against
unintentional spraying by turning the locking device.
Do not drag the implement along behind you by the
agent hose. Protect the agent hose against heat
sources and sharp edges.
Only spray aiming at the baking tins, baking trays or
bakery products, never aiming at people or animals.
Keep children, animals and other persons away from
the operation area of the implement - always ensure
a sufficient clearance.
2.8 Danger from residual energy
Be aware of pneumatic residual energies on the
implement and take corresponding measures in this
connection when instructing operating personnel.
Detailed hints will be given once more in the
individual chapters of this instruction manual.

6Basic safety instructions
Sprühboy 04s - Airless Edition 10.12
2.9 Cleaning, maintenance, repair and
remedy of faults
Carry out prescribed cleaning, maintenance and
inspection work in due time. Prior to all maintenance,
inspection and repair work:
•separate the implement from the compressed air
source and then
•actuate the spray gun and thus discharge the
residual air pressure in the system.
Check the firm seat of screw connections that have
been unscrewed beforehand. On completion of
maintenance work, check the function of all safety
devices.
2.10 Modifications
Never change anything on the implement, do not add
anything to the implement and do not convert the
implement without approval of the manufacturer.
All conversions require the written approval of
Messrs. boyens backservice GmbH.
Immediately exchange faulty implement parts.
Only use original spare- and wearing parts.
When using non original parts it cannot be
guaranteed that they had been designed and
manufactured in such a way that they correspond to
the operational and safety prescriptions.
2.11 Cleaning and disposing
Only use air, grease solvent and hot rinsing water for
cleaning purposes. Handle and dispose of all agents
and material in an appropriate manner.
To clean the implement, only use:
•a moist sponge or a moist cloth,
•never a high pressure cleaning device.

Description of the implement
7
Sprühboy 04s - Airless Edition 10.12
3 Description of the implement
3.1 Implement diagram
(1) Stainless steel pressure vessel
(2) Pressure vessel cover
(3) Pressure vessel cover closure
(4) Bleed valve, serves at the same time as
pressure-limiting valve
(5) Spray gun
(6) Spray gun retainer
(7) Agent-hose
(8) Agent vessel connection piece with non-return
valve nominal width (NW) 7.2
(9) Rapid coupling product
(10) Compressed air inlet connection with non-return
valve for external compressed air source The
inlet air pressure of the external compressed air
system may not exceed 6 bar

8Description of the implement
Sprühboy 04s - Airless Edition 10.12
3.2 Functional description
The Sprühboy 04s is an implement for low-
fog
spraying of egg wash, glazing agents or high-
quality
parting waxes and non-
resinous cutting and sliding
oils.
The Sprühboy 04s
consists of the stainless steel
pressure vessel (1) and the spray gun (2).
The special pressure-
relief valve technology
facilitates a safe, loss-fr
ee and rapid extraction of
parting agent from the stainless steel pressure
vessel. Unnecessary parting agent residues are
avoided.

Description of the implement
9
Sprühboy 04s - Airless Edition 10.12
3.3 Identification
The stainless steel pressure vessel's identification is
engraved directly onto the stainless steel vessel.
You will find the type plate on the back side of the
implement.

The implement Sprühboy 04s has been
designed according to the state of the
art and approved safety regulations in
accordance with good engineering
practices according to Article 3,
paragraph 3 of the Pressure Equipment
Directive 97/23/EC.
3.4 Technical data
Maximum permissible operating
pressure (PS): 6 bar
Minimum / maximum permissible
operating temperature (TS): -20°C to +80°C
Energy supply: An external compressed air source with a minimum pressure of 5
bar is required.
Compressed air connection: Nominal width (NW) 7.2
Agent pressure: at least 5 bar, at most 6 bar
Pressure relief valve, integrated in
bleed valve: Set to maximum 6 bar at the factory
Stainless steel pressure vessel content: 5 litres
Weight: 2.4 kg
Measurements: Diameter: 210 mm
Height: 250 mm
Length agent hose: 1.5 m
Agent-hose: Silicone
Spray gun: Airless

