Operation manual VULKAN Extrusion Pumps
Contents
1. 10 Translation of the original operation manual Extrusion Pump In this connection take care that the compressed air supply is interrupted e g by means of a compressed air stop valve An air maintenance unit or a compressed air regulator can be connected directly to the pump gt Connect a material hose or line to the material outlet of the extrusion pump gt optional version with high pressure filter fig 4 1 fig 4 1 gt Now fill Release agent into the adjusting cup The adjusting cup should be filled up to the half The Release agent is used for lubrication of the piston and to avoid hardening of the upper packing We recommend to use W WA Release Agent Order No 0163333 Fill the maintenance unit with pneumatic oil or anti freeze and take the setting as described in chapter 9 1 Maintenance on the maintenance unit This does not apply to machines delivered in a standard version with only a compressed air regulator Result Now the machine is ready for operation You can proceed with first cleaning Chapter 5 WIA EXP_BAoDB en 04 12 jw 5 Start up 5 1 Preparation Job You wish to erect the machine at the site and prepare it for operation Prerequisite The material to be worked is prepared All materials to be sprayed should be marked with informa tion on viscosity processing temperatures mixing propor tions etc If this is not the case please acquire this data from the r2. gt Keep pumping into an empty collecting vessel until clear material starts to run out optional version with high pressure filter Hold the drain hose into empty container and secu re it against slipping gt Open the drain valve on the high pressure filter gt Open the air tap lock Turn the air pressure regulator control knob clock wise until the pump slowly cycles gt As soon as coatings material comes out of the drain hose close the drain valve drain screw tightly For that pay attention to the following 1 Increase of the air pressure results in gt a higher material outlet pressure gt a higher material pumping capacity gt The maximum operating speed of the extrusion pump amounts to 30 double strokes per minute The slower the operating speed the lower the wear The required operating pressure is adjusted at the compressed air regulator gt When using a W WA air maintenance unit or a W WA compressed air regulator observe and adhere to the notes mentioned in Chapter 9 1 6 2 Interrupt the compressed air supply gt When using an extrusion gun press the trigger for a short while for pressure relieve Interruption of work 6 3 Cleaning Change of material Interrupt the compressed air supply When using an extrusion gun press the trigger for a short while for pressure relieve Job You wish to clean the extrusion pump before a longer standstill or before a change of materia
3. 9 Various brief instructions 9 1 Maintenance unit compressed air regulator Regulating the compressed air supply Increase the air pressure Turn spindle clockwise Reduce the air pressure Turn spindle anti clockwise Only for maintenance unit Lubricant or anti freeze agent Also check and if necessary top up the lubricant for the fan motor in the container of the service unit High humidity can cause icing of the motor Incase of icing use pure anti freeze agent Adjusting the fog oiler on the maintenance unit gt Allow the air motor to run slowly with an air inlet pres sure of approx 4 bar Inthe inspection glass of the fog oiler check whether one drop of lubricant is released into the compressed air with every 10 to 15 double strokes of the air motor Should this not be the case adjust the regulating screw on the lubricator accordingly Draining the condensation water Before each use and in case of high humidity also during operation drain of the accumulated condensa tion water through the drain valve 8 Only use the lubricants and anti freeze agents listed in the chapter 10 1 9 2 Follow plate Follow cover Problem definition Fitting a scoop piston pump with a follow plate follow cover Prerequisite The following is required gt 1 follow plate or follow cover gt 1 mounting kit for follow plate follow cover The use of a follow plate follow cover is highly application
4. specific The mounting kits must be ordered in compliance with the accessories used Please consult the 77 IA customer service or directly the 977 IA company to ask for the right selection and order number for follow plate follow cover and mounting kits WIVIA EXP_BAoDB en 04 12 jw Various brief instructions Procedure The scoop piston pump including accesso 1 ries must be switched off and depressurized before assembly disassembly Please follow the safety notes in chapter 2 Attach the follow plate Fig 9 2 3 and 9 2 4 respec tively the follow cover Fig 9 2 1 and 9 2 2 to the ram or directly to the extrusion pump Observe and adhere to the notes mentioned in Chapter 9 4 gt Connect the air hose of the ram to the hose spout Fig 9 2 1 to 9 2 4 Item 1 on the follow plate follow cover a fig 9 2 1 Follow cover large 200 Itr tank fig 9 2 2 Follow cover small 20 60 Itr tank ie fig 9 2 3 Follow plate large gt 200 Itr tank amp fig 9 2 4 Follow plate small 20 60 Itr tank for immersion into the material container Loosen the locking toggle Fig 9 2 1 to 9 2 4 Item 2 from the ventilating housing of the follow plate follow cover gt Insert the follow plate follow cover into the container together with the extrusion pump When doing this the air in the material container barrel is released through the opening Adhere
