Operating Manual MORTAR PUMP
Contents
1. BTA Operating Manual because it works MORTAR PUMP Type O 410 09 Serial number Type O 600 12 Translati wre ae ration Man BetonP_BA e n_1302 WIA Table of Contents 1 ORG WONG MREMERE RC NEN EE IRRE OE A 5 2 Sy 1 oS Ee 6 2 1 Explanation of symbol oosina aiee 6 2 2 Safety Note Srni E E E SEE PESER 8 2 3 geca e E E T A E E EA A 8 2 4 Information signs on the device uuusensnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 9 2 5 Safety features 20urssnaunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnn 9 2 5 1 Safety Valve een ai ia 10 2 5 2 Compressed air Shut off valve uersnserssennnnnnnnnsnnnnnnnnnnnnnnnnnnnn 10 2 6 Information on explosion protection ee eeeeeeeeeeeteeeeeeeeneeeeeeenaes 11 2 7 Notes on w atanty n een ee em 11 2 7 1 Conversions and alterations ursnsersnnnnnnnnnennnnnnnnnnnnnnnnnnnnn 11 2 7 2 Accessories and spare parts cccceceeeeeceecceeeeeeeeeeeeeeneaeeaeeeeeeeeess 11 2 8 Operating and maintenance personnel uusnnsersnnnnnnnnnennnnnnnnnnn 12 2 8 1 Machine owner s duties 2444s444HHnnnnen ernennen nnnnnnnen nn nnnr ern 12 2 8 2 Personnel qualification 2444444HHnnnnnn ernennen nnnnnnnnnennnnnnnen nen 12 2 8 3 Authorized operating personnel 2nmmsserssnnnnnnernnnnnnnn nenn nennen 12 2 8 4 Personal Protective Equipment PPE sessen 12 2 9 Emergency procedures cerasana iS 13 22. 2 1 Explanation of symbols gt we gt gt o Safety information warns you of potential risks of accidents and tell you the measures that are needed to prevent accidents In WIWA operating manuals safety information is specially highlighted and marked as follows Indicates danger of accidents if you ignore the safety notes there is a high risk of severe injury resulting up to and including death Indicates danger of accidents if you ignore the safety notes severe injury can result up to and including death Indicates danger of accidents if you ignore the safety notes severe injury can result Indicates important information on correct use of the machine Ignoring it can result in damage to the machine or in its vicinity In the safety notes about the risk of accidents different pictograms are shown after each hazard source examples General accident risk Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw HITA Safety Risk of explosion from explosive atmosphere Risk of explosion from explosive substances Risk of crushing by moving machine parts Risk of burning due to hot surfaces A Danger of injury due to electric voltage or electrostatic charging Mandatory safety instructions concern protective gear to be worn in the first instance They are particularly highlighted and marked as follows Wear protective clothing Indicates the require
3. 5 Air motor faulty control unit blocked 6 The control air feed on the spray tube is closed 1 Check the compressed air supply 2 Carefully clean the material hose or replace it 3 Dismantle and clean pump 5 Contact Customer Service 6 Open the control air feed The pump runs evenly but draws in hardly any material or none at all Pump is operating irregularly reduced pump performance The first ball sticks in the valve plate dried material 2 The material flow is leaky in the screw fitting 3 The material flow container outflow is contaminated 4 The viscosity of the conveying material is too high 1 Ball valves contaminated 2 The valves packings or piston rod are worn out 3 Pump pressure too low 4 The viscosity of the conveying material is too high 5 The material inlet is blocked 6 The air motor control is defective 7 The unit is overloaded 1 Lift the ball through the inlet hole to release it 2 Tighten the screw fitting of the suction pipe and reseal the screw fittings if necessary 3 Clean the material flow container outflow 4 Dilute conveyor agent or use a more powerful pump 1 Clean the machine and possibly leave it at a standstill filled with solvent 2 Replace worn parts 3 Increase the air inlet pressure 4 Dilute conveyor agent or use a more powerful pump Clean the material inlet Use a more powerful pump Pump continues to operate ev
4. 9 1 LEaKageSa salzen een teense 13 292 DUNGS Scie tects een lege 13 2 10 Handling auxiliary materials 244444e Henne nnnnnnnnn nenn nennen 14 3 Machine Description M se 15 3 1 Intendedi Use te ren 15 3 2 Machine Structure teren een 16 4 Installation and transportation unreesnnssennnnnnnennnnnnnnnnennnnnnneennnnnne 17 4 1 Safety measures at the installation location eeen 17 4 2 Transporting the machihO sessssrneea ia 17 5 ASSEMD ucine inea a E 18 6 Putting into operation unsnnsssnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnennnnnnn nennen 19 6 1 PPP ANUING sacs cae cect cece A A E A 19 6 2 Initial ClEANING e A E ee wield 19 Translation of the Original Operation Manual for Mortar Pumps 3 BetonP_BA_en_1302 jw 7 Operati 1 PEPRFSRRERE RE eiar aaaeei aa Ea eean anao EE eaaa dea daai Sedaan URN 20 7 1 Ge neral Notes ainiin ERUUEFELDELSFOREEERENETTEREELSEREETERELFIEREFELFEN 20 7 2 Tolda a EAA O A 20 7 2 1 Setting the working pressure uuerssensnnnessnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 21 7 3 FIUSHING ss Seca vats eat ce cs A caine ceaseesdveauandesapanseeeetneaved 21 8 DECOMMISSIONING 2 2s22e2seeeeee eee eeeeeeeeeneeeeeeeeeeeseeeenseeneeseeneeeeeeeeeeeeees 22 8 1 Interr pting u 0 1 Ceeecerecter pee errr ter ee ee 22 8 2 FINISHING work 0c eee eeeeeeeeeeenee eee eeeaaeeeeeeeaaeeeeeeeaaeeeeeeeaaeeeeeeeaeeeeenee 22 8 2 1 Cleaning the MAChiNG ec eeeee cece eeeeeee aa 22
