FLUID HEATER
Contents
1. For equipment which has been taken out of operation the check can be postponed up to the next start up The results of the checks must be recorded in writing and kept until the next check The checking certificate or a copy of it must be available at the place where the equipment is used Maintenance instructions for the spray equipment and ac cessories can be found in the corresponding User s Hand book 18 Translation of the original operation manual Fluid Heater 77 JA MDFE 0A e en 01 10 Rev 1211 cf e Malfunctions and trouble shooting 7 Malfunctions and trouble shooting Material in the heater does not beco me warm at all Material heats but does not reach the desired temperature Male adaptors or fluid hoses are leaking Material does not flow WITA MDFE 0A en 01 10 Rev 1211 cf e No electricity A Check that electricity is available The temperature limiter has shut gt B Check the power connection off the fluid heater Heating cartridges are defect Temperature limiter is defect Temperature is set incorrectly The amount of material passing throught the heater is too large Male adaptors and or fluid hoses are not tightened correctly or da maged Heat exchanger is clogged Translation of the original operation manual Fluid Heater and power supply cable and re place if necessary The above so lutions Point A and B may only be performed by qualified elec trical pe2. Observation of this information is abso lutely essential ELECTRICAL VOLTAGE This marks a situation where there is a danger of explosion through an electostatic charge Observation of this information is absolutely essen tial HOT SURFACES This marks a situation where there is danger of burns caused by hot surfaces Hot surfaces should not be touched unless wearing protective gloves WEAR PROTECTIVE GLOVES Wear protective gloves with lower arm protection to avoid burn injuries The warnings must be adhered to HEALTH DANGER This marks materials which are hazardous to your health Observation of this information is absolutely essen tial FIRST AID In case of injuries or accidents these instructions should be absolutely adhered to u X gt PPP iN Translation of the original operation manual Fluid Heater 2 2 The warning labels and symbols on the 3973374 Fluid Hea ter indicate possible sources of danger and must be obser ved accordingly Warning labels on the fluid heater Warning labels and symbols may not be removed from the equipment Damaged or illegible warning labels and symbols must be immediately replaced The following labels are found on the 3973571 Fluid Heater Warning label Attention Important Warning Achtung Wichtige Hinweise e Nur im kalten und spannungsfreien Zustand sp len e Flammpunkt des Spritzmaterials beachten Attention Important Warning
3. a brass washer must be fitted under the separating screw It must be removed again before using the screw to separate the heater hou sings Screw an adaptor into the outbound air connection on the Fluid Heater Connect a compressed air line between the upper housing of the air motor and the MDFE 0A e en 01 10 Rev 1211 cf e Start up Fluid Heater refer to Chap 3 1 3 2 The part no for the de icing kit is located in Chapter 8 1 Further part numbers for addtional connections can be obtained by contacting 39733741 Customer Ser vice 4 2 First cleaning This 39733574 Fluid Heater was function tested at 39 7 3374 factory using a test medium To ensure that no test medium is left in the pump the entire system should first be flushed using the solvent recommen ded by the manufacturer of the coating to be used Disconnect the heater from the power source Now complete all steps covering the initial flushing found in the spraying equipment s User s Handbook mina For best results we recommend flushing 1 minute the system for approximately one minute To avoid any danger of explosion do not allow the solvent to circulate for more than 5 minu max E minutes tes and ensure that the amount of available solvent corresponds to the size of the pump iilis P used Depending on the pump at least 8 to L se 25 liters 2 to 6 5 gallons of solvent are ne disce cessary approx
4. e Flush only in cold and unplugged state Watch the flash point of the spraying materials Picture 2 1 Warning label Danger Disconnect power supply before opening Picture 2 2 Warning label Hot surface Picture 2 3 Nameplate Please insure that the data on the type plate is in accor dance with the information in the user s handbook If there are discrepancies or if the nameplate is missing plea se notify us immediately wIWA GmbH amp Co KG D 35633 Lahnau Germany www wiwa de Dom aale e WIWA3500 Uu NEP NEM O 200 bar 5 30000 170000 Schutzart e e Picture 2 4 450 bar Fabr Nr Bauj MDFE 0A e en 01 10 Rev 1211 cf e 2 3 Dangers arising from the equip ment e This machine was designed and built in accor dance with all safety aspects It corresponds with the present standards of technical regulations and current rules for accident prevention 1 This equipment left the factory in perfect condition and gua rantees the highest level of safety However the following dangers exist if operated incorrectly or used inappropriately to life and limb of operator or third persons for the machine and other property belonging to owner of machine gt for the efficient working of the machine All personnel involved in the starting operation and main tenance of the machine must read the following notes ca refully and observe them It is a matte
