wiwa DUOMIX 270 User manual

Translation of the original operating instructions DUOMIX 270 3
DM270_BAoDB_en_1507 • rs
Contents
Contents
1 Foreword........................................................................................................6
2 Safety .............................................................................................................7
2.1 Explanation of symbols................................................................................7
2.2 Safety information........................................................................................9
2.2.1 Operating pressure............................................................................9
2.2.2 Risks due to the spray jet ..................................................................9
2.2.3 Risks due to electrostatic charging..................................................10
2.2.4 Risks due to hot or cold surfaces.....................................................10
2.2.5 Explosion protection ........................................................................ 11
2.2.6 Health risks...................................................................................... 11
2.3 Information signs on the machine..............................................................12
2.4 Safety equipment.......................................................................................12
2.4.1 Safety valves ...................................................................................13
2.4.2 Compressed air shut-off valve.........................................................14
2.4.3 Ground cables .................................................................................14
2.5 Operating and maintenance personnel......................................................15
2.5.1 Obligations of the machine owner ...................................................15
2.5.2 Personnel qualications...................................................................15
2.5.3 Authorised operator .........................................................................15
2.5.4 Personal protective equipment ........................................................15
2.6 Guarantee information ...............................................................................16
2.6.1 Conversions and alterations ............................................................16
2.6.2 Spare parts ......................................................................................16
2.6.3 Accessories......................................................................................16
2.7 Behaviour in an emergency .......................................................................17
2.7.1 Bring the machine to a standstill and relieve the pressure ..............17
2.7.2 Leaks ...............................................................................................17
2.7.3 Injuries .............................................................................................17
3 Machine description ...................................................................................18
3.1 Intended use ..............................................................................................18
3.2 Erroneous use............................................................................................18
3.3 Machine conguration................................................................................19
3.4 Compressed air regulation unit..................................................................21
3.5 Pressure and metering monitoring.............................................................21
3.6 Temperature displays.................................................................................22
3.7 Proportioning pump....................................................................................22
3.8 Mixing unit..................................................................................................23
3.9 Flushing pump ...........................................................................................24

4Translation of the original operating instructions DUOMIX 270
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Contents
3.10 Optional expansions and accessories .....................................................25
3.10.1 Fluid heaters..................................................................................25
3.10.2 Agitators.........................................................................................25
4 Transport, installation and assembly........................................................26
4.1 Transport....................................................................................................26
4.2 Installation site ...........................................................................................26
4.3 Assembly....................................................................................................28
4.3.1 Connect the spray hose and spray gun...........................................28
4.3.2 Ground the machine ........................................................................28
4.3.3 Insert lter inserts in the high pressure lter....................................29
4.3.4 Connect compressed air supply ......................................................29
5 Operation.....................................................................................................30
5.1 Putting the machine into operation ............................................................30
5.1.1 Start the machine.............................................................................30
5.1.2 Put the ushing pump into operation ...............................................31
5.1.3 Clean the machine...........................................................................31
5.1.4 Fill machine with processing material and vent ...............................31
5.2 Coating.......................................................................................................32
5.2.1 Adjusting spraying pressure.............................................................32
5.2.2 Setting the pressure and metering monitoring.................................32
5.2.3 Tips for good coatings......................................................................33
5.3 Flushing .....................................................................................................33
5.4 Pressure relief............................................................................................34
5.5 Complete cleaning .....................................................................................34
5.6 Material change .........................................................................................35
5.7 Decommissioning.......................................................................................35
5.8 Storage ......................................................................................................36
5.9 Disposal .....................................................................................................36
6 Maintenance ................................................................................................37
6.1 Regular testing...........................................................................................38
6.2 Maintenance schedule...............................................................................38
6.3 Maintenance unit........................................................................................39
6.3.1 Check and clean the water separator..............................................39
6.4 Proportioning pump....................................................................................40
6.4.1 Check the release agent level in the uid pumps ............................40
6.4.2 Check the release agent in the uid pumps for material residues...40
6.5 High pressure lters...................................................................................41
6.5.1 Cleaning the lter elements .............................................................41
6.5.2 Filter elements for high pressure lters............................................41

Translation of the original operating instructions DUOMIX 270 5
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Contents
6.6 Recommended operating materials...........................................................42
6.7 Special tools...............................................................................................42
7 Troubleshooting..........................................................................................43
8 Technical data .............................................................................................44
8.1 Machine card .............................................................................................44
8.2 Type plates.................................................................................................44

6Translation of the original operating instructions DUOMIX 270
DM270_BAoDB_en_1507 • rs
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
personnel 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.: [phone] • Fax.: [phone] • 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 com-
municate their contents, unless expressly authorised to do so. Infringement will lead to compensation.
All rights to any patent, utility model or design registrations reserved.

