Page 1
Translation of the Original
Operating Manual
For professional use.
Always follow the information in this manual,
particularly the safety instructions and the warning
instructions. Store the manual in a safe place.
2K COMFORT
Electronically Controlled
Multi-component System for
Lacquers
Software version 4.0x / 4.0x K
3.2x / 3.2x K
3.1x / 3.1x K
3.0x
Version 05/2017
B_05491
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VERSION 05/2017 ORDER NUMBER DOC 2357061
OPERATING MANUAL
Table of Contents
1 ABOUT THESE INSTRUCTIONS 7
1.1 Preface 7
1.2 Warnings, Notices and Symbols in these Instructions 7
1.3 Languages 8
1.3.1 Operating documents for individual components 8
1.4 USB Stick 2K COMFORT 9
1.5 Abbreviations 9
1.6 Terminology for the Purpose of this Manual 10
1.6.1 Low pressure / High pressure / XL 10
2 CORRECT USE 11
2.1 Device types 11
2.2 Type of Use 11
2.3 Field of application 11
2.3.1 Without Ex identication 11
2.3.2 With Ex identication 11
2.3.3 Accessories 12
2.4 Processible Working Materials 12
2.5 Misuse 12
3 IDENTIFICATION 13
3.1 Non-Ex System 13
3.2 Ex System 13
3.2.1 Control cabinet 13
3.2.2 Fluid section 13
3.2.2.1 Identication X 14
3.2.3 Use in areas subject to explosion hazards 14
3.3 Remote control (option) 15
3.4 Type plates 16
3.4.1 Control cabinet 16
3.4.2 Fluid section 16
4 BASIC SAFETY INSTRUCTIONS 17
4.1 Safety instructions for the operator 17
4.1.1 Electrical devices and equipment 17
4.1.2 A safe work environment 17
4.1.3 Personnel qualications 18
4.2 Safety instructions for sta 18
4.2.1 Use personal safety equipment 19
4.2.2 Safe handling of WAGNER spray devices 19
4.2.3 Ground the unit 20
4.2.4 Product hoses 20
4.2.5 Cleaning and Flushing 21
4.2.6 Touching hot surfaces 22
4.2.7 Maintenance and repair 22
4.2.8 Protective and monitoring equipment 22
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5 DESCRIPTION 23
5.1 Components 23
5.2 Mode of operation 23
5.3 Protective and monitoring equipment 24
5.4 Included items 24
5.5 Data 25
5.5.1 Technical data 25
5.5.1.1 Limitations for 2-circuit systems 28
5.5.2 Dimensions 29
5.5.3 Working areas of ow meters 30
5.5.4 Application limits of ow meters 32
5.6 Mixing types 34
5.7 Dump valve for waste separation (option) 37
5.8 AIS dosing system (option) 37
5.9 2-circuit system 37
5.10 Flow measurement 38
5.10.1 Flow meters 38
5.10.2 Stroke measuring 39
5.10.3 Flow meters and stroke sensors 40
6 ASSEMBLY AND COMMISSIONING 41
6.1 Training of Assembly/Commissioning Sta 41
6.2 Storage and installation conditions 41
6.3 Transportation 41
6.4 Assembly and Installation 41
6.4.1 Electrical connections 43
6.4.2 Pneumatic connections 43
6.4.3 Product connections 43
6.4.4 Flow meter monitoring 44
6.4.5 Lack-of-product protection 44
6.4.6 Ventilation of the spray booth 45
6.5 Grounding 45
6.6 Commissioning 48
6.6.1 Pre-cleaning 48
6.6.2 Initializing the controller 49
6.6.3 Venting the system 50
6.6.4 Pressure tightness test 50
6.6.5 Filling the system 51
6.6.6 Electrostatics 51
7 CONTROLLER 52
7.1 Training the operating sta 52
7.2 Safety instructions 52
7.3 Control cabinet 53
7.3.1 Main switch 53
7.4 Mechanical push-buttons 54
7.5 Operating panel basics 54
7.5.1 Select language 55
7.5.2 Keyboard input 55
7.5.3 Passwords 56
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7.6 Home page 56
7.6.1 Changing the paint recipe 56
7.6.2 Home page operation 57
7.7 Menu 58
7.8 Manual mode: open valves 59
7.9 Recipes 60
7.9.1 Add new recipes 60
7.9.2 Changing recipe and valve names 60
7.10 Enter ushing recipe 61
7.11 Enter paint recipe 62
7.12 Calibration 64
7.13 Settings 66
7.13.1 Password level 2 settings 66
7.13.2 Password level 3 settings 69
7.14 Operating panel for 2-circuit system 73
7.14.1 Change uid circuit 73
7.14.2 /K1 and /K2 74
7.14.3 Acknowledge alarms 74
7.14.4 White background: aects both uid circuits 74
8 OPERATION 75
8.1 Training the operating sta 75
8.2 Safety instructions 75
8.2.1 Emergency Deactivation 75
8.2.2 General rules for making adjustments to the spray gun 75
8.3 Switches the system on and o 76
8.4 Malfunction 76
8.5 Spraying mode 77
8.5.1 Prerequisites 77
8.5.2 A/B/C/D pressure ratio 77
8.5.3 Spraying without gun ush box 78
8.5.4 Spraying with gun ush box 79
8.5.5 Interrupting work 79
8.5.6 Changing the paint recipe 79
8.5.7 A valve selection at start 79
8.5.8 Circulation (option) 79
8.6 Flushing 80
8.7 Flow chart with paint recipe change 83
8.8 Pressure relief procedure 84
9 CLEANING AND MAINTENANCE 85
9.1 Cleaning 85
9.1.1 Cleaning sta 85
9.1.2 Safety instructions 85
9.1.3 Filter cleaning 85
9.1.3.1 Condensate drainage from the lter pressure regulator 85
9.1.4 Cleaning the system 86
9.1.5 Decommissioning 86
9.1.6 Long-term storage 86
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9.2 Maintenance 87
9.2.1 Maintenance sta 87
9.2.2 Safety instructions 87
9.2.3 Gear ow meter 88
9.2.4 Cleaning and replacing the product lter 89
9.2.5 Product valves 89
9.2.6 Product Hoses, Tubes and Couplings 90
10 TROUBLESHOOTING 91
10.1 Alarm messages 93
10.1.1 Fault rectication 98
10.2 Warning messages 105
10.2.1 Fault rectication 106
11 REPAIRS 107
11.1 Repair Sta 107
11.2 Safety instructions 107
11.3 Mounting materials 108
12 DISPOSAL 109
13 ACCESSORIES 110
13.1 Connections 110
13.1.1 I/O extension module 110
13.2 Connection table 2K COMFORT 111
13.3 Control cabinet diagrams 112
13.4 Expansion and accessory sets 112
13.4.1 Installation by customer or by WAGNER service department 113
13.4.1.1 Stroke measuring 115
13.4.2 Installation by WAGNER service department 115
13.4.2.1 AIS 116
13.4.3 Accessories sets for external ushing agent 117
13.5 Remote control (option) 117
13.5.1 Remote control assembling 118
13.5.1.2 Assembly on Control Cabinet 118
13.5.1.3 Testing and Commissioning 118
13.5.2 Safety Instruction Remote Control 119
13.5.3 Operation 120
14 SPARE PARTS 121
15 DECLARATION OF WARRANTY AND CONFORMITY 122
15.1 Important notes on product liability 122
15.2 Warranty claim 122
15.3 EU Declaration of Conformity for 2K COMFORT 123
15.4 EU Declaration of Conformity for 2K COMFORT (with Ex identication) 124
15.5 EC Declaration of Conformity for remote control 125
16 APPENDIX 126
16.1 Conversion of the mixing ratio specications 126
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1 ABOUT THESE INSTRUCTIONS
1.1 PREFACE
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device.
The operating manual is part of the device and must be available to the operating and
service personnel.
The device may only be operated by trained personnel and in compliance with this
operating manual.
Operating and service personnel should be instructed according to the safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this operating manual highlight particular dangers to users and to
the device and state measures for avoiding the hazard. These warning instructions fall into
the following categories:
DANGER
WARNING
CAUTION
NOTICE
Note
Explanation of warning:
Immediate risk of danger.
Non-observance will result in death or serious injury.
Potential risk.
Non-observance may result in death or serious injury.
Potentially hazardous situation.
Non-observance may result in minor injury.
Potentially hazardous situation.
Non-observance may result in damage to property.
Provides information about particular characteristics and how
to proceed.
LEVEL OF DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The measures for preventing the hazard and its consequences.
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1.3 LANGUAGES
The 2K COMFORT Operating Manual is available in the following languages:
Language Order No. Language Order No. Language Order No.
German 2357060 English 2357061 Spanish 2357065
French 2357062 Italian 2357064 Chinese 2357078
Dutch 2357063 Swedish 2357067 Japanese 2367166
Polish 2357075 -- -- -- --
2K COMFORT Software Documentation
Language Order No.
German 2357082
English 2357084
2K COMFORT Spare Parts Catalog 2K COMFORT XL Spare Parts Catalog
Language Order No. Language Order No.
German 2357085 German 2363593
English 2357086 English 2363595
Additional languages on request or at: www.wagner-group.com
1.3.1 OPERATING DOCUMENTS FOR INDIVIDUAL COMPONENTS
Paint valves (PV) and dosing valves (DV), GA (DN 2.6) operating manual
Language Order No. Language Order No. Language Order No.
German 2343270 English 2343275 Spanish 2343278
French 2343276 Italian 2343277 -- --
Paint valves (PV) and dosing valves (DV), GA (DN 4) operating manual
Language Order No. Language Order No. Language Order No.
German 2336797 English 2336798 Spanish 2336801
French 2336799 Italian 2336800 -- --
ADC-0301 / MPX-0403 operating manual (for stroke measurement)
Language Order No. Language Order No. Language Order No.
German 2382346 English 2382349 Spanish 2382352
French 2382350 Italian 2382351 -- --
User information for Coriolis Compact
Language Order No. Language Order No. Language Order No.
German 2359722 English 2359725 Spanish 2359730
French 2359727 Italian 2359728 -- --
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T0170.00BI pressure regulators operating manual
Language Order No. Language Order No. Language Order No.
German ZZB019GER English ZZB019ENG Spanish ZZB019SPA
French ZZB019FRE Italian ZZB019ITA -- --
2K Data 2K Archive
2K Data software documentation 2K Archive software documentation
Language Order No. Language Order No.
German 2382353 German 2361954
English 2382354 English 2361978
The 2KData software is contained on the
2KSMART USB stick (see Chapter 1.4).
Purpose: Transfer system settings, names, paint
and ushing recipes and the I/O conguration
via USB stick to the PC. View or change data on
the PC.
The 2KArchive software is available as an accessory.
Purpose:
Log and archive consumption data and error messages
on the PC.
Additional languages on request or at: www.wagner-group.com
1.4 USB STICK 2K COMFORT
All operating documents specied above, as well as the accessory set's assembly manuals
(with the description of the accessory's function) are also available as pdf les on a USB
stick. The USB stick is included in the system's scope of delivery.
The Order No. is: 2359808 (specify additionally the Serial No. of the system)
1.5 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part
One component
Two components
Three components
Q Flow
cc Cubic centimeters (cm
Spray gun 1
Spray gun 2
Spray gun 3
Spray gun 4
Fluid circuit 1 (in 2-circuit system)
Fluid circuit 2 (in 2-circuit system)
Four components
Double stroke
Nominal diameter
HP High pressure
Materials
Stainless steel
Polyethylene
Ultra-high molecular weight polyethylene
Polytetrauorethylene
AIS for component B
Carbide
AIS for component C
AIS for component D
3
)
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1.6 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Sta qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Electrically trained
person
Electrician Can assess the work assigned to him/her and detect possible
Skilled person in
accordance with TRBS
1203
(2010/Revision 2012)
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as
well as the necessary protective devices and measures.
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
A person who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge and is familiar with the relevant and generally
accepted rules of technology so that he/she can inspect and
assess the status of devices and coating systems based on
workplace safety.
1.6.1 LOW PRESSURE / HIGH PRESSURE / XL
These operating manual dierentiates for purposes of illustration between 2K COMFORT
low-pressure, high-pressure and XL version:
Maximum product pressure Maximum ow rate Fluid cabinet
Fluid section type plate, Ex
Low-pressure version up to 2.5 MPa; 25 bar; 362 psi
High-pressure version up to 32.5 MPa; 325 bar; 4,714 psi
XL version up to 53 MPa; 530 bar; 7,687 psi up to 25,000 cc/min 800 x 1,200 mm
Fluid section type plate,
Ex
up to 7,000 cc/min 800 x 800 mm
Width x height
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2 CORRECT USE
2.1 DEVICE TYPES
a) 2K COMFORT
b) 2K COMFORT (with Ex identication)
The 2K COMFORT system is also available as a 2-circuit system (1 control cabinet, 2 uid circuits).
2.2 TYPE OF USE
The device is suitable for mixing 2K, 3K and 4K liquid products such as paints and lacquers.
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Only operate the device as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
Follow the instructions in the operating manual.
2.3 FIELD OF APPLICATION
2.3.1 WITHOUT EX IDENTIFICATION
The control cabinet and the uid section may not be used in potentially explosive areas.
Remote control: The remote control (accessory) may always be used in potentially
explosive areas (zone 1 and zone 2).
See chapter 6.5.
2.3.2 WITH EX IDENTIFICATION
Control cabinet
The control cabinet may not be used in potentially explosive areas.
Fluid section
The 2K COMFORT uid section (with Ex identication) is suitable for use in potentially
explosive areas (zone 1 and zone 2)
See chapter 6.5.
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2.3.3 ACCESSORIES
Remote control
The remote control may be used in potentially explosive areas (zone 1 and 2).
See chapter 6.5.
Alarm horn
The alarm horn may be used in potentially explosive areas (zone 1 and 2).
2.4 PROCESSIBLE WORKING MATERIALS
Low-viscosity to high-viscosity 2K/3K/4K lacquers (e.g., epoxy, PU, DD) with a pot life of
more than 5 minutes.
− 2K water-based primer − 2K epoxy primer
− 2K solvent-based primer − 2K epoxy lacquers
− 2K PUR primer − 2K high solid primer
− 2K PUR lacquers − 2K high solid lacquers
− 3K and 4K combinations of above products
Solvent and water-based 2K products should not be processed using the same
system.
NOTICE
Abrasive working materials and pigments!
Greater wear of parts carrying the product.
Do not use any grainy and abrasive working materials with large, sharp-edged
pigments.
Use application-oriented pumps (ow rate/cycle, product, valves, etc.).
Check if the uids and solvents used are compatible with the pump construction
materials.
For explanations of the models and construction materials, consult the technical
data in Chapters 5.5.4 as well as the operating manuals for the pumps and valves or
contact a WAGNER service technician.
Wear caused by abrasive working materials is not covered by the warranty.
Materials in direct contact with the products
Stainless steel Carbide PTFE PE (UHMWPE)
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
No dry coating products, e.g. powder are processed;
No food, medicine or cosmetics are processed.
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3 IDENTIFICATION
3.1 NONEX SYSTEM
The 2K COMFORT system is not suitable for use in potentially explosive areas.
3.2 EX SYSTEM
As dened in Directive 2014/34/EU the 2K COMFORT system (with Ex identication) is
suitable for use in potentially explosive areas.
3.2.1 CONTROL CABINET
The control cabinet may not be used in potentially explosive areas.
CE CE mark (European Communities)
Explosion-proof equipment
3.2.2 FLUID SECTION
The 2K COMFORT system's uid section (with Ex identication) is suitable for use in potentially
explosive areas (zone 1 and zone 2).
CE CE mark (European Communities)
Explosion-proof equipment
II Device class II (not mining)
2 Category 2 device
(suitable for zone 1)
G Ex-atmosphere gas
II Device class II (not mining)
() eective in zone ...
(2) eective in zone 1
G Ex-atmosphere gas
Protection provided by
constructional safety
IIB Device class (Gas) IIB
X Special instructions exist for safe
operation.
Chapter "Identication X".
See the following
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3.2.2.1 IDENTIFICATION X
Ignition temperature
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature of the work piece.
Ambient temperature
Permissible ambient temperature: +5 °C to +40 °C; +41 °F to +104 °F.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Surface spraying, electrostatics
Do not spray device parts using electrostatic equipment.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the device.
3.2.3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS
Safe handling of WAGNER spray devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the device or components against steel or rusty iron.
Do not drop the device or components.
Use only tools that are made of a permitted material.
National regulations
Ensure that the national explosion prevention rules and regulations are observed
when setting up the device.
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3.3 REMOTE CONTROL OPTION
The remote control (Order No. 2341153) may be used in potentially explosive areas (zone 1 and 2).
CE CE mark (European Communities)
0102 Number of the notied body
which is used by WAGNER in the
production monitoring phase
(PTB in this case)
Explosion-proof equipment
II Device class II (not mining)
2 Category 2 device (suitable for
zone 1)
G Ex-atmosphere gas
Safety instructions
For safe operation, observe the safety data in Chapter 13.5.2.
