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wiwa HERKULES PFP Operation Manual

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Operation Manual
HERKULES PFP
Serial No.:
1pfp_BA_en_B0550044 ✓(2021/09/09)

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Summary of Contents for wiwa HERKULES PFP

  • Page 1 Operation Manual HERKULES PFP Serial No.: 1pfp_BA_en_B0550044 ✓(2021/09/09)

  • Page 2: Ec Declaration Of Conformity

    EC declaration of conformity in accordance with Annex II, No. 1 A of Machine Directive 2006 / 42 / EC, as amended by 2009 / 127 / EC The company WIWA Wilhelm Wagner GmbH & Co. KG 35633 Lahnau Gewerbestraße 1–3 Germany...

  • Page 3: Table Of Contents

    Contents Contents 1 Foreword 2 Safety 2.1 Explanation of symbols ....2.2 Safety notes ......2.2.1 Working pressure .
  • Page 4 Contents 4.3 Assembly ......4.3.1 Connecting the spraying hose and spray gun . 4.3.2 Grounding the machine ... . . 4.3.3 Connecting the compressed air supply .

  • Page 5: Foreword

    If questions should arise, we would be happy to assist you. We wish you excellent working results with your machine WIWA Wilhelm Wagner GmbH & Co. KG Original Operation Manual ✓(2021/09/09), Status: 2024/09/11 1pfp_BA_en_B0550044...
  • Page 6 Copyright © 2025 WIWA The copyright to this operation manual belongs to WIWA Wilhelm Wagner GmbH & Co. KG Gewerbestraße 1–3 • 35633 Lahnau • Germany Phone: +49 (0)6441 609-0 • Fax: +49 (0)6441 609-2450 Email: info@wiwa.de • Website: www.wiwa.de This operation manual is intended exclusively for the preparation, operating and maintenance personnel.

  • Page 7: Safety

    We recommend that the machine owner have this confirmed in writing. 2.1 Explanation of symbols Safety notes warn of potential accident risks and describe the mea- sures required for accident prevention. In the WIWA operation manu- als, safety notes are highlighted and labeled as follows: DANGER...
  • Page 8 Safety CAUTION Signals a risk of accidents that may result in injuries, if the safety note is not observed! Signals important information for proper handling of the machine. A failure to observe this may result in damage to the machine or its environment.
  • Page 9 Safety Risk of burning due to hot surfaces Risk of freezing due to cold surfaces The first line of the safety instructions indicates the personal protective equipment that must be worn. This is also highlighted and labeled as follows: Wear protective clothing Signals an instruction to wear the prescribed protective clothing, in order to prevent skin injuries due to the processing material or gases.

  • Page 10: Safety Notes

    Safety 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 slipping on slippery floors. Signals references to directives, work instructions and operation manuals that contain very important information and must be ob- served.

  • Page 11: Working Pressure

    Safety 2.2.1 Working pressure WARNING Parts that are not designed for the maximum permissible working pressure may rupture and cause serious injuries. It is essential to observe the prescribed maximum working pres- sures for all parts. With varying working pressures, the lowest value always applies as the maximum working pressure for the complete machine.

  • Page 12: Risks Due To Electrostatic Charge

    Never spray solvents or materials containing solvents into narrow- mouthed cans or drums with a bung opening! Only use electrically conductive material hoses. All original ma- terial hoses from WIWA are conductive and designed for our devices. Only use electrically conductive accessories/accessory parts.

  • Page 13: Risks Due To Hot Or Cold Surfaces

    10°C. Wear suitable protective gloves! 2.2.5 Explosion protection The following short designations are used in the instructions of WIWA: Ex protection: Explosion protection Ex area: potentially explosive or non-explosion protected area Non-Ex area: non-explosive or explosion protected area...
  • Page 14 Safety 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 can be identified by the corresponding mark on the type plate and/or the ATEX-declaration of conformity provided.

  • Page 15: Risks Due To Rams

    Safety 2.2.6 Risks due to rams WARNING During the lifting movement of the rams, fingers, hands or other body parts may be crushed by moving parts. Do not reach between the follower plate/cover and material drum, traverse, and cylinder cover of the pneumatic cylinder or the clamping piece and cylinder cover of the pneumatic cylinder.

  • Page 16: Health Risks

    Safety WARNING Objects placed on the rams may fall off during the lifting movement and cause injuries. Never place objects on the rams! Check the safe mounting of all attachments! WARNING If the attachments are lifted out of the material drum while the motor is running, ejected material or loose parts may cause serious injuries.

  • Page 17: Safety Signs

    Safety Only use suitable skin protection, skin cleansing and skincare prod- ucts for cleansing the skin. In systems that are closed or under pressure, dangerous chemical reactions may arise, if parts produced from aluminum or galvanized parts come into contact with 1,1,1 - trichloroethane, methylene chloride or other solvents that contain halogenated chlorinated hydrocarbons (CFCs).

