wiwa FLEXIMIX 2 PHOENIX Series User manual

FLEXI 2
MIX
Translation of the original operation manual
FMII_DBK_en_1312 · rs
Operation manual
Serial-No.
⸏ ⸏ ⸏ ⸏ ⸏ ⸏ ⸏ ⸏

Originalbetriebsanleitung FLEXIMIX 23
FMII_BAoDB_en_1401 • rs
Contents
Contents
1 Foreword........................................................................................................7
2 Safety .............................................................................................................8
2.1 Explanation of symbols................................................................................8
2.2 Safety notes...............................................................................................10
2.2.1 Operating pressure..........................................................................10
2.2.2 Risks caused by the spray jet..........................................................10
2.2.3 Risks caused by electrostatic charging............................................ 11
2.2.4 Explosion protection ........................................................................ 11
2.2.5 Health risks......................................................................................12
2.3 Information signs on the unit......................................................................12
2.4 Safety features...........................................................................................13
2.4.1 Safety valves ...................................................................................13
2.4.2 Master switch...................................................................................14
2.4.3 Compressed air shut-off valves .......................................................14
2.4.4 Spray gun lock.................................................................................14
2.4.5 Ground cable ...................................................................................15
2.5 Operating and maintenance personnel......................................................15
2.5.1 Unit owner's duties ..........................................................................15
2.5.2 Personnel qualication.....................................................................15
2.5.3 Authorized operating personnel.......................................................15
2.5.4 Personal Protective Equipment (PPE).............................................16
2.6 Notes on warranty......................................................................................16
2.6.1 Conversions and alterations ............................................................16
2.6.2 Spare parts ......................................................................................16
2.6.3 Accessories......................................................................................17
2.7 Emergency procedures..............................................................................17
2.7.1 Shutting down and depressurising the unit......................................17
2.7.2 Leakages .........................................................................................17
2.7.3 Injuries .............................................................................................17
3 Unit description...........................................................................................18
3.1 Intended use ..............................................................................................18
3.2 Unit conguration.......................................................................................18
3.2.1 PHOENIX series..............................................................................20
3.2.2 PROFESSIONAL series ..................................................................21
3.2.3 HERKULES series...........................................................................22
3.3 Compressed air control unit.......................................................................23
3.4 Control panel..............................................................................................23
3.5 Symbolism of the controls..........................................................................24
3.6 Maintenance unit........................................................................................24

4Originalbetriebsanleitung FLEXIMIX 2
FMII_BAoDB_en_1401 • rs
Contents
3.7 Mixing unit..................................................................................................25
3.7.1 Standard mixing unit........................................................................25
3.7.2 External mixing unit .........................................................................26
3.8 Material feed ..............................................................................................27
3.9 Metering pumps .........................................................................................28
3.10 Flushing pump .........................................................................................28
3.11 Optional expansion parts and accessories ..............................................29
3.11.1 Material Flow Heaters ....................................................................29
3.11.2 Frame extension ............................................................................29
3.11.3 Remote control...............................................................................30
3.11.4 USB interface.................................................................................31
3.11.5 Volumetric measurement valves ....................................................31
3.11.6 Spray gun ushing unit ..................................................................31
3.11.7 Mounting kit for atomizing air.........................................................32
3.11.8 Air ushing .....................................................................................32
3.11.9 Mounting kit “Error message”.........................................................32
3.11.10 Agitators.......................................................................................32
4 Transportation, installation and assembly ...............................................33
4.1 Transportation............................................................................................33
4.2 Installation location ....................................................................................33
4.3 Assembly....................................................................................................35
4.3.1 Assembling hose package...............................................................35
4.3.2 Assembling spray hose and spray gun............................................36
4.3.3 Grounding the unit ...........................................................................36
4.3.4 Inserting the lter elements into the high pressure lters ................36
4.3.5 Connecting compressed air supply and electric power supply........37
5 Control module ...........................................................................................38
5.1 Controls......................................................................................................38
5.2 Starting the unit..........................................................................................38
5.3 Menu structure...........................................................................................39
5.3.1 Navigation........................................................................................40
5.3.2 Symbolism of the buttons ................................................................40
5.4 Operation area...........................................................................................41
5.4.1 Function keys and overview ............................................................41
5.4.2 Main menu.......................................................................................42
5.4.3 Status display ..................................................................................42
5.4.4 Displaying the operating mode ........................................................43
5.4.5 Spraying mode (F2).........................................................................43
5.4.6 Flushing mode (F1)..........................................................................43
5.4.7 Circulation mode (F3) ......................................................................44
5.4.8 Unit stop (F5)...................................................................................44

