AAS HIGH PRESSURE AIRLESS APPLICATION SYSTEM

Transcription

1 AAS HIGH PRESSURE AIRLESS APPLICATION SYSTEM AIRLESS PUMP 1:26 1. SAFETY REGULATIONS Read the instruction manual carefully before starting the pump. These pumps should only be used by trained personnel and only for the process for which they are intended. Only use AAS high pressure, airless, equipment for the application of Ardrox Corrosion Inhibiting s. All components used with the AAS high pressure, airless, pump must be capable of withstanding the maximum fluid pressure in the system. The bursting pressure has to be 4 times the maximum product pressure. Do not exceed the maximum air pressure of 10 bar (145 p.s.i.). Where there is any danger of the pressure exceeding 10 bar (145 p.s.i.) a suitable safety pressure relief valve must always be installed in the pump air connection. Maintenance and repairs must always be carried out with the system unpressurized. Note that leaks or other fine jets of fluid are under high pressure and can cut the skin. It is especially important to be careful with AAS corrosion inhibiting compound (CIC) spray application equipment where pressures are high. Inspect the equipment for wear at regular intervals, paying particular attention to hoses and connections. Always use ear protectors when working near compressed air-powered machines. The maximum emitted noise level, measured at a distance of 1 m in accordance with SS- ISO 3747, is: Sound level Acoustic power level 101-dB (A) 109 db (A) relative to 1 pw. page IV-1

2 2. TECHNICAL DESCRIPTION GENERAL The pump consists of a drive section and a pump section. The drive section is normally an air motor driven by compressed air. The pressure ratio of the pumps states the ratio of the incoming air pressure to the fluid pressure. A pump with a pressure ratio of 1:26 thus gives a fluid pressure of 260 bar (3770 p.s.i.) at an air pressure of 10 bar (145 p.s.i.). The pressure ratio usually states the area ratio between the pump piston and the air piston. The practical pressure amplification may therefore vary somewhat for different compounds. The AAS compressed air driven pumps are fully automatic. They start automatically when the fluid (CIC) valve is opened. When the valve is closed they build up a back-pressure and stop. 3. ASSEMBLY AND INSTALLATION AAS PUMP Remove all protective plugs. Remove the CIC drum bung fitting by turning the upper knurled part counter-clockwise. The drum bung fitting can then be screwed into the drum. Place the pump into the drum or racket on the trolley Lock the suction pipe to the drum by turning the knurled part clockwise. Cover the opening around the suction pipe with a rag or similar so as to prevent dirt from entering and contaminating the CIC. If the compressed air contains moisture a water-separator should be installed in the airline before it connects to the AAS pump. The AAS pump does not require an oil-mist lubricators but if one is already installed it will only have a beneficial effect on pump life and need not be removed. Oil-mist lubricators are recommended under severe operating conditions. 4. STARTING UP The AAS pump may be damaged if it runs dry. For this reason it should be started up carefully, with low air pressure. When it has started to pump the CIC fluid the air pressure can be gradually increased. Run the pump until the CIC is free from air at the discharge point and then close the valve. The pump will then make a few more strokes and then stop. Check hoses and connections for leaks. The equipment is now ready for use. page IV-2

3 5. MAINTENANCE AND REPAIR PREVENTIVE MAINTENANCE Inspect the equipment regularly for leaks. If an oil-mist lubricator is fitted, make sure that it is filled. If a water separator is fitted, empty it regularly. Make sure that the CIC drum lid is properly fitted to prevent contamination of the contents. Make sure that the suction pipe is not resting on the bottom of the CIC drum. When changing drums, be careful not to get dirt on the suction pipe. CORRECTIVE MAINTENANCE Trouble-shooting Problem Pump does not start Pump starts but output is insufficient Pump does not stop although spray is not operating Air escapes from the air motor when the pump has stopped under pressure. Action Check air supply Check that outlet is not blocked Check the air motor, see Repair section Check that air pressure is not too low Check that pump is not sucking air Check that air filter is not clogged with dirt or ice Inspect the pump assembly and make sure there are no foreign objects in pump valves. Dismantle the pump section and make sure that seals and valves are intact, see Repair section Dismantle the air motor and inspect gaskets and seals and valves, see Repair section. page IV-3

4 CORRECTIVE MAINTENANCE - REPAIR GENERAL Before performing any service operation, always shut off the air supply and decompress the CIC fluid, i.e. let CIC fluid out so that the pressure within the system falls. Be careful not to damage any parts when dismantling. Shafts which do not have key flats must never be removed with a pipe wrench, or the like. The recommended way to remove shafts is to grip the component in a vice with aluminum or copper jaws, clamp the shaft in a hand-drill chuck and then turn the chuck by hand. Be careful when fitting O-rings and seals. Always lubricate them with oil or grease before fitting. They must never be threaded over sharp edges when being fitted and must be protected by some form of sleeve in such cases. Lubricate all moving parts. When trouble-shooting pay particular attention to the following: Contamination in or damage to valves Contamination in or damage to ball seats Damaged O-rings, seals and gaskets Scratches in sealing surfaces page IV-4

5 AAS HIGH PRESSURE EQUIPMENT START UP GUIDELINES PUMP UNIT 1:26 ART NO Assemble equipment according to the Manual Place the pump into the Corrosion Inhibiting (CIC) pail Reduce air pressure regulator to "0" Connect line air hose Increase the air pressure until the pump starts pumping slowly Open the pressure release valve on the distribution block Close it when the CIC starts to circulate Insert the extension hose and a large size nozzle on the spray gun Spray back into the CIC pail until all air is out of the system Short-term storage (less than 2 months) Proceed as follows: Disconnect the line air Release the pressure by opening the relieve valve on the distribution block Do not remove pump from the CIC pail Make sure that CIC pail is covered tightly and protected against dust and solvent evaporation Store at room temperature whenever possible Clean equipment externally Long-term storage (more than 2 months) Proceed as follows: Lift the pump out of the CIC pail Pump the remaining CIC back into the pail and close it tightly Place the pump into another pail containing appropriate solvent (white spirit or naphtha solvent) Clean the entire equipment by pumping the solvent (white spirit or naphtha solvent) through every nozzle back into the solvent pail Secure and cover solvent pail opening to avoid evaporation Disconnect the line air and relieve the pressure page IV-5

