Tip:
Highlight text to annotate it
X
Commissioning of the WIWA DUOMIX 333 PFP
Hello and a warm welcome.
This video provides practical tips
on the commissioning of the WIWA DUOMIX 333 PFP.
Specifically, this means what you need to do
to set up this system and carry out
coating operations with it.
The WIWA DUOMIX 333PFP is a dual-component
coating system for applying
insulation layer forming flame retardants
in commercial and industrial applications.
The WIWA DUOMIX 333PFP is used for coating
steel parts in structural engineering,
as well as in the oil and gas industry.
The instructions, tips and information
provided in this video are based
on the operating manual and the
safety notes for this system.
It is good practice to read the instructions
in advance, which will help you
better understand the guidelines
provided in this video.
Also consider that only WIWA service staff
or trained personnel are allowed to carry out
maintenance and repair work on the
WIWA DUOMIX 333PFP.
Let‘s begin, and that with the next safety note.
Do not start commissioning the system unless
you have the specified protective equipment.
For details on this topic, refer to the
corresponding operating manual.
Let‘s now consider the material
that you want to process. Always observe
the manufacturer‘s technical information
on this topic. You will need an adequate
amount of material and two containers
for collecting excess material.
These containers are not included
in the scope of delivery.
You must ensure that the system
is installed level and on a solid surface
to prevent it from tipping or tilting.
All controls should be easily accessible.
Make sure that the proper power supply
and compressor with a capacity
of 5000 l/min at 8 bar, or 150 cfm at 116 psi,
required for the operation of the system,
are available at the installation site.
You can use either a compressed air supply hose
with a diameter of 1“ or 2 with 3/4“ diameter.
Please observe the maximum permissible pressure
for the compressed air hoses used.
Here‘s an overview
of the first important points again:
1. Please read the operating manual.
2. Maintenance and repairs must only be
carried out by qualified and trained personnel.
3. Only work with the
specified protective equipment.
4. Follow the safety notes provided
in the operating manual.
5. Observe the technical notes of the
respective material manufacturer.
6. The unit must be installed
in a level position.
7. An adequate mains supply and compressor
capacity must be available.
In the next step, I‘ll point out
the individual system components.
Control box
Control unit for main pump, flush pump
and pressure tanks
Contact pressure gauge of the
pressure and dosing control
Adapter to connect the hose package
Fluid heaters + pressure gauges
Agitators
Control unit for feed pumps
Flush pump
Pressure tank for B component
Water circulation reservoir
Feed pump for A component
Feed pump for B component
Ram for B component
Ram for A component
Ram control
Cleaning agent tank
Air maintenance unit
Pressure tank for A component
Water circulation pump
Main proportioner pump
The frame is equipped as standard with wheels,
forklifting pockets,
and two crane lifting eyes.
This allows for easy transport
and installation of the unit.
I‘ll explain the system control components first.
I‘ll start with the control box which contains
all control elements, such as start/stop buttons,
the selector switch for manual or automatic operation
of the pressure and dosing control and the timer
to set the operating time for automatic operation
of the water heating and circulation pump.
The three-position on/off switches
of the circulation pump, water heater
and agitators are located next to the
error message signal lamp on the left.
In position „auto“, the corresponding system section
is automatically switched on and off in accordance
with the operating times set with the timer.
In position „0“, the corresponding system component
is switched off. In position „manual“, the corresponding
system component is switched on.
On the far left, you can see the on/off switch
for the material flow heaters.
Particularly important: Here you will find
the master switch to switch
the electric system on and off.
The contact pressure gauge of pressure
and dosing control is mounted below the control box.
The contact pressure gauge monitors the pressure
of the B component (the hardener) and switches
the system off when the operation tolerance is reached.
It is connected to the control box.
You can use the „Stop“ button
to manually shut down the system.
The „Start“ button is used
to restart the system after a shutdown.
The selector switch is used to activate monitoring
of the operation limits in the pressure range.
For start-up, the switch is set to „Manual“
to monitor only the upper operating pressure.
For spray operation, set the switch to “Automatic”,
as both limits should be monitored.
The control unit of the main pump,
the flush pump and the pressure tanks
is located here, next to the control panel.
