WALTHER PILOT PILOT WA 600, PILOT WA 610, PILOT WA 625, WA 600, WA 635 Operating Instructions Manual

WALTHER PILOT

Betriebsanleitung / Operating Instructions

Automatische Spritzpistolen / Automatic Spray Guns

PILOT WA 600 / WA 610 / WA 625

The WALTHER PILOT Product Range

• Manual spray guns

• Automatic spray guns

• HVLP spray guns

• Two-component spray guns

• Pressure containers

• Nonpressurized containers

• Agitator systems

• Airless equipment and fluid pumps

• Material circulation systems

• Two-pack systems

• Marking equipment

• Combined spraying and drying booths

• Spray booths with dry filtering

• Spray booths with wet filtering

• Powder booths

• Powder spraying equipment

• Adhesive spraying systems

• Dryers

• Air regulators / air filters

• Health protection equipment

Das WALTHER PILOT - Programm

• Hand-Spritzpistolen

• Automatik-Spritzpistolen

• Niederdruck-Spritzpistolen (System HVLP)

• Zweikomponenten-Spritzpistolen

• Materialdruckbehälter

• Drucklose Behälter

• Rührwerk-Syisteme

• Airless-Geräte und Flüssigkeitspumpen

• Materialumlaufsysteme

• 2-K - Anlagen

• Signieranlagen

• Kombinierte Spritz- und Trockenboxen

• Absaugsysteme mit Trockenabscheidung

• Absaugsysteme mit Nassabscheidung

• Pulversprühstände

• Pulverspritzgeräte

• Kleberspritzsysteme

• Trockner

• Zuluft-Systeme

• Atemschutz-Systeme und Zubehör

WALTHER Spritz- und Lackiersysteme GmbH

Kärntner Str. 18-30 • D-42327 Wuppertal

Tel.: 0202 / 787-0 • Fax: 0202 / 787-217

www.walther-pilot.de

E-mail: [e-mail]

WA 600 / WA 610 / WA 625

Rep.-Set Nr.:
Repair Set No.: V 16 600 02 .. 3

EG-Konformitätserklärung

Wir, der Gerätehersteller, erklären in alleiniger Verantwortung, dass das Produkt in
der untenstehenden Beschreibung den einschlägigen grundlegenden Sicherheits- und
Gesundheitsanforderungen entspricht.Bei einer nicht mit uns abgestimmten Änderung an
dem Gerät oder bei einer unsachgemäßen Verwendung verliert diese Erklärung ihre
Gültigkeit.

Wuppertal,den 7. Juli 2003

Name:Torsten Bröker
Stellung im Betrieb:Leiter der Konstruktion und Entwicklung

Diese Erklärung ist keine Zusicherung von Eigenschaften im Sinne der Produkthaftung. Die Sicherheitshinweise der
Produktdokumentation sind zu beachten.

Declaration of CE-Conformity

We, the manufacturers of the equipment, hereby declare under our sole responsibi­lity that the product(s) described below conform to the essential safety require- ments. This
declaration will be rendered invalid if any changes are made to the equipment without prior
consultation with us.

Wuppertal, the 7th of July 2003

Name:Torsten Bröker
Position:Manager, Design and Development

This Declaration does not give assurance of properties in the sense of product liability.The safety instructions provi­ded in the product documentaion must be observed at all times.

Manufacturer WALTHER Spritz-und Lackiersysteme GmbH

Kärntner Str. 18-30
D-42327 Wuppertal
Tel.: 0202 / 787-0
Fax: 0202 / 787-217 • www.walther-pilot.de

Type Designation Automatic Spray Gun PILOT WA 600 / WA 610 / WA 625

WA 600 V 20 600
WA 610 V 20 610
WA 625 V 20 607

Intended purpose Processing of sprayable media
Applied Standards and Directives

EU-Machinery Directive 98 / 37 CE
94 / 9 EC (ATEX Directives)
DIN EN 12100 Part 1
DIN EN 12100 Part 2 DIN EN 1953
DIN EN 1127 DIN EN 13463-1

Specification according 94 / 9 / CE

Category 2 Part marking II 2 G c T 5

Tech.File,Ref.:
2406

special remarks :

The named product is intended for installation in other equipment.Commissioning is pro­hibited until such time as the end product has been proved to conform to the provision of
the Directives 98 / 37 / CE.

