Assembly Instructions

Transcription

1 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page of 20 Assembly Instructions Hand Spray Valve SMS-6 Article Number: S6- NOTE Please read the Assembly Instructions carefully before first using the incomplete device and strictly adhere to the instructions! The incomplete device may only be worked with and worked on by persons who are familiar with the assembly instructions and the current regulations for industrial safety and accident prevention. Keep a translated version of the original Assembly Instructions at a safe place close to the device! The instructions must be available at all times!

2 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 2 of 20 Table of Contents Page EC DECLARATION OF INCORPORATION... 4 INTRODUCTION TARGET GROUP OF THE ASSEMBLY INSTRUCTIONS LIST OF SIGNS AND SYMBOLS SAFETY GENERAL INFORMATION DANGERS FROM RESIDUAL ENERGY WARRANTY AND LIABILITY CORRECT USE INCORRECT USE QUALIFICATION OF PERSONNEL TRANSPORT PACKAGING TASKS BEFORE TRANSPORT DESCRIPTION OF FUNCTION PURPOSE OF DEVICE TECHNICAL DATA TYPE LABEL COMMISSIONING MOUNTING AND INSTALLATION HOSE MOUNTING WIRING LAYOUT (SEPARATE CONTROLS) ADJUSTING THE DEVICE OPERATION GENERAL INFORMATION OPERATION INSTRUCTIONS / OPERATING CONDITIONS OPERATING ELEMENTS... 7 TAKING OUT OF SERVICE SHORT INTERRUPTION LONG-TERM INTERRUPTION SHUTDOWN OF DEVICE... 8 MAINTENANCE AND REPAIR GENERAL INFORMATION CLEANING REPLACING SEALING SCREW AND SEALING ELEMENTS REPLACING NEEDLE AND NOZZLE SPARE PARTS CUSTOMER SERVICE / SUPPORT TROUBLESHOOTING GENERAL INFORMATION MALFUNCTION: NOZZLE NEEDLE DOES NOT OPEN SPRAY IMAGES / ERRORS APPENDIX DIMENSIONED DRAWING WITHOUT NOZZLE EXTENSION Spare Parts Drawing Spare Parts List WEAR-AND-TEAR KIT... 8

3 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 3 of NOZZLES NOZZLE NEEDLES NOZZLE EXTENSIONS ACCESSORIES DATA SHEET MICRO SWITCH

4 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 4 of 20 EC Declaration of Incorporation in accordance with EU Machinery Directive 2006/42/EU, dated 7 May 2006, Appendix II B We herewith confirm that the below mentioned incomplete device meets the basic requirements for safety and health as stated in EU Machinery Directive 2006/42/EU for its design and construction as well as for the configuration released by us on the market. This machine component will not be operated before it has been determined that the incomplete system where the machine component will be installed also meets the requirements of the Directive (2006/42/EG). Manufacturer Walther Systemtechnik GmbH Hockenheimer Straße 3 D Germersheim Description Hand Spray Valve, Article No. S6- We also declare the conformity with other, product-relevant directives/guidelines: Mach. Direct. 2006/42/EU App. I, Clause:..2,..3,..5,..6,.3.2,.3.3,.3.4,.5.8,.5.9 EMC- Directive 204/30/EU, dated 26. February 204 Applied harmonized standards, in particular: DIN EN ISO 200 Safety of Machinery General Design Principles Risk Assessment and Risk Reduction (ISO 200:200) In addition, we also confirm that the special documentation according to Appendix VII Part B has been prepared. The manufacturer, respectively his authorized representative obligates himself to submit this documentation to the market surveillance authorities, if requested. This EC Declaration of Incorporation becomes invalid if the incomplete device will be altered or changed without consent of Walther Systemtechnik GmbH. Authorized representative for Technical Documentation: Stefan Hirl, Hockenheimer Straße 3, D Germersheim Germersheim, 9 April 206 (Place, Date) (Stefan Hirl, Management)