5. ration You can now commence with coating the desired object Payclose attention to the instructions found in the User s Handbook for the spraying equipment Never place hands or fingers in or near the spray jet If using a Hot Spray system without circulation cold material is still located in the hoses It is recommendable to pump the material back into its container until heated material exits the spray gun When using two component materials the pot life must be observed MDFE 0A e en 01 10 Rev 1211 cf e 5 2 The entire system has to be flushed thorough ly to avoid any possible chemical reaction with the new coatings material Change of material 1 Shutting down Follow all the instructions found in Chapter 5 3 Shutting down 2 Shutting down the equipment After disconnecting the heater from the electrical power supply perform all steps covering changing materials and or shutting down as found in the User s Handbook for the spray pump system 3 Flush Flush the complete system when the unit is cold disconnected from the electrical power supply approx 2 minutes Operation Use the solvent that is recommended by the coatings manufacturer Follow the instructions found in the pump s system s User s Handbook covering changing materials and or starting up the unit 4 Restarting the unit Follow the instructions found in the User s Handbook for t
6. work maintenance repair cleaning is performed Read and follow the operating manual for the spray equipment and accessories Switch the Fluid Heater to position l Disconnect the power supply Release the pressure in the heat exchanger of the Fluid Heater Upon stoppage or hardening of material in the equipment residual pressure can exist in spite of pressure release Takethisintoconsiderationwhenrepairingthe Fluid Heater Wear protective gloves and glasses and loosen the hose connections very carefully We recommend that you cover the connections with a rag when loosening to prevent the spraying of material Due to electro static charges only conductive material hoses should be used All original 39 73374 material ho ses are conductive and compatible with our equipment The maximum admissible working pressure on the ho ses must correspond to the maximum operating pres sure of each airless machine In closed or pressurised systems where alumini um or galvanised parts come into contact with the solvent dangerous chemical reactions can occur if 1 1 1 Trichlorethylene Methylene Chloride or other solvents containing halogenated chlorinated hydro carbons CFCs are used If you wish to work with the above solvents or with lacquers and paints which contain them we recommend you contact either M7WA customer services or W WA directly All fluid wetted parts of the 4973924 Fluid Heater are constructed of rust and acid re
7. Pressure Fluid Heater is suitable for hea ting materials to be applied in low pressure processes Futhermore the 3973371 Low Pressure Fluid Heater can be used for the supply of heated air to the air motor de icing or for preheating materials being fed to plural compo nent spraying systems BTA MDFE 0A e en 01 10 Rev 1211e cf e Machine description 3 2 Equipment versions Converting an Airless or Air Combi pump to an Airless or Air Combi Hot Spray version Picture 3 3 By adding a W WA Fluid Heater shorter curing times higher film builds and top quality finishes can be achieved In addition heating influences viscosity High viscosity ma terials that would be difficult to spray under normal circums Spray Gun tances can now be handeled more easily The required mounting kits are available for all 37737A Airless and Air Combi units Picture 3 3 Portable Fluid Heater Picture 3 4 This version is used additionally when high temperatures Spray Gun are required at the spray gun tip It is also applicable as an additional heating element when Aja lt working with long spray hoses to avoid line heat loss The following kit is required f Portable Frame for Fluid Heaters Order No 0632538 as Portable Fluid id well as a 3973971 Fluid Heater Heater Picture 3 4 Airless pump with frame mounted Fluid Heater and additional portable Fluid Heater 39 7A Translation of the original operation manu
8. When setting the desired temperature never exceed the flashpoint temperature of the material that has been stated by the mateirals manufacturer For each material sprayed the corresponding data sheets must be available The information surrounding the viscosity working temperature flashpoint and the mixing ratio stated by the manufacturer must be obser ved and followed closely BURN DANGER The temperature on the outside of the Fluid Heater can more than 80 C 176 F depending on the temperature setting Therefore it is important to always wear protec tive gloves Always observe that the fluid hoses do not come into contact with the hot surfaces of the Fluid Heater temperature selec ted the spray gun can become very hot Always wear the appropriate protective gloves and clot hing When starting the unit and after any repairs maintenance or cleaning have been performed make an optical check The of the equipment for any signs of leaks or other defects Never try to stop a leak at a fitting or high pressure hose using your hand or by wrapping with a rag etc When a leak is detected the entire system spray pump gun hose filter etc must be pressure released immedia tely and the defective parts must be replaced Follow the instructions in the User s Handbook for the spray equipment and accessories The entire system spray pump heater accessories must be shut down and pressure released before any
9. cleaning and servicing After maintenance and repair Checklist for inspection of the protective devices on the pressure released machine LI Inspect ground cable for damage L Inspect the ground cable connection to the unit and the ground circuit All Fluid Heaters are supplied with the following safety de vices Temperature Limiter The temperature limiter turns off the fluid heater when it ex ceeds the max allowed temperature 3 To reset press the button pict 2 5 Memorize the local emergency phone numbers Take care that sufficient information notes labels for fire prevention are provided Do not apply any other extinguishing agents than those which are prescribed by the manufacturer of the materi Picture 2 5 als The fluid heater is operating when the control lamp is illumi nated or when shown on the control panel Ground Cable A separate grounding of the Fluid Heater is required when no electrically conductive connection to the spray unit exists Connect the ground cable on the provided grounding screw Picture 2 10 2 39799 Order Number for the Ground Cable 0474487 Make sure that the unit is grounded either se parately or together with the equipment it is mounted to maximum resistance 106 QO ground potential equalization 8 Translation of the original operation manual Fluid Heater 4477 FA MDFE 0A e en 01 10 Rev 1211 cf e Safety The grounding screw is lo cated near the po
