Operating Manual Hose Retractor BAROLL 110P Product No.: S-110P-GB (Translation) Issue: 05/10-1 REITER GmbH + Co. KG Oberflächentechnik Telephone: +49 (0) 71 95 / 185-0 Berglenstraße 23-25 Telefax: +49 (0) 71 95 / 185-30 D-71364 Winnenden Internet: www.reiter-oft.de
Table of Contents 1.0 General...3 1.1 Introduction...3 1.2 Patent rights...3 1.3 Range of application...3 1.3.1 Inproper use...4 1.4 Guarantee...4 1.5 Copyright...4 2.0 Function...5 3.0 Technical data...5 4.0 Scope of delivery...5 5.0 Assembly instructions...6 5.1 Medium supply...7 6.0 Starting up (scouring)...8 7.0 Instructions for repairs and maintenance...9 7.1 General...9 7.2 Change of sealing...10 7.3 Changing the hose... 11 7.4 Exchange of chock...14 8.0 Handling and maintenance...15 8.1 How to unroll the paint/air-hose...15 8.2 How to roll up the paint/air-hose...15 8.3 Cleaning of the paint/air-hose...15 9.0 Spare parts...16 9.1 General Instructions...16 9.2 Spare parts order...16 1501\S-110Pgb 05/10-1 Page 2 of 16
1.0 General 1.1 Introduction This operating manual contains information for the installation, maintenance, and operation of the hose retractor BAROLL 110P. The technical data and procedures given here are to be regarded as standard and may vary from the different installations. Read this manual carefully to understand the mechanics of the hose retractor BAROLL 110P and to ensure reliable long term operation. Should you still be faced with problems, please contact our customer service or our parts department or one of our representatives who will be happy to help (see Chapter 9, Spare parts ). The specified test and troubleshooting should be performed in all cases before a service technician is requested. The operator is responsible for the proper installation, operation and maintenance. If you plan to use the equipment/plant for other operating conditions, our consent must be obtained. The operator is required to prepare, based on this operation manual, operating instructions, which regulate the operation, maintenance and cleaning of the hose retractor BAROLL 110P. These operating instructions must be enlarged by instructions based on national H&S prevention and environmental protection regulations. We reserve the right to alter any drawings and specifications necessary for the technical improvement of the installation. 1.2 Patent rights Our hose retractors are protected against imitation by: Deutsches Gebrauchsmuster (German utility model) No. G 90 03 716.2 Europäisches Patent (European patent) No. 0449246 Patent application for USA and Japan 1.3 Range of application The hose retractors are used in all fields where aggressive substances like paints, solvents, PVC etc. are involved. They are mainly used in paint shops of the car industry. However, it is also used in repair shops for vehicle bodies, in spot repair shops and in paint shops for small parts. The hose retractor BAROLL 110P is suitable for use in a manual spray booth assembled outside of the spray booth, and is used to transport the coating materials, coating excipients, or compressed air to the takeoff point. Here, the distance between the mounting and spray point is variable and determined by the pulled out hose length. The hose can be retracted after use. The manufacturer assumes liability for the product delivered. However, damages due to error in assembling or operating are not falling under the liability. Attention! Injury and damage! This equipment can be dangerous if it is not operated in accordance with the instructions of this manual. When processing highly corrosive or highly abrasive materials an increased need for spare parts can be expected. It is necessary to clarify the suitability on the basis of the material lists with the material manufacturer. 1501\S-110Pgb 05/10-1 Page 3 of 16
