Operation manual Low pressure pumps
Contents
1. cconcconcconncnnnionnnnnncncninannns 13 6 2 Compact Instructions Conventional Spraying Method cce 14 6 3 Compact Instructions LP Pump as Transfer PUMP ccooooccccccnnccnncnnnncnnnnnns 14 7 Service Repair eacuniiccicicii oia 15 Copyright Mel TES escoria colision rica 15 O 2009 WIWA 7 2 Lubricating Fluid and PackingS ooocccccconccnc 15 Esp n ee 7 3 Maintaining the Air Maintenance Unlit 16 opyright ownership for this user manual remains with WIWA WILHELM WAGNER GmbH 4 Co KG 7 4 Material Filter o cocccoccccnconioniconconionncnnnononancns 17 GewerbestraBe 1 3 35633 Lahnau Phone 49 0 6441 609 0 Fax 49 0 6441 609 50 E mail info 8 Disturbances during operation and Troubles wiwa de Internet www wiwa de NOONG restantes 19 This operating manual is solely intended for personnel involved in prepa 9 Compact Instructions cooonncocnnncononcconananonananas 20 ration operation and servicing It is prohibited to pass on this operating manual for reproduction utili 9 1 Follower Plate Follower Cover ccccccsseseeeeee 20 sation or communication of its contents unless this has been explicitly 9 9 Ram Press Single Post Ram Press 91 permitted Infringements incur an obligation to pay damage compensati A N on All rights reserved in the event of registration of the patented design 10 A NAIK aacsiis aidien aaa 22 industrial design or registered design2. forog pac A otaoxit765 DAT NPTIA ota0xtt75 5 DAT NPT A 9 otaoxtte1s Da NPTIA o foros Da NPT 9 0120x7745 165 Mes Yana forzosas es 288 a way evi E 50 Tejas Janes ma Tener oio O fer fe fse AO A oroso Nns fot fas fes sss fern usao fewn foiso or JN one a cl co a kurz a a A nal ci kurz A a ln a pe lang kurz DA Direktansaugung direct intake Water Pumps Q zll 2 JE gt z t a O OIO ue NL N_ gt gt N Nr Nr N Nr Nr at xN NL eos gt wo laln s wo fw O alol lalo ININ gt 2 Rapid Pumps Sound pressure level emitted at the work place The sound pressure level emitted at the work place has been determined according to the following standard DIN EN ISO 3744 DIN EN 31200 DIN EN 31201 and DIN 45635 20 Running at idle L a4 84 dB Running with load Exa 80 dB 10 2 Machinery materials Lubricating fluid We recommend to use the WIWA lubricating fluid Pneumatic oil for air maintenance units WIWA Order No 0163333 0 5 liter The factory supplies pneumatic oil Mobilarma 524 WIWA Order No 0632579 0 5 liter Materials required for maintenance and repair e Securing material WIWA Order No 0000015 50ml Anti freezing agent for air maintenance units Acid free grease WIWA Order No 0000025 400g For optimum protection we recommend the WIWA a
3. oo 10 1 Technical specificatiOns ooonccccoconnoncononos 22 This operating manual only applies in conjunction with the machine card 10 2 Machinery materials 03 that was given to you with the user manual for your equipment Please oe i be es te oo check that the type plate data is identical with the information on the 10 3 Certificate of Training and Operation 24 machine card Please notify us immediately if there are discrepancies 10 4 Machine card and spare parts lists 24 if the user manual has been incorrectly compiled or if the type plate is missing HITA Translation of the original operation manual low pressure pumps 3 NDP_BAoDB en 01 10 ju Safety 2 Safety 2 1 The signs and symbols used in this manual have the following meaning Description of symbols STOP 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 or very serious injuries could result DANGER OF EXPLOSION marks a situation where there is danger of explosion Observation of this information is absolutely essential ELECTRICAL VOLTAGE marks a situation where there is a danger of explosion through an electostatic charge Observation ofthis information is absolutely essential USE EAR PLUGS For health reasons it is ver
4. 013 M 100 black from 0 33 mm 013 to 0 38 mm 015 M 70 yellow from 0 38 mm 015 to 0 66 mm 026 M 50 orange from 0 66 mm 026 No filter element should be used with coatings which have coarse pigments or are filled with fibers e The use of a spray gun with reversible tip is recommen ded e Upon each change of material the filter insert must be cleaned or replaced e Upon each initial operation the equipment must be flushed as directed in the section First Cleaning e Close air supply valve turn back air pressure regulator release trigger of spraygun and engage safety lock e Place suction hose or tube into container C e Open air supply valve and adjust air pressure regulator to 1 2 bar e Hold the drain hose in container B e Open drain valve until material comes out of hose e Unlock spraygun and spray onto inner wall of container B until the material to be sprayed appears e Release trigger of spraygun and engage safety lock e Clean the spraygun with the recommended solvent e Install tip and reversible adaptor as appropriate on spraygun e Adjust the air pressure regulator for the required opera ting pressure Attention Operating pressure Air inlet pressure x Pressure ratio e Unlock spraygun and spray Removing from Operation e Close air supply valve e Adjust operating pressure to O bar e Open pressure release valve and release residual pressure e Unlock spraygun and spray residua
5. 10 1 393 7A Translation of the original operation manual low pressure pumps 11 NDP_BAODB en 01 10 ju Installation Transportation 4 Installation Transportation Safety measures at installation site gt When installing WIWA Low Pressure Pumps into an existing system i e in a paint circulation system the instructions found in the system s instruction manual must be adhered to strictly There must be a clear path leading to all safety facili ties Keep the working area especially all gangways and standing areas clean Remove spilled paint or solvent immediately Ensure there is sufficient ventilation at the workplace to prevent damage to health and property Observe the manufacturer s processing instructions at all times The owner operator of this equipment is required to ensure that proper protection against lightning strikes is available Comply strictly with the current rules for accident pre vention Transportation of the machine and additional equipment gt gt gt 12 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 stand under suspended loads or in the loading area due to exposing your life to danger Only use suitable transportation veh
