Practical Guide
WIWA DUOMIX HX: Hydraulic 2K System for High Pressures – Design, Setup & Workflow
If you process large quantities of material at high pressure and already operate a hydraulic system, the DUOMIX HX is a robust option: powerful, energy-efficient, low-maintenance – and featuring low pulsation due to fast stroke changeovers.
Note: All values in this guide – unless specified otherwise for a specific project – are to be understood as guidelines and must be cross-checked with the material data sheet/application.
Max. Operating Pressure (Guideline)
450 bar
For demanding 2K coatings with high pressure requirements.
Mixing Ratio (vol., Guideline)
1:1 – 10:1
Wide window for many 2K/multi-component systems.
Max. Output per Cycle (Guideline)
292 – 1100 cm³
Scalable depending on configuration & material requirements.
Product Overview: Variants, Applications, Benefits (Compact)
| Area | DUOMIX HX (hydraulic) | Practical Benefit |
|---|---|---|
| Drive / Integration | Hydraulic drive; integration into existing hydraulic systems possible | Ideal when compressed air is limited or a hydraulic infrastructure is already in place. |
| Pressure & Performance (Guidelines) | Up to 450 bar; Output per cycle 292–1100 cm³; Oil inlet pressure up to 200 bar | Reserve capacity for thick layers, high viscosities, and large surfaces. |
| Mixing Ratio (Guidelines) | Volumetric 1:1 to 10:1; Pressure ratio up to 4:1 | Flexible for different material systems – design is project-specific. |
| Pulsation / Handling | Low pulsation due to fast stroke changeover; quiet, "anti-icing" | Constant application, fewer surface defects, and more comfortable working conditions. |
| Typical Fields of Application | Fire protection, insulation, rail vehicle construction, mining, chemicals, apparatus/mechanical engineering, steel construction, offshore, wind power, pipes/pipelines, tunnels, industry | Effective when robust 2K application is required under "tough" construction site or industrial conditions. |
Values & application areas as an overview – final design depends on material, temperature, hose length, application type, and desired layer thickness.
Practical Tip (Quickly Implemented)
Plan the configuration not just based on "maximum pressure", but on stable process management:
Predefine the mix ratio, desired flow rate, and the working pressure range – then select the pump/output per cycle accordingly.
This reduces rework and avoids "at the limit" operation.
Configuration on Request – We Dimension to Match Your Material
The DUOMIX HX is available in many configurations. To ensure that mixture, pressure, and delivery rate truly match your material system, a brief project consultation is the fastest way to the correct design.
Recommended Basic Settings (Derived from Data – as Guidelines)
| Parameter | Guideline / Range | Why Relevant |
|---|---|---|
| Volumetric Mixing Ratio | 1:1 to 10:1 | Must match the material system (resin/hardener). Deviations lead to curing problems. |
| Pressure Ratio | up to 4:1 | Influences achievable working pressure and stability with high viscosities. |
| Max. Operating Pressure | up to 450 bar | Upper limit – in practice, a stable working range is defined project-specifically. |
| Output per Cycle | 292 – 1100 cm³ | Determines whether you reach the desired surface performance/layer thickness economically. |
| Oil Inlet Pressure | up to 200 bar | Limit value for hydraulic integration (dimensioning & protection). |
Important: These values are guidelines from manufacturer data. Actual process values depend on material viscosity, temperature, hose routing, and application tools.
Pro Workflow (5–7 Steps) for a Stable 2K Process
- Clarify material data: Target mixing ratio, pot life, recommended pressure range, temperature window, and permissible shear (data sheet/manufacturer).
- Select configuration: Choose output per cycle and mixing range so that your target delivery rate is achieved at a stable working pressure.
- Check hydraulic connection: Consider oil inlet pressure as well as supply/filtration/protection (observe limit values).
- Process check before start: Check tightness, filter condition, material supply, and perform a short ratio/flow check (preferably before starting on the component).
- Stabilize spray window: Adjust pressure/output so that the application runs smoothly and evenly (minimize pulsation, constant movement).
- Document & repeat: Note success parameters as job setup (material batch, temperatures, pressure range, mixing ratio, hose length).
- Plan cleaning/downtime: Perform appropriate cleaning and downtime routines according to runtime/pot life to keep the mixing zone clean.
Troubleshooting (4 Typical Problems + Measures)
1) Uneven Application / Visible Pulsation
- Stabilize working pressure range (do not run at the limit; design output appropriately).
- Check material supply & filters (undersupply creates pressure fluctuations).
- Optimize hose routing (avoid kinks, unnecessary length, sharp height changes).
2) Mixture Not Curing Properly / Sticky
- Check mixing ratio against data sheet (target ratio vs. set range).
- Check material temperature/environment (too cold can delay reaction).
- Exclude fresh batch issues / moisture entry (container handling & storage).
3) Pressure Drops / Delivery Rate Collapses
- Check hydraulic supply (oil pressure/volume flow during process).
- Check for blockage/filters/suction (tough material → fast filter buildup).
- Perform leakage search (couplings, seals, connections).
4) Streaky Surface / Uneven Layer
- Standardize movement/overlap (constant speed, defined paths).
- Stabilize viscosity & temperature (keep material in the optimal window).
- Coordinate delivery rate vs. application speed (too much/too little material per path).
Maintenance (5 Practical Points)
- Regularly check filters/material paths and replace based on contamination level (especially with high-viscosity systems).
- Periodically inspect seals, couplings, and connections for leaks.
- Keep the mixing area clean: plan downtime routines so that no reaction residues adhere.
- On the hydraulic side: keep supply, protection, and oil inlet pressure within the permissible range.
- Document job setups (parameters, material, environment): reduces restart times and troubleshooting.
FAQ (Practice-Relevant)
For which industries is the DUOMIX HX particularly useful?
Typical fields include fire protection, insulation, pipe/pipeline projects, offshore/wind power, steel and mechanical engineering, as well as tunnel and industrial sectors.
Which mixing ratios are possible?
Volumetrically, a range of 1:1 to 10:1 is provided. The specific target ratio always comes from the material data sheet and the application.
How high can the operating pressure be?
As a guideline, up to 450 bar is possible. In practice, a stable working range is defined that fits the flow rate, viscosity, and surface.
Can I integrate the DUOMIX HX into existing hydraulics?
Yes – the series is specifically designed to be integrated into existing hydraulic systems (consider limit values such as oil inlet pressure).
How do I choose the right power/output configuration?
Start from the desired surface performance (m²/h) and layer thickness. This determines the flow rate and stable pressure range – after which the output per cycle is chosen accordingly.
Conclusion
The WIWA DUOMIX HX is a hydraulic 2K system for applications where high pressure, high delivery rates, and robust process stability count. Those who design the process properly via mix ratio, working pressure range, and output get a powerful basis for demanding coating projects – ideally configured project-specifically.
Status: Manufacturer data/product page. Project-specific design may deviate (material, temperature, hose routing, application tools).