5. When the initial quantities of severely contaminated cleaning agent have drained hold the spray tube in the feed drum and allow the cleaning agent to circulate in the machine like this for a few minutes 12 Briefly close the control air feed to change the spray tube to a container for contaminated material 13 Open the control air feed and allow the cleaning agent to drain completely from the feed drum and the machines 14 Close the control air feed 15 Regulate the air pressure regulator back to O bar 16 Do not connect the material shut off valve until no cleaning agent comes out so that the pressure is entirely released 8 Decommissioning A Do not compress the material Always start and end the material flow by opening and closing the control air feed 8 1 Interrupting work 1 Interrupt the material flow by closing the control air feed on the spray tube 2 To entirely release the pressure do not close the material shut off valve until no material comes out 3 Close the compressed air shut off valve before the air maintenance unit 4 Now briefly open the material shut off valve on the spray tube to entirely release the air side pressure 8 2 Finishing work 8 2 1 Cleaning the machine 1 Depressurize the machine as described in Chapter 8 1 Interrupting work 2 Flush the machine Chapter 7 3 Flushing 3 Dismount the feed drum by releasing the screw fitting at the top and opening the quick conn
6. owner must protect the machine by implementing appropriate lightning protection measures Strictly comply with the valid accident prevention instructions 4 2 Transporting the machine gt v y y Disconnect the entire power supply for the machine even for short transport distances Empty the machine before transport Caution when loading Risk of injury Never stand under suspended loads or inside the loading area Ensure sufficient load bearing capacity of the hoisting gear Use only suitable transport vehicles Secure the load on the transport vehicle from slipping and falling off Parts or equipment that have been removed for transport purposes must be attached professionally and in accordance with the intended use before commissioning Translation of the Original Operation Manual for Mortar Pumps 17 BetonP_BA_en_1302 jw ALAN Assembly 5 Assembly 1 Mount the feed drum onto the cart Fig 5 1 and bolt the material feed on the container outflow securely to the pump Fig 5 2 Fig 5 1 Fig 5 2 2 Connect the atomizer air hose e and the control air pipe b to the air maintenance unit Fig 5 3 3 Connect the material hose d to the pump Fig 5 3 Fig 5 3 Item Designation Air hose on site Control air pipe Compressed air supply of air motor Material hose Atomizer air hose 10 Q 90 0 Condensate drain 4 Connect the atomiz
7. range of 7 2 Spraying accessories e g agitators in various sizes material preheating containers in different sizes material flow heaters Wear the specified protective clothing Flush the machine as described in Chapter P 3levery time before 1 carrying out recommissioning Have you closed the compressed air shut off valve Have you turned the air pressure regulator all the way back Have you closed the material shut off valve and the control air feed on the spray tube Mix the spraying material well and fill it in the feed drum 20 Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw E2 f FA 7 Operation A Do not compress the material Otherwise the liquid and solid components will separate and this can lead to clogging gt Always start and end the material flow by opening and closing the control air feed 5 Open the material shut off valve first and then the control air feed on the spray tube 6 Open the compressed air shut off valve and set the air pressure regulator to about 2 bar 7 Keep running the material into an empty container until clean material comes out 8 To interrupt the material flow close the control air feed on the spray tube The machine is now ready for spraying Depending on the hose length it may be necessary to fill up the feed 1 drum after filling the machine and the hoses 7 2 1 Setti
