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Material Pressure Regulator - en
Material Pressure Regulator - en
(WMDR)
Installation Instructions
Version Rev C
EN
EN
1 Introduction .................................................................................................................... 5
General Information ............................................................................................................................ 5
Order key ............................................................................................................................................ 5
Nomenclature ..................................................................................................................................... 5
Scope of Delivery................................................................................................................................ 6
Target Group of the Manual ............................................................................................................... 7
Structure of the Operating Manual ..................................................................................................... 7
Warranty and Liability ......................................................................................................................... 7
Copyright ............................................................................................................................................ 7
Warnings ............................................................................................................................................. 8
2 Safety Instructions .......................................................................................................... 9
General Information ............................................................................................................................ 9
Basic Safety Instructions .................................................................................................................... 9
Dangers from Using the Device .......................................................................................................... 9
Correct Use ....................................................................................................................................... 10
Incorrect Use .................................................................................................................................... 10
Required Qualification and Personal Protective Equipment............................................................. 11
3 Transport ...................................................................................................................... 12
Packaging ......................................................................................................................................... 12
Transport and Damages in Transport............................................................................................... 12
Location of Set-up ............................................................................................................................. 12
4 Description of Product ................................................................................................... 13
Design and Construction .................................................................................................................. 13
Dimensions ....................................................................................................................................... 14
Inside View WMDR ........................................................................................................................... 14
Description of Function ..................................................................................................................... 15
Type Label ........................................................................................................................................ 15
Performance Characteristics ............................................................................................................ 15
Technical and Relevant Data ........................................................................................................... 16
5 Start of Operation ......................................................................................................... 17
Mounting with Fastening Screws ...................................................................................................... 17
Fastening by Flanging to other Walther Products ............................................................................ 18
Mounting with a Holding Angle on the Wall ...................................................................................... 20
Rinsing before First Start of Operation ............................................................................................. 21
Connection Options .......................................................................................................................... 21
Assembly Set „Save“ ........................................................................................................................ 21
5.6.1 Assembly Set „Save“ – Installation ................................................................................................................ 22
5.6.2 Assembly Set „Save“ – Changing the Code ................................................................................................... 23
Filter Cleaning ................................................................................................................................... 24
1 Introduction
General Information
Material Pressure Regulators are used for controlling and constant-keeping of the material pressure.
Walther Material Pressure Regulators (WMDR) are suitable for applications with high pressures, and
can also be precisely set for low pressures; this way, they are extremely versatile. Thanks to their
compact and innovative modular construction, they can be installed in any medium line. The WMDR
balances pressure variations and reduces the inlet pressure so that the reduced outlet pressure will be
constantly kept. Walther Material Pressure Regulators were mainly designed for self-lubricating
materials such as greases and oils.
Order key
WMDR - XX - XX - XX - XX - X
Option
Manometer connection 2
Manometer connection 1
Index
Pressure Control Range (2 bis 50 bar)
Material Pressure Regulator
Nomenclature
Basic Type
WMDR-50-01 Walther Material Pressure Regulator
M1 = Manometer connection
00 Blind plug
MA Manometer angled
MS Manometer straight
DA Pressure sensor angled
M2 = Manometer connection
00 Blind plug
MA Manometer angled
MS Manometer straight
DA Pressure sensor angled
Option
0 -
S Save
WMDR-50-01 - MA - DA - S Example
50000114 WMDR-50-01-00-00-0
50000117 WMDR-50-01-00-00-S
50000123 WMDR-50-01-DA-00-0
50000113 WMDR-50-01-DA-00-S
50000111 WMDR-50-01-MA-00-0
50000100 WMDR-50-01-MA-00-S
50000120 WMDR-50-01-MS-00-0
50000112 WMDR-50-01-MS-00-S
50000122 WMDR-50-01-00-DA-0
50000121 WMDR-50-01-00-DA-S
50000118 WMDR-50-01-00-MA-0
50000116 WMDR-50-01-00-MA-S
50000119 WMDR-50-01-00-MS-0
50000115 WMDR-50-01-00-MS-S
Scope of Delivery
• the user has thorough knowledge of the contents of this operating manual;
• the user follows the instructions and information/warnings contained in this operating manual;
• the user does not rebuild or make changes on parts of the Advanced Degassing Station without
prior consent of Walther Systemtechnik GmbH.
Copyright
We reserve the copyright for this operating manual. This operating manual is exclusively designated for
the operator and his personnel.
Any copying – also only in part – or processing, or distribution or other use is strictly prohibited.
Warnings
Symbols are used to indicate dangerous situations and specific behavior. These symbols are also
used in this operating manual. All warning, danger and information symbols describe situations which
can be harmful to persons, material or environment if rules are not followed.