6. 19 picture 5 4 3 Clean the filter insert using the recommended solvent for the material Replace the filter insert if there are signs of damage Replace the O ring if there are signs of leakage gt Reassemble the material in the reverse order Note The postion numbers refer to the seperate spare pat lists For R and RD version high pressure filters To avoid seizing lightly grease the threads before assembly 4 ao A 18 Translation of the original operation manual low pressure pumps NDP_BAO0DB en 01 10 ju WIWA Disturbances during operation and Troubleshooting 8 Disturbances during operation and Troubleshooting Pump does not operate Pump operates smoothly but does not draw material Pump operates irregularly and looses performance Pump continues to operate although dispensing valve is closed The motor is icing rapidly WIWA NDP_BAODB en 01 10 ju 1 Air supply is interrupted 2 Fluid lines are clogged 3 Ball valves are clogged 4 Material filter is clogged 5 Air motor is defective Control system is blocked 1 Ball is stuck in inlet valve dried out material 2 The suction hose or tube is not attached tightly 3 The suction filter is clogged 4 The viscosity of the material is too high 1 The valves are clogged 2 The valves packings or piston are worn 3 Insufficient operating pressure 4 The viscosity of the material is too high 5 The sucti
7. Jain Gt G 355 estaxto9s fee Pee fe pee fer pope e pasm 42 256x1288 long eee ee ees ee 43 256x1288 long A a A 44 256x1288 long 600 03 N RS_ 3 1 600 le 24 aim at avd fot6oxo45 600 06 N RS 61 esoo a l s aru a1 600 12 was 12 1 600 a a4 farm Jars feim festaximo1____ eee ep ee 47 256x1288 long EE Ep E e A his fezes 48 256x1288 long ee ee Pe ee ese 256x1396 long MN 1060 1oszos was 51 ioso le Jao foro erez farm 7 1052 10 WRS_ 10 1 noso Je eo tero ar 1 0 o oo Io 266x301 22 Translation of the original operation manual low pressure pumps 477 FJA NDP_BAOoDB en 01 10 ju ab L V YN ab Soe Soe gt o I Equipment Type Max operating pressure gt an a Output per cycle cm3 fo amp iw gt lt o 2 U D gt Pump ratio Max Max tip size Material Inlet Air inlet Net weight kg ca Dimensions mm s O O 0 Q 5 A D 2 5 D A D Soe A O J Appendix Versions Available Output per cycle cm3 input air pressure Max operating pressure La La ke E La La i La Max tip size Material Inlet Air inlet Net weight kg ca Dimensions mm Equipment Type o 75 40 I AO es or 8 8 8 8 40 8 8 8 8 8 8 32 8 meso Jera Janer Jeizoaoo maeso 6 1 ener Jerzoxa9o res Jeri fenera
8. The checking certificate or a copy of it must be available at the place where the equip ment is used 7 2 Lubricating Fluid and Packings Adjuster cup For equipment with adjuster cup only Before each start up check the level of the lubricating liquid and if necessary refill lubricating liquid Cycle the pump until the piston is at the bottom of its stroke Fill the adjuster cup to just below the lip with lubricating fluid so that the piston is completely immersed Check lubricant once every 50 operating hours for discolouration with spraying material A change in color of the lubricating fluid indicates that the packings are leaking reducing the performance of the equipment When a change in color of the lubricating fluid is noti ced the packings may be adjusted for wear as follows Translation of the original operation manual low pressure pumps 15 Service Repair Packing adjustment does not apply to equipment with self adjusting Packings Before any adjustment of the packings first perform a pressure release of the equipment as follows e Turn back the pressure on the pressure regulator until the knob tap turns freely pressure gauge display O bar e Release trigger and engage safety lock of spraygun e Forversions with material filter only Openthe drain valve and release residual pressure into an empty container through the drain hose Stop the pump during the downstroke While the
9. material hoses and high pressure spray gun to ensure that no accidents occur due to residual pressure NDP_BAODB en 01 10 ju When working on the fluid filter for example to chan ge the filter the machine must first be turned off and depressurized Never remove the safety valve fitted and sealed on the operation side and never adjust its setting Should the safety valve need replacing please see the machine card for its order number Please ensure that new safety valves are set and sea led to the maximum permitted air inlet pressure for the WIWA Low Pressure Pumps see type plate machine card During operation ensure that sufficient feed of material is available to the pump in order to avoid heating due to friction caused when the material pump runs dry Observe closely no empty feed containers may be present during operation the suction system may not be clogged buckled or defect in any other way ifthe unit stops processing material shut it down immediately In closed or pressurised systems where aluminium or galvanised parts come into contact with the solvent dangerous chemical reactions can occur if 1 1 1 Tri chlorethylene Methylene Chloride or other solvents containing halogenated chlorinated hydrocarbons CFCs are used If you wish to work with the above solvents or with lacquers and paints which contain them we recommend you contact either WIWA custo mer services or WIWA d
10. open container C filled with the material to be processed Turn back the pressure on the pressure regulator until the knob tap turns freely Remove the filter element from the fluid filter as descri bed in Chap 5 4 Connect the inbound air supply hose Place the suction hose or pipe into container A Open the drain valve found on the fluid filter and hold the drain hose in container B Open the inbound air stop cock and set the air pressu re regulator at approx 2 bar Allow dirty solvent to flow into container B for at least 10 seconds using the drain hose Close the drain valve Release the spray gun safety and trigger Spray solvent against the inner wall of container B recommended 1 minute minimum 10 seconds maximum 5 minutes Remove suction hose or pipe from container A WIWA NDP_BAODB en 01 10 ju e Pump any remaining solvent out of the system e Turn back the inbound air pressure completely e Close the inbound air stop cock WIWA Operation 6 Operation 6 1 General Instructions gt All materials to be sprayed should be marked with in formation on viscosity processing temperatures mixing proportions etc If this is not the case please acquire this data from the relevant manufacturer The material to be sprayed must be slowly but tho roughly stirred before beginning work WIWA offers a broad selection of special attachments for the optimised preparation of spray
