wiwa AirCombi PHOENIX GX Series User manual

PHOENIX GX SERIES
Operation manual
Original operation manual
AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Airless /AirCombi spray devices

2Original operation manual
AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
EC declaration of conformity
according to Annex II No. 1 A of the Machine Directive 2006 / 42 / EC,
changed by 2009 / 127 / EC
The company WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestr. 1-3
35633 Lahnau
Germany
hereby declares
that the machine type Phoenix GX
with serial no. see technical data
conforms with the provisions of the above directives.
Responsible for documentation: WIWA GmbH, Tel. [phone]
Lahnau, 3/13/2018
Place, Date Graduate engineer Peter Turczak
Managing director
EC declaration of conformity
In accordance with ATEX Directive
The company WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestr. 1-3
35633 Lahnau
Germany
hereby declares
that the machine type Phoenix GX
with serial no. see technical data
conforms with the provisions of Directive 2014 / 34 / EU.
The listed machine is assigned to Group II Category 2G.
Labeling: II 2G cT4
Lahnau, 3/13/2018
Place, Date Graduate engineer Peter Turczak
Managing director

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AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Technical data
Manufacturer WIWA Wilhelm Wagner GmbH & Co. KG
35633 Lahnau, Germany
Designation PHOENIX GX
Type .......................................
Item no. ....................................
Serial no. ..................................
Date of manufacture ..........................
Pressure ratio ................................
Max. output at 60 DS (l/min / US gpm)..............
Delivery volume per DS (cm3 / US .oz.) ............
Max. air inlet pressure (bar/psi) / safety valve........
Maximum permissible working pressure (bar/psi) ....
Air consumption at 20 DS / min. at 1 bar (l/min / US gpm)
Air intake (maintenance unit) / connection thread .....
Material outlet (high pressure lter)................
Weight (kg / lbs) approx. ........................
Dimensions (LxWxH in mm / inches) approx. . . . . . . . .
DS = Double stroke

4Original operation manual
AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Emission sound pressure level in the workplace
was determined according to the standards DIN EN ISO 3744, DIN EN 31200,
DIN EN 31201 and DIN 45635-20
140 200
Sound pressure level at 15 DS with 8 bar LP84 dB (A)
Sound power level LW95 dB (A)
Ambient temperature - 30°C — + 50°C
- 22° F — + 122° F
Max. operating temperature 80 °C / 176° F

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AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Contents
1 Foreword ................................................................................... 9
2 Safety ....................................................................................... 10
2.1 Explanation of symbols ...................................................... 10
2.2 Safety notes ....................................................................... 12
2.2.1 Working pressure..................................................... 13
2.2.2 Risks due to the spray jet ........................................ 13
2.2.3 Risks due to electrostatic charge............................. 14
2.2.4 Risks due to hot or cold surfaces............................. 14
2.2.5 Explosion protection ................................................ 15
2.2.6 Health risks .............................................................. 16
2.3 Information signs on the machine ...................................... 17
2.4 Safety features................................................................... 17
2.4.1 Safety valve ............................................................. 18
2.4.2 Compressed air shut-off valve ................................. 19
2.4.3 Ground cable ........................................................... 19
2.5 Operating and maintenance personnel.............................. 20
2.5.1 Obligations of the machine owner ........................... 20
2.5.2 Personnel qualifications........................................... 20
2.5.3 Authorized operator ................................................. 20
2.5.4 Personal protective equipment ................................ 21
2.6 Warranty and liability.......................................................... 22
2.6.1 Spare parts .............................................................. 22
2.6.2 Accessories ............................................................. 22
2.7 How to respond in an emergency ...................................... 23
2.7.1 Bring the machine to a standstill and relieve the
pressure................................................................... 23
2.7.2 Leakage ................................................................... 23
2.7.3 Injuries ..................................................................... 23
3 Machine description ............................................................... 24
3.1 Intended use ...................................................................... 25
3.2 Erroneous use.................................................................... 25

