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Summary of Contents for wiwa FLEXIMIX GX PFP 2K
- Page 1 Operation Manual FLEXIMIX GX PFP Serial No.: 2fm2pfp_BA_en_B0550105 ✓(2024/11/25)
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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: Table Of Contents
Contents Contents 1 Foreword 2 Safety 2.1 Explanation of symbols ......2.2 Safety notes ....... 2.2.1 Working pressure . - Page 4 Contents 3.6 Flushing unit ......31 3.6.1 Flush pump ......32 3.6.2 Flushing agent tank .
- Page 5 Contents 6 Operation 6.1 Putting the machine into operation ....66 6.1.1 Switching on the machine ....67 6.1.2 Setting the controls .
- Page 6 Contents 9.2 Machine card ......99 9.3 Type plates ....... 99 9.3.1 Main type plate .
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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...
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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 Safety WARNING During the lifting movement of the rams, loose items of clothing may come between the follower plate or follower cover and the material drum itself or be caught on other unit parts, and be pulled into the container or upwards. Wear tight-fitting clothing with low tear-resistance, tight sleeves and no pro- jecting parts.
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Page 13: Hazards Due To Agitators
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 14: Risks Due To Hot Or Cold Surfaces
Prior to all work on the machine, heat air motors up to a temperature above 10°C. Wear suitable protective gloves! 2.2.8 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 15: Health Risks
Safety Please note that some parts have their own type plate with separate labeling according to ATEX. In this case, the lowest explosion protection of all labels displayed applies to the entire machine. If agitators, heaters or other electrically operated accessories are attached, the explosion protection must be checked. -
Page 16: Safety Signs
Safety 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. Also read and observe the safety notes in the operation manual! Additional symbols on the machine... -
Page 17: Emergency Stop Button
Safety Checklist on the pressureless machine: Seal on the safety valve OK? Safety valve externally free of damage? Ground cable free of damage? Mobility of the compressed air shut-off valve OK? Checklist on the pressurized machine: Function of the safety valve OK? (For function test, see section 7.4.1 on page 84.) When checking additional safety features, observe the operation manuals for the optional accessories. -
Page 18: Safety Valves
Safety 2.4.3 Safety valves Safety valves are located on the air motors on the machine ... for the proportioning pump (Fig. 4) behind the covering of the muffler, for the feed pumps, for the circulation pump for the water heat- ing, for the flush pump, Fig. -
Page 19: Ground Cable
Safety Furthermore, the machine is equipped with additional compressed air shut-off valves, with which it is possible to interrupt the air supply to individual components, such as e. g. the feed pumps. The functional principle of all compressed air shut-off valves installed on the machine is the same: Open ⇒... -
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 2. Close all compressed air shut-off valves (maintenance unit, pressure vessel, feed pumps, etc.). 3. Turn down all compressed air regulators (proportioning pump, flush pump, pressure vessel, feed pumps, etc.) completely. 4. Close the material outlets on the mixing unit. 5. -
Page 23: Description
WIWA (see section 2.6.1 on page 15), accessories are used that are not suitable for the machine (see section 2.6.2... -
Page 24: Construction
Description 3.3 Construction Fig. 8: FLEXIMIX GX PFP, B-side Designation Compressed air regulation unit Control cabinet Proportioning unit Type plates Drawbar (optional) Material fluid heater Hose holder Shackle with threaded bolt Proportioning pumps Agitators Electrical control cabinet Feed pumps Rams Frame Original Operation Manual ✓(2024/11/25), Status: 2024/11/25 2fm2pfp_BA_en_B0550105... - Page 25 Description Designation Wheels (optional) Forklift mount Pressure vessel Maintenance unit Material pumps Flush pump Water pump for the hose heater Main valve Flushing agent tank Regulator cluster for the rams Fig. 9: FLEXIMIX GX PFP, A-side Original Operation Manual ✓(2024/11/25), Status: 2024/11/25 2fm2pfp_BA_en_B0550105...