Translation of the original operating instructions DUOMIX 270 7
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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
measures 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
Risk of explosion due to explosive atmosphere

8Translation of the original operating instructions DUOMIX 270
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Safety
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
equipment 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
damage 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.

Translation of the original operating instructions DUOMIX 270 9
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Safety
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!

10 Translation of the original operating instructions DUOMIX 270
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Safety
2.2.3 Risks due to electrostatic charging
WARNING
The high ow speeds with the airless spray process can result in an electro-
static charge. Static charges can result in re and explosions.
➤Ensure that the machine is correctly earthed outside of EX zones!
➤Also earth the object that is to be coated.
➤Always use open containers!
➤Never spray solvents or materials containing solvents into narrow-
mouthed cans or barrels with a bung opening!
➤Set the container down on an earthed surface.
➤Use electrically conductive containers.
➤Always ensure contact between the spray gun and the container wall.
➤Only use electrically conductive material hoses.
All original material hoses from WIWA are conductive and designed for
our machines.
WARNING
If the machine becomes contaminated with material during operation, an
electrostatic charge may be generated with the increasing coating thickness.
Static charges can result in re and explosions.
➤Clean the machine of contaminants immediately.
➤Perform the cleaning work outside of EX zones.
2.2.4 Risks due to hot or cold surfaces
CAUTION
When using material heaters, the machine surfaces may become hot. A risk
of burns exists.
➤When processing heated materials always wear protective gloves with
forearm protection!
CAUTION
Air motors become very cold during operation. Localised freezing can arise
with contact.
➤Prior to all work on the machine, heat air motors up to a temperature
above 10 °C.
➤Wear suitable protective gloves!

Translation of the original operating instructions DUOMIX 270 11
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Safety
2.2.5 Explosion protection
WARNING
Machines that are not explosion-protected must not be used in operating
facilities that fall under the explosion protection ordinance!
Explosion-protected machines can be identied by the corresponding mark
on the type plate and/or the ATEX declaration of conformity provided.
Explosion-protected machines full the requirements of directive 94/9/EC for
the device group, device category and temperature class cited on the type
plate or in the declaration of conformity.
The owner is responsible for designating the zoning according to the stipulated
guidelines of 94/9/EC, Annex II, No. 2.1-2.3 in accordance with the provisions
of the responsible regulatory body. The owner is required to check and ensure
that all technical data and labelling comply with the applicable stipulations
according to ATEX.
Please note that some parts have their own type plate with separate labelling
according to ATEX. In this case, the lowest explosion protection of all labels
displayed applies to the entire machine. For applications, whereby a failure of
the machine could lead to dangers to personnel, the owner is required to imple-
ment appropriate safety measures.
If agitators, heaters or other electrically operated accessories are attached, the
explosion protection must be checked. 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, also if the accessory itself is explo-
sion protected.
WARNING
Heating solvents can lead to an explosion. The consequences may be seri-
ous physical injuries and property damage.
➤Observe the ashpoint and ignition temperature of solvents.
➤Switch all Material uid heaters off when carrying out the following work:
Cleaning, pressure testing, decommissioning, maintenance and repair.
2.2.6 Health risks
CAUTION
Depending on the materials being processed, solvent vapours may arise,
which could lead to damage to health and property.
➤Make sure the workplace is sufciently ventilated and aired.
➤Always observe the processing instructions of the material manufacturer.
When handling paint, solvents, oils, greases and other chemical substances,
observe the safety and metering instructions of the manufacturer and the
generally applicable regulations.
Only use suitable skin protection, skin cleansing and skincare products for
cleansing the skin.

