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- Page 1 Operation manual InjectIon DeVIceS Type: Inject HD 1 Inject HD 2 Serial-No. ⸏ ⸏ ⸏ ⸏ ⸏ ⸏ ⸏ ⸏ Original operation manual 1701_HD1_IG003_DBK_en · jw...
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Page 3: Table Of Contents
Contents Contents 1 Preface ......................4 2 Safety ......................4 2.1 Description of symbols 2.2 Dangers arising from the equipment 2.3 Application of the machine 2.4 Machine surroundings 2.4.1 Rebuilds and changes 2.4.2 Danger caused by attachments and spare parts 2.4.3 Emissions 2.5 Sources of danger 2.6 Operating staff 2.7 Installation site and Transporting and additional equipment 2.8 Behavior in case of emergency 2.9 Protective equipment 2.10 Handling of the machine and auxiliary materials 3 Machine description ................... 12 4 Start up ...................... -
Page 4: Preface
Thank you for your decision to purchase equipment. In the user’s handbook, you can find all information required for the proper handling of your Injection Pump. However, for safe operation there are further essential details which you should adhere to: Please read and observe the guidlines valid for your country. In Germany, the „Richtlinien für Flüssigkeitsstrahler“ (Guidelines for fluid sprayers) published by: Hauptverband der Gewerblichen Berufsgenossen- schaften (Industrial Employer‘s Liability Insurance Association), are valid. Additionally, the manufacturer‘s instructions and all processing guidelines covering injection materials are to be followed closely. No method of operation should be exercised which impairs the safety of products and the operating personnel. We wish you much success and excellent working results when appliying your Injection Pump. WIWA Wilhelm Wagner GmbH & Co. KG Copyright © 2011 WIWA Copyright ownership for this user manual remains with WIWA Wilhelm Wagner GmbH & 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 This operating manual is solely intended for personnel involved in preparation, operation and servicing. It is prohibited to pass on this operating manual for reproduction, utilisation or communication of its contents, unless this has been explicitly permitted. Infringements incur an obligation to pay damage compensation. All rights reserved in the event of registration of the patented design, industrial design or registered design. This operating manual only applies in conjunction with the machine card that was given to you with the user manual for your equipment. Please check that the type plate data is identical with ... -
Page 5: Safety
Safety 2 Safety 2.1 Description of symbols The signs and symbols used in this User‘s Handbook have the following meaning: NOTE This marks a section of text which is especially relevant 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. Observation of this information is absolutely essential. ELECTRICAL VOLTAGE This marks a situation, where there is a danger of explosion through an electostatic charge. Observation of this information is absolutely essential. USE EAR PLUGS For health reasons, it is very important to pay attention to this warning. USE BREATHING PROTECTION For health reasons, it is very important to pay attention to this warning. HEALTH DANGER This marks materials which are hazardous to your health. Observation of this information is absolutely essential. FIRST AID In case of injuries or accidents, these instructions should be absolutely adhered ... -
Page 6: Dangers Arising From The Equipment
Safety 2.2 Dangers arising from the equipment This machine was designed and built in accordance with all safety guidelines. It corresponds with the present standards of technical regulations and current rules for accident prevention. It left the factory in perfect condition and ensures a high level of safety. However, the following dangers exist if operated incorrectly or used inappropriately: to life and limb of operator or third personsorr third persons ➤ for the machine and other property belonging to owner of machine ➤ for the efficient working of the machine ➤ All personnel involved in the starting, operation and maintenance of the machine must read the following notes carefully and observe them. It is a matter of their safety! We recommend that the machine operation management have this confirmed in writing. Additionally, please pay attention to the following: We recommend adding a copy of all guidelines and accident prevention regulations into the user‘s manual. 2.3 Application of the machine This injection unit is designed according to the requirements found in German ZTV-Riss guidelines for pneumatically driven, single component, high- pressure equipment. It is recommended for use with low-viscosity injection materials made from epoxy or polyurethane and for processing sealant gels. This equipment is easy to transport and ideal for use on scaffoldings and in narrow shafts. The stroke rate of the motor informs the operator how close the injection work is to completion. When the motor stops, the bore hole being injected is full. To drive the pump, a portable 220V compressor with an air out- put of approx. 200/Nltr. should be sufficient. -
Page 7: Danger Caused By Attachments And Spare Parts
