wiwa OPTIMA 2100 User manual

Translation of the original operation manual
SPAC_Optima2100_1302_en • 0550012 • jw
Operation manual
Air Combi SPrAY GUN
oPTimA 2100

Inhaltsverzeichnis
1 Preface.............................................................................................5
2 Safety ...............................................................................................6
2.1 First read, then start..........................................................................6
2.2 Description of symbols......................................................................7
2.3 Dangers caused by rebuilds and changes........................................8
2.4 Dangers caused by attachments and spare parts ............................9
2.5 Dangers caused by emissions..........................................................9
2.6 Safety instructions...........................................................................10
2.7 Operating staff ................................................................................12
2.8 Safety measures at installation site ................................................13
2.9 Safety equipment............................................................................13
3 Description of equipment.............................................................14
3.1 Intended use ...................................................................................14
3.2 Assembly details.............................................................................16
3.3 Technical data.................................................................................17
3.3.1 Connected loads.............................................................................17
3.3.2 Material consumption and output values ........................................17
3.3.3 Air consumption ..............................................................................18
3.3.4 Workstation related sound pressure level.......................................18
4 Setting-up ......................................................................................19
5 Operation.......................................................................................21
6 Disturbances during operation and trouble-shooting...............26
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7 Maintenance and repair................................................................28
7.1 Lubrication ......................................................................................28
7.2 Cleaning..........................................................................................28
7.3 Exchanging parts ............................................................................30
8 Disassembly..................................................................................33
9 Disposal.........................................................................................34
10 Spare parts lists............................................................................35
10.1 Air Combi Spray Gun (without tip) ..................................................35
10.2 Air Combi Spray Gun (with tip) .......................................................38
Copyright
© 2008 WIWA
Copyright ownership for this operation manual remains with
WIWA WILHELM WAGNER GmbH & Co. KG
Gewerbestraße 1-3 • 35633 Lahnau
Phone: [phone] • Fax: [phone]
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 com-
munication of its contents, unless this has been explicitly permitted. Infringements
incur an obligation to pay damage compensation. All rights reserved in the event of
registration of the patented design, industrial design or registered design.
This operation manual only applies in conjunction with the machine card that was
given to you with the user manual for your equipment. Please check that the type
plate data is identical with the information on the machine card. Please notify us
immediately if there are discrepancies, if the user manual has been incorrectly
compiled or if the type plate is missing.
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1 Preface
This operation manual must always be available to operating
staff!
The operating authority of the equipment must ensure that
a user`s handbook is available to the operator in a language
which he understands.
Dear customer!
Thank you for your decision to purchase equipment.
In the user’s handbook, you can find all information required for the proper
handling of your spray gun. However, for safe operation, there are
further essential details which you should adhere to:
Please read and observe the guidelines valid for your country.
In Germany, the "Richtlinien für Flüssigkeitsstrahler" (Guidelines for Fluid
Sprayers) published by: Hauptverband der Gewerblichen Berufsgenos-
senschaften (Industrial Employer's Liability Insurance Association) are valid.
Manufacturer’s notes and operating guidelines for coating and pumping mate-
rials should be observed at all times.
No method of operation should be exercised which impairs the safety of the
operating personnel or product.
We wish you much success and excellent working results when using your
spray gun.
WIWA Wilhelm Wagner GmbH & Co. KG
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Preface

