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1. Make sure that the machine is free of residual pressure in both the air and the material side After the completion of work you must in any case check the function of all protective devices and the correct function of the machine Follow the safety notes and dosing information of the manufacturers and the generally applicable regulations when handling spraying materials cleaning agents oils greases and other chemical substances Rests of spraying material cleaning agent oils greases and other chemical substances must be collected in accordance with statutory provisions con cerning recycling and waste disposal The official local waste water laws are valid In case of leakage the system must be shut down immediately and the com plete system must be depressurized Switch off the unit by the EMERGENCY STOP switch s Make sure that the system has been depressurized Immediately replace the defective parts or have these replaced Immediately consult a physician if injured when handling fluid jets because of their cutting effect Read and comply with the instructions for fire alarm and escape routes which are displayed in your factory or at any work place Only use the extinguishing substances stipulated by the material manufac turer 2 5 FTA 3 1 Intended use of the machine 3 2 Notes on warranty 3 3 Machine environment 3 3 1 Emissions 3 3 2 Sound pressure level o Operating ma
2. Always store the machine and accessories in a closed room additional equipment 3 7 System variants with feed pumps 3 for 200 drums optionally with ge e optionally with diaphragm pumps bd a material return flow Fgura 22 gt hose bracket gt low pressure pumps Figure 3 3 with feed drum Capacity of drums 30 Figure 3 4 optionally with material return flow hose bracket Figure 3 4 Operating manual 3 3 PUA460 V1005 BAoDB 1005 en ski 3372722 3 Description of machine 3 8 System description 3 8 1 Without circulation Figure 3 5 3 8 2 With circulation Figure 3 6 3 8 3 Material flow D Figure 3 5 Figure 3 6 Operating manual 3 4 PUA460 V1005 BAoDB 1005 en ski 2972701 A Caution Ensure correct component allocation at all times 3 8 4 Compressed air control 3 8 5 Temperature control Operating manual PU460 V1005 BAoDB 1005 en ski 3 Description of machine Depending on the model version the material to be applied is directly filled into the feed drums or a feed pump is placed into the supply drum 200 bunghole barrels of each component We recommend to equip the drum with the B component isocyanate with an additional silica gel filter to prevent the material from reacting with humidity and causing crystallization of the material v2 Both components are fed to the proportioner pump and exactly metered for a 1 1 mixing ratio vg Each component is indivi
3. Make sure that the system is in parking position i i For short work breaks you may just switch the equipment to parking position The 7 1 Activate parking material temperature can be maintained T Activate parking in the display Press the n button 5x to access the PARKING touch screen gt Activate the Parking by pressing Eu The arrows indicate the current direction of rotation of the pump In parking position the pistons stop in bottom position Figure 7 1 gt Reduce the pressure by carefully pulling the trigger of the spray gun The pump switches off when the piston of the Iso material pump has reached bottom position Close the material valves on the spray gun e gt Residual ET I pressure Iso Poly appr 100 bar Operating manual 7 1 PUA60 V1005 BAODB 1005 en ski M A Oa ee 2 Switch off the heating only when required The heaters may remain activated in parking posi tion if necessary This maintains the material in the system at a uniform temperature 0 OFF bom Figure 7 2 3 Shut off the material and compressed air supply on the spray gun as described in chapter 10 3 8 End spraying P 10 7 Press the buttons Pes or switch off the equipment completely on the con 7 2 Deactivate trol cabinet parking Switch off the equipment completely if you want to take it out of operation for a 7 3 Take the system longer time out of service 1
4. drain gt Hold the return hoses into open containers to catch testing agent material mix gt Secure the hoses against accidental slipping out Operating manual 5 1 PU460_V1005_BAoDB_1005_ensski PD 4 Switch on the equipment mel Buttons L1 L3 light up 9 Switch on the unit O OFF press the green button The air inside the system Figure 5 2 must be pressed out slowly therefore do not yet apply any pressure to the meter ing system 5 Fill the material hoses incl the block with material Feed pumps and depending on the rial starts to run out Only one component 1 to 1 revolutions The specified pressures arem ial Cc ORD i i are only guide values iili pump p Duration until clean mate CE viscosity of the material or the hose length used may need to be adapted repeat with the other component Figure 5 3 6 Fill the proportioner pump with material o EEI v Both components 1 to 1 revolutions Feed pumps Duration until clean bubble free material starts to run out For initial filling with feed Proportion er pump Caution Ensure slow drums and initiual clean running of the ing with cleaning agent Pump the cleaning agent completely out of the containers Figure 5 4 Operating manual 5 2 PUA60 V1005 BAoDB 1005 en ski FTA Result Operating manual PU460 V1005 BAODB 1005 en ski 5 Comm
5. ing components has been relieved Air pressure valve on spray gun Figure 2 5 The air pressure valve must be locked for each break even for short interruptions of work Slide the air valve to position CLOSED 0 to do so With missing compressed air the material valves will stay closed All safety features must be checked before each start up of the equipment before starting work on or with the equipment after completion of setup work after cleaning and servicing work VV VV after maintenance and repair work 2 4 397733971 If any of the safety fea tures is not fully functional or any other fault is found on the machine the system must be shut down immediately Operation of the machine must only be resumed after the correct functional state has been re estab lished 2 5 Handling the system and auxillary materials 1 2 5 2 Handling auxillary materials 2 6 What to doin events of emergency Ai 2 6 1 Leakage 2 6 2 Injuries 2 6 3 Fire Operating manual PU460 V1005 BAoDB 1005 en ski 2 Safety information Check list to check the safety features on the depressurized unit Please check the lead seal on the safety valve for damage the safety valve for external damage the correct function of the master switch the function of the air pressure valve on the spray gun Before starting work you must interrupt the compressed air supply to the ma chine
6. Figure 7 7 8 Shut off the compressed air supply Operating manual 7 3 PUA60 V1005 BAODB 1005 en ski WIA 7 4 Shutting down the equipment Only use the preserving agent recommended by the material manufacturer and which matches the material 7 5 Pressure discharge 7 5 1 Without circulation and without drain hoses 7 5 2 With drain hoses optional Operating manual PU460 V1005 BAODB 1005 en ski 7 Decommissioning 1 Take the equipment out of service as described in chapter 7 3 Take the system out of service p 7 2 2 Exchange the material drums against containers with preserving agent Fill the system with preserving agent 3 Allow the residual pressure escape from system and hose package as described in chapter 7 5 Depressuring p 7 4 Disassemble the spray gun from the block as described in chapter 10 3 6 Dismantle the spray gun P 10 6 Relieve the block by opening both material valves O repeat with the other component System pres sure of this component has been relieved Figure 7 8 gt Open both drain valves on the outlet manifold to relieve the pressure Relieve the block by opening both material valves as described in chapter 7 5 1 Without circulation and without drain hoses P 7 4 Feed pumps Proportioner pump Figure 7 9 7 4 FTA 7 5 3 With circulation optional 7 6 Cleaning after spraying 7 6
7. Perform the work steps as described in chapter 7 1 Activate parking p 7 1 Switch the heating off also On versions with material feed container you must first pump out all material Figure 7 3 2 Regulate the compressed air controllers on proportioner pump and feed pumps completely back t D 0 Obar Feed pumps Obar Proportioner pump Figure 7 4 Operating manual 7 2 PU460 V1005 BAoDB 1005 en ski M A ju UM 3 Close the ball valves on the feed pumps optional 0 p EE Figure 7 5 4 Close the bungholes Close the material drums 5 Switching off the system D Switching off the system press the green button Lamps L1 L3 go out 4 Figure 7 6 The receptacles for the feed pumps must always be filled with release 6 Clean the spray gun as specified in 10 3 10 Cleanthespraygun P 10 9 agent 7 Put the feed pumps into storage only for designs with feed pumps The suction hoses of the feed pumps remain in the material drums or are stored for transportation in the receptacles fill with release agent gt For short working breaks the equipment does not need to be emptied please follow the notes of the mate rial manufacturer The material to be ap plied can be replaced by a preserving agent recommended by the material manufacturer if required Do not use any solvents secure each of the feed pumps with the safety chain
