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<strong>DX</strong> <strong>30</strong> <strong>GA</strong> VA<br />
Finespray Equipm<strong>en</strong>t<br />
Manufacturer:<br />
Dr. Tett<strong>en</strong>born GmbH<br />
Operating Manual<br />
page 1<br />
DETE<br />
No.<br />
Year
OPERATING MANUAL FOR DETE FINESPRAY EQUIPMENT<br />
WITH PNEUMATIC DRIVE<br />
CONTENTS:<br />
Information about manufacturer and technical data<br />
Introduction into FINESPRAY –PROCEDURE<br />
Parts of Finespray equipm<strong>en</strong>t<br />
Safety rules and regulations<br />
Function of DETE-Finespray equipm<strong>en</strong>t<br />
Installation of finespray equipm<strong>en</strong>t<br />
PUTTING INTO OPERATION<br />
Interruption of working procedure<br />
PUTTING OFF OPERATION and CLEANING of equipm<strong>en</strong>t<br />
MAINTENANCE<br />
Reasons of error and remedy<br />
Enclosed additional operating manuals and spare part drawings as<br />
follows:<br />
�� Piston pump (pneumatic drive / material part)<br />
�� Suction device<br />
�� Air control unit<br />
�� High pressure filter<br />
�� Pressure hoses<br />
�� Spraygun<br />
�� Nozzles<br />
page 2
Declaration of Conformity<br />
In Accordance with Annexe II A & EG Guidelines for Machines: 98/37/<br />
EG (MaschR)<br />
Manufacturer: DETE Dr. Tett<strong>en</strong>born GmbH<br />
Steinfeldstr. 15, D –90425 Nürnberg<br />
We declare herewith that the machines described below correspond to the<br />
appropriate standard Security & Health requirem<strong>en</strong>ts in accordance with<br />
EG-Machine guide lines, due to their conceivem<strong>en</strong>t and construction, as<br />
well as their design, brought into circulation by DETE<br />
If any changes to the machine is carried out, which have not be<strong>en</strong> agreed<br />
by DETE, th<strong>en</strong> this declaration will not be valid forthwith.<br />
Designation: <strong>DX</strong> <strong>30</strong> <strong>GA</strong> VA<br />
Type of Machine: Finespray Equipm<strong>en</strong>t complete ready to spray<br />
Number of Machine:<br />
Year of construction:<br />
Appropriate Guidelines: Maschin<strong>en</strong> RL 98/37/EG<br />
NiederspRL 2006/95/EG<br />
EMV-RL 2004/108/EG<br />
Specified Co-ordinated Standards: 1): DIN EN ISO 12100 -1 / -2<br />
EN 1953: 1998<br />
pr EN 12621:2000<br />
Specified National Standards<br />
& Technical Specification 2): ZH 1/406, BGV D25, BGV D15<br />
Date:<br />
Statem<strong>en</strong>t: Construction<br />
1) For a complete list of the applied standards & technical specification,<br />
please refer to the Production Docum<strong>en</strong>tation<br />
1) As far as no corresponding co-ordinated Standards are available.<br />
page 3
Operating Manual for DETE middle pressure piston pump<br />
with pneumatic drive<br />
Manufacturer: Fa. DETE Dr. Tett<strong>en</strong>born GmbH<br />
Steinfeldstraße 15<br />
90425 Nürnberg<br />
Tel.: 0911/34 77-0 Fax: 0911/34 77-40<br />
Dealer/Subsidiary: __________________<br />
__________________<br />
__________________<br />
Tel: ______________<br />
Fax: ______________<br />
Customer: __________________<br />
__________________<br />
__________________<br />
Year of construction __________________<br />
Type: <strong>DX</strong> <strong>30</strong> <strong>GA</strong> VA<br />
Article No.: _________<br />
Unit No.: _________<br />
Technical Data:<br />
1. Max. allowed pressure of ingoing air: 0,42 MPa<br />
2. Necessary curr<strong>en</strong>t of pressure air volume: 70 l/min<br />
3. Theoretical pressure ratio: 28 :1<br />
4. Max. allowed operating air pressure 12,0 MPa<br />
5. Max. volume curr<strong>en</strong>t 5 l/min<br />
6. Max. operating temperature 90 Grad C<br />
7. Perman<strong>en</strong>t sound pressure level 78 dBA<br />
This piston pump is used for suction of coating material and<br />
conveyance under pressure to the spraying device. In this spraying<br />
device the coating material is atomized with pressure and air support<br />
by means of a nozzle and will be sprayed onto the corresponding<br />
workspiece.<br />
page 4
INTRODUCTION INTO THE FINESPRAY PROCEDURE<br />
Besides the pure compressed air and airless atomization, finespray<br />
procedure is getting more and more important.<br />
With compressed air procedure the coating material is transported to<br />
the nozzle with 0-6 bar and will be atomized with pure compressed<br />
air betwe<strong>en</strong> 3-6 bar wh<strong>en</strong> spraying. With airless procedure<br />
atomization will be done with airless nozzle by means of high<br />
pressure up to 420 bar .<br />
With finespray procedure the coating material is put under<br />
pressure betwe<strong>en</strong> <strong>30</strong> and 120 bar after suction and pressed through<br />
a finespray nozzle.<br />
Due to a special form of the nozzle <strong>en</strong>d the outgoing jet is split in a<br />
flat drop fan with defined outgoing angle.<br />
In contrary to the pure airless procedure finespraying will be done<br />
with additonal compressed air support.<br />
This compressed air is divided into an inner air and horn air at the<br />
