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Operation Manual WIWA DUOMIX 230

1. t Compressed air connection Fd ERN NN S S NP T E i j I M System description 4 6 E 5 1 Ero Bi 5 1 Closed 7 Stop Flush gt e CO e e e Le none ao Ol Translation of the original operation manual DUOMIX 280 37 A DUOMIX230S en 1001 cf System description DUOMIX 230 on stationary rack 1 3 k os L a Od ED TI L ressed airm Comp E connection Position 1 1 Air motor 1 2 Material pump 1 3 Safety valve 1 4 Rack 1 9 Maintenance unit 1 5 1 Compressed air regulator 1 5 2 Compressed air shut off valve 1 5 3 Inspection glass 1 5 4 Drain valve seit _ I i i 1 1 Closed ig mi p Os I EN io rt i Open n B O 8 1 1 N v i rs H a0 m 5 a 1 6 High pressure filter 208 8 MI e 1 7 Return flow hoses Af JH 154 8 1 Standard mixer li pa gl ele 8 1 1 Lever Return flow du CN Stop Flush 45 8 1 2 Lever Spray Stop Flush dT T EN mon 8 a 8 1 optionally depending on customer s request NM I 154 ls ose 337 7A Translation of the original operation manual DUOMIX 230 13 DUOMIX230S en 1001 cf 3 System description DUOMIX 230 on 2 wheel rack 1 4 2 Oi e Fe 7 A
2. Step 2 Version with material flow heater Regulate the temperatures on material flow heat ers drum floor heaters and hose heaters com pletely back Step 3 Turn the compressed air regulator chapt 3 Pos 1 5 1 on the service unit back until it is light to move DUOMIX230S en 1001 cf Step 4 Version with pressure and dosing monitoring chapt 3 Pos 2 Setthe selector switch chapt 3 Pos 2 5 to MANUAL Setthe lever standard mixer Fig 7 1 1 Pos 8 1 2 external mixer Fig 7 1 2 Pos 8 2 2 to FLUSH The lever standard mixer Fig 7 1 1 Pos 8 1 1 external mixer Fig 7 1 2 Pos 8 2 1 remains in position CLOSED Return flow closed Figure 7 1 1 Step 6 Version with distributor Setall switches SPRAY to OFF and all switches FLUSH to ON For flushing the distributor set the switch FLUSH distributor to ON e On the distributor all switches SPRAY must be in position OFF Step 7 Setthe pressure regulators chapt 3 Pos 6 1 for the flushing pumps to a lower pressure Step 8 Open all spray guns as well as the flushing gun until clean solvent comes running out The complete mixing block the static mixer the distributor the material hoses and the spray guns are thereby cleaned The material inside the system up to the mixing block components A B may remain in the system because no curing will occur Do not use cone top c
3. e On the version with pressure and dosing moni toring option press the start button Fig 5 1 3 Pos 2 4 for a short moment e Set the lever standard mixer Fig 5 1 2 Pos 8 1 2 external mixer Fig 5 1 4 Pos 8 2 2 to STOP FLUSH e Set the lever standard mixer Fig 5 1 2 Pos 8 1 1 external mixer Fig 5 1 4 Pos 8 2 1 to OPEN Return flow open e Pump the solvent residues out of the system through the return flow hoses chapt 3 Pos 1 7 A B into the containers D until the mate rial to be applied starts to run out Keep holding the return flow hoses Version with filling funnel chapt 3 Pos 3 e Fill the material to be applied into the filling funnels chapt 3 Pos 3 A B e Open the ball valve Fig 5 1 1 Pos 1 5 2 on the service unit e Adjust the pressure regulator Fig 5 1 1 Pos 1 5 1 to a pressure of approx 0 5 1bar e Set the control button chapt 3 Pos 5 1 for the material flow heater option to the desired temperature e On the version with pressure and dosing moni toring option press the start button Fig 5 1 3 Pos 2 4 for a short moment e Set the lever standard mixer Fig 5 1 2 Pos 8 1 2 external mixer Fig 5 1 4 Pos 8 2 2 to STOP FLUSH e Set the lever standard mixer Fig 5 1 2 Pos 8 1 1 external mixer Fig 5 1 4 Pos 8 2 1 to OPEN Return flow open Translation of the original operation manual DUOMIX 230 23 e Pump the s
4. The accumulated condensate is automatically drained off through the drain valve For this purpose hold the hose into an empty collecting vessel Check the vessel regularly for dirt residues and clean it as required Silica gel filter moisture filter option If the drum with the B component is equipped with a screwed in moisture filter the granulate inside the filter must be dried at regular intervals Drying temperature approx 50 C Drying time approx 4 h Drying cycle always after application of 1000 of material e Only heat up the granulate 1 Heating up the complete filter can damage the housing Loosen the container Press down the slide and turn the container to the left Water separator Ensure correct fit of the O ring when assem bling Drain valve Hose Figure 8 4 1 BTA DUOMIX230S en 1001 cf Trouble shooting Fmh Posbecmse Remedy The feed pumps work without interruption With the relieve tap opened no material comes out of the output distributor The material container is empty The ball valve is closed The suction line is defective c Pump draws in air The feed pump s is are defective The feed pumps do not delver any The dirt trap before the material inlet material into the dual component on the dual component system is system soiled With the relieve tap
5. data of purchasing 972972 Translation of the original operation manual DUOMIX 230 39 DUOMIX230S en 1001 cf
6. Fig 2 2 1 on the high pressure filter P According to the accident pre ki vention instructions BGR 500 chapt 2 29 the owner is obliged to ground this piece of equip ment Please follow our operating instructions A Figure 2 2 1 WIWA 2K Duo Mix Base Komp A E cem Hardener Komp B LL eem Pressure Ratio Druck bers 1 a Ratio Mischungsverh 1 1 Type plate Fig 2 2 2 on the control cabinet of the dual component system Please check that the type plate data are identical with those on the machine card In case of discrepancies or m ifthe type plate is missing please notify us immediately Other type plates which are only valid for individual modules can be found on the following modules gt Metering pump A B Flushing pump optional Feed pumps A B optional Material flow heater optional Figure 2 2 2 E W IWA Safety information QD paa so E Fig 2 2 3 This sign lists Q AUT the most important safety SS information to be followed eee when handling or working 9 a with the unit o However you should still o Ic m read the information in the pc user manual E Figure 2 2 3 2 3 Dangers arising from this machine This unit has been designed and manufactured while taking into consideration all safety related aspects It corresponds to the current standard of technology and to applicable accident prevention regu
7. Maintenance work personnel trained by the 19713731 customer service Repair work personnel trained by the 1971371 customer service After the completion of work you must in any case check the function of all protective devices and the correct function of the machine Handling auxiliary materials Follow the safety notes and dosing information of the manufacturer and the generally applicable regulations when handling paints solvents oils greases and other chemical substances gt Rests of paints solvents oils greases and other chemical substances must be collected in accordance with statutory provisions concerning recycling and waste disposal The official local waste water laws are valid 33572372 Translation of the original operation manual DUOMIX 230 DUOMIX230S en 1001 cf DUOMIX 230 on 4 wheel rack A Or p Position 1 1 Air motor 1 2 Material pump 1 3 Safety valve 1 4 4 4 wheel rack 1 4 4 Transport bar 1 5 Maintenance unit 1 5 1 Compressed air regulator 1 5 2 Compressed air shut off valve 1 5 3 Inspection glass 1 5 4 Drain valve 1 6 High pressure filter lee Return flow hoses 3 Filling funnel 3 1 Ball valve 5 Material flow heater 5 1 Control button 6 Flushing pump 6 1 Compressed air regulator 6 2 Suction line 8 1 Standard mixer 8 1 1 Lever Return flow 8 1 2 Lever Spray Stop Flush optionally depending on customer s request 12 dia
8. operating personnel should still be provided with suitable noise protection equipment The operator is responsible for adhering to the accident prevention instruc tions Noise BGV B3 For this purpose pay particular attention to the conditions of the in stallation location e g will the noise exposure increase if the system is set up in or on hollow bodies Danger sources A G O Please remember that dual component systems work with extremely high pressures and may cause life threatening injuries if used inappropriately Please comply with the following instructions Material hoses must withstand the maximum working pressure whereby the safety factor must be provided by the unit Material hoses must never be repaired Never point the spray gun at yourself other persons or other living beings DUOMIX230S en 1001 cf Never hold your finger or hand in front of the spray gun and never reach into the jet spray Never try to seal leakages on connections and high pressure hoses by hand or by wrapping fabric around them If leaks occur immediately depressurize the entire system spray gun hose high pressure filter pump etc Defective parts must be replaced Always wear protective gloves when working with heated materials DANGER OF BURNING Secure the spray gun with each work break even if itis only very short and check the lock Fig 2 6 1 Always depressurize the entire sys
9. to mix smallest quantities e g for possible rework by hand Translation of the original operation manual DUOMIX 230 25 Prerequisites The following is required 2 material containers with the components A B 2 empty open measuring vessels C for the mate rial quantities of components A B to be measured subsequently 2 empty open containers C for the components A B 1attachment kit for the volumetric measuring unit Fig 5 3 1 Pos 1 8 3973974 order no 0643212 Do not use cone top cans or drums with bung hole Use a separate measuring vessel C or con tainer D for each material component to avoid undesired material reactions or to be able to return the material to the original drums Procedure Setthe lever standard mixer Fig 5 3 1 Pos 8 1 2 external mixer Chapt 3 Pos 8 2 2 to STOP FLUSH Set the lever standard mixer Fig 5 3 1 Pos 8 1 1 external mixer Chapt 3 Pos 8 2 1 to OPEN Return flow open Allow the material to cir culate in the system see chapter 5 1 step 10 Figure 5 3 1 Reduce the pressure by the compressed air regulator chapt 3 Pos 1 5 2 Set the lever standard mixer Fig 5 3 1 Pos 8 1 1 external mixer Chapt 3 Pos 8 2 1 to CLOSED Return flow closed Disconnect the return flow hoses Fig 5 3 1 Pos 1 7 from the material containers A B Assemble one double nipple and one valve attach ment kit for
10. 0 5 1 bar Translation of the original operation manual DUOMIX 230 37 FA DUOMIX230S en 1001 cf Commissioning Version with pressure and dosing monitoring chapt 3 Pos 2 e Set the selector switch MANUAL AUTOMATIC Fig 5 1 3 Pos 2 5 to MANUAL e Press the Start button Fig 5 1 3 Pos 2 4 gt Flush thoroughly through the return flow hoses chapt 3 Pos 1 7 A B Pump the contaminated material into the empty containers D provided for this purpose until clean solvent starts to run out Pull the lever Fig 5 1 4 Pos 8 2 1 to position CLOSED The material flow through the return flow hoses is now interrupted Setthe lever Fig 5 1 4 Pos 8 2 2 to position SPRAY Step 8 Version with distributor In the control cabinet of the distributor set all switches SPRAY to ON and all switches FLUSH to OFF Pull the trigger lever to open the spray gun Spray the contaminated solvent which is in the complete system into an open container D until clean solvent starts to run out A Step 9 Allow the system to drain empty Version with suction line chapt 3 Pos 4 e Place the suction of the material pumps A B into the solvent C e Interrupt the compressed air supply For this purpose turn the compressed air regu lator Fig 5 1 1 Pos 1 5 1 on the service unit completely anti clockwise Version with filling funnel chapt 3 Pos 3 e Place the material c