8. pressed air supply 11 Malfunctions and trouble shooting Faut Possilecause amp Remedy 7 Pressure differential Poly higher than Iso only in automatic mode 8 Pressure differential Iso highe than Poly only in automatic mode 9 Fuse has tripped 10 No compressed air available after starting the system 11 The control light of one or several phase monitoring features does not light e Note Filter Iso clogged Material drum Iso empty Filter Poly clogged Material drum Poly empty Short circuit Overloading of material flow heat ers or hose package Fuse for pneumatic valve defec tive Master switch not switched on One or several phases missing Fuse defective Clean Iso filter Replace or fill the Iso material drum Clean Poly filter Replace or fill the Poly material drum Have fuse checked and activated by a electrician Have the fuse replaced by a electrician according to the wiring diagram Switch on the master switch Have the phases checked by a electrician according to the wiring diagram Have the fuse replaced by a electrician according to the wiring diagram 1 The Reset button needs to be pressed each time a fault has been corrected If the system has shut down you must restart it by pressing the green Start button Operating manual PU4A60 V1005 BAODB 1005 en ski WIA 12 Appendix 12 1 Technical data Version wi
9. 1005 en ski M A OOOO UT 4 Installation and assembly 4 1 4 1 Setting up the unit 4 1 4 2 Assembling attachments and accessories 4 1 4 2 4 Connecting the hose package to the adapter 4 2 4 2 2 Connecting individual hose package segments 4 2 4 2 3 Connecting the hose package to the spray gun 4 2 4 3 Grounding the system 4 3 4 4 Checking the release agent level 4 3 4 5 Electric power connection 4 3 4 6 Compressed air connection 4 3 5 eeu 5 1 6 OLA oj ERR E E 6 1 7 Mileeninicrien me 7 1 7 1 Activate parking 7 1 ie Deactivate parking 7 2 7 3 Take the system out of service 7 2 7 4 Shutting down the equipment 7 4 7 5 Pressure discharge 7 4 7 5 1 Without circulation and without drain hoses 7 4 7 5 2 With drain hoses optional 7 4 7 5 3 With circulation optional 7 5 7 6 Cleaning after spraying 7 5 7 6 1 Cleaning the equipment 7 5 7 6 2 Cleaning the spray gun 7 5 8 Material change si s etweesenacese 8 1 9 uri Mete sa a a a S 9 1 9 1 Inspection schedule 9 1 9 2 Important notes 9 1 9 3 Working on the maintenance unit 9 1 9 3 1 Lubricant 9 1 9 3 2 Adjusting the fog oiler 9 2 9 3 3 Draining the condensation reservoir 9 2 9 3 4 Notes on oil reservoir and water separator 9 2 9 4 Inspection of release agent 9 3 Operating manual 0 4 PUA460 V1005 BAoDB 1005 en ski M A OO UT 10 Optional IN sa Ras 10 1 10 1 Circulation 10 1 10 1 1 Circulation system 10 1 10 1
10. compressed air no electric power supply Master switch in position OFF Equipment not switched on The material drum is empty The intake is defective A pump draws in air The intake screen is clogged Material feed pump s is are defective The dirt trap before the mate rial inlet on the dual component system is clogged The bottom valve of the pump without pressure is soiled or defective The piston valve of the pump without pressure is leaking The pump without pressure does not receive any material Both valves soiled or defective Return hoses optional mate rial hose or spray gun optional clogged The packings in the pump without pressure are leaking Filter in spray gun clogged Mixing chamber clogged Material hose or spray gun blocked by deposits The mixing chamber in the spray gun is clogged tric power supply Switch the master switch to ON Switch on the equipment Replace the material drum Replace the intake Clean or replace the intake screen Repair the feed pump s Clean the dirt trap of the dual component system Disassemble and clean the bot tom valve Replace defective ball or valve plate Disassemble and clean the piston valve Replace defective ball or valve plate Check the material supply Check the valves Check return flow hoses op tional and material hoses for free flow Check the valves Repair the pump without pre
11. key C2 gt the WWA display appears Figure 13 4 In this mask you can enter the permissible deviations for the heating separately for the material flow heaters for both components as well as for the hose pack age Figure 15 3 faktor the heating is switched off before the set temperature is reached so that overheating is avoided the higher the factor the earlier the heating will switch off input of how long the heating should remain switched off after the set temperature has been reached the higher this factor the longer the break en 337272 13 Service Symbol return to the preset basic settings The mask 3971371 settings is active over a limited period of time or can be exited by pressing this button 13 2 2 Quitting WIWA see chapter 13 1 3 Quitting Master settings P 13 2 Settings Operating manual 13 4 lt PU460 V1005 BAODB 1005 en ski SSA 13 Service Notes Operating manual 13 5 lt PU460 V1005 BAoDB 1005 en ski Head office and production site WIWA Wilhelm Wagner GmbH amp Co KG GewerbestraBe 1 3 35633 Lahnau Germany Phone 49 6441 609 0 Fax 49 6441 609 50 E mail info wiwa de Internet www wiwa de WIWA LP 3734A Cook Blvd Chesapeake VA 23323 USA Phone 1 757 436 2223 Fax 1 757 436 2103 Toll Free 1 866 661 2139 E mail info wiwa com Internet www wiwa com WIWA Taicang Co Ltd Add No 87 East Suzhou Rd Taic
12. or replace the mix module Regulate the material tempera ture accordingly Clean or replace the filter ele Check valves dirty ments Clean or replace the check valves 7 Gelated or hardened material in gt Incorrectly directed material air gt Clean or replace the check the air channels to the front cap in hoses valves 8 Material emerges from the back Sealing nut loose Slightly tighten the seal Se Spal gt Back side seal worn or damaged gt Replace the backside seal 9 Rapid build up of material on the Insufficient air flow to the front Increase the air flow to the front round jet nozzle or the front cap Cap Cap 10 Spray gun triggers only very gt O rings dry or worn gt Wet the spray gun with spray gun slowly oil gt Replace and lubricate the O rings gt Replace the O rings on slide valve 11 Pressure loss on air outlet gt Damaged O rings on slide valve gt Damaged O ring on piston Replace the O rings on piston Operating manual PU460 V1005 BAODB 1005 en ski FTA 11 3 Error messages on the control cabinet Fat Possibecause Remedy 1 Overpressure lso 2 Overpressure Poly 3 Overtemperature B Reset flash ing 4 Overtemperature A Reset flash ing Operating manual PU460 V1005 BAODB 1005 en ski gt Mixing element clogged on the Poly side opray gun filter clogged Dirt trap Poly clogged Sensor cable no
13. pumps and the spray gun The required working pressure for the feed pumps and the proportioner pump can be regulated by the pneumatic regulators on the control cabinet The maximum operating pressures must thereby be complied with see chapter Technical data v Figure 3 5 Figure 3 6 The temperatures for both material flow heaters and for the hose package are adjusted by thermostats on the control cabinet of the equipment The automatic temperature control prevents overheating of the material Depending on local conditions concerning electric power supply the power level for the material flow heaters can be reduced 3 5 3372522 3 Description of machine 3 9 System components optional design with low pressure pumps 3 1 Iso 3 5 Iso 3 2 Iso 3 6 Iso optional 3 3 Iso 6 2 6 Poly Iso Figure 3 7 Operating manual 3 6 PUA60 V1005 BAoDB 1005 en ski S A Operating manual PU460 V1005 BAODB 1005 en ski 3 Description of machine Proportioner pump Air motor Material pump Control cabinet see chap 3 9 Control cabinet Distributor Material hose connection Material pressure gauge Connection material hose hose package Connection compressed air hose spray gun Material pressure switch Connection return drain hose optional Maintenance unit Compressed air connection Connection compressed air line to proportioner pump Connection compressed air line to proport
14. setting Operating manual PUA460 V1005 BAODB 1005 en ski 3 Adjust the compressed air supply Feed pumps 2 pump Caution Proportioner 6 Operation Ensure slow running of the pump Figure 6 4 4 Switch on the heating system gt Roll out the hose package completely Adgjust the desired temperature in the display In this respect follow the notes in chapter S 10 Control cabinet p 3 8 Wait until the material has been heated up to spraying temperature Adjust the temperature for material flow heaters and hose package Press 3X Figure 6 5 gt Switch on the heating VON The switch only lights during the heating phase Once the nominal temperature is reached the light in the corresponding switch goes out x 0 OFF Figure 6 6 6 2 Switch on when re quired if the electric ally connected load is not high enough switch to 1 2 Caution This means that a lower heating power is also pos sible FTA Operating manual PU460 V1005 BAODB 1005 en ski 6 Operation 5 Pressure equalization of both components Due to the differences in material characteristics of standard component and hardener component the pressure in the system may have increased differently during the heating phase For optimal working results we recommend a maximum pressure difference of 10 20bar between both components max Druckdifferenz EC PTT Iso Pol
15. should be preferred in order to avoid contamination Before connecting the unit to the mains supply check whether the prescribed electrical data complies with that available at the installation site The machine must only be taken into service under frost free weather condi tions to avoid crystallization of material and thus damage to the equipment This system requires a solid mounting surface and sufficient free space for safe operation The access to the safety features must be kept clear Always keep the working area especially all walkways and standing areas clean and tidy Clean up spilled paint or cleaning agents immediately Always ensure for sufficient aeration and ventilation at the workplace to avoid damage to health and material objects Always observe the processing instructions issued by the material manufac turers Protect objects adjacent to the spraying object against possible damage caused by the paint mist 3 2 337272 3 Description of machine The owner must protect the entire system by undertaking appropriate lightning protection measures Protect the equipment against rain and moisture Do not store outside Strictly comply with the valid accident prevention instructions 1 gt Atthe place of use apply the parking brake for the wheels Figure 3 1 Pos 2 Store the machine in a frost free vibration free dry and preferably dust free 3 6 Storing the environment machine and
