Operation manual FLUID HEATER 1800 / 115V 3500 / 230V Serial-No.
Declaration of conformity according to ATEX-Directive 94 / 9 / EC The company WIWA Wilhelm Wagner GmbH & Co. KG Gewerbestr. 1-3 35633 Lahnau Germany herewith declares that the equipment types Fluid Heater WIWA 1000...3780 with Serial-No. ____________________ are in conformance with the provisions of the above-mentioned guideline, as well as the following standards: DIN EN 60079-0 : 03.2010 DIN EN 60079-1 : 04.
Content 1 Foreword................................................................................................... 5 2 Safety......................................................................................................... 6 2.1 Explanation of symbols 2.2 Safety instructions 2.2.1 Operating pressure 2.2.2 Power supply 2.2.3 Explosion protection 2.2.4 Risks caused by electrostatic charging 2.2.5 Health risks 2.3 Information signs on the unit 2.4 Protective devices 2.4.1 Temperature Limiter 2.4.
4.5 Ground the unit 4.6 Mount the fluid hoses 4.7 Mount de-icing assembly 25 26 26 5 Start-up and operation........................................................................... 27 5.1 5.2 5.3 5.4 5.5 5.6 First cleaning Pressure testing Unit preparation Change of material Shutting down Waste disposal 27 27 27 29 29 30 6 Checks and Maintenance....................................................................... 31 7 Malfunctions and trouble-shooting.............................................
Foreword 1 Foreword Dear Customer! We are delighted that you have decided in favour of a unit made by our company. This operation manual is intended for the operating and maintenance personnel. It contains all the information required to working with this unit.
Safety 2 Safety This unit has been designed and manufactured under due consideration of all safety-related aspects. It complies with the current standard of technology and the valid accident prevention instructions. The unit left the factory in perfect condition and guarantees a high level of technical reliability and safety.
Safety In the safety notes about the risk of accidents, different pictograms are shown after each hazard source - examples: General accident risk Risk of explosion from explosive atmosphere Risk of explosion from explosive substances Danger of injury due to electric voltage or electrostatic charging Risk of crushing by moving components Risk of burning due to hot surfaces Mandatory safety instructions concern personel protective equipment to be worn in the first instance.
Safety 2.2 Safety instructions Observe the operating instructions for the spray device! Material flow heaters are only used in conjunction with an appropriate spray device depending on the design (high-pressure or low-pressure) in high- or low-pressure processes and with appropriate spraying accessories. Inappropriate use can lead to severe injury. ➤➤ Read the operating manual of the spraying device and its accessories that are in use and follow the instructions the manual contains. 2.2.
Safety 2.2.3 Explosion protection WARNING Units that are designed without explosion protection must not be used in workshops that come under the explosion protection ordinance. Explosion-protected units meet the explosion protection requirements of Directive 94/9/EC for the explosion group, unit category and temperature class specified on the type plate or in the declaration of conformity.
Safety Warning Power supply cables which are not Ex-Proof may only be used outside of rooms where explosion-proofing is required, even when the Fluid Heaters themselves are explosion-proof. ➤➤ Always use an approved power supply cable which corresponds to the applicable Ex-Proof Zone. 2.2.4 Risks caused by electrostatic charging Warning High-pressure systems can charge electrostatically due to the high levels of friction. ➤➤ Only use conductive material hoses.
Safety When cleaning your skin, use only appropriate skin protection, skin cleaning and skin care products. In closed or pressurized systems dangerous chemical reactions may occur if parts made of aluminium or galvanized parts come into contact with 1.1.1 - trichloroethane, methylene chloride or other solvents containing halogenated hydrocarbons (CFC's).
Safety ➤➤ Warning label Danger! Hot surface! Pic. 2.3 ➤➤ Nameplate Please insure that the data on the type plate is in accordance with the information in the operation manual. If there are discrepancies, or if the nameplate is missing, please notify us immediately. Pic. 2.4 2.4 Protective devices If a protective device is not fully operative, or another defect is detected on the machine, interrupt the compressed air supply to the machine and disconnect the heater immediately from the power source.
Safety 2.4.1 Temperature Limiter The Temperature Limiter switches the heater off if the maximum allowed temperature is exceeded. If the Temperature Limiter has switched off the Fluid Heater, it can only be switched on manually by pressing the button Pic. 2.5 until the control lamp lights. 2.4.2 Ground Cable Pic. 2.5 A separate grounding of the Fluid Heater is required when no electrically-conductive connection to the spray unit exists. 1. Connect the ground cable on the provided grounding screw.