11. pump is stopped readjust the upper packing by using the supplied pin to tighten the adjuster cup as necessary gt Refill the adjuster cup with lubricating fluid If the lubricating fluid continues to become contamina ted by leaking material then the packings are worn and must be replaced p Fill Air motor lubricant Drain lubricant Fluid pump Picture 5 2 1 Filling and draining lubricate DA pumps 4 5 1 und 9 1 7 3 Maintaining the Air Maintenance Unit Only for equipment with air maintenance unit Oil and or anti freeze Check the amount of oil being added to the air entering the air motor located in the receptical found in the air maintenance unit Refill if necessary Fill and Drain Tubes Only for equipment with provisions to fill and drain the lubricating fluid Check the level of the lubricating fluid before each initial operation and add as necessary Check the lubricating fluid every 50 hours of operation for a color change due to contamination by material Upon aslight color change drain and refill the lubricating fluid The degree of color change can be checked by draining a small amount of lubricating fluid After checking add new fluid as necessary In the event of a strong change in color and large quantity of paint in the lubricant Clean the lubricant chamber change the upper pump pak king see list of spare parts for material pump and fill with new lubricant We recommend usin
12. pump mount or drum container e Mount components removed for transportation i e air maintenance unit pressure regulator fluid hose spray gun without tip including the grounding cable Warning All operating elements must be easily acces sible e The prescribed maximum operating pressure for WIWA elements is to be adhered to strictly i e pump safety valve fluid hose spray gun etc The data found on these items must equal or be higher that the values found on the type plate and machine card of the low pressure pump being used e Fill the unit with lubricant refer to Chap 5 2 Mainte nance Plan Warning Not applicable for Water Transfer Oil Trans fer and Rapid Low Pressure Pumps e Versions with air maintenance unit Fill pneumatic oil and antifreeze into the air maintenance unit and complete the proceedures described in Chap 5 3 Servicing the Air Maintenance Unit WIWA NDP_BAO0DB en 01 10 ju First Cleaning e Turn back the pressure on the pressure regulator until the knob tap turns freely e Connect the equipment to the local air supply system e Set equipment to draw flushing solvent ex place suc tion tube into solvent container e Open air supply valve and adjust air pressure regulator to max 2 bar e Flush equipment thoroughly e Remove equipment from solvent supply e Pump remaining solvent out of the system e Adjust air inlet pressure to O bar e Close air supply valve
13. 4 Generally Authorized Usage Low pressure pumps are designed to be used for paint supply in paint circulation systems and dispensing stations as well as for conventional paint spraying in trade and industry Depending upon the version low pressure pumps can be used to process lacquers and paints regardless of viscosity water lacquer solvent oil and grease strip ping agent mordant materials glue pasty materials jointing compound adhesive bitumen epoxy materials underseal roof coating and insulating materials sound insulation and other high viscosity materials with high solids contents m Depending on the material to be processed these pumps are designed with the corresponding packings and are available in carbon steel and stainless steel versions m Long version low pressure pumps can be used as immersion pumps m When being used in paint circulation systems constant delivery the pumps should not be run faster that 20 cycles per minute Your pump is especially designed to process the material you specify only Other usage is not in line with regulations Before WIWA equipment is used for other purposes or with other materials and therefore not according to the regulations permission should be obtained from the manufacturer as the guarantee is otherwise invalid The observation of technical documentation and the compliance with specified operational maintenance and starting guidelines are manditory in accorda
14. WIWA because it works Operation manual Low pressure pumps 150 sic SO p 402 600 702 ss 1092 sp X Low Pressure Pumps RN XK RX K BB p lt Pe 150 so X Water Pumps p lt X Oil Transfer Pumps X AO 82 X Transfer Pumps 2 1 4 1 4 5 1 6 1 7 1 9 1 10 1 Serial No X Rapid Pumps Xx NX NX RX ek BB p lt 100 Translation of the original operation manual low pressure pumps NDP DBK en 01 12 ju Contents 1 Contents 1 2 Table of contents 1 1 Preface 1 COMTOIUS ciaci n 3 O This User s Handbook must always be available 1 1 1 o A E EA 3 to operating staff 42 Tableof 3 The operating authority of the equipment must able Of contents ooocooccccccncncnononcnnnnncnnn cnn nn nano no canon ensure thata User s Handbookisavailabletothe 2 SL CU A EA In 4 operator in a language which he understands 2 1 Description Of SyYMDOIS ooccccoccnnccccnnccocnccnncnnnnnnnos 4 2 2 Warning instructions located on the machine 4 Dear customer 23 D sina f ih l 4 Thank you foryour decision to purchase WIA equipment angers arising ll e equIpMEnt sscsadisorinsin as Inthe User s Handbook you can find all information required 2 4 Generally Authorized USage stains sasancincssnoiarenessentoisuns 5 forthe proper handling of your HIIP A Low Pressure Pump 2 5 Machine surroundings sas ladera dad lechada ds 6 However for safe operation there are further essentia
15. anual low pressure pumps f Safety Although spraying fog is kept to a minimum when the BE rect pressure setting and proper method of opera A are observed the operating painter should wear a protective breathing mask Never use solvent or other materials which present a health hazard for cleaning skin Only suitable skin protective skin cleansing and skin care materials may be used 2 8 Behavior in case of emergency Leaks If leaks occur in the system it must be shut down immediately and the entire system depressurized Shut off the compressed air supply Drain the pressure from the entire system Replace defective parts immediately Injury Inthe event of injury go to a doctor and inform him of the material being processed as well as the solvent thinner used Be sure to obtain the safety data sheet containing supplier manufacturer s address telepho ne number material description and material number to present to the doctor Memorize where you can call for aid Memorize the local emergency phone numbers In any case become familiar with the first aid measu res vvyv Fires Read the instructions for fire alarm and escape routes put up in your factory Memorize the local emergency phone numbers Memorize the location and operation of fire alarms fire extinguishers and sprinkler installations gt gt 2 9 Protective equipment Safety valve The safety valve pre
