Operation manual HERKULES PFP
Contents
1. Open the compressed air shut off valve for the container ventilation Set the ram control lever to position Up to move the ram up OF a w NS s Once the sealing lip of the follow plate reaches the top of the material drum close the compressed air shut off valve for the container ventilation 6 Once there is sufficient space for removing the material drum set the ram control lever to position Stop Remove the material drum Unscrew the follow plate Take care that the seal between the follow plate and the pump is not lost 9 Clean the follow plate thoroughly The black rubber seal is not solvent resistant Do not soak in solvent but only wipe the seal clean 10 Place a drum with with 10 15 flushing agent below the pump e jie 11 Set the ram control lever to position Down an move the ram down until the suction of the pump immersed into the flushing agent 12 Hold the drain hose into the collecting vessel 13 Open the drain ball valve 14 Regulate the air inlet pressure on the air pressure regulator for the pump so that the pump runs slowly Do not trigger the spray gun during the intermediate flushing to prevent mix 1 ing of the solvent with the material in the spray hose 15 Allow the pump to run until the solvent runs out of the drain hose 16 Hold the drain hose into the flushing agent drum and allow the unit to run for 2 3 minutes so that all remaining2. gt ZH 1 406 Richtlinien f r Flussigkeitsstrahler Guidelines for Liquid Jets published by the German Hauptverband der Gewerblichen Berufsgenos senschaften gt BGR 500 Chapter 2 29 Application of Coating Materials gt BGR 500 chapter 2 36 Working with Fluid Spraying Equipment published by the employers liability insurance association for the gas remote heating and water management sectors We strongly recommend adding all relevant guidelines and accident prevention instructions to this operation manual Moreover the manufacturer s instructions and guidelines for coating or feeder 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 HERKULES PFP from WIWA Wilhelm Wagner GmbH amp Co KG Copyright 2014 WIWA This operation manual 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 operation manual is solely intended for personnel involved in preparation operation and servic ing It is prohibited to pass on this operation 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 registrati
3. Pry the spring housing from the HP head see Fig 22 6 Lower the dual piston to its lowest position using brief increases and decreases in the air pressure 7 Pry the intermediate body from the air mo tor It will be caught by the dual piston 8 Unscrew 2 3 of the threaded bolts to allow removal of the HP head and the dual pis ton from the coupling see Fig 23 9 Clean the piston piston valve bottom valve pressure cylinder intermediate body spring housing threaded bolts and nuts thoroughly using solvent Fig 23 Remove the HP head and the dual piston from the coupling 1 Take care that the dual piston packings seals and threads are not damaged Translation of the original operation manual HERKULES PFP 31 HERKULES PFP_BAoDB_en_1402_B rs Operation WIA 5 3 3 Assembling the fluid pump The drawing in the spare parts list can be very helpful for assembling the fluid pump Order No 0641416 1 Place the counter ring on the dual piston note correct direction followed by the intermediate body don t forget the seall A intermediate body ST h y dual piston Fig 24 Counter ring 2 Push the dual piston sidewards into the coupling on the air motor 3 Screw in the threaded bolts 4 Place the counter ring onto the lower packing followed by the spring 5 Place the spring housing material outlet towards the top loosely over the spring onto the pressure cylinder Place the 2nd s
4. pump only Remove the bottom valve and spray pressure can not be reached stops on the upwards stroke clean the ball and seat thoroughly when the spray gun is closed 3 Piston valve leaks pump only Clean the ball and seat in the dual stops on the downwards stroke piston and replace if necessary when the spray gun is closed 4 Upper or lower packings leak Replace packings wear Coating material spills out of the air 1 Packings are worn Replace packings Note Do not close or block the ventilation hole Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs 37 Technical data E gt f WA i 8 Technical data You find the technical data for your HERKULES PFP in the attached machine card or on the type plate 8 1 Machine card The machine card contains all important and safety relevant data and informa tion about the unit gt exact designation and manufacturer data technical data and limiting values equipment and test certificate data of purchasing unit identification components of the unit and accessories with article and spare parts numbers gt gt gt gt 8 2 Type plates The type plate of the HERKULES PFP is y A 35633 Lahnau Germany located on the traverse of the ram Gewerbestra e 1 3 EX 2G cT It contains the most important techni Druckluftbetriebene Kolbenpumpe Air operat h it Gerate Type Unit cal data of the unit FM p D
5. Intended use also includes compliance with the technical documentation and adherence to the prescribed operating servicing and maintenance guide lines Translation of the original operation manual HERKULES PFP 17 HERKULES PFP_BAoDB_en_1402_B rs Unit description PRTA 3 2 Unit configuration OO 000G r f Fig 5 Front view of the HERKULES PFP No Designation 1 Silencer 2 Air motor 3 Overflow with ventilation hole 4 Twin post ram 5 Fluid pump 6 Connection for the spray hose 7 Drain ball valve 8 Drain hose 9 Follow plate 10 Release agent filler neck 11 Release agent drain screw 12 Control lever for the ram 13 Pressure gauge for the ram 14 Compressed air shut off valve for the container ventilation 15 Connection for the container ventilation 18 Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs WIA Unit description 49 D D RD e2 3 Fig 6 Rear view of the HERKULES PFP No Designation 16 Maintenance unit 17 Ring screws for safe lifting with hoisting devices 18 Air pressure regulator for the ram 19 Air pressure regulator for the pump 20 Deicing system 21 Pressure gauge for the air inlet pressure 22 Compressed air shut off valve 23 Compressed air connection 24 Container ventilation with ball valve 25 Groundin
6. To do this engage the wheel brakes on the swivel rollers See Fig 7 Always keep the working area especially all walkways and standing areas clean and tidy Immediately remove any spilled material and solvents immediately Always ensure adequate ventilation at the work place to avoid damage to health and material objects At least a 5 fold air exchange must be ensured Always observe the processing instructions issued by the material manu facturers Even though there are no legal directives for low mist Airless spraying methods all hazardous solvent vapours and paint particles should be extracted Protect objects adjacent to the spraying object against possible damage caused by the material mist y Fig 7 Wheel brake y y y y 4 3 Assembly A If assembly work is carried out by people who have not been trained for this work you endanger yourself and other people and impair the safety and reliability of the unit Electrical components must only be mounted by trained time served electricians with all the other components e g the spray hose and the spray gun being assembled by trained personnel only The spray gun material hose and the spray gun were separately packed for transport Please assemble these parts before using the unit for the first time A Components that do not comply with the maximum permissible operating pressure may burst und cause severe injuries Before assembli