16. temperature the outer surface of the adapter can heat up considerably You should therefore always wear protective gloves when having to work on the adapter Changing the mixing ratio may cause a change in pressure ratio and thus require the adjustment of the max permissible air inlet pressure In this case the existing safety valve must be replaced Consultation with 4947341 is highly recommended The system should never be operated without safety valve If the safety valve needs to be replaced you can find the corresponding order number on the machine card The maximum operating pressure specified by us must generally be adhered to for all W WA parts e g pump heater hoses spray gun safety valve At varying operating pressures the lowest value is always valid as the maximum admissible operating pressure for the entire system General example Pump up to 240 bar Material hose up to 600 bar Spray gun up to 240 bar The maximum permissible operating pressure for the entire system in this example is 240 bar When used in atmospheres containing solvents there is the danger that the power cable could become flawed or porous gt Therefore the power cable must be checked for externally visible damage before each start up Never repair a power cable Damaged power cables must always be com pletely replaced This work must be carried out by a professional electrician 2 2 337 FA 2 Safety information 2
17. the mix module as follows Slide the module with the smaller diameter forward over the valve rod in the spray gun body Carefully align the pin of the module in the recess of the module seat ring Press the module firmly into its seat Figure 10 15 Check the correct seat of the pin once again The pin must match the slot in the module seat ring Inlet Poly and Iso are slightly offset to each other Section A A Rear view of the module Caution Drill only to the middle of the module Do not drill directly through the module Figure 10 17 gt Check the round jet nozzle for cleanliness The nozzle can be cleaned with a drill bit of appropriate size Apply a slight amount of grease to the round jet nozzle Slide the round jet nozzle over the mix module 10 8 337272 10 Optional equipment Mount the front cap over the round jet nozzle with the three screws Figure 10 14 Tighten the screws very tight SW8 Slightly grease the front face of the front cap Disassemble the spray gun from the block 10 3 10 Clean the spray 1 did gun Never submerge the spray gun in solvent for cleaning since this will cause dam age to the O rings and the slide valve of the trigger Pos Designation 2 Mix module 6 Filterelement O ring Figure 10 19 gt Remove all material residues from all parts and material conducting passages Use a cleaning agent soaked cloth to remove deposits e g caused
18. 1 5 Danger caused Never spray cleaning agent or materials cleaning agent containing into cone by explosion top cans or drums with bunghole Always use open containers Place the containers on a grounded surface When using metal containers avoid contact between spray gun and container wall due to 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 original 3973974 DUOMIX PU 460 is grounded via the electrical connection as standard Never operate the unit outside in case of a thunderstorm Because of the generated electrostatic charging you should only use conduc tive material hoses All original 4973974 material hoses are conductive and per fectly matched to our equipment The maximum permitted working pressures of the hoses must be higher than or equal the maximum operating pressure of the corresponding dual component system Switch off all heaters when working with cleaning agents in the material circuit e g complete cleaning Complete cleaning must only be performed after the system has cooled down 2 1 6 Danger caused The system must NOT be operated in explosion protection zones by disregarding the opraying equipment designed without explosion protection must not be used in explosion protection workshops that come under the explosion protection ordinance Persons under the age
19. 1 Cleaning the equipment For cleaning use only cleaning agents recom mended by the material manufacturer 7 6 2 Cleaning the spray gun Operating manual PU460 V1005 BAODB 1005 en ski 7 Decommissioning The material pressure in the system is relieved through the return flow hoses The material is returned into the material drums After relieving the system the pressure in the hose package be relieved by pulling the trigger on the spray gun once again Feed pumps Proportioner pump Figure 7 10 1 Take the equipment out of service as described in chapter 7 3 Take the system out of service p 7 2 2 After each use clean the equipment externally with the cleaning agent recommended by the material manufacturer 3 Fill the entire system with preserving agent Please observe the notes of the material manufacturer Clean the spray gun including the block as specified in chapter 10 3 10 Clean the spray gun P 10 9 7 5 FTA 8 Material change 1 Decommissioning gt Perform the work steps as described in chapter 7 3 Take the system out of Never allow the system to service p 7 2 run empty This prevents the intake of air which could cause faults in the 2 Clean the intake screen dirt trap pressure build up for both components and crystal lization of the isocyanate Replace empty material drums with full ones in due l time 3 Operation Clean the material screen of
20. 2 Circulation Ventilation 10 1 10 2 Silica gel filter 10 2 10 3 Spray gun 10 3 10 3 1 Spray gun components 10 3 10 3 2 Safety features 10 4 10 3 3 Notes on operation 10 4 10 3 4 Connecting the spray gun to the hose package 10 5 10 3 5 Check the spray gun 10 6 10 3 6 Dismantle the spray gun 10 6 10 3 7 Start spraying 10 6 10 3 8 End spraying 10 7 10 3 9 Spray gun maintenance 10 7 10 3 10 Clean the spray gun 10 9 11 Malfunctions and trouble shooting 11 1 11 1 General trouble shooting 11 1 11 2 Trouble shooting on the spray gun 11 3 11 3 Error messages on the control cabinet 11 4 12 Yl csaak E aa 12 1 12 1 Technical data 12 1 12 2 Auxiliary materials 12 2 12 3 Tools 12 2 12 5 Instruction Certificate 12 5 13 E de E A jaaa 13 1 13 1 Master settings 13 1 13 1 1 Pressure settings 13 1 13 1 2 Setting the stroke counters 13 2 13 1 3 Quitting Master settings 13 2 13 2 WIWA Settings 13 3 13 2 1 Settings for the permissible temperature differences 13 3 13 2 2 Quitting WIWA Settings 13 4 Operating manual 0 5 PUA460 V1005 BAoDB 1005 en ski FATA 1 1 1 2 Important for your safety Machine card m e Operating manual PU460 V1005 BAODB 1005 en ski 1 Foreword Operating personnel should always have access to this user manual The owner of the unit must ensure that the operator of the unit always has an operating manual at his her disposal in a language he she understands All persons i
21. 460 V1005 BAoDB 1005 en ski 3 Description of machine Disconnect the entire power supply for the machine even for short transport distances Empty the machine before transport Do not transport any other objects e g material containers while lifting or loading the device Remove all loose components e g tools from the unit Caution when loading with hoisting gear Ensure sufficient load bearing capacity of lifting gear and lifting tackle when loading the machine The device must only be lifted by the lifting and lashing points provided for this purpose Figure 3 1 Pos 1 Watch out for freely suspended suspension ropes When using a forklift truck make sure that the lifting fork is long enough at least 100 cm The lifting fork must only be inserted into the rack from the front towards the control cabinet and through all and fork openings Figure 3 1 Pos 3 Never stand under suspended loads or inside the loading area This poses a danger to life You will find the dimensions and weights of the equipment on the machine card Secure the load on the transport vehicle against slipping and falling off Figure 3 1 Pos 2 Parts or equipment that have been removed for transport purposes must be attached professionally and in accordance with the intended use before com missioning The 19 71371 DUOMIX PU 460 can be installed inside and outside spray booths and rooms However outdoor installation
22. FATA Table of Contents 1 FOWO s EEE AO 1 1 1 1 Important for your safety 1 1 1 2 Machine card 1 1 1 3 Pictograms 1 2 1 4 Labels on the machine 1 3 2 Safety I AT MA a 2 1 2 1 Danger sources 2 1 2 1 1 Dangers caused by the spray jet 2 1 2 1 2 Danger to health 2 2 2 1 3 Danger for equipment 2 2 2 1 4 Danger caused by electric voltage 2 2 2 1 5 Danger caused by explosion 2 3 2 1 6 Danger caused by disregarding the explosion protection 2 3 2 2 Operating personnel 2 3 2 2 1 Setup maintenance service and repair work 2 3 2 3 Protective equipment 2 3 2 4 Safety features 2 4 2 5 Handling the system and auxillary materials 2 5 2 5 2 Handling auxillary materials 2 5 2 6 What to do in events of emergency 2 5 2 6 1 Leakage 2 5 2 6 2 Injuries 2 5 2 6 3 Fire 2 5 3 Description OF machine sssaaa aa 3 1 3 1 Intended use of the machine 3 1 3 2 Notes on warranty 3 1 3 3 Machine environment 3 1 3 3 1 Emissions 3 1 3 3 2 Sound pressure level 3 1 3 4 Transporting the machine and additional equipment 3 2 3 5 Place of installation of the machine 3 2 3 5 1 Safety measures at the place of installation 3 2 3 6 Storing the machine and additional equipment 3 3 3 7 System variants 3 3 3 8 System description 3 4 3 8 1 Without circulation 3 4 3 8 2 With circulation 3 4 3 8 3 Material flow 3 4 3 8 4 Compressed air control 3 5 3 8 5 Temperature control 3 5 3 9 System components 3 6 3 10 Control cabinet 3 8 Operating manual 0 3 PU460 V1005 BAoDB
