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Table of Contents
Related Manuals for wiwa GX Series
Summary of Contents for wiwa GX Series
- Page 1 Operation manual GX SERIE Original operation manual AirlessGX_BA_en_1704 • jw...
- Page 3 Technical data WIWA Wilhelm Wagner GmbH & Co. KG Manufacturer 35633 Lahnau, Germany Herkules 270 / 333 GX Description Professional 230 GX Type ........
- Page 4 Emitted sound pressure level at the work place was determined in accordance with the DIN EN ISO 3744, DIN EN 31200, DIN EN 31201 and DIN 45635-20 standards Sound pressure level at 15 DS with 8 bar L 85 dB(A) 83 dB(A) 84,5 dB(A) Sound power level L...
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Page 5: Table Of Contents
Contents 1 Foreword ..................9 2 Safety ..................10 2.1 Explanation of symbols ............10 2.2 Safety information .............. 12 2.2.1 Working pressure ............12 2.2.2 Risks due to the spray jet ..........13 2.2.3 Risks due to electrostatic charging ........ 13 2.2.4 Dangers due to hot / cold surfaces ........ - Page 6 3.3 Machine design ..............25 3.4 Maintenance unit ..............30 3.5 Optional expansions and accessories ....... 31 3.5.1 Spraying accessory kits ..........31 3.5.2 Material fluid heater attachment kit........ 31 3.5.3 Agitator attachment kit ........... 32 4 Transport, installation and assembly ........34 4.1 Transport ................
- Page 7 6.3 Water separator ..............49 6.3.1 Checking the water separator ........49 6.3.2 Cleaning the container........... 49 6.4 High pressure pump ............49 6.4.1 Checking the release agent for material residues ..49 6.4.2 Filling the release agent and checking the fill level ..49 6.4.3 High pressure filter ............
- Page 8 WIWA Wilhelm Wagner GmbH & Co. KG Gewerbestr. 1-3 • 35633 Lahnau • Germany Tel: +49 6441 609-0 • Fax: +49 6441 609-50 • Email: info@wiwa.de • Web- site: www.wiwa.de This operation manual is intended exclusively for the preparation, operating and maintenance personnel.
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Page 9: Foreword
If questions should arise, we shall be happy to assist you. We wish you excellent working results with your machine WIWA Wilhelm Wagner GmbH & Co. KG Original operation manual AirlessGX_BA_en_1704 • 0550022 • jw... -
Page 10: Safety
Explanation of symbols Safety information warns of potential accident risks and describes the measures required for accident prevention. In the operation manual from WIWA, safety information is highlight- ed and labeled as follows: DANGER Signals a risk of accidents that are very likely to result in serious... - Page 11 Safety Signals important information for correct work with the machine. A failure to observe this may result in damage to the machine or its environment. A range of pictograms are used in the safety information for acci- dent risks that may result in injury, depending on the hazard source - examples: General risk of accident Risk of explosion due to explosive atmosphere...
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Page 12: Safety Information
Safety Use respiratory protection Signals an instruction to use respiratory protection, in order to prevent damage to the respiratory tract caused by gases, vapours or dust. Wear protective gloves Signals an instruction to wear protective gloves with forearm protection, in order to prevent a risk of burns due to heated material. Wear safety shoes Signals an instruction to wear safety shoes, in order to prevent foot injuries due to falling, toppling or rolling objects, as well as... -
Page 13: Risks Due To The Spray Jet
Safety Material hoses and hose connections must comply with the ➤ maximum operating pressure including the required safety factor. Material hoses must not exhibit leaks, kinks, signs of wear or ➤ bulges. Hose assemblies must be tight. ➤ 2.2.2 Risks due to the spray jet WARNING The material exits the spray gun under very high pressure. -
Page 14: Dangers Due To Hot / Cold Surfaces
Always ensure contact between the spray gun and the con- ➤ tainer wall. Only use electrically conductive material hoses. ➤ All original material hoses from WIWA are conductive and designed for our machines. Only use electrically conductive accessories / accessory ➤ parts. -
Page 15: Explosion Protection
Safety 2.2.5 Explosion protection WARNING Machines and accessories that are not explosion-protected may not be used in operating facilities that fall under the explosion protection ordinance! Explosion-protected machines and accessories can be identified by the corresponding mark on the type plate and/or the ATEX declaration of conformity provided. -