6Original operation manual
AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
3.3 Machine design.................................................................. 26
3.4 Optional expansions and accessories ............................... 27
3.4.1 Spraying accessory kits ........................................... 27
3.4.2 Hose holder attachment kit ...................................... 28
3.4.3 AirCombi attachment kit........................................... 28
4 Transport, installation, and assembly .................................. 29
4.1 Transport............................................................................ 29
4.2 Installation site ................................................................... 30
4.3 Assembly ........................................................................... 31
4.3.1 Connecting the spraying hose and spray gun ......... 31
4.3.2 Grounding the machine ........................................... 32
4.3.3 Connecting the compressed air ............................... 32
5 Operation................................................................................. 33
5.1 Putting the machine into operation .................................... 33
5.2 Spraying............................................................................. 34
5.2.1 Setting the spraying pressure .................................. 34
5.2.2 Tips for good coatings.............................................. 35
5.3 Flushing ............................................................................. 36
5.4 Material change ................................................................. 38
5.5 Relieving the pressure ....................................................... 38
5.6 Work interruption................................................................ 39
5.7 Decommissioning............................................................... 39
5.8 Storage .............................................................................. 40
5.9 Disposal ............................................................................. 40
6 Maintenance ............................................................................ 41
6.1 Regular testing................................................................... 42
6.2 Maintenance schedule ....................................................... 42
6.3 High pressure pump........................................................... 43
6.3.1 Checking the release agent for material residues ... 43
6.3.2 Filling the release agent and checking the fill level.. 43

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AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
6.4 High pressure filter............................................................. 43
6.4.1 Cleaning the filter element ....................................... 43
6.4.2 Filter elements for the high pressure filter ............... 45
6.5 Recommended operating fluids ......................................... 45
7 Eliminating operational faults ............................................... 46
8 Technical Information............................................................. 49
8.1 Type plate .......................................................................... 49
8.2 QR code............................................................................. 49

8Original operation manual
AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Copyright
© 2018 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] • E-Mail: [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.

Original operation manual 9
AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Foreword
1 Foreword
Dear valued customer!
We are delighted that you have chosen one of our machines.
This operation manual is directed at the operating and maintenance
personnel. It contains all information required in order to work with
this machine.
The machine owner 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 for the safe operation of the machine. Read and observe
the directives and accident prevention regulations valid in your
country.
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.
We would like to wish you successful results with your machine,
WIWA Wilhelm Wagner GmbH & Co. KG

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AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Safety
2 Safety
This machine has been designed and manufactured with
consideration to all safety aspects. It reflects current engineering
practice and the valid accident prevention regulations. The machine
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 machine and other property of the owner,
➤the efficient function of the machine.
Any method of work that has a negative influence on the safety
of the operating personnel and the machine is fundamentally
prohibited. All persons involved in the installation, commissioning,
operation, care, repair and maintenance of the machine must
have read and understood the operation manual beforehand – in
particular the “Safety” chapter.
Your safety depends on it!
We recommend that the machine owner have this confirmed 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 WIWA
operation manuals, 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!

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AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Safety
Signals important information for proper handling of the machine.
A failure to observe this may result in damage to the machine 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 lifting movements
Risk of cutting injuries due to rotating machine parts
Risk of burning due to hot surfaces
Risk of freezing due to cold surfaces
The first line of the safety instructions indicates the personal
protective equipment that must be worn. This is also highlighted
and labeled 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.

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AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Safety
Use eye protection
Signals an instruction to wear protective goggles, in order to
prevent eye injuries due to material spray, gases, vapors or dust.
Use ear defenders
Signals an instruction to wear ear defenders, in order to prevent
damage to hearing caused by noise.
Use respiratory protection
Signals an instruction to use respiratory protection, in order to
prevent damage to the respiratory tract caused by gases, vapors
or dust.
Wear protective gloves
Signals an instruction to wear protective gloves in order to
prevent injuries due to aggressive chemicals, fire injuries when
processing heated materials, or freezing due to contact with very
cold surfaces.
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 floors.
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 machine operates in a high pressure
process and can cause life-endangering injuries if handled
incorrectly!
Always observe and follow all information in this operation
manual and in the separate operation manuals for the individual
machine parts or the optionally available auxiliary devices.

