wiwa DUOMIX PU280 User manual

Operation manual
Translation of the original operation manual
1307_PU280_SV1018DV1020_DB_en • ski
WIWA 2K-DUOMIX PU 280
Type:
❍ 280
❍ 280+
Version:
❍ 400V
❍ 230V
Variants with:
❍ Feed pumps
Serial-No.
_ _ _ _ _ _ _ _

2 Translation of the EC-Declaration of Conformity
•1307_PU280_SV1018DV1020_DB_en•ski
EC-Declaration of Conformity
according to Appendix ll, No. 1 A of the Machinery Directive 2006 / 42 / EC
including last changed by 2009 / 127 / EC
The company WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestr. 1-3
35633 Lahnau
Germany
herewith declares that the equipment types PU 280
PU 280+
with Serial-No.:
are in conformance with the provisions of the above-mentioned directive.
Documentary authority: WIWA GmbH / Phone: [phone]
Lahnau,
Place, Date Heidrun Wagner-Turczak
Managing Director
Copyright
© 2013 WIWA
Copyright ownership for this user manual remains with
WIWA Wilhelm Wagner GmbH & Co. KG
Gewerbestr. 1-3 • 35633 Lahnau • Germany
Phone: [phone] • Fax: [phone]
E-Mail: [email protected] • Homepage: www.wiwa.de
This operating manual is solely intended for personnel involved in prepa-
ration, 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 manual for your equipment. Please
check that the type plate data is identical with the information on the ma-
chine card. Please notify us immediately if there are discrepancies, if the
user manual has been incorrectly compiled or if the type plate is missing.
10.07.2013

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Table of Contents
1 Foreword 1-1
1.1 Important for your safety 1-1
1.2 Machinecard 1-1
1.3 Pictogrammes 1-2
1.4 Noticesonthemachine 1-3
2 Safety Information 2-1
2.1 Dangersources 2-1
2.1.1 Dangerscausedbythesprayjet 2-1
2.1.2 Dangertohealth 2-2
2.1.3 Dangerforequipment 2-2
2.1.4 Dangercausedbyelectricvoltage 2-2
2.1.5 Dangercausedbyexplosion 2-3
2.1.6 Dangercausedbydisregardingtheexplosionprotection 2-3
2.2 Operatingpersonnel 2-3
2.2.1 Setup,cleaning,maintenanceandrepairwork 2-3
2.2.2 Protectiveequipment 2-4
2.3 Safetyfeatures 2-4
2.4 Handlingthesystemandauxiliarymaterials 2-5
2.5 Emergencyprocedures 2-5
2.5.1 Leakages 2-5
2.5.2 Injuries 2-5
2.5.3 Fires 2-5
3 Machine Description 3-1
3.1 Intendeduseofthemachine 3-1
3.2 Notesonwarranty 3-1
3.3 Machinesurroundings 3-1
3.3.1 Emissions 3-1
3.3.2 Soundpressurelevel 3-1
3.4 Transportingthemachineandadditionalequipment 3-2
3.5 Placeofinstallationofthemachine 3-2
3.6 Storingthemachineandadditionalequipment 3-3
3.7 Disposalofthemachineandadditionalequipment 3-3
3.8 Systemvariants 3-3
3.9 Systemdescription 3-4
3.9.1 Withoutcirculation 3-4
3.9.2 Withcirculation 3-4
3.9.3 Materialow 3-5
3.9.4 Compressedaircontrol 3-5
3.9.5 Temperaturecontrol 3-5
3.10 Systemcomponents 3-6