16. cordance with all safety aspects It corresponds with the present standards of technical regulations and current rules for accident prevention It left the factory in perfect condition and ensures a high level of safety However the following dangers exist if operated incorrectly or used inappropriately E to life and limb of operator or third persons E for the machine and other property belonging to owner of machine E for the efficient working of the machine All personnel involved in the starting operation and mainte nance 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 Please read and observe the guidlines valid for your country In Germany the Richtlinien fur Flussigkeitsstrahler Guidelines for liquid sprayers Published by Hauptverband der Gewerblichen Berufsge nossenschaften Industrial Employer s Liability Insurance Associations are valid We recommend adding a copy of all guidelines and accident prevention regulations into the user s manual 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 WIWA products or the operating personnel NDP_BAOoDB en 01 10 ju 2
17. dd the Unit for Spraying Set equipment to draw material ex place suction tube into materialcontainer e Open air supply valve e Adjust air pressure regulator to give the required ope rating pressure Attention Operating pressure Air inlet pressure x Pressure ratio Removing from Operation e Turn back the pressure on the pressure regulator until the knob tap turns freely Pressure gauge display O bar e Close air supply valve Change of Material e Set equipment to draw flushing solvent e Open air supply valve e Adjust air pressure regulator to 1 2 bar e Flush equipment thoroughly until clean solvent ap pears e Adjust air pressure regulator to O bar e Close air supply valve WIWA NDP_BAODB en 01 10 ju Service Repair 7 Service Repair 7 1 Testing According to the rules for the prevention of accidents Working with liquid jet systems BGR 500 chapt 2 36 the equipment must be checked and overhauled at regular intervals by a specialist WIWA Service 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 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
18. 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 according to EC regulation 94 9 EC Appendix II 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 techni cal specifications 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 ap plication 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 A or behaving strangely during operation the unit must be shut down immediately and WIWA Cus tomer Service contacted as soon as possible It must be ensured that the unitis grounded either separately or together with the equipment it is mounted to maximum re sistance 10 0 picture 2 4 1 Grounding Equalizing Potential Fig 2 4 1 ground screw on the high pressure filter Translation of the original operation manual low pressure pumps 5 Safety 2 5 Machine surroundings Rebuild
19. g WIWA flushing agent order no 0163333 Further service instructions for the individual components can be found in the attachment to the appropriate spare parts list Air motor Fill lubricant Drain lubricant Fluid pump Picture 5 2 2 Filling and draining lubricate DA pumps 2 1 4 1 7 1 und 10 1 Setting the air maintenance unit oiler Allow the air motor to slowly cycle at about 4 bar 58 psi Looking at the oiler s sight glass check whether one drop of oil is added to inbound air every 10 to 15 cycles If necessary adjust the drop rate by turning the regulating screw with a screwdriver High humidty can lead to icing of the air motor E bs tie l gt if 9 b 4 9 tit Check the oil level in the reservoir daily The air E a ia maintenance unit may not be operated without oil The maximum oil level is marked with a line around the reservoir To fill the reservoir remove the filler screw or 16 Translation of the original operation manual low pressure pumps 477 FJA NDP_BAOoDB en 01 10 ju remove the reservoir and fill directly Only use the oil and anti freeze listed in Chapter 8 2 Service Repair Drain condensed water The collected condensation will be automatically drai ned by the drain valve Place the hose into an empty catch basin Check the reservoirs regularly for contamination and clean as necessary a Ma Fog Oiler Adjusting Screw Filler Screw J Re
20. icles with sufficient load capacity Secure the load on the transportation vehicle against slippage and tipping Parts or equipment dismounted for transportation purposes must be properly remounted according to application by a specialist before start up Translation of the original operation manual low pressure pumps 5 Initial operation and assembly 5 1 Assembly 5 2 Mount the unit as instructed on a ram lift pump mount or drum container Mount components removed for transportation i e air maintenance unit pressure regulator fluid hose spray gun without tip including the grounding cable Warning All operating elements must be easily acces sable Initial Operation The prescribed maximum operating pressure for WIWA elements is to be adhered to strictly i e pump safety valve fluid hose spray gun etc The data found on these items must equal or be higher that the values found on the type plate and machine card of the low pressure pump being used Fill the unit with lubricant refer to Chap 5 2 Mainte nance Plan Warning Not applicable for Water Transfer il Transfer and Rapid Low Pressure Pumps Versions with air maintenance unit Fill pneumatic oil and antifreeze into the air maintenance unit and complete the proceedures described in Chap 5 3 Servicing the Air Maintenance Unit 5 3 First Cleaning E 1 open container A with at least 5 Itr flushing agent m 1 empty open container B E 1