1.3.1 Inproper use Inproper use is when: media other than listed in the instructions are passed through the material hose operating conditions differ from the ones mentioned in the instructions manual safety instructions for the operation, installation and maintenance are not complied unauthorized modifications or changes are made to the hose retractor, which impair the safety or functionality 1.4 Guarantee Therefore, it is recommended to read this operation manual carefully before start-up, as we cannot be held liable for damage or malfunctions resulting from the non-observance of this operation manual. During the guarantee period repair work and changes may only be carried out by our assemblers or with our consent. The system is designed only for the use according to the operating area described in chapter 1.3 Range of application. Any other use is considered improper and REITER can not be held liable for any possible damage. 1.5 Copyright The copyright for this operation manual is retained by REITER GmbH + Co. KG Oberflächentechnik. This operation manual is intended for personnel involved in installation, operation, and supervision. The operation manual includes regulations and technical drawings which may not be copied, distributed, used for commercial purpose, or given to others, either in full or in part. REITER GmbH + Co. KG Oberflächentechnik Phone: +49 (0) 71 95 / 185-0 Berglenstraße 23-25 Fax: +49 (0) 71 95 / 185-30 D-71364 Winnenden Email: info@reiter-oft.de 1501\S-110Pgb 05/10-1 Page 4 of 16
2.0 Function Hose retractor systems help to organise the work place and reduce the risk of accidents. Any hazard caused by paint hoses lying on the floor can be avoided, by storing the hoses, protected against any damage, inside the hose retractor. Furthermore, paint hoses which are not rolled up, can easily get dirty. Car bodies or other varnished products often get damaged by such paint covered hoses. Hose retractor systems solve these problems. The hoses are kept safely after use in a hose retractor. The restoring spring of the hose retractor BAROLL 110P can be released by pneumatic foot control or by press button. This will retract the paint hose. A revolving joint between the supply pipe and the paint hose allows the retraction of the paint hose. The paint hose can be unrolled by pulling at it till the required length is reached. The standard hose length of the hose retractor is up to 8 meters. For installation and test purposes, a manual release is provided. 3.0 Technical data Outside diameter BAROLL 110P: 450 x 450 x 80 mm Fastening front: flat head screw M8 x 12 Fastening rear: cylinder screw DIN 912 M10 x 12 Type of mounting, standard: vertically, on bracket Hose outlet: optionally, top or bottom Hose extraction: continuously, by friction brake Length of hose: up to 8 meters -standard- Medium supply: pipe stainless steel, 1/4 BSP - 3 x 90 swingable Hose connection: mounting thread G 3/8 or G 1/4 Hose connection for spray gun: conical screw connection with retainer nut Rp 3/8 or Rp 1/4 Wall entrance: diameter 70 mm, with sealing ring made of Viton Hose retraction (optional): by pneumatic release of break by press button Air requirements: approx. 3 ccm/stroke Pressure: 3 bar Pneumatic hose: diameter 4 x 1 or 6 x 1 Solvent resistant components: all components getting in touch with varnish or the other mediums are made of solvent resistant material. 4.0 Scope of delivery The hose retractor BAROLL 110P is packed in a cardboard box. Accessories attached separately, contains: 1 x manual release consisting of : - threaded bolt - control lever knob - pre-mounted - 1 x fastening bolt, front (Part No. 65044950) 1 x fastening bolt, back (Part No. 65044940) 1 x O-ring (Part No. 65044820) 1501\S-110Pgb 05/10-1 Page 5 of 16
5.0 Assembly instructions The basic construction of the hose retractor BAROLL 110P is designed to be mounted on a bracket. 1 2 3 The front screw (1) serves to align the hose retractor BAROLL 110P. It does not secure it. The rear screw (2) serves to secure/fasten the hose retractor BAROLL 110P. The hose retractor is to be mounted outside the booth. For the hose entrance into the cabin, a drill hole with a diameter of 72 mm is needed. The hole for the hose entrance will be sealed by an O-ring seal (3). The hose retractor must not be dis-tensioned, the drill hole diameter 72 mm should show a tolerance of +/- 0,5 mm. If the hose retractor is dis-tensioned, leakage may occur and the drum might drag along the housing. Note The drill hole 72 mm is 6,5 mm out of line to the middle axis of the hose retractor! Hose connection for spaying gun This refers to a conical screw connection with a retainer nut Rp 3/8 or Rp 1/4 made of stainless steel. 60 grommets are suitable as counterpart. The end of the hose is secured against damages by a protective anti kink spring made of stainless steel. 1501\S-110Pgb 05/10-1 Page 6 of 16