5. 10 1 12 Sean eee Tatlatla IOIC lIolc Fadfa 5 i OlOlOlOlOlololololololo welche opt cable glands r for connection of self 4 A ox regulating heating tape for connection from both ends of a resistance Sensor Heater Power Supply cable if voltage specification is different from 230V 2777 JA Translation of the original operation manual Extrusion Pump EXP_BAoDB en 04 12 jw 230V 10 50Hz if not otherwise stated 16A PT100 DIN 2 wire 3 C 15 C 0 100 C 0 250 C 150 400 C 30 60 C two limits controller 1 relay contacts HEATING ON Polycarbonate 130x130x75mm IP 66 520g 1x M12 2x M25 1xM25 1xM12 2xM20 17 Various brief instructions 9 4 Ram Single post ram press Operation Y VVVVY VY y Check if all accessories are correctly connected Set the compressed air control Fig 9 4 4 Item 3 on 2 bars Set the lever Fig 9 4 4 Item 1 on UP The extrusion pump is slowly lifted Place the material container barrel on the ram base Set the lever Fig 9 4 4 Item 1 on DOWN The extrusion pump is slowly lowered Pay attention that the container is placed in such a way that the sequence plate can be moved into the container Screw the locking toggle Fig 9 2 1 9 2 2 Item 2 and Fig 8 2 3 8 2 4 Item 2 off the sequence plate sequence cover to let the air go out Screw the locking toggle Fig 9 2 1 9 2 2 Item 2 and Fig 8 2 3 8 2 4 Item
6. MEDO CION aesa ae ne te eters eer en 13 WIWA Wilhelm Wagner GmbH amp Co KG 7 2 Maintenance plan ios ce nace awed ecee oven eartbececbatuceacstaess 13 8 Disturbances during operation and trouble 110 0 1 0 orssed aaa aaa ian 14 Copyright 9 Various brief inStructiOns cseccsseeesseeeees 15 2009 WIWA 9 1 Maintenance unit compressed air regulator 15 Cepyrignt ownerchipteriieaisermanualromsinawith 9 2 Follow plate Follow COVE soe ceeeeeeeeeeeeeneeteeteneeteetens 15 WIWA WILHELM WAGNER GmbH amp Co KG 9 3 Version with thermostat optional 08 17 GewerbestraBe 1 3 35633 Lahnau Ea 9 4 Ram Single post ram press 18 Phone 49 0 6441 609 0 Fax 49 0 6441 609 50 Eae 9 5 High pressuter Olidiana 19 l l l 10 APPEND saie 20 a cae ptr NR SEPT OE DEON IES 10 1 Technical Data and Order References 20 It is prohibited to pass on this operating manual for reproduction utili 10 2 Machine CMAN sect icsitcnsetocscetternrcicadebetantecsaerdetecsendes 21 sation or communication of its contents unless this has been explicitly permitted Infringements incur an obligation to pay damage compensati on 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 type plate data is identical
7. correspond to the material being sprayed gt be compatible with the spray tip used The mesh should always be a little finer that the bore of the tip being used Tip size mm from to M 200 white 0 23 009 i M 150 red 0 23 009 0 33 013 M 100 black 0 33 013 0 38 015 M70 yellow 0 38 015 0 66 026 Filter insert M50 orange 0 66 026 OOOO if working with heavily pigmented or fiber filled ma terials gt donot use a filter insert the standard suction sieve may need to be re placed with a sieve having a larger mesh size gt use a W WA reversible tip Translation of the original operation manual Extrusion Pump 19 Appendix 10 Appendix 10 1 Technical Data and Order Refer ences Max Max Version Order Number MADE ava Input Air Operating cles per per cy Pressure Pressure min l min cm3 bar bar 49 16 0642739 49 25 49 0642735 49 45 0642734 teat w osa e14 250 m s6 e 8 n2 osmos 0642455 60024 s0 24 1 196 eo 8 1e2 osaaa23 0642752 Machinery materials Release agent Best Nr 0163333 Plasticizer to fill into the release agent cup of the material Pneumatic oil 0 5 liter Best Nr 0632579 Pump 2 eee cai nti treezing agent est Nr 0631387 Materials required for cleaning and repair work see informa Securing material 50 ml Best Nr 000015 tion in spare parts lists Lubricant acid free grease Bes
8. for your 2 10 Transportation of the machine and additional country In Germany the Richtlinien fur Flussigkeitsst SOUS Mare aeiserca tise ried c srna aa 7 rahler Guidelines for liquid sprayers Published by 3 Machine description ssssesssseesssseseseseseees 9 Hauptverband der Gewerblichen Berufsgenossenschaften are valid 4 Erection and ASSCMDIY cccccssseeeeeeeeseeeeeseeneees 10 Manufacturer s notes and operating guidelines for coating j aa PEE E E E E ca E E EE A o and pumping materials should be observed at all times a ssem y Pe l l l l l 5 SRA UD sss ctsici peste cusscaenanemstoscteeusenescssmnedesnccamceemesecs 11 Since W WA extrusion pumps mainly with rams and lifts 5 4 ii i are installed in plants the operating instructions of such pad lan N E cane E E A E E eee ees devices and the accessories applied in this connection 52 FURS CIC ANN erse anaetenandeparsacantaanes 11 must also be observed and adhered to 6 Operation sosisini nidara 12 In principle no method of working should be exercised 6 1 Spraying pumping RVG VC Tal ie tomtracenneveacranseennenenee 12 which impairs the safety of WIWA products and the oper 6 2 Interruption Of WOTK edeceeearectannstexe uheercee cnderapsdeanaeds 12 ating personnel 6 3 Cleaning Change of material eee 12 We wish you much success and good working results for 7 Ham anangs and inspection ssssssssnnssnnnnnnnnnn 13 the application of your extrusion pump 7 1
9. to the notes mentioned in Chapter 9 4 Translation of the original operation manual Extrusion Pump 15 Various brief instructions gt Screw the locking toggle Fig 9 2 1 to 9 2 4 Item 2 back into the ventilating housing of the follow plate follow cover as soon as material protrudes from the Always switch off the unit before starting mainte Opening nance and repair work container barrel exchange Danger of burning Proceed as follows to move the extrusion pump out of an Depending on the temperature setting the tem empty container gt Make sure that the air hose has been properly con nected to the hose spout Fig 9 2 1 to 9 2 4 Item 1 on the follow plate follow cover gt Open the ball valve on the ram Chapter 8 3 and set the lever on the ram to UP Compressed air is blown A into the empty container barrel lifting the extrusion pump with the follow plate follow cover off the con tainer barrel gt Shut the ball valve on the ram Chapter 8 3 gt Exchange the container barrel damage to the unit jets directly towards the unit cleaning If required clean the outside of the follow plate follow cover Special notes for electrically heated follow plates Please comply with the following instructions 1 By using an electrically heated follow plate materials with high viscosity can be maintained flowable or heated up Heating is accomplished by a special heating element mounte
