WIWA Dual-Component Gel System
Contents
1. 2 2 1 Operating pressure A Components that do not comply with the maximum permissible operating pressure can burst and cause serious injury gt The specified maximum operating pressures must generally be com plied with for all components In case of varying operating pressures the lowest value is always the one to be taken as the maximum oper ating pressure for the entire machine Material hoses and hose assemblies must comply with the maximum working pressure including the required safety factor Material hoses must be leak tight and free of kinks signs of abrasion or bulges gt Hose connections must be tight 2 2 2 Risks caused by the injection pipe A A The material is discharged from the mixing unit under very high pressure Due to its cutting effect the spray jet can cause severe injuries by pene trating the skin or entering into the eyes gt Never point the mixing unit at yourself other people or animals gt Do not hold your fingers or hands in front of the mixing unit gt Do not reach with your hands into the material jet Unintentional material release from the mixing unit may cause personal injury or damage to property gt Every time you stop work always close all the levers on the mixing unit Before carrying out commissioning always check that the mixing unit is functioning correctly Original operating manual 14025 25015 1310 2KGel IG002 BAODB en2. No Designation Pressure gauge for metering pumps 2 Compressed air shut off valve the owner 3 Compressed air connection for compressed air supply provided by 4 Air pressure regulator for metering pumps 5 Compressed air connection for metering pumps 3 4 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski WIA Machine Description No Designation 6 Air pressure regulator for flushing pump 7 Compressed air connection for flushing pump 8 Pressure gauge for flushing pump 3 4 Mixing unit The dual component gel system is optionally available with a mixing unit There are three levers on the mixing unit that you can use to set the Inject Flush or Stop operating modes Designation INJECT STOP one hand lever Ball valve for FLUSHING A Ball valve for FLUSHING B Static mixer Fig 7 external mixer unit You can extend the lifetime of the ball valves on the mixing unit if you gt do not switch the levers over under pressure if you always push the levers to the end stop of the desired position e Operating modes Fig 10 Flush component A Open Fig 11 Flush component B Open Flush component B Closed Flush component A Closed Alternately open and close the flushing levers several times during f
3. ski 2 3 sata ATA 2 2 3 Risks caused by electrostatic charging A The high flow velocities associated with the injection method may cause electrostatic charging Static discharges can cause fire and explosion gt Make sure that the machine is earthed correctly Always use open containers that are electrically conductive Stand the containers on a grounded surface VV YV Never pump cleaning agent or materials that contain cleaning agent into cone top cans or drums with bungholes y When using metal containers always ensure that the mixing unit is in contact with the container wall Only use conductive material hoses All original material hoses from WIWA are conductive and perfectly adapted to our equipment A If the machine is contaminated by coating material during spraying the increase in the coating thickness can lead to static charging Static dis charges can cause fire and explosion Clean the machine from contamination due to coating material imme diately Carry out cleaning work outside areas subject to explosion hazards 2 2 4 Explosion protection A Machines that are designed without explosion protection must not be used in workshops that come under the explosion protection ordinance Explosion protected machines meet the explosion protection requirements of Directive 94 9 EC for the explosion group unit category and temperature class specified on the type plate
4. Original operating manual 14025 25015 5 4 1310 2KGel IG002 BAODB en ski Operation WIWA 5 4 Interruptions to work 1 moe Ca p 7 Set the one hand lever of the mixing unit to Stop The injection pumps are stationary Set the compressed air supply for the metering pumps all the way back Release the mixing unit from the packer nipple Hold the mixing unit laterally against the inner wall of a collecting vessel Relieve the material lines To do this briefly change positions of the one hand lever on the mixing unit between Inject and Stop Flush all the components that have come into contact with mixed mate rial as described in Chapter 5 3 1 Flushing the components that have come into contact with mixed material on page 5 4 Close the compressed air shut off valve When you restart work proceed as described in Chapter 5 2 Injecting on page 5 3 5 5 Pressure relief 1 2 End work as described in Chapter 5 4 Interruptions to work on page 5 5 Make sure that the compressed air shut off valve is closed and all air the pressure regulators have been regulated all the way back 3 Hold the mixing unit laterally against the inner wall of a collecting vessel Set the mixing unit s one hand lever to Stop and open the flushing ball valves to allow the material pressure to escape 5 6 Complete cleaning Complete cleaning of the machine is necessary gt gt g
5. WIA because it works Operating Manual WIWA Dual Component Gel System original Translation of the 1310 2KGel IG002 DB en ski O Suction system LL Lk ce wo Ww A E O O 4 L9 N 9 Version with O Hopper Factory No Type ope WIWA Contents Contents MONO WO o PAA AP wed eeececce 1 1 PAET ee SS eT oa 2 1 2 1 Explanation of SyMD0I aaa BAGA GAGA 2 1 2 2 Safety Note Sana AA NA A 2 3 2 2 1 Operating PrSSUle wisi aaa a AN kaaa 2 3 2 2 2 Risks caused by the injection pipe 0aassasasaaanananananaas 2 3 2 2 3 Risks caused by electrostatic charging 7 00072 aasusuwanaan 2 4 2 2 4 Explosion PrOleCtlON sce aaa asa AA aaa 2 4 22 8 Healhsksua Za aaah AA 2 5 2 3 Information signs on the MACHING eeeeeeeeeeeeeeeeeeeneeeeeeenaeeeeeee 2 5 2d Safety TOA Si aah NANANA AA 2 6 241 Safety NANG ia aan naam 2 7 2 4 2 Compressed air Shut Off valve umanaannwawananawannnawaannnuwannan 2 7 2 43 Groundibablg naaa a 2 7 2 5 Operating and maintenance personneL 3 ana anwwawanwwwannnnaawanaww aasawa 2 8 2 5 1 Machine owner s duties 00000200aaawsnanannanawanananannanasansannnanns 2 8 2 5 2 Personnel qualification sessies a 2 8 2 5 3 Authorized operating personnel eeeeeeeeeeeeeeeeeenteeeeeeeaees 2 8 2 5 4 Personal Protective Equipment 17masaawasanannnawanasannannanans 2 8 2 6 Notes OM Wia ve auc AA
6. NA AA 2 9 2 6 1 Conversions and alterations ccccccesceeceeeeeeeeeeeceeeeeestaeeeteneees 2 9 2 6 2 Spate pansinan edie shee Nha 2 9 2 6 3 IACCOSSOMOS akan Kaanak ALA 2 9 2 7 Emergency prone dures aaa ti era eee 2 10 2 74 Shutting down and depressurising the machine uss 2 10 P EE e E E naaa aha E 2 10 2o MMU OS n AA NAAN AA 2 10 3 Machine Description a aa 3 1 Sell Mendo USES a a aaa aa ANNA LIA a 3 1 3 2 Machine Structure ounsa a ia ae 3 1 3 2 1 Injection system with mounting kit for suction system 3 2 3 2 2 Injection system with mounting kit for hopper seses 3 3 3 3 Compressed air connection eceeeeeeeeeeeeeeeeeeeeteeeeeeeeeseeeeeesaaeeeeeeeee 3 4 Oe MEDO UN maa aa vn secu se tens anakan aa kana 3 5 Original operating manual 14025 25015 1310 2KGel IG002 BAoDB en ski Contents 4 Transportation installation and assembly seeecceseeeeeeeeeeeeeeeeees 4 1 AA TRAMSPOMAUOM maam haka ceria seach AA AA neers eee ea 4 1 4 2 Installation location mawananwwawawawnnnanawanaananasanasasanananasssassnnasssson 4 1 4 3 ASSEN DN yaman anga 4 2 4 3 1 Mounting the material hose and the mixing unit 4 3 4 3 2 Mounting the flushing agent hose 1 00070022000asusanasasuwwnnsas 4 4 4 3 3 Connecting the compressed air supply 027 0unannawaanawawannan 4 4 4 3 4 Grounding the machine c
