wiwa AIRCOMBI ProFit Series User manual

AIRCOMBI-DEVICES
Translation of the original operation manual AIRCOMBI
AirCombi_DBK_en_1405 · jw
Operation manual
Serial number:
__________________
Series:
❍ PROFIT
❍ PHOENIX
Design size:
__________________
[phone]
[phone]
www.wiwa-spray.com

Contents
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Contents
1 Foreword....................................................................................................7
2 Safety .........................................................................................................8
2.1 Explanation of symbols............................................................................8
2.2 Safety notes...........................................................................................10
2.2.1 Operating pressure ......................................................................10
2.2.2 Risks caused by the spray jet ......................................................10
2.2.3 Hazard from electrostatic charging .............................................. 11
2.2.4 Hazards from hot/cold surfaces ................................................... 11
2.2.5 Explosion protection ....................................................................12
2.2.6 Health risks ..................................................................................12
2.3 Information signs on the unit .................................................................13
2.4 Safety features ......................................................................................13
2.4.1 Safety valve .................................................................................14
2.4.2 Compressed air shut-off valve .....................................................15
2.4.3 Ground cable ...............................................................................15
2.5 Operating and maintenance personnel .................................................15
2.5.1 Unit owner's duties ......................................................................15
2.5.2 Personnel qualication.................................................................16
2.5.3 Authorized operating personnel...................................................16
2.5.4 Personal Protective Equipment (PPE).........................................16
2.6 Notes on warranty .................................................................................17
2.6.1 Conversions and alterations ........................................................17
2.6.2 Spare parts ..................................................................................17
2.6.3 Accessories..................................................................................17
2.7 Emergency procedures .........................................................................18
2.7.1 Stop the unit and release the pressure........................................18
2.7.2 Leakages .....................................................................................18
2.7.3 Injuries .........................................................................................18
3 Unit Description ......................................................................................19
3.1 Intended use..........................................................................................19
3.2 Unit design.............................................................................................20
3.2.1 PROFIT series .............................................................................21
3.2.2 PHOENIX series ..........................................................................22
3.3 Dual air regulator ...................................................................................23
3.4 Air maintenance unit..............................................................................24

Contents
4 Translation of the original operation manual AIRCOMBI
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3.5 Optional expansion parts and accessories............................................25
3.5.1 AirCombi spray gun .....................................................................25
3.5.2 Material uid heater .....................................................................25
3.5.3 Agitator.........................................................................................25
4 Transport, installation and assembly....................................................26
4.1 Transportation........................................................................................26
4.2 Installation location ................................................................................26
4.3 Assembly ...............................................................................................27
4.3.1 Mounting the wall bracket (optional) ............................................28
4.3.2 Assembling spray hose and atomizer air hose ............................28
4.3.3 Grounding the unit .......................................................................29
4.3.4 Connect compressed air..............................................................29
5 Operation.................................................................................................31
5.1 Commissioning the unit .........................................................................31
5.2 Spraying ................................................................................................32
5.2.1 Adjusting the spraying pressure...................................................32
5.2.2 Hints for achieving good coating results......................................33
5.3 Flushing .................................................................................................34
5.4 Material change .....................................................................................35
5.5 Releasing pressure................................................................................35
5.6 Interruptions to work ..............................................................................36
5.7 Decommissioning ..................................................................................36
5.8 Disposal.................................................................................................36
6 Maintenance ............................................................................................37
6.1 Regular inspections ...............................................................................38
6.2 Maintenance plan ..................................................................................38
6.3 Maintenance unit ...................................................................................39
6.3.1 Checking the lubricant level in the fog oiler .................................39
6.3.2 Checking and adjusting the fog oiler...........................................40
6.3.3 Checking and cleaning the water separator ...............................40
6.4 High pressure pump ..............................................................................40
6.4.1 Topping up release agent ............................................................40
6.4.2 Checking the release agent for material residue .........................40
6.5 High pressure lter ................................................................................41
6.5.1 Removing the lter element .........................................................41
6.5.2 Cleaning the lter element ...........................................................43
6.5.3 Filter elements for high pressure lters........................................43
6.6 Recommended operating materials.......................................................44
6.7 Special tools ..........................................................................................44

