wiwa DUOMIX PU 460 User manual

Translation of the original operation manual
PU460_DBK_en_1501 · jw
Operation manual
DUOMIX PU 460
Serial No.
⸏⸏⸏⸏⸏⸏⸏⸏
Type :
❍400 V
❍
230 V / 1-phase
❍230 V / 3-phase
Model with:
❍Diaphragm feed
pump
❍Piston feed pump
❍Feed tank
❍without supply

Translation of the operation manual DUOMIX PU 460 3
PU460_BAoDB_en_1501 · jw
Inhalt
Inhalt
1 Foreword........................................................................................................7
2 Safety .............................................................................................................8
2.1 Explanation of symbols...............................................................................8
2.2 Safety information.....................................................................................10
2.2.1 Operating pressure.........................................................................10
2.2.2 Risks due to the spray jet ...............................................................10
2.2.3 Risks due to electricity.................................................................... 11
2.2.4 Risks due to electrostatic charging................................................. 11
2.2.5 Risks due to hot or cold surfaces ................................................... 11
2.2.6 Explosion protection .......................................................................12
2.2.7 Health risks.....................................................................................13
2.3 Information signs on the machine.............................................................13
2.4 Safety equipment......................................................................................14
2.4.1 Safety valve....................................................................................14
2.4.2 Main switch / emergency off...........................................................15
2.4.3 Excessive temperature switch........................................................15
2.4.4 Material pressure sensors ..............................................................15
2.4.5 Ground fault circuit interrupter........................................................15
2.5 Operating and maintenance personnel ....................................................16
2.5.1 Obligations of the machine owner ..................................................16
2.5.2 Personnelqualications .................................................................16
2.5.3 Authorised operator........................................................................16
2.5.4 Personal protective equipment.......................................................16
2.6 Guarantee information..............................................................................17
2.6.1 Spare parts.....................................................................................17
2.6.2 Accessories....................................................................................17
2.7 Behaviour in an emergency......................................................................18
2.7.1 Bring the machine to a standstill and relieve the pressure.............18
2.7.2 Leaks..............................................................................................18
2.7.3 Injuries............................................................................................18
3 Machine description ...................................................................................19
3.1 Intended use.............................................................................................19
3.2 Erroneous use ..........................................................................................19
3.3 Machine design ........................................................................................20
3.4 Control cabinet .........................................................................................21
3.5 Materialow .............................................................................................22
3.6 Material supply .........................................................................................22
3.7 Proportioning pump ..................................................................................23
3.8 Materialuidheater..................................................................................23

4 Translation of the operation manual DUOMIX PU 460
PU460_BAoDB_en_1501 · jw
Inhalt
3.9 Intermediate piece....................................................................................24
3.10 Hose assembly.........................................................................................24
3.11 Optional expansions and accessories......................................................25
3.11.1 Material circulation .........................................................................25
3.11.2 Silicagellter .................................................................................26
3.11.3 Datalog / USB interface attachment kit ..........................................26
4 Machine controller......................................................................................27
4.1 Start-up screen.........................................................................................28
4.2 Display of the operating mode..................................................................28
4.3 Keypad .....................................................................................................28
4.4 Operating area..........................................................................................28
4.4.1 Temperature ...................................................................................29
4.4.2 System status.................................................................................29
4.4.3 Temperature settings......................................................................30
4.4.4 Stroke counter volume ...................................................................30
4.4.5 Parking ...........................................................................................30
4.4.6 Language switching........................................................................31
4.4.7 Brightness and version numbers....................................................31
4.4.8 Datalog...........................................................................................31
4.5 Setting area ..............................................................................................33
4.5.1 Pressure setting .............................................................................34
4.5.2 Stroke counter settings...................................................................35
4.5.3 Time setting....................................................................................35
4.5.4 Factory settings ..............................................................................36
4.6 Alarms ......................................................................................................36
5 Transport, installation and assembly .......................................................37
5.1 Transport ..................................................................................................37
5.2 Installation site..........................................................................................38
5.3 Installation ................................................................................................38
5.3.1 Connecting and installing the hose assembly ................................39
5.3.2 Connecting the spray gun ..............................................................40
5.3.3 Connecting the feed pumps ...........................................................40
5.3.4 Earthing the machine .....................................................................41
5.3.5 Connecting the machine to the power supply ................................41
5.3.6 Connecting the compressed air supply ..........................................42