Safety The machine may only be operated within the prescribed limits and machine parameters. 2.4.2 Danger caused by attachments and spare parts If you use original attachments and original spare parts from , the compatability with our equipment is guaranteed. It is, however, essential that the safety regulations of the attachments and spare parts are observed. 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 source, cannot guarantee the safety of the entire system. In this case, our guarantee does not cover any damage or injury caused by such attachments and spare parts. 2.4.3 Emissions It is possible for solvent vapours to occur, depending on the materials used. Therefore, please ensure the workplace is sufficiently ventilated in order to avoid damage to health and property. Always observe the processing information given by the material manufacturer. The sound pressure level of the equipment is below 85 db(A). Nevertheless, appropriate means of noise protection should be made available to the operating staff. The operator is responsible for compliance with the rules covering the prevention of accidents due to „noise“ (VGB 121). Therefore, pay special attention to the environmental conditions at the site, e. g. noise can be increased if the machine is installed in or on hollow bodies. Exact details regarding noise emission are mentioned in the Chapter 9.1 Technical specification. 2.5 Sources of danger Remember that Injection Pumps work under extreme pressures and that they can cause life-endangering injuries if used inappropriately. -
Page 8: Operating Staff
Safety The entire system is to be depressurized before maintenance and cleaning ➤ work is carried out. The compressed air tap lock must be closed. Never spray solvents or materials containing solvents into a narrow-necked ➤ can or barrels with bung hole.DANGER OF EXPLOSION! Always use an open container. When using metal containers, always ensure that the injection lance maintains contact with the container wall to avoid the build up of electrostatic charges. If the material being used clogs or clumps within the pump, residual pressure ➤ may still exist despite depressurization efforts. This must be kept in mind when carrying out repairs! Special care must be taken when dismantling the material hoses and injection lance to ensure that no accidents occur due to escaping residual pressure. We recommend covering the material hose fittings with a cloth during unscrewing in order to capture any fluid which might escape. Never remove the sealed safety valve installed by and never adjust ➤ its setting. Should the safety valve need replacing, please see the machine card for its order ➤ number (chapter 9.4). Please ensure that new safety valves are set and sealed to the maximum ➤ permitted air inlet pressure for the Injection Pumps (see nameplate/ machine card). In closed or pressurised systems where aluminium 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 hydrocarbons (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 customer services or directly. The maximum operating pressures given by us are to be adhered to in ➤... -
Page 9: Installation Site And Transporting And Additional Equipment
Safety The responsibilities for the different activities on the system must be laid down clearly and adhered to. No unclear responsibilities may remain as this 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 instructions about dangers and safety measures at regular intervals (at least once a year, for operators under the age of 21 twice a year). Personal protective equipment We call to your attention that the valid guidelines and requirements in accordance with work surroundings (mining, closed areas etc.) must be absolutely adhered to. Please, wear the prescribed protective clothing at all times, as solvent ➤ vapours and solvent splashes cannot be completely avoided. The sound pressure level of the equipment is below 85 db(A). Nevertheless, ➤ appropriate noise protection means should be made available to the operating staff. Although solvent fumes are minimized when the injection pumps is handled ➤ properly, it is still recommended that the operator wear breathing protection. Never use solvent or other materials which present a health hazard for ➤ cleaning skin. Only suitable skin protective, skin cleansing and skin care materials may be used. 2.7 Installation site and Transporting and additional equipment Safety measures at installation site The system must have a fixed position and sufficient space to ensure safe ... -
Page 10: Behavior In Case Of Emergency
Safety Transporting and additional equipment Cut off the air supply to the pump, even when transporting for short ➤ distances. Before transportation, empty the machine. ➤ Stay alert when loading the pump, whether a hoist is being used or not! ➤ Observe the max. load capacity of machines used for lifting. ➤ Never stand under suspended loads or in the lifting area. This is extremely ➤ dangerous! Only use suitable transportation vehicles with sufficient load capacity. ➤ Ensure the pump is properly secured to the vehicle transporting it to avoid ➤ slipping or tipping. Parts or equipment dismounted for transportation ➤ purposes must be properly remounted by a trained technician before start-up. To enable safe lifting, a grip is located on the injec- tion pump‘s air motor, (picture 2.1). ➤ Picture 2.1 2.8 Behavior in case of emergency Leaks If leaks occur in the system: it must be shut down immediately and the entire system depressurized: ➤... -
Page 11: Protective Equipment
Safety 2.9 Protective equipment All equipment is delivered with the following safety devices: Safety valve (picture 2.2) ➤ The safety valve prevents the maximum admissible entry air pressurebeing exceeded. In the event that the fixed maximum entry air pressure setting is surpassed, the safety valve blows open. Picture 2.2 Air lock (picture 2.3) ➤ The tap for locking compressed air makes it possible to switch off the machine immediately. Picture 2.3 All protection devices must be checked! Before each commissioning of the machine! ➤ Before beginning work on or with the machine! ➤ After all aligning work! ➤ After cleaning and servicing! ➤ After maintenance and repair! ➤ Check list for inspecting the protection features when the unit is in a depressurized state ➤... -