aircap. Horn air is always pres<strong>en</strong>t and is homog<strong>en</strong>izing the outgoing<br />
drop fan. The inner air can be op<strong>en</strong>ed and dosed with a bevel seat<br />
and is pressing/focusing the outgoing drop fan.<br />
Finespraying compared to airless procedure needs less pressure<br />
<strong>en</strong>gery and compared to airspraying much less atomizing air<br />
pressure, which leads to an <strong>en</strong>ormous reduction of overspray.<br />
Finespraying: an <strong>en</strong>ergy saving, little overspray prodedure<br />
having optimum surface quality for many<br />
applications.<br />
Suitable for coating workspieces with holes<br />
and edges.<br />
This procedure is oft<strong>en</strong> used in the<br />
furniture industry, joinery, metal and machine<br />
building!<br />
page 5
Parts from the finespray equipm<strong>en</strong>t<br />
The complete finespray equipm<strong>en</strong>t Art.No.:<br />
consists of the following compon<strong>en</strong>ts:<br />
1. High pressure pump Art.-No.:<br />
consisting of:<br />
- pneum. drive Art.-No.:<br />
- material part Art.-No.:<br />
- suction pipe Art.-No.:<br />
- Special lubricant 0,5 liter Art.-No.:<br />
2. Stand unit Art.-No.:<br />
Wall panel Art.-No.:<br />
Trolley Art.-No.:<br />
3. Air control unit Art.-Nor.:<br />
4. High pressure filter Art.-No.:<br />
5. High pressure hose Art.-No.:<br />
6. Finespray gun Art.-No.:<br />
7. Finespray nozzle upon choice Art.-No.:<br />
OPTION for suction device R 3/4“ VA:<br />
8. Grav. Feed suction unit Art.-No.:<br />
Feed device Art.-No.:<br />
Suction device Art.-No.:<br />
We have <strong>en</strong>closed the spare part drawings to the above m<strong>en</strong>tioned<br />
articles.<br />
In case of any questions to the individual parts please always<br />
indicate the corresponding article number.<br />
Alterations at the finespray equipm<strong>en</strong>t are only allowed in<br />
coordination with DETE!!!<br />
page 6
Safety Rules for the operation of<br />
DETE Finespray equipm<strong>en</strong>t<br />
1. SAFETY DEVICES<br />
Removing or not using of safety devices can lead to exceeding<br />
of pressure above the operating pressure.<br />
In case safety devices will be removed due to maint<strong>en</strong>ance<br />
or repair reasons, they have to be installed again before<br />
switching on the piston pump. Repair and maint<strong>en</strong>ance works<br />
at the pump are not allowed during operation respectively<br />
wh<strong>en</strong> pneumatic unit is in action.<br />
All works at the pump can only be done wh<strong>en</strong> pump is without<br />
pressure. Additionally the supply of the main air has to be<br />
separated from the pump and must be secured against new<br />
connection during the working.<br />
2. OPERATING STAFF<br />
The pump must only be operated by personnel who was<br />
instruced by a specialist by means of the operating manual<br />
and who was informed about the dangers which might occur<br />
in case of wrong operation.<br />
3. TEST OF PNEUMATIC PISTON PUMP<br />
The equipm<strong>en</strong>t has to be checked on demand, at least,<br />
however, every 12 months by a specialist for its safe function.<br />
If equipm<strong>en</strong>t was shut down, check can be interrupted until<br />
next putting into operation.<br />
We recomm<strong>en</strong>d to conclude a maint<strong>en</strong>ance contract.<br />
4. In view of health, fire and explosions please use equipm<strong>en</strong>t<br />
only in well v<strong>en</strong>tilated areas.<br />
Suction of overspray and solv<strong>en</strong>t vapours is necessary.<br />
5. Do not direct material or pressure air to persons or animals.<br />
page 7
6. During maint<strong>en</strong>ance/repair works or putting out of<br />
operation<br />
all material– and air guided parts have to be without<br />
pressure.<br />
(see putting out of operation).<br />
7. Due to the risks, which might arise by getting in contact with<br />
and /or by breething health <strong>en</strong>dangering material, gas,<br />
vapours, dust which could result from spraying of coating<br />
material, you have to carry your personal protective overall.<br />
8. Please pay att<strong>en</strong>tion to the recomm<strong>en</strong>dations and instructions<br />
of the manufacturer of the coating material. Demand the<br />
technical leaflets and safety data sheets from the<br />
manufacturer.<br />
9. Wh<strong>en</strong> working coating material which are subject to ex-proof,<br />
you have to install all parts which are not ex-proof outside of<br />
the ex-area.<br />
10. Please test equipm<strong>en</strong>t immediately after receipt. You have to<br />
inform us about obvious defects in writing<br />
within 14 days after receipt of the equipm<strong>en</strong>t.<br />
11. If necessary we will s<strong>en</strong>d you a list of the used working<br />
materials of the parts which touch the material.<br />
(subject to technical alterations).<br />
12. According to the spraying procedure (conv<strong>en</strong>tional air<br />