Contents
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7 Rectication of faults .............................................................................45
8 Technical data .........................................................................................47
8.1 PROFIT series.......................................................................................47
8.2 PHOENIX series....................................................................................47
8.3 Unit card ................................................................................................48
8.4 Type plate ..............................................................................................48

6 Translation of the original operation manual AIRCOMBI
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Foreword
1 Foreword
Dear Customer
We are delighted that you have decided in favour of a unit made by our
company.
This operation manual is intended for operating and maintenance personnel.
It contains all the information required for working with this unit.
The owner of the unit has to ensure that operators and maintenance
personnel always have an operation manual at their disposal in a
language that they understand.
Safe and reliable operation of the unit requires further information in addition
to this operation manual. You should have read and understood the guide-
lines and accident prevention regulations that apply in your country.
In Germany, these are as follows:
➤ZH 1/406 “Richtlinien für Flüssigkeitsstrahler” (Guidelines for Liquid
Jets), published by the German “Hauptverband der Gewerblichen Be-
rufsgenossenschaften”;
➤BGR 500, chapter 2.29 “Application of Coating Materials”;
➤BGR 500, chapter 2.36 “Working with Fluid Spraying Equipment” pub-
lished by the employers liability insurance association for the gas,
remote heating and water management sectors.
We strongly recommend adding all relevant guidelines and accident preven-
tion instructions to this operation manual.
Moreover the manufacturer's instructions and guidelines for coating or feed-
er materials must be respected at all times.
However, if you have any questions, please do not hesitate to contact us.
Best wishes for good results with your unit from
WIWA Wilhelm Wagner GmbH & Co. KG
Copyright
© 2014 WIWA
This operation manual remains the copyright of WIWA Wilhelm Wagner GmbH & Co. KG.
Gewerbestr. 1-3 • 35633 Lahnau • Germany
Tel.: [phone] • Fax.: [phone] • Email: [email protected] • Internet: www.wiwa.de
This operation manual is solely intended for personnel involved in preparation, operation and
servicing.
It is prohibited to pass on this operation manual for reproduction, utilisation or communication of its
contents, unless this has been explicitly permitted. Non-compliance may result in claims for damage
compensation. All rights reserved in the event of registration of the patented design, industrial design
or registered design.

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Safety
2 Safety
This unit has been designed and manufactured under due consideration of
all safety-related aspects. It complies with the current standard of technology
and relevant accident prevention regulations. The unit left the factory in per-
fect condition and guarantees a high level of technical reliability and safety.
Nevertheless, there are certain risks that can arise from incorrect operation
or misuse:
➤to life and limb of the operator or third parties,
➤to the unit and other material assets of the owner,
➤to the efcient working capacity of the unit.
You must refrain from any working methods that could affect the safety of op-
erating personnel and equipment. Everyone involved in set-up, commission-
ing, operation, maintenance, repair and servicing of the unit must have read
and understood the operation manual beforehand, especially the chapter
entitled “Safety”.
Your safety is at stake!
We recommend to the owner of this unit to have this conrmed in writing.
2.1 Explanation of symbols
Safety notes warn you of potential risks of accidents and tells you the mea-
sures that are required to prevent accidents.
In WIWA operation manuals, safety notes are specially highlighted and
marked as follows:
DANGER
Indicates danger of accidents; if you ignore the safety notes, there is a
high risk of severe injury including death!
WARNING
Indicates danger of accidents; if you ignore the safety notes, there is a
high risk of severe injury including death!
CAUTION
Indicates danger of accidents; if you ignore the safety notes, severe injury
can result!
Indicates important information on correct use of the unit. Ignoring it can
result in damage to the unit or in its vicinity.

