Test Station For Injectors Ft-Itd7 Workshop Manual Device: Technical Documentation

Technical Documentation
Test Station for Injectors

FT-ITD7
Workshop Manual Device
VERSION3-17.09.2018 1
The entire technical documentation for this
product comprises the following single
content
 Operating Instructions
 Pneumatic Switching Diagram
** Depending on the plant design, some individual content can be partially or completely
missing
VERSION3-17.09.2018 2
List of Contents
Customer:
Machine No.:
Year of construction: 08/2019
Project Number: 0000/2019
VERSION3-17.09.2018 3
Assignment of information:
All chapters are listed in chronological order in up to 3 consecutive folders.
Folder No.1 contains an additional data carrier with the same content and
other design and construction information.
Chapter target groups:
The individual chapters of the technical documentation are addressed to
different user groups
Chapter Designation Target

group
1 Preface, transport, setting up, copyright, All
disposal
2 Safety precautions and protective measures All
3 Plant equipment, technical data, declaration of All
conformity
4 Operating and display elements, menu Operator
navigation
5 Service instructions for lubrication and Maintenance
maintenance
6 Diagnostics, escalation and remedying errors or Maintenance
faults
7 Plant components Maintenance
8 Circuit diagrams Maintenance
9 Assembly instructions Maintenance
10 Spare parts lists Maintenance
11 Manufacturer's documentation Maintenance
Identification data:
System data
Project Number:
Year of construction:
Service life of the device:
The plant is designed for an operation duration of 6 years, provided that the
specified maintenance requirements are always complied with.
The manufacturer is not able to provide a guarantee regarding
comprehensive spare parts supply after this period has expired. Continued
operation can only be ensured by a general overhaul.
VERSION3-17.09.2018 4
This should be executed by the operator in consultation with the
aforementioned manufacturer.
VERSION3-17.09.2018 5
Content
1. Preface, transport, setting up, copyright, disposal ................................................................................................ 16
1.1 Preface ............................................................................................................................................................ 16
1.1.1 Scope of delivery ......................................................................................................................................... 16
1.1.2 Input control ............................................................................................................................................... 16
1.2 Setting up, initial commissioning................................................................................................................... 17
1.2.1 Reporting transport damage ...................................................................................................................... 17
1.2.2 Setting up.................................................................................................................................................... 17
The device should be set up on a workbench or laboratory table which is equipped with a vice. A compressed air
supply should be available in the immediate surroundings ..................................................................................... 17
1.2.3 Initial commissioning and approval ............................................................................................................ 17
The initial commissioning will be executed independently by the customer. .......................................................... 17
The following prerequisites are required: ................................................................................................................ 17
Compressed air supply from workshop network 3 - 6 bar (maximum) .................................................................... 17
NW7.2 hose connection ........................................................................................................................................... 17
1.3 Copyright ........................................................................................................................................................ 18
The copyright for these operating instructions remain with Foamatec GmbH. These operating instructions are only
intended for the operator. The reproduction and transmission to external people is not permitted. ......................... 18
1.3.1 Copying rights ............................................................................................................................................. 18
Foamatec GmbH retains the sole rights for the complete documentation and the plans, technical drawings and
lists contained therein. ............................................................................................................................................ 18
1.3.2 Liabilities / Scope of performance .............................................................................................................. 18
The documentation is not intended for regulating liabilities or any other obligations. This will be regulated
exclusively in the previous purchase contract.......................................................................................................... 18
1.4 Operating conditions / ambient conditions .................................................................................................. 18
The device is exclusively intended for commercial use. Operating location of the device has to fulfil and satisfy the
requirements of a commercially operating company. Only trained skilled personnel may operate the device. In
accordance with the regulations, access to the plant is prohibited for children under the age of 16. ........................ 18
1.5 Disposal .......................................................................................................................................................... 18
1.5.1 General information ................................................................................................................................... 18
The owner and/or operator is obliged to ensure the proper disposal of the device and all its operating resources.
................................................................................................................................................................................. 18
................................................................................................................................................................................. 18
Dismantling and disposal of the device must be executed by qualified skilled personnel. Disposal must comply
with all applicable local regulations. ....................................................................................................................... 18
1.5.2 Procedural method for disposal.................................................................................................................. 19
Dismantling and disposal of the device create immediate hazards for human health and the environment. ........ 19
It is essential to observe the “Safety” chapter to prevent and eliminate these hazards. ........................................ 19
 The device must be separated from all media supplies. Inspect to ensure that the device is depressurised .. 19
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 Dismantling the device material groups and assigning materials and substances. ....................................... 19
 Dispose of the device according to the local regulations. ............................................................................... 19
1.5.3 Assignment of materials ............................................................................................................................. 20
The device consists of different materials which must be separated before disposal. It is thereby important to
ensure that materials which could create damage for the environmental and/or health will be treated with
special care. ............................................................................................................................................................. 20
................................................................................................................................................................................. 20
Attention!! Various components can be subjected to mechanical stress (springs) and these must be relieved
before disposal. So that no injuries can be caused by elements which can spring out. ........................................... 20
Material ................................................................................................................................................................... 20
Example components............................................................................................................................................... 20
Copper / Copper Alloys ............................................................................................................................................ 20
Cables, motors, media valves .................................................................................................................................. 20
Steel / Steel Alloys.................................................................................................................................................... 20
Frame parts, chambers, bolts, screws, carriers, containers, connectors, housing................................................... 20
Aluminium/aluminium alloys ................................................................................................................................... 20
Protective fence, holder, covers, guides .................................................................................................................. 20
Plastics / Rubber ...................................................................................................................................................... 20
Cable ducts, switches, sensors, handles, covers ...................................................................................................... 20
Oil / grease / lubricant ............................................................................................................................................. 20
Transmission, hydraulic tank, guides ....................................................................................................................... 20
Electronic components............................................................................................................................................. 20
PLC, relays, circuit breakers, terminals, display ....................................................................................................... 20
Wood / Wood Composites ....................................................................................................................................... 20
Collection plates, floor elements.............................................................................................................................. 20
2. Safety information and protective measures......................................................................................................... 22
2.1 Safety Symbols .................................................................................................................................................... 22
This documentation utilises the following terms, designations and symbols for hazards: .............................................. 22
Always observe the definition!! ........................................................................................................... 22

DANGER ........................................................................................................................................................................... 22
Safety instructions which are marked with this signal word indicate a warning for an imminent occurring danger
which can lead to serious injury or even death! ............................................................................................................. 22
_____________________________________________________________ ................................................................. 22

WARNING ......................................................................................................................................................................... 22
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Safety instructions which are marked with this signal word indicate a warning for a possible occurring danger which
can lead to serious injury or even death! ........................................................................................................................ 22
_____________________________________________________________ ................................................................. 22