5.1 Medium supply 1 The hose retractor BAROLL 110P is equipped with a swingable pipe of stainless steel with an outside thread R 3/8 or R 1/4. The lid (1) is 90 swingable to each side. Therefore attaching the paint supply is possible from the top as well as from the bottom. For future maintenance and easier installation, a ball valve should be fitted in between the other end of the pipe and the supply pipe. Compressed air supply (optional) The paint hose is retracted by actuating a 3/2-port directional control valve. The pneumatic cylinder of the hose retractor BAROLL 110P is activated when the valve is put under pressure. This will release the friction brake. One valve with 240 litre/min airflow and a piping of pneumatic hose d=4x1 is sufficient to operate up to 10 hose retractors. If it is required to operate more hose retractors at the same time, another 3/2-port directional control valve with 1/4 flow is needed. Otherwise considerable time delay will occur when operating the friction brake. Required minimum pressure: 3 bar. 1501\S-110Pgb 05/10-1 Page 7 of 16
6.0 Starting up (scouring) When the assembly has been performed, the hose retractor can be started as follows: Scouring of the pipes At first flush the paint hose with solvent in order to remove dirt and possible existing chips from inside the hose. Chips are very dangerous for the packings of the hose retractor, thus the hose retractor should additionally be tested for leakage during the scouring. In case of leakage, packings need to be changed. After the scouring, the hose retractor can be filled with paint; open the valve slowly. By actuating the spray gun, the hose retractor will be bleeded. During operation, attention should be paid to the following: Attention!! In case of a prolonged period of idleness of the hose retractor, the paint could dry inside the hose - packing and hose are in danger! Therefore the hose retractor should be scoured with solvent before any longer period of idleness. When rolling up the paint hose the operator has to hold on to it fairly close at the spot the hose is extracted from. With the other hand the release valve can be operated. Then the hose can be rolled up slowly and under traction until the chock is reached. After usage (and when spray gun is removed), the paint hose should be dipped into a basin filled with solvent (protection against drying paint) 1501\S-110Pgb 05/10-1 Page 8 of 16
7.0 Instructions for repairs and maintenance 7.1 General 2 3 The restoring spring installed inside the hose stores energy. The spring shows even with completely retracted hose a polarizing potential; in case of improper handling a risk of injury is given. When disassembling the hose retractor, untension the spring first. Remove the paint hose first (see change of hose). Actuate manual release the drum will turn as long as the spring is untightened. The spring is mounted on a side plate and is secured against jumping out by a welded on sheet-plate. This sheet-plate must never be removed in no case.! This sheet-plate must never be removed in no case. Risk of injury by jumping out of spring 1501\S-110Pgb 05/10-1 Page 9 of 16
7.2 Change of sealing 2 1 4 3 The hose retractor has to be flushed with solvent first and then has to be removed from mounting bracket. Unscrew sealing lid (1) and then remove from axis (4) Remove support ring (2) from axis (4) Attention! Do not use any hard or sharp tools! Paint fouling is to be removed with thinner or ultra sonic method. Remove sealing ring (3) from lid (1) Check axis (4) and lid (1) on possible damage and clean the parts A new sealing ring (3) is to be evenly pressed in it s seat, with the sealing lip facing downwards Reassemble the hose retractor in reverse order. 1501\S-110Pgb 05/10-1 Page 10 of 16
7.3 Changing the hose 2 3 The hose retractor has to be flushed with solvent first, then has to be removed from mounting bracket. Pull out the hose up to the stop position Remove cover lid (2) Grab the hose at the hose outlet and actuate the manual release (3) Slide back the hose slowly, until the hose screwing will be visible in the mounting hole Release manual release Secure restoring spring against dropping out, by putting a cylinder screw M8 x 70 through the bore hole in the side plate and the drum! These precautions have to be performed in order to avoid risk of injury! 1501\S-110Pgb 05/10-1 Page 11 of 16