11. Translation of the original operation manual DUOMIX 230 DUOMIX230S en 1001 cf 15 Pressure and dosing monitoring Pos 2 Feed pump Pos 7 L ON F k 16 p Ol 4 Start 7 25 Manual Automatic i Tf f Pio S ITI ES e8 ERE m L TT 7 3 1 j System description Position 2 1 Pressure regulator with micro filter 2 2 Precision pressure regulator 2 3 Contact pressure gauge 2 4 Switch START 25 Switch MANUAL AUTOMATIC Position TA Pressure regulator 7 2 Ball valve T3 Suction Translation of the original operation manual DUOMIX 230 77277 DUOMIX230S en 1001 cf System description 3 Standard mixer Pos 8 1 Closed return flow closed Position Dl Lever CLOSED RETURN FLOW CLOSED OPEN RETURN FLOW OPEN 8 1 2 Lever SPRAY STOP FLUSH 9 Stop Flushing B 1 2 i m SI Return flow Return flow Comp A Comp B aN ar IT Pe ilk 8 2 2 8 2 Position 8 2 1 Lever CLOSED RETURN FLOW CLOSED OPEN RETURN FLOW OPEN 8 2 2 Lever SPRAY STOP FLUSH 37737A Translation of the original operation manual DUOMIX 230 17 DUOMIX230S en 1001 cf 3 System description Dual distributor optional Spray Su opray ON OFF eo Flush Flush Manifold Flush ON OFF ES Flush DISTRIBUTOR ON OFF Automatic valve Material flow reg
12. be changed 1 DUOMIX230S en 1001 cf uJ gt 4 Start 5 Manuell Automatik Figure 5 2 1 The actually available spraying pressure can be read by the black pointer The permissible spraying pressure with closed or opened spray gun can be set with the red trailing pointers 1 Spraying pressure adjustment with open spray gun Read the actually available spraying pressure indi cated by the black pointer Insert the enclosed key into the pressure gauge Fig 5 2 1 Pos 2 3 Move the lower red trailing pointer with the driver nee dle to a position 20 30 bar below the lower changeo ver point of the material pump lower black pointer Pullthe key back out 2 Spraying pressure adjustment with closed spray gun Read the actually available 20 par AIX spraying pressure indicated by the black pointer nsert the enclosed key into the pressure gauge Fig 5 2 1 Pos 2 3 Move the upper red trailing pointer with the driver needle to a position 20 bar above the dynamic pressure above the black pointer Pullthe key back out AR 20 bar Figure 5 2 2 The two pressure gauges on the high pressure 1 filters must always work synchronously 5 3 Inspection of the mixing ratio using the volumetric measuring unit Problem definition Use the volumetric measuring unit optionally available a to check the mixing ratio of components A B b
13. change or once per week see chapter 8 3 e Further maintenance notes for the individual components can be found in the appendix to the corresponding spare parts list 8 3 Maintenance of the high pressure filter Always switch off the complete power supply A and relieve the pressure from the system be fore starting to service the high pressure filter Changing and cleaning the filter element or the O rin Step 1 Perform the work steps as described in chapter 7 Decommissioning 1 6 Closed Figure 8 3 1 Step 2 Set the lever standard mixer Fig 8 3 1 Pos 8 1 2 external mixer Fig 8 3 2 Pos 8 2 2 to STOP FLUSH Figure 8 3 2 Step 3 Version with external mixer chapt 3 Pos 8 2 Shift the lever Fig 8 3 2 Pos 8 2 1 to position CLOSED Translation of the original operation manual DUOMIX 230 33 Step 4 Shift the lever between the high pressure filters Pos 8 1 1 to position OPEN Return flow open to make sure that the machine is relieved of any pressure Step 5 Use the stud driver to unscrew the cap from the high pressure filter Step 6 Loosen and remove the nut from the filter element Step 7 Clean the filter element with solvent For this purpose use only the solvent belong 1 ing to the Material Replace the filter element if it shows any signs of damage Step 8 gt Plug the filter element back on the stud and retighten
14. of fire when working with combustible or explosive solid fluid or gase ous substances WARNING A potentially dangerous situation is indicated Non observance can lead to death or very serious injury DANGER OF EXPLOSION Indicates a situation with potential danger of ex plosion Strict compliance with these notes is mandatory VOLTAGE A situation showing danger of explosion by elec trostatic charge is indicated Strict compliance with these notes is mandatory WEAR HEARING PROTECTION You should strictly follow these notices to protect your health USE RESPIRATORY PROTECTION You should strictly follow these notices to protect your health WEAR PROTECTIVE GLOVES Protective gloves with lower arm protection should be worn to protect against burns Strict compli ance with these notes is mandatory HARMFUL TO HEALTH Identifies hazardous substances Strict compli ance with these notes is mandatory FIRST AID In case of injuries or accidents it is imperative to respect all the regulations indicated 2 2 Appropriate information signs and symbols on the machine refer to possible danger areas and must be respected at all costs Warnings DUOMIX230S en 1001 cf Information signs and symbols must not be removed from the unit Damaged and illegible information signs and symbols must be replaced immediately The following signs can be found on the unit Warning concerning the ground ing of machines
15. opened material comes out of the output distributor The bottom valve of the hardener pump is defective No pressure built up by hardener pump during downwards stroke of metering pump The pressure of standard components rises 4 No pressure built up by hardener pump during upwards stroke of dosing pump 5 The hardener pump does not generate pressure in up and down stroke any material The burst disc on the high pressure filter is defective The ventilation valve of the hardening component is leaking The ball valve on the material inlet is closed During the up stroke the pressure of hardener and standard components is considerably higher than during the down stroke or the pressure of both components slowly increases synchronously A piston valve of the two A pumps does not work The standard component pumps do not generate any pressure in up stroke The pressure in the hardener side is very high WIWA DUOMIX230S en 1001 cf Translation of the original operation manual DUOMIX 230 Replace the material container Open the ball valve Replace the suction line repair the feed pump s Open the ball valve Clean the dirt trap of the dual component system Disassemble and clean the bottom valve Replace defective ball or valve plate valve Replace defective ball or valve plate The hardener pump does not receive Check the material feed Check
16. the burst dis for the hardening component on the high pressure filter Check the ventilation valve for the hardening component for function and leak tightness Open the ball valve Check and clean both piston valves Replace defective balls or valve plates Check and clean both piston valves Replace defective balls or valve plates 35 Trouble shooting 9 Fh Posbecmse Remedy In the up stroke the pressure One bottom valve of the A component Check and clean both bottom valves of hardener and standard pump does not work Replace defective balls or valve components is considerably higher plates than during the down stroke The feed hose swells up or the pressure relief valve on the output distributor opens and the material is fed back into the container through the return flow hose No pressure generated for the The standard component pump does Check the material supply standard component during up and not receive any material Check the burst discs on the high down stroke Burst discs on high pressure filter pressure filter for the standard The pressure in the hardener defective component component is very high Lever Pos 8 1 1 8 2 1 is leaking Check lever Pos 8 1 1 8 2 1 for Lever 8 1 2 8 2 2 is closed leak tightness and function Check lever 8 1 2 8 2 2 10 When bleeding the pressure of Lever Pos 8 1 1 8 2 1 do
17. the containers Thereby catch the material of components A B in separate containers e Close the ball valves chapt 3 Pos 3 1 A B on the drain valves of the filling funnels e Fill solvent into both filling funnels Version with feed pumps chapt 3 Pos 7 e Place the suction chapt 3 Pos 7 3 A B of the feed pumps into the solvent C belonging to the material e Open the ball valves chapt 3 Pos 7 2 A B e Turn the compressed air regulators chapt 3 Pos 7 1 A B of the feed pumps clockwise to set a pressure of approx 1 2 bar Step 5 Version with pressure and dosing monitoring chapt 3 Pos 2 Setthe selector switch MANUAL AUTOMATIC chapt 3 Pos 2 5 to MANUAL Step 6 Version with flushing pump chapt 3 Pos 6 Regulate the compressed air regulator chapt 3 Pos 6 1 to 3 6 5 bar depending on the length of the material hoses Step 7 Setthe pressure regulator chapt 3 Pos 1 5 1 on the service unit to such a pressure that the pump runs slowly Step 8 gt for version with filling funnel chapt 3 Pos 3 Shift the lever standard mixer Fig 7 1 1 Pos 8 1 1 external mixer Fig 7 1 2 Pos 8 2 1 to position OPEN Return flow open Setthe lever standard mixer Fig 7 1 1 Pos 8 1 2 external mixer Fig 7 1 2 Pos 8 2 2 to STOP FLUSH Allow the material to circulate through the system until the material residues of compone
18. the nut Step 9 Replace the O ring if it shows signs of wear Step 10 Screw the cap on the high pressure filter and tighten it with the stud driver for high pressure filters in R and RS design 1 It is mandatory to slightly grease the threads for easier assembly disassembly 8 4 Maintenance of the service unit Lubricant or anti freeze agent Also check and if necessary top up the lubricant for the fan motor in the container of the service unit High humidity can cause icing of the motor n case of icing use pure anti freeze agent Adjusting the fog oiler on the maintenance unit Allow the air motor to run slowly with an air inlet pres sure of approx 4 bar Inthe inspection glass of the fog oiler check whether one drop of lubricant is released into the compressed air with every 10 to 15 double strokes of the air motor Should this not be the case use a screwdriver to ad just the regulating screw on the lubricator accordingly Check the amount of oil in the oil container every day The maintenance unit must never be operated without oil The max oil level is indicated by a circumferential groove in the container To fill the oil container loosen the filler plug and fill the container directly 34 Translation of the original operation manual DUOMIX 230 Maintenance repair o Only use the lubricants and anti freeze agents 1 listed in the chapter 10 1 Draining the condensation water
19. 0 MIELA Place Date Heidrun WaQ per Turczak Managing Director Translation of the original declaration of conformity 77 7A DM230 DBK en 1001 cf Contents h L j Foreword Operating personnel should always have 1 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 Dear Customer We are delighted about your decision to buy one of our units The user manual contains all information required to operate and handle your W WA DUOMIX However other information is also essential for safe operation Read and comply with the applicable guidelines for your country In Germany these are the Richtlinien f r Fl ssig keitsstrahler Guidelines for Liquid Jets issued by the Hauptverband der Gewerblichen Berufsgenossen schaften Moreover the manufacturer s instructions and guide lines for coating or feeder materials are to be respected at all times In principle you should refrain from any work method that could affect the safety of 39 733741 products and operating personnel Much success and good work results with your 419719741 DUOMIX wishes WIA Wilhelm Wagner GmbH amp Co KG Copyright 2009 WIWA Copyright ownership for this user manual remains with WIWA WILHELM WAGNER GmbH amp Co KG GewerbestraBe 1 3 35633 Lahnau Phone 49 0 6441 609 0 Fax 49 0