WARNING ......................................................................................................................................................................... 22
Safety instructions which are marked with this signal word indicate a warning for a possibly hazardous situation
which can lead to minor injuries! .................................................................................................................................... 22
_____________________________________________________________ ................................................................. 22
Safety information: .......................................................................................................................................................... 22
These safety instructions should provide additional assistance to identify the sources of dangers, prevent accidents and
damage ............................................................................................................................................................................ 22
However, these safety instructions must not be used as a substitute for the accident prevention regulations of the
relevant bodies, committees or associations such as employers' liability insurance association and other institutions. 22
User information:............................................................................................................................................................. 22
The following pictograms are utilised to refer to important user information: ............................................................... 22
..................................................................................................................................................................... 22
ATTENTION....................................................................................................................................................................... 22
This symbol indicates the prevention of damage to equipment. If this is not observed, then the plant or product can be
damaged. ......................................................................................................................................................................... 23
_____________________________________________________________ ................................................................. 23
.......................................................................................................................................................................................... 23
This symbol indicates contents that contain comments, information, notes or tips. ....................................................... 23
2.2 Intended use .............................................................................................................................................................. 24
The device is designed exclusively for the inspection of filling injectors........................................................................... 24
Any other, exceeding use is considered to be unintended use! ........................................................................................ 24
The manufacturer will not be liable for any risks for resulting damage, the responsibility will be borne solely by the
owner and/or operator. Intended use also includes compliance with the servicing, maintenance, lubrication, and
inspection regulations and rules....................................................................................................................................... 24
All additional components, tools, aids and appliances are also included in the intended use. ........................................ 24
The device may only be used in a technically faultless condition, as well as in accordance with the provisions for safety
and hazard awareness, taking into account the operating instructions. ......................................................................... 24
The operating instructions cannot, for reasons of clarity, consider all conceivable operating variants which are required
for the intended use of the plant for qualified and trained skilled personnel. ................................................................. 24
2.2 Warranty and Liability........................................................................................................................................ 25
As a general principle, the guarantee conditions apply for the the owner (buyer) and operator of the plant no later than
at the conclusion of the contract. Warranty and liability claims for personal and property damage are excluded when
they are due to, or result from, one or more of the following causes: ............................................................................. 25
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• Unintended use ofthe device ................................................................................................................................... 25
• Improper assembly, installation, commissioning, operation and maintenance of the device by the owner, operator
or third parties. ................................................................................................................................................................. 25
• Operating the device with the supply media outside the limiting values. ............................................................... 25
• Failure to observe the operating instructions with regard to commissioning, operation, servicing and maintenance
25
• Incorrect operation .................................................................................................................................................. 25
• Arbitrary constructional alterations on the device .................................................................................................. 25
• Insufficient monitoring of components that are subject to wear. ........................................................................... 25
• Improper repairs ...................................................................................................................................................... 25
• Unsuitable operating resources ............................................................................................................................... 25
• Catastrophic events, foreign body influences or Force Majeure.............................................................................. 25
• Chemical, electrochemical or electrical influences .................................................................................................. 25
• Failure to observe the warnings .............................................................................................................................. 25
• Natural wear and tear ............................................................................................................................................. 25
• Use of non-specified components ............................................................................................................................ 25
• Negligent handling of identified residual risks ........................................................................................................ 25
2.4 Hazards caused by operation and maintenance....................................................................................................... 26
2.4.1 Safety-related handling .......................................................................................................................................... 26
The basic prerequisite for the safety-related handling and fault-free operation is the knowledge of the operating
instructions with the basic safety instructions and safety regulations............................................................................. 26
2.4.2 General hazards when operating the device ......................................................................................................... 26
The device has been constructed in accordance with the latest state of the art technology and the recognised technical
safety rules. Hazards can however still occur for people and/or property damage on the device itself during operation.
The device must only be operated for: ............................................................................................................................. 26
• For the intended use ................................................................................................................................................ 26
• In a technically, safety-related faultless condition .................................................................................................. 26
• Only by trained personnel ........................................................................................................................................ 26
2.4.4 Third-party resources.............................................................................................................................................. 26
The use of third-party resources (e.g. spray, cleaning products…) can create specific hazards. The safety and application
information for this medium should be read and complied with before utilisation. ........................................................ 26
2.4.5 Accident report ....................................................................................................................................................... 26
In the event of an accident or "near misses", the manufacturer must be informed immediately in order to initiate
appropriate action............................................................................................................................................................ 26
2.5 Obligations for the owner/operator ......................................................................................................................... 27
The owner (buyer) or operator hereby undertakes to only assign people to work with the device who: ........................ 27
• Are entrusted with, and familiar with, the basic provisions for occupational health and safety and accident
prevention ........................................................................................................................................................................ 27
• Have been instructed for handling of the device ..................................................................................................... 27
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• Have read and understood the safety chapter and the warning information provided in these operating
instructions and confirmed this by signature ................................................................................................................... 27
• The owner and/or operator must inspect the safety-aware working for the personnel in accordance with the
operating instructions at regular intervals ....................................................................................................................... 27
2.6 Obligations for the operating personnel................................................................................................................... 27
All people who are commissioned to work on the device hereby undertake, before starting work, to: .......................... 27
• Observe and comply with the basic regulations regarding occupational health and safety and accident prevention
27
• Read the complete operating instructions and confirm this by the signature to indicate that they have been
understood (Chapter 2.22 Instruction Verification) .......................................................................................................... 27
• Report dangerous situations / statuses and malfunctions / alterations in the operating behaviour immediately
and to stop the device immediately if necessary .............................................................................................................. 27
• Prohibit every safety critical operation! .................................................................................................................. 27
• Observe all safety instructions and hazard warnings on the plant.......................................................................... 27
• Observe order, tidiness and cleanliness in the environment of the plant ................................................................ 27
• Every person who is active on the device must know the next first aid providing position and auxiliary equipment.
27
2.7 Informal safety measures .......................................................................................................................................... 28
2.7.1 Operating Instructions ............................................................................................................................................ 28
The operating instructions must always be available at the operating location of the plant .......................................... 28
2.7.2 Generally valid regulations .................................................................................................................................... 28
In addition to the operating instructions, the generally valid safety regulations as well as the local regulations for the
prevention of accidents and for the protection of the environment and must be observed. ........................................... 28
2.7.3 Safety instructions and hazard warnings .............................................................................................................. 28
All safety instructions and hazard warnings on the device must be retained in a legible condition ................................ 28
2.8 Qualifying the operating personnel .......................................................................................................................... 29
2.8.1 Personnel ................................................................................................................................................................ 29
Only suitable, reliable, trained and instructed personnel may work with the device....................................................... 29
2.8.2 Responsibility of the personnel .............................................................................................................................. 29
The competence and responsibility for personnel must be clearly defined for the assembly, commissioning, operation,
servicing, maintenance and repair. .................................................................................................................................. 29
2.8.3 Personnel training .................................................................................................................................................. 29
Personnel to be educated, trained, or instructed may only work on the device under the supervision of an experienced
person. .............................................................................................................................................................................. 29
2.8.4 External personnel .................................................................................................................................................. 29
In general, working or remaining near the device is prohibited for external personnel. Any other personnel assigned for
work are subject to the same obligation (Chapter 2.6) as the company´s own operating personnel. ............................. 29
2.9 Hazards caused by pneumatic energy....................................................................................................................... 30
2.9.2 Pneumatic energy ................................................................................................................................................... 30
• Work on pneumatic devices or equipment can only be executed by people with special expertise. ....................... 30
• In general, always ensure that hoses, components or connectors have been depressurised before dismantling... 30
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• No operating with open lid, it is forbidden to open the lid of the device................................................................. 30
• Before turning the air pressure on, always consider loose components or hose connections ................................. 30
• Before turning the air pressure on, always ensure that no tools or loose parts are located directly in the work area
of the filling injector ......................................................................................................................................................... 30
• The test object (filling injector) must always be fixed securely before it is connected to the device ....................... 30
• Components which also represent a danger when in a pressure-free condition (e.g. pre-tensioned springs) must
only be dismantled with suitable auxiliary equipment. .................................................................................................... 30
• Opening of the injector must always be organised in such a way that dispersed dust does not affect third-party
people. .............................................................................................................................................................................. 30
• When the compressed air supply is switched on again, the pressure must be within the specified range. A
deviation may lead to erroneous functions and or up to the bursting of pneumatic elements. ...................................... 30
The compressed air supply must be switched off before executing any work on the compressed air system of the device.
.......................................................................................................................................................................................... 30
2.10 Personal Protection Equipment ............................................................................................................................... 31
Personal protection equipment to protect personnel is required in the case of certain work.......................................... 31
Some parts of the plant can reach temperatures of more than 80° during operating, upgrading, retrofitting and
servicing. For this reason, the following protective equipment must be worn................................................................. 31
Appropriate hearing protection must be worn during operation of the plant. ................................................................ 31
Safety helmet: .................................................................................................................................................................. 31
• Manual removal of foamed parts ............................................................................................................................ 31
• Maintenance and repair works ................................................................................................................................ 31
Hearing protection: ......................................................................................................................................................... 31
• In general, always .................................................................................................................................................... 31
Eye protection: ................................................................................................................................................................. 31
• All work where the eyes are at risk .......................................................................................................................... 31
• Manual removal of the foamed parts ...................................................................................................................... 31
• Certain maintenance and maintenance .................................................................................................................. 31
measures .......................................................................................................................................................................... 31
Protective clothing: .......................................................................................................................................................... 31
Safety or protective gloves: ............................................................................................................................................. 31
• When working on sharp-edged parts ...................................................................................................................... 31
• Setting up work ........................................................................................................................................................ 31
Safety shoes: .................................................................................................................................................................... 31
