wiwa Duomix 333 Instruction Manual

Hauptsitz und Produktion / Headquarter & Production:
WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestraße 1 – 3 • 35633 Lahnau, Germany
Tel [phone] • Fax [phone]
E-mail: [email protected] • Internet: www.wiwa.de
WIWA Wilhelm Wagner LP
3734A Cook Blvd. • Chesapeake, VA 23323, USA
Tel [phone] • Fax [phone]
Tel. (Toll Free) [phone]
E-mail: [email protected] • Internet: www.wiwa.com
WIWA Taicang Co., Ltd.
Add: No.87 East Suzhou Rd.,
Taicang city, Jiangsu province 215400, P.R.China
Tel: [phone]
Fax: [phone]
Email: [email protected]
Translation of the original operation manual
•303_208176_1004_en•ski
User‘s handbook
WIWA DUOMIX
Model: 333
Manufacturing-No.: … … … … … … … …
8000144

Translation of the original declaration of incorporation / Translation of the original declaration of conformity
•303_208176_1004_en•ski
Declaration of Incorporation
according to Appendix ll, No. 1 B of the Machinery Directive 2006 /42 /EG
To company: WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestraße 1 - 3
35633 Lahnau
Deutschland
herewith declares that the equipment types: DUOMIX 333
are incomplete units according to Article 2g and solely for installation or incorporation in
other machines or equipment.
These units are in compliance with the following health and safety requirements of the
above-mentioned directive:
Appendix I, Articles 1.1.2, 1.1.3, 1.1.5, 1.2.1, 1.2.2, 1.2.3,1.2.4.1, 1.2.4.3, 1.3.1, 1.3.2,
1.3.4, 1.3.7, 1.5.1, 1.5.2,1.5.3, 1.5.4, 1.5.6, 1.5.7, 1.5.8, 1.6.1, 1.6.2, 1.6.4
The commissioning of these incomplete units is prohibited until it is shown that the
equipment into which the above-mentioned unit(s) are to be installed or incorporated is in
compliance with the provisions of Machinery Directive 2006 /42 /EG.
The equipment-specic technical documentation was written in accordance with Appen-
dix VII, Part B of the above-mentioned directive.
Documentary authority: Heidrun Wagner-Turczak / Tel. [phone]
The manufacturer commits to electronic transmission of the equipment-specic docu-
mentation for the incomplete units to individual national authorities upon request.
Lahnau, 22.04.2010
Place, Date Heidrun Wagner - Turczak
Managing Director
Managing Director
Urheberrecht
© 2009 WIWA
Copyright ownership for this user manual remains with
WIWA WILHELM WAGNER GmbH & Co. KG
Gewerbestraße 1-3 • 35633 Lahnau
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.
This operating manual only applies in conjunction with the machine card that was given to you with the user ma-
nual for your equipment. Please check that the type plate data is identical with the information on the machine
card. Please notify us immediately if there are discrepancies, if the user manual has been incorrectly compiled
or if the type plate is missing.
of Incorporation

Translation of the original declaration of incorporation / Translation of the original declaration of confor-
mity
•303_208176_1004_en•ski
1 Preface .................................................................................................................. 4
1.1 First read, then start 4
1.2 Warning instructions 5
1.2.1 Warning instructions on the unit 5
1.2.2 Note about the guarantee of the product 5
1.3 Note about the user‘s handbook 6
1.4 Machine card 6
2 Safety .................................................................................................................... 7
2.1 Description of symbols 7
2.2 Sources of danger 8
2.3 Operating staff and personal protective equipment 10
2.4 Protective equipment 11
2.5 Handling of the machine and auxiliary material 12
2.6 Behavior in case of emergency 13
3 About the machine ............................................................................................. 14
3.1 Use of the machine 14
3.2 Danger arising from the equipment 14
3.3 Machine surroundings 15
3.4 Transport 15
3.5 Installation site 16
3.6 Component description 17
3.7 Diagram of the settings of the mixer 20
3.7.1 Circulate 20
3.7.3 Spraying with automatic monitoring 21
3.7.4 Flushing 21
4 Assembly and Setting up .................................................................................. 22
5 Commissioning .................................................................................................. 25
6 Operation ............................................................................................................ 32
6.1 Spraying coatings 32
6.2 Job commencement 33
6.3 Pause in work and end of work 34
6.4 Material Change 37
7 Complete cleaning ............................................................................................. 38
8 Maintenance ....................................................................................................... 42
8.1 General notes 42
8.2 Maintenance schedule 42
8.2.1 Cleaning of the High-Pressure lter 43
8.2.2 Cleaning of the suction lter 43
9 Disturbances during operation and trouble-shooting .................................... 44
10 Appendix ............................................................................................................. 49
10.1 Auxiliary materials and special tools 49
10.2 Certicate of Training and Operation 50
Contents
page
Contents

