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WIWA 2K-DUOMIX PU 460

1. relieved Repeat steps with the other component Fig 8 8 Translation of the original operating manual PU 460 8 5 1301_SV1016DV1016_BAoDB_ensski WiIVTA Decommissioning because it works 8 5 2 With relief hoses optional bar regulator oo eam o rm o esman Fig 8 9 8 5 3 With circulation optional The material pressure in the system is relieved through the return flow hoses The material is returned into the material drums After relieving the system the pressure in the hose package be relieved by pull ing the trigger on the spray gun once again Pressure Compressed air bar regulator Fig 8 10 8 6 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski PIFIA Decommissioning because it works 8 6 Cleaning after spraying 8 6 1 Cleaning the system 1 Stop operation of the system as specified in chap 8 3 Take the system out of service P 8 2 2 Thoroughly clean the system from outside after each use i Notice For cleaning use only cleaning agents recommended by the material manufacturer 3 Fill the entire system with preserving agent Please observe the notes of the material manufacturer 8 6 2 Cleaning the spray gun Clean the spray gun including the connection block as specified in chap 12 4 10 Cleaning the spray gun P 12 15 Translation of the original operating manual PU 460 8 7 1301_SV1016DV1016_BAoDB_enssk
2. though the system is pressed air supply switched on 13 No compressed air available Fuse for pneumatic valve Have the fuse replaced by after starting the system defective a skilled electrician accord ing to the wiring diagram 14 The control light of one or Master switch not switched gt Switch on the master switch several phase monitoring on features does not light gt One or several phases miss gt Have the phases checked by ing a skilled electrician accord ing to the wiring diagram Fuse defective Have the fuse replaced by a skilled electrician accord ing to the wiring diagram 15 System shuts down The ELCB is triggered due Get a qualified electrician to to the increased leakage inspect the heating conduc current on the heating con tor of the hose package and ductor on the hose package or cartridge for faults e g in and or the cartridge sulation faults and repair it Notice Each time a fault has been corrected the Reset button O must be pressed You access the menu which was active before the fault If the system has shut down you must restart it by pressing the green ON button O 13 5 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WF WA Malfunctions and Troubleshooting because it works 13 3 1 Replacing fuse A Caution Unprofessional work on live power lines can cause severe injuries caused by electric shock Any wo
3. Disregarding this notice can result in severe or even fatal injuries Danger of burning Highlights a dangerous situation caused by a hot surface Disregarding this information can result in severe injuries Notice Indicates an informative text passage You should pay particular attention when reading it 2 1 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA Safety Information because it works The following symbols indicate that protective equipment should be worn With your health in mind you should always comply with the recommendations of the material manufacturer Wear protective clothing Highlights the order to wear the prescribed protective clothing to protect against skin injuries caused by spraying material or gases Wear ear defenders Highlights the order to use ear defenders in order to prevent your sense of hearing from being damaged by noise Use eye protection Highlights the order to use eye protection in order to prevent your eyesight from being damaged by material splatter Use a respiratory protection mask Highlights the order to use a respiratory protection mask in order to prevent your respiratory tract from being damaged by gases fumes or dusts Wear protective gloves Highlights the order to use protective gloves in order to prevent the skin from being damaged by burning L Drum Poly Iso Cleaning Agent cleaning materi
4. or and within a period of 30 seconds setting value see Fig 4 4 Display at top right H Application during a short interruption of work with the material flow heaters switched on The system does not change to malfunction when the differential pressure is exceeded When resuming work differential pressure monitoring is automatically reactivated after 2 switching points 4 Use of the A button is strictly reserved for the WIWA Customer Service Translation of the original operating manual PU 460 4 4 1301_SV1016DV1016_BAoDB_ensski WIA Menu because it works 4 2 5 Time settings Month i gt ascending gt descending 4 2 6 Ending the Master setting Possible ways to exit this menu Possibility Description L Press until you have entered the mask SETTINGS 3 Activate Logout L The menu used last before making the settings opens _1 Press another function key Ed tz i Ea _1 Automatic logout after time has elapsed 4 5 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA Menu because it works 4 3 Actual temperature large display The current temperatures for both material flow heaters are displayed ACTUAL temperature value ACTUAL temperature value Fig 4 7 4 4 System status F The current temperatures for both material flow heaters and for the hose pack age are displayed The ACT
5. pump Both components Ensure slow running of the pump 1 to 1 turns Duration until noiseless bubble free material starts to run out For version with feed drums and initial clean ing with cleaning agent Pump the cleaning agent completely out of the containers Fig 6 3 Translation of the original operating manual PU 460 6 2 1301_SV1016DV1016_BAoDB_ensski RTEA Commissioning because it works 6 only for optional version with circulation relief L Open the circulation as described in chap 12 1 Circulation P 12 1 _1 Catch the testing medium material mix in the collecting container L Close the circulation as described in chap 12 1 Circulation P 12 1 as soon as clean material starts to run out 1 Fasten the return flow hoses to the material drum 7 Pressure tests Check the entire system for leakages Notice In case of leakages abort the start up process and have the malfunction cor rected by expert personnel 8 Open the deicing On the maintenance unit open the regulator for deicing the air motor Fig 6 4 Notice The deicing may stay open over the entire life cycle of the equip ment Result The system is ready for operation You may continue with the normal operation of the system as per chap 7 Operation P 7 1 or switch off the system as described in chap 8 Decom missioning P 8 1 6 3 Translation of the original operating man
6. Any unintended escape of material from the spray gun can cause damage to persons of property Always secure the spray gun even for shortest work breaks Always make sure that the spray gun is properly secured before each use Attention Components which do not comply with the maximum permissible working pressure may quickly burst and cause severe injuries Please check Material hoses and hose assemblies must comply with the maximum work ing pressure and the required safety factor Material hoses must be leak tight and free of kinks signs of abrasion or bulges Hose connections must be tight Attention From leakage points material can escape under very high pressure and cause serious bodily injuries and material damage Never try to seal leakages on connections and high pressure hoses by hand or by wrapping fabric around them gt Depressurize the the complete system gt Replace defective components gt Never repair material hoses oe 2 3 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA Safety Information because it works A Attention In case of material congestion or agglomeration of material in the spraying system residual pressures can still be present despite pressure discharge In case of necessary repair work on the plant escaping residual pressures may cause accidents Please bear in mind Repair work mu
7. Minimum pressure for both components P9 Determination for maximum difference between the components and the maximum duration of this difference When the difference is exceeded a clock is activated When the entered value for the maximum duration of the difference is exceeded the system will change to malfunction and switch off Graphic representation of pressures The scaling can be set gt selected unit 4 3 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_en ski because it works WIA ene 4 2 4 Stroke counter setting Take this value from the type plate of the metering pump or the infor mation in chap 14 1 Technical data P 14 1 This information is decisive for the daily or total quantity counters regarding the delivered volume per liter By pressing slangar all settings entered by you are deleted and reset to the factory default settings see chap 14 2 Type plates P 14 2 The H thereby lights up for a moment Monitoring the values for the permissible differential pressure Fig 4 4 can be activated and deactivated Monitoring activated by two switching points and the on pre set minimum pressure level being reached for both components see Fig 4 4 pos Display at top right Al Application System in automatic mode will be switched off if a malfunction occurs inactive gt monitoring must be deactivated after 2 switching points
8. Start spraying 12 11 12 4 7 End spraying 12 12 12 4 8 Disassembling the spray gun 12 12 12 4 9 Spray gun maintenance 12 12 12 4 9 1 Lubrication 12 12 12 4 9 2 Filter change 12 13 12 4 9 3 Changing the mix module 12 13 12 4 10 Cleaning the spray gun 12 15 13 Malfunctions and Troubleshooting cccccsccceesseeeesseeeeeseeseeseeeeesneeeees 13 1 13 1 General troubleshooting 13 1 13 2 Troubleshooting on the spray gun 13 2 13 3 Error messages on the control cabinet 13 4 13 3 1 Replacing fuse 13 6 1301_SV1016DV1016_BAoDB_ensski Contents 0 4 14 APPendiIX ccsesecsssecsseseesenees 14 1 Technical data 14 2 Type plates 14 3 Factory default settings 14 4 Operating means 14 5 Tools 14 6 Accessories 14 7 Instruction Certificate WiIVTA because it works Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA Foreword because it works 1 Foreword Operating personnel should always have access to this user manual The owner of the unit must ensure that the operator of the unit always has an operating manual at his her disposal in a language he she understands All persons involved in the set up commissioning operation maintenance repair and servicing of the machine must have read and understood the user manual beforehand and the chapter on Safety in particular We recommend to the owner of this unit to have this confirmed in writing In principle you should refrain from
9. bar The maximum admissible operating pressure for the entire system in this exam ple is 240 bar Translation of the original operating manual PU 460 2 4 1301_SV1016DV1016_BAoDB_ensski RTA Safety Information l because it works A Danger Any sudden overpressure in the system can lead to the bursting of compo nents This may result in damage to persons and property Never allow the system to run without safety valves If the safety valve needs to be replaced you can find the corresponding order number on the machine card Notice Changing the mixing ratio may cause a change in pressure ratio and thus require the adaptation of the max permissible air inlet pressure In this case the existing safety valve must be replaced Consultation with 7 is highly recommended 2 3 4 Danger caused by explosion A Caution The high flow velocities associated with the Airless spraying method may cause static charging Static discharges can cause fire and explosion Always use open containers Never spray solvents or solvent containing materials into cone top cans or drums with bunghole Stand the containers on a grounded surface gt When using metal containers watch out for contact between spray gun and container wall gt Only use conductive material hoses All original 714 material hoses are conductive and perfectly adapted to our equipment Risk of explosion Heating up cleaning agents can cause an e