Ex Electrical device corresponds to
ignition protection type
d Ignition protection class "Flame-
proof enclosure" EN 60079-1
IIB Device class (Gas) IIB
T6 Temperature class T6: maximum
surface temperature 85 °C; 185 °F
Gb Device protection level
suitable for use in Zone 1
CML 13 ATEX 1008X
ATEX certicate number
,
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B_05486
B_06264
OPERATING MANUAL
3.4 TYPE PLATES
3.4.1 CONTROL CABINET
Wagner International AG
1
Gerätetyp / Type:
2
3
El. Anschluss Spannung / Connection voltage
El. Anschluss Frequenz / Connection frequency
4
Anschlussleistung / Connection Power
5
Schutzart / Protection class
6
Temperatur Umgebung / Ambient temperature
7
Baujahr - Serie Nr. / Year of manufacture - Serial No.
8
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
9
CH-9450 ALTSTÄTTEN
MADE IN SWITZERLAND
2K Comfort Control unit
Only for a system with Ex identication:
II (2) G
Designation
1 Manufacturer and CE Identication
2 Device type: 2K COMFORT control cabinet
3 Electrical connection: voltage
4 Electrical connection: frequency
5 Connection power
3.4.2 FLUID SECTION
Wagner International AG
1
Gerätetyp / Type: 2K Comfort Fluid unit
2
3
Materialmenge pro Minute / Fluid volume per minute
Materialdruck / Fluid pressure
4
Luftdruckversorgung / Air pressure supply
5
Temperatur Material / Fluid temperature
6
Temperatur Umgebung / Ambient temperature
7
Baujahr - Serie Nr. / Year of manufacture - Serial No.
8
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
9
CH-9450 ALTSTÄTTEN
MADE IN SWITZERLAND
Designation
1 Manufacturer and CE Identication
2 Device type: 2K COMFORT uid section
3 Flow rate per minute
4 Product pressure
5 Air pressure supply
Designation
6 Protection class
7 Ambient temperature
8 Manufacturing year and serial number
9 Read operating manual before use!
Only for a system with Ex identication:
II 2G c IIB X
Designation
6 Product temperature
7 Ambient temperature
8 Manufacturing year and serial number
9 Read operating manual before use!
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4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Electric shock hazard!
Danger to life from electric shock
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, there is a danger from line voltage.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if it poses a hazard or is damaged.
Must be de-energized before work is commenced. Inform sta about planned work.
Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground
wire connection.
Keep liquids away from electrical devices.
4.1.2 A SAFE WORK ENVIRONMENT
Hazard due to dangerous uids or steam!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working are is static dissipative in accordance
withEN61340-4-1 (resistance must not exceed 100 M).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g. mechanical
stress, corrosion).
Ensure that product / air hoses adapted to the working pressure are used.
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Ensure that personal protective equipment (see section 4.2.1) is available and is
used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 M.
Ensure that during spraying, persons wear electrically conductive gloves. The grounding
takes place via the spray gun handle or the trigger.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 M.
Ensure that there are no ignition sources such as naked ames, sparks, glowing
wires, or hot surfaces in the vicinity. No smoking.
Ensure that the pipe joints, hoses, equipment parts and connections are permanently,
technically leak-proof:
– Periodic preventative maintenance and service (replacing hoses, checking
tightness strength and connections, etc.)
– Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g., daily before commissioning, at the end of work or weekly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Hazard due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.
4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.
In electrostatics application: anyone tted with a pacemaker must not enter the highvoltage area!
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4.2.1 USE PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or steam!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
When preparing or working with paint and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents, and cleaning
agents being used.
Take the specied protective measures. In particular wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient health and environmental safety: Operate the device in a spray booth or
on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.
4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Hazard due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint
or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
– Disconnect the control unit from the mains.
– In the event of functional faults: remedy the fault as described in the "Troubleshooting"
section.
If needed, the liquid ejection devices must be checked by experts (e.g., WAGNER
service technician) at least every 12 months for their work-safe condition in
accordance with DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36.
– For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure relief" section:
– If pressure relief is required.
– If the spraying work is interrupted or stopped.
– Before the device is cleaned on the outside, checked, or serviced.
– Before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
Danger due to recoil forces!
Actuating the trigger can causes strong recoil forces. Thereby the user can lose his balance
and injure himself during falling.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun briey in a position.
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4.2.3 GROUND THE UNIT
Hazard due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges.
Flames or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that all devices and tanks are grounded before each spraying process.
Make sure that the ground and potential equalization of all system parts are performed
reliably and continuously and can withstand the expected stress (e.g., mechanical
stress, corrosion).
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
Wear static dissipative gloves when spraying. The grounding takes place via the spray
gun handle or the trigger.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.
4.2.4 PRODUCT HOSES
Hazard due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
Ensure that the hose material is chemically resistant to the sprayed products and the
ushing agents used.
Ensure that the product hose and the ttings are suitable for the pressure generated.
Ensure that the following information can be seen on the high-pressure hose:
– Manufacturer
– Permissible operating pressure
– Date of manufacture
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
– in high traffic areas,
– on sharp edges,
– on moving parts or
– on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses
are never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Ensure that no work is ever performed with a damaged hose.
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 M.
Suction hoses may not be subjected to pressure.
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Several liquids have a high expansion coecient. In some cases their volume can rise with
consequent damage to pipes, ttings, etc. and cause uid leakage.
When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can
enter the tank. Thus a negative pressure is avoided. The vacuum could implode the tank
(squeeze) and can cause it to break. The tank would leak and the liquid would ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
4.2.5 CLEANING AND FLUSHING
Hazard due to cleaning and ushing
Explosion hazard and damage to the device.
Preference should be given to non-ammable cleaning and ushing agents.
When carrying out cleaning work with ammable cleaning agents, make sure that all
equipment and resources (e.g., collection tank, funnel, transport cart) are conductive
or static dissipative and grounded.
Observe the specications of the lacquer manufacturer.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical
ventilation.
Explosive gases are produced when aluminum comes into contact with halogenated
hydrocarbons. To clean aluminum, do not use liquids containing halogenated
hydrocarbons.
Take measures for workplace safety (see section 4.1.2).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
– Depending upon used coating product,
– Depending on the ushing agent (solvent) used,
an explosive mixture may temporarily exist inside the lines and items of equipment.
Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
Never spray into a closed tank when using solvents for ushing.
External cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Relieve the pressure from the device.
De-energize the device electrically.
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects
and never spray cleaning agents with a gun. Cleaning the device must not damage
it in any way.
Ensure that no electric component is cleaned with or immersed into solvent.
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4.2.6 TOUCHING HOT SURFACES
Hazard due to hot surfaces because of hot coating products!
Risk of burn injuries
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109 °F:
– Identify the device with a warning label, "Warning – Hot surface".
Instruction label: Order No. 9998910
Protection label: Order No. 9998911
Note: Order the two stickers together
4.2.7 MAINTENANCE AND REPAIR
Hazard due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in the 13"Spare parts" section and 14
that are assigned to the unit.
Do not use any defective components.
Exclusively use accessories listed in Chapter 13 and that are assigned to the unit.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
Observe the operating and service manual for all work.
4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
Hazard due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.
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5 DESCRIPTION
5.1 COMPONENTS
The 2K system is clearly structured. It can be controlled using easy-to-understand and
easily accessible operating elements.
Control cabinet
All electrical components are installed in the control cabinet. The system can be controlled
via the four push-buttons and the operating panel (touch screen). Information can be
displayed or be entered via the operating panel.
Fluid section
The uid section contains all parts which come into contact with the 2K products.
5.2 MODE OF OPERATION
The system is suitable for measuring (dosing) and for mixing two or multi-component
products.
An electronic controller monitors and regulates the predetermined ratio of
components. The controller regularly adds in the necessary quantity of hardener -in
short intervals (and by way of pulses)- via a valve to the ow of base lacquer.
The ow of the base lacquer and hardener is measured with ow meters. In the case
of piston pumps, stroke sensors can be used if desired.
The components and ushing agents are made available by supplying pumps or
pressure tanks (not supplied with the system).
Paint selection
The mixing ratio, pot life etc. are stored in the recipe. By means of a simple recipe change,
the paint can be changed.
Further characteristics and areas of application
For low to medium pressure (32.5 MPa; 325 bar; 4714 psi).
2K COMFORT XL for high-pressure (53 MPa; 530 bar; 7687 psi).
Modular structure - can be combined as required by the customer.
Electronic dosing precision guarantees consistent quality.
Processing even water-based 2K products, since all parts carrying the product are
suitable to do so - made, for example, of stainless steel.
The uid section of the Ex version is suitable for use in potentially explosive areas
(zone 1 and zone 2).
Many functions are displayed in a language-independent way with icons which are
easy to understand. Texts are displayed in the selected language.
The overview of consumption of each component and ushing agent, VOC documentation.
Storage of the last 700 error messages indicating date and time.
Security by permanently checking the system parameters, operator information, in
case of the slightest trouble, and if necessary, automatic interruption of the production.
Protection of the parameters by security code. Settings can be saved on a USB stick.
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Electronic adjustment of the mixing ratio between 0.1:1 and 50:1.
Up to 100 paint recipes. (Also with robot communication or Probus.)
Possibility of two separate uid circuits::
– for simultaneous operation,
– for quick paint changes,
– or to separate incompatible 2K products (e.g., PUR and epoxy lacquers).
Programmable ushing recipes to economize up to 60% of ushing agent compared
with previous systems.
Fully automatic control and monitoring of 1 to 4 guns.
The compatibility with solvent-based products and water-based products and
selective automatic cleaning with water and/ or solvent.
Use of hand or automatic spray guns.
Enabling of automatic booth, automatic gun ush box, etc.
Possibility of robot communication.
5.3 PROTECTIVE AND MONITORING EQUIPMENT
The following functions are provided for system safety:
– External release: e.g., interlock with spray booth's exhaust air
5.4 INCLUDED ITEMS
2K COMFORT scope of delivery Ex Non-Ex
Designation Order No. Order No.
Basic device - Control cabinet
- Fluid section
- Connection set
The scope of delivery of a basic device includes:
Declaration of Conformity. For details, see Chapter 15 2359625 2359623
Operating manual, German 2357060
Operating manual in the local language
The delivery note shows the exact scope of delivery.
- Control cabinet
- Fluid section
(Connection set only if
control cabinet and uid
section are separately)
see Chapter 1.3
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5.5 DATA
5.5.1 TECHNICAL DATA
Electrical
Voltage and frequency range 100–240 VAC / 120–350 VDC / 50–60 Hz + PE
Power consumption 60 W / 0.3 A
See electrical circuit diagram (delivered together with the system).
Pneumatic
Compressed air Inlet 0.7–0.8 MPa; 7–8 bar; 101–116 psi
Quality standard 7.5.4 according to ISO 8573.1, 2010
Air pressure quality:
free from oil and water
7: Particle concentration 5–10mg/m³
5: Humidity: pressure dew point ≤ +7 °C
4: Oil content ≤ 5mg/m
WARNING
Exhaust air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water.
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XL version
Low-pressure
version
Flushing agent: 0.8 MPa 32.5 MPa * 53 MPa * 40 MPa * 34.5 MPa *
Maximal inlet pressure
Compressed air ushing: 0.8 MPa
Maximal inlet pressure
Maximum inlet pressure of
components A/B/C/D. The
maximum pressure of the
pumps used may not exceed
this value.
Mixer product outlet 0.05–2.5 MPa *** 0.1–32.5 MPa 0.1–53 MPa 0.1–40 MPa 0.1–34.5 MPa
Application rate (depending
on the ow meters used, see
Chapters 5.5.3 and 5.5.4)
Product inlet (outside) G1/4" G3/8"
Product outlet (outside) G1/4" G3/8"
Viscosity of components
A/B/C/D (dependent on
ow, ow meters, hoses and
mixers)
Viscosity of mixed products
(depending on ow, ow
meters, hoses and mixers)
Chapter 5.5.4
Maximum particle size
8 bar 325 bar * 530 bar * 400 bar * 345 bar *
116 psi 4,714 psi * 7,687 psi * 5,800 psi * 5,000 psi *
8 bar
116 psi
2.5 MPa ** 32.5 MPa * 53 MPa * 40 MPa * 34.5 MPa *
25 bar ** 325 bar * 530 bar * 400 bar * 345 bar *
362 psi ** 4,714 psi * 7,687 psi * 5,800 psi * 5,000 psi *
0.5–25 bar *** 1–325 bar 1–530 bar 1–400 bar 1–345 bar
7–362 psi *** 14.5–4,714psi 14.5–7,687 psi 14.5–5,800 psi 14.5–5,000 psi
100–7,000 cc/min 50–25,000 cc/min
High-
pressure
version
see Chapters 5.5.3 and 5.5.4
5–10000 mPas
see Chapter 5.5.4
without Coriolis
Product valves
DN 4
DN 2.6
DN 10
with Coriolis
75–10,000
gr/min
* Maximal inlet pressure depends on:
Measurement method (see Chapter 5.5.4)
−
− Mixing
tube:
− XL version with product pressure regulator:
− XL version with -air ushing: Input pressure max. 2.5 MPa; 25 bar; 362 psi
** When air bubbles monitoring max. 0.8 MPa; 8 bar; 116 psi
*** When air bubbles monitoring or product pressure regulator max. 0.8 MPa; 8 bar; 116 psi
Mixing elements made of stainless steel in mixing tube set 6-32: max. 28.2 MPa; 282 bar;
4,090 psi
Mixing elements made of stainless steel in mixing tube set 8-32: max. 22.6 MPa; 226 bar;
3,278 psi
XL: Mixing elements made of stainless steel in mixing tube set 10-32: max. 40 MPa; 400 bar;
5,800 psi
Input pressure max. 4 MPa; 40 bar; 580 psi
Product outlet max. 0.8 MPa; 8 bar; 116 psi
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Lowpressure
version
Product pH value 3.5–9
Product temperature
Operation
Ambient
temperature
Relative humidity 10–95% (without condensation)
Mixing ratio, volumetric 0.1:1 … 50:1
A/B or (A+B)/C or (A+B+C)/D 0.00:1 (1K)
Dosing
precision
* The target mixing ratio at a precision level of ± 1% or ± 2%, is achieved after each completed cycle
(injection of hardener into base lacquer).
Precision of
− Proper use of the system in compliance with the operating manuals.
Correct calibration and function of the ow meters or stroke sensors in accordance with Chapter 7.12.
−
Correct adjustment of the compression ratio between the base lacquer and hardener.
−
see Chapter 8.5.2
− Correct adjustment of the hardener metering valve stroke, or use of the AIS.
− Exact setting of the system to suit the product used, in accordance with the processing specications
stipulated by the product manufacturer.
− For a homogenous density of the base lacquer and hardener it might be necessary to make respective
preparations in tanks, for example by applying an agitator.
− Correct use of the system in accordance with the specic operating conditions such as the permitted
product and ambient temperature, permitted viscosity and ow rate.
Regular maintenance has to be carried out by a qualied person (e.g., WAGNER Service Technician) in
−
accordance with Chapter 9.
Maximum number of A/B/C/D paint and dosing
valves**
Maximum number of A/B/C/D ushing valves** 10/5/5/5
Maximum number of guns** 4
Sound pressure level during alarm 110 dB(A)
(A-rated sound pressure level measured at 1 m distance, LpA1m, according to DIN EN 14462: 2005.)
Distance control cabinet - uid section up to 10 m; 32.8 ft / 15 m; 49.2 ft / special versions available
Weight (approx.) 80–250 kg 120–300 kg
** for 2-circuit system, see Chapter 5.5.1.1.
*** More valves for XL version available on request.
Assembly
Suspension
System with ow meters
(for all components)
System with stroke sensors
(min. one component)
1% or ± 2% is achieved under the following conditions:
25/10/10/10
Highpressure
version
+5 °C … +60 °C
+41 °F … +140 °F
+5 °C … +40 °C
+41 °F … +104 °F
0 °C … +40 °C
+32 °F … +104 °F
-20 °C … +60 °C
-4 °F … +140 °F
± 1% precision in mixing ratio *
± 2% precision in mixing ratio *
XL version
DN 10: 4/–/–/– ***
DN 4: 10/5/5/5 ***
DN 2.6: –/5/5/5 ***
DN 4: 1/1/1/1 ***
DN 2.6: –/1/1/1 ***
XL version +
Coriolis
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5.5.1.1 LIMITATIONS FOR 2CIRCUIT SYSTEMS
Limitations for 2-circuit systems opposite the data in Chapter 5.5.1:
Standard
system
2K / 3K / 4K system 2K / 3K / 4K 2K / 3K
Maximum number of A/B/C/D paint and dosing valves 25/10/10/10 10/5/5/–
Maximum number of A/B/C/D ushing valves 10/5/5/5 5/2/2/–
Maximum number of guns 4 2
Dump valve for waste separation
External ushing
agent:
Booster pump
* More valves for XL version available on request.