10. 2 back into the sequence plate sequence cover as soon as the material pro trudes Set the pressure on the requested operating pressure at the compressed air control Fig 9 4 4 Item 3 Switch off the compressed air supply when interrupting or stopping operation Exchange of the container gt gt gt gt 18 Open the ball tap Fig 9 4 4 Item 2 Set the compressed air on 2 bars at the compressed air control Fig 8 3 4 Item 3 Set the lever Fig 9 4 4 Item 1 on UP The extrusion pump is lifted Take off the container to the bottom detail fig 9 4 1 Ram wi with MAON plate 0 3 0 7 t B fig 9 4 2 ram press 0 3 t detail fig 9 4 3 Single post ram press 0 375 t fig 9 4 4 detail Translation of the original operation manual Extrusion Pump EXP_BAoDB en 04 12 jw WIA 9 5 High pressure filter Job Clean or replace the filter insert after shutting down the unit daily before every change of spray material if the pump does not cycle although the spray gun is triggered without tip or the drain valve drain screw for the high pressure filter is opened eyo y Prerequisite Required are gt An empty open container for the mixture of solvent spray material hereafter called container B gt 1 open end wrench Size 13 Warning If blockages occur residual pressure may still be in the system even after depressurizing Resi
11. AIFA because it works Operation manual VULKAN Extrusion Pumps Type O 49 Serial No Le DF C lt Translation of the original operation manual Extrusion pumps EXP DBK en 04 12 jw Contents 1 Contents 1 2 Table of Contents 1 1 Preface page 1 OOS NES sses o eanan 3 This User s Handbook must always be avail T Prof 3 1 able to operating staff Ee sara M nae Sanaa tesco E E A E TA The operating authority of the equipment must able of Contents ccecceeceeeeeeeeteeeeeteeeeeeneeeeaeees ensure that a user s handbook is available to 2 Safety Saane EEE EEE EEE EEETEELE EEE ERN Sa al the operator in a language which he under PA Description of symbols vcscsiisnivetereneictynacvecisnoedestnses 4 stands 2 2 Dangers arising from the equipment 08 4 2 3 Application of the machine cccccccseeeeeeeeeeeees 4 Dear customer 7 ee 2 4 Machine surroundings and Installation Site 5 et you for your decision to purchase a W WA equip 2 5 Sources of danger jchexarcncicsestesndatebnntieseaxtaesencaiaiesd 5 In the user s manual you can find all information required a Sede E EEA a for the proper handling of your WWA extrusion pump sadn a s 7 However for safe operation there are further essential 2 8 rotective equipment PEE kassereren settee details which you should adhere 2 9 Handling of the machine and auxiliary materials 7 Please read and observe the guidelines valid
12. If you use attachments and spare parts from another source W WA Cannot guarantee the safety of the entire system The guarantee is also not valid for damage or injury caused by such attachments and spare parts Emissions It is possible for solvent vapours to occur depending on the materials used Therefore please ensure the workplace is sufficiently ventilated in order to avoid damage to health and property Always observe the processing information given by the material manufacturer The sound pressure level of the equipment is below 80 db A Nevertheless appropriate noise protection means should be made available to the operating staff The op erator is responsible for compliance with the rules for the prevention of accidents for noise BGV B3 Therefore pay special attention to the environmental condi tions at the site e g noise can be increased if the machine is installed in or on hollow bodies Safety measures at installation site The system must have a fixed position and sufficient space to ensure safe operating The passage to the safety fittings must not be blocked gt Keep the working area especially all gangways and standing areas clean gt Ensure there is sufficient ventilation at the workplace to prevent damage to health and property Observe the manufacturer s processing instructions at all times gt The owner operator of this equipment is required to ensure that proper protection against lightning
13. and escape routes put up in your factory 2 8 Protective equipment All equipment is delivered with the following protective fitting Safety valve The safety valve prevents the maximum admissible air entry pressure being exceeded With the air pressure supply interrupted the pressure of the extrusion pump is released by shortly triggering the extrusion gun and or Opening the material outlet for a short time WIVA EXP_BAoDB en 04 12 jw Safety All protection devices must be checked Before each commissioning of the machine Before each start of machine operation gt After all aligning work After cleaning and servicing gt After maintenance and repair D If a protective device is not fully operative or 1 another defect is detected on the machine interrupt the compressed air supply to the ma chine immediately and open the drain valve The machine may be restarted only if perfect operation is restored 2 9 Handling of the machine and auxil lary materials Alignment servicing maintenance and repair of the machine gt Alignment when changing production as well as servic ing and cleaning may be carried out by trained operat ing personnel only Maintenance and repair may be carried out by trained qualified personnel only Before starting work the compressed air supply of the machine must be shut off Make sure that the machine is absolutely free from pressure For this hol
14. d inside the follow plate The temperature can be set by means of a thermostat optionally available The electrically heated follow plate is suitable for 216 5 drums The unit must not be operated in explosion en dangered environments materials can lead to explosion and thus cause severe injury to persons and material damage Please follow the processing instructions in the A data sheet provided by the material manufacturer especially the information concerning application temperature ignition temperature of the material Always make sure that the temperature of the material to be processed is lower than the ignition temperature specified by the manufacturer The electric connection must only be made by AN expert personnel with profound knowledge about electrical engineering Take note of the connected loads The connection must only be made with the unit switched off Heating solvent containing and easily inflammable 16 Translation of the original operation manual Extrusion Pump EXP_BA0DB en 04 12 jw peratures on the outside of the follow plate and on the drum may reach max 80 C You should therefore always wear protective gloves Any contact with solvents or water can cause Do not use any solvent containing materials for cleaning and do not direct high pressure or water Various brief instructions 9 3 Version with thermostat optional Electronic Temperature Controller Type ELTC 1 4 05