8. 8 2 2 Filing the machine with solvent uersesssssssnsnnnnnnnnnnnennnnnnnn en 23 9 Maintenance repairsS uuunneannsnnnnnnnnnannnnnnnnnnnnnnnnnnnnnnannunnnnnnnnnnnnnnnannnn 23 9 1 Recurring INSPOCHOMS sixes 44 2 er ege 24 9 2 Maintenance plan 44s4er nenn nnnnnnnnnn nennen nennen nnnnnnnnnr nn 25 9 3 Air maintenance Unit einen 25 9 3 1 Checking the fill level of the lubricant or anti freeze 25 9 3 2 Setting the f09 Oiler nun ne nennen 26 9 3 3 Draining the condensation water nnenersennnnnernnnnnnnn nenn nennen 26 10 Malfunctions and troubleshooting urrseennnnennnnnnnnnnnnnnnnnnnnnnnnnnnn 27 11 Appendix 28 11 1 Techniealdatt ceno egrnseitein 28 11 2 ACCESSOTIeS u u n er A N 28 11 3 Operating materials 4 uur4404nnnnnnnnnannnnnnnnnnnannnnnnnnnnnnnnnnnnnnnn 29 11 4 Instruction Certificate ssrsennnnnensnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnann 29 11 5 Machine card and lists of spare pats 30 Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw 37 GWA Foreword 1 Foreword The owner of the machine must ensure that its operator always has an operating manual at their disposal in a language they understand Operating personnel must always have access to this user manual Dear Customer We are delighted about your decision to buy one of our machines The user ma
9. air Trained personnel 1 Juveniles under the age of 16 are not allowed to operate this machine 12 Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw HITA Safety 2 8 4 Personal Protective Equipment PPE gt Wear protective clothing 9 Always wear the protective clothing prescribed for your work environment mining closed rooms etc and follow the recommendations in the safety data sheet issued by the material manufacturer Use eye protection Wear protective goggles to protect against eye injuries caused by material splatter gases fumes or dust Wear ear defenders Operating personnel should be provided with suitable noise protection equipment The operator is responsible for adhering to the accident prevention regulation Noise BGV B3 For this reason pay special attention to the conditions at the installation location the noise burden for example will increase if the system is installed in or on hollow bodies Use a respiratory protection mask We strongly recommend wearing a respiratory protection mask even though the paint mist has been minimized in Airless spray painting applications with correct pressure setting and working mode Wear protective gloves When applying heated materials you should wear protective gloves with lower arm protection to protect you against burn injuries Wear protective footwear Wear prote
10. ctive footwear to prevent injuries to the feet due to objects that may fall drop or roll around and to prevent sliding on slippery floors 2 9 Emergency procedures 2 9 1 Leakages In case of leakages you must shut down the system immediately and the complete system must be depressurized Interrupt the compressed air supply Depressurize the entire system Replace defective parts immediately 2 9 2 Injuries If injured by processing materials or solvents always have the safety data sheet address phone number material designation and material number of supplier or manufacturer available for the attending physician Translation of the Original Operation Manual for Mortar Pumps 13 BetonP_BA_en_1302 jw ALAN Safety 2 10 Handling auxiliary materials Follow the safety notes and dosing information of the manufacturer and the generally applicable regulations when handling paints solvents oils greases and other chemical substances Rests of paints solvents oils greases and other chemical substances must be collected in accordance with statutory provisions concerning recycling and waste disposal The official local waste water laws are valid 14 Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw 7 WA Machine Description 3 Machine Description 3 1 Intended use The WIWA range of mortar pumps is suitable for processing epoxy and water based high d
11. ector on the outlet 4 Dismount the coupling piece from the container 5 Dismount the 90 elbow on the base of the pump and dismantle it into an elbow and a coupling piece 6 Clean the individual parts thoroughly including the O ring in the quick connector 7 Mount all the parts including the feed drum back onto the machine 22 Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw E2 f AA Maintenance repairs 8 2 2 Filing the machine with solvent If you want to decommission the machine for a relatively long period of time fill it with solvent after cleaning to protect the machine from drying out 1 Follow the instructions in Chapter 8 2 1 2 Fill the feed drum with solvent 3 Hold the spray tube in the feed drum 4 Open the material shut off valve on the spray tube 5 Open the control air feed on the spray tube 6 Regulate the air inlet pressure such that the pump runs slowly 7 Allow the solvent to circulate in the machine for a few minutes 8 Close the control air feed 9 Regulate the air pressure regulator back to 0 bar 10 Do not connect the material shut off valve until no cleaning agent comes out so that the pressure is entirely released 11 Close the compressed air shut off valve 12 Clean the spray tube 9 Maintenance repairs Before starting work you must interrupt the compressed air supply to the machine Make sure that there is no residual pressure in