7. before each use Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs IVA Satety 2 2 3 Risks caused by electrostatic charging warnine O 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 unit and the object to be coated are earthed correctly gt Always use open containers Never spray solvents or materials containing solvents into cone top cans or drums with bunghole gt Stand the containers on a grounded surface gt When using metal containers watch out for contact between spray gun and container wall gt Only use conductive material hoses All original material hoses from WIWA are conductive and perfectly adapted to our equipment A If the unit is contaminated during spraying by coating material the increasing coating thickness may cause electrostatic charging Static discharges can cause fire and explosion gt Clean the unit immediately outside the hazardous area from contamina tion by coating material 2 2 4 Explosion protection A Units that are designed without explosion protection must not be used in workshops that come under the explosion protection ordinance Explosion protected units meet the explosion protection requirements of Di rective 94 9 EC for the explosion group unit category and temperature
8. material is flushed out of the unit 17 Move the ram up 18 Remove the flushing agent drum 19 Screw on the follow plate with seal 20 Place the new material container under the pump and fill the pump with material Collect the remaining solvent that exits the drain hose in a con tainer for waste material 21 Close the drain valve again as soon as the processing material exits the drain hose 22 Proceed with coating work Translation of the original operation manual HERKULES PFP 29 HERKULES PFP_BAoDB_en_1402_B rs Operation WIA 5 3 Decommissioning Overview of the work sequence for decommissioning 1 2 3 4 Flush the unit completely see chapter 5 3 1 on page 30 Shut down and depressurise the unit see chapter 2 7 1 on page 16 Disassemble and clean the fluid pump see chapter 5 3 2 on page 30 Assemble the fluid pump see chapter 5 3 3 on page 32 5 3 1 Complete flushing 1 If working with dual component materials the pot life must be observed The unit must be flushed and completely cleaned with the appropriate sol vent within the pot life given by the material manufacturer Dae ee N Flush the pump at first through the drain hose as described in chapter 5 2 4 on page 29 work steps 1 16 Lock the spray gun and remove the nozzle Clean the nozzle by hand Hold the spray gun into the collecting vessel Trigger the spray gun until clean flushing agent appears Hold the
9. stake We recommend to the owner of this unit to have this confirmed in writing 2 1 Explanation of symbols gt gt gt Safety information warns you of potential risks of accidents and tell you the measures that are needed to prevent accidents In WIWA operation 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 unit Ignoring it can result in damage to the unit or in its vicinity Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs BTA 00 09 PPPPPP Translation of the original operation manual HERKULES PFP Safety 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 components Risk of burning due to hot surfaces Mandatory safety instructions concern protectiv
10. they are worn You find the order numbers of the seals in the spare parts list No Designation Fastening screws 2 Seals 3 Clamping ring Fig 27 Seals on the follow plate 1 Loosen all screws which fasten the seals and the clamping ring on the follow plate Take off the clamping ring and the old seals Slightly wet the first thread pitches of the fastening screws with a screw retention agent 4 Turn the clamping ring with the new seals on to the follow plate 6 5 Recommended operating materials 36 Only user original operating materials from WIWA Operating materials WIWA order number Release agent 0 5 0163333 Release agent for isocyanate 0 5 1 0640651 Anti freeze agent 0 5 1 0631387 Pneumatic oil 0 5 1 0632579 Retention agent 50 ml 0000015 Lubricant acid free grease 0 4kg 0000025 Lubricant for stainless steel 0000233 1 Plasticizer to fill into the release agent cups of the main pump and the feed pumps 2 for air maintenance unit 3 Materials required for maintenance and repair work see information in spare parts lists The release agent and the pneumatic oil are available in large containers on request Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs PITA Troubleshooting 7 Troubleshooting Fault Possible cause s Remedy The pump does not cycle whether the s
11. with suitable noise protection equip ment The unit operator is responsible for adhering to the accident preven tion regulation Noise BGV B3 For this reason pay special attention to the conditions at the installation location the noise burden for example will increase if the system is installed in or on hollow bodies Wear a respiratory protection mask We strongly recommend that you wear a respiratory protection mask even though the paint mist has been minimized in the airless spray painting meth od given a correct pressure setting and correct working methods Wear protective gloves When applying heated materials you should wear protective gloves with lower arm protection to protect you against burn injuries Wear protective footwear Wear protective footwear to prevent injuries to the feet due to objects that may fall drop or roll around and to prevent slipping on a slippery floor 2 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 safe ty grounds Protective equipment should not be dismantled converted or bypassed gt The unit must only be operated within the specified limiting values and parameters gt When carrying out maintenance and repair work you must only use WIWA original spare parts Use of spare parts which have not been manufactured or deliver
12. 173 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 WIA 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 sales directors representatives and distributors in South America except Cuba and Mexico South East Asia Japan South Korea Australia and New Zealand Hoekstraat 57 3751 AL Spakenburg The Netherlands
13. H Output p cycle gt the marking according to ATEX nce jax Lufteingang Air Directive 94 9 EC Max Betriebsdruck Fluid gt the equipment type Max Temperat Serial no Model year the supply rate per cycle gt the pressure ratio Fig 28 Example of a type plate EJ gt the maximum air inlet pressure gt the maximum operating pressure gt the maximum material processing temperature and gt the serial number and the year of production Please check that the data on the type plate are identical to the specifica tions on the machine card Please notify us immediately in case of discrep ancies or if a type plate is missing e Additionally some unit components have a separate type plate such as the air operated piston pump and the twin post ram These type plates contain the technical data and serial numbers of the affected components 38 Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs PITA Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs 39 WIWA Service 49 0 6441 609 140 Headquarters and production WIWA Wilhelm Wagner GmbH amp Co KG Gewerbestr 1 3 35633 Lahnau Germany Phone 49 6441 609 0 Fax 49 6441 609 50 E Mail info wiwa de Homepage www wiwa de WIWA Partnership USA WIWA LP 107 N Main St P O Box 398 Alger OH 45812 Phone 1 419 757 0141 Fax 1 419 549 5