7. and water management sectors We strongly recommend adding all relevant guidelines and accident preven tion instructions to this operating manual Moreover the manufacturer s instructions and guidelines for coating or feed er materials must be respected at all times However if you have any questions please do not hesitate to contact us Best wishes for good results with your dual component gel system from WIWA Wilhelm Wagner GmbH amp Co KG Copyright 2013 WIWA This User Guide remains the copyright of WIWA Wilhelm Wagner GmbH amp Co KG Gewerbestr 1 3 35633 Lahnau Germany Tel 49 6441 609 0 Fax 49 6441 609 50 E mail info wiwa de Internet www wiwa de This operating manual is solely intended for personnel involved in preparation operation and servic ing It is prohibited to pass on this operating manual for reproduction utilisation or communication of its contents unless this has been explicitly permitted Infringements incur an obligation to pay damage compensation All rights reserved in the event of registration of the patented design industrial design or registered design This operating manual only applies in conjunction with the machine card that was given to you with the user manual for your machine Please check that the data on the type plate match those on the machine card Please notify us immediately if there are discrepancies if the user manual has been incorrectly compiled or if the
8. assignment to avoid unde sirable material reactions that lead to damage to the system Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski 4 2 Transportation installation and assembly Wf SA 4 3 1 Mounting the material hose and the mixing unit A A If the machine was delivered with WIWA material hoses and a WIWA mixing unit observe and comply with the information in this chapter Components that do not comply with the maximum permitted operating pressure of the machine can burst and cause serious injury Check the maximum permitted operating pressure of the material hos es and the mixing unit before assembly This must be greater than or equal to the maximum operating pressure of the machine as specified on the type plate If the hose couplings are subjected to tensile load these assemblies may shear off Material escaping under high pressure can cause injuries and material damage If tensile loads on the hose couplings are to be expected e g when moving the mixing unit strain relief is needed 1 Connect the material hoses to the material wa outlet of the associated material pump ae see Fig 12 pe When assigning components pay atten tion to the colour markings 2 Connect the material hoses to the mixing unit see Fig 13 3 Mount the coupling piece see Fig 14 for the packers on the mixi
9. ccccceeeeseeeeeeeeeeeeaeeeeseeeeeaeeeteneees 4 4 5 Operation AKALANG AA 5 1 5 1 Commissioning the Machine ccccccceeeeeeeeeeeeeeeeeeeeeeeseeeeeseeeeeeeeees 5 1 5 1 1 Put the feed pump into Operation eeeneeeeeentteeeeeeeaees 5 2 5 1 2 Cleaning the Machine sisisi 5 2 5 1 3 Filling the system with processing material and bleeding it 5 2 Bi MOCUNG kaa maa NAA AABANG AN 5 3 6 3 Flushingim a AA Naa AE AG Nha 5 4 5 3 1 Flushing the components that have come into contact with mixed PIAS e K end ne E E EE E 5 4 5 3 2 Flushing the complete machine ssseeesssssssesrrresrrrrnesrrnrnenerennens 5 4 5 4 Interruptions to Work aaa 5 5 5 5 Pressure Tall TANA AA 5 5 5 6 Complete cleaning nana anan ah AA DA 5 5 5 7 Material CHANG Os na AA TA NAIA NGA AA 5 6 5 8 Decommissioned a aka A REENA TERRORE ERAE 5 7 5 9 Replacing the mounting kitS a esanasiinneesrrrernnrrrnrininnnsrnirnnennnnnesnnnnnnna 5 7 SAUR sa sso a AA AA AN 5 7 6 Maintenange a GAGA AGA 6 1 6 1 Regular INSPOCUONS cinsore i EREA 6 1 6 2 Maintenance plan NAIA NAAN 6 2 6 3 Flushing pump uma naasa a pa neti tives Apa 6 2 6 3 1 Check condition of release agent 2 umunannawannawwaannaana 6 2 6 3 2 Checking the release agent for material residue 6 2 6 4 Recommended operating materials 772000000snanasnannwaasanannwans 6 3 7 Remedying operating faults a 7 1 0 4 Original operating ma
10. 14025 has a free flow output of up to 141 min gt The 25015 has a free flow output of up to 141 min It is possibly to optionally fit each system type with a mounting kit either for suction systems or for filling hoppers Both mounting kits are interchangeable at any time Depending on the machine type a flushing pump is mounted on the frame Original operating manual 14025 25015 3 1 1310 2KGel IG002 BAODB en ski Machine Description WI WA a Material hoses are connected to the pumps material outlets as well as to the external mixing unit As standard all the machine s components are mounted on a common cart 3 2 1 Injection system with mounting kit for suction system Fig 3 Front and rear view 2 o Designation Cart Air supply system Air motor metering pump Ground cable Material pump for component B Material pump for component A Flushing pump optional INIO A OJN Material pressure display for component A CO Material pressure display for component B ah oO Flushing agent suction system with flushing pump version only paa para Suction system for component A ah NI Suction system for component B 3 2 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski NIYA Machine Description 3 2 2 Injection system with mounting kit for hopper TIN LE CI 901 NIT CC AA i Dar PER Fig
11. 4 Interruptions to work on page 5 5 2 Clean the machine as described in Chapter 5 6 Complete cleaning on page 5 5 5 9 Replacing the mounting kits A 5 10 Disposal Disassembling pressurized parts of the machine can cause severe injuries to the body and eyes To guarantee that the safety of the operating personnel is not jeopardized gt Modifications must only be carried out by trained personnel The machine must be decomissioned as described in Chapter 5 8 Decommissioning on page 5 7 At the end of use you must shut down and dismantle the machine and dis pose of it in accordance with legal regulations Clean the machine thoroughly of all material residues gt Dismantle the machine and separate all materials dispose of metal together with scrap metal plastic parts can be disposed of as domestic waste gt The residue of injection material cleaning agent oils greases and other chemical substances must be collected in accordance with statutory pro visions concerning recycling and disposal The official local waste water laws are valid 5 7 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski WIWA Maintenance 6 Maintenance A A If maintenance and repair work is carried out by persons who have not been trained for this work they endanger themselves and other people and impair the safety and reliability of the machine gt Maintenance a
12. 4 Front and rear view 2 o Designation Cart Compressed air regulator Ground cable Filling hopper for component A Filling hopper for component B Air motor metering pump Material pressure display for component B Material pressure display for component A Material pump for component B ATO DM N B OA BN gt O Material pump for component A Original operating manual 14025 25015 3 3 1310 2KGel IG002 BAODB en ski Machine Description 3 3 Compressed air connection WIWA Here you make the connection of the compressed air hose provided by the owner Using the compressed air shut off valve you open or close the compressed air supply for the entire machine There are separate air pressure regulators for the metering pumps and the flushing pump You can read off the pressure on the pressure gauges The functional principle of all the air pressure regulators that are installed on the machine is identical Dual component gel systems gt gt without a flushing pump are fitted with an air pressure regu lator at the factory Dual component gel systems with a flushing pump are fitted with an air supply system at the factory Turn the adjusting screw clockwise to increase the pressure o Turn the adjusting screw anti clockwise to die reduce Fig 3 1 the pressure Fig 6 Air supply system