12. en when discharge points are closed 1 Wear on packing valves or piston rod 5 6 Contact Customer Service 7 1 Replace worn parts The air motor freezes 1 The number of strokes is too high 2 Inlet air contains too much condensate 3 Very unfavourable operating condi tions high air humidity or tempera tures around freezing point 1 Reduce the air inlet pressure Possibly use a more powerful pump 2 Install a maintenance unit if not already installed Empty water separator more often 3 Fill the oiler on the air maintenance unit with anti freeze and set it such that one drop is released every 5 to 10 double strokes Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw 27 Appendix WIA 11 Appendix 11 1 Technical data Type 410 09 600 12 Article No 0653609 0652595 Two wheel cart Two wheel cart Air motor 140 120 200 120 Material pump 410 120 R 600 120 R Feed drum 25 hopper 25 hopper with quick fastening with quick fastening Maintenance unit yes yes Pressure ratio 9 1 12 1 Max operating pressure bar 72 96 1392 3 Pump capacity per double stroke cm 410 600 Max pump capacity with 60 double strokes 24 6 36 litres Piston diameter of the air motor mm 140 200 Piston stroke of the air motor mm 120 120 Max air inlet pressure bar 8 8 Recommended
13. ensity solids and mortars with grain sizes of 0 4 mm such as cement mortar cement bonded fire protection materials and filled vinyl esters You can easily flush through and clean WIWA mortar pumps with thinner This makes these pumps highly suitable for processing epoxy based materials too By using quick release couplings you can quickly dismantle clean and reassemble the material pumps that comprise only a few parts The feed hopper is detachable The large volume pumps are fitted with extra large outlets and due to the slow pump speed have low wear even with high material throughput Possible areas of application include for example the decks of ships and ferries gt concrete repair and building renovation gt water proofing of basements fire protection Your unit has been specially adapted to the processing material and is suitable for this purpose only For the specific Technical Data for your device refer to the machine card Ho WIWA mortar pumps are not suitable for conventional spraying Any other use is deemed notto be the intended use The manufacturer s approval must be obtained before the unit is used for any other purpose or with other materials i e not in accordance with the intended use otherwise the warranty will become null and void Intended use also includes compliance with the technical documentation and adherence to the prescribed operating servicing and maintenance guidelines Translat
14. er air hose the control air pipe and the material hose to the spray tube Fig 5 4 18 Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw Wi WA Putting into operation Fig 5 4 b 5 Connect the on site air hose a Fig 5 3 Keep the compressed air shut off valve closed 6 Putting into operation 6 1 Preparing Make sure all system parts are leak free at all times If the system has been at a standstill for a long time test if for leaks Check that all the rotatable parts nuts screws and hose connections are seated tightly and tighten them if necessary such that no material can emerge from connections and cause injuries gt Check the stated maximum operating pressures The specified maximum operating pressures must always be adhered to for all WIWA parts pump safety valve material hose spray gun etc The data on these parts must match or be higher than the values stated on the type plate and the machine card gt Top up the fog oiler on the air maintenance unit with pneumatic oil or anti freeze and make the settings in accordance with Chapter 9 3 Air maintenance unit 6 2 Initial cleaning The machine was tested with a test medium before it left the factory Before using the machine for the first time you must flush out this test medium You require At least 51 of cleaning agent that matches the processed material Follow the recommendatio
15. f the O ring when assembling To fill the oil container loosen the filler plug and fill the container directly The maximum oil level is indicated by a groove on the circumference of the container High humidity can cause icing of the motor In case of icing you should use pure anti freeze instead of oil Translation of the Original Operation Manual for Mortar Pumps 25 BetonP_BA_en_1302 jw Maintenance repairs Wi WA 9 3 2 Setting the fog oiler gt Allow the air motor to run slowly with an air inlet pressure of approx 4 bar In the inspection glass of the fog oiler item 2 check whether one drop of lubricant is released into the compressed air after about 10 to 15 double strokes of the air motor If this is not the case screw the adjusting screw item 3 to set metering Only use the lubricants and anti freeze listed in chapter 8 2 9 3 3 Draining the condensation water The accumulated condensate is automatically drained off through the drain valve item 7 Put the hose into an empty collecting vessel gt Check the bowl regularly for dirt residues and clean it as required 26 Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw ATRA Malfunctions and troubleshooting 10 Malfunctions and troubleshooting Fault Possible cause Remedy Pump not running 1 Compressed air supply interrupted 2 Material hose is blocked 3 Ball valves blocked