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AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Safety
2.2.1 Working pressure
WARNING
Parts that are not designed for the maximum permissible working
pressure may rupture and cause serious injuries.
➤It is essential to observe the prescribed maximum working
pressures for all parts. With varying working pressures,
the lowest value always applies as the maximum working
pressure for the complete machine.
➤Material hoses and hose assemblies must comply with the
maximum operating pressure including the required safety
factor.
➤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 finger or hand in front of the spray gun!
➤Never reach into the spray jet!
WARNING
An unintended ejection of material from the spray gun can cause
personal injury and property damage.
➤Secure the spray gun whenever interrupting work!
➤Prior to each commissioning, always check the spray gun
lock!

14 Original operation manual
AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Safety
2.2.3 Risks due to electrostatic charge
WARNING
The high flow velocities during the airless spray process can
result in an electrostatic charge. Static discharges can result in
fire and explosions.
➤Ensure that the machine is correctly grounded outside of EX
zones!
➤Ground the object that is to be coated.
➤Always use open containers!
➤Never spray solvents or materials containing solvents into
narrow-mouthed cans or barrels with a bung opening!
➤Set the container down on a 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 machines.
➤Only use electrically conductive accessories /accessory parts.
WARNING
If the machine becomes contaminated with material during
operation, an electrostatic charge may be generated with the
increasing coating thickness. Static discharges can result in fire
and explosions.
➤Clean the machine of contaminants immediately.
➤Perform the cleaning work outside of EX zones.
2.2.4 Risks due to hot or cold surfaces
CAUTION
When using material heaters, the machine surfaces may become
hot. A risk of burns exists.
➤When processing heated materials always wear protective
gloves with forearm protection.

Original operation manual 15
AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Safety
CAUTION
The air motor becomes very cold during operation. Localized
freezing can arise with contact.
➤Prior to all work on the machine, the air motor should be
heated up to a temperature above 10°C.
➤Wear suitable protective gloves!
2.2.5 Explosion protection
WARNING
Machines that are not explosion-protected must not be used
in operating facilities that fall under the explosion protection
ordinance!
Explosion-protected machines can be identified by the
corresponding mark on the type plate and/or the ATEX
declaration of conformity provided.
Explosion-protected machines meet the requirements of the ATEX
Directive for the device group, device category and temperature
class cited on the type plate or in the declaration of conformity.
The owner is responsible for designating the zoning in accordance
with ATEX Directive, Appendix II, No. 2.1-2.3 in accordance with
the stipulations of the responsible regulatory body. The owner is
required to check and ensure that all technical data and labeling
comply with the applicable stipulations according to ATEX.
Please note that some parts have their own type plate with
separate labeling according to ATEX. In this case, the lowest
explosion protection of all labels displayed applies to the entire
machine. For applications, whereby a failure of the machine could
lead to dangers to personnel, the owner is required to implement
appropriate safety measures.
If agitators, heaters or other electrically operated accessories are
attached, the explosion protection must be checked. Plugs for
heaters, agitators, etc. that do not have explosion protection may
only be plugged in outside of areas that fall under the explosion
protection ordinance, also if the accessory itself is explosion
protected.

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AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Safety
WARNING
Heating solvents can lead to an explosion. Serious personal
injuries and property damage may result.
➤Observe the flashpoint and ignition temperature of solvents.
➤Switch all material fluid heaters off when carrying out the
following work: Cleaning, pressure testing, decommissioning,
maintenance and repair.
2.2.6 Health risks
CAUTION
Depending on the materials being processed, solvent vapors
may arise, which could cause damage to health and property.
➤Make sure the workplace is sufficiently ventilated and aired.
It is necessary to guarantee at least 5-times air exchange.
➤Always observe the processing instructions of the material
manufacturer.
When handling paint, cleaning agents, 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 aluminum or galvanized
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 to clarify their suitability for use.
A range of machines in rust and acid-resistant designs is available
for these types of materials.

