Combi Flash EX 655 Specifications

Operation manual
FLUID HEATER
1800 / 115V
3500 / 230V
Serial-No.
⸏⸏⸏⸏⸏⸏⸏⸏
3500 / 400V
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High-Pressure (HP)
Fluid Heater










Low-Pressure (LP)
Fluid Heater
—
0643430 A
0614335
0631636
0639850
0650797
0656099
0657725
0648374
0648704
0657716



0633599
0650081
0653207


0648375
0657494

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 : 04.2008
The listed euipment is assigned to Group II, Category 2 G
Marking:
II 2G Ex d IIB 165 °C (T3) Gb
Designated agency according to ATEX-Directive 94 / 9 / EC: Bureau Veritas
Consumer Products Service Germany GmbH
EC-type examination Certificate No.:
EPS 12 ATEX 1 453 X
ATEX QM-Certificate No.:
01 220 042 181
Designated agency for QM:
TÜV Rheinland Industrie Service GmbH,
Am Grauen Stein, 51105 Köln
Notified Body 0035
Lahnau,
Place, Date
2
Heidrun Wagner-Turczak
Managing Director
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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 2.4.2 Ground Cable
2.5 Operating and maintenance personnel
2.5.1 Unit owner's duties
2.5.2 Personnel qualification
2.5.3 Authorized operating personnel
2.5.4 Personal Protective Equipment (PPE)
2.6 Notes on warranty
2.6.1 Conversions and alterations
2.6.2 Spare parts
2.6.3 Accessories
2.7 Emergency procedures
2.7.1 Shutting down
2.7.2 Leakages
2.7.3 Injuries
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3 Unit description...................................................................................... 17
3.1 Intended use
3.1.1 Models 1800 and 3500 HP
3.1.2 Model 3500 LP
3.2 Description of function
3.3 Unit structure
3.4 Accessories
3.4.1 Temperature Gauge 3.4.2 Circulation Valve
3.5 Equipment versions
3.5.1 Converting an Airless or Air Combi pump to an Airless or Air
Combi Hot Spray version
3.5.2 Portable Fluid Heater
3.5.3 Heating of air motors (de-icing system) by using a Fluid Heater
3.5.4 Atomization Air Heating for Air-Combi Hot Spray Units
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4 Installation and preparation................................................................... 24
4.1 Safety measures at installation site
4.2 Operation manuals of the pump and accessories
4.3 Electrical power connection
4.4 Mount the Fluid Heater
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3

4.5 Ground the unit
4.6 Mount the fluid hoses
4.7 Mount de-icing assembly
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5 Start-up and operation........................................................................... 27
5.1 First cleaning
5.2 Pressure testing
5.3 Unit preparation
5.4 Change of material
5.5 Shutting down
5.6 Waste disposal
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6 Checks and Maintenance....................................................................... 31
7 Malfunctions and trouble-shooting....................................................... 33
8 Technical specifications......................................................................... 34
9 Certificate of training and operation..................................................... 35
10 Appendix................................................................................................ 36
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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.
The owner of the unit must ensure that operators and maintenance personnel always have an operation manual at their disposal in a language
that they understand!
Safe and reliable operation of the unit requires further information in addition
to this operation manual. You should have read and understood the guidelines and accident prevention regulations that apply in your country.
In Germany the following apply:
➤➤ ZH 1/406 “Richtlinien für Flüssigkeitsstrahler” (Guidelines for Liquid Jets),
published by the German “Hauptverband der Gewerblichen Berufsgenossenschaften”;
➤➤ BGR 500, Chapter 2.29 “Application of Coating Materials”;
➤➤ BGR 500, chapter 2.36 “Working with Fluid Spraying Equipment” published by the employers liability insurance association for the gas, remote
heating and water management sectors.
We strongly recommend adding all relevant guidelines and accident prevention instructions to this operation manual.
As the Fluid Heater can only be used in connection with spray equipment,
the operating manuals for the spray equipment and any accessories used
must be observed and followed.
Moreover the manufacturer's instructions and guidelines for coating or feeder materials must be respected at all times.
However, if you have any questions, please do not hesitate to contact us.
Best wishes for good results with your unit from
WIWA Wilhelm Wagner GmbH & Co. KG.