2 Safety
This spray gun was designed and built in accordance with all safety aspects.
It corresponds with the present standards of technical regulations and current
rules for accident prevention. It left the factory in perfect condition, insuring a
high level of safety.
However, the following dangers exist if operated incorrectly or used inappro-
priately:
 to life and limb of operator or third personso
 for the machine and other property belonging to owner of machine
 for the efficient working of the machine
All personnel involved in the starting, operation, and maintenance of the spray
gun and associated equipment must read the following notes and observe
them.
It is a matter of their safety!
2.1 First read, then start
Remember that airless paint spraying equipment works under
extreme pressure and that high levels of spraying pressure are
created!
 Never hold your finger or hand in front of the gun and never reach into
the spray.
 Never point the spray gun towards yourself, other people or other living
creatures.
 Always pay close attention to the references and specifications found in
the user's handbook!
Before each usage, be especially certain to:
 Check the grounding conditions (for the unit and the object to be
sprayed).
 Check the seal of all connecting and mounted parts.
 Observe the maximal allowed pressure of the unit and accessory parts.
Before beginning any work on the equipment, and at any pause during
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operation, it is absolutely required to:
 Shut down the spraying equipment in accordance with the instructions in
the user's handbook.
 Release the pressure found in the spray gun and hose.
 Secure the spray gun.
Pay attention to safety!
The accident prevention regulation "Handling of Coating Materials" (BGR500,
Kap.2.29) and the guidelines covering fluid sprayers (ZH1/406) from the Ger-
man Employer's Liability Insurance Association are to be observed without
fail. To ensure a safe operating environment, the condition of fluid sprayers
must be inspected by an expert every 12 months or sooner, if deemed neces-
sary. A written record of the inspection results is to be kept.
Remaining paint and solvent are to be disposed of according to legal regula-
tions. This also applies for environmentally friendly water based lacquer or
enamel systems.
In case of injuries, consult a physician or go to the next hospital without delay.
If paint/material or solvent has gone into the skin, the physician has to be
informed about the type of paint/material or the solvent applied.
Therefore, always ensure that the product specification sheet, with address
and telephone number of the manufacturer, is at your disposal!
2.2 Description of symbols
The signs and symbols used in this manual have the following meaning:
NOTE
marks a section of text which is especially relevant to safety. Spe-
cial attention should be paid to this section and its contents strictly
observed.
WARNING
marks a situation which could be dangerous. If not observed,death or
very serious injury could result.
Warning concerning electrostatic charging when spraying in
metal containers.
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Take care to ground the spray gun through contact with the contai-
ner in order to prevent a major static discharge.
DANGER OF EXPLOSION
marks a situation, where there is danger of explosion. Observation of
this information is absolutely essential.
USE BREATHING PROTECTION
For health reasons, it is very important to pay attention to this warn-
ing.
WEAR PROTECTIVE GLOVES
To prevent burns, wear protective gloves with lower arm protection.
Observation of this information is essential.
HEALTH DANGER
marks materials which are hazardous to your health. Observation of
this information is absolutely essential.
2.3 Dangers caused by rebuilds and changes
For safety reasons, it is not allowed to carry out rebuilds or changes without
authorization. Protective equipment may not be dismounted, altered or ne-
glected.
If using components which are not produced or delivered by , war-
ranty coverage is negated as well as liability.
The spray gun may only be operated within the prescribed limits and machine
parameters.
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2.4 Dangers caused by attachments and spare
parts
If you use original attachments and original spare parts from , the
compatibility with our equipment is guaranteed. It is, however, essential that
the safety regulations of the attachments and spare parts are observed. You
can find these safety regulations in the User’s Handbook located with the
spare parts lists.
If you use attachments and spare parts from another source, can-
not guarantee the safety of the entire system.
In this case, our guarantee does not cover any damage or injury caused by
such attachments and spare parts.
2.5 Dangers caused by emissions
It is possible for solvent vapours to occur, depending on the materials used.
Therefore, please ensure the workplace is sufficiently ventilated in order to
avoid damage to health and property. Always observe the processing informa-
tion given by the material manufacturer.
The spray gun itself produces no noise.
Please observe the maximum noise level of the spraying equipment.
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2.6 Safety instructions
Observe the following notes:
 The spray gun must meet or exceed the maximum operational pressure
of the paint spraying equipment being used.
 Because of the electrostatic charges produced by spraying, the spray
gun may only be mounted to conductive hoses. All original
hoses are conductive and matched to spray equipment.
 It is possible for a static charge to occur due to the high flow speeds
during the airless spraying procedure. Static charges can lead to fire and
explosions.
 Therefore, the complete unit (including the spray gun) and the
object to be sprayed must be grounded properly.
 Never point the spray gun towards yourself, other people or
other living creatures!
 Never hold your finger or hand in front of the gun and never reach into
the spray.
 Hold the spray gun securely, as the high operating pressure can result in
severe kickback.
 Never try to seal leaks on joints and high pressure hoses with your hand
or by binding the spot. Should a leak occur, the whole system (gun, hose,