6 WANDS Short-term storage (less than 2 months) Proceed as follows: Keep wands free from dust and debris. Quick disconnection couplings are particularly sensitive After use clean wands externally with aliphatic solvent (type white spirit or naphtha solvent) If wands are used frequently, no other precaution needs to be taken Long-term storage (more than 2 months) Proceed as follows: For storage longer than two weeks, all wands should be cleaned internally See under point "Long-term storage for the pump" This cleaning has to be performed together with cleaning of the pump Connect every individual wand to the spray gun and spray with solvent into the pail FILTERS Art No Every wand is equipped with a 200 mesh filter. Filters have to be cleaned once a month with white spirit or naphtha solvent and compressed air. Proceed as follows: Remove the filter. Clean it with solvent and line air Inspect for possible damage, such as screen perforation, deformation or shrinkage Damaged filters must be replaced. Even minor filter damage can cause jet to clog. Only use aliphatic solvents such as white spirit or naphtha for cleaning. Do not use paint solvent for cleaning!!! page IV-6

7 JETS Jests are cleaned together with wands during cleaning procedure. No additional cleaning is required. Used jets should be stored in solvent in a tight tin can in order to prevent clogging. Cleaning instructions Jet Nos 4 and 5 Remove the top of the jet only. Clean holes in the top according to instructions above. Clean the wand by spraying without top of the tip. Reassemble and tighten firmly. Jet Nos 8, 9 and 13 Remove the jet. Clean with solvent (white spirit or naptha) and line air. Use cleaning needles (Art No ) if necessary. Clean the wand by spraying with solvent without the jet before re-assembly. Jet No 11 Easyclean Twist the top by hand half a turn. Spray product back into the pail. Tighten it. The jet should now be clean. If not, repeat the same procedure again. page IV-7

8 CORRECT APPLICATION OF ARDROX AV CORROSION INHIBITING COMPOUNDS In order to achieve good corrosion prevention and fast, efficient treatment on aircraft and helicopters, the following points have to be taken into consideration TREATMENT GUIDELINES Ardrox AV Corrosion Inhibiting s (CIC) must be applied on all surfaces requiring corrosion protection treatment Acceptable film thickness wet: AV CIC Wet Film Thickness Micrometer (µ) AV CIC Wet Film Thickness Micrometer (µ) AV 8 15 to 30 AV to 50 AV to 90 AV to 100 AV to 100 AV 100D 120 to 200 A narrow stream of Ardrox AV CIC must remain along stringers, profiles and other joints in order to provide penetration. A stream of 3 5 mm is acceptable. Heavy over spray, or excess Ardrox AV CIC which has collected in pools or puddles must be removed. It can be soaked up by using absorbent rags or carpets. A narrow circle of Ardrox AV CIC must be visible around fasteners and rivets. Ardrox AV CIC is not a decorative finish to a surface. It must not be compared to a painted area. Runs, sags and drips are allowed. In order to provide optimal corrosion prevention, all stringers, longerons and frames have to be treated from an extremely short distance in order to cover the underside of the components. This will create heavy over-spray. Some of it can be removed, but runs will still not be eliminated and are acceptable. Apply sufficient Ardrox AV CIC. If too small an amount of CIC is applied then penetration into crevices will be limited. Penetration of the CIC into cracks and crevices to displace moisture is an essential part of the corrosion protection treatment. If the CIC does not penetrate into the cracks and crevices then there is a danger that condensing water will accumulate in these areas and cause corrosion. Brush application of Ardrox AV CIC will not promote sufficient penetration. Brush application of CIC should only be used where penetration is not required. For re-touching and small applications, an Ardrox AV CIC Aerosol can be used. Preferably together with the semi-flexible nozzle Art. No page IV-8 part 5a equipment - oct02.doc Page 8

9 PRACTICAL ADVICE TO TECHNICIANS Select a limited area for application between two stringers and frames or similar Treat all hidden surfaces like profiles, stringers and frames by using a 150 cone or 90 flat spray pattern wand Allow the Ardrox AV CIC to penetrate for some minutes Remove the surplus Ardrox AV CIC from plain, general surfaces Treat general surfaces to required film thickness MASKING Masking of vital components is very important Pipes, tubing or single wires do not need to be masked. However, they have to be kept free from CIC contamination Accidental over-spray of CIC has to be removed immediately ADVANTAGE OF WORKING SYSTEMATICALLY No missing spots on hidden surfaces Runs, drips and sags can easily be removed from general surfaces General surfaces can now be treated correctly and evenly without over spray Minimised fog and drips appearance page IV-9

