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InjectIon

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Original operation manual

1701_HD1_IG003_DBK_en · jw

Operation manual

Type:

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Inject HD 1

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Inject HD 2

Serial-No.

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Summary of Contents for Inject HD 1

Page 1: ...InjectioN DEVICES Original operation manual 1701_HD1_IG003_DBK_en jw Operation manual Type Inject HD 1 Inject HD 2 Serial No ...

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Page 3: ...vior in case of emergency 9 2 9 Protective equipment 10 2 10 Handling of the machine and auxiliary materials 11 3 Machine description 12 4 Start up 13 4 1 Set up and Assembly 13 4 2 Initial cleaning 14 4 3 Checking pressure 15 5 Operation 17 5 1 Equipment preparation 17 5 2 Injecting 19 5 3 Pauses in work and changing injection materials 20 5 3 1 Pauses in work 20 5 3 2 Change of material 20 6 Shu...

Page 4: ...hich 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 wi...

Page 5: ...erved 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 import...

Page 6: ...und 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 i...

Page 7: ...eans 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 t...

Page 8: ...s 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...

Page 9: ...e 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 ...

Page 10: ...up To enable safe lifting a grip is located on the injec tion pump s air motor 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 Cut off the compressed air supply with the air tap lock Injury Should an injury occur through contact with liquid spray we recommend a doctor be called immediately Inform ...

Page 11: ... 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 Inspect the safety valve leading or seal for damage Inspect the safety valve for visible damage Inspect the compressed air tap lock for perfect functioning If a prot...

Page 12: ...e 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 ins...

Page 13: ...l valve 3 4 5 6 7 9 10 2 1 8 Picture 3 2 HD 2 11 Picture 3 3 Injection lance with trigger lever Pos Description 1 Lifting handle 2 Air pressure regulator 3 Pressure gauge 4 Air tap lock 5 Inbound air connection 6 Air motor 7 Material pump Pos Description 8 Material feed container 9 Frame 10 Suction hose 11 Injection lance 12 Fluid hose 13 Holding pipe for the injection lance ...

Page 14: ...r the filter Procedure 1 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 2 Several components of the machine were dismounted ...

Page 15: ...ntainer 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 c...

Page 16: ...maximum of 5 minutes Result The machine is now completely flushed Continue with the pressure check found in chapter 4 3 4 3 Checking pressure Task You want to inspect the seal on all system components Procedure 1 Close the injection lance 2 Open the air tap lock and set the maximum allowable inlet pressure by turning the control screw on the air pressure regulator to the right Observe the maximum ...

Page 17: ...njection lance and completely pump out any remaining solvent still in the pump Ensure the injection lance remains in contact with the container wall 7 Adjust back the air regulator by turning the control screw to the left until it moves freely 8 Close the air tap lock 9 Close the injection lance Result The start up procedures are finished The pump is ready for use ...

Page 18: ...turning the control screw to the left until it moves freely 3 Connect to main air supply line 4 Fill solvent from container A into the pump s feed container 5 Open air lock tap 6 Open the injection lance while holding it into container B 7 Adjust air regulator to 1 2 bar by turning the control screw to the right 8 Hold the injection lance in such a way that the emerging solvent is sprayed sideways...

Page 19: ...y turning the control screw to the left until it moves freely 14 Close the air tap lock 15 Close the injection lance 16 Fill injection mateial into the material container C 17 Open the air tap lock and adjust air regulator to 1 2 bar 18 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 ...

Page 20: ...xample Pressure setting pressure gauge reading 4 bar pressure ratio Multiplier 33 4 bar x 33 132 bar The material is injected at132 bar 4 Open the injection lance ball valve The injection material is now pumped into the foreseen location Fill the injection hole with as little pressure as possible to ensure the maximum safety to operating personnel and the masonry structure When the hole is filled ...

Page 21: ... C as long as it is not mixed two component material 3 Fill the pump s feed container with solvent container A 4 Open the air tap lock 5 Turn the air regulator slowly to max 1 2 bar by turning the control screw to the right 6 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 7 Close the injection lance as soon...

Page 22: ...il it moves freely The pressure gauge must show 0 bar 3 Close the injection lance 4 Empty the unit s feed container Fill remaining material back into container C as long as it is not mixed two component material 5 Fill the unit s feed container with solvent from container A 6 Open the air tap lock and set the pressure gauge to a working pressure of 1 2 bar 7 Hold the injection lance in such a way ...

Page 23: ... 9 Close the injection lance 10 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 11 Close the air tap lock 12 Re open the injection lance shortly to release any remaining pressure from the system ...

Page 24: ...ntenance 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 If slightly discolored Change the release agent By draining a small amount...

Page 25: ...Suction hose blocked Replace the suction hose Bottom valve ball stuck Unscrew suction system Using a pin or a screw driver release ball in bottom valve from underneath Open injection lance ball valve Knock lightly on the side of the bottom valve with a hammer Bottom valve doesn t close Unscrew the bottom valve and thoroughly clean the ball and valve seat 3 Material exits the orifice but the pump c...

Page 26: ...n loss Thin down material add solvent Use bigger pump Suction system is not tight injection stream pulsates Check all seals on fittings of the suction pipe and hose and exchange if necessary Bottom valve is leaking pump only stops on the upward stroke when the injection gun lance is closed Unscrew bottom valve Thoroughly clean ball with seat or exchange if necessary Piston valve is leaking pump on...

Page 27: ...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 23x12 6x12 705x499x340 27 8x19 6x13 4 Approx net weight kg lbs 8 9 Sound pressure level emitted at the work place Running at idle LpAd dB 84 Running with load LpAd dB 80 9 2 Machinery materials Description Order No Release agent1 0163333 Anti freeze2 0 5l 0631387 Pneumatik oil 2 0 5 lit...

Page 28: ...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 important and relevant for safety exact designation and manufacturing data technical specification ...

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Page 30: ...7 0141 Fax 1 419 549 5173 Toll Free 1 855 757 0141 sales wiwa com www wiwausa com WIWA Subsidiary China WIWA Taicang Co Ltd Building A of Huaxin Industrial Park No 11 East Qingdao Road Taicang City Jiangsu Province 215400 P R China Tel 86 512 5354 8857 Fax 86 512 5354 8859 info wiwa china com www wiwa china com WIWA Middle East General Trading LLC Mohd Farhan Khan Jebel Ali Industrial 1 Dubai VAE ...

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