13. 6441 609 0 Fax 49 6441 609 50 E Mail info wiwa de Homepage www wiwa de WIWA Partnership USA WIWA LP 107 N Main St P O Box 398 Alger OH 45812 Phone 1 419 757 0141 Fax 1 419 549 5173 Toll Free 1 855 757 0141 E Mail jwold wiwalp com Homepage www wiwalp com WIWA Subsidiary China WIWA Taicang Co Ltd Building A of Huaxin Industrial Park No 11 East Qingdao Road Taicang City Jiangsu Province 215400 P R China Phone 86 512 5354 8858 Fax 86 512 5354 8859 E Mail info wiwa china com Homepage www wiwa china com WIWA Middle East General Trading LLC Mohd Farhan Khan Jebel Ali Industrial 1 Dubai UAE Phone 9714 884 8220 E Mail middleeast wiwa com WISA because it works WIWA worldwide field service Wolfgang Pucken Sales Director Northern Germany from the river Main Israel Hungary Romania Turkey Poland Malta India Pakistan Africa Morocco FrankenstraBe 37 53359 Rheinbach Oberdrees Germany Mobil 49 173 5432559 Phone 49 2226 12708 Fax 49 2226 13973 Robert Jansen Senior Sales Director Finland Sweden Norway Denmark Great Britain Southern Ireland Scotland England Holland Belgium France Spain Portugal Italy Croatia Greece Czech Republic Slovakia Slovenia Luxembourg Bulgaria Egypt Libya United Arab Emirates Oman Dubai Abu Dhabi Qatar Bahrain Kuwait Saudi Arabia Iran Iraq Cyprus Iceland Syria Lebanon Support of WIWA sal
14. Indicates the requirement to wear ear defenders to prevent your hearing from being damaged by noise Use a respiratory protection mask Highlights the order to use a respiratory protection mask to prevent your respiratory tract from being damaged by gases fumes or dusts Wear protective gloves Highlights the order to wear protective gloves with lower arm protection to protect against burn injuries caused by heated materials Wear protective footwear Highlights the order to wear protective footwear to prevent injuries to the feet due to objects that may fall drop or roll around or to hot or caustic liquids Indicates references to guidelines work instructions and operating manu als that contain important information which you must observe at all times 2 2 Original operating manual 14025 25015 1310_2KGel_IG002_BAoDB_en ski Safety WIWA 2 2 Safety notes Please remember that the machine works at high pressure and may cause life threatening injuries if used inappropriately Always observe and follow all instructions in this operating manual and in the separate operating manuals of individual machine parts and or the optionally available accessory devices The accident prevention instructions Application of Coating Materials BGR 500 chap 2 29 and the guidelines for liquid jets ZH1 406 of the employer s liability insurance association must strictly be complied with
15. als being applied solvent vapours may result that can cause damage to health and property Always ensure sufficient aeration and ventilation at the workplace Always observe the processing instructions issued by the material manufacturers When cleaning your skin use only appropriate skin protection skin clean ing and skin care products In closed or pressurized systems dangerous chemical reactions may occur if parts made of aluminium or galvanized parts come into contact with 1 1 1 trichloroethane methylene chloride or other solvents containing halogenated hydrocarbons CFC s If you want to process materials containing the afore mentioned substances we recommend to consult the material manufacturer to clarify the usability of such substances For these materials we have available a range of rust and acid proof ma chines 2 3 Information signs on the machine Information signs attached to the machine like safety information refer to possible danger areas and must be strictly observed They must not be removed from the machine Damaged and illegible information signs must be replaced immediately Apart from this you should also read and follow the safety notes in the oper ating manual Original operating manual 14025 25015 2 5 1310 2KGel IG002 BAODB en ski Safety ITA 2 4 Safety features A If one of the safety features is missing or not fully functional the operating
16. and cause serious bodily injuries and material damage Immediately shut down the machine and depressurize it gt Retighten any screw fittings and replace defective components only by trained personnel gt Do not try to seal leaks on the connections and high pressure hoses with the hand or by wrapping fabric around them gt Do not repair material hoses Before recommissioning the machine check the hoses and screw fittings for leaks 2 7 3 Injuries If injured by processing materials or cleaning agents always have available the safety data sheet address phone number material designation and material number of the supplier or manufacturer for the attending physician 2 10 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski NIYA Machine Description 3 Machine Description The 14025 and 25015 Dual Component Gel Systems are pneumatically oper ated dual component high pressure injection systems The mixing ratio of these machines is fixed with the output being between 80 144 cm per dou ble stroke depending on the system type Metering pumps feed the compo nents to a mixing unit As an option the systems can be equipped with a flushing pump and or a mixing unit The flushing agent pump allows you to immediately flush all the components that have come into contact with the mixed material The mixing unit is an external one and is available with different coupling pieces for con
17. ase agent is visible in the filler neck approximately 1 cm below the filler opening The total filling capacity is approx 50 ml Fig 18 Fill release agent 6 3 2 Checking the release agent for material residue Regularly check the release agent for discol ouration caused by spraying material To do this drain a small amount of release agent at the drain screw see Fig 19 If the release agent is found to be contaminat ed with material residues you must assume that the packing of the material pump in ques tion is worn Fig 19 Draining off release agent In this case have the pump packing replaced as soon as possible After the examination top up an appropriate amount of clean release agent through the filler openings We recommend using release agent from WIWA order number 0163333 6 2 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski WIWA eee 6 4 Recommended operating materials Only user original operating materials from WIWA Operating materials WIWA order number Release agent 0 5 0163333 Release agent for isocyanate 0 5 0640651 Retention agent 50 ml 0000015 Lubricant acid free grease 0 4kg 0000025 Lubricant for stainless steel 0000233 Release agent is also available in large containers on request Original operating manual 14025 25015 6 3 1310 2KGel IG002 BAoDB en ski Remedying operating faults 7 R
18. ata You can find the technical data for your machine in the attached machine card on the type plate or in the documentation for the individual components Type 14025 25015 Flush pump Article No 0641976 643500 0647884 0652174 0652381 Pressure ratio 25 1 15 1 33 1 Max free flow output 14 25 3 0 l min Pump output per double 80 144 33 stroke cm3 Max air inlet pressure bar 8 8 8 safety valve Max permissible operating 200 120 264 pressure bar Air requirement 7 bar 480 480 100 air inlet pressure and 30 double stroke Max material temperature 80 80 80 C Dimensions LxW xH in 55 x50 x 100 68 x55 x 100 55 x50 x 100 30x18x59 mm approx without suction system Weight kg approx 47 47 54 50 50 8 Emitted sound pressure level at the work place was determined in accordance with the DIN EN ISO 3744 DIN EN 31200 DIN EN 31201 and DIN 45635 20 standards in idle mode L a4 dB 75 80 under load L dB 73 84 pAd 8 1 Machine card The machine card contains all important and safety relevant data and infor mation about the machine gt Exact designation and manufacturer data gt Technical data and limit values gt Equipment and test certificate Data of purchasing Machine identification machine components and supplied accessories with item numbers and spare part numbers 8 1 Original operating manua