DANGER
Symbol „Danger“
This symbol warns against a potentially dangerous situation which will result in death
or severe injuries or considerable material damage, if you do not take the required
precautions.
WARNING
Symbol „Warning“
This symbol warns against a potentially dangerous situation which can result in death
or severe injuries or considerable material damage, if you do not take the required
precautions.
VORSICHT
This symbol warns against a potentially dangerous situation which can result in
lighter injuries, if you do not take the required precautions.
This signal word is also used for warnings against material damages.
IMPORTANT
Indicates tips for usage and other particularly useful information.
No dangerous situation.
2 Safety Instructions
General Information
The construction of the Material Pressure Regulator (WMDR) is according to the latest technology and
very reliable. The individual components as well as the complete WMDR are continuously checked by
our quality management team.
CAUTION
Hazards from incorrect use
It is the customer’s responsibility that all relevant safety measures are followed.
• The WMDR will only be used for the designated purpose.
• No changes will be made at the device. The customer carries the sole
responsibility for consequences resulting from failure to observe this guideline.
Please contact Walther Systemtechnik GmbH for any desired modifications.
• Make sure that the device is always in a safe operational condition. Checks for
proper function or damages have to be performed by specialists on a regular
basis. Dismounting will only be made by authorized personnel and while using
the operating manual. If requested, we will also offer trainings on the device in
order to teach your personnel the required knowledge.
• Check all lines, hoses and screwed joints regularly for leakages and apparent
damages! Repair damages immediately!
• Always make sure that the actual workstation and the WMDR are clean and
clearly arranged; and this is routinely checked.
• Please observe the guiding rules and regulations for accident prevention at
the workplace.
WARNING
Hazard from incorrect use
Use the device only for the designated purpose and in a safe and operational
condition.
Immediately correct failures which can adversely affect safety and security. Daily
check the WMDR. Worn-out or damaged part will be immediately replaced or
repaired.
CAUTION
Hazard 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.
Correct Use
CAUTION
Any other than the designated use will be regarded incorrect. The manufacturer
cannot be made liable for damages from incorrect use.
• Follow all instructions from this manual.
• Only use in non-explosive surroundings/atmosphere.
• Operate the WMDR with an inlet pressure of max. 150 [bar].
• Process non-aggressive media/fluids.
• Process (highly) viscous lubricants such as oils and greases.
• Medium purity / filtration
the operator is responsible that the employed medium is clean and pure; e.g.
use a filter system with a mesh size if ≤ 500 [µm].
Incorrect Use
CAUTION
Danger from incorrect use:
No other use than the designated!
The operator is liable for damages from incorrect use. The operator bears the
sole risk!
The following is regarded incorrect use with a foreseeable risk of malfunction:
• Operating the WMDR with insufficient knowledge of operation and maintenance.
• Making changes, extensions or alterations on the WMDR that may hamper its
safety without the prior consent of Walther Systemtechnik GmbH.
• Operating the WMDR with an operating pressure of more than 150 [bar].
• Operating the WMDR with media which are contaminated with particles, dirt etc.
• Processing aggressive media/fluids (e.g. acids, alkaline solutions, detergents,
chemicals, abrasive media), polar solvents (e.g. acetone, MEK, ethyl acetate),
low-molecular organic acids (formic acid and acetic acid), ammonia gas,
amines, alkalis and super-heated steam can cause malfunction, material
damages or even the destruction of the Walther Material Pressure Regulator
• Working on the WMDR when pressure or current are applied.
• Using the device in explosive areas, according to directive 2014/34/EU.
This operating manual was prepared for different target groups. Some chapters are reserved for a
certain group; the below table shows the respective assignment. Only the designated target group will
be authorized to carry out the tasks. All other contents of the operating manual have general
applicability for all target groups.
Operation X X
Assigning personnel X
3 Transport
Packaging
The WMDR will be prepared by Walther Systemtechnik GmbH for a transport to the first destination.
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.
The packing unit will not be exposed to any additional strain. Packaging and contents will be protected
against any kind of humidity. The temperature for transport and storage will strictly range between: –
20°C and + 40°C.
Location of Set-up
• At the actual location, clarify all legal requirements and make sure that you adhere to them.
• Check the floor/ground and space requirements before setting up the device in order to guarantee
a safe operation of the WMDR for both, personnel and the device.
• The WMDR was designed for rooms which are protected against atmospheric influences.
• Operation or storage in aggressive or humid surroundings or outside can cause damages from
corrosion for which Walther Systemtechnik GmbH cannot be made liable.
• All open parts and lines will be arranged in such a way that they will not cause injuries or damages.
4 Description of Product
This chapter contains information on the set-up and function of the Material Pressure Regulator.