Page 12: Handling Of The Machine And Auxiliary Materials
Safety 2.10 Handling of the machine and auxiliary 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 personnel only. Maintenance and repair may be carried out by trained, qualified personnel ➤ only. Before starting work, the compressed air supply of the pump must be shut- ➤ off. Make sure that the pump is absolutely free from pressure. ➤ In any case, the function of all protective devices, as well as perfect function ➤ of the machine, must be checked after completion of the work. Handling of auxiliary materials When working with injection materials and their related solvents (or other ➤ chemical substances), it is mandatory to observe the manufacturer‘s safety and dosage instructions as well as industry guidelines. Residual injection material, solvent and other chemical substances must ➤... -
Page 13: Machine Description
Machine description 3 Machine description Picture 3.1 HD 1 (Injection lance with ball valve) Picture 3.2 HD 2 Picture 3.3 Injection lance with trigger lever Pos. Description Pos. Description Lifting handle Material feed container Air pressure regulator Frame Pressure gauge Suction hose Air tap lock Injection lance Inbound air connection Fluid hose Air motor Holding pipe for the injection ... -
Page 14: Start Up
Start up 4 Start up 4.1 Set-up and Assembly Task You wish to erect the machine at the site and prepare it for operation. Prerequisite The material to be worked with is prepared. ➤ All materials to be sprayed should be marked with information on viscosity, ➤ processing temperatures, mixing proportions etc. If this is not the case, please, acquire this data from the relevant manufacturer. The material to be sprayed must be slowly but thoroughly stirred before ➤ beginning to work. When dealing with two-component materials, the potlife life must be ➤ observed. The machine must be flushed and completely cleaned with the specified cleaning agent within the potlife life as given by the manufacturer. Please, observe that the hardening time shortens at higher temperatures. It is recommendable to allow the solvent to circulate for a while. It must be made certain that no particles of paint remain in either the pump or the filter. Procedure The machine is to be set up securely on a level and solid surface. All operating elements must be easily accessible. In order that the necessary volume of air is guaranteed, the compressor capacity must comply with the amount of air needed by the machine and the diameter of the air supply hoses must correspond to the joints. Several components of the machine were dismounted and packed in a separate carton for shipping (i.e. fluid hose, injection lance, air pressure regulator). Assemble these components as described in chapter 3. Inspect all turnable parts, nuts, screws and hose connections and pull on them tightly to ensure that no material could leak out of these fittings which could lead to injuries. -
Page 15: Initial Cleaning
Start up The pump may now be filled with release agent (see chapter 7.2, Maintenance Plan). We recommend using release agent, order no.: 0163333. Result The machine is now ready for operation. Continue with the first cleaning (chapter 4.2). 4.2 Initial cleaning Task This machine was factory tested after assembly for perfect functioning with a test-medium. The entire system should be flushed with cleaning solvent before spray operation begins so that the material to be sprayed is not affected by the test-medium. Prerequisite You will need: 1 open container with approx. 5 liters of solvent, hereafter called container „A“. 1 empty, open container for the mixture of cleaning material and test-medium, hereafter called container „B“. Do not use narrow-necked cans or barrels with bung hole. Please, check whether the material hoses comply with the maximum working pressure and the prescribed safety factor. They should not have any leaks, kinks, signs of wear or bulges. The hose fittings must be securely attached and also comply with maximum pressure. Please wear protective clothing at all times, as solvent vapours and splashes of solvent cannot be avoided completely. Procedure The air tap lock must be closed. Connect the fluid hose to the injection lance. Connect the fluid hose (with the injection lance) to the fluid output on the material pump. Turn the air regulator control screw to the left until it turns freely. Connect the inbound air connection to the compressed air line. Original-Betriebsanleitung HD1+HD2 •HD1-2_BAoDB_en_1407•ski... -
Page 16: Checking Pressure
Start up Fill solvent (container „A“) into the unit‘s feed container. Open the air tap lock. Adjust the air regulator to a maximum of 2 bar by slowly turning the control screw to the right. Hold the injection lance into the open container „B“ and spray for at least 10 secondes against the inside wall. When using a metal container, ensure that contact is maintained between the injection lance and the container wall (due to possible electrostatic charging). We recommend a cleaning period of approx. one minute for a good cleaning result. In order to avoid the danger of explosion caused by the heating of cleaning material, it should not be pumped for longer periods of time (a maximum of 5 minutes). - Page 17 Start up Empty the unit‘s feed container. (Return remaining solvent to container „A“.) Slowly open the injection lance and completely pump out any remaining solvent still in the pump. Ensure the injection lance remains in contact with the container wall. Adjust back the air regulator by turning the control screw to the left until it moves freely. Close the air tap lock. Close the injection lance. Result The start-up procedures are finished. The pump is ready for use. Original-Betriebsanleitung HD1+HD2 •HD1-2_BAoDB_en_1407•ski...