20. 1 5 1 on the service unit to a lower spraying pressure Operate the spray gun Spray the rest of the solvent inside the spraying hose into a container D until coating material appears Slowly set the pressure regulator chapt 3 Pos 1 5 1 on the service unit to the desired spraying pressure Y VY Step 8 Allow the material to circulate in the system see chap ter 5 1 step 10 Step 9 Version with pressure and dosing monitoring Chapt 3 Pos 2 Setthe selector switch MANUAL AUTOMATIC chapt 3 Pos 2 5 to AUTOMATIC If the pointer of the contact pressure gauge does not move or moves only insignificantly the system must not be taken into operation RISK OF MIXING FAULTS 6 2 Coating work Unlock and open the spray gun for the coating work that is to be started next thin here thin layer to thick layer E wal Cj es wrong Figure 6 2 2 approx 30r40 cm Figure 6 2 1 Working pressure When the material is uniformly applied with shallowing out marginal zones the optimal working pressure is reached Operate the unit only with a working pressure as high as necessary to achieve a good atomization at a recom mended spraying distance of approx 30 40 cm Too high spraying pressure causes increased material consumption and paint mist Too low spraying pressure results in the appearance of stripes and differences in the coating thickness Translation of the orig
21. 6441 609 50 E mail info wiwa de Internet www wiwa de This operating manual is solely intended for personnel involved in prepara tion operation and servicing Itis prohibited to pass on this operating manual for reproduction utilisation or communication of its contents unless this has been explicitly permitted Infringements incur an obligation to pay damage compensation All rights reserved in the event of registration of the patented design industrial design or registered design This operating manual only applies in conjunction with the machine card that was given to you with the user manual for your equipment Please check that the type plate data is identical with the information on the ma chine card Please notify us immediately if there are discrepancies if the user manual has been incorrectly compiled or if the type plate is missing DUOMIX230S en 1001 cf 1 2 First read then start Please bear in mind that dual component A systems work in extreme pressure mode and therefore generate extremely high pressures Never hold your finger or hand in front of the spray gun and never reach into the jet spray Never point the spray gun at yourself other persons or other living beings Always observe and follow the notes and regulations in the user manual Always take care before starting operation Check the grounding device and spraying object Check all connections and fitments for leak ti
22. 94 9 EC Ap pendix II no 2 1 2 3 when observing the measures of the responsible inspecting authority The operator is responsible for checking and ensur ing that all technical data and markings according to ATEX correspond with the necessary requirements Make sure that several components have their own type plate with separate marking according to ATEX The respective lowest explosion protection of the marking attached applies for the entire unit Applications where the malfunction of the unit can lead to danger to personnel must be provided with respective safety measures by the operator Should problems can be noticed during operation the unit must be stopped immediately and 19733571 should be contacted immediately It must be assured that the unit is sufficiently grounded separately or in connection with the equipment it is mounted on max resistance 109 Q WW Fig 2 4 1 grounding equipotential EE bonding Any other use is deemed to not be in accordance with regulations The manufacturer s approval must be obtained before 3973374 the unit is 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 fi a Figure 2 4 1 Grounding screw on high pressure filter Intended use also includes compliance with the technical documentation and adherence to the prescribed operating servicing and maintenance guidelines 6 Translation o
23. ANUAL unit in position AUTOMATIC AUTOMATIC to position MANUAL The system can only be started for The material pressure of the Relieve the material pressure a short while only as long as the hardening component is higher than Replace the defective contact START button is held depressed the red contact indicator for high pressure gauge pressure warning The contact pressure gauge submits an incorrect signal WIWAP Translation of the original operation manual DUOMIX280 87 DUOMIX230S en 1001 cf 9 Trouble shooting Fh Posbecmse Remedy 22 The contact pressure gauge The contact pressure gauge is Replace the contact pressure gauge indicates pressure even though defective the system pressure has been relieved 23 The contact pressure gauge does The contact pressure gauge is Replace the contact pressure gauge not indicate any pressure or only defective oil has run out of the up to a certain pressure pressure transmitter of the pressure The system is under full air intake gauge When spraying the pointer sticks at certain pressure and does not pulsate 24 The dual component system does The potlife was disregarded Try to clean the components that had no longer work in switch positions Mixing unit material hoses and been hardened by the mixed material SPRAY and FLUSH spray gun were not flushed replace if necessary c the material has cured T
24. Headquarter and Production WIWA Wilhelm Wagner GmbH amp Co KG GewerbestraBe 1 3 35633 Lahnau Germany Tel 49 6441 609 0 Fax 49 6441 609 50 E mail info wiwa de Internet www wiwa de WIWA LP 107 N Main St Alger OH 45812 USA Tel 1 419 549 5180 Fax 1419 549 5173 Tel Toll Free 1 866 661 2139 E mail sales wiwalp com Internet www wiwalp com WIWA Taicang Co Ltd Add No 87 East Suzhou Rd Taicang city Jiangsu province 215400 P R China Tel 86 512 5354 8858 Fax 86 512 5354 8859 E mail info wiwa china com Operation Manual WIWA DUOMIA B JU ot were ee CALI foa 30009 EN a teses L4 5 3 ES q N Serial NO cee cee nee ees Translation of the original operation manual DUOMIX 230 DM230 DBK en 1001 cf EC Declaration of Conformity EC Declaration of Conformity according to Appendix ll No 1A of the Machinery Directive 2006 42 EG The company WIWA Wilhelm Wagner GmbH amp Co KG Gewerbestr 1 3 35633 Lahnau Deutschland herewith declares that the equipment types DOUMIX 230 are in conformance with the provisions of the above mentioned directive In addition the above mentioned equipment is in conformance with the provisions of the directive ATEX Directive 94 9 EG The listed equipment falls under Group II Category 2G Marking Il 2G cTA Documentary authority Heidrun Wagner Turczak Tel 06441 Lahnau 01 01 201
25. Return flow open for this purpose ing appropriate lightning protection measures Immediately replace the defective parts or inform the gt Strictly comply with the valid accident prevention WIWZ customer service instructions 9729 Translation of the original operation manual DUOMIX 230 9 DUOMIX230S en 1001 cf Injuries Immediately consult a physician if injured when han dling fluid jets because of their cutting effect Inform the physician about the sprayed material paint and the solvent used thinner For this purpose always keep the product safety data sheet supplier or manufacturer address their telephone number mate rial designation and the material number ready for the physician Always remember where you can call for help Keep a list of the local emergency telephone numbers at hand You should in any case make yourself familiar with First Aid measures VV Fires Read and comply with the instructions for fire alarm and escape routes which are displayed in your factory or at any work place Keep a list of the local emergency telephone numbers at hand Remember the location and operation of fire alarms fire extinguishers Ensure a sufficient amount of information signs for the avoidance of fire Only use the extinguishing substances stipulated by the material manufacturer VV yY Yy 2 10 Safety features All units are delivered with the following safety features Safe
26. TIC Fig 5 1 3 Pos 2 5 to MANUAL e Press the Start button Fig 5 1 3 Pos 2 4 H 2 4 Start 2 5 Manuell Automatik Figure 5 1 3 Flush thoroughly through the return flow hoses chapt 3 Pos 1 7 A B Pump the contaminated material into the empty containers D provided for this purpose until clean solvent starts to run out Pull the lever Fig 5 1 2 Pos 8 1 1 up CLOSED Return flow closed The material flow through the return flow hoses is now interrupted Set the lever Fig 5 1 2 Pos 8 1 2 to position SPRAY Version with external mixer Chapt 3 Pos 8 2 With this equipment design no Return flow hoses are connected to the high pressure filters these are part of the hose package for the external mixer and are to be connected there The lever between the high pressure filters Fig 5 1 4 Pos 8 2 1 is used to relieve the system pressure or to flush the high pressure filters see chapter 8 3 The system is vented through the external mixer Figure 5 1 4 gt VV V Y Shift the lever Fig 5 1 2 Pos 8 1 2 to position CLOSED Return flow closed Shift the lever Fig 5 1 4 Pos 8 2 1 to position OPEN Set the lever Fig 5 1 4 Pos 8 2 2 to position S TOP FLUSH Open the ball valve Fig 5 1 1 Pos 1 5 2 on the service unit Turn the compressed air regulator Fig 5 1 1 Pos 1 5 1 on the service unit clockwise to a pressure of approx
27. ainties with regard to competences as this might endanger user safety The owner must therefore ensure that only authorized per sons work with the unit He shall be responsible towards a third party within the operating area of this system Personal Protective Equipment We would like to point out that the valid guidelines and stipulations depending on the work environment min ing closed rooms etc must be respected in any case Always wear the protective clothing stipulated as solvent fumes and spilled cleaning agents cannot be entirely avoided BTA DUOMIX230S en 1001 cf Safety The sound pressure level of this unit is 85 db A However operating personnel should still be provided with suitable noise protection equipment Spray painting personnel must always wear respiratory protection masks even though the paint mist has been minimized in Airless spray painting applications with correct pressure setting and working mode When applying heated material the surface of the unit may also heat up Always wear safety gloves Do not use solvents or other harmful sub stances to clean your skin Use only appro priate skin protection skin cleaning and skin care products 2 8 Place of installation and transport Installation location The 539733724 DUOMIX can be installed inside and outside spray booths and rooms However outdoor installation should be preferred in order to avoid contamination Saf