spraying, finespraying or Airless) the spraygun and material<br />
hose, which are fixed at the equipm<strong>en</strong>t, have to correspond to<br />
the max. allowed operating overpressure (see operating<br />
manual). A perman<strong>en</strong>t marking on the high pressure hose<br />
must show the allowed operating overpressure, the<br />
manufacturer and the date of production. The electrical<br />
resistance betwe<strong>en</strong> the coupling pieces must be equal or<br />
smaller 1 Megaohm.<br />
page 8
Regulations / Standards / Guide Lines<br />
EG-Machine guide line 98/37/EG ( MaschR ) Annex II A<br />
1. DIN EN ISO 12100 -1 Safety of machines<br />
Basic terms, methodology<br />
2. DIN EN ISO 12100 -2 Safety of machines<br />
Technical basic principles and specifications.<br />
3. EN 1953:1998 Spraying equipm<strong>en</strong>ts for coating materials<br />
safety requirem<strong>en</strong>ts<br />
4. prEN12621:2001 Conveyer – and rotary equipm<strong>en</strong>ts for<br />
coating material under pressure safety<br />
requirem<strong>en</strong>ts.<br />
5. ATEX 94/9/EG Guide line for electrical and non-electrical<br />
devices.<br />
6. VBG 23 Working of coating material with perfor<br />
mance<br />
NEW BGV D25 instructions (UVV-BG)<br />
7. VBG 87 Working with liquid beamers with<br />
NEW BGV D15 performance instructions (UVV-BG)<br />
8. ZH 1/406 Guide lines for liquid beamers (Spraying<br />
equipm<strong>en</strong>ts)<br />
9. BGI 764 Electrostatic varnishing<br />
10. BGR 104 Guide lines in order to avoid danger by<br />
explosion capable atmosphere as per<br />
examples explosion-proof guide line<br />
(EX-RL)<br />
11. VDE 0165 Establishm<strong>en</strong>t of electrical equipm<strong>en</strong>ts in<br />
areas which are in danger of explosion.<br />
ZH 1 VBG (Carl Heymanns publishing house Köln/ VDE-VERLAG,<br />
Berlin)<br />
page 9
FUNCTION OF THE DETE FINESPRAY EQUIPMENT<br />
The pressure g<strong>en</strong>erator of the DETE finespraying equipm<strong>en</strong>ts is a<br />
pneumatically operated piston pump consisting of:<br />
REVERSAL/PNEUMATIC DRIVE<br />
RINSING AGENT CHAMBER AND MATERIAL PART<br />
The system of the pumps is based on the differ<strong>en</strong>tial piston principle.<br />
The theoretical ratio of the pressure transmission results from the ratio<br />
of the piston surface of the pneumatic drive and the piston surface of<br />
the material part-piston.<br />
The pneumatic drive performs axial up and down movem<strong>en</strong>ts which can<br />
be changed without delay by reversal. The axial movem<strong>en</strong>t will be<br />
transferred to the piston of the material part. Via suction device the<br />
coating material will be absorbed with the suction valve into the material<br />
part, and by means of pressure valve put under pressure in the<br />
corresponding ratio and conveyed via the high pressure filter to the<br />
spraygun.<br />
Suction and pressure area in the pressure material part are sealed with<br />
special sleeve packings.<br />
The adjusted ingoing air pressure of the regulator at the pneumatic<br />
drive and the ratio of the pressure transmission determine the operating<br />
overpressure, which provides in connection with the chos<strong>en</strong> nozzle size<br />
and the kind of the coating material, the outgoing quantity and the<br />
spraying quality.<br />
As already described with the introduction of the finespraying procedure<br />
the outgoing spraying jet will be homog<strong>en</strong>ized by means of additional<br />
air.<br />
A hose package will be used as connection betwe<strong>en</strong> high pressure filter<br />
exit and spraygun, as well as spraying air regulator exit and ingoing air<br />
at the spraygun.<br />
If you work with spraygun th<strong>en</strong> the piston pump is working. If you lock<br />
spraygun piston pump stops automatically.<br />
If you do not work with the equipm<strong>en</strong>t please secure spraygun against<br />
unint<strong>en</strong>tional pulling of trigger. Spraying equipm<strong>en</strong>t is further under<br />
pressure. Wh<strong>en</strong> working process is continued, piston pump starts<br />
working again.<br />
A safety valve at the pneumatic drive guarantees that the max allowed<br />
pressure of ingoing air of 0,42 Mpa(4,2 bar) will not exceeded.<br />
page 10
INSTALLATION OF DETE-FINESPRAY EQUIPMENT<br />
Design: fixed Can be moved<br />
Outer dim<strong>en</strong>sions: L<strong>en</strong>gth _________<br />
Depth _________<br />
Height _________<br />
Weight _________<br />
Compressed air<br />
connection: Make connection from the compressed air net<br />
to the ingoing air (NW 9). Max. pressure of<br />
ingoing air 0,42 Mpa. Make sure that the<br />
neccessary air quantity is available. We<br />
recomm<strong>en</strong>d to use an oil and water separator in<br />
order to keept the compressed air clean.<br />
Measurem<strong>en</strong>ts for<br />
grounding: Connect grounding cable at the grounding clip<br />
of the finespray equipm<strong>en</strong>t.<br />
Wh<strong>en</strong> using coating material with a flash point<br />
