Operation manual DUOMIX 230
Contents
1. A 1 Lever to open and close the return K flow During spraying and flushing ups C A Ng operation the return flow is closed AE l aan ONE Waa and is opened for material circulation ANE C or to relieve pressure a gt oe 2 Lever to switch the operating mode Spraying on and off 3 4 Levers to switch the operating mode Flushing on and off s EEN ANNA Aa KE Fig 18 External mixing unit With these levers you can set the operating modes Circulation Spraying und Flushing as follows Circulate Spray Flush see Fig 18 Fig 19 Circulate Fig 20 Flush Position of levers Operating mode Lever 1 Lever 2 Lever 3 Lever 4 Circulate ON OFF OFF OFF Spray OFF ON OFF OFF Flush OFF OFF ON OFF ON OFF 1 Alternately open and close the flushing levers several times during flushing to ensure that each component is separately flushed Finally flush with both levers in flushing position Translation of the original operation manual DUOMIX 230 23 DM230_BAoDB_en_1307 rs Unit description PRTA 3 5 Maintenance unit The DUOMIK 230 may be equipped with a standard maintenance unit or a main tenance unit with remote controlled compressed air control 3 5 1 Standard maintenance unit Fig 21 Standard maintenanc2. In closed or pressurized systems dangerous chemical reactions may occur if parts made of aluminium or galvanized parts come into contact with 1 1 1 trichloroethane methylene chloride or other solvents containing halogenated hydrocarbons CFC s If you want to process materials containing the afore mentioned substances we recommend to consult the material manufacturer to clarify the usability of such substances For these materials we have a range of rust and acid proof versions available 2 3 Information signs on the unit 10 Information signs attached to the unit such as safety information see Fig 1 refer to possible danger areas and must be strictly followed W IWA y Achtung N Sicherheitsinformationen er 901 mam aaga mae t ca 10 0 Benutzung der Spritzger te nur durch s und geschultes und eingewiesenes Personal Botriebsanieitung insbesondere die Sicher heitsbestimmungen unbedingt beachten und i They must not be removed from the unit Damaged and illegible information signs must be replaced immediately Apart from this you should also read and follow the safety notes in the operating manual Safety Information Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs BTA Satety 2 4 Safety features Safety features must be checked with the unit depressurized before initial commissioning gt always before starting work gt after c
3. Translation of the original operation manual DUOMIX 230 39 DM230_BAoDB_en_1307 rs Maintenance WIA 6 7 Recommended operating materials Use only original operating materials from WIWA Operating materials WIWA order number Release agent 0 5 0163333 Release agent for isocyanate 0 5 I 0640651 Anti freeze agent 0 5 1 0631387 Pneumatic oil 0 5 I 0632579 Retention agent 50 ml 0000015 Lubricant acid free grease 0 4 kg 0000025 Lubricant for stainless steel 0000233 1 Plasticizer to fill into the release agent cups of the main pump feed pumps and flush pump 2 For air maintenance unit 3 Materials required for maintenance and repair work see information in spare parts lists Release agents and pneumatic oil are on request also available in larger con tainers 6 8 Filter elements for high pressure filters mle 40 Insert the filter elements suitable for the spraying material and the spraying nozzle into the high pressure filters The mesh size should always be slightly finer than the bore of the nozzle used Filter element Nozzle size M 200 white up to 0 23 mm 009 M 150 red over 0 23 mm 009 bis 0 33 mm 013 M 100 black over 0 33 mm 013 bis 0 38 mm 015 M 70 yellow over 0 38 mm 015 bis 0 66 mm 026 M 50 orange over 0 66 mm 026 M 30 blue M 20 green Do not use a filter element when appl
4. 2 7 3 Injuries In case of injuries you should immediately consult a physician or visit the nearest hospital If injured by processing materials or solvents always have the safety data sheet address phone number material designation and material number of supplier or manufacturer available for the attending physician Always remember where you can call for help gt Keep alist of the local emergency telephone numbers at hand gt You should in any case make yourself familiar with First Aid measures 2 7 4 Fires Read and comply with the instructions for fire alarm and escape routes which are displayed in your factory or at any work place gt Keep alist of the local emergency telephone numbers at hand gt Become acquainted with the locations and operation of fire alarms and fire extinguishers within your reach Ensure a sufficient amount of information signs for the avoidance of fire gt Only use the extinguishing substances stipulated by the material manufac turer Translation of the original operation manual DUOMIX 230 15 DM230_BAoDB_en_1307 rs Unit description WIA 3 Unit description 3 1 Intended use e 16 The WIWA DUOMIX 230 is a dual component spray painting and coating unit Exact metering of both components is assured by the fixed mixing ratio The mixing ratio can be changed by exchanging the material pumps For the application of materials with higher viscosities the unit can
5. A material flow heater optional does not heat up 1 The electric power supply is interrupted 2 The ambient temperature is below 5 8 C 3 The material flow heater is defective Check the electric power supply Press the button of the overload protection until the glowing lamp stays on gt Have the material flow heater checked by expert personnel with profound knowledge in the field of electrical engineering 44 Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs WWF WA i Technical data 8 Technical data You find the technical data for your DUOMIX 230 in the attached machine card on the type plate and in the documentation of the individual components 8 1 Machine card The machine card contains all important and safety relevant data and informa tion about the unit gt exact designation and manufacturer data gt technical data and limiting values gt equipment and test certificate gt data of purchasing gt unit identification components of the unit and accessories with article and spare parts numbers 8 2 Type plates The type plate of the DUOMIK 230 is WIWA 2K Duo Mix usually located on the guard plate of Base Komp A 2x 60 ccm the contact pressure gauge Hardener Komp B 1x 30 ccm Pressure Ratio Druckibers 39 1 It contains the most important techni Mixing Ratio
6. Connect the spray gun to the spray hose as described in the operating manual for the spray gun Fig 25 Assembling spray hose 4 3 2 Inserting the filter elements into the high pressure filter Insert the filter elements suitable for the spraying material and the spraying nozzle into the high pressure filters For more information see chapter 6 8 on page 40 4 3 3 Connecting the compressed air supply To ensure an adequate air supply the compressor capacity must match the air requirements of the unit and the diameters of the air supply hoses must match the inlet connections Operation with contaminated or moist compressed air causes damage to the il pneumatic system Use only dried oil and dust free air 1 Make sure that the compressed air shut off valve on the air maintenance unit is closed and that all air pressure regulators have been fully regulated back 2 Connect the compressed air line to the air maintenance unit 4 3 4 Grounding the unit A The high flow velocities associated with the Airless spraying method may cause static charging Static discharges can cause fire and explosion gt The owner of the unit must get the unit properly grounded 28 Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs E2 EA WA Transport installation and assembly The DUOMIX 230 comes with a ground cable as standard This cable is already connected to one of the
7. E2 EA WA Transport installation and assembly 4 2 Installation location The DUOMIK 230 can be installed inside and outside spray booths However out door installation should be preferred in order to avoid contamination A If operating an outdoor unit during a thunderstorm a lightning can cause a life threatening situation for the operating personnel gt Do not operate an outdoor unit during a thunderstorm gt The owner must protect the unit by applying appropriate lightning protec tion measures Place the unit horizontally on a surface which is level firm and free of vibra i tion The unit must not be tilted or inclined All controls and safety features must be easily accessible Safety measures at the place of installation This unit requires a solid base and sufficient free space for safe operation The access to the safety features must be kept clear gt Secure the unit at its final location to protect it against unintended move ment gt Always keep the working area especially all walkways and standing areas clean and tidy Immediately remove any spilled material and solvents imme diately Always ensure adequate ventilation at the work place to avoid damage to health and material objects Always observe the processing instructions issued by the material manu facturers gt Even though there are no legal directives for low mist Airless spraying methods all hazardous solvent vapou