Copyright
© 2013 WIWA
This operation manual remains the copyright of
WIWA Wilhelm Wagner GmbH & Co. KG.
Gewerbestr. 1-3 • 35633 Lahnau • Germany
Tel.: +49 6441 609-0 • Fax.: +49 6441 609-50 • E-mail: info@wiwa.de • Internet: www.wiwa.de
This operation manual is solely intended for personnel involved in preparation, operation and servicing. It is prohibited to pass on this operation 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 operation manual only applies in conjunction with the unit card that was given to you with the
user manual for your equipment. Please check that the data on the type plate match those on the
machine card. Please notify us immediately if there are discrepancies, if the user manual has been
incorrectly compiled or if the type plate is missing.
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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.
Nevertheless, there are certain risks that can arise from incorrect operation
or misuse:
➤➤ to life and limb of the operator or third party,
➤➤ to the unit and other material assets of the owner,
➤➤ to the efficient working capacity of the unit.
You must refrain from any working methods that could affect the safety of operating personnel and equipment. All the people that are involved in set-up,
commissioning, operation, maintenance, repair and servicing of the spray
gun must have read and understood the operation manual beforehand, especially the chapter entitled “Safety”.
Your safety is at stake!
We recommend to the owner of this unit to have this confirmed in writing.
2.1 Explanation of symbols
Safety information warns you of potential risks of accidents and tell you the
measures that are needed to prevent accidents.
In WIWA operating manuals, safety information is specially highlighted and
marked as follows:
Danger
Indicates danger of accidents; if you ignore the safety information, there is
a high risk of severe injury resulting up to and including death!
Warning
Indicates danger of accidents; if you ignore the safety information, severe
injury can result up to and including death!
Caution
Indicates danger of accidents; if you ignore the safety information, severe
injury can result!
Indicates important information on correct use of the machine. Ignoring it
can result in damage to the machine or in its vicinity.
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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. They are particularly highlighted and marked as
follows:
Wear protective clothing
Highlights the order to wear the prescribed protective clothing to protect
against skin injuries caused by spraying material or gases.
Use eye protection
Indicates the requirement to wear protective goggles to protect against
eye injuries caused by gases, fumes or dust.
Wear ear defenders
Indicates the requirement to wear ear defenders to prevent your hearing
from being damaged by noise.
Use a respiratory protection mask
Highlights the order to use a respiratory protection mask to prevent your
respiratory tract from being damaged by gases, fumes or dusts.
Wear protective gloves
Highlights the order to wear protective gloves with lower arm protection to
protect against burn injuries caused by heated materials.
Wear protective footwear
Highlights the order to wear protective footwear to prevent injuries to the
feet due to objects that may fall, drop or roll around or to hot or caustic
liquids.
Indicates references to guidelines, work instructions and operation manuals that contain important information which you must observe at all times.
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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.
2.2.1 Operating pressure
WARNING
Unit components that do not comply with the maximum permissible operating pressure can burst and cause serious injury.
➤➤ The specified maximum operating pressures must generally be complied with for all unit components. In case of varying operating pressures, the lowest value is always the one to be taken as the maximum
operating pressure for the entire unit.
➤➤ Material hoses and hose assemblies must comply with the maximum
operating pressure, including the required safety factor.
➤➤ Material hoses must be leak tight and free of kinks, signs of abrasion
or bulges.
➤➤ Hose connections must be tight.
2.2.2 Power supply
Warning
Use in an area where solvent vapours exist can cause the power cable to
become porous or cracked.
➤➤ Therefore, the power cable must be inspected visually for damage
before each operation.
➤➤ Never make repairs to the power cable. It must be replaced completely
by a qualified technician.
Warning
➤➤ Before connecting the Fluid Heater to the electrical supply, check to
ensure that the point of hook-up is functioning correctly and no faults
are present.
➤➤ In case of power failure, disconnect the power supply to prevent the
Fluid Heater from switching on independently.
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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.
The operator is responsible for determining the zone allocation according
to the Directive of EC 94/9/EC, Appendix II, no. 2.1-2.3 when observing the
measures of the responsible inspecting authority. The operator is responsible for checking and ensuring that all technical data and markings according
to ATEX correspond with the necessary requirements.