Hersteller WALTHER Spritz-und Lackiersysteme GmbH

Kärntner Str. 18-30
D-42327 Wuppertal
Tel.: 0202 / 787-0
Fax: 0202 / 787-217 • www.walther-pilot.de

Typenbezeichnung Automatische Spritzpistole PILOT WA 600 / WA 610 / WA 625

WA 600 V 20 600
WA 610 V 20 610
WA 625 V 20 607

Verarbeitung spritzbarer Materialien

Angewandte Normen und Richtlinien

EG-Maschinenrichtlinien 98 / 37 EG
94 / 9 EG (ATEX Richtlinien)
DIN EN 12100 Teil 1
DIN EN 12100 Teil 2 DIN EN 1953
DIN EN 1127 DIN EN 13463-1

Spezifikation im Sinne der Richtlinie 94 / 9 / EG

Kategorie 2

Gerätebezeichnung

II 2 G c T 5

Tech.File,Ref.:
2406

besondere Hinweise :

Das Produkt ist zum Einbau in ein anderes Gerät bestimmt. Die Inbetriebnahme ist so
lange untersagt, bis die Konformität des Endproduktes mit der Richtlinie 98 / 9 / EG fest­gestellt ist.

Verwendungszweck

Listing of Replacement Parts WA 600, WA 610 and WA 625

Item Parts No. Description
1 V 10 151 30 039* Air Control Head 0,3 - 1,5 mm Ø

V 10 151 30 189* Air Control Head 1,8 - 2,2 mm Ø
2 V 10 151 40 .. 3* Material Nozzle

3 V 20 410 10 000 Front Part

4 V 09 001 80 000 Needle Packing compl.

5 V 20 310 09 003 Connection
6 V 20 410 40 000 Piston Casing

7 V 09 220 27 000 Cup Seal

8 V 09 103 22 001 O-Ring
9 V 20 410 24 004 Piston-Boss Bushing

10 V 09 102 67 000 O-Ring

11 V 20 410 23 004 Piston Bushing

12 V 09 220 28 000 Cup seal

13 V 20 410 18 004 Clamping Washer

14 V 09 102 20 001 O-Ring

15 V 20 410 39 004 Pressure Ring
16 V 20 410 16 004 Piston Screw
17 V 20 410 30 .. 3* Material Needle

18 V 20 410 17 000 Piston Spring

19 V 20 410 27 000 Threaded Ring

20 V 20 410 28 003 Needle Spring

21 V 20 410 29 000 Cap
22 V 20 410 36 000 Threaded Rod compl.
23 V 20 410 19 005 Atomizing Air Connection
24 V 66 101 53 322 Control Air Connection

25 V 09 001 81 000 Seal
26 V 09 002 51 000 Seal

27 V 20 410 13 003 Material Connection
28 V 20 410 37 003 Hexagonal Screw
29 V 20 410 20 000 Round- and Wide-Fan-Adjustment

Deviating spare parts Model WA 610

3 V 20 420 10 000 Front Part

Deviating spare parts Model WA 625

1 V 10 141 30 xx8 Air Control Head MP
6 V 20 60 701 000 Piston Casing
23 V 20 607 03 005 Atomizing Air Connection

* Please make sure to quote the required size when placing an order for replacement
parts,diameter: 0.3 • 0.5 • 0.8 • 1.0 • 1.2 • 1.5 • 1.8 • 2.0 • 2.2 mm

We recommend to hold all bold-faced replacement parts on stock.