16. fe way Personnel for electric electronics date name Foreman or responsible superior name department Translation of the Original Operation Manual for Mortar Pumps 29 BetonP_BA_en_1302 jw ATRA Appendix 11 5 Machine card and lists of spare parts This user manual is only valid in conjunction with the attached machine card The machine card contains all the important and safety relevant data and information about the device exact designation and manufacturer data technical data and limiting values equipment and test certificate data of purchasing The device device components and accessories with article and spare parts numbers Cococ Please ensure that the data on the machine card matches the data on the type plate In the case of discrepancies or if the type plate is missing please notify us immediately 30 Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw 7 WA Appendix Translation of the Original Operation Manual for Mortar Pumps 31 BetonP_BA_en_1302 jw Hauptsitz und Produktion WIWA Wilhelm Wagner GmbH amp Co KG Gewerbestr 1 3 35633 Lahnau Deutschland Tel 49 6441 609 0 Fax 49 6441 609 50 E Mail info wiwa de Homepage www wiwa de WIWA Partnerschaft USA WIWA LP 107 N Main St P O Box 398 Alger OH 45812 Tel 1 419 757 0141 Fax 1 419 549 5173 Toll Free 1 855 757 0141 E Mail jwold wiwalp com Homepa
17. ff valve 2 6 Information The red compressed air shut off valve on the air maintenance unit interrupts the air supply for the I entire device After the air supply has been cut off the device is still under pressure Fig 2 2 on explosion protection Machines that are designed without explosion protection must not be used in workshops that come under the explosion protection ordinance Explosion protected devices are labelled as such by means of an EC declaration of conformity in accordance with ATEX 94 9 EC and the Ex marking on the type plate Explosion protected machines meet the explosion protection requirements of Directive 94 9 EC for the explosion group unit category and temperature class specified on the type plate or in the declaration of conformity The operator is responsible for determining the zone allocation according to the Directive of EC 94 9 EC Appendix II no 2 1 2 3 when observing the measures of the responsible inspecting authority The operator is responsible 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 separate 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 safet
18. ge www wiwalp com WIWA Tochtergesellschaft China WIWA Taicang Co Ltd Building A of Huaxin Industrial Park No 11 East Qingdao Road Taicang City Jiangsu Province 215400 P R China Tel 86 512 5354 8858 Fax 86 512 5354 8859 E Mail info wiwa china com Homepage www wiwa china com because it works
19. ion of the Original Operation Manual for Mortar Pumps 15 BetonP_BA_en_1302 jw ALAN Machine Description 3 2 Machine structure Type 410 09 Type 600 12 Detail Dir maintenance unit nn ee ee eee ee ee eee ee eee ee ee een Item Designation Item Designation 1 Air motor 11 Compressed air shut off valve 2 Safety valve 12 Oil filler hole 3 Air maintenance unit see detail 13 Inspection glass 4 Cart 14 Fog oiler setting screw 5 Material pump 15 Pneumatic regulator with pressure gauge 6 Feed drum 251 16 Slide for opening the containers 7 Material shut off valve 17 Oil tank 8 Control air feed to switch the air motor ON 18 Water separator and OFF 19 Drain valve 9 Atomizer air OPEN CLOSED 10 Atomizer air regulator 16 Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw WIA Installation and transportation 4 Installation and transportation 4 1 Safety measures at the installation location gt gt gt gt The access to the safety features must be kept clear Always keep the working area especially all walkways and standing areas clean and tidy Clean up spilled paint or solvents immediately Always ensure for sufficient aeration and ventilation at the workplace to avoid damage to health and material objects Always observe the processing instructions issued by the material manufacturers The
20. le operating pressure can burst and cause serious injury gt The specified maximum operating pressures must generally be complied with for all components In case of varying operating pressures the lowest value is always the one to be taken as the maximum operating pressure for the entire machine Material hoses and hose assemblies must comply with the maximum working pressure including the required safety factor Material hoses must be leak tight and free of kinks signs of abrasion or bulges Hose connections must be tight If material pumps run dry the generated friction heat can cause fire or an explosion gt Always make sure thatthe material drums do notrun dry during operation gt However should this happen stop the corresponding pump immediately and top up material 2 3 Health risks 1 Follow the safety notes and dosing information of the manufacturer and the generally applicable regulations when handling paints solvents oils greases and other chemical substances Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw HIFA Safety A A Depending on the materials being applied solvent vapours may be generated which could cause damage to health and objects Always ensure sufficient aeration and ventilation at the workplace Always observe the processing instructions issued by the material manufacturers Solvents are n
