Operation Manual INTERNAL PIPE COATING SYSTEM
Contents
1. 24 4 3 4 Reducing the holder to the pipe diameter 24 5 Operatii weiss E 25 5 1 Commissioning the machine ssssseeeeeeeeenen 25 5 2 Coatings siete eie feudo 26 5 2 1 Hints for achieving good coating 27 5 39 eo ioo er oo RES tere Eros Ste xs A TT 27 5 4 Material changes work interruptions and decommissioning 28 5 5 DIS DOSE e Rm 29 30 6 1 Maintenance plan inen ette eet ttn ka ck nu kai etn ead adu 30 6 2 Checking cleaning adjusting the filter regulator 31 6 2 1 Adjusting the automatic condensate draining 31 6 2 2 Draining condensate manually 31 6 3 Cleaning the nozzle and the edge type 32 6 4 Supplied Rx un 32 7 Rectification of faults 33 4 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw ATA 1 Foreword Dear Customer We are delighted that you have decided in favour of a machine made by our company This operating manual is intended for the operating and maintenance per sonnel It2. 4 3 2 Connecting the automatic spray gun 1 Create a compressed air connection between mounting kit and lance The hose connectors for connecting the hoses are included in the delivery The compressed air hoses are not part of the delivery They are available from WIWA by the metre 2 Connect the pneumatic hoses between the pneumatic valve on the Gun ON OFF switch and the automatic spray gun Control air permanent 1 Open 4 Close 2 Fig 12 Connections to pneumatic valve ON OFF switch for automatic gun Fig 13 Connecting the automatic spray gun No Designation Material hose from high pressure filter or mixing unit Pneumatic hose for opening the valve Pneumatic hose for closing the valve Control air permanent from the mounting kit Aloin 3 Connect the material hose For one component systems connect the hose directly to the high pressure filter of the spraying device A mixer is interposed for two component systems Translation of the original operation manual 23 Rohrinnenbeschichtung BA en 1312 jw Transport installation and assembly WI 373 4 3 3 Connecting a lance with a hand held spray gun A filter regulator has to be used for a lance with a hand held spray gun This filter removes condensate and contaminations from the supplied air and allows adjustment of the air inlet pressure for the rotary atomizer motor This filter regulator has to be installed
3. RITA Operation Manual because it works INTERNAL PIPE COATING SYSTEM Serial number ITPA Declaration of Installation in accordance with Appendix II No 1 B of the Machine Directive 2006 42 EC as amended by 2009 127 EC WIWA Wilhelm Wagner GmbH amp Co KG Gewerbestr 1 3 35633 Lahnau Germany hereby declares that the machine of type INTERNRL PIPE CORTING SYSTEM with serial number are incomplete machines according to Article 2g and designed exclusively for installation or assembly with another machine or item of equipment These devices meet the following underlying safety and health and safety requirements from the above guideline 1 1 2 1 1 3 1 1 5 1 1 6 1 2 1 1 2 2 1 2 3 1 2 4 1 1 2 4 3 1 3 2 1 3 4 1 5 3 1 6 3 1 7 4 1 1 7 4 2 Commissioning of the incomplete machine is prohibited until it has been established that the end product into which this machine is to be installed corresponds to the conditions of the EC Machinery Directive 2006 42 EC The special technical documents are prepared in accordance with Appendix VII Part B of this guideline Responsible for documentation WIWA GmbH Tel 49 6441 609 0 The manufacturer undertakes to send by electronic means the special documents for the incomplete machine to single nation bodies upon request Lahnau 25 03 2014 y fg Place Date Heidrun iner Turczak Managerial Associate 2 Translation of the original operation ma
4. 1 3 35633 Lahnau Germany Tel 49 6441 609 0 Fax 49 6441 609 50 E mail info wiwa de Internet www wiwa de This operating manual is solely intended for personnel involved in preparation operation and servicing It is prohibited to pass on this operating manual for reproduction utilisation or communication of its contents unless this has been explicitly permitted Non compliance may result in claims for damage compensation All rights reserved in the event of registration of the patented design industrial design or registered design This operating manual only applies in conjunction with the machine card that was given to you with the user manual for your equipment Please check that the data on the type plate match those on the machine card Please notify us immediately if there are discrepancies if the user manual has been incorrectly compiled or if the type plate is missing Translation of the original operation manual 5 Rohrinnenbeschichtung BA en 1312 jw ITA 2 Safety This machine has been designed and manufactured under due consideration of all safety related aspects It complies with the current standard of tech nology and the valid accident prevention instructions The machine left the factory in perfect condition and guarantees a high level of technical reliability and safety Nevertheless there are certain risks that can arise from incorrect operation or misuse gt to life and limb
5. 13 zx IMEteH lllencrj 13 2 6 Emergency procedures ssssssseeeee eene eren 14 2 6 1 Shutting down and depressurising the machine 14 2 0 2 L GakageS8 i iiie eiusm ibus 14 2 16 53 NUM CS dent 14 3 Machine eui sexa e eee a 15 3 1 Intended USB rere er rn rte p 15 3 2 Functional descriptiO 2 tu e rete uua 15 3 9 Machno dos ner od ue ee extet atten edu xe dcm ER E dE 16 3 9 T Mounting Kil ssa aaa cootra ect tn ect ea nemen ttes teet 17 3 92 Lance wih molor i ie eee tee eiae aa Ede heus 18 9 350 Pipo 19 3 9 4 Rotary AOM ZET oerien EE AEE EEEE EEOAE 20 3 3 5 Automatic spray gun seem 20 4 Transport installation and assembly sse 21 4 1 TransportatlOHi cce odeur xe a bue hee eae 21 4 2 Installation uci eee ne eere ter tta cepa 21 Translation of the original operation manual 3 Rohrinnenbeschichtung BA en 1312 jw Contents AS ASSO DM Wes 22 4 3 1 Installing the mounting 22 4 3 2 Connecting the automatic spray gun 23 4 3 3 Connecting a lance with a hand held spray gun