Originalbetriebsanleitung FLEXIMIX 25
FMII_BAoDB_en_1401 • rs
Contents
5.4.9 Fill level indication............................................................................45
5.4.10 Recipe selection ............................................................................45
5.4.11 Information relating to mixing ratio and volume ............................46
5.4.12 Alarms............................................................................................46
5.4.13 Control measurement ....................................................................47
5.4.14 USB datalog...................................................................................48
5.4.15 Language selection........................................................................48
5.4.16 Alarm history..................................................................................48
5.4.17 Day and batch counters.................................................................49
5.4.18 Information.....................................................................................49
5.5 Setup..........................................................................................................50
5.5.1 Keypads...........................................................................................51
5.5.2 Volumetric measurement.................................................................51
5.5.3 Flush parameters.............................................................................52
5.5.4 Manual valve control........................................................................53
5.5.5 Filling parameters (Setup ll) ...........................................................54
5.5.6 Filling level monitoring .....................................................................56
5.5.7 Valve management..........................................................................56
5.5.8 Recipe management........................................................................57
5.5.9 Date and time ..................................................................................58
5.5.10 Software Update............................................................................58
6 Operation.....................................................................................................59
6.1 Put the unit into operation..........................................................................59
6.1.1 Switching on the unit........................................................................60
6.1.2 Setting up the control system ..........................................................60
6.1.3 Flushing mixing unit and spray gun .................................................60
6.1.4 Cleaning the unit..............................................................................60
6.1.5 Filling the unit with material to be applied and venting the unit .......61
6.1.6 Put the material ow heaters into operation ....................................61
6.1.7 Performing a control measurement .................................................62
6.2 Coating.......................................................................................................62
6.2.1 Adjust spraying pressure .................................................................62
6.2.2 Hints to achieve good coating results..............................................63
6.3 Flushing .....................................................................................................63
6.4 Pressure release........................................................................................63
6.5 Complete cleaning .....................................................................................64
6.6 Decommissioning.......................................................................................65
6.6.1 Temporary decommissioning...........................................................65
6.6.2 Decommissioning for a long period or permanently ........................66
6.7 Waste disposal...........................................................................................66

6Originalbetriebsanleitung FLEXIMIX 2
FMII_BAoDB_en_1401 • rs
Contents
7 Maintenance ................................................................................................67
7.1 Regular inspections ...................................................................................67
7.2 Maintenance plan.......................................................................................68
7.3 Recommended operating materials...........................................................68
7.4 Maintenance unit........................................................................................69
7.4.1 Check the lubricant level in the fog oiler..........................................69
7.4.2 Checking and adjusting the fog oiler................................................69
7.4.3 Checking and cleaning the water separator ....................................70
7.4.4 Setting the A to B pressure differential.............................................70
7.5 High pressure lters...................................................................................71
7.5.1 Clean the lter element in the high pressure lter ...........................71
7.5.2 Filter elements for high pressure lters............................................71
7.6 Metering pumps .........................................................................................72
7.6.1 Checking the release agent level in the metering pumps................72
7.6.2 Checking release agent in the metering pumps
for material residues ........................................................................72
7.6.3 Lubricating the gear wheels on the metering pump
shaft encoders .................................................................................73
7.7 Metering valves..........................................................................................73
7.7.1 Checking release agent in the metering valves
for material residues ........................................................................73
7.7.2 Setting the stroke limit on the hardener metering valve...................74
8 Troubleshooting..........................................................................................75
8.1 Mechanical faults .......................................................................................75
8.2 Alarms........................................................................................................76
9 Technical data .............................................................................................78
9.1 Machine card .............................................................................................78
9.2 Type plates.................................................................................................78
10 Hose volumes............................................................................................79

