BORMANN BAP7050 Airless Paint Sprayer User Guide

Built to last

BAP7050
071877

SAFETY INSTRUCTIONS

Warning: Read the manual carefully before use. Failure to follow the warnings and instructions may result in damage to the unit and/or physical injury. Store the manual in a safe place for future reference.

• Never put your fingers, hands or any other part of your body into the spray jet.
• Never point the spray gun at yourself or any other person.
• Never use the spray gun without the spray tip.
• Close the safety guard at any time except when spraying and cleaning.
• Release the pressure before performing repair and maintenance work on the unit.
• Don´t clean the machine with bleached water or solvent containing strong acid and alkali.
• The tool should be equipped with an appropriate electric pressure stabilizing device.
• Operate the unit only in well-lit areas.
• Never operate the unit in areas with sparks or combustible substances.
• Never operate the machine for longer than 10 seconds without paint.
• Paints with glue, pellets, strong corrosive chemicals or without solvent are prohibited.
• Never pull the power cord.
• Make sure that the voltage of the power source corresponds to that indicated on the unit’s nameplate.
• Never smoke when operating the machine.

MAIN PARTS

position is for spraying (OFF)
Oil slot| Slot for oiling (PLS oil)
Siphon hose| Siphons paint from bucket to the machine
Return tube| Paint or solvent flows from here in return state

TECHNICAL DATA

• The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described / illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired.
• To ensure the safety and reliability of the product and the warranty validity, all repair, inspection or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.
• Always use the product with the supplied equipment. Operation of the product with non-provided equipment may cause malfunctions or even serious injury or death. The manufacturer and the importer shall not be liable for injuries and damages resulting from the use of non-conforming equipment.

OPERATION

Preparation before operation

Preparation before operation

1. Link the siphon hose and return tube correctly and tighten them securely.
2. Link 15 meter high pressure nylon paint tube to the outlet fitting and rotate to tighten.
3. Link airless spray gun to the other end of paint tube with two wrenches and rotate to tighten.
4. Make sure the PRIME/SPRAY valve is set horizontal to position (ON).
5. Inject 5-6 drops of PLS oil into the oil slot.
6. Check the voltage with an electric meter and make sure it corresponds to the voltage on the nameplate of the machine.
7. Place the machine in a dry area at least 7.5 meters away from the work area.

First-time operation
Before operating the machine for the first time, the protective lubricating oil should be washed away with soapy water.

1. Put siphon hose in a bucket with clean soapy water.
2. Put return tube in a waste bucket.
3. Set the pressure control knob to medium pressure. Don´t tighten it too much.
4. Set the PRIME/SPRAY valve to the horizontal position.
5. Turn on the machine.
6. Operate the machine to circulate the soapy water until clean water flows out of the return tube.
7.  T urn off the machine.

Preparation before spraying

Before spraying, make sure the paint is in the right proportion. Also, circulate the special thinner. Follow the steps below:

1. Put siphon hose in a bucket full of special thinner or clean water.
2. Put return tube in a waste bucket.
3. Set pressure control knob to medium pressure. Don´t tighten it too much.
4. Set PRIME/SPRAY valve to the horizontal position.
5. Turn on the machine.
6. Let the machine work for 15-30 seconds, until clean thinner flows out of the return tube.
7. Turn off the machine.
8. Set PRIME/SPRAY valve to the vertical position.
9. Turn on the machine.
10. Open the safety guard.
11. Point the spray gun at the inside of waste bucket. Pull the trigger until clean solvent flows out so that old solvent in the paint tube and spray gun flows out.
12. Close the safety guard.
13. Slowly set pressure control knob to high pressure. Rotate it until it is tight.
14. Carefully check every component for leaks.
    – Ιn case of leaks, release the pressure according to the “pressure releasing procedure” then twist tight where it leaks.