Please note that several unit components have their own type plate with separate marking according to ATEX. In this case the lowest explosion protection of all attached markings applies for the entire unit. Applications where
malfunctioning of the unit can lead to danger to personnel must be provided
with appropriate safety measures by the operator.
However, if agitators, heaters or other electrically accessories are additionally mounted, one must check the explosion protection. Plugs for heaters,
agitators, etc. that do not have explosion protection, may only be plugged in
outside of areas that fall under the explosion protection ordinance, even if
the accessory equipment as such is explosion protected.
Warning
Heating up cleaning agents can cause an explosion. This may result in
serious injury to persons and damage to property.
➤➤ Pay attention to the flashpoint and the ignition temperature of the cleaning agent.
➤➤ Switch off the material flow heater if you need to perform the following
work: Cleaning, pressure testing, decommissioning, maintenance and
repair.
➤➤ Flush and clean with solvent only when the heater is cold and disconnected from the power source.
Never heat solvent in the Fluid Heater!
➤➤ The unit may not be opened when located in and exposed to explosive
environments
➤➤ Never spray solvent or material containing solvent into narrow-necked
cans or drums with bungholes!
➤➤ Always observe the flashpoint of matierals to be heated. When setting
the desired temperature, never exceed the flashpoint temperature of
the material that has been stated by the mateirals manufacturer.
➤➤ Smoking, open flames or any other possible ignition sources are not
allowed anywhere near the area of operation.
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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.
All original
material hoses are conductive and compatible with
our equipment.
2.2.5 Health risks
Warning
Depending on the set temperature, the outside of the heater and the spray
gun can get very hot.
➤➤ Wear suitable protective gloves when spraying too!
➤➤ The material hoses must not touch the hot surfaces of the material flow
heater.
Warning
Never try to stop a leak at a fitting or high pressure hose using your hand
or by wrapping with a rag, etc.
➤➤ When a leak is detected, the entire system (spray pump, gun, hose,
filter, etc.) must be pressure released immediately,
➤➤ The defective parts must be replaced
➤➤ Follow the instructions in the Operation manual for the spray equipment and accessories.
CAUTION
Depending on the materials being applied solvent vapours may be generated which could cause damage to health and objects.
➤➤ Always ensure sufficient aeration and ventilation at the workplace.
➤➤ Always observe the processing instructions issued by the material manufacturers.
Follow the safety notes and dosing information of the manufacturer and
the generally applicable regulations when handling paints, solvents, oils,
greases and other chemical substances.
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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). If you want to process materials containing the afore mentioned substances, we recommend to consult the material
manufacturer to clarify the usability of such substances.
For these materials, we have available a range of rust- and acid-proof units.
2.3 Information signs on the unit
The warning labels and symbols on the Fluid Heater indicate possible sources
of danger and must be observed accordingly.
They must not be removed from the unit.
Damaged and illegible information signs must be replaced immediately.
Apart from this you should also read and follow the safety notes in the operation manual.
The following labels are found on the Fluid Heater:
➤➤ Warning label
Achtung! Wichtige Hinweise!
 Nur im kalten und spannungsfreien
Zustand spülen!
 Flammpunkt des Spritzmaterials beachten!
Attention! Important Warning!
 Flush only when the heater is cold and
disconnected from the power source!
 Watch the flash point of the spraying
materials!
Pic. 2.1
➤➤ Warning label
Danger!
Disconnect power supply before opening!
Pic. 2.2
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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.
Follow the instructions in the Operation manual for the spray equipment.
The machine may be restarted only if perfect operation is restored.
All protective devices must be inspected for proper function:
➤➤ Before each commissioning of the machine!
➤➤ Before beginning work with the unit!
➤➤ After each alignment!
➤➤ After cleaning and servicing!
➤➤ After maintenance and repair!
Checklist for inspection of the protective devices on the pressure-released
machine:
;; Inspect ground cable for damage.
;; Inspect the ground cable connection to the unit and the ground circuit.
All Fluid Heaters are supplied with the following safety devices:
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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.
The grounding screw is located near
the power cable connection and is
(see Pic. 2.6).
marked with
Pic. 2.6 Grounding screw
2. Attach the clamp of the grounding cable to an electrically conductive
object.
Order-Number for the Ground Cable: 0474487
The object to be coated must always be grounded also!