6. machine Any condensate will collect in the storage container 1 and can be drained using a semi automatic drain valve Regularly check the storage container regularly for dirt residue and clean if necessary by removing the container 6 2 1 Adjusting the automatic condensate draining 1 Turn the drain screw 2 out until it only just remains in the thread The valve opens from a pressure of lt 1 5bar machines unpressurised The residual pressure is enough to force the condensate out of the container When pressure is applied again the valve closes at 1 5bar With this setting condensate will only be drained when there is no pressure For longer periods of operation however condensate may accumulate above the maximum filling level of the condenser and enter the compressed air system Drain condensate manually if necessary to prevent this 6 2 2 Draining conden sate manually on page 31 Fig 17 Filter regulator 6 2 2 Draining condensate manually 1 Turn the drain screw 2 in all the way so the condensate outlet is closed 2 Turn the drain screw out until condensate is released Manual condensate draining also works when the machine is under pres sure Automatic condensate draining does not work with this setting 6 2 7 Adjust ing the automatic condensate draining on page 31 Translation of the original operation manual 31 Rohrinnenbeschichtung BA en 1312 jw Maintenance 6 3 Cleaning
7. of the operator or third party to the machine and other material assets of the owner to the efficient working capacity of the machine You must refrain from any working methods that could affect the safety of operating personnel and equipment All the people that are involved in set up commissioning operation maintenance repair and servicing of the spray gun must have read and understood the operating manual beforehand especially the chapter entitled Safety Your safety is at stake We recommend to the owner of this unit to have this confirmed in writing 2 1 Explanation of symbols Safety information warns you of potential risks of accidents and tell you the measures that are needed to prevent accidents In WIWA operating manuals safety information is specially highlighted and marked as follows Indicates danger of accidents if you ignore the safety notes there is a high risk of severe injury resulting up to and including death Indicates danger of accidents if you ignore the safety notes severe injury can result up to and including death Indicates danger of accidents if you ignore the safety notes severe injury can result Indicates important information on correct use of the machine Ignoring it can result in damage to the machine or in its vicinity gt 6 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw ATA In the safe
8. system 4 2 Installation location A If the spraying device is used outside during a thunderstorm a lightning strike can cause a life threatening situation for the operating personnel gt Do not operate the spraying device during a thunderstorm The machine owner has to ensure that the spraying device is equipped with suitable lightning protection Safety measures at the place of installation Always keep the working area especially all walkways and standing areas clean and tidy Immediately remove any spilled material and cleaning agent Always ensure adequate ventilation at the work place to avoid damage to health and material objects Always observe the processing instructions issued by the material manufacturers Even though there are no legal regulations all hazardous cleaning agent vapours and paint particles should be extracted Protect objects adjacent to the spraying object against possible damage caused by the material mist Translation of the original operation manual 21 Rohrinnenbeschichtung BA en 1312 jw Transport installation and assembly WI WA 4 3 Assembly A If assembly work is carried out by people who have not been trained for this work you endanger yourself and other people and impair the safety and reliability of the machine Electrical components must only be mounted by trained time served electricians with all the other components e g the spray hos
9. the nozzle and the edge type filter No Designation Housing for valve filter Edge type filter Nozzle Seal Socket nipple 6 4 Supplied tools Unscrew the socket nipple 5 by countering the housing of the nozzle filter 1 Remove the nozzle 3 and the edge type filter 2 from the automatic gun If neces sary push the parts out of the socket nipple from the front Place both parts in a suitable cleaning agent In case of damage or permanent soiling the parts have to be replaced Also check the seal 4 Re insert all parts and tighten the socket nipple The following tools are included in the delivery 2 open end wrenches WAF 12 and WAF 17 for securing the rotary atom izer in the collet chuck of the motor Fig 18 Removing the nozzle and the edge type filter 32 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw BTA 7 Rectification of faults Rectification of faults Fault Possible cause s Remedy 1 no material output gt gun OFF switch ON the gun spraying device OFF or not working gt open compressed air supply for the spraying device and adjust spraying pressure gt check the spraying device note operating man ual for the spraying device material hose bent check material hose for bends and crushing gt nozzle filter clogged gt cl
10. Designation 1 Control air connection for closing the valve 2 Control air connection for opening the valve 3 Material inlet NPSM I WM 4 Edge type filter internal not shown incl M100 M60 5 Nozzle internal not shown incl 053 40 068 40 073 40 other sizes on request 6 Material outlet NPSM A Fig 11 Automatic spray gun 4 mm 0655976 20 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw Wi WA Transport installation and assembly 4 Transport installation and assembly The machine left the factory in flawless condition and was appropriately packed for transportation Check the machine receipt for any damage transit and for i completeness 4 1 Transportation Please follow these notes when transporting the machine Fold up the guide tightly Secure the load on the transport vehicle against slipping and falling off If the machine had already been in operation please observe the following Disconnect the entire power and paint supply for the device even for short transport distances gt Empty the machine before transport fluid residues may escape during transport despite this measure Remove all loose components e g tools from the machine Assemble the parts or fittings dismantled for transport purposes before start up and in compliance with the intended use of the