19. ation or repair of parts of the system which could affect safety gt after work breaks longer than 6 months gt but at least every 12 months For decommissioned machines the inspection can be postponed until the next commissioning The inspection results must be recorded in writing and kept until the next in spection The inspection report or a copy of it must be available at the place of use of the machine Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski 6 1 Maintenance WIWA 6 2 Maintenance plan 1 The information in the maintenance plan is a recommendation The inter vals may vary in dependence on the condition of materials used and outer influences Interval Activity Before each start up Check the release agent level of the flushing pump see Chapter 6 3 Flushing pump on page 6 2 1 xper week Visual inspection of the compressed air and material hoses every 50 operating hours Check the release agent of the flushing pump for material residue see Chapter 6 3 Flushing pump on page 6 2 Every three years Inspection of the compressed air and material hoses by an expert and replacement if neces sary 6 3 Flushing pump 6 3 1 Check condition of release agent Before every commissioning procedure check the level of the release agent Screw the vent plug off the filler neck see Fig 18 At an optimum filling level the rele
20. ctive Equipment on page 2 8 The material to be processed must be available in sufficient quantity In addition you will need two suitable collecting vessels for excess materi al These containers are not included in the scope of delivery During commissioning check that the machine or its individual components are leak proof by slowly building up pressure Overview of the work sequence for commissioning 1 Put the feed pump into operation 2 Clean the machine 3 Fill the system with processing material and bleed it 5 1 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski WIWA mao 5 1 1 Put the feed pump into operation o The flushing pump should always be ready for use while the system is 1 being used so that all components coming into contact with the mixed material can be flushed within the pot life specified You require gt an open container of the cleaning agent that is needed for the material to be processed and that the material manufacturer recommends gt an additional collecting vessel for the cleaning agent that is flushed out These containers are not supplied 1 Set the mixing unit s one hand lever to Stop and connect the flushing ball valves on the mixing unit Make sure that all air pressure regulators have been fully regulated back Place the suction pipe of the flushing pump into the cleaning agent drum Open the compressed air shut off valve p
21. e as possible to avoid endangering the safety of the operating personnel and the masonry Now slowly increase the pressure to the desired operating pressure Set the one hand lever of the mixing unit to Stop after the injection procedure is completed While carrying out injection keep an eye on the fill level of the material container Topping up material in good time means that you can avoid the pumps sucking in air which would make it necessary to bleed the system 7 8 Within the potlife of the material used change to the next packer and repeat steps 3 5 in this chapter Immediately after completing the last injection flush the mixing block until clean cleaning agent is discharged Always consider the potlife of the material used 5 3 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski WIWA ee Checking the injection pressure Check the function of both metering pumps by repeatedly opening and clos ing the one hand lever on the injection lance When doing this pay attention to the material pressure display Both pressure gauges must always show approximately the same values If you close the one hand lever during injection both material pressure gauges will show the same dynamic pressure When you open the one hand lever again the values must return to the oper ating pressure Fig 17 Material pressure display If this is not the case immediat
22. eady operated please observe the following gt gt Disconnect the entire system power supply even for short transporta tion distances Empty the machine before transportation fluid residues may escape during transportation despite this measure Remove all loose components e g tools from the machine Assemble the parts or fittings dismantled for transport purposes before start up and in compliance with the intended use of the system 4 2 Installation location The machine can be installed indoors and out of doors However outdoor installation should be preferred in order to avoid contamination Set the machine up horizontally on a foundation that is flat firm and vibra j tion free The machine must not be tipped or on an incline Ensure that all the operating elements and safety features are easy to reach 4 1 Original operating manual 14025 25015 1310_2KGel_IG002_BAoDB_en ski WIWA AN 4 3 Assembly A 1 Transportation installation and assembly If the machine is used outside during a thunderstorm a lightning strike can cause a life threatening situation for the operating personnel gt Do not operate a machine out of doors during a thunderstorm gt The machine owner must ensure that the machine is equipped with suitable lightning protection equipment Safety measures at the place of installation This machine requires a solid base and sufficient free
23. ely decommission the system and check the machine or contact WIWA s customer service 5 3 Flushing Always carry out flushing within the potlife of the material you are using as 1 specified by the manufacturer 5 3 1 Flushing the components that have come into contact with mixed material When interrupting work flush all the components that have come into con tact with the mixed material within the potlife specified by the manufacturer 1 Hold the mixing unit with the material being released towards the inner wall of the collecting vessel 2 Set the mixing unit s one hand lever to Stop 3 Alternately open the flushing ball valves on the mixing unit until clean flushing agent is discharged 4 Close the flushing ball valves on the mixing unit as soon as enough clean flushing agent has been discharged The flushing agent pump is stationary 5 3 2 Flushing the complete machine Flushing the complete machine is necessary gt At initial commissioning To ensure that the spraying material is not negatively affected by the test medium that was used at the factory to test that the machine was func tioning perfectly you must flush the machine with cleaning agent gt When changing material If work is interrupted and at decommissioning in the case of an interrup tion in spraying to flush spraying material out before it sets To do this proceed as described in Chapter 5 6 Complete cleaning on page 5 5
24. emedying operating faults WIWA Fault Possible cause Remedy 1 Pump does not start even though the mixing unit has been operated gt Compressed air shut off valve closed Open the compressed air shut off valve gt Air motor does not start or stops Press in the bolt on the air motor using a small screw driver Fig 20 Use only clean air Air motor defective Repair the air motor by following the spare parts list and the repair instructions if necessary call customer service for assistance 2 The pump is running but no injection material is being pumped to the mixing unit s outlet Suction hose clogged Replace the hose gt The mixing unit s one hand lever is in the Stop position Set the one hand lever of the mixing unit to Inject gt Ball of bottom valve does not lift off stuck Gently knock the bottom valve from the side ham mer Unscrew the suction system and loosen the ball of the bottom valve from below with a pin or a screwdriver gt The bottom valve does not close Unscrew the bottom valve thoroughly clean ball and seat 3 The pump delivers material but does not stop when the mixing unit is closed gt Packing or valve worn Replace parts 4 The pump runs uniformly but the required injection pressure is not reached gt The air pressure is too low or there is not enoug