4 Unscrew the hose clip (4) and cut in the paint hose along the hose liner with a sharp knife Pull out the paint hose Sicherungsschraube M8 x 70 6 5 Unscrew manual release (5) and rear plate (6) 1501\S-110Pgb 05/10-1 Page 12 of 16
7 Remove lamella hose stop device (7) and mount to the new hose Guide the new hose in the hose retractor Slide new hose clip over the hose liner Press hose on the hose liner (if necessary, enlarge the hose end by heating it up) then tighten the hose clip (4) Screw back on the rear plate (6) and the manual release (5) Remove cylinder screw, that was used to secure the restoring spring Hold on to the new hose right at the hose outlet Actuate the manual release and let the hose slide in slowly Put back on the cover lid (2) 1501\S-110Pgb 05/10-1 Page 13 of 16
7.4 Exchange of chock 3 4 2 6 1 Ensure that the hose is rolled up all the way to the lamella hose stop device. It is not necessary to disassemble the hose retractor Unscrew manual release (1) and rear plate (2) Remove the 4 hexagon cap screws (3), then take out the whole brake. Attention! Watch the pressure spring (4)! Exchange chock and then put the whole brake back in again 5 The distance between the adjusting screw (5) and the low-head screw of the pneumatic cylinder (optional) should be approx. 7 mm. The initial tension of the pressure spring (4) can be adjusted by the hexagon cap screw (6). This process changes the braking effect. 1501\S-110Pgb 05/10-1 Page 14 of 16
8.0 Handling and maintenance 8.1 How to unroll the paint/air-hose The operator has to pull out the hose as straight as possible up to the required length. The hose is to be pulled out with both hands and step by step. In order to avoid that the hose will kink and break off, the hose should be held on to at the hose-stop-device. When pulling out the hose, also a 60 angle to the longitudinal axis of the hose retractor must not be extended. When painting, do not stand on the hose possible damage of the hose may occur! The hose should never be pulled out more then necessary. The ideal length can easily be marked with some coloured sticky tape. 8.2 How to roll up the paint/air-hose After using the hose retractor the hose has to be checked. Possible dirt has to be removed (see cleaning of paint/air-hose). When rolling up the hose the operator has to hold on to it fairly close to where the hose comes out. With the other hand the release valve can be operated. Then the hose can be rolled up slowly and under traction till the hose-stop-device is reached.! The end of the hose must be held tight until the hose is completely rolled up. Handle with care, Operator could be injured! 8.3 Cleaning of the paint/air-hose The outside of the standard hose consists of Polyurethane, therefore solvents and paint thinner must not be used. For cleaning we recommend the cleaner DECOATER C3. Any other cleaner the customer might want to use has to be tasted on a sample hose over a couple of days. If the outside of the hose swells up the cleaner is not suitable. Never try any cleaner containing Xylol! 1501\S-110Pgb 05/10-1 Page 15 of 16
9.0 Spare parts 9.1 General Instructions A stock of the most important spare- and wearing parts is an important prerequisite for the constant and proper functionality and availability and the readiness for use. If possible, store those parts close to the place of installation. We provide guarantee only for original spare parts delivered by us. In case of damage resulting from the use of non-original spare parts and accessories, any liability or guarantee provided by REITER GmbH + Co. KG Oberflächentechnik is excluded. The stock keeping of spare parts is provision for any the validity of agreements involving system availability, service times, and guarantee or systems performance. 9.2 Spare parts order To order spare parts make use of the spare parts list in the part documentation and parts lists. All parts which are labelled with E are spare parts, all parts which are labelled with V are wearing parts. For the spare parts order the following data shall indicate: Order number (see acknowledgment) Part number (see parts list) Designation (see parts list) Parts lists designation 1501\S-110Pgb 05/10-1 Page 16 of 16