8. Designation Compressed air regulator 2 Ball valve 3 Suction pipe Fig 10 Suction pipes l NE N Yj 2 Fig 11 Feed drums Fig 12 Fig 13 Piston pump Diaphragm pump Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs BTA 3 4 Mixing unit Unit description The WIWA DUOMIX 230 can be equipped with three different mixing units the standard mixing unit the mixing unit with separate flushing levers or the exter nal mixing unit You can extend the lifetime of the ball valves if you i gt do not switch the levers over under high pressure always push the levers to the end stop of the desired position 3 4 1 Standard mixing unit No Description 1 Lever to open and close the return flow During spraying and flushing operation the return flow is closed and is opened for material circulation or to relieve pressure 2 Lever to toggle between the operating modes Spraying and Flushing With these levers you can set the operating modes Circulation Spraying und Flushing as follows Operating Lever 1 Lever
9. Ensure sufficient load bearing capacity of lifting gear and lifting tackle when loading the unit You find the dimensions and weights of the unit on the machine card The unit must only be lifted by the attachment points for lifting equipment When using a forklift make sure that the fork tines are long enough The fork tines must reach completely through each of the two opposite forklift lifting points on the rack When transporting with a forklift set the fork tines as far apart as possible to minimize the overturning moment Attention Danger of tipping over Ensure even load distribution to secure the unit against tipping over Do not transport any other objects e g material containers when lifting the unit Never stand under suspended loads or inside the loading area This poses a life hazard Secure the load on the transport vehicle against slipping and falling off If the unit has already been in use you should observe the following notes gt gt gt 26 Disconnect the entire power supply even for short transport distances Empty the unit before transportation fluid residues may escape during transport despite this measure Remove all loose components e g tools from the unit Assemble the parts or fittings dismantled for transport purposes before start up professionally and in compliance with the intended use Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs
10. Mischungsverh 4 4 cal data of the unit Displacement per Cycle F rdermenge Dh 150 ccm gt the supply rate per cycle for the PE a eer material pumps of base A com max Eingangsdruck SI bar ponent and hardener B compo max Working Pressure nent max Betriebsdruck 312 sd bar i Year of Construction Baujahr 2013 the pressure ratio _ Fig 39 Example of a type plate the mixing ratio the entire supply rate per cycle for the main pump the maximum permissible air inlet and operating pressure as well as the year of construction Please check that the type plate data are identical with those on the machine i card In case of discrepancies or if the type plate is missing please notify us immediately In addition some components of the unit have a separate type plate such as gt the air motor the material pumps for the A and B component as well as the flushing pump These type plates contain the technical data and the serial numbers of the respective components Translation of the original operation manual DUOMIX 230 45 DM230_BAoDB_en_1307 rs Headquarter and production WIWA Wilhelm Wagner GmbH amp Co KG Gewerbestr 1 3 35633 Lahnau Germany Tel 49 6441 609 0 Fax 49 6441 609 50 E Mail info wiwa de Homepage www wiwa de WIWA partnership in USA WIWA LP 107 N Main St P O Box 398 Alger OH 45812 Tel 1 419 757 0141 Fax 1 419 549 5173 T
11. 2 mode Circulate Opened Stop Flushing Spray Closed Spray Flush Closed Stop Flushing Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs Fig 14 Standard mixing unit 21 Unit description 3 4 2 Mixing unit with separate flushing levers 22 WIA No Description 1 Lever to open and close the return flow During spraying and flushing operation the return flow is closed and is opened for material circulation or to relieve pressure 2 Lever to switch the operating mode Spraying on and off 3 4 Levers to switch the operating mode Flushing on and off Fig 15 Mixing unit with separate flushing levers With these levers you can set the operating modes Circulation Spraying und Flushing as follows Circulate Spray Flush see Fig 15 Fig 16 Circulate Fig 17 Flush Position of levers Operating mode Lever 1 Lever 2 Lever 3 Lever 4 Circulate ON OFF OFF OFF Spray OFF ON OFF OFF Flush OFF OFF ON OFF ON OFF d Alternately open and close the flushing levers several times during flushing to ensure that each component is separately flushed Finally flush with both levers in flushing position Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs PIA Unit description 3 4 3 External mixing unit No Description
12. be equipped with optional accessories e g feed hoppers feed pumps material preheating systems or material flow heaters Please refer to the enclosed machine card technical data for the specifica tions of your unit The WIWA DUOMIX 230 is intended for the application of low medium and high viscosity spray painting and coating materials for commercial and industrial applications Any other use is considered unintended Should you intend to use the unit for other purposes or with other materials and thus not for the purpose it is intended for you must ask WIWA for permission otherwise 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 Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs BTA Unit description 3 2 Unit configuration Due to its modular design the WIWA DUOMIX 230 offers individual solutions for almost all possible areas of application The units shown in Fig 7 and 8 are examples for the manifold installation and extension variants Fig 7 Example of a DUOMIX 230 on an upright rack No Designation 1 Air motor of main pump 2 High pressure filter 3 Contact pressure gauge of pressure and dosing control 4 Lever to open and close the return flow 5 Control cabinet of pre
13. component 3 4 Flow of A component 5 Return flow of A component 4 tL Fig 28 Hose package connections on the external mixing unit Translation of the original operation manual DUOMIK 230 29 DM230_BAoDB_en_1307 rs Operation WIA 5 Operation A 1 Before starting operation check W Are all safety features of the unit present and fully functional Are all components of the unit leak tight If necessary re tighten the con nections M Is the oil reservoir of the fog oiler filled with an appropriate amount of lubri cant If fluid pumps run dry the generated friction heat can cause fire or an ex plosion gt Always make sure that the material drums do not run dry during opera tion gt However should this happen stop the corresponding pump immediately and feed material During work the flushing pump should always be ready for use so that all components which come in contact with the mixed material can be flushed within the specified potlife 5 1 Taking the unit into service 30 Requirements gt The unit must be properly placed and completely assembled gt Do not start commissioning the unit unless you have the specified protective equipment For details on this topic refer to chapter 2 5 4 on page 13 gt The material to be applied must be available in sufficient quantities Furthermore you need two appropriate containers for collecting excess material These conta
14. gt When using new safety valves make sure that the valves have been set to the max permissible air inlet pressure of the DUOMIX 230 as required for the mixing ratio see type plate or machine card and sealed with a lead seal Fig 2 Safety valve Changing the mixing ratio may cause a change in pressure ratio and thus 1 require the adaptation of the max permissible air inlet pressure of the main pump In this case you would have to replace the safety valve of the main pump and the type plate you should absolutely contact WIWA Translation of the original operation manual DUOMIK 230 11 DM230_BAoDB_en_1307 rs Satety BTA 2 4 2 Compressed air shut off valve The compressed air shut off valve on the air main tenance unit interrupts the air supply for the entire unit Once the air supply is cut off the unit is still under pressure The pressure relief of the unit must be done by the spray gun and the return flow ball valve on the high pressure filters Fig 3 Compressed air shut off valve 2 4 3 Ground cable The unit must be grounded to an electrically con ductive object with the ground cable to prevent electrostatic charging Adhesive labels on the high pressure filters expressly inform about the required grounding Please order the ground cable immediately order no 0474487 if lost or damaged Fig 4 Ground cable 2 4 4 Safety rupture discs Die Berstscheiben verhindern ein deutlic
15. high pressure filters upon delivery In order to ground the unit the clamp of the ground cable is connected to an electrically conductive object IAE Fig 26 Erdungskabel am Hochdruckfilter 4 3 5 Filling in release agent and pneumatic oil If the unit is delivered in horizontal position version with wall bracket any release agent and pneumatic oil has been drained off In this case you must fill in both operating media before initial start up see chapter 6 3 1 on page 37 and chapter 6 4 on page 38 4 3 6 Assembling the hose package and the external mixing unit optional A If the hose package couplings are subjected to tensile load these assem blies may be torn out Material escaping under high pressure can cause injuries and material damage If tensile loads on the hose package couplings are to be expected e g by positioning the mixing unit a strain relief is required If the hose package is too tightly bent hoses may buckle inside the hose 1 package gt The minimum bending radius of 30 cm must not be fallen short of Nr Connection Flow of A component Return flow of A component Oo O i Flushing Return flow of B component oA OJINJ Flow of B component 3 4 5 Fig 27 Hose package connections on adapter Nr Connection 1 2 1 Flushing p 2 Return flow of B component 2 3 Flow of B
