Walther SMS-02 Assembly Instructions Manual

Rev. 1.2

Assembly Instructions - Spray Valve SMS-02

Page 1 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de – [e-mail]

Assembly Instructions

Spray Valve SMS-02

Article Number: S02-….

Picture: Spray Valve SMS-02 with flat air cap and raster-needle lock

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 this translated version of the “Original Assembly Instructions“ at the incomplete

device! The instructions have to be available anytime!

Rev. 1.2

Assembly Instructions - Spray Valve SMS-02

Page 2 of 34

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

1 INTRODUCTION ................................................................................................................................................. 5

1.1 TARGET GROUP OF THE ASSEMBLY INSTRUCTIONS ............................................................................................................ 5

1.2 LIST OF SIGNS AND SYMBOLS ....................................................................................................................................... 5

2 SAFETY............................................................................................................................................................... 5

2.1 GENERAL INFORMATION ............................................................................................................................................. 5

2.2 DANGERS FROM RESIDUAL ENERGY ............................................................................................................................... 5

2.3 WARRANTY AND LIABILITY ........................................................................................................................................... 5

2.4 CORRECT USE ........................................................................................................................................................... 6

2.5 INCORRECT USE ........................................................................................................................................................ 6

2.6 QUALIFICATION OF PERSONNEL .................................................................................................................................... 6

3 TRANSPORT ....................................................................................................................................................... 7

3.1 PACKAGING .............................................................................................................................................................. 7

3.2 TASKS BEFORE TRANSPORT .......................................................................................................................................... 7

4 DESCRIPTION OF FUNCTION .............................................................................................................................. 7

4.1 PURPOSE OF THE DEVICE ............................................................................................................................................. 7

4.2 TECHNICAL DATA ....................................................................................................................................................... 8

4.3 TYPE LABEL .............................................................................................................................................................. 8

5 INSTALLATION AND START-UP ............................................................................................................................ 8

5.1 HOSE MOUNTING...................................................................................................................................................... 8

5.2 TOTAL VIEW / DESCRIPTION ......................................................................................................................................... 9

5.3 ADJUSTING THE DEVICE .............................................................................................................................................. 9

5.4 SMS-02 WITH RASTER-NEEDLE DETECTION ................................................................................................................. 10

5.4.1 Terminal Assignment for Needle Query..................................................................................................... 10

5.4.2 Terminal Assignment for Magnetic Valve.................................................................................................. 10

5.5 INSTALLATION DIAGRAM FOR COLOR-MARKING SYSTEMS ................................................................................................ 11

6 OPERATION ..................................................................................................................................................... 11

6.1 GENERAL INFORMATION ........................................................................................................................................... 11

6.2 OPERATION INFORMATION / OPERATING CONDITIONS .................................................................................................... 11

6.3 OPERATING ELEMENTS ............................................................................................................................................. 12

7 MAINTENANCE AND REPAIR ............................................................................................................................ 13

7.1 GENERAL INFORMATION ........................................................................................................................................... 13

7.2 CLEANING .............................................................................................................................................................. 13

7.3 EXCHANGING THE AIR VALVE (11.0.0) ........................................................................................................................ 13

7.4 EXCHANGING THE RETURN CHECK VALVE, COMPLETE (10.0.0)......................................................................................... 13

7.5 REPLACING THE NEEDLE (7.0.0) AND THE NOZZLE (2.1.0) .............................................................................................. 13

7.6 EXCHANGING THE SEALING BUSH (6.0.0) .................................................................................................................... 14

7.7 INSERTING GASKETS AND O-RINGS: ............................................................................................................................ 14

7.8 MAINTENANCE FOR OPERATION IN COLOR-MARKING SYSTEMS (NORMAL OPERATION) ........................................................ 14

7.9 SPARE PARTS .......................................................................................................................................................... 15

7.10 CUSTOMER SERVICE / SUPPORT ............................................................................................................................. 15

8 TROUBLESHOOTING ........................................................................................................................................ 16

8.1 GENERAL INFORMATION ........................................................................................................................................... 16

8.2 FAILURES: .............................................................................................................................................................. 16

8.3 SPRAY IMAGE/ TYPE OF DEFECT .................................................................................................................................. 17

9 TAKING OUT OF SERVICE ................................................................................................................................. 18

9.1 SHORT INTERRUPTION .............................................................................................................................................. 18

9.2 LONG-TERM INTERRUPTION ....................................................................................................................................... 18

Rev. 1.2

Assembly Instructions - Spray Valve SMS-02

Page 3 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
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9.3 FINAL SHUTDOWN OF DEVICE .................................................................................................................................... 18