Repair Set No.: V 16 600 02 .. 3

Includes all bold-faced wearing parts

Contents

1 General

1.1 Identification of Model Version

1.2 Normal Use

1.3 Improper use

2 Technical Description

3 Safety

4 Using the Spray Gun

4.1 Connections for Control Air, Atomising Air and Material

4.2 Spraying a Test Pattern

4.3 Changing the Spray Pattern

4.4 Correction of Spray Pattern Imperfections

5 Re-tooling the Spray Gun

5.1 Changing the Air Cap

5.2 Changing the Material Nozzle

5.3 Changing the Material Needle

5.4 Changing the Needle Seal

6 Troubleshooting

7 Cleaning and Maintenance

8 Technical Data

1 General

1.1 Identification of Model Version

Model: Automatic Spray Gun PILOT WA 600 / WA 610 / WA 625
Type: WA 600 V 20 600

WA 610 V 20 610
WA 625 V 20 607

Manufacturer: WALTHER Spritz- und Lackiersysteme GmbH
Kärntner Straße 18-30
D-42327 Wuppertal
Tel: [phone]
Fax: [phone] • www.walther-pilot.de

1.2 Normal Use

The automatic spray gun must be used only for processing sprayable materials, in parti­cular:

• lacquers and paints

• grease, oil and anti-corrosion agents

• adhesives, grease, oil and anti-corrosion agents

• ceramic glazes

• stains
If you intend to spray materials that are not listed here, please contact WALTHER
Spritz- und Lackiersysteme GmbH, Wuppertal.
The sprayable materials must be sprayed only on workpieces or objects.
The temperature of the material to be sprayed must not exceed 80°C.
The models PILOT WA 600, WA 610 and WA 625 are not a hand-held spray guns and
must therefore be mounted in a suitable bracket.
Proper use of the spray gun also includes the fact that you have read, understood and
observed all information, advice and safety requirements presented in this instruction
manual.

This equipment complies with the explosion protection requirements of Directive 94 / 9 /
EC (ATEX) for the explosion group, equipment category and temperature class indica­ted on the type plate. When using the equipment, the requirements specified in these
Operating Instructions must be observed at all times.

The technical data indicated on the equipment rating plates and the specifications in the
chapter "Technical Data" must be complied with at all times and must not be exceeded.
An overloading of the equipment must be ruled out.
The equipment may be used in potentially explosive atmospheres only with the authori­sation of the relevant supervisory authority.

The relevant supervisory authority or the operator of the equipment are respon­sible for determining the explosion hazard (zone classification).

The operator must check and ensure that all technical data and the marking of the
equipment in accordance with ATEX are compliant with the necessary require­ments.
The operator must provide corresponding safety measures for all applications in
which the breakdown of the equipment might lead to danger to persons.
If any irregularities are observed while the equipment is in operation, the equip­ment must be put out of operation immediately and WALTHER Spritz- und
Lackiersysteme must be consulted.
Grounding / Equipotential Bonding
You must ensure that the spray gun is properly earthed (grounded) either separa­tely or in connection with the equipment with which it is being used (maximum
resistance 10

6

Ω).

1.3 Improper Use

The spray gun must not be used in any other way than as described above in the
section 1.2 Normal Use.
Any other form of use is prohibited.
Improper use includes:

• spraying materials onto persons or animals

• spraying liquid nitrogen

2 Technical Description

The models PILOT WA 600, WA 610 and WA 625 are operated automatically by
compressed air and is controlled via 3/2-way control valves. Hand-operated, foot­operated or solenoid-valve-operated valves can be used for this purpose.
First, the atomising air is introduced by a 3/2-way valve.
Then, the 3/2-way control valve required for the control air is actuated.
The compressed air flowing into the cylinder chamber moves the control piston
and opens the material feed.
If the control air is interrupted by the 3/2-way valve, the compressed air in the
cylinder chamber is allowed to escape. The spring pressure of the piston spring
shuts off the material feed to the material nozzle.
After this, the atomising air is switched off by the 3/2-way valve.
Nozzle and needle are made of corrosion-free stainless steel.

