Walther MPP-02 User manual

Rev. 1.2
Assembly Instructions - MPP-02 Micro Point Pulse Valve
Page 1 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
Assembly Instructions
Micro Point Pulse Valve MPP-02
Article number: MPP-02
Fig. MPP-02 with standard nozzle MPP-01
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.
Always keep a translated version of the original Assembly Instructions at the incomplete device!
The assembly instructions have to be close at hand any time!

Rev. 1.2
Assembly Instructions - MPP-02 Micro Point Pulse Valve
Page 2 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
Table of Contents
Page
EC DECLARATION OF INCORPORATION ....................................................................................................................... 4
1INTRODUCTION ................................................................................................................................................. 5
1.1 TARGET GROUP OF THE ASSEMBLY INSTRUCTIONS ............................................................................................................ 5
1.2 LIST OF SIGNS AND SYMBOLS ....................................................................................................................................... 5
2SAFETY............................................................................................................................................................... 5
2.1 GENERAL INFORMATION ............................................................................................................................................. 5
2.2 DANGERS DUE TO RESIDUAL ENERGY ............................................................................................................................. 5
2.3 WARRANTY AND LIABILITY........................................................................................................................................... 5
2.4 CORRECT USE ........................................................................................................................................................... 6
2.5 INCORRECT USE ........................................................................................................................................................ 6
2.6 QUALIFIED PERSONNEL............................................................................................................................................... 6
3TRANSPORT....................................................................................................................................................... 7
3.1 PACKAGING .............................................................................................................................................................. 7
3.2 TASKS BEFORE TRANSPORT .......................................................................................................................................... 7
4FUNCTIONAL DESCRIPTION ............................................................................................................................... 7
4.1 FUNCTION................................................................................................................................................................ 7
4.2 TECHNICAL DATA OF THE INCOMPLETE DEVICE................................................................................................................. 7
4.3 TYPE LABEL OF THE INCOMPLETE DEVICE........................................................................................................................ 7
5INITIAL START-UP ............................................................................................................................................... 8
5.1 INSTALLATION ........................................................................................................................................................... 8
5.2 HOSE CONNECTION ................................................................................................................................................... 8
5.3 ADJUSTMENT OF THE INCOMPLETE DEVICE ..................................................................................................................... 8
5.4 RASTER-NEEDLE SENSOR ............................................................................................................................................ 8
5.4.1 Connection Scheme for Needle Sensor........................................................................................................ 8
5.5 CONNECTION SCHEME FOR PRESSURE SENSOR ................................................................................................................ 9
5.6 CONNECTION SCHEME OF THE MAGNETIC VALVE ............................................................................................................. 9
6OPERATION ..................................................................................................................................................... 10
6.1 GENERAL INFORMATION ........................................................................................................................................... 10
6.2 OPERATING INSTRUCTIONS ........................................................................................................................................ 10
7MAINTENANCE AND REPAIR ............................................................................................................................ 11
7.1 GENERAL INFORMATION ........................................................................................................................................... 11
7.2 CLEANING .............................................................................................................................................................. 11
7.3 REPLACING NEEDLE (5.0) AND NOZZLE (1.0) ............................................................................................................... 11
7.4 REPLACING SEALING SCREW (4.0) .............................................................................................................................. 11
7.5 REPLACING GASKETS AND O-RINGS............................................................................................................................. 11
7.6 TASKS TO BE PERFORMED REGULARLY........................................................................................................................... 12
7.7 SPARE PARTS .......................................................................................................................................................... 12
7.8 CUSTOMER SERVICE /SUPPORT.................................................................................................................................. 12
8TROUBLESHOOTING ........................................................................................................................................ 13
8.1 GENERAL INFORMATION ........................................................................................................................................... 13
8.2 FAILURE ................................................................................................................................................................. 13
9TAKING OUT OF SERVICE ................................................................................................................................. 13
9.1 SHORT INTERRUPTION .............................................................................................................................................. 13
9.2 LONG-TERM INTERRUPTION....................................................................................................................................... 13
9.3 FINAL SHUTDOWN OF SYSTEM /DEVICE ...................................................................................................................... 13
10 APPENDIX........................................................................................................................................................ 14