• In general, always .................................................................................................................................................... 31
Personnel with long hair, who have to execute work on technical equipment, are obliged to wear a hair net! ............ 31
3.1 Overview .................................................................................................................................................................... 34
3.1.1 General .................................................................................................................................................................... 34
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1 ........................................................................................................................................................................................ 34
Control module ................................................................................................................................................................. 34
2 ........................................................................................................................................................................................ 34
Suction and filling hose connection .................................................................................................................................. 34
3 ........................................................................................................................................................................................ 34
Compressed air connection .............................................................................................................................................. 34
4 ........................................................................................................................................................................................ 34
Clamping device (optional) ............................................................................................................................................... 34
5 ........................................................................................................................................................................................ 34
Specimen .......................................................................................................................................................................... 34
7 ........................................................................................................................................................................................ 34
USB connection................................................................................................................................................................. 34
8 ........................................................................................................................................................................................ 34
Air supply .......................................................................................................................................................................... 34
9 ........................................................................................................................................................................................ 34
Electrical Power supply 110..230V.................................................................................................................................... 34
10 ...................................................................................................................................................................................... 34
Selection switch for drive unit testing ON/OFF................................................................................................................. 34
.......................................................................................................................................................................................... 35
.......................................................................................................................................................................................... 35
3.2 Technical Data ........................................................................................................................................................... 36
3.2.1 Manufacturer´s information: ................................................................................................................................. 36
Noise development: ......................................................................................................................................................... 36
Noise measurement.......................................................................................................................................................... 36
Measured with Fluke SM20-A .......................................................................................................................................... 36
LwA < 82bB ....................................................................................................................................................................... 36
Environmental conditions:............................................................................................................................................... 36
Room temperature at the installation location ................................................................................................................ 36
0..35°C .............................................................................................................................................................................. 36
Operating temperature .................................................................................................................................................... 36
10..35°C ............................................................................................................................................................................ 36
Relative humidity .............................................................................................................................................................. 36
20..80% non-condensing .................................................................................................................................................. 36
Geographical height maximum ........................................................................................................................................ 36
2.200m above sea level .................................................................................................................................................... 36
Dimension: ....................................................................................................................................................................... 36
Dimensioning .................................................................................................................................................................... 36
Weight .............................................................................................................................................................................. 36
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4 kg ................................................................................................................................................................................... 36
Connection pressure: ....................................................................................................................................................... 36
Air ..................................................................................................................................................................................... 36
2.5..6.0 bar (g) .................................................................................................................................................................. 36
4. Operating and display elements ................................................................................................................................. 38
4.1 Hardware command and warning devices ............................................................................................................... 38
4.1.1 Display..................................................................................................................................................................... 38
4.2 Preparation ................................................................................................................................................................ 39
4.3 Operation ................................................................................................................................................................... 40
4.3.1 Main menu .............................................................................................................................................................. 41
4.3.4 Default settings .................................................................................................................................................... 51
4.4 Testing and inspecting ............................................................................................................................................... 54
4.4 Procedural method target/actual comparison ......................................................................................................... 57
5. Service performance for lubrication and maintenance .............................................................................................. 60
5.1 Hazard information ................................................................................................................................................... 60
_______________________________________________ ............................................................................................. 60
There may be a risk of accidents and injuries. ................................................................................................................ 60
The following safety information must be observed:..................................................................................................... 60
• Always observe the safety provisions and regulations in this technical documentation Chapter 2 ........................ 60
• Additional safety instructions in this lubrication and maintenance provisions ....................................................... 60
5.2 General ....................................................................................................................................................................... 61
The operating and assembly instructions for built-in components include special lubrication and maintenance
provisions. ........................................................................................................................................................................ 61
These provisions must be respectively adhered to for every component, they are an integral part of the entire technical
documentation or request them when necessary. ........................................................................................................... 61
Compliance with all the lubrication and maintenance provisions and a regular cleaning for the device customised to the
requirement are imperative: ............................................................................................................................................ 61
• For trouble-free operation ....................................................................................................................................... 61
• For the conservation of performance capability, operation and accident safety .................................................... 61
The manufacturer will not be liable for damages caused by insufficient maintenance and cleaning.............................. 61
Maintenance activities may only be executed by trained skilled personnel. .................................................................... 61
Handle sensitive parts with due care! .............................................................................................................................. 61
5.3 Cleaning ..................................................................................................................................................................... 61
• Cleaning agents must be utilised which are not aggressive and which do not especially attack plastic parts such as
cables, air hoses, seals etc. ............................................................................................................................................... 61
• Clean with compressed air, vacuum cleaner, plastic articles, cloths. Sharp objects must not be utilised. ............. 61
5.4 Disposal of cleaning agents ....................................................................................................................................... 61
The cleaning agents or soaked cloths must be disposed of according to local regulations. ............................................ 61
Repair and maintenance works create other hazards as those in fault-free operation................................................ 61
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The device must be only be serviced by people who have been trained specifically in relation to servicing and
maintenance. ................................................................................................................................................................... 61
5.5.1 General .................................................................................................................................................................... 62
The device is designed in such a way that the maintenance effort is low. ....................................................................... 62
Always consider the following points before commencing service or maintenance work: .............................................. 62
• Service and maintenance work may only be executed by the trained people who are aware of the hazardous or
dangerous areas and who know how to prevent a potential hazard. .............................................................................. 62
• All the protection measures described in Chapter 2 must be complied with. .......................................................... 62
• The maintenance instructions of the purchased-in parts must be observed in detail. ............................................ 62
• The operating personnel must be informed before the start of the maintenance work. ........................................ 62
5.6 Maintenance schedule ............................................................................................................................................... 62
This maintenance schedule is intended to be the basic scheduling for individual maintenance activities. ................. 62
Information legend: Y= year; M = month; D= day; nB= according to demand ................................................................. 62
Position ............................................................................................................................................................................. 62
Assembly........................................................................................................................................................................... 62
Interval ............................................................................................................................................................................. 62
Type of maintenance ........................................................................................................................................................ 62
8 ........................................................................................................................................................................................ 62
Airline ............................................................................................................................................................................... 62
8.1 ..................................................................................................................................................................................... 62
3 M ................................................................................................................................................................................... 62
Inspect hoses and hose connectors .................................................................................................................................. 62
8.2 ..................................................................................................................................................................................... 62
6 M ................................................................................................................................................................................... 62
Inspect pipework for leak tightness .................................................................................................................................. 62
8.3 ..................................................................................................................................................................................... 62
3 M ................................................................................................................................................................................... 62
Test the air pressure regulating valve 3bar ...................................................................................................................... 62
6. Diagnostics, escalation and remedying errors or faults ............................................................................................. 64
6.1 General ....................................................................................................................................................................... 64
_______________________________________________ ............................................................................................. 64
Malfunctions may only be remedied by trained and authorised personnel or send the device back to the
manufacturer. .................................................................................................................................................................. 64
_________________________________________________ ......................................................................................... 64
_________________________________________________ ......................................................................................... 64
Cause-related handling of the device may lead to errors. ................................................................................................ 64
If applicable, this will impair the function of the device. .................................................................................................. 64
7. Assembly instructions .................................................................................................................................................. 65
7.1 General assembly instructions .................................................................................................................................. 65
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_______________________________________________ ............................................................................................. 65
Assembly and putting together works may only be executed by trained and authorised personnel. ......................... 65
_________________________________________________ ......................................................................................... 65
_________________________________________________ ......................................................................................... 65
Cause-related assembly can result in property damage on the device. ........................................................................... 65
__________________________________________________ ....................................................................................... 65
VERSION3-17.09.2018 15
1. Preface, transport, setting up, copyright, disposal
1.1 Preface
This documentation serves as a support for the smooth operation of
the device. Always pay attention to the operating and safety
instructions listed here as they should help to prevent the risk of
accidents.
Technical alterations remain reserved for continuous process
improvement.
ParticleFoamService
Obertalstraße 17
56379 Winden
Telephone: +49 15116743536