1 Preface
4 Translation of the original operation manual
•303_208176_1004_en•ski
1 Preface
1.1 First read, then start
Remember that 2K-Units work under extreme pressure and that high levels of spray-
ing pressure are created!
➤Never hold your nger or hand in front of the gun and never reach into the spray!
➤Never point the spray gun* towards yourself, other people or other living creatures!
➤Always pay close attention to the references and specications found in the user‘s
handbook!
Before each usage, be especially certain to:
➤Check the grounding conditions (for the unit and the object to be sprayed).
➤Check the seal of all connecting and mounted parts.
➤Observe the maximal allowed pressure of the unit and accessory parts.
Before beginning any work on the equipment and at any pause during operation, be
absolutely required to:
➤Stop the unit.
➤Release the pressure found in the spraying gun and hose.
➤Secure the spraying gun.
Pay attention to safety!
The accident prevention regulation “Handling of Coating Materials” (Unfallverhütungs-
vorschriften „Verarbeiten von Beschichtungsstoffen“ (BGR 500, Kap. 2.29)) and the
guidelines covering uid sprayers (Richtlinien für Flüssigkeitsstrahler ZH1/406) from the
German Employer’s Liability Insurance Association are to be observed without fail. To
ensure a safe operating environment, the condition of uid sprayers must be inspected
by an expert every 12 months or sooner, if deemed necessary. A written record of the
inspection results is to be kept.
Remaining paint and solvent are to be disposed of according to legal regulations. This
also applies for environmentally friendly water lacquer or enamel systems!
In case of injuries, consult a physician or go to the next hospital without delay.
If paint/material or solvent has gone into the skin, the physician has to be informed about
the type of paint/material or the solvent applied.
Therefore, always ensure that the product specication sheet, with address and tele-
phone number of the manufacturer, is at your disposal!
Connecting equipment provided by the operator
When there is equipment not included in the delivery, but which is necessary for the
proper use of the unit, it is the responsibility of the operator to install this equipment
before the initial start-up.
This equipment is also listed in the description of the operational procedures and marked
with an asterisk (*) .

Preface 1
Translation of the original operation manual 5
•303_208176_1004_en•ski
1.2 Warning instructions
1.2.1 Warning instructions on the unit
Warning signs and symbols which have been placed on the machine are there to inform
of possible dangers and must be observed.
Warning signs and symbols may not be removed from the machine.
Damaged and illegible warning signs and symbols are to be replaced immediately.
The following signs are located on the machine:
➤Warning sign covering the grounding of the machine (picture 1.1):
On high pressure lter:
The proprietor is required according to the German Accident Prevention Regula-
tion („Unfallverhütungsvorschrift“) BGR 500, Kap. 2.29, to ensure that the ma-
chine is properly grounded.
Please, observe our instruction manual!
➤Nameplate (picture 1.2)
On the control cabinet of the 2K-Unit
Please observe that the information located on the nameplate corresponds to data
found on the machine card. We request immediate notication should there be any
discrepancies or if the nameplate is missing.
➤More nameplates for the sub assemblies are placed on the:
➤Flush pump
➤Air pressure motor
➤Material pump A + B
➤Feed pumps A and/or B (depending on model)
➤Material uid heater
➤Safety instruction sheet (picture 1.3)
There is a safety instruction sheet with the most important safety instructions attached
to the machine (picture 1.3). Nevertheless, please adhere to all the other instructions
in the user’s hand book.
1.2.2 Note about the guarantee of the product
Rebuilds and changes
For safety reasons, it is not allowed to carry out rebuilds or changes without authoriza-
tion.
Protective equipment may not be dismounted, changed or neglected.
If using components which are not produced or delivered by , warranty cover-
age is negated as well as liability.
The machine may only be operated within the prescribed limits and machine parameters.
Picture 1.1
Picture 1.2
Picture 1.3