16. incorrectly adjusted Open the stop cock on the air maintenance unit Only with pressure and dosing control Ensure compressed air supply on the control cabinet Set the pressure to 8 10 bar Only with pressure and dosing control The unit can only be started for a short while only as long as the START button is held depressed 1 The switch MANUAL AUTO MATIC is in position AUTO MATIC 2 The material pressure of the hardening component is higher than the red contact indicator for high pressure warning 3 The contact pressure gauge sub mits an incorrect signal gt Actuate the switch MANUAL AUTOMATIC to MANUAL gt Relieve the material pressure Replace the contact pressure gauge The contact pressure gauge indi cates pressure even though the pressure has been relieved The contact pressure gauge is defective Replace the contact pressure gauge The contact pressure gauge does not indicate any pressure or only up to a certain pressure The unit is under full air intake When spraying the pointer sticks at certain pressure and does not pulsate The contact pressure gauge is defective oil has run out of the pressure transmitter of the pressure gauge Replace the contact pressure gauge Hardener or paint runs out from the adapter below the air motor The seals on the material pumps are worn Replace packings and seals on the material pumps
17. the BGR 500 chapt 2 36 Arbeiten mit Flussigkeitsstrahlern Working with Liquid Jets both issued by the Berufsgenossenschaft der Gas Fern w rme und Wasserwirtschaft We strongly recommend to add all relevant guidelines and accident prevention instructions to this operating manual Moreover the manufacturer s instructions and guidelines for coating or feeder materials are to be respected at all times However if you have any questions please do not hesitate to contact us Excellent work results with your WIWA DUOMIX 230 wishes WIWA Wilhelm Wagner GmbH amp Co KG Copyright 2013 WIWA The copyright for this operating manual lies with WIWA Wilhelm Wagner GmbH amp Co KG Gewerbestr 1 3 35633 Lahnau Germany Phone 49 6441 609 0 Fax 49 6441 609 50 E Mail info wiwa de Internet www wiwa de This operating manual is solely intended for personnel involved in preparation operation and servicing It is 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 unit Please check that the type plate data is identical with
18. IWA their suitability for use with our units is guaranteed Ifyou use foreign accessories they must be suitable for the unit especial ly with regard to the operating pressure the power connection data and the connection sizes WIWA will not be liable for any damage or injury caused by these parts gt Itis however mandatory to respect the safety regulations of the accesso ries You will find these safety regulations in the corresponding operating manuals for the accessories Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs BTA Satety 2 7 Emergency procedures 2 7 1 Shutting down and depressurizing the unit In case of emergency you must shut down and depressurize the unit immedi ately 1 Close the compressed air shut off valve on the air maintenance unit 2 Set the levers at the mixing unit to Circulate 3 Operate the spray gun until the material pressure is relieved completely 2 7 2 Leakages A In case of leakages material can escape under very high pressure and cause serious bodily injuries and material damage gt Shut down and depressurize the unit immediately gt Re tighten the connections and replace defective components only by trained personnel gt Do not seal leakages on connections and high pressure hoses by hand or by wrapping fabric around them gt Do not repair material hoses Check hoses and connections for leaks before restarting
19. O rm Drain hose Fig 33 Maintenance unit 6 3 1 Checking the lubricant level in the fog oiler Operation of the unit must only be started if the oil reservoir of the fog oiler 1 contains a sufficient amount of oil for the air motors In case of high humidity you should use an antifreeze agent for lubrication to avoid icing of the air motor Translation of the original operation manual DUOMIX 230 37 DM230_BAoDB_en_1307 rs Haines WIA Check the lubricant level every day as follows 1 Press up the slide on the oil reservoir and unscrew the oil reservoir by turn ing it anti clockwise Take care of the O ring that seals the oil reservoir It may be displaced or even fall out when disassembling e Check whether the O ring fits correctly if necessary fit it correctly Check whether there is enough lubricant maximally filled the lubricant reaches to a point approx 2 cm below the upper edge of the oil reservoir 4 To up lubricant if necessary We recommend to use pneumatic oil order number 0632579 or the anti freeze agent order number 0631387 from WIWA 5 Reattach the oil reservoir to the air maintenance unit 6 3 2 Checking and adjusting the fog oiler Let the unit run slowly under load 2 Check in the fog oiler inspection glass whether 1 drop of lubricant is fed after each 10 to 15 double strokes 3 If this is not the case adjust the metering by turnin
20. Operation manual because it works DUOMIA 230 Translation of the original operation manual DM230_DBK_en_1206 rs BTA Contents Contents T FONO ona a 5 PAETE E E A E E E E E E E 6 21 Explanation Ol SYMONS sessies a n N 6 2 2 Safety NOLS aces an faites ct aed auon a a aAa EE aA aE NEA EENE 8 2 2 1 Operating PreSSUre csini aiana A RE 8 2 2 2 Risks due to the Spray jet ecccceeeceseeceeeeeeeeeeeeeeeneeeeeeeeneeneeeeeenenaes 8 2 2 3 Risks due to electrostatic charge eeeeeeeeeenneeeeeeeeneeeeeseenaeeeeeeenaes 9 2 2 4 Explosion protection c cccccesecceceeeeeeceeeeeeeeeeeeeeeseneeeeeeseeeeeeeeesenees 9 2221 TO AILINMISKS fs ceacishtes cd eatery a toeursaateteeneaance tt aviucacaceranty 10 2 3 Information Signs ON the UNit cceccceeeeseeeeeeeeeeeeeeeeeeeeeeeeeeneeneeeeeeneneaes 10 24 Safety features riian eves benasty aaa n vahe aa EAR a ER 11 2 4 1 Safety valves sssseeseeseessessesssisssrtssrersstnrssttsstnsrtnnesnnnennntnnnnt 11 2 4 2 Compressed air shut off valve seessseesseeeeeeseereserresrn rer nessnnesen ens 12 24 3 Ground Cable irinenn inana aaa ra eaae 12 2 4 4 Safety rupture GiSCS rrpp a ai 12 2 4 5 Spray QUID IOCK ceceeceececeeeeee cece eeeeeeeeeaaeeeeeeeeeceaeeeseeeeeseeeestaeeseeeees 12 2 5 Operating and maintenance personnel cccccceceeeeeeeeeeeeeeeeeeseeeeeeneees 13 2 5 1 Obligations of the UNit OWNET ccc ecceeeeeeee eect eeeeeeteeteeestaa
21. RE E R aAa E AE E n ea 31 5 2 1 Adjusting Spraying pProSsSUrE sssisisssorssininissaniiinsneiii ia 32 5 2 2 Adjusting the pressure and dosing control 32 52 3 Tips for good COALING gases sce sectec cad eacte EO 32 key FUSNIN ener crerertrre creer rer cree menres nrceert er rerer ee errant reer reer reer ter reer rere 33 DA Prosser lO onanan a a A A 33 9 9 DECOMMISSIONING araa O 33 5 6 Complete cleaning eesssessesssereettsesrressrnesrrttnnetnntenntnrnnstnenstnensrenssensnenn 34 5 7 Material Change eccccceeeenceeeeeeeneeeeeeeeeeeeeesaaeeeseeeseneeesesneeeeeeseeseneaes 35 6 8 Waste dISPOSals cesceetecedeeanstancepecveeeetstawsasstdaavwadgdttavtaesdeeg os tnedeigeereagstetes 35 6 Maint n ane reaa ESSEEN NSSE SEEN 36 6 1 Regular INSPECHIONS eciciiccccccecstecccconerestecneiaas ceccnereccccnesiaceceewetteel cncaenecceccnnees 36 6 2 Maintenance plaoe EEEE EEEE AAA AEREE 37 6 3 Maintenance Uniber EE E EEA 37 6 3 1 Checking the lubricant level in the fog oiler ceeeeeeeeeteeeeeeees 37 6 3 2 Checking and adjusting the fog oiler 38 6 3 3 Checking and cleaning the water Separator cceeeeeeeeereeees 38 6 4 Check release agent for material residues cccccseeeeeeessteeeeeeeesteeeeees 38 6 5 Cleaning the filter elements in the high pressure filters cceeeeeeees 39 6 6 Drying the moisture filter eee eee ee sent cette eeeeeeeeeseeeeeeeeeeeneeeeeeeneeneeeees 39 6 7 Recommend
22. Replace the suction system gt Repair the feed pump s Replace the material heater The feed pumps do not pump any material into the unit with the drain valve open material runs out of the outlet manifold 1 The ball valve on the material inlet is closed 2 The dirt trap before the material inlet is soiled Open the ball valve gt Clean the dirt trap No pressure built up by hardener pump during downwards stroke of metering pump The pressure of standard components rises The bottom valve of the hardener pump is defective gt Disassemble and clean the bot tom valve Replace defective ball or valve plate No pressure built up by hardener pump during upwards stroke of metering pump The pressure of standard components rises a The piston valve of the hardener pump is leaking 2 The bottom packing of the hard ener pump is worn Disassemble and clean the piston valve Replace defective ball or valve plate Replace the packing The hardener pump does not gener ate pressure in up and down stroke 1 The hardener pump does not receive any material 2 The burst disc on the high pres sure filter is defective 3 The ventilation valve of the hard ening component is leaking 4 The ball valve on the material inlet is closed Check the material supply Check the burst disk for the hard ening component on the high pressure filter Check the v