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AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Safety
2.3 Information signs on the machine
The information signs attached to
the machine, such as for example
the safety card (Fig. 1), indicate
possible hazard points and must be
observed.
They may not be removed from the
machine.
Damaged and illegible information
signs must be replaced immediately.
Also read and observe the safety
notes in the operation manual!
Fig. 1: Safety card
Für Ihre Sicherheit
For your safety •Pour votre sécurité
Por razones de seguridad •Для вашей безопасности
Güvenliğiniz için • Dla Twojego bezpieczeństwa
För din säkerhet • Para a sua segurança
© 05 / 2015 • 0642169
www.wiwa.de
www.wiwa.com
Spritzpistole nicht auf Personen oder Tiere richten
Do not point spray gun at persons or animals
Ne jamais diriger le pistolet de pulvérisation en direction de personnes ou d‘animaux
No dirigir la pistola pulverizadora hacia personas ni animales
Не направляйте пистолет-распылитель на людей или животных
Püskürtme tabancasını kişilere veya hayvanlara doğrultmayın
Pistoletu natryskowego nie kierować w stronę ludzi lub zwierząt
Rikta inte sprutpistolen mot människor eller djur
Não direccionar a pistola de pintura para pessoas ou animais
Nicht in den Spritzstrahl fassen
Do not reach into the spray jet
Ne pas toucher au jet
No interceptar el chorro de pulverización
Не прикасайтесь к струе распыляемого материала
Püskürtme huzmesine elinizi sokmayın
Nie sięgać w strumień rozpryskowy
Stick inte in händerna i sprutstrålen
Não tocar no jacto de pulverização
0
bar
psi
SOS
Im Notfall: Energiezufuhr absperren und Druck entlasten
In an emergency: Shut off power supply and relieve pressure
En cas d‘urgence : Bloquer l‘alimentation en énergie et relâcher la pression
En caso de emergencia: Cortar el suministro de energía y despresurizar el sistema
В экстренной ситуации: Заблокируйте подачу тока и сбросьте давление
Acil durumda: Enerji beslemesini kesin ve basıncı azaltın
W sytuacji awaryjnej: Zablokować dopływ energii i zredukować ciśnienie
Vid nödfall: Stäng av strömtillförsel och töm ut trycket
Em caso de emergência: Bloquear a alimentação de energia e despressurizar
In EX-Zonen nur Maschinen mit EX-Kennzeichnung betreiben
In EX zones, only operate machinery with EX labelling
Dans les zones soumises à un risque d‘explosion, exploiter uniquement
des machines présentant un marquage EX
En zonas con riesgo de explosión poner en servicio únicamente máquinas
con identicación EX
Во взрывоопасных зонах используйте только машины с маркировкой
взрывозащиты
EX bölgelerinde sadece EX işaretli makineleri işletin
W strefach zagrożonych wybuchem eksploatować wyłącznie maszyny z oznaczeniem EX
Endast EX-märkta maskiner får användas i EX-zoner
Nas zonas EX apenas operar máquinas com a identicação EX
bar
psi
max.
Zubehöre /Ersatzteile: max. Betriebsdruck der Maschine beachten!
Accessories / spare parts: Observe the max. operating pressure of the machine!
Accessoires/pièces de rechange : respecter pression de service max. de la machine !
Accesorios/piezas de repuesto: ¡Observar la presión de servicio máx. de la máquina!
Комплектующие / запчасти: учитывайте макс. рабочее давление машины!
Aksesuar / yedek parçalar: Makinenin maks. işletim basıncını dikkate alın!
Wyposażenie / części zamienne: przestrzegać maks. ciśnienia roboczego maszyny!
Tillbehör/reservdelar: ge akt på maskinens max. arbetstryck!
Acessórios / peças de substituição: ter em atenção a pressão de serviço máx. da máquina!
2.4 Safety features
WARNING
If one of the safety features is missing or is not fully functional,
the operating safety of the machine is not guaranteed!
➤Put the machine out of operation immediately if you detect
safety feature defects or any other faults on the machine.
➤Only put the machine back into operation once the faults have
been fully rectified.
Check the safety features on the machine:
➤Prior to commissioning,
➤Always prior to starting work,
➤After all set-up work,
➤After all cleaning, maintenance and repair work.
The machine is equipped with the following safety features:
➤Safety valve
➤Compressed air shut-off valve with automatic ventilation
➤Ground cable