11. Personnel qualification A differentiation is made between two groups of people in dependence on their qualifications Instructed operators have been verifiably instructed by the machine own er in the activities they are tasked with and the potential risks connected with them in the case of incorrect behaviour Trained personnel have been instructed by the machine builder such that they are capable of carrying out maintenance and repair work on the sys tem and recognising potential risks on their own initiative and of avoiding these risks 2 4 3 Authorized operating personnel Activity Qualification Set up and operation Instructed operator Cleaning Instructed operator Servicing Trained personnel Repair Trained personnel o Young persons under the age of 16 are not allowed to operate this 1 machine 2 4 4 Personal protective equipment Wear protective clothing Always wear the protective clothing prescribed for your work environment mining closed rooms etc and also follow the recommendations in the safety data sheet issued by the material manufacturer Use eye protection Wear protective goggles to protect against eye injuries caused by material splatter gases fumes or dust 12 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw IVA Safety Wear ear defenders Operating personnel should be provided with suitable noise protection equi
12. arranty null and void gt Using original WIWA accessories guarantees that they are usable in our machines f you use third party accessories they must be suitable for the machine particularly with regard to the operating pressure the electrical connection data and the connection sizes WIWA accepts no liability for damage or injuries resulting from the use of these parts gt You must observe the safety regulations of the accessories These safety regulations are found in the separate operating instructions for the acces sories Translation of the original operation manual 13 Rohrinnenbeschichtung BA en 1312 jw Sate ITPA 2 6 Emergency procedures 2 6 1 Shutting down and depressurising the machine In an emergency immediately shut down the machine and depressurise it 1 Close the compressed air shut off valves for the rotary atomizer motor and the spraying device 2 Open the ball valve on the high pressure filter of the spraying device 3 Operate the spray gun again briefly to relieve any residual material pressure ensuring full pressure release for the machine The machine has not been flushed The material in the machine hard en and clog it up This procedure is not suitable for decommissioning After remedying the emergency the machine has to be flushed see 5 3 Flushing on page 27 Pay attention to the potlife of the material used Observe the operating manual for the spra
13. aying the air inlet pressure for the rotary atomizer motor Air for driving the rotary atomizer motor inside the lance ON OFF switch for the automatic spray gun Control air for the automatic spray gun Filter with semi automatic outlet ON oO c RB Compressed air shut off valve Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw Machine Description WI WA 3 3 2 Lance with motor Fig 5 0656960 lance for automatic spray gun Fig 6 0656948 hand lance shown shortened with hand held spray gun No Designation 1 Material outlet in the rotary atomizer 2 Motor for rotary atomizer 3 Material line on the outside of the lance 4 Air line inside the lance 5 6 7 Material inlet Air inlet Compressed air shut off valve rotary atomizer ON OFF Pay attention to the operating manual for the spray gun used 18 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw ATA 3 3 3 Pipe guide Machine Description Fig 7 Guide with adjustable arms The guides see Fig 7 are available in different versions to cover diameters between 80 800 mm The design and the operating principle are the same for all guides The arms of the guides are adjustable and can be set contin uously to the required pipe diameter The setting is fixed by tightening the screws Gu
14. contains all the information required to working with this machine The owner of the machine must ensure that operators and maintenance personnel always have an operating manual at their disposal in a language that they understand me Safe and reliable operation of the machine requires further information in addition to this operating manual You should have read and understood the guidelines and accident prevention regulations that apply in your country In Germany these are as follows ZH 1 406 Richtlinien f r Fl ssigkeitsstrahler Guidelines for Liquid Jets published by the German Hauptverband der Gewerblichen Berufsgenos senschaften gt BGR 500 chapter 2 29 Application of Coating Materials gt BGR 500 chapter 2 36 Working with Fluid Spraying Equipment pub lished by the employers liability insurance association for the gas remote heating and water management sectors We strongly recommend adding all relevant guidelines and accident preven tion instructions to this operating manual Moreover the manufacturer s instructions and guidelines for coating or feed er materials must be respected at all times However if you have any questions please do not hesitate to contact us Best wishes for good results with your machine from WIWA Wilhelm Wagner GmbH amp Co KG Copyright 2013 WIWA This operating manual remains the copyright of WIWA Wilhelm Wagner GmbH amp Co KG Gewerbestr
15. e and the spray gun being assembled by trained personnel only 4 3 1 Installing the mounting kit A e o Components that do not comply with the maximum permitted operating pressure of the machine can burst and cause serious injury Check the maximum permitted operating pressure of the material hose and the spray gun before assembly It must be greater than or equal to the maximum operating pressure of the machine as specified on the type plate When using a hand held lance only a filter regulator not included has to be mounted before the compressed air shut off valve 4 3 3 Connecting a lance with a hand held spray gun on page 24 When using a lance with an automatic spray gun a mounting kit has to be additionally installed The mounting kit can be installed on the transport box of the pneumatic mixer using the mounting plates provided To connect the mounting kit please see Fig 4 Mounting kit 0655044 on page 17 The compressor capacity must match the air requirements of the machine and the diameters of the air supply hoses must match the connections such that an adequate air supply is ensured Operation with contaminated or moist compressed air causes damage to the machine s pneumatic system Use only dry dust and oil free air 22 Translation of the original operation manual Rohrinnenbeschichtung_BA_en_1312 jw wi WA Transport installation and assembly