21. ment to wear the prescribed protective clothing to protect against skin injuries caused by spraying material or gases Use eye protection 4 Indicates the requirement to wear protective goggles to protect against eye injuries caused by gases fumes or dust Wear ear defenders h Indicates the requirement to wear ear defenders to prevent your hearing from being damaged by noise Use a respiratory protection mask Indicates the requirement to wear a respiratory protection mask to prevent your respiratory tract from being damaged by gases fumes or dusts Wear protective gloves Indicates the requirement to wear protective gloves with lower arm protection to protect against burn injuries caused by heated materials Wear protective footwear Wear Indicates the requirement to wear protective footwear to prevent injuries to the feet due to objects that may fall or drop and to prevent sliding on slippery floors Translation of the Original Operation Manual for Mortar Pumps 7 BetonP_BA_en_1302 jw Safety WIV Indicates references to guidelines work instructions and operating manuals that contain important information which you must observe at all times 2 2 Safety notes A A A Mortar pumps can cause life threatening injuries if used improperly Please observe the safety notes below and act accordingly Components that do not comply with the maximum permissib
22. minimum compressor 3000 output l min Air inlet connection BSP 1 2 1 Material inlet connection BSP 1 1 Material outlet connection BSP 1 1 Spraying hose 25 x 1 25 x 1 Air consumption of pump 1 200 I min nominal 2 000 l min value 11 2 Accessories Accessory set Article No Containing 0653594 Hose package 10 5 m 7 5m 3 m Spray tube 330 mm with ball valve and nozzle 8 5 mm 28 Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw 77 WA Appendix 11 3 Operating materials Pneumatic oil for air maintenance unit 0 51 Article No 0632579 Anti freeze for air maintenance unit Article No 0631387 Materials required for maintenance and repair work Q Securing agent 50 ml Article No 000015 Q Lubricant acid free grease Article No 000025 11 4 Instruction Certificate This certificate follows the EC Directive for work equipment 85 655 EEC section Il article 7 The owner of the machine listed below has instructed the operating personnel Manufacturer type designation year of construction order number Instruction was conducted by the representative of the owner Foreman or responsible superior name department The instructed person has read and understood the user manual for the machine listed above in particular the chapter entitled Safety and declares that they are able to operate the unit in a sa
23. ne cannot be guaranteed gt Ifyou 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 completely eliminated Check the safety features with the device depressurised gt before commissioning always before starting work after all setup work VV YV after cleaning maintenance and repair work Checklist for testing the safety features Q Is the ground cable undamaged Q Is the ground cable connected correctly to the device as well as to the conductor Q Is it possible to activate the compressed air shut off valve The safety valve makes sure that the maximum permissible air inlet pressure on the air motor is not exceeded The safety valve will open and vent off air when the air inlet pressure exceeds the set limiting value Never remove the safety valve that is fitted and lead sealed at the factory or change its settings If the safety valve needs to be replaced you can find the corresponding order number on the machine card When using new safety valves make sure that they have been set to the maximum permissible air inlet pressure of the WIWA mortar pump see type plate machine card and are lead sealed 10 Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw WIV Safety 2 5 2 Compressed air shut o
24. ng the working pressure You need different working pressures for different materials In general a suitable air inlet pressure is in the range 1 5 3 5 bar You regulate atomizing of the spraying material by means of the air inlet pressure of the pump and by adding atomizer air via the spray tube To set the desired working pressure hold the spray tube in the feed drum or any other container while you test the various pressure settings 7 3 Flushing Flush the machine if you want to fill another material or you want to finish work or you want to decommission the machine Empty the feed drum by means of the spray tube End the material flow by closing the control air feed Regulate the air pressure regulator back to 0 bar Do not connect the material shut off valve until no material comes out so that the pressure is entirely released Remove the nozzle from the spray tube Fill the feed drum with cleaning agent that matches the material you are processing Pay attention to the manufacturer s recommendations Hold the spray tube into a container for contaminated material Open the material shut off valve on the spray tube Open the control air feed on the spray tube 0 Regulate the air inlet pressure such that the pump runs slowly o RON O gt ON Translation of the Original Operation Manual for Mortar Pumps 21 BetonP_BA_en_1302 jw ALAN Decommissioning 11