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3.11 Controlcabinet 3-7
3.11.1 Componentsonthecontrolcabinet 3-7
3.11.2 Systemcontrol 3-8
3.12 Menu 3-8
3.12.1 Welcomescreen=ACTUALtemperature 3-8
3.12.2 NOMINALtemperature 3-8
3.12.3 Alarm 3-9
3.12.4 Parking 3-9
3.12.5 Softwareversion 3-9
4 Installation and Assembly 4-1
4.1 Settinguptheunit 4-1
4.2 Assemblingattachmentsandaccessories 4-1
4.2.1 Connectionofthehosepackage 4-2
4.2.2 Connectingindividualhosepackagesegments 4-2
4.2.3 Connectionsprayguntothehosepackage 4-2
4.2.4 Connectionfeedpumps 4-3
4.3 Groundthesystem 4-3
4.4 Checktheconditionofthereleaseagent 4-3
4.5 Electricconnection 4-3
4.6 Compressedairconnection 4-4
5 Commissioning 5-1
6 Operation 6-1
7 Decommissioning 7-1
7.1 Activatingparking 7-1
7.2 Deactivatingparking 7-2
7.3 Takethesystemoutofservice 7-2
7.4 Shuttingdowntheequipment 7-4
7.5 Pressurerelief 7-5
7.5.1 Withoutcirculationandwithoutreliefhoses 7-5
7.5.2 Withreliefhoses(optional) 7-5
7.5.3 Withcirculation(optional) 7-6
7.6 Cleaningafterspraying 7-6
7.6.1 Cleaningthesystem 7-6
7.6.2 Cleanspraygun 7-6
8 Barrel change 8-1
8.1 Withoutcirculation 8-1
8.2 Withcirculation(optional) 8-3
9 Material change 9-1

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10 Maintenance 10-1
10.1 Checkcycles 10-1
10.2 Importantnotes 10-1
10.3 Maintenanceunit 10-2
10.4 Drainingthecondensationwater 10-2
10.5 Notesonoilreservoirandwaterseparator 10-2
10.6 Separators 10-3
11.1 Circulation 11-1
11.1.1 Circulationcircuit 11-1
11 Optional equipment 11-1
11.1.2 Circulation/ventilation 11-2
11.2 Silicagellter 11-3
11.3 Spraygun 11-5
11.3.1 Sprayguncomponents 11-5
11.3.2 Safetyfeatures 11-6
11.3.3 Notesonoperation 11-6
11.3.4 Connectthesprayguntothehosepackage. 11-7
11.3.5 Checkspraygun 11-8
11.3.6 Startspraying 11-8
11.3.7 Endspraying 11-8
11.3.8 Dismantlethespraygun 11-9
11.3.9 Spraygunmaintenance 11-9
11.3.10 Cleanspraygun 11-11
12 Malfunctions and Troubleshooting 12-1
12.1 Generaltroubleshooting 12-1
12.2 Troubleshootingonthespraygun 12-3
12.3 Errormessagesonthecontrolcabinet 12-4
13.1 Technicaldata 13-1
13 Appendix 13-1
13.2 Operatingmaterials 13-2
13.3 Tools 13-2
13.4 Accessories 13-3
13.5 InstructionCerticate 13-5

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1 Foreword
Operatingpersonnelshouldalwayshaveaccesstothisusermanual!
Theowneroftheunitmustensurethattheoperatoroftheunitalwayshasan
operatingmanualathis/herdisposalinalanguagehe/sheunderstands!
Allpersonsinvolvedintheset-up,commissioning,operation,maintenance,repair
andservicingofthemachinemusthavereadandunderstoodtheusermanual
beforehand,andthechapteronSafetyinparticular.Werecommendtotheowner
ofthisunittohavethisconrmedinwriting.
Inprincipleyoushouldrefrainfromanyworkmethodthatwouldaffectthesafety
of productsandtheoperatingpersonnel.
Pleasereadandcomplywith:
➤theapplicableguidelinesforyourcountry.
InGermany,thesearethe“RichtlinienfürFlüssigkeitsstrahler”(Guidelinesfor
LiquidJets),
issuedby:theHauptverbandderGewerblichenBerufsgenossenschaften.
➤themanufacturer'sinstructionsandprocessingguidelinesforcoatingortrans-
fermaterialsaretoberespectedatalltimes.
Thismachinehasbeendesignedandmanufacturedunderdueconsiderationof
allsafety-relatedaspects.Itcorrespondstothecurrentstandardoftechnology
andtoapplicableaccidentpreventionregulations.
Themachineleftthefactoryinperfectconditionandguaranteesahighlevelof
technicalreliabilityandsafety.Nevertheless,therearecertainrisksthatcanarise
fromincorrectoperationormisuse:
➤tolifeandlimboftheoperatororthirdparty,
➤tothemachineandothermaterialassetsoftheowner,
➤toefcientworkwiththemachine.
Thisusermanualisonlyvalidincombinationwiththefollowingmachinecard.
Themachinecardcontainsallimportantandsafetyrelevantdataandinforma-
tionaboutthemachine.
➤exactdesignationandmanufacturerdata
➤technicaldataandlimitingvalues
➤Equipmentandtestcerticate
➤Dataofpurchasing
➤Machineidentication(machinecomponentsandaccessorieswitharticleand
sparepartsnumbers)
The data on the machine card must match the data on the type plate.
In case of discrepancies or if the type plate is missing please notify us im-
mediately.
1.1 Important for
your safety
1.2 Machine card