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Page 26: Components Of The Machine Controls
Description 3.4 Components of the machine controls 3.4.1 Control cabinet Fig. 10: Control cabinet Designation See also Control module touch screen section 4 on page 35 Agitator on section 3.5.3 on page 26 Start button Horn off Spraying mode section 6.2 on page 72 Circulation mode section 6.8.2 on page 79 Stop button... -
Page 27: Compressed Air Regulation Unit
Description 3.4.2 Compressed air regulation unit The compressed air regulator and pressure gauge are combined in one regulator cluster, which is installed next to the control cabinet. Designation Circulation pump for the hose bundle heating Flush pump Proportioning pumps Pressure vessel for component A Pressure vessel for component B... -
Page 28: Regulator Cluster For The Rams
Description 3.4.3 Regulator cluster for the rams The controls for the rams are combined in one regulator cluster, which is installed between the two rams. Using the two control levers, the rams can be manually moved and stopped in order to position or exchange the material drums. Stop Fig. -
Page 29: Regulator Cluster For The Feed Pumps
Description 3.4.4 Regulator cluster for the feed pumps The regulator cluster for the feed pumps is installed between the two rams. It contains the shut-off valves, which are controlled by the level monitoring in the pressure vessels. If the fill level in one of the pressure vessels has dropped to the minimum quantity, the shut-off valve of this com- ponent is opened automatically. -
Page 30: Rams With Feed Pumps
Description Component A Component B Ram with Ram with feed pump feed pumps Pressure vessel Pressure vessel Proportion- Proportion- ing pump ing pump proportion- Material Material ing unit fluid heater fluid heater Mixing unit Static mixer Spray gun 3.5.2 Rams with feed pumps The feed pumps convey the material to be processed from the material drums to the pressure vessels. - Page 31 Description Designation Regulator cluster for the feed pumps (section 3.4.4) Compressed air shut-off valve for the feed pump Shut-off valve for the container ventilation Feed pump Material outlet Regulator cluster for the rams (section 3.4.3) Ventilation ball valve Breather valve Follower plate Original Operation Manual ✓(2024/11/25), Status: 2024/11/25 2fm2pfp_BA_en_B0550105...
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Page 32: Pressure Vessel With Agitators
Description 3.5.3 Pressure vessel with agitators Fig. 14: Pressure vessel Designation Safety valve (8 bar) Fill level sensor Pressure discharge valve with shut-off valve Compressed air connection with shut-off valve Safety valve (6 bar) Agitator motor Inspection hole with closure CAUTION Open the closure of the inspection hole only when the container is depressurized! Reduce the fill level before opening, as the material expands! -
Page 33: Proportioning Pump
Description Temperature control A thermostats are attached to the pres- sure vessels, which allows the tem- perature of the water heating to be regulated. The actual temperature can be read on the compressed air regulation unit (see section 3.4.2 on page 21). The agitators installed in the pressure vessels ensure an even heat and con- sistency of the material, not by stirring... -
Page 34: Material Fluid Heater
Description Each proportioning pump consists primarily of the air motor and the fluid pump. The rotary encoder translates the stroke movement of the proportion- ing pump into electrical impulses and sends these to the machine controls as a basis for the volume measurement. Designation Air motor Compressed air shut-off... -
Page 35: Proportioning Unit
Description Observe and follow the separate operation manual for the material heater. 3.5.6 Proportioning unit The hose bundle is connected to the proportioning unit, which serves as a material connection to the external mixing unit. The levers for opening and closing the return ball valves and the material outlets to the hose bundle as well as the shut-off valves for the supply and return of the hose bundle heating are located here. -
Page 36: Mixing Unit
Description 3.5.7 Mixing unit The external mixing unit is connected to the proportioning unit on the frame of the machine via a hose bundle. The material flows unmixed up to the mixing unit. The external mixing unit features five levers that can be used to activate the ball valves of the mixing unit: Function Spraying... -
Page 37: Flushing Unit
Description Flushing Open and close the flushing valves multiple times in alternation during flushing to ensure that each component is flushed out separately. Finally, flush with both ball valves simultaneously. You can extend the life span of the ball valves if the levers are not activated while the pressure is high and are always pushed to the end stops in the desired position. -