Originalbetriebsanleitung FLEXIMIX 27
FMII_BAoDB_en_1401 • rs
Foreword
1 Foreword
Dear Customer!
We are delighted that you have decided in favour of a FLEXIMIX 2made by
our company.
This operation 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 operators and maintenance person-
nel always have an operation manual at their disposal in a language that
they understand!
Safe and reliable operation of the unit requires further information in addition
to this operation manual. You should have read and understood the guidelines
and accident prevention regulations that apply in your country.
In Germany the following apply:
➤ZH 1/406 “Richtlinien für Flüssigkeitsstrahler” (Guidelines for Liquid Jets),
published by the German “Hauptverband der Gewerblichen Berufsgenos-
senschaften”;
➤BGR 500, Chapter 2.29 “Application of Coating Materials”;
➤BGR 500, chapter 2.36 “Working with Fluid Spraying Equipment” published
by the employers liability insurance association for the gas, remote heating
and water management sectors.
We strongly recommend adding all relevant guidelines and accident prevention
instructions to this operation manual.
Moreover the manufacturer's instructions and guidelines for coating or feeder
materials must be respected at all times.
However, if you have any questions, please do not hesitate to contact us.
Best wishes for good results with your FLEXIMIX 2from
WIWA Wilhelm Wagner GmbH & Co. KG.
Copyright
© 2014 WIWA
This operation manual remains the copyright of
WIWA Wilhelm Wagner GmbH & Co. KG.
Gewerbestr. 1-3 • 35633 Lahnau • Germany
Tel.: [phone] • Fax.: [phone] • E-mail: [email protected] • Internet: www.wiwa.de
This operation manual is solely intended for personnel involved in preparation, operation and servicing.
It is prohibited to pass on this operation 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 operation 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 data on the type plate match those 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.

8Originalbetriebsanleitung FLEXIMIX 2
FMII_BAoDB_en_1401 • rs
Safety
2 Safety
This unit has been designed and manufactured under due consideration of
all safety-related aspects. It complies with the current standard of technolo-
gy and the valid accident prevention instructions. 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 unit and other material assets of the owner,
➤to the efcient working capacity of the unit.
You must refrain from any working methods that could affect the safety of
operating personnel and equipment. All the people that are involved in set-up,
commissioning, operation, maintenance, repair and servicing of the unit must
have read and understood the operation manual beforehand, especially the
chapter entitled “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 information warns you of potential risks of accidents and tell you the
measures that are needed to prevent accidents.
In WIWA operation manuals, safety information is specially highlighted and
marked as follows:
DANGER
Indicates danger of accidents; if you ignore the safety notes, there is a high
risk of severe injury resulting up to and including death!
WARNING
Indicates danger of accidents; if you ignore the safety notes, severe injury
can result up to and including death!
CAUTION
Indicates danger of accidents; if you ignore the safety notes, severe injury
can result!
Indicates important information on correct use of the unit. Ignoring it can
result in damage to the unit or in its vicinity.

Originalbetriebsanleitung FLEXIMIX 29
FMII_BAoDB_en_1401 • rs
Safety
In the safety notes about the risk of accidents, different pictograms are shown
after each hazard source - examples:
General accident risk
Risk of explosion from explosive atmosphere
Risk of explosion from explosive substances
Danger of injury due to electric voltage or electrostatic charging
Risk of crushing by moving components
Risk of burning due to hot surfaces
Mandatory safety instructions concern protective gear to be worn in the rst
instance. They are particularly 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
Indicates the requirement to wear protective goggles to protect against eye
injuries caused by gases, fumes or dust.
Wear ear defenders
Indicates the requirement to wear ear defenders to prevent your hearing
from being damaged by noise.
Use a respiratory protection mask
Highlights the order to use a respiratory protection mask 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 objects that may fall, drop or roll around or to hot or caustic liquids.
Indicates references to guidelines, work instructions and operation manuals
that contain important information which you must observe at all times.

10 Originalbetriebsanleitung FLEXIMIX 2
FMII_BAoDB_en_1401 • rs
Safety
2.2 Safety notes
Please remember that the unit works at high pressure and may cause
life-threatening injuries if used inappropriately!
Always observe and follow all instructions in this operation manual and in the
separate operation manuals of individual unit components and/or the option-
ally available accessory devices.
2.2.1 Operating pressure
WARNING
Unit components that do not comply with the maximum permissible operat-
ing pressure can burst and cause serious injury.
➤The specied maximum operating pressures must generally be complied
with for all unit components. In case of varying operating pressures, the
lowest value is always the one to be taken as the maximum operating
pressure for the entire unit.
➤Material hoses and hose assemblies must comply with the maximum
operating 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 penetrat-
ing 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 during every work break!
➤Always check that the safety mechanism on the spray gun works before
each use!