15. d the drain hose into an open container and open the drain valve In any case the function of all protective devices as well as perfect function of the machine must be checked after completion of the work Handling of auxiliary materials gt When handling the materials to be worked solvents oils greases and other chemical substances comply with the safety and dosing instructions of the manufac turer and the generally applicable prescriptions gt Remains of solvents oils greases and other chemical substances must be collected according to the legal prescriptions for recycling and waste disposal The local official laws for the protection of waste water must be observed Translation of the original operation manual Extrusion Pump T Safety 2 10 Transportation of the machine and gt Y Y Y VY VY VY additional equipment Interrupt the complete power supply of the machine even for short transport routes Before transportation empty the machine Pay attention when loading with our without hoisting devices When loading the machine with hoisting devices pay attention to sufficient load capacity Never stay under swivelling loads or in the loading area due to exposing your life to danger Only use suitable transportation vehicles with sufficient load capacity Secure the load on the transportation vehicle against slipping and falling down Parts or equipment dismounted for transportation purposes must be p
16. dual pressure can lead to serious injuries to the body or eyes Before starting any work on the high pressure filter the pump must be turned off Briefly trigger the spray gun To drain pressure open the drain valve screw on the high pressure filter Disassemble the high pressure filter very carefully Replace worn parts with new ones gt gt gt gt gt Procedure Hold the drain hose into container B Close the air tap lock for the pump To depressurize open the drain valve Fig e 9 5 1 pos fig 9 5 1 WIVIA EXP_BAoDB en 04 12 jw Various brief instructions Removing the filter insert Unscrew the cap Picture 9 5 1 pos 1 with the span ner Picture 9 5 1 pos 2 Unscrew the nut Picture 9 5 1 pos 3 with a fork wrench and remove the filter insert Picture 9 5 1 pos 4 Clean the filter insert Use only the appropriate solvent for the material being worked with Replace the filter insert should any sign of damage be present gt Replace the o ring Picture 9 5 1 pos 5 should any sign of leakage be present Mounting the filter insert gt Mount the high pressure filter in reserve order Instructions Before restarting the pump ensure that the unit is properly grounded amp R corrosion resistant RS stainless versions 1 Lightly grease all threads to ease assembly disassembly Filter insert selection The insert must gt
17. e to the notes of the operating instructions of the applied rams lifts Hold the material hose respectively extrusion gun if existing into the empty container Slowly open the compressed air stop valve of the equipment When using a W WA maintenance unit or a W WA compressed air control observe and adhere to the notes mentioned in Chapter 9 1 gt Pump solvent into the empty container until clean ma terial is protruding gt optional version with high pressure filter gt Remove the filter insert from the high pressure filter in accordance with chapter 9 5 Hold the drain hose Fig 5 1 Pos 2 into empty containe and secure it against slipping gt Open the relief tap on the high pressure filter Fig 5 1 Pos 1 gt Open the main air supply tap Fig 5 1 Adjust the air regulator to a maximum of 2 bar 30 psi by slowly turning the regulating screw to the right gt Allow the Wash Thinner soiled with the test me dium to run out of the relief hose into the empty open container for at least 10 seconds gt Close the relief tap Fig 5 1 Pos 1 1 y y y Recommended cleaning time T max 2 bar mind 10 Sekunden fig 5 1 Switch off the compressed air supply Open the drain valve for pressure relieve and let the protruding material flow into the container with the contaminated material If you do not use an extrusion gun connect the material hose to the device provided for this purpose
18. ed of the pump as well as the abrasive properties of the material will cause wear to the top packing in the high pressure head of the material pump chapter 3 WIVIA EXP_BAoDB en 04 12 jw Maintenance and inspection Undesired material leaks on the piston can thus lead to pump damage In order to prevent this from happening we recommend to check and if necessary readjust the packing at regular intervals gt during initial commissioning gt after the first 2 work days later 1 x per week Exact intervals must be matched to the prevailing condi tions of the application and should be determined as necessary In order to prevent dangerous physical injuries A caused by escaping material and crushing of limbs you should only replace the packing with the unit completely depressurized The higher the running speed of the pump and 1 the abrasive properties of the material the higher the re adjustment frequency For this purpose switch off the unit and relieve the pressure 4 The pump must be downward stroke Insert the attached stud driver into a free bore in the adjustment cup gt Turn the adjustment cup anti clockwise to loosen gt Turn the adjustment cup clockwise until slight resist ance can be felt Then turn 1 4 of a turn further Replace the complete packing if release agent comes out through the packing can be noticed by a permanent loss of release agent the packin