2.5 Operating and maintenance personnel
2.5.1 Unit owner's duties
The unit owner:
➤➤ is responsible for the training of the operating and maintenance staff,
➤➤ must instruct the operating and maintenance staff in correct handling of
the unit as well as in wearing the correct work clothing and personal protective equipment,
➤➤ must make the user manual available to the operating and maintenance
staff and ensure that it always remains available,
➤➤ must ensure that the operating and maintenance staff have read and understood the user manual.
Only then may the unit be brought into service.
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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.
➤➤ Trained personnel have been instructed by the unit builder such that they
are capable of carrying out maintenance and repair work on the system
and recognising potential risks on their own initiative and of avoiding these
risks.
2.5.3 Authorized operating personnel
Activity
Qualification
Setup and operation
Instructed operator
Cleaning
Instructed operator
Servicing
Trained personnel
Repair
Trained personnel
Juveniles under the age of 16 are not allowed to operate this unit.
2.5.4 Personal Protective Equipment (PPE)
Wear protective clothing
Always wear the protective clothing prescribed for your work environment
(mining, closed rooms, etc.) and follow the recommendations in the safety
data sheet issued by the material manufacturer.
Use eye protection
Indicates the requirement to wear protective goggles to protect against eye
injuries caused by material splatter gases, fumes or dust.
Wear ear defenders
Operating personnel should be provided with suitable noise protection
equipment. The unit operator is responsible for adhering to the accident
prevention regulation “Noise” (BGV B3). For this reason, pay special attention to the conditions at the installation location – the noise burden, for
example, will increase if the system is installed in or on hollow bodies.
Wear a respiratory protection mask
We strongly recommend that you wear a respiratory protection mask,
even though the paint mist has been minimized in the airless spray painting method given a correct pressure setting and correct working methods.
Wear protective gloves
When applying heated materials you should wear protective gloves with
lower arm protection, to protect you against burn injuries.
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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.
2.6.2 Spare parts
➤➤ When carrying out maintenance and repair work, you must only use WIWA
original spare parts.
➤➤ Use of spare parts which have not been manufactured or delivered by
WIWA renders any warranty null and void.
2.6.3 Accessories
➤➤ Using original WIWA accessories guarantees that they are usable in our
units.
➤➤ If you use third-party accessories, they must be suitable for the unit – particularly with regard to the operating pressure, the electrical connection
data and the connection sizes. WIWA accepts no liability for damage or
injuries resulting from the use of these parts.
You must observe the safety regulations of the accessories. These safety regulations are found in the separate operating instructions for the accessories.
2.7 Emergency procedures
2.7.1 Shutting down
In an emergency, the unit must be shut down and depressurised immediately.
Please observe, that the associated spraying system must be depressurized.
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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.
➤➤ Do not repair material hoses!
➤➤ Check hoses and screw fittings for leaks when recommissioning the
unit.
2.7.3 Injuries
In the case of injuries by processing materials or solvents, always have
available the manufacturer's safety data sheet (address, phone number,
material designation and material number of the supplier or manufacturer)
for the attending physician.
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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. operating pressure: 450 bar / 6525 psi
The
High-Pressure Fluid Heater is especially suitable for use with Airless spraying systems, Airless plural component units und Air Combi systems.
The advantages of the hot-spray process include higher coating thickness,
shorter drying times and top-quality finishes.
Coating materials which are normally difficult or impossible to process due to
their consistency become easily sprayable when warmed up using a
Fluid Heater.
With the addition of a mounting kit, the fluid heater can simultaneously be
used for heating of the compressed air supply:
a) as pre-heater for a
air motor, to prevent icing caused by low outside temperatures and high humidity.
b) for the heating of the atomizing air for Air-Combi systems. Through additional heating of the atomizing air, the quality of the finish is improved
further and the drying time is shortened.
3.1.2 Model 3500 LP
Max. operating pressure: 200 bar / 2900 psi
The
Low-Pressure Fluid Heater is suitable for heating materials to be
applied in low-pressure processes.
Futhermore, the
Low-Pressure Fluid Heater can be used for the supply of heated air to the air motor (de-icing) or for preheating materials being
fed to plural component spraying systems.
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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. heating temperature
85°C/185°F).