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Safety
In the safety notes about the risk of accidents, different pictograms are
shown after each hazard source – examples:
General accident risk
Risk of explosion from explosive atmosphere
Risk of explosion from explosive substances
Danger of injury due to electric voltage or electrostatic charging
Risk of crushing by moving unit parts
Risk of burning due to hot surfaces
Mandatory safety instructions primarily concern personal protective equip-
ment to be worn. They are particularly highlighted and marked as follows:
Wear protective clothing
Indicates the requirement to wear the prescribed protective clothing to
protect against skin injuries caused by spraying material or gases.
Use eye protection
Indicates the requirement to wear protective goggles to protect against
eye injuries caused by gases, fumes or dust.
Wear ear defenders
Indicates the requirement to wear ear defenders to prevent your hearing
from being damaged by noise.
Use a respiratory protection mask
Indicates the requirement to use a respiratory protection mask to prevent
your respiratory tract from being damaged by gases, fumes or dusts.
Wear protective gloves
Indicates the requirement to wear protective gloves with lower arm
protection to protect against burn injuries caused by heated materials.
Wear protective footwear
Indicates the requirement to wear protective footwear to prevent injuries
to the feet due to objects that may fall, drop or roll around or due to hot or
caustic liquids.
Indicates references to guidelines, work instructions and operating
manuals that contain important information which you must observe at all
times.

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Safety
2.2 Safety notes
Please remember that the unit works at high pressure and may cause
life-threatening injuries if used inappropriately!
Always observe and follow all instructions in this operation manual and
in the separate operating manuals of individual unit parts and/or the
optionally available accessory devices.
2.2.1 Operating pressure
WARNING
Components that do not comply with the maximum permissible operating
pressure can burst and cause serious injury.
➤The specied maximum operating pressures must generally be com-
plied with for all components. In case of varying operating pressures,
the lowest value is always the one to be taken as the maximum oper-
ating pressure for the entire unit.
➤Material hoses and hose assemblies must comply with the maximum
working pressure, including the required safety factor.
➤Material hoses must be leak tight and free of kinks, signs of abrasion
or bulges.
➤Hose connections must be tight.
2.2.2 Risks caused by the spray jet
WARNING
The material is discharged from the spray gun under very high pressure.
Due to its cutting effect the spray jet can cause severe injuries by pene-
trating the skin or entering into the eyes.
➤Never point the spray gun at yourself, other persons or animals.
➤Do not hold your ngers or hands in front of the spray gun!
➤Do not reach into the spray jet with your hands!
WARNING
Unintentional material release from the spray gun may cause personal
injury or damage to property.
➤Always secure the spray gun during every work break!
➤Always check that the safety mechanism on the spray gun works
before each use!

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Safety
2.2.3 Hazard from electrostatic charging
WARNING
The high ow velocities associated with the Airless spraying method may
cause electrostatic charging.
Static discharges can cause re and explosion.
➤Ensure that the unit has been properly grounded outside of explosive
atmosphere areas!
➤Also ground the object to be coated.
➤Always use open containers!
➤Never spray solvents or materials containing solvent into cone-top
cans or drums with a bunghole!
➤Place the containers on a grounded surface.
➤Avoid contact between spray gun and container wall.
➤Use only electrically conductive material hoses.
All original material hoses from WIWA are conductive and perfectly
adapted to our equipment.
➤Use only electrically conductive accessories/accessory parts.
WARNING
If the unit is contaminated by material during operation, the increased
coating thickness can lead to electrostatic charging. Static discharges can
cause re and explosion.
➤Clean the unit immediately to remove any contamination.
➤Carry out cleaning work outside areas with explosive atmospheres.
2.2.4 Hazards from hot/cold surfaces
CAUTION
The use of material heaters can cause the surfaces of the unit to
become hot. Risk of burns.
➤Always wear protective gloves with lower arm protection (gauntlet)
when working with heated materials!
CAUTION
The air motor becomes very cold during operation. There is a high risk of
local frostbite.
➤The air motor should have warmed up to a temperature above 10 °C
before starting any work on the unit.
➤Always wear suitable protective gloves!

