wiwa 250 User manual

Operation manual
Original operation manual
SPAM250_300_0550002_en_1608 • jw
Airless automatic spray gun
WIWA 250 / 300

2 Original operation manual WIWA Automatic 250 / 300
SPAM250_300_0550002_en_1608 • jw

Contents
4 Original operation manual WIWA Automatic 100 / 400
SPAM250_300_0550002_en_1608 • jw
Contents
1 Foreword ................................................................................. 7
2 Safety....................................................................................... 8
2.1 Explanation of symbols............................................................. 8
2.2 Safety notes............................................................................ 10
2.2.1 Working pressure .......................................................... 10
2.2.2 Risks due to the spray jet ...............................................11
2.2.3 Risks due to electrostatic charge....................................11
2.2.4 Risk due to hot surfaces ................................................ 12
2.2.5 Explosion protection ...................................................... 12
2.2.6 Health risks.................................................................... 13
2.3 Operating and maintenance personnel .................................. 14
2.3.1 Obligations of the device owner .................................... 14
2.3.2 Personnel qualications................................................. 14
2.3.3 Authorized operator ....................................................... 14
2.3.4 Personal protective equipment ...................................... 15
2.4 Guarantee instructions ........................................................... 15
2.4.1 Spare parts .................................................................... 15
2.4.2 Accessories ................................................................... 16
2.5 How to respond in an emergency........................................... 16
2.5.1 Leakage......................................................................... 16
2.5.2 Injuries ........................................................................... 16
3 Device description................................................................ 17
3.1 Intended use........................................................................... 17
3.2 Erroneous use ........................................................................ 18
3.3 Device design ......................................................................... 18
3.4 Model overview....................................................................... 19
3.5 Optional expansions and accessories .................................... 20
4 Transport and assembly ...................................................... 22
4.1 Assembly ................................................................................ 22
4.1.1 Insert the spray nozzle .................................................. 22
4.1.2 Installing the spray gun.................................................. 23
4.1.3 Connecting the material hose........................................ 23
4.1.4 Connecting the control air.............................................. 24

Original operation manual WIWA Automatic 250 / 300 5
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5 Operation............................................................................... 25
5.1 Putting the spray gun into operation....................................... 25
5.1.1 Setting the spraying pressure........................................ 25
5.1.2 Tips for good coatings ................................................... 25
5.2 Work interruption .................................................................... 26
6 Maintenance.......................................................................... 27
6.1 Maintenance schedule............................................................ 27
6.2 Retightening the packing ........................................................ 28
6.3 Replacing the sleeves ............................................................ 29
7 Troubleshooting ................................................................... 30
7.1 Replacing the valve needle .................................................... 31
7.1.1 For WIWA automatic spray gun 250.............................. 31
7.1.2 For WIWA automatic spray gun 300.............................. 32
7.2 Replacing the valve seat ........................................................ 33

6 Original operation manual WIWA Automatic 250 / 300
SPAM250_300_0550002_en_1608 • jw
Copyright
© 2016 WIWA
The copyright to this operation manual belongs to
WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestr. 1-3 • 35633 Lahnau • Germany
Tel.: [phone] • Fax: [phone] • Email: [email protected]
Website: www.wiwa.de
This operation manual is intended exclusively for the preparation, operating
and maintenance personnel. It is expressly prohibited to distribute this
operation manual, duplicate, exploit or communicate its contents, unless
expressly authorized to do so. Infringement will lead to compensation.
All rights to any patent, utility model or design registrations reserved.