12 Translation of the original operating instructions DUOMIX 270
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Safety
In systems that are closed or under pressure, dangerous chemical reactions
may arise, if parts produced from aluminium or galvanised parts come into
contact with 1.1.1 - trichloroethane, methylene chloride or other solvents that
contain halogenated chlorinated hydrocarbons (CFCs). If you wish to process
materials that contain the aforementioned substances, we recommend that you
contact the material manufacturer in order to clarify their suitability for use.
A range of machines in rust and acid-resistant designs is available for these
types of materials.
2.3 Information signs on the machine
The information signs displayed on the
machine, like the safety card (see Fig. 1),
indicate possible hazard points and must
be observed.
They must not be removed from the ma-
chine.
Damaged and illegible information signs
must be replaced immediately.
Also read and observe the safety informa-
tion in the operating instructions!
Für Ihre Sicherheit
For your safety •Pour votre sécurité
Por razones de seguridad •Для вашей безопасности
Güvenliğiniz için • Dla Twojego bezpieczeństwa
För din säkerhet • Para a sua segurança
© 05 / 2015 • 0642169
www.wiwa.de
www.wiwa.com
Spritzpistole nicht auf Personen oder Tiere richten
Do not point spray gun at persons or animals
Ne jamais diriger le pistolet de pulvérisation en direction de personnes ou d‘animaux
No dirigir la pistola pulverizadora hacia personas ni animales
Не направляйте пистолет-распылитель на людей или животных
Püskürtme tabancasını kişilere veya hayvanlara doğrultmayın
Pistoletu natryskowego nie kierować w stronę ludzi lub zwierząt
Rikta inte sprutpistolen mot människor eller djur
Não direccionar a pistola de pintura para pessoas ou animais
Nicht in den Spritzstrahl fassen
Do not reach into the spray jet
Ne pas toucher au jet
No interceptar el chorro de pulverización
Не прикасайтесь к струе распыляемого материала
Püskürtme huzmesine elinizi sokmayın
Nie sięgać w strumień rozpryskowy
Stick inte in händerna i sprutstrålen
Não tocar no jacto de pulverização
0
bar
psi
SOS
Im Notfall: Energiezufuhr absperren und Druck entlasten
In an emergency: Shut off power supply and relieve pressure
En cas d‘urgence : Bloquer l‘alimentation en énergie et relâcher la pression
En caso de emergencia: Cortar el suministro de energía y despresurizar el sistema
В экстренной ситуации: Заблокируйте подачу тока и сбросьте давление
Acil durumda: Enerji beslemesini kesin ve basıncı azaltın
W sytuacji awaryjnej: Zablokować dopływ energii i zredukować ciśnienie
Vid nödfall: Stäng av strömtillförsel och töm ut trycket
Em caso de emergência: Bloquear a alimentação de energia e despressurizar
In EX-Zonen nur Maschinen mit EX-Kennzeichnung betreiben
In EX zones, only operate machinery with EX labelling
Dans les zones soumises à un risque d‘explosion, exploiter uniquement
des machines présentant un marquage EX
En zonas con riesgo de explosión poner en servicio únicamente máquinas
con identicación EX
Во взрывоопасных зонах используйте только машины с маркировкой
взрывозащиты
EX bölgelerinde sadece EX işaretli makineleri işletin
W strefach zagrożonych wybuchem eksploatować wyłącznie maszyny z oznaczeniem EX
Endast EX-märkta maskiner får användas i EX-zoner
Nas zonas EX apenas operar máquinas com a identicação EX
bar
psi
max.
Zubehöre /Ersatzteile: max. Betriebsdruck der Maschine beachten!
Accessories / spare parts: Observe the max. operating pressure of the machine!
Accessoires/pièces de rechange : respecter pression de service max. de la machine !
Accesorios/piezas de repuesto: ¡Observar la presión de servicio máx. de la máquina!
Комплектующие / запчасти: учитывайте макс. рабочее давление машины!
Aksesuar / yedek parçalar: Makinenin maks. işletim basıncını dikkate alın!
Wyposażenie / części zamienne: przestrzegać maks. ciśnienia roboczego maszyny!
Tillbehör/reservdelar: ge akt på maskinens max. arbetstryck!
Acessórios / peças de substituição: ter em atenção a pressão de serviço máx. da máquina!
Fig. 1: Safety card
2.4 Safety equipment
WARNING
If safety equipment is missing or is not fully functional, the operating safety of
the machine is not guaranteed!
➤Put the machine out of operation immediately if you detect safety equip-
ment defects or any other faults on the machine.
➤Only put the machine back into operation once the faults have been fully
rectied.
The machine is equipped with the following safety equipment:
➤Safety valves
➤Compressed air shut-off valves
➤Ground cable
Check the safety equipment on the machine:
➤Prior to starting up
➤Always prior to starting work
➤After all set-up work
➤After all cleaning, maintenance and repair work