19. elevant manufacturer WWA offers a broad selection of accessories for the optimum processing of coating materials e g Follow plate Follow cover Ram Lift Air maintenance unit or compressed air regulator Non return valve Material hoses of various lengths and cross sections Extrusion gun Extrusion nozzles Collecting trays for condensed water VVVVVVVVVY For further accessories and more details do not hesitate to directly contact w a or the Wma Customer Service 5 2 First cleaning Job This machine was factory tested after assembly for per fect functioning with a test medium However the extrusion pump and or the entire system should first be flushed with solvent before spray operation begins so that the material to be sprayed is not affected by the test medium Prerequisite You will need gt open pail or barrel with a cleaning agent that is compatible with the material and that has been recom mended by the manufacturer gt empty open pail to hold the rest material which is in the extrusion pump The extrusion pump is properly installed in the plant all material and air connections are correctly established Procedure gt compressed air supply is shut off gt Move the extrusion pump into the solvent container WIVIA EXP_BAoDB en 04 12 jw Start up If using a follow plate or follow cover pay at tention to the notes mentioned in Chapter 9 2 Furthermore observe and adher
20. ely adhered to 2 2 Dangers arising from the equipment This machine was designed and built in accordance with all safety aspects It corresponds with the present stand ards of technical regulations and current rules for accident prevention It left the factory in perfect condition and war rants a high level of safety However the following dangers exist if operated wrongly or used inappropriately gt to life and limb of operator or third persons 4 Translation of the original operation manual Extrusion Pump for the machine and other property belonging to owner of machine for the efficient working of the machine All personnel involved in the starting operation and maintenance of the machine must read the following notes carefully and observe them It is a matter of their safety We recommend that the machine operation management have this confirmed in writing Additionally please pay attention to the following Manufacturer s notes and operating guidelines for coating material and pumping material should be observed at all times In principle no method of working should be exercised which impairs the safety of 77Mva products and the oper ating personnel The rules for the prevention of accidents Machining of coating materials Verarbeiten von Beschichtungsstoffen BGR 500 chap 2 29 as well as the directives for liquid jet systems ZH1 406 Richtlinien fur Flussigkeitsstrahler of the professional associa
21. for wall mounting 1 contactor Description The electronic temperature controller type ELTC is designed for use as an ambient thermostat or surface thermostat with remote sensor Cable glands and terminations are provided for the power connection The unit is supplied in a weather proof polycarbonate casing for wall mounting with a transparent ELTC O5 grey cover The controller should be protected from direct sunlight when used outdoors Function If the sensed temperature is lower than the adjusted set point the relay contact closes and the heating switches on The yellow LED glows while the contact is closed During sensor discontinuity or sensor short circuit the heating is switched off Installation as outside controller The sensor cable is to be shortened so that the sensor cover can be secured inside of the M12 cable gland There should be 15mm of the sensor cover exposed after securing the sensor into the gland Suggested setting for frost protection 3 C temperature ie S __eltherm ELTC PEE A O E IS TSO 197916 Green PT 100 Heizkreis Netz S 2J Technical Data Supply voltage switching capacity measuring input adjustment ranges ELTC 05 ELTC 1 ELTC 2 ELTC 3 ELTC 4 ambient temperature control characteristic Controller ouou ELTC 1 4 05 LED yellow Ses pa E t i ir material of case 1234 5678 9
22. g can no longer be adjusted there is no clearance between adjustment cup and high pressure head Translation of the original operation manual Extrusion Pump 13 Disturbances during operation and trouble shooting 8 Disturbances during operation and trouble shooting Extrusion pump does not start despite 1 Air stop valve is closed 1 Open the air stop valve having triggered extrusion gun or 2 Material outlet is clogged 2 Clean the material outlet opened material outlet 3 Defective air motor 3 Repair the air motor e Replace the air motor This work has to be carried out by trained personnel only Pay attention to the respective spare parts lists Extrusion pump is working regularly 1 Air pressure too low 1 Increase the air pressure however the required pressure is not 2 Material outlet too big e Check the air lines for correct reached 3 Nozzle too big when using an cross sections extrusion gun 2 Reduce material outlet 3 Insert a smaller nozzle Extrusion pump is working irregularly 1 Viscosity of the material to be 1 Increase the operating pressure does not reach the required pressure worked is too high of the ram does not stop even with closed extru 2 Leaky valves and packings e Use a bigger extrusion pump sion gun or closed material outlet e Eventually heat the material to be worked 2 Replace wear parts 14 Translation of the original operation manual Extrusion Pump 4277 AO EXP_BAoDB en 04 12 jw
23. l Prerequisite The solvent recommended by the material manufacturer is available Procedure Interrupt the compressed air supply Carry out pressure relieve of the extrusion pump gt Slowly lift the extrusion pump from the material con tainer gt Put the extrusion pump into the container filled with solvent gt Apply compressed air to the extrusion pump 2 bars are sufficient gt Put the material hose respectively the extrusion gun into the empty waste bin until clean solvent agent protrudes Clean all accessories with the solvent recommended by the material manufacturer Observe and adhere to the notes mentioned in the respective instructions y gt Switch off the compressed air supply l l P l gt Hold the extrusion gun over the surface to be coated gt optional version with high pressure filter gt Supply the scoop piston pump with compressed air Clean the filter insert or replace it if it is damaged again Place the cleaned or replacement filter insert into the high pressure filter according to Chapter 9 5 12 Translation of the original operation manual Extrusion Pump 2277 AO EXP_BAoDB en 04 12 jw 7 Maintenance and inspection 7 1 1 Inspection According to the rules for the prevention of acci dents Working with liquid jet systems Arbeiten mit Flussigkeitsstrahlern BGR 500 chap 2 36 the equipment must be checked and overhauled at regular intervals by a speciali