10. connected with material drums and distributor Translation of the original operating manual PU 460 12 1 1301_SV1016DV1016_BAoDB_ensski RTEA ional ipmen Optional equipment because it works Pressure Compressed bar air regulator Metering pump Fig 12 2 2 Open the circulation and start to supply with compressed air Z 9 OIOFF VON Pressure Compressed bar air regulator Fig 12 3 12 2 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA tional equipment because it works Op ote eee oe Pressure Compressed bar air regulator Metering i Adjust the desired spraying pressure Fig 12 4 Translation of the original operating manual PU 460 12 3 1301_SV1016DV1016_BAoDB_ensski Optional equipment RTEA because it works 12 2 Silicagel filter 12 4 The silicagel filter is a moisture filter for installation in the drum lid of the Iso component If humidity saturation is reached granulate colour changes from orange to colourless For the filter to function properly the granulate needs to be regu larly dried Fig 12 6 Fig 12 7 During operation the ball valve on the silicagel filter must be opened L Only close the ball valve during longer downtimes of the system to pre vent humidity from entering through the filter Fig 12 5 Version without return flow Version with return flow Fig 12 5 Regenera
11. dual component system and the object to be coated must be prop erly earthed System component Description of earthing Dual component system The unit is earthed via the mains cable Spray gun Grounding is accomplished in connection with the W WA material hoses WIA Material hoses are conductive Material supply containers Earthing acc to local regulations external object to be sprayed Cleaning agent container external 5 5 Electric connection A Caution Unprofessional work on live power lines can cause severe injuries caused by electric shock Any work on live power lines must solely be performed by professional electri cians and with the power shut off Locally valid regulations must be followed at all times Caution When using in atmospheres containing solvents there is the danger that the power cable could become flawed or porous which could result in dangerous injuries caused by electric shock gt You should therefore check the power cable for externally visible damage before each start up gt Never repair a power cable Damaged power cables must always be com pletely replaced 1 Before connecting the unit to the mains supply check whether the pre scribed electrical data complies with that available at the installation site 2 Connect the unit to the local mains supply 5 5 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA because
12. must only be performed by personnel trained by 7 or the WIWA Customer Service 1 Check _1 the filling level in the release agent container before each start up 200ml L for discolouration caused by spraying material at regular intervals 2 Change the pump seals see spare parts list for material pump LJ in case of excessive discolouration of the release agent _1 if the level in the release agent container rises 4 Notice To protect the packings use WA release agent Fig 11 4 11 4 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA tional equipment because it works Op liad ti cele 12 Optional equipment 12 1 Circulation Before applying the coating you must vent the entire system Advantages Air in the system is forced out e g after barrel change Continuous discharge of both material components is assured No falsification of spray pattern by sudden air shocks Uniform material temperature and consistency throughout the entire system Material flow heaters maintain the material at operating temperature 12 1 1 Circulation circuit Distributor gt Q O 2 E E mo l E g z C T aa Material Flow Material Flow Heater Heater gt ae e Metering pump Fig 12 1 12 1 2 Circulation ventilation 1 End compressed air supply and secure spray gun The return flow hoses are reliably
13. pumps for switching off the feed pumps 2 7 Handling the system and auxiliary materials Follow the safety notes and dosing information of the manufacturers and the generally applicable regulations when handling spraying materials cleaning agents oils greases and other chemical substances Translation of the original operating manual PU 460 2 8 1301_SV1016DV1016_BAoDB_ensski WiIVTA Safety Information because it works 2 8 Emergency procedures 2 8 1 Leakages Incase of leakages the system must be shut down immediately and the complete system must be depressurized L Switch off the unit by the EMERGENCY STOP switch L Make sure that the system has been depressurized _1 Immediately replace the defective parts or have these replaced 2 8 2 Injuries gt Immediately consult a physician if injured when handling fluid jets because of their cutting effect 2 8 3 Fires Read and comply with the instructions for fire alarm and escape routes which are displayed in your factory or at any work place Only use the extinguishing substances stipulated by the material manufac turer 2 9 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski because it works 7 WA System Description 3 System Description 3 1 Intended use of the machine The W WA DUOMIX PU 460 is most suitable for the application of solvent free dual component plastic materials polyurea This system enab
14. the receptacle Filling level up to 3cm below receptacle Fig 8 6 7 Shut off the compressed air supply Notice 1 For short working breaks the equipment does not need to be emptied please follow the notes of the material manufacturer The material to be applied can be replaced by a preserving agent recom mended by the material manufacturer if required Do not use any solvents Compressed air connection on either side 8 4 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA Decommissioning because it works 8 4 Shutting down the equipment 1 Stop operation of the system as specified in chap 8 3 Take the system out of service P 8 2 2 Exchange the material drums against containers with preserving agent 3 Fill the system with preserving agent Only use the preserving agent recommended by the material manufacturer and which matches the material 4 Allow the residual pressure escape from system and hose package as de scribed in chap 8 5 Pressure relief P 8 5 8 5 Pressure relief 8 5 1 Without circulation and without relief hoses 1 Disassemble the spray gun from the connection block as described in chap 12 4 8 Disassembling the spray gun P 12 12 2 Relieve the connection block by opening both material valves open until the system pressure of this compo Only one component 1 to 1 turns nent has been
15. 6 The air pressure valve must be locked for each break even for short interruptions of work Slide the air valve to position CLOSED 0 With missing compressed air the material valves will stay closed Overtemperature switch not illustrated These elements switch off the equipment when the maximum permissible temperature in the material flow heaters is exceeded This malfunction is sig nalized on the control cabinet After the material flow heater has cooled down and the malfunction has been acknowledged the plant can be operated again Material pressure relief sensor not illustrated In the factory both pressure relief sensors were set to the maximum admissi ble operating pressure When this value is exceeded the equipment including the heaters will switch off completely This malfunction is signalized on the control cabinet Trouble free operation can only be resumed after the pressure on the corre sponding components has been relieved ELCB not illustrated If the maximum permissible leakage current on the hose packages is excee ded the ELCB s fuse is triggered The plant switches off Trouble free operation cannot be resumed until the fault has been eliminated Compressed air shut off valve not illustrated The compressed air shut off valve is for interrupting the compressed air sup ply gt On the air maintenance unit for switching off the entire plant optionally available On the feed
16. Connect or repair the sensor nected or defective cable gt Air in system Ventilate the system Mixing element clogged on gt Dismantle the spray gun and 2 Display readings Overpressure Poly the iso side relieve the valve of the Iso component gt Spray gun filter Iso clogged gt Clean spray gun filter Iso Dirt trap Iso clogged Clean dirt trap Iso gt Sensor cable not connected gt Connect or repair the sensor or defective cable Air in system Ventilate the system Display readings gt Switch off heating ISO Overtemperature ISO Reset flashing g Temperature sensor defec gt Have the temperature sen tive sor inspected by a skilled electrician Control defective Have the control inspected by a skilled electrician Sensor line not connected or gt Check the sensor line defective _ Display readings a gt Switch off heating Poly Overtemperature Poly Temperature sensor defec gt Have the temperature sen Reset flashing tive sor inspected by a skilled electrician Control defective Have the control inspected by a skilled electrician Display readings Sensor defective or sensor gt Repair the sensor or connect Sensor Poly or cable not connected the sensor cable Sensor Iso or Sensor hose Display readings gt Cable breakage Poly press sensor or ISO
17. RIFA Operation manual because it works WIWA eK DUOMIA PU 460 Type O 400V O 230V 1 phase O 230V 3 phase Variants with O Feed pumps O Feed drums Serial No Translation of the original operation manual 1301_SV1016DV1016_DB_en ski WIA because it works Contents Contents t ORS Woran E ET 1 1 2 Safety Info mahon sasoun aaa 2 1 2 1 Pictogrammes 2 1 2 2 Notes on the plant 2 2 2 3 General safety notes 2 3 2 3 1 Dangers caused by the spray jet 2 3 2 3 2 Danger to health 2 4 2 3 3 Notices on the permissible operating pressure 2 4 2 3 4 Danger caused by explosion 2 5 2 3 5 Danger caused by disregarding the explosion protection 2 5 2 4 Operating personnel 2 6 2 5 Protective equipment 2 6 2 6 Safety features 2 7 2 7 Handling the system and auxiliary materials 2 8 2 8 Emergency procedures 2 9 2 8 1 Leakages 2 9 2 8 2 Injuries 2 9 2 8 3 Fires 2 9 3 System Description cicvicesccc st cndecicnisnseienincvencucsenecienssacdessticateebsnestieniesseetanstence 3 1 3 1 Intended use of the machine 3 1 3 2 Notes on warranty 3 1 3 3 Plant environment 3 2 3 3 1 Emissions 3 2 3 3 2 Sound pressure level 3 2 3 4 Transport 3 2 3 5 Place of installation of the machine 3 3 3 6 Storing the machine and additional equipment 3 4 3 7 Disposal of the machine and additional equipment 3 4 3 8 System variants 3 4 3 9 System description 3 5 3 9 1 Without circulation 3 5 3 9 2 With circulation 3 5 3 9 3 Material flow 3 6 3 9 4 Compressed a
18. Spray gun components 12 8 o lt 7 KS f Fig 12 13 Description Protection bow Trigger Front cap Round jet nozzle Connection block Material shut off valve comp Iso Spray jet regulation Pos 6 Screw to mount the connection block to the spray gun 8 9 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA because it works Optional equipment 12 4 2 Safety features The spray gun can be secured as follows gt Air pressure valve trigger lock gt The spray gun cannot be operated without air pressure in the air pressure cylinder To lock the spray gun press the air pressure valve back away from the com pressed air cylinder which is thereby relieved through the valve Material shut off valves No material comes out of the spray gun when the valves are closed In order to secure the the spray gun additionally this way you must turn the valves in clockwise direction until they are closed Fig 12 14 Attention During operation both components are applied to the material valves with high pressure Unintended material leakage from the material valves can cause serious injuries and material damage Only open the material valves with the spray gun closed if the material outlets of the connection block are directed into a suitable container 12 4 3 Notes on operation gt gt VV VY For spraying both material valves mus
19. UAL values can be directly compared with the NOMINAL values Once the system has switched to automatic mode the actual pressures for both components are displayed and differential pressure monitoring between the two components is activated d Notice If the indicated ACTUAL temperature continually changes between 0 0 C and 999 9 C the temperature lies within the freezing zone A correct temperature indication only takes place above 0 C ACTUAL temperature values NOMINAL temperature values ACTUAL ATRAL pressure a values a aan numerical Graphic value Differential pressure graphic setting see gt selected unit chap 4 2 Pre settings P 4 1 Fig 4 8 Translation of the original operating manual PU 460 4 6 1301_SV1016DV1016_BAoDB_ensski sas WIA because it works 4 5 NOMINAL temperature F Here the NOMINAL temperatures are specified for each component and for the hose package Pressing the corresponding numerical field opens a keyboard to enter the value Press ENT to confirm the input factory setting eg gt selected unit Loweriimit 20 68 Fig 4 9 4 6 Stroke counter F The total and daily volume of applied material is displayed in dependence on the pulses The daily counters can be reset to zero by pressing the Reset button Resetting is confirmed in field d Notice The day counter is only active when the pre set minimum pressure level of bot