Translation of the original operating instructions DUOMIX 270 13
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Safety
Checklist on the pressureless machine:
5Seal on the safety valve OK?
5Safety valve externally free of damage?
5Ground cable free of damage?
5Ground cable connections on unit and conductor in good condition?
5Compressed air shut-off valves movable?
Checklist on the pressurised machine:
5Function of the safety valve OK?
When checking further safety equipment observe the operating instructions
for the optional accessories.
2.4.1 Safety valves
Safety valves are tted to the DUOMIX 270:
➤In the air motor of the proportion-
ing pump (see Fig. 2)
➤In the air motor of the ushing
pump
The safety valves prevent the maxi-
mum permissible air intake pressure
from being exceeded. If the air intake
pressure for the machine compo-
nents monitored by the safety valve
exceeds the limit value setting, the
safety valve installed here discharges. Fig. 2: Safety valve
Check the function of a safety valve this way:
Increase the air intake briey to approx. 10% above the maximum permissible
value according to the type plate. The safety valve must discharge.
WARNING
If the maximum permissible air intake pressure is exceeded, parts may rup-
ture. The consequences may be personal injuries and property damage.
➤Never operate the machine without safety valves or with defective safety
valves!
➤If it is necessary to replace a safety valve, please refer to the machine
card for the order number.
➤With new safety valves, please ensure that these are set to the maxi-
mum permissible air intake pressure of the machine (see type plate or
machine card) and sealed.
Changing the mixing ratio changes the pressure transmission and therefore
also the maximum permissible air intake pressure.
In this case the existing safety valve must be replaced following agreement
with WIWA.

14 Translation of the original operating instructions DUOMIX 270
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Safety
2.4.2 Compressed air shut-off valve
The compressed air shut-off valve on
the maintenance unit interrupts the air
supply to the entire machine.
The machine will stop immediately.
The functional principle:
➤Open  Position ball valve in the
ow direction
➤Close Position ball valve trans-
verse to the ow direction
After the air has been shut off the
equipment will be vented automati-
cally. However, some pressure may
remain in the material. Carry out a
complete pressure release before
starting any work on the equipment!
open
closed
Fig. 3: Compressed air shut-off valve
2.4.3 Ground cables
In order to prevent an electrostatic charging, the machine must be grounded.
The ground cables for all components
for which grounding is required are
merged into the grounding terminal.
In order to ground the machine,
connect the main ground cable rst
to clamp 1 of the grounding terminal
and then to an electrically conductive
object outside hazardous areas. Fig. 4: Main ground cable
If an ground cable is lost or defective, it must be replaced immediately!

Translation of the original operating instructions DUOMIX 270 15
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Safety
2.5 Operating and maintenance personnel
2.5.1 Obligations of the machine owner
The machine owner:
➤is responsible for training the operating and maintenance personnel,
➤must instruct the operating and maintenance personnel on correct handling
of the machine, and on wearing the correct work clothing and protective
equipment,
➤must make work aids (such as lifting gear for transporting the machine or
tank) available to the operating and maintenance personnel,
➤must make the user manual accessible to the operating and maintenance
personnel and must ensure that this remains constantly available,
➤must ensure that the operating and maintenance personnel have read and
understood the user manual.
Only then are they permitted to put the machine into operation.
2.5.2 Personnel qualications
Differentiation is made between 2 groups of personnel, depending on their
qualications:
➤Instructed operator has received veried instruction from the machine
owner regarding the tasks entrusted to him and the possible risks in the
event of incorrect conduct.
➤Trained personnel are capable – due to instruction provided by the machine
manufacturer – of carrying out maintenance and repair work on the ma-
chine, independently recognising possible dangers and avoiding risks.
2.5.3 Authorised operator
Activity Qualication
Set-up and operation Instructed operator
Cleaning Instructed operator
Maintenance Trained personnel
Repair Trained personnel
Young persons under the age of 16 are not permitted to operate this machine.
2.5.4 Personal protective equipment
Wear protective clothing
Always wear the protective clothing stipulated for your working environment
(e.g. antistatic protective clothing in potentially explosive areas) and also
observe the recommendations in the safety datasheet of the material manu-
facturer.
Use eye protection
Wear safety goggles, in order to prevent eye injuries due to material spray,
gases, vapours or dust.