10 APPENDIX ........................................................................................................................................................ 19

10.1 DIMENSIONED DRAWING (FLAT JET) ....................................................................................................................... 19

10.2 DIMENSIONED DRAWING (ROUND JET) ................................................................................................................... 19

10.3 SPARE PARTS DRAWING SMS-02 (STANDARD) ......................................................................................................... 20

10.3.1 Spare Part List for SMS-02 (Standard) .................................................................................................. 21

10.4 SPARE PART DRAWINGS SMS-02 (RASTER-NEEDLE DETECTION) ................................................................................. 22

10.4.1 Spare Part List for SMS-02 (Raster-Needle Detection) .......................................................................... 23

10.5 ARTICLE NUMBERS FOR AIR CAPS .......................................................................................................................... 24

10.6 ARTICLE NUMBERS FOR NOZZLES ........................................................................................................................... 25

10.7 ARTICLE NUMBERS FOR NOZZLE NEEDLES ................................................................................................................ 27

10.8 ARTICLE NUMBERS FOR VALVES ............................................................................................................................. 28

10.9 ARTICLE NUMBERS FOR THREADED JOINTS ............................................................................................................... 28

10.10 ARTICLE NUMBERS FOR OTHER PARTS ..................................................................................................................... 29

10.11 WEAR-AND-TEAR PARTS ...................................................................................................................................... 30

10.12 ACCESSORIES ..................................................................................................................................................... 31

10.13 DESCRIPTION PNEUMATIC NEEDLE-STROKE ADJUSTMENT 97800037 .......................................................................... 33

Rev. 1.2

Assembly Instructions - Spray Valve SMS-02

Page 4 of 34

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

Spray Valve SMS-02, Article-No. S02-…

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 - Spray Valve SMS-02

Page 5 of 34

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

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 this 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 Energy

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 Association (VDMA), Walther Sys­temtechnik 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 - Spray Valve SMS-02

Page 6 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
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http://www.walther-2000.de – [e-mail]

2.4 Correct Use

This device is a needle valve and will be used for processing materials which can be sprayed in continuous
or intermitting operation. Under no circumstances shall aggressive media such as acids, alkaline solutions,
detergents, chemicals or others be sprayed. If you are not sure, please contact the manufacturer if a certain
spray medium is suitable for this device.

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 malfunc-

tioning safety devices.

 Using unsuitable materials.
 Handling the incomplete 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

-

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Assembly Instructions - Spray Valve SMS-02

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Walther Systemtechnik GmbH – D 76726 Germersheim
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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 Description of Function

The spray valves of SMS-02 series are suitable for the application of liquid up to viscous media, such as
grease, oil, separating agents, colors or glues. One of the major characteristics of SMS-02 series is the
integrated spray air valve with which you can adjust the post-spray duration for cleaning the nozzles.
Depending on the individual air cap, a round or flat jet is produced. And depending on the viscosity of the
applicable medium, the application image can be adjusted individually via the nozzle size or the atomized air
pressure or also the material pressure. Three different hoses are supplying atomized air, control air and
medium.

4.1 Purpose of the Device

CAUTION

The use of other media can cause functional failures, damages or even the destruction of the
device.

Spray valve SMS-02 is a pneumatically controlled application device for processing sprayable materials,
such as glues, grease, colors etc. The control air lines were kept short due to a directly flanged 5/2-way
magnetic valve (17.0.0) and they produce fast and very precise open/close movements of the needle (7.0.0).
The working piston is firmly connected to the needle (7.0.0) and receives air pressure from the 5/2-way
magnetic valve for the larger piston surface. This results in the opening movement of the needle. As soon as
the air pressure on the larger surface of the working piston is turned off, the control air on the smaller surface
of the working piston will initiate the closing movement.
During the operation, the closing spring (9.6.3) is disabled. This happens through the control air which is
permanently pending on the smaller working surface and which also simultaneously compresses the closing
spring (9.6.3) above the closing piston (9.8.3). Thereby the closing spring cannot hamper the fast switching
times of the needle. The closing spring will only be operational in case of failure or turn-off of the compressed
air supply. This will guarantee that no sprayable medium will be released during a defect in the air supply.
The device uses pre-supply/after-supply air (Setting-up of System, see also 6.3) for cleaning the nozzle
(2.1.0).

The device is used for spraying applications. The material pressure has to correspond with the desired spray
image and also with the atomizing air pressure. Spraying can be intermitting as well as continuous. The
control air pulses will be transferred via the 5/2-way magnetic valve (17.0.0) to the working piston.
Depending on the individual case of operation, it is important to adapt the control air pressure to the
switching frequency. For 5 intermissions already, this pressure has to be set to 5 bar.