25. ns of the material manufacturer C gt ir 1 empty open container B CBD Translation of the Original Operation Manual for Mortar Pumps 19 BetonP_BA_en_1302 jw Operation ALAN 7 7 1 AUN 8 9 Have you turned the air pressure regulator all the way back Is the compressed air pipe connected Fill the cleaning agent into the feed drum Hold the spray tube in container B open the material shut off valve first and then the control air feed on the spray tube Open the compressed air shut off valve and set the air pressure regulator to about 2 bar Allow the cleaning agent to run completely via the spray tube into container B Let the pump run for a little while even after all the cleaning agent has been used to ensure that the cleaning agent drains completely from the machine too Connect the control air feed to the spray tube first and then connect the material shut off valve Turn the air pressure regulator all the way back 10 Close the compressed air shut off valve Operation General notes Always follow the processing instructions provided by the material manufacturers All the materials to be processed should be supplied by the manufacturer with data concerning the viscosity application temperatures mixing ratios etc If this is not the case please consult the respective manufacturer about this data For optimum preparation of the materials WIWA offers a wide
26. nual contains all information required to operate and handle your WWA mortar pump However other information is also essential for safe operation Read and comply with the applicable guidelines for your country gt In Germany these are the Richtlinien fur Fl ssigkeitsstrahler Guidelines for Liquid Jets issued by the Hauptverband der Gewerblichen Berufsgenossenschaften gt Moreover you must respect at all times the manufacturer s instructions and coating or feeder materials gt In principle you must refrain from any work method that could affect the safety of W WA products and operating personnel Wishing you lots of success and good work results your WWA Wilhelm Wagner GmbH amp Co KG Copyright 2013 WIWA The copyright in this user manual is retained by WIWA WILHELM WAGNER GmbH amp Co KG Gewerbestra e 1 3 35633 Lahnau Tel 49 6441 609 0 Fax 49 6441 609 50 E mail info wiwa de Internet www wiwa de This operating manual is solely intended for personnel involved in preparation operation and servicing It is prohibited to pass on this operating manual for reproduction utilisation or communication of its con tents unless this has been explicitly permitted Infringements incur an obligation to pay damage compen sation All rights reserved in the event of registration of the patented design industrial design or registered design This operating manual only applies in conj
27. ot suitable for cleaning you skin and can damage your health gt Useonly appropriate skin protection skin cleaning 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 4 Information signs on the device The warning signs and symbols on the machine refer to possible danger areas and must be respected at all costs Warning signs and symbols must not be removed from the device Warning signs that are damaged and illegible must be replaced immediately The following signs are located on the device gt Type plate Please check that the type label data are identical with those on the machine card In case of discrepancies or ifthe type plate is missing please notify us immediately Translation of the Original Operation Manual for Mortar Pumps 9 BetonP_BA_en_1302 jw Safety ATRA 2 5 Safety features A 2 5 1 Safety valve A If one of the safety features is missing or not fully functional the operating safety of the machi
28. r decommissioned machines the inspection can be postponed until the next commissioning The inspection results must be recorded in writing and kept until the next inspection The inspection report or a copy of it must be available at the place of use of the machine Please observe the specifications that apply in the country of use 24 Translation of the Original Operation Manual for Mortar Pumps BetonP_BA_en_1302 jw 7 WA Maintenance repairs 9 2 Maintenance plan gt 5 x E fe c 5 g E amp For more information refer to Check setting and oil quantity on fog oiler x Chapter 9 3 2 Setting the fog oiler Check condensation water container for dirt residues x Clean the hoses x Replace the hoses x Further maintenance notes for the individual components can be found in the appendix to the corresponding spare parts list 9 3 Air maintenance unit Item Designation Oil filler screw Inspection glass Fog oiler setting screw Slide for opening the containers Oil tank Water separator NO OP O ND Drain valve Fig 9 1 9 3 1 Checking the fill level of the lubricant or anti freeze gt Check the amount of oil in the oil container item 5 every day The maintenance unit must never be operated without oil Opening containers Press the slide downwards and turn the container to the left Ensure correct fit o
