Manufactured by Bersch & Fratscher GmbH
1
OPTIMA 2100
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. S
AFETY REFERENCES FOR THE OPERATOR ........................................................................................................... 3
2.1.1 Qualification of the personnel ................................................................................................................. 3
2.1.2 Security of the working environment..................................................................................................... 3
2.2 S
AFETY 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 A
DHESION................................................................................................................................................................
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 O
PERATION OF THE HIGH PRESSURE SPRAY GUN....................................................................................................
8.4 F
LAT JET REGULATION .......................................................................................................................................... 6
8.5 TRIGGER FORCES ....................................................................................................................................................
8.6 R
OUND 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 F
ILTER SELECTION................................................................................................................................................. 8
8.10 A
DJUSTMENT OF PRE-AIR ...................................................................................................................................... 8
9. MAINTENANCE............................................................................................................................................................ 8
9.1 CLEANING.............................................................................................................................................................. 8
9.2 C
LEANING OF THE NOZZLE .................................................................................................................................... 8
9.3 CLEANING OF THE FILTER ...................................................................................................................................... 8
9.4 L
UBRICATION......................................................................................................................................................... 8
10. REPLACEMENT OF PARTS................................................................................................................................. 8
10.1 P
AINT NEEDLE ....................................................................................................................................................... 8
10.2 N
EEDLE SEAL- INVERTED CUP SEAL 1248-10 DEFECTIVELY ................................................................................ 9
10.3 V
ALVE SEAL........................................................................................................................................................... 9
10.4 C
HANGE OF COMPLETE NOZZLE SET 001248-U8 ................................................................................................. 9
10.5 G
ASKET 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.
Service Manual
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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