Walther Systemtechnik SMS-05 Assembly Instructions Manual

Rev. 1.3

Assembly Instructions – Spray Valve SMS-05

Page 1 of 31

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

Assembly Instructions

Spray Valve SMS-05

Article Number: S05-….

Figure: Spray Valve SMS-05 with flat-jet 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. 1.3

Assembly Instructions – Spray Valve SMS-05

Page 2 of 31

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 DESIGNATED PURPOSE ................................................................................................................................................ 7

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

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

5 MOUNTING AND FIRST START-UP ...................................................................................................................... 8

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

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

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

5.4 SMS-05 WITH RASTER NEEDLE SENSOR ...................................................................................................................... 10

5.4.1 Terminal Assignment for Needle Detection ............................................................................................... 10

5.4.2 Terminal Assignment for Solenoid Valve ................................................................................................... 10

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

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

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

6.2 OPERATION INSTRUCTIONS / OPERATING CONDITIONS .................................................................................................... 11

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

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

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

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

7.3 REPLACING THE SEALING SCREW ................................................................................................................................ 13

7.4 REPLACING NOZZLE AND NEEDLE ................................................................................................................................ 14

7.5 REPLACING SEALING ELEMENTS (RASTER NEEDLE SENSOR) .............................................................................................. 14

7.6 MAINTENANCE FOR USE IN COLOR MARKING SYSTEMS (NORMAL OPERATION) ................................................................... 15

7.7 SPARE PARTS .......................................................................................................................................................... 16

7.8 CUSTOMER SERVICE / SUPPORT .................................................................................................................................. 16

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

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

8.2 MALFUNCTIONS: ..................................................................................................................................................... 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

9.3 SHUTDOWN OF DEVICE ............................................................................................................................................. 18

Rev. 1.3

Assembly Instructions – Spray Valve SMS-05

Page 3 of 31

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

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

10.1 DIMENSIONED DRAWING SMS-05 ........................................................................................................................ 19

10.1.1 Spare Part Drawing SMS-05 ................................................................................................................. 20

10.1.2 Spare Part Liste SMS-05 ........................................................................................................................ 21

10.2 ARTICLE NUMBERS FOR AIR CAPS .......................................................................................................................... 22

10.3 ARTICLE NUMBERS FOR NOZZLES ........................................................................................................................... 23

10.4 ARTICLE NUMBERS FOR NOZZLE NEEDLES ................................................................................................................ 24

10.5 ARTICLE NUMBERS FOR VALVES ............................................................................................................................. 25

10.6 ARTICLE NUMBERS THREADED JOINTS..................................................................................................................... 25

10.7 WEAR-AND-TEAR PARTS ...................................................................................................................................... 26

10.8 ACCESSORIES ..................................................................................................................................................... 27

10.8.1 Center hole for Centering sleeve 97320602 .......................................................................................... 28

10.8.2 Add-on Elements .................................................................................................................................. 29

10.8.3 Description of Pneumatic Needle-Stroke Adjustment 978000037 ........................................................ 30

Rev. 1.3

Assembly Instructions – Spray Valve SMS-05

Page 4 of 31

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-05, Article No. S05-…

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, 19 April 2018
(Place, Date) (Stefan Hirl, Management)

Rev. 1.3

Assembly Instructions – Spray Valve SMS-05

Page 5 of 31

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. 1.3

Assembly Instructions – Spray Valve SMS-05

Page 6 of 31

Walther Systemtechnik GmbH – D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
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

-

Rev. 1.3

Assembly Instructions – Spray Valve SMS-05

Page 7 of 31

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 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

4.1 Designated Purpose

The spray valves of SMS-05 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 the SMS-05 series is the
stepless adjusting of the spraying width as well as the integrated control valve for pre air and purging air.
Depending on the viscosity of the medium to be applied, the application pattern can be individually adjusted
via the nozzle size, the atomizing air pressure and material pressure. The supply line of the atomizing air,
control air and the medium takes place via three hoses. Connections No. 7.0 and No. 8.0 are additional op­tional material connections for the material circulation (i.e. circulation via nozzle head).