25. es directors representatives and distributors in South America except Cuba and Mexico South East Asia Japan South Korea Australia and New Zealand Hoekstraat 57 3751 AL Spakenburg The Netherlands Mobil 31 6 18 88 40 97 Phone 31 3 34 94 69 81 Fax 31 3 34 94 75 83 E Mail rob wiwa gmail com Otto Dietrich Sales Director Russia Ukraine Belarus Moldavia Baltic States Lithuania Latvia Estonia Caucasian countries Armenia Azerbaijan Georgia Asian countries Kazakhstan Uzbekistan Turkmenistan Kyrgyzstan Tajikistan Lindenhof 6 56154 Boppard Germany Mobil 49 160 1574385 Phone 49 6742 899336 Fax 49 6742 899337 E Mail o dietrich wiwa de Michel Laksander Technical Sales Director France 2 Bis rue de leglise F 02240 Brissy Hamegicourt France Phone 33 32 36 21 120 Mobil 33 63 70 19 297 E Mail laksander orange fr JK Tan Sales Director Korea Japan Australia South East Asia Mobil 6012 223 7706 Phone Fax 603 8024 7706 E Mail jktan wiwa com
26. etering pump gt on the air motor of the flushing pump A If the maximum permissible air inlet pressure is exceeded components may burst This may result in damage to persons and property gt Never allow the machine to run without a safety valve or with a defec tive one Ifthe safety valve needs to be replaced you can find the correspond ing order number on the machine card With new safety valves ensure that they have been set to the max imum permissible air inlet pressure of the machine see type plate machine card and sealed with a lead seal 2 4 2 Compressed air shut off valve The compressed air shut off valve on the metering pump interrupts the air supply to the entire machine when closed this valve prevents the machine from starting up in an uncontrolled way Apart from this there is a compressed air shut off valve on the flushing pump that you can use to interrupt the compressed air supply to just this pump Principle of function Gum Close gt across the direction of flow gt Open gt in the direction of flow see Fig 1 closed Fig 1 Compressed air shut off valve OPEN The functional principle of all the air pressure regulators that are installed on the machine is identical o After the air supply has been cut off the machine is still under pressure j Before starting maintenance and repair work this means that you mu
27. gnore the safety notes there is a high risk of severe injury resulting up to and including death Indicates danger of accidents if you ignore the safety notes severe injury can result up to and including death Indicates danger of accidents if you ignore the safety notes severe injury can result Indicates important information on correct use of the machine Ignoring it can result in damage to the machine or in its vicinity Original operating manual 14025 25015 1310_2KGel_IG002_BAoDB_en ski 2 1 Safety gt gt BBBBBB y ATA In the safety notes about the risk of accidents different pictograms are shown after each hazard source examples General accident risk Risk of explosion from explosive atmosphere Risk of explosion from explosive substances Danger of injury due to electric voltage or electrostatic charging Risk of crushing by moving machine parts Risk of burning due to hot surfaces Mandatory safety instructions concern protective gear to be worn in the first instance They are particularly highlighted and marked as follows Wear protective clothing Highlights the order to wear the prescribed protective clothing to protect against skin injuries caused by spraying material or gases Use eye protection Indicates the requirement to wear protective goggles to protect against eye injuries caused by gases fumes or dust Wear ear defenders
28. h air Increase the air pressure on the pneumatic regulator or check the air line for correct cross section Air motor iced runs to slowly If possible reduce the air inlet pressure Install a maintenance unit with oiler if one is not yet present Fill the oiler with anti freeze agent eth ylene glycol and adjust as instructed in the operating manual Reference value 1 drop per approx 10m dou ble strokes 7 1 Original operating manual 14025 25015 1310_2KGel_IG002_BAoDB_en ski NIT WA Remedying operating faults Fault Possible cause Remedy 5 The pump runs irregularly The suction system is The seals on all the screw this can be noticed by dif leaking fittings of the suction pipe ferences in the up and down gt The bottom valve is leaking gt Unscrew the bottom valve stroke speeds and does not pump only stops in upward thoroughly clean ball and reach the required injection stroke when the mixing unit seat if necessary replace pressure is closed ball or valve seat Piston valve leaking pump gt Clean ball and valve in the only stops in downward double piston replace ball stroke when the mixing unit and valve seat as neces is closed sary gt Bottom or top packing leak gt Replace the packing ing wear Original operating manual 14025 25015 7 2 1310 2KGel IG002 BAODB en ski Technical data NT WA 8 Technical d
29. itions at the installation location the noise burden for example will increase if the system is installed in or on hollow bodies Wear a respiratory protection mask We strongly recommend that you wear a respiratory protection mask even though the paint mist has been minimized in the airless spray paint ing method given a correct pressure setting and correct working methods Wear protective gloves Always wear antistatic protective gloves to prevent your skin coming into direct contact with the material being processed When processing heated materials you must wear lower arm protection in addition to protective gloves to prevent burns Wear protective footwear Wear antistatic protective footwear to prevent injuries to the feet due to objects that may fall drop or roll around and to prevent slipping on a slip pery floor 2 6 Notes on warranty 2 6 1 Conversions and alterations 2 6 2 Spare parts 2 6 3 Accessories Unauthorized conversions or alterations should not be undertaken on safety grounds Protective equipment should not be dismantled converted or bypassed gt The machine must only be operated within the specified limiting values and machine parameters gt When carrying out maintenance and repair work you must only use WIWA original spare parts Use of components which have not been manufactured or delivered by WIWA renders any warranty null and void Using origi
30. l 14025 25015 1310 2KGel IG002 BAODB en ski WIWA 8 2 Type plate me The type plate is located on the metering pump s air motor It contains the most important technical data for the machine Technical data WIWA D 35633 Lahnau CE II 2G cl4 Crucklufthetriebene Kolbenpumpe Air operated piston pump Gerate Type Unit TG p OH Output p cycle Obers Verhal tnis Ratio Max Lufteingang Air Max Betriebsdruck Fluid Max Temperatur Serial no Model year 106 42 106 en 3 58 NGH 42 1 bar 115 PSI bar 4872 PSI TSE FE Fig 21 Example of a type plate Please check that the data on the type plate is identical to the specifica tions on the machine card Please notify us immediately in case of dis crepancies or if the type plate is missing Additionally some machine components have a separate type plate such as gt Flushing pump if present These type plates contain the technical data and serial numbers of the af fected components 8 3 Type designation e g 14025 14025 14 0 25 Model series Pumping Release Pressure ratio x 1 capacity location Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski WIWA Service 49 0 6441 609 140 Headquarters and production WIWA Wilhelm Wagner GmbH amp Co KG Gewerbestr 1 3 35633 Lahnau Germany Phone 49
