wiwa DUOMIX PU280, Operation Manual

Page 1: ...Operation manual Translation of the original operation manual 1307_PU280_SV1018DV1020_DB_en ski WIWA 2K DUOMIX PU280 Type 280 280 Version 400V 230V Variants with Feed pumps Serial No _ _ _ _ _ _ _ _...

Page 2: ...rmany Phone 49 6441 609 0 Fax 49 6441 609 50 E Mail info wiwa de Homepage www wiwa de This operating manual is solely intended for personnel involved in prepa ration operation and servicing It is proh...

Page 3: ...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 Mac...

Page 4: ...onnection 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 co...

Page 5: ...pray 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...

Page 6: ...ating 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 standa...

Page 7: ...is indicated Strict compliance with these notes is mandatory HOT SURFACES Identifies a situation involving the danger of burning on a hot surface Do not touch hot surfaces without wearing gloves The...

Page 8: ...ine 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 no...

Page 9: ...akages 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...

Page 10: ...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...

Page 11: ...g agents in the material circuit e g complete cleaning Complete cleaning must only be performed after the system has cooled down The system must NOT be operated in explosion protection zones Spraying...

Page 12: ...nterrupted Material may still be under pressure in the system Safety valve Figure 2 4 The safety valve on the air motor of the metering pump makes sure that the max permissible air inlet pressure is n...

Page 13: ...chemical substances In case of leakages the system must be shut down immediately and the com plete system must be depressurized Switch off the unit by the EMERGENCY STOP switch Make sure that the sys...

Page 14: ...only be operated within the prescriptive limit values and machine parameters If original accessories and spares of Wilhelm Wagner GmbH Co KG are used usability with our units is guaranteed It is howe...

Page 15: ...be attached professionally and in accordance with the intended use before com missioning The DUOMIX PU280 can be installed inside and outside spray booths and rooms However outdoor installation shoul...

Page 16: ...e materials Take metal parts to scrap metal services Plastic parts can be disposed of through the household waste Rests of spraying material cleaning agent oils greases and other chemical substances m...

Page 17: ...original Operation Manual 3 4 1307_PU280_SV1018DV1020_BAoDB_en ski en Machine Description Poly Iso Iso Poly Figure 3 2 Poly Iso Iso Poly Figure 3 3 3 9 System description 3 9 1 Without circulation 3 9...

Page 18: ...component with a 3m whip end The temperature sensor is integrated in the whip end Mixing of material only takes place in the pneumatically controlled spray gun the spray pattern can be pneumatically...

Page 19: ...4 Connection compressed air hose spray gun 3 5 Pressure switch 3 6 Return flow relief hose with material shut off valve optional for circulation relief 4 Maintenance unit 4 1 Compressed air connection...

Page 20: ...air regulator feed pumps 3 Compressed air regulator metering pump 4 Button SYSTEM ON 5 Display 6 Button reset malfunction 7 Heating hose package ON OFF 8 Master switch 9 Material flow heater ON OFF co...

Page 21: ...l value by one digit F5 Exit settings F6 Confirm settings Figure 3 7 After switching on the system the display shows the actual temperature for both material flow heaters as well as for the hose packa...

Page 22: ...2 Line Sensorerror Poly Sensorerror Iso Sensorerror Hose Figure 3 11 You should always move the equipment to parking position when interrupting work or at the end of work to prevent the system from b...

Page 23: ...st match the connections on the equipment Stand the unit on a level and firm base Consider the required floor space see chapter 13 1 Technical data p 13 1 All operating elements must be easily accessi...

Page 24: ...e individual material hoses can be recognized by the colour coding 3 phase max 3 hose package segments Pos Designation 1 Material hose 2 Material hose 3 Compressed air hose for spray gun 4 Plug of tem...

Page 25: ...return flow on drum lid of Poly components optional Screw fitting return flow on silicagel filter on drum lid of Iso components optional Figure 4 3 The high flow velocities associated with the Airles...

Page 26: ...nstallation and Assembly Connect the unit to the local compressed air supply Spray Gun Feed Pump Proportioner Pump 0 bar 0 psi 0 bar 0 psi 0 bar 0 psi Compressed air connection on either side Figure 4...