5 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 5 of 20 Introduction. Target Group of the Assembly Instructions Operating Personnel Maintenance Personnel.2 List of Signs and Symbols The assembly instructions warn users of operations which may put their health at risk. The warnings are indicated by combinations of text and symbols as follows: 2 Safety DANGER Describes a potentially dangerous situation. Death, grievous bodily harm or severe material damage WILL occur if the respective measures of precaution have not been taken WARNING Describes a potentially dangerous situation. Death, grievous bodily harm or severe material damage MAY occur if the respective measures of precaution have not been taken. CAUTION Describes a potentially dangerous situation. Slight injuries CAN occur if the respective measures of precaution have not been taken. This signal word is also used to describe possible property damages. Indicates tips for usage and other particularly useful information. No dangerous situation. 2. General Information The construction of this device is according to the latest technology and is absolutely reliable. The individual components as well as the complete device are continuously checked by our quality management. 2.2 Dangers from Residual Energy Please instruct the operating personnel on the respective measures to be taken against the occurrence of mechanical, hydraulic, pneumatic and electric / electronic residual energies. 2.3 Warranty and Liability According to the conditions laid down by the German Engineering Association (VDMA), Walther Systemtechnik GmbH has a guarantee of 2 months under normal European operating conditions on its own parts (spare parts are excluded); or according to the conditions of the manufacturer. This guarantee can only be granted by Walther Systemtechnik GmbH, if: the user has thorough knowledge of the content of the assembly instructions; the user follows the instructions and notes contained in the assembly instructions; the user does not rebuild or make changes on parts of the device without prior consent of WST Systemtechnik GmbH.

6 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 6 of Correct Use This device is a needle valve and will be used for processing materials which can be sprayed in continuous or intermitting operation. Under no circumstances shall aggressive media such as acids, alkaline solutions, detergents, chemicals or others be sprayed. If you are not sure, please contact the manufacturer if a certain spray medium is suitable for this device. 2.5 Incorrect Use Operating the device with insufficient knowledge about the operation, maintenance and care of the device. Making changes, extensions or alterations on the device that may hamper its safety without the prior consent of Walther Systemtechnik GmbH. Operating the device with defective safety installations or not properly attached or malfunctioning safety devices. Using unsuitable materials. Handling the device while energized 2.6 Qualification of Personnel Only trained and instructed personnel may conduct work on the equipment. The responsibilities of the personnel for assembly work, operation, repair work or maintenance work must be clearly assigned to individuals! Persons in training may work with the equipment only under supervision of an experienced person. Personnel Task Instructed Personnel Personnel with Technical Qualification Specialist Supervisor Packaging, Transport X Commissioning X X - Operation X - Troubleshooting, general X X - Troubleshooting mechanical - X - - Troubleshooting electrical - - X - Setting up - X - - Maintenance - X - - Repair - X X - Taking out of service, Storage - X X -

7 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 7 of 20 3 Transport 3. Packaging The type of packaging depends on the individual mode of shipping. If not separately contracted, the packaging is in accordance with the rules and regulations of Walther Systemtechnik GmbH. This rule is in accordance with the Federal Association for Packaging HPE. 3.2 Tasks before Transport The following has to be done before transport: Disconnect all power lines. The actual transport of the incomplete device and its individual parts requires special care in order to prevent damages from external forceful impact or careless on- and off-loading. Depending on the mode of transportation, suitable transport and load securing has to be selected. The incomplete device will be aligned and leveled by appropriate fastening elements. 4 Description of Function The hand spray valves of the SMS-6 series are suitable for the application of liquid and viscous media, such as greases, oils, abherents, adhesives or colors. One of the major characteristics is the stepless adjustability of the sprayed quantity. Pre- and post-air will be controlled through separate 3/2-way valves. Depending on the viscosity of the applied medium, the spraying image can be individually adjusted through either the nozzle size, or the atomizer air pressure or the material supply pressure. Atomizer air, control air and material will be supplied via three hoses. 4. Purpose of Device CAUTION The use of other media can cause functional failures, damages or even the destruction of the device. The hand spray valves of the SMS-6 series are pneumatically controlled and are suitable for the finest application of liquid media, such as separating agents or colors. An extension is required for the actual use (not included in scope of delivery). The spraying process is produced through the control air, the material supply pressure and the atomizer. Depending on the selected air cap, a flat jet or a round or even a ring jet will be produced. Control air will be supplied to the spraying device via a pilot valve (not included in delivery); when in basic position, it must not have a passage. No material will be discharged. The atomizer air will be supplied to the spraying device through a second pilot valve (not included in scope of delivery) and will also not have a passage. The hand spray valve will be controlled in the following way: when the micro switch is activated, first the pilot valve of the atomizer air receives a signal in order to produce a pre-air, and shortly afterwards the pilot valve of the control air receives a signal to open the needle. Now the material can be discharged and will be atomized by the atomizer air. Once the micro switch is released, the signal for the pilot valve of the control air is deactivated first so that the spring inside the piston chamber will push the needle into the nozzle and stop the material flow. The signal for the pilot valve of the atomizer air comes with a time delay (depending on the desired post-air time) after the signal for the control air. This function has two impacts: the material will be immediately atomized when it leaves the nozzle, and the nozzle tip will be clear-sprayed from the medium by the post-air when the needle closes. The atomizer air divides the medium into a spray jet. Function of the spray air controls: pre-air / post-air The needles function: opening by air pressure / closing by spring pressure. If the control air fails, the spraying device will be closed by the needle spring. The medium itself is supplied to the valve from a pressured container or via a pump.