10. for the inbound air supplying the equip ment Depressurize the system by opening the spray gun or the pressure drain for the pump i e at the high pressu re filter When doing this the instructions found in the User s Handbook for the pump and accessories are to be adhered to strictly Defective parts must be replaced immediately Injury Should an injury occur through contact with liquid spray we recommend a doctor be called immediately Inform the doctor about the type of material paint and the solvent thinner used Have the product data sheet at hand address and telephone number of supplier or manufacturer name of material and material number Memorize the local emergency phone numbers nany case become familiar with the first aid measures 1 Fire Read the instructions for fire alarm and escape routes put up in your factory gt Protective devices e If a protective device is not fully operative or another defect is detected on the machine in terrupt the compressed air supply to the machi ne and disconnect the heater immediately from the power source Follow the instructions in the User s Handbook for the spray equipment The machine may be restarted only if perfect operation is restored All protective devices must be inspected for proper function Before each commissioning of the machine Before beginning work with the unit After each alignment After
11. heated to 25 C 77 F in one minute with 2 0 kW one liter of water can be heated to 28 C 82 F in one minute with 3 5 kW one liter of water can be heated to 50 C 122 F in one minute fluid hoses must be used 8 2 Accessories These hoses are then mounted to the outbound connection on the Fluid Heater and the inbound connection on the cir Temperature Gauge Picture 1 2 3 to read the temperatu culation valve Picture 1 2 5 re at the material outlet of the Fluid Heater The circulation valve is to be mounted in the direction of x material flow between the material pump and suction hose Please note the arrow on the valve housing Depending on the pump model the circulation valve either comes standard Picture 1 2 5 or optionally Picture 1 2 6 with a pressure drain valve The desired circulation speed can be set using the regulating knob Picture 1 2 4 Pos 1 Picture 1 2 3 Fluid Heater with High Pressure Filter and Tempe rature Gauge Temperature Indicator If using long spray hoses or if the exact material temperatu re at the tip has to be monitored a thermometer is required that is both long and capable of handling the spray pressure at the tip The thermomoter must be held into the spray jet with at least 5 cm 2 in distance from the spray tip Never place hands or fingers into or near to the spray jet Circulation Valve Picture 1 2 4 for circulation systems Circulati
12. not Ex Proof may only be used outside of rooms where explosion proofing is required Use in an area where solvent vapours exist can cause the power cable to become porous or cra cked Therefore the power cable must be inspec ted visually for damage before each operation Never make repairs to the power cable It must be repla ced completely by a qualified technician Before connecting the Fluid Heater to the electrical sup ply check to ensure that the point of hook up is functio ning correctly and no faults are present In case of power failure disconnect the power supply to prevent the Fluid Heater from switching on independ ently Residual material left in the Fluid Hea ter can harden and lead to damage of the unit The heater must be completely flushed with an ap propriate solvent within the potlife given by the mate rial manufacturer but only when the heater is cold Please observe that the potlife of plural component ma terials is shortend considerably by heating DANGER EXPLOSION Flush and clean with solvent only when the heater is cold and disconnected from the power source Never heat solvent in the Fluid Heater DANGER OF EXPLOSION Never spray solvent or material containing solvent into narrow necked cans or drums with bungholes DANGER OF EXPLOSION The unit may not be opened when located in and ex posed to explosive environments DANGER OF EXPLOSION Always observe the flashpoint of matierals to be heated
13. with spraying equipment Therefore all instructions covering unit preparation commissio ning operation and shutting down must be compa red to those covering the spraying equipment itself for compatability Read and observe the instructions found in the user s handbooks for the spraying equipment the fluid heater and any additional spray accessories Pay special attention to chapters covering safety in the user s handbooks Mi gt The risk of solvent fumes and or splashes can 3 never be fully eliminated Always wear proper m protective clothing to avoid injury 2 a Connect the power supply Fluid heater with temperature setting knob The heater is equipped with a permanent power con nection cable without plug For versions without cable and cable connection mount cable connectors Before connecting the Fluid Heater to the electrical sup ply check to ensure that the point of hook up is functio ning correctly and no faults are present This should only be done by trained electrical A personnel Note this equipment is not suitable for use in Ex proof zones 2 6 Connect power supply and temperature sensor fluid heater without temperature setting knob For fluid heaters with connection for remote control Unsrcew the cover of the heater and mount the con nection cable and temperature sensor PT100 3 wire sensor on the bus bar according to the wiring diagram This should only be done by tra