1 Preface
6 Translation of the original operation manual
•303_208176_1004_en•ski
Danger caused by attachments and spare parts
If you use original attachments and original spare parts from Wilhelm Wagner
GmbH & Co. KG, the compatibility with our equipment is guaranteed. It is, however,
essential that the safety regulations of the attachments and spare parts are observed.
You can nd these safety regulations in the user’s handbook located with the spare parts
lists.
If you use attachments and spare parts from another source, cannot guarantee
the safety of the entire system. In this case, our guarantee does not cover any damage
or injury caused by such attachments and spare parts.
1.3 Note about the user‘s handbook
The operating authority of the equipment must ensure, that a user’s handbook is
available to the operator, in a language which he understands.
Dear customer!
Thank you for your decision to purchase equipment.
In the user’s handbook,
you can nd all information required for the proper handling of your DUOMIX.
However, which you should adhere to:
➤Please read and observe the guidelines valid for your country.
In Germany, the “Richtlinien für Flüssigkeitsstrahler” (Guidelines for uid spray-
ers), published by: Hauptverband der Gewerblichen Berufsgenossenschaften (Indus-
trial Employer’s Liability Insurance Association),
are valid.
➤Manufacturer’s notes and operating guidelines for coating and pumping materials
should be observed at all times.
➤No method of operation should be exercised which impairs the safety of
products and the operating personnel.
1.4 Machine card
This user’s manual is valid only in connection with the following machine card.
The machine card includes all machine specications and details which are important
and relevant for safety:
➤exact designation and manufacturing data
➤technical specication and limit values
➤equipment and checking certicate
➤data for purchase
➤machine features (machine components and accessories included in the supply with
article and spare parts number)
Please pay attention that the machine card specication is in accordance with the ma-
chine label. In case of any deviations or default of a label we would ask you to advise
us without delay.
Caution!
This User’s Handbook
must always be avail-
able to operating staff!

Safety 2
Translation of the original operation manual 7
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2 Safety
2.1 Description of symbols
The signs and symbols used in this manual have the following meaning:
NOTE
Marks a section of text which is especially relevant to safety.
Special attention should be paid to this section and it‘s contents strictly observed!
WARNING
Marks a situation which could be dangerous.
If not observed, death or very serious injuries could result!
DANGER OF EXPLOSION
Marks a situation, where there is danger of explosion.
Observation of this information is absolutely essential!
ELECTRICAL VOLTAGE
Marks a situation, where there is a danger of explosion through an electrostatic charge.
Observation of this information is absolutely essential!
CONSULT INSTRUCTION FOR USE
Marks a section of text which is especially relevant to safety.
Please adhere to the operation manual of the optional accessory equipment,
WEAR PROTECTIVE GLOVES
Wear protective gloves with lower arm protection to avoid burn injuries.
The warnings must be adhered to!
USE EAR PLUGS
For health reasons, it is very important to pay attention to this warning!
USE BREATHING PROTECTION
For health reasons, it is very important to pay attention to this warning!
SMOKING PROHIBITED
Marks a situation in which a re hazard arises through the use of ammable or poten-
tially explosive solid, uid or gaseous materials.
HEALTH DANGER
Marks materials which are hazardous to your health.
Observation of this information is absolutely essential!
FIRST AID
In case of injuries or accidents, these instructions should be absolutely adhered to!
General pictograms
Container A
Marks a container with the manufacturer’s recommended thinner, which the operator
needs when mentioned in the text.
Container B
Marks an empty container to collect contaminated thinner or spraying uid.
Container C
Marks a container with spray material needed as mentioned in the text.

2 Safety
8 Translation of the original operation manual
•303_208176_1004_en•ski
2.2 Sources of danger
Always remember, plural component systems operate at very high pressure levels and
unauthorized usage could lead to life-threatening injuries.
Observe and adhere to all instructions found in the user‘s handbooks for optional acces-
sories. Pay close attention to the chapter “Safety” found in the separate user’s manuals.
Pay attention to the following notes:
Danger when spraying
➤Never point the spray gun* towards yourself, other people or other living creatures!
➤Never hold your nger or hand in front of the gun and never reach into the spray.
➤Material hoses have to be more than conforming with maximum working pressure.
Material hoses are never to be „patched“!
➤Never try to seal leaks on joints and high pressure hoses with your hand or by bind-
ing the spot. Should a leak occur, the whole system (gun, hose, high pressure lter,
pump, etc.) are to be depressurized immediately. Defective parts are to be replaced.
➤The gun is to be secured and the safety device checked during every interruption
while working, regardless how short (picture 2.1).
➤The entire system is to be depressurized before maintenance and cleaning work is
carried out.
The compressed air tap lock on the maintenance unit (picture 2.2) as well as the air
pressure regulator of the main pump must be closed.
➤If the material being used clogs or clumps within the unit, remnant pressure may still
exist despite depressurization efforts. This must be kept in mind when carrying out
repairs!
Special care must be taken when dismantling the high pressure lter, material hoses
and high pressure spray gun* to ensure that no accidents occur due to escaping rem-
nant pressure.
We recommend covering the material hoses’ ttings with a cloth during unscrewing, in
order to capture any uid which might escape.
➤When working on the high pressure lter, for example to change the lter, the ma-
chine must rst be turned off and depressurized.
Danger to health
➤If working with heated materials, always wear the proper hand protection.
BURN DANGER!
➤Heated solvent can release poisonous fumes that could injure the operator.
➤In closed or pressurised systems where aluminium or galvanised parts come into
contact with the solvent, dangerous chemical reactions can occur if 1.1.1-Trichlor-
ethylene, Methylene Chloride or other solvents containing halogenated chlorinated
hydrocarbons (CFCs) are used. If you wish to work with the above solvents or with
lacquers and paints which contain them, we recommend you contact either
customer services or directly.
➤We call your attention to the fact that a series of 2K-units equipment including ver-
sions which are rust- and acid-proof are available for such materials.
Picture 2.1
Picture 2.2