8 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 8 of Technical Data General Data Dimensions [mm] w/o bracket ca. 68 x 45 x 5 Dimensions [mm] with bracket ca. 2.5 x 56 x 5 Weight [g] ca. 500 (with bracket ca. 600) Energy Supply Control air pressure [bar] Atomizer air pressure [bar] (minimum 0.5 bar lower than control pressure) Material pressure [bar] max. 35 bar 4.3 Type Label The type label was etched into the casing. The serial number is also hammered into this label. 5 Commissioning 5. Mounting and Installation The SMS-6 Spray Valve can be installed in any position. The distance to the application area depends on the desired application width. The larger the distance of the nozzle opening to the application area, the wider will be the actual application of material. 5.2 Hose Mounting There are three functional hoses for the supply of compressed air and material to the spray valve; they which will be connected as follows (see below) Atomizer Air (blue) M5 connection Z : to 3/2-way magnetic valve Control Air (black) M5 connection S : close control air to 3/2-way magnetic valve Material (transparent or white) /8" connection M : to pressured container or pump Connection Atomizer air "Z" Connection Material M Connection Control air "S"

9 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 9 of Wiring Layout (separate controls) Control unit not included in scope of delivery 5.4 Adjusting the Device The needle stroke adjustment will be used to regulate the actual material quantity. Left turn at the raster needle lock screw will increase the material amount. Right turn at the raster needle lock screw will decrease the material quantity. A finely ascending precision thread results in a needle stroke which will experience a stroke change of 0.5mm with one turn of the raster head. Raster needle setting WICHTIG The maximum turn anti-clockwise if the raster needle lock screw is when there are no more raster steps. Then the maximum stroke regulation is already exceeded. If you keep on turning, this will cause the raster needle lock screw to dislocate completely! WICHTIG Nozzle and nozzle needle can be damaged by wrong handling. Never reduce material quantity (right turn at the regulating screw) when no material is discharged. When the nozzle is closed, do not attempt to turn the regulating screw further to the right!

10 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 0 of 20 6 Operation 6. General Information This device may only be operated if the safety-related equipment is permanently effective and not suspended during operation or altered in its intended effectiveness. Please observe the following instructions for setting and operating the device! Every spray valve hast o equipped with its own pressure reducer for atomizer air ZL. If several spray valves are supplied through one material pressure container, they cannot spray simultaneously. Make sure that the material line between material pressure containers and spray valve is not longer than 2000mm. If the break time is a multiple of the spray time, a repeated activation of the spray valve has to be planned for optimizing the application. Also, a clear-spraying can be planned alternatively in a separate position. After standstills of 5 min. or more, perform a clear-spraying by repeated triggering (3-5 x). 6.2 Operation Instructions / Operating Conditions CAUTION Never point the jet at people. The wearing of eye protection is strongly recommended. The spraying process can create noise depending on the air and fluid pressures used. Ear protection should be worn, if required. WARNING Danger caused by flammable, harmful fluid. Always follow the safety instructions on the container or the safety data sheet for the fluid. Spray valves of the SMS-6 series generally operate with a control pressure of bar. The atomizer pressure has to be lower than the material pressure in order to avoid a repulse of the material. Atomized air pressure and material pressure should be closely correlated. Atomizer air will be controlled in such a way that it activates prior to opening the needle and turns off after closing the needle (makes it almost maintenance-free). In case high material pressures are required, make sure that the accident prevention regulations of the trade associations will be strictly followed! The application can be controlled as intermitting or continuous. Depending on the individual use, the control pressure has to be adjusted to the set switching frequency on the one hand and to the higher or lower material pressures on the other. Under appropriate operating conditions (material pressure, control pressure, needle stroke, and short supply lines) a total of 30 strokes per second can be reached. A device-specific set-up is required for an optimum adjustment of the application image. Basic results from lab tests can be used. Of course, these may have to be adjusted for the individual device. The parameters nozzle size, opening time, opening stroke, material pressure and if required, also temperature have to be combined. For longer standstills, the material can remain in the valve, if it remains under pressure (no contact to outside air).