18 Original operation manual
AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Safety
Checklist on the pressureless machine:
5Seal on the safety valve OK?
5Safety valve externally free of damage?
5Ground cable free of damage?
5Mobility of the compressed air shut-off valve OK?
Checklist on the pressurized machine:
5Function of the safety valve OK? (For function test, see chap.
2.2.1 ‘Working pressure’ on page 13)
When checking additional safety features, observe the operation
manuals for the optional accessories.
2.4.1 Safety valve
A safety valve is located on the air motor hidden behind the covering
of the muffler on the machine.
The safety valve prevents
the maximum permissible
air inlet pressure from
being exceeded. If the air
inlet pressure exceeds the
permanently set threshold
value, the safety valve blows
off.
This is how to check the
function of the safety valve: Fig. 2: Safety valve
Increase the air inlet pressure briefly by approx. 10% over the
maximum permissible pressure according to the type plate. – The
safety valve must discharge.
WARNING
If the maximum permissible air inlet pressure is exceeded, parts
may rupture. The consequences may be personal injuries and
property damage.
➤Never operate the machine without a safety valve or with a
defective safety valve!
➤If it is necessary to replace the safety valve, please refer to
the spare parts list for the order number.
➤With new safety valves, make sure that these are set to the
maximum permissible air inlet pressure of the machine (see
type plate or technical data) and sealed.

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AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Safety
2.4.2 Compressed air shut-off valve
The compressed air shut-off valve on the maintenance unit
interrupts the air supply to the entire machine. The machine
immediately stops and the compressed air is released.
The functional principle:
➤To open / opened Position
in the flow direction
Fig. 3: Compressed air shut-off
valve OPEN
➤To close / closed Position
transverse to the flow direction
Fig. 4: Compressed air shut-off
valve CLOSED
After shutting off the air, the machine remains under pressure
with regards to material. Perform a complete pressure relief
before all work on the machine (see chap. 5.5 ‘Relieving the
pressure’ on page 38!
2.4.3 Ground cable
The ground cable serves to
prevent electrostatic charging
of the machine.
The ground cable is already
connected to the machine at
the time of delivery (e.g. to
the high pressure filter, the
grounding rail, or the like).
Fig. 5: Ground cable
If the ground cable is lost or defective, replace it immediately
(art. no. 0659675)!

20 Original operation manual
AirlessPhoenixGX_BA_en_1803 • 0550010-en • jw
Safety
2.5 Operating and maintenance personnel
2.5.1 Obligations of the machine owner
The machine owner:
➤is responsible for training the operating and maintenance
personnel,
➤must instruct the operating and maintenance personnel on
correct handling of the machine, and on wearing the correct
work clothing and protective equipment,
➤must make work aids, such as e.g. lifting gear for transporting
the machine or container, available to the operating and
maintenance personnel,
➤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 machine into operation.
2.5.2 Personnel qualifications
Differentiation is made between 2 groups of personnel, depending
on their qualifications:
➤Instructed operators have received verified instruction from the
machine owner regarding the tasks entrusted to him and the
possible risks if the correct procedure is not followed.
➤Trained personnel have received instruction provided by
the machine manufacturer and are capable of carrying out
maintenance and repair work on the machine, independently
recognizing possible dangers and avoiding risks.
2.5.3 Authorized operator
Activity Qualification
Set-up and operation Instructed operator
Cleaning Instructed operator
Maintenance Trained personnel
Repair Trained personnel