Walther WDVHP-02-HG User manual

Rev. 1.1
Assembly Instructions –Hand Dosing Device WDVHP-0x-HG
Page 1 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de –[e-mail]
Assembly Instructions
Hand Dosing Device
Article Number:
WDVHP-02-HG Dosing volume 0,010 –0,200 cm³
WDVHP-03-HG Dosing volume 0,100 –2,000 cm³
WDVHP-04-HG Dosing volume 1,000 –6,000 cm³
WDVHP-02-HG
WDVHP-03-HG / WDVHP-04-HG
NOTE
Please read these Assembly Instructions carefully before first using the device and strictly
adhere to the instructions!
This 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 this translation of the “Original Assembly Instructions“ at the device!
The manual has to be available anytime!

Rev. 1.1
Assembly Instructions –Hand Dosing Device WDVHP-0x-HG
Page 2 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
Telefon: [phone] Telefax: [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 FROM RESIDUAL ENERGIES............................................................................................................................. 5
2.3 WARRANTY AND LIABILITY........................................................................................................................................... 5
2.4 CORRECT USE ........................................................................................................................................................... 6
2.5 INCORRECT USE ........................................................................................................................................................ 6
2.6 QUALIFICATION OF PERSONNEL .................................................................................................................................... 6
3TRANSPORT ....................................................................................................................................................... 7
3.1 PACKAGING .............................................................................................................................................................. 7
3.2 TASKS BEFORE TRANSPORT .......................................................................................................................................... 7
4DESCRIPTION OF FUNCTION .............................................................................................................................. 7
4.1 DESIGNATED USE OF INCOMPLETE DEVICE ...................................................................................................................... 7
4.2 TYPE LABEL OF INCOMPLETE DEVICE ............................................................................................................................. 7
4.3 FUNCTION................................................................................................................................................................ 7
4.4 TOTAL VIEW /DESCRIPTION......................................................................................................................................... 8
4.5 CONNECTIONS .......................................................................................................................................................... 8
4.6 TECHNICAL DATA ....................................................................................................................................................... 9
5INITIAL START-UP ............................................................................................................................................. 10
5.1 MOUNTING AND INSTALLATION .................................................................................................................................. 10
5.2 ADJUSTING THE INCOMPLETE DEVICE .......................................................................................................................... 10
6OPERATION ..................................................................................................................................................... 11
6.1 GENERAL INFORMATION ........................................................................................................................................... 11
6.2 OPERATION INSTRUCTIONS /OPERATING CONDITIONS .................................................................................................... 11
6.3 OPERATING ELEMENTS ............................................................................................................................................. 11
7TAKING OUT OF SERVICE ................................................................................................................................. 12
7.1 SHORT INTERRUPTION .............................................................................................................................................. 12
7.2 LONG-TERM INTERRUPTION....................................................................................................................................... 12
7.3 SHUTDOWN OF DEVICE............................................................................................................................................. 12
8MAINTENANCE AND REPAIR ............................................................................................................................ 13
8.1 GENERAL INFORMATION ........................................................................................................................................... 13
8.2 ROUTINE TASKS....................................................................................................................................................... 13
8.3 SPARE PARTS .......................................................................................................................................................... 13
8.4 CUSTOMER SERVICE /SUPPORT.................................................................................................................................. 13
9TROUBLESHOOTING ........................................................................................................................................ 14
9.1 GENERAL INFORMATION ........................................................................................................................................... 14
9.2 MALFUNCTIONS ...................................................................................................................................................... 14
10 APPENDIX ........................................................................................................................................................ 15
10.1 DIMENSIONED AND SPARE PART DRAWING –DOSING VALVE WDVHP-02-HG .............................................................. 15
10.1.1 Spare Part List –Dosing Valve WDVHP-02-HG ..................................................................................... 16
10.2 DIMENSIONED AND SPARE PART DRAWING –DOSING VALVE WDVHP-03/04-HG.......................................................... 17
10.2.1 Spare Part List –Dosing Valve WDVHP-03-HG ..................................................................................... 18
10.2.2 Spare Part List –Dosing Valve WDVHP-04-HG ..................................................................................... 18
10.3 ACCESSORIES ..................................................................................................................................................... 19