Page 38: Flush Pump
Description 3.6.1 Flush pump During flushing mode, the flush pump moves the flushing agent out of the flushing agent container via the hose bundle and the mixing unit to the spray gun. The compressed air supply is set on the com- pressed air regulation unit. -
Page 39: Water Heating
Description Observe the following information during operation and maintenance of the tubular heater: During operation, the tubular heater and the sensor protective tube must be sufficiently surrounded by water on all sides. The heat-induced water flow may not be impeded. The ambient temperature on the housing may not exceed 80 °C. -
Page 40: Circulation Pump
Description 3.7.2 Circulation pump The circulation pump circulates the heated water in the circulation circuit. It is connected to the central compressed air supply. Its running speed is set on the compressed air regulation unit (section 3.4.2 on page 21). Fig. -
Page 41: Control Module
Control module 4 Control module After switching on the machine, the touch screen for the control module initially displays the start screen. After a few seconds, it automatically switches to the overview. The overview is the basic display for the controls. Fig. -
Page 42: Status Display
Control module 4.1.1 Status display The controls signal certain operating via the status display. The following symbols can appear: A fault (alarm) exists. The machine is flushed. The pot life has expired. A material drum is emptied to the minimum quantity. If multiple operating states are present simultaneously (e. -
Page 43: Navigation
Control module 4.1.3 Navigation The individual menu windows can be selected via the corresponding buttons in the overview, main menu, or set-up menu. Furthermore, the following standard functions are available for navigation in the menu structure: Home: return to the basic display (overview) Level up: change to the next higher menu level Forward: page forward on the same menu level Back: page back on the same menu level... - Page 44 Control module Operate the touch screen only with your fingers or with a suitable stylus! Other objects (e. g. screwdriver) damage the touch screen. The control buttons are identified through the following symbols: Symbol Meaning Alarm Alarm history Ratio check Data log Timer or date and time Diagram...
- Page 45 Control module Symbol Meaning Mixing ratio Info Control measurement Recipes Service Set-up Flushing program Valve management Counter Original Operation Manual ✓(2024/11/25), Status: 2024/11/25 2fm2pfp_BA_en_B0550105...
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Page 46: Menu Structure
Control module 4.2 Menu structure The controls are divided into two areas: 1. the general operating area, accessible via the overview menu and 2. the password-protected settings area, accessible via the main menu. Original Operation Manual ✓(2024/11/25), Status: 2024/11/25 2fm2pfp_BA_en_B0550105... -
Page 47: Operating Area
Control module 4.2.1 Operating area WIWA Start screen Language automatic Mixing ratio Overview Diagram Fill mea- Control Supply oper- suring cup measurement ating mode A 82 - B 83 Alarms Main menu Pumps A 84 - B 85 Supply tem-... -
Page 48: Settings Area
Control module 4.2.2 Settings area Manual valve controls Fill level 1-3 Fill level 4-6 Fill level 7-9 Fill level 10 Filling 1 setup Filling 2 setup Set date/time Ratio check A Ratio check A Flushing measured measuring cup parameters volume Ratio check B Ratio check B Setup 1... -
Page 49: Operating Area
Control module 4.3 Operating area All operating functions can be performed with the buttons in the overview and in the main menu, as well as with the buttons on the control cabinet. 4.3.1 Overview Fig. 33: Overview Designation Display of the mixing ratio Display of the pending material pressure Display of the material temperature Display of the remaining pot life... -
Page 50: Main Menu
Control module 4.3.2 Main menu Designation Display current alarm (if present) Timer Control measurement Information for the mixing ratio and volume Language selection Display alarm history Recipe selection Settings area (only with pass- word) Day, total and lot counters Fig. 34: Main menu Info (software versions of the display and the controls) 4.3.3 Alarms... - Page 51 Control module to check the proportioning pumps and dosing valves for proper function. To complete a control measurement, the machine must be filled with processing material and ventilated. 1. Ensure that a sufficient quantity of measuring cups are available, the compressed air regulator of the proportioning pumps is turned down completely, the return flow ball valves are closed and the compressed air shut-off valves at the proportioning pumps that are used...
