WAGNER TwinControl Original Operating Manual

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TwinControl

Electronically Controlled 2K Systems for Lacquers

Valid for systems with software version V 4.xx

Version 10/2018

0102

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VERSION 10/2018 ORDER NUMBER DOC 2339321

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 Manuals for the Individual Components 8

1.4 TwinControl CD 9

1.5 Abbreviations 10

1.6 Terminology for the Purpose of this Manual 10

2 CORRECT USE 11

2.1 Device Types 11

2.2 Type of Use 11

2.3 For Use in Potentially Explosive Areas 11

2.4 Processible Working Materials 12

2.5 Misuse 12

3 IDENTIFICATION 13

3.1 Explosion-Proof Marking for Devices with Turbines 13

3.1.1 Use in Areas Subject to Explosion Hazards 14

3.2 Identication for Devices with a Mains Power Supply 15

3.3 Type Plates 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 Qualications 18

4.2 Safety Instructions for the Personnel 18

4.2.1 Personal Safety Equipment 19

4.2.2 Safe Handling of WAGNER Spray Devices 19

4.2.3 Grounding 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

5 DESCRIPTION 23

5.1 Components 23

5.1.1 TwinControl Finishing and Protective Coating 24

5.2 Mode of Operation 24

5.3 Protective and Monitoring Equipment 24

5.4 Included Items 25

5.5 Technical Data 25

5.5.1 Materials of Paint-wetted Parts 25

5.5.2 Control Units with Turbines 26

5.5.3 Control Units with Mains Power Supply (Cable) 28

5.5.4 Entire System 28

5.5.5 Pumps 30

5.5.6 Dimensions 31

5.5.7 Weights 33

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5.6 Overview of TwinControl Controllers 34

