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PHOENIX GX SERIES

Operation Manual

Air

less/AirCombi

Serial No.:

Summary of Contents for PHOENIX GX Series

Page 1: ...1alpg_BA_en_bb 0550010 PHOENIX GX SERIES Operation Manual 1K Airless AirCombi Serial No...

Page 2: ...35633 Lahnau Gewerbestra e 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...

Page 3: ...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...

Page 4: ......

Page 5: ...ligations of the owner 16 2 5 2 Personnel qualifications 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...

Page 6: ...6 1 Regular testing 46 6 2 Maintenance schedule 47 6 3 Safety valve 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 agen...

Page 7: ...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 fluid jets both from the pr...

Page 8: ...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 it...

Page 9: ...ine 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 c...

Page 10: ...s 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 explo...

Page 11: ...ive 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 n...

Page 12: ...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 incorrect...

Page 13: ...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 h...

Page 14: ...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 mou...

Page 15: ...t 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 ar...

Page 16: ...easures 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 machi...

Page 17: ...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 aluminu...

Page 18: ...an emergency Shut off power supply and relieve pressure En cas d urgence Bloquer l alimentation en nergie et rel cher la pression En caso de emergencia Cortar el suministro de energ a y despresurizar...

Page 19: ...wing safety features Safety valve Compressed air shut off valve with automatic ventilation and Ground cable Check the safety features on the machine Prior to commissioning Always prior to starting wor...

Page 20: ...exceeds the permanently set threshold value the safety valve blows off Fig 2 Safety valve for Phoenix GX 140 AirCombi WARNING If the maximum permissible air inlet pressure is exceeded parts may ruptu...

Page 21: ...le To open opened Position in 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 shuttin...

Page 22: ...ble for training the operating and maintenance person nel must instruct the operating and maintenance personnel on correct handling of the machine and on wearing the correct work clothing and protecti...

Page 23: ...sible 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 per...

Page 24: ...ical resistant protective gloves with forearm protection to prevent injuries due to aggressive chemicals burns when processing heated materials or freezing due to contact with very cold surfaces Wear...

Page 25: ...t be liable for any damage or injuries due to these parts It is essential to observe the safety provisions applicable to the accessories You can find these safety provisions in the separate operation...

Page 26: ...relieve the pressure Tighten threaded connections and replace defective parts must be performed by trained personnel Do not seal leakage at connections and on high pressure hoses with the hand or by...

Page 27: ...ed solely through the material pressure and the nozzle incorporated in the spray gun Fig 6 Flow chart during airless spraying No Description 1 Airless spray device 2 Airless spray gun 3 High pressure...

Page 28: ...s spraying in the airless version and air supported spraying in the AirCombi version of coating materials and additives in surface technology The Phoenix GX series was especially developed for the woo...

Page 29: ...us use applies in particular if impermissible materials are processed unauthorized modifications or changes are implemented the safety features are removed modified or bypassed spare parts are install...

Page 30: ...with air motor 140 on cart No Designation Further information 1 Muffler 2 Compressed air shut off valve section 2 4 2 on page 15 3 Compressed air regulator 4 Filler opening for release agent section 6...

Page 31: ...f valve 9 Connection for spraying hose section 4 3 1 on page 32 10 Relief hose 11 Fluid pump 12 Folder for operation manual 13 Air motor 140 or 200 14 Cart 3 3 1 Machine design variants Fig 9 Phoenix...

Page 32: ...og can be found at www wiwa de For further information and order numbers you can also contact a WIWA dealer or WIWA customer service 3 4 1 Spraying accessory kits The spraying accessory is not part of...

Page 33: ...the spray gun 3 4 2 Hose holder attachment kit The optional hose holder enables the space saving storage of the spraying hose on the device Fig 12 Installing the hose holder Fig 13 Winding the hose Or...

Page 34: ...pump AirCombi devices are equipped with an additional compressed air regulator to regu late the atomizer air pressure The 2nd compressed air regulator for the AirCombi operation can be retrofitted as...

Page 35: ...ing and loading Attention danger of tipping When loading the machine ensure sufficient load bearing capacity of the lifting gear and lifting accessories The dimensions and weight of the machine can be...

Page 36: ...achine during transport Remove all loose parts e g tools from the machine 4 2 Installation site The machine is intended for installation outside of Ex zones by default Installation inside of Ex zones...

Page 37: ...venting of the workplace It is necessary to guarantee at least five times air exchange Although there are no legal regulations for the low mist injection process itself dangerous solvent vapors and ma...

Page 38: ...pment re moved for transport purposes as required for the intended use Carry out further assembly work and establish the connections in accordance with the descriptions below 4 3 1 Connecting the spra...

Page 39: ...operation can result in an electrostatic charge Static discharges can result in fire and explosions Ensure that the machine is properly grounded outside of Ex zones Ensure correct grounding of the obj...

Page 40: ...t free compressed air which corresponds to purity class 7 5 4 according to DIN ISO 8573 1 2010 1 Ensure that the compressed air shut off valve is closed the compressed air regulator is completely thro...

Page 41: ...material These containers are not included in the scope of delivery Observe and follow the material and safety data sheets of the respec tive material manufacturer when processing and storing process...

Page 42: ...the work steps for commissioning must have been performed see chap Putting the machine into operation on page 1 Put the suction into the spraying material 2 Open the compressed air shut off valve 3 A...

Page 43: ...spraying pressure The optimum spraying pressure has been attained when an even application with fading edge zones is obtained Only operate the machine with as much pressure as required in order to at...