16. ean nozzle filter replace if worn or damaged gt material feed faulty gt Is there still enough spraying material note the operating manual of the spraying device 2 not enough material gt nozzle clogs up clean nozzle filter output gt feed rate too high move more slowly 3 too much material nozzle worn gt replace nozzle output feed rate too slow gt move faster 4 rotary atomizer rotates too slowly or not at all air inlet pressure for the rotary atomizer motor too low or non existent gt open the compressed air shut off valve increase air inlet pressure for rotary atomizer gt motor stuck gt check repair motor replace if necessary air hose bent gt check air hose for bends and crushing replace if necessary 5 uneven material appli cation in the pipe gt rotary atomizer rotates too slowly or not at all see item 2 gt material too liquid gt increase rotary atomizer speed gt material too viscid decrease viscosity of the material e g through material heaters thinning etc gt material already unevenly distributed in the rotary atomizer gt material too liquid viscid see above Try installing several distributed material outlets in the rotary atomizer Please contact WIWA customer service Translation of the original operation manual Rohrinn
17. enbeschichtung BA en 1312 jw 33 WIWA Service 49 0 6441 609 140 Headquarters and production WIWA Wilhelm Wagner GmbH amp Co KG Gewerbestr 1 3 35633 Lahnau Germany Phone 49 6441 609 0 Fax 49 6441 609 50 E Mail info wiwa de Homepage www wiwa de WIWA Partnership USA WIWA LP 107 N Main St P O Box 398 Alger OH 45812 Phone 1 419 757 0141 Fax 1 419 549 5173 Toll Free 1 855 757 0141 E Mail jwold wiwalp com Homepage www wiwalp com WIWA Subsidiary China WIWA Taicang Co Ltd Building A of Huaxin Industrial Park No 11 East Qingdao Road Taicang City Jiangsu Province 215400 P R China Phone 86 512 5354 8858 Fax 86 512 5354 8859 E Mail info wiwa china com Homepage www wiwa china com WIWA Middle East General Trading LLC Mohd Farhan Khan Jebel Ali Industrial 1 Dubai UAE Phone 9714 884 8220 E Mail middleeast wiwa com 2973371 because it works WIWA worldwide field service Wolfgang Pucken Sales Director Northern Germany from the river Main Israel Hungary Romania Turkey Poland Malta India Pakistan Africa Morocco FrankenstraBe 37 53359 Rheinbach Oberdrees Germany Mobil 49 173 5432559 Phone 49 2226 12708 Fax 49 2226 13973 Robert Jansen Senior Sales Director Finland Sweden Norway Denmark Great Britain Southern Ireland Scotland England Holland Belgium France Spain Portugal Italy Croatia Greece Czech Republic S
18. er if agitators heaters or other electrically accessories are addition ally mounted one must check the explosion protection Plugs for heaters agitators etc that do not have explosion protection may only be plugged in outside of areas that fall under the explosion protection ordinance even if the accessory equipment as such is explosion protected Translation of the original operation manual 9 Rohrinnenbeschichtung BA en 1312 jw Safety A 2 2 5 Health risks 1 rio WIA PWARNING 00000 Heating up cleaning agents can cause an explosion This may result in serious injury to persons and damage to property gt Pay attention to the flashpoint and the ignition temperature of the cleaning agent Switch off the material flow heater if you need to perform the following work Cleaning pressure testing decommissioning maintenance and repair Follow the safety notes and dosing information of the manufacturer and the generally applicable regulations when handling paints cleaning agents oils greases and other chemical substances Depending on the materials being applied solvent vapours may result that can cause damage to health and property Always ensure sufficient aeration and ventilation at the workplace Always observe the processing instructions issued by the material manufacturers When cleaning your skin use only appropriate skin protection skin cleaning and sk
19. erials containing solvents with the inter nal pipe coating system Observe the technical notes of the respective material manufacturer Observe the operating manual for the spraying device used 5 1 Commissioning the machine Prerequisites for commissioning The machine has to be fully assembled Do not commission the machine unless you have the specified protective equipment For details refer to chapter 2 4 4 on page 12 gt A sufficient quantity of the spraying material has to be available gt A sufficient quantity of a suitable cleaning agent has to be available for flushing the system parts filled with mixed material within the potlife Observe the operating manual for the spraying device used Check whether all safety features are installed and fully operational Check the level of lubricant in the oil container of the air maintenance unit if fitted and top up if required Flush the machine see chapter 5 3 on page 27 to remove the facto ry test medium for first operation or any residue of previous spraying material During commissioning flushing check whether all machine parts are tight and re tighten the connections if required gt Ensure correct grounding of the spraying device and of the object to be coated see operating manual of the spraying device Translation of the original operation manual 25 Rohrinnenbeschichtung BA en 1312 jw Operation 5 2 Coatin
20. g ITPA Before coating carry out the steps for commissioning see chapter see 5 1 Commissioning the machine 1 Calculate the surface area to be coated e g inside pipe area 5 m 2 Calculate the required volume of material e g layer thickness 2 mm x surface area 5 m total volume 10 1 When calculating the total volume take into account that certain materi als release moisture during drying which decreases the thickness of the dried layer Add these drying losses to the total volume 3 Take into account the duration for the pipe coating process as this pro vides the flow volume per minute e g 101 in 4 min 2 5 l min The time factor is often determined by the previous and or subsequent steps 4 Measure the material output conveyed by the system without rotary atom izer in one minute Run the system e g with 2 bar air inlet pressure while counting the dou ble strokes of the pump during that time If e g a flow volume of 2 results after one minute and 13 double strokes increasing the air inlet pressure to 2 5 bar or approx 16 double strokes could already produce the desired result of 2 5 l min Repeat the test if necessary 5 f the test without rotary atomizer was successful you should carry out a test coating of a pipe with rotary atomizer If steps 1 4 were carried out properly the result of the test coating should already correspond to the target values The rotary atomizer reaches very hi
