wiwa 300 User manual

Operation Manual
Original operation manual
1411_DM 333_DBK_en • jw
DUOMIX 300 / 333
Type:
❍ 300
❍ 333
Serial-No.
_______________
3D-BILDER!!!
2K-Proportioning pump 333
(Fig. includes optional accessories)

2Original declaration of conformity
1411_DM 333_DBK_en • jw

Original operating instructions DUOMIX 300 / 333 3
DM333_BAoDB_en_1608 • rs
Contents
Contents
1 Foreword........................................................................................................7
2 Safety .............................................................................................................8
2.1 Explanation of symbols...............................................................................8
2.2 Safety information.....................................................................................10
2.2.1 Operating pressure.............................................................................10
2.2.2 Risks due to the spray jet ...................................................................10
2.2.3 Risks due to electricity........................................................................ 11
2.2.4 Risks due to electrostatic charging..................................................... 11
2.2.5 Risks due to hot or cold surfaces ....................................................... 11
2.2.6 Explosion protection ...........................................................................12
2.2.7 Health risks.........................................................................................13
2.3 Safety signs..............................................................................................13
2.4 Safety equipment......................................................................................14
2.4.1 Safety valves ......................................................................................15
2.4.2 Compressed air shut-off valves..........................................................15
2.4.3 Ground cable......................................................................................16
2.4.4 Stop/emergency stop button ..............................................................16
2.4.5 Rupture discs .....................................................................................17
2.4.6 Overpressure valves (optional) ..........................................................17
2.4.7 Switch for automatic spray gun (optional) ..........................................17
2.5 Operating and maintenance personnel ....................................................18
2.5.1 Obligations of the machine owner ......................................................18
2.5.2 Personnel qualications .....................................................................18
2.5.3 Authorised operator............................................................................18
2.5.4 Personal protective equipment...........................................................18
2.6 Guarantee information..............................................................................19
2.6.1 Spare parts.........................................................................................19
2.6.2 Accessories ........................................................................................19
2.7 Behaviour in an emergency......................................................................20
2.7.1 Bring the machine to a standstill and relieve the pressure.................20
2.7.2 Leaks..................................................................................................20
2.7.3 Injuries................................................................................................20
3 Machine description ...................................................................................21
3.1 Intended use.............................................................................................21
3.2 Erroneous use ..........................................................................................21
3.3 Modular machine conguration ................................................................22
3.4 Conguration examples............................................................................23
3.4.1 DUOMIX 333 on mobile frame ...............................................................23
3.4.2 DUOMIX 333 on stacker frame with heaters and hose heating .............24
3.4.3 DUOMIX 333 on mobile frame with heated material tanks ....................25
3.4.4 DUOMIX 333 on mobile frame with feed tanks ......................................26

4 Original operating instructions DUOMIX 300 / 333
DM333_BAoDB_en_1608 • rs
Contents
3.5 Proportioning pump ..................................................................................27
3.6 Maintenance unit ......................................................................................28
3.7 Control cabinet .........................................................................................29
3.8 Compressed air regulation unit.................................................................31
3.9 Mixing units...............................................................................................31
3.9.1 Manual mixing unit on the frame ........................................................32
3.9.2 External mixing unit with manual operation........................................33
3.9.3 Pneumatic mixing unit on the frame with 2 ushing valves ................34
3.9.4 Pneumatic mixing unit with one ushing valve ...................................35
3.9.5 External pneumatic mixing unit ..........................................................36
3.10 Intermediate pieces ..................................................................................36
3.11 Flushing pump..........................................................................................38
3.12 Material supply .........................................................................................38
4 Optional expansions and accessories......................................................40
4.1 Material warming and heating systems ....................................................40
4.1.1 Material uid heater............................................................................40
4.1.2 Barrel oor heater...............................................................................40
4.1.3 Barrel heating tape and heating sleeves ............................................41
4.1.4 Screw-in heating element...................................................................41
4.2 Hose heating ............................................................................................42
4.2.1 Hose heating with hot water circulation..............................................42
4.2.2 Hose heating with heating coil............................................................43
4.3 Agitators ...................................................................................................43
4.4 Level monitoring .......................................................................................44
4.5 Ratio check unit........................................................................................44
4.5.1 Flow rate measuring device ...............................................................45
4.5.2 Cycle counter .....................................................................................45
4.5.3 Internal pipe coater.............................................................................46
4.5.4 Distributor for spray guns ...................................................................46
5 Transport, installation and assembly........................................................47
5.1 Transport ..................................................................................................47
5.2 Installation site..........................................................................................48
5.3 Installation ................................................................................................49
5.3.1 Installing the hose assembly ..............................................................50
5.3.2 Connect the spray hose and spray gun..............................................51
5.3.3 Ground the machine...........................................................................52
5.3.4 Insert lter inserts in the high pressure lter.......................................52
5.3.5 Connect ushing pump.......................................................................52
5.3.6 Connect feed pumps ..........................................................................52
5.3.7 Connect the owner's optional expansions and attachment devices...53
5.3.8 Establish the mains connection..........................................................53
5.3.9 Connect compressed air supply .........................................................54

