Operating instructions and spare parts list

Operating instructions and spare
parts list
DOK-265-GB
Rev.
0
designation
airless spray appliance
type
30-20
Order-No.: 7120-000
- keep for further use -
Dokumentation
DOK-265-GB.doc Rev.0
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
1 The Airless process
Atomization and agent application are brought about without the use of air, thus the term Airless. The agent is being atomized by squeezing it under an extremely high pressure through
the small bore of the material nozzle. In the process the agent is disintegrated into individual
particles.
The pressure required for the Krautzberger Airless process may attain up to 480bar and is
generated by compressed air operated positive-displacement piston pumps.
Advantages of the Airless spray
upgrated spray performances
instant surface coating due to a full and saturated homogeneous spray pattern and
instant film formation
reduced spray time
increased material yield due to minimized spray fogs and low material rebound.
fatigueless working brought about by a light and handy spray gun design equipped
with only on material supply hose
optimized atomisation even of high viscous materials
2 Method of operation of the positive-displacement pump
By means of an independently controlled air motor which is alternately applying pressure
onto the motor piston, the recuperator piston of the pump is moved upwards and downwards.
Air motor and recuperator piston are interconnected via an coupling system.
Whilst moving upwards the suction valve is opened and the agent is sucked into the lower
chamber of the hydraulic unit. Simultaneously the pressure valve located in the piston is being closed and the recuperator piston feeds the agent into the hydraulic unit.
The set spray pressure and the adopted nozzle size determine the stroke frequency, the air
consumption. and thus the respective spray performance of the positive-displacement pump.
All agent conveying pump components consist of special steel 18/8
3 Mounting and installation
The Airless pump is to be installed in such a way as to render it easily accessible for maintenance and cleaning purposes.
The pump holder is provided with an earthing srew to which the ground wire must be connected in order to ground the static charge generated by the agent flowing within the hose.
2
Dokumentation
DOK-265-GB.doc Rev.0
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
Connect the Airless pump only with a heavy duty compressed-air supply net: designed for a
maximum compressed air consumption.
PRIOR TO START-UP, CLOSE THE PRESSURE REGULATOR OF THE AIRLESS PUMP
BY COUNTER-CLOCKWISE TURNING THE HAND-WHEEL.
The piping supplying compressed air to the Airless-pump should have a nominal width of 9.
Furthermore we recommend to provide the compressed air supply net with an oil- and water
separator in order to prevent foreign bodies from penetrating into both air motor and independently operating control system.
If need be a compressed air-oiler with deicing agent maybe installed between airless pump
and oil/water separator.
Use only the original suction gear in order to ensure proper pump sucking.
Engage spray gun`s safety catch and connect the material supply hose at the outlet of the
high-pressure filter.
WHEN IT COMES TO MATERIAL SUPPLY HOSES WITH SAFETY CONDUCTOR IN ORDER TO PREVENT ELECTROSTATIC CHARGES FROM BEING GENERATED.
CAUTION:
With regard to operating the Airless pump we prefer to the safety rules edited and published
by the applicable employers liability insurance.
4 Start-up
Entirely close pressure regulator at motor
connect compressed air-hose (max. 8bar)
in case the pump is provided with a material filter, (strongly recommended by us) a filter mesh matching the nozzle requirements must be used. See table
Fill rinsing agent into the rinsing chamber, until the sight glass shows a 70% fillin level
Slowly open pressure regulator until air motor starts working.
Rinse the Airless pump by means of the rinsing agent in order to get the preservatives out of the pump
put the suction hose into the spray agent
open spray gun in order to evacuate the air still contained in the system
When the spray agent starts to emerging from the spray gun, close spray gun and set
the required working pressure at the pressure regulator (max 8bar)
CAUTION!
PAY ATTENTION TO THE PRESSURE TRANSFORMATION RATIO!
3
Dokumentation
DOK-265-GB.doc Rev.0
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
Under no-load conditions the AIrless-pump must only be operated for a short time and at a
slow running level.
Otherwise motor, suction valve, piston valve and the pump sealing may be damaged.
CAUTION!
The spay jet emerging from the spray gun is dangerous. For this reason aim the spray gun
only downwards.