31. l e N Set the air pressure regulator of the flushing pump to a low pressure such that the pump starts up slowly Regulate the flushing pump s run ning speed to about 15 double strokes per minute 6 As soon as you open the flushing ball valves on the mixing unit s mixing block the flushing pump starts working When flushing always aim the discharge outlet on the mixing unit s static il mixer into an empty container to be able to catch the mixture of material that is discharged 5 1 2 Cleaning the machine After assembly this machine was factory tested for flawless function using a test substance This means that at initial commissioning you must perform complete cleaning to flush out any test medium residue For more details refer to Chapter 5 6 Complete cleaning on page 5 5 5 1 3 Filling the system with processing material and bleeding it 1 Connect the material feed With metering pumps that are supplied with material via a suction system set the suction systems into the corresponding material containers of components A and B gt With metering pumps that are supplied with material via a filling hopper fill the material of components A and B into the corre sponding filling hopper and if necessary open the stop cocks on the material inlet of the metering pumps 2 Hold the mixing unit with the material being released towards the inner wall of the collecting vessel 3 Set the one hand lever of the mixi
32. lushing to ensure that each component is flushed separately Finally open both flushing levers Original operating manual 14025 25015 3 5 1310 2KGel IG002 BAoODB en ski Transportation installation and assembly INIT SA 4 Transportation installation and assembly The machine left the factory in flawless condition and was appropriately packed for transportation Check the machine on receipt for any damage in transit and for j completeness 4 1 Transportation Please follow these notes when transporting the machine gt gt gt Ensure sufficient load bearing capacity of lifting gear and lifting tackle when loading the machine You will find the dimensions and weights of the machine on the machine card Use only appropriate transport vehicles with sufficient load bearing capacity The machine must only be lifted by the lifting and lashing points provided for this purpose Never lift the machine using the eye hook that may be present on a mounted pump or another accessory These transportation aids are only rated for the mounted part and not for the entire weight of the machine including the attached parts Do not transport any other objects e g material drums while lifting or loading the machine Never stand under suspended loads or inside the loading area There is a risk of death Secure the load on the transport vehicle against slipping and falling off If the machine was alr
33. nal WIWA accessories guarantees that they are usable in our machines If you use third party accessories they must be suitable for the machine particularly with regard to the operating pressure the electrical connection data and the connection sizes WIWA accepts no liability for damage or injuries resulting from the use of these parts Original operating manual 14025 25015 1310_2KGel_IG002_BAoDB_en ski 2 9 Sate ATA You must observe the safety regulations of the accessories These safety regulations are found in the separate operating instructions for the accessories 2 7 Emergency procedures 2 7 1 Shutting down and depressurising the machine In an emergency immediately shut down the machine and depressurize it 1 Close the compressed air shut off valve 2 Operate the one hand lever on the mixing unit again for a moment to relieve any residual flushing pressure so that the pressure in the entire system has been relieved A The machine has not been flushed The material in the machine can hard en and clog it up This procedure is not suitable for decommissioning for more informa tion on this topic see Chapter 5 8 Decommissioning on page 5 7 gt After remedying the emergency you must flush the machine see Chapter 5 3 Flushing on page 5 4 Pay attention to the potlife of the material used 2 7 2 Leakages A In case of leakages material can escape under very high pressure
34. nd repair work on electrical components must only be carried out by trained electricians any other maintenance and repair work must be performed by WIWA customer service or by specially trained personnel Before maintenance and repair work 1 Inthe case of metering pumps that are supplied with material via filling hoppers you must pump out all of the material that is still in the filling hoppers 2 Cut off the compressed air supply 3 Completely depressurize the machine Despite releasing the pressure material congestion or agglomeration of material may mean that there are residual pressures still present These may suddenly release during disassembly work and can result in serious injuries gt You must be particularly careful during disassembly work gt When disconnecting material hoses you should cover the screw fitting with a cloth to catch any escaping material sprays Carry out maintenance work as described in Chapter 6 2 Maintenance plan on page 6 2 After completing maintenance and repair work check the func tion of all the safety features and that the machine is functioning correctly 6 1 Regular inspections 1 According to the accident prevention instructions for Work with fluid spraying equipment BGV D15 the machine must be inspected and ser viced regularly by a specialist The machine must be inspected gt before initial commissioning gt after the modific
35. ne A The high flow velocities associated with the Airless spraying method may cause electrostatic charging Static discharges can cause fire and explosion gt Make sure that the machine and the object to be coated are earthed correctly On delivery the ground cable is already connected to the machine To earth the machine connect the terminal of the ground cable to an electrically conductive object outside the area at risk from explosion Original operating manual 14025 25015 4 4 1310_2KGel_IG002_BAoDB_en ski Operation 5 Operation WIVVA Before starting work check if vl Are all the safety features present and fully functional gt Asafety valve gt Compressed air shut off valve gt Ground cable vl Are all machine parts tight If required tighten up these connections Observe the technical notes of the respective material manufacturer If material pumps run dry the generated friction heat can cause fire or an explosion gt Always make sure that the material drums do not run dry during operation gt However should this happen stop the corresponding pump immediately and feed material 5 1 Commissioning the machine Prerequisites The machine must have been set up correctly and completely assembled gt Do not start commissioning the machine unless you have the specified protective equipment For more details refer to Chapter 2 5 4 Personal Prote
36. necting the packer For details of you machine s technical data refer to the attached machine card and or Chapter 8 Technical data on page 8 1 3 1 Intended use The dual component gel system is intended for use in building refurbish ment including amongst other things for sealing cracks and applying mois ture barriers You can only use it to process water based acrylate gels and silicate injection materials Depending on customer requirements two versions are available gt Adual component gel system with a mounting kit for a suction system This machine is only suitable for processing low viscosity materials with components A and B having to have virtually the same viscosity gt Adual component gel system with a mounting kit for a filling hopper Using this machine it is possible to process high viscosity materials with different viscosities Any other use is considered to be unintended If you intend to use the machine for other purposes or with other materials and thus not for the purpose for which it is intended you must ask WIWA for permission oth erwise the warranty will be invalidated e Intended use also includes compliance with the technical documentation and adherence to the prescribed operating servicing and maintenance guidelines 3 2 Machine structure Two variants of the dual component gel system can be supplied that differ by virtue of their outputs gt The