11 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page of Operating Elements Regulating screw Raster needle setting Hand release Activate process 7 Taking out of Service 7. Short Interruption A short interruption (5 min and more) will always be followed by a clean-spraying. NOTE Please follow the operating instructions! 7.2 Long-term Interruption The following will be observed for a long-term interruption of the device/machine: Depressurize material supply lines Clean nozzle with a special thinner and a soft cloth. Make sure that no cloth fibers are left on the nozzle tip. NOTE Please follow the maintenance instructions! 7.3 Shutdown of Device The following is important for a shutdown of the machine / device: Clean spray valve with a special thinner. NOTE Please follow the maintenance instructions!

12 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 2 of 20 8 Maintenance and Repair 8. General Information CAUTION Before starting any maintenance or repair work, ensure that all air-operated tools are depressurized and disconnected from the air supply. Before opening the spray valve it must be disconnected from the air and fluid supply. Otherwise, ejected components can cause injuries. The spray valves of the SMS-6 series are high-quality precision devices which will not fail if treated correctly and will operate almost maintenance-free. All mobile parts should be regularly oiled and also the threads should be greased when the nozzles are cleaned or exchanged. Always keep clean and observe minimum instructions to maintain a long life of the valve. Always use clean and filtered material only. The control air must also be clean and slightly oiled, if necessary. Maintenance also depends on the individual operating conditions and the type of media used. 8.2 Cleaning Only use soft brushes for outside cleaning of the nozzle tips. Never use metal tools with sharp edges. Wash equipment thoroughly after use to remove residues and dirt, especially if the nozzle needle has to be exchanged. 8.3 Replacing Sealing Screw and Sealing Elements Make sure all connections are pressure-less and the material and energy supply are turned off! Unscrew locking screw (7) and remove pressure spring (6). Pull out the nozzle needle (5) by using long-nose pliers. Unscrew the sealing screw (3) with a screwdriver: fig. 6.3/2 Remove all O-rings and the Variseal; mount new O-rings and Variseal and slightly grease. After replacing the O-rings, reassemble in reverse order. Sealing and gaskets can be easily damaged. Therefore do not use any sharp-edged or metal tools for removing and inserting the gaskets.

13 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 3 of Replacing Needle and Nozzle Make sure all connections are pressure-less and the material and energy supply are turned off! Unscrew both fastening screws M5 () and pull out. Pull out the valve from the handle case (2). Unscrew the regulating lock (8) and remove the pressure spring (7). Remove the nozzle needle (6) with long-nose pliers. Remove the retainer ring (3). Use a wrench to loosen the nozzle (4) and completely unscrew. Slightly grease new nozzle needle (6) and insert. Remove the residues from greasing at the nozzle tip with a soft cloth. Screw in the new nozzle (4). Reassemble in reverse order. Nozzle (3) and nozzle needle (6) should always be replaced at the same time. 8.5 Spare Parts When installing nozzles and nozzle needles which have already been in use, rinse the nozzle with a suitable thinner to make sure that no residues of material remain. Also the needles shaft will be thoroughly cleaned from residual particles. Needle shafts with cured material can cause damages at the sealing element. Only use original spare parts from the manufacturer! Wrong or defective spare parts from other manufacturers can damage the device. If other than original spare parts of the manufacturer will be used, all obligations from the manufacturer or his sales partners, such as guarantees, service contracts etc will be forfeited without further notice. 8.6 Customer Service / Support Walther Systemtechnik GmbH Hockenheimer Straße 3 D Germersheim Germany Phone ++49(0) Telefax ++49(0) info@walther-2000.de Internet