Safety 2.5.2 Personnel qualification A differentiation is made between two groups of people in dependence on their qualifications: ➤➤ Instructed operators have been verifiably instructed by the unit owner in the activities they are tasked with and the potential risks connected with them in the case of incorrect behaviour.
Safety Wear protective footwear Wear protective footwear to prevent injuries to the feet due to objects that may fall, drop or roll around and to prevent slipping on a slippery floor. 2.6 Notes on warranty 2.6.1 Conversions and alterations ➤➤ Unauthorized conversions or alterations should not be undertaken on safety grounds. ➤➤ Protective equipment should not be dismantled, converted or bypassed. ➤➤ The unit must only be operated within the specified limiting values and parameters. 2.6.
Safety 2.7.2 Leakages WARNING In case of leakages material can escape under very high pressure and cause serious bodily injuries and material damage. ➤➤ Immediately shut down the unit and depressurize it. ➤➤ Retighten any screw fittings and replace defective parts (only by trained personnel). ➤➤ Do not try to seal leaks on the connections and high-pressure hoses with the hand or by wrapping fabric around them.
Unit description 3 Unit description 3.1 Intended use The Fluid Heater can be used, according to version (HP or LP), in high- or low-pressure applications for heating the applied materials and/or the compressed air supply. The following types of coating materials may be heated: ➤➤ Paint and lacquers ➤➤ Protective coatings (oil and grease) ➤➤ Stripping agents ➤➤ Insulation and fire-protection coatings ➤➤ Tar-epoxy and bituminous paints ➤➤ Polyurethane ➤➤ Water 3.1.1 Models 1800 and 3500 HP Max.
Unit description 3.2 Description of function The Fluid Heater are heated electrically. The Fluid Heater Pic. 3.1 consists of two main parts: ➤➤ Housing with electrical switch and heating elements. ➤➤ Heat exchanger with material inlet and outlet connections. Material flows through the heat exchanger and is warmed by the heat produced by electrical heating elements in the the housing. Housing Heat exchanger Pic. 3.1 The desired temperature is freely adjustable using the temperature knob Pic. 3.2 (max.
Unit description 3.
Unit description 3.4 Accessories 3.4.1 Temperature Gauge The Temperature Gauge Pic. 3.3 to read the temperature at the material outlet of the Fluid Heater. Pic. 3.3 Materialdurchflusserhitzer mit Hochdruckfilter und Temperaturanzeige 3.4.2 Circulation Valve The return flow control valve Pic. 3.4 is used for circulation systems. Circulating avoids heat loss of material in hoses or feed lines during pauses in spraying. If a circulation valve is used, a spray gun with two inbound fluid hoses must be used.
Unit description Spray Gun Connection Circulation Valve (with pressure drain valve) Circulation Valve (without pressure drain valve) Pic. 3.5 Pic. 3.6 3.5 Equipment versions 3.5.1 Converting an Airless or Air Combi pump to an Airless or Air Combi Hot Spray version By adding a Fluid Heater, shorter curing times, higher film builds and top quality finishes can be achieved. In addition, heating influences viscosity.
Unit description 3.5.2 Portable Fluid Heater This version is used additionally when high temperatures are required at the spray gun/tip. It is also applicable as an additional heating element when working with long spray hoses, to avoid line heat loss.. The following kit is required: Portable Frame for Fluid Heaters, Order No. 0632538, as well as a Fluid Heater. Cart-mounted Airless Pump Spray Gun Portable Fluid Heater Pic. 3.
Unit description 3.5.4 Atomization Air Heating for Air-Combi Hot Spray Units Designed for reaching an optimal spray pattern, improved paint dispersion and shorter curing times. To avoid pre-heated material from cooling when coming in contact with the atomizing air, the Fluid Heater can also be used to heat the air before it goes into the spray gun. A portion of the inbound air is tapped from the main line and routed through the Fluid Heater and then out to the gun.
Installation and preparation 4 Installation and preparation 4.1 Safety measures at installation site Comply strictly with the current rules for accident prevention. ➤➤ For each material sprayed, the corresponding data sheets must be available. The information surrounding the viscosity, working temperature (flashpoint) and the mixing ratio stated by the manufacturer must be observed and followed closely. ➤➤ Mount the Fluid Heater securely on the spray unit, a wall bracket or the frame with carrying handle.
Installation and preparation 4.2 Operation manuals of the pump and accessories Fluid Heaters can only be used in conjunction with spraying equipment. Therefore, all instructions covering unit preparation, commissioning, operation and shutting-down must be compared to those covering the spraying equipment itself for compatability. ➤➤ Read and observe the instructions found in the operation manuals for the spraying equipment, the fluid heater and any additional spray accessories.