Fax: +49
E-Mail: borish@particlefoamservice.com
Home: www.particlefoamservice.com
1.1.1 Scope of delivery
The scope of delivery corresponds to the confirmed delivery

and can be found in the accompanying documents
1.1.2 Input control
The supplied device should be inspected on arrival for

transport and loading damage. The integrity
should also be checked.
Deviations from the scope of delivery as well as transport and/or

loading damage must be notified immediately to the
aforementioned
address!
VERSION3-17.09.2018 16
1.2 Setting up, initial commissioning
1.2.1 Reporting transport damage
All the parts must be immediately inspected for transport damage

upon arrival and then notified to the carrier. Always notify damage to
ParticleFoamService which will require replacement parts.
Commissioning may only be initially executed when all transport
damage has been remedied.
1.2.2 Setting up
The device should be set up on a workbench or laboratory table
which is equipped with a vice. A compressed air supply should be
available in the immediate surroundings
1.2.3 Initial commissioning and approval
The initial commissioning will be executed independently by the

customer.
The following prerequisites are required:
Compressed air supply from workshop network 3 - 6 bar

(maximum)
NW7.2 hose connection
All screwed connections must be re-tightened after an operating phase

of 24 hours.
VERSION3-17.09.2018 17
1.3 Copyright
The copyright for these operating instructions remain with Foamatec

GmbH. These operating instructions are only intended for the operator.
The reproduction and transmission to external people is not permitted.
1.3.1 Copying rights
Foamatec GmbH retains the sole rights for the complete

documentation and the plans, technical drawings and lists
contained therein.
1.3.2 Liabilities / Scope of performance
The documentation is not intended for regulating liabilities or any

other obligations. This will be regulated exclusively in the previous
purchase contract.
1.4 Operating conditions / ambient conditions
The device is exclusively intended for commercial use. Operating

location of the device has to fulfil and satisfy the requirements of a
commercially operating company. Only trained skilled personnel may
operate the device. In accordance with the regulations, access to the
plant is prohibited for children under the age of 16.
1.5 Disposal
1.5.1 General information

The owner and/or operator is obliged to ensure the proper
disposal of the device and all its operating resources.
Dismantling and disposal of the device must be executed by

qualified skilled personnel. Disposal must comply with all
applicable local regulations.
VERSION3-17.09.2018 18
1.5.2 Procedural method for disposal
Dismantling and disposal of the device create immediate hazards
for human health and the environment.
It is essential to observe the “Safety” chapter to prevent and
eliminate these hazards.
 The device must be separated from all media supplies.
Inspect to ensure that the device is depressurised
 Dismantling the device material groups and assigning
materials and substances.
 Dispose of the device according to the local regulations.
VERSION3-17.09.2018 19
1.5.3 Assignment of materials
The device consists of different materials which must be
separated before disposal. It is thereby important to ensure that
materials which could create damage for the environmental and/or
health will be treated with special care.
Attention!! Various components can be subjected to

mechanical stress (springs) and these must be relieved
before disposal. So that no injuries can be caused by
elements which can spring out.
Material Example components

Copper / Copper Alloys Cables, motors, media valves
Steel / Steel Alloys Frame parts, chambers, bolts, screws, carriers,
containers, connectors, housing
Aluminium/aluminium Protective fence, holder, covers, guides
alloys
Plastics / Rubber Cable ducts, switches, sensors, handles,
covers
Oil / grease / lubricant Transmission, hydraulic tank, guides
Electronic components PLC, relays, circuit breakers, terminals, display
Wood / Wood Composites Collection plates, floor elements
VERSION3-17.09.2018 20
documentation
version3-17.09.2018
Safety Information and Protective Measures
VERSION3-17.09.2018 21
2. Safety information and protective measures
2.1 Safety Symbols
This documentation utilises the following terms, designations and symbols for
hazards:
Always observe the definition!!

