Operating Manual for Automatic sprayvalve KA
Contents
1. Operating Manual for Automatic sprayvalve KA 2 GT KA 2 GT round spray KA 2 GT flat spray with clamp option with clamp option Read this manual carefully before installing operating or servicing this equipment Keep always handy for further use 1 Introduction The automatic spray valve KA 2 GT is designed and constructed for finest application of thin materials f i release agents colours or other fluids of low viscosity Depending on air cap this spray valve sprays in flat or roundspray Depending on viscosity of fluid the application can be adjusted individually via nozzle dimension atomizing air pressure and material pressure The supply of atomizing air control air and material should be done via three hoses Spray valves are precision tools Always keep clean and observe minimum instructions to maintain a long usefull life of the valve 2 Safety 2 1 Duties of the user The user must read this service manual carefully before performing any operations Application and service operations should not be carried out if the user is not absolutely sure of the purpose and consequence of the operations 2 2 Definitive Use The automatic spray valve KA 2 GT is a pneumatically controlled spray valve It is suitable for sprayable materials It is not suitable for spraying aggressive or heated materials In case of doubt contact the manufacturer 2 3 Warning against danger This operating manual warn2. 5 Repair and Maintenance Before starting maintenance or repair work ensure that all air operated tools are disconnected from the air supply WARNING Danger caused by combustible and noxious spraying material Safety instructions on fluid can and material data of fluid manufacturer must definitly be observed WARNING Before opening the spray valve it has to be disconnected from the air and fluid supply Otherwise ejected elements can cause danger These spray valves are high precision tools Always keep clean and observe minimum instructions to maintain a long and useful life of valve We recommend lubricating moveable parts regularly and greasing threads especially the nozzle threads when replacing or cleaning the nozzle 5 1 Cleaning To clean valve spray solvent until pure solvent leaves nozzle Do not submerge entire valve in solvent At longer working interruptions it is advisable to clean air cap and nozzle by putting these parts only into solvent If necessary use a soft brush Moving parts and threads should alway be greased slightly The spray valve should be cleaned using an appropiate thinner To clean small drill holes use our special nozzle cleaning needles 5 2 Trouble shooting If seal 6 is worn exchange this gasket removing needle see Changing nozzle set Changing needle gasket If drops form on the nozzle either needle or nozzle is worn out and should be replaced Or needle is not closin
3. 6 Sparepartslist 2 nozzle stainless steel part no see overleef 3 collar ring 4 main body stainless steel 4 1 o ring 5 connection M5 o ring 7 needle stainless steel complete part no see overleef Ti o ring needle spring regulating screw 8 x 13 M6 x 0 5 version GT 10 o ring closing plate stainless steel lock screw 910015 clamp complete Be SEEN 4 ECN a 561 ESTE i paren ego 10 part no see page 8 When ordering nozzles needles and air caps please indicate nozzle dimension Available dimensions 0 2 0 3 0 5 0 8 1 0 1 2 1 5 2 0 and 2 5mm Y If nozzle size is to be changed always change all these three parts Change the complete set also when only one of the parts is defect 7 Technical data measurements with air cap flat spray 42mm length x 25mm x 25mm without connections with air cap round spray 39mm length x 25mm x 25mm without connections weight 140g with clamp 1859 air consumption 103ltr at 3 bar 0 5mm nozzle and 2m hose pressure for control air 3 6 bar pressure for atomizing air 0 5 6 bar material pressure max 3 bar Special designs on request Technical alterations reserved August 2000 8 Manufacturer declaration The spray valve KA 2 GT were constructed and produced by ALFRED SCHUTZE Apparatebau GmbH Hannoversche StraBe 69 71 28309 Bremen Germany in accordance with the guidelines and standards of DIN EN 292 This spray valve can
4. be combined with other modules or machines which comply to DIN EN 292 without limiting the conformity Place Date Signatura of manufacturer Bremen 25 08 2000 6 1 part no of needles nozzles and air caps needle nozzle draw no part no Description 0 2 0 3mm 2 210110 0 2mm 210111 0 3mm 210112 0 5mm 210113 0 8mm 7 110159 1 2mm 1 0mm 7 tot60 1 5mm 1 2mm 210116 1 5mm 210117 2 0mm 5mm air cap flat spray 45 1 0 310038 for nozzle 0 2 1 0mm 1 0 310039 for nozzle 1 2 1 8mm air cap flat spray 60 standard Description or nozzle 0 2 1 0mm or nozzle 1 2 1 8mm or nozzle 2 0mm or nozzle 2 5mm air cap flat spray 90 Description or nozzle 0 2 1 0mm or nozzle 1 2 1 8mm or nozzle 2 0mm or nozzle 2 5mm air cap round spray 15 Description or nozzle 0 2 1 0mm or nozzle 1 2 1 8mm 1 1 or nozzle 2 0mm or nozzle 2 5mm