21. gh speeds This may cause injuries from touching the rotary atomizer and or from ejected materials Only operate the rotary atomizer inside a pipe Switch off the rotary atomizer before removing the lance from the pipe Never stop the rotary atomizer by hand or with another body part Never touch the rotating rotary atomizer Changes to certain parameters can have a crucial influence on the coating result e g Nozzle size small nozzle less material output Temperature higher temperature decreases the viscosity gt more material output if the nozzle size allows Pressure higher air inlet pressure gt more material output if the nozzle size allows Feed rate slower gt thicker layer 26 Original operating manual Rohrinnenbeschichtung BA en 1312 jw ATA Operation 5 2 1 Hints for achieving good coating results 1 5 3 Flushing 1 gt To coat a pipe insert the lance completely into the pipe and start at the other end of the pipe The lance is pulled back through the pipe That means that the pipe is coated behind the lance without touching or even damaging the applied coating Ensure an even feed rate particularly when using hand held lances Switch on the rotary atomizer before starting the material feed That way you will achieve perfect soft and smooth overlapping of the spray jet and avoid excessively thick application of material at the beginning of
22. hould cover the screw fitting with a cloth to catch any escaping material sprays After completing maintenance and repair work check the function of all the safety features and that the machine is functioning correctly 6 1 Maintenance plan 1 The information in the maintenance plan is a recommendation The intervals may vary in dependence on the condition of materials used and outer influences Interval Activity Reference before each start up check machine for external damage daily clean nozzle and filter on the spray 6 3 Cleaning the nozzle and the gun edge type filter on page 32 weekly check and clean the filter regulator 6 2 Checking cleaning adjusting the filter regulator on page 31 visually check the compressed air and material hoses for damage bends and crushing 30 Translation of the original operation manual Rohrinnenbeschichtung_BA_en_1312 jw ATA oe Interval Activity Reference after max 1 000 check the fins of the rotary This task may only be carried out operating hours atomizer motor for wear and by WIWA customer service or replace if necessary specially trained personnel every three years inspection of the compressed air and material hoses by an expert and replacement if necessary 6 2 Checking cleaning adjusting the filter regulator The filter regulator prevents condensation and dirt particles from entering the
23. ide see Fig 7 Article no 400 800 0656956 80 400 0656954 steel 0656949 aluminium For pipe diameters below 80 mm small holders with rollers are used instead of a guide Holder with rollers Holder without rollers Fig 8 Fig 9 The holders with rollers see Fig 8 are not adjustable The rollers can be made smaller to adjust the holders to the desired pipe diameter 4 3 4 Re ducing the holder to the pipe diameter on page 24 Holder with rollers see Fig 8 Article no 69 78 8 0657948 77 5 97 0657949 The holders without rollers see Fig 9 are used for pipe diameters below 70 mm They are available in sizes 050 60 and 65 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw Machine Description WI WA Holder without rollers see Fig 9 Article no 050 0658050 60 0658051 65 0658052 3 3 4 Rotary atomizer The rotary atomizer is mounted in the collet chuck of the motor at the tip of the lance recommended tightening torque 8 Nm No Designation 1 Elongated holes through which the material is ejected onto the surface 2 Shaft 8mm for mounting in the collet chuck M8 Fig 10 Rotary atomizer Rotary atomizer see Fig 10 Article no 33 0656957 45 0656958 90 0656959 3 3 5 Automatic spray gun No
24. in care products In closed or pressurized systems dangerous chemical reactions may occur if parts made of aluminium or galvanized parts come into contact with 1 1 1 trichloroethane methylene chloride or other solvents containing halogenated hydrocarbons CFC s If you want to process materials containing the afore mentioned substances we recommend to consult the material manufacturer to clarify the usability of such substances For these materials we have available a range of rust and acid proof machines 10 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw ATA Safety 2 3 Safety features If one of the safety features is missing or not fully functional the operating safety of the machine cannot be guaranteed f you discover any faults in the safety features or other deficiencies on the machine stop operation of the machine immediately Only resume operation of the machine after the fault has been com pletely eliminated Safety features must be checked with the machine depressurised gt before initial commissioning always before starting work after set up work gt after all cleaning servicing and repair work The machine is equipped with the following safety features Spray gun lock only for hand held spray gun gt Compressed air shut off valve Check list 1 Check correct function of spray gun lock vl Check correct f