Page 27: ...ar the specified protective clothes The unit has been set up and connected as specified in chapter 4 Installation and Assembly p 4 1 1x 1x 2x 2x if required 1 Prepare the material Open the bungholes o...

Page 28: ...i 4 bar 58 psi 1 bar 14 5 psi Clean the material outlet Figure 5 3 6 only with optional version with circulation relief Open the circulation as described in chapter 11 1 Circulation p 11 1 Catch the t...

Page 29: ...tire system for leakages In case of leakages abort the start up process and have the malfunction cor rected by expert personnel The system is ready for operation You may continue with the normal opera...

Page 30: ...Electrical connection System vented Circulation relief closed optional Spray gun secured Pressure tests Separators 1 Switch on the equipment Switching the unit on press the green button Figure 6 1 2 S...

Page 31: ...and com ponents the pressure in the system may have increased differently during the heating phase For optimal working results we recommend a maximum pressure difference of 10 20bar 145 290 psi betwee...

Page 32: ...re compensation Figure 6 7 After this pressure compensation close the valve again 6 Mounting the spray gun Mount the spray gun to the block Follow the notes in chapter 11 3 4 Connect the spray gun to...

Page 33: ...Activate parking in the display Adjust the park modus in the display In this respect follow the notes in chapter 3 12 4 Parking of page 3 9 Figure 7 1 Reduce the pressure by carefully pulling the trig...

Page 34: ...for a longer time 1 Perform the work steps as described in chap chap 7 1 Activating park ing P 7 1 Switch the heating off too On versons with material feed container you must first pump out all mater...

Page 35: ...ns with feed pumps The suction hoses of the feed pumps remain in the material drums or are stored for transportation in the receptacles fill with release agent In this case you must close the bunghole...

Page 36: ...ibed in chapter 7 3 Take the system out of service p 7 2 2 Exchange the material drums against containers with preserving agent Fill the system with preserving agent 3 Allow the residual pressure to e...

Page 37: ...ction block by opening the material valves open until the system pres sure of this component has been relieved repeat with the other component Only one component 11 4 to 11 2 revolutions Figure 7 12 S...

Page 38: ...psi Figure 7 14 1 Take the equipment out of service as described in chapter 7 3 Take the system out of service p 7 2 2 After each use clean the equipment externally with the cleaning agent recommende...

Page 39: ...barrel change 1 End spraying process Figure 8 1 2 Exchange empty material drums for full ones Place the feed pumps securely into the filled material drums 3 Ventilate the system Catch the material in...

Page 40: ...back into the material drum Disassemble the spray gun from the connection block as described in chapter 11 3 8 Dismantle the spray gun p 11 9 Spray Gun Feed Pump Proportioner Pump 6 bar 87 psi 6 bar...

Page 41: ...m as per chapter 6 Operation p 6 1 Pay attention to the pressure equalization of both components 1 End spraying process Figure 8 4 2 Exchange empty material drums for full ones Place the feed pumps se...

Page 42: ...valves as soon as bubble free noiseless material starts to run out Spray Gun Feed Pump Proportioner Pump 6 bar 87 psi 6 bar 87 psi 1 bar 14 5 psi Figure 8 6 4 Take system into service You may continu...

Page 43: ...ce p 7 2 2 Clean the intake screen dirt trap Clean the material screen of each component on the metering pump or re place it if excessively soiled 3 Take system into service Perform all work steps as...

Page 44: ...12 months For decommissioned units the inspection can be postponed until the next com missioning The inspection results must be recorded in writing and kept until the next inspection The inspection re...

Page 45: ...motor 6 Connection compressed air line to controlunit metering feed pumps 7 Shut off valve The accumulated condensate is automatically drained off through the drain valve For this purpose hold the hos...

Page 46: ...tart up approx 60 80ml 0 02 gal for discolouration caused by spraying material at regular intervals Change the pump seals see spare parts list for material pump in case of excessive discolouration of...

Page 47: ...out e g after barrel change Continuous discharge of both material components is assured No falsification of spray pattern by sudden air shocks Uniform material temperature and consistency throughout...

Page 48: ...ow hoses are reliably connected with material drums and ball valves on material flow heater Spray Gun Feed Pump Proportioner Pump 6 5 bar 94 psi 6 bar 87 psi 0 bar 0 psi Figure 15 1 2 Open the circula...