23. ack to the welcome screen Adjustments password protected Alarm display Figure 3 9 Display overview F1 F2 F3 F4 F5 return previ Welcome Temperature ous menu screen System status Stroke coun Temperature ter settings setting Master password Adjustments Alarms Pressure settings Master password WIWA Set Stroke coun tings ter volume WIWA Password Language selection Brightness 3 9 3 Description of machine WIA Navigation F Pre settings MASE and WIWA are password protected Changes can only be made by persons with access rights Master and or WIWA Operating manual PUA460 V1005 BAODB 1005 en ski 1 Welcome screen After switching on the system the display shows the welcome screen During C you can return to the welcome screen at any time by pressing the button Figure 3 10 In each other mask the following symbols may appear in the top right hand cor Caution A malfunction is reported leg To display the malfunction press button on the display Follow the notes in chapter 11 Malfunctions and trouble shooting The system runs in automatic mode Pressure differential monitoring is deactivated Input changes can be made in the SETTINGS mask password protected Press the button iz to reach the mask SETTINGS In this menu you can make influential settings for the work process We recommend to determine the follow
24. ang city Jiangsu province 215400 P R China Phone 86 512 5354 8858 Fax 86 512 5354 8859 E mail info wiwa china com
25. aterial hoses with a cloth to catch possible material spatter Check the lubricant for the air motor in the reservoir of the maintenance unit and top up if required High humidity can cause icing of the motor Pos Description 5 1 Connection compressed air line operator side JE 2 Connection compressed air line to Do E LX proportioner pump B LE 3 Connection compressed air line to spray gun 4 Connection compressed air line to feed pumps Goo 6 ems J 8 Water separator Figure 9 1 9 1 WIA 9 3 2 Adjusting the fog oiler Only use the lubricants and anti freeze agents mentioned in chapter 12 2 Auxiliary materials 9 3 3 Draining the condensation reservoir 9 3 4 Notes on oil reservoir and water separator Operating manual PU460 V1005 BAODB 1005 en ski 9 Maintenance Letthe proportioner pump run slowly Check 1 drop of lubricant after approx every 10 15 double strokes of the air motor If necessary adjust the regulating screw on the lubricator with a screw driver gt Check the amount of oil in the oil reservoir every day The maintenance unit must never be operated without oil The max oil level is indicated by a circumferential groove in the bowl 1 Lubricant 10 15 double strokes Figure 9 2 The accumulated condensate is automatically drained off through the drain valve For this purpose place the hose in
26. ay pattern control valve for spraying fog gt Front cap for leakage gt Therear seals in the nut for leakages Figure 10 9 Tighten the nut only so far that leakages are eliminated Do not overtighten Figure 10 11 10 3 6 Dismantle the 1 Connectthe material valves to the block spray gun 2 Close the air pressure valve and pull off the compressed air hose 3 Operate the trigger on the spray gun once again 4 Loosen the fastening screws on the block 10 3 7 Start spraying Open the material valves Open the air pressure valve Pull the trigger Figure 10 12 Operating manual 10 6 PUA460 V1005 BAoDB 1005 en ski 337272 10 Optional equipment 10 3 8 End spraying 1 Release the trigger 2 Connect the material valves to the block 3 Remove possibly stick ing material plugs by pulling the trigger once again 4 Close the air pressure valve Figure 10 13 10 3 9 Spray gun Lubrication maintenance gt Lubricate the air inlet every day with 2 3 drops of spray gun oil gt Lubricate the grease nipple regularly with grease until clean grease appears in the module receptacle Figure 10 12 Figure 10 14 Filter change e Soiled or damaged material filters can cause malfunctions in the spraying 1 Note process such as overpressure of a component You should therefore clean the filters at regular intervals The filter size depends on Use the material filters recommended be the material manufacturer fo
27. before starting maintenance and cleaning work on the unit or the spraying accessories Figure 2 2 gt n case of material congestion or agglomeration of material in the spraying system residual pressure can still be present despite pressure discharge Pay full attention to this when performing repair work Material hoses and spray gun in particular must be disassembled with great est care to avoid accidents caused by release of residual pressure When disconnecting material hoses we recommend to cover the hose con nection with a cloth to catch any escaping material sprays 2 1 WIA 2 1 2 Danger to health A 2 1 3 Danger for equipment A A 2 1 4 Danger caused by electric voltage A Operating manual PU460 V1005 BAoDB 1005 en ski 2 Safety information 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 39739741 customer service or W WA directly We would like to point out that we have a series of dual component sys tems in rust and acid proof design available for such materials DANGER OF BURN INJURY Depending on the set
28. by spray fog from the spray gun 3 Clean the block Clean the outside of the block with a cloth soaked in cleaning agent gt Thoroughly remove any material residues from the material outlet opening Caution Use only lubrication 4 Grease the contact areas on spray gun and block greases recommended by the material manufacturer Operating manual 10 9 PUA60 V1005 BAODB 1005 en ski S A 11 Malfunctions and trouble shooting 11 1 General trouble shooting Fh Pobecme Remedy 1 The equipment does not start Energy supply interrupted no Ensure compressed air and elec The feed pumps work without interruption no material comes out of the spray gun The feed pumps do not delver any material into the dual compo nent system No pressure built up by a pump during downwards stroke of pro portioner pump The pressure of the other components rises No pressure built up by a pump during upwards stroke of propor tioner pump A pump does not generate pres sure in up and down stroke The pressure of the other compo nent is very high When venting the pressure of one component remains applied The pressure of the other compo nent drops When spraying the pressure of a component always increases in comparison with the other com ponent When spraying not enough pres sure or material is transferred to the spray gun even though the pressure in the system is high enough
29. ck above the flag into the field The selected language is identified with a green bar Figure 3 17 other languages optional Press Ef Setting the brightness 9 ux By pressing the buttons 4 v you can match the brightness of the display to the local conditions ES ER E Figure 3 18 Operating manual 3 14 ePU460_V1005_BAoDB_1005_en ski 3 Description of machine S A Alarm 10 Here you will be informed about possible malfunctions Display of malfunctions in case of overpressure to trigger a fuse or concerning excessive temperatures Display of malfunctions which may occur in the material flow heaters or in the hose package e g faults on the temperature Ll a 2 Line to display the pressure differential 1 Text line 2 Text line 3 Text line Figure 3 19 Operating manual 3 15 lt PU460 V1005 BAoDB 1005 en ski FTA 4 1 4 2 Prerequisites Setting up the unit Assembling attachments and accessories Operating manual PU460 V1005 BAODB 1005 en ski 4 Installation and assembly The material to be applied is readily available Prepare the material by following the instructions of the material manufacturer All materials to be sprayed must be supplied from the manufacturer with data concerning viscosity application temperatures mixing ratios etc If this is not the case consult the corresponding manufacturer and ask for these data F
30. dually heated to the required processing temperature in a material flow heater The temperature is automatically regulated in accord ance with the temperature setting Preset upper temperature limits make sure that the material will not be overheated For short breaks the heating may remain switched on v The material flow is controlled on the outlet manifold a for spraying to the spray gun b only optional to vent the system back into the delivered drum v When spraying the material is directed through the heated hose package to the spray gun The hose package contains a compressed air line to supply the spray gun with compressed air as well as a material hose for each component with a 3m whip end Secand temperature sensor is integrated in the whip end v Mixing of material only takes place in the pneumatically controlled spray gun The spray pattern can be pneumatically influenced with the jet regulating screw as required The material flow is controlled by opening and closing the mixing chamber With the spray gun closed the material residue in the mixing chamber is mechanically forced out A material plug that may possibly be stuck in the outlet opening can be removed with the help of compressed air v Figure 3 5 Figure 3 6 The compressed air supply provided by the customer is connected to the main tenance unit of the equipment From there the compressed air is directed to the proportioner pump the feed
31. each component on the proportioner pump or replace it if excessively soiled Perform the work steps as described in chapter 6 1 Start of work p 6 1 Operating manual 8 1 PUA60 V1005 BAODB 1005 en ski FATA 9 1 Inspection schedule 9 2 Important notes 9 3 Working on the maintenance unit 9 3 1 Lubricant Operating manual PU460 V1005 BAODB 1005 en ski 9 Maintenance 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 a trained W WA 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 service breaks longer than 6 months butatleast every 12 months For decommissioned units the inspection can be postponed until the next com missioning The inspection results must be recorded in writing and kept until the next inspection The inspection report or a copy thereof must be available at the place of use of the equipment Disassembling the pressurized spraying unit can cause severe injuries to body and eyes Always switch off the equipment before starting maintenance and repair work Depressurize the complete system Beextremely careful when disassembling material hoses and spray gun Before disassembly cover the screw connections on the m
