Optima 2100 Betriebsanleitung

Manufactured by Bersch & Fratscher GmbH 1

OPTIMA 2100

Professional Air Combi Paint Spray Gun

Air

Combi

Version 10/2008

Technical

Service Manual

II 2G X

Service Manual

Manufactured by Bersch & Fratscher GmbH 2

version 10/2008 OPTIMA 2100

Table of contents

1. INTENDEND USE......................................................................................................................................................... 3

2. SAFETY REFERENCES ............................................................................................................................................. 3

2.1. SAFETY REFERENCES FOR THE OPERATOR ........................................................................................................... 3

2.1.1 Qualification of the personnel ................................................................................................................. 3

2.1.2 Security of the working environment..................................................................................................... 3

2.2 SAFETY REFERENCES FOR THE OPERATORS ......................................................................................................... 3

2.2.1 Safe handling of OPTIMA paint spray guns ......................................................................................... 4

2.2.2 Grounding.......................................................................................................................................................

2.2.3 Material-and air hoses ............................................................................................................................... 4

2.2.4 Cleaning ........................................................................................................................................................ 4

2.2.5 Handling liquids, lacquer and colors .......................................................................................................

2.3 ADHESION................................................................................................................................................................

3. CONNECTED LOADS ................................................................................................................................................. 5

4. MATERIAL CONSUMPTION AND THROUGHPUT VALUES .............................................................................. 5

5. AIR CONSUMPTION ................................................................................................................................................... 5

6. DESCRIPTION OF FUNCTION.................................................................................................................................. 6

7. START-UP ..................................................................................................................................................................... 6

8. OPERATION ................................................................................................................................................................. 6

8.1 AIR CONNECTION.................................................................................................................................................... 6

8.2 PAINT CONNECTION..................................................................................................................................................

8.3 OPERATION OF THE HIGH PRESSURE SPRAY GUN ....................................................................................................

8.4 FLAT JET REGULATION .......................................................................................................................................... 6

8.5 TRIGGER FORCES ....................................................................................................................................................

8.6 ROUND JET REGULATION ....................................................................................................................................... 7

8.7 ADJUSTMENT OF ATOMIZER AIR CAP ........................................................................................................................

8.8 PAINTING DISTANCE AND SPRAY GUN GUIDANCE .....................................................................................................

8.8.1 Atomizer air cap adjust.............................................................................................................................. 7

8.8.2 Spray gun guidance ................................................................................................................................... 7

8.9 FILTER SELECTION................................................................................................................................................. 8

8.10 ADJUSTMENT OF PRE-AIR ...................................................................................................................................... 8

9. MAINTENANCE............................................................................................................................................................ 8

9.1 CLEANING.............................................................................................................................................................. 8

9.2 CLEANING OF THE NOZZLE .................................................................................................................................... 8

9.3 CLEANING OF THE FILTER ...................................................................................................................................... 8

9.4 LUBRICATION......................................................................................................................................................... 8

10. REPLACEMENT OF PARTS................................................................................................................................. 8

10.1 PAINT NEEDLE ....................................................................................................................................................... 8

10.2 NEEDLE SEAL- INVERTED CUP SEAL 1248-10 DEFECTIVELY ................................................................................ 9

10.3 VALVE SEAL........................................................................................................................................................... 9

10.4 CHANGE OF COMPLETE NOZZLE SET 001248-U8 ................................................................................................. 9

10.5 GASKET DEFECTIVELY – SEAL RETAINING SCREW 001248-U5 ............................................................................ 9

11. POSITIVE PRESSURE........................................................................................................................................... 9

12. WORKSTATION RELATED SOUND PRESSURE LEVEL .............................................................................. 9

13. DISPOSAL ............................................................................................................................................................. 10

14. TROUBLE POSSIBILITIES ................................................................................................................................. 10

15. AVAILABLE ACCESSORIES ORDER NUMBER ........................................................................................... 10

16. DECLARATION OF CONFORMITY................................................................................................................... 11

17. DECLARATION OF GUARANTEE ........................................................................................................................