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Safety
2.2.5 Explosion protection
WARNING
Units that are designed without explosion protection must not be used in
workshops that are subject to the explosion protection ordinance.
Whether your unit has explosion protection is indicated by the symbol
on the type plate and/or on the enclosed ATEX declaration of conformity.
Explosion-protected machines meet the explosion protection requirements
of Directive 94/9/EC for the explosion group, unit category and temperature
class specied on the type plate or in the declaration of conformity.
The operator is responsible for determining the zone allocation according
to the Directive of EC 94/9/EC, Appendix II, no. 2.1-2.3 when observing the
measures of the responsible inspecting authority. The operator is responsi-
ble for checking and ensuring that all technical data and markings according
to ATEX correspond with the necessary requirements.
Please note that several components have their own type plate with sepa-
rate marking according to ATEX. In this case the lowest explosion protection
of all attached markings applies to the entire unit. Applications where the
malfunction of the unit can lead to danger to personnel must be provided
with respective safety measures by the operator.
However, if agitators, heaters or other electrically operated accessories are
additionally mounted, explosion protection has to 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 ordi-
nance, even if the accessory equipment as such is explosion protected.
WARNING
Heating up solvents can cause an explosion. This may result in serious
injury to persons and damage to property.
➤Pay attention to the ashpoint and the ignition temperature of the
solvent.
➤Switch off the material uid heater if you need to perform the following
work: cleaning, pressure testing, decommissioning, maintenance and
repair.
2.2.6 Health risks
CAUTION
Depending on the materials being applied, solvent vapours may be
generated which could cause damage to health and objects.
➤Always ensure sufcient aeration and ventilation at the workplace.
➤Always observe the processing instructions issued by the material
manufacturers.

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Safety
Follow the safety notes and dosing information of the manufacturer and
the generally applicable regulations when handling paints, cleaning
agents, oils, greases and other chemical substances.
When cleaning your skin, use only appropriate skin protection, skin
cleaning and skin care products.
In closed or pressurized systems, dangerous chemical reactions may occur
if parts made of aluminium or galvanized parts come into contact with 1.1.1 -
trichloroethane, methylene chloride or other solvents containing halogenated
hydrocarbons (CFC's). If you want to process materials containing the afore
mentioned substances, we recommend to consult the material manufacturer
to clarify the usability of such substances.
For these materials, we have available a range of rust- and acid-proof units.
2.3 Information signs on the unit
Information signs attached to the unit, such
as safety information (Fig. 1), refer to possible
danger areas and must be strictly observed.
They must not be removed from the unit.
Damaged and illegible information signs must
be replaced immediately.
Apart from this you should also read and
follow the safety notes in the operation
manual.
Fig. 1: Safety Information
2.4 Safety features
WARNING
If one of the safety features is missing or not fully functional, the operating
safety of the unit cannot be guaranteed!
➤If you discover any faults in the safety features or other deciencies on
the unit, stop operation of the unit immediately.
➤Only resume operation of the unit after the fault has been completely
eliminated.
Safety features must be checked on the unit:
➤before initial commissioning,
➤always before starting work,
➤after set-up work,
➤after all cleaning, servicing and repair work.

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Safety
The unit is equipped with the following safety features:
➤Safety valve
➤Compressed air shut-off valve
➤Ground cable
Please observe the operation manual for use for the optional accessories
when testing other safety features.
Checklist
on the depressurized unit:
5Lead seal on the safety valve still intact?
5Safety valve free of external damage?
5Ground cable free of damage?
5Operability of compressed air shut-off valve correct?
on the pressurized unit:
5Function of safety valve correct? (see Chapter 2.4.1 Safety valve on
page 14)
Please observe the operation manual for use for the optional accessories
when testing other safety features.
2.4.1 Safety valve
There is a safety valve on the air motor of the unit:
➤The safety valve prevents the maximum
permissible air inlet pressure from being
exceeded. The safety valve will open
and vent off air when the air inlet pres-
sure exceeds the set limiting value.
➤How to check the function of the safety
valve:
Briey increase the air inlet pressure by
about 10 % above the maximum permit-
ted pressure as stated on the type plate.
The safety valve has to discharge.
Fig. 2 Safety valve
WARNING
If the maximum permissible air inlet pressure is exceeded, components
may burst. This may result in damage to persons and property.
➤Never allow the unit to run without a safety valve or with a defective
one!
➤If the safety valve needs to be replaced, you can nd the correspond-
ing order number on the unit card.
➤With new safety valves, ensure that they have been set to the maxi-
mum permissible air inlet pressure of the unit (see type plate/unit card)
and sealed with a lead seal.