25. in the air hose before the compressed air shut off valve of the lance 1 Connect the com pressed air supply 1 2 Connect the material hose 2 Fig 14 Connecting material and air supply 2 to the hand lance 4 3 4 Reducing the holder to the pipe diameter Guides cannot be used on pipe diameters below 80 mm as the guides are thicker Holders with rollers are used instead The holders with rollers are not adjustable The rollers can be made smaller to adjust the holders to the desired pipe diameter On request we can adapt the holders to the required pipe diameter according to your specifications Fig 15 Holder with rollers 1 Release the screws 1 in the roller axes and remove the roller 2 Place the roller into a lathe and turn the roller p until it has reached the desired size O Please note that all rollers have to be turned the same producing a triple reduction in the overall diameter of the holder 3 Re attach the rollers to the holder Fig 16 Removing the roller 24 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw ATA 5 Operation A Explosion hazard Processing solvents or materials containing solvents in connection with an rotary atomizer device can cause sparks and therefore explosions This may result in serious injury to persons and damage to property Do not use any solvents or mat
26. lovakia Slovenia Luxembourg Bulgaria Egypt Libya United Arab Emirates Oman Dubai Abu Dhabi Qatar Bahrain Kuwait Saudi Arabia Iran Iraq Cyprus Iceland Syria Lebanon Support of WIWA sales directors representatives and distributors in South America except Cuba and Mexico South East Asia Japan South Korea Australia and New Zealand Hoekstraat 57 3751 AL Spakenburg The Netherlands Mobil 31 6 18 88 40 97 Phone 31 3 34 94 69 81 Fax 31 3 34 94 75 83 E Mail rob wiwa gmail com Otto Dietrich Sales Director Russia Ukraine Belarus Moldavia Baltic States Lithuania Latvia Estonia Caucasian countries Armenia Azerbaijan Georgia Asian countries Kazakhstan Uzbekistan Turkmenistan Kyrgyzstan Tajikistan Lindenhof 6 56154 Boppard Germany Mobil 49 160 1574385 Phone 49 6742 899336 Fax 49 6742 899337 E Mail o_dietrich wiwa de Michel Laksander Technical Sales Director France 2 Bis rue de l glise F 02240 Brissy Hamegicourt France Phone 33 32 36 21 120 Mobil 33 63 70 19 297 E Mail laksander orange fr JK Tan Sales Director Korea Japan Australia South East Asia Mobil 6012 223 7706 Phone Fax 603 8024 7706 E Mail jktan wiwa com
27. n the internal pipe coating system consists of several components such as Lance with pneumatically driven motor for the rotary atomizer and supply lines for air and spraying material Pipe guide or holder optional Rotary atomizer Spray gun automatic or hand held Mounting kit with compressed air shut off valve air pressure regulator pressure gauge ON OFF switch for the spray gun and air maintenance unit if required Fig 2 Sample system structure in combination with a one component spraying device No Designation Spray gun Mounting kit with filter regulator and pressure gauge ON OFF switch for the spray gun Spray gun shown here automatic Lance with guide and rotary atomizer Fig 3 Machine structure with hand held lance 16 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw ATA Machine Description No Designation 1 Rotary atomizer with different diameters 2 Guide for different pipe diameters 3 Lance in different lengths 4 Spray gun automatic or hand held 3 3 1 Mounting kit Fig 4 Mounting kit 0655044 No Designation Connection to a pressure outlet e g on the air maintenance unit of the spraying device Air pressure regulator Setting can be fixed by pressing down the regulator Pressure gauge for displ
28. ne or two com ponents The internal pipe coating system can be used with automatic or hand held spray guns on spray lances with pipe guides for different diame ters This also allows internal coating of installed pipes using robot technolo gy and an rotary atomizer Any other use is considered to be unintended If you intend to use the machine for other purposes or with other materials and thus not for the purpose for which it is intended you must ask WIWA for permission otherwise the warranty will be invalidated Intended use also includes compliance with the technical documentation and adherence to the prescribed operating servicing and maintenance guidelines 3 2 Functional description The internal pipe coating system is pulled centrally through the inside of the pipe using an automatic feeding unit not provided by WIWA or a mechan ical guide Supply lines connect the internal pipe coating system to the spraying device or the mixing unit as well as to the compressed air supply An rotary atomizer is located in front of the material outlet It is driven by a separate air motor and reaches very high speeds The rotary atomizer ejects the emitted coating material almost vertically onto the inner wall of the pipe to achieve an even coating Translation of the original operation manual 15 Rohrinnenbeschichtung BA en 1312 jw Machine Description WI WA 3 3 Machine design Depending on the system desig
29. ns must be tight 2 2 2 Hazard from rotating parts WARNING A Clothing long hair scarves and other items may become entangled in the rotating rotary atomizer This can result in crushing or strangulation gt Only operate the rotary atomizer inside a pipe Wear the required work clothing gt Tie back long hair gt Do not wear scarves baggy clothing PCAUTION 0 0 0 0 AN The rotary atomizer reaches very high speeds This may cause injuries from touching the rotary atomizer and or from ejected materials gt Only operate the rotary atomizer inside a pipe gt Switch off the rotary atomizer before removing the lance from the pipe gt Never stop the rotary atomizer by hand or with another body part Never touch the rotating rotary atomizer 8 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw ATA Safety 2 2 3 Hazard from electrostatic charging The high speeds of the rotary atomizer may cause electrostatic charging Static discharges can cause fire and explosion Ensure that the spraying device and the object to be coated are earthed correctly Always use open containers Never spray inside cone top cans or drums with bungholes Never operate the rotary atomizer with solvent or materials containing solvents Place the containers on a grounded surface Always use electrically conductive containers Avoid contact between s
30. nual Rohrinnenbeschichtung BA en 1312 jw ATA Contents Contents WONG e E E E E E E A 5 DASNY uc E a E E rU E etes 6 2 1 Explanation of Symbols ione aiena a EEEE 6 2 2 Safety 8 2 2 1 Operating pressure iii EL aa nara ados ca uae 8 2 2 2 Hazard from rotating 8 2 2 3 Hazard from electrostatic 9 224 Explosion protection iniu ue teorie RR 9 2 2 5 FISKS sacado det meat a erret A 10 2 9 Safety feature S usnisa ee FRI IRL ORDER M EEEE 11 2 3 1 Compressed air Shut Off 11 2 9 2 Spray gun lOCK oorpore ceo etic oda 11 2 4 Operating and maintenance 12 2 4 1 Machine owner s duties 12 2 4 2 Personnel gualia nceann 12 2 4 3 Authorized operating 12 2 4 4 Personal protective equipment sese 12 2 5 Notos On wanan s cocci eene 13 2 5 1 Conversions and 13 2 5 2 Spare parts nennen enne nnns