Service Manual

Manufactured by Bersch & Fratscher GmbH 3

version 10/2008 OPTIMA 2100

1. Intended use

Pneumatically operated paint spray gun with pump support in the high pressure range (up to

max. 250 bar) for processing liquid, sprayable media with consideration of the manufacturer

references. The high pressure spray gun is led by hand and operated by the operator to coat

the work piece.

2. Safety references

2.1. Safety references for the operator

a) Read all safety references and instructions. Failure to adhere to the safety references and

instructions can lead to danger and/or cause serious injuries.

b) Save all safety references and instructions for the future and keep them at the operating

place available, so that they can be seen by the operator as well as the personnel.

c) Make sure that all local guidelines for the industrial safety and rules for the prevention

of accidents are followed at any time.

2.1.1 Qualification of the personnel

The equipment may only be set up, operated and repaired by qualified and trained

personnel.

2.1.2 Security of the working environment

a) Ensure that the work area is always kept clean and well lit. Clutter or dim work areas can

lead to accidents.

b) Ensure that the floor of the work area is antistatic, in accordance with EN50053 part of 1,

§ 7-2, measurement according to DIN 51953 and that all persons within the work area

wear antistatic shoes, e.g. shoes with leather soles.

c) Ensure that the operators wear antistatic gloves for grounding over the handle of the

spray gun when painting.

d) Obey all local regulations concerning the overspray exhaustion and make sure that they

exist at the operating place and that they are used properly.

e) In addition the following components of a safe working environment must exist and/or be

available:

- Make sure that for the high operating pressure there are appropriate material

and air hoses available and used.

- Make sure that the personnel has personal protection equipment available and

uses it. Using personal protection equipment, such as breath and skin

protection, as well as if necessary. skid-proof safety shoos, reduce the risk of

injuries.

f) Guarantee that no ignition sources such as open fire, spark, glowing wires

or hot surfaces are present in the work area and that there is no smoked in the

work area.

2.2 Safety refereces for the operators

Read the operating instructions completely and in detail before start-up of the spray gun. All

information in this manual is to be followed particularly the general safety references and the

warning references.

Local guidelines for industrial safety and rules for the prevention of accidents

are to be followed at all times.

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Manufactured by Bersch & Fratscher GmbH 4

version 10/2008 OPTIMA 2100

2.2.1 Safe handling of Optima paint spray guns

a) Examine before each start-up, in particular after maintenance and cleaning works the firm seat

of all screws and nuts/mothers.

b) Attention: The spray jet is under pressure and can cause serious injuries.

c) The following safety instructions should be followed at all times the spray gun is used:

- Avoid in any case injection of colour or cleaning agents.

- Never aim the spray gun to yourself, other persons or animals and never put your

hand or any other body parts into the spray jet.

- Separate the energy and compressed air supply at all times before working on the

equipment, as well as work interruptions and malfunctions.

- In case of work interruptions secure the spray gun against operation.

- Relieve spray gun and equipment from pressure.

- In case of malfunctions, please repair the error according to chapter. „ Trouble

shooting " page 10.

d) Danger of skin injuries:

Note in case of skin injuries by colour or cleaning agent, which colour and/or cleaning agent you

used and consult immediately a physician.

f) Danger by recoil forces:

- In order to counter recoil forces, make sure that during operation you stand safely and change

your position regularly to avoid fatigue.

2.2.2 Grounding

Due to the high flow rate of the colour and air electrostatic loading of the equipment is possible.

When unloading these can cause sparks or flames.

- Make sure the equipment is grounded while operating and also ground the work pieces to be

coated.

- All persons within the work area should be grounded, e.g. by wearing antistatic shoes and when

operating the spray gun antistatic gloves should be word for grounding over the handle of the spray

gun.

2.2.3 Material- and air hoses

- Ensure that only material and air hoses are used which are laid out for the appropriate operating

pressures.

- Make sure that the material of the material hose is chemically steady against the sprayed

materials.

- Make sure that on the used high-pressure hose the manufacturer, the manufacturing date and

permissible operating pressure are recognizable.

