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wiwa DUOMIX 230 MINI Operation Manual

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Operation Manual
DUOMIX 230 MINI
Serial No.:
2dm230mini_BA_en_B0550047 ✓(2021/10/19)

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Summary of Contents for wiwa DUOMIX 230 MINI

  • Page 1 Operation Manual DUOMIX 230 MINI Serial No.: 2dm230mini_BA_en_B0550047 ✓(2021/10/19)

  • Page 2: Ec Declaration Of Conformity

    EC declaration of conformity in accordance with Annex II, No. 1 A of Machine Directive 2006 / 42 / EC, as amended by 2009 / 127 / EC The company WIWA Wilhelm Wagner GmbH & Co. KG 35633 Lahnau Gewerbestraße 1–3 Germany...

  • Page 3: Eu Declaration Of Conformity

    EU declaration of conformity in accordance with ATEX Directives The company WIWA Wilhelm Wagner GmbH & Co. KG 35633 Lahnau Gewerbestraße 1–3 Germany hereby declares that the machine DUOMIX 230 MINI type with serial no. conforms with the provisions of Directive 2014 / 34 / EU.

  • Page 5: Table Of Contents

    Contents Contents 1 Foreword 2 Safety 2.1 Explanation of symbols ......2.2 Safety notes ....... 2.2.1 Working pressure .
  • Page 6 Contents 4.3.3 Inserting the filter elements in the high pressure filter ..29 4.3.4 Connecting the compressed air supply ... . 29 5 Operation 5.1 Putting the machine into operation ....30 5.1.1 Switching on the machine .

  • Page 7: Foreword

    If questions should arise, we would be happy to assist you. We wish you excellent working results with your machine WIWA Wilhelm Wagner GmbH & Co. KG Copyright © 2025 WIWA The copyright to this operation manual belongs to WIWA Wilhelm Wagner GmbH &...

  • Page 8: Safety

    We recommend that the machine owner have this confirmed in writing. 2.1 Explanation of symbols Safety notes warn of potential accident risks and describe the measures required for accident prevention. In the WIWA operation manuals, safety notes are high- lighted and labeled as follows: DANGER...
  • Page 9 Safety General risk of accident Risk of explosion due to explosive atmosphere Risk of explosion due to explosive substances Risk of accident due to electricity or electrostatic charge Warning of crushing Warning of corrosive substances Risk of injuries due to rotating machine parts Risk of burning due to hot surfaces Risk of freezing due to cold surfaces The first line of the safety instructions indicates the personal protective equipment...

  • Page 10: Safety Notes

    Safety Wear protective gloves Signals an instruction to wear protective gloves in order to prevent injuries due to aggressive chemicals, burns when processing heated materials, or freezing due to contact with very cold surfaces. 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 floors.

  • Page 11: Working Pressure

    Safety 2.2.1 Working pressure WARNING Parts that are not designed for the maximum permissible working pressure may rupture and cause serious injuries. It is essential to observe the prescribed maximum working pressures for all parts. With varying working pressures, the lowest value always applies as the maximum working pressure for the complete machine.

  • Page 12: Risks Due To Electricity

    Never spray solvents or materials containing solvents into narrow-mouthed cans or drums with a bung opening! Only use electrically conductive material hoses. All original material hoses from WIWA are conductive and designed for our devices. Only use electrically conductive accessories/accessory parts. WARNING Dirty machines can become electrostatically charged.

  • Page 13: Explosion Protection

    Prior to all work on the machine, heat air motors up to a temperature above 10°C. Wear suitable protective gloves! 2.2.6 Explosion protection The following short designations are used in the instructions of WIWA: Ex protection: Explosion protection Ex area: potentially explosive or non-explosion protected area Non-Ex area: non-explosive or explosion protected area...

  • Page 14: Health Risks

    Safety 2.2.7 Health risks CAUTION Depending on the materials being processed, solvent vapors may arise, which could cause damage to health and property. Make sure the workplace is sufficiently ventilated and aired. Always observe the safety data sheets and processing instructions of the material manufacturer.

  • Page 15: Safety Signs

    Safety Lubricate threaded connections during assembly. 2.3 Safety signs The safety signs attached to the ma- chine, such as the orange tag (see Fig. 1), indicate possible dangers and must be observed. By scanning the QR code, the most important safety information for this machine can be accessed.

  • Page 16: Emergency Stop Button (Optional)

    Safety After all set-up work, After all cleaning, maintenance, and repair work. Checklist on the pressureless machine: Seal of the safety valves OK? Safety valves free of external damage? Compressed air shut-off valves move freely? Ground cable free of damage? Connections of the ground cable to the machine and to the conductor OK? Has material escaped into the collecting vessel of the rupture disc pressure protection?