24. ly during operation the unit must be shut down immediately and w wa Customer Service contacted as soon as possible It must be ensured that the unit is grounded either sepa rately or together with the equipment it is mounted to maximum resistance 10 QO Other use is not in line with the regulations Before W WA equipment is used for other purposes or with other materials and therefore not according to the regulations permission should be obtained from the manu facturer as the guarantee is otherwise invalid The observation of technical documentation and compli ance with specified operation maintenance and starting guidelines are a component of the use in accordance with the regulations 2 4 Machine surroundings and Installa tion Site Rebuilds and changes For safety reasons it is not allowed to carry out rebuilds or changes without authorization Protective equipment must not be dismounted changed or neglected If using components which are not produced or delivered EXP_BAoDB en 04 12 jw Safety by W WA any warranty expires The machine may only be operated within the prescribed limits and machine parameters Danger caused by attachments and spare parts If you use original attachments and original spare parts from w Wwa Spray and Pump Systems the usability with Our equipment is guaranteed It is however essential that the safety regulations of the attachments and spare parts are observed
25. n dismantling the material hoses and extrusion gun especially Only conductive material hoses should be used All original WWA material hoses are conductive and compatible with our equipment The maximum admissible working pressure on the hoses must correspond to the maximum operating pressure of each airless machine Should the safety valve need replacing please see the enclosed machine card for its order number Take care that the safety valve corresponds with the maxi mum admissible air inlet pressure of the extrusion pump Never use other safety valves than w w original valves Never use this equipment outdoors during a thunderstorm During operation ensure that sufficient feed of material is available to the pump in order to avoid heating due to fric tion caused when the material pump runs dry Observe closely gt no empty feed containers may be present during operation the suction system may not be clogged buckled or defect in any other way if the unit stops processing material shut it down im mediately 6 Translation of the original operation manual Extrusion Pump The maximum operating pressures given by W WA are to be adhered to in principle for all 77Mva parts When using substances containing the following materials Trichlorofluormethane R 11 1 1 2 Trichlorine 1 1 2 2 Tetrachlorine 1 2 2 Fluorethane R 113 1 2 Difluorethane R 112 Tetrachloroethane Perchloroethylene Trichl
26. or to the equipment VV Result The extrusion pump is ready for operation Translation of the original operation manual Extrusion Pump 11 Operation 6 Operation 6 1 Job The material to be processed is to be applied to the sur face to be coated Spraying pumping material Prerequisite You will need gt open pail or barrel containing the material to be worked gt empty open pail to hold the rest material which is in the extrusion pump The extrusion pump is properly installed in the plant all material and air connections are correctly established Procedure gt compressed air supply is shut off gt optional version with high pressure filter Depressurize the system Open the relief tap on the high pressure filter Place a filter element according to Chapter 8 3 into the high pressure filter gt Move the extrusion pump into the material container If using a follow plate or follow cover pay at 1 tention to the notes mentioned in Chapter 9 2 Furthermore observe and adhere to the notes of the operating instructions of the applied rams lifts Hold the material hose respectively extrusion gun if existing into the empty container gt Slowly open the compressed air stop valve of the equipment gt When using a W WA maintenance unit or a WWA compressed air control observe and adhere to the notes mentioned in Chapter 9 1 gt Supply the scoop piston pump with compressed air again
27. oroethane Trichloroethylene Dichloromethane Methylenechloride other solvents with halogenated chlorohydrocarbon FCKW it is essential to use a rustproof extrusion pump as other wise dangerous chemical reactions are possible If you wish to work with the above solvents or with lacquers or paints or materials which contain them we recommend you to contact either W7A customer services or W WA directly VV VVVVVVY ignition sources are not allowed anywhere Q Smoking open flames or any other possible near the area of operation 2 6 Operating staff Authorised Operators People under the age of 16 should not operate this equip ment The management in charge of the operation of the ma chine must make the user s handbook available to the operator and must make sure that he has read and under stood it Only then may the system be put into operation We recommend the manager has this confirmed in writing The operator of the machine is obliged to report any changes in the machine which might affect its safety to the manager as he must ensure that the machine is functional The responsibilities for the different activities on the sys tem must be laid down clearly and adhered to No unclear competences may remain as these could endanger the safety of the users The operator must make sure that only authorised persons work on the machine He is responsible to third parties in the working vicinity of the system The ope