23. ation limits are reached m 2 The Start button is used to restart the unit after a shutdown Regulate the air inlet pressure of O O the main pump completely back beforehand 3 With the selector switch Manual Automatic P you decide whether both operation limits should P be monitored Automatic or only the upper one Manual For start up set the selector switch to Manual For spray operation set the selector switch to Automatic Fig 23 Pressure and dosing control 3 6 2 Material heating To heat up the material one may use material flow heaters see Fig 24 drum floor heaters drum heating belts or hose trace heating systems individually or in combination Always pay attention to the corre sponding separate operating manuals when connecting or operating material heaters Fig 24 Material flow heaters Translation of the original operation manual DUOMIX 230 25 DM230_BAoDB_en_1307 rs Transport installation and assembly wi WA 4 Transport installation and assembly The unit has left the factory in flawless condition and was appropriately packed for transport Upon arrival you should check the unit for completeness and any apparent 1 transport damage 4 1 Transport Please follow these notes when transporting the unit gt gt gt
24. d B component 2 3 4 5 Control cabinet of pressure and dosing control 6 7 8 Maintenance unit 9 External mixing unit on rack 10 Feed drum 11 Collecting vessel for safety rupture disc safety device 12 3 wheel rack 13 Ground cable with clamp Translation of the original operation manual DUOMIK 230 19 DM230_BAoDB_en_1307 rs Unit description 3 3 Material feed 3 3 1 Suction pipes 3 3 2 Feed drums 3 3 3 Feed pumps 20 WIA For feeding material to the material pumps you may use suction pipes feed drums or feed pumps Suction pipes are directly placed into the material drums The suction pipe is fitted with a sieve which needs to be cleaned at regular intervals No Designation Suction pipe 2 Suction system with sieve Feed drums are mounted to the rack of the unit The feed of material from the feed drum to the material pump can be interrupted by means of a ball valve With the drain valve any material residues can be drained from the feed drums No Designation Feed drum 2 Stop cock Feed drums are connected to the compressed air supply of the main tenance unit via the pressure distrib utor and are controlled by a dedi cated air pressure regulator They support the material pumps when pumping highly viscous materials Piston pumps Fig 12 or dia phragm pumps Fig 13 can be used as feed pumps No
25. e hardening component ponent pump are leaking pump replace the packing When spraying the pressure of 1 The high pressure filter element gt Clean the filter element for the the hardener component always for the hardening component high pressure pump or install a increases in comparison with the starts to block up coarser element standard component 2 The packings of the standard Repair the standard component component pump are leaking pumps replace the packings When spraying not enough pres 1 The filter elements of the high gt Clean filter elements or replace sure or material is transferred to the pressure filters are excessively with coarser ones spray gun even though the pres soiled sure in the unit is high enough 2 Mixing block static mixer Clean or replace mixing block material hose or spray gun are static mixer material hoses ad blocked spray gun 3 The spray gun nozzle is clogged gt Replace the spraying nozzle in the spray gun 4 The viscosity is too high Replace the material heater When flushing the standard mixer The check valves in the mixing block gt Clean the mixing block with a pressure relieved unit and do not work gt Replace defective balls valve closed ventilation the one or both seats or springs contact pressure gauges indicate rising pressure The flushing pump does not work 1 The flushing pump is defective Check whether the flushing when changing from SPAY to pump is operati
26. e unit No Description 1 Compressed air shut off valve to open and close the compressed air supply 2 Air pressure regulator of main pump 3 5 2 Maintenance unit with remote controlled compressed air control 1 Flush Pum 4 Fig 22 Maintenance unit with remote controlled compressed air control No Description Remote controlled air pressure valve 2 Remote controlled air pressure regulator of main pump 24 Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs PIPA Unit description No Description 3 Optional remote controlled air pressure regulator of the flushing pump 4 Compressed air shut off valve to open and close the compressed air supply Instead of the remote controlled compressed air control units with 2 com pressed air regulators and pressure gauges the DUOMIK 230 can be equipped with a remote controlled compressed air control unit with 4 compressed air regulators and pressure gauges enabling central regulation of main pump flushing pump and feed pumps 3 6 Optional extensions and accessories 3 6 1 Pressure and dosing control The pressure and dosing control include the following control elements No Description EN a 1 The contact pressure gauge monitors the Xx SY pressure of the B component hardener and switches the unit off when the oper
27. each material change A If the unit has not been depressurized when opening a high pressure filter material may escape under very high pressure and cause severe injuries Depressurize the unit completely before you open a high pressure filter 1 Unscrew the cap of the high pressure filter using the T handle intended for this purpose see Fig 36 on page 41 2 Loosen the nut on the filter element with an open end spanner and remove the filter element 3 Clean the filter element For this purpose use only solvents that match the material to be applied Replace the filter element if it shows any damage Check the O ring replace if damaged Assemble the high pressure filter as described in work steps 1 and 2 but in reverse order With high pressure filters versions R and RS you should strictly lubricate all j threads with the lubricant for stainless steel WIWA order no 0000233 to enable easier assembly and disassembly 6 6 Drying the moisture filter If the material drum of the hardener is fitted with a moisture filter the granulate in the filter must be dried at the latest when it is saturated With increasing moisture content the colour of the granulate changes from orange to transpar ent When transparent the granulate is saturated gt Drying temperature approx 50 C gt Drying time approx 4h Only heat up the granulate Heating up the complete filter can damage the 1 housing
28. ed operating materials cc ceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeees 40 6 8 Filter elements for high pressure filters eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 40 6 9 Special tool Sitini anao iaaa EENE ESERE ERS 41 7 Rectification of faults 220 eee eee eeeeee eee eeeeeeeeeeeneaeeeeseeeaaeeeeeeeaaaes 42 8 Technical dala oseraies tea scattered nets 45 Bi 1 Machine CAd assioni EEEN 45 O2 TYPE PIAS eaae EEEN EEE 45 Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs IVA ee 1 Foreword Dear Customer We are delighted that you have decided in favour of a DUOMIX 230 from our company This operating manual is intended for the operating and maintenance person nel It contains all the information required to working with this unit The owner of the unit must ensure that the operator of the unit always has i an operating manual at his her disposal in a language he she understands Safe and reliable operation of the unit requires further information in addition to this operating manual Read and comply with the applicable guidelines and accident prevention instructions for your country In Germany these are gt the Richtlinien fur Flussigkeitsstrahler Spritzgerate Guidelines for Liquid Jets issued by the Hauptverband der Gewerblichen Berufsge nossenschaften gt the BGR 500 chapt 2 29 Verarbeiten von Beschichtungsstoffen Applica tion of Coating Materials gt
29. eeneeees 13 2 5 2 Personnel Quallification cccccsccccceeeseececeeseeeceeeeeeneeeeeeesnsneeeeneteaes 13 2 5 3 Authorized operating personnel cccceeeeeseeeeeeeeeeteeeeeeenaeeeeeeens 13 2 5 4 Personal protective equipment ee eeeeeeeceenteeeeteeenteeeeeeenaaeeeeeeeaa 13 2 6 Notes OM Warranty ressida a aaan Aa aa EEE EAER 14 2 6 1 Conversions and alterations cccccceeeeeeeeeceeeeeeeeeeeeeeeeeseaeeneeees 14 20 2 Spate pars mirena e E R E NS 14 2 0 3 ACCOSSOMOS x ccs ieccttavesssneeeaxuasceeneen aipceniavesancteeevusiceeavieninc tiaviihacteeheeaee 14 2 7 EMe rgency proCeCUures ecececceceeeeeeeeeeeeeeneeeeeeseneeseeeneneeeeeeneeneeeeeenennees 15 2 7 1 Shutting down and depressurizing the unit 15 22 Loak Sepsa Secerancce sa ease veo eeeaete cxpiaatexs Sees eee 15 2 teed MUNG E E T A E T TT 15 2T AFOS oieri Eee EEN ENN 15 3 Unit description cinnin aiiiar 16 Sel IMLSMOSC USC anon anean bein tenaseete dete excepted eed 16 32 UMIMCONTGUPATION a s tecct ba teshede Hag Roee deri a ated beew aateneees eee dete 17 9 3 Material Tool saena a tee deceased Seidel tect ein eta ceteterdebieventectas ieee ates 20 3 3 1 SUCTION PIPE Serinin dania eanas aieiaa eNA iR ETEEN ESE 20 33A Fogd OUM sssr EENE 20 33 3 Feed PUMPS encino aenn EEEE 20 SA MIXING UNM eccirni erna EAR EAEE EEEE EEEE 21 3 4 1 Standard MIKIN UNit ess N 21 3 4 2 Mixing unit with separate flushing levers n c 22 3 4 3 External MIXING UNIt osii
30. entilation valve for the hardening component for function and leak tightness Open the ball valve 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 standard component pumps does not work Check and clean both piston valves Replace defective balls or valve plates Both standard component pumps do not generate any pressure in up stroke The pressure in the hardener side is very high The piston valves of the two stand ard component pumps do not work Check and clean both piston valves Replace defective balls or valve plates In the up stroke the pressure of both components is considerably higher than during the down stroke The feed hose inflates or the pressure relief valve on the outlet manifold opens A bottom valve of the two standard component pumps does not work gt Check and clean both bottom valves Replace defective balls or valve plates 42 Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs BTA Fault Possible cause s Rectification of faults Remedy No pressure generated for the standard component during up and 1 Standard component pumps do not receive any material gt Check the material supply down s