of < 21 degrees (A1) an additional conducting<br />
connection betwe<strong>en</strong> the original painting<br />
container and pump (grounding cable) has to be<br />
installed. (grounding cable has to be of copper<br />
wire 4 qmm)<br />
1. Install piston pump stable and safe so that operation and<br />
maint<strong>en</strong>ance can be done easily.<br />
2. Prev<strong>en</strong>t dirt at piston pump and place of piston pump (clean<br />
regularily)<br />
3. During working of coating materials which are subject to ex-proof<br />
please install all not ex-proof parts outside of EX area.<br />
4. Install all necessary spraying devices and material hoses (if not<br />
already done by factory)<br />
page 11
5. ATTENTION! Use only spraying devices and material<br />
hoses, which are suitable for the max. allowed operating<br />
overpressure!<br />
See TECHNICAL DATA<br />
6. Fill in special lubricant (softmaker) into the lubricant chambers<br />
until it is visible in the inspection glass.<br />
Use only DETE lubricant:<br />
0,5Ltr. Art.No. : 94005050<br />
1,0Ltr. Art.No. : 94005000<br />
7. Make sure that all air– and material connections are fixed and<br />
examine possible transport damages (e.g. folded parts)<br />
8. Use equipm<strong>en</strong>t only in well v<strong>en</strong>tilated areas with regard to<br />
health, fire and explosions.<br />
9. Provide catch basin for varnish– and solv<strong>en</strong>t.<br />
10. Please secure equipm<strong>en</strong>t against tipping over or falling off<br />
during transport to place of installation.<br />
PUTTING INTO OPERATION OF THE EQUIPMENT<br />
page 12
page 13
AIR CONTROL UNIT LM 84 <strong>GA</strong><br />
page 14
PNEUMATIC CONTROL LM 84 <strong>GA</strong><br />
page 15
Input of pressure air<br />
Exit of spraying air<br />
Item 2<br />
page 16<br />
Atomizing air<br />
Pump air<br />
Item 1<br />
Item.4<br />
Item.3<br />
Pump air re<br />
gulator<br />
Regulator of atomizing air<br />
Item 5
After correct adjustm<strong>en</strong>t of the equipm<strong>en</strong>t you have to put it into<br />
operation.<br />
The material part of the DETE piston pump is tested from factory<br />
with an emulsion and therefore conserved. You have to rinse the<br />
equipm<strong>en</strong>t with solv<strong>en</strong>t before you start filling the equipm<strong>en</strong>t with<br />
coating material.(Use solv<strong>en</strong>t recomm<strong>en</strong>ded by varnish supplier)<br />
1. RINSING OF EQUIPMENT AT FIRST PUTTING INTO OPERATION<br />
a) Make sure that you have compressed air connection and the<br />
ingoing air regulator for the pump drive item 1 is adjusted to 0<br />
bar.<br />
b) Install solv<strong>en</strong>t container at equipm<strong>en</strong>t.<br />
c) Dive suction pipe of suction device item 2 into the solv<strong>en</strong>t<br />
container. (Pay att<strong>en</strong>tion that level of filling of solv<strong>en</strong>t is above<br />
suction filter so that no air can be sucked.<br />
d) Put disposal container underneath drain cock.<br />
e) Op<strong>en</strong> drain cock item 3 at high pressure filter item 4.<br />
f) Op<strong>en</strong> slowly ingoing air regulator item 1 for the pump drive by<br />
turning of adjusting wheel to the right (min. 1,5 bar) until pump<br />
starts working and clean solv<strong>en</strong>t emerges regularily and<br />
without bubbles from the drain cock.<br />
g) Lock drain cock item 3.<br />
h) Unlock gun without nozzle and hold it over disposal unit. Pull<br />
trigger until clean solv<strong>en</strong>t is emerging regularily and without<br />
bubbles.<br />
ATTENTION<br />
- Solv<strong>en</strong>t splashes wh<strong>en</strong> spraying jet meets bottom of<br />
disposal container.<br />
- Do not spray into closed containers.<br />
- Never direct gun against yourself or other people or<br />
animals<br />
- Never touch the spraying jet with your fingers or<br />
hand.<br />
- Wh<strong>en</strong> working with electrostatic spraying units, you<br />
principally have to switch off the electrostatic during<br />
rinsing.<br />
I) Lock spraygun again and secure against pulling the trigger.<br />
j) Adjust ingoing air regulator item 1 to 0 bar, unlock spraygun,<br />
hold gun over solv<strong>en</strong>t unit and carefully pull trigger<br />
page 17
k) Take out suction device from solv<strong>en</strong>t unit and let it drip off.<br />
Op<strong>en</strong> ingoing air regulator item 1 to start up of pump; hold<br />
spraygun with nozzle over solv<strong>en</strong>t unit, and pull trigger until<br />
solv<strong>en</strong>t stops emerging. Adjust ingoing air regulator item 1 to<br />
0 bar.<br />
Secure spraygun.<br />
OPERATING CONDITION: EQUIPMENT COMPLETELY RINSED<br />
AND WITHOUT PRESSURE / REGULATOR ITEM 1 = 0 BAR<br />
page 18
2. FILLING OF THE EQUIPMENT WITH COATING MATERIAL<br />
a) Install varnish container with prepared spraying medium at<br />
spraying equipm<strong>en</strong>t. (Spraying medium is adjusted to spraying<br />
viscosity).<br />
b) Dive suction pipe of suction device item 2 into varnish<br />