28. rator of the equipment is obliged to repeat instruc tions about dangers and safety measures at regular inter vals at least once a year for young persons twice a year TFA EXP_BAoDB en 04 12 jw Personal protective equipment We call to your attention that the valid guidelines 1 and requirements in accordance with work sur roundings mining closed areas etc must be adhered to absolutely Please wear the prescribed protective clothing at all times as solvent vapours and solvent splashes cannot be completely avoided 2 7 Behaviour in case of emergency A Leaks If leaks occur in the system it must be shut down immedi ately and the entire system de pressurised gt Cut off the compressed air supply gt Open the Drain Valve Replace defective parts immediately Injury gt Should an injury occur through contact with liquid spray we recommend a doctor is called immediately Inform the doctor of the material sprayed e g paint and the solvent thinner Have the product data sheet at hand address and telephone number of supplier or manufacturer name of material and material number gt Memorize the local emergency phone numbers In any case get familiar with the first aid measures The sound pressure level of the equipment is below 80 db A Nevertheless appropriate noise protection means should be made available to the operating staff Fires Read the instructions for fire alarm
29. roperly remounted according to ap plication by a specialist before start up Translation of the original operation manual Extrusion Pump EXP_BAoDB en 04 12 jw 3 Machine description Models Models 49 iio nee 134 269 13 269 27 269 36 521 14 521 19 680 14 269 62 521 32 521 40 680 24 680 30 Fig 3 1 Fig 3 2 Translation of the original operation manual Extrusion Pump EXP_BAoDB en 04 12 jw Machine description Pos Description Muffler Safety valve 3 Air inlet connection for air mainte nance unit compressed air regulator or compressed air stop valve 6 Adjustingcup oo Material outlet Connection for non return valve Pressure relief plug Connection for drain valve Material pump O Z o o Material pump Filling pipe Erection and Assembly 4 Erection and Assembly 4 1 Erection amp Extrusion pumps can be integrated in plants 1 inside or outside of production rooms Dimensions of the equipment are indicated in Chapter 9 1 The machine is to be set up securely on a level and solid surface All operating elements must be easily accessible In order that the necessary volume of air is guaranteed the compressor capacity must comply with the amount of air needed by the machine and the diameter of the air supply hoses must correspond to the joints Depending on the pump version supplied certain optional accessories may ha
30. rotection Due to the possibility that explosive gases and overspray may be created this unit is to be considered as Group II Equipment Catagory 2G The flash point for the materials being sprayed as well as the solvent being used must be above 200 C This cor responds to the temperature class T3 When operating this equipment the User s Handbook must be followed closely The required inspection and maintenance intervals must be adhered to strictly All information found on the unit s signs or plates must be adhered to and not exceeded Do not allow this unit to be overloaded It is the responsibility of the operator of this equipment to determine the explosion risk Zone determination accord ing to EC regulation 94 9 EC Appendix Il Nr 2 1 2 3 in the area of usage in accordance with local regulatory authority guidelines Furthermore it is the responsibility of the operator on sight to check and ensure that the technical specifica tions and markings according to ATEX are compliant with local requirements Please observe that some components have their own nameplate with separate markings according to ATEX The marking with the lowest rating for explosion protection becomes valid for the entire system If the intended application could lead to injury of personnel if this equipment malfunctions on sight precautions and preventive measures must be implemented If this equipment appears to be malfunctioning or behaving strange
31. st W M A Serv ice The equipment must be checked before the first start up after changes and repairs of equipment parts having an effect on safety after an interruption of operation of more than 6 months gt however at least every 12 months For equipment which has been taken out of operation the check can be postponed up to the next start up The results of the checks must be recorded in writing and kept until the next check The checking certificate or a copy of it must be available at the place where the equip ment is used 7 2 Maintenance plan Release agent control Before each start up check the level of the Release agent and if necessary refill release agent The adjusting cup should be filled up to the half Please proceed as follows Once the piston has reached top position switch off the unit Relieve the pressure from the complete unit Usea wire as dipstick and insert it carefully in a release agent filler opening in the adjustment cup to check the filling level Ifthe adjustment cup holds less than the specified mini mum quantity you must fill in release agent through the filler opening The filling quantity depends on the corresponding pump size With a maximum filling level the release agent will be visible at the bottom edge of the filler Openings Readjusting the top packing The prevailing local operating conditions for the pump Operating time running spe