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Page 52: Detail View Of Mixing Ratio And Volume
Control module 9. Check whether the displayed values for volumes/weight match the actual filling quantities, whether the filling quantities of both components match the mix- ing ratio specified in the recipe. Fig. 38: Display during control measurement If this is not the case, the proportioning pumps of the components used in the current recipe need to be calibrated (see section 4.4.2 on page 53). -
Page 53: Alarm History
Control module The menu language for the controls can be set in the language selection. To open the language selection, press the button displayed on the left in the main menu. The menu languages available are listed in the language selection. You can scroll up or down in the list using the arrow keys. -
Page 54: Information
Control module The consumption of VOC solvents (VOC = Volatile Organic Compounds) can be found in the column “VOC”. When resetting a day or lot counter, this value is also reset to “0”. The arrow buttons can be used to page forwards and backwards between both menu windows. -
Page 55: Datalogger (Optional)
Control module 4.3.11 Datalogger (optional) With the WIWA Datalogger, the operating data of the machine can be reported on a job-related and user-related basis. To open the menu window for reporting the operating data, press the button displayed on the left in the overview menu. - Page 56 Control module Fig. 46: Diagram The current operating mode can be seen by means of the colored background of the machine components: Color Operating mode gray Automatic mode ⇒ Off Manual mode ⇒ Off blue Automatic mode ⇒ On green Machine component ⇒...
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Page 57: Settings Area
Fig. 47: Notice of operating mode Please note that this menu is password-protected and may only be accessed by authorized persons. The responsible personnel have the password. If it is lost, please contact WIWA. Original Operation Manual ✓(2024/11/25), Status: 2024/11/25 2fm2pfp_BA_en_B0550105... -
Page 58: Keypads
Fig. 48: Password entry Function Ratio check Set up flushing program Set up valve management Setting the date and time Change to the service area (only accessible by WIWA technicians) Manual valve controls Recipe management Filling setup Fig. 49: Settings menu 4.4.1 Keypads... -
Page 59: Ratio Check
Control module Function Home Move cursor to the first position Move cursor to the last position Delete to right Delete to left » Move cursor right « Move cursor left Shift Select the character at the top of the button (capital letters) Confirm entry (enter) Delete all (clear) 4.4.2 Ratio check... -
Page 60: Flushing Parameters
Control module 5. Upon request from the controls, fill a certain amount of material into a measuring cup via the ratio check valves (normally 1000 ccm / 1 kg) and acknowledge this step with ⇒. 6. Close the ratio check valves as soon as the filling process is ended. -
Page 61: Valve Management
Control module The flushing parameters are entered step by step. First, enter the volume or the duration of the respective work step in ccm or seconds. By clicking the button behind the input field, the unit can be switched between “sec” and “ccm”. -
Page 62: Date And Time
Fig. 57: Setting the date and time 3. Confirm the entry with “Enter”. 4.4.6 Service Access to the service area is reserved only for WIWA technicians. 4.4.7 Manual valve controls To open the menu window for the manual valve controls, press the button dis- played on the left in the settings menu. -
Page 63: Recipe Management
Control module At the beginning and end of the functional check for a material valve, the flushing valves must always be activated to avoid a possible chemical reaction among remaining material components. 4.4.8 Recipe management Before you can set up the recipe, the data of the valve/pump combination used in the machine must be recorded in the valve management. -
Page 64: Filling Parameters (Filling Setup)
Control module Press the “Save” button to save your entries. 4.4.9 Filling parameters (filling setup) To open the menu window for entering the filling parameters, press the button displayed on the left in the settings menu. The following data is entered in this menu window: Spraying hose volume: The vol- ume of the spraying hose used. -
Page 65: Transport, Installation, And Assembly
Transport, installation, and assembly 5 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. 5.1 Transport Fig. 61: Transport equipment of the FLEXIMIX GX PFP Designation Shackle with threaded bolt Drawbar (optional) -
Page 66: Installation Site
