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42 

Translation of the original operation manual 

DUOMIX 230  

 

DM230_BAoDB_en_1307 · rs

Rectification of faults

7  Rectification of faults

Fault

Possible cause/s

Remedy

The feed pumps work without inter-

ruption. With the relieve tap opened 

no material comes out of the output 

distributor.

1.  The material drum is empty. 

2.  The suction system is defective 

and the pump sucks in air.

3.  Material feed pump(s) is (are) 

defective.

4.  The viscosity is too high.

 

Ö

Replace the material drum or fill 

it up.

 

Ö

Replace the suction system. 

 

Ö

Repair the feed pump(s). 

 

Ö

Replace the material heater.

The feed pumps do not pump any 

material into the unit (with the drain 

valve open material runs out of the 

outlet manifold).

1.  The ball valve on the material 

inlet is closed.

2.  The dirt trap before the material 

inlet is soiled.

 

Ö

Open the ball valve. 

 

Ö

Clean the dirt trap.

No pressure built up by hardener 

pump during downwards stroke of 

metering pump. The pressure of 

standard components rises.

The bottom valve of the hardener 

pump is defective.

 

Ö

Disassemble and clean the bot-

tom valve.

 

Ö

Replace defective ball or valve 

plate.

No pressure built up by hardener 

pump during upwards stroke of 

metering pump. The pressure of 

standard components rises.

1.  The piston valve of the hardener 

pump is leaking. 

 

2.  The bottom packing of the hard-

ener pump is worn.

 

Ö

Disassemble and clean the 

piston valve.

 

Ö

Replace defective ball or valve 

plate.

 

Ö

Replace the packing.

The hardener pump does not gener-

ate pressure in up and down stroke.

1.  The hardener pump does not 

receive any material.

2.  The burst disc on the high pres-

sure filter is defective. 

3.  The ventilation valve of the hard-

ening component is leaking. 

4.  The ball valve on the material 

inlet is closed.

 

Ö

Check the material supply. 

 

Ö

Check the burst disk for the hard-

ening component on the high 

pressure filter.

 

Ö

Check the ventilation valve for 

the hardening component for 

function and leak tightness.

 

Ö

Open the ball valve.

During the up stroke the pressure of 

hardener and standard components 

is considerably higher than during 

the down stroke, or the pressure of 

both components slowly increases 

synchronously.

A piston valve of the two standard 

component pumps does not work.

 

Ö

Check and clean both piston 

valves.

 

Ö

Replace defective balls or valve 

plates.

Both standard component pumps 

do not generate any pressure in up 

stroke. The pressure in the hardener 

side is very high.

The piston valves of the two stand-

ard component pumps do not work.

 

Ö

Check and clean both piston 

valves.

 

Ö

Replace defective balls or valve 

plates.

In the up stroke the pressure of both 

components is considerably higher 

than during the down stroke. The 

feed hose inflates or the pressure 

relief valve on the outlet manifold 

opens.

A bottom valve of the two standard 

component pumps does not work.

 

Ö

Check and clean both bottom 

valves.

 

Ö

Replace defective balls or valve 

plates.

Summary of Contents for Duomix 230

Page 1: ...Translation of the original operation manual DM230_DBK_en_1206 rs Operation manual DUOMIX 230 Serial No...

Page 2: ......

Page 3: ...ns of the unit owner 13 2 5 2 Personnel qualification 13 2 5 3 Authorized operating personnel 13 2 5 4 Personal protective equipment 13 2 6 Notes on warranty 14 2 6 1 Conversions and alterations 14 2...

Page 4: ...e 30 5 2 Coating 31 5 2 1 Adjusting spraying pressure 32 5 2 2 Adjusting the pressure and dosing control 32 5 2 3 Tips for good coating 32 5 3 Flushing 33 5 4 Pressure relief 33 5 5 Decommissioning 33...