Attention:

The electrical resistance of the complete high-pressure hose must be smaller than 1 MOhm.

2.2.4 Cleaning

- Decouple the equipment from the pneumatic inlet and relieve the pressure.

- Make sure that the ambient temperature is at least 5°C under the flash point of the used cleaning

agents.

- Use for cleaning only solvent-damp rags and brushes. Use in any case hard articles and never

spray apply cleaning agents with a spray gun.

Attention: In closed containers a combustible gas air mixture can form. Therefore never spray

during equipment cleaning with solvents into a closed container.

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Manufactured by Bersch & Fratscher GmbH 5

version 10/2008 OPTIMA 2100

2.2.5 Handling liquids, lacquers and colours

Consider all handling specifications of the manufacturer’s of all used paints, solvents and cleaners

during the paint preparation, the paint application as well as the cleaning process.

Obey all prescribed preventive measures; carry an eye protector, protective clothing and - gloves

and use if necessary skin protection cream.

Always carry a protective mask and/or use a respirator when painting, as well as during preparation

and cleaning.

Operate the spray gun only in a spray booth or at a spray wall with operating ventilation (to exhaust

the overspray) in order to guarantee a sufficient health and environmental protection.

Carry when processing hot materials (max. 60°C) appropriate protective clothing.

2.3 Adhesion

Bersch & Fratscher declines any liability for damages, which result from not intended use. The

equipment may be used only for processing material recommended by Bersch & Fratscher. The

equipment may only be operated as a complete unit. Protection devices may not be disabled. Only

Bersch & Fratscher original spare parts and - accessories may be used. In case of self

disassembly the liability is void.

3. Connected loads

A) Maximum permitted air pressure 8 bar, recommended operating pressure 1.5 - 3 bar.

Operating pressure depends on viscosity, nozzle size and kind of spray system (Airless - Air Combi).

B) Maximum permitted material temperature by operation without gloves is 40 degrees Celsius.

C) Maximum permitted material temperature by operation with gloves is 60 degrees Celsius

D) Maximum permitted material pressure 250 bar

4. Material consumption and throughput values

a) Material consumption values – depending on nozzle bore and pump pressure.

b) Material throughput values

Measurement based on the following values:

Operating pressure: 100 bar

Nozzle size: 0.23 mm

Material viscosity: 45 seconds. DIN 4 mm/20 degrees Celsius

Material throughput: approx. 0.26 l/min.

5. Air consumption

Air consumption of the high pressure paint spray gun (total air regulating valve 1248 - to U6 adjusted fully on max.,

see description of function Table designation „B “,.)

Round jet Flat jet

1,0 bar = 5,0 cbm/h = 84.0 l/min. 1,0 bar = 4.3 cbm/h = 72.0 l/min.

2,0 bar = 8.1 cbm/h = 136.0 l/ min. 2,0 bar = 6.9 cbm/h = 115.0 l/min.

3,0 bar =11,1 cbm/h = 185.0 l/ min. 3,0 bar = 9.2 cbm/h = 154.0 l/min.

These values can be reduced by operating the total air adjustment 1248-U6

by approx. 80% (i.e. values are than only approx. 20 %)

Service Manual

Manufactured by Bersch & Fratscher GmbH 6

version 10/2008 OPTIMA 2100

6. Description of function

Description Order no.

A Hook -

B Flat jet regulation 1248-U6

C Round jet regulation 1240-U5

D Spring pressure reinforcement 1236-5

E Swivelling air connection 1133-U11

F Ball bearing material connection 1248-U7

G Trigger 1248-U4

H Trigger lock 1237-3

I Filter 1233-75

J Air cap 1248-U2

K Nozzel carrier 1248-U8

L Closing piece 1240-7

M Union nut 1248-4

Table to illustration 1/ paint spray gun optima 2100 Illustration 1/paint spray gun optima 2100

7. Start-up

Before the first use, flush the material supply inclusive nozzle with solvent resp. cleaning agent.

Material flow and spraying picture depend on the size of the spray nozzle, the material viscosity

and the material pressure. See nozzle selection table, page 12 – table 2 “trouble-shooting page 10”.

