wiwa DUOMIX 333 PFP User manual

Translation of the original operation manual
PFP_Version 2_DBK_en_1205 · rs
Operation manual
DUOMIX 333 PFP
Type:
❍230 V
❍400 V
❍440 V
Serial-No.
⸏ ⸏ ⸏ ⸏ ⸏ ⸏ ⸏ ⸏

Translation of the original operation manual DUOMIX 333 PFP 3
PFP_Version 2_BAoDB_en_1410 · rs
Contents
Contents
1 Foreword........................................................................................................6
2 Safety .............................................................................................................7
2.1 Explanation of symbols................................................................................7
2.2 Safety notes.................................................................................................9
2.2.1 Operating pressure ............................................................................9
2.2.2 Risks caused by the spray jet ............................................................9
2.2.3 Hazard from electrostatic charging ..................................................10
2.2.4 Hazards from hot or cold surfaces...................................................10
2.2.5 Explosion protection ........................................................................ 11
2.2.6 Risks due to the rams ...................................................................... 11
2.2.7 Health risks ......................................................................................12
2.3 Information signs on the equipment...........................................................13
2.4 Safety features...........................................................................................13
2.4.1 Main switch and stop button on control cabinet ..............................13
2.4.2 Safety valves ...................................................................................14
2.4.3 Compressed air shut-off valves .......................................................14
2.4.4 Safety rupture discs .........................................................................15
2.4.5 Ground cable ...................................................................................15
2.4.6 Spray gun lock .................................................................................15
2.4.7 Thermistor-motor protection-trigger .................................................15
2.5 Operating and maintenance personnel......................................................16
2.5.1 Obligations of the plant owner .........................................................16
2.5.2 Personnel qualication.....................................................................16
2.5.3 Authorized operating personnel.......................................................16
2.5.4 Personal Protective Equipment .......................................................16
2.6 Notes on warranty......................................................................................17
2.6.1 Conversions and alterations ............................................................17
2.6.2 Accessories and spare parts............................................................17
2.7 Emergency procedures..............................................................................18
2.7.1 Leakages .........................................................................................18
2.7.2 Injuries .............................................................................................18
2.7.3 Fires.................................................................................................18
3 Unit description...........................................................................................19
3.1 Intended use ..............................................................................................19
3.2 Unit conguration.......................................................................................20
3.3 System control components.......................................................................22
3.3.1 Control cabinet.................................................................................22
3.3.2 Pressure and dosing control ............................................................23
3.3.3 Control unit for metering pump, ushing pump
and pressure vessels ......................................................................23

Contents
4 Translation of the original operation manual DUOMIX 333 PFP
PFP_Version 2_BAoDB_en_1410 · rs
3.3.4 Ram control .....................................................................................24
3.3.5 Regulator cluster for feed pumps.....................................................24
3.4 Material feed components..........................................................................25
3.4.1 Flow diagram ...................................................................................25
3.4.2 Rams with feed pumps ....................................................................25
3.4.3 Pressure vessels with agitators .......................................................26
3.4.4 Metering pump.................................................................................27
3.4.5 Material Flow Heaters......................................................................27
3.4.6 Intermediate piece ...........................................................................28
3.4.7 Mixing unit........................................................................................29
3.5 Flushing unit...............................................................................................30
3.6 Water circulation components....................................................................30
3.6.1 Flow diagram ...................................................................................30
3.6.2 Provision tank ..................................................................................31
3.6.3 Circulation pumps ............................................................................31
3.7 Air maintenance unit ..................................................................................32
4 Transport, installation and assembly........................................................33
4.1 Transport....................................................................................................33
4.2 Installation location ....................................................................................34
4.3 Assembly....................................................................................................35
4.3.1 Assembling the hose package.........................................................35
4.3.2 Assembling spray hose and spray gun............................................36
4.3.3 Grounding the unit ...........................................................................36
4.3.4 Connecting the compressed air supply............................................36
4.3.5 Connecting to the electric power supply..........................................37
4.3.6 Opening the ventilation screw on the contact pressure gauge........37
5 Operation.....................................................................................................38
5.1 Taking the system into service ...................................................................38
5.1.1 Starting the system ..........................................................................39
5.1.2 Put the ushing unit and the water circulation into operation ..........39
5.1.3 Flush mixing unit and spray gun ......................................................39
5.1.4 Cleaning the system ........................................................................40
5.1.5 Fill the pressure vessels with material to be applied .......................41
5.1.6 Bleed the system .............................................................................42
5.1.7 Adjust the deicing system ................................................................42
5.1.8 Put the material ow heaters into operation ....................................42
5.1.9 Filling the hose package ..................................................................43
5.1.10 Checking the mixing ratio ..............................................................43
5.2 Coating.......................................................................................................44
5.2.1 Adjusting spraying pressure.............................................................44
5.2.2 Adjusting the pressure and dosing control ......................................44
5.2.3 Tips on coating.................................................................................45