- Flushing over a period of time
- Flushing with ow monitor
- Flushing with ow meter
(option) --
(option) (option)
(option) (option)
(option) - (option) --
2-circuit system
per circuit per circuit
2-circuit system
XL
DN 10: 4/–/–/– *
DN 4: 10/5/5/– *
DN 2.6: –/5/5/– *
DN 4: 1/1/1/– *
DN 2.6: –/1/1/– *
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5.5.2 DIMENSIONS
Control cabinet and/or uid cabinet
− Standard system
− Ex system
− 2-circuit system
− XL system (control cabinet)
A
C
B
F
E
D
B_05637
XL system (uid cabinet)
A
H
J
G
B_05669
Dimensions
Measurement mm inch
A 800 31.50
B 1,133 44.61
C 1,960 77.17
D 350.5 13.80
E 410.5 16.16
f 573.8 22.59
G 1,650 64.96
H 1,225 48.23
J 1,200 47.24
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5.5.3 WORKING AREAS OF FLOW METERS
Flow meters: A/B: 0.02 – 3 l/min Viscosity: A: min. 5 mPa·s
5
4
3
2
Working area
1
B: min. 5 mPa·s
0
Flow-mixed product A+B [l/min]
0 5 10 15 20 25 30 35 40 45 50
[5:1]
Mixing ratio (volumetric) A:B (0 = only A)
Flow meters: A: 0.02 – 3 l/min Viscosity: A: min. 5 mPa·s
B: 0.005 – 2 l/min B: min. 5 mPa·s
5
4
3
2
Working area
1
B_04677
[50:1]
0
Flow-mixed product A+B [l/min]
0 5 10 15 20 25 30 35 40 45 50
[5:1]
Mixing ratio (volumetric) A:B (0 = only A)
B_04678
[50:1]
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Flow meters: A: 0.02 – 3 l/min Viscosity: A: min. 5 mPa·s
B: 0.005 – 2 l/min B: min. 5 mPa·s
c: 0.005 – 0.5 l/min c: 1-100 mPa·s
5
4
3
Working area
2
1
Max. amount A+B+C with corresponding mixing ratio
A:B, and
C = 0.25 l/min (for maximum value) or 5cc/min
(for minimum value)
Flow-mixed product A+B+C [l/min]
0
0 5 10 15 20 25 30 35 40 45 50
[5:1]
Mixing ratio (volumetric) A:B (0 = only A)
Flow meters: A: 0.1 – 7 l/min Viscosity:
B: 0.02 – 3 l/min Maximum viscosity depending on ow rate
12
11
10
9
8
7
6
5
4
3
2
1
0
Flow-mixed product A+B [l/min]
0 5 10 15 20 25 30 35 40 45 50
Working area
[5:1]
Mixing ratio (volumetric) A:B (0 = only A)
B_04675
[50:1]
B_04676
[50:1]
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Flow meters: A: 0.5 – 25 l/min Viscosity:
B: 0.1 – 7 l/min Maximum viscosity depending on ow rate
Working area
A+B [L/min]
Flow-mixed product
B_01660
Mixing ratio volumetric A:B [A:1] (0= only A)
5.5.4 APPLICATION LIMITS OF FLOW METERS
Standard
Viscosity
All viscosity information in this chapter are approximate values. The viscosities are recommended
limit values for commercial operation.
Particle size
Gear ow meters
Measuring range
from 0.02 l/min
Measuring range
from 0.005 l/min
Micro ow meter
0.005-0.25 Ex
120 µm 60 µm 40 µm
Maximum particle size
0.12 mm 0.06 mm 0.04 mm
0.0047 inch 0.0024 inch 0.0016 inch
Product ltration required min. 100 mesh/inches min. 200 mesh/inches min. 300 mesh/inches
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Low pressure /
Flow rate
Max.
XL
High pressure /
Application
measuring range
pressure*
/ / --
/ / --
/ / --
suitable for demineralised
water
/ / --
/ /
/ /
-- / -- /
high percentage of solid
530 0.005–1 for high-precision dosing
objects
/ /
/ /
better starting performance
with small quantities
/ / --
-- / -- /
thin media without solid
high percentage of solid
objects
objects, highly viscous media
Product ltration
Viscosity limit values*** for
1 l/min 2 l/min 3 l/min
Flow rate
measuring range
Gear ow meter, 0.005 – 0.5 KL Ex 2343974 250 0.005–0.5 1–100 (at 0.005–0.5 l/min) ≥ 200
Gear ow meter, 0.005-2 KL Ex 2334770 400 0.005–2 5–500 5–200 -- ≥ 200
530 0.005–1 5–400 -- -- ≥ 200
9955686
(with Pickup)
Gear ow meter, 0.005–1 GL Dual Pickup Ex **
Gear ow meter, 0.5-25 GL Ex 2311958 530 0.5–25 up to 8,000 up to 4,200 up to 3,200 ≥ 100
Coriolis compact, 0.075–5 Ex 2359845 345 0.075–5 kg/min up to 600 up to 350 up to 250 --
Gear ow meter, 0.1-7 GL Ex 2311948 530 0.1–7 5–4,000 5–2,100 5–1,600**** ≥ 100
Coriolis compact, 0.15–10 Ex 2359846 345 0.15–10 kg/min up to 1200 up to 700 up to 500 --
Micro ow meter, 0.005-0.25 Ex 2311618 100 0.005–0.25 0.5–6 (at 0.005–0.25 l/min) ≥ 300
* The maximum pressure of the ow meter must be greater than the maximum product pressure of the system (Fluid section type plate).
** Can not be combined with stroke measurement
*** All viscosity information are approximate values. The viscosities are recommended limit values for commercial operation.
**** at 7 l/min: 5–1000 mPas
Max.
pressure *
Note
(without Pickup) bar l/min
WAGNER Order No.
Gear ow meter, 0.02-3 GL Ex 2343971 Standard slide bearing 400 0.02–3 Standard
Flow meter type
Gear ow meter, 0.02-3 KL Ex 2343972 Standard ball bearing 400 0.02–3 Water-based lacquers
Gear ow meter, 0.005-2 GL Ex 2343973 Small quantity slide bearing 400 0.005–2 Small quantities
Gear ow meter, 0.005-2 KL Ex 2334770 Small quantity ball bearing 400 0.005–2
Slide bearing Dual Pickup
9955686
Gear ow meter, 0.005 – 0.5 KL Ex 2343974 Ball bearing 250 0.005–0.5
Gear ow meter, 0.005–1 GL Dual
ow meter
(with Pickup)
Gear ow meter, 0.1-7 GL Ex 2311948 7 l/min slide bearing 530 0.1–7 highly viscous media
Pickup Ex **
Gear ow meter, 0.5-25 GL Ex 2311958 25 l/min slide bearing 530 0.5–25 extremely viscous media
Coriolis compact, 0.075–5 Ex 2359845 Coriolis DN 4 345 0.075–5 kg/min
Coriolis compact, 0.15–10 Ex 2359846 Coriolis DN 6 345 0.15–10 kg/min
Micro ow meter 0.005–0.25 Ex 2311618 Micro quantity 100 0.005–0.25
Maximum viscosities for economical operation of the owmeters
(without Pickup) bar l/min mPa s mPa s mPa s Mesh/inches
WAGNER Order No.
Flow meter type
Gear ow meter, 0.02-3 GL Ex 2343971 400 0.02–3 5–1200 5–700 5–500 ≥ 100
Gear ow meter, 0.02-3 KL Ex 2343972 400 0.02–3 5–1200 5–700 5–500 ≥ 100
Gear ow meter, 0.005-2 GL Ex 2343973 400 0.005–2 5–500 5–200 -- ≥ 200
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5.6 MIXING TYPES
For mixing components A, B, C and D, three versions are available:
A) With mixing block (standard) B) With mixing head valve C) With external mixer
A) Mixing block (standard)
A Flushing (air)
B1 Flushing
Example: 3K system with 6 A valves,
4 B valves, 2 C valves and 2 guns
Valves B1, B2 and C are cycled.
Flushing A
B2 Flushing
A3
A1
A4
A2
B1
B2
C
C Flushing
Air bubble sensor
Inline lter
Flow meter
Non-return valve
Mixing block AB+C
Mixing block A+B
Static-mixer A+B Static-mixer AB+C
Flushing gun 1
Flushing gun 2
Splitter valve with ushing
Product pressure regulator
B_04681
Dump valve for waste
Gun 2
Gun 1
separation
Dump valve
The dump valve can also be installed before the gun in the gun hose.
Example with simple dump valve:
B_04685
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B) Mixing head valve
A Flushing (air)
B1 Flushing
B2 Flushing
Flushing A
Example: 3K system with 6 A
valves, 4 B valves, 2 C valves and
2 guns
The mixing head valves B and C are
cycled and regulated with the AIS
A3
A1
A4
A2
B1
B2
C
dosing system.
C Flushing
Air bubble sensor
Inline lter
Mixing head valve with
cycle and AIS
83 84
83 Flushing mixing head valve B
84 Flushing mixing head valve C
AIS AIS
Flow meter
Non-return valve
Mixing block
Static-mixer
Flushing gun 1
Flushing gun 2
Splitter valve with ushing
Product pressure regulator
B_05639
Dump valve for waste
separation
Dump valve
The dump valve can also be installed before the gun in the gun hose.
Example with simple dump valve:
B_04685
Gun 2
Gun 1
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C) External mixer
Flushing A
A3
A1
Air bubble sensor
Inline lter
Flow meter
Non-return valve
A Flushing (air)
A4
A2
B_04683
B1 Flushing
B1
B2 Flushing
B2
C
Example: 3K system
with 6 A valves,
4 B valves, 2 C valves
and 2 guns
Valves B1, B2 and C are
cycled.
C Flushing
Gun
Flushing
External mixer
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5.7 DUMP VALVE FOR WASTE SEPARATION OPTION
In addition to the simple dump valve, there is also a dump valve for waste separation. When
lling and when ushing, the system separates the ushing agent from the remaining
product. For this purpose, a double valve is used: one output for ushing agent, another
for waste (mixed product).
With an average number of paint changes and pot lives which are not too short, the dump
valve can be an alternative to a gun ush box for waste separation.
Not available for 2-circuit systems.
5.8 AIS DOSING SYSTEM OPTION
The hardener dosing valve's stroke is regulated automatically via the AIS (option). The AIS
(Adaptive Injection System) dosing system optimizes injection amounts and cycles and
adapts these continually to the changing ow rates. Thereby, the AIS ensures optimum
dosing and constant coating quality.
5.9 2CIRCUIT SYSTEM
The 2-circuit system consists of:
− 2 uid circuits
− 1 control cabinet with:
− 4 mechanical push-buttons per uid circuit
− 1 operating panel for both uid circuits
The control cabinet controls both uid circuits. It is
possible to work with two uid circuits simultaneously.
Limitations for 2-circuit systems: see Chapter 5.5.1.1.
B_05641
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5.10 FLOW MEASUREMENT
The ow of components A, B, C and D can be measured as follows:
− with ow meters
− Gear ow meters
− Coriolis ow meters (contact-free)
− with stroke sensors (contact-free, from software version 4.0x / 4.0x K)
Only one measuring method can be used within a component. It is however possible, for
example, to use stroke sensors for component A and ow meters for component B.
5.10.1 FLOW METERS
For every component, there is a ow meter installed upstream of the mixing block (gear or
Coriolis ow meter).
Control cabinet
Touch screen /
controller
Zener barriers
Non-Ex zone
B_04356
Ex zone
Example: 2K system with 4 pumps in
potentially explosive zone
A1
A2
Flow meter
A
A+B
B
Flushing
B
Flow meter
For operating ranges and technical data of the ow meters, see Chapters 5.5.3 and 5.5.4.
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5.10.2 STROKE MEASURING
For piston pumps, the ow can be measured contact-free with stroke sensors (from
software version 4.0x / 4.0x K). For this, each pump must be equipped with a stroke sensor.
There are three types of stroke sensors:
Stroke sensor type Field of application Working method
Stroke sensor short e.g., IceBreaker pumps up to 70 cm/DH
Stroke sensor long e.g., IceBreaker pumps up to 100 cm/DH
Pressure sensor Flushing pump
Detects the exact position of the piston.
Detects the piston's upper and lower
reversal points.
Non-Ex zone
Control cabinet
Touch screen /
controller
1
2
3
4
Ex zone
Stroke sensor
B_04357
Example: 2K system with 4 pumps in
potentially explosive zone
1
231/
1/3
Stroke sensor
1/1
1/2
A1
Piston pump
A2
1
232/
2/1
Pressure sensor
A
A+B
Flushing
B
B
A/D Converter (ADC)
The analog stroke sensor signals are evaluated in an A/D converter (ADC) and converted
into digital signals. Up to four A/D converters, with three inputs each, can be used. The ADC
automatically recognizes, whether a stroke sensor or a pressure sensor is connected to its
inputs (1, 2, 3).
Multiplexer (MPX)
In the control cabinet, a multiplexer processes the A/D converter's digital signals and
transmits the signals, of the currently active pumps, to the controller.
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5.10.3 FLOW METERS AND STROKE SENSORS
Flow meters and stroke sensor can be used simultaneously.
The following should be noted:
Only one measuring method can be used within a
component.
As soon as stroke sensors are used, the ushing pump
must be equipped with a pressure sensor.
Correct
Example: 2K system with 4 pumps in potentially explosive zone.
− Stroke sensors for component A.
− Flow meter for component B.
A1
A2
A
B_04364
Incorrect
Control cabinet
Touchscreen /
controller
Zener barriers
Non-Ex zone
1
2
3
4
B_04363
Ex zone
1
231/
1/3
Stroke sensor
1/1
1/2
A1
Piston pump
A2
Pressure sensor
A
A+B
Flushing
B
B
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6 ASSEMBLY AND COMMISSIONING
6.1 TRAINING OF ASSEMBLY/COMMISSIONING STAFF
The assembly and commissioning sta must have the technical skills to safely commission
the device.
When assembling, commissioning and carrying out all work, read and follow the
operating manuals and safety regulations for the additionally required system
components.
A skilled person must check to ensure that the device is in a reliable state after it is installed
and commissioned.
6.2 STORAGE AND INSTALLATION CONDITIONS
Until the point of assembly, the device must be stored in a dry location, free from vibrations
and with a minimum of dust. The device must be stored in closed rooms.
For ambient temperature and air humidity, see Chapter 5.5.1.
Long-term storage
See chapter 9.1.6.
For recommissioning, proceed according to following chapters.
6.3 TRANSPORTATION
The system can be transported in the specially designed transportation box.
System Unit Length Width Height
Non-Ex System mm; inch 1,800; 70.9 1,178; 46.4 400; 15.75
Ex System mm; inch 1,800; 70.9 1,178; 46.4 800; 31.5
2-circuit
(1 separate uid section)
2-circuit
(2 separate uid sections)
XL mm; inch 1,800; 70.9 1,178; 46.4 800; 31.5
6.4 ASSEMBLY AND INSTALLATION
The mixing units are normally installed by WAGNER technicians directly or by their agents.
If this is not the case, the material has to be checked for damage on receipt of the system.
mm; inch 1,800; 70.9 1,178; 46.4 800; 31.5
mm; inch 1,800; 70.9 1,178; 46.4 1,200; 47.25
WARNING
Inclined ground!
Risk of accidents if the device rolls away/falls.
Place the device on horizontal oor.
Rollers should be locked in position or replaced by leveling feet and secured.
Do not tilt the device during shifting / transporting.
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B_05489
Ensure a sucient secure stance.
Fix the xing attachments of leveling feets on the oor.
WARNING
Electric shock hazard inside the control unit!
Danger to life from electric shock.
May only be installed/maintained by skilled electricians or under their supervision.
Operation according to the safety regulations, re protection and electrotechnical
rules.
Must be de-energized before work is commenced on active parts.
DANGER
Incorrect installation of the device!
Explosion hazard and damage to the device.
Set up the system outside the spray booth / spray zone.
The control cabinet should not be set up within the Ex zone.
Protect the control cabinet from extreme temperature and moisture changes as well
as dirt.
The uid section (non-Ex version) must not be installed in the explosion zone in the
2K COMFORT.
Lay and x the connecting cable correctly and protect it against tripping, dirt and
trac.
Use only feed pumps and components which are suitable for 2K products.
Use hardener pump with PE/T packing (T = PTFE).
No contact of 2K products with non-ferrous metals.
With water based lacquers: pumps and product-wetted parts of stainless steel.
Use product lters at the feed pumps.
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6.4.1 ELECTRICAL CONNECTIONS
An electric connection cable with plug is standardly provided.
When exchanging the connection cable, please observe the following:
Carry out the electrical connections and the grounding inside the control unit using
a 3-wire cable of 1.5 mm; in accordance with the enclosed circuit diagram.
6.4.2 PNEUMATIC CONNECTIONS
Check whether the line pressure is sucient. It has to be between 0.7 and 0.8 MPa;
7to 8 bar; 101-116 psi.
WARNING
Overpressure!
Risk of injury from bursting components.
The operating pressure must not exceed the value shown on the type plate.
Check whether ecient lter systems and condensate precipitators are available in
the air line.
The compressed air must be free of oil and water. For compressed air quality, see
Chapter 5.5.1.
Every day, discharge all contamination and the condensate (if any) which has
accumulated in the equipment air lter.
WARNING
Brittle lter pressure regulator!