28. ans or drums with bung 1 hole to avoid possible electrostatic charging When using metal containers you must always take care not to touch the container wall with the spray gun Step 9 Regulate the compressed air regulator chapt 3 Pos 1 5 1 on the service unit back anti clockwise until it is light to move Translation of the original operation manual DUOMIX 230 29 Step 10 Version with feed pumps chapt 3 Pos 7 Regulate the compressed air regulators for the feed pumps chapt 3 Pos 7 1 A B anti clockwise until they are light moving Close the ball valves chapt 3 Pos 7 2 on the feed hoses Step 11 Regulate the compressed air regulators Pos 6 1 on the flushing pumps back anti clockwise until they are light to move Step 12 To relieve the pressure shift the lever standard mixer Fig 7 1 1 Pos 8 1 1 ex ternal mixer Fig 7 1 2 Pos 8 2 1 forward to position OPEN Return flow open until both pressure gauges on the high pressure filters chapt 3 Pos 1 6 or the pointer of the contact pressure gauge chapt 3 Pos 2 3 of the pressure and dosing moni toring unit optional indicates 0 bar Figure 7 1 2 Step 13 After the ventilation return the lever standard mixer Fig 7 1 1 Pos 8 1 1 external mixer Fig 7 1 2 Pos 8 2 1 to position CLOSED Return flow closed Step 14 Operate the spray gun once again for a moment to re lieve any fl
29. appropriate solvent container C Step 11 Allow the material to circulate in the system for the purpose of ventilation This results in a uniform consistency of the material and when using a material flow heater a uniform ma terial temperature throughout the system 1 Perform this step before every start of work Hold the return hoses chapt 3 Pos 1 7 A B into the original drums or filling funnels depending on the material and secure them against accidental slipping out Commissioning Version with flushing pumps chapt 3 Pos 6 e Regulate the compressed air regulators chapt 3 Pos 6 1 on the service unit for the flushing agent pump to 3 6 5 bar depending on the length of the material hoses Version with material flow heaters e Allow the material to circulate until a uniform temperature distribution in the materie2 4 Start been reached Check the temperature with a 2 5 Manual temperature sensor optionally availat i a Material flow heater chapt 3 Pos 5 e Set the regulating button chapt 3 Pos 5 1 to the desired temperature 0 80 C e Observe and follow the notes in the separate user manual for the material flow heater b Drum floor heater e Switch on the drum floor heater and set the regulating button to the desired material tem perature 0 80 C c Hose heater e Switch on the hose heater and set the regulat ing button to the desired material temper
30. ature 0 80 C Slowly pump the material until the complete sys tem has been ventilated Shift the lever standard mixer Fig 5 1 2 Pos 8 1 1 external mixer Fig 5 1 4 Pos 8 2 1 up to position CLOSED Return flow closed Setthe lever standard mixer Fig 5 1 2 Pos 8 1 2 external mixer Fig 5 1 4 Pos 8 2 2 to SPRAY Version with distributor Set all switches SPRAY to ON Slowly turn the regulator Fig 5 1 1 Pos 1 5 1 on the service unit to adjust the desired spraying pressure Operate the spray gun with the installed spray noz zle to compensate the pressure of both compo nents Thereby spray the emerging material into an open container D hole to avoid possible electrostatic charging When using metal containers you must always take care not to touch the container wall with the spray gun p Do not use cone top cans or drums with bung Step 12 Check the reading of the pressure gauges for the high pressure filters chapt 3 Pos 1 6 1 These must show almost identical pressure values 24 Translation of the original operation manual DUOMIX 230 977 WZ DUOMIX230S en 1001 cf Commissioning Version with pressure and dosing monitoring chapt 3 Pos 2 4 20 bar WA i wv J KC 20 bar Upper contact pointer with closed spray gun s Lower contact pointer with opened spray gun s Any change in spraying pressure requires a new settin
31. e 397339731 DUOMIX 230 is most suitable for the ap plication of low medium and also high viscosity paints and coating materials 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 hardener or standard component Use of the unit in explosion endangered areas x II 2G px The unit fulfils the explosion protection requirements of the Directive 94 9 EC for explosion group unit category and temperature class specified on the type plate Marking Safety The unit is suitable for being installed in explosion protec tion zone The unit of group Il must be assigned to unit category 2G due to the possible generation of explosion producing atmospheres resulting from gasses and paint mist The ignition temperature of the materials and solvents to be used must be higher than 200 C When operating the unit the specifications in this operat ing manual must be observed in all cases The specified inspection and maintenance intervals must be strictly complied with The data specified on the type plates must be strictly complied with and should never be exceeded An overloading of the unit must be excluded The operator is responsible for determining the zone allocation according to the Directive of EC
32. ection we recommend the 39734574 pneumatics oil order no 0632579 and the 3973974 anti freeze agent order no 0631387 Result The machine is now ready for operation You can continue with initial start up chapter 5 1 20 Translation of the original operation manual DUOMIX 230 9977 WZ DUOMIX230S en 1001 cf Commissioning 5 1 Initial start up Problem definition After assembly in the factory the correct functioning of this machine was checked with a testing medium You must flush the complete system with the solvent that belongs to the application material to protect the sprayed material against being impaired by the test medium Prerequisites Always wear the protective clothing stipulated as solvent fumes and spilled cleaning agents cannot be entirely avoided The following is required 2 open containers with the material to be applied component A B hereafter referred to as container A B 2 open containers with solvent hereafter referred to as container C For each material component A B you should have a separate solvent container C available to prevent material reactions and damage to the system 2 empty open containers for solvent test medium mixture hereafter referred to as container D Use a separate container D for each material component to avoid material reactions and thus possible damage to the system Do not use cone top cans or drums with bunghole When usin
33. ents Contents Foreword First read then start Safety Explanation of symbols Warnings Dangers arising from this machine Using this machine Machine environment Danger sources Operating personnel Place of installation and transport What to do in events of emergency Safety features Handling the device and auxiliary materials System description Installation and assembly Commissioning Initial start up Spraying pressure monitoring using the pressure and dosing monitoring feature Inspection of the mixing ratio using the volumetric measuring unit Operation Start of work Coating work Decommissioning End of work only for version with flushing pump Complete cleaning Material change Maintenance repair Inspection cycles Maintenance plan Maintenance of the high pressure filter Maintenance of the service unit Trouble shooting Appendix Operating means special tools Instruction Certificate Machine card Ow A OO OONN OO 0101 C CI 12 20 21 21 25 25 27 27 27 29 29 30 32 33 33 33 33 34 35 39 39 39 39 Translation of the original operation manual DUOMIX 230 9739 DUOMIX230S en 1001 cf Safety 2 1 Explanation of symbols The notices and symbols used in this manual have the following meanings e Note Indicates an informative text passage You should pay particular attention when reading it NO SMOKING Indicates a situation with risk
34. es not Check lever Pos 8 1 1 8 2 1 the standard component remains open Check return flow hoses for free applied Return flow hoses are clogged flow The high pressure filter element is Clean the high pressure filter excessively soiled 11 When bleeding the pressure of Lever Pos 8 1 1 8 2 1 of Check lever Pos 8 1 1 8 2 1 the hardening component remains hardening component does not Check return flow hoses for free applied open flow The pressure of standard Return flow hoses are clogged Clean the high pressure filter components drops The high pressure filter element is excessively soiled 12 When spraying the pressure of The high pressure filter element for Clean the high pressure filter the standard component always the standard component starts to element or install a coarser element increases in comparison with the block up Repair the hardener component hardener component The seals of the hardener pump renew the seals component pump are leaking 13 When spraying the pressure of The high pressure filter element for Clean the filter element for the high the hardener component always the hardening component starts to pressure pump or install a coarser increases in comparison with the block up element standard component The seals of the standard Repair the standard component component pump are leaking pump renew the seals 14 When spraying not enough The filter ele
35. esign avail able for such materials The maximum operating pressure specified by us must generally be adhered to for all 3973374 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 Example Pump up to 420 bar Material hose up to 600 bar Spray gun up to 500 bar The maximum permissible operating pressure for the entire system is 420 bar Smoking or handling open fire or possible sources of ignition is not permitted within the entire working area Alway pay attention to and follow all notes in the user manuals for the optionally offered accessory equip ment 2 7 Operating personnel Authorized operating personnel Juveniles under the age of 16 have no permission to oper ate 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 Only then the system may be taken into service We recommend to the owner of this unit to have this confirmed in writing The person operating this system is obliged to notify the owner of any changes to this unit which might affect its safety as the owner is responsible for maintaining flawless function of this unit All responsibilities for the various types of operation with this system must be clearly defined and respected There must be no uncert
36. ety measures at the installation location This system requires a solid base and sufficient free space for safe operation The access to the safety features must be kept clear Lock the unit at the place of use Version with carrier Kick down all wheel brakes on the rack This secures the device against unintended mov ing Before transportation pull the immobilizer brakes up to release Always keep the working area especially all walk ways and standing areas clean and tidy Remove any spilled material and or solvent immediately Always ensure adequate ventilation ate the work place to avoid damage to health and objects Always observe the processing instructions issued by the material manufacturers Transport Disconnect the entire power supply for the machine even for short transport distances Empty the machine before transport Caution when loading with hoisting gear Ensure sufficient load bearing capacity of lifting gear and lifting tackle when loading the machine You find the dimensions and weights of the device on the machine card The device must only be lifted by the lifting and lashing points provided for this purpose Take care of free hanging ropes if necessary use a yoke The length of the transportation ropes must be at least 3 m Fasten the lifting tackle properly on all lifting eyes chapter 3 Pos 1 4 1 or 1 4 2 Caution Danger of tipping over Ensure even load distribution to secu