31. event your eyesigh from being damaged by material splatter gases vapors or dust Wear ear defenders Highlights the order to use ear defenders in order to prevent your sense of hearing from being damaged by noise Use a respiratory protection mask Highlights the order to use a respiratory protection mask in order to prevent your respiratory tract from being damaged by gases fumes or dusts Wear protective gloves Highlights the order to wear protective gloves with lower arm protection to protect against burn injuries caused by heated materials Wear protective footwear Highlights the order to wear protective footwear to prevent injuries to the feet due to tumbling falling or rolling objects and a slip on slippery surfaces Reading is an absolute must Highlights references to guidelines work and operating manuals which must be strictly followed Translation of the original operation manual DUOMIX 230 7 DM230_BAoDB_en_1307 rs Safety WIA 2 2 Safety notes Please remember that the DUOMIX 230 works with extremely high pressures and may cause life threatening injuries if used inappropriately Always observe and follow the information in this operating manual as well as in the separate operating manuals for individual components of the unit or the optionally available accessories 2 2 1 Operating pressure Components that do not comply with the maximum permissible operating pressu
32. g pump fully back Operate the spray gun once again for a moment to relieve the flushing pressure completely Perform the following work steps to clean the section between material inlet and mixing unit Both components must be strictly kept separated also during cleaning Use a separate solvent and collecting container for each component to avoid material reactions and thus possible damage to the unit A Explosive gases may be generated by the evaporation of flushing agent which may ignite on hot heat sources Before you start cleaning work you must switch off all material heaters and allow the unit to cool down Quicker cooling can be achieved by circulating the material through the unit max 20 minutes Ilo 4 Guide the return flow hoses into separate collecting vessels and secure them against accidental slipping out 5 Connect the flushing agent feed For units with suction system place the suction pipes of the material pumps into the drum with flushing agent belonging to the material For units with feed drums drain the material off through the drain valves then fill in the flushing agent belonging to the material For units with feed pumps insert their suction pipes into the flushing agent belonging to the material open the ball valves and set the air pressure regulators on the feed pumps to a pressure of approx 2 3 bar Set the levers at the mixing unit to Circulate Regulate the ai
33. g the regulating screw on the fog oiler with a screwdriver 6 3 3 Checking and cleaning the water separator The accumulated condensation water is automatically drained off through the drain valve For this purpose hold the hose into an empty collecting vessel Check the bowl regularly for dirt residues and clean it as required disassembly and assembly as with the oil reservoir 6 4 Check release agent for material residues Each of the 3 material pumps on the main pump contains approx 100 ml of re lease agent In order to check the release agent for material residues you must drain off a small amount of release agent from the drain screws I Fig 34 Drain screws for release agent Fig 35 Filler openings for release agent If the release agent is found to be contaminated with material residues you must assume that the packing of the related material pump is worn In this case have the pump packing replaced as soon as possible 38 Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs BTA pains After the examination top up the amount of fresh release agent through the filler openings We recommend to use release agent from WIWA order no 0163333 6 5 Cleaning the filter elements in the high pressure filters The cleaning interval for the filter elements in the high pressure filters depends on the type and cleanliness of the material Clean the the filter elements at least 1 x per week and after
34. harges can cause fire and explosion Always use open containers Never spray solvents or solvent containing materials into cone top cans or drums with bunghole gt Stand the containers on a grounded surface gt When using metal containers watch out for contact between spray gun and container wall gt Only use conductive material hoses All original material hoses from WIWA are conductive and perfectly adapted to our units 2 2 4 Explosion protection A Units designed without explosion protection must not be used in workshops that come under the explosion protection ordinance Explosion protected units fulfil the explosion protection requirements of the Directive 94 9 EC for the explosion group unit category and temperature class specified on the type plate or in the declaration of conformity The operator is responsible for determining the zone allocation according to the Directive of EC 94 9 EC Appendix II no 2 1 2 3 when observing the measures of the responsible inspecting authority The operator is responsible for checking and ensuring that all technical data and markings according to ATEX corre spond with the necessary requirements Please note that several components have their own type plate with separate marking according to ATEX In this case the lowest explosion protection of all attached markings applies for the entire unit Applications where the malfunc tion of the unit can lead to danger to pe
35. hes ber schreiten des zul ssigen Betriebsdrucks Sie befinden sich in der Verschraubung hinter den Hochdruckfiltern If a safety rupture disc is damaged material will escape into the collecting vessel of the rupture disc safety system X I x a s f Fig 5 Safety rupture disc In this case the safety rupture disc must be replaced immediately You find the corresponding ordering data on the machine card A new safety rupture disc must be installed with the coloured side facing towards the pressure 2 4 5 Spray gun lock The spray gun must always be secured against unintended operation even for the shortest of work breaks Set the safety lever horizontally to secure the spray gun Fig 6 Spray gun lock 12 Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs BTA Satety 2 5 Operating and maintenance personnel 2 5 1 Obligations of the unit owner The owner of the unit is responsible for training the operating and maintenance personnel gt must direct the operating and maintenance personnel to handle the unit appropriately and to wear correct work clothes and protective equipment gt must make the user manual accessible to the operating and maintenance personnel and ensure that it remains available at all times gt must ensure that the operating and maintenance personnel have read and understood the user manual Only then the unit may be taken into service 2 5 2 Personne
36. iners are not included in the scope of delivery Observe the technical notes of the respective material manufacturer Check the tightness of the unit or single components of the unit by slow pres sure build up during the commissioning 1 Place the suction pipe of the flushing pump into the flushing agent drum Make sure that all air pressure regulators have been fully regulated back Open the compressed air shut off valve on the air maintenance unit Set the levers at the mixing unit to Flush iF Sh On the pressure regulator of the flushing pump set a pressure of 3 6 bar depending on the length of the material hoses Open the spray gun until clean flushing agent starts to run out 7 Only on versions with pressure and dosing control see chapter 3 6 1 on page 25 Set the switch Manual Automatic to Manual and press the start button Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs BTA Operation After assembly this unit was factory tested for flawless function by means of a test substance During initial start up you must therefore perform a complete cleaning in order to flush out any test medium residues see chapter 5 6 on page 34 8 10 11 12 13 5 2 Coating Connect the material feed For units with suction system place the suction pipes of the material pumps into the corresponding material drums with components A and B For
37. ing pressure you use the two red pointers to set the operation limits for the current work process as follows 1 Insert the attached key into the contact pres KR ates sure gauge ms 2 Use the driver needle to turn the lower red 20 bar Le ww YS slave pointer to a value of approx 20 bar below the minimum pressure that is indicated when the spray gun is opened 3 Use the driver needle to turn the upper red slave pointer to a value of approx 20 bar above the maximum pressure that is indicated when the spray gun is closed 4 Pull the key back out Fig 30 Operation limits The pressure and dosing control must be readjusted each time the spraying 1 pressure has been changed If the pointer of the contact pressure gauge does not move or moves only insignificantly the unit must not be put into operation due to the danger of mixing faults 5 2 3 Tips for good coating Hold the spray gun at a right angle 90 to the area to be coated If the spray gun is held at a different angle the coating becomes irregular and blotchy see Fig 31 gt Move the spray gun with your arm and not with your wrist gt Begin moving the spray gun before pulling the Fig 31 Spraying angle trigger This way you will achieve perfect soft and smooth overlapping of the spray jet and excessively thick application of material at the beginning of the coating process is avoided 32 Translation of the origina