14. 8 25l 2 6 5 gal 4 3 Pressure testing The maximum operating pressure of the 39739731 Fluid Heater must be equal to or greater than the max operating pressure of the spraying equipment and any accessories The lowest value is to be taken for the complete system Disconnect the heater from the power source gt Ensure that the 39733 4 Fluid Heater and been connec ted according to the instructions found in Chapter 3 1 and that all fittings are tightened properly Now complete all steps found in the spray equipment s User s Handbook covering pressure testing of the sy stem 3377297731 Translation of the original operation manual Fluid Heater 15 MDFE 0A en 01 10 Rev 1211 cf e Operation 5 Operation 5 1 Equipment preparation 1 Safety Always remember that the 39733741 Fluid Hea ter may only be flushed when cold an discon nected from the electrical power supply Always observe the working temperature given by the manufacturer of the coating to be hea ted Check to ensure that accessories i e temperature gauges back pressure valves are connected correctly Check to ensure that the pressure ratings of all system components and accessorires corre spond to the maximum operating pressure of the 3973974 Fluid Heater Check for the proper ground of spray pump Fluid Heater accessories Object to be coated Observe all instructions found in the User s Handbook for the spra
15. E 0A e en 01 10 Rev 1211e cf e Machine description 3 3 Designation of components Mounting screw for the heat exchanger M 10 Torque 13 Nm 9 6 ft Ib Separating screw for remo ving the heat exchanger from the housing M 12 for air motor de icing and additional brass seal must be For use with air motor de icing these holes must be pluged Use the screws M 10 included in the assembly kit Air Motor De lcing mounted Inbound air G 14 Mounting screw for the heat exchanger M 10 only for de icing Torque 13 Nm 9 6 ft Ib Main housing with all electrical switches and heating elements P S qi y pe 1 L Li PT fr E 38 8 Schutzart d L Er w 3500 S Erhitzer Typ WIE DALET 0E Wilh Wagner Gm Outbound air G only for de icing Connection for inbound material Pea NPSM LP d Heat exchanger Connection for outbound material HP 3 NPSM LP 3 Fluid heater without temperature setting Fluid heater with temperature setting knob knob for remote control Button to reset the temperature limiter Control lamp Temperature setting knob Temperature sensor Power supply 337723723 Translation of the original operation manual Fluid Heater 13 MDFE 0A en 01 10 Rev 1211 cf e Start up 4 Start up 4 1 Erection and preparation 1 Obseve the User s Handbooks for the pump and ac cessories o 79A Fluid Heaters can only be used in con junction
16. Headquarter amp Production WIWA Wilhelm Wagner GmbH amp Co KG R GewerbestraBe 1 3 35633 Lahnau Germany Tel 49 6441 609 0 Fax 49 6441 609 50 E mail info wiwa de Internet www wiwa de WIWA LP 3734A Cook Blvd Chesapeake VA 23323 USA Tel 1 757 436 2223 Fax 1 757 436 2103 Tel Toll Free 1 866 661 2139 E mail sales wiwalp com Internet www wiwa com WIWA Taicang Co Ltd Add No 87East Suzhou Rd Taicang city Jiangsu province 215400 P R China Tel 86 512 5354 8858 Fax 86 512 5354 8859 E mail info wiwa china com User s Handbook FLUID HEATER High Pressure HP Fluid Heater Fluid Heater 3500R 230V_ 0649442 3500R 40V O 0653488 0 Reg 3500R 440V 3 phase 0648376 O 0648377 O 0657724 3500R 440V i phase O 0654017 Manufacturing No Ce 337723723 Translation of the original operation manual Fluid Heater MDFE oA en 01 10 cf Content 1 Content 1 1 Preface This User s Handbook must al ways be available to operating staff The operating authority of the equipment must ensure that a User s Handbook is available to the operator in a language which he under stands Dear customer Thank you for your decision to purchase 3973374 equip ment In the User s Handbook you can find all information requi red for the proper handling of your 39733241 Fluid Heater However for safe operation ther
17. al Fluid Heater 11 MDFE 0A en 01 10 Rev 1211 cf e Machine description Heating of air motors de icing system by using a Fluid Heater Picture 3 5 Air Motor Upper Housing Air Motor Upper Housing _ Air Maintenance Unit Connection Picture 3 5 When operating with adverse ambient temperatures and high humidity a 7737A Fluid Heater can be used to provi de the air motor with heated air to avoid icing de icing sys tem A portion of the inbound air is tapped from the main line and routed through the Fluid Heater and then back to the air motor This pre heated air is then patched into the air drain chan nels in the air motor to reduce the possibility of icing The following kit is required Air Heating Kit for 39 73374 Fluid Heater Order No 0632629 Atomization Air Heating for Air Combi Hot Spray Units Picture 3 6 Spray Gun i Picture 3 6 12 Translation of the original operation manual Fluid Heater Designed for reaching an optimal spray pattern improved paint dispersion and shorter curing times To avoid pre heated material from cooling when coming in contact with the atomizing air the 37737A Fluid Heater can also be used to heat the air before it goes into the spray gun A portion of the inbound air is tapped from the main line and routed through the Fluid Heater and then out to the gun To avoid line heat loss the air and material hoses should be bound together and insulated MDF