37. ng hoppers Fill the cleaning agent associated with the material into each filling hopper 5 Open the compressed air shut off valve 6 Hold the mixing unit with the material being released towards the inner wall of the collecting vessel 7 Set the one hand lever of the mixing unit to Inject 8 Adjust a low air inlet pressure on the air pressure regulator for the meter ing pumps 9 Set the one hand lever of the mixing unit to Stop as soon as clean flushing agent is discharged 10 Set the compressed air supply for the metering pumps all the way back 11 Close the compressed air shut off valve 12 Relieve the material lines by briefly opening and closing the one hand lever on the mixing block 5 7 Material change 1 Flush the machine seesee Chapter 5 6 Complete cleaning on page 5 5 2 Recommission the machine When doing this observe and follow the in structions from Chapter 5 1 3 Filling the system with processing material and bleeding it on page 5 2 onwards Original operating manual 14025 25015 1310 2KGel IG002 BAoDB en ski 5 6 Operation WIWA 5 8 Decommissioning If there is a long interruption to work you must decommission the machine For exact information on how long the unmixed material can stay in the ma chine refer to the material manufacturer s recommendations When doing this proceed as follows 1 Interrupt your work as described in Chapter 5
38. ng unit s static mixer Choose the coupling piece to match the type of packer you are using Item 1 coupling G 1 4 Item 2 mouth piece M10x1 IG Item 3 slide coupling M10x1 Fig 14 Coupling pieces for packers 4 3 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski NIT WA Transportation installation and assembly 4 3 2 Mounting the flushing agent hose Depending on the type of machine the dual component gel system is fitted with a flushing agent pump 1 Mount the yellow flushing agent hose on the material outlet of the flushing pump see Fig 15 pump 2 Connect the other end of the hose to the manifold of the mixing unit see Fig 16 Fig 16 Connecting to the mixing unit 4 3 3 Connecting the compressed air supply The compressor capacity must match the air requirements of the machine and the diameters of the air supply hoses must match the connections such that an adequate air supply is ensured o Operation with contaminated or moist compressed air causes damage to j the machine s pneumatic system Use only dry dust and oil free air 1 Make sure that all the air pressure regulators have been turned all the way back the compressed air shut off valve is closed 2 Close the air hose on the compressed air connection of the air pressure regulator the air supply system 4 3 4 Grounding the machi
39. ng unit to Inject 4 Start up the injection pumps slowly To do this regulate the air inlet pres sure to about 1 2bar Original operating manual 14025 25015 5 2 1310_2KGel_IG002_BAoDB_en ski Operation 5 2 Injecting ATA As soon as mixed material components A and B is discharged from the mixing unit you have completed the filling and bleeding process Set the one hand lever of the mixing unit to Stop The metering pumps are stationary To test the material reactions fill a suitable vessel containing about 0 21 with the material to be processed To do this repeat steps 3 5 in this chapter Immediately flush the mixing block until clean cleaning agent is dis charged see Chapter 5 3 1 Flushing the components that have come into contact with mixed material on page 5 4 Before injecting you must have always commissioned the machine see Chapter 5 1 Commissioning the machine on page 5 1 The necessary packer nipples are attached in the location to be injected 1 2 Regulate the air pressure regulator on the metering pump all the way back Set the one hand lever of the mixing unit to Stop Connect the coupling piece on the mixing unit s material outlet to the packer nipple 4 Set the one hand lever of the mixing unit to Inject 5 Adjust a low air inlet pressure on the air pressure regulator for the meter 6 ing pumps Start injection at as low a pressur
40. nual 14025 25015 1310 2KGel IG002 BAODB en ski WIWA Contents 8 Technical data AA AA ANA aaa 8 1 8 1 Machine cardi anG NG GNG Ana NANG 8 1 8 2 Type plat iaon araa aa Aga AEEA TEE EE AAEE EEEE 8 2 8 3 Typedesighal0Na maa SEa AO 8 2 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski pier WISA 1 Foreword Dear Customer We are delighted that you have decided to purchase a dual component gel system from our company This operating manual is intended for the operating and maintenance per sonnel It contains all the information required to working with this machine The owner of the machine must ensure that operators and maintenance personnel always have an operating manual at their disposal in a lan guage that they understand e Safe and reliable operation of the machine requires further information in addition to this operating manual You should have read and understood the guidelines and accident prevention regulations that apply in your country In Germany these are as follows ZH 1 406 Richtlinien f r Fl ssigkeitsstrahler Guidelines for Liquid Jets published by the German Hauptverband der Gewerblichen Berufsgenossenschaften gt BGR 500 Chapter 2 29 Application of Coating Materials gt BGR 500 chapter 2 36 Working with Fluid Spraying Equipment pub lished by the employers liability insurance association for the gas remote heating
41. or in the declaration of conformity The operator is responsible for determining the zone allocation according to the Directive of EC 94 9 EC Appendix II no 2 1 2 3 when observing the measures of the responsible inspecting authority The operator is responsi ble for checking and ensuring that all technical data and markings according to ATEX correspond with the necessary requirements Please note that several components have their own type plate with sepa rate marking according to ATEX In this case the lowest explosion protection of all attached markings applies for the entire machine Applications where the malfunction of the unit can lead to danger to personnel must be provided with respective safety measures by the operator 2 4 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski WIWA 2 2 5 Health risks 1 A Ele Safety However if agitators heaters or other electrically accessories are addition ally mounted one must check the explosion protection Plugs for heaters agitators etc that do not have explosion protection may only be plugged in outside of areas that fall under the explosion protection ordinance even if the accessory equipment as such is explosion protected Follow the safety notes and dosing information of the manufacturer and the generally applicable regulations when handling paints cleaning agents oils greases and other chemical substances Depending on the materi