Original operating instructions DUOMIX 300 / 333 5
DM333_BAoDB_en_1608 • rs
Contents
6 Operation.....................................................................................................55
6.1 Putting the machine into operation...........................................................55
6.1.1 Overview of the working steps during commissioning........................56
6.1.2 Start the machine ...............................................................................56
6.1.3 Put the ushing pump into operation..................................................56
6.1.4 Clean the machine .............................................................................56
6.1.5 Ready the processing material...........................................................57
6.1.6 Fill machine with processing material and vent..................................57
6.1.7 Set the de-icing system ......................................................................59
6.1.8 Clean and ll hose assembly and spray gun......................................59
6.1.9 Put the heating systems into operation ..............................................60
6.1.10 Put hose heating into operation with hot water ..................................60
6.1.11 Calibration — check the mixing ratio..................................................60
6.2 Spraying ...................................................................................................61
6.2.1 Set spray pressure .............................................................................62
6.2.2 Setting the pressure and metering monitoring ...................................63
6.2.3 Tips for good coatings ........................................................................63
6.3 Flushing....................................................................................................64
6.3.1 End material feed and ready cleaning uid ........................................64
6.3.2 Flush mixing unit and spray gun.........................................................65
6.3.3 Clean the machine thoroughly............................................................66
6.4 Material change........................................................................................67
6.5 Relieve pressure.......................................................................................67
6.6 Decommissioning .....................................................................................68
6.7 Putting out of use......................................................................................69
6.8 Storage.....................................................................................................69
6.9 Disposal....................................................................................................69
7 Maintenance ................................................................................................70
7.1 Regular testing .........................................................................................71
7.2 Maintenance schedule..............................................................................71
7.3 Maintenance unit ......................................................................................72
7.3.1 Check lubricant level in the oil mister .................................................72
7.3.2 Check and adjust the oil mister ..........................................................72
7.3.3 Check and clean the water separator.................................................73
7.4 Proportioning pump ..................................................................................73
7.4.1 Check the release agent level ............................................................74
7.4.2 Check release agent for material residues and top up.......................74
7.5 Feed pumps..............................................................................................74
7.5.1 Check the release agent level ............................................................74
7.6 High pressure lter ...................................................................................75
7.6.1 Clean lter insert ................................................................................75
7.6.2 Filter inserts for high pressure lters ..................................................76

6 Original operating instructions DUOMIX 300 / 333
DM333_BAoDB_en_1608 • rs
Contents
7.7 Silica gel lter ...........................................................................................76
7.7.1 Disassemble silica gel lter ................................................................77
7.7.2 Drying the granulate ...........................................................................77
7.7.3 Fit silica gel lter.................................................................................77
7.8 Clean dirt trap...........................................................................................78
7.9 Replacing the material pumps..................................................................79
7.9.1 Disassemble material pump(s)...........................................................79
7.9.2 Fit material pump(s) ...........................................................................80
7.10 Recommended operating uids................................................................81
7.11 Special tool...............................................................................................82
8 Eliminating operational faults....................................................................83
9 Technical data .............................................................................................87
9.1 Machine card............................................................................................87
9.2 Type plates ...............................................................................................87

Foreword
Original operating instructions DUOMIX 300 / 333 7
DM333_BAoDB_en_1608 • rs
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
Federation 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
professional 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
© 2016 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.

Safety
8 Original operating instructions DUOMIX 300 / 333
DM333_BAoDB_en_1608 • rs
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 meas-
ures 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

Safety
Original operating instructions DUOMIX 300 / 333 9
DM333_BAoDB_en_1608 • rs
Risk of explosion due to explosive atmosphere
Risk of explosion due to explosive substances
Risk of accident due to electricity or electrostatic charge
Risk of crushing due to moving machine parts
Risk of burning due to hot surfaces
Risk of freezing due to cold surfaces
The rst line of the safety instructions indicates the personal protective equip-
ment that must be worn. This is also highlighted and labelled as follows:
Wear protective clothing
Signals an instruction to wear the prescribed protective clothing, in order to
prevent skin injuries due to spray material or gases.
Use eye protection
Signals an instruction to wear safety goggles, in order to prevent eye injuries
due to material spray, gases, vapours or dust.
Use hearing protection
Signals an instruction to wear hearing protection, in order to prevent damage
to hearing caused by noise.
Use respiratory protection
Signals an instruction to use respiratory protection, in order to prevent
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.

Safety
10 Original operating instructions DUOMIX 300 / 333
DM333_BAoDB_en_1608 • rs
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!