Translation of the operation manual DUOMIX PU 460 5
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Inhalt
6 Operation.....................................................................................................43
6.1 Putting the machine into operation...........................................................44
6.1.1 Work steps during commissioning..................................................44
6.1.2 Setting the machine controller........................................................44
6.1.3 Starting the machine ......................................................................44
6.1.4 Filling and draining the machine.....................................................45
6.1.5 Filling and draining the machine with circulation ............................45
6.1.6 Filling and draining the machine with discharge hoses ..................46
6.1.7 Opening the de-icing ......................................................................46
6.1.8 Switching on the heating system....................................................46
6.1.9 Equalising the pressure of both components .................................47
6.2 Spraying ...................................................................................................48
6.3 Flushing....................................................................................................48
6.3.1 Cleaning the machine.....................................................................48
6.3.2 Emptying and cleaning the feed tank .............................................49
6.4 Work interruption ......................................................................................49
6.5 Changing the drum...................................................................................50
6.6 Material change........................................................................................50
6.7 Decommissioning .....................................................................................50
6.7.1 Storing feed pumps ........................................................................51
6.8 Relieving the pressure..............................................................................52
6.8.1 Pressure relief without circulation or discharge hoses ...................52
6.8.2 Pressure relief with circulation or discharge hoses ........................52
6.9 Putting out of use......................................................................................52
6.10 Storage.....................................................................................................52
6.11 Disposal....................................................................................................53
7 Maintenance ................................................................................................54
7.1 Regular testing .........................................................................................54
7.2 Maintenance schedule..............................................................................55
7.3 Maintenance unit ......................................................................................55
7.3.1 Check lubricant level in the oil mister .............................................56
7.3.2 Check and adjust the oil mister ......................................................56
7.3.3 Check and clean the water separator.............................................56
7.4 Proportioning pump ..................................................................................57
7.4.1 Check the release agent level ........................................................57
7.4.2 Check release agent for material residues.....................................57
7.5 Silicagellter ...........................................................................................58
7.5.1 Disassemblingthesilicagellter ...................................................58
7.5.2 Regenerating / drying the granulate ...............................................58
7.5.3 Installingthesilicagellter.............................................................58
7.6 Recommendedoperatinguids................................................................59

6 Translation of the operation manual DUOMIX PU 460
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Inhalt
8 Malfunctions and their elimination............................................................60
8.1 General troubleshooting ...........................................................................60
8.2 Error messages on the display.................................................................61
9 Technical data .............................................................................................63
9.1 Machine card............................................................................................64
9.2 Type plates ...............................................................................................64

Translation of the operation manual DUOMIX PU 460 7
PU460_BAoDB_en_1501 · jw
Foreword
1 Foreword
Valued Customer!
We are delighted that you have opted for one of our machines.
These operating instructions are directed at the operating and maintenance
personnel. They contain all information required in order to handle this ma-
chine.
The machine owner must ensure that the operating and maintenance per-
sonnel always have access to a copy of the operating instructions
in a language that they understand.
In addition to the operating instructions, further information is also essential
for the safety operation of the machine. Read and observe the directives and
accident prevention regulations valid in your country.
In Germany, these are:
➤ZH 1/406 “Guidelines for liquid jet sprayers (spray devices)” from the Fed-
eration of Institutions for Statutory Accident Insurance and Prevention,
➤BGR 500, chap. 2.29 “Processing Coating Materials”,
➤BGR 500, chap. 2.36 “Working with liquid jet sprayers”, both from the pro-
fessional association for gas, district heating and water management.
We recommend enclosing all relevant directives and accident prevention regu-
lations with the operating instructions.
Furthermore,alwaysobservethemanufacturer’sinstructionsandprocessing
guidelines for coating or conveyance materials.
If questions should arise, we shall be happy to assist you.
We wish you excellent working results with your machine
WIWA Wilhelm Wagner GmbH & Co. KG.
Copyright
© 2015 WIWA
The copyright to these operating instructions belongs to
WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestr.1-3•35633Lahnau•Germany
Tel.:+496441609-0•Fax.:+496441609-50•Email:[email protected]•Website:www.wiwa.de
These operating instructions are intended exclusively for the preparation, operating and maintenance
personnel. It is expressly prohibited to distribute these operating instructions, duplicate, exploit
or communicate their contents, unless expressly authorised to do so. Infringement will lead
to compensation. All rights to any patent, utility model or design registrations reserved.