14. Hold the drain hose into the collecting vessel see Fig 13 9 Open the drain ball valve Fig 13 Drain hose 10 Regulate the air inlet pressure on the air pressure regulator for the pump so that the pump runs slowly 11 Allow the flushing agent soiled with the test medium to run out of the drain hose into the collecting vessel for at least 10 seconds 12 Close the drain ball valve 13 Hold the spray gun into the collecting vessel 14 Unlock the spray gun and spray for a minimum of 10 seconds against the inner wall of the container We recommend a cleaning period of approx one minute for a good cleaning result A Heating up flushing agents can cause an explosion This may result in seri ous injury to persons and damage to property In order to avoid the danger of explosion caused by heating up the flush ing agent it must not be pumped longer than 5 minutes Translation of the original operation manual HEAKULES PFP 25 HERKULES PFP_BAoDB_en_1402_B rs Operation 15 Close and lock the spray gun WIA 16 Set the ram control lever to position Up to move the ram with the pump up 17 Once there is sufficient space for removing the flushing agent container set the ram control lever to position Stop 18 Remove the flushing agent container 19 Screw on the follow plate with seal 5 1 3 Adjust the deicing system 1 1 Turn the adjusting screw for the deicing system at the air m
15. Mobil 31 6 18 88 40 97 Phone 31 3 34 94 69 81 Fax 31 3 34 94 75 83 E Mail rob wiwa gmail com Otto Dietrich Sales Director Russia Ukraine Belarus Moldavia Baltic States Lithuania Latvia Estonia Caucasian countries Armenia Azerbaijan Georgia Asian countries Kazakhstan Uzbekistan Turkmenistan Kyrgyzstan Tajikistan Lindenhof 6 56154 Boppard Germany Mobil 49 160 1574385 Phone 49 6742 899336 Fax 49 6742 899337 E Mail o_dietrich wiwa de Michel Laksander Technical Sales Director France 2 Bis rue de l glise F 02240 Brissy Hamegicourt France Phone 33 32 36 21 120 Mobil 33 63 70 19 297 E Mail laksander orange fr JK Tan Sales Director Korea Japan Australia South East Asia Mobil 6012 223 7706 Phone Fax 603 8024 7706 E Mail jktan wiwa com
16. Operation manual because it works HERKULES PFP Translation of the original operation manual BTA Contents Contents T FOWO Pereerereret errr rretrerr etree E crrcerre tre errr errr reece creer rer cre 5 2 SAN OUY aeae a aae ER asst aber aa a aAA yatta va E seen canes 6 2 1 Explanation Of SYMDOIS secina aE Eaa aii 6 2 2 Safety NOtes ecceeesceeccceeeeneee cence eteaaeeeeeeeceaaeeeeaaeesaaeseeeaaesneeeeseaaeseeeeeeee 8 2 2 1 Operating preSSUre a tent adicsiadiieiic aii dine 8 2 2 2 Risks caused by the spray jet cceeeeeeeeeeeeeeneeeeseeeneeeeseenaaeeeeeeenaes 8 2 2 3 Risks caused by electrostatic ChArging ceceeeeeesteeeeeeenteeeeeeenaes 9 2 2 4 Explosion protection enne 9 2 2 5 Risks due to the aMSN aN 10 222 6 IFS AlN TISKS 5 cesasecs a A 11 2 3 Information SIGNS ON the UNit eee eeeeeeeee eee eeeeeaeeeeeeeaaeeeeeeeaeeeeeeeaaes 11 2 4 Safety feature Sasirnane iaaa biel A E ERRA 12 2 4 1 Compressed air shut off valves 0 0 0 ecceeeceeececeeeeeeeeeeeeeeeeeaaeeeeneees 12 PAD Safety VANE gortinen nnair a ana da AA E A e aR Nan 13 2 4 3 Grounding Wheels naniii E 13 2 44 Grounding cable sussies ianen aa 13 2 5 Operating and maintenance personnel ccccscceeeeeeeeeeeeseeeeeeesaeeeeneees 14 225 1 Unit OWNER SOULE iis sstcceeetsastexters aceeeesaenneeeesanidedies RNE 14 2 5 2 Personnel quallification c cc ceeceeeeeeeeeeeeeeeeeenaeeeeeeeneeeeeeeenaeeeeeeeaa 14 2 5 3 Authorized operating personn
17. aning the water Separator ccceeeeeeeeeeeees 35 6 4 Fluid DUMP ionrata diea ienie eased 35 6 4 1 Checking the release agent level n ssssnsssssrnnneernnneenr rrene nn nnen n enn 35 6 4 2 Checking release agent for material residues 0 ccceceeeeeeeeeee 36 6 4 3 Replacing the seals on the follow plate ce eeeseeeeeentteeeeeeenaees 36 6 5 Recommended operating materials ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeees 36 7 Troubleshooting a EEEE 37 8 lechnical dala oera aha a O 38 8A Machine Card saccsivasnatecsaetassancanttesesniteSanetcana dena aa aaa a a A 38 8 2 Type platsi i A daa a AERE AAEE SAAE RR 38 Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs IVA ad 1 Foreword Dear Customer We are delighted that you have decided in favour of a HERKULES PFP made by our company This operation manual is intended for the operating and maintenance person nel It contains all the information required to working with this unit The owner of the unit must ensure that operators and maintenance person il nel always have an operation manual at their disposal in a language that they understand Safe and reliable operation of the unit requires further information in addition to this operation manual You should have read and understood the guidelines and accident prevention regulations that apply in your country In Germany the following apply
18. 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 corre spond with the necessary requirements Please note that several unit components have their own type plate with sep arate marking according to ATEX In this case the lowest explosion protection of all attached markings applies for the entire unit Applications where mal functioning of the unit can lead to danger to personnel must be provided with appropriate safety 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 Translation of the original operation manual HERKULES PFP 9 HERKULES PFP_BAoDB_en_1402_B rs Safety A BTA Heating up cleaning agents can cause an explosion This may result in seri ous injury to persons and damage to property Pay attention to the flashpoint and the ignition temperature of the clean ing age
19. e gear to be worn in the first instance They are particularly highlighted and marked as follows Wear protective clothing Highlights the order to wear the prescribed protective clothing to protect against skin injuries caused by spraying material or gases Use eye protection Indicates the requirement to wear protective goggles to protect against eye injuries caused by gases fumes or dust Wear ear defenders Indicates the requirement to wear ear defenders to prevent your hearing from being damaged by noise 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 operation manuals that contain important information which you must observe at all times HERKULES PFP_BAoDB_en_1402_B rs Safety 2 2 Safety notes WIA Please remember that the unit works at high pressure and may cause life threatening injuries if used inappropriately Always observe and follow all instructio