container. (Pay att<strong>en</strong>tion that level of varnish filling is above<br />
suction filter so that no air can be sucked).<br />
c) Put disposal container underneath drain cock item 3.<br />
d) Op<strong>en</strong> drain cock item 3 at high pressure filter item 4.<br />
e) Op<strong>en</strong> slowly ingoing air regulator item 1 for the pump drive by<br />
turning of adjusting wheel to the right (approx. 1 bar) until<br />
pump starts working and clean spraying medium is emerging<br />
regularily and without bubbles from drain cock .<br />
f) Lock drain cock item 3.<br />
g) Unlock spraygun without nozzle at trigger and hold it over<br />
disposal container. Th<strong>en</strong> pull trigger until clean spraying<br />
medium is emerging regularily and without bubbles.<br />
h) Secure spraygun against pulling trigger.<br />
i) Chose suitable finespray nozzle and adjust it with nozzle<br />
sealing and nozzle nut onto the spraygun.<br />
SEE INSTRUCTIONS: SPRAYGUN AND NOZZLE<br />
j) Increase ingoing air regulator item 1 to necessary min.<br />
operating pressure (ask varnish supplier)<br />
Unlock spraygun and pull trigger against one suction.<br />
Examine visually spraying jet width for spraying angles and<br />
homog<strong>en</strong>eous .atomization; ev<strong>en</strong>tually increase respectively<br />
reduce operating pressure, or chose differ<strong>en</strong>t nozzle size.<br />
page 19
k) In order to homog<strong>en</strong>ize and change spraying jet width, adjust<br />
air regulator item 5 for the atomized air by turning the adjusting<br />
wheel to the right.<br />
More adjustm<strong>en</strong>ts of atomized air at spraygun are possible.<br />
l) With adjustm<strong>en</strong>t of material– and compressed air you<br />
achieve optimum results.<br />
Test spraying pattern on paper or smooth surface.<br />
Operating condition:<br />
Complete equipm<strong>en</strong>t is filled and v<strong>en</strong>tilated.<br />
Complete equipm<strong>en</strong>t is under operating pressure.<br />
Complete equipm<strong>en</strong>t is ready for spraying.<br />
Att<strong>en</strong>tion: Always secure spraygun if equipm<strong>en</strong>t is under<br />
pressure! Att<strong>en</strong>tion if you work at the nozzles!<br />
WORK INTERRUPTIONS<br />
page 20
BASICALLY IS VALID: According to type of coating material and<br />
operating ratio, the max. possible work interruption has to be fixed<br />
without activating the rinsing process.<br />
This max. time of interruption should be determined with the supplier<br />
of the coating material.<br />
PROCEDURE<br />
1. Put ingoing air regulator item 1 to 0 bar until there will<br />
absolutely be no pressure.<br />
2. Hold spraygun with nozzle over the varnish container, delock<br />
it and slowly pull trigger so that equipm<strong>en</strong>t will be without<br />
pressure.<br />
3. Lock and secure spraygun.<br />
4. Leave suction device item 2 immersed in varnish container or<br />
dip it into the corresponding solv<strong>en</strong>t container.<br />
The coating material must not dry out in the complete<br />
system.<br />
5. In case you wish cleaning of nozzles, see operating instruction<br />
of spraygun.<br />
ATTENTION:<br />
Wh<strong>en</strong> working of two compon<strong>en</strong>t coating material cleaning has to be<br />
done immediately (in any case before reaching gelling time or<br />
potlife; which means at modification of spraying viscosity)<br />
Ask your supplier of coating material!<br />
In order to continue the work make sure that suction device in the<br />
varnish container is suffici<strong>en</strong>tly filled up and that nozzle is adjusted<br />
correctly.<br />
Increase ingoing air regulator item 1 to operating pressure, delock<br />
spraygun and pull trigger.<br />
page 21
PUTTING OUT OF OPERATION AND CLEANING OF EQUIPMENT<br />
A daily cleaning of the complete equipm<strong>en</strong>t should be done so that<br />
unit is ready for operating the next day. Please prev<strong>en</strong>t that<br />
reman<strong>en</strong>t varnish is drying and sticking in the system.<br />
We recomm<strong>en</strong>d installation of a cleaning program and it s daily<br />
application.<br />
ATTENTION: Only use solv<strong>en</strong>t which is recomm<strong>en</strong>ded from varnish<br />
supplier.<br />
OPERATING CONDITION: EQUIPMENT IS FILLED/IS UNDER<br />
OPERATING PRESSURE AND READY TO SPRAY<br />
PROCEDURE OF PUTTING OUT OF OPERATION:<br />
1 ) Adjust ingoing air regulator of pump air item 2 to 0 bar until<br />
pressure is completely unloaded.<br />
2 ) Put below drain cook item 3 of varnish container.<br />
3 ) Slowly op<strong>en</strong> draín cook item 3 to unload pressure.<br />
4 ) Lock drain cook item 3.<br />
5 ) Wh<strong>en</strong> spraygun is locked, dismount nozzle sealing and nozzle<br />
nut (see operating instructions spraygun).<br />
6 ) Adjust ingoing air regulator of pump air item 1 to approx. 1<br />
bar.<br />
7 ) Pull out suction device item 2 out of varnish container,<br />
let it drip off and lock it over varnish container.<br />