Spraying

1. Put siphon hose into paint bucket.
2. Put return tube into waste bucket.
3. Set pressure control knob to medium pressure. Don´t tighten it too much.
4. Set PRIME/SPRAY valve to the horizontal position.
5. Turn on the machine.
6. Make the machine work until the paints flow out of return tube.
7. Turn off the machine.
8. Put return tube into paint bucket.
9. Set PRIME/SPRAY valve to the vertical position.
10. Turn on the machine.
11. Open the safety guard.
12. Point the spray gun at the inside of waste bucket. Pull the trigger until paint sprays out so that solvent remnants flow out.
13. Close the safety guard.
14. Turn off the machine.
15. Attach the spray tip cover and spray tip, rotate until they are tight.
16. Turn on the machine.
17. Slowly set pressure control knob to medium pressure or high pressure. Start spraying a surface and slowly increase paint flow pressure until paint is totally atomized. Normal operation can then commence.

Pressure releasing procedure
Warning: Before performing cleaning, maintenance or repair work on the unit, as well as when operation is interrupted, release the pressure by following the steps below.

1. Close the safety guard.
2. Turn on the machine.
3. Set pressure control knob to low pressure. Rotate until it is loose.
4. Open the safety guard, reverse the spray tip by 180°.
5. Point the spray jet at the inside of paint bucket. Pull the trigger to release the pressure inside the machine and the tube.
6. Close the safety guard.
7. Set PRIME/SPRAY valve to the horizontal position to release all remaining pressure.

Spraying technique (Fig. 1-3)

• Hold the gun perpendicular to the surface and always at equal distance from the surface.
  – Depending on the type of material, surface, or desired spray pattern, the gun should be held at a distance of 30 to 35 cm from the surface.

• Move the gun either across or up and down the surface at a steady rate.
  – Moving the gun at a consistent speed conserves material and provides even coverage.

• Holding the gun closer to the surface deposits more paint on the surface and produces a narrower spray pattern. Holding the gun farther from the surface produces a thinner coat and wider spray pattern.

• If runs, sags, or excessive paint occur, change to a spray tip with a smaller orifice.

• If an insufficient amount of paint is deposited on the surface or you desire to spray faster, a large orifice tip should be selected.

• Maintain uniform spray stroke. Spray alternately from left to right and right to left.

• Start moving the gun before pulling the trigger.

• Avoid arcing (fig. 2) or holding the gun at an angle (fig. 3).

• Figure 1 shows the correct spraying technique.

Practice

1. Turn the pressure control knob counterclockwise to its lowest setting.
2. Turn the PRIME/SPRAY valve up to its SPRAY position.
3. Turn the pressure control knob clockwise to its highest setting.
4. Unlock the gun trigger lock.
5. Trigger the spray gun to bleed air out of the hose.
6. When paint reaches the spray tip, spray a test area to check the spray pattern.
7. Use the lowest pressure setting necessary to get a good spray pattern.

MAINTENANCE – CLEANING

Daily maintenance measures

• After spraying, clean the machine and all components thoroughly.
• After cleansing, roll the hose, making sure that no knots are created.
• In case of long-term storage, a protective solution should be circulated inside the machine in order to prevent component corrosion. Let the machine siphon a little lubricating oil and inject PLS oil.

Cleaning

1. Let out the pressure and the paint inside the machine according to the “pressure releasing procedure”.
2. Remove the the spray tip and its cover.
3. Put siphon hose into special thinner or clean water bucket.
4. Put return tube into waste bucket.
5. Set PRIME/SPRAY valve to the horizontal position.
6. Set pressure control knob to medium pressure. Don’t tighten it too much.
7. Turn on the machine.
8. Circulate the solvent inside the machine and let out the remaining paint until clean solvent or clean water flows out of return tube.
9. Turn off the machine.
10. Set PRIME/SPRAY valve to the vertical position and open safety guard.
11. Turn on the machine.
12. Pull the trigger to make solvent or clean water flow through the paint pipe and remove any remaining paint inside the spray gun until clean solvent or clean water sprays out.
13. Close the safety guard.
14. Attach the spray tip cover and open the safety guard.
15. Rotate the spray tip 180° counterclockwise, keep pulling the trigger for 1-2 seconds in order to clean the spray tip.
16. Remove the spray tip and its cover and then wash them with a brush.
17. Wipe the entirety of the machine, the paint pipe and the spray gun with a rag wetted with clean water or solvent until the machine is totally clean.
18. Inject 5-6 drops PLS oil into the oil slot.
19. Put the machine in a dry, clean and well-ventilated place.