Rev. 1.1
Assembly Instructions –Hand Dosing Device WDVHP-0x-HG
Page 3 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de –[e-mail]
10.3.1 Data Sheet –Dosing Piston Sensor (Article No. WDV-DS) .................................................................... 19

Rev. 1.1
Assembly Instructions –Hand Dosing Device WDVHP-0x-HG
Page 4 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
Telefon: [phone] Telefax: [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 Hand Dosing Device,
Article No. WDVHP-02-HG
WDVHP-03-HG
WDVHP-04-HG
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, 1.5.9
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, 19 April 2016
(Place, Date) (Stefan Hirl, Management)

Rev. 1.1
Assembly Instructions –Hand Dosing Device WDVHP-0x-HG
Page 5 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de –[e-mail]
1 Introduction
1.1 Target Group of the Assembly Instructions
Operating Personnel
Maintenance Personnel
1.2 List of Signs and Symbols
Symbols are used to identify hazards and certain practices. Symbols are also used in the assembly
instructions. The below symbols for hazards and information describe circumstances which can result in
damages to persons, objects and environment if not observed.
The following terms and symbols are used in the assembly instructions to identify hazards:
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 this 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 from Residual Energies
Please instruct the operating personnel on the respective measures to be taken against the occurrence of
mechanical, hydraulic, pneumatic and electric / electronic residual energies.
2.3 Warranty and Liability
According to the conditions laid down by the German Engineering 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 these assembly instructions;
the user follows the instructions and notes contained in these assembly instructions;
the user does not rebuild or make changes on parts of the (incomplete) device without prior consent
of WST Systemtechnik GmbH.

Rev. 1.1
Assembly Instructions –Hand Dosing Device WDVHP-0x-HG
Page 6 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de –[e-mail]
2.4 Correct Use
This device will not be operated under other than the described conditions.
It has solely been designed for the dosing of media in accordance with the detailed information of this operat-
ing manual.
Any other type of use or beyond is considered as not intended. The manufacturer cannot be made liable for
damages resulting from such incorrect use.
Correct use of the device also includes:
Observing and adhering to all operating instruction s stated in this manual.
Adherence to inspection and maintenance tasks.
2.5 Incorrect Use
The manufacturer cannot be made liable for damages resulting from such incorrect use; incorrect use
includes among others:
Processing aggressive media (such as acids, alkaline, cleaning agents, chemicals etc.) or media
which have not been approved in writing by the manufacturer;
Using corrosive and / or curable materials;
Operating the device with insufficient knowledge about the operation, maintenance and care of the
device.
Making changes, extensions or alterations on the device that may hamper its safety without the prior
consent of Walther Systemtechnik GmbH.
Operating the device with defective safety installations or not properly attached or malfunctioning
safety devices.
Handling the device while energized
2.6 Qualification of Personnel
Only trained and instructed personnel may conduct work on the equipment.
The responsibilities of the personnel for assembly work, operation, repair work or maintenance work must be
clearly assigned to individuals!
Persons in training may work with the equipment only under supervision of an experienced person.
Personnel
Task
Instructed
Personnel
Personnel with Technical
Qualification
Specialist
Supervisor
Packaging, Transport
X
-
-
-
Commissioning
X
X
-
Operation
X
-
Troubleshooting, general
X
X
-
Troubleshooting
mechanical
-
X
-
-
Troubleshooting electrical
-
-
X
-
Setting up
-
X
-
-
Maintenance
-
X
-
-
Repair
-
X
X
-
Taking out of service,
Storage
-
X
X
-

Rev. 1.1
Assembly Instructions –Hand Dosing Device WDVHP-0x-HG
Page 7 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
Telefon: [phone] Telefax: [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 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 device will be aligned and leveled by
appropriate fastening elements.
4 Description of Function
4.1 Designated Use of Incomplete Device
The special construction enables the supply of a specific lubricant in a specific amount at a specific time and
location. The Dosing Valves are also suitable for use with oil.
4.2 Type Label of Incomplete Device
The Dosing Valve is marked on the side of the housing by an engraving that contains the manufacturing date
and the article number.
IMPORTANT
Always indicate the engraved data and the information from the type label for spare
part orders or technical support from WST.
4.3 Function
The pneumatic part of the dosing valve is controlled by a 5/2-way valve which is integrated in the handgrip.
This initiates the grease dosing. The dosing pressure depends on the lubricant feed pressure (medium).
Air and grease chamber are separated.