The operating principle of all the
compressed air regulators installed
on the system is the same:
turn to the left or to the right
to reduce or increase the pressure, respectively.
Here you will find the water circulation
temperature indicator and the A and B
component temperature indicators,
with scales for both Fahrenheit
and Celsius readings.
The ram control unit is located
in the center of the ram system.
Here you will find the air pressure regulators,
and the control levers for the A and B component rams
and the pressure gauges used to indicate
the operating pressure of the system components.
The control levers are used to move the rams up
and down when changing the material containers.
Here at the top, you will find
the A and B component feed pump control unit,
the shutoff valves and the pressure gauges
that indicate the operating pressure of the
A and B component feed pumps.
The two shutoff valves are controlled
by the level monitoring in the pressure tanks.
Once the minimum material quantity is reached
in one of the pressure tanks,
the shutoff valve of the component
is opened automatically.
The corresponding feed pump then
delivers material into the pressure tank
until the maximum level is reached.
The shutoff valve is then automatically closed
and the feed pump is switched off.
Now, I would like to explain
the fluid handling components.
First, I will show you the flow diagram
for the material in the system.
Rams with feed pumps > Pressure tanks > Main pump >Material flow heaters
> Adapter for the hose-package (with return flow to the pressure tanks)
> Mixing unit > Spray gun
The two rams here assist the feed pumps
in transferring the material to be processed.
You can place the material drums here
once you have run up the rams.
The feed pumps deliver the material
from the drums into the pressure tanks.
The double-walled pressure tanks
with the agitators are located here.
Circulation water flows through the area
between the outer and the inner container.
The material is stored and heated in the inner container.
Hint: A temperature controller is installed
at the inlet of the hot water circulation
on the A component pressure tank,
which can be used to adjust the temperature
of the circulation water in the two pressure tanks.
Always observe the operating instructions
for the temperature controller.
The agitators mounted on the pressure tanks
provide for uniform heating and consistency
of the material by drawing it from the wall
into the middle of the container,
rather than stirring it up from the bottom.
You can turn on the agitators at the control box.
The material to be processed is transported
by the main pump from the pressure tanks
through the material flow heater
to the hose package, the mixing unit
and the spray gun.
The air motor drives three material pumps,
two for component A and one for component B.
The mixing ratio results from the ratio of the pump sizes.
Depending on the material requirements,
the mixing ratio can be adjusted
by exchanging material pumps.
The only thing you need is the proper tools
and the appropriate pumps.
Three material flow heaters are located
in the lower section of the system.
They can be switched on and off at the control box.
The temperature regulators are located
directly on the heaters.
From here, the material is transferred
to the adapter for the hose package.
There are five levers on the adapter,
used to open and close the material outlets
to the hose package, the return flow
to the pressure tanks,
for example for circulation,
and the feed and return flow
of the hose heating water.
The hose package is mounted here
and heats the material as it is transferred
to the mixing unit and gun.
The mixing unit has four levers
used to select the Stop, Spray, Flush,
and Volume Control operating modes as follows:
For the Stop mode, set the „Volume Control“ lever
and the large „Spray“ lever to „OFF“.
Set the two small „Flush“ levers to „OFF“.
For the „Volume Control“ operating mode,
the „Volume Control“ lever must be set to „ON“,
the „Spray“ lever set to „OFF“,
and the „Flush“ lever also set to „OFF“.
To switch to the „Spray“ mode,
set the „Volume Control“ lever to „OFF“,
the „Spray“ lever to „ON“,
and the two „Flush“ levers to „OFF“.
For the „Flush“ mode, set the „Volume Control“
and „Spray“ levers to „OFF“.
Set the two small „Flush“ levers to „ON“.
A very important component
is the flushing unit,
which is used to clean the components
which come into contact with mixed material,
before the potlife is exceeded.
The flushing unit consists of a flush pump,
cleaning agent reservoir, drain valve,
heater and temperature controller.
The cleaning agent reservoir
can be connected directly to a
cleaning agent supply system (not included).
In this case, a float automatically
regulates the cleaning agent supply.
The unit is designed for flushing with water.
For flushing with solvent
you need the appropriate mounting kit.