5 Switching off
Switching-off
Entirely close pressure regulator at motor
disconnect spray gun and render the system pressureless.
remove and clean the spray nozzle
remove suction hose out of the spray agent and put it in a thinner
slowly open pressure regulator whilst the spay gun is being opened, until the air motor starts working
rinse spray gun and pump by means of a thinner. In the process make sure that the
motor runs at a slow level only
for rough cleaning of the filter during rinsing , shortly open the cock at filter
Maintenance
Daily check rinsing agent level during operation. Sight glass must show a 70% filling level.
In case the rinsing agent is contaminated by the spray agent, replace the rinsing agent. If, after a short time only, the rinsing agent should again be contaminated or should the rinsing
agent level displayed by the sight glass increase, we recommend to replace the gasket set,
item 22 and item 30.
By replacing these gasket sets, the recuperator piston prevented from being worn out pematurely.
We recommend to open the material filter at fixed intervals in order to clean the filter housing,
mesh inclusive.
CAUTION!
Prior to opening material filter refer to instructions
4
Dokumentation
DOK-265-GB.doc Rev.0
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
6 Technical data
Air consumption
Example
input air pressure:
4,0bar
pump type:
30-20
air consumption/double stroke:
5.45litres
pressure transformation ratio
30:1
delivery volume/double stroke
40ccm
max. recommended double strokes/minute
50
max. air pressure
8bar
max. spray agent pressure in bar
240bar
recommended delivery volume
2,0l/min (50 double strokes/minute)
max. delivery volume
4,0l/min (100 double strokes/minute)
5
Dokumentation
DOK-265-GB.doc Rev.0
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
7 Trouble shooting guide
kind of malfunction
origin of malfunction (unit)
drive
hydraulic unit
pump does
not start or
Stopps running durin
operation
no or insufficient pump
sucking
spray pressure to low
clean control
and defective
parts
high pressure
filter
insufficient
venting, leaking screwing
between hydraulic unit
and suction
gear
mesh basket
obstructed
filter contaminated, check for passage and
cleanliness
high pressure
material hose
choked hose, check for passage and cleanliness
suction gear
suction/pressure
valve
sealing sets
pump continues running even
though
spray gun is
closed
pump feeds
agent into
rinsing
chamber
clean control
and defective
parts
insufficient
venting, leaking screwing
between hydraulic unit
and suction
gear
mesh basket
obstructed
iced control
pump runs
too fast
worn or blocked, replace defective parts
upper gasket
set leaking
leaking gaskets
atomizer nozzle
pressure reducing valve
nozzle bore
choked
air pressure
too low
compressed
air piping
insufficient air
quantity, air
pressure too
low
spray agent
uneven operation of
pump
excessive
nozzle bore
air pressure
too low
insufficient air
quantity, air
pressure too
low
viscosity too high
6
excessive
nozzle bore
Dokumentation
DOK-265-GB.doc Rev.0
8 Units of the airless-pump 30-20
7
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
Dokumentation
DOK-265-GB.doc Rev.0
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
Item
designation
Order No.
1
motor, compl.
7120-080-0456
2
control unit, compl.
7120-080-3141
3
pump, compl.
7120-090-0005
4
filter compl.
7120-080-0013
5
suction gear, compl.
7120-080-0298
8
Dokumentation
DOK-265-GB.doc Rev.0
8.1
spare parts drawing motor 125
9
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
Dokumentation
DOK-265-GB.doc Rev.0
8.1.1
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
spare parts list motor 125
Item
designation
Order No.