31. pment The machine operator is responsible for adhering to the accident prevention regulation Noise BGV B3 For this reason pay special attention to the conditions at the installation location the noise burden for example will increase if the system is installed in or on hollow bodies Wear a respiratory protection mask We strongly recommend that you wear a respiratory protection mask even though the paint mist has been minimized in the airless spray painting method given a correct pressure setting and correct working methods Wear protective gloves When applying heated materials you should wear protective gloves with lower arm protection to protect you against burn injuries Wear protective footwear Wear protective footwear to prevent injuries to the feet due to objects that may fall drop or roll around and to prevent slipping on a slippery floor 2 5 Notes on warranty 2 5 1 Conversions and alterations 2 5 2 Spare parts 2 5 3 Accessories Unauthorized conversions or alterations should not be undertaken on safety grounds Protective equipment should not be dismantled converted or bypassed The machine must only be operated within the specified limiting values and machine parameters When carrying out maintenance and repair work you must only use WIWA original spare parts Use of components which have not been manufactured or delivered by WIWA renders any w
32. pray gun and container wall Use only electrically conductive material hoses All original material hoses from WIWA are conductive and perfectly adapted to our equipment Y Vv Y Y 2 2 4 Explosion protection A Machines that are designed without explosion protection must not be used in workshops that are subject to the explosion protection ordinance Whether your machine has explosion protection is indicated by the symbol on the type plate and or on the enclosed ATEX declaration of conformity Explosion protected machines meet the explosion protection requirements of Directive 94 9 EC for the explosion group unit category and temperature class specified on the type plate or in the declaration of conformity The operator is responsible for determining the zone allocation according to the Directive of EC 94 9 EC Appendix II no 2 1 2 3 when observing the measures of the responsible inspecting authority The operator is responsi ble for checking and ensuring that all technical data and markings according to ATEX correspond with the necessary requirements Please note that several components have their own type plate with sepa rate marking according to ATEX In this case the lowest explosion protection of all attached markings applies for the entire machine Applications where the malfunction of the unit can lead to danger to personnel must be provided with respective safety measures by the operator Howev
33. rotection mask to prevent your Indicates references to guidelines work instructions and operating manuals that contain important information which you must observe at all times Translation of the original operation manual 7 Rohrinnenbeschichtung BA en 1312 jw HITRA 2 2 Safety notes Please remember that the machine works at high pressure and with very high speeds and may cause life threatening injuries if used inappropriately Observe and follow all information in this operating manual and in the operating manual of the spraying device used at all times The accident prevention instructions Application of Coating Materials BGR 500 chap 2 29 and the guidelines for liquid jets ZH1 406 of the employer s liability insurance association must strictly be complied with 2 2 1 Operating pressure Components that do not comply with the maximum permissible operating pressure can burst and cause serious injury The specified maximum operating pressures must generally be com plied with for all components In case of varying operating pressures the lowest value is always the one to be taken as the maximum oper ating pressure for the entire machine Material hoses and hose assemblies must comply with the maximum working pressure including the required safety factor Material hoses must be leak tight and free of kinks signs of abrasion or bulges Hose connectio
34. separate all materials dispose of metal together with scrap metal plastic parts can be disposed of as domestic waste gt Rests of spraying material cleaning agent oils greases and other chem ical substances must be collected in accordance with statutory provisions concerning recycling and waste disposal The official local waste water laws are valid Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw 29 Maintenance ITA 6 Maintenance If maintenance and repair work is carried out by persons who have not been trained for this work you endanger yourself other persons and impair the safety and reliability of the machine Maintenance and repair work on electrical components may only be carried out by trained electricians any other maintenance and repair work has to be performed by WIWA customer service or by specially trained personnel Before maintenance and repair work 1 Switch off the spraying device 1 Cut off the compressed air supply 2 Ensure full pressure release on spraying device and internal pipe coating system Despite releasing the pressure material congestion or agglomeration of material may mean that there are residual pressures still present These may suddenly release during disassembly work and can result in serious injuries You must be particularly careful during disassembly work When disconnecting material hoses you s