Foreword
Original operation manual WIWA Automatic 250 / 300 7
SPAM250_300_0550002_en_1608 • jw
1 Foreword
Dear valued customer,
We are delighted that you have chosen one of our spray guns.
This operation manual is directed at the operating and maintenance
personnel. It contains all information required in order to handle this
device.
The device operator must ensure that the operating and
maintenance personnel always have access to a copy of the
operation manual in a language that they understand.
In addition to the operation manual, further information is also
essential to operate the device safely. Read and observe the
directives and accident prevention regulations valid in your country.
In Germany, these are:
➤ZH 1/406 "Guidelines for uid jets (spray devices)" from the
Federation of Institutions for Statutory Accident Insurance and
Prevention,
➤BGR 500, chap. 2.29 "Processing Coating Materials",
➤BGR 500, chap. 2.36 "Working with uid jets", both from the
professional association for gas, district heating and water
management.
We recommend enclosing all relevant directives and accident
prevention regulations with the operation manual.
Furthermore, always observe the manufacturer's instructions and
processing guidelines for coating or conveyance materials.
If questions should arise, we shall be happy to assist you.
WIWA Wilhelm Wagner GmbH & Co. KG wishes you successful
results with your spray gun.

Safety
8 Original operation manual WIWA Automatic 250 / 300
SPAM250_300_0550002_en_1608 • jw
2 Safety
This device has been designed and manufactured considering
all safety aspects. It reects current engineering practice and the
valid accident prevention regulations. The device left the factory in
faultless condition and guarantees a high level of technical safety.
However, improper operation and misuse will pose a risk to:
➤the life and limb of the operator or third parties,
➤the device and other property of the owner,
➤efcient work with the device.
It is fundamentally prohibited to implement any methods of work
that have a negative inuence on the safety of the operating
personnel and the device. All persons involved in the installation,
commissioning, operation, care, repair and maintenance of the
device must have read and understood the operation manual
beforehand - in particular the "Safety" chapter.
Your safety depends on it!
We recommend that the device owner has this conrmed in writing.
2.1 Explanation of symbols
Safety notes give warning of potential accident risks and describes
the measures required for accident prevention.
In the operation manual from WIWA, safety notes are highlighted
and labeled as follows:
DANGER
Signals a risk of accidents that are very likely to result in serious
injuries and even death, if the safety note is not observed!
WARNING
Signals a risk of accidents that may result in serious injuries and
even death, if the safety note is not observed!
CAUTION
Signals a risk of accidents that may result in injuries, if the safety
note is not observed!

Safety
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Signals important information for working correctly with the
device. A failure to observe this may result in damage to the
device or its environment.
Various pictograms are used in the safety notes for accident
risks that may result in injury, depending on the hazard source -
examples:
General risk of accident
Risk of explosion due to explosive atmosphere
Risk of explosion due to explosive substances
Risk of accident due to electricity
or electrostatic charge
Risk of crushing due to moving machine parts
Risk of burning due to hot surfaces
The rst line of the safety instructions indicates safety devices
that must be incorporated. This is also highlighted and labelled as
follows:
Wear protective clothing
Signals an instruction to wear the prescribed protective clothing,
in order to prevent skin injuries due to spray material or gases.
Use eye protection
Signals an instruction to wear protective goggles, in order to
prevent eye injuries due to material spray, gases, vapours or dust.
Use ear defenders
Signals an instruction to wear ear defenders, in order to prevent
damage to hearing caused by noise.

Safety
10 Original operation manual WIWA Automatic 250 / 300
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Use respiratory protection
Signals an instruction to use respiratory protection, in order
to prevent damage to the respiratory tract caused by gases,
vapours or dust.
Wear protective gloves
Signals an instruction to wear protective gloves with forearm pro-
tection, in order to prevent a risk of burns due to heated material.
Wear safety shoes
Signals an instruction to wear safety shoes, in order to prevent
foot injuries due to falling, toppling or rolling objects, as well as
slipping on slippery oors.
Signals references to directives, work instructions and operation
manuals that contain very important information and must be
observed.
2.2 Safety notes
Always remember that the spray gun is operated with very high
pressures and can cause life-threatening injuries if handled
incorrectly!
Always observe and follow all the information in this operation
manual and in the operation manual of the spraying device on
which the spray gun is operated.
2.2.1 Working pressure
WARNING
Devices which are subjected to a higher pressure than the
maximum permitted working pressure for which they are
designed can burst and cause serious injuries.
➤The maximum permitted working pressure of the spray gun
must be the same or greater than the maximum permitted
operating pressure of the spraying device on which it is
operated.
➤Material hoses and hose connections must comply with the
maximum working pressure including the required safety
factor.