  • Page 17: Safety Valves

    Safety 2.4.2 Safety valves Safety valves are located on the machine: on the air motors of the proportioning pumps (Fig. 3) and on the air motor of the flush pump. Fig. 3: Safety valve The safety valves prevent the maximum permissible air inlet pressure from being exceeded.

  • Page 18: Compressed Air Shut-Off Valves

    Safety 2.4.3 Compressed air shut-off valves The compressed air shut-off valves are used to interrupt the compressed air supply to the individual machine components, e. g. to the proportioning pumps. I / ON 0 / OFF I / ON 0 / OFF Fig.

  • Page 19: Rupture Disc Pressure Protection

    Safety The grounding points on this machine are labeled with the symbol shown on the left. 2.4.5 Rupture disc pressure protection Rupture discs are installed in the screw con- nection behind the high pressure filters. Rupture discs are pressure protection with a disposable membrane.

  • Page 20: Personnel Qualifications

    Safety 2.5.2 Personnel qualifications Differentiation is made between two groups of personnel, depending on their qualifications: Instructed operators have received verified instruction from the machine owner regarding the tasks entrusted to him and the possible risks if the correct procedure is not followed. Trained personnel have received instruction provided by the machine manu- facturer and are capable of carrying out maintenance and repair work on the machine, independently recognizing possible dangers and avoiding risks.

  • Page 21: Warranty And Liability

    When repairing and maintaining the machine, original spare parts from WIWA must be used. If spare parts are used that have not been produced or supplied by WIWA, the warranty is void and all liability shall be excluded. 2.6.2 Accessories If you use original WIWA accessories, their suitability for use in our machines is guaranteed.

  • Page 22: Leakage

    Safety 3. To relieve the material side pressure, open the relief valve on the high pressure filter. CAUTION Despite pressure relief, a residual pressure can remain in the machine. Exercise particular caution when proceeding further. This process is not suitable for decommissioning. The machine is not flushed. For controlled decommissioning, please observe section 5.7 on page 38.

  • Page 23: Description

    3.1 Intended use Using the DUOMIX 230 MINI, 2-component coatings with a fixed mixing ratio can be applied. It is possible to process low to high viscosity 2 component materials that are solvent-free or contain solvents, even with extremely short pot lives (e. g.

  • Page 24: Construction

    3.3 Construction The DUOMIX 230 MINI is offered with suction hoses or with hoppers. Fig. 7: DUOMIX 230 MINI with suction hoses (rear view) Designation Regulator cluster...

  • Page 25: Compressed Air Connections And Compressed Air Regulation

    Description Fig. 8: DUOMIX 230 MINI with suction hoses (front view) Fig. 9: DUOMIX 230 MINI with hoppers (front view) Designation Proportioning pump Cart Flush pump High pressure filter for component A Suction hose for component A Suction hose for component B...
  • Page 26 Description Fig. 10: Connections and regulator on the regulator cluster Designation Pressure gauge for the proportioning pump Pressure gauge for the flush pump Pressure gauge for the atomizing air (AirCombi, optional) Compressed air regulator for the atomizing air (optional) Compressed air regulator for the flush pump Compressed air regulator of the proportioning pump Compressed air connection Compressed air shut-off valve...

  • Page 27: Proportioning Pump

    In this case, Fig. 11: Proportioning pump the safety valve for the proportioning pump must be replaced after consultation with WIWA. Designation Muffler Air motor Intermediate body Fluid pump for component B...

  • Page 28: Mixing Unit

    Description 3.6 Mixing unit The two components of the processing material are only combined once in the mixing unit. Actual mixing takes place in the static mixer, which is mounted at the material outlet of the mixing unit. From there, the material reaches the spray gun via the spraying hose.
  • Page 29 Description Circulation Spraying Flushing Stop Open the circulation/relief ball valves only when the air motor is at a standstill and only at the same time! Open and close the flushing ball valves multiple times in alternation during flushing to ensure that each side of the mixer block is flushed out separately. Finally, flush with both ball valves simultaneously.

  • Page 30: Flush Pump

    The detailed accessory catalog can be found at www.wiwa.de. For further infor- mation and order numbers, you can also contact an approved WIWA dealer or WIWA customer service. Observe and follow the separate operation manuals for all accessories used.