pressure filter, pump, etc.) are to be depressurized immediately. Defec-
tive parts are to be replaced.
The spray gun is to be secured and the safety device checked during
every interruption while working, regardless how short.
 If working with heated materials, always wear the proper hand
protection. BURN DANGER!
Upon work interruption and decommissioning of the spraying unit the
entire system has to be depressurized. Read and follow the instructions
in the operation manual for the spray equipment. Trigger the spray gun
briefly at the end of work to release any residual pressure.
The entire system is to be depressurized before maintenance and clean-
ing work is carried out. Read and follow the user's handbook for the
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spray equipment.
 Remove the spray gun from the spraying equipment before carrying out
this work.
 Never spray solvents or materials containing solvents into a narrow-
necked can or barrel with bung hole.
DANGER OF EXPLOSION!
 Always use an open container. Due to possible electrostatic
charges, it is imperative to ensure that the spray gun is groun-
ded to the container walls when working with metal containers.
 Never dip a hot spray gun into solvent.
DANGER OF EXPLOSION!
 Never use this equipment outdoors during a thunderstorm.
 In closed or pressurised systems where aluminium or galvanised parts
come into contact with the solvent, dangerous chemical reactions can oc-
cur if 1.1.1-trichlorethylene, methylene chloride or other solvents contain-
ing halogenated chlorinated hydrocarbons (CFCs) are used.
These materials combine with water to produce acids which corrode the
surfaces of the spray gun and other parts. Never expose the spray gun
to acids or paint remover.
Repeatedly recovered solvents can also become acidic through increas-
ing water content.
If you wish to work with the above solvents, or with lacquers and paints
which contain them, we recommend you contact either the customer
service of your distributor or directly.
 A list of materials used in the construction of the spray gun can be provid-
ed upon request in order to determine the compatibility with the materials
to be sprayed.
 Smoking, open flames or any other possible ignition sources are not al-
lowed anywhere near the area of operation
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2.7 Operating staff
The device may only commissioned, operated and repaired by qualified
and trained personnel.
Authorised Operators
People under the age of 16 should not operate this equipment.
operators qualification
adjusting work trained operator
servicing work trained operator
cleaning work trained operator
maintenance work personnel trained by customer
service
The management in charge of the operation of the spray gun must make the
user’s handbook available to the operator and must make sure that he has
read and understood it. Only then may the system be put into operation. We
recommend that the manager has this confirmed in writing.
The operator must make sure that only authorised persons work on the equip-
ment.
Personal protective equipment
Please wear the prescribed protective clothing at all times, as solvent
vapours and solvent splashes cannot be completely avoided.
We call to your attention that the valid guidelines and requirements in accor-
dance with work surroundings (mining, closed areas etc.) must be absolutely
adhered to.
Although spraying fog is kept to a minimum when the correct pres-
sure setting and proper method of operation are observed, the oper-
ating painter should wear a protective breathing mask.
To avoid burns, use protective gloves when working with heated ma-
terials.
Never use solvent or other materials which present a health hazard
for cleaning skin. Only suitable skin protective, skin cleansing and
skin care.
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2.8 Safety measures at installation site
 Ensure there is sufficient ventilation at the workplace to prevent dam-
age to health and property as well as to minimize the danger of fire and
explosion. The spray gun may not be operated in closed areas lacking
ventilation.
 Observe the manufacturer’s processing instructions at all times.
 Protect all objects in the vicinity of the objects to be sprayed from dam-
age by overspray.
 The owner / operator of this equipment is required to ensure that proper
protection against lightning strikes is available.
Comply strictly with the current rules for accident prevention.
2.9 Safety equipment
The safety devices on the spray gun are required by law and
may in no case be removed!
Locking the spray gun
Fig. 2.1
By placing the lever in the horizontal position (pict. 2.1), the
spray gun is secured against accidental discharge. The
spray gun must be locked at each work interruption, regard-
less how short.
All protection devices must be checked:
before each commissioning of the spray gun!
before beginning work on/with the spray gun!
after all aligning work!
after cleaning and servicing!
after maintenance and repair!
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If a safety device is not fully functional, the spray gun may not
be operated.
The spray gun may only be used again when the proper func-
tion has been restored.
3 Description of equipment
3.1 Intended use
This pneumatically operated paint spray gun with pump support in the high
pressure range (up to max. 250 bar) is suitable for processing liquid, sprayable
media with consideration of the manufacturer references.
The high pressure spray gun is led by hand and operated by the operator to
coat the work piece.
Fig. 3.1
A marking with the allowable working pressure range can
be found on each spray gun (pict. 3.1)
Use of the units in explosion hazardous areas
Marking: II 2G x
The unit fulfils the explosion protection requirements of the Directive
94/9/EC for explosion group, unit category and temperature class speci-
fied on the type plate.
The unit is suitable for being installed in explosion-protection zone I. The unit
of group II must be assigned to unit category 2G due to the possible genera-
tion of explosion producing atmospheres resulting from gasses and paint mist.
The ignition temperature of the materials and solvents to be used must lie
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Description of equipment