5.7 Principle Diagram 35

5.7.1 Controller 1 / 9 / 10 for Pumps 5-60 to 35-150 35

5.7.2 Controllers 2 / 3 / 6 / 8 for Pumps 48-110 to 8-600 36

5.8 Operating Elements and Control Unit Connections 37

5.9 Pneumatic Diagram 39

5.9.1 TwinControl 1 39

5.9.2 TwinControl 2 / TwinControl 3 40

5.9.3 TwinControl 6 / TwinControl 8 41

5.9.4 TwinControl 9 / TwinControl 10 42

5.10 List of Service Functions 43

5.11 Dry Running Protection 46

5.12 Heater (option) 46

5.13 AIS Dosing System (option) 46

5.14 Automatic Electrostatic System for Electrostatic Gun GM5000 (Option) 46

5.15 Connection Kit for Gun Flush Box (Option) 47

5.16 Feed Pump (Option) 47

5.16.1 EvoMotion 5-125 Feed Pump 48

5.17 Maintenance Work on the Pumps 48

6 ASSEMBLY AND COMMISSIONING 49

6.1 Training of Assembly/Commissioning Personnel 49

6.2 Storage and Installation Conditions 49

6.3 Transportation 50

6.4 Assembly and Installation 51

6.4.1 Pneumatic Connections 52

6.4.2 Product Connections 52

6.5 Grounding 53

6.5.1 Grounding of Components on Frame or Trolley 54

6.5.2 Example of Grounding Scheme for TwinControl with Turbine 55

6.5.3 Example of Grounding Scheme for TwinControl with Mains Power Connection (Cable) 55

6.6 Commissioning 56

6.6.1 Preparation Before Commissioning 56

6.6.2 Basic Flushing and Pressure Tightness Test 57

6.6.3 Replacing Flushing Agent with Working Media 60

6.6.4 Calibrating the System 62

7 CONTROLLER 65

7.1 Training the Operating Personnel 65

7.2 Safety Instructions 65

7.3 Operating the Control Unit 66

7.3.1 Entering Numbers [SET] 67

7.4 Password Protection and User Functions 68

7.5 Basic Functions for the Painter 69

7.6 Extended Functions with Password Protection 70

7.6.1 Calibration 74

7.6.2 Flushing Programs 75

7.6.3 AIS 77

7.6.4 Check for Leaks in A and B Fluid Section 79

7.6.5 "Batch Mode" Filling Mode 80

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8 OPERATION 81

8.1 Training the Operating Personnel 81

8.2 Safety Instructions 81

8.2.1 General Rules for Making Adjustments to the Spray Gun 81

8.3 Malfunction 82

8.4 Emergency Deactivation 82

8.5 Switching the System On 83

8.6 Switching o the System 85

8.7 Spraying Mode 86

8.8 Flushing 87

8.9 Pressure Relief / Work Interruption 88

8.10 Automatic Electrostatic System Set for Electrostatic Gun GM5000 (Option) 90

8.10.1 Commissioning and Settings 90

8.10.2 Paint Filling 90

8.10.3 Spraying Mode 91

8.10.4 Work Interruption (Stop) 91

8.10.5 Flushing 91

8.11 Connection Kit for Gun Flush Box (Option) 91

8.12 Soft Circulation (Option) 92

8.13 External Mixers (Option) 93

8.13.1 Manual External Mixers DN2.6 and DN4 93

8.13.2 Manual External Mixer DN 8 93

8.14 Remote Control and ESTA Remote Control (Option) 94

8.14.1 Explosion Protection 94

8.14.2 TwinControl Remote Control 94

8.14.3 ESTA Remote Control 95

8.15 2A Switchbox for Second A-Pump (Option) 96

9 CLEANING AND MAINTENANCE 97

9.1 Cleaning 97

9.1.1 Cleaning Personnel 97

9.1.2 Safety Instructions 97

9.1.3 Filter Cleaning 97

9.1.4 Cleaning the System 98

9.1.5 Decommissioning 98

9.1.6 Long-term Storage 98

9.2 Maintenance 99

9.2.1 Maintenance Personnel 99

9.2.2 Maintenance Instructions 99

9.2.3 Safety Checks and Maintenance Intervals 100

9.2.4 Service Plug 100

9.2.5 Connections for Stroke Measurement 100

9.2.6 Turbine 100

9.2.7 Non-return Valves 101

9.2.8 Emptying System 101

9.2.9 Filling Empty System 101

9.2.10 Cleaning or Replacing the Product Filter 102

9.2.11 Product Hoses, Pipes and Couplings 104

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10 TROUBLESHOOTING 105

10.1 Alarm Messages and Fault Rectication 107

11 REPAIRS 110

11.1 Repair Personnel 110

11.2 Repair Notes 110

11.3 Assembly Aids 111

12 DISPOSAL 112

13 ACCESSORIES 113

13.1 Mixer 113

13.2 Remote Control 115

13.3 Horn Alarm 116

13.4 Suction Hoses 116

13.5 Mixing Hoses 117

13.6 AIS 117

13.7 Heater 118

13.8 Splitter Valve 120

13.9 Product Pressure Regulator 120

13.10 Flushing Pressure Set 120

13.11 Additional Parts for Second Paint (2A) 121

13.12 Extension Cables 122

13.13 TC VM5000 Automatic Electrostatic System 122

13.14 GFB Connection Kit 122

13.15 Feed Pump 123

13.16 AirCoat Regulator 123

13.17 Archiving Software 124

14 SPARE PARTS 125

14.1 Where Can Spare Parts Be Found? 125

14.2 Serial Number 125

14.3 Turbine 125

15 DECLARATION OF CONFORMITY 126

15.1 Devices with Turbines 126

15.2 Devices with Cable for Mains Power Supply 127

16 APPENDIX 128

16.1 Conversion of the Mixing Ratio Specications 128

16.2 Hose Volume Table 129

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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 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

Notice

Explanation of warning notice:

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 notice.

The measures for preventing the hazard and its consequences.

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1.3 LANGUAGES

The TwinControl operating manual is available in the following languages:

Original operating manual

Language Order no.

German 2339287

Translation of the original operating manual

Language Order no. Language Order no. Language Order no.

English 2339321 Spanish 2339330 Romanian 2372826 French 2339322 Italian 2339323 Polish 2396599 Japanese 2344161 Turkish 2386987 -- --

Additional languages on request or at: www.wagner-group.com

Spare parts for the TwinControl systems and TwinControl accessories are to be found in two separate spare parts catalogs. The catalogs are available in the following languages:

Spare parts catalog for TwinControl Finishing

(Small frame / small trolley / small wall):

Language Order no. Language Order no.

German 2339290 English 2339331

Spare parts catalog for TwinControl Protective Coating (PC)

(Large frame / large trolley):

Language Order no. Language Order no.

German 2339293 English 2339332

TwinControl CD: see Chapter 1.4

1.3.1 OPERATING MANUALS FOR THE INDIVIDUAL COMPONENTS

EvoMotion 5-60 operating manual

Language Order no. Language Order no. Language Order no.

German 2333562 English 2333563 Spanish 2333566 French 2333564 Italian 2333565 -- --

Operating manual

Wildcat 10-70, 18-40 / Puma 28-40, 15-70, 21-110, 15-150 / Leopard 35-70, 35-150, 48-110

Language Order no. Language Order no. Language Order no.

German 2333537 English 2333538 Spanish 2333541 French 2333539 Italian 2333540 -- --

Operating manual Puma 8-300, 3-600 / Leopard 18-300, 8-600 / Jaguar 38-300

Language Order no. Language Order no. Language Order no.