  • Page 31: Aircombi Attachment Kit

    Description 3.8.2 AirCombi attachment kit In addition to the compressed air reg- ulator for the air inlet pressure of the pump, AirCombi devices are equipped with an additional compressed air regu- lator to regulate the atomizer air pres- sure. The 2nd compressed air regulator for the AirCombi operation can be retrofitted as an attachment kit.

  • Page 32: Transport, Installation, And Assembly

    Transport, installation, and assembly 4 Transport, installation, and assembly The machine left the factory in faultless condition, packaged correctly for transport. Check the machine at the time of receipt for any transport damage and for com- pleteness. 4.1 Transportation Please follow these notes when transporting the machine: Ensure sufficient load bearing capacity of lifting gear and lifting tackle when loading the machine.

  • Page 33: Assembly

    Transport, installation, and assembly Ambient temperature: minimum: 0 °C or 32 °F maximum: 40 °C or 104 °F WARNING If the machine is used outdoors during a storm, a life-endangering situation may arise for the operating personnel due to lightning! Never operate a machine outdoors during a storm! The owner must ensure that the machine is equipped with suitable lightning protection equipment.

  • Page 34: Connecting The Spraying Hose And Spray Gun

    Transport, installation, and assembly WARNING During assembly work, ignition sources may arise (e. g. due to mechanical sparks, electrostatic discharge, etc.). Carry out all assembly work outside of potentially explosive areas. When using the machine in Ex zones, the specialist personnel must have knowl- edge of ATEX.

  • Page 35: Grounding The Machine

    Transport, installation, and assembly 4.3.2 Grounding the machine WARNING The high flow velocities during operation can result in an electrostatic charge. Static discharges can result in fire and explosions. Ensure that the machine is properly grounded outside of Ex zones! Ensure correct grounding of the object to be coated.

  • Page 36: Operation

    Operation 5 Operation Only put the machine into operation if you are equipped with the prescribed personal protective equipment. Details on this can be found in section 2.5.4 on page 14. The machine must be correctly installed and fully assembled. The air inlet pressure can be found in the information on the type plate (sec- tion 8.2 on page 50).

  • Page 37: Switching On The Machine

    Operation Overview of the work steps during commissioning: 1. Start the machine. 2. Put the flush pump into operation. 3. Flush out remains of the test substance (only during initial commissioning). 4. Fill machine with processing material and ventilate. 5.1.1 Switching on the machine 1.

  • Page 38: Flushing Out The Remains Of The Test Substance

    Operation 5.1.3 Flushing out the remains of the test substance Following assembly, the machine was tested in the factory for faultless function with a test substance. During initial commissioning, it is therefore necessary to first completely clean the machine to flush out the remaining test substance (section 5.4 on page 35).

  • Page 39: Coating

    Operation 5.2 Coating Prior to coating, the machine must have been put into operation. 1. Switch the mixing unit to spraying mode. 2. Set a low air inlet pressure at the compressed air regulator for the proportioning pump. 3. Hold the spray gun in a collecting vessel - watch out for contact of the spray gun with the container wall.

  • Page 40: Tips For Good Coatings

    Operation 5.2.2 Tips for good coatings Hold the spray gun at a right angle (90°) to the surface to be coated. As soon as you hold the spray gun at a different angle, the coating will become uneven and patchy (see Fig.

  • Page 41: Cleaning The Machine Completely

    Operation 2. Switch the mixing unit to flushing mode according to section 3.6 on page 22. The operating modes “Spraying” and “Ventilating/Circulation” are switched off. 3. Unlock the spray gun. 4. Hold the spray gun in a collecting vessel. Ensure contact between the spray gun and the container wall while doing so.
  • Page 42 Operation WARNING Explosive gases may develop due to flushing agents evaporating and these may ignite on hot heat sources. If the machine is equipped with material heaters, then you must switch these off prior to cleaning and allow the machine to cool down. You can achieve faster cooling by circulating the material in the machine (max.

  • Page 43: Pressure Relief

    The machine has been specially configured for your application case. It is necessary to check compatibility of the materials used with other materials in each individual case. WIWA is happy to help determine the suitability of your machine for another material.

  • Page 44: Decommissioning

    Operation 5.7 Decommissioning In case of decommissioning, flush the machine, relieve the pressure, and shut off the machine. 1. Turn all compressed air regulators down completely. 2. Shut down all attachments. 3. Set the mixing unit to circulation mode. 4. Pull the spray gun trigger until the material pressure is completely relieved. 5.

  • Page 45: Maintenance

    Maintenance 6 Maintenance Only perform maintenance on the machine if you are equipped with the prescribed personal protective equipment. Details on this can be found in section 2.5.4 on page 14. WARNING If untrained personnel carry out maintenance and repair work, they endanger themselves and others, and risk the operational safety of the machine.