20. e safety notes in the operation manual Fig 1 Safety Information Translation of the original operation manual HERKULES PFP 11 HERKULES PFP_BAoDB_en_1402_B rs Satety BTA 2 4 Safety features A If one of the safety features is missing or not fully functional the operating safety of the unit cannot be guaranteed gt If you discover any faults in the safety features or other deficiencies on the unit stop operation of the unit immediately gt Only resume operation of the unit after the fault has been completely eliminated Safety features must be checked with the unit depressurized gt before initial commissioning gt always before starting work gt after set up work gt after all cleaning servicing and repair work The unit is equipped with the following safety features gt Compressed air shut off valves gt Safety valve gt Grounding wheels gt Grounding cable Check list Function of compressed air shut off valves correct Lead seal on the safety valves still intact Safety valves externally free of damage Grounding wheel clean and free of damag Grounding cable free of damage Grounding cable connections on unit and conductor in good condition NXAQARBARAA 2 4 1 Compressed air shut off valves The compressed air shut off valve on the air maintenance unit see Fig 2 interrupts the air supply for the unit Furthermore the unit is equipped with a further compre
21. ed by WIWA renders any warranty null and void Using original WIWA accessories guarantees that they are usable in our units If you use third party accessories they must be suitable for the unit par ticularly with regard to the operating pressure the electrical connection data and the connection sizes WIWA accepts no liability for damage or injuries resulting from the use of these parts gt You must observe the safety regulations of the accessories These safety regulations are found in the separate operating instructions for the acces sories Translation of the original operation manual HERKULES PFP 15 HERKULES PFP_BAoDB_en_1402_B rs Safety WIA 2 7 Emergency procedures 2 7 1 Shutting down and depressurising the unit In an emergency the unit must be shut down and depressurised immediately 1 oo f 2 BF 2 7 2 Leakages A In gt gt gt cause serious bodily injuries and material damage Regulate the compressed air pressure regulators for the pump and the ram fully back Close the compressed air shut off valve on the air maintenance unit Close and lock the spray gun Hold the drain hose into a collection container and ensure that it can not slip Open the drain valve case of leakages material can escape under very high pressure and Immediately shut down the unit and depressurize it Retighten any screw fittings and replace defective parts only by trained personn
22. eels The two swivel rollers of the chassis are electrically conductive They contact the unit to the floor in order to discharge static electricity Check the grounding wheels 1 regularly for dirt and clean them if necessary Fig 4 Grounding wheels 2 4 4 Grounding cable In order to prevent to prevent electrostatic charging the unit must be grounded with the grounding cable to an electrically conductive object see chapter 4 3 3 on page 22 If the grounding cable ist defect or lost you must order a new immediately Translation of the original operation manual HERKULES PFP 13 HERKULES PFP_BAoDB_en_1402_B rs Safety WIA 2 5 Operating and maintenance personnel 2 5 1 Unit owner s duties The unit owner gt is responsible for the training of the operating and maintenance staff gt must instruct the operating and maintenance staff in correct handling of the unit as well as in wearing the correct work clothing and personal protective equipment 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 un derstood the user manual Only then may the unit be brought into service 2 5 2 Personnel qualification A differentiation is made between two groups of people in dependence on their qualifications gt Instructed operators have been verifiably ins
23. el cccceeeeeeeeeeeeeeeeteeeeeeentaeeeeeeens 14 2 5 4 Personal Protective Equipment PPE cccesssceeeeeeeeeseeeeeeees 14 2 6 Notes on Warranty ecceecceceeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeaaeeeeeeseeneeeseeeeeneeeeeeneneees 15 2 6 1 Conversions and alterations c ccceeeceeececeeeeeeeeeeeteeeeeeeeeeeeeees 15 2 6 2 Spare paris sce sasee Sete ca bete Aates cave sabe tnnse e N E S 15 2 36 39 ACCESSOMNGS sicie AAN ENE 15 2 Emergency PrOCCCUIES x asna E 16 2 7 1 Shutting down and depressurising the unit eeeeeeeeeeeeeeeeee ene 16 27 2 LOAKAGES ercer EEE EEA EEEE ERA 16 ERRE E A A A T E 16 3 Unit d striptom sisisi EENEN NERE 17 Bed IMON do d USG enan a A 17 32 UNLCONNGUTAU O etsi aN RESE 18 4 Transportation installation and assembly 20 A Tanpo dl Oina Oa anne 20 A2 INStAllAtOM JOCATON sessen Naa 20 AD ASSEMBLY ai a E E 21 4 3 1 Open the ventilation hole ssesseeseeeieeieeeressiressrresrrresrrrserrssnesns 22 4 3 2 Assembling spray hose and spray gun sessesssssssrisrrrrrisssrrinnss 22 Translation of the original operation manual HERKULES PFP 3 HERKULES PFP_BAoDB_en_1402_B rs Contents 4 3 9 Grounding The UN its scccesscciedesees aa E AES 22 4 3 4 Connecting the compressed air SUPDPIY ccceeeseeeeereeetteeeeeeeees 23 5 Operation cece cece ee eeeeeeeeeeeeeeaaeeneaeeecaaaeseeaaeeseaaeeeeaaaeseeaeeesaaeeeeeees 24 5 1 Put the Unit Into Operation seeriana Eaa KEE 24 5 1 1 Performi
24. el Do not try to seal leaks on the connections and high pressure hoses with the hand or by wrapping fabric around them Do not repair material hoses Check hoses and screw fittings for leaks when recommissioning the unit 2 7 3 Injuries In the case of injuries by processing materials or solvents always have avail able the manufacturer s safety data sheet address phone number material designation and material number of the supplier or manufacturer for the attending physician 16 Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs wwf WA Unit description 3 Unit description The HERKULES PFP is a coating unit for insulating layer forming flame retardants It was designed to meet special customer requirements material to be applied mixing ratio transfer quantity etc The unit is used for coating steel parts in structural engineering as weil as in the oil and gas industry The technical data for your unit can be found in the attached machine card 3 1 Intended use The HERKULES PFP is intended for the application of insulating layer forming flame retardants in commercial and industrial applications Any other use is considered to be unintended If you intend to use the unit 1 for other purposes or with other materials and thus not for the purpose for which it is intended you must ask WIWA for permission otherwise the warranty will be invalidated
25. ext in spection The inspection report or a copy of it must be available at the place of use of the unit Translation of the original operation manual HERKULES PFP 33 HERKULES PFP_BAoDB_en_1402_B rs Maintenance WIA 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 Check the lubricant level in the fog oiler Check the release agent level in the fluid pump before each start up before each start up 1 x per week Check and adjust the fog oiler 1 x per week Check and clean the water separator Check release agent of the fluid pump for mate rial residues every 50 operating hours 6 3 Maintenance unit z S Designation Fog oiler adjusting screw Inspection glass Oil filler plug Locking slide Oil tank Water separator Drain valve ONO a O mM Drain hose Fig 25 Maintenance unit 6 3 1 Check the lubricant level in the fog oiler lo 34 The unit must only be commissioned if the oil reservoir of the fog oiler con tains enough oil In case of high humidity use antifreeze for lubrication to avoid icing of the air motor Check the lubricant level every day as follo