Rev. 1.1
Assembly Instructions –Hand Dosing Device WDVHP-0x-HG
Page 8 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de –[e-mail]
4.4 Total View / Description
Legend
Position
Description
1
Regulating sleeve
2
Connection Medium G1/8
3
Outlet Medium M6
4
Connection Control Air M5
5
Trigger / Release
6
Handgrip
4.5 Connections
IMPORTANT
We recommend a maintenance unit for the control air.
The special construction allows choosing between bottom or grip of the device for the connection of grease
and air. If not used, the connections will be sealed by screws
1
2
5
6
3
4
Material
Control air

Rev. 1.1
Assembly Instructions –Hand Dosing Device WDVHP-0x-HG
Page 9 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de –[e-mail]
4.6 Technical Data
Article Number
WDVHP-02-HG
Dosing range [cm³] / [mm³]
0.010 –0.200
10 –200
Material inlet [mm]
Internal thread G 1/8
Material outlet [mm]
Internal thread M61
Compressed air supply
[mm]
Internal thread M 5
min. / max. material inlet
pressure [bar]
20 / 200
min. / max. pneumatic
operating pressure [bar]
5 / 7
Dimensions [mm]
ca.133x23x155
1Do not exceed the max. screw-in depth!
Article Number
WDVHP-03-HG
WDVHP-04-HG
Dosing range [cm³] / [mm³]
0,100 –2,000
100 –2000
1,000 –6,000
1000 –6000
Material inlet [mm]
Internal thread G 1/8
Material outlet [mm]
Internal thread M61
Compressed air supply
[mm]
Internal thread M 5
min. / max. material inlet
pressure [bar]
20 / 160
min. / max. pneumatic
operating pressure [bar]
5 / 7
Dimensions [mm]
ca.246x37x166
Article Number
WDV-DS
Version [mm]
2.9 x 16.8 x 4.5
Switching outlet
PNP
Switching function
Make contact (NO)
Electrical design
DC, direct voltage
Rated operating voltage [V DC]
24
Rated operational current [mA]
100
Ambient temperature min. [C°]
-25
Ambient temperature max. [C°]
+85
Connection
Cable with plug-in connection
Protection type according to DIN 40050
IP 67
Material of housing
PA 12

Rev. 1.1
Assembly Instructions –Hand Dosing Device WDVHP-0x-HG
Page 10 of 19
Walther Systemtechnik GmbH –D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de –[e-mail]
5 Initial Start-up
5.1 Mounting and Installation
IMPORTANT
We recommend adding a maintenance unit to the control air.
5.2 Adjusting the Incomplete Device
IMPORTANT
Check if the air pressure for the control air is at approx. 6 bar. This will guarantee an
optimum function of the valves.
The supply material pressure to the valve should not rise above 200 bar. Check the
pressure ratio of the supply pump. A pressure reducing valve will help you control the
supply pressure easily (a pressure reduction valve is an advantage but not mandatory
as long 200 bar will not be exceeded).
IMPORTANT
All dosing valves will be thoroughly checked before leaving our factory. It is therefore
possible that some residues of the test medium remain in the valve.
1) Make sure that the lubricant feed hose is filled with lubricant and all air is removed. Then connect
feed hose and air connectors according to drawing.
2) For first operation, set valve to maximum dosage (i.e. turn adjustment screw to outmost position.
3) If the adjustment screw cannot be turned, change position of change-over-valve. The adjustment
screw should now be unlocked.
4) Execute a first shot of lubricant. Then set the adjustment screw to the desired grease quantity.
5) Keep the distance short between the dosing valve and the greasing point. This allows for improved
metering precision and repeatability.
6) The cycle time depends on the viscosity of the lubricant, as well as on the lubricant feed pressure.