10 Selection of AAS High Pressure Airless Spray System Corrosion Inhibiting BASIC SET: 1 AAS Pump Set 1 : 26 Art No AAS Wand 1 (150 FC Rigid) Art No AAS Wand 8 (80 FT Rigid) Art No AAS Extension Hose Art No Cleaning needle set Art No AAS Filter 200 mesh Art No Spare jets for Wand 1 Art No Spare jets for Wand 8 Art No Seal kit for AAS Pump 1:26 Art No Seal kit for AAS Air Motor 1:26 Art No Repair kit for AAS Air Motor 1:26 Art No Repair kit for AAS Spray Gun Art No Recommended range of use Basic structural elements in easily accessible configurations. Medium treatments and / or medium sized aircraft. Treatment frequency: medium term EXTENDED SET - The Basic Set plus: 1 AAS Wand 6 (360 RF Rigid) Art No AAS Wand 10 (150 FC Flexible) Art No Wand 13 (15 FC Rigid) Art No Spare jets for Wand 6 Art No Spare jets for Wand 10 Art No Spare jets for Wand 13 Art No Recommended range of use All structural elements in accessible configurations Extensive treatments and / or larger size aircraft Treatment frequency: medium - high page IV-10

11 COMPLETE SET - The Basic Set plus Extended Set and in addition: 1 AAS Wand 2 (95 FT Rigid) Art No AAS Wand 5 (180 RF Rigid) Art No AAS Wand 7 (150 FC Flexible) Art No AAS Wand 9 (95 FT Rigid) Art No AAS Wand 11 (80 FT Rigid) Art No AAS Spare jet for Wands 11 Art No AAS Spare jet for Wand 9 Art No AAS Spare jets for Wand 3 Art No AAS Spare jets for Wand 5 Art No AAS Extension Unit Art No Recommended range of use All structural elements in most configurations. Extensive treatments and large aircraft. Treatment frequency: medium high page IV-11

12 AAS Airless Pump Set 1: 26 Art No Corrosion Inhibiting High Pressure Gauge Line Air Treatment Unit Distribution Block Spray Gun Set Pneumatic, high pressure, airless pump 1:26, complete, for 20 litre pails, including trolley, compound hose, twin hose connection, spray gun and air-treatment unit. Technical data: Capacity per stroke 14.8 ccm (0.04 Gallon) Ratio 1:26 Max. line air pressure 10 bar (145 p.s.i.) Max. pump capacity 2,5 l (0.66 Gal.) / min Max. compound pressure 260 bar (3770 p.s.i.) Air consumption 13 litres per stroke at 6 bar (0.8 Gal at 87psi) This unit is the basis of the Airless Application System - AAS. By fitting a second spray gun (Art No ) it can service two working areas simultaneously. The trolley is designed to use standard 20 litre (5 gallon) pails of CIC. This equipment will provide maximum workplace flexibility, it is light in weight and can be easily moved to any convenient location. It is equipped with both line air and compound pressure gauges for exact adjustment. Spare parts: Spray Gun Set Art No Distribution Block Complete Art No Service Kit for Pump Art No Gasket Set Pump 1 : 26 Art No Service Set Air Motor 1 : 26 Art No Gasket Set Air Motor 1 : 26 Art no Line Air Treatment Unit Art No High Pressure Gauge Art No page IV-12

13 AAS Spray Gun Set Art No Technical data: Spray gun set, high pressure, airless, including 10 metre hose, Z swivel, male quick disconnect coupling and spray gun. Method High Pressure Airless Can be used as a spare gun or as a second gun doubling the working capacity of the AAS Pump Unit. A second spray gun increases the flexibility of the AAS CIC equipment. It enables the operator to service 2 application areas simultaneously taking full advantage of the capacity of the AAS Pump Unit Spare parts: 1 Spray gun (see below) Art No Product Hose, 10 m Art No Quick-disconnect Coupling, Female Art No Quick-disconnect Coupling, Male Art No Z Swivel Art No Service Set for Spray Gun (see below) Art No O-Rings for Quick-Disconnect (Female) Art No page IV-13

14 AAS Spray Gun Art No Spray gun or high pressure, airless application Technical data: Method High Pressure Airless Weight 800g (1.76 lb.) Product pressure Max. 250 bar (3500p.s.i.) Connection thread 1/8, internal Note: The gun should be used with tools of the airless application system (AAS). To avoid damaging the quick disconnect coupling and to enhance the flexibility of the system, always use the Extension Hose, Art No , when connecting rigid wands to this spray gun a b c d e f g 3 4 Spare parts: Service Set positions 1, 2, 3, 4, 5 Art No page IV-14

15 AAS Wand 1 (150 FC Rigid) Art No High pressure, airless, 150 x 8 mm for low viscosity compounds. Spray pattern 150, full cone, Easyclean jet. Capacity 0.3 l/min. Technical data: Method High Pressure Airless Length 150 mm (5.9 ins.) Spray pattern 150 Full Cone (FC) Easyclean Diameter 8 mm (0.04 ins.) Capacity 0,3 litre / min at 40 bar (0.08 Gal. at 580 p.s.i.) Note: For the application of low and medium viscosity compounds in small cavities and areas difficult to access such as behind stringers and frames. The jet provides good atomisation combined with low material capacity and allows the application of a controlled film thickness. To avoid damaging the quick disconnect coupling and to enhance the flexibility of the system, always use the Extension Hose, Art No , when connecting this wand to the spray gun Spare parts: 1. Jet No 11 Easyclean Art No Filter 200 Mesh Art No Quick Disconnect Coupling - Male Art No Wand Guide (Set of 5) Art No page IV-15

16 AAS Wand 2 (95 FT Rigid) Art No High pressure, airless, 400 x 8 mm, for low viscosity compounds. Spray pattern 95 flat fish tail. Capacity 0.2 l/min Technical data: Method High Pressure Airless Length 400 mm (31.5 ins.) Spray pattern 95 Flat Fishtail (FT) Diameter 8 mm (0.04 ins.) Capacity 0,2 litre / min at 40 bar (0.05 Gal. at 580 p.s.i.) Note: For the application of low and medium viscosity compounds in small cavities and areas difficult to access, such as behind stringers and frames. The jet provides good atomisation combined with low material capacity and allows the application of a controlled film thickness. To avoid damaging the quick disconnect coupling and to enhance the flexibility of the system, always use the extension hose, Art No , when connecting this wand to the spray gun Spare parts: 1. Jet No 8 Art No Filter 200 Mesh Art No Quick Disconnect Coupling - Male Art No Wand Guide (Set of 5) Art No page IV-16