  • Page 18: Safety Features

    Safety 2.4 Safety features WARNING If one of the safety features is missing or is not fully functional, the operating safety of the machine is not guaranteed! Put the machine out of operation immediately if you detect safety feature defects or any other faults on the machine. Only put the machine back into operation once the faults have been fully rectified.

  • Page 19: Safety Valve

    Safety Checklist on the pressurized machine: Function of the safety valve OK? (For function test, see section 6.3.1 on page 50.) When checking additional safety features, observe the operation manuals for the optional accessories. 2.4.1 Safety valve A safety valve is located on the air mo- tor of the machine behind the covering of the muffler.

  • Page 20: Compressed Air Shut-Off Valve

    Safety 2.4.2 Compressed air shut-off valve After shutting off the air, the machine remains under pressure. It is therefore necessary to fully relieve the pressure prior to any mainte- nance and repair work! The compressed air shut-off valve on the maintenance unit (see section 6.4 on page 52) interrupts the air supply to the entire machine.

  • Page 21: Operating And Maintenance Personnel

    Safety The grounding points on this machine are labeled with the symbol shown on the left. 2.5 Operating and maintenance personnel 2.5.1 Obligations of the owner The owner: is responsible for training the operating and maintenance person- nel, must instruct the operating and maintenance personnel on correct handling of the machine, and on wearing the correct work clothing and protective equipment, must make work aids, such as e.

  • Page 22: Authorized Operator

    Safety 2.5.3 Authorized operator Activity Qualification Set-up and operation Instructed operator Cleaning Instructed operator Maintenance Trained personnel Repair Trained personnel Children, young persons under the age of 16 and untrained person- nel may not operate this machine. 2.5.4 Personal protective equipment Wear protective clothing Always wear the protective clothing stipulated for your working envi- ronment (e.g.

  • Page 23: Warranty And Liability

    When repairing and maintaining the machine, original spare parts from WIWA must be used. If spare parts are used that have not been produced or supplied by WIWA, the warranty is void and all liability shall be excluded. Original Operation Manual ✓(2021/09/09), Status: 2024/09/11 1pfp_BA_en_B0550044...

  • Page 24: Accessories

    – in particular with respect to the working pressure, the current connection data, the connection variables, and use in Ex- zones, if applicable. WIWA will not be liable for any damage or injuries due to these parts. It is essential to observe the safety provisions applicable to the accessories.

  • Page 25: Leakage

    Safety This process is not suitable for decommissioning. The machine is not flushed. For controlled decommissioning, please observe section 5.3 on page 44. After remedying the emergency situation, the machine must be flushed (see section 5.3.1 on page 44). Observe the pot life of the materials used.

  • Page 26: Description

    Description 3 Description The HERKULES PFP is a coating machine for intumescent flame proofing materials. It has been designed according to specific cus- tomer requirements (material to be processed, output, etc.). This machine is used for coating steel parts in the oil and gas industry, for example.

  • Page 27: Construction

    3.3 Construction Fig. 5: Front view of the HERKULES PFP Designation Muffler Air motor Twin-column ram Connection for the spraying hose Original Operation Manual ✓(2021/09/09), Status: 2024/09/11...
  • Page 28 Description Designation Relief valve Relief hose Follower plate Wheel brake Control lever for the ram Pressure display for the ram Compressed air regulator for the ram Connection for container ventilation Fluid pump Container ventilation with shut-off valve Original Operation Manual ✓(2021/09/09), Status: 2024/09/11 1pfp_BA_en_B0550044...
  • Page 29 Description Fig. 6: Rear view of the HERKULES PFP Designation Eye bolts (only for lifting the high pressure pump!) Maintenance unit (see section 6.4 on page 52) Compressed air shut-off valve Compressed air connection Hook wrench Base plate Ground cable at the grounding point...
  • Page 30 Description Designation Container ventilation with ball valve Original Operation Manual ✓(2021/09/09), Status: 2024/09/11 1pfp_BA_en_B0550044...

  • Page 31: Transport, Installation, And Assembly

    Transport, installation, and assembly 4 Transport, installation, and assembly The machine left the factory in faultless condition, packaged correctly for transport. Check the machine at the time of receipt for any transport damage and for completeness. 4.1 Transport When transporting the machine, observe the following information: When loading the machine, ensure sufficient load-bearing capacity of the lifting gear and lifting accessories.

  • Page 32: Installation Site

    Transport, installation, and assembly Empty the machine prior to transport - residual liquids may still leak out of the machine during transport. Remove all loose parts (e. g. tools) from the machine. 4.2 Installation site The machine is intended for installation outside of Ex-zones by default. Installation inside of Ex-zones is only possible with the explosion- protected version of the machine.
  • Page 33 Transport, installation, and assembly Safety measures at the installation site: Position the machine horizontally on a floor that is level, firm and free of vibrations. The machine may not be tilted or tipped. Fasten the machine to its installation site, in order to secure it against unintended movement.