10 Description of the implement
Sprühboy 04s - Airless Edition 10.12
3.5 Technical features
•Portable implement – particularly flexible use
•Absolutely hygienic acc. to HACCP
•Simple operation
•Most economic product processing
•Clean working
•Low-fog spraying of products
•Stainless steel pressure vessel 5 litres
•Special hoses
•Rapid coupling product
•Agent vessel connection piece with non-return
valve
•Compressed air vessel connection piece with
non-return valve
•Ergonomic spray gun with a bayonet lock for
quick change of nozzles

Putting into operation
11
Sprühboy 04s - Airless Edition 10.12
4 Putting into operation
When operating the implement it is
imperative to observe the instructions
regarding the
•intended use
•training of personnel.
Never leave the implement unattended
while the implement is connected to an
external compressed air system.
Never drag the implement along behind
you by the agent hose.
Protect the spray gun during spraying
pauses against unintentional spraying
by turning the locking device (1).

12 Putting into operation
Sprühboy 04s - Airless Edition 10.12
4.1 General requirements on the
compressed-air source
For filling with compressed air that is safe for all
foods, the implement may be connected to an
existing compressed air source or to the compress
or
Airboy 04
. The implement requires a material
pressure of at least 5 bar and a maximum of 6 bar.
The implement may only be operated with food safe
compressed air.

You may only fill the implement with a
maximum agent pressure of 6 bar. If
your compressed-
air source has no
means of limiting the maximum agent
pressure to 6 bar, we recommend the
use of our compressed-
air control unit
(1).

It is i
mperative that you use only clean,
dry and food safe compressed air to
operate the implement. Oil lubricated
compressors, possibly with pressure
vessel with uncoated inside,
contaminate the compressed air and
consequently the agent to be sprayed.
If no fil
ter unit (maintenance unit) to
clean the compressed air and also no air
dryer is available behind the
compressor, oil and rust particles get
into the stainless steel pressure vessels
enter and contaminate the agent.

If your present compressed-air
source
does not meet the above requirements,
we recommend you use our three-
stage
special filter unit.
The three-stage special filter unit consists of:
1. 1 x DV 1000. Prefilter
with filter element and
automatic condensate discharge with float valve
and differential pressure manometer.
2. 1 x DF 1000. Superfine filter
with filter element
and automatic condensate discharge with float
valve and differential pressure manometer. For
higher quality compressed air for pneumatic
control systems.
3. 1 x DA 1000. Activated-carbon filter
with filter
element, stopper and closing plate. For highest
quality compressed air as inhaled air, e.g. in
luxury food processing.
4. 2 x Filter housing threaded joint.
For
connection of filter units.
5. 1 x Assembly kit. For wall fastening of fi
lter
units.

Putting into operation
13
Sprühboy 04s - Airless Edition 10.12
4.2 Filling the stainless steel pressure vessel
Always pull the bleed valve (1) until the
excess pressure has been completely
discharged fr
om the stainless steel
pressure vessel (2). If the hissing noise
stops, the stainless steel vessel has
been depressurised and you can open
the pressure vessel cover.
-
Separate the compressed air supply from the
external compressed air source. Refer to chapter
"Filling the Sprühboy 04s with the required agent
pressure", page 14 in this regard.
-
Pull the bleed valve (1) until the hissing noise
stops.
-
Swing the pressure vessel cover closure (4) to the
top.
- Turn the pressure vessel cover closure (1) by 90°.
-
Remove the pressure vessel cover (2) from the
stainless steel pressure vessel opening.
-
Fill the stainless steel pressure vessel via the
stainless steel pressure vessel opening at the
most up to the red mark (3).

Only fill the stainless steel pressure
vessel with lump-
free, clear products. If
the product is not lump-
free, the agent
nozzle in the spray gun will clog.
-
Close the stainless steel pressure vessel with the
pressure vessel cover (2) in reverse order.
-
Fill the stainless steel pressure vessel with an
agent pressure of 6 bar.