Installation and preparation 4.6 Mount the fluid hoses ➤➤ Material heating Pic. 4.11, pos. 1 + 2): Remove the yellow caps from the heat exchanger's material inlet and outlet. ➤➤ Use a male adaptor to mount the fluid hoses to the Fluid Heater. The connections must be sealed using either teflon tape or mediumstrength thread sealant (i.e. Loctite®). ➤➤ Approximately 80 Nm (59 ft.lb.) torque must be applied. ➤➤ Further part numbers for addtional connections can be obtained by contacting Customer Service. Pos.
Start-up and operation 5 Start-up and operation 5.1 First cleaning mind. 1 minute max. 5 minutes approx. 8-25 l (2-6.5 gal.) This Fluid Heater was function tested at factory using a testmedium. To ensure that no test medium is left in the pump, the entire system should first be flushed using the solvent recommended by the manufacturer of the coating to be used. ➤➤ Disconnect the heater from the power source.
Start-up and operation have been performed, make an optical check of the equipment for any signs of leaks or other defects. 3. Prepare paint spray equipment Follow the instructions for preparing the system for spraying found in the Operation manual for the equipment. 4. Flush Due to the possibility that solvent or solvent fumes can still be found within the Fluid Heater and/or spray system, the coating must first be sprayed cold for approx. one to two minutes back into the material feed container. 5.
Start-up and operation 5.4 Change of material The entire system has to be flushed thoroughly to avoid any possible chemical reaction with the new coatings material. 1. Shutting down Follow all the instructions found in chap. 5.5 Shutting down on page 29. 2. Shutting down the equipment After disconnecting the heater from the electrical power supply, perform all steps covering changing materials and/or shutting down as found in the Operation manual for the spray pump/system. 3.
Start-up and operation Follow additionally the instructions located in the corresponding Operation manual for the spray equipment being used. According to the rules for the prevention of accidents „Working with liquid jet systems“ BGR 500, Kap. 2.36 the equipment must be checked and overhauled at regular intervals by a specialist ( Service). 5.6 Waste disposal At the end of use, you must shut down and dismantle the unit and dispose of it in accordance with legal regulations.
Checks and Maintenance 6 Checks and Maintenance WARNING If maintenance and repair work is carried out by persons who have not been trained for this work you endanger yourself, other persons and impair the safety and reliability of the unit. ➤➤ Maintenance and repair work on electrical components must only be carried out by trained electricians – any other maintenance and repair work must be performed by WIWA customer service or by specially trained personnel. Before maintenance and repair work: 1.
Checks and Maintenance where the equipment is used. Maintenance instructions for the spray equipment and accessories can be found in the corresponding Operation manual.
Malfunctions and trouble-shooting 7 Malfunctions and trouble-shooting Fault Material in the heater does not become warm at all Possible Cause ➤➤ No electricity ➤➤ The temperature limiter has shut off the fluid heater Material heats but does not reach the desired temperature Male adaptors or fluid hoses are leaking Solution ➤➤ A: Check that electricity is available ➤➤ B: Check the power connection and power supply cable and replace if necessary.
Technical specifications 8 Technical specifications Max. Amperage (Ampere) Max. Wattage (kW) Max. Temperature* (°C / °F) Max. Operating Pressure (bar / psi) 9 2,0 60 / 140 16 230 11 1,8 16 2,5 3x 3x 230 230 3,5 3,5 9 3,5 400 9 85 / 0657716 0648704 0648374 0657725 230 0639850 115 0650797 0656099 230 0614335 0643430A Max. Voltage (± 10 %) (± 10 %) (V) 0631636 High-Pressure (HP) Fluid Heater Order No. 6 3,8 185 450 / 6525 Temp.
Certificate of training and operation 9 Certificate of training and operation 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.
Appendix 10 Appendix 36 Translation of the original operation manual MDFE_mAtex_1307_en • jw
Appendix Translation of the original operation manual MDFE_mAtex_1307_en • jw 37
Your contacts throughout the world Michel Laksander Sales Representative France 2 Bis rue de léglise F-02240 Brissy Hamegicourt, France Tel.: +33 32 36 21 120 Mobil: +33 63 70 19 297 E-Mail: laksander@orange.fr Wolfgang Pucken Director International Sales North of Germany, Israel, Hungary, Romania, Turkey, Poland, Malta, India, Pakistan, Africa, Morocco Headquarter and production WIWA Wilhelm Wagner GmbH & Co. KG Gewerbestr. 1 - 3 35633 Lahnau, Germany Tel.