16 Translation of the original operating instructions DUOMIX 270
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Safety
Use hearing protection
Suitable noise protection equipment must be made available to the operat-
ing personnel. The machine owner is responsible for compliance with the
accident prevention regulation "Noise" (BGV B3). It is therefore necessary to
pay particular attention to the conditions at the installation site – for example
noise pollution can increase if the machine is installed in or on hollow bodies.
Use respiratory protection
Although the airless spray process minimises the material mist with the right
pressure setting and correct method of work, we recommend that you wear a
respirator.
Wear protective gloves
Wear antistatic, chemical resistant protective gloves with forearm protection,
in order to prevent injuries due to aggressive chemicals, burns due to heated
material as well as freezing due to very cold surfaces.
Wear safety shoes
Wear antistatic safety shoes, in order to prevent foot injuries due to falling,
toppling or rolling objects, as well as slipping on slippery oors.
2.6 Guarantee information
Observe our general terms and conditions of business (T&Cs) at
www.wiwa.de.
2.6.1 Conversions and alterations
➤Unauthorized conversions or alterations should not be undertaken on safe-
ty grounds.
➤Protective equipment should not be dismantled, converted or bypassed.
➤The machine must only be operated within the specied limiting values and
parameters.
2.6.2 Spare parts
➤When repairing and maintaining the machine, only use original spare parts
from WIWA.
➤If spare parts are used, that have not been produced or supplied by WIWA
then the guarantee is voided and all liability shall be excluded.
2.6.3 Accessories
➤If you use original accessories from WIWA their suitability for use in our
machines is guaranteed.
➤If you use third-party accessories then these must be suitable for the
machine – in particular with respect to the operating pressure, the current
connection data, the connection sizes and where necessary the use in haz-
ardous areas. WIWA shall not be liable for any damage or injuries arising
due to these parts.

Translation of the original operating instructions DUOMIX 270 17
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Safety
➤It is essential to observe the safety provisions applicable to the accessories.
You can nd these safety provisions in the separate operating instructions
for the accessories.
2.7 Behaviour in an emergency
2.7.1 Bring the machine to a standstill and relieve the pressure
In an emergency you must bring the machine to a standstill immediately and
relieve the pressure.
1. Close the compressed air shut-off valve on the maintenance unit.
2. Set the levers at the mixing unit to "Circulation".
3. Trigger the spray gun, until the material pressure has been fully relieved.
This process is not suitable for decommissioning. The machine is not ushed.
➤For controlled decommissioning please observe Chap. 5.7 on page 35.
➤After remedying the emergency situation, the machine must be ushed
(see Chap. 5.3 on page 33). Observe the pot life of the materials used.
2.7.2 Leaks
WARNING
In case of leaks, material may escape under very high pressure and cause
serious physical injuries and property damage.
➤Bring the machine to an immediate standstill and relieve the pressure.
➤Tighten threaded connections and replace defective parts (must be per-
formed by trained personnel).
➤Do not seal leaks at connections and on high pressure hoses with the
hand or by wrapping.
➤Do not patch material hoses!
➤Check hoses and threaded connections for leak-tightness when starting
the machine up again.
2.7.3 Injuries
In case of injuries caused by processing material or solvents, always have the
manufacturer's datasheet ready to show the doctor (supplier or manufacturer
address, their telephone number, material designation and material number).

18 Translation of the original operating instructions DUOMIX 270
DM270_BAoDB_en_1507 • rs
Machine description
3 Machine description
The DUOMIX 270 has been designed according to your specic requirements
(process material, mixing ratio, output, etc.).
The process material is fed directly to the proportioning pump or via feed sys-
tems. The proportioning pump transports both components – correctly metered
– to the mixing unit, in which the two components are combined. The precise
metering of the two components is ensured by the xed mixing ratio. Because
the mixing of the two components only takes place in the mixing unit, a very
small quantity of cleaning uid is required. The mixed material nally arrives at
the spray gun via the spray hose.
In order to process materials with special characteristics it is possible to equip
the machine with optional accessories (e.g. feed pumps, agitators, a range of
heating systems, ram presses and many more besides).
The technical data for your machine can be found in the machine card
enclosed, or on the type plate.
3.1 Intended use
Using the DUOMIX 270 it is possible to apply 2K coatings with a xed mixing
ratio to a surface. It is possible to process low to high viscosity 2K materials
that are solvent-free or contain solvents, also with extremely short pot lives
(e.g. 30 seconds).
If the machine bears an EX mark, it may be used in potentially explosive areas.
Observe the mark on the type plate and on the machine card, as well as the
information in Chap. 2.2.5 on page 11.
Intended use also includes:
➤observing the technical documentation and
➤complying with the operating, maintenance and servicing guidelines.
3.2 Erroneous use
Any use other than that stipulated in the technical documentation is deemed to
be erroneous use and may result in personal injury or property damage.
Erroneous use applies in particular if
➤impermissible materials are processed,
➤unauthorised modications or changes are implemented,
➤safety equipment is modied, removed or bypassed,
➤unsuitable spare or accessory parts are used (see chap. 2.6.2 and 2.6.3 on
page 16),
➤machines that are not marked as EX machines are used in potentially
explosive areas,
➤the machine is operated outside of the operating limits (see type plate).