Page 5: ...evant guidelines and accident prevention instructions to this operating manual Moreover the manufacturer s instructions and guidelines for coating or feeder materials are to be respected at all times...

Page 6: ...et up commis sioning operation maintenance repair and servicing of the unit must have read and understood the operating manual beforehand especially the chapter Safety Your safety is at stake We recom...

Page 7: ...gases Use eye protection Highlights the order to use eye protection in order to prevent your eyesigh from being damaged by material splatter gases vapors or dust Wear ear defenders Highlights the ord...

Page 8: ...ys valid as the maximum admissible operating pressure for the entire unit Material hoses and hose assemblies must comply with the maximum ope rating pressure including the required safety factor Mater...

Page 9: ...tegory and temperature class specified on the type plate or in the declaration of conformity The operator is responsible for determining the zone allocation according to the Directive of EC 94 9 EC Ap...

Page 10: ...are not suitable to clean your skin and can result damage to health Use only appropriate skin protection skin cleaning and skin care products In closed or pressurized systems dangerous chemical react...

Page 11: ...s equipped with safety valves in the air motors of the main pump see Fig 2 the flushing pump and the feed pumps if present The safety valves ensure that the max permissible air inlet pressure is not e...

Page 12: ...required grounding Please order the ground cable immediately order no 0474487 if lost or damaged Fig 4 Ground cable 2 4 4 Safety rupture discs Die Berstscheiben verhindern ein deutliches ber schreiten...

Page 13: ...een verifiably instructed by the unit owner in the activities they are tasked with and the potential risks connected with them in the case of incorrect behaviour Trained personnel have been instructed...

Page 14: ...al ling or rolling objects and a slip on slippery surfaces 2 6 Notes on warranty 2 6 1 Conversions and alterations Unauthorized conversions or alterations should not be undertaken on safe ty grounds P...

Page 15: ...r material hoses Check hoses and connections for leaks before restarting 2 7 3 Injuries In case of injuries you should immediately consult a physician or visit the nearest hospital If injured by proce...

Page 16: ...r material flow heaters Please refer to the enclosed machine card technical data for the specifica tions of your unit 3 1 Intended use The WIWA DUOMIX 230 is intended for the application of low medium...

Page 17: ...variants Fig 7 Example of a DUOMIX 230 on an upright rack 1 2 3 4 5 6 7 9 8 10 12 13 11 8 No Designation 1 Air motor of main pump 2 High pressure filter 3 Contact pressure gauge of pressure and dosin...

Page 18: ...3 Compressed air shut off valve 4 2 wheel rack 5 Collecting vessel for safety rupture disc safety device 6 Suction pipes of main pump 7 Main pump with muffler air motor and material pumps for A and B...

Page 19: ...mp 2 High pressure filter 3 Contact pressure gauge of pressure and dosing control 4 Remote controlled compressed air control unit 5 Control cabinet of pressure and dosing control 6 Lever to open and c...

Page 20: ...ck of the unit The feed of material from the feed drum to the material pump can be interrupted by means of a ball valve With the drain valve any material residues can be drained from the feed drums No...

Page 21: ...the levers to the end stop of the desired position 3 4 1 Standard mixing unit No Description 1 Lever to open and close the return flow During spraying and flushing operation the return flow is closed...

Page 22: ...vers to switch the operating mode Flushing on and off Fig 15 Mixing unit with separate flushing levers 1 3 4 2 With these levers you can set the operating modes Circulation Spraying und Flushing as fo...

Page 23: ...vers to switch the operating mode Flushing on and off Fig 18 External mixing unit 1 2 3 4 With these levers you can set the operating modes Circulation Spraying und Flushing as follows Circulate Spray...

Page 24: ...intenance unit Fig 21 Standard maintenance unit OPEN CLOSE 1 2 No Description 1 Compressed air shut off valve to open and close the compressed air supply 2 Air pressure regulator of main pump 3 5 2 Ma...