18. ay remain as these could endanger the safety of the users The operator must make sure that only authorised persons work on the machine He is responsible to third parties in the working vicinity of the system The operator of the equipment is obliged to repeat instructi ons about dangers and safety measures at regular intervals at least once a year for young persons twice a year Operating staff Personal protective equipment We call to your attention that the valid guidelines and requirements in accordance with work sur roundings mining closed areas etc must be ab solutely adhered to Please wear the prescribed protective clothing at all times as solvent vapours and solvent splashes cannot be completely avoided To prevent burn injuries never touch the Fluid Hea ter unless wearing protective gloves Never use solvent or other materials which present a health hazard for cleaning skin Only suitable skin protective skin cleansing and skin care mate rials may be used xc WITA MDFE 0A en 01 10 Rev 1211 cf e Safety 2 7 Safety measures at installation site j gt MounttheFluid Heater securely onthe spray unit Installation site a wall bracket or the frame with carrying handle The system must have a fixed position and suf ficient space to ensure safe operating The pas sage to the safety fittings must not be blocked eG For versions without cable and cable connec 1 tion the own
19. e are further essential de tails which you should adhere to Please read and observe the guidlines valid for your coun try In Germany the Richtlinien fur Flussigkeitsstrahler Guidelines for Fluid Sprayers published by Hauptverband der Gewerblichen Berufsgenossenschaften Industrial Em ployer s Liability Insurance Association are valid Manufacturer s notes and operating guidelines for coa ting and pumping materials should be observed at all times As the 3973971 Fluid Heater can only be used in connec tion with spray equipment the operating manuals for the spray equipment and any accessories used must be obser ved and followed No method of operation should be exercised which impairs the safety of 39733741 products and the operating person nel We wish you much success and excellent working results when appliying your 9 73373 Fluid Heater WIWA Wilhelm Wagner GmbH amp Co KG 2 Translation of the original operation manual Fluid Heater Read before starting 3973741 Fluid Heaters are designed for use in either high pressure HP or low pressure LP applications depending upon the model Im proper use especially in high pressure appli cations can cause life threatening injury 1 2 o 1 Always observe the instructions and regulations given in the User s Handbook It is important to check prior to each use Proper grounding pump and object to be sprayed All connections and accessories fo
20. eater 9 MDFE 0A en 01 10 Rev 1211 cf e Machine description 3 Machine description 3 1 The 39739741 Fluid Heater can be used according to versi on HP or LP in high or low pressure applications for hea ting the applied materials and or the compressed air supply The following types of coating materials may be heated Paint and lacquers Protective coatings oil and grease Stripping agents Insulation and fire protection coatings Tar epoxy and bituminous paints Polyurethane Water Application of the machine VVVVYYY The Fluid Heater Picture 1 2 1 consists of two main parts Housing with electrical switch and heating elements Heat exchanger with material inlet and outlet connec tions Picture 3 1 Material flows through the heat exchanger and is warmed by the heat produced by electrical heating elements in the the housing The lower part of the housing is conical The heat exchan ger has a matching conical form Should a blockage occur in the heat exchanger it can be removed from the housing by using the separating screw and then exchanged The desired temperature can be steplessly adjusted max temperature 85 C at the temperature setting knob on the fluid heater pict 3 2 or for fluid heaters without tempera ture setting knob at the control panel 10 Translation of the original operation manual Fluid Heater Picture 3 2 e The heater may not be used in areas with risk 1 of exp
21. er operator of the equipment has to mount cable connectors are used This work may onl be perfor A med by a qualified electrician Observe the Ex Proof zoning of the workplace Before connecting the Fluid Heater to the electrical sup ply check to ensure that the point of hook up is functio ning correctly and no faults are present The owner operator of this equipment is required to ensure that proper protection against lightning strikes is available Keep the working area especially all gangways and standing areas clean Remove spilled paint or solvent immediately Pay attention that no moisture ex through rain high pressure cleaning etc gets into the Fluid Heater The Fluid Heater must never be immersed in a container of liquid ex solvent Ensure there is sufficient ventilation at the workplace to prevent damage to health and property Observe the manufacturer s processing instructions at all times Read and follow the instructions in the User s Handbook for the spray equipment and accessories Comply strictly with the current rules for acci dent prevention Translation of the original operation manual Fluid Heater Safety 2 8 Behaviour in case of emergency A Leaks If any leaks occur from the Fluid Heater the electrical power supply is to be disconnected immediately The entire system including the Fluid Hea ter must then immediately be depressuried Close the air tap
22. erved You can find these safety regulations in the User s Handbook located with the spare parts lists If you use attachments and spare parts from another sour ce 3973371 cannot guarantee the safety of the entire sy stem In this case our guarantee does not cover any dama ge or injury caused by such attachments and spare parts j Danger caused by attachments and spare parts Emissions It is possible for solvent vapours to occur depen ding on the materials used Therefore please ensure the workplace is sufficiently ven tilated in order to avoid damage to health and property Al ways observe the processing information given by the ma terial manufacturer The operation of the fluid heater is noiseless 2 5 Sources of danger and safety war nings The 397339741 Fluid Heater may only be used according to version HP or LP in high or low pressure applications with the corresponding spray equipment and accessories The User s Handbook for the spray equipment and acces sories must be read and followed Inappropriate use can lead to severe injury It is especially important to note that when used as a com ponent in Air Combi Airless or Airless 2K spray units that this is high pressure equipment which can cause life th reatening injury Translation of the original operation manual Fluid Heater o Depending on the Safety Please observe and obey the following AAAAG Power supply cables which are