CAUTION

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

The SMS-05 Spraying Valve is an electro-pneumatically controlled application device. Extremely short
control air paths, facilitated by the directly attached 3/2-way solenoid valve (pos.18.0), bring about a fast and
very exact opening and closing of the needle (pos.13.0). The air valve (pos.12.0) connected with the needle
(pos.13.0) receives air pressure on the surface via the 3/2-way solenoid valve. This opens the air valve
(pos.12.0) such that the atomizing air (“pre air”) is released. Not until the spring (pos.12.4) is completely
compressed, the air valve (pos. 12.0) moves the needle (pos.13.0), and the medium comes out of the
nozzle. If the control air is switched off or fails, this spring (pos. 14.0) will cause the needle to close, whereby
the needle first closes the nozzle and thereafter the air valve (“purging air”) will close. The pre air and the
purging air help to keep the nozzle (pos. 3.0) clean.

The material pressure (1/8"-connection - pos. 5.0) must be adjusted to the desired spray pattern and, thus, to
the atomizing air pressure (1/8"-connection - pos. 17.0).
It can be used for continuous as well as intermittent spraying. The control air impulses (M5-connection - pos.

16.0) are transmitted to the working piston via the 3/2-way solenoid valve (pos. 18.0).
Depending on the particular application case it must be ensured that the control air is adjusted to the number
of operating cycles.

Rev. 1.3

Assembly Instructions – Spray Valve SMS-05

Page 8 of 31

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

4.2 Technical Data

General Data

Dimensions [mm]

ca.126 x 22 x 82.5 with air cap – round jet
ca.129 x 22 x 82.5 with air cap – flat je

Weight [g]

ca. 500

Energy Supply

Control air pressure [bar]

4.5 – 6

Atomizer air pressure [bar]

0.5 – 5 (minimum 0.5 bar lower than control pressure)

Material pressure [bar]

max. 15 bar

4.3 Type Label

The type designation is etched in the casing. The serial number is
also inscribed in this area.

5 Mounting and First Start-up

The valves can be installed in any position. The spraying width for middle air (ML) and cone air (HL) can be
individually regulated. The possibility for using either round or flat spray air caps is given.
Vibrations of the valve caused by fast intermitting cycles require solid and tight installation. Excessive
machine vibrations to the valves should be avoided.

5.1 Hose Mounting

The three functional hoses will be connected as follows:

Atomizing air (blue)

Connection ZL (17.0): M5

Control air (black)
Connection SL (16.0): 1/8"

Material (transparent)

Connection M (5.0): 1/8"-to
pressure tank or pump

Material circulation (Op­tional)

Connection M (5.0): M5 – to
pressure tank or pump

Material circulation (Op­tional)

Connection M (5.0): M5- to
pressure tank or pump

Rev. 1.3

Assembly Instructions – Spray Valve SMS-05

Page 9 of 31

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

5.2 Total View / Description

1

Basic casing

2

Nozzle with air cap and retainer ring

3

Raster needle lock

4

3/2-way solenoid valve

5

Material connection

6

Atomizer air connection

7

Control air connection

8

2x fastening thread M5

5.3 Adjusting the Device

The amount of material can be regulated via the stroke adjustment of the needle. A left turn of the regulating
knob increases the material amount. A fine precision thread affects a needle rise that results in an adjust­ment of 0.5 mm 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 turning
it! The maximum fluid outlet has been reached!
A further turning will damage the raster needle screw!

IMPORTANT

Nozzle and needle can be damaged by wrong handling. Only decrease the material flow (by a
right turn of the regulating knob) if material spills out. Do not turn the regulating knob further to
the right after the nozzle is closed!

NOTE

The duration of the post-spray air will be individually adjusted from outside at the spray valve.
Turn the regulating screw (10.4.0) which is inserted in the side (view in spray direction: right)
with a screwdriver in order to control the duration of the post-spray air as follows:

 right turn = longer duration of post-spray air
 left turn = shorter duration of post-spray air

Basic setting = screw is flush with basic body; then make one full turn to the

right

3 8 6 7 4 2 5

1

Rev. 1.3

Assembly Instructions – Spray Valve SMS-05

Page 10 of 31

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

5.4 SMS-05 with 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 Terminal Assignment for Needle Detection

5.4.2 Terminal Assignment for Solenoid Valve

+

-

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

Raster needle sensor