wiwa PHOENIX GX Series User manual

1alpg_BA_en_bb-0550010 ✓
PHOENIX GX SERIES
Operation Manual
1K Airless/AirCombi
Serial No.:

EC declaration of conformity
in accordance with Annex II, No. 1 A of Machine Directive 2006 / 42 / EC,
as amended by 2009 / 127 / EC
The company WIWA Wilhelm Wagner GmbH & Co. KG
35633 Lahnau
Gewerbestraße 1–3
Germany
hereby declares that the ma-
chine type
PHOENIX GX SERIES
with serial no.
conforms with the provisions of the above directives.
Responsible for documentation: WIWA, [phone]
Lahnau, October 21, 2021
Place, Date Dipl.-Ing. (FH) Peter Turczak
Managing Director
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EU declaration of conformity
in accordance with ATEX Directives
The company WIWA Wilhelm Wagner GmbH & Co. KG
35633 Lahnau
Gewerbestraße 1–3
Germany
hereby declares that the ma-
chine type
PHOENIX GX SERIES
with serial no.
conforms with the provisions of Directive 2014 / 34 / EU.
The listed machine is assigned to Group II, Category 2G.
Labeling: II 2G Ex h IIB T4 Gb
Lahnau, October 21, 2021
Place, Date Dipl.-Ing. (FH) Peter Turczak
Managing Director
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Contents
Contents
1 Foreword 1
2 Safety 3
2.1 Explanation of symbols . . . . . . . . . . . . . . . . . 3
2.2 Safetynotes........................ 6
2.2.1 Working pressure . . . . . . . . . . . . . . . . 7
2.2.2 Risks due to the spray jet . . . . . . . . . . . . 7
2.2.3 Risks due to electrostatic charge . . . . . . . . 8
2.2.4 Risks due to hot or cold surfaces . . . . . . . . 9
2.2.5 Explosion protection . . . . . . . . . . . . . . . 9
2.2.6 Health risks . . . . . . . . . . . . . . . . . . . . 11
2.3 Safetysigns........................ 12
2.4 Safety features . . . . . . . . . . . . . . . . . . . . . . 13
2.4.1 Safety valve . . . . . . . . . . . . . . . . . . . . 14
2.4.2 Compressed air shut-o valve . . . . . . . . . . 15
2.4.3 Ground cable . . . . . . . . . . . . . . . . . . . 16
2.5 Operating and maintenance personnel . . . . . . . . . 16
2.5.1 Obligations of the owner . . . . . . . . . . . . . 16
2.5.2 Personnel qualications . . . . . . . . . . . . . 17
2.5.3 Authorized operator . . . . . . . . . . . . . . . 17
2.5.4 Personal protective equipment . . . . . . . . . 17
2.6 Warranty and liability . . . . . . . . . . . . . . . . . . . 18
2.6.1 Spare parts . . . . . . . . . . . . . . . . . . . . 19
2.6.2 Accessories . . . . . . . . . . . . . . . . . . . . 19
2.7 How to respond in an emergency . . . . . . . . . . . . 19
2.7.1 Shutting down the machine and relieving the
pressure...................... 19
2.7.2 Leakage...................... 20
2.7.3 Injuries ...................... 20
3 Description 21
3.1 Intendeduse ....................... 22
3.2 Erroneous use . . . . . . . . . . . . . . . . . . . . . . 23
3.3 Machine design . . . . . . . . . . . . . . . . . . . . . . 24
3.3.1 Machine design variants . . . . . . . . . . . . . 25
3.4 Optional expansions and accessories . . . . . . . . . 26
3.4.1 Spraying accessory kits . . . . . . . . . . . . . 26
3.4.2 Hose holder attachment kit . . . . . . . . . . . 27
3.4.3 AirCombi attachment kit . . . . . . . . . . . . . 28
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Contents
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 . 32
4.3.2 Grounding the machine . . . . . . . . . . . . . 33
4.3.3 Connecting the compressed air supply . . . . . 33
5 Operation 35
5.1 Putting the machine into operation . . . . . . . . . . . 35
5.2 Spraying.......................... 36
5.2.1 Setting the spraying pressure . . . . . . . . . . 37
5.2.2 Tips for good coatings . . . . . . . . . . . . . . 38
5.3 Flushing.......................... 38
5.4 Material change . . . . . . . . . . . . . . . . . . . . . 41
5.5 Pressure relief . . . . . . . . . . . . . . . . . . . . . . 41
5.6 Work interruption . . . . . . . . . . . . . . . . . . . . . 42
5.7 Decommissioning . . . . . . . . . . . . . . . . . . . . 42
5.8 Storage .......................... 43
5.9 Disposal.......................... 44
6 Maintenance 45
6.1 Regular testing . . . . . . . . . . . . . . . . . . . . . . 46
6.2 Maintenance schedule . . . . . . . . . . . . . . . . . . 47
6.3 Safetyvalve........................ 47
6.3.1 Checking the safety valve . . . . . . . . . . . . 47
6.3.2 Replacing the safety valve . . . . . . . . . . . . 49
6.4 High pressure pump . . . . . . . . . . . . . . . . . . . 49