26. g terminal with grounding cable The functional principle of all pressure regulators that are installed on the unit is identical gt Turn clockwise to increase the pressure os gt turn anti clockwise to reduce the pressure Translation of the original operation manual HERKULES PFP 19 HERKULES PFP_BAoDB_en_1402_B rs Transportation installation and assembly WWI WA 4 Transportation installation and assembly The unit left the factory in flawless condition and was appropriately packed for transportation 1 Check the unit on receipt for any damage in transit and for completeness 4 1 Transportation Please follow these notes when transporting the unit gt gt gt Ensure sufficient load bearing capacity of lifting gear and lifting tackle when loading the unit You will find the dimensions and weights of the unit on the machine card The unit must only be lifted by the lifting and lashing points provided for this purpose Caution danger of tipping Ensure even load distribution to secure the sys tem against tipping over Do not transport any other objects e g material drums while lifting or loading the unit Never stand under suspended loads or inside the loading area This poses a life hazard Secure the load on the transport vehicle against slipping and falling off If the unit was already operated please observe the following gt gt gt gt Disconnect the entire sy
27. he ram Open the ventilation ball valve at the follow plate see Fig 16 Set the ram control lever to position Down to move the ram down Once all air has escaped from the material container close the ventilation ball valve on the follow plate Hold the drain hose into the collecting vessel Open the drain ball valve Fig 16 Ventilation ball valve Regulate the air inlet pressure on the air pressure regulator for the pump so that the pump runs slowly Close the drain valve again as soon as the processing material exits the drain hose Hold the spray gun into the collecting vessel Unlock the spray gun and operate it until the processing material exits the spray gun 12 Close and lock the spray gun The unit is ready for operation You can start coating Prior to coating the unit must be commissioned 1 2 3 Clean the spray gun outlet Screw the nozzle back into the spray gun Adjust the optimal spraying pressure using the air pressure regulator for the pump see chapter 5 2 1 5 2 1 Adjusting the spraying pressure Translation of the original operation manual HERKULES PFP Please observe the following information when adjusting the spraying pressure gt Optimal spraying pressure is indicated by a uniform application of material with fading out peripheral zones Operate the unit only with an air pressure as high as necessary to achieve a good atomiza tion at the recom
28. m Exchange the material drum when it is empty e 1 age of the pump see chapter 5 2 4 After processing of 6 material drums the pump must be flushed intermedi ately in order to remove material deposits from the unit and prevent a block Set the ram control lever to Stop rf SS PS Regulate the air inlet pressure of the pump completely back Open the compressed air shut off valve for the container ventilation Set the ram control lever to position Up to move the ram up Once the sealing lip of the follow plate reaches the top of the material drum close the compressed air shut off valve for the container ventilation 6 Once there is sufficient space for removing the material drum set the ram control lever to position Stop Remove the old material drum Place the new material drum centered below the follow plate 9 Open the ventilation ball valve at the follow plate 10 Set the ram control lever to position Down to move the ram down 11 Once all air has escaped from the material container close the ventilation ball valve on the follow plate 12 Adjust the optimal spraying pressure using the air pressure regulator for the pump 28 Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs IVA Operation 5 2 4 Intermediate flushing Regulate the air inlet pressure of the pump completely back Set the ram control lever to Stop
29. mended spraying distance of approx 30 40 cm or 12 16 inches Too high spraying pressure causes increased material consumption and paint mist Too low spraying pressure results in the appearance of stripes and differences in the coating thickness Fig 17 Spraying distance 27 HERKULES PFP_BAoDB_en_1402_B rs Operation 5 2 2 Hints to achieve good coating results Hold the spray gun at right angles 90 to the area to be coated If the spray gun is held under a different angle the coating becomes irregular and blotchy see Fig 18 Ensure an even speed and move the spray gun parallel to the area to be coated Waving the spray gun causes irregular coating see Fig 19 gt Move the spray gun with your arm and not with your wrist Already move the spray gun before pulling the trigger In this way you will achieve perfect soft and smooth overlapping of the spray jet and avoid excessively thick application of ma terial at the beginning of the spraying process Release the trigger before stopping the move ment Replace the spray nozzles before these are worn Fig 18 Spray angle thin thick thin layer layer layer Area to be coated yi i y TE j Cory ee TSi wrong Fig 19 Do not wave Worn nozzles cause higher material consumption and have a negative effect 1 on the quality of coating 5 2 3 Changing material dru
30. n order to ground the unit connect the main grounding cable first to clamp 1 of the grounding terminal and then to an electrically conductive object outside the hazardous area Fig 10 Grounding terminal 22 Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs Wf WA Transportation installation and assembly 4 3 4 Connecting the compressed air supply The compressor capacity must match the air requirements of the unit and the diameters of the air supply hoses must match the connections such that an adequate air supply is ensured e Operation with contaminated or moist compressed air causes damage to the i unit s pneumatic system gt Use only dry dust and oil free air 1 Make sure that the compressed air shut off valves are closed and all air pressure regulators have been fully regulated back 2 Connect the compressed air sup ply hose to the air maintenance unit Toe Fig 11 Compressed air connection Translation of the original operation manual HERKULES PFP 23 HERKULES PFP_BAoDB_en_1402_B rs Operation WIA 5 Operation Before starting work check Vl Are all the safety features present and fully functional see chapter 2 4 on page 12 M Are all unit components tight If required tighten up these connections W Is there enough lubricant in the fog oiler s oil container see chapter 6 3 1 on page 34 I Is there enough release agen