21. ing materials eg agitators in various sizes material pre warming containers in various sizes fluid heaters When using fluid heaters the entire system must first be allowed to cool down before being flushed with solvent DANGER OF EXPLOSION Observe the solvent s flash point Inspect all turnable parts nuts screws and hose connectons and pull on them tightly to ensure that no material could leak out of these fittings which could lead to injuries gt Ensure the seal of all system components After long periods of downtime make a test of all seals Always wear protective clothing and glasses as sol vent vapours and solvent spray cannot be completely avoided Do not use small necked containers Observe and follow the instructions for installing low pressure pumps in an existing system i e as feed pumps for a dual component system found in the system s instruction manual Translation of the original operation manual low pressure pumps 13 NDP_BAODB en 01 10 ju Operation 6 2 Compact Instructions Conventional Spraying Method Prepare the Unit for Spraying e Place a filter element into the fluid filter Warning The filter insert must correspond to the mate rial being sprayed as well as the spray gun being used The mesh size should be finer than the size of the tip bore being used Filter Insert Tip Bore M 200 white to 0 23 mm 009 M 150 red from 0 23mm 009 to 0 33 mm
22. irectly We call your attention to the fact that a series of low pressure pumps including versions which are rust and acid proof is available for such materials The maximum operating pressures given by us are to be adhered to in principle for all WIWA parts eg pump heater hoses gun safety valve The inbound air pressure must be clearly visible on a pressure gauge WIWA pumps equipped with either an air maintenance unit or pressure regulator come standard with a pressure gauge Smoking open flames or any other possible igni tion sources are not allowed anywhere near the area of operation WIA NDP_BAODB en 01 10 ju Safety If using your low pressure pump for conventional spraying please observe the following instructions Never point the spray gun towards yourself other peo ple or other living creatures Never hold your finger or hand in front of the gun and never reach into the spray The gun is to be secured and the safety device che cked during every interruption while working regard less how short Never spray solvents or materials containing solvents into a narrow necked can or barrels with bung hole DANGER OF EXPLOSION Please always use an open container Due to possible electro static charges it is imperative to ensure that the spraying gun has contact to the container walls when working with metal containers 2 7 Operating staff Authorised Operators People unde
23. l details 2 6 Sources of dang T ooonnnincococcccnnccnonananaannnnnnnnnnnnas 6 which you should adhere to 2 7 Operating Stallone at aie geet oie Steed 7 2 8 Behavior in case Of eMergenCy ooooocnccccicnncnonnnnns 8 Please read and O Ane the guidlines valid for your eon 2 9 Protective CQUIDIMOINE sisia 8 In Germany the l Richtlinien f r Fl ssigkeitsstrahler 2 10 Handling of the machine and auxiliary materials 9 Guidelines for fluid sprayers published by Hauptverband der Gewerblichen Berufsge 3 Machine description oommmomocccccccccononnnanaacccnnnnnnas 10 nossenschaften Industrial Employer s Liability Insurance 3 1 Low Pressure and Water Transfer Pumps 10 Association are valid 3 2 Low Pressure Water Transfer Pumps and o DASS oeeie tiara 11 Manufacturer s notes and operating guidelines for coating and pumping materials should be observed at all times 4 Installation Transportation sssseeseeeeees 12 No method of operation should be exercised which impairs 5 Initial operation and ASSEMDIY ccceeeeeeeeeees 12 the safety of WIA products and the operating personnel 5 1 Assembly o A E Ean Geen ek ae 12 5 2 Initial Operation sosa 12 We wish you much success and excellent working results 5 3 First Cleaning cccccconnncccconnnnnononnenonnnnnnnnonnnnnnnos 12 when appliying your 1471274 Low Pressure Pump f WIWA Wilhelm Wagner GmbH amp Co KG 6 a nn 13 6 1 General InstructiONS
24. l material into con tainer C e Remove and clean tip and reversible adaptor as ap propriate on spraygun Recommended Soak tip and reversible adaptor as appropriate in solvent e Remove suction hose or tube from container C and wipe off paint residue 14 Translation of the original operation manual low pressure pumps e Place suction hose or tube into container A e Open air supply valve e Adjust operating pressure to 1 2 bar e Unlock spraygun and operate trigger e Spray material onto inner walls of container until clean solvent appears e Release spraygun trigger and engage safety lock e Adjust operating pressure to O bar Release residual material and pressure through the drain hose e Remove filter insert from material filter and clean e Adjust operating pressure to 1 bar e Open drain valve and flush equipment for 10 seconds e Close drain valve e Adjust operating pressure to O bar e Close air supply valve e Open drain valve briefly Change of Material e Follow all steps in the section Removing from Operati on e Clean material filter as described in Chap 5 4 Ser vicing the High Pressure Filter 6 3 Compact Instructions LP Pump as Transfer Pump Requierments Follow all steps in the section Initial Operation e The material to be sprayed is onhand Aminimum of 5 liters of cleaning solvent is onhand Initial Operation e Mount the unit as instructed on a ram lift
25. lations for recycling and waste disposal The local official laws for the protection of waste water must be observed HITA Translation of the original operation manual low pressure pumps NDP_BAODB en 01 10 ju Safety Machine description 3 Machine description 3 1 Low Pressure and Water Transfer Pumps P a m LPP 150 short LPP 150 long LPP 375 new serial new serial available versions with self adjusting or manually adjustable packings Air Pressure Regulator with Pressure Gauge and Stop Cock Accessories Inbound Air Con nection bo Air Maintenance Unit Accessory Air Motor including Exhaust Muffler Lubrication Cup aterial Outlet M f Material Pump g Material Inlet h Foot Stand not part of the low pressure pump Standfuss gt 1 j nicht Bestandteil der Nieder AIERPUrapO Water Transfer Pump h LPP 150 LPP 402 old serial LPP 702 LPP 1052 10 Translation of the original operation manual low pressure pumps 4773273 NDP_BAODB en 01 10 ju Machine description 3 2 Low Pressure Water Transfer Pumps and DA pumps Pos description a Inbound Air Connection o farmor e EE e Ka Material Pump Co Mariane oT Sg long version short version Rapid 100 02 Rapid 100 02 Rapid 200 01 Rapid 200 01 Oil Transfer Pump g g DA 4 5 1 DA 2 1 DA 4 1 DA 9 1 DA 7 1 DA