8 ) Hold spraygun with nozzle over varnish container, delock<br />
it,and pull trigger until equipm<strong>en</strong>t is completely empty and no<br />
varnish is emerging.<br />
9 ) Lock spraygun.<br />
page 22
10) Clean outside of suction device item 2 with solv<strong>en</strong>t over the<br />
disposal container and dip into the solv<strong>en</strong>t container.<br />
11) Put disposal container under drain cock item 3.<br />
12) Op<strong>en</strong> drain cock item 3 until clean solv<strong>en</strong>t emerges equally<br />
and without bubbles.<br />
13) Lock drain cock.<br />
14) Hold spraygun over disposal container delock and pull trigger<br />
until clean solv<strong>en</strong>t emerges.<br />
15) Adjust ingoing air regulator of pump air item 1 to 0 bar until<br />
complete unloading of compressed air.<br />
16) Close and lock spraygun.<br />
Operating condition: Equipm<strong>en</strong>t completely rinsed<br />
Equipm<strong>en</strong>t is without pressure at<br />
material and compressed air<br />
Secure equipm<strong>en</strong>t against switching on<br />
again<br />
17) Carefully clean hose package and spraygun from outside.<br />
18) Take out nozzle from solv<strong>en</strong>t, clean it, ev<strong>en</strong>tually use nozzle<br />
cleaning needles to clean nozzle core from dirt.<br />
19) Please also clean high pressure filter if available (see<br />
instruction manual high pressure filter).<br />
page 23
MAINTENANCE<br />
Maint<strong>en</strong>ance only by trained and instructed personnel.<br />
All workings only to be done wh<strong>en</strong> equipm<strong>en</strong>t is without<br />
pressure!<br />
Secure equipm<strong>en</strong>t against restart during working!<br />
Examination of equipm<strong>en</strong>t upon requirem<strong>en</strong>t, however, at least all<br />
12 months by a specialist. Equipm<strong>en</strong>ts which are put out of service<br />
can be examined with next putting into operation.<br />
We recomm<strong>en</strong>d to complete a maint<strong>en</strong>ance contract.<br />
Regularily examine equipm<strong>en</strong>t for leakage test and fixation of<br />
connecting elem<strong>en</strong>ts.<br />
Keep off dirt from whole equipm<strong>en</strong>t.<br />
Regularily clean earthing contacts from dirt.<br />
AT PNEUMATIC DRIVE<br />
(In case oiler and separator are available)<br />
Compressed air oiler Regularily examine oil cont<strong>en</strong>ts in oiler.<br />
Always immerse oil pipe into oil.<br />
Use only recomm<strong>en</strong>ded oil,<br />
Spezial-oil 1 Liter, Article No.:<br />
94006000<br />
Adjust with choke screw to approx. 1<br />
drop per 10 double lifts.<br />
Filter-water separator : Maint<strong>en</strong>ance in shorter distances<br />
(daily)<br />
Drain off cond<strong>en</strong>sate (cond<strong>en</strong>sate level<br />
. must never exceed<br />
MAXIMUM MARK bounce-disk:)<br />
AT PNEUMATIC DRIVE UNIT<br />
page 24
Visual check at control unit by taking off side parts of hood.<br />
If necessary grease control rod and guide.<br />
AT RINSING CHAMBER<br />
Visually check lubricant level in sight glass.<br />
Level of lubricant has to be at least one third or half in sight glass<br />
during operation of equipm<strong>en</strong>t.<br />
If you find spraying residuals in rinsing chamber you immediately<br />
have to r<strong>en</strong>ew the lubricant.<br />
ATTENTION: ev<strong>en</strong>tually leaky gasket – see error analysis<br />
Use only DETE Lubricant:<br />
0,5 Liter Article No: 94005050<br />
1,0 Liter Article No: 94005000<br />
AT MATERIAL PART<br />
Check all connections if they are fixed and leakproof.<br />
AT FILTER UNIT<br />
In case equipm<strong>en</strong>t has a filter, this will be op<strong>en</strong>ed and cleaned.<br />
ATTENTION: Wh<strong>en</strong> working with filter first stop input of<br />
compressed air and relieve of pressure.<br />
Cleaning of filter please see description of filter.<br />
From other parts<br />
See separately <strong>en</strong>closed descriptions.<br />
page 25
DISTURBANCE REASON REMEDY<br />
Pump does not<br />
start<br />
or stops during<br />
operation<br />
Pump does not<br />
or only insuffici<strong>en</strong>tly<br />
draw in<br />
Air supply interrupted Prepare again<br />
Defekt/ingoing air regulator<br />
defect<br />
page 26<br />
Check, evtl. repair<br />
(see spare parts drawing)<br />
Filter scre<strong>en</strong> plugged Clean see spare parts dwg.<br />
Nozzle plugged Clean (see description)<br />
Suction filter plugged Take off suction filter and<br />
clean<br />
Suction pipe/hose<br />
plugged<br />
Coarse contamination<br />
in material part<br />
Dirty suction/pressure<br />
valve<br />
Viscosity of coating<br />
material too high<br />
Take off suction pipe/hose<br />
and clean<br />
Rinse material part with suitable<br />
solv<strong>en</strong>t<br />
If rinsing of material part is<br />
not suffici<strong>en</strong>t, take off both<br />
valves by trained personnel<br />
and clean. Check balls and<br />
seat if they are damaged,<br />
evtl. r<strong>en</strong>ew.<br />
If possible thin material;<br />
consult your supplier