20. afety features on the depressurized unit L Please check _ the lead seal on the safety valve for damage L the safety valve for external damage L the correct function of the master switch L the function of the air pressure valve on the spray gun Attention Not fully functional safety features or other deficiencies on the machine can lead to malfunctions This may cause serious injuries to persons and damage to property gt Stop operation of the system immediately Operation of the system must only be resumed after the correct functional state has been re established All units are delivered with the following safety features Master switch Fig 2 4 0 OFF ON When the master switch on the control cabinet is switched to position 0 OFF both the electric power and compressed air supply are immediately cut off Note The compressed air supply to the spray is not inter rupted Material may still be under pressure in the system Es kann noch Materialdruck im System anstehen Safety valve Fig 2 5 The safety valve on the air motor of the metering pump makes sure that the max permissible air inlet pressure is not exceeded The safety valve will open and vent off air when the air inlet pressure exceeds the set limiting value Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA Safety Information because it works Air pressure valve on spray gun Fig 2
21. aking piston valve of metering pump Replace defective ball or valve plate Apump does not generate The pump without pressure gt Check the material supply pressure in up and down does not receive any mate stroke The pressure of the rial oth component is very gt Both valves soiled or defec gt Check the valves Ign tive When venting the pressure gt Return flow hoses optional gt Check return flow hose op of one component remains material hose or spray gun tional and material hoses for applied are clogged free flow The pressure of the other gt Check the valves component drops When spraying the pres The packings in the pump gt Repair the pump without sure of a component always without pressure start leak pressure renew the pack increases in comparison with ing ings the other component gt Filter in spray gun clogged gt Clean the filter Mixing chamber clogged gt Clean the mixing chamber 13 1 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA Malfunctions and Troubleshooting because it works Fat Possiblecause Remedy 9 When spraying not enough gt Material hose or spray gun Clean or replace material pressure or material is trans connection blocked by de hoses and spray gun ferred to the spray gun even posit growth though the pressure inthe gt The mixing chamber inthe gt Replace the mixing chamber sys
22. al Identifies a drum containing the material to be applied which the user requires at the corresponding location in the manual Drum empty Identifies an empty collecting vessel to be used by the user to collect contami nated spraying material 2 2 Notes on the plant Appropriate information signs and symbols on the machine refer to possible danger areas and must be respected at all costs Information signs and symbols must not be removed from the machine Damaged and illegible information signs and symbols must be replaced imme diately The following signs can be found on the machine Warning label Caution Electric voltage on control cabinet Fig 2 1 Translation of the original operating manual PU 460 2 2 1301_SV1016DV1016_BAoDB_ensski Caf 4 tad ln fA nna Aat An Safety Information RTA because it works Warning label Caution Hot surface on adapter Fig 2 2 Fig 2 2 2 3 General safety notes 2 3 1 Dangers caused by the spray jet A an XR A A Attention The material leaves the spray gun under high pressure Due to its cutting effect the spray jet can cause severe injuries by penetrating the skin or entering into the eyes gt Never point the spray gun at yourself other persons or other living beings gt Do not hold your fingers or hands into the spray jet Do not reach with your hands into the spray jet Attention
23. alve Heated hose package Reverse flow spray gun see chap 12 4 Spray gun P 12 8 Connection compressed air hose Connection of heated hose package connection compressed air line 8 oa 9 Release agentcontainer 10 Receptacle O O Material Flow Heater 2 Rak 3 Toolbox Translation of the original operating manual PU 460 3 9 1301_SV1016DV1016_BAoDB_ensski System Description WiIVTA because it works 3 11 Control cabinet 3 11 1 Components on the control cabinet 3 10 Gt Ue C9 D8 Ss H ee amp i W WA Description Description Touch screen monitor Touch screen monitor 7 USB port optional Button SYSTEM ON 9 Control lamp phase monitoring phase 3 10 Control lamp phase monitoring phase 2 12 16 Compressed air regulator feed pumps 17 Compressed air regulator metering pump Compressed air pressure gauge metering pump not available for 1 phase design Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA tem D ription because it works Syste escriptio 3 11 2 System control The touch screen display is used to enter or read the following values gt ACTUAL and NOMINAL temperature individually for both material flow heat ers and for the hose package gt ACTUAL value for the applied material quantity gt Activation of parking position Display of malfunctions Language selection But
24. any work method that would affect the safety of W WA products and the operating personnel Please read and comply with gt the applicable guidelines for your country In Germany these are the Richtlinien fur Flussigkeitsstrahler Guide lines for Liquid Jets issued by the Hauptverband der Gewerblichen Beruf sgenossenschaften gt The manufacturer s instructions and processing guidelines for coating or transfer materials are to be respected at all times This machine has been designed and manufactured under due consideration of all safety related aspects It corresponds to the current standard of technology and to applicable accident prevention regulations The machine left the factory in perfect condition and guarantees a high level of technical reliability and safety Nevertheless there are certain risks that can arise from incorrect operation or misuse to life and limb of the operator or third party to the machine and other material assets of the owner gt to efficient work with the machine Notice about additional documentation This user manual is only valid in combination with the following machine card The machine card contains all important and safety relevant data and informa tion about the machine exact designation and manufacturer data technical data and limiting values gt equipment and test certificate data of purchasing Machine identification machine components and accessori
25. ble gt Connect the air supply and ger open the air valve Insufficient air pressure Set the air pressure to 5 5 available 9bar Rear sealing nut excessively gt Slightly loosen the nut tightened 2 Spray fog on round jet noz gt Screws on front plate loose gt Tighten the screws on the zle even though the trigger front plate with a spanner has not be actuated gt The rear side of the front gt Clean the front plate and plate is soiled check for score marks Mix module bore worn Replace the mix module Translation of the original operating manual PU 460 13 2 1301_SV1016DV1016_BAoDB_ensski WiIVTA Malfunctions and Troubleshooting Recast wore Fault Possibleeause Remedy 3 Increased overspraying gt Excessive air flow to the gt Reduce the air flow with the front cap regulator Material pressure set too Reduce the material pres high sure 4 Round spray pattern forms The round jet nozzle is Clean the round jet nozzle fingers or is deformed soiled or worn with an appropriate drill Replace the round jet noz zle 5 Pressure fluctuations gt Mix module inlets and out Clean the mix module inlets lets soiled or worn and outlets with an appropri ate drill or replace the mix module Viscosity of components not gt Regulate the material tem uniform perature accordingly Filter element dirty gt Clean or replace the filter el
26. depends on the material to be pro cessed Consult your material manufacturer Disassembly 1 Disassemble the spray gun as described in chap 12 4 8 Disassembling the spray gun P 12 12 before you start the replacement 2 After removing the front cap _4_ the round jet nozzle 3 _ and the mix module 2 _ check the inlets and outlets of the filter element and the mix module for cleanliness and possible connection blockage Use a drill of appropriate diameter to remove possible material residues 3 Use the mix module size recommended by the material manufacturer for your spraying material Translation of the original operating manual PU 460 12 13 1301_SV1016DV1016_BAoDB_ensski PIFFA ional ipmen Optional equipment because it works 5 Description 5 Screws Y Fig 12 24 Assembly 1 Slide the module with the smaller diameter forward over the valve rod in the spray gun body _1 Carefully align the pin of the module in the recess of the module seat ring L Press the module firmly into its seat Fig 12 25 L Check the correct seat of the pin once again The pin must match the slot in the module seat mq Inlet Poly and Iso are slightly Rear view of the module offset to each Section A A other Attention Drill only in the middle of the module Do not drill directly through the module Fig 12 25 2 Check the round jet nozzle for cleanliness The nozzle can be cleaned
27. display 5 Notice The arrows indicate the current direction of rotation of the pump In parking position the pistons stop in bottom position L Press the ED button 5x to access the PARKING menu 1 Activate the button Parken by pressing _On Fig 8 1 Translation of the original operating manual PU 460 8 1 1301_SV1016DV1016_BAoDB_ensski WiIVTA Decommissioning because it works _1 Reduce the pressure by carefully pulling the trigger of the spray gun The pump switches off when the piston of the material pump has reached bottom position L Close the material valves on the spray gun Residual pres CA sure SO approx 100 bar 2 Switch off the heating only when required 5 Notice The heaters may remain activated in parking position if necessary This maintains the material in the system at a uniform temperature Fig 8 2 3 Shut off the material and compressed air supply on the spray gun as de scribed in chap 12 4 7 End spraying P 12 12 8 2 Deactivating parking Press the button Paren or switch off the equipment completely on the control cabinet 8 3 Take the system out of service Switch off the equipment completely if you want to take it out of operation for a longer time 1 Perform the work steps as described in chap 8 1 Activating parking P 8 1 Switch the heating off too On versons with material feed container you must first pump out all
28. e material to be applied is readily available Prepare the material by following the instructions of the material material manufacturer All materials to be sprayed must be supplied from the manufacturer with data concerning viscosity application temperatures mixing ratios etc If this is not the case consult the corresponding manufacturer and ask for these data For optimal preparation of the spraying materials we offer w WwA a wide range of accessories like e g agitators in various sizes material preheating containers The compressor power must match the air requirements of the equipment so that an adequate air supply is ensured see chap 14 1 Technical data P 14 1 The diameters of the air supply hoses must match the connections on the equipment 5 1 Setting up the unit Stand the unit on a level firm and vibration free base d Notice Consider the required floor space see chap 14 1 Technical data P 14 1 All operating elements must be easily accessible The access to the safety features must be kept clear 5 2 Assembling attachments and accessories Various system components were removed and packed in a separate cardboard box for transport heated hose package gt spray gun optional A Attention Material emerging from the connections can cause severe physical injuries and damage to property All connections must comply with the specified machine parameters Chec