37. f the original operation manual DUOMIX 230 77 WZA DUOMIX230S en 1001 cf Safety 25 Machine environment Conversions and alterations 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 339 73374 renders any warranty null and void The unit should only be operated within the prescriptive limit values and machine parameters Dangers from accessories and spares If original accessories and spare parts of the company 1971171 are used usability with our units is guaran teed It is however mandatory to respect the safety regulations of the accessories and spare parts These safety regulations are found in the corresponding accessory user manuals If foreign accessories or spare parts are used the company 39733741 cannot guarantee the safety of the entire system Liability also becomes null and void for damage or injuries resulting from the use of such ac cessories and spare parts Emissions Depending on which materials are processed solvent fumes may occur 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 is sued by the material manufacturers The sound pressure level of this unit is 85 db A However
38. for the dual component system Consultation with WIWA is highly recommended You should never operate the system without safety valve If the safety valve needs to be replaced you can find the corresponding order number on the machine card When using new safety valves make sure that the valves have been set to the max permissible air inlet pressure of the 3973373 DUOMIX as required for the mixing ratio see type plate machine card and sealed with a lead seal During operation keep checking the material feed to the unit to prevent the development of friction heat caused by dry running of the material pumps Please note no empty material drums while the material pumps are running suction systems must not be clogged kinked or defective the unit must immediately switch off if no material is delivered n closed rooms or with pressurized systems in which aluminium components or galvanized parts have contact with the solvent hazardous chemical reac tions 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 197119 customer service or directly 8 Translation of the original operation manual DUOMIX 230 Safety We would like to point out that we have a series of dual component systems in rust and acid proof d
39. g metal containers you must always take care not to touch the container wall with the spray gun because of possible electrostatic charging Check whether the material hoses are suitable for the maximum working pressure and have the specified safety factor Material hoses must be leak tight and free of kinks signs of abrasion or bulges Hose assem blies must be tight and compliant with the maximum pressures When using material flow heaters option make sure that these are cold during cleaning Before starting the material flow heater the spraying material must circulate in cold condition because there may still be solvent residues in the material flow heater or in the entire system Procedure If the device is not equipped with one of the following ac cessories you can skip the corresponding section DUOMIX230S en 1001 cf Close the compressed air shut off valve Fig 5 1 1 Pos 1 5 2 and the compressed air regulator Fig 5 1 1 Pos 1 5 1 on the service unit Figure 5 1 1 2 4 Start Step 2 gt Connect the ye compressed air supply Step 3 Insert suitable and clean filter elements into the high pressure filters chapt 3 Pos 1 6 Observe and follow the notes in chapter 7 3 The mesh size should always be slightly finer than the bore of the nozzle used M 200 white 0 23 mm 009 M 150 red 0 23 mm 009 0 33 mm 013 Filter element M 100 black 0 33 mm 013 0 38
40. g of the contact pressure gauge If the pointer of the contact pressure gauge does not move or moves only insignificantly the system must not be taken into operation RISK OF MIXING FAULTS Set the red contact pointer in the contact pressure gauge chapt 3 Pos 2 by using the enclosed key see chapter 5 2 approx 20 bar approx 20 bar Set the selector switch MANUAL AUTOMATIC Fig 5 1 3 Pos 2 5 to AUTOMATIC This changeover is mandatory as otherwise the system will not be monitored When set to auto matic mode the system is optimally monitored and dosing faults are prevented Step 13 Start coating work 5 2 Spraying pressure monitoring us ing the pressure and dosing moni toring feature This optional feature enables pressure monitoring of the B component hardener by means of a contact pressure gauge Fig 5 2 1 Pos 2 3 to avoid mixing faults The spraying pressure monitoring range for this component can be adjusted With the switch MANUAL AUTOMATIC set to MANUAL Fig 5 2 1 Pos 2 5 monitoring for the pressure range below the set spraying pressure is not activated However in the pressure range above the set spraying pressure is maintained for safety reasons In the factory the pressure regulator with fine filter Fig 5 2 1 Pos 2 1 in the control cabinet was set to 6 bar and the precision pressure regulator Fig 5 2 1 Pos 2 2 to 1 4 bar These settings must not
41. g the spray gun until no material comes out anymore Set the lever standard mixer Fig 5 3 1 Pos 8 1 1 external mixer Chapt 3 Pos 8 2 1 to CLOSED Return flow closed Set the lever standard mixer Fig 5 3 1 Pos 8 1 2 external mixer Chapt 3 Pos 8 2 2 to STOP FLUSH Disconnect the double nipples and the valves from each of the return flow hoses Fig 5 3 1 Pos 1 7 Y VV V NN Carefully disassemble the volumetric meas 1 uring unit to prevent accidents caused by escaping residual pressures We recommend to cover the screw fitting with a cloth when unscrewing the volumetric measuring unit to catch any escaping material sprays Clean the mixer immediately a on versions with flushing pump as specified in chapt 7 1 end of work b on versions without flushing pump as specified in e chapt 7 2 complete cleaning 1 Clean the volumetric measuring unit For this purpose use the solvent belonging to the material and recommended by the material manufac turer or connect the volumetric measuring unit to an available flushing pump for cleaning Compare the filling level in the measuring vessels for the two components Determine the mixing ratio by calculating Always consider the potlife of the material 20 Translation of the original operation manual DUOMIX 230 977 WZ DUOMIX230S en 1001 cf Operation 6 1 Start of work Problem definition You would like to p
42. ghtness Observe the maximum permissible pressure of the device and accessory parts Strictly observe the following before starting work on the system and during breaks Switch off the system Relieve spray gun and material hoses Secure the spray gun Ensure safety The accident prevention instructions Application of Coat ing Materials BGR 500 chapt 2 25 and the guidelines for liquid jets ZH1 406 of the employer s liability insurance association must strictly be complied with The safe condi tion of liquid jets must be inspected by an expert whenever required but at least every 12 months The results of this inspection must be recorded in writing Paint and solvent residues must be disposed of in compli ance with legal regulations This also applies for environ mentally friendly water varnish systems In case of injuries you should immediately consult a physician or visit the nearest hospital If paint or solvent has penetrated the skin you must inform the physician about this spraying material and the solvent used For this purpose you should always have the product data sheet with the manufacturer s ad dress and phone number at hand Translation of the original operation manual DUOMIX 230 3 1 3 1 1 1 2 2 1 2 2 2 3 2 4 2 5 2 6 2 2 8 2 9 2 10 2 11 5 1 5 2 5 3 6 6 1 6 2 7 7 1 17 2 7 3 8 8 1 8 2 8 3 8 4 9 10 10 1 10 2 10 3 Contents Table of Cont
43. h pressure filter Transfer pumps Spraying Distributor hoses Spray gun Take care that all hoses and pumps are only used with the components intended for this purpose A or B Standard component A Blue A Check all rotatable parts nuts screws and hose con nections and tighten these so that no material will emerge from connections and cause injuries The dual component system must be connected to an electrically conductive object with the grounding cable to prevent electrostatic charging The object to be coated must also be grounded Check the permissible highest pressure for material hose and spray gun It must be higher than or equal the maximum operating pressure of the system as specified on the type plate Compare the maximum air input pressure of the safety valve with the specifications in the machine card These data must match Now fill the system with the release agent see chapter 7 2 Maintenance plan We recommend to use the W VVA release agent Order Nro 0163333 Fill the lubricator on the service unit with pneumatics oil or anti freeze agent or a corresponding mixture and perform the settings described in chapter 8 4 Mainte nance of the service unit Only use the pneumatics oil specified in chapter 10 1 Dual component systems work with very high pressures VV Translation of the original operation manual DUOMIX 230 19 4 Installation and assembly For optimal prot
44. he com pressed air regulator chapt 3 Pos 6 1 Step 17 Lift the suction lines out of the solvent containers Version with filling funnel chapt 3 Pos 3 e Drain the solvent from the filling funnels Step 18 Version with distributor n the control cabinet of the distributor set all switches SPRAY to ON Operate the spray gun once again for a moment to re lieve any flushing pressure residues so that the entire system has been relieved The system must be completely pressureless before it is shut down Decommissioning 7 3 Material change 1 Decommissioning Perform the work steps described for decommissioning complete cleaning chapter 7 2 e For a paint change EPOXY POLYURETHANE 1 the system must be thoroughly cleaned The system must be thoroughly cleaned with the solvent belonging to the material before it is filled with new material N Filter inspection Check and clean the filter elements in the high pres sure filters as described in chapter 8 3 1 before chang ing the material 3 Material change Prepare the material supply Standard component A Blue Version with suction line chapt 3 Pos 4 e Place the suction of the material pumps A B into the material A B to be applied Version with filling funnel chapt 3 Pos 3 e Close the ball valves chapt 3 Pos 3 1 e Fill the material to be applied into the filling funnels A B Version with feed
45. he pilot hoses are not leak tight 25 Hardener or paint emerging from The seals on the material pumps are Replace the seals on the material the bottom part of the air motor worn pumps 26 A possibly installed material flow The electric power supply is Observe and follow the separate heater does not heat up interrupted user manual for the material flow The ambient temperature is below heater 5 8 C Check the electric power supply Technical defect in the material flow Press the button of the overload heater protection until the glowing lamp stays on Have the material flow heater checked by exper personnel with profound knowledge in the field of electrical engineering 38 Translation of the original operation manual DUOMIX 230 977 WI DUOMIX230S en 1001 cf Appendix 10 1 Operating means special tools Release agent Release agent 0 5 I 397994 order number 0163333 Materials required for maintenance and repair work Retention agent 49734 order number 0000015 50 ml Lubricant 9739 order number 0000025 acid free grease 0 4 kg gt Anti freeze agent 3973971 order number 0631387 0 5 I Pneumatic oil 9739 order number 0632579 0 5 I Fig 10 1 1 Key to open the high pres sure filter Attention The high pres sure filter must only be opened after the pressure has been relieved Fig 10 1 2 Key to open the control cabinet option for version with p