32. strikes is available gt Comply strictly with the current rules for accident pre vention 2 5 Sources of danger Remember that wwa Extrusions Pumps works under extreme pressure procedures and that it can cause life endangering injuries if used inappropriately A Pay attention to the following notes For design reasons the danger of getting squashed or sheared in the material feed area of the pump and be Translation of the original operation manual Extrusion Pump 5 Safety tween the air motor and the material pump is very high Before working in such areas release the pressure from the extrusion pump by interrupting the compressed air supply Material hoses must conform with maximum working pressure whereby a safety factor must be included in the statement Do not repair defected material hoses Never try to seal leaks on joints and high pressure hoses with your hand or by binding the spot Should a leak occur the whole system are to be de pressurised immediately Defective parts are to be replaced If working with heated materials always wear the proper hand protection BURN DANGER Before maintenance and cleaning work at the equipment and jet system accessories take the pressure from the complete system The compressed air supply must be interrupted If the machine stops up pressure may still exist despite de pressurisation This must be kept in mind when carrying out repairs Special care must be taken whe
33. t Nr 000025 20 Translation of the original operation manual Extrusion Pump 2277 AO EXP_BAoDB en 04 12 jw Appendix Dimensions in mm Dimensions mensions O S FACATA TNES 642 385 1027 G I G Il 70 234 389 T a o ony orol e es 680 24 681 651 1332 Gi l Gi I 80 370 463 68024 6e1 651 1902 E This user s manual is valid only in connection with the following machine chart 10 2 Machine chart The machine chart includes all machine specifications and details which are important and relevant for safety exact designation and manufacturing data technical specification and limit values equipment and checking certificate data for purchase machine features machine components and accessories included in the supply with article and spare parts number VVVVY Please pay attention that the machine chart specification is in accordance with the machine label In case of any deviations or default of a label we would ask you to advise us without delay 339 A Translation of the original operation manual Extrusion Pump 21 EXP_BAoDB en 04 12 jw
34. tion must be complied with under all circumstances Liquid jet systems have to be checked for safe operation by a specialist upon require ment however at least every 12 months The results of such check must be recorded in writing We recommend to enclose all directives and rules for the prevention of accidents in the user s manual In case of injuries consult a physician or go to the next hospital without delay If paint material or solvent has gone into the skin the physician has to be informed about the type of paint material or the solvent applied Therefore always see to it that the product specification sheet with address and telephone number of the manufacturer is at your disposal 2 3 Application of the machine The extrusion pump is designed for pumping and applying non flowing coating materials such as grease adhesives sealing compounds mastic etc The extrusion pump is mounted mainly on a ram or a lift and installed in an exist ing plant or before a dosing unit Using this equipment in areas requiring protection from explosions is not valid for extrusion pumps with electrically heated follow plates Marking Ex Il 2G cT4 This equipment fulfills the explosion proof require ments found in the guideline 94 9 EC for the type of explosion equipment catagory and temperature class EXP_BAoDB en 04 12 jw found on the nameplate This equipment is able to be installed in areas requiring Zone explosion p
35. ve been unscrewed and packed ina separate card box e g Extrusion gun Air maintenance unit or Compressed air regulator Please add these parts in accordance with the dia gram of the machine enclosed in the user s handbook chapter 3 When using accessories observe and adhere to the respective operating instructions VVVYV y 4 2 Assembly Extrusion pumps are operating at high pressures gt Check all parts that can be turned nuts screws and hose couplings and tighten them to avoid material from passing through these connections and causing injuries Check the permissible maximum air pressure for the material hose and extrusion gun It must be greater than or equal to the maximum operational pressure for the system which is shown on the type plate on the extrusion pump or on the machine card chapter 10 3 gt Compare the maximum operating pressure of the safety valve with the information on the machine card chapter 10 3 or the type plate This information must correspond Prepare the plant where the extrusion pump shall be integrated w WA offers various rams and lifts for ap plication with the extrusion pump A w w follow plate or w wA follow cover can be attached to each device see Chapter 9 2 Observe and adhere to the corresponding operating instructions of these devices Install the extrusion pump into the existing plant Connect the extrusion pump to the compressed air supply VV
36. with the information 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 2777777 Translation of the original operation manual Extrusion Pump 3 EXP_BAoDB en 04 12 jw Safety 2 Safety 2 1 The signs and symbols used in this manual have the fol lowing meaning Description of symbols NOTE marks a section of text which is especially relevant to safety Special attention should be paid to this section and it s contents strictly observed WARNING marks a situation which could be dangerous If not observed death and very serious injuries can result DANGER OF EXPLOSION marks a situation where there is danger of explo sion Observation of this information is absolutely essential ELECTRICAL VOLTAGE marks a situation where there is a danger of explosion through an electrostatic charge Observation of this information is absolutely es sential HOT SURFACES marks a situation where there is danger of burns caused by hot surfaces Hot surfaces should not be touched unless wear ing protective gloves WEAR PROTECTIVE GLOVES Wear protective gloves with lower arm protection to avoid burn injuries The warnings must be adhered to USE EAR PLUGS For health reasons it is very important to pay at tention to this warning FIRST AID In case of injuries or accidents these instructions should be absolut
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