Rev. 1.2
Assembly Instructions - MPP-02 Micro Point Pulse Valve
Page 3 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
10.1 DIMENSIONED DRAWING ..................................................................................................................................... 14
10.1.1 Spare Parts Drawing............................................................................................................................. 15
10.1.2 Spare Parts List ..................................................................................................................................... 16
10.2 ARTICLE NUMBERS FOR NOZZLES ........................................................................................................................... 17
10.3 ARTICLE NUMBERS FOR NOZZLE NEEDLES ................................................................................................................ 18
10.4 ARTICLE NUMBERS FOR RASTER NEEDLE LOCK ........................................................................................................... 19
10.5 WEAR PARTS KITS............................................................................................................................................... 19
10.6 ACCESSORIES ..................................................................................................................................................... 19
10.6.1 Add-on elements .................................................................................................................................. 20

Rev. 1.2
Assembly Instructions - MPP-02 Micro Point Pulse Valve
Page 4 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
EC Declaration of Incorporation
in accordance with EU Machinery Directive 2006/42/EU, dated 17 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- 76726 Germersheim
Description MPP-02 Micro Point Pulse Valve, article-No. MPP-02
We also declare the conformity with other, product-relevant directives/guidelines:
Mach. Direct. 2006/42/EU App. I, Clause: 1.1.2, 1.1.3, 1.1.5, 1.1.6, 1.3.2, 1.3.3,
1.3.4, 1.5.1, 1.5.8, 1.5.9
EMC- Directive 2014/30/EU, dated 26. February 2014
Applied harmonized standards, in particular:
DIN EN ISO 12100 Safety of Machinery –General Design Principles –
Risk Assessment and Risk Reduction (ISO
12100:2010)
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- 76726 Germersheim
Germersheim, 04 April 2017
(Place, Date) (Stefan Hirl, Management)

Rev. 1.2
Assembly Instructions - MPP-02 Micro Point Pulse Valve
Page 5 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
1 Introduction
1.1 Target Group of the Assembly Instructions
Operating personal
Maintenance personal
1.2 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:
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.
IMPORTANT
Indicates tips for usage and other particularly useful information.
No dangerous situation.
2 Safety
2.1 General Information
The construction of the incomplete 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 due to Residual Energy
Please instruct the operating personnel on the respective measures to be taken against the occurance of
mechanical, hydraulic, pneumatic and electric / electronic residual energies.
2.3 Warranty and Liability
According to the conditions laid down by the German Engineering Federation (VDMA), Walther Systemtech-
nik GmbH has a guarantee of 12 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 Sys-
temtechnik GmbH.

Rev. 1.2
Assembly Instructions - MPP-02 Micro Point Pulse Valve
Page 6 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
2.4 Correct Use
The incomplete device is a needle valve suitable for the processing of sprayable media in continuous as well
as intermittent use. It is not suitable for spraying aggressive fluids such as acids, alkaline solutions, cleaning
agents, chemicals, etc. In case of doubt, please contact the manufacturer.
2.5 Incorrect Use
Operating the incomplete device with insufficient knowledge about the operation, maintenance and
care of the device.
Making changes, extensions or alterations on the incomplete device that may hamper its safety
without the prior consent of Walther Systemtechnik GmbH.
Operating the incomplete device with defective safety installations or not properly attached or mal-
functioning safety devices.
Using unsuitable materials.
Handling the incomplete device while energized.
2.6 Qualified 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
-

Rev. 1.2
Assembly Instructions - MPP-02 Micro Point Pulse Valve
Page 7 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
3 Transport
3.1 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 Functional Description
4.1 Function
The MPP-02 Micro Point Pulse Valve is an incomplete, pneumatically controlled application device designed
for the application of materials such as sealants, adhesives, greases, paints, oils, etc. The needle piston is
alternately impinged on by air, triggering an opening and closing of the needle. If the control air is cut off or
fails, the spring closes the needle. The medium is transported to the valve either out of a pressure tank or a
pump. The valve discharges a full jet.
4.2 Technical Data of the Incomplete Device
General data
Dimensions [mm]
Approx. Length (size is depending on employed nozzle) x 15 x 82
(Dimensioned drawing –see attachment!)
Weight [g]
approx. 375
Switching frequency [Hz]
40 (depending on the medium used!)
Switching time [ms]
10
Energy supply
Control air pressure [bar]
min. 5 –max. 8
Material pressure [bar]
max. 100
Voltage [VDC]
24
Power input [W]
1.6
4.3 Type Label of the Incomplete Device
The type designation is etched in close to the material connection. The serial number is also inscribed in this
area.