26. lease Oil Reservoir To remove reservoir Press re lease downwards and turn reservoir counter U air maintenance unit with connection Ge 7 4 Material Filter Size Type 01 Always disconnect the power supply and drain any pressure before starting maintenance work on the material filter Clean the filter insert in the material filter daily or after every change of material Apply the drain tap often to avoid clogging of the draining system Pressure release Inthe conventional spray method stop spraying Release the trigger and engage the safety lock of the spraygun Adjust the air pressure regulator to O bar Close the air supply valve Hold the drain hose in an open empty container Open the pressure release valve on the material filter The material remaining in the equipment will drain into the empty container In the conventional spray method press the trigger of the spraygun again briefly VVVYV y WIWA NDP_BAODB en 01 10 ju clockwise i L Take care during as gt l Water drain sembly that the O ring Rpp Woy Drain Valve is seated properly in i the housing Hose air maintenance unit with connection 1 Replacement and cleaning of filter insert and O ring Unscrew the retaining nut with a 27mm wrench picture 5 4 1 Remove the spring and filter in
27. ly during work interruptions and at end of workday Replacement of container WIWA Open the ball valve picture 7 2 4 pos 2 Adjust the air pressure regulator Bild 7 2 4 Pos 3 to 2 bar Turn the lever picture 7 2 4 pos 1 to the UP posi tion The low pressure pump will be raised slowly Pull the container downwards and away to remove NDP_BAODB en 01 10 ju Compact Instructions lt Detail Follower Plate 0 7T im x 5 lt Detail Picture7 2 2 Ram Press 0 3T on Detait gt Picture 7 2 3 Single Post Ram Press 0 375T Picture 7 2 4 Detail Translation of the original operation manual low pressure pumps 21 Appendix 10 Appendix 10 1 Technical specifications 150 03 N RS 1 G 1 NPT A 1 120 x 699 5 1 short 120x1390 lang 150 03 5 N RS 28 G I 1 9 NPT A 120 x 700 short is Y 120 x 1330 long 150 05 N RS 5 1 40 16 I 1 3 NPT A 17 120 x 695 5 20 short 120 x 1390 long me epep e e a e es 17 5 120x1330 long wee pep e e e e paa 17 5 200 x 1425 long see epe e e e p pena 22 160 x 1425 long a ep e e e er PA 22 a 200 x 1425 long a a a A E 160x1523 5 long wee ep e e e a E 200x1523 5 long i ep a a E ni 200x1523 5 long 375 19 N 19 1 1375 8 152
28. nce with the valid regulations The following table specifies which low pressure pumps are applicable for various materials Type of pump Material to be processed Low Pressure Pump Series 150 375 402 600 702 1052 Series Rapid 200 100 Lacquer and Paint Water Lacquer Solvent Oil low viscosity materials Oil Transfer Pumps Series 40 82 Water Pumps Series 75 150 Transfer Pumps Series DA Oil and Grease Adhesive Glue Lacquer and Paint WIWA NDP_BAoDB en 01 10 ju Safety Using this equipment in areas requiring protection from explosions Only applies for low pressure pumps water pumps and the oil transfer pump 0623709 Ex ll 2G cT4 This equipment fulfills the explosion proof requirements found in the guideline 94 9 EC ATEX 95 for the type of explosion equipment catagory and temperature class found on the nameplate This equipment is able to be installed in areas requiring Zone explosion protection Due to the possibility that explosive gases and overspray may be created this unit is to be con sidered 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 corresponds to the temperature class T3 Marking 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
29. nti free zing agent WIWA Order No 0631387 0 5 liter 3937 7A Translation of the original operation manual low pressure pumps 23 NDP_BAODB en 01 10 ju Appendix 10 3 Certificate of Training and Operation This certificate corresponds to the EU guideline for working substances 85 655 EWG Paragraph Il Article 7 The owner of the following machine has trained the operating personnel Make Model Year of Construction Order Number The training was conducted by the following desi gnated person Foreman or responsible Superior Name Department The persons trained have read and understood the user s handbook for the above mentioned machine especially the chapter Safety and are certain that they can operate this machine safely Personnel Electric Electronics Date Name 24 Translation of the original operation manual low pressure pumps 10 4 Machine card and spare parts lists This user s manual is valid only in connection with the follo wing machine card The machine card includes all machine specifications and details which are important and relevant for safety e exact designation and manufacturing data e technical specification and limit values equipment and checking certificate e data for purchase e machine features machine components and accessories included in the supply with article and spare parts number Please pay attention that the machine chart specification is in acco
30. on filter or material filter is clogged 6 The air motor control system is defective 7 The equipment is overworked 1 The valves packings or piston are worn 1 The operating speed is too high 2 Air supply contains too much water 3 Difficult climatic conditions high hu midity or temperature near freezing Translation of the original operation manual low pressure pumps 1 Check air supply system 2 Clean or replace fluid lines 3 Disassemble and clean pump 4 Clean or replace material filter 5 Contact customer service 1 Lift the ball through the inlet valve Opening to free it 2 Tighten the suction hose or tube Reapply sealer as necessary 3 Clean the suction filter 4 Reduce the viscosity of the material ex add solvent heat or choose a higher performance pump 1 Clean the equipment soak parts in cleaning solvent 2 Replace the worn parts 3 Increase the air inlet pressure 4 Reduce the viscosity of the material ex add solvent heat or choose a higher performance pump 5 Clean the filters 6 Contact customer service 7 A higher performance pump must be used 1 Replace the worn parts 1 Reduce the air inlet pressure or choose a higher performance pump 2 Install air maintenance unit or em pty water separator more frequently 3 Fill oiler with antifreeze and adjust for one drop every 5 10 cycles 19 Compact Instructions 9 Compact Instructions 9 1 Follo