This is the circulation water reservoir,
which is used to store and heat
the circulation water.
The temperature regulators are located
at the back of the reservoirs.
The temperatures of the cleaning agent
and circulation water are adjustable
and can be read on the control unit
for the main pump, flush pump
and pressure tanks.
The heater elements are turned on and off
with the water circulation switch
on the control box.
Important: To maintain an adequate supply
of heated water for flushing,
it is recommended that the water circulation
remains “On” during system operation.
The circulation pump provides
for recirculation of the heating water.
Finally, we come to the air maintenance unit.
The maintenance unit prevents
condensed water and dirt particles
from entering the motor and supplies oil
to the compressed air for lubrication
of moving parts.
The deicing system adjusting screw
is also located here.
Preparing for Commissioning
So, now you have a first impression
of the WIWA DUOMIX 333PFP
and we can take a look at commissioning of this system.
Secure the system at its final location.
For this purpose, use the wheel chocks
which are clipped onto the unit frame.
After transporting the unit,
position the yoke vertically
and secure it with the locking pin
to avoid the danger of stumbling and injury.
Before proceeding to the installation,
check the maximum permissible pressures
for the spray hose, spray gun,
and all accessories.
These must be higher than or equal to
the maximum operating pressure of the system
as specified on the machine type plate.
Compare the maximum operating pressure
of the safety valve with the specifications
in the machine card or on the type plate.
The data must match.
The hose package, the mixing unit,
the spray hose and the spray gun
were packed separately for transportation.
I‘ll show you how to assemble these parts
before the first use of the system:
To mount the hose package,
take a position in front of the yoke.
First, connect the hose for the A component
at the far left of the adapter.
Then connect the hose for the B component
to the second line from the left.
Then attach the return hose of the hose heating,
the feed hose of the hose heating
and the flush hose on the far right.
Next, connect the hose package to the mixing unit.
Make sure you connect the A and B components
and the flushing hose in the proper positions.
Connect the spray gun to the spray hose.
Connect the spray hose
on the outlet side of the mixing unit.
The advantage of this system is
that the ready-mixed material is only present
in this section of the material lines.
The system is now fully assembled.
Now, I will show you how to connect
the air supply, the electric power supply
and open the venting screw
on the contact pressure gauge.
The maximum air consumption
is 5,000 litres per minute or 150 cfm.
To ensure an adequate air supply,
the compressor capacity must match
the air requirements of the unit
and the diameters of the air supply hoses
must match the inlet connections.
Make sure that the compressed air shutoff valves
are closed and all air pressure regulators
have been set to zero.
Connect the compressed air line
to the air maintenance unit.
Electrical connection
1. Check that the factory-set
electric power supply is enabled.
2. Make sure that the main switch
on the control cabinet is in the „OFF“ position.
3. Connect the power cable
in accordance with the wiring
diagram inside the control cabinet
of the PFP system.
4. Check the rotational direction of the agitators.
If the cable is connected correctly,
the rotation will match the direction
of the arrow on the agitator housing.
Now that you have completed the above steps,
the venting screw on the contact pressure gauge
must be opened with a screwdriver
before starting up the system.
Detailed instructions can be found
on the label of the contact pressure gauge.
Commissioning
The preparations for commissioning
have now been completed
and I can show you how to put
the system into operation.
We will start the system now,
but first, please make sure that:
All compressed air shutoff valves have been closed.
All air pressure regulators have been set to zero.
The control levers of both rams are in the „Stop“ position.
The spray gun lock is engaged.
Open the compressed air shutoff valve
on the air maintenance unit.
Turn the main switch on the control cabinet to „ON“,
set the „Manual / Automatic“ switch to „Manual“
and press the “Start” button.
Now we are going to put the flushing unit
into operation.
During work, the flush pump
should always be ready for use,
so that all components which come
in contact with mixed material
can be flushed within the specified potlife!
Connect the cleaning agent supply line
to the cleaning agent tank
and fill with cleaning agent. Here, water is used.
The unit is designed for flushing with water.
For flushing with solvent you need
the appropriate mounting kit.
Turn the heater element on with
the water circulation switch on the control box.