Safety
Original operation manual WIWA Automatic 250 / 300 11
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➤Material hoses may not exhibit leakage, kinks, signs of wear
or bulges.
➤Hose assemblies must be tight.
2.2.2 Risks due to the spray jet
WARNING
The material exits the spray gun under very high pressure. The
spray jet can cause serious injuries through its cutting action, or
by penetrating the skin or eyes.
➤Never aim the spray gun at yourself, other persons or
animals!
➤Never hold the nger or hand in front of the spray gun!
➤Never reach into the spray jet!
➤Always hold the spray gun tightly in your hands while working
since great recoil forces can arise at high working pressures.
WARNING
An unintended ejection of material from the spray gun can cause
personal injury and property damage.
➤Lock the spray gun with all interruptions to work!
➤Prior to each commissioning, always check the spray gun
lock!
2.2.3 Risks due to electrostatic charge
WARNING
The high ow velocities during the airless spray process can
result in an electrostatic charge. Static discharges can result in
re and explosions.
➤Make sure that the spraying device on which the spray gun is
operated and the object to be coated are correctly earthed!
➤Always use open containers!
➤Never spray solvents or materials containing solvents into
narrow-mouthed cans or barrels with a bung opening!

Safety
12 Original operation manual WIWA Automatic 250 / 300
SPAM250_300_0550002_en_1608 • jw
➤Set the container down on an grounded surface.
➤Use electrically conductive containers.
➤Always ensure contact between the spray gun and the
container wall.
➤Only use electrically conductive material hoses.
All original material hoses from WIWA are conductive and
designed for our devices.
WARNING
Dirty devices can become electrostatically charged. Fire and
explosion can be triggered by severe static discharges.
➤Keep the machine clean.
➤Always perform the cleaning work outside of EX zones.
2.2.4 Risk due to hot surfaces
CAUTION
The spray gun can get hot when using material heaters on the
spraying device being used. A risk of burns exists.
➤When processing heated materials always wear protective
gloves with forearm protection.
2.2.5 Explosion protection
WARNING
Devices that are not explosion-protected must not be used
in operating facilities that fall under the explosion protection
ordinance!
Explosion-protected devices full the requirements of directive
94/9/EC for the device group, device category and temperature
class cited on the device or in the declaration of conformity.
The owner is responsible for designating the zoning according
to the stipulated guidelines of 94/9/EC, Annex II, No. 2.1-2.3 in
accordance with the provisions of the responsible regulatory body.
The owner is required to check and ensure that all technical data
and labelling comply with the applicable stipulations according to
ATEX.
For applications, whereby a failure of the device could lead

Safety
Original operation manual WIWA Automatic 250 / 300 13
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to dangers to personnel, the owner is required to implement
appropriate safety measures.
WARNING
Heating solvents can lead to an explosion. Serious personal
injuries and property damage may result.
➤Observe the ashpoint and ignition temperature of solvents.
➤Never immerse a hot spray gun in solvent.
2.2.6 Health risks
CAUTION
Depending on the materials being processed, solvent vapours
may arise, which could lead to damage to health and property.
➤Make sure the workplace is sufciently ventilated and aired.
➤Always observe the processing instructions of the material
manufacturer.
When handling paint, solvents, oils, greases, and other chemical
substances, observe the safety and portioning instructions of the
manufacturer and the generally applicable regulations.
Only use suitable skin protection, skin cleansing and skincare
products for cleansing the skin.
In systems that are closed or under pressure, dangerous
chemical reactions may arise, if parts produced from aluminium
or galvanised parts come into contact with 1.1.1 - trichloroethane,
methylene chloride or other solvents that contain halogenated
chlorinated hydrocarbons (CFCs). If you wish to process materials
that contain the aforementioned substances, we recommend
that you contact the material manufacturer in order to clarify their
suitability for use.