The tank on the lter pressure regulator becomes brittle through contact with solvents
and can burst. Flying parts can cause injury.
Do not clean the tank on the lter pressure regulator with solvents.
6.4.3 PRODUCT CONNECTIONS
Carry out the following connections:
Product hose from the mixing tube or splitter valve to the gun.
Electrostatic guns must be used without electrostatics during commissioning.
−
First commission the electrostatic system after all steps are carried out up to
Chapter 6.6.6.
The product hoses from the feeding pumps to the system's product inlets may not
be connected until the preliminary ushing of the hoses (see Chapter 6.6.1) has been
done (contamination of the unit)!
Circular pipeline
If the unit is connected to a circular pipeline, suitable shut-o devices must be installed
− to prevent the products from mixing in case of leakage in the 2K system.
− These shut-o devices must always be closed at the end of work.
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6.4.4 FLOW METER MONITORING
For safe operation it is necessary for the 2K system to receive a signal, when the gun is
open and there is 2K product ow. Otherwise for example no B product is added when the
A ow meter is blocked, although A product continues owing through the leakage in the
ow meter (possibly not visible).
The signal (product ow yes/no) can be made available on ways that follow:
for AirSpray- or AirCoat manual spray guns: AirSpray + AirCoat gun monitoring
(atomizing air-ow switch);
for Airless- or HVLP manual spray guns: ow monitor (lacquer-ow switch in the lines
to the guns);
for automatic spray guns: automatic gun monitoring (pressure switch);
for digital robot communication: robot signal ("gun signal 1/2/3/4");
for bus communication (e.g., CAN Probus Gateway): signal by superordinate control
("gun monitoring 1/2/3/4").
Gun monitoring for each gun
If possible, each gun should be monitored separately.
NOTICE
Caution with only one gun monitoring for multiple guns!
If for several spray guns only one gun monitoring is installed, the controller does not
know which gun in each case is in operation.
Then the product ow is divided to all guns.
The pot lives in the gun hoses and guns can be exceeded without a pot life alarm.
WARNING
Incorrect installation of the device!
Explosion hazard and damage to the device.
The ow monitor is non-Ex-proof and has to be installed outside the explosion zone.
Lay and x the connection pipes correctly and protect them against tripping, dirt and
damage.
No air consuming equipment, other than the feed pumps for a 2K system, may be
installed after the ow monitor (e.g., pumps circular pipeline and stirrer).
6.4.5 LACKOFPRODUCT PROTECTION
Make sure that product without air bubbles is supplied to the mixing and dosing system.
The ow meters can not detect whether product or air is delivered.
This may lead to mixing errors. (An air bubbles monitoring system is optionally
available for the low-pressure model).
A lack-of-product protection can be achieved by installing a level probe in the A-product
tank or by always having the coater make sure that sucient product is in the tanks.
Otherwise false coating may occur.
If, e.g., the A-tank's level probe indicates the minimum level, a signal can stop the 2K system
(STOP) or electronic consumption measuring equipment warns of a lack of product.
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The lack-of-product protection with level probe is not supplied with the 2K system and has
to be realized on-site.
6.4.6 VENTILATION OF THE SPRAY BOOTH
WARNING
Toxic and/or ammable vapor mixtures!
Risk of poisoning and burns.
Operate the device in a spray booth approved for the working materials.
-orOperate the device on an appropriate spraying wall with the ventilation (extraction)
switched on.
Observe national and local regulations for the exhaust air speed.
6.5 GROUNDING
WARNING
Fire, explosion and electric shock hazard
Danger to life by electric shock and explosion.
The device must be electrically connected to the equipotential bonding (ground);
the ground in the electrical system is not sucient.
A qualied electrician must complete all grounding and wiring connections and check
the resistance.
Operation according to the safety regulations, re protection and electrotechnical
rules.
Must be de-energized before work is commenced on active parts.
WARNING
Heavy paint mist if grounding is insucient!
Danger of poisoning.
Insucient paint application quality.
Ground all device components.
Ground the work pieces to be coated.
Make sure to include the control cabinet and the uid cabinet in the local equipotential
bonding.
The 2K system, the pumps, all accessories and all parts that come into contact with the
sprayer have to be grounded non-Ex or Ex according to the following grounding scheme.
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Grounding scheme - example for 2K COMFORT non-Ex
Non-Ex zone Ex zone
1
9
3
6
8
5
2
4 7
Designation
1 Controller
2 Fluid section (non-Ex)
3 Pump
4 Paint tank
Designation
6 Conveyor
7 Floor, static dissipative
8 Pneumatic alarm horn (option)
9 Remote control Ex (option)
5 Work piece
Grounding cables Fluid hoses
Cable cross sections
2K system, pump 4 mm; AWG 12
Paint tank / collection tank 6 mm; AWG 10
Conveyor 16 mm; AWG 6
Spray booth 16 mm; AWG 6
Spraying stand 16 mm; AWG 6
Connect all ground cables using a short and direct route.
R max.
< 1 MOhm
B_04657
Ex zone
All devices and equipment must be suitable for use in potentially explosive areas.
Tank
All paints, ushing agents and waste tanks have to be electrically conductive.
All tanks must be grounded.
Stroke measuring
Grounding ADC-0301: see "ADC-0301 / MPX-0403" operating manual (for Order No.,
see Chapter 1.3.1)
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Grounding scheme - example for 2K COMFORT Ex
Non-Ex zone Ex zone
6
1
8
2
3
B_04656
Designation
1 Controller
2 Fluid section (Ex)
3 Pump (Ex)
4 Paint tank
4 7
Designation
6 Conveyor
7 Floor, static dissipative
8 Pneumatic alarm horn (option)
9 Remote control Ex (option)
5 Work piece
Grounding cables Fluid hoses
9
5
R max.
< 1 MOhm
Cable cross sections
2K system, pump 4 mm; AWG 12
Paint tank / collection tank 6 mm; AWG 10
Conveyor 16 mm; AWG 6
Spray booth 16 mm; AWG 6
Spraying stand 16 mm; AWG 6
Connect all ground cables using a short and direct route.
Ex zone
All devices and equipment must be suitable for use in potentially explosive areas.
Tank
All paints, ushing agents and waste tanks have to be electrically conductive.
All tanks must be grounded.
Stroke measuring
Grounding ADC-0301: see "ADC-0301 / MPX-0403" operating manual (for Order No.,
see Chapter 1.3.1)
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6.6 COMMISSIONING
WARNING
Gas mixtures can explode if there is an incompletely filled device!
Danger to life from ying parts.
Ensure that the device is always completely lled with ushing agent or working
medium.
Do not spray the device empty after cleaning.
WARNING
High-pressure spray jet!
Danger to life from injecting paint or solvent.
Never reach into the spray jet.
Never point the spray gun at people.
Consult a doctor immediately in the event of skin injuries caused by paint or solvent.
Inform the doctor about the paint or solvent used.
Never seal defective high-pressure parts; instead relieve the pressure from them and
replace them immediately.
Wear the appropriate protective clothing, gloves, eyewear, and respirator
NOTICE
Fluctuating supply pressures!
Poor coating result.
The supply pressure of component B should be adjusted to a higher value (approx. 5-10%)
than that of component A.
The supplying pressure should be constant.
Electrostatic gun
Electrostatic guns must be used without electrostatics during commissioning. First
commission the electrostatic system after all steps are carried out up to Chapter 6.6.6.
6.6.1 PRECLEANING
The devices are tested at the factory using emulsied oil, plain oil or solvent, according to
the kind of uid being pumped.
Before commissioning the pump with a product, it is recommended to ush both
circuits and supply pumps with an appropriate ushing agent.
WARNING
Incompatibility of ushing agent and working medium!
Risk of explosion and danger of poisoning by toxic gases.
Examine the compatibility of the ushing agents and working medium on the basis
of the safety data sheets.
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Pre-cleaning
Before the product hoses are connected to the system, they should be ushed, together
with the corresponding pumps, with the ushing agent to be used.
Unless this preliminary ushing is executed, the ow meters can already be clogged
due to contamination during the rst ow through!
For preliminary cleaning of the pumps, carefully follow the corresponding pump
instructions.
After all pumps and product hoses to the device have been ushed, the product hoses
can be connected to the system.
The ushing agent still remains in the pumps.
Note:
The ushing agent used for the rst cleaning may not be used again since it might contain
oil residues.
6.6.2 INITIALIZING THE CONTROLLER
The controller is already individually pre-congured upon delivery. Additional settings
must be entered on-site.
Switch on the system with the main switch.
The initialization programs starts when the system is switched on for the very rst
time. It allows quick input of the most important settings, which must still be entered.
The initialization program can also be called up later (with password level 3, setting
"Reset initialization").
Dene one after the other on the operating panel:
− Language (touch desired language, then proceed with the arrow key
− Volumes measuring unit (liters or US gallons, touch eld to change);
− Lengths measuring unit (meter or inch);
− Hose lengths and diameters;
− Number of paint recipes (maximum 100) and number of ushing recipes
(maximum 10);
− Mixing ratio input type (A:B or percentage).
At the end, a note appears, explaining what should be done next. Perform one after
the other (password level 1):
Enter names of valves, ushing recipes and paint recipes (see Chapter 7.9.2);
−
Enter ushing recipes (see Chapter 7.10);
−
Enter paint recipes (see Chapter 7.11), still without calibration.
−
If necessary, implement further settings.
);
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6.6.3 VENTING THE SYSTEM
First bleed the system via the gun with little product pressure:
Prepare a grounded metal bucket, that is suitable to collect all products to be disposed of.
Menu
Select each A side valve, one after the other and perform the following steps:
− Open the valve with the large valve icon.
− Bleed, via the gun, with low product pressure until clean ushing agent ows out
of the gun.
− Close the valve icon again.
Do the same for the B side (and C/D, if available) and for the ushing valves.
6.6.4 PRESSURE TIGHTNESS TEST
(see Chapter 7.8)
WARNING
Overpressure!
Risk of injury from bursting components.
The operating pressure must not exceed the value shown on the type plate.
For pressure tightness control of the entire installation, the ushing agent pressure is
slowly increased, step by step, until the maximum pressure of the individual pumps is
achieved.
Menu
(see Chapter 7.8)
One after the other and in each component (A, B, ush, ...) for each product valve
(A1, A2, ...):
− Select valve and open it with the large valve button.
− Slowly increase the pressure at the respective pumps, step-by-step, until the
maximum pressure specied on the type plate has been reached.
− Hold the maximum pressure for at least 2 minutes.
− If there is a leak, mend it.
After the test, relieve pressure from the entire system according to Chapter 8.8.
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6.6.5 FILLING THE SYSTEM
NOTICE
Interchange of the two components A and B!
Device damage by hardened product.
Label device components and paint tank so that the components A and B are not
mixed up.
Menu
Example for a hardener valve with the name B1:
1. Prepare the hardener components' tank and put the suction pipe in the respective
pump.
2. Select [B] components, then select valve B1.
Open the valve with the large valve button.
3. Set the hardener pump slightly under pressure. Open the hardener valve with the
large valve button.
4. Point the guns into the grounded metal bucket and open it step by step. Avoid
splashback.
After the hardener is lled, calibrate the hardener straight away, if necessary, according
5.
to Chapter 7.12.
6. Close the valve via the [Valve] eld or close the STOP button again.
Then, in the same way, ll the system with the other components.
Note:
The solvent used for the rst cleaning may not be used again since it might contain oil
residues.
Calibration
Components with ow meter:
− In all paint recipes, calibrate the components as well as the ushing agent.
If the components were already calibrated during lling, the K factors must be entered
in the dierent recipes.
In accordance with Chapter 7.12.
Components with Coriolis measuring system:
−
K factor = Enter 60 ,000 Imp/l according to Chapter 7.12.
Perform zero point adjustment in accordance with "Coriolis Compact" user information
(Order No., see Chapter 1.3.1)
(see Chapter 7.8)
6.6.6 ELECTROSTATICS
With an electrostatic gun:
Commissioning the electrostatics according to the corresponding assembly manual.
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7 CONTROLLER
7.1 TRAINING THE OPERATING STAFF
The operating sta must be qualied to operate the entire system.
The operating sta must be familiar with the potential risks associated with improper
behavior as well as the necessary protective devices and measures.
Before work commences, the operating sta must receive appropriate system training.
7.2 SAFETY INSTRUCTIONS
Before carrying out any work, ensure that commissioning is carried out in accordance with
Chapter 6.6.
WARNING
Incorrect operation!
Risk of injury and damage to the device.
If contact with lacquers or cleaning agents causes skin irritation, appropriate
precautionary measures must be taken, e.g., wearing protective clothing.
The footwear worn by operating sta must comply with EN ISO 20344. The measured
insulation resistance must not exceed 100megohms.
The protective clothing, including gloves, must comply with ENISO 1149-5. The measured
insulation resistance must not exceed 100 megohms.
WARNING
Unintentional putting into operation!
Risk of injury.
Before any work on the device, in the event of work interruptions and malfunctions:
Relieve the pressure from the spray gun and unit.
Secure the spray gun against actuation.
Switch o the energy/compressed air supply.
Disconnect the control unit from the mains.
In the event of functional faults: remedy the fault as described in the "Troubleshooting"
chapter.
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7.3 CONTROL CABINET
There are four push-buttons and an operating panel (touch screen) for the system
controller in the control cabinet. The touchscreen and the push-buttons can be used to
communicate with the controller.
Initialization program for commissioning: see Chapter 6.6.2
Basic operating principles: see Chapter 7
Workow: see Chapter 8
Detailed software documentation is separately available (see Chapter 1.3).
USB connection
The USB port is located at the control panel on the inside of the control cabinet.
Standard system of the control cabinet 2-circuit system of the control cabinet
1
2
3
B_05490
Designation
1 Control cabinet
2 Operating panel (touchscreen)
3 Mechanical push-buttons
3a Mechanical push-buttons, Circuit 1
3b Mechanical push-buttons, Circuit 2
4 Main switch
1
2
3a
4
4
3b
B_05641
2-circuit system
It is possible to work with two uid circuits
simultaneously. The operation of both uid
circuits is at any time immediately possible with
mechanical push-buttons (3a or 3b).
The operating panel can be switched at any time
quickly from one uid circuit to the other.
7.3.1 MAIN SWITCH
The main switch, on the right side of the control cabinet, switches the controller on and o.
When switched o, all valves close automatically.
Switching the system on and o: see Chapter 8.3.
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7.4 MECHANICAL PUSHBUTTONS
The system's basic functions are controlled by four mechanical push-buttons:
START STOP Flushing RECIPE CHANGE
R
Starts spraying mode.
Flashes green during
lling.
Lights up green as soon
as the system is ready for
spraying. The AirCoat air
is activated (option).
Display of lling
progress:
7.5 OPERATING PANEL BASICS
highlighted (yellow)
All elds with frames can be touched. For example, to trigger an
action, select a dierent recipe, or enter a number.
Ends the spraying
or ushing process.
(Depending on setting,
it may not be possible to
end the ushing process
early.)
Alarm
Warning Flashes red.
Starts end ushing of
the last paint recipe
used. (With external
mixer if necessary mixer
ushing.)
Lights up blue during
Lights up red.
Some buttons are highlighted by a yellow
background color. The highlighted buttons indicate
our current location.
ushing process.
Display of ushing
progress:
Gun symbol ashes Open gun.
Switches to next paint
recipe.
STOP + recipe change
jumps 10 steps.
Recurring operating elements
Scroll up screen Conrm selection Saves the data
Scroll down screen Cancel selection
Dierences in screen displays
The controller's functions dier depending on system, accessories installed, and user
settings. The screens shown in the following chapters may therefore contain additional
input options, or some of the buttons and elds shown may not be present in your version.
The screen will only ever show what is actually installed.
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OPERATING MANUAL
7.5.1 SELECT LANGUAGE
1. [Menu] button (second button in bottom row)
2.
3. Touch language: [English]
7.5.2 KEYBOARD INPUT
A keyboard with numbers or letters appears as necessary when elds with frames are
touched. The input is conrmed with [ ENT ] or canceled with [ ESC ].
Keyboard with
Minimum and
maximum values
Cursor (eld with frame) =
Current input position
numbers and special
characters
Min:
Max:
Keyboard Controls
Move cursor to right
Move cursor to left
Conrm input
Delete all
of cursor (backspace)
5.0
Conrm input
Cancel
Delete character
Delete character to left
Spaces
Cancel input
Keyboard with upper
case letters
R_blue
B_04641
Conrm input
Changing over keyboard with letters
Switch to keyboard with upper case letters
Switch to keyboard with lower case letters
Switch to keyboard with numbers and
special characters
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7.5.3 PASSWORDS
Some functions and input options are protected by passwords. The following password
levels exist:
Password level Responsibility Functions
0 Painter Spraying mode
1 Painter with control jobs
2 Foreman Plus system settings
3 Service customer Plus basic system settings
4
WAGNER Service
Department
The passwords, which are set by WAGNER at the time of the equipment delivery, are not
contained in the manual for safety reasons. The valid passwords are communicated to the
customer separately.