German 2333547 English 2333548 Spanish 2333551 French 2333549 Italian 2333550 -- --

Operating manual Jaguar 75-150, 55-200 / Tiger 72-300

Language Order no. Language Order no. Language Order no.

German 2340281 English 2340282 Spanish 2340286 French 2340285 Italian 2340284 -- --

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Operating manual EvoMotion 5-125 (Accessory, use as feed pump)

Language Order no. Language Order no. Language Order no.

German 2316595 English 2316596 Spanish 2316600 French 2316597 Italian 2316599 -- --

Operating manual Paint and dosing valves DN 2.6 (for valves PV 400, DV 400, GA 400DV)

Language Order no. Language Order no. Language Order no.

German 2343270 English 2343275 Spanish 2343278 French 2343276 Italian 2343277 -- --

Operating manual Paint valve PV 100-DN4

Language Order no. Language Order no. Language Order no.

German 2343280 English 2343281 Spanish 2343286 French 2343282 Italian 2343284 -- --

Operating manual Paint and dosing valves PV 530, DV 530

Language Order no. Language Order no. Language Order no.

German 2372892 English 2372893 Spanish 2372900 French 2372895 Italian 2372897 -- --

Operating manual Automatic Airless spray gun GA 400AL (for valve GA 400AL / soft circulation)

Language Order no. Language Order no. Language Order no.

German 350939 English 350941 Spanish 350949 French 350946 Italian 350948 -- --

Continuous-ow heater operating manual

Language Order no. Language Order no. Language Order no.

German 65860 English 65860 Dutch 65860 French 65860 Italian 65860 Danish 65860

Product pressure regulator operating manual

Language Order no. Language Order no. Language Order no.

German ZZB019GER English ZZB019ENG Spanish ZZB019SPA French ZZB019FRE Italian ZZB019ITA -- --

1.4 TWINCONTROL CD

All operating documents specied previously are also available as PDF les on a compact disk (CD). The CD is included in the system's scope of delivery.

The order no. is: 2339342

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1.5 ABBREVIATIONS

Abbreviations in the text

Number of pieces TC 1.4404 TwinControl for acidic hardeners Position Protective coating: heavy duty corrosion protection Marking in the spare parts lists HP High pressure 4-50 MPa; 40-500 bar; 580-7,250 psi

Order no. Order number HPP Highest pressure over 50 MPa; 500 bar; 7,250 psi

Double stroke ESTA Electrostatically charged device Nominal diameter Materials Two components Stainless steel

Fluorine elastomer

GFB Gun ush box

TwinControl Polytetrauorethylene

Abbreviations in the text and control unit

A component Mixing ratio B component Job total Flushing agent Pot life Flushing on A-side Flow rate / pot life Flushing on B side -- --

Polyamide

1.6 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning

Cleaning Manual cleaning of devices and device parts with cleaning agent. Flushing Internal ushing of paint-wetted parts with ushing agent.

Personnel qualications

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 sucient technical knowledge in the areas of explosion protection, protection from pressure hazards and electric hazards (if applicable) 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.

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2 CORRECT USE

2.1 DEVICE TYPES

A) TwinControl, turbine B) TwinControl, cable with mains supply

2.2 TYPE OF USE

A) Systems with a turbine

The device is suitable for processing 2K liquid products such as paints and lacquers in accordance with their classication into explosion classes IIA or IIB.

B) Systems with a mains power supply

The device is suitable for processing 2K 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. 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 FOR USE IN POTENTIALLY EXPLOSIVE AREAS

A) Systems with a turbine

The system with turbine complies with Explosion Protection Directive 2014/34/EC (Atex) and can be used as a Category 2 device in Ex Zone 1. It is designed with ignition protection type "intrinsic safety" and has the marking:

The remote control (accessory) may be used along with a system with a turbine in potentially explosive areas (zone 1, zone 2). The same applies to the 2A switchbox (accessory).

B) Systems with a mains power supply

The system with mains power supply (cable) must not be operated in potentially explosive areas (zone 0, 1, 2). The remote control (accessory) may not be used along with a system with a mains power supply (cable) in potentially explosive areas. The same applies to the 2A switchbox (accessory).

(See Explosion Protection Identication, Chapter 3)

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2.4 PROCESSIBLE WORKING MATERIALS

Low-viscosity to high-viscosity 2K lacquers (e.g., epoxy, PU, DD) with a pot life of more than 5 minutes.

- 2K water-based priming - 2K epoxy priming

- 2K solvent-based priming - 2K epoxy lacquers

- 2K PUR priming - 2K high-solid priming

- 2K PUR lacquers - 2K high-solid lacquers

- 2K products with acidic hardeners (only with TwinControl systems for acidic hardeners) Solvent and water-based 2K products should not be processed using the same system.