Page 44: ...a faultless soft and smooth overlapping of the spray jet and avoid an excessively thick material application at the start of the coating process Release the trigger before stopping the movement Chang...

Page 45: ...turn off the material fluid heater optional and let it cool off completely You will need at least 5 l of cleaning agent that is suitable for the material to be processed and is recommended by the mat...

Page 46: ...ure to escape slowly Remove the blockages Observe the fault table see section 7 on page 55 7 Remove the nozzle from the spray gun Observe and follow the information in the user manual for the spray gu...

Page 47: ...ing the spray gun until air escapes 3 Completely reduce the air inlet pressure 0 bar 4 Close and lock the spray gun 5 Relieve the pressure in the device see section 5 5 on page 41 6 Check the filter e...

Page 48: ...e in section 7 on page 55 5 6 Work interruption Lock the spray gun for even the shortest interruptions to work Observe the pot life of the materials used in particular when using a multi component mat...

Page 49: ...nst slipping out unintentionally Briefly open the relief valve to release the remaining material pressure The cleaning agent that is still in the machine remains in the machine until it is restarted s...

Page 50: ...water protection laws apply At the end of the machine s use it must be put out of use disassembled and disposed of according to the legal regulations Thoroughly clean the machine of material residues...

Page 51: ...by WIWA customer service or specially trained personnel WARNING W021 D During maintenance work ignition sources may arise e g due to mechanical sparks electrostatic discharge etc Carry out all mainte...

Page 52: ...achine 6 1 Regular testing The machine must be inspected and maintained regularly by a spe cialist prior to first commissioning after changes to the servicing of parts of the installation that affect...

Page 53: ...lease agent if necessary section 6 4 2 on page 50 Once per week Visual inspection of the compressed air and material hoses section 6 6 on page 53 Every 50 operating hours Check the high pressure pump...

Page 54: ...mum permissible pressure according to the type plate The safety valve must discharge Safety valve with 1 2 connection Only perform the test by hand To prevent damage to the safety valve do not use any...

Page 55: ...panner to the spanner flat Fig 21 on page 48 and Fig 22 on page 48 and unscrew the safety valve by turning counter clockwise 2 Check the connection point It must be free of blockages and clean 3 Inser...

Page 56: ...ng bottle 2 The release agent overflow is located below the screw connection of the air motor with the material pump 3 The release agent should be at the center of the inspection glass for optimal fil...

Page 57: ...lief valve 4 on the high pressure filter and briefly trigger the gun to make sure that the machine is absolutely pressureless 2 Release the cap 2 using the hook wrench 1 3 Unscrew the nut 6 and remove...

Page 58: ...0628 M 100 black 0 33 mm 013 up to 0 38 mm 015 0162760 0160059 M 70 yellow 0 38 mm 015 up to 0 66 mm 026 0162779 0160601 M 50 orange 0 66 mm 026 0162787 0163023 M 30 blue 0467782 0463779 M 20 green 06...

Page 59: ...al hoses must be checked by a specialist every three years The duration of use of a hose line including any possible storage duration may not exceed six years The manufacturing date of a hose line mon...

Page 60: ...as well as the dosing valves On the model with maintenance unit Materials required during maintenance and repair work see infor mation in the spare parts lists The release agent and pneumatic oil are...

Page 61: ...f not pos sible compressed air shut off valve closed Relief hose or relief ball valve clogged High pressure filter blocked Carefully loosen threaded connec tions and cover them with a cloth Remove har...

Page 62: ...shut off valve No air inlet pressure compressed air regulator at 0 bar Increase air inlet pressure Spray gun clogged Check clean and if necessary replace nozzle filter element Relief hose or ball valv...

Page 63: ...high pressure filter Move the bottom valve to the side with a slight impact rubber hammer Unscrew suction system and release the ball in the bottom valve from below using a pin or a screwdriver Bottom...

Page 64: ...ase the air pressure on the compressed air regulator or check the air line for the correct cross section Spray nozzle new is too large Insert a smaller nozzle or use a larger pump Spray nozzle worn to...

Page 65: ...e and replace if necessary see the spare parts list for the suction hose and the direct intake Bottom valve is leaking pump only stops in the upstroke when spray gun is closed Unscrew the bottom valve...

Page 66: ...pport for your device type on the WIWA website You can find further information for your device there such as e g spare parts lists repair instructions etc Scan the QR code using your mobile device e...

Page 67: ...Technical Information Ambient temperature 30 C to 50 C 22 F to 122 F Max operating temperature 80 C 176 F Original Operation Manual Status 2021 07 23 1alpg_BA_en_bb 0550010 61...

Page 68: ...put at 60 DS l min gpm Delivery volumne per DS cm3 fl oz Max air inlet pressure bar psi safety valve Max permissible working pressure bar psi Air consumption at 20 DS min at 1 bar l min gpm Air intake...

Page 69: ...Technical Information Original Operation Manual Status 2021 07 23 1alpg_BA_en_bb 0550010 63...

Page 70: ...Technical Information 64 Original Operation Manual Status 2021 07 23 1alpg_BA_en_bb 0550010...

Page 71: ...Technical Information Original Operation Manual Status 2021 07 23 1alpg_BA_en_bb 0550010 65...

Page 72: ...1 3 35633 Lahnau Germany Phone 49 0 6441 609 0 Fax 49 0 6441 609 2450 Email info wiwa de Website www wiwa de WIWA subsidiary USA LLC USA Kanada Lateinamerika 107 N Main St P O Box 398 Alger OH 45812 U...

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