46. inal operation manual DUOMIX 230 27 6 Operation Spray painting Hold the spray gun under a right angle 90 to the area to be coated If the spray gun is held under a different angle the coating becomes irregular and blotchy Fig 6 2 1 Move your arm evenly Ensure an even speed and move the spray gun paral lel to the area to be coated Move the spray gun with your arm and not with your wrist Waving the spray gun causes irregular coating Fig 6 2 2 Already move the spray gun before pulling the trigger This way you will achieve perfect soft and smooth overlapping of the spray jet and excessively thick ap plication of material at the beginning of the spraying process is avoided Release the trigger before stopping the movement Work break Always lock the trigger if you interrupt your work for a few minutes Version with flushing pump chapt 3 Pos 6 Flush all components mixing block chapt 3 Pos 8 1 8 2 static mixing pipe distributor material hose spray gun which had contact with the mixed material within the specified potlife Observe and follow the notes in chapter 7 1 End of work Version without flushing pump Flush the complete system Observe and follow the notes in chapter 7 2 Com plete cleaning Spray nozzles Replace the spray nozzles before these are worn Worn nozzles cause higher paint consumption 1 and have a negative effect on the quality of pa
47. int application 28 Translation of the original operation manual DUOMIX 230 977 WZ DUOMIX230S en 1001 cf Decommissioning 7 1 End of work only for version with flushing pump Problem definition After the end of work shut down the system and clean all system components that had contact with the mixed materials Prerequisites Components that had contact with the mixed material can only be flushed if a flushing pump is used Otherwise the complete system needs to be cleaned chapter 7 2 after work to avoid cur ing of the material in the system and related damage Always wear the protective clothing stipulated as solvent fumes and spilled cleaning agents cannot be entirely avoided The following is required 2 material containers with the components A B here after referred to as container A B 1 open container with solvent with the solvent belong ing to the material and recommended by the manufac turer hereafter referred to as container C 1 empty open container for contaminated cleaning agent material mixture hereafter referred to as con tainer D e Do not use cone top cans or drums with bung 1 hole Take care that all hoses and pumps are only used with the components intended for this purpose A or B Procedure If the device is not equipped with one of the following ac cessories you can skip the corresponding section Step 1 Close and secure the spray gun
48. istributor Set all switches on the distributor to OFF Step 7 Vent the complete system a Version with standard mixer chapt 3 Pos 8 1 1 6 Figure 5 1 2 On this equipment ver sion the return hoses Fig 5 1 2 Pos 1 7 are connected to the high pressure filters The circulation of material through the system or the drainage and or relieving the pressure from the equipment is controlled by operating the lever Fig 5 1 2 Pos 8 1 1 This circulation results in a uniform material consistency throughout the complete system or the ventilation of the equipment Closed Circulation ventilation The return flow hoses Fig 5 1 2 Pos 1 7 run from the high pressure filters to the material con tainers Drainage of containers relieving the pressure The return flow hoses Fig 5 1 2 Pos 1 7 run from the high pressure filters to the empty material containers Shift the lever Fig 5 12 Pos 8 1 1 to position OPEN Return flow open Set the lever Fig 5 1 2 Pos 8 1 2 to position 22 STOP FLUSH gt Commissioning Open the ball valve Fig 5 1 1 Pos 1 5 2 on the service unit Turn the compressed air regulator Fig 5 1 1 Pos gt chapt 3 Pos 2 persz ETT zT dp u J 1 5 1 on the service unit clockwise to a pressure of approx 0 5 1 bar Version with pressure and dosing monitoring e Set the selector 2 3 switch MANUAL AUTOMA
49. lations The unit left the factory in perfect condition and guarantees a high level of technical reliability and safety Translation of the original operation manual DUOMIX 230 5 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 to the efficient working capacity of the unit All persons concerned with the set up commissioning op eration maintenance repair and servicing of the unit must have read and understood the user manual beforehand especially the chapter on Safety Your safety is at stake We recommend to the owner of this unit to have this confirmed in writing e The following must be strictly observed at any time in addition to the user manual Read and comply with the applicable guidelines for your country In Germany these are the Richtlinien f r Fl ssig keitsstrahler Guidelines for Liquid Jets ZH1 406 issued by the Hauptverband der Gewerblichen Berufsg enossenschaften We recommend to include all guidelines and accident pre vention regulations into the user manual The manufacturer s instructions and processing guidelines for coating or transfer materials are to be respected at all times In principle you should refrain from any work method that would affect the safety of 39 73374 products and the oper ating personnel 2 4 Using this machine Th
50. lvent and collecting container for each component to avoid material reactions and thus possible damage to the system The solvent temperature should not rise too high DANGER OF EXPLOSION Procedure If the device is not equipped with one of the following accessories you can skip the corresponding section Step 1 Switch of the plant completely gt For this purpose regulate the compressed air regulator chapt 3 Pos 1 5 A B on the service unit completely back Close and secure the spray gun Step 2 Version with material flow heater Make sure that the temperature regulators on material flow heater drum floor heater and hose heater have been regulated back completely Step 3 Place the return flow hoses chapt 3 Pos 1 7 into the containers D Secure these against accidental slipping out Version with filling funnel chapt 3 Pos 3 e Insert the return flow hoses into the filling funnels A B e Secure these against accidental slipping out 30 Translation of the original operation manual DUOMIX 230 477 WZ DUOMIX230S en 1001 cf Decommissioning Step 4 Prepare the solvent supply Version with suction line chapt 3 Pos 4 e Place the suction of the material pumps A B each into a container with the solvent C be longing to the material Version with filling funnel chapt 3 Pos 3 e Open the ball valves chapt 3 Pos 3 1 A B on the drain valves e Empty
51. ments are excessively Clean the filter elements of the pressure or material is transferred soiled high pressure filters or use coarser to the spray gun even though Mixing block static mixer paint hose elements the pressure in the system is high or spray gun are blocked Clean the mixing block enough The spray gun nozzle is clogged Clean or replace static mixer material hoses and spray gun Replace the spray gun nozzle 36 Translation of the original operation manual DUOMIX 230 77 WZ DUOMIX230S en 1001 cf Trouble shooting 9 Fh Posbecmse Remedy 15 When spraying the air motor of Insufficient compressed air supply Close the spray gun so that the the dual component system runs The cross section of the compressed pressure can build up again jerkily air supply line is too narrow Increase the cross section of the The spraying pressure indicated The air pressure in the supply compressed air line by the pressure gauges and the air network is too low Increase the air pressure in the net pressure drop when the spray gun The air pressure set on the Turn the maintenance unit slightly is opened maintenance unit is identical with the back pressure in the net 16 When flushing the mixing block The check valves in the mixing block Clean the mixing block with a pressure relieved dual do not work Replace defective balls valve plates component sy
52. mm 015 M 70 yellow 0 38 mm 015 0 66 mm 026 M 50 orange 0 66 mm 026 EE Q Donotuse a filter element when applying coarse pigmented or fibre filled materials However the standard suction screen chapt 3 Pos 4 2 should remain in the screen housing or be replaced by a coarse mesh screen In case of a material change both the filter element in the high pressure filter and the metal screen in the suction system must be cleaned or if necessary replaced Step 4 Hold the return hoses chapt 3 Pos 1 7 each into an empty container D and secure these against acciden tal sliiping out Step 5 Prepare the solvent supply Always keep the solvent for each component separate Translation of the original operation manual DUOMIX 230 21 Version with suction line chapt 3 Pos 4 e Place the suction of the material pumps A B into the solvent C belonging to the material Version with filling funnel chapt 3 Pos 3 e Close the ball valves chapt 3 Pos 3 1 A B on the drain valves e Fill solvent into the filling funnels Version with feed pumps chapt 3 Pos 7 Step 6 e Place the suction chapt 3 Pos 7 3 A B of the feed pumps into the solvent C belonging to the material e Open the ball valves chapt 3 Pos 7 2 A B e Turn the compressed air regulators chapt 3 Pos 7 1 A B of the feed pumps clockwise to set a pressure of approx 1 2 bar Version with d
53. n order to avoid contamination Stand the unit on a level and firm base All operating elements must be easily accessible The compressor power must match the air requirements of the unit and the diameters of the air supply hoses must match the connections so that an adequate air supply is en sured Various system components were removed and packed in a separate cardboard box for transport Install these parts by following the machine sketch attached to the user manual QConnect as follows external mixer distributor with material hose Flushing pump distributor with flushing agent hose Pressure and dosing monitoring Control cabinet for distributor with compressed air hose Distributor Spray gun s with material hose Inthe control cabinet of the distributor set all switches SPRAY and FLUSH to OFF Close and secure the spray gun before con necting it to the distributor Close the material outlet on each material pres sure regulator or distributor to which no spray gun with material hose is to be connected with a plug The plug must be designed to withstand the pressure applied to the material output see machine card DUOMIX230S en 1001 cf When mounting a distributor the use of a flush ing pump is mandatory 1 Supplement the disassembled hoses as follows Component Hoses running drawing from Feed hoses Feed pump Dosing system or optional material container Hig
54. nder the explosion protection ordinance even if the acces sory equipment as such is explosion protected Translation of the original operation manual DUOMIX 230 7 Because of the generated electrostatic charging you should only use conductive material hoses All original 497194 material hoses are conductive and designed to work optimally with our units The maximum permit ted working pressures of the hoses must be higher than or equal the maximum operating pressure of the corresponding dual component system Incase of material congestion or agglomeration of material in the spraying system residual pressures can still be present despite pressure discharge Pay full attention to this when performing repair work High pressure filter material hoses and spray guns in particular must be disassembled with greatest care to avoid accidents caused by released residual pres sures We recommend to cover the screw fitting with a cloth when unscrewing the material hoses to catch any escaping material sprays Before working on the high pressure filter e g when changing the filter the system must be completely switched off and depressurized Changing the mixing ratio may cause a change in pressure ratio and thus require the adaptation of the max permissible air inlet pressure nthis case the existing safety valve must be replaced On this occasion 3973971 will supply you with a new exchangeable type plate with the valid data