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Page 18: Operation
Operation 5 Operation 5.1 Equipment preparation Task You want to prepare the pump for injecting. Prerequisite You will need: 1 open container with approx. 5 liters of flushing agent (use the solvent which corresponds to the injection material and is recommended by the manufacturer), hereafter called container „A“. 1 empty, open container for the soiled cleaning material/material mixture, hereafter called container „B“ 1 material container, hereafter called container „C“. Do not use narrow-necked cans or barrels with bung holes. Procedure The air tap lock must be closed. Adjust back the air regulator by turning the control screw to the left until it moves freely. Connect to main air supply line. Fill solvent from container „A“ into the pump‘s feed container. Open air lock tap. Open the injection lance while holding it into container „B“. Adjust air regulator to 1-2 bar by turning the control screw to the right. Hold the injection lance in such a way that the emerging solvent is sprayed sideways onto the inside wall of the open container „B“. When using metal containers, ensure that contact is maintained between the injection lance and the wall of the container to avoid electrostatic charging. As soon as clean solvent is released, the flushing process can be ended. After long periods without use, you should carry out the following in order to test the tightness of the seals and joints in the equipment, but only with the injection lance ball valve closed: Original-Betriebsanleitung HD1+HD2... - Page 19 Operation Increase the pressure on the compressed air regulator to the given maximum air inlet pressure. Inspect the joints for tightness on the parts which carry material. Turn the air regulator slowly back to 1-2 bar by turning the control screw to the left. Return any remaining solvent in the unit‘s feed container to container „A“ and pump out any remaining solvent in the system. Turn the air regulator back by turning the control screw to the left until it moves freely. Close the air tap lock. Close the injection lance. Fill injection mateial into the material container „C“. Open the air tap lock and adjust air regulator to 1-2 bar. Open the injection lance. Pump any solvent remaining in the fluid hoses and injection lance into the open container „B“ until pure injection material exits the lance. Ensure to maintain contact between the lance and contai- ner wall. Close the injection lance. Clean the injection lance coupling with solvent and a brush. Regulate working pressure with the air regulator. Result The pump‘s preparation is completed. You may now proceed with injecting. Original-Betriebsanleitung HD1+HD2 •HD1-2_BAoDB_en_1407•ski...
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Page 20: Injecting
Operation 5.2 Injecting You want to begin injecting. Prerequisite You have prepared the unit according to chapters 4 and 5. ➤ Appropriate packers are available for the injection lance. ➤ Procedure Set the required packers into the wall which is to be injected. Connect the injection lance nipple to a packer. Set the required injection pressure using the air pressure regulato. The injection pressure is calculated as follows: The pressure set with the injection pump‘s regulating screw (visible on the pressure gaugeture) is multiplied by pressure ratio. Example: Pressure setting (pressure gauge reading) 4 bar pressure ratio (Multiplier) ... -
Page 21: Pauses In Work And Changing Injection Materials
Operation Result The material has been injected successfuly. We recommend to flush the pump between jobs, depending on the material and amount to be processed. Be certain to follow the instruction in chapter 5.3 „Pauses in work and changing materials“ closely to avoid damage to the unit. 5.3 Pauses in work and changing injection materials 5.3.1 Pauses in work Close the injection gun if you make a pause of more than a couple of minutes while injecting. Fill any remaining injection material in the feed container back into container „C“, as long as it is not mixed two component material. Fill the pump‘s feed container with solvent (container „A“). Open the air tap lock. Turn the air regulator slowly to max. 1-2 bar by turning the control screw to the right. Hold the injection lance in such a way that the soiled injection material is sprayed sideways onto the inside wall of the open container „B“. Close the injection lance as soon as clean solvent emerges. Closely observe the potlife stated by the manufacturer for the injection material being used. -
Page 22: Shutting Down
Shutting down 6 Shutting down Task Once the job is completed, the pump is to be cleaned and shut down. Prerequisite You will need: 1 open container with approx. 5 liters of flushing agent (use the solvent which corresponds to the injection material and is recommended by the manufacturer), hereafter called container „A“. 1 empty, open container for the soiled cleaning material/material mixture, hereafter called container „B“ 1 material container, hereafter called container „C“ Do not use narrow-necked cans or barrels with bung holes. Procedure Close the air tap lock. Turn back the air regulator by turning the the control screw to the left until it moves freely. The pressure gauge must show 0 bar. Close the injection lance. Empty the unit‘s feed container. Fill remaining material back into container „C“, as long as it is not mixed two component material. Fill the unit‘s feed container with solvent from container „A“. Open the air tap lock and set the pressure gauge to a working pressure of 1-2 bar. Hold the injection lance in such a way that the soiled injection material is sprayed sideways onto the inside wall of the open container „B“. Run the pump until clean solvent emerges. When using metal containers, ensure that contact is maintained between the injection lance and the wall of the container to avoid electrostatic charging. To avoid unnecessary loss of injection material, we recommend to spray the remaining material in the hoses back into container „C“... - Page 23 Shutting down Close the injection lance. Turn back the air regulator by turning the the control screw to the left until it moves freely. The pressure gauge must show 0 bar. Close the air tap lock. Re-open the injection lance shortly to release any remaining pressure from the system. Original-Betriebsanleitung HD1+HD2 •HD1-2_BAoDB_en_1407•ski...