  • Page 46: Regular Testing

    The test certificate or a copy of this must be available at the machine’s place of use. Have repair work carried out exclusively by WIWA Service or trained specialist personnel (in/from authorized workshops if necessary). When using the machine in Ex zones, the specialist personnel must have knowl- edge of ATEX.

  • Page 47: Safety Valve

    Maintenance Time frame Activity for further reading Every 3 years Check of the com- section 6.6 on page 46 pressed air and material hoses by a specialist and replacement if nec- essary Every 6 years at the Complete replacement section 6.6 on page 46 latest of the compressed air and material hoses...

  • Page 48: Replacing The Safety Valve

    Maintenance Safety valves with a ” connection: Only perform the test by hand. To prevent damage to the safety valve, do not use any tools to release the knurled nut. 1. Reduce the air inlet pressure on the completely filled machine to approx. 10 % below the maximum permissible pressure according to the type plate.

  • Page 49: Checking The Release Agent Level In The Fluid Pumps

    Maintenance Depending on the characteristics of the mate- rial to be processed, signs of wear will appear on the fluid pump packing after a certain time in operation. The material may be pressed by the packing in this case, and may then harden.
  • Page 50 Maintenance WARNING If the machine’s pressure is not relieved when a high pressure filter is opened, material can escape under very high pressure and cause serious injuries. Fully relieve the machine pressure before opening a high pressure filter! Blockages may result in residual pressures in the machine. Open the high pressure filter cautiously! High pressure filter on the frame (standard mixing unit) Designation...

  • Page 51: Filter Elements For The High Pressure Filter

    Insert a filter element in the high pressure filter that is appropriate for the processing material and fits the spray nozzle. The mesh size should always be somewhat finer than the hole in the nozzle used. Filter element Nozzle size WIWA order number M 200 (white) up to 0.23 mm/.009” 0659107-200 M 150 (red) >...

  • Page 52: Checking The Compressed Air And Material Hoses

    The duration of use of a hose line, including any possible storage duration, may not exceed six years. The manufacturing date of a hose line (month/year) is stamped on the ferrule. 6.7 Recommended operating fluids Only use original operating fluids from WIWA: Operating fluid WIWA order number Release agent, yellow, standard (0.5 l)¹...

  • Page 53: Special Tool

    Fig. 23: Hook wrench Air motor ø [mm] Wrench size [mm] WIWA order number 79 / 134 / 330 / 580 50 / 68 / 75 0666533 80 / 90...

  • Page 54: Eliminating Operational Faults

    Eliminating operational faults 7 Eliminating operational faults Only eliminate operational faults if you are equipped with the prescribed personal protective equipment. Details on this can be found in section 2.5.4 on page 14. fault possible cause remedy During the downstroke of the Bottom valve of the fluid pump Remove and clean the bottom proportioning pump, the fluid...
  • Page 55 Compressed air is leaking at the Gaskets of the air motor worn. Have the air motor re-sealed by guide axes on the air motor. WIWA customer service. The air motor no longer oper- Air motor controls defective. Have the air motor repaired by ates, although the compressed WIWA customer service.

  • Page 56: Technical Data

    The QR code contains a link which will direct you to the machine support on the WIWA website. You can find further information for your machine there, such as e. g. spare parts lists, repair instructions, etc. The QR code can be scanned using your mobile device (e.

  • Page 57: Hose Volume

    Technical data Output of component A in cm³ and fl. oz., Output of component B in cm³ and fl. oz., Pressure ratio, Mixing ratio, Total output per double stroke in cm³ and fl.oz., Max. intake pressure in bar and psi, Max.
  • Page 58 Technical data �� �� �� �� �� �� �� �� 4 mm 40 m 503 ml 10 mm 40 m 3142 ml 4 mm 50 m 628 ml 10 mm 50 m 3927 ml 5 mm 98 ml 12 mm 565 ml 5 mm 7.5 m...
  • Page 59 Technical data Original Operation Manual ✓(2021/10/19), Status: 2024/09/11 2dm230mini_BA_en_B0550047...
  • Page 60 Headquarter and production WIWA Wilhelm Wagner GmbH & Co. KG Gewerbestraße 1–3 35633 Lahnau Germany Phone: +49 (0)6441 609-0 Fax: +49 (0)6441 609-2450 Email: info@wiwa.de Website: www.wiwa.de WIWA subsidiary USA WIWA LLC – USA, Kanada, Lateinamerika 107 N. Main St.

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