Password input
1. [Menu] button
2. If [Log Out] button appears: [Log Out] ( The button switches to [Log In].)
3. [Log In]
4. Touch password input eld.
A numerical keyboard appears.
5. Enter the password.
6. [ENT]
The password level is displayed briey, for example: "Level 1".
The menu buttons for the corresponding password level then appear.
Plus enter ushing and paint recipes,
diagnosis, calibration
−
7.6 HOME PAGE
NOTICE
Wrong mixing ratio!
Poor quality of paint application.
Before changing the lacquer, check the mixing ratio on the display and modify it if
necessary, if individual components have dierent mixing ratios.
7.6.1 CHANGING THE PAINT RECIPE
Press RECIPE CHANGE push button
R
Switches to next paint recipe.
Or:
1. Touch paint recipe eld (see above).
2. Select desired paint recipe from the list.
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7.6.2 HOME PAGE OPERATION
Number of current paint recipe
Paint recipe
Opens choice of all
paint recipes.
A : B
AB : C
D
Gun
Menu Act.
All elds with frames can be touched.
Mixing ratio (volumetric)
Pot life
Remaining pot life in minutes or seconds.
Gun selection
Flow regulation
The system regulates the ow to a set
value.
of ABC
minPot life
Batch AIS
PC
As of password level 1:
calibration of ow regulation
Flow
contrl
B_05461
Flushing
Opens a menu with
various ushing
options.
Menu
Opens a menu containing
other functions.
Home
Returns to home page at any time.
The 'Home' button is emphasized using reversed colors –
on screen with light background. This shows us our current
location: on the home page.
Tank
Filling level
monitoring of paint
tank.
Act. (=current)
Shows the current lacquer
consumption values.
AIS
Preset the dosing valve
stroke.
PC Data Archiving
Chapter 1.3.1
Batch
Produce recurring,
predetermined ow rate.
* Only present with corresponding
setting (with password level 3, see
Chapter 7.13.2).
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7.7 MENU
Button Function
Alarm
Calls up list of the last 700 warning messages.
Manual operation
Specic opening and closing of product or ushing valves. Chapter 7.8
Tank
Software Documentation
Change name (password level 1)
Chapter 7.9.2
Flushing recipes (password level 1)
Chapter 7.10
Paint recipes (password level 1)
Chapter 7.11
Diagnosis (password level 1)
Mixing amount, e.g., QB: As soon as the mixture has the correct mixing ratio,
the mixing amount is reset to zero. The system stops when the maximum is
exceeded (=QB-control, see Chapter 7.13.1).
Btkt = The dosing valve's cycle length
% open per cycle = dosing valve's opening time. If too short: slowly reduce
the dierence in pressure between A and B.
Output
Input
Totals (password levels 1 / 2)
View / zero product consumption and working times.
Display the output signal status.
Display the input signal status.
USB
I/O
Cong
Stroke
sensor
VOC quantities (password levels 1 / 2)
View / zero VOC quantities, enter VOC factors. Chapter 7.11
Info (password level 1)
View software version number, set date and time.
Calibration (password level 1)
Chapter 7.12
Settings (password levels 2 / 3)
Chapter 7.13
USB (password levels 2 / 3)
Back up alarms, totals, and conguration data on USB stick.
Service (password level 2)
Service intervals for dosing valves and ow meters.
Input / Output conguration (password level 3)
Assign inputs and outputs.
Stroke sensor conguration (password level 3), from software version 4.0x /
4.0x K. see software documentation
see software documentation
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7.8 MANUAL MODE: OPEN VALVES
Menu
Valve used by paint recipe.
(See other used valves: buttons A/B/C/D.)
Current ow
Flow rate since
the valve was last
opened
Set product
pressure.
(Only with
"Automatic product
pressure regulator"
option, see Chapter
7.13.2.)
Menu
Manual operation
Status of selected valve
Select paint recipe (for A/B/C/D).
Or select ushing valve (for A/B/C/D ushing valves).
The buttons with reversed colors show our
current location:
A
B
cc / minQ
ccVjob
C
D
A
Select component
A/B/C/D.
bar
Output
Valves
Leak
inspec.
B
C
D
Leak inspection
(only for piston pumps with
stroke sensor)
Displays list of A/B/
C/D ushing valves.
see software documentation
Valve is closed
Touch to change
Valve is open
Manual mode is used for troubleshooting or to ll a pump, for example.
Only one valve can be opened at any one time. If another valve is touched, the controller
closes all valves.
With a gun ush box, the valve for the gun is also opened: either for gun 1 (if gun 1 or 1+x
is selected on the home page), or for gun 2 (if gun 2 is selected on the home page).
Ext. ushing agent
The valve for the external ushing agent can not be opened on this page. If necessary, the
calibration function can be used for this, without saving the measured value (password
level 2, Chapter 7.12).
Open several valves / output
signals at the same time
With password level 3,
see Chapter 7.13.2.
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7.9 RECIPES
7.9.1 ADD NEW RECIPES
Create a new ushing recipe:
1.
Increase the "Number of ushing recipes" in the settings by one (see Chapter 7.13.1).
2.
Change the ushing recipe's automatically assigned name (see Chapter 7.9.2).
3.
Enter the ushing recipe (see Chapter 7.10).
Create a new paint recipe:
Increase the "Number of paint recipes" in the settings by one (see Chapter 7.13.1).
1.
2.
Change the paint recipe name automatically assigned (see Chapter 7.9.2).
3.
Enter paint recipe (see Chapter 7.11).
7.9.2 CHANGING RECIPE AND VALVE NAMES
Menu
ABC
(with password level 1 or higher)
Change valve names (for example: red, yellow,
hardener_1, ushing agent_1).
First select components (A, B, ushing A, ...), then
touch the valve names.
others
Other valve names
No valve open
Flushing starting from mixing head
Generates an information signal
Wait
* from version 3.2x / 3.2x K
Flushing from external mixer
(option)
valve (option)
Flushing starting from splitter valve
for gun 1 or gun 2
Demand gun change. (With 2-4
guns and only one gun ush box.)
Last used A/B/C/D product
Change ushing recipe name.
For example: R-R ushing (= recipe change ushing),
end ushing, gun ushing.
Change paint recipe name.
For example: red-90, red-95, yellow_customer-1, yellow_
customer-2.
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7.10 ENTER FLUSHING RECIPE
Menu
Select existing ushing recipe.
(New ushing recipe: see Chapter 7.9.1)
Current ushing step for input on this page.
Dene total number of ushing steps for this recipe.
1–16
Example with splitter valve,
dump valve and product
pressure regulator
Select action for this ushing step.
Flushing valve to open, or
(=wait)
(=extend gun change)
(Chapter 7.13.2, level 3, page 21)
(last used A/B/C/D
product)
Step
Flushing Qty
Menu
Opens the distributor valve for a
single gun (1, 2, 3 or 4) or for all
guns (1-x).
1 / 2 / 3 / 4 / 1-x
With several guns, separate ushing steps
must be dened for each gun.
Only those guns which were in use are
ushed automatically.
Exception: if a system has already been
ushed, the guns indicated are ushed in
any case when ushing is repeated.
20.0
bar
B_05202
Set ushing pressure.
(Only with "Automatic
product pressure
regulator" option)
Flushing via dump valve:
on or o.
(Only with "Dump valve"
option)
Enter ushing quantity or ushing time
for this ushing step.
0.0–9999.9
Enter short ushing steps rst (rough
ushing) to begin with, then long ushing
steps (approx. twice the hose content).
(No inuence on: " ")
Switch between ushing quantity
and ushing time.
cc or seconds
Go to next ushing step.
Repetitions can be
entered after the last
ushing step
(for examples, see
software documentation).
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7.11 ENTER PAINT RECIPE
Menu
A : B
AB : C
D
Menu
(with password level 1 or higher)
Select existing paint recipe.
New recipe: see Chapter 7.9.1
of ABC
B_05476
Go to next pageSave paint recipe.
Enter mixing ratio (volume) for the selected
recipe
0.1:1–50.00:1
0.02% – 1,000.00%
If one or several components are not required:
enter 0.00:1 or 0.00%.
1K application: Enter 0.00:1 or 0.00% for all
components except for one.
The ow is measured by volume and the mixing
ratio is entered and controlled volumetrically by
default.
Select product valves for available
components.
If one or several components are not required:
B valve = "---------"
1K application: Enter "---------" for all components
except for one.
Page 2
− Enter pot life.
− Select ushing recipes to be used:
Is carried out, ...
End: ... after this paint recipe has been used when end ushing is being carried out.
R-R: ... after this paint recipe has been used when the recipe is changed.
Mix: * ... when ushing just from the external mixer to the gun.
Pre: * ... before using this paint recipe.
(For whether a recipe change and / or end ushing comes rst: see Chapter 7.13.2, "Pre-ushing
after paint change ush" or "Pre-ushing after end ushing").
* May also be missing, depending on conguration.
Select empty eld if no ushing recipe is to be active.
Page 3 (option)
− Product pressure when lling and working.
Prerequisite: low-pressure system with automatic product pressure regulator.
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Page 4 (option)
− Flow regulation: pre-dene ow set value for this paint recipe.
Settings: "Flow regulation" see Chapter 7.13.2 (password level 3, page 19)
Page 5 (option)
− Flow monitoring: enter minimum and maximum ow in cc/min. (For example, with
robot applications to monitor nozzle wear and nozzle blockages.)
Prerequisite: gun monitoring or ow monitor.
Settings:
−
Activate "Flow monitoring" see Chapter 7.13.2 (password level 3, page 2)
"Alarm delay for ow monitoring" see Chapter 7.13.1 (password level 2, page 2)
−
If ow falls below or exceeds the limits, the system stops with alarm A121 or A122.
Page 6 (option)
− Batch Mode: pre-dene the Batch quantity for this paint recipe.
Prerequisite: accessories set for automatic lling + external signal transmitter
(e.g., foot-operated switch)
− Save recipe.
− VOC = Volatile Organic Compounds
If the local specications require a VOC measurement, then the corresponding VOC factor
must be entered in every paint recipe for each component.
Menu
1. Select newly entered paint recipe.
2. One after the other, touch components A / B / C / D and ushing A / B / C / D and
for each:
−
Enter the corresponding VOC factor in percent or g/L or g/G. The VOC measuring
unit is dened in the settings (see Chapter 7.13.1).
− Only if the corresponding factor is to be saved for all paint recipes:
− Calibration for the newly entered paint recipe:
According to Chapter 7.12.
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7.12 CALIBRATION
Coriolis measuring system: K factor = 60, 000 Imp/L
1. Enter "60, 000" in the Kn eld in all paint recipes for components with Coriolis
measuring system and then save.
2.
Perform zero point adjustment in accordance with "Coriolis Compact" user information
(Order No., see Chapter 1.3.1)
Flow meters and stroke sensors
Flow meters or stroke sensors must be calibrated. This produces a K factor for every
component. The K factors may vary depending on the lacquer (A1, A2, A3, ...). Therefore,
the K factors for each paint recipe are saved separately.
Flow meter: The default is the average from the calibration report. The default is
accurate and is a good match for most products. A calibration is therefore, not usually
necessary.
Stroke sensor: Calibration must be carried out.
When a calibration is performed, it should always be a precise process. Particular care
must be taken, to measure the volume in the measuring cup exactly and without air
bubbles.
Menu
Example: K factor for paint recipe
1. Select paint recipe:
2. Select component: B.
3. The system is under spraying pressure and the selected component is already in the
spray gun. Select the spray nozzle, so that pressure and product ow approximately
meet subsequent work processes.
[Start]
4. Start the measurement: [Start].
5. Use the gun to ll a certain quantity of the corresponding lacquer (e.g., 500 ml) into
a measuring cup. Use a protective tube against overspray if necessary.
The ow measured by the system is displayed on the screen.
6. Close the gun and push the [STOP] button. Wait until no more product ows.
7. Exactly measure the quantity lled into the measuring cup by weight, with one of
the following versions.
8. Enter the determined volume in the measuring cup eld.
9. The controller calculates and saves the new K factor and displays it in the Kn eld.
10. Press the [
11. Carry out the calibration several times in order to check the values.
In case of large deviations, eliminate the cause:
[Stop] Wait until no more product ows.
] icon in order to accept the new K factor.
Selection possibility: If the dierent lacquers of the same components have
similar characteristics, then the K factor can immediately be saved for all recipes.
Otherwise, only for the current recipe.
− Air in the lines
− Air mixture in the measuring cup
calculate the volume.
− The ow is not measured properly.
clean it and check it for any damage.
(with password level 1 or higher)
and for component B with ow meter.
.
ll the lines with product and check the suction system.
gauge the calibration and use the density to
Dismount the ow meter or stroke sensor,
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12. In all paint recipes, calibrate all components.
With identical ow meters (identical components) and identical lacquers or
lacquers with similar characteristics, the K factor can be taken over: Enter the
value directly in the Kn eld and then save.
Exact calibration, version 1 (Lacquer density is known)
− Weigh the quantity lled into the cup.
− Divide the weight in grams (g) by the lacquer's density. This directly equals the volume
in cc, that is entered in the measuring cup eld.
Exact calibration, version 2 (Lacquer density is unknown)
− First, manually measure precisely e.g., 500 cc of product into a measuring cup and
establish the product weight in "g" grams.
− Set empty measuring cup on the scale. When calibrating, use the gun to ll the cup
with the exact weight measure above.
− The initial volume (e.g., 500 cc) is entered in the measuring cup eld.
Select paint recipe (for A/B/C/D).
Flow quantity measured by the system.
Or select ushing valve (for A/B/C/D ushing valves).
Valve used by paint recipe.
0 bar
0cccc
0
Kn
K
Menu
K = Current K factor for selected component
(A,B,...).
Is saved in the selected paint recipe.
Imp/L
Imp/L
Start
Enter pressure at which calibration takes place.
(Only with "Automatic product pressure regulator" option.)
A
B
Select component A/B/C/D.
C
D
A
B
C
Displays list of A/B/C/D ushing
valves.
D
others
B_05458
Replaces the current K factor (K) for the selected
component (A,B,...) with the new K factor (Kn).
Depending on selection in the query which appears:
either only in the selected paint recipe,
or in all paint recipes.
Calibrate external ushing agent.
Kn = Newly calculated K factor
Input of quantity calculated with measuring cup
and scale.
Start measurement
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7.13 SETTINGS
7.13.1 PASSWORD LEVEL 2 SETTINGS
Menu
Level 2
There are 24 pages of settings. Depending on conguration, pages may be jumped.
The page numbers with a gray background always appear, the others are optional. (Detailed
descriptions of these pages can be found in the 2K COMFORT Software Documentation.)
1 Number of paint recipes and number of ushing recipes.
QB, QC, QD Control
See the software documentation, "Diagnosis" chapter.
Gun Delay Delay time for alarms A106 to A113 (set "Minimum ow" and "Maximum
ow" Chapter 7.13.2, level 3, page 4)
2 Post-alarm for pot life Once the pot life + post-alarm times have passed, the
system stops (alarms A132–A144). The alarm is repeated until the system is ushed.
If "Automatic ushing at pot life alarm" is activated, and the guns are in the gun ush
box, ushing is started automatically.
Alarm delay Flow monitoring Delay time for alarms A121 and A122. (Activate
"Flow monitoring", Chapter 7.13.2, level 3, page 2. Enter the limits in the paint
recipe see Chapter 7.11)
Atomizing air at alarm stop
Atomizing air at end of ushing
VOC measuring unit
Percent or gram per Liter.
So that coating can be completed without dripping.
To blow the air cap free.
Password for password level 1.
3 Hose dimensions from product valves A and B to mixer.
4 For 3K system: hose dimensions from product valve C to mixer.
5 For 4K system: hose dimensions from product valves C/D to mixer.
6 Hose dimensions from mixer to splitter valve.
7+8 − Page 7: Hose dimensions from mixer to gun 1.
− Page 8: Hose dimensions from splitter valve to gun 1.
Gun content of gun 1
Gun 1: Filling via the dump valve
Quantity (as a percentage), which should be
discharged via the dump valve. (The remainder passes via the gun.)
Gun 1: Flush atomizing air % hose content
When ushing: What percentage of the
hose content from the mixer to the gun, can still be used for coating. The atomizing
air (and electrostatics) for gun remains activated for this period when ushing.
See also "Flushing pause" (level 2, page 16).
Gun 1: dump valve ushing time after lling. (Only with ushable dump valve.)
9 Hose dimensions from gun 1 to the dump valve. (Only with "Dump valve as return ow".)
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10+11 Like pages 8 + 9, but for gun 2.
12+13 Like pages 8 + 9, but for gun 3.
14+15 Like pages 8 + 9, but for gun 4.
16 The ushing pause indicates that with "Atom.air on ush % of hose volume" the
remainder must be sprayed into the waste tank. The atomizing air remains on during
the ushing pause.
Pot life alarm
Additional spraying is also possible with "O".
Mixing alarm
(A100–A118, A128–A131, A145–A148). Additional spraying is also possible with "O".
Mixing alarm
(A100–A118, A128–A131, A145–A148). Additional spraying is also possible with "O".
17 Filling greater than hose content What percentage of the total hose content is
also to be lled between product valve and gun to ensure that there is no ushing
agent left in the hose.