32. em 4 4 Checking the release agent level 4 5 Electric power connection A 4 6 Compressed air connection Result Operating manual PU460 V1005 BAODB 1005 en ski 4 Installation and assembly The high flow velocities associated with the Airless spraying method may cause static charging Static charges can cause fire and explosion System component Description of grounding polyurea unit Spray gun Grounding is accomplished in connection with the W7WA material hoses W7WJA Material hoses are conductive Material supply containers external Object to be sprayed Cleaning agent container gt Check the release agent level see also chapter 9 4 Checking the release agent p 9 3 Grounding acc to local regulations gt Connect the unit to the local mains supply This work must only be carried out by professional electricians Locally valid regulations must be followed at all times gt Connect the unit to the local compressed air supply O yu n eo me i Feed pumps Proportioner pump Compressed air connection on either side Figure 4 3 The machine has been set up for initial start up 4 3 FATA 5 Commissioning After assembly in the factory the correct functioning of this machine was checked with a testing medium All material hoses and the proportioner pump must first be filled with the material Do not switch on any to be applied heater w
33. ge segments A Caution Ensure correct component allocation at all times 4 2 3 Connecting the hose package to the spray gun Operating manual PU460_V1005_BAoDB_1005_ensski 4 Installation and assembly gt Connect all hoses and cables to the adapter as follows Figure 4 1 viewed from the front towards the control cabinet Pos Designation ES Material hose Mame EN Material hose Iso Compressed air hose for spray gun Plug of temperature sensor 6 Plug for hose package heater Figure 4 1 gt Connect the individual hose package segments Figure 4 2 The hose package can be made up of several hose package segments of 15m each The assignment of the individual material hoses can be recognized by the colour coding gt 3 phase max 6 hose package segments whereby only 2 hose package segments of the same type max 2x L1 2x L2 2xL3 may be connect ed so that optimal power distribution is assured at all phases gt 1 phase connect max 3 hose package segments type L1 Hose package Hose package e g L1 e g L2 Material hose Poly Material hose Compressed air hose for spray gun Plug of temperature sensor Plug for hose package heater gt Connectthe spray gun to the hose package Respect and follow the notes in chapter 10 3 4 Connecting the spray gun to the hose package p 10 5orinthe associated operating instructions for the spray gun used 4 2 FTA 4 3 Grounding the syst
34. hen using The entire system should first be flushed with the cleaning agent recommended cleaning agents by the material manufacturer and belonging to the material before it is filled with the material to be applied to make sure that the spraying material is not contami 9oo000 nated by the testing medium Always wear the specified protective clothing The equipment has been set up and connected as specified in chapter 4 nstalla Prerequisites tion and assembly p 4 1 The following is required aim 1x if required Poly a Cleaning Procedure 1 Prepare the material Open the bungholes on the material containers A Caution gt Connect the material and compressed air sides of the feed pumps to the external material containers or fill the material to be applied into the feed fun allocation at all times The Iso material has a tendency to crystallize when coming into contact with humidity We therefore recommend to have the material container for this component additionally fitted with an optional 3973471 silica gel filter see chapter 10 2 Silica gel filter p 10 2 Please observe the notes of the material manufacturer siis guit Open the shut off valves for compressed air and material optional on each feed pump Poly Iso Figure 5 1 2 Disassemble the spray gun from the block see chapter 70 3 4 Dismantle the spray gun p 10 6 3 For optional version with circulation
35. ies do not belong to the scope of delivery of the equipment but can be purchased optionally after consultation with 7 A jOrdernmber Description 10 10 10 10 0 0654652 Mounting kit for hose bracket for 15m 30m 45m hose package 0654696 Mounting kit for hose bracket for 60m 75m 90m hose package no picture 0654784 Protective hose black with hook amp loop fastener without insulation for hose Raed i 0654785 Protection hose clear foil for hose Protection hose clear foil for hose package its 0654481 Diaphragm pump 0654676 Mounting kit with stainless steel container 0654688 Mounting kit for Circulation with drain 0654689 Mounting kit for Circulation with return Operating manual 12 3 PU460 V1005 BAoDB 1005 en ski 12 Appendix Order number Description 1 1 1 1 1 0654664 Mounting kit for silica gel filter for feed pump without return 0641716 Mounting kit for silica gel filter for feed pump with return 0654671 Protection hood for control cabinet Impingement mix spray gun 0654523 Mounting kit for spray gun connecting nipple 0654546 Accessory kit for spray gun no picture see spare parts list for Mix modules and round jet nozzles for spray gun spray gun Operating manual 12 4 PUA60 V1005 BAoDB 1005 en ski FTA 12 5 Instruction Certificate Operating manual PU460 V1005 BAODB 1005 en ski 12 Appendix Manufacturer type designation year of const
36. igure 1 2 Warning label Caution Hot surface on adapter Figure 1 3 1 3 FTA 2 1 Danger sources 2 1 1 Dangers caused by the spray jet Figure 2 1 Jr 9 ILL i W WA SR 0 OFF ON Figure 2 2 Operating manual PU460 V1005 BAODB 1005 en ski 2 Safety information 2 Safety information Please remember that dual component systems work with extremely high pres sures and may cause life threatening injuries if used inappropriately Always pay attention to and follow all notes in the user manuals for the optionally offered accessory equipment Pay particular attention to the chapter on safety notes for the corresponding components Please comply with the following instructions Never point the spray gun at yourself other persons or other living beings Never hold your fingers or hand in front of the spray gun and never reach into the jet spray Material hoses must be able to withstand pressures beyond the maximum working pressure Material hoses must never be repaired Never try to seal leakages on connections or high pressure hoses by hand or by wrapping fabric around them In case of leakages immediately depressu rize the entire system spray gun hose pump etc Defective parts must be replaced Lockthe spray gun s each time work is interrupted even for short breaks and check that it is properly secured Figure 2 1 Switch off the machine
37. ilhelm Wagner GmbH amp Co KG are used usability with our units is guaranteed It is however mandatory to respect the safety regulations of the accessories and spare parts These safety regulations are found in the corresponding user manuals for the accessories If foreign accessories or spare parts are used the company WIA cannot guar antee the safety of the entire system Similarly liability is null and void for dam ages or injuries incurred through use of those accessories and spare parts Depending on which materials are processed hazardous fumes may be gener ated For this purpose always ensure for sufficient aeration and ventilation at the workplace for avoiding damage to your health and property You should always follow the processing information issued by the material manufacturers The sound pressure level of this unit is lower than 85 db A However operating personnel should still be provided with suitable noise protec tion equipment The operator is responsible for adhering to the accident preven tion regulation Noise BGV B3 For this purpose pay particular attention to the conditions of the installation location e g will the noise exposure increase if the system is set up in or on hollow bodies 3 1 WIA 3 4 Transporting the machine and additional equipment Figure 3 1 3 5 Place of installation of the machine 3 5 1 Safety measures at the place of installation Operating manual PU
38. ing parameters before starting work gt Units for display values Press the corresponding button to choose the unit in which the values should be u Press again to return to the previous window Figure 3 11 3 10 FTA Display of current temperature Large display E Display of the system status E Operating manual PU460 V1005 BAODB 1005 en ski 3 Description of machine gt Print setting Master password protected gt WIWA settings WIWA password protected The current temperatures for both material flow heaters and for the hose package are displayed ACTUAL temperature values ACTUAL temperature values Figure 3 12 4 The current temperatures for both material flow heaters and for the hose package are displayed These can be directly compared with the NOMI NAL values The display additionally shows the current pressures of both components as well as the pressure differential between both components NOMINAL tem perature values Temperatur IST Werte Pressure Pressure ACTUAL ACTUAL values values numerical graph value Pressure differential graph gt selected unit Figure 3 13 3 11 WIA Displays the nominal temperature Display of stroke counters Operating manual PU460_V1005_BAoDB_1005_ensski 3 Description of machine Here the NOMINAL temperatures are specified for each component and for the hose package P