8. Operation

8.1 Air connection

Swivelling air connection 1133-U11, connecting thread G ¼ “ Air supply for flat jet air cap and round jet air.

-clean and dry air increases your spraying quality and extends the life span of your high pressure spray gun.

8.2 Paint connection

(- Attention high pressure!! – Consider all safety regulations)

Swivelling material connection 1248-U7, Connecting thread NPSM ¼ “. Use only permissible high-pressure hose.

Take care of the right position of the ball-cone seal.

8.3 Operation of the high pressure spray gun

a) Turn trigger lock 1237 - 3

90 degrees downwards (Spray gun is now released)

b) Pull trigger 1248 - U4 up to the first pressure point (pre-air)

c) Pull trigger 1248 - U4 completely, high pressure colour jet starts

d) After ending the spraying procedure secure spray gun at all times

by turning the trigger lock 90 degrees upwards again (see illustration 1).

Note: In order to avoid a drop formation at the spray gun keep the pre air valve

1-2 sec. after spraying open.

8.4 Flat jet regulation

By means of the flat jet regulation 1248-U6 atomization air is added to the flat jet.

Clockwise rotation little air - little atomization

Counter clockwise rotation - much air - high atomization.

OPTIMA 2100

Service Manual

Manufactured by Bersch & Fratscher GmbH 7

version 10/2008 OPTIMA 2100

8.5 Trigger forces

Trigger pressure adaptation according to the material pressure.

- The spring force is adjustable from approx. 80 - 250 bar ( 1.138 - 3.557 PSI ).

- 250 bar tighten screw 1236-5 completely.

- 80 bar -unscrew screw 1236-5 to tappet.

For pressures in between 80 and 250 bar choose a correspondingly intermediate adjustment of the screw 1236-5

8.6 Round jet regulation

By means of the round jet regulation 1240-U5 atomization air is added to the flat jet cap from the sides.

Clockwise rotation little air - little adjustment to round jet.

Counter clockwise rotation much air - high adjustment to round jet.

8.7 Adjustment of atomization air cap

a.) Put pump pressure at 0 , release trigger 1248-U4 completely - pressure of hose relieves.

b.) Secure spray gun by a 90 ° clockwise rotation of the safety lever 1237-3.

c.) Release lock nut 1248-4 by hand.

d.) Put atomization cap 1248-U2 into required position.

e.) Tighten lock nut 1248-4 well by hand.

(see illustration 1)

8.8 Painting distance and spray gun guidance

8.8.1 Adjustment of atomization air cap

The position of the atomization air cap and the spraying nozzle determines the direction of the spray jet.

Turn the atomisation cap according to the desired spray direction (the spraying nozzle turns with it)

Illustration 2: Air cap adjustment

8.8.2 Spray gun guidance

OPTIMA 2100

Illustration 3: Spray gun guidance

The paint spray gun must always be held at a 90° angle to the painting surface.

25-30 cm

Service Manual

Manufactured by Bersch & Fratscher GmbH 8

version 10/2008 OPTIMA 2100

8.9 Filter selection

The mesh size of the filter should not be bigger than the nozzle size!

8.10 Adjustment of pre-air

a.) Unscrew breech ring cap 1240-7 and take out needle.

b.) Release needle carrier 1248-13 with screw wrench SW 6, to counter hold the needle end 1248-14.

c.) Adjust needle:

More pre-air - screw out needle

Less pre-air - screw in needle

d.) Fixate needle, by tightening needle carrier 1248-13 - to counter hold the needle end 1248-14.

(see illustration 4)

9. Maintenance

9.1 Cleaning

Immediately after usage or longer interruptions the spray gun has to be scavenged with

the relevant thinner for the paint in question (cleaner).

In this case it is necessary to scavenge the spray gun with thinner with the assistance

of the feeding pump until the cleaner leaves the gun clear. Never immerse the paint

spray gun in the cleaning agent.