31. ng check the maximum permissible pressure for the separately packaged components and accessories It must be higher than or equal to the maximum operating pressure of the unit as specified on the type plate gt Compare the maximum operating pressure of the safety valves with the specifications in the machine card or on the type plate These data must match Translation of the original operation manual HERKULES PFP 21 HERKULES PFP_BAoDB_en_1402_B rs Transportation installation and assembly wi WA 4 3 1 Open the ventilation hole When being used for the first time the sticker with the text remove be fore use and the sealing plug is to be removed from the ventilation hole The ventilation hole is located in the elbow with the openeing facing down ward overflow 4 3 2 Assembling spray hose and spray gun Fit the spray hose to the material out let of the fluid pump see Fig 9 Connect the spray hose to the spray gun as described in the operating manual for the spray gun Fig 9 Connection for the spray hose 4 3 3 Grounding the unit 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 unit and the object to be coated are properly grounded The grounding cables for all compo nents for which grounding is required are merged into the grounding termi nal I
32. ng pressure ChECK eeeecceeeeseeeeeeeeenneeeeeeeenaeeeeeeeaaeeeeneeaa 24 5 1 2 Flushing residues of the test medium eeceeeeeeeneeeeetenteeeeeeeeee 25 5 1 3 Adjust the deicing SYStOM secadero 26 5 1 4 Preparing the material to be applied eee eeeeeesteeeeeeenteeeeeeeeee 26 5 1 5 Fill the unit with material and bleed it eee eeeneeeeeeenteeeeeeeeee 27 52 gt COAUNG EEEN A E A A A S EAEN N 27 5 2 1 Adjusting the spraying preSsure essseissesiissrrriinsrerrrsssrrrrnnsns 27 5 2 2 Hints to achieve good coating results eeeeeeeeeeennnnnnnn 28 5 2 3 Changing material Arum sissors aaaea 28 5 2 4 Intermediate flushing 2 0 0 2 eee cette ee eenee eee eeeeaaeeeeeeeaaeeeeeeeaaeeeeeeeaa 29 5 3 DECOMMISSIONING assisia nE EEEN EEREN 30 5 3 1 Complete fl shing nsike on a a aE 30 5 3 2 Disassembling and cleaning the fluid pump ssssccesscceseereneenn 30 5 3 3 Assembling the fluid PUMP esris 32 5 4 Waste diSpOSAl ee cece ee eeeeeee eee eeeeeeeeeeeeeaeeeeeeeeeaeeeeeeneaaeeeeeeeaeeeeeneaaes 32 6 Mainten anes icc ciiceiecentetecccetined eccdectte a aii EE 33 6 1 Regular INSPOCHONS sanernransnak nnne hee eaeeh ered 33 6 2 Maintenance PlaNsisacicnerssancaduiatsseadeuusssnarvedesaasanceeebsanwusuassouddeeba E 34 6 3 Mamondnco Unt cece c6 oes detect dccadede na O 34 6 3 1 Check the lubricant level in the fog Oiler ccceeeeeeeeeteeeeeeneeeee 34 6 3 2 Checking and adjusting the fog oiler renren 35 6 3 3 Checking and cle
33. ns in this operation manual and in the separate operation manuals of individual unit components and or the option ally available accessory devices 2 2 1 Operating pressure A Unit components that do not comply with the maximum permissible operat ing pressure can burst and cause serious injury gt The specified maximum operating pressures must generally be complied with for all unit 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 unit Material hoses and hose assemblies must comply with the maximum operating 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 2 2 2 Risks caused by the spray jet A A The material is discharged from the spray gun under very high pressure Due to its cutting effect the spray jet can cause severe injuries by penetrat ing the skin or entering into the eyes gt Never point the spray gun at yourself other persons or animals gt Do not hold your fingers or hands in front of the spray gun gt Do not reach with your hands into the spray jet Unintentional material release from the spray gun may cause personal injury or damage to property Always secure the spray gun during every work break gt Always check that the safety mechanism on the spray gun works
34. nt Switch off the material flow heater if you need to perform the following work Cleaning pressure testing decommissioning maintenance and repair 2 2 5 Risks due to the rams gt gt be gt o 10 While the rams are lifting the moving components can crush your fingers hands or other parts of the body Do not reach between the follow plate and the material drum the tra verse and cylinder cover of the pneumatic cylinder or the clamping piece and the cylinder cover of the pneumatic cylinder While the rams are lifting loose clothing can get between the follow plate or the follow cover and the material drum or catch on other moving components or be pulled upwards Wear tight fitting working clothes that are not very tear resistant that have tight fitting sleeves and no protruding parts While the rams are lifting the moving components can cause crushing or impact injuries gt While the rams are lifting nobody must be in the lifting area Accidental starting of the rams can result in crushing and impact injuries gt Each time work is interrupted set the ram control levers to the Stop position Objects placed on the rams may fall down during a stroke movement and cause injuries gt Never place any objects on the rams Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs WIA Satety 2 2 6 Health risks Follo
35. on of the patented design industrial design or registered design This operation manual only applies in conjunction with the machine card that was given to you with the user manual for your unit Please check that the data on the type plate match those on the machine card Please notify us immediately if there are discrepancies if the user manual has been incorrectly compiled or if the type plate is missing Translation of the original operation manual HERKULES PFP 5 HERKULES PFP_BAoDB_en_1402_B rs Safety 2 Safety WIA This unit has been designed and manufactured under due consideration of all safety related aspects It complies with the current standard of technolo gy and the valid accident prevention instructions The unit left the factory in perfect condition and guarantees a high level of technical reliability and safety Nevertheless there are certain risks that can arise from incorrect operation or misuse gt to life and limb of the operator or third party to the unit and other material assets of the owner gt to the efficient working capacity of the unit 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 unit must have read and understood the operation manual beforehand especially the chapter entitled Safety Your safety is at
36. otor slowly counter clockwise minimum one and maximum three turns Exact settings should be made individually and as required because the degree of icing depends on various factors such as e g pres sure number of double strokes per minute air humidity ambient temperature Fig 14 Adjusting screw for the deicing system When interrupting work or in case of decommissioning the adjusting screw of the deicing system remains open 5 1 4 Preparing the material to be applied 26 Observe the technical notes of the respective material manufacturer If necessary heat up the containers of the A and B component to the pro cessing temperature recommended by the material manufacturer If permissable for the material used mix some solvents into the A component using the hand mixer Mix the B component into the A compo nent using the hand mixer Clean the hand mixer with solvent and leave it standing in the container with sol vent This work is best done by a second person so that there is no loss of working time for the mixed material a7 Fig 15 Mixing of material Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs BTA Operation 5 1 5 Fill the unit with material and bleed it 5 2 Coating 10 11 Place the material drum centered below the follow plate Regulate a pressure of 2 3 bar on the air pressure regulator for t