5. g liability for industrial safety and insurance When you are certain that fluid pressure stands up to the nozzle actuate 2 2 way solenoid for atomizing air After that actuate 3 2 way solenoid for control air This way you receive socalled pre air prior to opening fluid flow After each cycle solenoids are to be actuated in reverse order so you will still have purging air after needle has closed nozzle and fluid flow was stopped This prevents fluid to form out drops instead of being atomized Set working pressure of atomizing air and fluid pressure according to required spray droplet sizes Two seperate pressure reducers must be available if fluid is fed via pressure tank Standard version of valve has flat spray air cap If round spray cone jet is required install round spray air cap Flat spray air cap can be positioned for horizontal vertical or any in between position of jet Depending on viscosity of fluid different nozzle diameters are available in 0 2 0 3 0 5 0 8 1 0 1 2 1 5 2 0 and 2 5mm IMPORTANT Fluid flow can be regulated with regulating screw 9 turn right less fluid flow turn left more fluid flow IMPORTANT Wrong handling can damage nozzle and needle Reduce fluid flow clockwise turn of regulating screw only when fluid flows throught nozzle After fluid flow is nil never turn regulating screw 9 further right For longer working interruptions and if the fluid is under pressure it can stay in valve
6. g properly f i because particle residues within nozzle If there is an uneven or not steady spray jet make sure that nozzle is screwed in tight Other reason could also be dirt residue within air cap 5 3 Changing the nozzle set 1 IMPORTANT LA Py x Nozzles gaskets and gasket seats can be damaged Do not use metallical aid to remove and insert those parts A nozzle set includes needle 7 nozzle 2 and air cap 1 or 1 1 If nozzle size is to be changed always change all these three parts Change the complete set also when only one of the parts is defect Take off closing plate 11 by unscrewing screws 13 Pull out needle 7 and needle spring 8 Take off air cap 1 0 or 1 1 after unscrewing collar ring 3 Screw out nozzle 2 with wrench size SW 6 Before unscrewing nozzle please observe that needle is never under spring pressure Reassemble in reverse order To prevent damage to the needle seat during replacement the needle 7 must only be inserted into firmly installed nozzle 5 4 Changing needle gasket After pulling out needle 7 see Changing the nozzle set needle gasket 6 can be taken out of the valve body by means of using a pointed object Re assemble by laying the new gasket into the provided slot L width 25 25 approx 44 40 57 pply not in standard su optional
7. oid control air S 5 hose black gt to 3 2 way solenoid fluid M 5 hose transparent gt to feeding device Connections 5 can either be mounted alternatively on the upper side or the rear side of the valve Connection threads not used must be closed by lock screws using f i Loctite no 221 Before Starting When connecting the pressure hoses to the spray valve ensure that all the connection screws are tight Follow the application notes of the spraying material manufacturer 4 2 Operating instructions CAUTION Never point the spray valve against persons Wearing eye protection is strongly recommended Spraying procedures cause noises depending on the used pressure If necessary wearing of ear protection is recommend WARNING Danger caused by combustible and noxious spraying material Safety instructions on fluid can and material data of fluid manufacturer must definitly be observed Do not smoke when spraying paints or solvents which have combustible properties All electrical installations within the spraying area must be explosionproof Observe working safety regulations in respect of protective clothing masks clothing ear protection etc The valve KA 2 GT needs 3 6 bar pressure for control air The atomizing air should be 0 5 6 bar The maximum material pressure is 3 bar If higher material pressure is necessary please observe the regulations of the professional trade association havin
8. s users of operations which may put their health at risk The warnings are indicated by combinations of text and symbols corresponding to the different danger classes WARNING Signs a possible dangerous situation If you don t avoid death or severe injuries can follow CAUTION Indicates a situation which may be dangerous Failure to heed the caution may result in personal injury This indication is also used where material damage is possible IMPORTANT Indicates tips for usage and other helpful information 3 Function Description The spray valve KA 2 GT is pneumatically controlled air open spring return The spraying material is to be fed to the valve via pressure tank or pump The separate controlled atomizing air atomizes the material to a spray jet Depending on mounted air cap valve sprays a flat or roundspray jet 4 Installation The KA 2 GT can be installed in any position The use of clamp 16 is recommended Distance to spraying surface varies width of application Vibrations of the valve caused by fast intermitting cycles require solid and massive installation Vibration of the equipped machine to the valve should be limited as far as possible 4 1 Hose connection Connect hoses for atomizing air and control air seperately to control valves pressure reducers and solenoids Then fluidhose to material pressure tank or other means of feeding as under e atomizing air Z 5 hose blue gt to 2 2 way solen
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