39. ioner pump Connection compressed air line to feed pumps Deicing of control valve FF Heated hose package Reverse flow spray gun see chapter 3 10 Spray gun Connection compressed air hose spray gun Connection ot heated hose package 7 Feed pump design Diaphragm pump 8 jReleaseagentchambe 9 Receptacle 0000 10 Material Flow Heater o Frame 000000000000 00000000000 Frame 12 Too 3 7 33722722 3 Description of machine 3 10 Control cabinet 11 10 9 8 7 3 10 1 Components on the control cabinet 12 13 T cc 14 6 5 15 v B 4 3 N 2 Figure 3 8 Position Description 6 Touch screen monitor S 7 Button SYSTEM ON Button SYSTEMON 00 9 Control lamp phase monitoring phase 2 14 Compressed air regulator proportioner pump Compressed air pressure gauge proportioner pump not available for single phase design Operating manual 3 8 ePU460_V1005_BAoDB_1005_en ski FTA 3 10 2 System control Operating manual PU460 V1005 BAODB 1005 en ski 3 Description of machine The touch screen display is used to enter or read the following values ACTUAL and nominal temperature individually for both material flow heaters and for the hose package ACTUAL value for the applied material quantity gt Activation of parking position Display of malfunctions Language selection G to call up the desired menu back to the previous menu b
40. issioning 7 only for optional version with circulation drain gt Open the circulation as described in chapter 10 1 Circulation p 10 1 Catch the testing medium material mix in the collecting container gt Connect the circulation as described in chapter 10 1 Circulation p 10 1 as soon as clean material starts to run out Fasten the return hoses to the material container 8 Pressure test gt Check the entire system for leakage In case of leakage abort the start up process and have the malfunction corrected by trained personnel 9 Open the deicing Onthe maintenance unit open the regulator for deicing the air motor Figure 6 4 The deicing may stay open over the entire life cycle of the equipment Figure 6 1 The unit is ready for operation You may continue with the normal operation of the system as per chapter 6 Operation p 6 1 or switch off the system as described in chapter 7 Decommissioning p 7 1 5 3 FATA 6 Operation IK 2 h a XC Wr Iso P as O 0 Always wear the specified protective clothing The following is required 1x ans Poly Prerequisites gt The equipment has been prepared as specified in chapter 5 Initial start up UNE 5 1 Short Short description Test state state Comment Material is available miu INE EM a Compressed air connection closed Always observe and follow the warnings and data sheets of the materia
41. l manufacturer menea a vented Circulation drain closed optional A 1 Switch on the equipment Caution pne Buttons L1 L3 light up 2 O Switch on the unit O OFF press the green button Make sure that the equip ment is never left unat tended during operation In events of emergency you must be able to react instantaneously Figure 6 2 2 Secure the material feed or fill the material teed funnels with the material to be applied Open the shut off valves for compressed air and material optional on each feed pump Figure 6 3 Operating manual 6 1 PUA60 V1005 BAODB 1005 en ski The specified pressures are only quide values and depending on the viscosity of the material or the hose length used may need to be adapted Mum The nominal tem beatis of the material flow heaters are much quicker reached than the temperatures of the hose package Therefore switch on the hose package first and the heater for the material flow heating with a slight delay To be able to achieve an optimal spraying result the entire system includ ing the hose package must have been heated up to the pre set tempera ture before spraying is started Caution If the pressure of the proportioner pump is set too high during the heating phase the pressure of one of the components may increase to overpres sure ad thus switch off the equipment You should therefore ensure a low pressure
42. ling is adjustable selected unit Operating manual 13 1 lt PU460 V1005 BAoDB 1005 en ski 337272 13 Service 13 1 2 Setting the stroke Press rz counters Take this value from the type plate of the proportioner pump or the information in chapter 12 1 Technical data p lt gt This information is for the daily or total quantity counters regarding the delivered volume per litre see Figure 3 13 Figure 13 3 13 1 3 Quitting Master Possibilities to exit this menu settings Possibility Description 1 E Press until you have entered the mask Settings Activate Logout The mask used last before making the settings with open Press another function key Eg Ea Eg eg gt Automatic logout after time has elapsed Operating manual 13 2 lt PU460 V1005 BAODB 1005 en ski S A 13 2 WIWA Settings The WIWA Customer Service has unlimited Master rights see chapter 13 1 Master settings P 13 1 After logging in you can use Fa only to navigate between the masks Set tings Pressure Settings Stroke Counter Settings and WIWA Settings 13 2 1 Settings for the permissible temperature differences Operating manual PU460 V1005 BAODB 1005 en ski 13 Service Changing of W WA settings is strictly reserved for the 49473971 customer service You can access the corresponding display by gt gt uli pressing gt Enter your W WA password and confirm with the ENT
43. mount the block to the spray gun Front cap 10 Trigger guard Spray jet control Operating manual 10 3 lt PU460 V1005 BAODB 1005 en ski WIA 10 3 2 Safety features Do not open these valves if the spray gun is not con nected or when the mate rial outlets of the block are not directed into a suitable container 10 3 3 Notes on operation Operating manual PU460_V1005_BAoDB_1005_ensski 10 Optional equipment gt The spray gun can be secured as follows gt gt gt gt gt gt D Air pressure valve trigger lock Figure 10 4 The spray gun cannot be operated without air pressure in the air pressure cylinder To lock the spray gun press the air pressure valve back away from the compressed air cylinder which is thereby relieved through the valve D Material shut off valves Figure 10 4 No material comes out of the spray gun when the valves are closed In order to lock the spray gun additionally this way you must turn the valves in a clockwise direction until they are closed Figure 10 6 For spraying both material valves must be opened 1 turn and com pressed air must be connected When the spray gun is not in operation you must keep the air pressure adapt ers free of foreign particles Use only clean and dry compressed air to avoid the formation of droplets in the spray pattern The front plate of the spray gun must be very clean and free of score marks The fr
44. nual PU460 V1005 BAODB 1005 en ski 3 Description of machine The W WA DUOMIX PUis most suitable for the application of solvent free dual component polymer materials polyurea This system enables the seamless application of coatings and linings Your dual component system was designed to meet your special requirements material to be applied mixing ratio transfer quantity etc Exact metering of both components is assured by the fixed mixing ratio The mixing ratio can only be changed by exchanging the material pumps hardener or standard component Any other use is deemed to not be in accordance with regulations The manufacturer s approval must be obtained before the W WA equipment is used for any other purpose or with other materials and therefore not for the pur pose it is intended for otherwise the warranty will become null and void Intended use also includes compliance with the technical documentation and adherence to the prescribed operating servicing and maintenance guidelines Unauthorized conversions or alterations should not be undertaken on safety grounds Protective equipment should not be dismantled converted or bypassed Use of components which have not been manufactured or delivered by W WAP 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 spares of WIA W
45. nvolved in the set up commissioning operation maintenance repair and servicing of the machine must have read and understood the user manual beforehand and the chapter on Safety in particular We recommend to the owner of this unit to have this confirmed in writing In principle you should refrain from any work method that would affect the safety of W WA products and the operating personnel Please read and comply with the applicable guidelines for your country In Germany these are the Richtlinien f r Fl ssigkeitsstrahler Guidelines for Liquid Jets issued by Publisher the Hauptverband der Gewerblichen Berufsgenossenschaften The manufacturer s instructions and processing guidelines for coating or transfer materials are to be respected at all times This machine has been designed and manufactured under due consideration of all safety related aspects It corresponds to the current standard of technology and to applicable accident prevention regulations The machine left the factory in perfect condition and guarantees a high level of technical reliability and safety Nevertheless there are certain risks that can arise from incorrect operation or misuse gt to life and limb of the operator or third party tothe machine and other material assets of the owner to efficient work with the machine This user manual is only valid in combination with the following machine card The machine card contains all impor
46. of 16 are not permitted to operate this equipment 2 2 Operating The owner of the machine must ensure that the user manual is made available to personne the user and make sure that the user has read and understood its contents x Setup maintenance Activity Qualification of personnel service and repair work Setup work instructed user Service work instructed user Cleaning work instructed user Maintenance work personnel trained by the W WA customer service Repair work personnel trained by the W WA customer service We would like to point out that the valid guidelines and stipulations applcable 2 3 Protective to the work environment mining closed rooms etc must be observed in any equipment FAN Always wear the protective clothes specified by the material manufacturer to avoid injuries gt tis recommended that the operator should always wear a respiratory protec tion mask even though the paint mist has been minimized in Airless spray painting applications with correct pressure setting and working mode Wear protective goggles to protect against eye injuries caused by mechanical or chemical influences Operating manual 2 3 lt PU460 V1005 BAODB 1005 en ski 2 4 Safety features 0 OFF ON Figure 2 3 Figure 2 5 Operating manual PU460 V1005 BAODB 1005 en ski 2 Safety information Wear protective gloves with lower arm protection to avoid burn injuries The sound press