17 AAS Wand 3 (150 FC Rigid) Art No High pressure, airless, 800 x 8 mm for low viscosity compounds, spray pattern 150 full cone, Easyclean. Capacity 0.3 l/min. Technical data: Method High Pressure Airless Length 800 mm (31.5 in) Spray pattern 150 Full Cone (FC), Easyclean Diameter 8 mm (0.04 ins.) Capacity 0,3 litre / min at 40 bar (0.08 Gal. at 580 p.s.i.) Note: For the application of low and medium viscosity compounds in small cavities and areas difficult to access such as behind stringers and frames. The jet provides good atomisation combined with low material capacity and allows the application of a controlled film thickness. To avoid damaging the quick disconnect coupling and to enhance the flexibility of the system, always use the extension hose, Art No , when connecting this wand to the spray gun Spare parts: 1. Jet No 11 Easyclean Art No Filter 200 Mesh Art No Quick Disconnect Coupling - Male Art No Wand Guide (set of 5) Art No page IV-17

18 AAS Wand 5 (180 RF Rigid) Art No Lance, high pressure, airless, 1500 x 8 mm, for low viscosity compounds. Spray pattern 180 radial flat. Capacity 0.4 l/min. Technical data: Method High Pressure Airless Length 1500 mm (59.1 in) Spray pattern 180 Radial Flat (RF) Diameter 8 mm (0.04 in) Capacity 0.4 litre / min at 40 bar (0.32 Gal. at 580 p.s.i.) For application of low and medium viscosity compounds, in wide box - sections, where visual control of the treatment is difficult. The circumferential, narrow spray pattern and the good atomisation provided by the jet allows the application of a controlled film thickness. Note: To avoid damaging the quick disconnect coupling and to enhance the flexibility of the system, always use the Extension Hose, Art No , when connecting this wand to the spray gun Spare parts: 1. Jet No 4 Art No Filter 200 Mesh Art No Quick Disconnect Coupling - Male Art No page IV-18

19 AAS Wand 6 (360 RF Rigid) Art No Lance, high pressure, airless, 1500 x 8 mm for low viscosity compounds. Spray pattern 360, radial flat. Capacity 1.2 l/min. Technical data: Method High Pressure Airless Length 1500 mm (59.1 in) Spray pattern 360 Radial Flat (RF) Diameter 8 mm (0.04 in) Capacity 1,2 litre / min at 40 bar (0.32 Gal. at 580 p.s.i.) Note: For the application of low and medium viscosity compounds, in narrow box sections, where visual control of the treatment is difficult. The circumferential, narrow spray pattern and the good atomisation provided by the jet allow the application of a controlled film thickness. To avoid damaging the quick disconnect coupling and to enhance the flexibility of the system, always use the Extension Hose, Art No , when connecting this wand to the spray gun Spare parts: 1. Jet No 5 Art No Filter 200 Mesh Art No Quick Disconnect Coupling - Male Art No page IV-19

20 AAS Wand 7 (150º FC Flexible) Art No Flexible Lance, 2000 x 8 mm, high pressure, airless, for low viscosity compounds. Spray pattern 150 full cone, Easyclean. Capacity 0.3 l/min. Technical data: Method High Pressure Airless Length 2000 mm (78.75 in) Flexible Section: 1290 mm (51 in) Spray pattern 150 Full Cone (FC) Easyclean Diameter 8 mm (0.04 in) Capacity 0,3 litre / min at 40 bar (0.08 Gal. at 580 p.s.i.) For the application of low and medium viscosity compounds, in narrow box sections, where visual control of the treatment is difficult. Gives an open, full cone spray pattern. The jet provides good atomisation and allows the application of a controlled film thickness Spare parts: 1. Jet No 11 Easyclean Art No Filter 200 Mesh Art No Quick Disconnect Coupling - Male Art No page IV-20

21 AAS Wand 8 (80 FT Rigid) Art No High pressure, airless, 400 x 8 mm, for low viscosity compounds. Spray pattern 80 flat fishtail. Capacity 0.3 l/min. Technical data: Method High Pressure Airless Length 400 mm (31.5 in) Spray pattern 80 Flat Fishtail (FT) Diameter 8 mm (0.04 in) Capacity 0,3 litre / min at 40 bar (0.08 Gal. at 580 p.s.i.) Note: For application of low and medium viscosity compounds for general purpose spray application. The jet provides good atomisation and allows the application of a controlled film thickness. To avoid damaging the quick disconnect coupling and to enhance the flexibility of the system, always use the Extension Hose, Art No , when connecting this wand to the spray gun Spare parts: 1. Jet No 9 Art No Filter 200 Mesh Art No Quick Disconnect Coupling - Male Art No Wand Guide (Set of 5) Art No page IV-21

22 AAS Wand 9 (95 FT Rigid) Art No High pressure, 800 x 8 mm, airless, for low viscosity compounds. Spray pattern 95 flat fish tail. Capacity 0.2 l/min. Technical data: Method High Pressure Airless Length 800 mm (31.5 in) Spray pattern 95 Flat Fishtail (FT) Diameter 8 mm (0.04 in) Capacity 0.2 litre / min at 40 bar (0.05 Gal. at 580 p.s.i.) Note: For application of low and medium viscosity compounds, in small cavities and areas difficult to access, such as behind stringers and frames. The jet provides good atomisation and allows the application of a controlled film thickness. To avoid damaging the quick disconnect coupling and to enhance the flexibility of the system, always use the Extension Hose, Art No , when connecting this wand to the spray gun Spare parts: 1. Jet No 8 Art No Filter 200 Mesh Art No Quick Disconnect Coupling Male Art No Wand Guide (Set of 5) Art No page IV-22