Rev. 1.2
Assembly Instructions - MPP-02 Micro Point Pulse Valve
Page 8 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
5 Initial Start-up
5.1 Installation
The valves can be installed in any position. The distance to the surface to be applied with the medium
depends on the spray pattern.
Vibrations of the valve caused by fast intermitting cycles require solid and tight installation. Machine
vibrations to the valves should be avoided.
5.2 Hose Connection
The two function hoses are to be connected as fol-
lows:
1 control air to plug connection for 6mm hose
(11.0)
2 medium to 1/8"-connection (can be ordered
as accessories)
5.3 Adjustment of the Incomplete Device
The amount of material can be regulated via the stroke adjustment of the needle (7.0). A left turn of the regu-
lating knob increases the material amount. A fine precision thread affects a needle rise that results in an
adjustment of 0.5mm with each turn of the adjusting knob.
IMPORTANT
Do not turn the regulating knob further to the left if no more stops are noticeable while turn-
ing it! The maximum fluid outlet has been reached.
IMPORTANT
Nozzle and needle can be damaged by wrong handling. Only decrease the material flow by
a right turn of the regulating knob.
5.4 Raster-Needle Sensor
Optionally, you can use a raster-needle lock with a pre-installed, inductive proximity switch. It will release a
signal when the needle piston with the needle is open. This will help you in digitally monitoring the status
„nozzle open“.
5.4.1 Connection Scheme for Needle Sensor
2
1

Rev. 1.2
Assembly Instructions - MPP-02 Micro Point Pulse Valve
Page 9 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
5.5 Connection Scheme for Pressure Sensor
pin assignment
white –out / ground
brown –24 VDC
5.6 Connection Scheme of the Magnetic Valve
+
-
Operating voltage of the control 24 V DC

Rev. 1.2
Assembly Instructions - MPP-02 Micro Point Pulse Valve
Page 10 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
phone: [phone] fax: [phone]
http://www.walther-2000.de –[e-mail]
6 Operation
6.1 General Information
The incomplete device may only be operated if the safety-related equipment is permanently effective and not
suspended during operation or altered in its intended effectiveness.
6.2 Operating Instructions
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 pro-
tection should be worn, if required.
WARNING
Danger caused by flammable, harmful fluid. Always follow the safety instructions on the con-
tainer or the safety data sheet for the fluid.
The MPP-02 Micro Point Pulse Valve usually works with a control air pressure of 5 –6 bar and material
pressures of up to 30 bar. To obtain a consistent application pattern, the air supply must be kept constant
without any fluctuations.
IMPORTANT
Accident prevention directions will be strictly followed when applying high material pres-
sures. Please strictly follow the following instructions when planning and constructing appli-
cation systems!
The valves are suitable for contactless and regular application and can be controlled for intermittent or con-
tinuous use. According to the individual application, the control air must be adjusted to the operating cycles
and to the higher or lower material pressures. 40 tacts per second can be reached under appropriate operat-
ing conditions (material pressure, control air pressure, needle stroke, and short conductions). The valve
works with an opening time from 10ms upwards. The opening time (in real time) must correspond with the
theoretical value, in order to enable constant opening and closing.
IMPORTANT
A plant-specific setting is required for an optimal adjustment of the application pattern. Start-
ing values from laboratory tests can be used as a basis. However, these may need to be
adjusted for the specific plant. A combination of the following parameters is necessary: noz-
zle size, opening time, opening stroke, material pressure and temperature (if applicable).
It is harmless to leave fluid in the valve during longer standstills if system stays under pressure (no connec-
tion to outside air).