38. l operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs PITA Operation Ensure an even speed and move the spray thin gun parallel to the area to be coated Waving lever CES the spray gun causes irregular coating see 7 j Fig 32 1 Release the trigger before stopping the move ment gt Replace the spray nozzle before it is worn D thick thin layer layer wrong Fig 32 Do not wave Worn nozzles cause higher paint consumption and have a negative effect on i the quality of coating 5 3 Flushing When interrupting work you should flush all components that had contact with the mixed material within the potlife specified by the manufacturer 1 Close and secure the spray gun 2 Set the levers at the mixing unit to Flush 3 Keep spraying the material mix in the unit into a collecting vessel until clean flushing agent starts flowing out 4 Close and secure the spray gun The section between mixing unit and spray gun has been cleaned The materi al in the section between material inlet and mixing unit may remain in the unit because no mixing will take place 5 4 Pressure relief 1 Close the compressed air shut off valve on the maintenance unit 2 Set the levers at the mixing unit to Circulate 3 Operate the spray gun until the material pressure is relieved completely 5 5 Decommissioning When interrupting work for a longer time e g at finishing time take the u
39. l qualification A differentiation is made between two groups of people in dependence on their qualifications Instructed operators have been verifiably instructed by the unit owner in the activities they are tasked with and the potential risks connected with them in the case of incorrect behaviour Trained personnel have been instructed by the unit manufacturer such that they are capable of carrying out maintenance and repair work on the unit and recognising potential risks on their own initiative and of avoiding these risks 2 5 3 Authorized operating personnel Activity Qualification Setup and operation Instructed operators Cleaning Instructed operators Servicing Trained personnel Repair Trained personnel 2 Di Juveniles under the age of 16 have no permission to operate this unit 2 5 4 Personal protective equipment gt Wear protective clothing N y Always wear the protective clothing prescribed for your work environment l mining closed rooms etc and follow the recommendations in the safety data sheet issued by the material manufacturer Use eye protection Wear protective goggles to protect against eye injuries caused by material splatter gases vapors or dust Translation of the original operation manual DUOMIX 230 13 DM230_BAoDB_en_1307 rs Safety WIA Wear ear defenders Operating personnel should be provided with suitable noise protecti
40. nce and repair work on electrical components must only be per formed by skilled electricians any other maintenance and repair work only by the WIWA Customer Service or specially trained personnel Before maintenance and repair work 1 Shut off the compressed air supply 2 Switch off the electric power supply if present 3 Depressurize the unit completely In case of material congestion or agglomeration of material residual pressu res can still be present despite pressure relief When disassembling residual pressures can escape suddenly and cause serious injury gt Be extremely careful when disassembling gt When disconnecting material hoses you should cover the screw fitting with a cloth to catch any escaping material sprays After completing work check the function of all safety features and the correct functioning of the unit 6 1 Regular inspections 1 36 According to the accident prevention instructions for Work with fluid spray ing equipment BGV D15 the unit needs to be inspected and serviced regu larly by an expert WIWA Customer Service The unit needs to be inspected gt before initial commissioning gt after the modification or repair of parts of the unit which could affect safety gt after work breaks longer than 6 months gt but atleast every 12 months For decommissioned units the inspection can be postponed until the next com missioning The ins
41. ng FLUSH gt Check the function of the flush ing pump 2 The flushing ball valves on the gt Check the flushing ball valves mixing block do not open gt If necessary disconnect the flushing hose from the mixing unit and replace it with a manual spray gun Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs 43 Rectification of faults Fault Possible cause s WIA Remedy The air motor ices very quickly and the performance decreases 1 The deicing system optional is not switched on 2 The water separator is full 3 The unit is overloaded Switch on the deicing system and if necessary the material flow heater gt Drain the water separator Make sure the unit does not run too fast reference value approx 25 double strokes a minute Compressed air escaping from the air motor at the guide axes The air motor seals are closed gt Seal the air motor again The air motor no longer works even though the compressed air supply is assured No material pressure available in the unit The air motor control is defective Have the air motor repaired in the WIWA Service workshop The unit cannot be started 1 The stop cock on the air mainte nance unit is closed Only with pressure and dosing control 1 The pressure supply for the con trol cabinet is interrupted 2 The filter pressure regulator on the control cabinet is
42. nit out of service 1 Close and secure the spray gun 2 Set the levers at the mixing unit to Circulate 3 Only on versions with pressure and dosing control see chapter 3 6 1 on page 25 Set the switch Manual Automatic to Manual 4 Regulate the compressed air pressure regulator for the main pump fully back Operate the spray gun until the material pressure is relieved completely Flush the unit as described in chapter 5 3 Regulate the air pressure regulator for the flushing pump fully back Translation of the original operation manual DUOMIX 230 33 DM230_BAoDB_en_1307 rs Operation WIA 8 Close the compressed air shut off valve on the maintenance unit 9 Only for version with material heaters Regulate the temperature controller on material flow heaters drum floor heaters or hose heaters completely back 10 Only for version with feed pumps Regulate the air pressure regulators for the feed pumps fully back and close the ball valves on the feed hoses 11 Operate the spray gun once again for a moment to relieve any flushing pressure residues so that the entire unit has been relieved 5 6 Complete cleaning During initial commissioning material change and decommissioning for a lon ger period the unit must be cleaned completely 1 Perform all work steps as described in chapter 5 3 in order to clean the section between mixing unit and spray gun Regulate the air pressure regulator for the flushin
43. nsa iania 23 3 5 Maintenance UNit cenere iria aE Ea a AA Ena EErEE EEEE ia 24 3 5 1 Standard maintenance UNit cccccccceccceccesseesssseeseeeeeeeeeeeeeeseerees 24 3 5 2 Maintenance unit with remote controlled compressed air control 24 Translation of the original operation manual DUOMIX 230 3 DM230_BAoDB_en_1307 rs Contents 3 6 Optional extensions and accessories cceeeeeeeeeeeceeeeeeeeteeseeeeeeseaeeteeneees 25 3 6 1 Pressure and dosing CONVO aisciai 25 302 Matna Geta 2es ca astees chan Sine bare oe cies tance cae dacieettee Ree ddeiine ee ienauace 25 4 Transport installation and assembly 26 Ao ANS POM E A E T E entered evn easels 26 4 2 Installation JOCAUON sasise EENEN 27 aea a i A E A E T E E T E E 27 4 3 1 Assembling spray hose and spray gun ssssssssisssesrirssrrrrissrrrrnsss 28 4 3 2 Inserting the filter elements into the high pressure filter 28 4 3 3 Connecting the compressed air SUPDPIY ccceeeeeeeeeeeeestteeeeeeees 28 4 3 4 Grounding the Unit cece ceceeeeeeeeeaeeeeeeeeeeaaeeeeaaeeeeeaeeseaaaesneeees 28 4 3 5 Filling in release agent and pneumatic Oil ee eeeeeeeeeeeeeeeeeeeee 29 4 3 6 Assembling the hose package and the external mixing unit optional 29 5 OCCT ACO MN 5s ccic sce teedeb a da bs ance tu lance a A A S a cede 30 5 1 Taking the unit into SOrViCe cc ceeeeecceeeeeeeeceteeeeeeeeeeeeneneeeeeeseeeeeseeeneneees 30 52 COUN Gs erie na ee EEEN
44. oll Free 1 855 757 0141 E Mail jwold wiwalp com Homepage www wiwalp com WIWA subsidiary in China WIWA Taicang Co Ltd Building A of Huaxin Industrial Park No 11 East Qingdao Road Taicang City Jiangsu Province 215400 P R China Tel 86 512 5354 8858 Fax 86 512 5354 8859 E Mail info wiwa china com Homepage www wiwa china com because it works