Flow monitoring during lling
the dosing quality. Set limits with "Max. lling ow" or "Min. lling ow". If necessary,
the A valve cycles (see gure).
Reset pot life
Flushing "On" = Flushing is mandatory after a pot life alarm.
Flushing "On" = Flushing is mandatory after a mixing error alarm
Filling "On" = Filling is mandatory after a mixing error alarm
"On" = The ow is limited when lling to optimize
Pot life is reset manually.
Flow monitoring during lling
c
"A" valve open
a
"A" valve closed
b
(a)
During lling, the ow is regulated by a longer or shorter opening of the A valve.
(b)
"Filling time period" (in seconds)
(c)
"Maximum time period open" (in percent of (b))
Time
B_06130
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18 Save Start/Stop totals USB stick "On": Start/Stop totals are written continuously
to a USBstick (USB stick must be plugged in).
PC data archiving "On": Data are archived continuously on PC. (Operating manual
for PC data archiving, see Chapter 1.3.1)
19 For AIS-B:
AIS warning limit
valve as a percentage). If the value falls below this, a warning is triggered (W123 W125).
AIS lower limit
(Default value = 50%)
AIS upper limit
Thereby smooth operation is ensured. (Default value = 80%)
Valve > open AIS open
the stated time, too little product can ow through. The AIS allows more product
through. (Default value 1.0 sec.) Repetition after each repetition interval AIS open.
(Default value 0.5 sec.)
AIS open when stopped
operation is ended. (Default value 3)
AIS min. ow
(Default value 20 cc/min)
Minimum injection quality (opening time of hardener dosing
If the value falls below this, the AIS optimizes the injection quality.
If the value exceeds this, the AIS limits the injection quality.
If the B valve is continuously opened for longer than
Number of steps which the AIS is to open when mixing
Minimum ow of all components for AIS to undertake regulation.
20 For AIS-B:
AIS hysteresis
(e.g., close open) and are therefore inserted at the switchover points. (Default value
1)
AIS Number of cycles with X guns
close when an additional gun is switched on or o.
21+22 Like pages 19 + 20, but for AIS-C.
23+24 Like pages 19 + 20, but for AIS-D.
Number of steps which do not yet have impact when AIS switches
Number of steps which the AIS is to open or
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7.13.2 PASSWORD LEVEL 3 SETTINGS
Menu
Level 3
There are 23 pages of settings. (Detailed descriptions of these pages can be found in the
2K COMFORT Software Documentation.)
1 2K-, 3K- or 4K system (with 2-circuit system maximally 3K)
Measuring units for volume (liters / US gallons) and lengths (meter / inch)
Gun closed
Valves closed "On": When the gun is closed, all product valves are
also closed automatically. Benecial for low-pressure applications. Prerequisite: gun
monitoring (not ow monitor).
External release
"On" = External releasing (e.g. locking with spray booth's exhaust air)
Number of installed Universal CAN I/O modules
2 Number of guns (1–4, with 2-circuit system 1–2)
Gun monitoring for all available guns.
Splitter valve (Prerequisite: minimum 2 guns)
Flush guns separately
"On" = splitter valve with ushing (separate gun ushing
valves). Prerequisite: maximum 2 guns, splitter valve = On.
Number of gun ush boxes (GFB)
Automatic ushing at pot life alarm (Prerequisite: GFB)
Flow monitoring (On/O). Prerequisite: gun monitoring or ow monitor. Sets o
Alarms A121 and A122. ("Alarm delay for ow monitoring" Chapter 7.13.1, level 2,
page 2. Enter the limits in the paint recipe see Chapter 7.11)
3 Dump valve "On" = There is a dump valve installed for every gun. Or a dump valve
ushable. If a dump hose is present between gun and dump valve (not ushable), the
option dump valve as return line is activated. Dump valve for waste separation
is possible with double valves (not ushable) (not for 2-circuit system). Precision of
waste separation: 0 = exact, each additional number = 25% of the dump hose safety
margin (default value 2).
Dump valve outputs can be inverted
"O" = Compressed air opens dump valve
with non-ushable dump valves without waste separation.
"On" = Compressed air closes dump valve.
4 For component A:
Number of valves and ushing valves.
Minimum and maximum ow. Sets o Alarms A106 to A113. (Delay time "Gun Delay"
see Chapter 7.13.1, level 2, page 1)
Air bubbles monitoring (On/O)
Coriolis ow meter
Flow measurement with stroke sensors (On/O ), from software version 4.0x / 4.0x K.
To congure stroke sensors: see 2K COMFORT software documentation.
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5 Only for Coriolis:
Density area lower and upper value. The actual density must correspond to the
density display of the C-ow measuring transducer (with liquid in the system).
Correct the value here if necessary.
Temperature range lower and upper value. The actual temperature must
correspond to the temperature display of the C-ow measuring transducer (with
liquid in the system). Correct the value here if necessary.
6 Like page 4, but for component B.
7 For component B:
AIS (On/O)
Mixing head valve with cycles
valve cycles. "O" = B valve cycles.
Mixing head valve ushing
valve.
Input type for mixing ratio (A:B oder %B)
8 Like page 5, but for component B.
9–11 Like pages 6–8, but for component C.
12–14 Like pages 6–8, but for component D.
If a mixing head valve is tted: "On" = Mixing head
"On" = A ushing valve is attached to the mixing head
15 Alarm delay for air bubbles monitoring How long can an air bubble be present
before the system stops ( alarms A114–A117).
Alarm delay no ow during lling
alarm occurs (alarm A124). If set to 0.0 seconds, the function is deactivated.
Alarm delay no ow during ushing
before an alarm occurs (alarm A125)? When ushing, this alarm takes the place of
the pot life alarm. If the setting is "0.0 seconds", the function is deactivated, the pot
life continues and a pot life alarm occurs.
Alarm delay for Coriolis error (alarms A128–A131).
Remote control (On/O)
Robot (no/digital/bus): "Digital" = Robot is digitally connected. "Bus" = Robot is
connected via gateway.
Timeout for automatic logout
dened time, then the password level is automatically reset to level 0. ("0 sec" = no
automatic logout.)
How long can lling be interrupted before an
How long can ushing be interrupted
If the touch panel is not activated during the
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16 Batch Mode Allows a recurring and pre-dened ow rate to be discharged
(see software documentation).
Measuring unit for pot life
changeovers!)
Booster pump (O / A-side / Mix-side)
A valve selection at start
valve is to be used for the selected recipe.
Number of tanks for lling level monitoring.
17 Pre-ushing after end ushing "On" = After an end ushing, a pre-ushing must
be undertaken. Prerequisite: pre-ush recipe is dened and selected in the paint
recipes.
Pre-ushing after paint change ushing
undertaken after a recipe change ushing. Prerequisite: pre-ush recipe is dened
and selected in the paint recipes.
Flush interruption ok?
the new paint lled. "O" = The entire ushing process must be undertaken rst. If
ushing is aborted, the process starts again afresh.
Air ushing valve (On/O) "On" = Air ushing is tted.
External mixer (On/O)
Flushing external mixer as standard
mixer ushing ("Mix") of the last paint recipe used. ( Flushing from external mixer)
"O" = The FLUSHING push button starts end ushing ("End") of the last paint recipe
used.
minutes or seconds. (Change recipes accordingly after
"On": After starting, a prompt appears asking which A
"On" = A pre-ushing must be
"On" = The ushing process can be interrupted and e.g.,
"On" = The FLUSHING push button starts
18 Number of automatic product pressure regulators (0 / 1 / number of guns). "1" =
Automatic product pressure regulator in front of splitter valve. "Number of guns" =
An automatic product pressure regulator is tted for each gun.
Maximum product pressure for automatic product pressure regulator.
Pressure regulator fully open during ushing
For manual product pressure regulators: "On" = During ushing, the product pressure
regulator is subjected to full air pressure.
For automatic product pressure regulators: No function.
Pulse time at ush for prod.press reg.
For manual product pressure regulators, if the above function is switched on:
pulse time for changes between working pressure and full air pressure.
For automatic product pressure regulators: pulse time for changing between
ushing pressure (specied in recipe) and 0 bar.
"0.0 sec"= no cycling.
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19 Flow regulation (On/O).
P- (proportional-)part and I- (integral-)part of controller.
Number of ow measurements, which are included in the calculation.
Time period between the ow measurements.
20 Flow meter in external ushing agent (On/O).
Flow switch in external ushing agent (On/O).
Flushing monitoring in seconds (ushing with paint valves / ushing external mixer
/ gun ushing / dump ushing):
"no" = The ushing time runs, regardless of whether or not ushing agent ows.
"Gun monitoring" = The ushing time only runs when there is a gun signal.
Prerequisite: gun monitoring signal from ow monitor or robot, not from air
monitoring.
"Flow switch" = The ushing time only runs when there is a signal from the ow
switch. Prerequisite: "Flow switch in external ushing agent" is activated (see above).
21 * An information signal can be generated:
− As soon as the lling is complete (Setting "Filling complete: -> Information signal").
− As soon as the gun in the gun ush box must be changed (Setting "GFB gun change:
-> Information signal").
−
During the ushing process (see Chapter 7.10).
Duration of the alarm horn sounds according to "Information signal switch-on time"
and "Information signal break time". ("Number of cycles for information signal" =
How many information signal cycles should sound as soon as the lling is complete.)
22 * Warning signal on alarm horn (On/O ). Duration of sounds according to "Warning
signal switch-on time“ and "Warning signal break time".
23 ** Password level 2 / 3 Password input for password level2 / 3.
Reset initialization
initialization program starts (e.g., for training purposes). The current settings are
preset, nothing is lost.
Start software update
is required for this purpose (observe separate manual).
*from version 3.2x / 3.2x K
** Page 21 until version 3.1x / 3.1x K
"OK" = When the system is switched on the next time, the
"OK" = A software update is executed. Special knowledge
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7.14 OPERATING PANEL FOR 2CIRCUIT SYSTEM
The operating panel controls either the uid
circuit 1 or the uid circuit 2.
Example: Home page for circuit 1
A : B
AB : C
Gun
Pot life
Menu Act.
7.14.1 CHANGE FLUID CIRCUIT
Batch
PC
min
min
Current uid circuit:
= Fluid circuit 1
= Fluid circuit 2
1/2 = aects both uid circuits
Touch = Go to the other uid circuit
1
Background color of page:
Turquoise = Fluid circuit 1
Orange = Fluid circuit 2
White = both uid circuits
On the home page are always both pot lives,
each with the appropriate background
color:
Pot life Circuit 1
Pot life Circuit 2
Touch the current upper right uid circuit, for example:
Thereafter, the controller switches to the other uid circuit. The page remains the same.
Example: the controller changes from the menu page for circuit 1 to the menu page for
circuit 2.
Change not possible
This error message appears if the current page is not available in the other uid circuit:
Change to circuit X is not possible.
Go to another page (for example to the home page). Then change the uid circuit.
On some pages, the current uid circuit is framed in gray. Then a change to another circuit
is also not possible. Remedy is the same:
Go to another page. Then change the uid circuit.
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7.14.2 /K1 AND /K2
Names and alarm messages, which refer to a specic uid circuit, are marked with "/K1" or "/K2".
Name / Alarm message Meaning
…/K1 … Circuit 1
…/K2 … Circuit 2
… aects the total system
Gun name (example) Gun P2/K1 Gun P2 of circuit 1
Signal name (example) A1 valve/K2 A1 valve for circuit 2
Alarm message (example) A123 ushing rst/K1 Circuit 1 has to be ushed
Software version identication
2-circuit systems software versions are marked after the version number with the letter "K":
"x.xx K"
7.14.3 ACKNOWLEDGE ALARMS
STOP button Acknowledge alarm
Alarm Fluid circuit 1 STOP button Circuit 1 lights up Press the STOP button Circuit 1. *
Alarm Fluid circuit 2 STOP button Circuit 2 lights up Press the STOP button Circuit 2. *
Alarm System Both STOP buttons light up Press one of both STOP buttons. *
* Or touch the [Reset] button on the screen.
7.14.4 WHITE BACKGROUND: AFFECTS BOTH FLUID CIRCUITS
Everything relates to both circuits has a white background.
Fluid circuit 1 Fluid circuit 2 Valid for both uid circuits
Fluid circuit display (upper right)
1/2
Background color Turquoise Orange White
Example: Settings
Turquoise = Circuit 1. White = both circuits. Recipe change
2K, 3K or 4K
Measuring unit volume
Measuring unit length
Gun closed
External release
Number of universal CAN I/O
modules
Menu
Valves closed
Level 2
Level 3
2K
Liters
Meters
O
O
1
Recipe change
7 :R7
1
2
1
2
3 :R3
1/2
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8 OPERATION
Below, operation with manual guns is described. For automatic guns the same workow
applies correspondingly.
8.1 TRAINING THE OPERATING STAFF
The operating sta must be qualied to operate the entire system.
The operating sta must be familiar with the potential risks associated with improper
behavior as well as the necessary protective devices and measures.
Before work commences, the operating sta must receive appropriate system training.
8.2 SAFETY INSTRUCTIONS
Before carrying out any work, ensure that commissioning is carried out in accordance with
Chapter 6.6.
8.2.1 EMERGENCY DEACTIVATION
In the case of unforeseen occurrences:
− Switch o main switch.
− Switch o air supply of system and pumps.
− Point the manual gun into a grounded metal bucket. Open the gun's trigger mechanism
step by step in order to relieve the pressure. Avoid splashback.
− Secure the gun.
− Provide appropriate return tanks and relieve pressure from the pumps via the return valves.
− Inform the security personnel / foreman / superiors.
8.2.2 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN
Observe the operating manual of the spray gun.
WARNING
High-pressure spray jet!
Danger to life from injecting paint or solvent.
Never reach into the spray jet.
Never point the spray gun at people.
Consult a doctor immediately in the event of skin injuries caused by paint or solvent.
Inform the doctor about the paint or solvent used.
Never seal defective high-pressure parts, instead relieve the pressure from them and replace
them immediately.
Use personal protective equipment (protective clothing, gloves, eyewear and respiratory
protection).
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8.3 SWITCHES THE SYSTEM ON AND OFF
Switching the system on
1. Turn red-yellow main switch on the right side of the control cabinet to ON. The software
is started.
2. Turn on the air supply of the system and of all feed pumps. Prepare feed pumps,
lacquer tank etc. for operation. Provide grounded metal bucket to collect the
products to be disposed of.
Switching o the system
1. Press the STOP push button.
Flush system if necessary (see Chapter 8.6).
2.
3. Make sure that the system has been ushed and that the pot life has been increased.
Relieve pressure from the system and from all feed pumps (see Chapter 8.8).
4.
5. Switch o main switch (OFF).
6. Switch o air supply of system and pumps.
8.4 MALFUNCTION
If a fault occurs, it is indicated by the following:
The system stops and the alarm horn sounds
The red STOP push button lights up (control cabinet and remote control).
The fault is indicated on the screen.
Acknowledge fault
By means of the STOP push button or, on the screen, with the [Reset] button.
Alarm messages + fault rectication
see Chapter 10.
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8.5 SPRAYING MODE
8.5.1 PREREQUISITES
Optimum painting results are obtained if:
− The system parameters are set correctly.
− Product data such as the mixing ratio and pot life correspond to the working material.
− The ushing program is dened.
− The supply pressures are constant.
The A/B/C/D pressure ratio is set correctly (see Chapter 8.5.2).
−
− AIS is used.
Or without AIS: If the dosing valve (B side) is set using the valve stroke such that as many
cycles are undertaken as possible (depending on ow rate and mixing ratio every
0.5 - 2 seconds). See the operating manual for the valves (Order No. in Chapter 1.3.1).
− The product pumps can draw in the product perfectly and no cavitation occurs with
piston pumps (pump breaking through during down stroke). If necessary, the product
must be fed with a feed pump.
Optimum operation is fullled under the following conditions:
− When the ushing agent pressure for the ushing pumps as well as the product
pressure for the A, B and C pumps are always present on the device.
− When lling the mixed product in the product hose ensure that the nozzle is inserted
in the gun.
− When the ushing process is performed without the nozzle in the gun.
− When the levels in the product and ushing agent tanks are checked visually, in order
to prevent unintended interruptions in the spray process.
Prerequisites
At the start, all pumps must be lled with working material and the system must be
−
ready to start, as described in Chapter 6.6.5.
− The nozzle is inserted into the gun. Gun secured.
− Operating manuals for the aected components must be known.
− With an electrostatic gun:
Commissioning the electrostatics according to corresponding operating manual.
8.5.2 A/B/C/D PRESSURE RATIO
− Set the pressure ratio between base lacquer and hardener correctly. With a mixer:
B must be approx. 5–10% higher than A. C approx. 2–5% higher than B, D approx. 2–5%
higher than C.
− The pressure drop between pressure gauge and mixer can be dierently for A/B/C/D.
For longer distances, dierent ow rates and viscosities that may be relevant (e.g., for
external mixer or if the pressure gauges are at the pumps).
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8.5.3 SPRAYING WITHOUT GUN FLUSH BOX
Provide grounded metal bucket to collect the products to be disposed of.