Page 16: Health Risks
Safety 2.2.6 Health risks CAUTION Depending on the materials being processed, solvent vapours may arise, which could lead to damage to health and property. Make sure the workplace is sufficiently ventilated and aired. ➤ It is necessary to guarantee at least 5-times air exchange. Always observe the processing instructions of the material ➤... -
Page 17: Information Signs On The Machine
For your safety • Pour votre sécurité the machine, such as for example Por razones de seguridad • Для вашей безопасности Güvenliğiniz için • Dla Twojego bezpieczeństwa www.wiwa.de För din säkerhet • Para a sua segurança www.wiwa.com the safety card (Fig. 1), indicate... -
Page 18: Safety Valve
Safety The machine is equipped with the following safety features: Safety valve ➤ Compressed air shut-off valve with automatic ventilation ➤ Ground cable ➤ Checklist on the pressureless machine: Seal on the safety valve OK? Safety valve externally free of damage? Ground cable free of damage? Mobility of the compressed air shut-off valve OK? on the pressurized machine:... -
Page 19: Compressed Air Shut-Off Valve
Safety WARNING If the maximum permissible air inlet pressure is exceeded, parts may rupture. The consequences may be personal injuries and property damage. Never operate the machine without a safety valve or with a ➤ defective safety valve! If it is necessary to replace the safety valve, please refer to ➤... -
Page 20: Ground Cable
Safety 2.4.3 Ground cable The ground cable serves to prevent an electrostatic charging of the machine. The ground cable is already connected to the machine at the time of delivery (e.g. to the high pressure filter, the grounding rail, or the like). Fig. -
Page 21: Authorised Operator
Safety Trained personnel has received instruction provided by the ma- ➤ chine manufacturer and is capable of carrying out maintenance and repair work on the machine, independently recognizing possible dangers and avoiding risks. 2.5.3 Authorised operator Activity Qualification Set-up and operation Instructed operator Cleaning Instructed operator... -
Page 22: Guarantee Information
➤ spare parts from WIWA may be used. If spare parts are used, that have not been produced or sup- ➤ plied by WIWA then the guarantee is voided and all liability shall be excluded. 2.6.2 Accessories If you use original accessories from WIWA that are designed for ➤... -
Page 23: Behaviour In An Emergency
Safety Behaviour in an emergency 2.7.1 Shut down the machine and relieve the pressure In an emergency, bring the machine to an immediate standstill and relieve the pressure. Close the compressed air shut-off valve. Actuate the spray gun briefly once more. Open the relief valve on the high pressure filter, so that no further material pressure is present and the machine has been fully relieved of pressure. -
Page 24: Machine Description
(see p. 3) or on the type plate. Intended use The WIWA airless devices are suitable exclusively for airless spray- ing of coating materials and additives in surface technology. Die Herkules GX Serie wurde speziell für den Einsatz bei großen Flächen mit hohen Schichtstärken entwickelt. -
Page 25: Erroneous Use
➤ ing to the type plate. Machine design The construction of the Hercules GX series and the Professional GX series is absolutely identical. In the following, the various sizes and design variants are shown as examples. - Page 26 Machine description Fig. 7 Airless 270 on cart Original operation manual AirlessGX_BA_en_1704 • 0550022 • jw...
- Page 27 Machine description No. Designation Further information Crane eyes for lifting Muffler Maintenance unit Chap. 3.4 on page 30 Air motor Filler opening for release agent Airless device type plate Chap. 8.1 on page 58 Lift trolley type plate Inspection glass for release agent Chap.
- Page 28 Machine description Fig. 8 Airless 270 on lift trolley (with material fluid heater as optional accessory) No. Designation Further information Operation for lift trolley Temperature gauge Material outlet Material inlet Material fluid heater separate operation manual Parking brake Original operation manual AirlessGX_BA_en_1704 •...
- Page 29 Machine description Fig. 9 Herkules 333 GX on wall bracket No. Designation Further information wall bracket Kap. 4.3.1 on page 36 Original operation manual AirlessGX_BA_en_1704 • 0550022 • jw...