If you use only water as a cleaning agent,
set the desired temperature on the heater
of the cleaning agent tank. Important:
If a cleaning agent other than water is used,
ensure that the temperature controller
is adjusted to “zero”.
Flush mixing unit and spray gun
Now I‘ll show you how to flush
the mixing unit and the spray gun.
Remove the nozzle from the spray gun.
Select the operating mode „Flushing“
on the mixing unit.
Hold the spray gun into an empty container.
Unlock the spray gun and operate it,
until uncontaminated cleaning agent runs out.
Depending on the length of the hose package,
set a pressure of 3 to 6 bar on the pressure regulator
of the flush pump.
Close and lock the spray gun.
Select the operating mode „Stop“
on the mixing unit.
Cleaning the system
The next step: We have to clean the system.
After assembly, this unit was factory tested
for flawless function by means of a test substance.
During initial start-up you must therefore
perform a complete cleaning in order to flush out
any test medium residues.
Before we start cleaning the system,
please make sure that:
The compressed air shutoff valves
on both feed pumps are closed.
Both ram control levers are in position "Down"
Set a pressure of 1.5 - 2 bar
on the air pressure regulators of both rams.
Set the control lever of the B component ram
to position "up" to drive the feed pump up
using the ram. Once there is sufficient space
for the material drum under the follow plate,
set the ram control lever to "stop".
Place a container with flushing agent
on the centering plate under the feed pump.
Set the ram control lever to position "Down"
to move it down again.
Open the compressed air shutoff valve
on the B component feed pump.
Adjust the air regulator
for the B component feed pump
to a low pressure
To clean the unit please fill each component
with approx. 30 l of cleaning agent.
After filling, close the air supply valve
for the feed pump.
The parts of the system which came in contact
with the A- component need to be cleaned, as well.
Please repeat the steps for the ram press
and feed pump of the B- component
for the ram press and feed pump
of the A-component also.
Open the shutoff valves
on both main pump material inlets.
Open the return flow valves
on the hose package adapter.
Adjust a pressure of 1 - 1.5 bar
on the air pressure regulator of the main pump.
Let the cleaning agent circulate
through the system for about 1 min.
Close the return flow valves on the adapter
and open the material outlet valves.
Select the „Spray“ operating mode on the mixer.
Hold the spray gun into an empty container.
Unlock the spray gun and operate it
until uncontaminated cleaning agent runs out.
Caution! Material may splash out of the container!
Close and lock the spray gun.
The main pump will stop.
Select the operating mode "Stop" on the mixing unit.
Place the volumetric measurement outlets
of the mixing unit into separate empty containers.
Select the operating mode „Volume Control“
on the mixing unit.
Let the system run
until no more cleaning agent comes out.
Caution! Material may splash out of the container!
Set the compressed air pressure regulator
on the main pump to zero.
Set the mixing unit to the "Stop" mode.
Open the air supply ball valve for the follow plate.
Set the control lever of the B component ram
to position "Up" to drive the feed pump up
using the ram.
Once the sealing lip of the follow plate
reaches the top of the container,
quickly close the air supply ball valve
for the follow plate.
Once there is sufficient space,
set the ram control lever to position "Stop".
Remove the cleaning agent container.
Remove the other cleaning agent container
in the same manner.
Filling the system with material
When the system is fully cleaned,
you can fill the pressure tanks
with the material to be processed.
Make sure that the components
are assigned correctly.
Both components must only come
into contact with the system components
intended for this purpose.
Standard component (A) is BLUE,
hardener (B) is RED.
Place the container with the hardener
on the centering plate under the
B component feed pump.
Open the ventilation ball valve on the follow plate
and set the ram control lever to position "Down"
to move it down again.
Once all air has escaped from the material drum,
close the ventilation ball valve on the follow plate.
Switch on the agitators at the control box.
Open the compressed air shutoff valve
on the B component feed pump.
The steps shown for the ram press
and feed pump of the B-component
need to be done accordingly
for the ram press and feed pump
of the A-component.
As a result, material will be pumped
into the pressure tanks until the level monitors
of the pressure tanks switch the feed pumps off
automatically.
To fill up the pressure tank completely with material,
several drums of the A-component and the
B- component are needed.