29. e the flag into the text field The selected language is identified with a green bar further languages optionally available Fig 4 12 4 9 Brightness You can match the brightness of the display to the local condi tions by pressing the buttons Fig 4 13 4 10 Datalog The following information is saved to a USB stick Date gt Time gt Daily volume Temperature Poly Iso Hose Pressure Poly Iso Faults Total volume Fig 4 14 4 9 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA because it works 4 11 Alarm E Reset button Sz Menu Here you will be informed about possible malfunctions Once the malfunction has been eliminated it must be acknowledged with the The previously activated menu will appear again 1 Text line No Error Fig 4 15 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski 2 Text line 3 Text line 1 Text line Display of faults in case of overpressure excessive tem peratures defective hose heat ing or tripping of a fuse 2 Text line to display the pressure differ ential 3 Text line Display of malfunctions which may occur in the material flow heaters or in the hose package e g faults on the temperature sensor 4 10 WiIVTA Installation and Assembly ee emits 5 Installation and Assembly Prerequisites Th
30. eat up considerably and cause burn injuries on your hands You should therefore always wear appropriate protective gloves when hav ing to work on the adapter switch on when required if the electri cally connected load is not high enough switch to 1 2 The switch only lights during the heating phase Once the nominal temperature is reached the light in the corresponding switch goes out Attention This means that a lower heating power is also possible Fig 7 4 Notice If the pressure of the metering pump is set too high during the heating phase the pressure of one of the components may increase to overpres sure ad thus switch off the equipment You should therefore ensure a low pressure setting 5 Pressure equalization of both components Due to the differences in material characteristics of and IKIM com ponents the pressure in the system may have increased differently during the heating phase For optimal working results we recommend a maximum pressure difference of 10 20 bar between both components Translation of the original operating manual PU 460 7 3 1301_SV1016DV1016_BAoDB_ensski W V A ration Operatio because it works max differential pressure Pressure display Fig 7 5 _1 To relieve the pressure open the valve of the component with the higher pressure n P ey Use a collecting vessel for the corresponding compo a gt nent L After this pressure compensatio
31. ements gt Check valves dirty Clean or replace the check valves Gelated or hardened mate gt Incorrectly directed material gt Clean or replace the check rial in the air channels to the air in hoses valves front cap Material emerges from the Sealing nut loose gt Slightly tighten the sealing back side seal nut Back side seal worn or dam gt Replace the backside seal aged Rapid build up of material on gt Insufficient air flow to the Increase the air flow to the the round jet nozzle or the front cap front cap front cap Spray gun triggers only very gt O rings dry or worn Wet the spray gun with spray gun oil Replace and lubricate the O rings 10 Pressure loss on air outlet Damaged O rings on slide Replace the O rings on slide valve valve Damaged O ring on piston gt Replace the O rings on piston 13 3 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski PTRA Malfunctions and Troubleshooting because it works 13 3 Error messages on the control cabinet Fat Possiblecause Remedy 1 Display readings gt Mixing element clogged on Dismantle the spray gun and Overpressure Iso the Poly side relieve the valve of the Poly component gt Spray gun filter Poly Clean spray gun filter Poly clogged Dirt trap Poly clogged Clean dirt trap Poly gt Sensor cable Poly not con gt
32. ent of the material hoses can be identified by a colour marking Translation of the original operating manual PU 460 5 2 1301_SV1016DV1016_BAoDB_ensski WiIVTA Installation and Assembly Because st work Compressed air Druckluft Fig 5 2 2 Connect the electric supply cable d Notice The operating voltage of the hose package is defined by the plug of the temperature sensor Plug temperature sen sor pos 4 Fig 5 1 Low voltage gt 230 V 2 pins assigned arrangement in dependence on operating voltage Plug heater hose pa 4 pin gt 230V ckage pos 5 Fig 5 1 gt 400V gt Connect the plug Place the plug Thereby ensure opposite arrangment of plug to the associated cable This prevents the plug cable from being damaged in case of a possible tensile load acting on the hose package Fix the connection with adhesive tape 5 3 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski because it works E f WA Installation and Assembly 5 2 3 Connection spray gun to the hose package Connect the spray gun to the hose package d Notice Take notice and follow the notes in chap 12 4 4 Connect the spray gun to the hose package P 12 10 or in the associated operating instructions for the spray gun used 5 2 4 Connection feed pumps 1 Open the bungholes on the material drums 2 Insert the feed pumps into the material dru
33. ention instructions Translation of the original operating manual PU 460 3 3 1301_SV1016DV1016_BAoDB_ensski WiIVTA m Description Syste escriptio because it works 3 6 Storing the machine and additional equipment Store the machine in a frost free vibration free dry and possibly dust free environment The machine and its implements must under no circumstances be stored outside closed rooms 3 Disposal of the machine and additional equipment Clean the unit thoroughly of all material residues Disassemble the entire unit and separate the materials L Take metal parts to scrap metal services _1 Plastic parts can be disposed of through the household waste gt Rests of spraying material cleaning agent oils greases and other chemi cal substances must be collected in accordance with statutory provisions concerning recycling and waste disposal The official local waste water laws are valid 3 8 System variants optionally N for 2001 drums optionally with feed pumps ee HO with gt diaphragm pumps T ig hose bracket Fig 3 2 Sik gt Circulation gt piston pumps gt owe gt Relief Fig 3 3 optionally a with 301 drum capacity with feed drum a Fig 3 4 optionally with hose bracket gt Circulation gt Relief 3 4 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA because it works 3 9 System description 3 9 1 Without circ
34. eratures for both material flow heaters and for the hose package are adjusted by entering the temperature on the control cabinet of the system The automatic temperature control prevents overheating of the material Depend ing on local conditions concerning electric power supply the power level for the material flow heaters can be reduced Translation of the original operating manual PU 460 3 7 1301_SV1016DV1016_BAoDB_ensski W1 IV A m Description Syste escriptio because it works 3 10 System components optional Version with feed pump OmGE a Poly Iso 62 6 ool m So i mp e e optional optional Fig 3 7 3 8 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA because it works System Description LS Metering pump Air motor 1 2 Material pump Control cabinet See chap 3 11 Control cabinet P 3 10 fet 3 mz Distributor Material hose connection Material pressure gauge Connection material hose hose package Connection compressed air hose spray gun Pressure sensor Return flow relief hose with material shut off valve optional l for circulation relief 7 Maintenance unit l Compressed air connection Connection of compressed air line to metering pump controller Connection of compressed air line to metering pump controller l Connection of compressed air line to feed pump controller l Deicing of control v
35. ere 7 1 o DECOMMISSIONING sensis aa aa 8 1 8 1 Activating parking 8 1 8 2 Deactivating parking 8 2 8 3 Take the system out of service 8 2 8 4 Shutting down the equipment 8 5 8 5 Pressure relief 8 5 8 5 1 Without circulation and without relief hoses 8 5 8 5 2 With relief hoses optional 8 6 8 5 3 With circulation optional 8 6 8 6 Cleaning after spraying 8 7 8 6 1 Cleaning the system 8 7 8 6 2 Cleaning the spray gun 8 7 1301_SV1016DV1016_BAoDB_enseski WIA because it works Contents 9 Barel change sisone a EEES 9 1 9 1 Without circulation 9 1 9 2 With circulation optional 9 3 10 Material Change iscia ENa aai 10 1 TI Mamt antE senansa a a a e ai a ala a a a a a aa 11 1 11 1 Check cycles 11 1 11 2 Important notes 11 1 11 3 Maintenance unit 11 2 11 3 1 Components of maintenance unit 11 2 11 3 2 Check lubricant 11 2 11 3 3 Adjusting the fog oiler 11 3 11 3 4 Draining the condensation water 11 3 11 3 5 Notes on oil reservoir and water separator 11 4 11 4 Release agents 11 4 12 Optional equipment cceeeeeeeeeeeeseeeeeneeeeeseceesseeeessoeesseeeesseeenneeeenees 12 1 12 1 Circulation 12 1 12 1 1 Circulation circuit 12 1 12 1 2 Circulation ventilation 12 1 12 2 Silicagel filter 12 4 12 3 Mounting kit USB port 12 6 12 4 Spray gun 12 8 12 4 1 Spray gun components 12 8 12 4 2 Safety features 12 9 12 4 3 Notes on operation 12 9 12 4 4 Connect the spray gun to the hose package 12 10 12 4 5 Check spray gun 12 11 12 4 6
36. es with article and spare parts numbers Notice The data on the machine card must match the data on the type plate In case of discrepancies or if the type plate is missing please notify us imme diately Translation of the original operating manual PU 460 1 1 1301_SV1016DV1016_BAoDB_ensski RTEA Safety Information j because it works 2 Safety Information Please remember that dual component systems work with extremely high pres sures and may cause life threatening injuries if used inappropriately Always pay attention to and follow all notes in the user manuals for the option ally offered accessory equipment 2 1 Pictogrammes The notices and symbols used in this manual have the following meanings Danger marks a potentially dangerous situation Disregarding this information can result in severe or even fatal injuries Attention marks a potentially dangerous situation Disregarding this information can result in severe injuries Caution marks a potentially dangerous situation Disregarding this information can result in minor injuries A A A Caution marks a potentially dangerous situation Disregarding this information can result in material damage Risk of explosion Highlights a situation with potential danger of explosion Disregarding this information can result in severe or even fatal injuries Danger of electric shock Highlights a dangerous situation caused by electrostatic charge
37. essure 20bar 2s differential Pol a so e O o 2 Fig 14 3 14 4 Operating means 0640616 0 51 0633538 51 Lubricant acid free grease 0 4kg 0000025 Anti freeze agent 0 51 0631387 Pneumatic oil 0 51 0632579 14 3 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA because it works Appendix 14 5 Tools The tool does not belong to the scope of delivery of the equipment but can be purchased optionally after consultation with W WA Designation Ed Assembly to on Open end spanner SW 17 Compressed air line to spray gun SW 19 Return flow distributor SW 22 Material hoses spray gun SW 30 Return flow hoses material drum Tool set for spray gun 1 Connection block spray gun Order No 0654521 Translation of the original operating manual PU 460 14 4 1301_SV1016DV1016_BAoDB_ensski WiIVTA because it works Appendix 14 6 Accessories The accessories do not belong to the scope of delivery of the equipment but can be purchased optionally after consultation with W W 0654652 Hose bracket mounting kit for 15m 30m 45m hose package 0654696 Hose bracket mounting kit for 60m 75m 90m hose package 0654481 Diaphragm pump 0654897 Piston pump 2 1 0654676 Mounting kit with stainless steel con tainer 0654688 Mounting kit relief 14 5 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski FTA because
38. gulations are found in the corresponding user manuals for the accessories If foreign accessories or spare parts are used the company 734 cannot guarantee the safety of the entire system Similarly liability is null and void for damages or injuries incurred through use of those accessories and spare parts Translation of the original operating manual PU 460 3 1 1301_SV1016DV1016_BAoDB_ensski RTEA m Description Syste escriptio because it works 3 3 Plant environment 3 3 1 Emissions Depending on which materials are processed hazardous fumes may be gen erated For this purpose always ensure for sufficient aeration and ventilation at the workplace for avoiding damage to your health and property You should always follow the processing information issued by the material manufacturers 3 3 2 Sound pressure level The sound pressure level of this unit is less than 85 db A However operating personnel should still be provided with suitable noise protection equipment The operator is responsible for adhering to noise and vibration protection regulations For this purpose pay special attention to the conditions of the setting up location e g will the noise exposure increase if the system is set up in or on hollow bodies 3 4 Transport Notice 1 The systems leave the factory in flawless condition and are appropriately packed for transport Upon arrival you should check the system for any apparent transport da