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Foreword
The notices and symbols used in this manual have the following meanings:
NOTICE
Indicatesaninformativetextpassage.
Youshouldpayparticularattentionwhenreadingit.
WARNING
Apotentiallydangeroussituationisindicated.
Non-observancecanleadtodeathorveryseriousinjury.
DANGER OF EXPLOSION
Indicatesasituationwithpotentialdangerofexplosion.
Strictcompliancewiththesenotesismandatory.
VOLTAGE
Asituationshowingdangerofexplosionbyelectrostaticchargeisindicated.
Strictcompliancewiththesenotesismandatory.
HOT SURFACES
Identiesasituationinvolvingthedangerofburningonahotsurface.Donot
touchhotsurfaceswithoutwearinggloves.
Thefollowingsymbolsindicatethatprotectiveequipmentshouldbeworn.With
yourhealthinmindyoushouldalwayscomplywiththerecommendationsofthe
materialmanufacturer.
WEAR PROTECTIVE CLOTHES
USE RESPIRATORY PROTECTION
USE EYE PROTECTION
WEAR PROTECTIVE GLOVES
WEAR HEARING PROTECTION
Drum “Poly” + “Iso” + “Cleaning Agent”
Identiesadrumcontainingthematerialtobeapplied,whichtheuserrequiresat
thecorrespondinglocationinthemanual.
Drum “empty”
Identiesanemptycollectingvesseltobeusedbytheusertocollectcontami-
natedsprayingmaterial.
1.3 Pictogrammes

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Foreword
Appropriateinformationsignsandsymbolsonthemachinerefertopossibledan-
gerareasandmustberespectedatallcosts.
Informationsignsandsymbolsmustnotberemovedfromthemachine.
Damagedandillegibleinformationsignsandsymbolsmustbereplacedimmedi-
ately.
The following signs can be found on the machine:
➤Typeplateonplantcontrolcabinet,(Figure 1.1).
Pleasecheckthatthetypeplatedataareidenticalwiththoseonthemachine
card.
Incaseofdiscrepancies or if the type plate is missing please notify us im-
mediately.
➤Typeplateonplantcontrolcabinet,(Figure 1.2).
Beforeconnectingtheunittothemainssupply,checkwhethertheprescribed
electricaldatacomplieswiththatavailableattheinstallationsite.
➤Warninglabel“Caution!ElectricalVoltage”oncontrolcabinet,(Figure1.3).
➤Warninglabel“Caution!Hotsurface”ondistributor,(Figure 1.4).
1.4 Notices on
the machine
Figure 1.1
Figure 1.2
Figure 1.3
Figure 1.4