45. ompletion of setup work gt after cleaning maintenance and repair work Check list Lead seal on the safety valve still intact Safety valves externally free of damage Function of compressed air shut off valve correct Ground cable free of damage Ground cable connections on unit and conductor in good condition Correct functioning of safety levers on spray gun QHNANARARA A If one of the safety features is missing or not fully functional the operating safety of the unit cannot be guaranteed gt If you discover any faults on the safety features or other deficiencies on the unit stop operation of the unit immediately gt Only resume operation of the unit after the fault has been completely rectified 2 4 1 Safety valves The DUOMIK 230 is equipped with safety valves in the air motors of the main pump see Fig 2 the flushing pump and the feed pumps if present The safety valves ensure that the max permissible air inlet pressure is not exceeded If the air inlet pressure exceeds the fixed limiting value at one of the points mentioned above the corresponding safety valve will blow off A If the maximum permissible air inlet pressure is exceeded components may burst This may result in damage to persons and property gt Never allow the unit to run without or with defective safety valves Ifa safety valve needs to be replaced you can find the corresponding order number on the machine card
46. on equip ment The operator is responsible for adhering to the accident prevention regulation Noise BGV B3 For this purpose pay special attention to the conditions of the installation location the noise burden will increase if the unit is installed in or on hollow bodies Use a respiratory protection mask We strongly recommend to wear a respiratory protection mask even though the paint mist has been minimized in Airless spray painting applications with correct pressure setting and working mode Wear protective gloves When applying heated materials you should wear protective gloves with low er arm protection to prevent burns Wear protective footwear Wear protective footwear to prevent injuries to the feet due to tumbling fal ling or rolling objects and a slip on slippery surfaces 2 6 Notes on warranty 2 6 1 Conversions and alterations 2 6 2 Spare parts 2 6 3 Accessories 14 Unauthorized conversions or alterations should not be undertaken on safe ty grounds Protective equipment should not be dismantled converted or bypassed The unit should only be operated within the prescriptive limit values and parameters gt For the maintenance and repair of the unit only original spare parts from WIWA may be used If you use spare parts not manufactured or supplied by WIWA any warran ty and liability will become null and void Ifyou use original accessories from W
47. pection results must be recorded in writing and kept until the next in spection The inspection report or a copy thereof must be available at the place of use of the unit Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs BTA airs 6 2 Maintenance plan The information in the maintenance plan are recommendations The inter il vals may vary in dependence on the condition of materials used and outer influences Interval Activity before each start up Check the lubricant level top up if necessary 1 x per week Checking and adjusting the fog oiler 1 x per week Checking and cleaning the water separator every 50 operating hours Check release agent of the main pump for material residues depending on the type and Clean the filter elements in the high pressure cleanliness of the material or filters with every material change depending on the saturation Dry the moisture filter if present of the granulate 6 3 Maintenance unit The maintenance unit prevents condensation water and dirt particles from entering into the unit and supplies the compressed air with oil for lubrication of moving parts The maintenance unit is equipped with the following maintenance facilities z o Designation Fog oiler adjusting screw CM 2 3 Inspection glass Oil filler plug Slide Oil tank Water separator Drain valve DOIN IDO aA R
48. perating manuals from WIWA safety notes are particularly highlighted and marked as follows Highlights accident hazards which if disregarding the safety note will result most likely in severe or even fatal injuries Highlights accident hazards which if disregarding the safety note can result in severe or even fatal injuries Highlights accident hazards which if disregarding the safety note can result in injuries Highlights important information for the proper use of the unit Disregarding this information can result in damage to the unit or to the en vironment Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs Safety Depending on the hazard source different pictograms are used in safety notes about accident hazards with risk of injury examples General accident hazard Risk of explosion from explosive atmospheres Risk of explosion from explosive substances Accident hazard from voltage or static electricity Danger of crushing from moving components of the unit Risk of burns from hot surfaces Security orders primarily indicated to wear protective equipment They are also highlighted and marked as follows Wear protective clothing Highlights the order to wear the prescribed protective clothing to protect against skin injuries caused by spraying material or gases Use eye protection Highlights the order to use eye protection in order to pr
49. pumps fully back The unit is now fully cleaned and pressure relieved and thus prepared for a prolonged decommissioning 5 7 Material change 1 Clean the unit completely see chapter 5 6 on page 34 When changing the material from epoxy to polyurethane the unit needs to be 1 thoroughly flushed with the flushing agent belonging to the material before the new material is filled in 2 3 5 8 Waste disposal Check and clean the filter elements in the high pressure filters see chapter 6 5 on page 39 Restart the unit At the end of use you must shut down disassemble and dispose of the unit in accordance with legal regulations gt gt gt Clean the unit thoroughly of all material residues Disassemble the unit and separate all materials dispose metal together with scrap metal plastic parts can be disposed of as domestic waste Rests of spraying material cleaning agent oils greases and other chem ical substances must be collected in accordance with statutory provisions concerning recycling and waste disposal The official local waste water laws are valid Translation of the original operation manual DUOMIX 230 35 DM230_BAoDB_en_1307 rs Maintenance WIA 6 Maintenance A A If maintenance and repair work is carried out by persons who have not been trained for this work you endanger yourself other persons and impair the safety and reliability of the unit Maintena
50. r pressure regulator of the main pump so that the main pump runs slowly 8 Close the return flow as soon as clean flushing agent starts to run out of the return flow hoses 34 Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs PITA 10 11 12 13 14 15 16 17 Operation Guide the return flow hoses into the flushing agent drums and secure them against accidental slipping out Open the return flow again and allow the flushing agent to circulate through the unit for approx 3 7 minutes depending on the length of the material hoses Set the levers at the mixing unit to Spray Operate the spray gun until clean flushing agent starts to run out Set the levers at the mixing unit again to Circulate Regulate the compressed air pressure regulator for the main pump fully back Close the compressed air shut off valve on the maintenance unit Once both pressure gauges on the high pressure filters show O bar close the return flow on the mixer with the corresponding ball valve Stop the flushing agent feed For units with suction system take the suction pipes of the material pumps out of the flushing agent drums For units with feed drums drain the flushing agent off through the drain valves For units with feed pumps take the suction pies of the feed pumps out of the flushing agent drums close the ball valves and regulate the air pressure regulators on the feed
51. re may burst and cause severe injuries gt The specified maximum operating pressures must generally be com plied with for all components In case of varying operating pressures the lowest value is always valid as the maximum admissible operating pressure for the entire unit Material hoses and hose assemblies must comply with the maximum ope rating pressure including the required safety factor Material hoses must be leak tight and free of kinks signs of abrasion or bulges gt Hose connections must be tight 2 2 2 Risks due to the spray jet A The material is discharged from the spray gun under very high pressure Due to its cutting effect the spray jet can cause severe injuries by penetrating the skin or entering into the eyes gt Never point the spray gun at yourself other persons or animals gt Do not hold your fingers or hands in front of the spray gun gt Do not reach with your hands into the spray jet A Any unintended escape of material from the spray gun can cause damage to persons or property Always secure the spray gun even for shortest work breaks gt Always make sure that the spray gun is properly secured before each use 8 Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs IVA Satety 2 2 3 Risks due to electrostatic charge A The high flow velocities associated with the Airless spraying method may cause Static charging Static disc
52. rial to be processed starts flowing out Regulate the air pressure regulator on the main pump to the optimal spray ing pressure see chapter 5 2 1 Only for version with pressure and dosing control Set the operation limits for the current work step on the contact pressure gauge see chapter 5 2 2 and set the switch Manual Automatic to Automatic Check the pressure indication on the pressure gauges of the high pressure filters These must show almost identical pressure values The unit is now ready for operation You can start coating Translation of the original operation manual DUOMIX 230 31 DM230_BAoDB_en_1307 rs Operation WIA 5 2 1 Adjusting spraying pressure Please observe the following instructions when adjusting the spraying pressure gt Optimal spraying pressure is indicated by a uniform application of material with fading out peripheral zones gt Operate the unit only with an air pressure as high as necessary to achieve a good atomiza tion at the recommended spraying distance of approx 30 40 cm gt Too high spraying pressure causes increased material consumption and paint mist gt Too low spraying pressure results in the appearance of stripes and differences in the Fig 29 Spraying distance coating thickness 5 2 2 Adjusting the pressure and dosing control The black pointer in the contact pressure gauge shows the actual pressure Once you have set the optimal spray