39. h components is exceeded see chap 4 2 3 Pressure settings P 4 3 The total quantity counter cannot be reset 139329223222 139323 9 a gt Selected unit Fig 4 10 4 7 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski FTA Menu because it works 4 7 Activate deactivate parking Notice 1 You should always move the equipment to parking position when interrupting work or at the end of work to prevent the system from being damaged by cur ing of material Fig 4 11 Symbol E Activating deactivating the standby mode for the unit Display Parking mode active Display Parking mode deactivated The display P no longer shows this symbol Further possibilities for deactivation Reset the malfunction with the RESET lt Restart the system with O The arrows indicate the current direction of rotation of the me tering pump In parking position the metering pump remains in bottom posi While approaching the parking position you are asked to check the material pressure of both components The parking position has been reached The display shows the symbol P in the right hand top corner Translation of the original operating manual PU 460 4 8 1301_SV1016DV1016_BAoDB_ensski Menu E ZA because it works 4 8 Language selection You can choose the language to guide you through the display For this purpose click abov
40. he spray gun once again 3 Close the air pressure valve and pull off the compressed air hose 4 Loosen the fastening screws on the connection block 12 4 9 Spray gun maintenance 12 4 9 1 Lubrication 12 12 Lubricate the air inlet every day with 2 3 drops of spray gun oil Lubricate the grease nipple regularly with grease until clean grease appears in the module receptacle Grease Fig 12 22 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski because it works 7 WA Optional equipment 12 4 9 2 Filter change Soiled or damaged material filters can cause malfunctions in the spraying process such as e g overpressure of a component You should therefore clean the filters in regular intervals Use the material filters recommended be thy material manufacturer for your spraying material Make sure that each O ring that is applied to the filter is clean and free of damage 4 Notice The filter size depends on the mix module used Fig 12 23 12 4 9 3 Changing the mix module Replace the mix module before it is worn Using a worn module will cause extremely high paint consumption and adverse ly affects the quality of material application i Notice Filter and mix module must always be kept clean to avoid malfunction of the spray gun Notice e Mix module and round jet nozzle as well as cleaning drill must be matched to each other The size of the mix module
41. i WIVTA Barrel chan arrei Change because it works 9 Barrel change Change material drum before it is completely empty Never allow the system to run empty This prevents the intake of air which could cause faults in the pressure build up for both components and crystallization of the isocyanate The heating can remain switched on during the barrel change Notice Ensure correct component allocation at all times The following is required XC P 9 1 Without circulation 1 End spraying process ORP ma am K Fig 9 1 2 Exchange empty material drums for full ones Place the feed pumps securely into the filled material drums 3 Ventilate the system Possibility 1 Catch the material in the empty collecting vessel Disassemble the spray gun from the connection block as described in chap 12 4 8 Disassembling the spray gun P 12 12 9 1 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA Barrel chan because it works aha age Compressed air regulator Metering pump Use a collecting vessel for the corresponding com ponent Open both material shut off valves until material runs out bubble free and noiseless 1 to 1 revolutions Fig 9 2 Possibility 2 Pump the material back into the material drum Disassemble the spray gun from the connection block as described in chap 12 4 8 Disassembling the spray gun P 12 12 Pressure Co
42. ir control 3 7 3 9 5 Temperature control 3 7 3 10 System components 3 8 3 11 Control cabinet 3 10 3 11 1 Components on the control cabinet 3 10 3 11 2 System control 3 11 1301_SV1016DV1016_BAoDB_ensski WIVTA Contents because it works A NTR ieee tect tects deer ete seceee eeoceeee tetera cesta cose enewaceyedae 4 1 4 1 Welcome screen 4 1 4 2 Pre settings 4 1 4 2 1 Units for display values 4 2 4 2 2 Master settings 4 2 4 2 3 Pressure settings 4 3 4 2 4 Stroke counter setting 4 4 4 2 5 Time settings 4 5 4 2 6 Ending the Master setting 4 5 4 3 Actual temperature large display 4 6 4 4 System status 4 6 4 5 NOMINAL temperature 4 7 4 6 Stroke counter 4 7 4 7 Activate deactivate parking 4 8 4 8 Language selection 4 9 4 9 Brightness 4 9 4 10 Datalog 4 9 4 11 Alarm 4 10 5 Installation And ASSCMDIY cccsccceesseeeseeeeeeeeeeeeeeeeeeeeneeeeneeeeseeeeneeneneeneaes 5 1 5 1 Setting up the unit 5 1 5 2 Assembling attachments and accessories 5 1 5 2 1 Connecting the hose package to the adapter 5 2 5 2 2 Connecting individual hose package segments 5 2 5 2 3 Connection spray gun to the hose package 5 4 5 2 4 Connection feed pumps 5 4 5 3 Check the condition of the release agent 5 4 5 4 Ground the system 5 5 5 5 Electric connection 5 5 5 6 Compressed air connection 5 6 60 COMMISSIONING csi ciserpecinncets nage antitteemcmeenmateameceanmeasendsmdeusesdreecaanneteeccions 6 1 lO ol 1 1 o Aare eee eee ener te E crt ere merc mente mer c
43. it works 5 6 Compressed air connection Connect the unit to the local compressed air supply fy N Pressure Compressed gt eta boa bar air regulator 3 o Swor C re EJ Feed Pump Compressed air connection oy on either side Metering pump Fig 5 8 Notice The air inlet pressure in this system is monitored If the minimum pressure value is fallen short of over a period of 1 s the sys tem will automatically shut down Result The machine has been set up for initial start up Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_en sski Installation and Assembly Commissioning WIVTA because it works 6 Commissioning 6 1 After assembly in the factory the correct functioning of this machine was checked with a testing medium All material hoses and the metering pump must first be filled with the material to be applied The entire system can first be flushed with the cleaning agent recommended by the material manufacturer and belonging to the material before it is filled with the material to be applied to make sure that the spraying material is not con taminated by the testing medium Prerequisites The unit has been set up and connected as specified in chap 5 Installation and Assembly P 5 1 The following is required 1X 1x gt if required T cleaning material Iso Poly Always wear the specified protective clo
44. it works Appendix Order No Description i 0654689 Mounting kit circulation 0654943 Mounting kit silicagel filter for feed pump without return flow 0654954 Mounting kit silicagel filter for feed pump with return flow 0654457 Mounting kit USB port 0654671 Protection hood for control cabinet 0654522 Reverse flow spray gun 0654784 Protective hose black with velcro closure without no picture N insulation for hose package 0654785 Contamination protection transparent no picture for hose package 0654896 Heating sleeve for 200 drum 0654435 Protective film for small display 0654436 Protective film for large display 0653560 Counterflow gun Probler P2 no picture 0654523 Mounting kit for spray gun connecting i nipple 0653560 Translation of the original operating manual PU 460 14 6 1301_SV1016DV1016_BAoDB_ensski Appendix 14 7 WiIVTA because it works der No Description OO 0000393 Filter against organic inorganic va no picture pours for respiratory protection mask type 3M 0000286 Visor protection film for respiratory no picture protection mask type 3M 14 7 Instruction Certificate This certificate follows the EC Directive for working utensils 85 655 EEC section II article 7 The owner of the device specified below has instructed the operating personnel Yearofoonstucon OOS Seimu OOO O The instruction was conducted by the representat
45. ive of the owner Foreman or respon sible superior name department The instructed person has read and understood the user manual for the equip ment listed above especially the chapter about safety and declares that he is able to operate the unit in a safe way Personnel for Date name Operation Repair and maintenance Electrics electronies Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_en ski Headquarter and production WIWA Wilhelm Wagner GmbH amp Co KG Gewerbestr 1 3 35633 Lahnau Germany Tel 49 6441 609 0 Fax 49 6441 609 50 E Mail info wiwa de Homepage www wiwa de WIWA partnership in USA WIWA LP 107 N Main St P O Box 398 Alger OH 45812 Tel 1 419 757 0141 Fax 1 419 549 5173 Toll Free 1 855 757 0141 E Mail jwold wiwalp com Homepage www wiwalp com WIWA subsidiary in China WIWA Taicang Co Ltd Building A of Huaxin Industrial Park No 11 East Qingdao Road Taicang City Jiangsu Province 215400 P R China Tel 86 512 5354 8858 Fax 86 512 5354 8859 E Mail info wiwa china com Homepage www wiwa china com
46. k all rotatable parts nuts screws and hose connections and tighten these properly 5 1 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA l Installation and Assembly because it works 1 Check the permissible highest pressure for material hose spray gun and ac cessories It must be higher than or equal the maximum operating pressure of the equipment as specified on the type plate or the machine card 2 Compare the maximum operating pressure of the safety valve with the speci fications in the machine card or the type plate These data must match 5 2 1 Connecting the hose package to the adapter Connect alls hoses and cables to the adapter as follows Fig 5 1 viewed from the front towards the control cabinet os Designation O Material hose IKIM 3 Material hose 3 Compressed air hose for spray gun Plug of temperature sensor 4 Plug for hose package 5 heater 5 2 2 Connecting individual hose package segments Connect the individual hose package segments Fig 5 2 The hose package can be made up of several hose package segments of 15m each The individual hose package segments are colour marked Notice Only connect at most the permitted number of hose packages of the same type so that an optimum power distribution is guaranteed across all phases Example for 400 V max 3xL1 3xL2 3xL3 1 Connect material hoses In each hose package segment the assigm
47. klift eyelet 3 5 Place of installation of the machine gt The 7 7 DUOMIX PUYEO can be installed inside and outside spray booths and rooms However outdoor installation should be preferred in order to avoid contamination Protect the equipment against rain and wetness Do not store outside gt The machine must only be taken into service under frost free weather condi tions to avoid crystallization of material and thus damage to the equipment gt The owner must protect the entire system by undertaking appropriate light ning protection measures Attention If the unit is used outdoors a lightning can cause a dangerous situation for the operator Never operate the unit outdoors when there is a thunderstorm This system requires a solid base and sufficient free space for safe operation The access to the safety features must be kept clear At the place of use apply the parking brake for the wheels Fig 3 1 Always keep the working area especially all walkways and standing areas clean and tidy Clean up spilled paint or cleaning agents immediately gt Always ensure for sufficient aeration and ventilation at the workplace to avoid damage to health and material objects Always observe the processing instructions issued by the material manufac turers Protect a objects adjacent to the spraying object against possible damage caused by the paint mist gt Strictly comply with the valid accident prev