Transport, installation, and assembly When transporting the machine, observe the following information: When loading the machine, ensure sufficient load-bearing capacity of the lifting gear and lifting accessories. The dimensions and weight of the machine can be found on the machine card and type plate. When using a crane, the machine may only be lifted at the shackles. -
Page 67: Assembly
Transport, installation, and assembly Safety measures at the installation site: Position the machine horizontally on a floor that is level, firm and free of vibrations. The machine may not be tilted or tipped. For the model with wheels: Fasten the machine to its installation site, in order to secure it against unintended movement. -
Page 68: Connecting The Hose Bundle
Transport, installation, and assembly Carry out further assembly work and establish the connections in accordance with the descriptions below. 5.3.1 Connecting the hose bundle The hose bundle establishes the connection from the proportioning unit on the machine to the mixing unit. Material hoses for components A and B, the flushing agent hose, and the ring line for the hose bundle heating are located in the hose bundle. -
Page 69: Connecting The Spraying Hose And Spray Gun
Transport, installation, and assembly 5.3.2 Connecting the spraying hose and spray gun WARNING Parts that are not designed for the maximum permissible working pressure of the machine may rupture and cause serious injuries. Prior to installation, check the maximum permissible working pressure of the spraying hose and the spray gun. -
Page 70: Connecting The Compressed Air Supply
Transport, installation, and assembly 5.3.4 Connecting the compressed air supply CAUTION Lines laid on walking surfaces are a tripping hazard capable of causing injuries to the operating personnel. Place the compressed air line so that a tripping hazard for the operating personnel cannot result. -
Page 71: Connecting The Power Supply
Transport, installation, and assembly 5.3.5 Connecting the power supply WARNING If untrained personnel carry out work on the electrical installation, they endanger themselves and others, as well as risking the operational safety of the machine. The machine may only be connected to the electric power supply by specialist personnel with an electrical qualification. -
Page 72: Operation
Operation 6 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 9.3 on page 99). -
Page 73: Switching On The Machine
Operation 6.1.1 Switching on the machine 1. Make sure that all compressed air shut-off valves are closed and all compressed air regulators are turned all the way down. 2. Switch the machine on with the master switch on the control cabinet. Fig. -
Page 74: Flushing Out The Remains Of The Test Substance
Operation The machine is designed for flushing with water. For flushing with solvents, the corresponding attachment kit is required. 2. Activate the water heating at the control cabinet. 3. If you are using water as the flushing agent: Set the desired flushing agent temperature at the thermostat for the flushing agent container. - Page 75 Operation The hose bundle heating is supplied from the pressure vessel A (see section 3.7.1 on page 33). A conversion kit is available from WIWA to operate it with water from the flushing circuit. CAUTION Heating solvents can lead to an explosion. Serious personal injuries and property damage may result.
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Page 76: Filling The Pressure Vessels With Processing Material
Operation 5. Set a low pressure on the compressed air regulator cluster for the water heating so that the heating water circulates slowly in the system. 6. Set the compressed air regulator for the proportioning pumps such that the proportioning pumps run slowly. 7. -
Page 77: Setting The Stroke Limit Of The Hardener Dosing Valve
Operation 7. Set the running speed for the agitator with the adjusting screw at the air intake of the agitator. 8. Set a pressure of 1–2 bar at the compressed air regulator for the feed pump. The processing material is then pumped into the pressure vessel for component B. To completely fill the pressure vessel with material, you will need several buckets of component B. -
Page 78: Performing The Control Measurement
Operation 6.1.8 Performing the control measurement At the end of commissioning, perform a control measurement to check the mixing ratio between components A and B and the proper function of the proportioning pump. To complete a control measurement, the machine must be filled with processing material, heated and ventilated. - Page 79 Operation Only operate the machine with as much pres- sure as required, in order to attain good atom- ization at the recommended spray distance of approx. 30 –40 cm (12”-16”). An overly high spraying pressure increases material consumption and paint mist. If the spraying pressure is too low, this leads to streaking and varying coating thickness.