  • Page 34: Assembly

    Transport, installation, and assembly 4.3 Assembly WARNING If untrained personnel carry out assembly work, they endanger them- selves and others, and risk 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. the spraying hose and spray gun, may only be installed by personnel trained for this.

  • Page 35: Grounding The Machine

    Transport, installation, and assembly 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 pump (see Fig. 8). Connect the other end of the spray- ing hose to the spray gun.

  • Page 36: Connecting The Compressed Air Supply

    Transport, installation, and assembly The grounding of all machine com- ponents takes place via the ground- ing point on the base plate. To ground the machine, the ground cable fastened to the grounding point is clamped to an electrically conductive object outside of the potentially explosive area.
  • Page 37 Transport, installation, and assembly 1. Make sure that all compressed air shut-off valves are closed and all compressed air regula- tors are completely turned down. 2. Connect the compressed air line to the maintenance unit. Fig. 10: Compressed air connection Original Operation Manual ✓(2021/09/09), Status: 2024/09/11 1pfp_BA_en_B0550044...

  • Page 38: Operation

    Operation 5 Operation Only put the machine into operation if you are equipped with the prescribed personal protective equipment. Details on this can be found in section 2.5.4 on page 18. The machine must be correctly installed and fully assembled. The air inlet pressure can be found in the information on the type plate (section 8.2 on page 59).

  • Page 39: Performing The Pressure Test

    Operation Are all safety features of the machine present and fully functional (see section 2.4 on page 14)? Are all machine parts leak-tight? Tighten connections as required. Is there enough release agent in the high pressure pump? Overview of the work steps during commissioning: 1.

  • Page 40: Flushing Out The Remains Of The Test Substance

    Operation 4. Check if all parts of the machine are leak-tight. 5. Briefly increase the air inlet pressure to approx. 10% above the maximum permissible value – the safety valve must discharge. 6. Turn the compressed air regulator for the high pressure pump down completely.
  • Page 41 Operation 6. Place a container with 10-15 l of flushing agent underneath. 7. Set the ram control lever to “Down” and lower the ram until the suction of the high pressure pump is im- mersed in the flushing agent. 8. Hold the relief hose in the collecting vessel (see Fig.

  • Page 42: Preparing The Processing Material

    Operation 5.1.3 Preparing the processing material Observe and follow the technical information of the respective mate- rial manufacturer. 1. If necessary, heat the container for components A and B to the ap- plication temperature recommended by the material manufacturer. 2. If permissible for the material, stir some solvent into component A using the hand mixer.

  • Page 43: Coating

    Operation 2. Set a pressure of 2-3 bar at the compressed air regulator for the ram. 3. Open the ventilation ball valve on the follower plate (see Fig. 14) 4. Set the ram control lever to “ ” in order to move it down. 5.

  • Page 44: Setting The Spraying Pressure

    Operation 5.2.1 Setting the spraying pressure Observe the following information when setting the spraying pressure: The optimum spraying pressure has been attained when an even application with fading edge zones is obtained. Only operate the machine with as much pressure as required, in order to attain good atomization at the recommended spray distance of approx.

  • Page 45: Tips For Good Coatings

    Operation 5.2.2 Tips for good coatings Hold the spray gun at a right angle (90°) to the surface to be coated. As soon as you hold the spray gun at a dif- ferent angle, the coating will become uneven and patchy (see Fig.

  • Page 46: Changing The Material Drum

    Operation 5.2.3 Changing the material drum As soon as the material drum is pumped empty, it must be changed. After processing 6 material drums in each case, the high pressure pump must be intermediately flushed to loosen material residues and prevent clogging of the pump (see section 5.2.4) 1.
  • Page 47 Operation 5. As soon as the sealing lip of the follower plate reaches the edge of the container, close the shut-off valve for the container ventilation. 6. As soon as there is sufficient space under the follower plate to remove the material drum, set the ram control lever to “Stop”. 7.

  • Page 48: Decommissioning

    Operation 17. Move the ram up. 18. Remove the flushing agent container. 19. Screw on the follower plate with gasket. 20. Place the new material drum underneath and fill the high pressure pump with material. Collect any solvent that is still in the pump and escapes at the relief hose in a container for contaminated materials.

  • Page 49: Pressure Relief

    Operation 6. Hold the spray gun in the flushing agent container and allow the machine to pump via the spray gun for 2-3 minutes. 7. Replace the solvent container with a clean bucket of new solvent and repeat the flushing process via the relief hose and spray gun. 8.