Insert spray nozzle into manual gun.
The product pressure of the components is set depending on the required product
ow rate. Thereby, keep in mind that the the B-component pressure must be higher
(5 to 10%) than that of the A-component.
Select the requested paint recipe on the screen (home page). In case of two spray
guns, select the requested gun(s).
Start the coating process by means of the START push button.
Filling
For electrostatic spray guns: switch o electrostatics.
Point the manual gun with inserted spray nozzle into the grounded metal bucket.
Open the trigger mechanism of the spray gun step by step. Avoid splashback.
The 2K product starts to ow and the B-component is dosed proportionally to the
A-component. During lling, three screens in turn inform you of lling progress:
B_04637
B_04638
B_04639
From product valves to mixer.
From mixer to splitter valve.
From splitter valve to gun.
As soon as the complete high-pressure hose is lled with 2K product, the following
will happen:
− "Filling" screen switches to the home page.
− The green START push button begins to light up.
− Remote control (Option): The green lamp begins to light up.
− Atomizing air is added (option).
Correctly mixed product is not transported from the gun until after lling.
Coating
For electrostatic spray guns: safety precautions according to corresponding the
operating manual.
Start coating of an object.
The ushing agent pressure for A and B must always be applied at the device.
The ow rate of the system depends on:
− the product pressure,
− the hose lengths and cross-sections,
− the nozzle and
− the viscosity of the products.
Without AIS, the B pulse valve should operate every 0.5 to 3 seconds, according to the
ow rate. The switching frequency can be optimized by adjusting the pressure of the
hardener pump or through the stroke length of the hardener dosing valve. The higher
the pulse rate is, the more homogeneous is the mixing of the two components.
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8.5.4 SPRAYING WITH GUN FLUSH BOX
Same procedure as in Chapter 8.5.3, however:
before actuating the START push button, insert the spray gun into the gun ush box.
Remove the spray gun after lling.
8.5.5 INTERRUPTING WORK
The STOP push button stops the coating process. All product valves are closed.
For electrostatic spray guns: switch o electrostatics.
8.5.6 CHANGING THE PAINT RECIPE
The recipe change ush is executed on all spray guns while the spray
nozzle is inserted.
Actuate the STOP push botton.
Select the new paint recipe on the screen (home page).
Without gun ush box With gun ush box
− Press START push button. − Insert spray gun(s) in gun ush box.
− Point the spray gun into the metal
bucket. Open the gun step by step.
Avoid splashback. − Press START push button.
The system is ushed (recipe change ushing " ").
Subsequently the new lacquer is lled.
As soon as the green START push button lights up and the home page appears on the
screen, the system is ready for spraying.
8.5.7 A VALVE SELECTION AT START
Possibly, a list of the A valves appears for selection at the start. Touch desired valve.
The option is set with the setting "Select A valve during start" (see Chapter 7.13.2).
8.5.8 CIRCULATION OPTION
If necessary, the A, B or C components not in use have to be circulated.
The spray gun is automatically opened
as necessary.
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8.6 FLUSHING
DANGER
Exploding gas / air mixture!
Danger to life from ying parts and burns.
Never spray into a closed tank.
Ground the tank.
If a high-pressure gun is used, remove the spray nozzle before ushing.
The pressure has to be relieved before removing the spray nozzle (see Chapter 8.8).
−
Wear protective goggles.
Apply the lowest possible product pressure for ushing so that the maximum ow rate
of the ow meter is not exceeded.
WARNING
High-pressure spray jet!
Danger to life from injecting paint or solvent.
Never reach into the spray jet.
Never point the spray gun at people.
Consult a doctor immediately in the event of skin injuries caused by paint or solvent.
Inform the doctor about the paint or solvent used.
Never seal defective high-pressure parts; instead relieve the pressure from them and
replace them immediately.
Use personal protective equipment (protective clothing, gloves, eyewear and respiratory
protection).
The system has to be ushed:
in case of recipe change (recipe change ushing, system ushes automatically);
in case of extended interruption of work or end of work (end ushing);
if pot life has been exceeded (end ushing).
WARNING
Discharge of the electrostatics in atmospheres containing solvents!
Fire and explosion hazard.
Turn o the electrostatics before ushing the gun or before placing the gun in the
gun ush box.
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End ushing
The FLUSHING push button normally starts the end ushing of the last
paint recipe used.
1. Stopping the system.
2. For electrostatic spray guns: switch o electrostatics.
3.
4. Point the opened gun(s), with or without nozzle, into a waste tank until the ushing
During ushing, the blue FLUSHING push button lights up. The screen gives step by step
information about the individual ushing steps.
Step
Finally, all valves are closed.
If cleaning is insucient, ushing can be repeated. The ushing recipe can be corrected
subsequently.
Flush with external mixer
Actuate FLUSHING push button.
process has been terminated.
1
3
Current ushing recipe
Flushing step 1 of 5
Flushing valve currently open
Progress indication
Guns to open during this ushing step.
Gun symbol ashes
Open gun.
Setting "Flushing ext.
mixer is standard" *
On
O Starts the end ushing ("End") of the last paint recipe used.
* see Chapter 7.13.2
Atomizing air ushing
The system can be set such that the atomizing air remains switched on for ushing during
a certain time. Thus, the mixed product in the hose can be sprayed. A short ushing pause
indicates that the remainder has to be sprayed into the waste tank. (Settings, see
Chapter 7.13.1.)
FLUSHING push button
Starts the mixer ushing ("Mix") of last paint recipe used.
Flushing from external mixer.
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Start other ushing recipes
For electrostatic spray guns: switch o electrostatics.
On the screen's home page.
Depending on the conguration, various selection possibilities appear:
− Manual ushing: select a recipe from the list of all recipes.
− Start end ushing: starts end ushing of the last paint recipe used.
− Start ushing external mixer: ushing from external mixer. The product hoses between
valves and mixer are not ushed.
− Flushing spray guns: ushing from splitter valve. The product hoses between valves
and splitter valve are not ushed.
Flushing with dump valve (option)
Flushing via a dump valve is quicker than via the gun. However, the gun has also to be
ushed briey.
When the ushing process stops and the spray gun symbol on the screen ashes, the
corresponding guns have to be opened. Point opened gun(s) with or without nozzle
in a waste tank.
1
Step
2
As soon as the gun symbol stops ashing, close gun again.
Flushing with gun ush box
Same procedure as without gun ush box, but:
Before ushing, insert the spray gun into the gun ush box.
− Atomizing air ushing: the ushing pause indicates when the gun is to be inserted
into the gun ush box.
Remove the spray gun after ushing.
As long as the gun symbol
ashes, open the corresponding
spray gun (here gun 2).
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8.7 FLOW CHART WITH PAINT RECIPE CHANGE
Example for 2K system:
Spraying with paint recipe
Recipe change ushing
Mixed
product R-R FlushingA Filling
1. Stop
2.
3. Start
Pre-ushing
Pre-ushing may be necessary between
R-R ushing and lling (see Chapter 7.11).
Filling of A and B up to
mixing block separately
B
Filling
Spraying with paint recipe
A+B
Filling
Filling the spray hose with mixed
products
Mixed
product End ushing
1. Stop
2. End ushing
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8.8 PRESSURE RELIEF PROCEDURE
The system pressure must be manually relieved to prevent the system from starting or spraying
accidentally.
To reduce the risk of an injury from injection, splashing uid or moving parts, follow the
steps in this chapter whenever:
you are instructed to relieve the pressure;
spraying is stopped;
part of the system is checked or maintained;
the nozzle is installed or cleaned.
WARNING
High-pressure spray jet!
Danger to life from injecting paint or solvent.
Never reach into the spray jet.
Never point the spray gun at people.
Consult a doctor immediately in the event of skin injuries caused by paint or solvent.
Inform the doctor about the paint or solvent used.
Never seal defective high-pressure parts; instead relieve the pressure from them and
replace them immediately.
Use personal protective equipment (protective clothing, gloves, eyewear and respiratory
protection).
Pressure relief procedure for the whole system
1. Press the STOP push button.
2. Relieve the product pressure and air pressure in all pumps or pressure tanks. Use return
/ circulation, according to the instructions in the corresponding operating manuals.
3. For electrostatic spray guns: switch o electrostatics.
4.
Menu
One after the other and in each component (A, B, ush, ...) for each product valve (A1, A2, ...):
− Select valve and open it with the large valve button.
− Point the manual gun into a grounded metal bucket. Open the gun's trigger
mechanism step by step in order to relieve the pressure. Avoid splashback.
− Close and secure gun.
5. Press the [STOP] button.
(see Chapter 7.8)
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9 CLEANING AND MAINTENANCE
9.1 CLEANING
9.1.1 CLEANING STAFF
Cleaning work should be undertaken regularly and carefully by qualied and trained sta.
They should be informed of specic hazards during their training.
The following hazards may arise during cleaning work:
− Health hazard from inhaling solvent vapors
− Use of unsuitable cleaning tools and aids
9.1.2 SAFETY INSTRUCTIONS
Before all work on the device and in the event of work interruptions:
− Relieve pressure from spray guns, high-pressure hoses and all devices.
− Secure spray guns against actuation.
− Switch o the energy and compressed air supply.
− Disconnect the control unit from the mains.
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the device.
9.1.3 FILTER CLEANING
Product lter: check and clean lter insert and lter body. When opening the lter,
ensure that no product drips on the ow meter's electronics.
The lters of the piston pumps and guns should be cleaned in accordance with the
corresponding operating manuals.
9.1.3.1 CONDENSATE DRAINAGE FROM THE FILTER PRESSURE REGULATOR
Frequently drain the condensate that may accumulate in the air lter.
− Make sure the water level in the lter cup never reaches the max. level marked
on the cup itself.
WARNING
Brittle lter pressure regulator!
The tank on the lter pressure regulator becomes brittle through contact with solvents
and can burst. Flying parts can cause injury.
Do not clean the tank on the lter pressure regulator with solvents.
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9.1.4 CLEANING THE SYSTEM
The system should be cleaned for maintenance purposes. Ensure that no remaining
product dries on and sticks to the device.
A cleaned system allows an easy localization of any leakage and quick repair.
Procedure:
1.
Relieve the pressure according to Chapter 8.8.
2. Service guns and pumps according to their operating manuals.
3. Clean and check the suction systems and suction lter.
4. Product lter: check and clean lter insert and lter body.
5. Put the whole system back together.
6. Clean the outside of the system.
9.1.5 DECOMMISSIONING
1.
Clean the system according to Chapter 9.1.4.
Fill the entire system with ushing agent. As laid down in Chapter 6.6.5, but with
2.
ushing agent.
WARNING
Gas mixtures can explode if there is an incompletely filled pump!
Danger to life from ying parts.
Ensure that the device is always completely lled with ushing agent or working medium.
Do not spray the device empty after cleaning.
9.1.6 LONGTERM STORAGE
If storing the system for a prolonged period of time, thorough cleaning and corrosion
protection are necessary. For the last rinse, replace the water or solvent in the product
pumps with a suitable preservative. Fill separating agent cup with separating agent.
Store pump vertically.
Procedure:
1.
Clean the system according to Chapter 9.1.4.
Fill the entire system with ushing agent. As laid down in Chapter 6.6.5, but with
2.
ushing agent.
Fill the entire system with preservative according to Chapter 6.6.5 and the lacquer
3.
supplier's instructions.
4. If the discharge duct is to be removed, seal product outlet with plug.
5. If the suction system is to be removed, seal product inlet with plug.
Storage according to Chapter 6.2.
6.
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9.2 MAINTENANCE
9.2.1 MAINTENANCE STAFF
Maintenance work should be undertaken regularly and carefully by qualied and trained
sta. They should be informed of specic hazards during their training.
The following hazards may arise during maintenance work:
− Health hazard from inhaling solvent vapors
− Use of unsuitable tools and aids
An authorized person must ensure that the device is checked for being in a reliable state
after maintenance work is completed.
9.2.2 SAFETY INSTRUCTIONS
Prior to maintenance
−
Cleaning and ushing the device. Chapters 8.6 and 9.1.4.
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Only repair and replace parts that are listed in the "Spare parts" chapter and that are
assigned to the unit.
Before all work on the device and in the event of work interruptions:
− Relieve pressure from spray guns, high-pressure hoses and all devices.
− Secure spray guns against actuation.
− Switch o the energy and compressed air supply.
− Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
Repair or replacement of devices or parts of devices are only allowed to be performed
outside the hazard area by qualied personnel.
After maintenance
−
Put the system into operation and check for leaks. Section 6.6
In accordance with DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36:
− The liquid ejection devices should be checked by an expert (e.g., WAGNER
service technician) for their safe working conditions as required and at least
every 12 months.
− For shut down devices, the examination can be suspended until the next start-up.
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9.2.3 GEAR FLOW METER
The gear ow meters (A/B/C/D) are cleaned by ushing.
If individual parts have to be cleaned, the ow meter should be disassembled. Care should
be taken that these parts are installed again in their original positions.
1. Remove the electronic sensor (1) from the ow meter.
− The electric sensor can be removed by
loosening the two screws (10) from the holes
without removing the cover (11).
2. Unscrew the screws (2) - two opposite screws
should be left, temporarily screwed in by two turns.
3. Carefully take the lid (3) o the ow meter parallelly.
− If necessary, softly knock on the lid with a
plastic hammer so that it loosens.
− The lid must be removed parallelly so that
the internal bearings are not stressed and the
shaft (5) does not break.
− For this reason do not use screwdrivers as levers.
3
2
5
5
12
7
1
11
10
B_04655
4. Remove the screws which had previously been left screwed in.
5. Remove the lid, the gears (7) and the shafts (5).
− In most cases a dirt particle in the ow meter causes the problem.
− If the parts cannot be disassembled easily, put the ow meter into a suitable
solvent and then disassemble the parts.
− Do not disassemble the parts by force!
− It is important that the gears turn on the shaft, if they don't, the ow meter is not
suitable for the lacquer.
Contact WAGNER Service Department for further information.
Assembly
After cleaning the gear ow meter and assembling the shafts and gears into the housing,
check whether they turn easily, without any obstruction. This has to be the case even when
a nger slightly presses against the shafts laterally.
1. Mount the lid again in parallel position and adjust it in the correct position by means
of both dowel pins (12).
These pins must never be removed from the ow meter housing.
2. Tighten the screws with 15 Nm; 11.06 lb/ft.
3. Check if the gears turn by using a short pulse of compressed air, maximum 0.1 MPa;
1 bar; 14.5 psi.
4. Mount the electronic sensor again. Do not interchange A/B/C ow meters.
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9.2.4 CLEANING AND REPLACING THE PRODUCT FILTER
1. Flush the pump and inline lter in accordance with pump's
operating manual. Flush using the gun so that the ushing
agent ows through the inline lter. Maximize the ow (remove
the nozzle, open the dosing valve if necessary).
2. Empty the pump in a controlled manner in accordance with
pump's operating manual.
3. Place the grounded collection tank under the inline lter.
4. Unscrew the lter by turning the handle (4).
5. Remove the lter insert (3).
6. If the inline lter has any leaks, replace the seal (1).
7. Insert the new lter insert (3). Note the installation position:
Closed end in direction of ow.
8. If necessary, coat the thread with anti-seize paste (10).
9. Assemble the turning handle (4), inlet housing (2) and outlet
housing(5) and tighten by turning the handle.
10. Fill the pump in accordance with pump's operating manual.
9.2.5 PRODUCT VALVES
Example 2.6 mm valve
Leakage hole
53MPa; 530bar; 7,687psi
2
1
3
Flow direction
* For Order No., see spare parts catalog
Rod seal
(pneumatic O-ring)
4
5
B_05273
Check the leakage behavior of the product valves
(air or product discharge from the leakage hole) in regular
intervals (once per week).
In case of air leakage: change rod sealing.
In case of product discharge:
− 2.6 mm valve: re-tighten sealing screw or change the seals.
− 4 mm valve: change the seals.
Check the leakage behavior of the valve seats at regular intervals, by executing a
pressure retention test in accordance with Chapter 6.6.4.
Disassembly and assembly, see valve operating manual (Order No. in Chapter 1.3.1).
Product sealings
Sealing screw
B_04679
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9.2.6 PRODUCT HOSES, TUBES AND COUPLINGS
The service life of the complete hoses between product pressure generator and application
device is reduced due to environmental inuences even when handled correctly.
Check hoses, pipes, and couplings every day and replace if necessary.
Additionally, the operator must regularly check the complete hoses for wear and tear
as well as for damage at intervals that he/she has set. Records of these checks must
be kept.
Undamaged complete hoses are to be replaced when one of the two following intervals
has been exceeded:
− 6 years from the date of the hose crimping (see tting embossing).
− 10 years from the date of the hose imprinting.
Fitting embossing
(if present)
xxx bar Pressure
yymm Crimping date (year/month)
XX Internal code
Hose imprinting Meaning
WAGNER Name / Manufacturer
yymm Date of manufacture (year/month)
xxx bar (xx MPa)
e.g., 270 bar (27 MPa)
XX Internal code
DNxx (e.g., DN10) Nominal diameter
Meaning
Pressure
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10 TROUBLESHOOTING
If a fault occurs, it is indicated by the following:
The system stops.