48. les the seamless and jointless application of coatings and linings Your dual component system was designed to meet your special requirements material to be applied mixing ratio transfer quantity etc Exact metering of both components is assured by the fixed mixing ratio The mixing ratio can only be changed by exchanging the material pumps Any other use is deemed to not be in accordance with regulations The manufacturer s approval must be obtained before vwa units are used for any other purpose or with other materials i e not in accordance with the intended use otherwise the warranty will become null and void Intended use also includes compliance with the technical documentation and adherence to the prescribed operating servicing and maintenance guidelines 3 2 Notes on warranty Unauthorized conversions or alterations should not be undertaken on safety grounds Protective equipment should not be dismantled converted or bypassed Use of components which have not been manufactured or delivered by w a renders any warranty null and void The unit should only be operated within the prescriptive limit values and ma chine parameters Notice Dangers caused by accessories and spare parts If you use original 7MA accessories and spare parts their suitability for use with our equipment is guaranteed It is however mandatory to respect the safety regulations of the accessories and spare parts These safety re
49. lied Open the compressed air and material stop cocks on each feed pump Ao v Fig 7 2 3 Adjust the compressed air supply Notice The specified pressures are only guide values and depending on the vis cosity of the material or the hose length used may need to be adapted Pressure Compressed air bar regulator Metering pump Ensure slow running of the pump 4 Switch on the heating system L Roll out the hose package completely L Adjust the desired temperature in the display In this respect follow the notes in chap 3 11 Control cabinet P 3 10 mie Adjust the temperature for material flow heaters and hose package Press 3X Fig 7 3 7 2 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA ration because it works Operatio L Switch on the heating Wait until the material has been heated up to spraying temperature d Notice The nominal temperatures of the material flow heaters are reached much faster than the temperatures of the hose package Therefore switch on the hose package first and the heater for the material flow heating with a slight delay To be able to achieve an optimal spraying result the entire system includ ing the hose package must have been heated up to the pre set tempera ture before spraying is started Danger of burning Depending on the set temperature the outer surface of the adapter can considerably h
50. m pressed air regulator Only open the material valve of one component 1 to 1 turns Duration until noiseless bubble free material starts to run out Fig 9 3 6 Thoroughly clean the material outlet opening on the connection block before repeating the procedure with the other components Translation of the original operating manual PU 460 9 2 1301_SV1016DV1016_BAoDB_ensski WiIVTA Barrel chan arreli Change because it works 4 Operation You can now resume normal operation as specified in chap 7 Operation P 7 1 4 Notice Pay attention to the pressure equalization of both components 9 2 With circulation optional 1 End spraying process e Poly A s Fig 8 11 2 Exchange empty material drums for full ones _ Place the feed pumps securely into the filled material drums L Mount the return flow hoses and secure them against accidental slipping out Screw fitting return flow on Screw fitting return flow on drum lid silicagel filter on drum lid of Iso of Poly component optional components optional Fig 9 4 3 Ventilate the system 9 3 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski PTRA Barrel chan because it works ae enang Pressure Com pressed air regulator A e won 3 Metering pump Close ball valves as soon as bubble free noiseless material starts to run out Fig 9 5 4 Taking the system into se
51. mage Disconnect the entire power supply for the machine even for short transport distances gt Empty the machine before transport Do not transport any other objects e g material drums while lifting or load ing the machine gt Remove all loose components e g tools from the unit gt Caution when loading with hoisting gear L Ensure sufficient load bearing capacity of lifting gear and lifting tackle when loading the machine _1 The system must only be lifted by the lifting and lashing points provided for this purpose Fig 3 1 L Watch out for freely suspended suspension ropes L When using a forklift truck make sure that the lifting fork is long enough at least 100cm The lifting fork must only be inserted into the rack from the front towards the control cabinet and through all fork openings Fig 3 1 L Never stand under suspended loads or inside the loading area This poses a danger to life gt You will find the dimensions and weights of the equipment on the machine card gt Secure the load on the transport vehicle against slipping and falling off 3 2 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA tem D ription because it works Syste escriptio Parts or equipment that have been removed for transport purposes must be attached professionally and in accordance with the intended use before com missioning Crane eyelet Parking brake For
52. material 8 2 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA Decommissioning because it works n A Fig 8 3 2 Regulate the compressed air controllers on metering pump and feed pumps completely back 5 Notice The compressed air settings for the spray gun can remain unchanged H N Pressure Compressed U J bar air regulator a e oman ZN Fig 8 4 4 Switch off the system Switching off the system press the green button Lamps L1 L3 go out a ze a on Fig 8 5 A Attention The system remains pressurized to avoid crystallization of material in the material hoses Any unintended escape of material from the spray gun can cause damage to persons Do not open any shut off ball valves or valves Translation of the original operating manual PU 460 8 3 1301_SV1016DV1016_BAoDB_ensski WIVTA Decommissioning because it works 5 Clean the spray gun as specified in chap 12 4 10 Cleaning the spray gun P 12 15 6 Put the feed pumps into storage only for designs with feed pumps The suction hoses of the feed pumps remain in the material drums or are stored for transportation in the receptacles fill with release agent In this case you must close the bungholes on the material drums Notice The receptacles for the feed pumps must always be filled with release io up to 3 cm below
53. ms Ensure horizontal mounting position and secure hold of pumps We recommend assembly on a drum lid d Notice Ensure correct component allocation at all times blue Poly components Folyol 3 Connect the material and compressed air sides of the feed pumps to the external material containers or fill the material to be applied into the feed funnels Notice The Iso material has a tendency to crystallizing when coming into contact with humidity We therefore recommend to have the material container for this component additionally fitted with an optional w w silicagel filter see chapter chap 12 2 Silicagel filter P 12 3 Please observe the notes of the material manufacturer 4 Guide the return flow hoses optional into the corresponding material drums and secure them against accidental slipping out Screw fitting return flow on Screw fitting return flow on silicagel filter on drum lid of Iso drum lid of Poly component components optional optional Fig 5 7 5 3 Check the condition of the release agent Check the release agent level see chap 11 4 Release agents P 11 4 Translation of the original operating manual PU 460 5 4 1301_SV1016DV1016_BAoDB_ensski WiIVTA Installation and Assembly SE 5 4 Ground the system A Caution The high flow velocities associated with the Airless spraying method may cause static charging Static charges can cause fire and explosion Both the
54. n close the valve again Fig 7 6 6 Mounting the spray gun Mount the spray gun to the connection block Fasten the return flow hoses to the material container Follow the notes in chap 12 4 4 Connect the spray gun to the hose pack age P 12 10 7 Adjust the desired spraying pressure Pressure Compressed air bar regulator ja 6 Feed Pump Metering pump 8 Start spraying L Unlock the spray gun L Start the spraying process on a test area away from the area to be covered Observe the chap 12 4 6 Start spraying P 12 11 7 4 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski because it works E f WA Decommissioning 8 Decommissioning Switch off the equipment if you want to interrupt work If coating is to be continued with the material in the system you must return the unit to parking position In case of longer work breaks and or when changing materials the equipment needs to be shut down Notice To avoid malfunctions of the equipment you should take notice of the following Never allow the system to run empty Do not use any solvents Make sure that the system is in parking position The following is required Always wear the specified protective clothes 8 1 Activating parking For short work breaks you may just switch the equipment to parking position The material temperature can be maintained 1 Activate parking in the
55. n of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA tional equipment because it works Op ote ee oe Occurring malfunctions are saved numerically in a alarm register Example of data saved to the stick TIME Vol_tag Dati Temp_Poly_ Temp_lso_Di Temp_Schlat Druck_Poly_ Druck_lso_D Alarmregiste Alarmregiste Vol_ 16 15 29 28 21 53 5 86 75 0 0 16 15 32 28 21 53 5 86 75 2 0 16 15 34 28 21 53 5 86 75 0 3 16 15 35 28 21 53 5 86 75 5 0 16 15 38 28 21 53 5 86 75 0 0 16 15 40 28 21 53 5 86 75 2 0 16 15 41 28 21 53 9 86 75 1 4 16 15 46 28 21 53 5 86 75 0 0 16 15 48 28 21 53 5 86 75 3 0 16 15 50 28 21 53 5 86 75 4 0 16 15 52 28 21 53 5 86 75 6 0 16 15 54 28 21 53 5 86 15 0 0 16 15 58 28 21 53 5 86 75 8g 0 16 16 00 28 21 53 5 86 75 2 0 16 16 02 28 21 53 5 86 75 0 0 Fig 12 12 In the alarm register each malfunction is saved with a code see following table This way you can assign a certain malfunction to each saved value Alarm register 1 Alarm register 2 Individual malfunction in the sys z Cable breakage and sensor fault tem 0 nomaffunction no malfunction Iso overtemperature Iso press sensor fault Pressure differential Poly higher than Iso Pressure differential Iso higher 7 than Poly 8 Insufficient compressed air supply A Translation of the original operating manual PU 460 12 7 1301_SV1016DV1016_BAoDB_ensski Optional equipment FTA because it works 12 4 Spray gun 12 4 1
56. nd Troubleshooting REE work 13 Malfunctions and Troubleshooting 13 1 General troubleshooting C Fat Possiblecause Remedy 1 The equipment does not Energy supply interrupted Ensure compressed air and no compressed air no elec electric power supply tric power supply Master switch in position gt Switch the master switch to OFF ON gt Equipment not switched on gt Switch on the equipment The material drum is empty gt Replace the material drum The intake is defective Replace the intake a pump draws in air The intake screen is clogged Clean or replace the intake screen Material feed pump s gt Repair the feed pump s are defective The feed pump does not The dirt trap before the mate Clean the dirt trap of the dual deliver any material into the rial inlet on the dual compo component system dual component system nent system is soiled Start The feed pumps work with out interruption no material comes out of the spray gun No pressure built up by a gt The bottom valve of the Disassemble and clean the pump during downwards pump without pressure is bottom valve stroke of metering pump soiled or defective gt Replace defective ball or The pressure of the other valve plate components rises No pressure built up by a The piston valve of the pump gt Disassemble and clean the pump during upwards stroke without pressure is le
57. nection block to the spray gun Make sure that the filter elements are seated correctly in the spray gun and that the O rings on filter element and connection block are present Grease the sur face to prevent sticking of the O rings Fig 12 17 12 10 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski because it works 7 WA Optional equipment 4 Connect the compressed air hose to the spray gun Fig 12 18 12 4 5 Check spray gun Before operation check the correct use of the spray gun Spray pattern regulating valve for spraying fog Front cap for leakages the rear seals on the nut for leakages Fig 12 19 Tighten the nut only so far that leakages are eliminated Do not overtighten Fig 12 19 12 4 6 Start spraying 1 revolutions l Fig 12 20 1 Open the material valves 2 Open the air pressure valve 3 Pull the trigger 4 Adjust spray jet regulating screw Translation of the original operating manual PU 460 12 11 1301_SV1016DV1016_BAoDB_ensski FTA because it works Optional equipment 12 4 7 End spraying Fig 12 21 1 Release the trigger 2 Connect the material valves to the connection block 3 to remove possibly adhering material plugs by pulling the trigger once again 4 Close the air pressure valve 12 4 8 Disassembling the spray gun 1 Connect the material valves to the connection block 2 Operate the trigger on t