23 AAS Wand 10 (150º FC Flexible) Art No Flexible Lance, 1100 x 8 mm, high pressure, airless, for low viscosity compounds. Spray pattern 150 full cone, Easyclean. Capacity 0.3 l/min. Technical data: Method High Pressure Airless Length 1100 mm x 8 mm Flexible section: 800 mm Spray pattern 150 Full Cone (FC), Easyclean Diameter 8 mm (0.04 in) Capacity 0,3 litre / min at 40 bar (0.08 Gal. at 580 p.s.i.) For the application of low and medium viscosity compounds, in narrow box sections (for example in the aft cargo hold of a B 747) where visual control of the treatment is difficult. The wide open full cone spray pattern and the good atomisation provided by the jet allows application of a controlled film thickness Spare parts: 1. Jet No 11 Easyclean Art No Filter 200 Mesh Art No Quick Disconnect Coupling - Male Art No page IV-23

24 AAS Wand 11 (80 FT Rigid) Art No High pressure, airless, 150 x 8 mm, for low and medium viscosity compounds. Spray pattern 80 flat fishtail. Capacity 0.3 l/min. Technical data: Method High Pressure Airless Length 150 mm (10 in) Spray pattern 80 Flat Fishtail (FT) Diameter 8 mm (0.04 in) Capacity 0.3 litre / min at 40 bar (0.08 Gal. at 580 p.s.i.) Note: For the application of low and medium viscosity compounds, on open surfaces. The jet gives extremely good atomisation combined with low capacity and allows the even application of a controlled film thickness. This wand can be attached directly to the spray gun, it can also be used in combination with the Extension Hose, Art No , for greater flexibility Spare parts: 1. Jet No 9 Art No Filter 200 Mesh Art No Quick Disconnect Coupling - Male Art No page IV-24

25 AAS Wand 13 (15º FC Rigid) Art No High pressure, airless, 250 x 4 mm, for low and medium viscosity compounds. Spray pattern 15 full cone. Capacity 0.8 l/min. Technical data: Method High Pressure Airless Length 250 mm (10 ins.) Spray pattern 15 Full Cone (FC) Diameter 4 mm (0.02 in) Capacity 0.8 litre / min at 40 bar (0.21 Gal. at 580 p.s.i.) Note: For the application of low and medium viscosity compounds in cavities with restricted access, such as ventilation holes. The long narrow spray pattern allows application to areas some distance from the spray gun. Typical application areas include the keel beam and floor cavities. To avoid damaging the quick disconnect coupling and to enhance the flexibility of the system, always use the Extension Hose, Art No , when connecting this wand to the spray gun Spare parts: 1. Jet No 13 (with Lance) Art No Filter 200 Mesh Art No Quick Disconnect Coupling - Male Art No page IV-25

26 AAS Extension Hose Art No hose, 1000 mm, for high pressure airless application. To be connected between spray tool and gun. Technical data: Method High Pressure Airless Length 1000 mm (39 in) Note: The use of this Extension Hose is strongly recommended whenever rigid spray wands need to be connected to the spray gun. It enhances working flexibility and the quality of the treatment, it can also reduce wear or breakage of the quick disconnect coupling. The Extension Hose can also be connected to flexible spray wands if extra length is required for access to remote or otherwise inaccessible areas and cavities. Extension hose should be checked periodically for signs of wear or damage. Dripping from spray nozzle after spray gun trigger has been released can indicate that the extension hose has become worn and needs to be replaced Spare parts: 1 Quick Disconnect Coupling, Female Art No Quick Disconnect Coupling, Male Art No O Rings for Quick Disconnect (Female) Art No page IV-26

27 AAS Wand Extension Unit Art No High pressure, airless, 700 x 8 mm. For extension of rigid lance to a desired length. Technical data: Method High Pressure Airless Length 700 mm (27.6 in) Diameter 8 mm (0.31 in) Instructions: Note: To extend the reach of rigid lances. The outside diameter of the connection stud does not exceed the diameter of the Jet, which allows smooth and easy access using the extended tool. It can be used in multiple lengths. Remove the jet from the spray wand. Replace the jet on the extension. Tighten the extension onto the spray wand. To avoid damaging the quick disconnect coupling and to enhance the flexibility of the system, always use the Extension Hose, Art No , when connecting the Extension Unit to the spray gun. page IV-27

28 Wand Guide Art No Technical Data Size: Teflon washer with a lock screw 28 mm diameter x 7 mm thick Range of Use This unit is designed to fit the AAS (high pressure airless) or the ACS (low pressure airmix) nozzles and jets. The purpose is to prevent the jet from touching the surface being sprayed which would otherwise kill the spray pattern. This is particularly important when treating the lower side of stringers and profiles. The guide will prevent the jet from entering under the stringer and protect the surface against scratches or other damage. Installation Press the guide over the jet. Allow 2 to 3 mm distance from the end of the jet to the guide washer. Lock with the lock screw. page IV-28

29 AAS Filter 200 Mesh Art No Technical data: The screen of 200 mesh. Mesh size 0,07 mm For low viscosity compounds Filters are part of the standard equipment installed in every wand AAS Filter Screen (Set of 10) Art No page IV-29