Safety
14 Original operation manual WIWA Automatic 250 / 300
SPAM250_300_0550002_en_1608 • jw
2.3 Operating and maintenance personnel
2.3.1 Obligations of the device owner
The device owner:
➤is responsible for training the operating and maintenance
personnel,
➤must instruct the operating and maintenance personnel on
correct handling of the device, and on wearing the correct work
clothing and protective equipment,
➤must make the user manual accessible to the operating and
maintenance personnel and must ensure that this remains
constantly available,
➤must ensure that the operating and maintenance personnel
have read and understood the user manual.
➤Only then are they permitted to put the device into operation.
2.3.2 Personnel qualications
Differentiation is made between 2 groups of personnel, depending
on their qualications:
➤Instructed operator has received veried instruction from the
device owner regarding the tasks entrusted to him and the
possible risks in the event of incorrect conduct.
➤Trained personnel are capable - due to instruction provided
by the device manufacturer - of carrying out maintenance and
repair work on the device, independently recognising possible
dangers and avoiding risks.
2.3.3 Authorized operator
Activity Qualication
Set-up and operation Instructed operator
Cleaning Instructed operator
Maintenance Trained personnel
Repair Trained personnel
Young persons under the age of 16 are not permitted to operate
this device.

Safety
Original operation manual WIWA Automatic 250 / 300 15
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2.3.4 Personal protective equipment
Wear protective clothing
Always wear the protective clothing stipulated for your working
environment (e.g. mining, enclosed spaces etc.) and also
observe the recommendations in the safety data sheet of the
material manufacturer.
Use eye protection
Wear protective goggles to prevent eye injuries due to material
spray, gases, vapours, or dust.
Use ear defenders
The spray gun itself does not cause any noise. However,
depending on the sound pressure level of the spraying device
used, the operating personnel must be provided with suitable
noise protection devices, if necessary.
Use respiratory protection
Although the airless spray process minimizes the paint mist with
the right pressure adjustment and correct method of work, we
recommend that you wear a respiratory protection mask.
Wear protective gloves
When processing heated materials, wear protective gloves with
forearm protection in order to prevent burns.
Wear safety shoes
Wear safety shoes to prevent foot injuries due to falling, toppling
or rolling objects, as well as slipping on slippery oors.
2.4 Guarantee instructions
Observe our general terms and conditions of business (T&Cs) at
www.wiwa.de.
2.4.1 Spare parts
➤When maintaining and repairing the device, only use original
spare parts from WIWA.

Safety
16 Original operation manual WIWA Automatic 250 / 300
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➤If spare parts are used, that have not been produced or
supplied by WIWA then the guarantee is voided and all liability
shall be excluded.
2.4.2 Accessories
➤If you use original accessories from WIWA, their suitability for
use in our devices is guaranteed.
➤If you use third-party accessories, these must be suitable for
the device - in particular with respect to the working pressure
and the connection variables. WIWA shall not be liable for any
damage or injuries arising due to these parts.
➤It is essential to observe the safety provisions applicable to
the accessories. You can nd these safety provisions in the
separate operation manual for the accessories.
2.5 How to respond in an emergency
2.5.1 Leakage
WARNING
In case of leakage, material may escape under very high pressure
and cause serious physical injuries and property damage.
➤Immediately shut down the spraying device and relieve the
pressure. Observe and follow the information in the user
manual of the spraying device for this.
➤Tighten threaded connections and replace defective parts
(must be performed by trained personnel).
➤Do not seal leakage at connections and on high pressure
hoses with the hand or by wrapping.
➤Do not patch material hoses!
➤Check hoses and threaded connections for leak-tightness
when starting the spraying device up again.
2.5.2 Injuries
If case of injuries caused by processing material or solvents,
always have the manufacturer's safety data sheet ready to show
the doctor (supplier or manufacturer address, their telephone
number, material designation and material number).