14 Putting into operation
Sprühboy 04s - Airless Edition 10.12
4.3 Fill the Sprühboy 04s with the
required agent pressure

It is imperative that you comply with the
chapter "General requirements on the
compressed air source", page 12.

The external compressed air source
must supply a minimum pressure of 5
bar.
The desired spray pattern determines
the required agent pressure.
The agent pressure must be at least
5 bar to result in
a reasonable spray
pattern.
The bleed valve (1) opens if the
maximum permissible implement
pressure of 6 bar is exceeded.
- Connect the comp
ressed air connection (2) from
the Sprühboy 04s via the spiral hose (3) to an
external compressed air source, here to the
compressed air connection (4) from the
compressor Airboy 04.

The external compressed air source fills
the Sprühboy 04s with compressed air.
-
Switch on the compressor Airboy 04. The
compressor starts and fills the Sprühboy 04s with
compressed air. If the permissible operating
pressure (6 bar) has been reached, the
compressor switches off automatically.
- Pull the spiral hose off the c
ompressed air
connection (2) on the Sprühboy 04s.
- The Sprühboy 04s is now ready for operation.

Putting into operation
15
Sprühboy 04s - Airless Edition 10.12
4.4 Selecting and exchanging the
agent-nozzle
Three different agent nozzles (type TP-
nozzle) with
different nozzle cross-
sections are available to
choose from:
•TP-nozzle '50', Article-No.: 943.
•TP-nozzle '33', Article-No.: 1347.
•TP-nozzle '25', Article-No.: 1407.
Exchanging the agent-nozzle
- Secure the spray
gun by means of the locking
device (1) against unintended spraying.
-
Manually slacken the bayonet cap (2) and
remove.
- Remove the agent-
nozzle (3) from the bayonet
cap.
- Insert another agent-nozzle into the bayonet cap.
- Screw the bayonet cap back onto the spray gun.

16 Putting into operation
Sprühboy 04s - Airless Edition 10.12
4.5 The spraying procedure
Only spray aiming at the bakery
products, baking tins or baking trays,
never aiming at people or animals.
Spraying bakery products, baking tins or baking
trays:
- Unlock the spray gun locking device (1).
-
Hold the spray gun at a distance of approx. 10 cm
directly above the bakery products, baking tin or
baking tray.
- Pull the spray gun trigger (2) and s
pray the bakery
products, baking tin or baking tray.

The desired spray pattern determines
the required agent pressure. The agent
pressure must be at least 5
bar and at
most approx. 6 bar.
Interrupting the spraying procedure:
-
Release the trigger (2). The agent immediately
stops discharging from the spray gun.
At the end of work, lock the spray gun
locking device (1) against unintentio
nal
spraying and place the spray gun into
the spray gun retainer (3).

Fill the Sprühboy 04s with the required
agent pressure if there are deviations
from the desired spray pattern.

Cleaning, maintenance and repair
17
Sprühboy 04s - Airless Edition 10.12
5 Cleaning, maintenance and
repair

Carry out prescribed cleaning and
maintenance work in due time. Prior to
all cleaning, maintenance and repair
work
•
separate the implement from the
compressed air source.
•
discharge the excess pressure from
the stainless steel pressure vessel.
Refer to chapter "Filling the stainless
steel pressure vessel", page 13
in this
regard.
Most malfunctions are caused by
contamination of the compressed air and
the agent to be processed.

Agent nozzle, mesch filter and seal kit
are wearing parts. We
recommend you
always keep one spare set of these
components in stock.

To clean the implement, only use
•hot rinsing water.
•grease solvent.
•disinfecting cleaning agents.
•compressed air.
•a moist sponge or a moist cloth.
•
never a high pressure cleaning
device.
•
never any alkaline solutions, in
particular no salt brines.
Dispose of all cleaning residues incurred
in an environmentally compatible
manner.
Clean the agent-
hose at regular
intervals.

In case of leaks in the compressed air
system, slightly ti
ghten screw
connections on the spray gun and other
compressed air system components.
These bolted connections may work
loose:
•
because the system is constantly
moving due to the compressed air
and the agent to be sprayed.
•because of improper handling, e.g.
if
the spray gun is dropped.