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2 Safety Information
Pleaserememberthatdualcomponentsystemsworkwithextremelyhighpres-
suresandmaycauselifethreateninginjuriesifusedinappropriately.
Alwayspayattentiontoandfollowallnotesintheusermanualsfortheoptionally
offeredaccessoryequipment.Payparticularattentiontothechapteronsafety
notesforthecorrespondingcomponents.
Please comply with the following instructions:
➤Neverpointthespraygunatyourself,otherpersonsorotherlivingbeings!
➤Neverholdyourngersorhandinfrontofthespraygunandneverreachinto
thejetspray.
➤Materialhosesmustbeabletowithstandpressuresbeyondthemaximum
workingpressure.
➤Materialhosesmustneverberepaired!
➤Nevertrytosealleakagesonconnectionsandhighpressurehosesbyhand
orbywrappingfabricaroundthem.Incaseofleakagesimmediatelydepres-
surizetheentiresystem(spraygun,hose,pump,etc.).Defectivepartsmust
bereplaced.
➤Securethespraygun(s)eachtimeworkisinterrupted,evenforshortbreaks,
andcheckthatitisproperlysecured,(Figure 2.1).
➤Switchoffthemachinebeforestartingmaintenanceandcleaningworkonthe
unitandthesprayingaccessories,(Figure 2.2).
➤Incaseofmaterialcongestionoragglomerationofmaterialinthespraying
system,residualpressurescanstillbepresentdespitepressuredischarge.
Payfullattentiontothiswhenperformingrepairwork!
➤Materialhosesandsprayguninparticularmustbedisassembledwithgreat-
estcaretoavoidaccidentscausedbyreleasedresidualpressures.
➤Whendisconnectingmaterialhoseswerecommendtocoverthescrewtting
withaclothtocatchanyescapingmaterialsprays.
2.1 Danger
sources
2.1.1 Dangers caused
by the spray jet
Figure 2.1
0/OFF I/ON
Figure 2.2

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SafetyInformation
➤Inclosedroomsorwithpressurizedsystems,inwhichaluminiumcomponents
orgalvanizedpartshavecontactwiththesolvent,hazardouschemicalreac-
tionsmayoccurwhenusing1.1.1-trichloroethane(TCE),methylenechloride
orothersolventscontainingchlorinatedhydrocarbons(CFCs).Ifyouwish
tousetheaforementionedsolventsorvarnishesandpaintscontainingsuch
solvents,weadviseyoutoconsultthe -customerserviceor
directly.
➤Wewouldliketopointoutthatwehaveaseriesofdualcomponentsys-
temsinrustandacidproofdesignavailableforsuchmaterials.
➤DANGEROFBURNING!
Dependingonthesettemperature,theoutersurfaceoftheadaptercanheat
upconsiderably.Youshouldthereforealwayswearprotectivegloveswhen
havingtoworkontheadapter!
➤Changingthemixingratiomaycauseachangeinpressureratioandthus
requiretheadaptationofthemax.permissibleairinletpressure.Inthiscase
theexistingsafetyvalvemustbereplaced.Consultationwith is highly
recommended.
➤Thesystemshouldneverbeoperatedwithoutsafetyvalve!
Ifthesafetyvalveneedstobereplaced,youcanndthecorrespondingorder
numberonthemachinecard.
➤Themaximumoperatingpressurespeciedbyusmustgenerallybeadhered
to for all parts(e.g.pump,heater,hoses,spraygun,safetyvalve).
Atvaryingoperatingpressuresthelowestvalueisalwaysvalidasthemaximum
admissibleoperatingpressurefortheentiresystem.
➤Generalexample:
Pump upto250bar/3625psi
Materialhose upto600bar/8700psi
Spraygun upto240bar/3480psi
Themaximumpermissibleoperatingpressurefortheentiresysteminthisexam-
pleis240bar.
➤Whenusinginatmospherescontainingsolventsthereisthedangerthatthe
powercablecouldbecomeawedorporous.
➤Thereforethepowercablemustbecheckedforexternallyvisibledamage
beforeeachstart-up.
➤Neverrepairapowercable.Damagedpowercablesmustalwaysbecom-
pletelyreplaced.
➤Thisworkmustbecarriedoutbyaprofessionalelectrician.
2.1.2 Danger to health
2.1.3 Danger for
equipment
2.1.4 Danger caused
by electric
voltage