47. ons of the material manufacturer WEAR PROTECTIVE CLOTHES USE RESPIRATORY PROTECTION USE EYE PROTECTION WEAR PROTECTIVE GLOVES WEAR HEARING PROTECTION Drum Poly Iso Cleaning material Identifies a drum containing the material to be applied which the user requires at the corresponding location in the manual Drum empty Identifies an empty collecting vessel to be used by the user to collect contami nated spraying material S A 1 4 Labels on the machine E 35633 Lahnau Germany Gewerbestrafe 1 3 II 2G cT4 Druckluftbetriebene Kolbenpumpe Air operated piston pump Ben te Type Unit p DH Output p cycle o bers Verh ltms Matio Serial no Model year Figure 1 1 Figure 1 2 Figure 1 3 Operating manual PU460 V1005 BAODB 1005 en ski 1 Foreword Appropriate information signs and labels on the machine refer to possible danger areas and must be respected at all costs Information signs and symbols must not be removed from the machine Labels with damaged and illegible information or symbols must be replaced immediately The following signs can be found on the machine Type plate on unit control cabinet Figure 1 1 Please check that the type plate data are identical with those on the machine card In case of discrepancies or if the type plate is missing please notify us immediately Warning label Caution Electric voltage on control cabinet F
48. ont plate must remain attached at all times when the manual valves are open The front plate screws must be tightly fastened with a spanner wrench Before starting spraying check the function of the trigger The spray jet can be adjusted with the spray jet regulating screw if required max 1 4 1 revolutions Consult the material manufacturer concerning suitable cleaning and flush ing agents Make sure that the cleaning agents will not cause swelling of the O rings Do not soak O rings or the mix module in solvents Solvents must solely be used for cleaning and should then be wiped off again immediately Never submerge the complete spray gun in solvent This could damage the O rings 10 4 FTA 10 3 4 Connecting the spray gun to the hose package Operating manual PU460 V1005 BAODB 1005 en ski 10 Optional equipment 1 Connect the material valves to the block NA ee N Figure 10 7 2 Assemble the material hoses to the block Figure 10 8 3 Mount the block to the spray gun Make sure that the filter elements are seated correctly in the spray gun and Grease the sur that the O rings On face to prevent filter element and sticking of the block are present O rings Figure 10 9 4 Connect the compressed air hose to the spray gun Figure 10 10 10 5 337272 10 Optional equipment 10 3 5 Check the Before operation check the correct use of the spray gun Spray gun gt Spr
49. or optimal preparation of the spraying materials 49794 offers a wide range of accessories like e g agitators in various sizes material preheating containers The compressor power must match the air requirements of the equipment so that an adequate air supply is ensured see chapter 12 1 Technical data p 12 1 The diameters of the air supply hoses must match the connections on the equipment Place the unit on a level and firm base gt Consider the required floor space see chapter 12 1 Technical data p 12 1 All operating elements must be easily accessible The access to the safety features must be kept clear Various system components were removed and packed in a separate carton for transport 1 heated hose package 2 spray gun optional Material emerging from the connections can cause severe physical injuries and damage to property Check all threaded parts nuts screws and hose connections and tighten these properly gt Check the permissible highest pressure for material hose spray gun and ac cessories It must be higher than or equal the maximum operating pressure of the equipment as specified on the type plate or the machine card gt Compare the maximum operating pressure of the safety valve with the specifi cations in the machine card or the type plate The data must match 4 1 WIA 4 2 1 Connecting the hose package to the adapter 4 2 2 Connecting individual hose packa
50. r your the mix module used spraying material Make sure that each O ring that is mounted to the filter is clean and free of damage Pos Designation Material filter Figure 10 15 Operating manual 10 7 PUA60 V1005 BAODB 1005 en ski Mix module and round jet nozzle as well as cleaning drill must be matched to each other The size of the mix module depends on the material to be processed Consult your material manufacturer Filter and mix module must always be kept clean to avoid malfunction of the spray gun Operating manual PU460 V1005 BAODB 1005 en ski 10 Optional equipment Changing the mix module Replace the mix module before it is worn Using a worn module will cause extremely high paint consumption and ad versely affects the quality of material application gt Disassemble the spray gun from the block as described in 10 3 6 Disman tle the spray gun P 10 6 before you start the replacement gt After removing the front cap 9 of the round jet nozzle and the mix module check the inlets and outlets of the filter element and the mix module for cleanliness and possible blockage Use a drill bit of appropriate diameter to remove possible material residues gt Use the mix module size recommended by the material manufacturer for your spraying material Pos Designation 1 Spray gun body 2 Mix module Round jet nozzle Front plate Figure 10 16 Assemble
51. rating manual 11 2 PU460 V1005 BAODB 1005 en ski 11 Malfunctions and trouble shooting FTA 11 2 Trouble shooting on the spray gun Fat Possibecause Remedy 1 Slight loss of pressure on the side gt This is normal of the front cap 2 The valve rod does not trigger No action required gt No air pressure available gt Connectthe air supply and open Spray fog on round jet nozzle even though the trigger has not be actuated Increased overspraying Round spray pattern forms fin gers or is deformed Pressure fluctuations Insufficient air pressure available Rear sealing nut excessively tightened Screws on front plate loose The rear side of the front plate is soiled Mix module bore worn Excessive air flow to the front cap Material pressure set too high The round jet nozzle is soiled or worn Mix module inlets and outlets soiled or worn Viscosity of components A and B not uniform Filter element dirty gt gt the air valve Set the air pressure to 80 130 psi Loosen the nut slightly Tighten the screws on the front plate with a spanner Clean the front plate and check for score marks Replace the mix module Reduce the air flow by the needle valve Reduce the material pressure Clean the round jet nozzle with an appropriate drill Replace the round jet nozzle Clean the mix module inlets and outlets with an appropriate drill
52. ressing the corresponding numerical field opens a keyboard to enter the value Press ENT to confirm the input Lower limit 20 68 Figure 3 14 The total and daily volume of applied material is displayed in dependence on the pulses The daily counters can be rest to zero by pressing the Reset button Resetting is confirmed in field The total quantity counter cannot be reset Figure 3 15 2972701 Activate deactivate parking F You should always move the equipment to parking position when interrupting work or at the end of work to prevent the system from being damaged by curing of material Operating manual PU460 V1005 BAODB 1005 en ski 3 Description of machine Display Parking mode deactivated text deleted The display P no longer shows in symbol Further possibilities for deactivation reset the fault with the RESET 2 ON Restart the system with The arrows indicate the current direction of rotation of the pro portioner pump In parking position the proportioner pump remains in bottom position While approaching the parking position you are asked to check the material pressure of both components The parking position has been reached The display shows the symbol P in the right hand top corner 3 13 337 320528 3 Description of machine Language selection You can choose the language to guide you through the display For this purpose cli
53. ruction 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 12 5 S A 13 Service 13 1 Master Changing master settings is strictly reserved for trained service personnel and the settings W7WJA Customer Service You can access the corresponding display by pressing CD gt Enter your Master password and confirm with the ENT key 2 gt the Master display appears After logging in you can use only to navigate between the masks Set tings Pressure Settings and Stroke Counter Set tings Figure 13 1 13 1 1 Pressure settings Press rz GQ Differenz G Zeit Figure 13 2 Upper limit for the maximum permissible material pressure for each com ponent When a value is exceeded the system will change to malfunc tion and switch off Determination for maximum difference between the components and the maximum duration of this difference When the difference is exceeded a time delay is activated When the en tered value for the maximum duration of the difference is exceeded the system will change to malfunction and switch off Graphic representation of pressures The sca