30 ACS LOW-PRESSURE AIRMIX Application System GENERAL INFORMATION ACS Spray Gun Art No ACS Pressure Pot Art No Change of cartridge, refers to the gun Release pressure from the container by pulling the relief valve. Remove the container and insert an opened ARDROX AV Corrosion Inhibiting cartridge. Replace the container, ensuring that it is tight. Adjust the line air pressure to approx. 4-6 Bar (60 to 90 p.s.i.) and connect the line air to the spray gun. Adjusting spray pattern Spray pattern must be adjusted to suit every compound / tool combination. The quality of the aerosol is determined by the compound / air ratio, which is adjusted by turning the valve on top of the gun. The total volume of the aerosol supplied to the tool can be determined by turning the choke valve on the Extension Hose Art No , or on the gun. To avoid damage to the quick disconnect coupling, always use the Extension Hose, Art No , when connecting ACS Spray Wands to the gun. Connecting and disconnecting of tools Press the tool / extension hose carefully into the quick disconnect coupling of the spray gun until the lock snaps in. When disconnecting, pull the lock ring away from the tool, until it is released. The quick disconnect coupling must be handled with care, as aggressive handling can cause damage. Cleaning For shorter breaks, press the spray gun trigger to its first position, air will blow out the surplus compound from the gun / tool. When a job is finished, fill the container with white spirit or naphtha solvent or similar, press the trigger and flush the entire system. The gun / tool external surfaces can be cleaned with a solvent soaked cloth. Malfunction If the gun should get clogged, open the quick disconnect coupling and the adjacent mixing chamber and flush / clean it with solvent. Caution! Never point the gun / tool at people. Maintenance and repairs must always be carried out with the system unpressurized. page IV-30

31 Selection of ACS Low-Pressure Airmix Application System Corrosion Inhibiting BASIC SET I 1 ACS Spray Gun Art No Service set for ACS Gun Art No ACS Wand 2 (45 FC Rigid) Art No ACS Extension Hose Art No Recommended range of use: Basic structural elements in easy accessible configurations. Smaller treatments and / or medium sized aircraft. Treatment frequency: low - medium BASIC SET II 1 ACS Pressure Pot Art No ACS Hose Set for Pressure Pot Art No ACS Spray Gun Art No ACS Wand 2 (45 FC Rigid) Art No ACS Extension Hose Art No Recommended range of use: Basic structural elements in easy accessible configurations. Medium treatments and / or medium sized aircraft. Treatment frequency: medium EXTENDED SET - Basic Set I or II plus: 1 ACS Wand 3 (360 Flexible) Art No ACS Wand 4 (360 Semi-Flexible) Art No ACS Wand 6 (12 FC Rigid) Art No ACS Wand 10 (45 FC Rigid) Art No Recommended range of use: All structural elements in accessible configurations Extensive treatments and / or larger size aircraft Treatment frequency: medium - high COMPLETE SET - Basic Set I or II plus Extended Set plus: 1 ACS Wand 1 (45 FC Rigid) Art No ACS Wand 7 (180 R Rigid) Art No ACS Wand 8 (360 R Rigid) Art No ACS Wand 9 (45 FC Flexible) Art No Recommended range of use: All structural elements in most configurations. Extensive treatments and large aircraft. Treatment frequency: medium high part 5a equipment - oct02.doc page IV-31

32 ACS Pressure Pot Airmix Art No Pressure pot ACS for low-pressure airmix application. Volume 5.7 l Operational pressure 0.6 MPa Technical data: Method Low Pressure Airmix System (ACS) Weight 2.5 kg Air Pressure Max 100 N (10 bar, 145 psi) Air Consumption 100 l per minute at 6 bar Instructions: CAUTION: Pressurised 5 l pot, complete with 2 m hose and spray gun. For spraying low and high viscosity compounds. Can be easily transported. is filled directly into pot and pressurised by connecting to line air. A pressure gauge and pressure regulator are included. Remove lid of pot, fill with 5 l of compound, replace and secure lid. Connect line air, adjust regulator to give specified air pressure. Adjust compound flow on spray gun. Use recommended ACS spray wand and nozzle for application. Clean with white spirit or naphtha solvent. DO NOT USE PAINT THINNERS. Do not point spray towards yourself or at other people. Spare Parts: Item Art No Hose Set Reduction Valve + Pressure Gauge Gasket Set for ACS 5 l Pressure Pot Service Kit for ACS Spray Gun Spray Gun for 5 l ACS Pressure Pot page IV-32

33 ACS Pressurised Spray Gun HRS-E-RV Art No Spray Gun (ACS) for low pressure, airmix application. Volume 1 litre. Operational pressure 0.6 MPa. Technical data: Method ACS Low Pressure Airmix Weight 1.4 kg Air Pressure Max 100 N (10 bar, 145 psi) Air Consumption 100 l per minute at 6 bar Instructions: CAUTION: Pressurised 1 litre container with integral spray gun. For spraying low and high viscosity compounds. is filled directly into pot and pressurised by connecting to line air. Pour compound directly into 1 litre container, attach spray gun and screw to tighten and seal. Connect line air, adjust compound flow on spray gun. Use recommended ACS spray wand and nozzle for application. Do not point spray towards yourself or at other people. Spare Parts: Service Kit for ACS Spray Gun Art No page IV-33

34 ACS Wand 1 (45 FC Rigid) Art No Wand 1 ACS. Hook 400 x 8 mm, low pressure, airmix, for low viscosity compounds. Spray pattern 45 full cone, capacity 0.5 l/min. Technical data: Method Low Pressure Airmix Length 400 mm (15.75 in) Spray pattern 45 Full Cone (FC) Diameter 8 mm (0.32 in) Capacity 0,5 l / min at 6 bar (0.13 Gal. at 87p.s.i.) Note: For application of low viscosity compounds onto large, open surfaces, or in wide cavities. The spray can be directed toward remote surfaces giving good coverage. The treatment of long, closed cavities may be limited, if too high a pressure is created at the far end of the cavity. This can result in an "air pillow" effect, which inhibits good coverage. This phenomenon is typical of airmix spray application in confined cavities. In this case, airless application may be appropriate. To avoid damaging the quick disconnect coupling, always use extension hose, Art No , when connecting this wand to the spray gun. page IV-34