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Safety
2.4.2 Compressed air shut-off valve
The compressed air shut-off valve enables immediate shutting down of the
unit.
Principle of function:
➤Open
 set in the direction of ow
Fig. 3 Compressed air shut-off valve
OPEN
➤Close
 across the direction of ow
Fig. 4 Compressed air shut-off valve
CLOSE
After shutting off the air, the unit is still pressurized. This means that
before carrying out maintenance and repair work, you must always carry
out a complete pressure release!
2.4.3 Ground cable
The ground cable prevents the
electrostatic charge of the unit.
The ground cable is already connected to
the unit when it is delivered (e.g. on the
high pressure lter, the ground bar, etc.).
Replace the ground cable immediately if it
lost or damaged! Fig. 5: Ground cable
2.5 Operating and maintenance personnel
2.5.1 Unit owner's duties
The unit owner:
➤is responsible for the training of the operating and maintenance staff,
➤must instruct the operating and maintenance staff in correct handling
of the unit as well as in wearing the correct work clothing and personal
protective equipment,
➤must provide tools to the operating and maintenance personnel such as
e.g. lifting equipment for transporting the unit or containers,
➤must make the user manual available to the operating and maintenance
staff and ensure that it always remains available,
➤must ensure that the operating and maintenance staff have read and
understood the user manual.
Only then may the unit be brought into service.

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Safety
2.5.2 Personnel qualication
A differentiation is made between two groups of people depending on their
qualications:
➤Instructed operators have been veriably instructed by the unit owner in
the activities they are tasked with and the potential risks connected with
them in the case of incorrect behaviour.
➤Trained personnel have been instructed by the unit builder so that they
are capable of carrying out maintenance and repair work on the system
and recognising potential risks on their own initiative and of avoiding
these risks.
2.5.3 Authorized operating personnel
Activity Qualication
Set-up and operation Instructed operator
Cleaning Instructed operator
Servicing Trained personnel
Repair Trained personnel
Young persons under the age of 16 are not allowed to operate this unit.
2.5.4 Personal Protective Equipment (PPE)
Wear protective clothing
Always wear the protective clothing specied for your work environment
(e.g. antistatic protective clothing in areas subject to explosion hazards)
and also follow the recommendations in the safety data sheet issued by
the material manufacturer.
Use eye protection
Wear protective goggles to protect against eye injuries caused by material
splatter, gases, fumes or dust.
Wear ear defenders
Operating personnel should be provided with suitable noise protection
equipment. The unit operator is responsible for adhering to the accident
prevention regulation “Noise” (BGV B3). For this reason, pay special
attention to the conditions at the installation location – the noise burden,
for example, will increase if the unit is installed in or on hollow bodies.
Wear a respiratory protection mask
We strongly recommend that you wear a respiratory protection mask,
even though the paint mist has been minimized in the airless spraying
method given a correct pressure setting and correct working methods.