above 200 °C.
When operating the unit, the specifications in this operating manual must be
observed in all cases.
The specified inspection and maintenance intervals must be observed.
The details on the unit plates or the details in the chapter Technical Data
must be observed under all circumstances and should not be exceeded.
An overloading of the unit must be excluded.
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 mea-
sures of the responsible inspecting authority. The operator is responsible for
checking and ensuring that all technical data and markings according to ATEX
correspond with the necessary requirements.
Make sure that several components have their own type plate with separate
marking according to ATEX.
The respective lowest explosion protection of the marking attached applies
for 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.
In case problems can be noticed during operation, the unit must be stopped
immediately and contact should be established with WIWA.
You must make sure that the unit is earthed separately or together with the
unit that it is mounted on (max. resistance 106 Ω).
Any other use is deemed not in accordance with regulations. The manufac-
turer's approval must be obtained before the spray gun is used for any other
purpose or with other materials, i.e. not in accordance with the intended use,
otherwise the warranty will become null and void.
Intended use also includes compliance with the technical documentation and
adherence to the prescribed operating, servicing and maintenance guidelines.
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Description of equipment

3.2 Assembly details
Pos. Description
1air cap with tip
2 union nut
3hook
4flat jet regulation
5 round jet regulation
6spring adjustment
Pos. Description
7 trigger
8trigger lock bolt
9paint tube with filter insert
10 fluid connection 1/4"
11 air connection 1/4"
1 2
5
7
9
8
10
6
3 4
11
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Description of equipment

3.3 Technical data
3.3.1 Connected loads
Maximum permitted air pressure 8 bar
Recommended operating pressure
Operating pressure depends on viscosity, nozzle size and
kind of spray system (Airless - Air Combi)
1,5 - 3 bar
Maximum permitted material temperature by operation
without gloves
40 °C
Maximum permitted material temperature by operation with
gloves
60 °C
Maximum permitted material pressure 250 bar
For short positive pressures of 10 - 12 bar ( 143 – 170 psi ) at the air supply
and higher pump pressures (above 250 bar – 3.556 psi material pressure)
there is no danger of damage to the high pressure spray gun.
Positive pressure in the material area are compensated by automatic release
of the paint needle.
Caution! This releases spraying material!
3.3.2 Material consumption and output values
Material consumption values: vary depending on nozzle bore and pump
pressure
Material output values: Measurement based on the following values:
Operating pressure 100 bar
Nozzle size 0,23 mm
Material viscosity 45 sec. DIN 4 mm/20 °C
Material output approx. 0,26 l/min
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Description of equipment

3.3.3 Air consumption
Air consumption of the high pressure paint spray gun (total air regulating valve
adjusted fully on max.)
Round jet Flat jet
1 bar 5 m3/h 84 l/min 1 bar 4,3 m3/h 72 l/min
2 bar 8,1 m3/h 136 l/min 2 bar 6,9 m3/h 115 l/min
3 bar 11,1 m3/h 185 l/min 3 bar 9,2 m3/h 154 l/min
These values can be reduced by operating the total air adjustment by approx.
80% (i.e. values are than only approx. 20 %)
3.3.4 Workstation related sound pressure level
Measured values:
Round jet Flat jet
1,0 bar 67 dB/A 69 dB/A
1,5 bar 71 dB/A 74 dB/A
2,5 bar 78 dB/A 79 dB/A
The measurements and datas are based on the following rules of the measur-
ing technique:
Regulation for equipment safety law DIN 45635 Part 1/04.84
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4 Setting-up
Read and follow additionally the instructions in the user's
handbook for the spray equipment!
Flush the material passages incl. tip with solvent/cleaning fluid
prior to the initial operation.
 Secure the spray gun with the trigger lock (Fig. 4.1) for
setting-up.
 Observe and follow the operation manual of the spray-
ing equipment.
Installation of the spray tip
The proper tip size for your requirements can be found in the attached spare
parts list.
The correct tip size depends on the spray application, the
spray material and the characteristics of the work piece.
1. Place the trigger lock (see assembly details, Pos. 8) in the horizontal
position to prevent the accidental discharge of material.
Before each tip replacement, the air supply must be interrupted
and the spray gun pressure released!
2. Unscrew the swivel nut.
3. Remove the air cap.
Fig. 4.1
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4. Place the spray tip into the air
cap so that the groove in the tip
matches the pin in the air cap
(fig. 4.2).
This prevents the tip from rotat-
ing in the cap.
Fig. 4.2
Pos. Description
1 Groove on the spray tip
2 Pin on the air cap
2
1
5. Place the air cap with tip into the
spray gun.
6. Screw the swivel nut onto the
spray gun.
Installation of the filter
1. Select a filter from the table in the attached spare parts list.
The mesh spacing should not be larger than the tip orifice!
2. Use an open-end wrench to loosen the fluid tube lower.
3. Remove the previously installed filter, if any.
4. Place the new filter in the fluid tube upper.
5. Screw the paint tube lower piece onto the paint tube upper piece.
Take care that the gasket is correctly positioned!
Connecting the air and fluid hoses
Install the required tip, before the air and material hoses for the spray unit are
attached to the spray gun.
Screw the material hose onto the connecting threads of the spray gun (s.
Assembly Details, Pos. 10).
Use only authorized high pressure hoses!
Ensure there is proper seating of the ball/cone seal !
Screw the air hose onto the connecting threads of the spray gun. (s.
Spray gun assembly, Pos. 11)
Clean and dry air increases the quality of the spray pattern and
extends the life of the spray gun!
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