23. he owner of the following machine has trained the operating personnel Make Model Year of Construction Order Number The training was conducted by the following designated person Foreman or responsible Superior Name Department The persons trained have read and understood the User s Handbook for the above mentioned machine especially the Chapter Safety and are certain that they can operate this machine safely Personnel Electric Electronics Date Name 8 4 EC Declaration of conformity We WIWA Wilhelm Wagner GmbH amp Co KG GewerbestraBe 1 3 D 35633 Lahnau hereby declare in sole responsibility that the product Fluid Heater machine types Fluid Heater 3500 to which this declaration relates complies with the following standards and documents in accordance with the EC low voltage directive 2006 95 EG Documentary authority Heidrun Wagner Turczak Lahnau 01 01 2010 Jun igi 7 Place date Heidrun Wagner Turczak Managing Director 20 Translation of the original operation manual Fluid Heater 97 FA MDFE 0A e en 01 10 Rev 1211 cf e
24. he spraying equipment being used Complete the instructions found in Chapter 5 1 Step 4 6 WITA MDFE 0A en 01 10 Rev 1211 cf e Operation 5 3 Shutting down Turn off the Fluid Heater Turn off the Fluid Heater 10 minutes before work is com pleted To do this turn the temperature knob to the position l Picture 5 3 1 This will enable the operater to use the residual heat up until the end of work while shortening the cooling time until the unit can be flushed V VY Y Temperature setting knob 10 minutes before s the end of work Picture 5 3 2 Disconnect from electrical power supply Disconnect the heater from the electrical power supply 3 Flush Avoid damage to the unit and the entire system by tho roughly flushing after every shutdown Follow additionally the instructions located in the cor responding User s Handbook for the spray equipment being used Translation of the original operation manual Fluid Heater 17 Checks 6 Checks e According to the rules for the prevention of acci 1 dents Working with liquid jet systems BGV D15 the equipment must be checked and overhauled at regular intervals by a specialist W WA Service The equipment must be checked before the first start up after changes and repairs of equipment parts having an effect on safety gt after an interruption of operation of more than 6 months however at least every 12 months
25. ined electrical A personnel Note this equipment is not suitable for use in Ex proof zones 14 Translation of the original operation manual Fluid Heater 3 Mount the Fluid Heater gt Securely mount the W WA Fluid Heater to your spray equipment on a wall mount oder on a portable frame refer to Chap 3 1 4 Ground the unit To avoid electrostatic charging the 39 733243 Fluid Hea ter must be grounded to a conductive object by way of the grounding cable The object to be coated must be grounded as well 5 Mount the fluid hoses Remove the yellow caps from the heat exchanger s ma terial inlet and outlet De lcing Picture 4 1 1 Pos 1 2 Use a male adaptor to mount the fluid hoses to the Fluid Heater The connections must be sealed using either teflon tape or medium strength thread sealant i e Loctite Approximately 80 Nm 59 ft lb torque must be ap lied The part no for the male adaptor can be found in Chapter 8 1 Further part numbers for addtional connections can be obtained by contacting 39 73371 Customer Ser vice Inbound Material IN Outbound Material OUT Picture 4 1 6 Mount De Icing Assembly for 300 and 333 air motors and the mounting kit for 200 and 230 air motors De lcing Picture 4 1 Pos 3 4 Mount the kit to the Fluid Heater gt For the inbound air connection an elbow fitting is mounted to the bottom of the unit Furthermore
26. losion Before 3973371 equipment is used for other purposes or with other materials and therefore not according to the regulations permission should be obtained from the manu facturer as the guarantee is otherwise invalid The obser vation of technical documentation and the compliance with specified operational maintenance and starting guidelines are manditory in accordance with the valid regulations Models 3973374 3500 HP Max operating pressure 450 bar 6525 psi The 397339741 High Pressure Fluid Heater is especially sui table for use with Airless spraying systems Airless plural component units und Air Combi systems The advantages of the hot spray process include higher coating thickness shorter drying times and top quality fi nishes Coating materials which are normally difficult or impossible to process due to their consistency become easily spraya ble when warmed up using a 3973374 Fluid Heater With the addition of a mounting kit the fluid heater can si multaneously be used for heating of the compressed air supply a as pre heater for a 39739741 air motor to prevent icing caused by low outside temperatures and high humidity b for the heating of the atomizing air for Air Combi sy stems Through additional heating of the atomizing air the quality of the finish is improved further and the dry ing time is shortened Model 3973374 3500 LP Max operating pressure 200 bar 2900 psi The 3973971 Low