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Page 80: Tips For Good Coatings
Operation 6.2.2 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 81: Changing The Material Drum
Operation 6.2.3 Changing the material drum 1. Set the control lever of the respective ram to “Stop”. 2. Close the compressed air shut-off valve of the feed pump. 3. Open the shut-off valve for the container ventilation. 4. Set the control lever of the ram to “ ”. -
Page 82: Cleaning The Static Mixer
Operation 6.4 Cleaning the static mixer Daily maintenance includes manually cleaning the static mixer. Preferably, this is performed after the flushing process described in section 6.3. WARNING All maintenance work requires a completely depressurized machine. 1. Unscrew the spraying hose from the static mixer. 2. - Page 83 Operation 4. Place the flushing agent container on the centering under the feed pump. 5. Open the venting ball valve on the follower plate for component B. 6. Set the control lever on the ram for component B to “ ”.
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Page 84: Material Change
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 85: Work Interruption
Operation WARNING If parts of the machine are blocked (e. g. spray nozzle, material filter for the spray gun, material hose, suction screen, etc.), it is not possible to fully relieve the pressure. During disassembly work, residual pressure may escape and cause serious injuries. -
Page 86: Storage
Operation 6.10 Storage The location for storing the machine must be clean, dry, frost-free and protected against direct sunlight. Storage temperature: minimum: 0 °C or 32 °F maximum: 40 °C or 104 °F 6.11 Disposal Residues of processing material, flushing agents, oils, greases and other chemi- cal substances must be collected according to the legal regulations for recycling or disposal. -
Page 87: Maintenance
Maintenance and repair work on electrical parts may only be performed by specialist personnel with electrical qualifications — all other maintenance and repair work may only be done by WIWA customer service or specially trained personnel. WARNING During maintenance work, ignition sources may arise (e. -
Page 88: Regular Testing
The results of the tests must be recorded in writing and stored until the next test. 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). 7.2 Maintenance schedule The information in the maintenance schedule constitutes recommendations only. -
Page 89: Maintenance Unit
Maintenance Time frame Activity for further reading Every 50 operating Check release agent section 7.6 on page 87 hours of the dosing valves for material residues Every 3 months Lubricate the toothed section 7.5.2 on page wheels and pinions of the rotary encoder Every three years Inspection of the com-... -
Page 90: Safety Valve
Maintenance Any condensation water that occurs is semi-automatically drained via the drain valve. For this purpose, route the hose into an empty collecting vessel. 1. Route the hose into an empty collecting vessel. The drain valve opens as soon as the compressed air shut-off valve is closed. 2. -
Page 91: Replacing The Safety Valve
Maintenance Description Hexagon nut Knurled nut This is how to check the function of the safety valve: Safety valves with a ” connection: 1. Increase the air inlet pressure on the completely filled machine briefly to approx. 10 % over the maximum permissible pressure according to the type plate. The safety valve must discharge! Safety valves with a ”... -
Page 92: Proportioning Pumps
Maintenance 7.5 Proportioning pumps To prevent damage due to material hardening at the proportioning pumps, the release agent chambers of the fluid pumps must be filled with release agent to soften the material. Depending on the characteristics of the material to be processed, signs of wear will appear on the fluid pump packing after a certain time in operation. -
Page 93: Lubricating The Toothed Wheels And Pinions Of The Rotary Encoder
Next, apply acid-free grease to the toothed wheel and the pinion (see Fig. 76). Fig. 75: Protective plate Fig. 76: Toothed wheel and pinion We recommend using lubricant from WIWA (order no. 0000025). 7.6 Dosing valves In order to prevent damage to the dosing valves due... -
Page 94: Feed Pumps
Maintenance 7.7 Feed pumps To prevent damage to the feed pumps due to material hardening, the adjusting cups of the feed pumps must be filled with release agent to soften the material. The top packing of the feed pumps is adjustable and only requires replacement if material leaks out at the adjusting cup and it is no longer possible to adjust the packing. -
Page 95: Replacing The Top Packing Of The Feed Pumps
Maintenance 7.7.3 Replacing the top packing of the feed pumps You must have the top packing of a feed pump replaced if: material comes through into the release agent, release agent ejects from the packing (this is indicated by constant loss of release agent), the packing can no longer be adjusted, there is no play between the adjusting cup and the high pressure head. -
Page 96: Recommended Operating Fluids
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. 7.9 Recommended operating fluids Only use original operating fluids from WIWA: Operating fluid WIWA order number Release agent, yellow, standard (0.5 l)¹... - Page 97 Maintenance Designation Hook wrench 80/90 mm for assembly and disassembly of the fluid pumps Assembly aid for suspending the fluid pumps Jacket ring for needle change on automatic spray guns Pin for jacket ring Allen key 4.0 mm Allen key 5.0 mm Double-ended ring wrench 19/22 mm Double open end spanner 13/15 mm Single open end wrench 12 mm...