8 Translation of the operation manual DUOMIX PU 460
PU460_BAoDB_en_1501 · jw
Safety
2 Safety
This machine has been designed and manufactured with consideration to all
safetyaspects.Itreectscurrentengineeringpracticeandthevalidaccident
prevention regulations. The machine left the factory in faultless condition and
guarantees a high level of technical safety. However, erroneous operation and
misuse result in a risk to:
➤the life and limb of the operator or third parties,
➤the machine and other property of the owner,
➤theefcientfunctionofthemachine.
It is fundamentally prohibited to implement all methods of work that have
anegativeinuenceonthesafetyoftheoperatingpersonnelandthemachine.
All persons involved in the installation, commissioning, operation, care, repair
and maintenance of the machine must have read and understood the operating
instructions beforehand - in particular the “Safety” chapter.
Your safety depends on it!
Werecommendthatthemachineownerhavethisconrmedinwriting.
2.1 Explanation of symbols
Safety information warns of potential accident risks and describes the mea-
sures required for accident prevention. In the operating instructions from
WIWA, safety information is highlighted and labelled as follows:
DANGER
Signals a risk of accidents that are very likely to result in serious injuries and
even death, if the safety information is not observed!
WARNING
Signals a risk of accidents that may result in serious injuries and even death,
if the safety information is not observed!
CAUTION
Signals a risk of accidents that may result in injuries, if the safety information
is not observed!
Signals important information for correct work with the machine. A failure to
observe this may result in damage to the machine or its environment.
A range of pictograms are used in the safety information for accident risks that
may result in injury, depending on the hazard source - examples:
General risk of accident

Translation of the operation manual DUOMIX PU 460 9
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Safety
Risk of explosion due to explosive atmosphere
Risk of explosion due to explosive substances
Risk of accident due to electricity or electrostatic charge
Risk of crushing due to moving machine parts
Risk of burning due to hot surfaces
Risk of freezing due to cold surfaces
Therstlineofthesafetyinstructionsindicatesthepersonalprotectiveequip-
ment that must be worn. This is also highlighted and labelled as follows:
Wear protective clothing
Signals an instruction to wear the prescribed protective clothing, in order to
prevent skin injuries due to spray material or gases.
Use eye protection
Signals an instruction to wear safety goggles, in order to prevent eye injuries
due to material spray, gases, vapours or dust.
Use hearing protection
Signals an instruction to wear hearing protection, in order to prevent damage
to hearing caused by noise.
Use respiratory protection
Signals an instruction to use respiratory protection, in order to prevent dam-
age to the respiratory tract caused by gases, vapours or dust.
Wear protective gloves
Signals an instruction to wear protective gloves with forearm protection,
in order to prevent a risk of burns due to heated material.
Wear safety shoes
Signals an instruction to wear safety shoes, in order to prevent foot injuries
duetofalling,topplingorrollingobjects,aswellasslippingonslipperyoors.
Signals references to directives, work instructions and operating instructions
that contain very important information and must be observed.

10 Translation of the operation manual DUOMIX PU 460
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Safety
“Poly” + “Iso” + “Cleaning agent” container
Identiesacontainerwithamaterialtobeprocessed,whichtheuserrequires
at the relevant passage in the manual.
“Empty” container
Identiesanemptycollectioncontainerwithwhichtheusercancollect
contaminated spray material.
2.2 Safety information
Always remember that the machine operates in a high pressure process and
can cause life-endangering injuries if handled incorrectly!
Always observe and follow all information in these operating instructions
and in the separate operating instructions for the individual machine parts or
the optionally available auxiliary devices.
2.2.1 Operating pressure
WARNING
Parts that are not designed for the maximum permissible operating pressure
may rupture and cause serious injuries.
➤It is essential to observe the prescribed maximum operating pressures
for all parts. With varying operating pressures, the lowest value always
applies as the maximum operating pressure for the complete machine.
➤Material hoses and hose connections must comply with the maximum
operating pressure including the required safety factor.
➤Material hoses must not exhibit leaks, kinks, signs of wear or bulges.
➤Hose connections must be tight.
2.2.2 Risks due to the spray jet
WARNING
The material exits the spray gun under very high pressure. The spray jet can
cause serious injuries through its cutting action, or by penetrating the skin or
eyes.
➤Never aim the spray gun at yourself, other persons or animals!
➤Neverholdthengerorhandinfrontofthespraygun!
➤Never reach into the spray jet!
WARNING
An unintended ejection of material from the spray gun can cause personal
injury and property damage.
➤Lock the spray gun with all interruptions to work!
➤Prior to each start-up, always check the spray gun lock!