Translation of the original operation manual DUOMIX 333 PFP 5
PFP_Version 2_BAoDB_en_1410 · rs
Contents
5.2.4 Changing material drums.................................................................45
5.3 Flushing .....................................................................................................46
5.4 Cleaning the static mixer............................................................................46
5.5 Work breaks...............................................................................................47
5.5.1 Short interruption of work.................................................................47
5.5.2 Longer work break ...........................................................................47
5.6 Placing the system out of operation...........................................................47
5.7 Storage ......................................................................................................48
5.8 Waste disposal...........................................................................................48
6 Maintenance ................................................................................................49
6.1 Regular inspections ...................................................................................49
6.2 Maintenance plan.......................................................................................50
6.3 Air maintenance unit ..................................................................................50
6.3.1 Checking the lubricant level in the fog oiler .....................................50
6.3.2 Checking and adjusting the fog oiler................................................50
6.3.3 Checking and cleaning the water separator ....................................51
6.4 Metering pump...........................................................................................51
6.4.1 Checking release agent for material residues .................................51
6.5 Feed pumps...............................................................................................51
6.5.1 Checking the release agent level in the feed pumps.......................51
6.5.2 Readjust the upper packing of the feed pumps ...............................52
6.5.3 Changing the upper packing of the feed pumps..............................52
6.5.4 Replacing the seals on the follow plate ...........................................52
6.6 Recommended operating materials...........................................................53
6.7 Special tools...............................................................................................53
7 Rectication of faults .................................................................................54
8 Technical data .............................................................................................57
8.1 Machine card .............................................................................................57
8.2 Type plates.................................................................................................57

6 Translation of the original operation manual DUOMIX 333 PFP
PFP_Version 2_BAoDB_en_1410 · rs
Foreword
1 Foreword
Dear Customer!
We are delighted that you have decided in favour of a DUOMIX 333 PFP 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
an operating manual at his/her disposal in a language he/she understands!
Safe and reliable operation of the system requires further information in addi-
tion to this operating manual.
➤Read and comply with the applicable guidelines for your country.
In Germany, these are the “Richtlinien für Flüssigkeitsstrahler” (Guidelines
for Liquid Jets), issued by: the Hauptverband der Gewerblichen Berufs-
genossenschaften.
➤Moreover the manufacturer’s instructions and guidelines for coating or
feeder materials are to be respected at all times.
We strongly recommend to add all relevant guidelines and accident prevention
instructions to this operating manual.
However, if you have any questions, please do not hesitate to contact us.
Excellent work results with your WIWA DUOMIX 333 PFP wishes
WIWA Wilhelm Wagner GmbH & Co. KG.
Copyright
©2014 WIWA
The copyright for this operating manual lies with
WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestraße 1-3 • 35633 Lahnau • Germany
Phone: [phone] • Fax.: [phone] • E-mail: [email protected] • 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.