DANGER
Safety instructions which are marked with this signal word indicate a warning for an
imminent occurring danger which can lead to serious injury or even death!
_____________________________________________________________

WARNING
Safety instructions which are marked with this signal word indicate a warning for a
possible occurring danger which can lead to serious injury or even death!
_____________________________________________________________

WARNING
Safety instructions which are marked with this signal word indicate a warning for a
possibly hazardous situation which can lead to minor injuries!
_____________________________________________________________
Safety information:
These safety instructions should provide additional assistance to identify the

sources of dangers, prevent accidents and damage
However, these safety instructions must not be used as a substitute for the
accident prevention regulations of the relevant bodies, committees or
associations such as employers' liability insurance association and other
institutions.
User information:
The following pictograms are utilised to refer to important user information:
ATTENTION
VERSION3-17.09.2018 22
This symbol indicates the prevention of damage to equipment. If this is not
observed, then the plant or product can be damaged.
_____________________________________________________________
This symbol indicates contents that contain comments,

information, notes or tips.
VERSION3-17.09.2018 23
2.2 Intended use
The device is designed exclusively for the inspection of filling injectors.

Any other, exceeding use is considered to be unintended use!
The manufacturer will not be liable for any risks for resulting damage, the
responsibility will be borne solely by the owner and/or operator. Intended use
also includes compliance with the servicing, maintenance, lubrication, and
inspection regulations and rules.
All additional components, tools, aids and appliances are also included in the
intended use.
The device may only be used in a technically faultless condition, as well as in
accordance with the provisions for safety and hazard awareness, taking into
account the operating instructions.
The operating instructions cannot, for reasons of clarity, consider all
conceivable operating variants which are required for the intended use of the
plant for qualified and trained skilled personnel.
VERSION3-17.09.2018 24
2.2 Warranty and Liability
As a general principle, the guarantee conditions apply for the the owner
(buyer) and operator of the plant no later than at the conclusion of the
contract. Warranty and liability claims for personal and property damage are
excluded when they are due to, or result from, one or more of the following
causes:
• Unintended use ofthe device
• Improper assembly, installation, commissioning, operation and
maintenance of the device by the owner, operator or third parties.
• Operating the device with the supply media outside the limiting values.
• Failure to observe the operating instructions with regard to
commissioning, operation, servicing and maintenance
• Incorrect operation
• Arbitrary constructional alterations on the device
• Insufficient monitoring of components that are subject to wear.
• Improper repairs
• Unsuitable operating resources
• Catastrophic events, foreign body influences or Force Majeure
• Chemical, electrochemical or electrical influences
• Failure to observe the warnings
• Natural wear and tear
• Use of non-specified components
• Negligent handling of identified residual risks
VERSION3-17.09.2018 25
2.4 Hazards caused by operation and maintenance
2.4.1 Safety-related handling

The basic prerequisite for the safety-related handling and fault-free operation
is the knowledge of the operating instructions with the basic safety
instructions and safety regulations.
2.4.2 General hazards when operating the device

The device has been constructed in accordance with the latest state of the art
technology and the recognised technical safety rules. Hazards can however
still occur for people and/or property damage on the device itself during
operation. The device must only be operated for:
• For the intended use
• In a technically, safety-related faultless condition
• Only by trained personnel
2.4.4 Third-party resources

The use of third-party resources (e.g. spray, cleaning products…) can create
specific hazards. The safety and application information for this medium
should be read and complied with before utilisation.
2.4.5 Accident report

In the event of an accident or "near misses", the manufacturer must be
informed immediately in order to initiate appropriate action.
VERSION3-17.09.2018 26
2.5 Obligations for the owner/operator
The owner (buyer) or operator hereby undertakes to only assign people to

work with the device who:
• Are entrusted with, and familiar with, the basic provisions for
occupational health and safety and accident prevention
• Have been instructed for handling of the device
• Have read and understood the safety chapter and the warning
information provided in these operating instructions and confirmed this
by signature
• The owner and/or operator must inspect the safety-aware working for
the personnel in accordance with the operating instructions at regular
intervals
2.6 Obligations for the operating personnel
All people who are commissioned to work on the device hereby undertake,
before starting work, to:
• Observe and comply with the basic regulations regarding occupational
health and safety and accident prevention
• Read the complete operating instructions and confirm this by the
signature to indicate that they have been understood (Chapter 2.22
Instruction Verification)
• Report dangerous situations / statuses and malfunctions / alterations in
the operating behaviour immediately and to stop the device immediately
if necessary
• Prohibit every safety critical operation!
• Observe all safety instructions and hazard warnings on the plant
• Observe order, tidiness and cleanliness in the environment of the plant
• Every person who is active on the device must know the next first aid
providing position and auxiliary equipment.
VERSION3-17.09.2018 27
2.7 Informal safety measures
2.7.1 Operating Instructions
The operating instructions must always be available at the operating location

of the plant
2.7.2 Generally valid regulations
In addition to the operating instructions, the generally valid safety regulations

as well as the local regulations for the prevention of accidents and for the
protection of the environment and must be observed.
2.7.3 Safety instructions and hazard warnings
All safety instructions and hazard warnings on the device must be retained in
a legible condition
VERSION3-17.09.2018 28
2.8 Qualifying the operating personnel
2.8.1 Personnel
Only suitable, reliable, trained and instructed personnel may work with the
device.
2.8.2 Responsibility of the personnel
The competence and responsibility for personnel must be clearly defined for
the assembly, commissioning, operation, servicing, maintenance and repair.
2.8.3 Personnel training
Personnel to be educated, trained, or instructed may only work on the device

under the supervision of an experienced person.
2.8.4 External personnel
In general, working or remaining near the device is prohibited for external

personnel. Any other personnel assigned
for work are subject to the same obligation (Chapter 2.6) as the company´s
own operating personnel.
VERSION3-17.09.2018 29
2.9 Hazards caused by pneumatic energy
2.9.2 Pneumatic energy
• Work on pneumatic devices or equipment can only be executed by

people with special expertise.
• In general, always ensure that hoses, components or connectors have
been depressurised before dismantling.
• No operating with open lid, it is forbidden to open the lid of the device
• Before turning the air pressure on, always consider loose components
or hose connections
• Before turning the air pressure on, always ensure that no tools or loose
parts are located directly in the work area of the filling injector
• The test object (filling injector) must always be fixed securely before it is
connected to the device
• Components which also represent a danger when in a pressure-free
condition (e.g. pre-tensioned springs) must only be dismantled with
suitable auxiliary equipment.
• Opening of the injector must always be organised in such a way that
dispersed dust does not affect third-party people.
• When the compressed air supply is switched on again, the pressure
must be within the specified range. A deviation may lead to erroneous
functions and or up to the bursting of pneumatic elements.
2.11 Danger caused by compressed air
The compressed air supply must be switched off before executing any work
on the compressed air system of the device.
VERSION3-17.09.2018 30
2.10 Personal Protection Equipment
Personal protection equipment to protect personnel is required in the case of

certain work.
Some parts of the plant can reach temperatures of more than 80° during
operating, upgrading, retrofitting and servicing. For this reason, the following
protective equipment must be worn.
Appropriate hearing protection must be worn during operation of the plant.
Safety helmet:
• Manual removal of foamed parts
• Maintenance and repair works
Hearing protection:
• In general, always
Eye protection:
• All work where the eyes are at risk
• Manual removal of the foamed parts
• Certain maintenance and maintenance
measures
Protective clothing:
Safety or protective gloves:

• When working on sharp-edged parts
• Setting up work
Safety shoes:
• In general, always
Personnel with long hair, who have to execute work on technical equipment,
are obliged
to wear a hair net!
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documentation
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Technical Information
VERSION3-17.09.2018 33
3.1 Overview
3.1.1 General
1 Control module
2 Suction and filling hose connection
3 Compressed air connection
4 Clamping device (optional)
5 Specimen
7 USB connection
8 Air supply
9 Electrical Power supply 110..230V
10 Selection switch for drive unit testing ON/OFF
2
1 3
4 6
5
VERSION3-17.09.2018 34
9
8
10
VERSION3-17.09.2018 35
3.2 Technical Data
3.2.1 Manufacturer´s information:
Noise development:
Noise measurement Measured with Fluke SM20-A
LwA < 82bB
Environmental conditions:
Room temperature at the 0..35°C
installation location
Operating temperature 10..35°C
Relative humidity 20..80% non-condensing
Geographical height 2.200m above sea level
maximum
Dimension:
Dimensioning
Weight 4 kg
Connection pressure:
Air 2.5..6.0 bar (g)
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documentation
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Operating and display elements

Test and Inspection Sequence
VERSION3-17.09.2018 37
4. Operating and display elements
4.1 Hardware command and warning devices
The device has the following display and operating elements

3.5" touch screen colour display
Check plugs
4.1.1 Display
System messages
The following system messages will be shown on the display. These will be
concealed with the acknowledge button.
The USB device is not connected: USB Stick has been detected by the
control system
The USB device is not plugged in: USB stick is incorrect or not plugged into
the device
Secondary or primary storage is missing or not enough storage space: An
error was detected when writing on the USB stick
Causes:
- USB stick is not present
- USB stick has wrong format (necessary format is FAT32)
- USB stick is full or not enough storage available
VERSION3-17.09.2018 38
4.2 Preparation
The preparation and test sequence will be implemented as described below:

- Provide the device with compressed air
- Plug in the mains plug of the device
- Securely position the injector
- Create hose connections accordingly
Control device must always be operated as closed!!
DANGER
VERSION3-17.09.2018 39
4.3 Operation
The Start screen will appear after a start-up time of approx. 20 seconds.
Press the Start button to display the following instructions:
These should always be followed for successful testing

Press the Next button to display the main screen:
VERSION3-17.09.2018 40
4.3.1 Main menu
The main menu contains all functions relevant for testing the injector.
Function keys:
OPEN: Moves the injector sleeve inwards and air exits from the mouthpiece
of the injector.
Attention!! If the work surface is not clean, then dust can be stirred
up.
CLOSE: Moves the injector sleeve to the closed position.
Vacuum: A vacuum is generated on the test plug.
V1: Ventilation injector on opening side
V2: Ventilation injector on closing side
Test: The button initiates a test sequence
Menu buttons:
Default setting: Switch to the "Configuration" menu. This button

is password protected. The master password [050710] must be
entered in the Password input field. If no active input is made within
the menu, then the button is locked again after 5 seconds.
Results: Switch to the "Results" menu. The results of the last

measurement are displayed here. The submenus for "Graph" and
"Drive unit test" are located on this page.
VERSION3-17.09.2018 41
Alarms: All current alarms are displayed in this menu.
Input fields:
Injector ID 1: Input field for the test digit or code number of the 1st injector
part (6-digit numerical value) marked with "R" for pipe.
Injector ID 2: Input field for the test digit or code number of the 2nd injector
part (6-digit numerical value) marked with "A" for drive unit.
Password: Input field for the master password or the operator password
Display fields:
P1 Pressure display: Display of the pressure in chamber for injector close /

cylinder extend.
P2 Pressure display: Display of the vacuum in the test hose / Display of the
pressure in the chamber for injector open / cylinder retraction
OP: The 2-digit code number of the tester is displayed when the
corresponding operator has logged in.
Test result: Display OK/NOK - Result of the test.
Display vacuum measurement off / on
Display drive unit test injector off / on
Display drive unit test core pull off / on
USB stick not recognised / recognised

!!Logging is only executed when the stick is detected!
Prerequisite: Connect injector, insert test plug into injector
VERSION3-17.09.2018 42
Sequence:
If the "Drive unit test selector switch" hardware is switched on, then the
test sequence starts at this point.
- Injector is opened
- Injector chamber opening is pressurised with air, pressure in opening
chamber and pressure in closing chamber are measured
- Air is switched off
- The pressure in the opening chamber is measured after the measuring
time.
If the pressure in the opening chamber has fallen below the limit value
and the pressure in the closing chamber has not risen, then the error for
seal sleeve will be issued. If the pressure in the closing chamber has
increased, then the error for seal closed is issued. If the pressure drops
within the limit, then no error is issued. The system switches to the
following test sequence.
- Chambers are vented:
- Injector is closed
- Injector chamber closing is pressurised with air, pressure in opening
chamber and pressure in closing chamber are measured
- The pressure in the closing chamber is measured after the measuring
time.
- If the pressure in the closing chamber has fallen below the limit value
and the pressure in the closing chamber has not risen, then the error for
seal end cap will be issued. If the pressure in the closing chamber has
increased, then the error for seal opened is issued. If the pressure
drops within the limit, then no error is issued. There will be a switch over
to the following test sequence.
- Chambers are vented, test sequence is concluded
- Test result is displayed
- Test result is written onto the stick
VERSION3-17.09.2018 43
If the "Drive unit test selector switch” hardware is switched off, then the
test sequence begins as follows, the test continues with switched on
drive unit test.
- Injector is closed, approx. 2 sec.