6.4.1 Checking the release agent for material residues 49
6.4.2 Filling the release agent and checking the ll level 50
6.5 High pressure lter . . . . . . . . . . . . . . . . . . . . 50
6.5.1 Cleaning the lter element . . . . . . . . . . . . 50
6.5.2 Filter elements for high pressure lters . . . . . 52
6.6 Checking the compressed air and material hoses . . . 53
6.7 Recommended operating uids . . . . . . . . . . . . . 53
7 Eliminating operational faults 55
8 Technical Information 60
8.1 Typeplate......................... 60
8.2 QRcode.......................... 60
8.3 Emission sound pressure level in the workplace . . . . 60
8.4 Technical data . . . . . . . . . . . . . . . . . . . . . . 62
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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 owner must ensure that the operating and maintenance per-
sonnel 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.
In Germany, these are:
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 preven-
tion regulations with the operation manual.
Furthermore, always observe the safety data sheets, manufacturer’s
instructions and processing guidelines for coating or conveyance
materials.
If questions should arise, we would be happy to assist you.
We wish you excellent working results with your machine
WIWA Wilhelm Wagner GmbH & Co. KG
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1

Foreword
Copyright
© 2021 WIWA
The copyright to this operation manual belongs to
WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestraße 1–3 • 35633 Lahnau • Germany
Phone: [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 autho-
rized to do so. Infringement will lead to compensation. All rights to any patent,
utility model or design registrations are reserved.
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Safety
2 Safety
This machine has been designed and manufactured taking into con-
sideration all safety aspects. It conforms to the current state of the
art and the applicable 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 ecient function of the machine.
It is fundamentally prohibited to implement any method of work that
has a negative inuence on the safety of the operating personnel and
the machine. 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 conrmed in writing.
2.1 Explanation of symbols
Safety notes warn of potential accident risks and describe the mea-
sures required for accident prevention. In the WIWA operation manu-
als, 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!
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Safety
CAUTION
Signals a risk of accidents that may result in injuries, if the safety
note is not observed!
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
Warning of crushing
Warning of corrosive substances
Risk of cutting injuries due to rotating machine parts
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Safety
Risk of burning due to hot surfaces
Risk of freezing due to cold surfaces
The rst 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 the processing material or
gases.
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, burns when processing heated
materials, or freezing due to contact with very cold surfaces.
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Safety
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 ob-
served.
Indicates a special note on explosion protection.
Indicates a special note on grounding.
2.2 Safety notes
Always remember that this machine operates at high pressures and
can cause life-threatening injuries if handled incorrectly!
Do not leave the machine unattended during operation. You must be
able to intervene immediately in an emergency.
Always observe and follow all information in this operation manual
and in the separate operation manuals for the individual machine
parts and optional accessories.
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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 pres-
sures 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 maxi-
mum 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 your ngers 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.
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Safety
WARNING
An unintended ejection of material from the spray gun can cause
personal injury and property damage.