MAINTENANCE SCHEDULE

Daily or each time you spray
Inspect motor shield vents for blockage.| Daily or each time you spray
Fill TSL by adding through TSL fill point.| Daily or each time you spray
Inspect motor carbon brushes for wear. Note: Carbon brushes do not wear at same rate on both sides of motor. Check both carbon brushes.| Every 3785 liters
Check sprayer stall. With sprayer gun not triggered, sprayer motor should stall and restart when gun is triggered again. If sprayer starts spraying with gun not triggered, inspect pump for internal/external leaks and check prime valve for leaks.| Every 3785 liters
Throat packing adjustment. When pump packing begins to leak after extended use, tighten packing nut down until leakage stops or lessens. This allows approximately 378 liters of additional operation before replacement of the packing is required. The packing nut can be tightened without O-ring removal.| As necessary depending on usage

REPAIRS

Repairing siphon hose components
Before the maintenance or repair, siphon hose and return tube should be disconnected from the unit. Follow the steps below:

1. Remove six screws from the upper front cover with a Phillips screwdriver.
2. Loosen and disconnect the return tube with wrench.
3. Remove the siphon hose clip and take the siphon hose out of the foot valve housing.
4. To facilitate this procedure, incline the machine a little backward when taking the siphon hose out.

Repairing the ball valve
Among all components, the ball valve is most likely to get blocked, which could cause abnormal operation. Therefore, it´s very important to clean and maintain the ball valve.

1. Remove the whole pump with the wrench as well as the foot ball valve.

2. Carefully check and clean every part. Damaged parts should be replaced.

3. Turn the upper ball valve to loosen it and remove it from the piston rod with a wrench. Check whether there is any blockage or it has any wear and tear.
   Clean or replace it when necessary.

4. Check whether the foot ball valve is blocked or or if it has any wear and tear. Clean or replace it when necessary.

5. After cleaning the ball valve, assemble it into siphon components.
   Note: When foot ball valve gets blocked, it usually cannot siphon. If foot ball valve works normally, disassemble the upper ball valve. Use a clean soft cotton rag to clean the ball valve. Cleaning with harsh substances is prohibited.

Replacing the sealing washer (Fig. 4)

1. Remove and disassemble the pump according to “Repairing the ball valve”.

2. Carefully check the piston rod and sealing washer. Replace them immediately in case of wear and tear.

3. Assemble the piston rod’s components and tighten them with the wrench.

4. Inlay upper sealing washer (“U” tip should be downward) and upper bushing into retainer nut and assemble the sealing nut into the pump. Tighten it.

5. Assemble the finished piston rod upwards from the bottom of upper pump and knock the piston rod gently into the upper pump with a hammer until the piston rod reaches the correct position.
   – Note: Apply a little lubricating oil when assembling the piston rod and all the components.

6. Tighten the retainer nut with the wrench.

7. Assemble the lower sealing washer and the lower bushing into the bottom of the upper valve housing.

8. Tighten the finished lower valve housing components, lower ball valve and the upper valve housing.

9. Inlay the whole finished piston rod into the “N”.

10. Wring the pump upward until it is mounted in the pump housing.

11. Tighten the lock nut.

12. Assemble the siphon hose onto the lower pump and stabilize it.

13. Assemble the return tube onto the siphon components and tighten it.

14. Assemble the front cover and stabilize it with nuts.

15. Operate the machine and check whether there are any leaks.

ACCESSORIES

Airless tip selection

• Tips are selected by the orifice size and fan width. The proper selection is determined by the fan width required for a specific job and by the orifice size that will supply the desired amount of fluid and accomplish proper atomization.
• For light viscosity fluids, smaller orifice tips generally are desired. For heavier viscosity materials, larger orifice tips are preferred. Refer to the table below.
• The following chart indicates the most common sizes and the appropriate materials to be sprayed.
  Note: Do not exceed the machine’s recommended tip size.