Device description
Original operation manual WIWA Automatic 250 / 300 17
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3 Device description
The WIWA Automatic series 250 / 300 spray guns have been
developed especially for airless spraying in automatic painting and
coating units
The operating limits for which
your automatic spray gun is
approved can be found on
the spray gun cover.
This data is also engraved
directly onto the spray gun
cover like the CE and ATEX
marking.
No. Meaning
1 Serial number
2Max. working pressure
3 CE marking
4ATEX marking
Fig.1 Specications on the
spray gun cover
3
2
1
4
The WIWA Automatic series 250 / 300 spray guns can be used in
connection with all known airless spraying devices.
3.1 Intended use
The WIWA Automatic series 250 / 300 spray guns are intended
for installation on a spraying system in automatic painting and
coating mode. It is possible to arrange multiple automatic spray
guns next to each other simultaneously or in a circulation circuit.
The automatic spray gun is suitable for airless spraying of all uids
that can be sprayed. The automatic spray gun can also be used as
an automatic valve.
Intended use also includes:
➤observing the technical documentation and
➤complying with the operating, maintenance and servicing
guidelines.

Device description
18 Original operation manual WIWA Automatic 250 / 300
SPAM250_300_0550002_en_1608 • jw
3.2 Erroneous use
Any use other than that stipulated in the technical documentation
is deemed to be erroneous use and may result in personal injury or
property damage.
Erroneous use applies in particular if
➤impermissible materials are processed,
➤ unauthorized modications or changes are implemented,
➤ the safety features are modied, removed or bypassed,
➤ unsuitable spare or accessory parts are used (see chap. 2.4.1
and 2.4.2),
➤machines that are not marked as EX machines are used in
potentially explosive areas,
➤the machine is operated outside of the operating limits (see
type plate).
3.3 Device design
Fig.2 WIWA Airless automatic spray gun (cover and side view)
31 2 4
5
6
9
8 7
10
No. Designation
1 Through hole
2Protective cover for the packing screw
3 Double nipple for the connection of the material hose
4 Sleeve nut
(can be removed and replaced with a nozzle protector for
example)

Device description
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No. Designation
5Spray nozzle (not supplied as standard)
6Cap nut with ball (is removed for the connection of
a circulation or return ow hose)
7Screws for clamping the guide rail
8 "Open" control air connection
9 Gun body
10 "Close" control air connection or
opening for pressure relief
3.4 Model overview
The number in the model designation stands for the maximum
working pressure. This produces the following overview:
Type 250 300
Art no.
0630713 0630876 0632419 0642048 0642184 0630479 0640022
Valve needle ∅4 mm ∅3 mm
Material hose
connections
1 / 8"NPT(I)
1 / 4"NPT(A)
1 / 4"NPS(I)
1 / 4"NPT(A) 1 / 4"NPT(A)
1 / 4"NPS(A) 1 / 4"NPS(A)
Max. control
air pressure 8 bar
Control air
connection G 1 / 8"(I)
Max.
material
temp.
80 °C
Additional information on the thread and connection variables
can be found in the equipment lists.

Device description
20 Original operation manual WIWA Automatic 250 / 300
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3.5 Optional expansions and accessories
The following list contains just some of the most common
accessories and expansions. You can nd the detailed accessory
catalogue at www.wiwa.de. For further information and order
numbers, you can also contact a WIWA dealer or WIWA customer
service.
Standard nozzles
The standard nozzles can be used for all airless spray guns.
They are manufactured out of high-quality carbide. The nozzle
size conforms to the application of the spray gun. A tabular list of
the nozzle sizes and applications can be found in the accessory
catalogue.
Adjustable nozzles
They are especially suitable for
spraying highly abrasive material.
Adjustable nozzles can be used in
every airless spray gun.
Blockages on the nozzle can be easily remedied by briey
opening the nozzle. Furthermore, the spray jet can be set on the
adjustable nozzle without having to disassemble the nozzle from
the spray gun. Adjustable nozzles are suitable for a permitted
spraying pressure up to a maximum of 250 bar.
Reversible nozzles
These nozzles are manufactured out of high-quality carbide
and are suitable for all spray guns that are equipped with an
appropriate nozzle protector and a reversing switch. The nozzle
size conforms to the application of the spray
gun.
Nozzle lter (disc lter)
with housing, prevents clogging of
the spray nozzle.