Do not clamp the trigger of the spray gun during operation!
Secure the spray gun whenever interrupting work!
Prior to each commissioning, always check the spray gun lock!
2.2.3 Risks due to electrostatic charge
WARNING
The high ow velocities can result in an electrostatic charge. Static
discharges can result in re and explosions.
Ensure that the machine is correctly grounded!
Also ground the object that is to be coated.
Always use open, electrically conductive containers and put them
on a grounded surface.
Never spray solvents or materials containing solvents into narrow-
mouthed cans or barrels with a bung opening!
Only use electrically conductive material hoses. All original ma-
terial hoses from WIWA are conductive and designed for our
devices.
Only use electrically conductive accessories/accessory parts.
WARNING
Dirty machines can become electrostatically charged. Static dis-
charges can result in re and explosions.
Keep the machine clean.
Always perform the cleaning work outside of EX zones.
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Safety
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.
CAUTION
Air motors can become very cold during operation. Local frostbite
can occur due to contact with very cold surfaces.
Prior to all work on the machine, heat air motors up to a temper-
ature above 10°C.
Wear suitable protective gloves!
2.2.5 Explosion protection
The following short designations are used in the instructions of WIWA :
Ex protection: Explosion protection
Ex area: potentially explosive or non-explosion protected area
Non-Ex area: non-explosive or explosion protected area
Ex zone: Explosion protection zone according to ATEX Directive
ATEX knowledge: Knowledge of explosion protection according to
ATEX Directive
WARNING
Machines and accessories that are not explosion-protected may not
be used in operating facilities that fall under the explosion protection
ordinance!
Explosion-protected machines can be identied by the corresponding
mark on the type plate and/or the ATEX-declaration of conformity
provided.
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Safety
When using the machine in Ex zones, the specialist personnel must
have knowledge of ATEX.
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.
For applications, in which a failure of the machine could lead to dangers
to personnel, the owner is required to implement appropriate safety
measures.
Please note that some parts have their own type plate with separate la-
beling according to ATEX. In this case, the lowest explosion protection
of all labels displayed applies to the entire machine.
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.
WARNING
Heating solvents can lead to an explosion. Serious personal injuries
and property damage may result.
Observe the ashpoint and ignition temperature of solvents.
Switch all heating systems o when carrying out the following
work: Cleaning, pressure testing, decommissioning, mainte-
nance and repair.
Never immerse a hot spray gun in solvent.
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Safety
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 suciently ventilated and aired.
Always observe the safety data sheets and processing instruc-
tions 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 prod-
ucts 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 chlo-
ride or other solvents that contain halogenated chlorinated hydro-
carbons (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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Safety
2.3 Safety signs
The safety signs attached on the machine,
such as for example the safety card (see
Fig. 1), indicate possible hazard points and
must be observed.
The symbolism on the safety signs corre-
sponds to the labeling of the safety notes
described in section 2.1 on page 3.
The safety signs may not be removed from
the machine.
Damaged and illegible safety signs must be
replaced immediately.
Also read and observe the safety notes in
the operation manual!
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
0bar
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!
Fig. 1: Safety card
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Safety
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 rectied.
The machine is equipped with the following safety features:
Safety valve,
Compressed air shut-o valve with automatic ventilation and
Ground cable.
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.
Checklist on the pressureless machine:
Seal on the safety valve OK?
Safety valve externally free of damage?
Ground cable free of damage?
 Is the ground cable connected to the machine and OK at the circuit
board?
Mobility of the compressed air shut-o valve OK?
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Safety
Checklist on the pressurized machine after all cleaning, mainte-
nance, and repair work:
 Function of the safety valve OK? (For function test, section 6.3 on
page 47.)
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 on the machine (for example,
see Fig. 2).
The safety valve prevents the maximum
permissible air inlet pressure from be-
ing exceeded. If the air inlet pressure
exceeds the permanently set threshold
value, the safety valve blows o.
Fig. 2: Safety valve for Phoenix
GX 140 AirCombi
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 de-
fective 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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