Pic. 3.2
The lower part of the housing is conical. The heat exchanger has a matching
conical form. Should a blockage occur in the heat exchanger, it can be removed from the housing by using the separating screw and then exchanged.
For versions with permanent power connection, an explosion proof cable lead
in accordance with IP54 is mounted on the housing.
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Unit description
3.3 Unit structure
Separating screw (M 12) for removing the heat exInbound air (G 1/4“) changer from the housing (for air motor de-icing and
(only for de-icing) additional brass seal must be mounted)
Mounting screw* for the
heat exchanger (M 8)
Mounting screw* for the heat
exchanger (M 8)
For use with air motor de-icing, these
holes must be pluged
Use the screws (M 10) included in the
assembly kit „Air Motor De-Icing“
*) Tightening torque for fastening bolts: Tighten the first bolt to 20 Nm and the second one tight
Main housing with all electrical
switches and heating elements
Exhaust air (G 1/8“)
(only for de-icing)
Connection for material inlet
(HP: 3/8" NPSM / LP: 3/4")
Heat exchanger
Connection for material outlet
(HP:3/8" NPSM / LP: 3/4")
Button to reset
the temperature limiter
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Control lamp
Temperature Setting Knob
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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. These hoses are then mounted to the outbound connection on the Fluid
Heater and the inbound connection on the circulation valve Pic. 3.4.
The circulation valve is to be mounted in the
direction of material flow between the material
pump and suction hose. Please note the arrow
on the valve housing.
Depending on the pump model, the circulation
valve either comes standard Pic. 3.6 or optionally Pic. 3.5 with a pressure drain valve.
The desired circulation speed can be set using
the regulating knob Pic. 3.4, pos.1.
20


Flow Direction
Pic. 3.4
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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. High-viscosity materials that would
be difficult to spray under normal circumstances can now be handeled more
easily.
The required mounting kits are available for all
Airless and Air-Combi
units.
Cart-mounted Airless Pump
Cart-mounted Fluid
Heater
Spray Gun
Pic. 3.7
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21
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. 3.8 Airless pump with frame-mounted Fluid Heater and additional portable Fluid Heater.l
3.5.3 Heating of air motors (de-icing system) by using a Fluid Heater
When operating with adverse ambient temperatures and high humidity, a
Fluid Heater can be used to provide the air motor with heated air to
avoid icing (de-icing system). A portion of the inbound air is tapped from the
main line and routed through the Fluid Heater and then back to the air motor.
This pre-heated air is then patched into the air/drain channels in the air motor
to reduce the possibility of icing.
The following kit is required:
Air Heating Kit for
Fluid Heater, Order No. 0632629
Air Maintenance Unit Connection
Air Motor
Upper Housing
Air Motor
Upper Housing
Pic. 3.9
22
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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. To avoid line heat loss, the air and
material hoses should be bound together and insulated.
Cart-mounted Air Combi unit
Spray Gun
Pic. 3.10
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23
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.
The system must have a fixed position and sufficient space to ensure
safe operating. The passage to the safety fittings must not be blocked.
➤➤ In case the heater is connected to the power supply in areas with risk of
explosion, the connection must be fitted with the appropriate Ex-Proof
rating.
➤➤ For versions without cable and cable connection, the owner / operator of
the equipment has to ensure that approved cable connectors (according
to EG-Baumusterprüfbescheinigung „X“, Pt. 17: Special Conditions) are
used.
Cable and cable connections must be designed for 165°C.
Warning
This work may only be performed by a qualified electrician.
Observe the Ex-Proof zoning of the workplace.
➤➤ Before connecting the Fluid Heater to the electrical supply, check to
ensure that the point of hook-up is functioning correctly and no faults are
present.
➤➤ The owner / operator of this equipment is required to ensure that proper
protection against lightning strikes is available.
➤➤ Keep the working area, especially all gangways and standing areas,
clean. Remove spilled paint or solvent immediately.
➤➤ Pay attention that no moisture (ex: through rain, high-pressure cleaning,
etc.) gets into the Fluid Heater.
The Fluid Heater must never be immersed in a container of liquid (ex:
solvent).
➤➤ Ensure there is sufficient ventilation at the workplace to prevent damage
to health and property. Observe the manufacturer’s processing instructions at all times.
➤➤ Read and follow the instructions in the Operation manual for the spray
equipment and accessories.
24
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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.