37. 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 Cut off the compressed air supply 2 Depressurize the unit completely A 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 After completing maintenance and repair work check the function of all the safety features and that the unit is functioning correctly 6 1 Regular inspections According to the accident prevention instructions for Work with fluid spray 1 ing equipment BGV D15 the unit must be inspected and serviced regularly by a specialist WIWA customer service The unit must be inspected before initial commissioning gt after the modification 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 units the inspection can be postponed until the next commissioning The inspection results must be recorded in writing and kept until the n
38. pray gun is triggered or the 1 The compressed air shut off valve is closed S Open the compressed air shut off valve motor anti vaccum hole drain valve is opened 2 The air motor is defect Repair the air motor contact customer service if necessary Pump runs but no material is en 1 Bottom valve ball does not rise gt Hit the bottom valve lightly from couraged stuck the side hammer if that does not help press on the ball from below using a peg or screwdriver until loose 2 Bottom valve does not close Remove the bottom valve and clean the ball and seat thoroughly Pump cycles but does not stop when 1 Packing and or valve worn gt Replace parts the spray gun is closed Pump cycles evenly but the required 1 Air supply pressure is too low Increase the inbound air pressure operating pressure can not be with the regulator and check the reached diameter of the inbound air hose 2 Spray nozzle is too big gt Use a smaller spray nozzle 3 Spray nozzle is worn Replace the spray nozzle 4 Air motor is frozen runs too gt If possible reduce the inbound slow air pressure Fill the oiler with anti freeze Gly santine and adjust it Pump cycles unevenly different 1 The viscosity of the coating is too gt Dilute or warm up the coating stroke speeds on the upward and high suction loss material downward strokes and the required 2 Bottom valve leaks
39. pring in the top of the spring housing Lower the ram carefully until the dual piston slides through the spring housing into the pressure cylinder All threaded bolts must pass sufficiently through the connecting ring to avoid damaging the threads Place the washers on the bolts and screw on the nuts Tighten the nuts step wise in a crossing pattern to pull the pump evenly together Torque finally to 110 Nm and add the lock nuts 10 Screw on the follow plate with seal 5 4 Waste disposal At the end of use you must shut down and dismantle the unit and dispose of it in accordance with legal regulations gt Clean the unit thoroughly of all material residues gt Dismantle the unit and separate all materials dispose of metal together with scrap metal plastic parts can be disposed of as domestic waste gt Rests of spraying material cleaning agent oils greases and other chem ical substances must be collected in accordance with statutory provisions concerning recycling and waste disposal The official local waste water laws are valid 32 Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs IVA apna 6 Maintenance A If maintenance and repair work is carried out by persons who have not been trained for this work you endanger yourself other persons and impair the safety and reliability of the unit gt Maintenance and repair work on electrical components must only be car ried
40. slowly to the maximum permissible value given on the type plate 3 Check that all parts of the machine are tight 24 Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs IVA Operation 4 Increase the air inlet pressure for a short time by about 10 above the maximum permissible value The safety valve must blow off 5 Regulate the air pressure regulator for the pump fully back 5 1 2 Flushing residues of the test medium After assembly this unit was factory tested for flawless function by means of a test substance The unit must be flushed with a flushing agent during initial commissioning so that the material to be sprayed is not affected by the test medium 1 Remove the nozzle from the spray gun 2 Unscrew the follow plate Take care that the seal between the follow plate i and the pump is not lost 3 Regulate a pressure of 1 5 2 bar on the air pres sure regulator for the ram 4 Set the ram control lever to position Up to move the ram with the pump up Fig 12 Ram control lever 5 Once there is sufficient space under the pump for the flushing agent container set the ram control lever to Stop middle position as shown in Fig 12 6 Place a drum with with 10 15 flush ing agent below the pump 7 Set the ram control lever to position Down an move the ram down until the suction of the pump immersed into the flushing agent 8
41. spray gun into the flushing agent drum and allow the pump to circulate flushing agent via the spray gun for 2 3 min Exchange the flushing agent drum for a clean one with new flushing agent and repeat the complete flushing procedure via the drain hose and the spray gun 5 3 2 Disassembling and cleaning the fluid pump A 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 A The parts of the fluid pump are heavy At best work In pairs and position a soft mat to catch falling parts 30 Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs BTA Operation 1 Unscrew the material outlet and the drain hose 2 Drain the release agent Mesamoll into a catch container 3 Unscrew the nuts on the 6 threaded bolts see Fig 20 4 Pry the pressure cylinder from the spring housing using a pry bar or screwdriver see Fig 21 Fig 20 Unscrew the nuts on the threaded bolts hd i 4 4 Fig 21 Pry the pressure cylinder Fig 22 Pry the spring housing from the spring housing from the HP head 5
42. ssed air shut off valve for interrupting the air supply to the container ventilation The functional principle of all com pressed air shut off valves that are installed on the unit is identical Fig 2 Compressed air shut off valve gt Open gt set in the direction of flow Close gt set across the direction of flow After closing the air the unit is still pressurized This means that before car rying out maintenance and repair work you must always carry out complete pressure release Io 12 Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs BTA Satety 2 4 2 Safety valve The safety valve is installed in the air motor of the HERKULES PFP The safety valve ensures that the max permissible air inlet pressure is not exceeded If the air inlet pressure exceeds the fixed limiting value the safety valve will blow off Fig 3 Safety valve A If the maximum permissible air inlet pressure is exceeded unit components may burst This may result in damage to persons and property gt Never allow the unit to run with or without defective safety valves Ifa safety valve needs to be replaced you can find the corresponding order number on the machine card With new safety valves ensure that they have been set to the maximum permissible air inlet pressure of the unit See type plate machine card and sealed with a lead seal 2 4 3 Grounding wh