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Assembly Instructions - Spray Valve SMS-02

Page 8 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
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4.2 Technical Data

General Data

Size with flat-jet air cap [mm]

130 x 80 x 22

Size with round-jet air cap [mm]

127 x 80 x 22

Weight [g]

ca. 525

Air consumption [l/min]

ca. 150 (at 3 bar; nozzle- 1.0 mm and flat-jet)

Switching time [ms]

ca. 100 (for color marking systems ca. 200)

Energy Supply

Control air pressure [bar]

4.5-6

Atomizer air pressure [bar]

0.5 – 5 (at least 0.5 bar lower than control pressure)

Material pressure [bar]

max. 35

Voltage [VDC]

24

Power consumption [W]

1,8

4.3 Type Label

The type label was etched into the casing. The serial number is
hammered into this label.

5 Installation and Start-up

The valves can be installed in any position. The distance to the application area depends on the desired
application width. An intermitting operation of the device will cause natural oscillations; therefore a solid
installation is most important. Try to avoid excessive natural oscillations (transmission from device to valve).

5.1 Hose Mounting

There are three functional hoses which will be con­nected as follows:

1 Material to G 1/8-connection (matching screw

connections can be ordered as accessories!)

2 Control air SL to screw connection for 6mm-

hose (21.0.0)

3 Atomizer air ZL to screw connection for 6mm-

hose (21.1.0)

1 3 2

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Assembly Instructions - Spray Valve SMS-02

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Walther Systemtechnik GmbH – D 76726 Germersheim
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5.2 Total View / Description

1

Basic casing

2

Nozzle with air cap and retainer ring

3

Raster needle lock

4

5/2-way magnetic valve

5

Material connection

6

Connection for atomizer air

7

Connection for control air

8

2x Fastening thread M5

5.3 Adjusting the Device

The stroke adjustment of the needle (Pos. 7.0) will be used for setting the material quantity. A left turn of the
raster-needle locking screw will increase the material quantity. A finely ascending precision thread results in
a needle stroke which changes 0.5mm with one turn of the raster head.

IMPORTANT

The maximum turn of the raster-needle locking screw anti-clockwise should not exceed the
noticeable raster steps. This will already exceed the maximum needle stroke adjustment.
If you continue turning, the raster-needle locking screw will be dislocated!

IMPORTANT

Nozzle and nozzle needle can be damaged by wrong treatment. Only reduce the material flow
with emerging material (right turn of adjusting screw). Do not turn adjusting screw further to
the right after closing of the nozzle!

NOTE

The duration of the after-supply air will be individually set from the outside at the spray valve.
The adjusting screw (10.4.0) is flush-mounted at the side and will be turned (in spray direction:
to the right) with a screwdriver in order to adjust the duration of the after-supply air as follows.

 right turn = longer after-supply air duration
 left turn = shorter after-supply air duration

Basic setting = screw flush-mounted with basic body; then one turn to the

right

3 8 6 7 4 2 5

1

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Assembly Instructions - Spray Valve SMS-02

Page 10 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
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5.4 SMS-02 with Raster-Needle Detection

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 Terminal Assignment for Needle Query

5.4.2 Terminal Assignment for Magnetic Valve

+

-

Standard plug 24V valve (left [+] and right [-])

Raster-Needle Detection

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Assembly Instructions - Spray Valve SMS-02

Page 11 of 34

Walther Systemtechnik GmbH – D 76726 Germersheim
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5.5 Installation Diagram for Color-Marking Systems

6 Operation

6.1 General Information

This 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 Operation Information / Operating Conditions

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 pro­tection should be worn, if required.

WARNING

Danger caused by flammable, harmful fluid. Always follow the safety instructions on the con­tainer or the safety data sheet for the fluid.

Spray valves of the SMS-02 series generally operates with a control pressure of 5 - 6 bar. The atomizer
pressure has to be lower than the material pressure in order to avoid a repulse of the material. Atomized air
pressure and material pressure should be closely correlated.

IMPORTANT

Accident prevention directions will be strictly followed when applying high material
pressures. Please strictly follow the following instructions when planning and constructing
application systems!

 Each spraying valve must be equipped with its own pressure regulator for atomizing air.
 In case several spraying valves are supplied by one and the same material pressure tank, these

valves must not spray simultaneously.

 The supply route for the material between material pressure tank and spraying valve must not exceed

2 m.

Connection ZL

Connection SL

ca. 5-6 bar

Raster-needle lock for
spray medium adjustment

Connection M

max. 35 bar