9.2 Cleaning of nozzle

a.) Adjust the pump pressure at 0 bar, release trigger 1248-U4 completely - pressure of hose relieves.

b.) Secure spray gun by a 90 ° clockwise rotation of the safety lever 1237-3

c.) Remove the lock nut 1248-4 by hand

d.) Take off nozzle set 1248-U2 and blow it through, from the front side

e.) Insert nozzle set 1248-U2 and adjust it

f.) Tighten lock nut 1248-4 by hand

(see illustration 1)

9.3 Cleaning of filter

We recommend to clean the filter (depending on the used paint) from time to time in order to avoid that the paint

residues get hard which could make the dismantling impossible.

a.) Put pump into a pressure less condition.

b.) Depending on the paint tube - see spare parts drawing -.

Release lower paint hose part 1248-U7 with a screw wrench SW17

(see illustration 1)

Attention !!

Make sure to support the upper paint hose part of the paint tube by clamping it with an additional screw

wrench SW 11.

c.) Unscrew the filter downwards out of the paint tube.

d.) Clean the filter with a brush (not a wire brush)

Mounting of the parts vice versa, please be thoroughly and take care of the right position

of o-ring 104-0022 in the upper paint hose part of the paint tube. Filter should jut out from paint tube

approx.. 4 mm.

9.4 Lubrication

O-ring, needle guidance, needle seal, as well as lever bearing need to be lubricated regularly with

silicone-free oil and/or silicone-free grease.

10. Replacement of parts

In any case detach the gun from the pump!!!

10.1 Paint needle

a.) Unscrew breech ring cap 1240-7

b.) Take out needle with pressing disc and spring at its end backwards.

c.) Insert new needle with pressing disc and spring. (see illustration 1)

Service Manual

Manufactured by Bersch & Fratscher GmbH 9

version 10/2008 OPTIMA 2100

10.2 Needle seal – inverted cup seal no. 1248 - 10 defectively

a.) Dismantle needle according to point 10.1.

b.) Dismantle trigger 1248-U4, by loosening trigger screw 1248-33; remove trigger axle 1248-17

c.) Screw out tightening nut 1240-9

d.) Pull out complete connection piece 1248-3 to the front

Attention!! Between connection piece 1248-3 and gun body there are for sealing purposes

one o-ring 104 – 0018 and two sealings 1240 – 63.

e.) Unscrew packing gland 1248-12 , substitute distancing gland 1248-11 and

inverted cup seals 1248-10 with o-rings 104-0020.

f.) Mount the parts vice versa - please take care that packing gland 1248-12 is not tightened to strong.

(see illustration 4).

10.3 Valve seal

a.) Dismantle lever according to point 10.2. b)

b.) Turn out valve packing gland 1134-4 to the front

c.) Pull out valve packing gland seal 1133-42 to the front

d.) Insert new valve packing gland seal 1133-42

e.) Mount the parts vice versa

(see illustration 4)

10.4 Change of complete nozzle set no. 1248 – U8

a.) Adjust the pump pressure at 0 bar, release trigger 1248-U4 completely - pressure of hose relieves.

b.) Secure spray gun by a 90 ° clockwise rotation of the safety lever 1237-3

c.) Remove the lock nut 1248-4 by hand.

d.) Take off nozzle set 1248-U2 to the front side.

e.) Push out nozzle carrier from nozzle set backwards.

e.) Deposit nozzle carrier complete in cleaning fluid respectively install another nozzle carrier complete

according to these steps vice versa. (Cleaning needle for nozzle order-number 00345-44)

g) Replace if necessary , seal 1240-58.

h) Assembly in reverse order (see illustration 4)

10.5 Gesket devectively – sealing retaining screw complete no. 1248 – U5

a.) Adjust the pump pressure at 0 bar, release trigger 1248-U4 completely - pressure of hose relieves.

b.) Secure spray gun by a 90 ° clockwise rotation of the safety lever 1237-3.

c.) Remove the lock nut 1248-4 by hand.

d.) Take off nozzle set 1248-U2 to the front side.

e.) Release packing gland 1248-12.

f.) Unscrew breech ring cap 1240-7 and take off needle piece complete with springs and pressing discs,

pull out backwards.

g.) Unscrew sealing retaining screw by using socket wrench SW 10 and replace in connection with sealing

ring 1240-25. At the same time check the ball on needle piece 1248-U3

h.) Mounting of the parts according to these steps vice versa.