To do this, the procedure just shown
needs to be repeated several times.
Putting the water circulation into operation
Once the materials to be processed
have been filled into the pressure tanks,
you can put the water circulation system into operation.
Fill a mixture of 3 parts water and 1 part antifreeze
to 10 cm below the top of the water heating reservoir.
Switch on the water heating
and circulation pump at the control box.
Both water heaters will be switched on
simultaneously.
Open both ball valves for the hose heating
at the hose package adapter.
Set the desired temperature on the
water circulation heater on the reservoir.
Bleeding the system
Now I’ll show you how to bleed the system.
Open the return flow
and close the material outlets
on the hose package adapter.
Use a 27mm open end wrench
to disconnect the return hose
from the pressure tank of the B component
and a 24 mm open end wrench
to prevent loosening of the ***.
Hold the return hose for the B component
in a collection container.
Use a 27mm open end wrench to disconnect
the return hose from the pressure tank
of the A component and a 24 mm open end wrench
to prevent loosening of the ***.
Hold the return hose for the A component
in a second collection container.
Set a pressure of 1 - 2 bar
on the air pressure regulator of the main pump.
The pump should run slowly.
Once clean material comes out of the
return flow hoses for both components,
close the return flow on the adapter.
Use a 27mm open end wrench
to connect the return hose
to the pressure tank of the B component.
Use a 24 mm open end wrench
on the *** to counter-tighten ist.
Use a 27mm open end wrench to
connect the return hose
to the pressure tank of the A component.
Use a 24 mm open end wrench
on the *** to counter-tighten it.
Adjusting the de-icing system
Now we can proceed to the adjustment
of the deicing system.
Turn the deicing system adjusting screw
on the air outlet of the air maintenance unit
for the main pump slowly counterclockwise.
A minimum of one and maximum of three turns.
Exact settings should be made individually
and as required, since the degree of icing
depends on various factors such as pressure,
pump speed, air humidity and ambient temperature.
When interrupting work, or in case of
decommissioning, the adjusting screw
of the deicing system should remain open.
Now we are going to put the
material flow heaters into operation.
Putting the material flow heaters into operation
Switch on the material flow heaters
at the control box.
Set the desired material temperature
on the temperature regulators
of the material flow heaters.
Close the pressure relief valves
on both pressure tanks.
Open the shutoff valves on the
compressed air connections
of both pressure tanks.
Set the desired air pressure on the regulators
of the two pressure tanks to a maximum
of 6 bar or 87 psi.
Open the return flow valves
on the hose package adapter.
Allow the material to circulate
until the processing temperature has been reached.
The temperature of both components,
as well as the temperature of the
water circulation system,
should be approx. 50 °C or 122 °F.
Now you will learn how to fill the hose package.
Filling the hose package
Close the return flow valves on the adapter
and open the material outlets to the hose package.
Hold the volumetric measurement outlets
of the mixing unit into separate empty containers.
Select the operating mode „Volume Control“
on the mixing unit.
The hose package slowly fills up with material.
The air inlet pressure on the main pump
may need to be increased slightly to overcome
the resistance in the hose package.
Once clean material exits
the volumetric measurement outlets
on the mixing unit,
set the mixing unit to the „Stop“ mode.
Now we’ll perform a volumetric measurement
of the system.
With the volumetric measurement,
you can check the actual mixing ratio
of the components.
Always perform a volumetric measurement
before starting work!
Place clean, weighed containers
under the volumetric measurement outlets
of the mixing unit.
On the mixing unit select the operating mode
„Volumetric measurement“.
Fill the container with a certain amount of material.
Select the „Stop“ mode on the mixing unit.
Use the filled quantities to calculate
the actual mixing ratio and check
whether this complies with the nominal value.
If the actual mixing ratio differs
from the nominal value:
Check the material temperatures
of both components.
Check the pressure in the pressure tanks
for both components.
And check the mixing ratio again.
It is possible to slightly adjust the mixing ratio
by changing the settings for the temperature
and/or the pressure on the pressure tanks
of the components.
We recommend to preheat the mixing block,
spray hose and spray gun, by flushing with hot water.