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Page 98: Eliminating Operational Faults
Clean return flow hose and re- valve blocked. turn ball valve and replace if necessary. Air motor defective. Repair air motor – request WIWA customer service if neces- sary. Main valve closed. Open main valve. Compressed air valve is not Enable compressed air valve. - Page 99 Eliminating operational faults fault possible cause remedy Proportioning pump runs, but no Material drum empty. Fill or replace material drum. material or too little material is Suction screen clogged. Clean suction screen, replace if transported. necessary. Suction hose blocked Clean the suction hose and replace as required The ball in the bottom valve Move the bottom valve to the...
- Page 100 Eliminating operational faults fault possible cause remedy Air leaks out of the relief bore of Grooved ring is leaking. Replace the grooved ring. the dosing valve. Ram does not carry out a lifting The air connection is not estab- Establish the air connection. movement.
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Page 101: Alarms
Eliminating operational faults 8.2 Alarms Alarm possible cause remedy Dosing error The mixing ratio deviates from Check: the target value (the actual mix- Is sufficient material in the ing ratio is displayed). containers? Is the mixing unit blocked? Switch the machine to flush- ing mode and check during alternating flushing if flushing agent is being transported... - Page 102 Eliminating operational faults Alarm possible cause remedy Stroke A/B up too quickly The proportioning pump se- For the A or B side proportioning lected according to the current pump, check: recipe on the A or B side exe- Is sufficient material in the cutes the upstroke too quickly.
- Page 103 Eliminating operational faults Alarm possible cause remedy Stroke A/B down too quickly The proportioning pump se- For the A or B side proportioning lected according to the cur- pump, check: rent recipe on the A or B side Is sufficient material in the executes the downstroke too container? quickly.
- Page 104 Eliminating operational faults Alarm possible cause remedy Remote control emergency stop The emergency stop plunger Check if the button has been button on the remote control has pressed. If safe operation is been pressed. ensured, acknowledge the alarm and unlock the emergency stop plunger button.
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Page 105: Technical Data
Technical data 9 Technical data You can find the technical data for your machine on the machine card enclosed, on the type plate or in the documentation for the individual components. 9.1 Emission sound pressure level in the workplace Sound pressure level L at 15 DS with 8 bar 84.5 Sound power level L... -
Page 106: Main Type Plate
QR code 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.g. smartphone, tablet). -
Page 107: Hose Volume
Technical data 9.3.3 Hose volume A hose volume is calculated using the following formula: �� ∗ �� ∗ �� �� �� = �� = hose volume = inner diameter of the hose �� �� �� = hose length The following table shows the volume of conventional hoses: ��... - Page 108 Technical data �� �� �� �� �� �� �� �� 6 mm 40 m 1131 ml 16 mm 40 m 8042 ml 6 mm 50 m 1414 ml 16 mm 50 m 10053 ml 8 mm 251 ml 20 mm 1571 ml 8 mm 7.5 m...
- Page 109 Technical data Original Operation Manual ✓(2024/11/25), Status: 2024/11/25 2fm2pfp_BA_en_B0550105...
- Page 110 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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