- Vacuum is built up, approx. 5 sec.
- Initial value of negative pressure is recorded
- Set test time expires
- Final value of the vacuum is recorded
- Test result is displayed (without pressure test)
- Test result is written onto the stick (without pressure test)
VERSION3-17.09.2018 44
4.3.2 Results
This menu displays the results of the last measurement.
Button:
Drive unit test menu is called up (optional)
The Graph menu is called up
VERSION3-17.09.2018 45
4.3.2.1 Drive unit test
Function buttons
Vacuum ON/OFF: Switches the vacuum test on / off
Injector / Cylinder: Switches between drive unit test of

injector and core pull off cylinder
(optional)
Display fields
Open maximum leakage: Limit value for pressure drop in the opening
chamber
Close maximum leakage: Limit value for pressure drop in the closing
chamber
Hold time: Active pressurisation to determine the preconditions
Test time: Measuring time without active pressurisation of the respective
chamber side
VERSION3-17.09.2018 46
If the core pull off test is switched on, then the main image amends as shown
below.
Sequence:
If the "Selector switch for chamber test” hardware is switched on and
the selector switch is set to cylinder in the menu shown above,

then core pull off cylinder test is executed.
.
- Cylinder is retracted
- Cylinder is vented
- Cylinder chamber retraction is pressurised with air, pressures in both
chambers are measured
- The pressure in the retraction chamber is measured after the measuring
time.
If the pressure in the retraction chamber has fallen below the limit value
and the pressure in the extension chamber has not risen, then the error
for seal retraction will be issued. If the pressure in the extension
VERSION3-17.09.2018 47
chamber has increased, then the error for drive unit seal is issued. If the
pressure drops within the limit, then no error is issued. The system
switches to the following test sequence.
- Chambers are vented:
- Cylinder is extended
- Cylinder is vented
- Cylinder chamber for extending is pressurised with air, pressures in
both chambers are measured
- The pressure in the extension chamber is measured after the
measuring time.
If the pressure in the extension chamber has fallen below the limit value
and the pressure in the retraction chamber has not risen, then the error
for seal extension will be issued. If the pressure in the retraction
chamber has increased, then the error for drive unit seal is issued. If the
pressure drops within the limit, then no error is issued. There will be a
switch over to the following test sequence.
- Chambers are vented, test sequence is concluded
- Test result is displayed
- Test result is written onto the stick
VERSION3-17.09.2018 48
4.3.2.2 Graph
The Graph menu displays a graph of the pressure measured during the last
120 seconds. The recording only runs when the test is in progress.
VERSION3-17.09.2018 49
4.3.3 Alarm menu
The current alarms are displayed here.
Wire break sensor: An internal test sensor is defective!
VERSION3-17.09.2018 50
4.3.4 Default settings
The basic data of the device are set here.
Input fields
Measuring range: Sensor scaling; usually -1...9bar.

Pressure difference: Maximum permissible pressure difference which must
not be exceeded after the test period has expired.
Test time: This time elapses after the vacuum is switched off. In the optimum
case, there is no pressure difference in the vacuum within this time. Time and
pressure difference determine whether the injector is considered fully
functional or not.
Closing time: Set the adjustable time at the beginning of the test cycle for
standard injectors 1-5 seconds, for long-stroke injectors 5-8 seconds.
Button
2.Number ON / OFF: Switches the 2nd serial number input on / off.
Press this button to enter the date/time menu where you can set the
time, date and language.
This button will enable one to access the operator settings which are
explained below.
VERSION3-17.09.2018 51
4.3.5 Operator settings
This is where the various operator data is set.

The example shows the default settings "ABC" as operator or user password
for Operator 44.
Up to 9 operators and/or users can be configured.
VERSION3-17.09.2018 52
4.3.6 Date / Time
The flags on the right side are utilised to set the language - German, English
and Spanish are available.
The current date and time of the controller, which are also used for logging,
are displayed at the bottom left.
In order to amend the date and time, enter the current time and date in the
white input fields and subsequently actuate the "SET” button.
!! It is important that all values are entered except seconds !!
VERSION3-17.09.2018 53
4.4 Testing and inspecting
After the injector has been positioned and pneumatically connected, the
corresponding operator and/or user password must be entered. The two
injector IDs are then entered. For better illustration, a yellow arrow flashes
when a required entry has not yet been actuated.
Once all entries have been executed, then the function and leakage test can
be implemented.
All compressed air connections must be tested and

inspected for safe connection!
DANGER
Function test: Injector open / close

A general function test can be executed in the main menu. This inspects the
mechanical behaviour in the OPEN and CLOSE positions.
If the vacuum function is selected here, then the injector suction behaviour
can be adjusted.
Attention!!
When controlling the function for "injector on", air comes out of the
mouthpiece of the injector! Dust turbulence can lead to impaired
vision.
Leakage test: Vacuum-On
VERSION3-17.09.2018 54
When the injector is closed and the vacuum is switched on, then the vacuum
reached determines the tightness of the injector. The test plug must be
inserted into the material connection of the injector.
Test plug
Test plugs must always be equipped with a hole or slot

nozzle in order to avoid contamination and malfunctions in the
pneumatic system!
Warning
Error messages during testing
The error messages are displayed in the field below the function test buttons.
Vacuum error:
A general test is initially executed in which vacuum is applied to the hose
connection (test plug). The pressure rise (vacuum loss) at the injector is then
inspected. With this test, all seals in the filling chamber are tested towards the
outside. Therefore sleeve [1.] and hose connection [5.].
Sleeve seal:
In the following pressure test, the opening chamber is pressurised and the
pressure drop in the opening chamber is initially inspected. In case of a
VERSION3-17.09.2018 55
pressure drop > the pressure limit for injector on and no pressure rise in the
closing chamber, then seal [6.]. (depending on injector type [1.]) is defective.
Seal Open -> Close:

If during the pressure test in the opening chamber a rise in pressure in the
closing chamber has been detected, then one can detect a defect in the seal
[2]. / [3.] close.
Seal Close -> Open:

A reference inspection is executed in the opposite direction. If during the
pressure test in the closing chamber a rise in pressure in the closing chamber
has been detected, then one can detect a defect in the seal [3]. / [2.] close.
End cap seal:

If a pressure drop has been detected during the pressure test of the closing
chamber but there is still no pressure increase in the opening chamber, then
the seal of the end cap can be closed [4.].
Error messages for core pull off test
Drive unit seal:

VERSION3-17.09.2018 56
If a pressure increase has been measured in the other respective chamber
during the pressure test of the running-in or running-out chamber, then this
error is issued. [A]
Retraction seal:
If a pressure loss has been measured during the pressure inspection for the
retraction chamber but no pressure increase can be determined in the
extension chamber, then this error is issued. [B]
Extension seal:
If a pressure drop was measured during the pressure test of the extension
chamber but no pressure increase was detected in the retraction chamber,
then this error is issued. [C]
4.4 Procedural method target/actual comparison

The following is an example for how a testing can be designed:
VERSION3-17.09.2018 57
Procedure Pressure
Example QM gauge Result
Vacuum basic position

Injector basic position
Injector closed
Injector open
Vacuum on
Target
Test / Inspection [bar] Actual [bar] OK NOK
Barrel completely closed x x x
The barrel can be moved by hand x x x
Barrel completely retracted x x x
Suction vacuum in the target range x x -0.4bar -0.5bar x
Achieved vacuum for leak tightness x x -0.6bar -0.5bar x
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documentation
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Service Performance
Lubrication
Maintenance
VERSION3-17.09.2018 59
5. Service performance for lubrication and maintenance
5.1 Hazard information