31. r is responsible for compliance with the rules covering the prevention of accidents due to noise VGB 121 Therefore pay special attention to the environmental conditions at the site e g noise can be increased if the machine is installed in or on hollow bodies Exact details regarding noise emission are mentioned in the Chapter 9 1 Technical specification 2 6 Sources of danger Observethatlow pressure pumps can cause life threatening injuries if used improperly Pay attention to the following notes 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 gun hose pressure filter pump etc are to be depressurized immediately 6 Translation of the original operation manual low pressure pumps Defective parts are to be replaced If working with heated materials always wear the pro per hand protection BURN DANGER Material hoses must conform to the prescribed maxi mum working pressure allowing for a suitable saftey factor Material hoses are never to be patched The entire system is to be depressurized before main tenance and cleaning work is carried out Interrupt the inbound air supply for the entire system Close the air stop cock It is possible for a static charge to occur due to the high flow speeds during the airless spraying procedure Static charges can lead to fire and explosions The equipment must the
32. r the age of 16 should not operate this equipment The management in charge of the operation of the machine must make the user s handbook available to the operator and must make sure that he has read and understood 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 machi ne 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 system must be laid down clearly and adhered to No unclear responsibilities 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 Personal protective equipment We call to your attention that the valid guidelines and requirements in accordance with work surroundings mining closed areas etc must be absolutely adhered to Always wear the prescribed protective clothing inclu ding glasses and gloves refer to the safety data sheet of the material being processed as solvent fumes and splashes can not be completely avoided The sound pressure level of the equipment is below 85 db A Nevertheless appropriate noise protection means O should be made available to the operating staff Translation of the original operation m
33. rdance with the nameplate label In case of any deviations or default of a label we would ask you to advise us without delay NDP_BAO0DB en 01 10 ju
34. re 7 1 1 Follower Cover large for 200L container dh Picture 7 1 2 Follower Cover small for 20 60L container Ss gt Picture 7 1 3 Follower Plate large for 200L container Picture 7 1 4 Follower Plate small for 20 60L container Translation of the original operation manual low pressure pumps 477 FJA NDP_BAO0DB en 01 10 ju 9 2 Ram Press Single Post Ram Press Operation Check for proper connection of all accessories Adjust the air pressure regulator picture 7 2 4 pos 3 to 2 bar Turn the lever picture 7 2 4 pos 1 to the UP posi tion The low pressure pump will be raised slowly Place the material container onto the bottom plate of the ram press Turn the lever picture 7 2 4 pos 1 to the DOWN position The low pressure pump will be lowered slowly Insure that the container is positioned to allow the follower plate to enter Loosen the T handle picture 7 1 1 pos 2 and picture 7 1 2 pos 2 in the bleed hole of the follower plate or follower cover to release the air in the container Tighten the T handle picture 7 1 1 pos 2 and picture 7 1 2 pos 2 in the bleed hole of the follower plate or follower cover as soon as material appears Adjust the air pressure regulator picture 7 2 4 pos 3 to the desired operating pressure Note Shut off air supp
35. refore always be appropriately grounded When using a WIWA Fluid Heater ensure to connect a grounding cable to the ground screw Picture 2 6 1 Picture 2 6 1 Never use this equipment outdoors during a thunders torm Transfer pumps that are not protected against explosi ons may not be used in workplaces which fall under the regulation covering explosion protection Pneumatically driven WIWA Low Pressure Pumps are not affected by this Should however additional electrically driven accesso ries be mounted to these machines such as agitators or heaters the regulation covering explosion prevention must be checked for compliance Electrical plugs for heaters agitators etc which are not protected against explosions may only be plugged into sockets located outside of areas that fall under the regulation covering explosion prevention even if the accessory being used is explosion protected Due to electrostatic charges only conductive mate rial hoses should be used All original WIWA material hoses are conductive and compatible with our equip ment The maximum admissible working pressure on the hoses must correspond to the maximum operating pressure of each airless machine Ifthe material being used clogs or clumps within the machine residual pressure may still exist despite de pressurization efforts This must be kept in mind when carrying out repairs Special care must be taken when dismantling the fluid filter
36. s and changes For safety reasons it is not allowed to carry out rebuilds or changes without authorization Protective equipment may not be dismounted modified or neglected If using components which are not produced or delivered by WIWA warranty coverage is negated as well as liability 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 WIWA Wilhelm Wagner GmbH amp Co KG the compatibility with our equipment is guaranteed lt is however essential that the safety regulations of the attachments and spare parts are observed You can find these safety regulations in the User s Handbook located with the spare parts lists If you use attachments and spare parts from another source WIWA cannot guarantee the safety of the entire system In this case our guarantee does notcover any 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 85 db A Nevertheless appropriate means of noise protection should be made available to the operating staff The operato