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Page 30: Maintenance Unit
Machine description Maintenance unit The maintenance unit prevents the penetration of condensation water and dirt particles into the machine. Fig. 10 Maintenance elements No. Designation Compressed air shut-off valve with automatic ventilation function / EMERGENCY OFF Pressure gauge for displaying the air inlet pressure Compressed air regulator Compressed air connection / input (G 1") (coupling piece is to be provided by the owner) -
Page 31: Optional Expansions And Accessories
The following list contains just some of the most common accesso- ries and expansions. You can find the detailed accessory catalogue at www.wiwa.de. For further information and order numbers, you can also contact a WIWA dealer or WIWA customer service. -
Page 32: Agitator Attachment Kit
Machine description 3.5.3 Agitator attachment kit Since many coating materials have a solids content, the use of an agitator can make sense in order to create the greatest possible homogeneity in the delivery container. No. Designation Air motor of the agitator Fog oiler (see chap. - Page 33 Machine description Attach the ground cable to the frame next to the agitator holder. Attach the compressed air hose to the plug coupling for optional accessories on the maintenance unit (page 29 no.6). Fig. 14 Attach ground cable Change the position of the agitator depending on the distance to the container by loosening the wing screws and pulling out or pushing in the agitator holder.
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Page 34: Transport, Installation And Assembly
Transport, installation and assembly 4 Transport, installation and assembly The machine left the factory in faultless condition, packaged cor- rectly for transport. Check the machine at the time of receipt for any transport damage and for completeness. Transport When transporting the machine, observe the following information: When loading the machine ensure sufficient load-bearing ca- ➤... -
Page 35: Installation Site
Transport, installation and assembly Installation site The machine can be installed inside or outside spray booths. However, in order to avoid contamination an external installation is preferable. WARNING If the machine is used outdoors during a storm, a life-endan- gering situation may arise for the operating personnel due to lightning! Never operate a machine outdoors during a storm! ➤... -
Page 36: Assembly
Transport, installation and assembly Assembly WARNING If untrained personnel carry out assembly work, they endanger themselves and others, as well as risking the operational safety of the machine. Electrical and electronic parts may only be installed by ➤ specialist personnel with electrical training - all other parts, e.g. -
Page 37: Installing The Spray Hose And Spray Gun
Only use conductive material hoses. ➤ All original material hoses from WIWA are conductive and designed for our machines. Connect the spraying hose to the material outlet on the high pressure filter (Fig. -
Page 38: Grounding The Machine
Transport, installation and assembly 4.3.3 Grounding the machine WARNING The high flow velocities with the airless spray process can result in an electrostatic charge. Static discharges can result in fire and explosions. Ensure that the machine is properly grounded outside of EX ➤... -
Page 39: Operation
Operation 5 Operation The machine must be correctly installed and fully assembled. ➤ Only put the machine into operation if you are equipped with the ➤ prescribed personal protective equipment. Details on this can be found in 2.5.4 ‘Personal protective equipment’ on page 21. The spray material must be available in sufficient quantity. -
Page 40: Spraying
Operation Spraying Before spraying, the work steps for commissioning must have been performed (see 5.1 ‘Putting the machine into operation’ on page 39). Put the intake into the spray material. Open the compressed air shut-off valve. Adjust the air inlet pressure such that the pump runs slowly. Unlock the spray gun and trigger it until the spray material runs out clean and free of bubbles. -
Page 41: Tips For Good Coatings
Operation Only operate the machine with as ➤ 30-40 cm much air pressure as is required to attain good atomization at the recommended spray distance of approx. 30 - 40 cm. An overly high spray pressure ➤ leads to increased material con- sumption and paint mist. -
Page 42: Flushing
Operation Change the spray nozzle before this becomes worn. ➤ Worn nozzles lead to excessively high material consumption and adversely affect the quality of the coating. Flushing Flushing the machine is necessary during initial commissioning ➤ so that the spray material is not adversely affected by the test substance that was used to test the faultless function of the machine in the factory, the machine must be flushed with a cleaning agent. - Page 43 Operation Close the compressed air shut-off valve. Hold the relief hose in the collecting vessel. Briefly open the relief valve to relieve the pressure. CAUTION If parts of the machine are clogged (e.g. spray nozzle, material filter for the spray gun, material hose, high pressure filter, suction strainer, etc.), the pressure can not completely escape.