Every operator may check compressed
air supplies and repair leaky
compressed air supplies.

18 Cleaning, maintenance and repair
Sprühboy 04s - Airless Edition 10.12
5.1 Cleaning intervals
Clean the agent hose with the spray gun daily. Use
the cleaning adapter WRA for this purpose (1).
5.2 Cleaning

There are two different kinds of cleaning
processes:
•
cleaning the spray gun and agent
hose at the end of every production
run, e.g. if the fi
lled stainless steel
pressure vessel is stored in cold
storage and
•cleaning the entire implement.
Always clean the spray gun and the
agent hose at the end of every
production run with hot rinsing water
and a disinfecting, grease solving
cleaning agent.

Rinse the implement for hygienic
reasons with hot rinsing water regularly.
Also carry out this cleaning process with
disinfecting cleaning agents. Rinse the
implement very thoroughly with clear
water after every use of disinfecting
cleaning agents. Comple
tely spray out
any water residues. Use compressed air
to blow dry the individual components.
The vessel must be absolutely dry
before it is filled again. If even a single
drop of water gets into the system, this
water drop could get lodged in front of
the
agent nozzle and prevent agent
discharging from the nozzle.

Cleaning, maintenance and repair
19
Sprühboy 04s - Airless Edition 10.12
5.2.1 Spray gun and agent-hose
If you do not wish to clean the entire system, the
cleaning adapter WRA (1) facilitates rapid cleaning of
spray gun and agent-
hose at the end of a production
run.

However, for hygienic reasons, rapid
cleaning of spray gun and agent-
hose
cannot replace complete cleaning, as
described in chapter "Complete device"
,
page 20.
-
Pull the rapid coupling (1) from the agent vessel
connection piece (2).
-
Connect the cleaning adapter WAR (1) to a water
pipe carrying hot water.
-
Connect rapid coupling (2) and cleaning adapter
WAR (1).
-
Turn on the water supply and spray until a clean,
clear jet of water issues from the spray gun. If
clear water issues fr
om the spray gun, the agent
channel has been cleaned.

20 Cleaning, maintenance and repair
Sprühboy 04s - Airless Edition 10.12
5.2.2 Entire implement
-
Separate the compressed air supply from the
external compres
sed air source. Refer to chapter
"Filling the Sprühboy 04s with the required agent
pressure", page 14 in this regard.
-
Pull the bleed valve until the hissing noise stops.
Refer to chapter "Filling
the stainless steel
pressure vessel", page 13 in this regard.
-
Pull the rapid coupling (1) from the agent vessel
connection piece (2).
-
Put down the agent hose with the spray gun in a
safe place.
- Open the
pressure vessel cover once the stainless
steel pressure vessel is pressure less. Refer to
chapter "Filling the stainless steel pressure
vessel", page 13 in this regard.
- Empty the stainless steel pressure vessel.
-
Fill the stainless steel pressure vessel with hot
rinsing water and disinfecting cleaning agent.
-
Reseal the stainless steel pressure vessel with the
pressure vessel lid cover.
-
Vigorously shake the stainless steel pressure
vessel.
- Empty the stainless steel pressure vessel.
-
Dispose of the cleaning residues in an
environmentally compatible manner.
-
Refill the stainless steel pressure vessel with
approx. 2 litres of hot rinsing water and
disinfecting cleaning agent.
- Reseal the stainless steel pressure
vessel with the
pressure vessel lid cover.
-
Push the rapid coupling (1) back onto the agent
vessel connection piece (2).
- Connect the compressed
air supply with the
external compressed air source.
- Fill the implement with compressed air.
-
Afterwards, spray the entire contents of the
stainless steel pressure vessel into a collecting
basin. Agent hose and spray gun are cleaned
through this.
- Afterwards
, fill the stainless steel pressure vessel
once more with clear rinsing water.
-
Rinse the entire system with the clear rinsing
water.
- Afterwards, clean the spray gun's agent-nozzle.