Page 25: ...nts No Description 1 The contact pressure gauge monitors the pressure of the B component hardener and switches the unit off when the operation limits are reached 2 The Start button is used to restart...

Page 26: ...ough each of the two opposite forklift lifting points on the rack When transporting with a forklift set the fork tines as far apart as possible to minimize the overturning moment Attention Danger of t...

Page 27: ...ays keep the working area especially all walkways and standing areas clean and tidy Immediately remove any spilled material and solvents imme diately Always ensure adequate ventilation at the work pla...

Page 28: ...igh pressure filter Insert the filter elements suitable for the spraying material and the spraying nozzle into the high pressure filters For more information see chapter 6 8 on page 40 4 3 3 Connectin...

Page 29: ...e 38 4 3 6 Assembling the hose package and the external mixing unit optional WARNING If the hose package couplings are subjected to tensile load these assem blies may be torn out Material escaping und...

Page 30: ...missioning the unit unless you have the specified protective equipment For details on this topic refer to chapter 2 5 4 on page 13 The material to be applied must be available in sufficient quantities...

Page 31: ...control button to the desired material temperature 0 80 C Drum floor heater or hose heaters must be switched on before Observe and follow the notes in the separate user operating manual for the mater...

Page 32: ...contact pres sure gauge 2 Use the driver needle to turn the lower red slave pointer to a value of approx 20 bar below the minimum pressure that is indicated when the spray gun is opened 3 Use the driv...

Page 33: ...flowing out 4 Close and secure the spray gun The section between mixing unit and spray gun has been cleaned The materi al in the section between material inlet and mixing unit may remain in the unit b...

Page 34: ...kept separated also during cleaning Use a separate solvent and collecting container for each component to avoid material reactions and thus possible damage to the unit WARNING Explosive gases may be...

Page 35: ...rain valves For units with feed pumps take the suction pies of the feed pumps out of the flushing agent drums close the ball valves and regulate the air pressure regulators on the feed pumps fully bac...

Page 36: ...residual pressures can escape suddenly and cause serious injury Be extremely careful when disassembling When disconnecting material hoses you should cover the screw fitting with a cloth to catch any e...

Page 37: ...in the high pressure filters depending on the saturation of the granulate Dry the moisture filter if present 6 3 Maintenance unit The maintenance unit prevents condensation water and dirt particles fr...

Page 38: ...glass whether 1drop of lubricant is fed after each 10 to 15 double strokes 3 If this is not the case adjust the metering by turning the regulating screw on the fog oiler with a screwdriver 6 3 3 Check...

Page 39: ...e Fig 36 on page 41 2 Loosen the nut on the filter element with an open end spanner and remove the filter element 3 Clean the filter element For this purpose use only solvents that match the material...

Page 40: ...il are on request also available in larger con tainers 6 8 Filter elements for high pressure filters Insert the filter elements suitable for the spraying material and the spraying nozzle into the high...

Page 41: ...the high pressure filters Attention The high pressure filter must only be opened after the pressure has been relieved Fig 36 Fig 37 Key to open the control cabinet optional for version with pressure a...

Page 42: ...le and clean the piston valve Replace defective ball or valve plate Replace the packing The hardener pump does not gener ate pressure in up and down stroke 1 The hardener pump does not receive any mat...

Page 43: ...p 2 The seals of the hardener com ponent pump are leaking Clean the high pressure filter element or install a coarser element Repair the hardening component pump replace the packing When spraying the...

Page 44: ...can only be started for a short while only as long as the START button is held depressed 1 The switch MANUAL AUTO MATIC is in position AUTO MATIC 2 The material pressure of the hardening component is...

Page 45: ...the material pumps of base A com ponent and hardener B compo nent the pressure ratio the mixing ratio WIWA 2K Duo Mix Base Komp A ccm Hardener Komp B ccm Pressure Ratio Druck bers 1 Mixing Ratio Misc...

Page 46: ...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...

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