(see illustration 4)

11. Positive Pressure

For short positive pressures of 10 - 12 bar ( 143 – 170 psi ) at the air supply and higher pump pressures (above 250 bar

– 3.556 psi material pressure) there is no danger of the destruction of the high pressure spray gun.

Positive pressure in the material area are compensated by automatic release of the paint needle.

( Note: Leaving spraying material)

12. Workstation related sound pressure level

Technical equipment - total air adjustment 1248 - U6 on max. –

Measured values:

Round jet Flat jet

1,0 bar = 67 dB/A 1,0 bar = 69 dB/A

1,5 bar = 71 dB/A 1,5 bar = 74 dB/A

2,5 bar = 78 dB/A 2,5 bar = 79 dB/A

The measurements and datas are based on the following rules of the measuring technique:Regulation for equipment

safety law DIN 45635 Part 1/04.84

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Manufactured by Bersch & Fratscher GmbH 10

version 10/2008 OPTIMA 2100

13. Disposal

The high pressure spray gun is not subject to special disposal regulations.

14. Trouble possiblilities

Functional disturbance Possible cause Repair

14.1. Decrease in paint flow

when spraying: * Filter of gun clogged.

* Viscosity too high.

* Too low material pressure.

Clean the filter ( see point 9.3. )

Water down the paint.

Increase air inlet pressure of the pump.

14.2. Irregular jet: * Airless nozzle clogged.

* Filter of gun clogged.

* Nozzle to wide or worn out.

* Viscosity to high.

* No, or not enough atomizer air.

* Air slits dirty.

* Atomizer air pressure to high or too low.

Replace nozzle ( see point. 10.4. )

Clean the filter ( see point 9.3. ) or change the filter.

Insert new nozzle ( see point 10.4. )

Water down the paint.

Open regulation no. 1248 – U6 ( see point 8.4)

Clean with a brush. Do not u use a wire brush!

Adjust pressure regulation valve.

14.3. Spray gun still sprays

when closing: * Seal washer or needle ball worn out.

* Needle spring has lost stress.

* Needle seal too strong thus needle can

not be moved through the spring.

* Needle and needle sealing dirty.

Change parts ( see point 10.1 to 10.5. )

Replace spring ( see point 10.1. )

Change sealings ( see point 10.2 )

14.4. Spray gun leaks paint

on needle seal:

* Needle seal worn.

* Packing gland is not installed

tight enough.

Replace sealings ( see point 10.2. )

Tighten packing gland.

14.5. Spray gun is blowing: * Valve spring fatigue.

* Valve sealing worn.

* Valve defective.

Replace spring no.1136 -20

Change valve sealing ( see point 10.3. )

Change valve.

14.6. Spray gun has no or to little

pre-air:

* Pre-air stroke screw not properly

adjusted.

Adjust pre-air ( see point 8.10. )

Regularly cleansing and servicing prolongs the life-span of the high pressure spray

gun. For a general cleansing we offer a professional service in our company.

15. Available accessories Order number

Insert filter 50 µm / 295 msh red colour 001233-74

100 µm / 150 msh yellow colour 001233-75

150 µm / 80 msh white colour 001233-76

Nozzle carrier complete with nozzle bores in diameters 01248-U8

0,18 ; 0,23 ; 0,28 ; 0,33 ; 0,38 ; 0,43 mm

(and further sizes in different spraying angles

are also on stock available,

deviating nozzle bores on request.

Nozzle cleaning needles 000345-44

AirCombi hose pair 7,5 meter , G1/4“air connection

NPS1/4“ material connection 2462-U1

AirCombi soft hose pair 7,5 meter , G1/4“air connection

NPS1/4“ material connection 2462-U2

Repair kit 000345-172

Air hose Pk 6 endless 003633.05

(cut to length on request and on both sides G ¼ “union nut).

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