➤➤ Pay special attention to chapters covering safety in the operation manuals.
4.3 Electrical power connection
The heater is equipped with a permanent power connection cable without
plug.
➤➤ Connect the heater to the power supply.
IIn areas with risk of explosion the power connection must be explosion proof.
For versions without cable and cable connection, mount approved cable connectors.
Warning
This should only be done by trained electrical personnel. Observe the explosionproof zoning for your workplace.
➤➤ Before connecting the Fluid Heater to the electrical supply, check to
ensure that the point of hook-up is functioning correctly and no faults are
present.
4.4 Mount the Fluid Heater
Depending on the application, you can mount the material flow heater in different ways (see chap. 3.5 Equipment versions on page 21):
➤➤ On a holder onto the spray device or system,
➤➤ On a wall bracket
➤➤ On a carrier base
There are four drilled holes on the housing to screw the material heater tight
to the holder.
4.5 Ground the unit
A separate grounding of the Fluid Heater is required when no electrically-conductive connection to the spray unit exists (refer chap. 2.4.2 Ground Cable on
page 13).
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25
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.
1
2
3
1


3
4
Material inlet (IN)
Material outlet (OUT)
Air inlet
Air outlet


4
Description
2
Pic. 4.1
4.7 Mount de-icing assembly
(for 300 and 333 air motors) and the mounting kit (for 200 and 230 air motors)
➤➤ De-Icing Pic. 4.1, pos. 3 + 4). Mount the kit to the Fluid Heater.
➤➤ For the inbound air connection, an elbow fitting is mounted to the bottom
of the unit.
➤➤ Furthermore, a brass washer must be fitted under the separating screw.
It must be removed again before using the screw to separate the heater
housings.
➤➤ Screw an adaptor into the outbound air connection on the Fluid Heater.
Connect a compressed air line between the upper housing of the air motor and the Fluid Heater.
➤➤ Further part numbers for addtional connections can be obtained by contacting
Customer Service.
26
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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.
➤➤ Now complete all steps covering the initial flushing found in the spraying
equipment's Operation manual.
For best results, we recommend flushing the system for approximately one
minute. To avoid any danger of explosion, do not allow the solvent to circulate
for more than 5 minutes and ensure that the amount of available solvent corresponds to the size of the pump used. Depending on the pump, at least 8 to
25 liters (2 to 6.5 gallons) of solvent are necessary.
5.2 Pressure testing
The maximum operating pressure of the
Fluid Heater must be
equal to or greater than the max. operating pressure of the spraying
equipment and any accessories.
The lowest value is to be taken for the complete system.
➤➤ Disconnect the heater from the power source.
➤➤ Ensure that the
Fluid Heater has been connected correctly
according to the instructions in chap. 3.3 Unit structure on page 19 and
that all fittings are tightened properly.
➤➤ Now complete all steps found in the spray equipment's Operation manual
covering pressure testing of the system.
5.3 Unit preparation
➤➤ Always remember that the
Fluid Heater may only be flushed
when cold an disconnected from the electrical power supply.
➤➤ Always observe the working temperature given by the manufacturer of
the coating to be heated.
➤➤ Check to ensure that accessories (i.e.temperature gauges, back pressure
valves) are connected correctly.
➤➤ Check to ensure that the pressure ratings of all system components
and accessorires correspond to the maximum operating pressure of the
Fluid Heater.
➤➤ Check for the proper ground of:
–– spray pump
–– Fluid Heater
–– accessories
–– object to be coated
➤➤ Observe all instructions found in the Operation manual for the spray
pump and all accessories.
➤➤ When starting the unit and after any repairs, maintenance or cleaning
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27
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. Power supply connection
Connect the Fluid Heater power supply cable to a corresponding electrical
connection.
The Fluid Heater must be rated for the available power supply (voltage, amperage, wattage).
Warning
Fluid Heater is to be used in an area that falls under exploIf the
sion-proof regulations, ensure that an approved electrical power connection
is used.
6. Setting the temperature
Set the desired temperature on the temperature knob
(see Pic. 5.1).
The control lamp remains lit while the Fluid Heater
is heating. Once the set temperature is reached, the
lamp goes out. If the heater begins heating again, the
lamp will turn on again.