27. luid heater Safety Explanation of symbols Warning labels on the fluid heater Dangers arising from the equipment Application of the machine Machine surroundings Sources of danger and safety warnings Operating staff Installation site Behaviour in case of emergency Protective devices Content Handling of the machine and auxiliary materials 11 Machine description Equipment versions Designation of components Start up Erection and preparation First cleaning Pressure testing Operation Shutting down Equipment preparation Change of material Shutting down Checks Malfunctions and trouble shooting Appendix Technical specifications Certificate of training and operation Declaration of conformity 12 12 14 15 15 16 16 17 17 18 18 19 20 21 21 22 22 Safety 2 Safety 2 1 The signs and symbols used in this manual have the follow ing meaning Explanation of symbols NOTE This marks a section of text which is especially re levant to safety Special attention should be paid to this section and the contents strictly observed SMOKING PROHIBITED This marks a situation in which a fire hazard arises through the use of flammable or explodable solid fluid or gaseous materials WARNING This marks a situation which could be dangerous If not observed death or very serious injuries could result DANGER OF EXPLOSION This marks a situation where there is danger of explosion
28. ng avoids heat loss of material in hoses or feed li nes during pauses in spraying If a circulation valve is used a spray gun with two inbound hoa RR Flow Direction Picture 1 2 4 Circulation Valve without pressure drain valve 20 Translation of the original operation manual Fluid Heater 597 FA MDFE 0A e en 01 10 Rev 1211 cf e Appendix Ih an SEAT Ea lE db l SSSSSS ilg Se cut N Spray Gun Circulation Valve with Connection pressure drain valve Picture 1 2 5 Circulation Valve without pressure drain valve Picture 1 2 6 Portable frame for HP incl all mounting parts 0632538 N 0639788 R Portable frame for LP incl all mounting parts Wall mount for HP and LP Mounting kit for air heating on Air Motor D300 Mounting kit for air heating on Air Motor D200 Mounting kit for air heating on 2K System Mounting kit for atomization air heating 9999999 Male adaptor for material inlet and outlet HP hose 0484970 N NPT 0219096 RS NPT Male adaptor for material inlet and outlet LP hose 0212776 R Temperature gauge 0620661 0634706 Copper paste 0000233 337723771 Translation of the original operation manual Fluid Heater 21 MDFE 0A en 01 10 Rev 1211 cf e Appendix 8 3 Certificate of training and operation This certificate corresponds to the EU guideline for working substances 85 655 EWG Paragraph Il Article 7 T
29. nufacturer s address and telephone number In case of injury proceed immediately to the nearest doctor or medical facility MDFE 0A e en 01 10 Rev 1211 cf e Copyright 2008 WIWA Copyright ownership for this user manual remains with WIWA WILHELM WAGNER GmbH amp Co KG GewerbestraBe 1 3 35633 Lahnau Germany Phone 49 0 6441 609 0 Fax 49 0 6441 609 50 This operating manual is solely intended for personnel involved in preparation operation and servicing It is prohibited to pass on this operating manual for reproduc tion utilisation or communication of its contents unless this has been explicitly permitted Infringements incur an obligation to pay damage compensation All rights reserved in the event of registration of the patented design industrial design or regis tered design This operating manual only applies in conjunction with the machine card that was given to you with the user manual for your equipment Please check that the type plate data is identi cal 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 BTA MDFE 0A en 01 10 Rev 1211 cf e 1 3 2 10 2 11 3 1 3 2 4 1 4 2 4 3 5 1 5 2 5 3 Translation of the original operation manual Fluid Heater Table of contents Contents Preface Read before starting Table of contents Description of the f
30. r of their safety We recommend that the machine operation management have this confirmed in writing e Additionally please pay attention to the follo 1 wing N read and observe the guidlines valid for your coun n Germany the Richtlinien f r Fl ssigkeitsstrahler Guidelines for liquid sprayers Published by Hauptver band der Gewerblichen Berufsgenossenschaften are valid We recommend adding a copy of all guidelines and acci dent prevention regulations into the user s manual Manufacturer s notes and operating guidelines for coa ting material and pumping material should be observed at all times In principle no method of working should be exercised which impairs the safety of 39 73371 products or the opera ting personnel WITA MDFE 0A en 01 10 Rev 1211 cf e Safety 2 4 Machine surroundings Rebuilds and changes A For safety reasons it is not allowed to carry out rebuilds or changes without authorization Protective equipment may not be dismounted changed or neglected If using components which are not produced or delivered by 3973971 warranty coverage is negated as well as liability The machine may only be operated within the prescribed limits and machine parameters If you use original attachments and original spa re parts from 39739741 the compatability with our equipment is guaranteed It is however essential that the safety regulations of the attachments and spare parts are obs
31. r tightness leaks Observe the maximum allowable operating pressure for the fluid heaters the spray equipment and any acces sories Before performing repairs on the unit and upon each work interruption it is important to Adjust the fluid heater temperature to the minimum set ting turn temperature setting knob to position I or ad just at control panel Disconnect the heater from the power source Release pressure from the entire system Cleaning of the equipment is required Before initial operation Before longer interruptions in work Upon each change of material Immediately after use of 2K Materials but only after co oldown observe the pot life of the material Pay attention to safety The accident prevention regulations Working with Coating Materials BGV D25 and the regulations for liquid spray ers ZH1 406 from the Association of Industrial Liability must be observed Liquid sprayers must be inspected for safe working condition at least once every 12 months by a qualified technician The results of the inspection are to be recorded in writing Paint and solvent residues must be disposed of in accor dance with regulations This applies to environmentally friendly water based paints also 1 If paint or solvent has penetrated the skin the doctor must be informed about the type of material and solvent which was used Always have the material data sheet available with the ma