Safety 2
Translation of the original operation manual 9
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Danger to the unit
➤A change of the mixing ratio may have the consequence of the change of the pres-
sure ratio and a required change of the maximum allowed compressed air pressure.
The installed safety valve must be changed. In this case you get from an
exchangeable nameplate with the new now valid data of the 2K-unit.
We recommend strongly to consult in this case.
➤The unit should never be operated without safety valve!
Should the safety valve need replacing, please see the machine card for its order
number.
With new safety valves take care that these are set and leaded at the maximum allow-
able inlet compressed air pressure of the DUOMIX (see nameplate/machine
chart) corresponding to the mixing ratio.
➤During operation, ensure that sufcient feed of material is available to the pump in
order to avoid heating due to friction, caused when the material pump runs dry.
Observe closely:
➤no empty feed containers may be present during operation.
➤the suction system may not be clogged, buckled or defect in any other way.
➤if the unit stops processing material, shut it down immediately.
➤The maximum operating pressures are to be adhered to in principle for all
parts (eg. pump, heater, hoses, gun, safety valve).
By differing allowable operating pressures, the lowest value is always the maximum
allowable operating pressure for the entire system.
General example:
Pump up to 420 bar
Material hose up to 600 bar
Spraying gun up to 500 bar
The maximum allowable operating pressure for this example would be 420 bar.
Danger through explosion
➤Never spray solvents or materials containing solvents into a narrow-necked can or
barrels with bung hole!
DANGER OF EXPLOSION!
➤Please, always use an open container. Due to possible electrostatic charges, it is
imperative to ensure that the spraying gun has contact to the container walls when
working with metal containers.
It is possible for a static charge to occur due to the high ow speeds during the airless
spraying procedure. Static charges can lead to re and explosions.
The equipment must, therefore, always be appropriately grounded (picture 2.3).
The original DUOMIX is tted with a ground cable as standard. If lost or
defective, please, order an immediate replacement (for order no. please refer to the
machine card).
➤Never use this equipment outdoors during a thunderstorm.
➤Due to electrostatic charges, only conductive material hoses should be used. All
original material hoses are conductive and compatible with our equipment.
The maximum admissible working pressure on the hoses must correspond to the
maximum operating pressure of the unit.
Picture 2.3

2 Safety
10 Translation of the original operation manual
•303_208176_1004_en•ski
➤If you use thinner in the material hoses (e.g. for the complete cleaning) all connected
material heaters must be turned off.
Complete cleaning may only be done when the unit has cooled.
DANGER OF EXPLOSION!
➤Smoking, open ames or any other possible ignition sources are not allowed any-
where near the area of operation
Danger caused by not complying the explosion protection
This unit may NOT be used in explosion-proof areas !!
Spraying equipment, which is not explosion-proof protected, is not allowed in places which
are subject of the explosion-proof regimentation.
2.3 Operating staff and personal protective equipment
Authorised Operators
People under the age of 16 should not operate this equipment.
The management in charge of the operation of the machine must make the user’s hand-
book available to the operator and must make sure that he has read and understood it.
Only then may the system be put into operation.
We recommend the manager has this conrmed in writing.
The operator of the machine is obliged to report any changes in the machine which might
affect its safety to the manager, as he must ensure that the machine is functional.
The responsibilities for the different activities on the system must be laid down clearly
and adhered to. No unclear competencies may remain as these could endanger the
safety of the users.
The operator must make sure that only authorised persons work on the machine. He is
responsible to third parties in the working vicinity of the system.
Personal protective equipment
➤We call to your attention that the valid guidelines and requirements in accordance
with work surroundings (mining, closed areas etc.) must be absolutely adhered to.
➤Please, wear the prescribed protective clothing at all times, as solvent vapors and
solvent splashes cannot be completely avoided.
➤The sound pressure level of the equipment is below 85 db(A).
Nevertheless, appropriate noise protection means should be made available to the
operating staff.
➤Although spraying fog is kept to a minimum when the correct pressure setting and
proper method of operation are observed, the operating painter should wear a protec-
tive breathing mask.
➤Never use solvent or other materials which present a health hazard for cleaning skin.
Only suitable skin protective, skin cleansing and skin care materials may be used.