14 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 4 of 20 9 Troubleshooting 9. General Information First check all supply lines for connection and serviceability. In case of serious problems that cannot be resolved, please contact the Walther Systemtechnik GmbH customer service. 9.2 Malfunction: Nozzle needle does not open Failure Possible cause Action Nozzle needle does not Nozzle needle is clogged in the Clean complete needle sealing open needle sealing Control air pressure is too low Check if sufficient control air pressure is available at the spray valve Needle stroke is too small Increase needle stroke by turning the raster screw O-Ring defective Replace O-Ring Pilot valve does not activate. Check pilot valve No atomizer air Atomizer air pressure too low Check if sufficient atomizer air pressure is available at the spray valve. No material discharged Nozzle clogged by material Clean nozzle and needle. Material pressure too low Check id sufficient material pressure is available at the spraying device. Bad spray image Dirty air cap Clean air cap. Wrong air ratio Spray images /Errors

15 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 5 of Spray Images / Errors SPRAY IMAGE PROBLEM CAUSE ACTION Normal spray image (flat jet) Normal spray image (round jet) Spray image shaped too much upwards and downwards Soiled air cap Soiled nozzle Clean nozzles Spray image too much left-sided or right-sided Soiled air cap Soiled nozzle Clean nozzles Heavy application in the middle of the spray image Too much material Material too thick Reduce material supply Dilute material Split spray image Too little material Pressure flat jet too high Increase material supply Increase pressure for round jet

16 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 6 of 20 0 Appendix 0. Dimensioned Drawing without Nozzle Extension

17 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 7 of Spare Parts Drawing

18 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 8 of Spare Parts List Pos. Article No. Qty Description Cylinder screw with slot DIN Micro switch Cylinder screw with inner hex DIN Handle case Hanging bracket Retainer ring 7.0 * Nozzle, stainless steel Main body, cpl. Main body, beamed Plug-in nipple, brass Reduction screw joint, stainless steel * Material sealing kit O-Ring / Vitonƒ Variseal Plastic cover sleeve * Article numbers can be found on the following pages. Sealing screw, complete, Viton Sealing screw O-Ring / Viton Nozzle needle, complete O-Ring / Viton Pressure spring Standard Reinforced pressure spring Raster needle lock Lock washer DIN 6799 Stop sleeve Raster locking screw Needle-stoke raster head Always indicate the inscribed serial numbers when ordering spare parts! 0.2 Wear-and-Tear Kit Article No. Description Material wear-and-tear kit for SMS-6 (Standard), VITON 0.3 Nozzles 7.0 Nozzle, Standard, Stainless steel, Ø 2 x 8 mm Article No. Description Nozzle, 0.2mm, Stainless steel, 2 x 8mm, SW Nozzle, 0.3mm, Stainless steel, 2 x 8mm, SW Nozzle, 0.5mm, Stainless steel, 2 x 8mm, SW Nozzle, 0.8mm, Stainless steel, 2 x 8mm, SW Nozzle,.0mm, Stainless steel, 2 x 8mm, SW Nozzle,.2mm, Stainless steel, 2 x 8mm, SW Nozzle,.5mm, Stainless steel, 2 x 8mm, SW Nozzle, 2.0mm, Stainless steel, 2 x 8mm, SW Nozzle, 2.5mm, Stainless steel, 2 x 8mm, SW6

19 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 9 of Nozzle Needles 2.0 Nozzle needle, Standard, Stainless steel, Diam. 3 x 27mm Article No. Description Nozzle needle, 0.2/0.3mm, complete Nozzle needle, 0.5mm, complete Nozzle needle, 0.8mm, complete Nozzle needle,.0mm, complete Nozzle needle,.2mm, complete Nozzle needle,.5mm, complete Nozzle needle,.8/2.0mm, complete Nozzle needle, 2.5mm, complete 0.5 Nozzle Extensions Available upon request! 0.6 Accessories Figure Article Number Description Cleaning set (see also Product catalog ACCESSORIES)

20 Rev.. Assembly Instructions - Hand Spray Valve SMS-6 Page 20 of Data Sheet Micro Switch