Translation of the original operating instructions DUOMIX 270 19
DM270_BAoDB_en_1507 • rs
Machine description
3.3 Machine conguration
Fig. 5: Front view of the DUOMIX 270
1
2
345
6
7
8
9
10
13
14
15
12
11
No. Designation
1 Compressed air regulation unit
2 Control cabinet for the pressure and metering monitoring
3 Main switch
4 Contact manometer for the pressure and metering monitoring
5 Temperature displays for the A and B component
6 Pressure gauge for the material pressure of the A-component
7High pressure lter for the A component
8 Mixing unit
9 Static mixer
10 Connection for the spay hose
11 Pressure gauge for the material pressure of the B-component
12 High pressure lter for the B component
13 Compressed air shut-off valve
14 Maintenance unit
15 Compressed air connection

20 Translation of the original operating instructions DUOMIX 270
DM270_BAoDB_en_1507 • rs
Machine description
Fig. 6: Rear view of the DUOMIX 270
16
17
18 19
21
24
23
22
20
No. Designation
16 Proportioning pump
17 Agitator
18 Feed tank for the B component
19 Feed tank for the A component
20 Frame
21 Control box for electrical connections of the uid heaters
22 Flushing pump
23 Fluid heater for the B component
24 Fluid heater for the A component

Translation of the original operating instructions DUOMIX 270 21
DM270_BAoDB_en_1507 • rs
Machine description
3.4 Compressed air regulation unit
By default, the air regulators and pressure
gauges for the air inlet pressure of the pro-
portioning pump and the ushing pump are
installed in the compressed air regulation
unit (see Fig. 7). Depending on the congu-
ration of the machine, further air regulators
and pressure gauges can be added for
optional extensions and accessories.
The compressed air regulators and pres-
sure gauges in the compressed air control
unit are marked by symbols:
Proportioning pump
Flushing pump
Fig. 7: Compressed air regulation unit
The functional principle of all compressed air regulators
on the machine is the same:
➤In order to increase the pressure, turn them clock-
wise,
➤in order to decrease the pressure, turn them anti-
clockwise.
3.5 Pressure and metering monitoring
The 2 buttons and the selector switch on the control cabinet beside the com-
pressed air regulation unit as well as the contact pressure gauge belong to the
pressure and metering monitoring.
Fig. 8: Controls of the pressure and metering monitoring
1
2
3
4
No. Designation and function
1 The “Stop” button is used to shutdown the machine manually.
2The “Start” button is used to restart the system after a shutdown. Regulate
the air inlet pressure of the metering pump completely back beforehand!

22 Translation of the original operating instructions DUOMIX 270
DM270_BAoDB_en_1507 • rs
Machine description
No. Designation and function
3 With the selector switch “Manual/Automatic” you decide whether both
operation limits should 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”.
4 The contact pressure gauge monitors the pressure of the B-component
(hardener) and switches the machine off when the operation limits are
reached.
3.6 Temperature displays
The DUOMIX 270 is equipped with 2
thermometers which display the
material temperatures of the A and
the B component. The displays with
Fahrenheit and Celsius scales are
marked according to the component
afliation by symbols and colors.
The measurement is carried out by
temperature sensors installed in the
high-pressure lters.
A
B
45,6 °C
44,8 °C
Fig. 9: Temperature displays
3.7 Proportioning pump
During spray operation or circulation operation, the proportioning pump delivers
the two components of the processing material separately to the mixing unit.
No. Designation
1Mufer
2 Air motor
3Intermediate body
4Fluid pumps of the A component
5Fluid pump of the B component
6Fluid inlet of the A component
7Fluid inlet of the B component
The air motor drives usually 3 uid pumps
– two for A component and one for B compo-
nent. The mixing ratio results from the ratio of
pump sizes.
Maschines with mixing ratio 1:1 are equipped
with two equal-sized uid pumps – the middle
pump (No. 5) is omitted.
Depending on the material requirements, the
mixing ratio can be adjusted by exchanging
the uid pumps. All you need are the proper
tools and the appropriate uid pumps. Fig. 10: Proportioning pump
1
2
5
4
67
3