  • Page 50: Disposal

    Operation dry, frost-free and protected against direct sunlight. Storage temperature: minimum: 0 °C or 32 °F maximum: 40 °C or 104 °F 5.5 Disposal Residues of processing material, flushing agents, oils, greases and other chemical substances must be collected according to the legal regulations for recycling or disposal.

  • Page 51: Maintenance

    Maintenance and repair work on electrical parts may only be performed by specialist personnel with electrical qualifications — all other maintenance and repair work may only be done 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 52: Regular Testing

    Maintenance WARNING 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 pressure may escape and cause serious injuries.

  • Page 53: Maintenance Schedule

    Maintenance Have repair work carried out exclusively by WIWA Service or trained specialist personnel (in/from authorized workshops if necessary). 6.2 Maintenance schedule The information in the maintenance schedule constitutes recom- mendations only. The time frames may vary depending on the characteristics of the materials used, as well as external influences.

  • Page 54: Safety Valve

    Maintenance 6.3 Safety valve 6.3.1 Checking the safety valve Only perform the function test with a filled pump! Depending on the size of the pump used and the required working pressure, safety valves with a ” or ” connection are used. ”...

  • Page 55: Replacing The Safety Valve

    Maintenance Safety valves with a ” connection: Only perform the test by hand. To prevent damage to the safety valve, do not use any tools to release the knurled nut. 1. Reduce the air inlet pressure on the completely filled machine to approx.

  • Page 56: Maintenance Unit

    Maintenance 6.4 Maintenance unit The maintenance unit prevents the penetration of condensation water and dirt particles into the machine. Fig. 20: Maintenance unit Designation Compressed air shut-off valve with automatic ventilation function / EMERGENCY OFF Pressure gauge for displaying the air inlet pressure Compressed air connection for optional accessories (e.g.

  • Page 57: Checking And Cleaning The Water Separator

    Maintenance Designation Air outlet for the automatic venting Compressed air connection / input (G 1”) (coupling piece is to be provided by the owner) Compressed air regulator 6.4.1 Checking and cleaning the water separator The water separator filters moisture and particles of dirt ( > 5 μm) from the compressed air.

  • Page 58: High Pressure Pump

    6.5.1 Checking the release agent level Check the release agent level at the inspection glass before each com- missioning. When necessary, refill the release agent. We recommend using the release agent from WIWA (order no. 0163333). Description To fill the release agent,...

  • Page 59: Replacing The Gasket Of The Follower Plate

    Maintenance 6.5.3 Replacing the gasket of the follower plate If the gasket of the follower plate is worn, it must be replaced. The order number for the gasket can be found in the spare parts list. Designation Fastening screws Gasket Clamping ring Fig.

  • Page 60: Recommended Operating Fluids

    The manufacturing date of a hose line (month/year) is stamped on the ferrule. 6.7 Recommended operating fluids Only use original operating fluids from WIWA: Operating fluid WIWA order num- Release agent, yellow, standard (0.5 l)¹...

  • Page 61: Eliminating Operational Faults

    Eliminating operational faults 7 Eliminating operational faults Only eliminate operational faults if you are equipped with the prescribed personal protective equipment. Details on this can be found in section 2.5.4 on page 18. fault possible cause remedy High pressure pump Compressed air shut- Open the compressed does not start up de-...
  • Page 62 Eliminating operational faults fault possible cause remedy High pressure pump Air pressure low or too Increase the air pres- runs smoothly, but the little air. sure on the com- required spraying pres- pressed air regulator sure is not achieved. or check the air line for the correct cross- section.

  • Page 63: Technical Data

    Technical data 8 Technical data You can find the technical data for your machine on the machine card enclosed, on the type plate or in the documentation for the individual components. 8.1 Machine card The machine card contains all important and safety-relevant data and information for the machine.
  • Page 64 Technical data Please ensure that the data on the type plate matches the information on the machine card. If there are discrepancies, or the type plate is missing, please inform us immediately. Furthermore, some machine components have a separate type plate, e.
  • Page 65 Technical data Original Operation Manual ✓(2021/09/09), Status: 2024/09/11 1pfp_BA_en_B0550044...
  • Page 66 Technical data Original Operation Manual ✓(2021/09/09), Status: 2024/09/11 1pfp_BA_en_B0550044...
  • Page 67 Technical data Original Operation Manual ✓(2021/09/09), Status: 2024/09/11 1pfp_BA_en_B0550044...
  • Page 68 Headquarter and production WIWA Wilhelm Wagner GmbH & Co. Gewerbestraße 1–3 35633 Lahnau Germany Phone: +49 (0)6441 609-0 Fax: +49 (0)6441 609-2450 Email: info@wiwa.de Website: www.wiwa.de WIWA subsidiary USA WIWA LLC – USA, Kanada, Lateinamerika 107 N. Main St. P.O. Box 398, Alger, OH 45812...

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