This document describes the KREMLIN AIRMIX® PUMP and AIRSPRAY PUMP with differential air motor, a pneumatic pumping system designed for use in spray booths. It is manufactured by KREMLIN REXSON, located at 150, avenue de Stalingrad, 93245 Stains Cedex, France. The manual, identified as 0309 573.001.212, was issued on 12/09/03 and supersedes the 12/06/03 version.
Function Description:
The KREMLIN pump is a pneumatic system designed for drawing in and forcing fluid under pressure for spraying applications. It consists of an alternating air motor (B) and a hydraulic section (C) mechanically coupled to the air motor. The air motor is supplied with compressed air, and its alternating movement drives the piston of the hydraulic section. This design ensures that the fluid pressure is directly related to the air motor's pressure multiplied by the pump's ratio. The system allows for the adjustment of both fluid flow rate and spray air pressure, making it versatile for various spraying tasks. The pump is specifically designed for installation in a spray booth, indicating its intended use in controlled environments for coating applications.
Important Technical Specifications:
The pump is declared in conformity with the EC - Machinery Directive (98/37/EC) and the Ex - ATEX Directive (94/9/EC), categorized as II 2 G (group II, class 2, gas). This ATEX classification signifies its suitability for use in areas where explosive atmospheres due to gas, vapours, mists, or air mixtures with dusts are likely to appear.
Key specifications, as indicated on the label marking (e.g., TYPE 20-15), include:
- Pump Model: e.g., TYPE 20-15
- Fluid Pressure (P prod): Maximum fluid pressure at the pump outlet, e.g., 120 bar / 1741 psi.
- Air Supply Pressure (P air): Maximum air supply pressure for the pump motor, e.g., 6 bar / 87 psi.
- Ratio: Pump pressure ratio, e.g., 20. This ratio determines the fluid pressure relative to the air motor pressure.
- Serial Number: Unique identifier for the pump.
The operating pressure of these equipments is particularly high, necessitating strict adherence to safety precautions. Users must never exceed the components' maximum working pressure. Hoses used with the pump must have a maximum burst-proof pressure at least four times the maximum service pressure of the pump. Only air hoses with static conductors should be used to connect the pump with the spray gun. A relief valve, set at 6.5 bar / 94 psi, is fitted on the pump air motor to protect it from overpressure. A protection spring is mounted between the air motor and the fluid section to protect the operator during pump piston motion.
Usage Features:
The pump's operation involves several steps for start-up, priming, work, and shutdown.
- Start-up Procedure:
- Ground the pump.
- Fill the pump fluid outlet flange with KREMLIN "T" lubricant or an appropriate cleaning solvent.
- Unscrew air regulators (D and F).
- Connect the equipment to the air pressure network (clean air - P < 6 bar / 87 psi), installing a water drop (model 3/8) if necessary.
- Connect all hoses (air and fluid) and the gun (O).
- Remove the gun air cap by unscrewing the cap ring.
- Flushing with Solvent:
- Immerse the suction rod (L) into a material container.
- Open the pump air pressure valve (H).
- Point the spray gun (not supplied with air) towards the material container and press the trigger.
- Increase the air regulator (D) to make the pump run slowly (pressure between 0.5 and 1 bar / 7.25 to 14.503 psi). Release the trigger when material flows out regularly.
- Priming with Material:
- Remove the suction rod (L) from the solvent container and immerse it in the material container, taking appropriate precautions for flammable solvents.
- Point the spray gun (not supplied with air) towards the material container and trigger the gun until the material flows out regularly.
- Work:
- Reinstall the ring and aircap on the gun.
- Adjust air regulator (D) for the appropriate material pressure and flow rate.
- Gradually open air regulator (F) to adjust spraying air for the desired spray pattern.
- Shutdown (Short Duration):
- Decrease material pressure via pump air regulator (D) to 0 bar / 0 psi on gauge (E).
- Trigger the gun to depressurize the system.
- Unscrew the spray gun air regulator (F) or disconnect the air inlet at the spray gun.
- Remove the air cap and spray tip (for AIRMIX® gun only) and place them in solvent (do not place plastic air caps in solvent).
- Shutdown (Long Duration):
- Decrease air regulator pressure (D) to 1 bar / 14.503 psi on gauge (E).
- Decrease gun air regulator (F) or disconnect air inlet at the spray gun.
- Remove air cap and spray tip (for AIRMIX® gun only) and place them in solvent.
- Remove the suction rod from the material container and immerse it in a solvent-filled container.
- Point the spray gun towards the material container and trigger it. When solvent flows out, point the gun into a recovery container.
- Release the gun trigger when the solvent flows out clear and clean. Note: Release the gun trigger only when the pump piston is in a low position to prevent seal damage during start-up.
- Fully unscrew air regulator (D) and shut off the main compressed air valve (H).
- Trigger the gun again to decompress the hoses, leaving the pump and hoses filled with solvent at atmospheric pressure.
Maintenance Features:
Regular maintenance is crucial for extending the equipment's working life and ensuring safe operation.
- General Maintenance:
- Never modify the equipment.
- Check daily, keep in good condition, and replace worn parts only with KREMLIN parts.
- Before cleaning or removing components, stop the pump by shutting off the compressed air supply, point the gun into a waste receptacle, and press the trigger to depressurize the system.
- Pump Maintenance:
- Ensure the pump is clean and in good condition.
- Keep the pump fluid outlet flange filled with "T" lubricant (which will normally be colored by the paint).
- Regularly clean the wetting cup with solvent after draining the lubricant.
- Ensure the suction strainer and the filter (pump outlet, if optional) are clean and in good condition.
- Flush the pump as often as necessary, especially when spraying pigment-filled material.
- For short duration shutdowns without flushing, leave the pump filled with material.
- For long duration shutdowns after flushing, leave the pump filled with solvent.
- Spray Gun Maintenance: Comply with the usual instructions for spray gun servicing (refer to the spray gun manual).
- Filter Maintenance: If the pump has a filter at the fluid outlet, comply with the usual instructions for filter servicing (refer to the filter manual).
Safety Instructions:
- Any misuse can cause damage, serious injury, fire, or explosion.
- Personnel must be aware of all safety requirements.
- Read all instruction manuals and equipment tags before operation.
- Ground the equipment.
- Use only in a well-ventilated area. Do not smoke in the spray area.
- Never stock paints and solvents in the spray area; always close pots and tins.
- Keep the spray area clean and free from debris.
- Read paint and solvent manufacturer's technical instructions.
- Use protective equipment (respirator mask, hand cream, glasses) when spraying hazardous materials.
- Never wipe the tip with fingers.
- Always depressurize air and hoses before servicing the gun.
- Never point the spray gun at anyone or any part of the body.
- Do not use products or solvents incompatible with pump components.
- Use appropriate solvent for the material being sprayed.
- Ensure hoses are not crimped, leaking, or unrolled, and are in good condition.
- All fittings must be tight and in good condition.
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