58. press sensor gt Repair or replace cable Translation of the original operating manual PU 460 13 4 1301_SV1016DV1016_BAoDB_ensski PIA Malfunctions and Troubleshooting RE EE Fallt Possiblecause Remedy 7 Display readings Filter Iso clogged Clean Iso filter Material drum Iso empty Replace or fill the Iso Pressure differential Poly higher than Iso only in automatic mode Display readings Filter Poly clogged gt Clean Poly filter Pressure differential Iso gt Material drum Poly empty gt Replace or fill the Poly higher than Poly material drum only in automatic mode material drum Display readings gt Short circuit have fuse checked and acti Fuse has tripped gt Overloading of material flow vated by a skilled electrician heaters or hose package 10 Display reading Reset button pressed longer Release the reset button Reset blocked than 30 seconds 11 Display readings no temperature increase Have the hose 3m whip hose package heating despite the heating being inspected by a skilled System shuts down switched on electrician or replace it 12 Insufficient compressed air gt Air inlet pressure below 4 supply bar gt Set the air inlet pressure to min 4 bar Use acompressed air line Increase the compressor power gt no compressed air even Check and ensure the com
59. process We recommend to determine the following parameters before starting work Units for display values Fig 4 2 Master settings Master password protected Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski FTA Menu because it works 4 2 1 Units for display values E Press the corresponding button to choose the unit in which the values should be displayed Press iz again to return to the previous menu Fig 4 2 4 2 2 Master settings The menus with Maser access rights are used to adapt pressure and stroke counter settings d Notice maser and WWA are password protected The password is made available in a separate document Changing settings is strictly reserved for trained service personnel and the w wA Customer Service You can access the menu by 1 press iz 1 2 Enter your Master password and press ENT 2 to confirm the Mae display appears 2 Fig 4 3 Notice After logging in you can use Ed to navigate between the menus for settings pressure and stroke counter settings Translation of the original operating manual PU 460 4 2 1301_SV1016DV1016_BAoDB_ensski Menu 4 2 3 Pressure settings FTA because it works Upper limit for the maximum permissible material pressure for each component When exceeding a value the system will change to malfunction and switch off Value to start automatic pressure monitoring
60. rk on live power lines must solely be performed by professional electri cians and with the power shut off Locally valid regulations must be followed at all times lt ome INIA g Sa naD pe oe a AD NS F i ig dq i oF fon K k d Fig 13 1 Fuse in the control cabinet 1 Take the system out of service 2 Tip housing forward Fig 13 2 3 Open casing cover Fig 13 3 4 Replace fuse TE Fig 13 4 Translation of the original operating manual PU 460 13 6 1301_SV1016DV1016_BAoDB_ensski FTA because it works Appendix 14 Appendix 14 1 Technical data pneumatic motor Max inlet pressure a 8 Air consumption at bei 4 _ displacement _ Electric connection Phases ssi J 63 3 1 15m io 12 15m 2 L3 15m 2 2 2 Emitted sound pressure level at the work place in idle mode L dB 84 under load L 4 dB Dimensions length width height mm Version with feed pumps 990 x 730 x 1410 Version with feed pumps and hose bracket 1140 x 730 x 1470 Version with feed drum 1400 x 750 x 1410 Version with feed drum and hose bracket 1550 x 750 x 1470 14 1 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski PTRA because it works Appendix Version with pneumatic motor Spray gun optional max operating pressure bar min air inlet pressure bar max air inlet pressure bar min ma
61. rvice You can now resume normal operation as specified in chap 7 Operation P 7 1 1 Notice Pay attention to the pressure equalization of both components Translation of the original operating manual PU 460 9 4 1301_SV1016DV1016_BAoDB_ensski because it works Material change FF WA 10 Material change 1 Notice Exchange the material drum in due time against a full one to prevents the intake of air 1 Take the system out of service Perform all work steps as described in chap 8 3 Take the system out of service P 8 2 2 Clean the intake screen dirt trap Clean the material screen of each component on the metering pump or replace it if excessively soiled 3 Taking the system into service Perform all work steps as described in chap 7 Operation P 7 1 10 1 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA Maintenance because it works 11 Maintenance 11 1 Check cycles According to the accident prevention instructions for Work with fluid spraying equipment BGR 500 chapter 2 36 the unit needs to be regularly inspected and serviced by an expert w wa Customer Service The unit needs to be inspected before initial commissioning after the modification or repair of parts of the system which could affect safety after work breaks longer than 6 months gt but at least every 12 months For decommissioned units
62. st only be performed by trained personnel gt Be extremely careful when disassembling material hoses and spray gun gt When disconnecting material hoses you should cover the screw fitting with a cloth to catch any escaping material sprays gt Switch off the machine before starting maintenance and cleaning work on the unit and the spraying accessories oi ol g it i co oy a a X SS 2 3 2 Danger to health In closed or pressurized systems in which aluminium components or galva nized parts have contact with the cleaning agent hazardous chemical reactions may occur when using 1 1 1 trichloroethane TCE methylene chloride or other solvents containing chlorinated hydrocarbons CFCs If you wish to use the aforementioned solvents or varnishes and paints containing such solvents we advise you to consult the 7 customer service or 7A directly We would like to point out that we have a series of dual component systems in rust and acid proof design available for such materials 2 3 3 Notices on the permissible operating pressure The maximum operating pressure specified by us must generally be adhered to for all 71A parts e g pump heater hoses spray gun safety valve At varying operating pressures the lowest value is always valid as the maximum admissible operating pressure for the entire system General example Pump up to 250 bar Material hose up to 600 bar Spray gun up to 240
63. t be opened 1 turns and com pressed air must be connected When the spray gun is not in operation you must keep the air pressure adapters free of foreign particles Use only clean and dry compressed air to avoid the formation of droplets in the spray pattern The front plate of the spray gun must be very clean and free of score marks The front plate must remain attached at all times when the manual valves are open The front plate screws must be tightly fastened with a spanner Before starting spraying check the function of the trigger The spray jet and the air needed to clean the nozzle can be adapted with the spray jet regulating screw if required max 1 4 revolutions Translation of the original operating manual PU 460 12 9 1301_SV1016DV1016_BAoDB_ensski WIVTA ional ipmen Optional equipment because it works Consult the material manufacturer concerning suitable cleaning and flush ing agents Make sure that the cleaning agents will not cause swelling of the O rings Do not soak O rings or the mix module in solvents Solvents must solely be used for cleaning and should then be wiped off again immediately Never submerge the complete spray gun in solvent This could damage the O rings 12 4 4 Connect the spray gun to the hose package 1 Connect the material valves to the connection block Fig 12 15 2 Assemble the material hoses to the connection block Fig 12 16 3 Mount the con
64. tem is high enough spray gun is clogged in the spray gun 10 Compressed air escaping The air motor seals are worn gt Seal the air motor from the air motor at the guide axes When spraying the air motor gt The cross section of the Increase the cross section of of the metering pump runs compressed air supply line is the compressed air line jerkily too small The spraying pressure indicated by the pressure gauges and the air pressure drop when the spray gun is opened The air pressure inthe sup gt Increase the air pressure in ply network is too low the network 12 The air motor no longer The air motor control is de gt Have the air motor repaired works even though the fective by the wvwar Service compressed air supply is as sured Fuse for pneumatic valve Have the fuse replaced by a No material pressure avail defective skilled electrician according able in the system to the wiring diagram 13 The filling level of the release gt The seals on the material Replace the seals on the agent container and or the pumps are worn material pumps colour of the release agent changes 14 A material flow heater does gt Technical defect in the mate gt Have the material flow heater not heat up rial flow heater examined by a skilled electri cian 13 2 Troubleshooting on the spray gun C Fat Possiblecause Remedy 1 The valve rod does not trig gt No air pressure availa
65. terial flow in 06 max material flow i max fluid temperature C 14 G Compressed air connection l quick release coupling Connection of Iso component 14 NPSM Connection of Poly component M14 x 1 5 Dimensions length width height mm 17 15 6 67 10 8 Weight ko 14 2 Type plates Type plate on plant control cabinet Fig 14 1 J Ea Gewerbestrafie 1 3 C Please check that the type plate data are identical with svsuutestriccene rottennnnessir cerata miston nm Gerate Type unit Po those on the machine card cp Vont o elel FoF In case of discrepancies or if the type plate is missing please notify us immediately Type plate at the plant control cabinet Fig 14 2 WIW Eri Before connecting the unit to the mains supply check co 35633 Lahnau Germany whether the prescribed electrical data complies with Schaltschrank Control panel that available at the installation site call Sips Nennspannun g Voltage nom Nennstrom Rating nom Translation of the original operating manual PU 460 14 2 1301_SV1016DV1016_BAoDB_ensski Appendix WIA because it works 14 3 Factory default settings Designation Factory default setting Unit of temperature display C Unit of volume display Volume factor 0 264 NOMINAL temperature for 85 C Poly Iso hose Pressure settings max switch off 250 bar Scaling 250 bar Monitoring is 50 bar activated at Pr
66. the inspection can be postponed until the next com missioning The inspection results must be recorded in writing and kept until the next inspection The inspection report or a copy thereof must be available at the place of use of the equipment 11 2 Important notes A Attention Disassembling the pressurized spraying unit can Cause severe injuries to body and eyes Always switch off the equipment before starting maintenance and repair work Depressurize the the complete system gt Be extremely careful when disassembling material hoses and spray gun Before disassembly cover the screw connections on the material hoses with a cloth to catch possible material spatter Translation of the original operating manual PU 460 11 1 1301_SV1016DV1016_BAoDB_en sski WiIVTA Maintenance because it works 11 3 Maintenance unit 11 3 1 Components of maintenance unit 5 6 l d pA 6 a EEE eee a EHIE O wae 1 GE po o O a O O Sy E M S n a a O po TT a SS D a a A Fig 11 1 Pos Designation 0 6 Filo 8 ol 9 Connection compressed air ine to feed pumps Connection compressed air line to spray gun Water separator 11 3 2 Check lubricant Check the lubricant for the air motor in the container of the maintenance unit and top up slightly if required d Notice High humidity can cause icing of the motor In case of icing use pure anti freeze agent 11 2 Transla
67. thes Procedure Risk of explosion Heating up cleaning agents can cause an explosion This can cause severe injuries to body and eyes Do not switch on any heater when using cleaning agents 1 Prepare the material L Open the bungholes on the material drums _1 Insert the feed pumps into the material drums Ensure secure hold of pumps L Open the shut off valves for compressed air and material optional on each feed pump Fig 6 1 2 Disassemble the connection connection block from the spray gun see chap 12 4 8 Disassembling the spray gun P 12 12 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_en sski WIA Commissioning because it works 3 With optional version with circulation relief _1 Hold the return flow hoses into open containers to catch testing agent material mix L Secure the hoses against accidental slipping out 4 Switch on the equipment 1 Notice The air inside the system needs to be pressed out slowly You should therefore not yet apply any pressure to the metering pump Buttons L1 L3 light up O OFF omit switch on the unit oress the 4 4 p A a a Fig 6 2 5 Fill the metering pump with material Notice The specified pressures are only guide values and depending on the vis cosity of the material or the hose length used may need to be adapted io Pressure Compressed bar air regulator 0 5 Metering