DISTURBANCE REASON REMEDY<br />
Pump works unregularily<br />
(spraying jet<br />
collapses)<br />
Material nozzle<br />
is plugging more<br />
oft<strong>en</strong> during<br />
operation<br />
Coarse contaminatination<br />
in material part,<br />
stick valves<br />
Weared valves, packings<br />
and pistons<br />
Not <strong>en</strong>ough spraying<br />
pressure<br />
page 27<br />
Rinse material part with appropriate<br />
solv<strong>en</strong>t; evl. keep in<br />
solv<strong>en</strong>t for some time.<br />
R<strong>en</strong>ew parts by trained personnel<br />
Increase pressure of ingoing<br />
air<br />
(use smaller nozzle)<br />
Viscosity too high Thin coating material<br />
Defect control valve Check wear parts evtl. r<strong>en</strong>ew<br />
control valve<br />
Filter scre<strong>en</strong> plugged Clean, or r<strong>en</strong>ew<br />
Defect filter scre<strong>en</strong> R<strong>en</strong>ew<br />
Filter scre<strong>en</strong> and size<br />
of material nozzle do<br />
not correspond<br />
Contamination in material<br />
hose and spraygun<br />
Check (see nozzle chart)<br />
Rinse with appropriate solv<strong>en</strong>t<br />
Nozzle contaminated Remove nozzle and clean.<br />
Remove coarse particles by<br />
means of nozzle cleaning<br />
needles<br />
Coating material Evtl. filter (contact your<br />
supplier)
Error - Disturbance REASON REMEDY<br />
Pump operates<br />
with closed spraygun<br />
Drop of air pressure<br />
during spraying<br />
procedure<br />
Lubricant or coating<br />
material emerges<br />
out of lubricant<br />
ag<strong>en</strong>t filling socket<br />
Pneumatic drive<br />
freezes at reversing<br />
valve<br />
Gaskets, valves, piston<br />
parts are weared<br />
page 28<br />
R<strong>en</strong>ew by trained personnel<br />
Needle valve seat leaky Check, clean, evtl. r<strong>en</strong>ew<br />
Hose connections leaky Prüf<strong>en</strong>, Nachzieh<strong>en</strong>,<br />
ggf. erneuern<br />
Check, fix, evtl. r<strong>en</strong>ew<br />
Gaskets are leaky R<strong>en</strong>ew<br />
Suction/pressure seat leaky<br />
Clean, evtl. r<strong>en</strong>ew<br />
Nozzle too big Take smaller nozzle<br />
Spraying pressure too low Increase spraying pressure<br />
Viscosity too high Thin spraying material<br />
Upper set of sealing is<br />
weared<br />
Too much lift frequ<strong>en</strong>cy can<br />
cause freezing<br />
Much cond<strong>en</strong>se water in<br />
ingoing air supply<br />
Unfavourable operating<br />
conditions, humidity, temperatures<br />
R<strong>en</strong>ew set of sealing<br />
Smaller nozzle, lower<br />
ingoing air pressure.<br />
Main<strong>en</strong>tance unit<br />
(need of water separator<br />
and oiler )<br />
Optimize local operating<br />
conditions
Operating instruction for high pressure filter<br />
Type of filter: Type 31 VA<br />
Article-No.: 65.31.00.00<br />
Max.allowed operating<br />
overpressure: <strong>30</strong> MPa (<strong>30</strong>0 bar)<br />
Input material: R 3/8“<br />
Output material: M 16 x 1,5<br />
Emptying exit: R 1/4“<br />
Only carry out maint<strong>en</strong>ance works by instructed and trained personnel.<br />
Only carry out all works with equipm<strong>en</strong>t being without pressure.<br />
Lock against new putting under pressure.<br />
For cleaning do not use wire brush<br />
Working procedure for cleaning of filter or changing scre<strong>en</strong>s:<br />
1. Adjust ingoing air regulator at pneumatic drive of piston<br />
pump to 0 bar and lock against new start.<br />
2. Slowly op<strong>en</strong> varnishing container below drain cock item 10<br />
until no material emerges.<br />
3. Slowly op<strong>en</strong> drain cock item 10 until no material emerges.<br />
4. Op<strong>en</strong> filter cover item 3 with supplied tool into left direction.<br />
5. Take off filter cover and clean.<br />
6. Take away scre<strong>en</strong> item 5 and spring and clean both articles<br />
with suitable solv<strong>en</strong>t. Check scre<strong>en</strong> and spring if they are<br />
damaged and ev<strong>en</strong>tually r<strong>en</strong>ew.<br />
7. Put disposal container underneath drain cock item 10.<br />
Carefully clean filter housing item 1 inside with brush.<br />
Check O-ring item 2 if damaged; ev<strong>en</strong>tually r<strong>en</strong>ew.<br />
8. Clean drain cock item 10 inside with round brush.<br />
9. Put scre<strong>en</strong> item 5 into filter housing item 1 with sheet metal<br />
bunch into the bore at the bottom of the filter housing.<br />
page 29
10. Put spring item 4 into the scre<strong>en</strong> item 5.<br />
11. Check if O-Ring item 2 has be<strong>en</strong> put correctly into nut.<br />
12. Screw filter cover item 3 and fix with filter tool.<br />
13. Lock drain cock item 10.<br />
Filter is ready for r<strong>en</strong>ewed putting into operation.<br />
Choice of scre<strong>en</strong>s:<br />
No. of scre<strong>en</strong>: 65.00.... according to width of meshes available<br />
in 9 sizes. You can find size number of scre<strong>en</strong> at<br />
the outer edge.<br />