Select the “Flush” operating mode
at the mixing block,
unlock and trigger the spray gun.
Heat up the system
until you reach the appropriate temperature
and switch the flushing ball valves to “Stop”
Coating work
The system is now ready for operation
and you can start the coating work.
Prior to coating, a system start-up
must always be performed.
Select the „Spray“ operating mode on the mixer.
Unlock the spray gun and operate it,
until clean processing material
starts to run out.
Caution! Material may splash out of the container!
Close and lock the spray gun.
Screw the nozzle back onto the spray gun.
Adjusting spraying pressure
Adjust the optimal spraying pressure
using the air pressure regulator
on the main pump.
Please observe the following instructions
when adjusting the spraying pressure:
Optimal spraying pressure is indicated
by a uniform application of material
with feathered peripheral zones.
Operate the unit with an air pressure
only as high as necessary to achieve
a good atomization at the recommended
spraying distance of approx. 30-40 cm
or 12-16 inches.
Excessive spraying pressure causes
increased material consumption
and paint fogging.
Insuficient spraying pressure
results in the appearance of stripes
and a varying coating thickness
Adjusting the pressure and dosing control
Set the operation limits for the current work process
on the contact pressure gauge
of the pressure and dosing control.
The black pointer in the contact pressure gauge
shows the actual pressure.
Once you have set the optimal spraying pressure,
you use the two red pointers
to set the operation limits
for the current work process as follows:
Insert the attached key
into the contact pressure gauge.
Use the driver needle
to turn the upper red slave pointer
to a value of approx. 20 bar or 300 psi
above the maximum pressure
that is indicated
when the spray gun is closed.
Use the driver needle to turn
the lower red slave pointer
to a value of approx. 20 bar or 300 psi
below the minimum pressure
that is indicated when the spray gun
is opened. Pull the key back out.
Switch the pressure and dosing control
to the „Automatic“ position.
The pressure and dosing control
must be readjusted each time
the spraying pressure has been changed.
If the pointer of the contact pressure gauge
does not move or moves only insignificantly
the system must not be put into operation due
to the danger of mixing faults!
To properly clean the system components
which came in contact with mixed material,
please proceed as follows:
Set the pressure at the regulator
of the main pump to “0”
Press the trigger of the gun,
until the pressure at the gauge
drops below 150 bar.
Caution! Material may splash out of the container!
Set the mode “Spray” at the mixer to “Stop”
Dismantle the tip.
Select the “Flush” operating mode
at the mixer and trigger the spray gun.
Alternately close and open both valves
for flushing (at least 5 times)
to clean the mixing block properly.
Now open both valves for flushing
at the mixer and let hot cleaning agent run
until only clear cleaning agent comes out.
Close both valves, put the tip back in the gun
and briefly flush to clean it.
Lock the spray gun
and close the valves for flushing again.
Tips on coating
Finally, a few important tips on coating:
Hold the spray gun at a right angle (90°)
to the spraying area.
If the spray gun is held at a different angle,
the coating becomes irregular and blotchy.
Ensure an even speed and move the spray gun
parallel to the area to be coated.
Waving the spray gun causes irregular coating.
Move the spray gun with your arm
and not with your wrist.
Begin moving the spray gun
before pulling the trigger.
This way you will achieve perfect,
soft and smooth overlapping
of the spray jet and excessively thick
application of material at the beginning
of the spraying process is avoided.
Release the trigger before
stopping the movement.
Replace the spray nozzle before it is worn.
Worn nozzles cause higher paint consumption
and have a negative effect
on the quality of the paint finish.
The DUOMIX 333 PFP can be installed inside,
as well as outside spray booths.
However, outdoor installation is preferred
in order to avoid damage to the unit
by overspray.
Protect the objects adjacent to the sprayed object
against possible contamination
caused by material fogging.
As the owner, if the system is to be
installed outdoors, you are required to take
the appropriate lightning protection measures.
This is a great deal of information to take in,
but it will make it an awful lot easier for you
to carry out your daily work
on the WIWA DUOMIX 333PFP system.
For further information, please contact
our headquarters in Lahnau or our partners
and affiliates in the USA and China.
We will show you their addresses
at the end of this video.
We wish you every success!