1
lower part
7120-040-438
2
upper part
7120-040-0439
3
cylinder tube
7120-040-0440
4
piston
7120-040-0441
5
piston rod
7120-040-0030
6
tappet rod (2pcs)
7120-040-0034
9
control unit compl. (8bar air pressure)
7120-080-3141
9
control unit compl. (6bar air pressure)
7120-080-3142
10
bushing
7120-040-0041
11
pressure spring (2 pcs)
7120-020-0076
12
ring bolt
7120-030-0143
13
screw (2 pcs)
7120-030-0310
14
screw (2 pcs)
7120-030-0315
15
screw (4 pcs)
7120-030-0512
16
screw
7120-030-0354
17
safety disk (4 pcs)
7120-030-0706
18
safety disk (4 pcs)
7120-030-0714
19
safety ring
7120-030-0718
20
safety dis (2 pcs)
7120-030-0719
21
disk (2 pcs)
7120-030-2857
22
disk (2 pcs)
7120-030-2856
23
disk
7120-030-2867
24
disk
7120-040-0042
*25
gasket (2 pcs)
7120-010-0247
*26
o-ring (2 pcs)
7120-010-0241
*27
o-ring
7120-010-0254
*28
o-ring (2 pcs)
7120-010-0255
*29
gasket
7120-010-0898
*30
gasket
7120-010-0257
31
coupling (2 pcs)
7120-040-0062
32
spring clip
7120-020-0150
7
8
10
Dokumentation
DOK-265-GB.doc Rev.0
8.2
spare parts drawing control unit., 8bar
11
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
Dokumentation
DOK-265-GB.doc Rev.0
8.2.1
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
spare parts list control unit., 8bar
Item
designation
Order-No.
1
air distributor
7120-080-0197
2
control valve, incl. item. 21-25
7120-130-0305
3
connector
7120-040-0446
4
screw (2 pcs)
7120-030-0294
5
safety disk (2 pcs)
7120-030-0706
6
manometer
7120-030-0720
*7
gasket
7120-010-0251
*8
o-ring
7120-010-0243
*9
gasket
7120-010-0244
*10
gasket
7120-010-0245
*11
gasket (2 pcs)
7120-010-0287
12
extension
7120-030-0708
13
bend
7120-030-2020
14
double nipple (2 pcs)
7120-030-1991
15
silencer
7120-030-0711
16
pressure reducer
7120-030-1313
17
safety valve ,8bar
7120-130-0179
18
angle fitting
7120-080-0207
19
fitting
7120-030-2406
20
pipe, length 82mm
7120-100-0439
21
5/2 way valve compl.
7120-080-3017
22
3/2 way valve, compl. (2 pcs)
7120-130-0306
23
screw (8 pcs)
7120-030-0294
24
safety disk (8 pcs)
7120-030-0706
*25
o-ring (6 pcs)
7120-010-0636
12
Dokumentation
DOK-265-GB.doc Rev.0
8.3
spare parts drawing hydraulic system
13
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
Dokumentation
DOK-265-GB.doc Rev.0
8.3.1
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
spare parts list hydraulic system
Item
Designation
Order-no.
1
pump holder
7120-080-0006
2
screw
7120-030-0524
3
safety disk
7120-030-0714
4
thread plug
7120-030-0516
5
ring
7120-040-0460
6
clip ring
7120-040-0458
7
disc
7120-030-2869
8
screw
7120-030-0514
9
upper part tube
7120-040-0607
10
piston
7120-040-0611
11
ball
7120-030-2746
12
ball valve seat
7120-040-0598
13
fastener srew
7120-080-0005
14
lower part tube
7120-040-0608
15
ball
7120-030-2749
16
pump fastener
7120-080-0003
17
gasket
7120-010-0287
18
screw in socket
7120-040-0600
19
rinsing chamber
7120-040-0060
20
gauge
7120-030-1879
21
gasket
7120-010-0244
22
gasket, compl. PTFE (standard)
7120-010-0302
22
gasket, compl. PTFE-leather
7120-010-0314
22
gasket. compl. leather
7120-010-0315
23
pressure ring
7120-040-0590
26
double nippel
7120-0040-0601
27
gasket
7120-010--0260
29
pressure ring
7120-040-0591
30
gasket compl. PTFE (standard)
7120-010-0303
30
gasket compl. PTFE-leather
7120-010-0316
30
gasket compl. leather
7120-010-0317
31
gasket
7120-010-0262
32
gasket
7120-010-0263
33
disk
7120-030-2874
34
hexagonal nut