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Page 44: Operating The Lift Trolley
Operation Operating the lift trolley The lift trolley (optional) is operated on the rotary switch on the frame (see page 28 no. 17) Stop Down Fig. 22 Operating the lift truck Material change Flush the machine as described in chap. 5.3 ‘Flushing’ on page Let the machine run to empty by taking the intake out of the cleaning agent and triggering the spray gun until air escapes. -
Page 45: Work Interruption
Operation CAUTION If parts of the machine are blocked (e.g. spray nozzle, material filter for the spray gun, material hose, high pressure filter, suction screen, etc.), it is not possible to fully relieve the pressure. During disassembly work, residual pressures can escape and cause serious injuries Protect yourself against the sudden emergence of material by ➤... -
Page 46: Storage
Operation Close the compressed air shut-off valve. Hold the spray gun sideways against the inner wall of the col- lecting vessel and trigger it again. Hold the relief hose in the collecting vessel and briefly open the relief valve to relieve the pressure. The cleaning agent that is still in the machine remains in the machine until it is restarted so that the machine parts do not stick together. -
Page 47: Maintenance
- all other maintenance and repair work must be carried out by WIWA customer service or specially trained personnel. WARNING During maintenance work ignition sources may arise (e.g. due to mechanical sparks, electrostatic discharge, etc.). -
Page 48: Regular Testing
Maintenance function of all safety equipment and faultless function of the ma- chine. Regular testing The machine must be inspected and maintained by a specialist: prior to first commissioning, ➤ after changes to / the servicing of parts of the installation that ➤... -
Page 49: Water Separator
After performing the check, add an appropriate quantity of fresh release agent through the filler openings. We recommend using the release agent from WIWA (order no. 0163333). 6.4.2 Filling the release agent and checking the fill level Prior to every commissioning, check the release agent level if pos- sible. -
Page 50: High Pressure Filter
Maintenance No. Description To fill the release agent, slide the cover for the filler opening to the side and press the re- lease agent in by means of the dosing bottle. The release agent should be at the center of the inspection glass for optimal filling. -
Page 51: Filter Elements For High Pressure Filters
Insert a filter element in the high pressure filter that is appropriate for the spray product and fits the spray nozzle. The mesh size should always be somewhat finer than the hole in the nozzle used: Filter element Nozzle size WIWA order number M 200 (white) up to 0.23 mm/.009“ 0659107-200 M 150 (red) >... -
Page 52: Fog Oiler
Maintenance Do not use a filter element with coarse pigmented or fibre-filled materials. The suction screen installed as standard should remain in the screen housing or be replaced with a coarse- meshed screen. In the case of a material change, the filter element of the high pressure filter and the material screen of the suction system must be cleaned or replaced if necessary. -
Page 53: Recommended Operating Fluids
(order number 0631387) from WIWA. Fig. 25: Fog oiler Firmly screw the oil tank back onto the fog oiler. Recommended operating fluids Only use original operating fluids from WIWA: Operating fluid WIWA order number Release agent, yellow (0.5 l) ¹ 0163333 (used by default) Release agent, red (0.5 l).¹... -
Page 54: Special Tool
Maintenance Special tool The following special tool is enclosed in the delivery for mainte- nance and repair work: Hook wrench ➤ for opening the high pressure filter and for disassembly/assembly of the fluid pump Wrench size Art no. 80/90 mm 0660287 110/115 mm 0660288... -
Page 55: Trouble Shooting
Trouble shooting Original operation manual AirlessGX_BA_en_1704 • 0550022 • jw... - Page 56 Trouble shooting Original operation manual AirlessGX_BA_en_1704 • 0550022 • jw...
- Page 57 Trouble shooting Original operation manual AirlessGX_BA_en_1704 • 0550022 • jw...
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Page 58: Technical Information
The QR code is located on the front on the cart (see Fig. 7) and on the back of this operation manual and contains a link which will direct you to machine support for your device type on the WIWA website. - Page 59 Technical information Original operation manual AirlessGX_BA_en_1704 • 0550022 • jw...
- Page 60 Headquarters and production WIWA Wilhelm Wagner GmbH & Co. KG Gewerbestr. 1 - 3 35633 Lahnau, Germany Tel.: +49 (0)6441 609-0 Fax +49 (0)6441 609-2450 info@wiwa.de www.wiwa.de WIWA Subsidiary USA WIWA LLC - USA, Canada, Latin America 107 N. Main St.