35 ACS Wand 2 (45 FC Rigid) Art No Venturi hook, 400 x 8 mm, low pressure airmix for low and high viscosity compounds. Spray pattern 45 full cone. Capacity 0.5 l/min. Technical data: Method Low Pressure Airmix Length 400 mm (15.75 in) Spray pattern 45 Full Cone (FC), venturi jet Diameter 8 mm (0.32 in) Capacity 0,5 litre/min at 6 bar (0.13 gal. at 87p.s.i.) For application of low and high viscosity compounds onto large, open surfaces, or into wide cavities. The spray can be directed toward remote surfaces giving good coverage. The treatment of long, closed cavities may be limited, if too high a pressure is created at the far end of the cavity. This can result in an "air pillow" effect, which inhibits good coverage. This phenomenon is typical of airmix spraying in confined cavities. In this case, airless application may be appropriate. The venturi jet enhances atomisation particularly when high viscosity and/or thixotropic compounds are being applied. It also allows the application of an extremely thin film of compound. Note: To avoid damaging the quick disconnect coupling, always use Extension Hose, Art No , when connecting this wand to the spray gun. page IV-35

36 ACS Wand 3 (360 Flexible) Art No Wand 3 ACS. Flexible wand, 1500 x 8 mm, low pressure, airmix for low viscosity compounds. Spray pattern 360 radial, ball-like. Capacity 0.4 l/min. Technical data: Method Low Pressure Airmix Length 1500 mm (59.1 in) Spray pattern 360 ball-like Diameter 8 mm (0.32 in) Capacity 0,4 litre/min at 6 bar (0.11 gal. at 87p.s.i.) Note: For application of low viscosity compounds in closed cavities with complicated structural geometry. The ball-like spray pattern enables effective spraying of complicated structural components within cavities. The extended length and flexibility of this wand gives good application characteristics including into long profiles and tubular cavities. This wand can be connected directly to the spray gun. page IV-36

37 ACS Wand 4 (360 Semi-flexible) Art No Semi-rigid lance, 1100 x 8 mm, for low viscosity compounds. Spray pattern 360 radial, ball-like. Capacity 0.4 l/min. Technical data: Method Low Pressure Airmix Length 1100 mm (43.3 in) Spray pattern 360 ball-like Diameter 8 mm (0.32 in) Capacity 0,4 l/min at 6 bar (0.11 gal. at 87p.s.i.) Note: For application of low viscosity compounds in closed cavities with complicated structural geometry. The ball-like spray pattern gives good coverage of complicated structural elements within cavities. The extended length gives good application characteristics including into long profiles and tubular cavities. It is semi-flexible and can be used as a lance or as a flexible hose. To avoid damaging the quick disconnect coupling, always use Extension Hose, Art No , when connecting this wand to the spray gun. page IV-37

38 ACS Wand 6 (12 FC Rigid) Art No Wand 6 ACS. Hook 300 x 4 mm, for low viscosity compounds. Spray pattern 12 full cone. Capacity 0.2 l/min. Technical data: Method Low Pressure Airmix Length 300 mm (11.8 in) Spray pattern 12 full cone Diameter 4 mm (0.16 in) Capacity 0,2 l / min at 6 bar (0.052 gal. at 87p.s.i.) For application of low viscosity compounds in closed cavities with extremely small access holes. Treatment of long, closed cavities may be limited, if too high pressure is created at the far end of the cavity. This can result in an "air pillow" effect, which inhibits good coverage. In this case, airless application may be appropriate. Note: To avoid damaging the quick disconnect coupling, always use Extension Hose, Art No , when connecting this wand to the spray gun. page IV-38

39 ACS Wand 7 (180 R Rigid) Art No Wand 7 ACS. Rigid lance, 1100 x 8 mm, for low viscosity compounds. Spray pattern 180 radial. Capacity 0.2 l/min. Technical data: Method Low Pressure Airmix Length 1100 mm (43.3 in) Spray pattern 180 radial Diameter 8 mm (0.32 in) Capacity 0,2 l/min at 6 bar (0.052 gal. at 87p.s.i.) Note: For application of low viscosity compounds in wide box sections. The radial spray pattern enables good spray coverage of complicated structural elements within the treated cavity. The extended length of this wand allows good spray application onto remote surfaces. To avoid damaging the quick disconnect coupling, always use Extension Hose, Art No , when connecting this wand to the spray gun. page IV-39

40 ACS Wand 8 (360 R Flexible) Art No Wand 8 ACS. Flexible wand 3000 x 6.5 mm, for low viscosity compounds. Spray pattern 360 ball-like radial. Capacity 0.4 l/min. Technical data: Method Low Pressure Airmix Length 3000 mm (118.1 in) Spray pattern 360 radial and forwards Diameter 6.5 mm (0.26 in) Capacity 0,4 litre/min at 6 bar (0.11 gal. at 87p.s.i.) For application of low viscosity compounds in closed cavities with complicated geometry. The radial forward spray pattern gives good coverage of very complicated structural elements within the treated cavity. The extended length and flexibility of this wand gives good application characteristics including into long profiles and other tubular cavities. The small diameter of the wand makes it possible to enter through very small openings and into confined cavities Note: This wand can be connected directly to the gun. page IV-40