3 Safety

• The spray gun must be used only by trained and qualified persons.

• All relevant rules of safety and workers' safety regulations applicable in the coun­ try or area of use must be fully observed.

• Observe the instructions given by the manufacturers of the spraying material and
the cleaning agents with regard to safety and proper use.

• Use the spray gun only in well-ventilated rooms. Fire, naked flames and smoking
are prohibited within the working area.

2 3

• Always wear the regulation breathing masks, protective clothing and hearing protection
when using the spray gun.

• Exhaust air which contains particles must be kept away from the working area and
operating personnel. Make sure that adequate exhaust extraction is provided.

• When spraying materials, keep your hands and other parts of the body away from the
pressurised nozzle of the spray gun.

• Do not direct the spray gun at persons or animals.

• Before carrying out maintenance or servicing, ensure that the air and material feed to
the spray gun have been depressurised.

• You must ensure that the spray gun is properly earthed (grounded) either separately or

in connection with the equipment with which it is being used (maximum resistance
10

6

Ω).

• After carrying out assembly and maintenance work, ensure that all nuts, bolts and
screw connections have been fully tightened.

• Use only original spare parts, since WALTHER can only guarantee safe and fault-free
operation for original parts.

For further information on the safe use of spraying equipment, please contact
WALTHER Spritz- und Lackiersysteme GmbH, Wuppertal.

4 Using the Spray Gun

Before using the spray gun, ensure that the following conditions apply:

• The control air pressure is applied to the spray gun

• The atomising air pressure is applied to the spray gun

• The material pressure is applied to the spray gun

4.1 Connections for Control Air, Atomising Air and Material

• Connect the control air connector (via the 3/2-way valve) to the spray gun and set the
control air pressure (min. 4.5 bar).

• Connect the atomising air connector to the air hose (filtered compressed air sup­ply) and to the atomising air connection.

• Switch on the compressed air and set the required atomising air pressure at the
reducing valve (max. 8 bar).

• Fill the pressure pot with the material to be sprayed and close the lid.

• Connect the material feed hose to the pressure pot or the pump and to the
material connection. Set the required material pressure (max. 8 bar).

• Open the material valve on the pressure pot.

4.2 Spraying a Test Pattern

A test spray pattern should always be made whenever:

• the spray gun is used for the first time

• the spraying material is changed

• the spray gun has been disassembled for maintenance or servicing.

The test pattern can be sprayed on a test workpiece, panel, cardboard or paper.

4.3 Changing the Spray Pattern

• Round-fan or wide-fan air caps are available.

• The fan width can be varied by changing the atomising air.

• The material flow rate is determined by the material pressure and the diameter

of the material nozzle.

4.4 Correction of Spray Pattern Imperfections

The following table shows how to correct a defective spray pattern.
Desired Spray Pattern

1 2 3

1 2 3

1 = Material connection 2 = Control air connection 3 = Atomizing air connection

5

4

Spray pattern test Fault Necessary adjustment

Swollen centre • Spray jet should be flatter

Swollen ends • Spray jet should be rounder

Coarse pearl effect • Increase atomising air pressure
Unduly thin paint

layer in centre

• Decrease atomising air pressure

Split centre

• Increase nozzle diameter

• Reduce atomising air pressure

• Increase material pressure

Split centre

• Decrease material pressure

• Increase atomising air pressure

5 Retooling the Spray Gun

The combination of air cap, material nozzle and needle for a certain spraying material
forms a specially matched unit - the nozzle assembly.
Always exchange the complete nozzle assembly in order to maintain the desired spray
pattern quality.

Warning

Air and material inputs must be shut off prior to re-tooling - risk of injury.