42. own er in the activities they are tasked with and the potential risks connected with them in the case of incorrect behaviour Trained personnel have been instructed by the machine builder such that they are capable of carrying out maintenance and repair work on the system and recognising potential risks on their own initiative and of avoiding these risks 2 5 3 Authorized operating personnel Activity Qualification Setup and operation Instructed operator Cleaning Instructed operator Servicing Trained personnel Repair Trained personnel 1 Juveniles under the age of 16 are not allowed to operate this machine 2 5 4 Personal Protective Equipment Wear protective clothing Always wear the protective clothing specified for your work environment e g antistatic protective clothing in areas subject to explosion hazards and also follow the recommendations in the safety data sheet issued by the material manufacturer 2 8 Original operating manual 14025 25015 1310_2KGel_IG002_BAoDB_en ski Safety Use eye protection Wear protective goggles to protect against eye injuries caused by material splatter gases fumes or dust Wear ear defenders Operating personnel should be provided with suitable noise protection equipment The machine operator is responsible for adhering to the acci dent prevention regulation Noise BGV B3 For this reason pay special attention to the cond
43. safety of the machine cannot be guaranteed If you discover any faults in the safety features or other deficiencies on the machine stop operation of the machine immediately gt Only resume operation of the machine after the fault has been com pletely eliminated Safety features must be checked with the machine depressurized gt before initial commissioning gt always before starting work after set up work gt after all cleaning servicing and repair work Check list vl Lead seal on the safety valve still intact Safety valve free of external damage Function of compressed air shut off valve correct q A A Are the ball valves and the one hand lever on the mixing block function ing correctly I Ground cable free of damage lvl Are the ground cable connections on the machine and the conductor in good condition The machine is equipped with the following safety features gt Asafety valve on the metering pump and the flushing pump gt Compressed air shut off valve gt Ground cable 2 6 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski WIWA Satety 2 4 1 Safety valve The safety valve prevents the maximum permissible air inlet pressure from being exceeded The safety valve will open and vent off air when the air inlet pressure exceeds the set limiting value There is one safety valve on the machine gt inthe air motor of the m
44. space for safe operation Always keep the working area especially all walkways and standing are as clean and tidy Immediately remove any spilled material and cleaning agent Always ensure adequate ventilation at the work place to avoid damage to health and material objects You must guarantee an air change rate of 5 Always observe the processing instructions issued by the material man ufacturers gt Even though there are no legal directives for low mist injection methods all hazardous solvent vapours and paint particles should be extracted Protect objects adjacent to the object from possible damage caused by the material mist If assembly work is carried out by people who have not been trained for this work you endanger yourself and other people and impair the safety and reliability of the machine gt Electrical components must only be mounted by trained time served electricians with all the other components e g the material hose and the mixing unit being assembled by trained personnel only Some system components are possibly packed separately for transportation Please assemble these parts again before using the equipment for the first time To ensure correct connection of the material hoses and the suction system the markings below were applied to the system and the material hoses Blue component A Red component B Yellow flushing agent In all subsequent uses you must keep to this
45. st completely discharge the pressure 2 4 3 Ground cable To prevent electrostatic charging you must ground the machine to n electrically conductive object using the ground cable see Chapter 4 3 4 Grounding the machine on page 4 4 If the ground cable is defective or you lose it please order a replacement immediately Order Number 0474487 Fig 2 Ground cable Original operating manual 14025 25015 2 7 1310_2KGel_IG002_BAoDB_en ski Safety ITPA 2 5 Operating and maintenance personnel 2 5 1 Machine owner s duties The machine owner is responsible for the training of the operating and maintenance staff gt must instruct the operating and maintenance staff in correct handling of the machine as well as in wearing the correct work clothing and personal protective equipment gt must make aids available to the operating and maintenance personnel like lifting equipment for transporting the machine or containers for example gt must make the user manual available to the operating and maintenance staff and ensure that it always remains available gt must ensure that the operating and maintenance staff have read and understood the user manual Only then may the machine be brought into service 2 5 2 Personnel qualification A differentiation is made between two groups of people in dependence on their qualifications Instructed operators have been verifiably instructed by the machine
46. t At initial commissioning to flush out any test medium residue When changing material if the machine is to be shut down for a relatively long period of time Inthe case of metering pumps that are supplied with material via filling hoppers you must completely empty the filling hoppers Completely pump out any material that may be present Interrupt your work as described in Chapter 5 4 Interruptions to work on page 5 5 5 5 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski WIWA e 1 Operation The next steps are to flush the from the material inlet to the mixing unit You must also keep both components strictly separate during cleaning Use separate material and collecting containers for each component to avoid material reactions and thus possible damage to the machine 3 Release the pressure as described in Chapter 5 5 Pressure relief on page 5 5 4 Connect the cleaning agent feed With metering pumps that are supplied with material via a suction system Take the material intake lines of both components out of the material containers Wipe off the material on them into the asso ciated containers Put each of the material intake lines into a separate container with the cleaning agent associated with the material Inthe case of metering pumps that are supplied with material via filling hoppers Usea rag to remove the residual material in the filli
47. type plate is missing 1 1 Original operating manual 14025 25015 1310 2KGel IG002 BAODB en ski WIWA 2 Safety Safety This machine has been designed and manufactured under due consideration of all safety related aspects It complies with the current standard of tech nology and the valid accident prevention instructions The machine left the factory in perfect condition and guarantees a high level of technical reliability and safety Nevertheless there are certain risks that can arise from incorrect operation or misuse to life and limb of the operator or third party gt tothe machine and other material assets of the owner gt tothe efficient working capacity of the machine You must refrain from any working methods that could affect the safety of op erating personnel and equipment All the people that are involved in set up commissioning operation maintenance repair and servicing of the spray gun must have read and understood the operating manual beforehand es pecially the chapter entitled Safety Your safety is at stake We recommend to the owner of this unit to have this confirmed in writing 2 1 Explanation of symbols gt gt e Safety information warns you of potential risks of accidents and tell you the measures that are needed to prevent accidents In WIWA operating manuals safety information is specially highlighted and marked as follows Indicates danger of accidents if you i
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