Choice of scre<strong>en</strong>: Size of scre<strong>en</strong> is determined by nozzle size.<br />
(See fine spray / airless nozzle chart)<br />
HD– Filter Type 31 VA No. 65.31.00.00<br />
Pos Art No Specification Quantity<br />
5 65000006 + Scre<strong>en</strong> type <strong>30</strong>, size 6 or upon choice 1<br />
4 65<strong>30</strong>0400 + Spring stainless steel (VA) 1<br />
1 65310100 Filter housing Type 31 VA 1<br />
2 65310200 + PTFE O-RING 1<br />
3 65310<strong>30</strong>0 Filter cover type 31 VA 1<br />
10 92500570 + Drain cock 1/4" VA middle pressure 1<br />
9 9<strong>30</strong><strong>30</strong>670 Double nipple R 1/4” counter VA 1<br />
7 9<strong>30</strong><strong>30</strong>870 Double nipple R 3/8" counter VA 1<br />
8 9<strong>30</strong>50<strong>30</strong>0 Transition nipple 1<br />
94011400 Cleaning brush 45 mm without image 1<br />
94150000 Filter Key type 15 without image 1<br />
99133513 Straight screwed-in connection EGV12LRWD<br />
Only for bigger pump types<br />
+ = Wear parts ( Subject to technical changes)<br />
page <strong>30</strong><br />
0
HP Filter Type 31 VA No. 65.31.00.00<br />
page 31
13<br />
14<br />
26<br />
23<br />
12<br />
25<br />
22<br />
21<br />
20<br />
3<br />
42<br />
2<br />
3<br />
4<br />
PNEUMATIC DRIVE LM 84 <strong>GA</strong><br />
8<br />
15 9 17<br />
36<br />
37<br />
44<br />
24<br />
43<br />
page 32<br />
40<br />
16<br />
38<br />
41<br />
39<br />
11<br />
12<br />
10<br />
5<br />
9<br />
19<br />
<strong>30</strong><br />
28<br />
27<br />
31<br />
29<br />
33<br />
34<br />
32<br />
18<br />
1
List of spareparts LM 84 <strong>GA</strong><br />
Pos. Art. Bezeichnung Stück<br />
1 13770200 MOTORUNTERTEIL JO/TR/<strong>DX</strong> 1<br />
2 13762101 KOLBENSTANGENFÜHRUNG 1<br />
3 11009700 DICHTRING BN 2<br />
4 11100401 TASTERVENTIL 2<br />
5 51650602 T-STECKVERSCHR. M5 PK3 1<br />
6 99134517 WINKEL 1/8" PK3 2<br />
7 51050204 LUFTSCHLAUCH 4x0,65 PA 1<br />
8 99134519 WINKEL M5 PK3 3<br />
9 93150510 DOPPELNIPPEL R 1/4 " I/A 1<br />
10 9<strong>30</strong><strong>30</strong>600 DOPPELNIPPEL R 1/4 " KON. 2<br />
11 13385600 SCHNELLENTLÜFTUNGSVENTIL L -SEV-1/4" 2<br />
12 51660400 WINKEL-STECKVERSCHRAUBG.WED 8-1/4 3<br />
13 93252701 MUFFENNIPPEL 1/4"A/3/8"I 2<br />
14 13605101 SCHALLDÄMPFER 3/8" 2<br />
15 68350506 ERDUNGSKLEMME BIS 16 MM² 1<br />
16 64111012 BEFESTIGUNGSMUTTER 2<br />
17 93150520 DOPPELNIPPEL R1/4" I/A L 1<br />
18 13391003 SPÜLMITTEL-EINFÜLLSTUTZEN 1<br />
19 14061000 ZYLINDERDECKEL 1<br />
20 51650210 LUFTVERSCHR. CK-1/8-PK6 2<br />
21 42210002 BLINDSTOPFEN R 1/8" 2<br />
22 661<strong>30</strong><strong>30</strong>0 O-RING 2<br />
23 11100402 5/2-WEGE-PNEUMATIKVENTIL 1<br />
24 11073700 MUTTER M8 2<br />
25 13605102 SCHALLDÄMPFER BRONZE R 1/4" 2<br />
26 11084100 HALTESCHRAUBE M5x25 2<br />
27 14062500 PNEUMATIKKOLBEN 1<br />
28 13609600 O-RING 1<br />
29 1406<strong>30</strong>00 KOLBENSTANGE 1<br />
<strong>30</strong> 13603500 DICHTUNGSRING 2<br />
31 14003410 LUFTZYLINDER NEU L=91 MM 1<br />
32 14005900 STIFTSCHRAUBE 4<br />
33 13602400 FEDERRING 4<br />
34 11062600 KONTERMUTTER 4<br />
36 13863900 SCHRAUBE DIN 933 M8x50 2<br />
37 13380200 HALTESCHRAUBE M8 x <strong>30</strong> 2<br />
38 14096001 HAUBE 1<br />
39 29900 SCHALLSCHLUCK MAT. 0,4<br />
40 64111000 DRUCKREGELVENTIL 1/4" KPL: 2<br />
41 64600010 MANOMETER 0-10 BAR 2<br />
42 51650010 KST-SCHLAUCH PU 6 SCHWARZ 0,4<br />
43 13773500 KUPPLUNG page M8x1 33 F. TR./<strong>DX</strong> 1
Dete Material Part <strong>DX</strong> VA No. 20380070<br />
page 34
Dete Material Part <strong>DX</strong> VA No. 20380070<br />
Art. No. Description Wear<br />
partsl<br />
page 35<br />
Quantity<br />
in pcs.<br />
13773500 Connector 1<br />
20184570 Suction valve compl. * 1<br />
20184670 Suction valve guide stainless steel 1<br />
20<strong>30</strong>1070 Hydraulic piston <strong>DX</strong> stainless steel * 1<br />
20<strong>30</strong>5<strong>30</strong>0 Spring <strong>DX</strong> * 1<br />
20381200 Set of gasket PE-UHMW below * 1<br />
20382500 Set of gasket PE-UHMW above * 1<br />
20385070 Hydraulic cylinder <strong>DX</strong> stainless steel 1<br />
20385570 Piston flange <strong>DX</strong> stainless steel 1<br />
20501500 Valve seat compl. * 1<br />
20501670 Valve guide 1<br />
20501700 Valve ball * 1<br />
20504400 Gasket * 1<br />
21084400 Flat sealing ring * 2<br />
21201700 Valve ball * 1<br />
21209500 Pressure comp<strong>en</strong>sating valve * 1<br />
21209501 Copper sealing * 1<br />
52100375 Suction pipe ( without picture ) 1<br />
52101173 Suction filter ( without picture) 1<br />
9<strong>30</strong>60670 Suction nipple ( without picture ) 1<br />
93101101 Copper sealing ( without picture ) * 1<br />
13863900 Screw M 8x50 ( without picture ) 2<br />
13380200 Screw M 8x<strong>30</strong> ( without picture ) 2<br />
13363901 Disc A 8,4 ( without picture ) 2<br />
11073700 Nut M 8 ( without picture ) 4
DETE Dr. Tett<strong>en</strong>born GmbH<br />
Steinfeldstraße 15<br />
D-90425 Nürnberg<br />
Telefon: 0911/34 77 0<br />
Telefax: 0911/ 34 77 40<br />
E-mail: dete@dete.de<br />
Hompage: www.dete.de<br />
page 36