55. nts A B have been mixed with the solvent in the containers Close the circulation Guide the return flow hoses separately into sepa rate containers D and fasten them Open the circulation Empty the filling funnels through the return flow hoses Y VV VY DUOMIX230S en 1001 cf Guide the return flow hoses into the filling funnels and fasten them Take care of the exact assignment blue blue or red red o Keep repeating this step until clean solvent 1 comes running out Fill some more solvent into the filling funnels to clean the mixer Quide the return flow hoses separately into sepa rate containers D and fasten them Step 9 Shift the lever standard mixer Fig 7 1 1 Pos 8 1 1 external mixer Fig 7 1 2 Pos 8 2 1 up to position CLOSED Return flow closed Version without distributor gt Set the lever standard mixer Fig 7 1 1 Pos 8 1 2 external mixer Fig 7 1 2 Pos 8 2 2 to SPRAY Version with distributor gt Set the lever standard mixer Fig 7 1 1 Pos 8 1 2 external mixer Fig 7 1 2 Pos 8 2 2 to FLUSH n the control cabinet of the distributor set all switches SPRAY to ON Step 10 Pullthe trigger lever to unlock and open the spray gun Version with distributor Open the flushing gun to clean the distributor Spray the contaminated solvent which is in the com plete system into an open container D until clean solvent s
56. ollecting vessel under the drain valves on the filling funnels e Open the ball valves chapt 3 Pos 3 1 e Empty the filling funnels e Close the ball valves chapt 3 Pos 3 1 Do not use cone top cans or drums with bung hole to avoid possible electrostatic charging When using metal containers avoid contact between spray gun and container wall e Interrupt the compressed air supply For this purpose turn the compressed air regu lator Fig 4 2 1 Pos 1 5 1 on the service unit completely anti clockwise Version with feed pumps chapt 3 Pos 7 e Take the suction chapt 3 Pos 7 3 A B out of the solvent C belonging to the material e Completely regulate the compressed air regula tor chapt 3 Pos 7 1 A B back by turning anti clockwise DUOMIX230S en 1001 cf e Interrupt the compressed air supply For this purpose turn the compressed air regu lator Fig 5 1 1 Pos 1 5 1 on the service unit completely anti clockwise Step 10 Prepare the material supply Standard component A Blue Version with suction line chapt 3 Pos 4 e Place the suction chapt 3 Pos 4 1 A B into the material A B to be applied e Open the ball valve Fig 5 1 1 Pos 1 5 2 on the service unit e Adjust the pressure regulator Fig 5 1 1 Pos 1 5 1 to a pressure of approx 0 5 1bar e Set the control button chapt 3 Pos 5 1 for the material flow heater option to the desired temperature
57. olvent residues out of the system through the return flow hoses chapt 3 Pos 1 7 A B into the containers D until the mate rial to be applied starts to run out 1 Keep holding the return flow hoses Version with feed pumps chapt 3 Pos 7 e Place the suction chapt 3 Pos 7 3 A B into the material A B to be applied e Open the ball valve Fig 5 1 1 Pos 1 5 2 on the service unit e Adjust the pressure regulator Fig 5 1 1 Pos 1 5 1 to a pressure of approx 0 5 1bar e Set the control button chapt 3 Pos 5 1 for the material flow heater option to the desired temperature e On the version with pressure and dosing moni toring option press the start button Fig 5 1 3 Pos 2 4 for a short moment e Set the lever standard mixer Fig 5 1 2 Pos 8 1 2 external mixer Fig 5 1 4 Pos 8 2 2 to STOP FLUSH Set the lever standard mixer Fig 5 1 2 Pos 8 1 1 external mixer Fig 5 1 4 Pos 8 2 1 to OPEN Return flow open e Open the ball valve chapt 3 Pos 7 2 A B e Set the compressed air regulators chapt 3 Pos 7 1 A B for both feed pumps to 3 4 bar e Pump the solvent residues out of the system through the return flow hoses chapt 3 Pos 1 7 A B into the containers D until the mate e rial to be applied starts to run out 1 Keep holding the return flow hoses Version with flushing pumps chapt 3 Pos 6 Place the suction line chapt 3 Pos 6 2 into the
58. om g Compressed air 4 2 4 2 B 1 1 E Open Position 1 1 Air motor 1 2 Material pump 8 1 2 1 4 2 wheel rack a ie 1 4 2 Transport eyes 1 5 3 1 5 Maintenance unit 1 5 1 Compressed air regulator an 1 5 2 Compressed air shut off valve rl 1 5 3 Inspection glass 1 9 1 5 4 Drain valve 1 5 4 1 6 High pressure filter 1 9 2 4 Suction line 4 1 Suction hose 4 2 Suction screen 8 1 Standard mixer LL 8 1 1 Lever Return flow 8 1 2 Lever Spray Stop Flush optionally depending on customer s request 14 Translation of the original operation manual DUOMIX 230 993 294 DUOMIX230S en 1001 cf System description 3 DUOMIX 230 on wall bracket with pressure and dosing monitoring 1 6 i1 3 9 4 1 54 Z AP B 4 1 CT I TPS Closed IAA ee A ak ee LS LI B f 4 m P Spray un H Eien E A 1 4 G a regum i g L 8 1 Bol LP EINE s 4 5 I Es T x g f y n ca ii ar FP Lg Open LA LL Lob DN a h mr i 9 Stop Flush 8 1 2 E 1 5 4 iv 2 1 5 2 9 O O 3E c 5 8 Position 1 1 Air motor 1 2 Material pump 1 4 Wall bracket 1 5 Maintenance unit 1 5 1 Compressed air regulator 1 5 2 Compressed air shut off valve 1 5 3 Inspection glass 1 5 4 Drain valve 1 6 High pressure filter 8 1 Standard mixer 8 1 1 Lever Return flow 8 1 2 Lever Spray Stop Flush optionally depending on customer s request 33572372
59. pumps chapt 3 Pos 7 e Place the suction of the feed pumps A B into the material A B to be applied Version with flushing pumps chapt 3 Pos 6 e Place the suction line into the appropriate solvent container C 4 Start of work Observe and follow the notes given in chapter 5 1 32 Translation of the original operation manual DUOMIX230 77 WZ DUOMIX230S en 1001 cf Maintenance repair 8 1 Inspection cycles According to the accident prevention instructions for Work with fluid spraying equipment BGR 500 chapter 2 36 the unit needs to be inspected and serviced regularly by an expert 3973374 Customer Service The unit needs to be inspected gt before initial commissioning after the modification or repair of parts of the system which could affect safety after work breaks longer than 6 months but at least every 12 months For decommissioned units the inspection can be post poned until the next commissioning The inspection results must be recorded in writing and kept until the next inspec tion The inspection report or a copy thereof must be avail able at the place of use of the equipment 8 2 Maintenance plan Warning Disassembling the pressurized spraying unit can cause severe injuries to body and eyes Always switch off the spraying unit before starting maintenance and repair work Depressurize the the complete system Be extremely careful when disassembling high press
60. re the system against tipping over Do not transport any other objects e g material con tainers while lifting or loading the device Remove all loose components e g tools from the unit Never stand under suspended loads or inside the load ing area This poses a danger to life Secure the load on the transport vehicle against slip ping and falling off Parts or equipment that have been removed for trans port purposes must be attached professionally and in accordance with the intended use before commission ing 2 9 What to do in events of emergency Leakages In case of leakages the system must be shut down imme diately and the complete system must be depressurized Interrupt the complete compressed air supply of the system Regulate the pressure regulator chapter 3 Pos 1 5 1 fully back and close the compressed air shut off valve chapter 3 Pos 1 5 2 gt Even though there are no legal directives for low mist Open the spray gun and hold it into an open empty Airless spraying methods all hazardous solvent va container Take care of contact with the container pours and paint particles should be extracted gt Set the lever chapter 3 Pos 8 1 2 8 2 2 to position gt Protect a objects adjacent to the spraying object STOP FLUSH against possible damage caused by the paint mist gt Set the lever chapter 3 Pos 8 1 1 8 2 1 to position gt The owner must protect the entire system by undertak
61. repare the equipment for coating and spray painting work Prerequisites Always wear the protective clothing stipulated as solvent fumes and spilled cleaning agents cannot be entirely avoided Check all system components once again for leaks and tighten the connections Do not use cone top cans or drums with bunghole Take care that all hoses and pumps are only used with the components intended for this purpose A or B Procedure If the device is not equipped with one of the following ac cessories you can skip the corresponding section Step 1 QConnect the unit to the compressed air supply Step 2 Version with material flow heaters Adjust the desired temperature for material flow heater drum floor heater and hose heater Step 3 Version with feed pumps chapt 3 Pos 7 Regulate the compressed air regulator chapt 3 Pos 7 1 to 3 4 bar Step 4 Set the lever standard mixer Chapt 3 Pos 8 1 2 external mixer Chapt 3 Pos 8 2 2 to SPRAY Step 5 Version with distributor Set all switches SPRAY to ON Step 6 Version with pressure and dosing monitoring Chapt 3 Pos 2 The pressure and dosing unit was set acc to chapt 4 3 Setthe selector switch MANUAL AUTOMATIC chapt 3 Pos 2 5 to MANUAL Operate the start button chapt 3 Pos 2 4 for a moment DUOMIX230S en 1001 cf Step 7 Slowly set the pressure regulator chapt 3 Pos
62. ressure and dosing unit Attention Open only for repair purposes Figure 10 1 2 Fig 10 1 3 Key to adjust the spraying pressure 10 10 2 Instruction Certificate This certificate follows the EC Directive for working uten sils 85 655 EEC section II article 7 The owner of the device specified below has instruct ed the operating personnel Manufacturer type designation year of construction order number The instruction was conducted by the representative of the owner Foreman or responsible superior name department The instructed person has read and understood the user manual for the equipment listed above especially the chapter about safety and declares that he is able to operate the unit in a safe way Personnel for electric electronics date name 10 3 Machine card o This user manual is only valid in combination with 1 the following machine card The machine card contains all important and safety rel evant data and information about the machine exact designation and manufacturer data technical data and limiting values equipment and test certificate Machine identification machine components and ac cessories with article and spare parts numbers Make sure that the data on the machine card match the data on the type plate In case of discrepancies or if the type plate is missing please notify us immediately option for version with pressure and dosing unit Figure 10 1 3