29. ries incurred because of the use of those accessories and spare parts becomes null and void Operating and maintenance personnel 2 8 1 Machine owner s duties The machine owner gt gt is responsible for the training of the operating and maintenance staff must instruct the operating and maintenance staff in correct handling of the machine as well as in wearing the correct work clothing and personal protective equipment must make the user manual available to the operating and maintenance staff and ensure that it always remains available must ensure that the operating and maintenance staff have read and understood the user manual Only then may the machine be brought into service 2 8 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 owner 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 8 3 Authorized operating personnel Activity Qualification Setup and operation Instructed operator Cleaning Instructed operator Servicing Trained personnel Rep
30. the machine After completing work you must always check the function of all the protective devices and correct functioning of the machine Relieve the machine pressure before starting maintenance and cleaning work Disconnect the compressed air supply to the entire system Close the compressed air shut off valve and release the pressure In case of material congestion or agglomeration of material in the machine residual pressures can still be present despite pressure discharge Pay full attention to this when performing repair work Material filters and hoses and the spray gun in particular must be dismounted with the greatest of care to avoid accidents caused by released residual pressures gt When working on the material filter e g when changing the filter the machine must be completely switched off and depressurized Translation of the Original Operation Manual for Mortar Pumps 23 BetonP_BA_en_1302 jw ATHA Maintenance repairs 9 1 Recurring inspections In Germany you must have the machine inspected and serviced regularly by an expert WIWA Customer Service in accordance with the accident prevention instructions for Work with fluid spraying equipment BGV D15 Chapter 2 36 The machine must be inspected before initial commissioning after the modification or repair of parts of the system which could affect safety after work breaks longer than 6 months gt but at least every 12 months Fo
31. unction with the machine card that was given to you with the user manual for your equipment Please check that the type plate data is identical with the information on the machine card Please notify us immediately if there are discrepancies if the user manual has been incorrectly compiled or if the type plate is missing Translation of the Original Operation Manual for Mortar Pumps 5 BetonP_BA_en_1302 jw Safety WIA 2 Safety This machine has been designed and manufactured under due consideration of all safety related aspects It complies with the current standard of technology 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 tothe machine and other material assets of the owner to the efficient working capacity of the machine You must refrain from any working methods that could affect the safety of operating personnel and equipment All the people that are involved in set up commissioning operation maintenance repair and servicing of the spray gun must have read and understood the operating manual beforehand especially the chapter entitled Safety Your safety is at stake We recommend to the owner of this unit to have this confirmed in writing
32. y measures by the operator However if agitators heaters or other electrically accessories are additionally 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 2 7 Notes on warranty 2 7 1 Conversions and alterations Unauthorized conversions or alterations should not be undertaken on safety grounds Protective equipment should not be dismantled converted or bypassed Use of components which have not been manufactured or delivered by WIWA renders any warranty null and void gt The machine must only be operated within the specified limiting values and machine parameters Translation of the Original Operation Manual for Mortar Pumps 11 BetonP_BA_en_1302 jw Safety WIA 2 7 2 Accessories and spare parts 2 8 gt gt If you use original accessories and spare parts from WIWA their suitability for use with our machines is guaranteed Itis however mandatory to respect the safety regulations of the accessories and spare parts You will find these safety regulations in the corresponding operating manuals for the accessories and spare parts If third party accessories or spare parts are used WIWA cannot guarantee the safety of the whole machine Liability for damages or inju
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