54. ssure renew the packings Clean the filter Clean the mixing chamber Clean or replace material hoses and spray gun Replace the mixing chamber in the spray gun 10 Compressed air escaping from gt The air motor seals are worn gt Seal the air motor the air motor at the guide axes Operating manual 11 1 PUA60 V1005 BAoDB 1005 en ski 11 Malfunctions and trouble shooting Few Posiiecmse Remedy 11 When spraying the air motor of gt The cross section of the com gt Increase the cross section of the the proportioner pump runs jerk pressed air supply line is too compressed air line ily small The spraying pressure indicated by the pressure gauges and the air pressure drop when the spray gun is opened The air pressure in the supply gt Increase the air pressure in the network is too low network 12 The air motor no longer works The air motor control is defective gt Have the air motor repaired in the even though the compressed air W WA Service workshop supply is assured No material pressure available in the system 13 The filling level of the release The seals on the material pumps gt Replace the seals on the material agent container and or the colour are worn pumps of the release agent changes 14 A material flow heater does not Technical defect in the material Have the material flow heater heat up flow heater examined by a trained electrician Ope
55. t connected or defective Air in system Mixing element clogged on the Iso side opray gun filter clogged Dirt trap Iso clogged Sensor cable not connected or defective Air in system Temperature sensor defective Control defective Sensor line not connected or defective Temperature sensor defective Control defective no compressed air even though the system is switched on 11 Malfunctions and trouble shooting Dismantle the spray gun and relieve the valve of the compo nent Poly Clean the spray gun filter Clean the dirt trap Poly Connect or repair the sensor cable Ventilate the system Dismantle the spray gun and relieve the valve of the compo nent Iso Clean the spray gun filter Clean the dirt trap Iso Connect or repair the sensor cable Ventilate the system Switch off heating B Iso Have the temperature sensor inspected by a electrician Have the control inspected by a electrician gt gt Check the sensor line Note After rectification press Reset and Start button Switch off heating A Poly Have the temperature sensor inspected by a electrician Have the control inspected by a electrician Note After rectification press Reset and Start button Operator side Set the air inlet pressure to min 4 bar Use a compressed air line Increase the compressor power Operator side gt gt Check and ensure the com
56. tant and safety relevant data and information about the machine exact designation and manufacturer data technical data and limiting values equipment and test certificate data of purchase VV Y Y Machine identification machine components and accessories with article and spare parts numbers The data on the machine card must match the data on the type plate In case of discrepancies or if the type plate is missing please notify us im mediately Conversions and alterations 1 1 WIA 1 3 Operating manual Pictograms e gt gt PP me PUA460 V1005 BAoDB 1005 en ski 1 Foreword The notices and symbols used in this manual have the following meanings NOTICE Indicates an informative text passage You should pay particular attention when reading it 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 explosion Strict compliance with these notes is mandatory VOLTAGE A situation showing danger of explosion by electrostatic charge is indicated Strict compliance with these notes is mandatory HOT SURFACES Identifies a situation involving the danger of burning on a hot surface Do not touch hot surfaces without wearing gloves The following symbols indicate that protective equipment should be worn With your health in mind you should always comply with the recommendati
57. th Pressure ratio Application capacity max 98 Temperature of material to be applied C F Air consumption 9 at a displacement 1000 264 of 41 1gal Electric power connection 400 3 25 42 68 Number of hose L1 15m 49 21 ft packages 2 gt 2 Emitted sound pressure level at the work place in idle mode L dB under load L dB Dimensions length width height mm inch Version with feed pumps 990 x 730 x 1410 40 x 29 x 55 5 Version with feed pumps and hose bracket 1140 x 730 x 1470 45 x 29 x 58 Version with feed drum 1400 x 750 x 1410 55 x 30 x 55 5 Version with feed drum and hose bracket 1550 x 750 x 1470 61 x 29 5 x 58 Spray gun Dimensions length width height 17 15 X 6 67 x 10 8 mm inch 0 68 x 0 26 x 0 43 Weight kg Ibs gt S N I Operating manual 12 1 PUA60 V1005 BAoDB 1005 en ski 12 2 Auxiliary materials Release agent 0640616 0 51 0 13gal Multi purpose grease for spray gun 0 085 kg 0 191bs Thread sealant 0 0501 0 01 gal Lubricant acid free grease 0 4kg 0 88 Ibs Anti freeze agent 0 51 0 13gal Pneumatic oil 0 51 12 3 Tools This certificate follows the EC Directive for working utensils 85 655 EEC section ll article 7 The owner of the device specified below has instructed the operating personnel Operating manual 12 2 PUA60 V1005 BAoDB 1005 en ski 12 4 Accessories The accessor
58. to an empty collecting vessel gt Check the bowl regularly for dirt residues and clean it as required Figure 9 3 Disassembly Press the slide down Turn the bowl anti clockwise Assembly Make sure the O ring is correctly fitted 9 2 9 Maintenance FTA 9 4 Inspection of gt To protect the packings use W WA release agent release agent gt Check gt the fill level in the release agent container before each start up 200 ml the release agent at regular intervals for discolouration caused by spraying material Replace the pump packings gt in case of excessive discolouration of the release agent if the level in the release agent container rises see spare parts list for material pump This work must only be performed by WIA trained personnel or the W WA customer service DOO A OK OK A C EUROS CE E a a CNCX CA CROCI E 200 ml pomas mmm DS B Ll 4i Figure 9 4 Operating manual 9 3 PUA60 V1005 BAODB 1005 en ski FATA 10 Optional equipment Before applying the coating you must vent the entire system Advantages gt Air in the system is forced out 10 1 Circulation gt Continuous discharge of both material components is assured gt No disruption of spray pattern by sudden air shocks Uniform material temperature and consistency throughout the entire system gt Material flow heaters maintain the material at operating tempera
59. ture 10 1 1 Circulation sys tem en Distributor lt z z 2 Proportioner pump s a3 a c ir mit Material Flow Material Flow Heater Heater Material drum gt Material drum Iso Poly Figure 10 1 10 1 2 Circulation Ventilation gt The returnhoses are securely connected with material drums and outlet mani fold Prerequisite The spray gun is locked The unit is ready for operation 1 Open the circulation and start to supply with compressed air Feed pumps Proportioner pump Caution Ensure slow running of the pump Figure 10 2 Operating manual 10 1 PUA60 V1005 BAODB 1005 en ski FTA 10 2 Silica gel filter Only heat up the granu late Heating up the com plete filter can damage the housing Operating manual PUA460 V1005 BAODB 1005 en ski 10 Optional equipment 2 Stop circulation Figure 10 3 The silica gel filter is a moisture filter for installation on the drum lid of the Iso component The granulate in the filter must be dried regularly Drying temperature approx 50 C Drying time approx 4h Drying is required in case of discolouration of the granulate Figure 10 4 10 2 337272 10 Optional equipment 10 3 Spray gun 10 3 1 Spray gun components ON O C Figure 10 5 Description Material hose comp Poly Material hose comp Iso Material shut off valve comp Poly Material shut off valve comp Iso Screw to
60. ure level of this unit is less than 85 db A However operating personnel should still be provided with suitable noise pro tection equipment All units are delivered with the following safety features Master switch Figure 2 3 When the master switch on the control cabinet is switched to position 0 OFF both the electric power and compressed air supplies are immediately cut off Note The compressed air supply to the spray is not interrupted Material may still be under pressure in the system Safety valve Figure 2 4 The safety valve on the air motor of the proportioner pump makes sure that the max permissible air inlet pressure is not exceeded The safety valve will open and vent off air when the air inlet pressure exceeds the set limiting value Thermocouples not shown These elements switch off the equipment when the maximum permissible tem perature in the material flow heaters or in the hose package is exceeded This malfunction is signalled on the control cabinet Operation of the equipment can be resumed after the fault has been rectified Material pressure relief valves not shown In the factory both pressure relief valves were set to the maximum admissible operating pressure When this value is exceeded the equipment including the heaters will switch off completely This malfunction is signalled on the control cabinet Trouble free operation can only be resumed after the pressure on the correspond
61. y Figure 5 5 gt Torelieve the pressure open the valve of the component with the higher pressure Carefully open only the material valve of the component with too high pressure to allow pressure compensation 6 iha aW Use a collecting vessel for the C 3C 2 corresponding component Figure 5 6 After this pressure compensation close the valve again 6 Mounting the spray gun Mount the spray gun to the block Fasten the return flow hoses to the material container Follow the notes in chapter 10 3 4 Connecting the spray gun to the hose package p 10 5 7 Adjust the desired spraying pressure 1 pump Figure 6 7 8 Start spraying Unlock the spray gun Start the spraying process on a test area away from the area to be covered Observe the chapter 10 3 7 Start spraying p 10 6 6 3 FATA 7 Decommissioning Switch off the equipment if you want to interrupt work If coating is to be continued with the material in the system you must return the unit to parking position In case of longer work breaks and or when changing materials the equipment needs to be shut down 1x 1x 2X The following is required tiim gt Poly Iso ES Always wear the specified protective clothing To avoid malfunctions of the equipment you should observe of the following General notes gt Never allow the system to run empty e gt Do not use any solvents 1

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