Page 49: ...l filter is a moisture filter for installation in the drum lid of the Iso com ponent If humidity saturation is reached granulate colour changes from orange to col ourless For the filter to function pr...

Page 50: ...the granulate from orange to colourless Drying temperature approx 130 C 160 C Renewed adsorption capacity after colouration from colourless to orange 3 Install silicagel filter Fill in the dried granu...

Page 51: ...Material hose comp Poly 2 Material hose comp Iso 3 Material shut off valve comp Poly 4 Material shut off valve comp Iso 5 Screw to mount the connection block to the spray gun 6 Connection block 7 Fro...

Page 52: ...ompressed air to avoid the formation of droplets in the spray pattern The front plate of the spray gun must be very clean and free of score marks The front plate must remain attached at all times when...

Page 53: ...o the connection block Figure 11 10 3 Mount the connection block to the spray gun Grease the surface to prevent sticking of the O rings Make sure that the filter elements are seated correctly in the s...

Page 54: ...nut only so far that leakages are eliminated Do not overtighten Figure 11 13 1 Open the material valves 2 Open the air pressure valve 3 Pull the trigger 4 Adjust spray jet regulat ing screw Figure 11...

Page 55: ...ease until clean grease appears in the module receptacle Figure 11 17 Grease Figure 11 16 Soiled or damaged material filters can cause malfunctions in the spraying process such as e g overpressure of...

Page 56: ...g material Pos Designation 1 Spray gun body 2 Mix module 3 Round jet nozzle 4 Front plate 5 Screws Figure 11 18 Assemble the mix module as follows Slide the module with the smaller diameter forward ov...

Page 57: ...7 O ring Figure 11 21 Remove all material residues from all parts and material conducting passages Use a cleaning agent soaked cloth to remove deposits e g caused by spray fog from the spray gun 3 Cl...

Page 58: ...ssure built up by a pump during upwards stroke of meter ing pump The piston valve of the pump without pressure is leaking Disassemble and clean the piston valve Replace defective ball or valve plate 6...

Page 59: ...se the air pressure in the network 12 The air motor no longer works even though the compressed air supply is assured No material pressure available in the system The air motor control is defective Fus...

Page 60: ...the round jet nozzle with an appropriate drill Replace the round jet nozzle 5 Pressure fluctuations Mix module inlets and outlets soiled or worn Viscosity of components not uniform Filter element dirt...

Page 61: ...or defective Air in system Dismantle the spray gun and relieve the valve of the Iso com ponent Clean spray gun filter Iso Clean dirt trap Iso Connect or repair the sensor cable Ventilate the system 3...

Page 62: ...1020_BAoDB_en ski en Malfunctions and Troubleshooting Figure 12 1 1 Tip housing forward 2 Open casing cover 3 Replace fuse Attention This work must only be carried out by profes sional electricians Lo...

Page 63: ...ar 243 at 116 psi Compressed air connection Coupling DN 7 2 Coupling DN 7 2 Electric connection Rated voltage max v 400 230 400 Phases 3 3 3 Rated current max A 16 26 16 Individual performance materia...

Page 64: ...6 67 x 10 8 0 68 x 0 26 x0 43 Weight kg lbs 1 2 2 Designation Order number Separators 0640651 0 5l 0 01gal 0647360 5l 0 01gal Multi purpose grease for spray gun 0 085kg 0 01gal 0654576 Retention agen...

Page 65: ...h velcro closure without insulation for hose package no picture 0654785 Contamination protection transparent for hose pack age 0654481 Diaphragm pump 0654688 Mounting kit relief 0654689 Mounting kit c...

Page 66: ...ay gun connecting nipple 0653560 no picture 0000264 Protective suit paper size L no picture 0000347 Protective suit paper size XL no picture 0000377 Protective suit paper size XXL no picture 0000287 R...

Page 67: ...nation year of construction order number The instruction was conducted by the representative of the owner Foreman or responsible superior name department The instructed person has read and understood...

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Page 69: ...3 5432559 Tel 49 2226 12708 Fax 49 2226 13973 Robert Jansen Sales Director Finland Sweden Norway Denmark Scotland England Holland Belgium France Spain Portugal Italy Croatia Greece Czech Republic Slov...