The alarm horn sounds.
Control cabinet: The red STOP push button lights up.
The fault is indicated on the screen.
Remote control (option): The red LED STOP lights up.
Acknowledge fault
Stop with the STOP push button.
Or by means of the [Reset] push button on the screen.
List of alarm messages and warning messages: see Chapter 10
Fault rectication
See the following table and Chapters 10.1.1 and 10.2.1.
For troubleshooting, it is important which work steps were last carried out.
The troubleshooting within the electric cabinet should be carried out by qualied
persons (e.g., industrial electrician)!
WARNING
Electric shock hazard inside the control unit!
Danger to life from electric shock.
May only be installed/maintained by skilled electricians or under their supervision.
Operation according to the safety regulations, re protection and electrotechnical
rules.
Must be de-energized before work is commenced on active parts.
Malfunction Remedy
System does not start up− Check air supply line connection.
− Check the pressure value on the system's pressure gauge for the air supply to the
valves.
− Check the voltage supply (does the control panel light up?)
− Check the selected valves.
− Check the fuses.
System is in operation
(a pump is running),
but there is no product
ow
System does not supply
any product, pumps do
not run
− Check the supply lines of the components as well as lters (clogging) and suction
tubes (leakage).
− Check the component level in the supply tanks.
− Check the viscosity of the components or the pressure loss.
− Check the mixing tube and feed hoses.
− Check the guns and the gun lter.
− Clean the lines by ushing or cleaning manually.
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Malfunction Remedy
The 2K product does
not react correctly
Flow rate is too low − Check the mixing tube and feed hoses.
Product valves: − See product valve's operating manual.
− Product- or air
emission from
leakage hole
− No product
transportation
− Contamination
Interruption of circuit
over a longer period of
time
A fuse is defective.
LED lights up
The system supplies
product, but the spray
pattern is inadequate
Flow rate is too high − Replace gun nozzle (Airless and AirCoat).
− Check the mixing ratio value.
− Check the suction lines (leakage).
− Check the ow meter with a calibration process.
Check pressure dierences. see Chapter 8.5.2
−
− Check AIS function (see software documentation, "Diagnosis" chapter).
− Without AIS: Optimize the switching behavior of the hardener dosing valve in
spraying mode (0.5 - 3 seconds) via the dierential pressure of B to A or via the
stroke setting of the valve.
− Check the lacquer specications.
− Check the guns and the gun lter.
− Clean the lines by ushing or cleaning manually.
− Increase the pressure of the supply pumps.
− With external compressed air, manually open the ushing valve and distributor
valve (option).
− Check on the basis of the control cabinet diagram whether a cable is damaged.
− Replace the fuse.
− Ensure that the supply pressures are constant.
Adjust the A/B/C/D pressure ratio. see Chapter 8.5.2
−
− Increase the pressure of the supply pumps.
− AirCoat: Set the atomizing air correctly.
− Check product lter on pumps, 2K systems and guns.
− Replace gun nozzle with a more suitable nozzle (Airless and AirCoat).
− Check the viscosity of the product and dilute it in accordance with the lacquer
manufacturer's instructions. If necessary correct the mixing ratio.
− AirCoat: Ensure that only dry, clean atomizing air is used in the spray gun.
− Check the lines for leakage.
− Set the opening of the gun needle correctly (air guns only).
− Decrease the pressure of the supply pumps.
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10.1 ALARM MESSAGES
In the case of an alarm message, the system stops. The alarm horn sounds.
The red STOP push button lights up (control cabinet and remote control).
The fault is indicated on the screen.
Alarm No. Alarm message in the display Meaning
A100 B+ tol. alarm
Mixing ratio outside of tolerance range. B+/C+/D+: too much B/C/D.A101 C+ tol. alarm
A102 D+ tol. alarm
A103 B– tol. alarm
Mixing ratio outside of tolerance range. B–/C–/D–: too little B/C/D.A104 C– tol. alarm
A105 D– tol. alarm
A106 A+ ow rate
A107 B+ ow rate
A108 C+ ow rate
A109 D+ ow rate
A110 A– ow rate
A111 B– ow rate
A112 C– ow rate
A113 D+ ow rate
A114 Air bubble A
A115 Air bubble B
A116 Air bubble C
A117 Air bubble D
A118 Flow meter A Flow meter A is blocked.
A119 Gun monitoring No gun signal, although product is owing.
A120 No enabling signal External release missing.
A121 Flow fault – The ow rate is below the limit entered in the paint recipe.
A122 Flow fault + The ow rate is above the limit entered in the paint recipe.
A123 Flushing rst The system has to be ushed.
A124 No ow during lling The lling procedure is interrupted for too long.
A125 No ow during ushing The ushing procedure is interrupted for too long.
A126 Gun monitoring disabled
A127 K factor is 0! A K factor for the current paint recipe is zero. Calibrate.
Maximum ow of components A/B/C/D exceeded.
Falls below minimum ow of components A/B/C/D.
Air bubble in the line (only with low-pressure).
Function is selected, which requires gun monitoring. However,
the gun monitoring is deactivated.
Acknowledge alarm: By means of the STOP push button or on the screen with the [Reset]
button.
Fault rectication: see Chapter 10.1.1
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Alarm No. Alarm message in the display Meaning
A128 Coriolis A
A129 Coriolis B
A130 Coriolis C
A131 Coriolis D
A132 Pot life gun 1
A133 Pot life gun 2
A134 Pot life gun 3
A135 Pot life gun 4
A136 Pot life gun hose 1
A137 Pot life gun hose 2
A138 Pot life gun hose 3
A139 Pot life gun hose 4
A140 Pot life to spl. valve The pot life + post-alarm time from mixer to splitter valve have expired.
A141 Pot life dump hose 1
A142 Pot life dump hose 2
A143 Pot life dump hose 3
A144 Pot life dump hose 4
A145 Tank A is empty
A146 Tank B is empty
A147 Tank C is empty
A148 Tank D is empty
A149 Tank ushing agent is empty Flushing agent tank is empty.
A150 Flow is too low
A151 Flow is too high
For Coriolis error, see operating manual of Coriolis ow meter.
Pot life + post-alarm time of guns 1/2/3/4 have expired.
Pot life + post-alarm time of gun hoses 1/2/3/4 have expired.
Pot life + post-alarm time of dump hoses 1/2/3/4 have expired.
Tank for component A/B/C/D is empty.
The setpoint ow is not reached with the ow regulation.
Acknowledge alarm: By means of the STOP push button or on the screen with the [Reset]
button.
Fault rectication: see Chapter 10.1.1
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Alarm messages with stroke measurement
Alarm No. Alarm message in the display Meaning / Fault rectication
A200 Unknown error Error number unknown.
A201–
A204
A205–
A208
A209–
A212
A213–
A216
A217–
A220
A221–
A224
A225–
A228
A229–
A232
A237–
A240
A241 Unknown operating mode
A242 SensorA unknownSelection
A243 SensorB unknownSelection
A244 SensorC unknownSelection
A245 SensorD unknownSelection
A246 Sending: unknown SensorNo.
A247 Sending: unknown Parameter
A248 Wrong data value
A249 Reading: unknown SensorNo.
A250 Reading: unknown Parameter
A254 MPX sends in operation
A256 MPX transfer error
A257 Data conict Dierent settings data on MPX / ADC and touch panel.
A258 MPX is not sending data
A259 MPX is not responding
A260 Sending to MPX interrupted
A261 Data from wrong sensor Communication error
Sensor A/B/C/D signal is lost
SensorA/B/C/D
LowerReversePoint
SensorA/B/C/D
UpperReversePoint
Sensor A/B/C/D dry run down Pump sags in downward stroke, pump cavitating.
A/B/C/D sensor dry run up Pump sags in upward stroke, pump cavitating.
Sensor A/B/C/D initialization Stroke sensor initialization error.
Sensor A/B/C/D unknown.
error
Sensor A/B/C/D wrong type Stroke sensor type does not match the setting.
ADC1/2/3/4 no response Communication error
Stroke sensor cable breakage or sensor signal lost
(sensor is in lower idle position).
Lower stroke sensor reversal point not detected.
Upper stroke sensor reversal point not detected.
Error number unknown.
Communication error
Communication errorA255 MPX unknown message
Communication error
The sending of settings data to the MPX and ADC was not
terminated.
Acknowledge alarm: By means of the STOP push button or on the screen with the [Reset]
button.
Fault rectication: see Chapter 10.1.1
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CAN I/O modules alarm messages
Alarm No. Alarm message in the display Meaning
A500 Initialisation error Internal error when starting up the touch panel.
A501 CAN master error The touch panel CAN master process not possible.
A502 CAN master alone
A503 SDO sending error
A504 SDO receiving error
A505 Saving interrupted Error while saving on the PC.
A600 Module D2 no communication
A601 Module D3 no communication
A602 Module D4 no communication
A603 Module D5 no communication
A604 Gateway D6 no communication
A606 Module D2 CAN emergency
A607 Module D3 CAN emergency
A608 Module D4 CAN emergency
A609 Module D5 CAN emergency
A610 Gateway D6 CAN emergency
A612 Module D2 CAN error
A613 Module D3 CAN error
A614 Module D4 CAN error
A615 Module D5 CAN error
The touch panel CAN master found no connected
slaves on the CAN bus.
Error while sending or receiving SDO telegrams.
No communication to the corresponding module.
Module sends an emergency telegram.
Slave reports communication problems.
Acknowledge alarm: By means of the STOP push button or on the screen with the [Reset]
button.
Fault rectication: see Chapter 10.1.1
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Alarm No. Alarm message in the display Meaning
A616 Module D2 hardware error EEPROM
A617 Module D3 hardware error EEPROM
A618 Module D4 hardware error EEPROM
A619 Module D5 hardware error EEPROM
A620 Module D2 hardware error ADC
A621 Module D3 hardware error ADC
A622 Module D4 hardware error ADC
A623 Module D5 hardware error ADC
A624 Module D2 hardware errror TIMER
A625 Module D3 hardware errror TIMER
A626 Module D4 hardware errror TIMER
A627 Module D5 hardware errror TIMER
A628 Module D2 unknown hardware error
A629 Module D3 unknown hardware error
A630 Module D4 unknown hardware error
A631 Module D5 unknown hardware error
A632 Module D2 hardware error counter
A633 Module D3 hardware error counter
A634 Module D4 hardware error counter
A635 Module D5 hardware error counter
A640 Module D2 DO group1
A641 Module D2 DO group2
A642 Module D2 DO group3
A643 Module D2 DO group4
A644 Module D3 DO group1
A645 Module D3 DO group2
A646 Module D3 DO group3
A647 Module D3 DO group4
A648 Module D4 DO group1
A649 Module D4 DO group2
A650 Module D4 DO group3
A651 Module D4 DO group4
A652 Module D5 DO group1
A653 Module D5 DO group2
A654 Module D5 DO group3
A655 Module D5 DO group4
Hardware error in I/O module.
Voltage supply error.
Acknowledge alarm: By means of the STOP push button or on the screen with the [Reset]
button.
Fault rectication: see Chapter 10.1.1
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10.1.1 FAULT RECTIFICATION
A100/A101/A102 B+/C+/D+ tol. alarm
The mixing ratio within a specic control quantity (QB/QC/QD control) was not reached:
too much B, C or D.
−
Reduce pressure of B/C/D: see Chapter 8.5.2
− Without AIS:
− The stroke at the B/C/D valve is too long. Close the regulating screw a little.
− Check the cycle length of the hardener dosing valve (menu
0.5 to 3 seconds are optimal. If the cycle length is too long, then the dierence
in pressure is still too great or the stroke is too long.
− With AIS:
− If the stroke of the B/C/D valve is far from its ideal position, the adjustment can
take a long time under some circumstances.
AIS position a bit.
− Check whether valve closes. Clean valve.
−
The ow meter A is blocked by soiling. The LED at the ow meter has to light up during
product ow, otherwise it is clogged (cleaning, see Chapter 9.2.3).
− Check whether nozzles, mixer or lter are clogged.
− Check the level of the paint tank, condition of the feed pumps, etc.
− The QB/QC/QD control quantity may be set too low (standard 150 cc). If the quantity is
increased, the control algorithm becomes more stable because more time is available
in order to achieve the mixing ratio.
Home page: [AIS], then reduce the
diagnosis).
A103/A104/A105 B–/C–/D– tol. alarm
The mixing ratio within a specic control quantity (QB/QC/QD control) was not reached:
too little B, C or D.
−
Increase the pressure of B/C/D: see Chapter 8.5.2
− Without AIS:
− The stroke at the B/C/D valve is too short. Open the regulating screw a little.
− Check the cycle length of the hardener dosing valve (menu
3 seconds are optimal. If the valve is always open (cycle check display is almost
continuously lit), then the dierence in pressure is still too small or the stroke is
too short.
− With AIS:
− If the stroke of the B/C/D valve is far from its ideal position, the adjustment can
take a long time under some circumstances.
the AIS position a bit.
− Check whether the valve opens. Clean valve.
−
The ow meter B or C or D is blocked by soiling. The LED at the ow meter has to light
up during product ow, otherwise it is clogged (cleaning, see Chapter 9.2.3).
− Check whether nozzles, mixer or lter are clogged.
− Check the level of the paint tank, condition of the feed pumps, etc.
− The QB/QC/QD control quantity may be set too low (standard 150 cc). If the quantity is
increased, the control algorithm becomes more stable because more time is available
in order to achieve the mixing ratio.
Home page: [AIS], then enlarge
diagnosis). 0.5 to
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A106/A107/A108/A109 A+/B+/C+/D+ ow rate
The ow is greater than the upper limit of the ow meter "Maximum ow" (see Chapter 7.13.2,
level 3, page 4).
− The ow rate has to be reduced.
− Insert nozzle.
− Possibly worn nozzle, leaking hose or other leaking parts.
A110/A111/A112/A113 A–/B–/C–/D– ow rate
Gun monitoring signal is present, even though no product is owing (gun closed).
− Check the atomizing air for leaks.
− Check whether the gun monitoring operates correctly.
−
Possibly, the "Gun delay" is set too short (see Chapter 7.13.1).
− The alarm can occur if the atomizing air continues to ow from the gun during short
spray breaks.
The A/B/C/D-component ow is less than the lower limit "Minimum ow"
−
(see Chapter 7.13.2, level 3, page 4).
− Clean ow meters.
− Possible further causes such as for alarm A100…A105.
Release the gun trigger completely or increase the gun delay time.
A114/A115/A116/A117 Air bubble A/B/C/D
Air bubble in the line (only with low-pressure). Fill product tank.
A118 Flow meter A
The ow meter A is blocked by soiling. The LED at the ow meter has to light up during
product ow, otherwise it is clogged (cleaning, see Chapter 9.2.3).
A119 Gun monitoring
Product ows through the A ow meter and for 50 seconds, there is no signal indicating
that the gun is open.
− This means that the gun monitoring is defective or that there is no contact.
− Repair or replace the gun monitoring.
A120 No enabling signal
External release missing (booth ventilation etc.)
A121 Flow fault –
The ow rate is below the limit entered in the paint recipe (see Chapter 7.11).
− Check the mixing tube and feed hoses.
− Check the guns and the gun lter.
− Clean the lines by ushing or cleaning manually.
− Increase the pressure of the supply pumps.
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A122 Flow fault +
The ow rate is above the limit entered in the paint recipe (see Chapter 7.11).
− Replace gun nozzle (Airless and AirCoat).
− Check the lines for leakage.
− Set the opening of the gun needle correctly (air guns only).
− Decrease the pressure of the supply pumps.
A123 Flushing rst
The system has to be ushed.
The "Mixing alarm
life alarm has occurred.
A124 No ow during lling
The lling procedure is interrupted for too long (longer than the "Alarm delay no ow
during lling" setting).
− Possibly, the lling procedure is waiting for the gun to be opened:
− With gun ush box: check whether the gun is inserted correctly.
− Without gun ush box: point spray gun into waste tank and open it.
− Check dump valve: clogging, function.
flushing" or "Pot life alarm flushing" is activated and a mixing or pot
A125 No ow during ushing
The ushing procedure is interrupted for too long (longer than the "Alarm delay no ow
during ushing" setting).
− Possibly, the ushing procedure is waiting for the gun to be opened:
− With gun ush box: check whether the gun is inserted correctly.
− Without gun ush box: point spray gun into waste tank and open it.
− Check dump valve: clogging, function.
A126 Gun monitoring deactivated
Function is selected, which requires gun monitoring. However, the gun monitoring is
deactivated. Activate the gun monitoring or deactivate the relevant function.
Functions which require gun monitoring:
− Flow monitoring (settings password level 3).
− Spray gun closed
− Dump valve as return line (settings password level 3).
A127 K factor is 0!
The new K factor "Kn" is 0 and can therefore not be saved.
A128/A129/A130/A131 Coriolis A/B/C/D
For Coriolis error, see operating manual of Coriolis ow meter.
valves closed (settings password level 3).
A132/A133/A134/A135 Pot life gun 1/2/3/4
Pot life + post-alarm time have expired. Continue working immediately or ush.
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