CAUTION
Hazard from incorrect use
Processing aggressive media such as acids, alkaline solutions, detergents,
chemicals, abrasive media etc. can cause malfunctions, material damages or even
the destruction of individual parts/the device.
6
5
3 9
3
3
3
10
2
1
11
6 Lock nut
Dimensions
Figure 3 – Dimensions
1 4
5
Description of Function
From the inlet of the regulator (medium inlet opening), the medium flows to the valve seat with an inlet
pressure of maximum 150 bar. There, the medium will be adjusted to the desired outlet pressure when
flowing through the valve, and then flows to the medium outlet opening. Use the regulating screw for
adjusting the desired outlet pressure. The regulating screw is connected to a spring which exercises
force onto the membrane. Corresponding to the equilibrium of the forces from spring and outlet
pressure, the membrane will move up and down. This will activate the plunger together with a ceramic
ball, and the valve is opened slightly or more. This way, you will regulate the outlet pressure and keep
it constant.
If a manometer is connected to the material pressure regulator, it will display the adjusted medium
pressure. Make sure that the applied medium pressure is always higher than the controlled pressure.
Type Label
The type label is located on one side and contains the following information.
Article Number: WMDR-50-01
Seral Number: DR0001
Operating temperature: +4°C … +50°C
Max. inlet pressure: 150 [bar]
Regulating range outlet
2 – 50 [bar]
pressure:
Year of manufacture: 2019
Walther Systemtechnik GmbH
Hockenheimer Straße 3
D-76726 Germersheim
Performance Characteristics
• Precise adjusting to the medium pressure set point
• Lowest impact on outlet pressure during variations of inlet pressure
• Integrated filter strainer (630 [µm]) keeps soiling away
• Precise and correct adjusting
• Compact and innovative design
• Versatile
Other Values
IMPORTANT
Holding angles for the Material Pressure Regulator (WMDR) are an optional
accessory.
5 Start of Operation
WARNING
Hazard from contact or inhalation of toxic fluids, gases, mist, vapors or dust
Strictly follow the safety data sheets of the employed media.
The operator company is responsible for providing the required personal protective
equipment which has to be worn. All rules and regulations for workplace safety,
accident prevention and environmental protection will be followed for the location,
and a yearly safety training will be conducted.
CAUTION
Prior to any service or maintenance work, make sure that the hydraulic, pneumatic
and electric system are disconnected from pressure and secured against
unauthorized operation.
1
1
IMPORTANT
Make sure that you keep the direction of flow when flanging to other Walther
products. The direction flow is indicated by direction markings and must be kept.
HINWEIS
Please refer to the Installation Instructions of the Module Connector Set “MVS-BA-
10“ for further information on the module connector set.
Connection Options
Material inlet/Material outlet and Manometer connection
4
1
2 Protection cylinder with lid 4 Lock nut for the adjusting screw
Filter Cleaning
CAUTION
Prior to any service or maintenance work, make sure that the hydraulic, pneumatic
and electric system are disconnected from pressure and secured against
unauthorized operation.
Wear personal protective equipment, such as goggles and gloves.
The filter comes with a mesh width of 630 [µm]. it offers an ideal protection against gross soiling. For
finest contamination, contact Walther Systemtechnik GmbH for a respective filter.
Replacing Membrane
Take the following steps for replacing the membrane:
Unscrew the cylinder-head screws (10 each)
Completely remove upper housing
1 1
Remove spring
3
HINWEIS
Reassemble in reverse order.
make sure that you keep the press
size of 47,75 mm so that the Press size
membrane will seal perfectly. 47,75 mm
Routine Tasks
CAUTION
Prior to any service or maintenance work, make sure that the hydraulic, pneumatic
and electric system are disconnected from pressure and secured against
unauthorized operation.
Wear personal protective equipment, such as goggles and gloves.
Weekly
Troubleshooting
IMPORTANT
First check that all supply lines are properly connected and functioning.
Table 4 – Troubleshooting
In case of serious problems that cannot be resolved, please contact the Walther Systemtechnik GmbH
customer service.
Short Interruption
For short interruptions, such as overnight or weekends, make sure that pressure is removed from all
supply lines.
Long-term Interruption
When the WMDR is not in use for a longer time, take the following steps:
• No pressure will be left in the system
• No pressure in the material supply line; turn off
Shutdown of WMDR
CAUTION
Danger of accidents and environmental hazard. Do not spill medium.
Medium and parts of the device will be properly disposed of (hazardous waste).
The below table shows you all available spare parts for this product series.
50000083 Membrane
50000104 Save
The wear-and-tear parts set for the WMDR contains the following parts:
7
8
2
1
5
3
4
9
6