Reset temperature
If the ambient temperature is under 10°C (50°F), the
knob
reset button (see Pic. 5.1) must be pressed until the
Pic. 5.1
control lamp turns on.
If the maximum allowable temperature is surpassed, a temperature limiter will
turn off the Fluid Heater.
To turn the Fluid Heater back on, press the reset button (see Pic. 5.1) until the
control lamp goes on again.
7. Operation
Warning
Never place hands or fingers in or near the spray jet.
The spray system and Fluid Heater are now ready for operation.
–– You can now commence with coating the desired object.
–– Pay close attention to the instructions found in the operation manual
for the spraying equipment.
–– If using a Hot Spray system without circulation, cold material is still
located in the hoses.
It is recommendable to pump the material back into its container until
heated material exits the spray gun.
–– When using two-component materials, the potlife must be observed.
28
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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. Flush
Flush the complete system:
–– when the unit is cold
–– disconnected from the electrical power supply
Use the solvent that is recommended by the coatings manufacturer.

approx.
2 minutes
Follow the instructions found in the operation manual of your spraying
equipment covering changing materials and/or starting up the unit.
4. Restarting the unit
Follow the instructions found in the Operation manual for the spraying
equipment being used.
Complete the instructions found in see chap. „5 Start-up and operation“,
P. 27, Step 4-6.
5.5 Shutting down
1. Turn off the Fluid Heater
–– Turn off the Fluid Heater 10 minutes before
work is completed.
–– To do this, turn the temperature knob to the
position „I“ Pic. 6.1.
–– This will enable the operator to use the residual
heat up until the end of work while shortening
the cooling time until the unit can be flushed.
Pic. 6.1
2. Disconnect from electrical power supply
Disconnect the heater from the electrical power supply.
3. Flush
Avoid damage to the unit and the entire system by thoroughly flushing after
every shutdown.
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29
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.
➤➤ Clean the unit thoroughly of all material residues.
➤➤ Dismantle the unit and separate all materials – dispose of metal together
with scrap metal; plastic parts can be disposed of as domestic waste.
➤➤ Rests of spraying material, cleaning agent, oils, greases and other chemical substances must be collected in accordance with statutory provisions
concerning recycling and waste disposal. The official local waste water
laws are valid.
30
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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. Cut off the compressed air supply of the entire system.
2. Disconnect the power supply.
3. Depressurize the unit completely.
Read and follow the operation manual for the spray equipment and accessories.
WARNING
Despite releasing the pressure, material congestion or agglomeration of
material may mean that there are residual pressures still present. These
may suddenly release during disassembly work and can result in serious
injuries.
➤➤ You must be particularly careful during disassembly work!
➤➤ When disconnecting material hoses you should cover the screw fitting
with a cloth to catch any escaping material sprays.
Residual material left in the Fluid Heater can harden and lead to damage
of the unit.
➤➤ The heater must be completely flushed with an appropriate solvent
within the potlife given by the material manufacturer, but only when the
heater is cold.
Please observe that the potlife of plural component materials is shortend considerably by heating.
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,
➤➤ however at least every 12 months.
For equipment, which 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
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31
Checks and Maintenance
where the equipment is used.
Maintenance instructions for the spray equipment and accessories can be
found in the corresponding Operation manual.
32
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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.
The above solutions (Point A and B) may only
be performed by qualified electrical personnel
➤➤ C: Press the reset button until the control lamp
lights.
➤➤ Heating cartridges are
defect
➤➤ Contact Customer Service
➤➤ Temperature is set
incorrectly
➤➤ Reset the temperature using the temperature
knob
➤➤ Temperature limiter is
defect
➤➤ Contact Customer Service
➤➤ The amount of material
passing throught the
heater is too large
➤➤ Lower material flow (smaller tip size)
➤➤ Add a second Fluid Heater in series to the system
➤➤ Male adaptors and/
or fluid hoses are not
tightened correctly or
damaged
Material does not ➤➤ Heat exchanger is
flow
clogged
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➤➤ Re-tighten the male adaptors and/or fluid hoses
or replace as necessary
➤➤
If the material in the heater
is not completely cured, it may be possible to remove it by flushing under high pressure: HP max.
450 bar (6525 psi) / LP max. 200 bar (2900 psi).
➤➤ Due to the danger of explosion, the Fluid Heater
may only be flushed when completely cold.