TROUBLESHOOTING

MECHANICAL PROBLEMS / FLUID FLOW

valve and clean. Check balls and seats for nicks. Replace if necessary. See pump manual. Strain paint before using to remove particles that could clog pump.
Fluid filter or tip filter is clogged or dirty.| Clean filter.
Prime valve leaking.| Follow pressure relief procedure, then repair prime valve.
Verify pump does not continue to stroke when gun trigger is released. (Prime valve not leaking)| Service the pump.
Leaking around throat packing nut which may indicate worn or damaged packings.| Replace packings. Also check piston valve seat for hardened paint or nicks and replace if necessary. Tighten packing nut.
Pump rod damage.| Repair pump.
Piston packings are worn or damaged.| Replace packings.
O-ring in pump is worn or damaged.| Replace O-ring.
Intake valve ball is packed with material.| Clean intake valve.
Large pressure drop in hose with heavy materials.| Reduce overall length of hose.
Check whether the extension cord is of the correct size.| Use an extension cord with an undamaged ground contact. If an extension cord is necessary, use a 3-wire, 12 AWG (2.5 mm2) minimum. Note: Smaller gauge or longer extension cords may reduce sprayer performance.
Loose motor carbon brushes and terminals.| Tighten terminal screws. Replace carbon brushes if leads are damaged.
Worn motor carbon brushes. (Brush minimum length: 13mm)| Replace carbon brushes.
Broken and misaligned motor carbon brush springs. Rolled portion of spring must rest squarely on top of brush.| Replace spring if broken. Realign spring with brush.
Motor carbon brushes are binding in brush holders.| Clean brush holders, remove carbon dust with a small cleaning brush. Align brush lead with slot in brush holder to assure free vertical brush movement.
Motor runs but pump does not stroke| Connecting rod assembly damaged.| Replace connecting rod assembly.
Gears or drive housing damaged.| Inspect drive housing assembly and gears for damage and replace if necessary.
Excessive paint leakage into throat packing nut| Throat packing nut is loose.| Remove throat packing nut spacer. Tighten throat packing nut just enough to stop leakage.
Throat packings are worn or damaged.| Replace packings.
Displacement rod is worn or damaged.| Replace rod.
Fluid is spitting from gun| Air in pump or hose.| Check and tighten all fluid connections. Cycle pump as slowly as possible during priming.
Spray tip is partially clogged.| Clear tip.
Fluid supply is low or empty.| Refill fluid supply. Prime the pump. Check fluid supply often to prevent dry running the pump.
Pump is difficult to prime| Air in pump or hose.| Check and tighten all fluid connections. Cycle pump as slowly as possible during priming.
Intake valve is leaking.| Clean intake valve. Be sure ball seat is not nicked or worn and that the ball seats well. Reassemble the valve.
Pump packings are worn.| Replace pump packings.
Paint is too thick.| Thin the paint according to supplier recommendations.
Unit operates for 5 to 10 minutes and then stops| Pump packing nut too tight. When pump packing nut is too tight the packings on the pump rod restrict pump action, leading to motor overload.| Loosen pump packing nut. Check for leaks around throat. If necessary, replace pump packings.