_______________________________________________
There may be a risk of accidents and injuries.
The following safety information must be observed:
• Always observe the safety provisions and regulations
in this technical documentation Chapter 2
• Additional safety instructions in this lubrication and
maintenance provisions
VERSION3-17.09.2018 60
5.2 General
The operating and assembly instructions for built-in components include

special lubrication and maintenance provisions.
These provisions must be respectively adhered to for every component, they
are an integral part of the entire technical documentation
or request them when necessary.
Compliance with all the lubrication and maintenance provisions and a regular
cleaning for the device customised to the requirement are imperative:
• For trouble-free operation
• For the conservation of performance capability, operation and accident
safety
The manufacturer will not be liable for damages caused by insufficient

maintenance and cleaning.
Maintenance activities may only be executed by trained skilled personnel.
Handle sensitive parts with due care!
5.3 Cleaning
• Cleaning agents must be utilised which are not aggressive and which
do not especially attack plastic parts such as cables, air hoses, seals
etc.
• Clean with compressed air, vacuum cleaner, plastic articles, cloths.
Sharp objects must not be utilised.
5.4 Disposal of cleaning agents
The cleaning agents or soaked cloths must be disposed of according to local

regulations.
5.5 Cyclic maintenance
Repair and maintenance works create other hazards as

those in fault-free operation.
The device must be only be serviced by people who
have been trained specifically in relation to servicing
and maintenance.
VERSION3-17.09.2018 61
5.5.1 General
The device is designed in such a way that the maintenance effort is low.
Always consider the following points before commencing service or
maintenance work:
• Service and maintenance work may only be executed by the trained
people who are aware of the hazardous or dangerous areas and who
know how to prevent a potential hazard.
• All the protection measures described in Chapter 2 must be complied
with.
• The maintenance instructions of the purchased-in parts must be
observed in detail.
• The operating personnel must be informed before the start of the
maintenance work.
5.6 Maintenance schedule
This maintenance schedule is intended to be the basic scheduling for

individual maintenance activities.
Information legend: Y= year; M = month; D= day; nB= according to demand
Position Assembly Interval Type of maintenance
8 Airline
8.1 3M Inspect hoses and hose connectors
8.2 6M Inspect pipework for leak tightness
8.3 3M Test the air pressure regulating valve 3bar
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documentation
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Diagnostics, escalation and remedying errors or faults
VERSION3-17.09.2018 63
6. Diagnostics, escalation and remedying errors or faults
6.1 General
_______________________________________________
Malfunctions may only be remedied by trained and
authorised personnel or send the device back to the
manufacturer.
_________________________________________________
_________________________________________________
Cause-related handling of the device may lead to errors.
If applicable, this will impair the function of the device.
_____________________________
VERSION3-17.09.2018 64
7. Assembly instructions
7.1 General assembly instructions

_______________________________________________
Assembly and putting together works may only be
executed by trained and authorised personnel.
_________________________________________________
_________________________________________________
Cause-related assembly can result in property damage on the
device.
__________________________________________________
The device is designed and constructed in such a way that an assembly prior
to initial commissioning is not necessary. It is only necessary to ensure that
the air connections to the test object are connected correctly and no faulty
hoses, connectors and couplers have been utilised.
All connecting elements, including the test object itself, must be able to
withstand the network pressure for operation and be designed accordingly.
The network pressure should be between 2.5 and 6 bar, however it should
not be higher than 8 bar in any case.
VERSION3-17.09.2018 65
EC Conformity Declaration
The manufacturer:
FoamaTec GmbH
Hauptstrasse 48
D-56357 Bogel /Ts
Sold / distributed by Messrs. ParticleFoamService - Boris Hillenbrand
hereby declares that the following product:
Designation Injector Test device FT_ITD7
Manufacturer: FoamaTec GmbH

Hauptstrasse 48
D-56357 Bogel /Ts
Serial number: FT-ITD7 Version1/2019
Year of construction: 2019
meets all relevant requirements of the Machinery Directive (2006/42/EC).

The device furthermore meets all requirements of the Electromagnetic Compatibility Directive
(2004/108/EC).
The following harmonised standards were observed:
DIN EN ISO 12100 Safety of machinery - General principles for design - Risk assessment and risk
reduction
DIN EN 60204-1 Safety of machinery - Electrical equipment of machines, Part I:

General Requirements
DIN EN ISO 4414– Pneumatic fluid power -- General rules and safety requirements for systems
and their components
Name of Authorised Documentation Officer: Eugen Laubach

Address of Authorised Documentation Officer: See above
Bogel,05.06.18 Dipl. Ing (FH) Eugen Laubach Managing Partner

___ __ _________________ ___________ ____________
Date Signatory, Title or Position Signature
VERSION3-17.09.2018 66

Test Station For Injectors Ft-Itd7 Workshop Manual Device: Technical Documentation

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Technical Documentation

Test Station for Injectors

Chapter Designation Target

Service life of the device:

Always observe the definition!! ........................................................................................................... 22

Always observe the definition!! ........................................................................................................... 22

Always observe the definition!! ........................................................................................................... 22

Telephone: +49 15116743536

1.1.1 Scope of delivery

The scope of delivery corresponds to the confirmed delivery

1.1.2 Input control

The supplied device should be inspected on arrival for

Deviations from the scope of delivery as well as transport and/or

1.2.1 Reporting transport damage

All the parts must be immediately inspected for transport damage

1.2.3 Initial commissioning and approval

The initial commissioning will be executed independently by the

The following prerequisites are required:

Compressed air supply from workshop network 3 - 6 bar

All screwed connections must be re-tightened after an operating phase

The copyright for these operating instructions remain with Foamatec

1.3.1 Copying rights

Foamatec GmbH retains the sole rights for the complete

1.3.2 Liabilities / Scope of performance

The documentation is not intended for regulating liabilities or any

1.4 Operating conditions / ambient conditions

The device is exclusively intended for commercial use. Operating

1.5.1 General information

Dismantling and disposal of the device must be executed by

Attention!! Various components can be subjected to

Material Example components

Safety Information and Protective Measures

2.1 Safety Symbols

Always observe the definition!!

Always observe the definition!!

Always observe the definition!!

These safety instructions should provide additional assistance to identify the

The following pictograms are utilised to refer to important user information:

This symbol indicates contents that contain comments,

The device is designed exclusively for the inspection of filling injectors.

2.4.1 Safety-related handling

2.4.2 General hazards when operating the device

2.4.4 Third-party resources

2.4.5 Accident report

The owner (buyer) or operator hereby undertakes to only assign people to

2.6 Obligations for the operating personnel

2.7.1 Operating Instructions

The operating instructions must always be available at the operating location

2.7.2 Generally valid regulations

In addition to the operating instructions, the generally valid safety regulations

2.7.3 Safety instructions and hazard warnings

2.8.2 Responsibility of the personnel

2.8.3 Personnel training

Personnel to be educated, trained, or instructed may only work on the device

2.8.4 External personnel

In general, working or remaining near the device is prohibited for external

2.9.2 Pneumatic energy

• Work on pneumatic devices or equipment can only be executed by

2.11 Danger caused by compressed air

Personal protection equipment to protect personnel is required in the case of

Safety or protective gloves:

Operating and display elements

4.1 Hardware command and warning devices