Translation of the original operation manual DUOMIX 333 PFP 7
PFP_Version 2_BAoDB_en_1410 · rs
Safety
2 Safety
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:
➤to life and limb of the operator or third party,
➤to the machine and other material assets of the owner,
➤to the efcient working capacity of the unit.
In principle you should refrain from any work method that could affect the safety
of operating personnel and equipment. All persons involved in set-up, com-
missioning, 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
conrmed in writing.
2.1 Explanation of symbols
Safety notes warn of potential accident hazards and identify the necessary
measures to prevent accidents. In the operating manuals from WIWA safety
notes are particularly highlighted and marked as follows:
DANGER
Highlights accident hazards which if disregarding the safety note will result
most likely in severe or even fatal injuries!
WARNING
Highlights accident hazards which if disregarding the safety note can result
in severe or even fatal injuries!
CAUTION
Highlights accident hazards which if disregarding the safety note can result
in injuries!
Highlights important information for the proper use of the equipment.
Disregarding this information can result in damage to the equipment or to the
environment.
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

8 Translation of the original operation manual DUOMIX 333 PFP
PFP_Version 2_BAoDB_en_1410 · rs
Safety
Risk of explosion from explosive substances
Accident hazard from voltage or static electricity
Risk of crushing by moving unit parts
Risk of burns from hot surfaces
Risk of frostbite from cold 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 prevent 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 333 PFP 9
PFP_Version 2_BAoDB_en_1410 · rs
Safety
2.2 Safety notes
Please remember that the DUOMIX 333 PFP 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 system components or
the optionally available accessories.
The accident prevention instructions „Application of Coating Materials“ (BGR
500, chapt. 2.25) and the guidelines for liquid jets ZH1/406 of the employer‘s
liability insurance association must strictly be complied with.
2.2.1 Operating pressure
WARNING
Components that do not comply with the maximum permissible operating
pressure may burst und cause severe injuries.
➤The specied 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 system.
➤Material hoses and hose assemblies must comply with the maximum wor-
king pressure, including the required safety factor.
➤Material hoses must be leak tight and free of kinks, signs of abrasion or
bulges.
➤Hose connections must be tight.
2.2.2 Risks caused by the spray jet
WARNING
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 penetra-
ting the skin or entering into the eyes.
➤Never point the spray gun at yourself, other persons or animals!
➤Do not hold your ngers or hands in front of the spray gun!
➤Do not reach with your hands into the spray jet!
WARNING
Unintentional material release from the spray gun may cause personal injury
or damage to property.
➤Always secure the spray gun, even for shortest work breaks!
➤Always make sure that the spray gun is properly secured before each use!

10 Translation of the original operation manual DUOMIX 333 PFP
PFP_Version 2_BAoDB_en_1410 · rs
Safety
2.2.3 Hazard from electrostatic charging
WARNING
The high ow velocities associated with the Airless spraying method may
cause static charging. Static discharges can cause re and explosion.
➤Ensure that the unit has been properly grounded outside of explosive
atmosphere areas!
➤Also ground the object to be coated.
➤Always use open containers!
➤Never spray solvents or materials containing solvent into cone-top cans
or drums with a bunghole!
➤Place the containers on a grounded surface.
➤Always use electrically conductive containers.
➤Achten Sie stets auf Kontakt der Spritzpistole mit der Behälterwand.
➤Watch out for contact between spray gun and container wall.
➤Only use conductive material hoses. All original material hoses from
WIWA are conductive and perfectly adapted to our equipment.
WARNING
If the unit is contaminated by material during operation, the increased
coating thickness can lead to electrostatic charging. Static discharges can
cause re and explosion.
➤Clean the unit immediately to remove any contamination.
➤Carry out cleaning work outside areas with explosive atmospheres.
2.2.4 Hazards from hot or cold surfaces
CAUTION
The use of material heaters can cause the surfaces of the unit to become
hot. Risk of burns.
➤Always wear protective gloves with lower arm protection (gauntlet) when
working with heated materials!
CAUTION
The air motors become very cold during operation. There is a high risk of
local frostbite.
➤The air motors should warm up to a temperature above 10 °C before
starting any work on the unit.
➤Always wear suitable protective gloves!