ELECTRICAL PROBLEMS

firmly connected. Clean circuit board terminals. Securely reconnect leads.
For loose motor brush lead connections and terminals.| Tighten terminal screws. Replace brushes if leads are damaged.
Carbon brush length. Carbon brush length must be 13mm minimum. Note: Carbon brushes do not wear at the same rate on both sides of motor. Check both carbon brushes.| Replace carbon brushes.
Broken or misaligned motor carbon brush springs. Rolled portion of spring must rest squarely on top of carbon brush.| Replace spring if broken. Realign spring with carbon brush.
Binding of motor carbon brushes in carbon brush holders.| Clean brush holders. Remove carbon with small cleaning brush. Align brush leads with slot in brush holder to assure free vertical brush movement.
Unit does not shut off| Control board.| Replace control board.
Unit does not run at all| Check transducer or transducer connections.| 1. Check transducer and connections to control board.
2.  Disconnect transducer from control board socket. Check that transducer and control board contacts are clean and secure.
3.  Reconnect transducer to control board socket. Connect power, turn ON/OFF switch ON and control knob 1/2 turn clockwise. If sprayer does not run properly, turn ON/OFF switch OFF and go to next step.
4.  Install new transducer. Connect power, turn ON/OFF switch ON and turn control knob 1/2 turn clockwise. Replace control board if unit does not run properly.
Motor is hot or there is a fault in the motor thermal device.| Allow the machine to cool. If the machine runs when cool, correct cause of overheating. Keep unit in a well-ventilated place with lower temperature. Make sure motor air intake is not blocked. If unit still does not run, replace motor.
Check voltage supply to the unit (incoming voltage too low for unit operation).| Turn ON/OFF switch OFF and disconnect power to the unit.

ENVIRONMENTAL DISPOSAL

In order to avoid damages on transportation, the tool has to be delivered in solid packaging. Packaging as well as the unit and accessories are made of recyclable materials and can be disposed accordingly. The tool’s plastics components are marked according to their material, which makes it possible to remove environmental friendly and differentiated because of available collection facilities.
Only for EU countries
Do not dispose of electric equipment together with household waste material!
In observance of European Directive 2002/96/EC on waste electrical and electronic equipment and its implementation in accordance with national law, electric tools that have reached the end of their life must be collected separately and returned to an environmentally compatible recycling facility.

WARRANTY

The power tools have been manufactured according to strict standards, set by our company, which are aligned with the respective European quality standards. The power tools of our company are provided with a warranty period of 24 months for non-professional use, 12 months for professional use and 12 months for chargers and batteries. The warranty is valid from the date of purchase of the product. Proof of the warranty right is the purchase document of the tool (retail receipt or invoice). Under no circumstances shall the company cover the relevant cost of spare parts and respective required working hours unless a copy of the purchase document is presented. In case the repair has to be done by our service department the cost of transportation (to and from) is entirely borne by the sender (client).
The tools must be sent for repair to the company or to an authorized workshop in the appropriate way and means of transport.
WARRANTY EXEMPTIONS AND RESTRICTIONS:

1. Spare parts that wear out naturally as a consequence of being used (brushes, cables, switches, chargers, chucks etc.).
2. Tools damaged as a result of non-compliance with the instructions of the manufacturer.
3. Tools poorly maintained.
4. Use of improper lubricants or accessories.
5. Tools given to third entities free of charge.
6. Damage due to an electrical connection at a voltage other than that indicated on the appliance plate.
7. Connection to a non-earthed power supply.
8. Change in current voltage.
9. Damage resulting from the use of salty water (e.g., washing machines, pumps).
10. Damage or malfunction resulting from improper cleaning procedure of the tool.
11. Contact of the tool with chemicals, or damage as a result of moisture or corrosion.
12. Tools that have been modified or opened by unauthorized personnel.
13. Broken parts/components as a result of inappropriate use.
14. Tools used for rent.

The warranty covers only the free of charge replacement of the component that presents a manufacturing defect or material failure. In case of lack of a specific spare part the company reserves the right to replace the tool with another corresponding model. After all warranty procedures have been concluded, the warranty period of the tool shall not be extended or renewed. Replacement of a spare part with repair charge is covered by a 1 year warranty of good operation, subject to compliance with the warranty terms. The spare parts or tools that are replaced remain in the possession of our company. Requirements, other than those mentioned in this warranty form, regarding power tools repair or damage thereof, do not apply. Greek law and relative regulations apply to this warranty.

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