7120-030-0499
* = gasket set 010-0867
** = wearing parts
14
Dokumentation
DOK-265-GB.doc Rev.0
8.3.2
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
spare parts drawing hydraulic system (with built-on filter)
15
Dokumentation
DOK-265-GB.doc Rev.0
8.3.3
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
spare parts list hydraulic system (with built-on filter)
Item
designation
Order-No
1
pump holder
7120-080-0006
2
screw
7120-030-0524
3
safety disk
7120-030-0714
4
thread plug
7120-030-0516
5
ring
7120-040-0460
6
filter panel
7120-040-0456
7
disc
7120-030-2869
8
screw
7120-030-0514
9
upper part tube
7120-040-0607
10
piston
7120-040-0611
11
ball
7120-030-2746
12
ball valve seat
7120-040-0598
13
fastener srew
7120-080-0005
14
lower part tube
7120-040-0608
15
ball
7120-030-2749
16
pump fastener
7120-080-0003
17
gasket
7120-010-0287
18
screw in socket
7120-040-0600
19
rinsing chamber
7120-040-0060
20
gauge
7120-030-1879
21
gasket
7120-010-0244
22
gasket, compl. PTFE (standard)
7120-010-0302
22
gasket, compl. PTFE-leather
7120-010-0314
22
gasket. compl. leather
7120-010-0315
23
pressure ring
7120-040-0590
25
gasket
7120-010-0265
26
filter connection
7120-040-0602
27
gasket
7120-010-0260
29
pressure ring
7120-040-0591
30
gasket, compl. PTFE (standard)
7120-010-0303
30
gasket compl. PTFE-leather
7120-010-0316
30
gasket compl. leather
7120-010-0317
31
gasket
7120-010-0262
32
gasketP
7120-010-0263
33
disk
7120-030-2874
34
hexagonal nut
7120-030-0499
* = gasket set 010-0867
** = wearing parts
16
Dokumentation
DOK-265-GB.doc Rev.0
8.4
spare parts drawing built-on filter
spare parts list
Item
1
2
3
4
5
6
7
8
8
11
12
13
14
15
16
17
Designation
locking srew
intermediate piece
gasket
nut
filter mesh
Stopp cock
gasket
connection nipple R ¼"
connection nipple R
3/8"
support spring
filter housing
gasket
fastener
cylinder screw
safety ring
hexagonal nut
Order-no.
7120-030-0526
7210-040-0464
7210-010-0264
7210-030-1452
7210-030-1427
7210-030-0960
7210-010-0260
7210-040-0601
7210-040-0061
7210-020-0056
7210-040-0463
7210-010-0244
7210-040-0604
7210-030-0585
7210-030-0714
7210-030-2903
17
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
Dokumentation
DOK-265-GB.doc Rev.0
8.5
spare parts drawing filter (direct mounting)
Spare parts list
Item
1
2
3
4
5
Designation
locking srew
intermediate piece
gasket
nut
filter mesh
6
7
8
Stopp cock
gasket
connection nipple
R¼"
connection nipple
R 3/8"
support spring
filter housing
dichtung
fastener
cylinder screw
safety ring
hexagonal nut
8
11
12
13
14
15
16
17
Order-no.
7210-030-0526
7210-040-0464
7210-010-0264
7210-030-1452
7210-0301427/35
7210-030-0960
7210-010-0260
7210-040-0601
7210-040-0061
7210-020-0056
7210-040-0463
7210-010-0244
7210-040-0604
7210-030-0585
7210-030-0714
7210-030-2903
18
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
Dokumentation
DOK-265-GB.doc Rev.0
8.6
spare parts drawing suction gear
spare parts list
item
1
2
3
4
1-4
5
6
7
Designation
srew cap
sleeve
hose
hose clip
Hose, compl.
tube
hose clip
mesh dia. ø 85 (Standard)
Order-no.
7210-040-1246
7210-040-1300
7210-110-0005
7210-030-1397
7210-080-0677
7210-040-0886
7210-030-1396
7210-080-0066
7
mesh dia ø 40
7210-080-0014
19
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
Dokumentation
DOK-265-GB.doc Rev.0
9 Declaration of conformity
30-20
7120-000
20
Bezeichnung HD-Pumpe
Typ
30-20
Artikel
7120-000
Download PDF
Similar pages