32. rsonnel C Press the reset button picture 5 1 1 page 15 until the control lamp lights Contact Customer Service Contact Customer Service Reset the temperature using the temperature knob Lower material flow smaller tip size Add a second Fluid Heater in series to the system He tighten the male adaptors and or fluid hoses or replace as neces sary If the material in the heater is not completely cured it may be pos sible to remove it by flushing under high pressure HP max 450 bar 6525 psi LP max 200 bar 2900 AAA Due to the danger of explosion the Fluid Heater may only be flushed when completely cold Thoroughly flush the heat exchan ger or replace if necessary If the material is fully cured especi ally with two component materials the heat exchanger must be repla ced The heat exchanger may only be replaced when the Fluid Heater is cold and disconnected from the electrical power supply To remove loosen the two moun ting screws and screw in the sepa rating screw Chapter 3 2 until the heat exchanger has separated from main housing Before mounting the cone shaped surface inside the heat exchanger must be coated completely with copper paste 3973571 Order No 0000233 19 Appendix 8 Appendix 8 1 Technical specifications High Pressure HP Low Pressure LP Order No 0649442 0648376 0648377 0653488 0654017 0657724 with 1 8 kW one liter of water can be
33. sistant material For processing of the above mentioned materials use only spray equipment and accessories in the rust and acid resistant version maximum operating pressure given by 197194 must be observed for each component pump heater hoses spray gun safety valve etc The lowest value is to be taken for the complete system Example Pump 420 bar 6090 psi Hose 600 bar 8700 psi Spray gun 500 bar 7250 psi Tip guard 350 bar 5075 psi The maximum permissible operating pressure for this complete system would be 350 bar 5075 psi Smoking open flames or any other possible ignition sources are not allowed anywhere near the area of ope ration Translation of the original operation manual Fluid Heater 4477 FA MDFE 0A e en 01 10 Rev 1211 cf e 2 6 Authorised Operators People under the age of 16 should not operate this equip ment The management in charge of the operation of the machine must make the user s handbook available to the operator and must make sure that he has read and unders tood it Only then may the system be put into operation We recommend the manager has this confirmed in wri ting The operator of the machine is obliged to report any changes in the machine which might affect its safety to the manager as he must ensure that the machine is functional The responsibilities for the different activities on the sys tem must be laid down clearly and adhered to No unclear responsibilities m
34. wer cable connection and is marked with Picture 2 6 2 10 Handling of the machine and auxi liary materials Alignment servicing maintenance and repair of the machine Alignment when changing production as well as servicing and cleaning may be carried out by trained operating per sonnel only Maintenance and repair may be carried out by trained qua lified personnel only Before starting work the compressed air supply to the machine must be shut off and the Fluid Heater disconnec ted from the power source Residual pressure must be released through the spray gun or the drain on the High Pressure Filter Read and follow the instructions in the User s Handbook for the spray equipment After finishing work the equipment and all protective devi ces should be inspected for proper function Read and follow the instructions in the User s Handbook for the spray equipment and accessories Handling of auxiliary materials When handling auxillary materials such as paint solvents oils grease and other chemical substances comply with the safety and dosing instructions of the manufacturer and the generally applicable regulations Left over solvents oils grease and other chemical sub stances must be collected according to the legal regulations for recycling and waste disposal The local official laws for the protection of waste water must be observed 337723721 Translation of the original operation manual Fluid H
35. y pump and all acces sories 2 Prepare paint spray equipment Follow the instructions for preparing the system for spraying found in the User s Handbook for the equipment 3 Flush Due to the possibility that solvent or solvent fumes can still be found within the Fluid Heater and or spray system the coating must first be sprayed cold for approx one to two s back into the material feed container 4 Power supply connection Connect the Fluid Heater power supply cable to a corresponding electrical connection The Fluid Heater must be rated for the available power supply voltage amperage wattage 16 Translation of the original operation manual Fluid Heater 5 Setting the temperature Set the desired temperature on the temperature knob Picture 5 1 1 The control lamp remains lit while the Fluid Heater is hea ting Once the set temperature is reached the lamp goes out If the heater begins heating again the lamp will turn on again If the ambient temperature is under 10 C 50 F the reset button Picture 5 1 1 must be pressed until the control lamp turns on Reset Button Temperature setting knob Picture 5 2 If the maximum allowable temperature is surpassed a tem perature limiter will turn off the Fluid Heater To turn the Fluid Heater back on press the reset button Picture 5 1 1 until the control lamp goes on again 6 Operation The spray system and Fluid Heater are now ready for ope
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