35. the spraying process gt Stop the material feed before switching off the rotary atomizer Replace the spray nozzle before it is worn Worn nozzles cause higher material consumption and therefore thicker layers of coating Flushing the machine is necessary Atinitial commissioning The machine has to be flushed with a cleaning agent to ensure that the spraying material is not negatively affected by the test medium that was used at the factory to test correct functioning When changing materials gt For work interruptions and at decommissioning in the case of an interruption in spraying to flush spraying material out before it sets Take note of the potlife of the materials used particularly when using two component materials Original operating manual Rohrinnenbeschichtung BA en 1312 jw 27 Operation TRA Explosion hazard Processing solvents or materials containing solvents in connection with an rotary atomizer device can cause sparks and therefore explosions This may result in serious injury to persons and damage to property Therefore follow these instructions during cleaning and while materials containing solvent may be in the system Always clean the rotary atomizer device outside of explosion endan gered environments e g in well ventilated rooms or outdoors gt Turn down the air pressure regulator on the rotary atomizer device completely and close the compressed air sh
36. ty notes about the risk of accidents different pictograms are shown after each hazard source examples General accident risk Risk of explosion from explosive atmosphere Risk of explosion from explosive substances Danger of injury due to electric voltage or electrostatic charging Risk of crushing by moving machine parts Risk of burning due to hot surfaces Mandatory safety instructions concern protective gear to be worn in the first instance They are particularly highlighted and marked as follows Wear protective clothing Highlights the order to wear the prescribed protective clothing to protect against skin injuries caused by spraying material or gases Use eye protection Indicates the requirement to wear protective goggles to protect against eye injuries caused by gases fumes or dust Wear ear defenders Indicates the requirement to wear ear defenders to prevent your hearing from being damaged by noise respiratory tract from being damaged by gases fumes or dusts Wear protective gloves Highlights the order to wear protective gloves with lower arm protection to protect against burn injuries caused by heated materials Wear protective footwear Highlights the order to wear protective footwear to prevent injuries to the feet due to objects that may fall drop or roll around or to hot or caustic liquids Usea respiratory protection mask Ww Highlights the order to use a respiratory p
37. unction operability of compressed air shut off valve V Also check the correct function of the safety features on the spraying device used in line with the operating manual 2 3 1 Compressed air shut off valve 2 3 2 Spray gun loc The compressed air shut off valve interrupts the air supply to the rotary atomizer motor Principle of function Open gt in the direction of flow gt Close across the direction of flow k Hand held spray guns are equipped with a safety lever for locking the trigger The spray gun must always be secured against unintended operation even for the shortest of work breaks Set the safety lever horizontally to secure the spray gun Fig 1 Spray gun lock Translation of the original operation manual 11 Rohrinnenbeschichtung BA en 1312 jw ITPA 2 4 Operating and maintenance personnel 2 4 1 Machine owner s duties The machine owner is responsible for the training of the operating and maintenance staff must instruct the operating and maintenance staff in correct handling of the machine as well as in wearing the correct work clothing and personal protective equipment must make the user manual available to the operating and maintenance staff and ensure that it always remains available must ensure that the operating and maintenance staff have read and understood the user manual Only then may the machine be brought into service 2 4 2
38. ut off valve for the internal pipe coating A Heating up cleaning agents can cause an explosion This may result in serious injury to persons and damage to property Before flushing the machine switch off the material flow heater tional and leave it to cool completely You will need atleast 5 of cleaning agent which suits the processed material and is recommended by the material manufacturer in an open container an additional collecting vessel for the flushed out cleaning agent These containers are not included in the scope of delivery 1 Dismount the rotary atomizer using the supplied tool 2 Clean the rotary atomizer by hand using a suitable solvent 3 Use the spraying device to flush a suitable cleaning agent through the lance instead of the spraying material Observe the operating manual for the spraying device used 5 4 Material changes work interruptions and decommissioning Flush the machine within the potlife stated by the manufacturer of the spraying material Observe the operating manual for the spraying device used 28 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw ATA 5 5 Disposal Operation At the end of use you must shut down and dismantle the machine and dis pose of it in accordance with legal regulations Clean the machine thoroughly of all material residues Dismantle the machine and
39. ying device used 2 6 2 Leakages In case of leakages material can escape under very high pressure and cause serious bodily injuries and material damage Immediately shut down the machine and depressurise it Re tighten any screw fittings and replace defective components only by trained personnel gt Do not try to seal leaks on the connections and high pressure hoses with the hand or by wrapping fabric around them Do not repair material hoses Before recommissioning the machine check the hoses and screw fittings for leaks 2 6 3 Injuries If injured by processing materials or cleaning agents always have available the safety data sheet address phone number material designation and material number of the supplier or manufacturer for the attending physician 14 Translation of the original operation manual Rohrinnenbeschichtung BA en 1312 jw ATA Machine Description 3 Machine Description 3 1 Intended use Internal pipe coating is required in many areas of technology to protect pipes hollow bodies and profiles against corrosion and other harmful influ ences This device can be used to apply one component and two compo nent coatings without rotating the pipe The technical data for your machine can be found in the attached machine card This device is used for applying internal coatings to pipes etc The device is intended for assembly with an airless spraying device o
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