➤➤ Thoroughly flush the heat exchanger or replace if
necessary.
➤➤ If the material is fully cured (especially with twocomponent materials), the heat exchanger must
be replaced.
➤➤ The heat exchanger may only
➤➤ be replaced when the Fluid Heater is cold and
disconnected from the electrical power supply.
➤➤ To remove, loosen the two mounting screws
and screw in the separating screw until the heat
exchanger has separated from main housing.
➤➤ Before mounting, the cone-shaped surface inside
the heat exchanger must be coated completely
with copper paste (
Order No. 0000233).
33
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. Class (°C / °F)
165 (T3) / 329
Connection Threads
3
Dimensions (L x W x H) (mm / in.)
/8 NPSM inner thread
405 x 220 x 180 / approx. 16 x 9 x 7
Weight (kg / lbs.)
17,6 / 38.8
*with 1.8 kW one liter of water can be heated to 25°C (77°F) in one minute.
*with 2.0 kW one liter of water can be heated to 28°C (82°F) in one minute.
*with 3.5 kW one liter of water can be heated to 50°C (122°F) in one minute.
Low-Pressure (LP) Fluid Heater
Order No.
0633599
0653207
0650081
0648375
0657494
Max. Voltage (± 10%) (± 10%) (V)
230
3x 230
400
Max. Amperage (Ampere)
16
9
6
Max. Wattage (kW)
3,5
3,5
3,8
Max. Temperature* (°C / °F)
Max. Operating Pressure (bar/psi)
85 / 185
200 / 2900
Temp. Class (°C / °F)
165 (T3)) / 329
Connection Threads
G 3/4“ inner thread
Dimensions (LxWxH) (mm / in.)
Weight (kg / lbs.)
34
405 x 220 x 180 / (approx. 16 x 9 x 7)
17,6 / 38.8
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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.
Manufacture
Type designation
Year of construction
Serial-number
The instruction was conducted by the representative of the owner:
Foreman or responsible superior, name,
department
The instructed person has read and understood the user manual for the equipment listed above, especially the chapter about safety, and declares that he is
able to operate the unit in a safe way.
Personnel for:
Operation
Repair
maintenance
Date, name
and
Electrics / electronics
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35
Appendix
10 Appendix
36
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Appendix
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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.: +49 6441 609-0
Fax +49 6441 609-50
E-Mail: info@wiwa.de
Homepage: www.wiwa.de
WIWA partnership in USA
WIWA LP
107 N. Main St.
P.O. Box 398, Alger, OH 45812
Tel.: +1 (419) 757-0141
Fax: +1 (419) 549-5173
Toll Free: +1(855) 757-0141
E-Mail: jwold@wiwalp.com
Homepage: www.wiwalp.com
WIWA subsidiary in 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 8858
Fax: +86 512-5354 8859
E-Mail: info@wiwa-china.com
Homepage: www.wiwa-china.com
WWW.WIWA.DE
Frankenstraße 37
53359 Rheinbach-Oberdrees, Germany
Mobil: +49 173 5432559
Tel.: +49 2226 12708
Fax: +49 2226 13973
Robert Jansen
Director International Sales
Finland, Sweden, Norway, Denmark, Scotland, England,
Holland, Belgium, France, Spain/Portugal, Italy, Croatia,
Greece, Czech Republic, Slovakia, Slovenia, Luxembourg,
Bulgaria, Egypt, Libya, Dubai, Abu Dhabi, Catar, Bahrain,
Kuwait, Saudi Arabia, Iran, Oman
Rietgans 38
3752 KH Bunschoten, Netherlands
Mobil: +31 6 18 88 40 97
Tel.: +31 33 494 69 81
Fax: +31 33 494 75 83
E-Mail: rob.wiwa@gmail.com
Otto Dietrich
Director International Sales
Russia, Ukraine, Belarus, Moldavia, Lithuania, Latvia, Estonia,
Azerbaijan, Georgia, Armenia, Kazakhstan, Uzbekistan,
Kyrgyzstan, Turkmenistan, Tajikistan
Lindenhof 6
56154 Boppard, Germany
Mobil: +49 160 1574385
Tel.: +49 6742 899336
Fax: +49 6742 899337
E-Mail: o_dietrich@wiwa.de