53. rs and paint particles should be extracted gt Protect objects adjacent to the spraying object against possible damage caused by the material mist 4 3 Assembly A If assembly work is carried out by persons who have not been trained for this work you endanger yourself other persons and impair the safety and reliability of the unit Electrical components must only be assembled by skilled electricians any other components such as the spray hose and spray gun only by specially trained personnel If so various components of the unit were packed separately for transport These parts must be assembled properly as well as the accessories before operating the unit Please observe the notes on warranty in chapter 2 6 2 on page 14 when i using non original accessories from WIWA Translation of the original operation manual DUOMIK 230 27 DM230_BAoDB_en_1307 rs Transport installation and assembly E24 WA 4 3 1 Assembling spray hose and spray gun A Components that do not comply with the maximum permissible operating pressure may burst und cause severe injuries Before assembling check the maximum permissible pressure for the spray hose and spray gun It must be higher than or equal to the maxi mum operating pressure of the unit as specified on the type plate Connect the spray hose to the material outlet of the mixing unit see example for standard mixing unit in illustration at the left
54. rsonnel must be provided with respec tive safety measures by the operator 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 under the explosion protection ordinance even if the accessory equipment as such is explosion protected Translation of the original operation manual DUOMIK 230 9 DM230_BAoDB_en_1307 rs Safety 2 2 5 Health risks 1 A A BTA Follow the safety notes and dosing information of the manufacturer and the generally applicable regulations when handling paints solvents oils grea ses and other chemical substances Rests of paints solvents oils greases and other chemical substances must be collected in accordance with statut ory provisions concerning recycling and waste disposal The official local waste water laws are valid Depending on the materials being applied solvent vapours may be genera ted which could cause damage to health and objects Always ensure sufficient aeration and ventilation at the workplace Always observe the processing instructions issued by the material manu facturers Solvents or other harmful substances are not suitable to clean your skin and can result damage to health Use only appropriate skin protection skin cleaning and skin care products
55. ssure and dosing control 6 Mixing unit with separate flushing levers 7 Material pumps of main pump 8 Collecting vessel for safety rupture disc safety device 9 Spraying hose connection 10 Rack 11 Maintenance unit 12 Material Flow Heater 13 Flushing pump Translation of the original operation manual DUOMIK 230 17 DM230_BAoDB_en_1307 rs Unit description 18 WIA Fig 8 Example of a DUOMIX 230 on a 2 wheel rack Designation Flushing pump Maintenance unit Compressed air shut off valve 2 wheel rack Collecting vessel for safety rupture disc safety device Suction pipes of main pump N OO oO RR O hM Main pump with muffler air motor and material pumps for A and B component 8 High pressure filter 9 Lever to open and close the return flow 10 Control cabinet of pressure and dosing control 11 Standard mixing unit 12 Return hoses for A and B component 13 Static mixer 14 Spraying hose connection Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs E24 WA Unit description 00 00O Fig 9 Example of a DUOMIX 230 on a 3 wheel rack No Designation Air motor of main pump High pressure filter Contact pressure gauge of pressure and dosing control Remote controlled compressed air control unit Lever to open and close the return flow Return hoses for A an
56. the information on the machine card Please notify us immediately if there are discrepancies if the user manual has been incorrectly compiled or if the type plate is missing Translation of the original operation manual DUOMIX 230 5 DM230_BAoDB_en_1307 rs Safety 2 Safety WIA 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 regulations The unit 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 gt to the unit and other material assets of the owner gt to the efficient working capacity of the unit In principle you should refrain from any work method that could affect the safety of operating personnel and the unit All persons involved in set up commis sioning operation maintenance repair and servicing of the unit must have read and understood the operating manual beforehand especially the chapter Safety Your safety is at stake We recommend to the owner of this unit to have this confirmed in writing 2 1 Explanation of symbols gt gt gt Safety notes warn of potential accident hazards and identify the necessary measures to prevent accidents In the o
57. troke The pressure in the 2 Burst discs on high pressure Check the burst discs on the high hardener component is very high filter defective pressure filter for the standard component 3 The bleeding valve of the stand gt Check bleeding valve of stand ard component is leaking ard components for function and leakage 4 The ball valve on the material Open the ball valve inlet is closed When bleeding the pressure of 1 Bleeding valve of standard com Check the bleeding valve the standard component remains ponent does not open applied 2 Return flow hoses are clogged gt Check return flow hoses for free The pressure of hardening compo 3 The high pressure filter element flow nent drops is excessively soiled Clean high pressure filter When bleeding the pressure of 1 Bleeding valve of hardening gt Check the bleeding valve the hardening component remains component does not open applied 2 Return flow hoses are clogged gt Check return flow hoses for free The pressure of standard compo flow nents drops 3 The high pressure filter element gt Clean high pressure filter is excessively soiled When spraying the pressure of 1 The high pressure filter element gt Clean the high pressure filter the standard component always for the standard component element or install a coarser increases in comparison to the hard starts to block up element ener component 2 The seals of the hardener com gt Repair th
58. units with feed drums fill components A and B into the correspond ing feed drums gt For units with feed pumps insert their suction pipes into the correspond ing material drums with components A and B open the ball valves and set the air pressure regulators on the feed pumps to a pressure of approx 3 4 bar Guide the return flow hoses for components A and B into the corresponding material drums and secure them against accidental slipping out Set the levers at the mixing unit to Circulate Regulate the air pressure regulator of the main pump so that the main pump runs slowly Only for version with material heaters Set the control button to the desired material temperature 0 80 C Drum floor heater or hose heaters must be switched on before Observe and follow the notes in the separate user operating manual for the material heaters Allow the material to circulate until the material flowing out of the return flow hoses is free of air bubbles and on versions with material heaters the required processing temperature has been reached You can check the material temperature with a temperature measuring probe optionally available Before coating the unit must be taken into service 1 2 Set the levers at the mixing unit to Spray Regulate the air pressure regulator of the main pump to a low air inlet pres sure Keep spraying the flushing agent residues in the unit into a collecting ves sel until mate
59. ying coarse pigmented or fibre filled materials The standard suction screen 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 suc tion system must be cleaned or if necessary replaced Translation of the original operation manual DUOMIX 230 DM230_BAoDB_en_1307 rs BTA 6 9 Special tools Maintenance The DUOMIX 230 comes with the following special tools Fig 37 Translation of the original operation manual DUOMIK 230 DM230_BAoDB_en_1307 rs T handle to open the high pressure filters Attention The high pressure filter must only be opened after the pressure has been relieved Key to open the control cabinet optional for version with pressure and dosing control Attention Open only for repair purposes Key to adjust the operation limits on the contact pressure gauge optional for version with pressure and dosing control 41 Rectification of faults 7 Rectification of faults Fault Possible cause s WIA Remedy The feed pumps work without inter ruption With the relieve tap opened no material comes out of the output distributor 1 The material drum is empty 2 The suction system is defective and the pump sucks in air 3 Material feed pump s is are defective 4 The viscosity is too high Replace the material drum or fill it up
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