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Safety
Wear protective gloves
Wear antistatic protective gloves. When processing heated materials, you
must wear lower arm protection in addition to protective gloves to prevent
burns.
Wear protective footwear
Wear antistatic protective footwear to prevent injuries to the feet due
to objects that may fall, drop or roll around and to prevent slipping on a
slippery oor.
2.6 Notes on warranty
Please note our Terms and Conditions at www.wiwa.de.
2.6.1 Conversions and alterations
➤Unauthorized conversions or alterations should not be undertaken on
safety grounds.
➤Protective equipment should not be dismantled, converted or bypassed.
➤The unit must only be operated within the specied limiting values and
unit parameters.
2.6.2 Spare parts
➤When carrying out maintenance and repair work, you must only use
WIWA original spare parts.
➤Use of components which have not been manufactured or delivered by
WIWA renders any warranty null and void.
2.6.3 Accessories
➤Using original WIWA accessories guarantees that they are usable in our
units.
➤If you use third-party accessories, they must be suitable for the unit –
particularly with regard to the operating pressure, the electrical connec-
tion data and the connection sizes. WIWA accepts no liability for damage
or injuries resulting from the use of these parts.
➤You must observe the safety regulations of the accessories. These
safety regulations are found in the separate operation manual for the
accessories.

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Safety
2.7 Emergency procedures
2.7.1 Stop the unit and release the pressure
In an emergency, immediately shut down the unit and release the pressure.
1. Close the compressed air shut-off valve.
2. Operate the spray gun again briey to relieve any residual material pres-
sure, ensuring full pressure release for the unit.
This procedure is not suitable for decommissioning. The unit has not been
ushed.
➤For controlled decommissioning please see Chapter 5.7 Decommis-
sioning on page 36.
➤After remedying the emergency, the unit has to be ushed (see Chap-
ter 5.3 Flushing on page 34).
Pay attention to the potlife of the material used.
2.7.2 Leakages
WARNING
In case of leakages material can escape under very high pressure and
cause serious bodily injuries and material damage.
➤Stop the unit immediately and release the pressure.
➤Re-tighten any screw ttings and replace defective components (only
by trained personnel).
➤Do not try to seal leaks on the connections and high pressure hoses
by hand or by wrapping material around them.
➤Do not repair material hoses!
➤Before recommissioning the unit, check the hoses and screw ttings
for leaks.
2.7.3 Injuries
If injured by processing materials or cleaning agents, always have the safety
data sheet (address, phone number, material designation and material num-
ber of the supplier or manufacturer) ready for the attending physician.

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Unit Description
3 Unit Description
The WIWA AirCombi systems are divided into two series which basically
differ in the size of the high pressure pumps.
➤PROFIT
➤PHOENIX
Using this method, the spraying material is transferred to the AirCombi spray
gun under moderate pressure and pre-atomized. The very ne spray dis-
tribution is achieved by applying regulated compressed air as the paint is
discharged. A soft, controllable spray jet is produced with minimum paint mist
and rebound.
Fig. 6: Flow chart for AirCombi operation
1
2
3
4 5
6
No. Description
1 AirCombi spraying equipment
2 AirCombi spray gun
3High pressure lter
4 Atomizer air hose
5 Material hose
6 Container with spraying
material
The technical data of your unit can be found on the attached unit card or on
the type plate.
3.1 Intended use
The WIWA AirCombi devices are only suitable for spraying of coating and
ancillary materials for surface treatment.
The AirCombi spraying process is ideal for very ne painting tasks covering
large areas and for shaped or small workpieces.
The devices are primarily used in trade workshops such as carpenter's work-
shops for coating wood, but also in the industry for very delicate surfaces.
They are suitable for virtually all sprayable paints and varnishes.
Water-based paints and media that can be thinned with water can only be
processed in devices with rust-proof and acid-resistant nishes.
Any other use is considered to be unintended. If you intend to use the unit
for other purposes or with other materials and thus not for the purpose for
which it is intended, you must ask WIWA for permission – otherwise the
warranty will be invalidated.
Intended use also includes compliance with the technical documentation
and adherence to the prescribed operating, servicing and maintenance
guidelines.

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Unit Description
3.2 Unit design
The machines can be mounted on different frames, e.g. on
➤20 l container
➤Frame with hopper and feed drum
➤Cart
➤Tripod
➤Wall Brackets
The frame makes no difference to the function of the unit.