37. sert picture 5 4 2 Clean the filter insert using the recommended solvent for the material Replace the filter insert if there are signs of damage Replace the O ring if there are signs of leakage gt Reassemble the material in the reverse order For R and RD version high pressure filters To avoid seizing lightly grease the threads before assembly Translation of the original operation manual low pressure pumps 17 Service Repair Material Filter Size Il lll Type 11 Always disconnect the power supply and drain any pressure before starting maintenance work on the material filter Clean the filter insert in the material filter daily or after every change of material Apply the drain tap often to avoid clogging of the draining system Pressure release Inthe conventional spray method stop spraying Release the trigger and engage the safety lock of the spraygun Adjust the air pressure regulator to O bar Close the air supply valve Hold the drain hose in an open empty container Open the pressure release valve on the material filter The material remaining in the equipment will drain into the empty container In the conventional spray method press the trigger of the spraygun again briefly VVVYV y Replacement and cleaning of filter insert and O ring Unscrew the cap Pos 1 with the spanner Pos 2 Unscrew the nut Pos 20 with a fork wrench and remove the filter insert Pos
38. vents the maximum admissible entry air pressure being exceeded In the event that the fixed maximum entry air pressure setting is surpassed the safety valve will blow open Grounding cable In order to avoid an electrostatic charge from building the airless machine must be grounded to an electrically conductive object by using the grounding cable Versions with a fluid filter are already equipped with a groun ding cable Air Stop For conventional spraying always mount an inbound air stop cock if not already equipped to the air inlet found on the low pressure pumps This enables the pump to be shut off immediately Before commencing any work on the pump the pressure must be released to ensure that all residual pressure within the pump is eliminated All protection devices must be checked Before each commissioning of the machine Before beginning work on or with the machine After all aligning work After cleaning and servicing After maintenance and repair Check list for inspecting the protection features when the unit is in a depressurized state Inspect the safety valve leading or seal for damage Inspect the safety valve for visible damage Inspect the grounding cable for damage Inspect the grounding cable s connection to the unit and to the conductive object VVVYV gt Take care that sufficient information notes labels for fire gt Inspect the compressed air tap lock for perfect functio prevention are pro
39. vided ning Do not apply any other extinguishing agents than AN se which are prescribed by the manufacturer of the If a protective device is not fully operative or erials another defectis detected on the machine inter rupt the compressed air supply to the machine immediately and open the drain valve The machine may be restarted only if perfect operation is restored 8 Translation of the original operation manual low pressure pumps 4773373 NDP_BAOoDB en 01 10 ju 2 10 Handling of the machine and auxiliary materials Alignment servicing maintenance and repair of the machine Alignment when changing production as well as servicing and cleaning may be carried out by trained operating per sonnel only Maintenance and repair may be carried out by trained qua lified personnel only Before starting work the compressed air supply of the ma chine must be shut off Make sure that the machine is absolutely free from pressure 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 When handling auxillary materials such as paint solvents oils grease and other chemical substances comply with the safety and dosing instructions of the manufacturer and the generally applicable regulations Left over solvents oils grease and other chemical substan ces must be collected according to the legal regu
40. wer Plate Follower Cover Mount the follower plate picture 7 1 3 or 7 1 4 or follower cover picture 7 1 1 or 7 1 2 on the ram press or directly onto the low pressure pump following the instructions in Chap 7 2 Attach the ram press air hose to the connection Pos 1 on the follower plate follower cover Instructions for placement into container Loosen the T handle Pos 2 in the bleed hole of the follower plate or follower cover Guide the follower plate or follower cover together with the low pressure pump into the container following the instructions in Chap 7 2 The air in the container will escape through the bleed hole Tighten the T handle Pos 2 in the bleed hole of the follower plate or follower cover as soon as material appears at the bleed hole Instructions for replacement of container Proceed as follows to remove the low pressure pump from the container Insure that the air hose is properly connected Pos 1 to the follower plate or follower cover Open the ball valve on the ram press Chap 7 2 and place the lever in the UP position Compressed air will enter the container lifting the follower plate or follower cover out of the container together with the low pressure pump Close the ball valve on the ram press Chap 7 2 Replace the container with a new one Instructions for cleaning 20 Clean the external surfaces of the follower plate or follower cover only Pictu
41. y important to pay atten tion to this warning USE BREATHING PROTECTION For health reasons it is very important to pay atten tion to this warning HEALTH DANGER marks materials which are hazardous to your health Observation of this information is absolutely essential FIRST AID In case of injuries or accidents these instructions should be absolutely adhered to x 2 2 Warning instructions located on the machine Warning signs and symbols which have been placed on the machine are there to inform of possible dangers and must be observed Warning signs and symbols may not be removed from the machine Damaged and illegible warning signs and symbols are to be replaced immediately 4 Translation of the original operation manual low pressure pumps The following signs are located on the machine m Warning sign covering the grounding of the machine Only found on units having a fluid filter The propietor is required according to the German Accident Prevention Regulation Unfallverh tungs vorschrift BGR 500 Kap 2 25 to ensure that the machine is properly grounded Please observe our operation manual m Nameplate Please observe that the information located on the type plate corresponds to data found on the machine card We request immediate notification should there be any discrepancies or if the typeplate is missing 2 3 Dangers arising from the equipment This machine was designed and built in ac
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