43. stem power supply even for short transportation distances Empty the unit before transportation fluid residues may escape during transportation despite this measure Remove all loose parts e g tools from the unit 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 A ale 20 The HERKULES PFP can be installed inside and outside spray booths However outdoor installation should be preferred in order to avoid contamination If the unit is used outside during a thunderstorm a lightning strike can cause a life threatening situation for the operating personnel gt Do not operate a unit out of doors during a thunderstorm gt The unit owner must ensure that the unit is equipped with suitable light ning protection equipment Set the unit up horizontally on a foundation that is flat firm and vibration free The unit must not be tipped or on an incline Ensure that all the operating elements and safety features are easy to reach Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs Wf WA Transportation installation and assembly Safety measures at the place of installation This unit requires a solid base and suffi cient free space for safe operation gt Secure the unit at its final location to pro tect it against unintended movement
44. t in the pump WARNING A 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 opera tion gt However should this happen stop the pump immediately and feed material 5 1 Put the unit into operation Prerequisites gt The unit must have been set up correctly and completely assembled Do not start commissioning the unit unless you have the specified protec tive equipment For details refer to chapter 2 5 4 on page 14 gt The material to be processed must be available in sufficient quantity In ad dition you will need one suitable collecting vessel for excess material This container is not included in the scope of delivery Overview of the work sequence for commissioning 1 Perform pressure check Flush residues of the test medium only during initial commissioning Adjust the deicing system Prepare the material to be applied oS Se lS Fill the unit with material and bleed it 5 1 1 Performing pressure check Check list before pressure check Have all compressed air shut off valves been closed Have all air pressure regulators been regulated completely back Is the control levers of the ram in Stop position Is the spray gun locked Open the compressed air shut off valve on the air maintenance unit er Bake Increase the air inlet pressure with the air pressure regulator for the pump
45. tructed by the unit 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 unit 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 1 Activity Qualification Setup and operation Instructed operator Cleaning Instructed operator Servicing Trained personnel Repair Trained personnel Juveniles under the age of 16 are not allowed to operate this unit 2 5 4 Personal Protective Equipment PPE A 14 Inside hazardous areas static charges can result in serious accidents Wear inside hazardous areas only antistatic protective clothing overall protective gloves and protective footwear Wear protective clothing Always wear the protective clothing prescribed for your work environment and follow the recommendations in the safety data sheet issued by the mate rial manufacturer Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs Safety Use eye protection Indicates the requirement to wear protective goggles to protect against eye injuries caused by material splatter gases fumes or dust Wear ear defenders Operating personnel should be provided
46. umatic hoses is to be expected The accumulated condensation water is automatically drained off through the drain valve For this purpose hold the hose into an empty collecting vessel Check the bowl regularly for dirt residues and clean it as required No Designation 1 Release agent filler pipe 2 Inspection glass 3 Release agent drain screw Fig 26 Fluid pump 6 4 1 Checking the release agent level Check the amount of release agent before every start up The release agent level must be at least half the inspection glass If required top up the amount of release agent through the filler pipe We recommend using release agent from WIWA order number 0163333 Translation of the original operation manual HERKULES PFP 35 HERKULES PFP_BAoDB_en_1402_B rs Maintenance WIA 6 4 2 Checking release agent for material residues In order to check the release agent for material residues you must drain off a small amount of release agent from the drain screw If the release agent is found to be contaminated with material residues you must assume that the packing of the fluid pump is worn In this case have the pump packing replaced as soon as possible by WIWA customer service or by specially trained personnel After the examination top up the amount of fresh release agent through the filler pipe 6 4 3 Replacing the seals on the follow plate You must replace seals on the follow plate when
47. w the safety notes and dosing information of the manufacturer and the i generally applicable regulations when handling paints solvents oils greas es and other chemical substances A Depending on the materials being applied solvent vapours may be generat ed 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 man ufacturers When cleaning your skin use only appropriate skin protection skin cleaning il 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 tri chloroethane 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 units 2 3 Information signs on the unit Information signs attached to the unit like safety information see Fig 1 refer to possible danger J Achtung areas and must be strictly observed WIWA They must not be removed from the unit Damaged and illegible information signs must be replaced immediately Apart from this you should also read and follow th
48. ws 1 Press up the locking slide on the oil reservoir and unscrew the oil reservoir by turning it anti clockwise Take care of the O ring that seals the oil reservoir It may be displaced or even fall out at dismantling 2 Check whether the O ring fits correctly if necessary fit it correctly Translation of the original operation manual HERKULES PFP HERKULES PFP_BAoDB_en_1402_B rs PITA Maintenance 3 Check whether there is enough lubricant when filled completely the lubricant reaches to a point approx 2 cm below the upper edge of the oil reservoir 4 Top up lubricant if necessary We recommend using pneumatic oil order number 0632579 or antifreeze order number 0631387 from WIWA 5 Reattach the oil reservoir to the air maintenance unit 6 3 2 Checking and adjusting the fog oiler 1 Let the main pump run slowly under load 2 Check in the fog oiler inspection glass whether 1 drop of lubricant is fed after each 10 to 15 double strokes of the air motor 3 If this is not the case adjust the metering by turning the regulating screw on the fog oiler with a screwdriver 6 3 3 Checking and cleaning the water separator 6 4 Fluid pump The water separator prevents condensation water and dirt particles from enter ing into the unit In addition a filter is installed in the water separator which fil ters out particles gt 40 u from the compressed air Therefore no static charging of the pne
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