63. stem and closed or compression springs ventilation the contact pressure gauge of the pressure and dosing unit indicates rising pressure 17 The flushing pump does not work The flushing pump is defective Check whether the flushing pump is when changing from SPAY to The lever Pos 8 1 2 8 2 2 on the operating FLUSH mixing block does not open Check lever 8 1 2 8 2 2 replace if necessary f necessary disconnect the flushing hose from lever 8 1 2 8 2 2 and replace it with a manual spray gun Check the function of the flushing pump 18 Compressed air escaping from the The air motor seals are worn Seal the air motor air motor at the guide axes 19 The air motor no longer works Have the air motor repaired in the even though the compressed air WIWA Service workshop supply is assured No material pressure available in the system 20 The system cannot be started The ball valve on the service unitis Open the ball valve on the service However the pressure gauge on closed unit the maintenance unit indicates Only with pressure and dosing unit Only with pressure and dosing unit pressure The pressure supply for the control Adjust the compressed air supply for cabinet is interrupted the control cabinet to 8 10 bar The filter pressure regulator on the control cabinet is incorrectly adjusted 21 Only with pressure and dosing The switch MANUAL AUTOMATIC is Set the switch M
64. tarts to run out e Do not use cone top cans or drums with bung 1 hole to avoid possible electrostatic charging When using metal containers avoid contact between spray gun and container wall Step 11 Shift the lever standard mixer Fig 7 1 1 Pos 8 1 1 external mixer Fig 7 1 2 Pos 8 2 1 down to position OPEN Return flow open Version without distributor Set the lever standard mixer Fig 7 1 1 Pos 8 1 2 external mixer Fig 7 1 2 Pos 8 2 2 to STOP FLUSH Version with distributor Inthe control cabinet of the distributor set all switches SPRAY to OFF Translation of the original operation manual DUOMIX 230 31 Step 12 Pump the material residues out of the system through the return flow hoses Pos 1 7 A B into the contain ers D until clean solvent starts to run out Keep holding the return flow hoses Shift the lever standard mixer Fig 7 1 1 Pos 8 1 1 external mixer Fig 7 1 2 Pos 8 2 1 up to position CLOSED Return flow closed Step 14 Version with feed pump chapt 3 Pos 7 Completely reduce the pressure by the com pressed air regulator chapt 3 Pos 7 1 Close the ball valves chapt 3 Pos 7 2 Step 15 Regulate the compressed air regulator chapt 3 Pos 1 5 1 on the service unit back anti clockwise until it is light to move Step 16 Version with flushing pump chapt 3 Pos 6 Completely reduce the pressure by t
65. tem before starting maintenance and cleaning work on device and spraying accessories Both the compressed air shut off valve Fig 2 6 2 Pos 1 and the com pressed air regulator Fig 2 6 2 Pos 2 on the service unit must be closed Never spray solvent or solvent containing materials into cone top cans or drums with bunghole DANGER OF EXPLOSION Always use an open container When using metal con tainers avoid contact between spray gun and container wall because of possible electrostatic charging The high flow velocities associated with the Airless spraying method may cause static charging Static discharges can cause fire and explosion The unit must therefore always be properly grounded Fig 2 6 3 The original 39733743 DUOMIX 230 is equipped with an ground cable as standard Please order immediately order no 0474487 if lost or dam aged Never operate the unit outside in case of a thunderstorm Figure 2 6 2 Figure 2 6 3 Spraying equipment designed without explosion protection must not be used in workshops that come under the explosion protection ordinance The dual component system is suitable for installation in zone 1 DIN EN 1127 1 However if agitators heaters or other electrically accessories are additionally mounted one must check the explosion protection Plugs for heaters agitators etc that do not have explosion protection may only be plugged in outside of areas that fall u
66. tures on the depres surized unit Compressed air shut off Check the lead seal on the safety valve for damage Fig 2 10 2 Check the safety valve for external damage The compressed air shut off gt Check the grounding cable for damage valve Pos 1 enables im Check the grounding cable connections on unit and IE mediate shutting down of the conductor Il unit Check the correct function of the compressed air Before starting work on the shut off valve i system the complete system Check the function of the Airless spray gun locking BIS including the feed pumps lever must be shut down and de Check the burst discs for damage pressurized 10 Translation of the original operation manual DUOMIX 230 TIRA DUOMIX230S en 1001 cf Safety If any of the safety features is not fully function 1 al or any other fault is found on the machine the system must be shut down immediately Operation of the machine must only be re sumed after the correct functional state has been re established 2 11 Handling the device and auxiliary materials Setup work maintenance servicing and repair work Before starting work you must interrupt the com pressed air supply to the machine Make sure that the machine is free of residual pressure in both the air and the material side Activity Qualification of personnel Setup work instructed user Maintenance work instructed user Cleaning work instructed user
67. ty valve Fig 2 10 1 The safety valve 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 limit ing value Safety Spray gun lock Fig 2 10 3 The spray gun must be locked for each break even for short interrup tions of work Setting the safety lever to horizontal position locks the spray l ad gun against accidental operation Figure 2 10 3 Ground cable Fig 2 10 4 The dual component system must be connected to an electrically conduc tive object with the grounding cable to prevent electrostatic charging Burst discs Fig 2 10 5 The burst discs prevent excessive exceeding of the permissible operat i ing pressure They are located inn the screw fittings behind the high pressure filters If damaged all burst discs must be replaced You can take the ordering data from the machine card Figure 240 5 Safety valve on the outlet manifold of the feed pumps no illustration feed pumps optionally available This safety valve is factory set to a maximum operating pressure of 70 80 bar This setting must not be changed All safety features must be checked Before each start up of the system Before starting work on or with the system After setup work After cleaning and servicing work After maintenance and repair work Check list to check the safety fea
68. ulator SPRAY GUN optional 250 bar Automatic valve DISTRIBUTOR FLUSHING Automatic valve SPRAY GUN 250 bar Automatic valve HOSE FLUSHING Wall bracket optional 18 Franslation of the original operation manua DUOMIX 230 VZMAA DUOMIX230S en 1001 cf Installation and assembly Problem definition You want to set up the system at the work place and pre pare it for operation Prerequisites The material to be applied is readily available 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 With dual component materials the potlife must be taken into consideration After completion of or when interrupt ing work the part of the system that had contact with the mixed material must be cleaned with the specified clean ing agent within the potlife specified by the manufacturer Please remember that higher temperatures reduce the potlife For optimal preparation of the spraying materials 9 7 324 offers a wide range of accessories like e g agitators in various sizes material preheating containers in different sizes Material Flow Heater Procedure High pressure spraying devices and systems can be installed inside and outside spray booths and rooms However outdoor installation should be preferred i
69. ure filters material hoses and spray gun Before disassembly cover the screw connections on the material hoses with a cloth to catch possi ble material spatter Check the release agent Before each start up check the release agent level in the release agent chamber if necessary add release agent up to the highest possible level Regularly check the release agent for discolouration caused by spraying material Discolouration of the release agent can be checked by draining off a small amount of release agent After the examination top up the amount of release agent that had been drained off Incase of excessive discolouration and high spray ing material content e Clean the release agent chamber e Change the pump seals see spare parts list for material pump e Fill in new release agent e We recommend to use the 3973374 release agent Order Nro 0163333 This work must only be performed by personnel trained by 3973971 or the 3973371 Customer Service DUOMIX230S en 1001 cf Filling in and drain off release agent Fig 8 2 1 The total filling quantity is approx 100 ml of release agent per pump Luftmotor air motor t T T Cr eribeTeem N C9 f mittel T 1 1T filling holes LT for lubricant Materialpumpen fluid sections Figure 8 2 1 Maintenance of the high pressure filter Clean the high pressure filter at least after every material
70. ushing pressure residues so that the entire system has been relieved The system must be completely pressureless before it is shut down Step 15 Setall switches on the control cabinet of the distributor to OFF Q In order to avoid unnecessary interruptions 1 of work make sure that the containers always contain material so that the pumps will not draw in air However if this should happen the system will automatically switch off only version with pressure and dosing monitoring Always vent the system before continuing coating work Decommissioning 7 2 Complete cleaning Problem definition You want to clean the system completely after the end of work or before changing the material Prerequisites Always wear the protective clothing stipulated as solvent fumes and spilled cleaning agents cannot be entirely avoided The following is required 2 open container with cleaning agent with the solvent belonging to the material and recommended by the manufacturer hereafter referred to as container C For each material component A B you should have a separate solvent container C available to prevent material reactions and damage to the system 2 empty open container for contaminated cleaning agent material mixture hereafter referred to as con tainer D o Do not use cone top cans or drums with bung 1 hole Both components must be kept separate also when flushing Use a separate so
71. volumetric measuring uni each to each return flow hose Fig 5 3 1 Hold the return flow hoses separately into the contain ers D and secure them against accidental slipping Out Setthe lever standard mixer Fig 5 3 1 Pos 8 1 1 external mixer chapt 3 Pos 8 2 1 to OPEN Return flow open Setthe compressed air regulator chapt 3 Pos 1 5 2 on the service unit to such a pressure that material runs out of the valves of the volumetric measuring unit into the containers Check the reading of the pres sure gauges for the high pressure filters Fig 5 3 1 Pos 1 6 o The two pressure gauges on the high pressure filters must always work synchronously Commissioning Setthe lever standard mixer Fig 5 3 1 Pos 8 1 1 external mixer chapt 3 Pos 8 2 1 to CLOSED Return flow closed Hold the return flow hoses separately into the measur ing vessels D and secure them against accidental slipping out Set the lever standard mixer Fig 5 3 1 Pos 8 1 1 external mixer chapt 3 Pos 8 2 1 to OPEN Return flow open Dose the required material quantities of components A B Completely reduce the pressure by the compressed air regulator chapt 3 Pos 1 5 2 Set the lever standard mixer Fig 5 3 1 Pos 8 1 2 external mixer Chapt 3 Pos 8 2 2 to SPRAY Set all switches SPRAY on the distributor to ON Hold the spray gun into an empty open container To relieve the pressure keep operatin

Operation Manual WIWA DUOMIX 230

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