68. through the heated hose package to the spray gun The hose package contains a compressed air line to supply the spray gun with compressed air as well as a material hose for each component with a 3m whip end Another temperature sensor is integrated in the whip end vL Mixing of material only takes place in the pneumatically controlled spray gun the spray pattern can be pneumatically influenced with the jet regulating screw as required The material flow is controlled by opening and closing the mixing chamber With the spray gun closed the material residue in the mixing chamber is mechanically forced out A material plug that may possibly be stuck in the outlet opening can be removed with the help of compressed air 3 6 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA tem D ription because it works Syste escriptio 3 9 4 Compressed air control v7 Fig 3 5 Fig 3 6 The compressed air supply provided by the customer is connected to the main tenance unit of the equipment From there the compressed air is directed to the metering pump the feed pumps and the spray gun The required working pres sure for the feed pumps spray gun and metering pump can be regulated by the pneumatic regulators on the control cabinet The maximum operating pressures must thereby be complied with see chap 14 1 Technical data P 14 1 3 9 5 Temperature control v8 Fig 3 5 Fig 3 6 The temp
69. ting granulate 1 Disassemble silicagel filter Eo Cn 0 vn Remove granu late from con tainer Fig 12 6 2 Dry granulate Drying is required in case of discolouration of the granulate from orange to colourless Drying temperature approx 130 C 160 C Renewed adsorption capacity after colouration from colourless to orange Caution Only heat up the granulate Heating up the complete filter can damage the housing Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_en sski EZ gf WA Optional equipment because it works 3 Install silicagel filter Fill the dried granulate DI Make sure the O ring is correctly fitted 65g into the container There must be no granu late jammed within the screw fitting Sie Fig 12 7 Translation of the original operating manual PU 460 12 5 1301_SV1016DV1016_BAoDB_ensski Optional equipment 12 3 Mounting kit USB port Mounting kit USB port p mm i menus tf Ji MZR ig 5 H i z i Fig 12 9 Fig 12 10 Fig 12 11 12 6 BTA because it works Plug the USB stick not included in the scope of delivery into the front panel of the control cabinet 2 ry the datalog menu with i 3 Press button Save data log Saving is in progress Loading active 5 Saving finished Download finis hed gt remove the USB stick Translatio
70. tion of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski because it works A z WA l Maintenance 11 3 3 Adjusting the fog oiler 1 Let the metering pump run slowly 2 Check 1 drop of lubricant after approx every 10 15 double strokes of the air motor If necessary adjust the regulating screw on the lubricator with a screw driver 3 Check the amount of oil in the oil container every day L The maintenance unit must never be operated without oil _1 The max oil level is indicated by a circumferential groove in the bowl L To fill the oil bowl loosen the filling screw and fill the reservoir directly 1 lubricant 10 15 double strokes Notice Only use the lubricants and anti freeze agents mentioned in chap 14 4 Op erating means P 14 3 11 3 4 Draining the condensation water 1 The accumulated condensate is automatically drained off through the drain valve For this purpose hold the hose into an empty collecting vessel 2 Check the bowl regularly for dirt residues and clean it as required Fig 11 3 Translation of the original operating manual PU 460 11 3 1301_SV1016DV1016_BAoDB_ensski FTA Maintenance because it works 11 3 5 Notes on oil reservoir and water separator 1 Disassembly L Press the slide down _1 Turn the bowl anti clockwise 2 Assembly L Make sure the O ring is correctly fitted 11 4 Release agents Notice 1 This work
71. ton Description OOO IC ent N teiomeen teen Ed back to the previous Systemstatus menu Temperature setting Stroke counter volume Pressure settings Master password i i Stroke counter Differential pressure monitoring settings master password Time settings master password Language selection Brightness WIWA settings WIWA password Translation of the original operating manual PU 460 3 11 1301_SV1016DV1016_BAoDB_ensski Menu 4 Menu BRITA because it works 4 1 Welcome screen F After switching on the system the display shows the welcome screen operation you can return to the welcome screen at any time by pressing Durin the E3 button Fig 4 1 In each other mask the following symbols may appear in the top right hand corner Attention A malfunction is reported To display the malfunction press button E on the display Observe and follow the notes in chap 13 Malfunctions and Trou bleshooting P 13 1 The system runs in manual mode Pressure monitoring is deactivated The system runs in automatic mode Pressure differential monitoring is deactivated Input changes in menu PRESSURE SETTINGS possible password protected Pressing button eg brings you to the menu fa The system is in parking position 4 2 Pre settings 4 1 F In this menu you can make influential settings for the work
72. ual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA ration because it works Operatio 7 Operation Prerequisite The unit has been prepared as specified in chap 6 Commissioning P 6 1 4 Notice Always observe and follow the warnings and data sheets of the material manu facturer Checklist Comecton cuang eating BR Maio alis avala at EN Compressed ar commocion amg closed Compressed arsupoy ag Be Electrical connection a Circulation relief closed optional System vented Separators Attention If the system does not switch off automatically in case of a malfunction pressure in the system may rise up to a dangerous level which could cause bursting of components and thus lead to severe bodily injuries and material damage Make sure that the equipment is never left unattended during operation In events of emergency you must be able to react instantaneously The following is required 1x gt 1x gt 2X Iso Poly s N y N A P N A N 4 4 N Always wear the specified protective clothes Translation of the original operating manual PU 460 7 1 1301_SV1016DV1016_BAoDB_ensski WiIVTA ration Operatio because it works Procedure 1 Switch on the equipment 7 VON O OFF al Buttons L1 L3 light up switch on the unit press the green button A Fig 7 1 2 Secure the material feed or fill the material feed funnels with the material to be app
73. ulation W WA 399 ie Fig 3 5 3 9 2 With circulation System Description Fig 3 6 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski 3 5 WiIVTA m Description Syste escriptio because it works 3 9 3 Material flow i Notice Ensure correct component allocation at all times blue Poly components Polyol Fig 3 5 Fig 3 6 Depending on the model range the material to be applied is directly filled into the feed drums or a feed pump is placed into the delivered drum 200 bung hole barrels of each component We recommend to equip the drum with the Ilso component isocyanate with an additional silicagel filter to prevent the material from reacting with humidity and thus crystallization of the material v2 Both components are fed to the metering pump and exactly metered with the respective mixing ratio see machine card L Each component is individually heated to the required processing temperature in a material flow heater The temperature is automatically regulated in accord ance with the temperature setting Preset top temperature limits make sure that the material will not be overheated For short breaks the heating may remain switched on v4 The material flow is controlled on the distributor a for spraying to the spray gun b to vent the system back into the delivered drum only optional v When spraying the material is directed
74. user Cleaning work instructed user Maintenance work personnel trained by wvwa Customer service Repair work personnel trained by wvwa Customer service 2 5 Protective equipment We would like to point out that the valid guidelines and stipulations depending on the work environment mining closed rooms etc must be respected in any case Always wear the protective clothes specified by the material manufacturer to avoid injuries The sound pressure level of this unit is less than 85 db A However operating personnel should still be provided with suitable noise protection equipment It is recommended that the operator should always wear a respiratory protec tion mask even though the paint mist has been minimized in Airless spray painting applications with correct pressure setting and working mode Wear protective goggles to protect against eye injuries caused by mechanical or chemical influences Wear protective gloves with lower arm protection to avoid burn injuries Translation of the original operating manual PU 460 2 6 1301_SV1016DV1016_BAoDB_ensski Safety Information FTA because it works 2 6 Safety features 2 7 All safety features must be checked before each start up of the equipment gt before starting work on or with the equipment after completion of setup work after cleaning and servicing work after maintenance and repair work Check list to check the s
75. with a drill of appropriate size 3 Apply a slight amount of grease to the round jet nozzle Slide the round jet nozzle over the mix module 4 Mount the front cap _ 5 _ over the round jet nozzle Fig 12 24 with the three screws 4 L Tighten the screws very tight SW8 L Slightly grease the front face of the front cap 12 14 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA ional ipmen because it works Optional equipment 12 4 10 Cleaning the spray gun 1 Disassemble the spray gun from the connection block Fig 12 26 2 Dismantle and clean the spray gun 6 Fitereement Fig 12 27 Remove all material residues from all parts and material conducting passages Notice Use a cleaning agent soaked cloth to remove deposits e g caused by spray ni fog from the spray gun Never submerge the spray gun in solvent for cleaning since this will cause damage to the O rings and the slide valve of the trigger 3 Clean the connection block Clean the outside of the connection block with a cloth soaked in cleaning agent Thoroughly remove any material residues from the material outlet opening 4 Grease the contact areas on spray gun and connection block 7 Notice Use only lubrication greases recommended by the material manufacturer Translation of the original operating manual PU 460 12 15 1301_SV1016DV1016_BAoDB_ensski WiIVTA Malfunctions a
76. xplosion This can cause severe injuries to body and eyes Pay attention to the flashpoint and the ignition temperature of the cleanin gagent gt Switch off the material flow heater if you need to perform the following work on the system Cleaning Pressure tests Preparation work Decommissioning Maintenance and repair 2 3 5 Danger caused by disregarding the explosion protection The system must NOT be operated in explosion protection zones Spraying equipment designed without explosion protection must not be used in workshops that come under the explosion protection ordinance 2 5 Translation of the original operating manual PU 460 1301_SV1016DV1016_BAoDB_ensski WIA Safety Information because it works 2 4 Operating personnel Juveniles under the age of 16 have no permission to operate this equipment The owner of the machine must ensure that the user manual is made available to the user and make sure that the user has read and understood its contents Setup cleaning maintenance and repair work Before starting work you must interrupt the compressed air supply to the machine Make sure that the machine is free of residual pressure in both the air and the material side After the completion of work you must in any case check the function of all protective devices and the correct function of the machine Activity Qualification of personnel Setup work instructed user Service work instructed

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