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Page 24: Maintenance / Repair
Maintenance / Repair 7 Maintenance / Repair 7.1 Checks According to the rules for the prevention of accidents „Working with liquid jet systems“ BGR 500, Chap. 2.36 the equipment must be checked and overhauled at regular intervals by a specialist ( Service). The equipment must be checked: before the first start-up, ➤ after changes and repairs of equipment parts having an effect on safety, ➤ after an interruption of operation of more than 6 months, ➤ at the latest, every 12 months. ➤ For equipment that 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. 7.2 Maintenance plan Before every start-up check the amount of release agent in the release agent ➤ chamber. Amount to refill: Fill until lubricant appears in the filling pipe (approx. 1cm under the opening, approx. 50 ml release agent) Check release agen once every 50 operating hours for discoloration due to ➤ mixing with injection material. -
Page 25: Disturbances During Operation And Troubleshooting
Disturbances during operation and troubleshooting 8 Disturbances during operation and troubleshooting Faults Probable Causes Remedies 1. Pump does not operate, Lack of compressed air. Check the inlet air ➤ ➤ even though the injection connection. lance is triggered.. Air tap lock is closed. Open air tap lock. ➤ ➤ ➤ ➤ Air motor is defect. Repair the air motor using ➤ ➤ ➤ ➤ the spare parts list and Repair Instructions. Packings or valve worn. Suction hose or bottom valve Clean the suction hose or ... - Page 26 Disturbances during operation and troubleshooting Faults Probable Causes Remedies 5. Pump cycles unevenly and The viscosity of the material Thin down material (add ➤ ➤ ➤ does not reach the required is too high (suction loss). solvent). injection pressure. (The Use bigger pump.. ➤ uneven cycling of the pump is recognizable by the diffe- Suction system is not tight Check all seals on fittings of ➤ ➤ ➤ ➤ rence of the cycling speed of (injection stream pulsates). the suction pipe and hose the upward and downward and exchange if necessary. strokes) Bottom valve is leaking Unscrew bottom valve. ➤ ➤ ➤...
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Page 27: Appendix
Appendix 9 Appendix 9.1 Technical specifications Model Injekt-HD 1 Injekt-HD 2 Order-No. 0644426 0644517 0655848 0660410 Pressure ratio 33:1 33:1 42:1 Max. free-flow output (ltr/min) Output per cycle (ccm) Max. input air pressure(bar/psi) 8/116 8/116 Max. operating pressure (bar/psi) 264/3828 264/3828 336/4873 Material outlet 1/4“ NPS(A) 1/4“ NPS(A) Air inlet 1/4“ 1/4“ Container volume /ltr/gallons) 1,5/0,4 6/1,6 Approx. dimensions: LxWxH (mm/inch: 595x320x305 705x499x340 23x12,6x12 27,8x19,6x13,4... -
Page 28: Instruction Certificate
Appendix 9.3 Instruction Certificate This certificate follows the EC-Directive for working utensils 85/655/EEC, section II article 7. The owner of the device specified below has instructed the operating personnel. Manufacture Type designation Year of construction Serial-number The instruction was conducted by the representative of the owner: Foreman or respon- sible superior, name, department The instructed person has read and understood the user manual for the equip- ment listed above, especially the chapter about safety, and declares that he is able to operate the unit in a safe way. Personnel for: Date, name Operation Repair and maintenance 9.4 Machine card This User’s Handbook is valid only in connection with the following ma- chine card: The machine card includes all machine specifications and details which are ... - Page 30 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.
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