Note

Please refer to the exploded view at the beginning of this manual to perform the steps
detailed below.

5.1 Changing the Air Cap

1. Unscrew the air cap nut.

2. Remove the air cap (Pos.1).

5.2 Changing the Material Nozzle

1. Unscrew the air cap nut.

2. Remove the air cap.

3. Unscrew the material nozzle (Pos.2) from the spray gun head.

4. Installation takes place in reverse order.

5.3 Changing the Material Needle

1. Unscrew the threaded rod (Pos. 22).

2. Unscrew the air cap (Pos. 21).

3. Remove the needle spring (Pos 20).

4. Unscrew the threaded ring (Pos. 19).

5. Withdraw the piston (Pos. 11) together with the material needle (Pos. 17).

6. Unscrew the material needle from the piston.

7. The distance between the tip of the material needle and the piston should be set at
79,0 mm.

8. Installation takes place in reverse order.

5.4 Changing the Needle Seal

1. Unscrew the front part from the piston casing.

2. Remove the seal.

3. Remove the complete needle packing using a strong wire with a hook at its end.

4. Lubricate the new needle seal packing..

5. Installation takes place in reverse order.

6 Troubleshooting

Warning

Prior to any servicing and repair work the spray gun should be inunpressurised
state, i.e. all control air and atomising air pressure as well as all material inputs
must be shut off - risk of injury.

7 Cleaning and maintenance

• To ensure that the spray gun functions properly and to maximise its service life,

the spray gun must be maintained, cleaned and lubricated regularly.

• Before carrying out any maintenance, ensure that the control air and atomising

air as well as the material feed are depressurised.

• Cleaning should be carried out after every colour and material change or accor-

ding to the degree of contamination.

• For cleaning the spray gun, use only those cleaning agents that are specified by

the material manufacturer and ensure that they do not contain any of the follo­ wing components:

- halogenated hydrocarbons,( e.g. 1,1,1-trichloroethane, methylene chloride,etc.)

- acids or acidic cleaning agents,

- paint strippers,

- regenerated solvents (cleaning thinners).

• Never immerse the whole spray gun in solvent or cleaning agent, as this could

harm the correct functioning of the gun.

Spray pattern Fault Adjustment

Gun drips Material needle or nozzle

dirty
Material needle or nozzle

damaged

Remove and clean

Replace

Gun does not open Control air pressure too low Increase control air pressu-

re to min. 4.5 bar

Irregular or splattering
spray

Insufficient material in con­tainer

Fill up with material (see
instructions from material
manufacturer)

Gun sprays when swit­ched off

O-ring Item 7 damaged Replace

Material bubbling in
material container

Atomising air is entering the
material container via the
material channel. Material
nozzle or air cap not proper­ly tightened

Clean the parts, tighten or
replace

Spray fan one-sided Air cap horn bore dirty Remove and clean

6

7

• Do not use sharp or hard objects to clean the spray gun, as this might cause
damage to precision parts and impair the spraying result.

• WALTHER Spritz- und Lackiersysteme cannot accept any liability for damage caused
by improper treatment of the spray gun.

8 Technical Data

Weight: 360 g
Connections

Atomising air: G 1/4
Control air CK 1/8 PK 4
Material feed: G 3/8

Pressure range:
Control air pressure: min. 4,5 bar
Material pressure: max. 8 bar
Atomising air pressure: max. 8 bar

Noise Level
(measured at a
distance of ca. 1 m
from spray gun) 83 dB (A)

Air Consumption:

Air input: Round fan Wide fan
1,0 bar 150 L/min. 180 L/min.

2,0 bar 210 L/min. 260 L/min.
3,0 bar 250 L/min. 310 L/min.
4,0 bar 280 L/min. 360 L/min.
5,0 bar 310 L/min. 400 L/min.
6,0 bar 340 L/min. 430 L/min.

Technical data are subject to change.

8