Practical Guide
WIWA INJECT GUARD: Data Logger & Process Control for 2K Injections up to 400 bar
If you want to cleanly document 2K injections, make material consumption transparent, and detect deviations in the mixing ratio early on, the WIWA INJECT GUARD is made exactly for this job. It monitors defined parameters and creates traceable protocols – directly on the display or via browser via WiFi.
- For injections up to 400 bar
- Suitable for all WIWA 2K injection devices
- Recording of pressure & volume (e.g., per packer)
Product image (Example)
Why the INJECT GUARD really helps in daily operations
KPI #1
Up to 400 bar
Designed for demanding 2K injections with high pressures – including pressure recording via sensors.
KPI #2
Volume per Packer
Documents consumption per packer (A/B and total) – ideal for proof of work, billing, and quality management.
KPI #3
WiFi + Browser
Parameters & evaluations directly on the display or via browser through password-protected WiFi – no special software required.
Practical Tip:
Define fixed "Trades"/sections in your documentation logic beforehand for recurring component zones (e.g., tunnel sections, wall panels).
This way, you get continuous daily and section logs instead of individual paperwork – and you can detect outliers (pressure/consumption) immediately.
Product Overview: Variants & Scope of Delivery (Short)
The INJECT GUARD is available as a basic unit and as a complete set matching the WIWA 2K series (including hose package and mixing unit depending on the system). Values and article numbers should be checked according to the configuration.
| Variant | Suitable for | Typical Content (Excerpt) | Note |
|---|---|---|---|
| INJECT GUARD Basic Unit | WIWA 2K INJECT | Control cabinet with touch display, data logger, flow cells (up to 400 bar), pressure sensor, documentation functions (e.g., volume/pressure per packer). | Ideal as a retrofit/QM module |
| INJECT GUARD Complete Set | INJECT 2K 140 | Basic unit + specific hose package + matching mixing unit | Assembled depending on the system |
| INJECT GUARD Complete Set | INJECT 2K 230 | Basic unit + hose package (with sensor connection) + Inject Guard mixing unit | Typical for documentation in tunnel/large-scale projects |
Recommended Basic Settings (Guide Values)
The following settings should be understood as guide values, as building material, temperature, hose lengths, and packer setup influence the actual values. Start conservatively – and work your way up to stable limit values in a controlled manner.
- Max. air inlet pressure (guide value): up to 8 bar (observe system-side limits).
- Max. operating pressure monitoring: up to 400 bar possible (INJECT GUARD), work with project-related alarm/stop thresholds below that.
- Stop/Signal logic: Once a predefined pressure or target volume is reached, use a signal (light) or optional shutdown to remain reproducible.
- Activate documentation fields: User/operator, date/time, batches A/B, volume per packer (A/B/total) – these are the "mandatory fields" for clean proof of work.
- Secure WiFi access: Keep password protection active and only allow authorized devices.
Professional Workflow (5–7 Steps)
- Define project logic: Define section/trade (e.g., component field, tunnel meter, wall axis) and standardize packer numbering.
- System check: Check sensors (pressure/flow), flow cells, hose package, and mixing unit for correct fit.
- Set parameters: Define target volume per packer and pressure limits as guide values (alarm/signal/optional stop).
- Execute injection: Start/stop cleanly per packer, record packer data (time, pressure range, volume A/B).
- Address deviations immediately: In case of warnings (e.g., mixing ratio), perform an immediate cause check: tank level, suction, valves, mixing unit.
- Generate protocols: Export/archive packer protocol + daily/section protocol (QM/billing).
- Cleaning & completion: Mixing/flushing routine according to system (flush components separately if intended), then visual inspection and data backup.
Troubleshooting: 4 Typical Problems
1) No browser connection / WiFi not reachable
- Check if the end device is logged into the system's password-protected WiFi.
- Reduce distance/shielding (metal containers/tunnel environment can dampen radio signals).
- Allow only authorized devices (access is intentionally restricted).
2) Warning "Mixing Ratio / Shift"
- Check tank levels A/B (empty tanks/suction problems are the most common trigger).
- Check suction lines, return/venting, and valves for tightness & passage.
- Clean/check mixing unit (check valves, static mixer, ball valves).
3) Pressure peaks / unstable pressure curve
- Check packer fit and connection coupling (leakage/partial blockage creates peaks).
- Check hose package for kinks/crushing; guide protective hose correctly.
- Set limit values tighter (alarm/signal) to remain reproducibly below project maxima.
4) Volume per packer seems "implausible"
- Check flow cells/volume measurement for clean flow (contamination/adhesion).
- Maintain clean start/stop per packer (no "intermediate flows" outside the packer session).
- Check batch and section assignment (wrong trade/stage distorts evaluation).
Maintenance (5 Points for Stable Protocols)
- Regularly check flow cells and pressure sensors visually and keep them clean (ensure measurement quality).
- Clean the mixing unit modularly and keep an eye on wear parts (check valves/ball valves).
- Check hose package (including protective hose) for abrasion, kinks, and coupling seals.
- Control password/WiFi access organizationally (parameter changes only by authorized persons).
- Establish data export/archiving as a routine (daily protocol + section protocol).
FAQ (Practical)
1) Which devices is the INJECT GUARD intended for?
It is designed for WIWA 2K injection devices and can be used as a complete set (with hose package/mixing unit) depending on the system.
2) What exactly is documented?
Among other things, pressure and volume values per packer, volume A/B, batch information, date/time, user, and totals per day/section.
3) Can I see the data on mobile?
Yes – the display is possible directly on the screen and additionally via browser through a password-protected WiFi connection.
4) What happens when a target value is reached?
At a previously defined pressure or volume, there is a display (e.g., light signal); optionally, the system can also shut down if desired – ideal for reproducible processes.
5) Does this also help with cost transparency?
Yes – through consumption and pressure control plus packer protocols, material usage becomes traceable and documentation becomes suitable for billing and QM.
Conclusion
The WIWA INJECT GUARD is the pragmatic answer to the two biggest practical questions in 2K injections: "What did we really inject?" and "Was the process stable?". With pressure/volume documentation per packer, warnings, and browser access, gut feeling turns into solid evidence – leading to more quality, fewer discussions, and better cost control.
To the Product
Do you want to use the INJECT GUARD directly with your WIWA 2K system (including the matching set/components)? Then go to the product here:
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