41 ACS Wand 9 (45 FC Rigid) Art No Wand 9 ACS. Hook, 750 x 8 mm, for low viscosity compounds. Spray pattern 45 full cone. Capacity 0.5 l/min. Technical data: Method Low Pressure Airmix Length 750 mm (29.5 in) Spray pattern 45 Full Cone (FC) Diameter 8 mm (0.32 in) Capacity 0.5 l / min at 6 bar (0.13 Gal. at 87p.s.i.) Note: For application of low viscosity compounds on large, open surfaces, or in wide cavities. The extended length of this wand enhances good application possibilities also on a certain distance to the substrate. The 600 mm (24") long spray pattern gives good coverage of remote surfaces. The treatment of long, closed cavities may be limited, if too high pressure is created at the far end of the cavity. This can result in an "air pillow" effect, which inhibits good coverage. This phenomenon is typical of airmix spray application in confined cavities. In this case, airless application may be appropriate. To avoid damaging the quick disconnect coupling, always use extension hose, Art No , when connecting this wand to the spray gun. page IV-41

42 ACS Wand 10 (45 FC Rigid) Art No Wand 10 ACS. Venturi hook, 750 x 8 mm, for low and high viscosity compounds. Spray pattern 45 full cone. Capacity 0.5 l/min. Technical data: Method Low Pressure Airmix Length 750 mm (29.5 in) Spray pattern 45 Full Cone (FC), venturi jet Diameter 8 mm (0.32 in) Capacity 0.5 litre/min at 6 bar (0.13 gal. at 87p.s.i.) Note: For application of low viscosity compounds on large, open surfaces, or in wide cavities. The extended length of this wand enhances good spray application. The 600 mm (24") long spray pattern gives good coverage of remote surfaces. The treatment of long, closed cavities may be limited, if too high pressure is created at the far end of the cavity. This can result in an "air pillow" effect, which inhibits good coverage. This phenomenon is typical of airmix spray application in confined cavities. In this case, airless application may be appropriate. The venturi jet enhances atomisation particularly when high viscosity and/or thixotropic compounds are being applied. It also allows the application of an extremely thin film of compound. To avoid damaging the quick disconnect coupling, always use Extension Hose, Art No , when connecting this wand to the spray gun. page IV-42

43 ACS Extension Hose 700 Art No hose, 700 mm, for low pressure airmix application. To be used between gun and spray tools. Technical data: Method Low Pressure Airmix Length 700 mm, (27.6 in) Diameter 6 / 12 mm Note: For use with the ACS Airmix Application System to enhance working flexibility of the system. The swivel eliminates the risk of unnecessary wear of the quick disconnect couplings. The choke valve allows adjustment of the aerosol flow. This feature can provide every tool with optimum spray pattern and cuts unnecessary overspray The extension hose should be used when connecting rigid ACS wands to the spray gun. page IV-43

44 Semi-flex Extension, 600 Art No Set of two Aerosol wand. Semi rigid wand, 600 x 4 mm, for aerosol cans. A set of two. Spray pattern 360 radial flat and full cone ball-like. Technical data: Method For Aerosol Spray Cans Length 600 mm (23.6 in) Spray pattern, Wand Radial Spray pattern, Wand 2 80 Full Cone (FC) Forwards Diameter 4 mm (0.16 in) This extension improves the versatility and the quality of treatment, when using aerosol spray cans. The diameter of the extension is extremely small and allows access through narrow gaps and holes. As the wands are semi-flexible, they can be pre-formed to a required shape to allow wand to be threaded through small openings to the spot to be treated. The spray pattern allows good coverage of about 400 mm (15 in) around the jet. page IV-44

45 Brush Can Art No Brush can applicator for low and medium viscosity compounds. Capacity 0.25 l. Technical data: Method Brush-on, rechargeable Size 65 x 18 mm (2.6 x 0.71 in) Capacity 0.25 l (8.45 fl.oz.) Notes: Flush out and remove dried product using white spirit or naphtha solvent. page IV-45

46 Cleaning Needle Set Art No Instructions: For cleaning of clogged jets. Clean the blocked jet with the needle. Combine the cleaning with solvent and compressed air. The set contains 6 needles, packed in a hard box. page IV-46

47 Wand Guide Art No Technical Data Size: Teflon washer with a lock screw 28 mm diameter x 7 mm thick Range of Use This unit is designed to fit the AAS (high pressure airless) or the ACS (low pressure airmix) nozzles and jets. The purpose is to prevent the jet from touching the surface being sprayed which would otherwise kill the spray pattern. This is particularly important when treating the lower side of stringers and profiles. The guide will prevent the jet from entering under the stringer and protect the surface against scratches or other damage. Installation Press the guide over the jet. Allow 2 to 3 mm distance from the end of the jet to the guide washer. Lock with the lock screw. page IV-47

48 Wet Film Gauge Art No ARDROX WET FILM GAUGE MICRON Technical Data Size: 60 x 52 x 1.5 mm (2.4 x 2.0 x 0.06 in) Measurement Range: 5 to 1500 micron 0.2 to 60 mil Example: Instructions: For the measurement of wet or dry CIC films within the specified range. The gauge indicates the film thickness of the applied film between two values. If the 50 tooth touches the film and the 70 tooth does not, then the film thickness is more than 50 micron but less than 70 micron thick. Measurements should be made on flat surfaces not curved. Measurement of Wet Film Thickness Press the gauge through the film to the metal and observe the teeth touching the film. The result can be more easily seen by pressing the film gauge onto white paper and examining the marks left by the teeth. Measurement of Dry Film Thickness: Pull the gauge across the surface of the film and observe the lines left by the measuring teeth. Note: The correct film thickness of the compound is given in the relevant Technical Data Sheet. page IV-48