Materials in direct contact with the products: see Chapter 5.5.1

NOTICE

Abrasive working materials and pigments!

Greater wear of product-wetted parts.

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 / 5.5.5 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.

TwinControl for acidic hardeners

Example of hardener pump

Check products for compatibility: see Chapter 5.5.1

Parts made of stainless steel 1.4404 are labeled with "1.4404" (see example).

1.4404

B_07123

WARNING

Acidic hardeners!

Risk of burns and injury for skin, tissue and organs.

Observe the lacquer manufacturer's safety data sheets and take prescribed safety measures.

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.

Designation "1.4404"

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3 IDENTIFICATION

3.1 EXPLOSIONPROOF MARKING FOR DEVICES WITH TURBINES

– Turbines

As dened in the Directive 2014/34/EU (ATEX), the TwinControl control unit (turbine) is suitable for use in potentially explosive areas.

Device type: TwinControl Manufacturer: Wagner International AG

9450 Altstätten Switzerland

Identication:

CE mark (European Communities) Number of the notied body that is used by WAGNER in the production

monitoring phase (PTB Germany in this case) Explosion-proof equipment Device class II (not mining)

Category 2 device (suitable for zone 1) Ex-atmosphere gas

Ex Electrical device corresponds to ignition protection type

Ignition protection type "Intrinsic safety" EN 60079-11, safety level "ia" Device category (gas) IIB (ethylene, city gas) Temperature class T4: maximum surface temperature 135°C; 275°F

Test center and year of issue French abbreviation for "ATmosphères EXplosibles" Certicate number Special instructions exist for safe operation (see Chapter5.5.2.1).

Permissible ambient temperature range during operation:

Explosion protection identication and special notices regarding pumps

See operating manuals for pumps

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3.1.1 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 and tools against steel or rusty iron. Do not drop the device or components and tools.

Ignition temperature of the pumped product

Check that the ignition temperature of the pumped product is higher than the max. permissible surface temperature.

Medium supporting atomizing

To atomize the product, use only weakly oxidizing gases, e.g., air.

Operation without uid

Avoid running the pump so that it sucks in air (without uid inside). The air, combined with the vapor of ammable uids, can generate internal areas with an explosion hazard.

Periodically check that the pumps are working smoothly, paying special attention to the presence of air in the pumped uid, which may be caused by damaged packings.

Avoid operating the pump with damaged packing. Ensure that the separating agent tank is lled with sucient separating agent.

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.

National regulations

Ensure that the national explosion prevention rules and regulations are observed when setting up the device.

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3.2 IDENTIFICATION FOR DEVICES WITH A MAINS POWER SUPPLY

, cable with mains power supply

The system with mains power supply (cable) must not be operated in potentially explosive areas (zone 0, 1, 2).

The remote control (accessory) may not be used along with a system with a mains power supply (cable) in potentially explosive areas. The same applies to the 2A switchbox (accessory).

Device type: TwinControl Manufacturer: Wagner International AG

9450 Altstätten Switzerland

Identication:

CE mark (European Communities)

Identication and special notices regarding pumps

See operating manuals for pumps

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3.3 TYPE PLATES

– Turbines

1 Manufacturer

Made in Switzerland

Type / Typ:

Serial No unit.:

Serie Nr. Anlage:

Wagner International AG CH 9450 Altstätten

TwinControl

2 Device type: TwinControl 3 Serial number of system 4 CE identication 5 Year of manufacture 6 Serial number of controller 7 Air pressure supply 8 Ambient temperature

9 Protection class 10 Dust-protected 11 Splash-proof 12 Do not dispose of used electrical equipment with

household refuse.

13 Read operating manual before use!

10 11

Year of construction / Baujahr:

Serial No. controller:

Serie Nr. Steuerung:

Air pressure supply:

Luftdruckversorgung:

Ambient temperature:

Temperatur Umgebung:

IP Code:

Schutzart:

II 2 G Ex ia II B T4 ZELM 08 ATEX 0385 X +5°C < Ta < +40°C

+5°C < Ta < +40°C

0.6 - 0.8 MPa 6 - 8 bar

87 - 116 psi

+5 / +40 °C

IP 54

B_06434

Check manual before use!

Vor Gebrauch Betriebsanleitung beachten!

– cable with mains power supply

Wagner International AG CH 9450 Altstätten

Type / Typ:

Year of construction / Baujahr:

Serial No unit.:

Serie Nr. Anlage:

Serial No. controller:

Serie Nr. Steuerung:

Voltage:

Spannung:

Line Power:

Eingangsleistung:

Ambient temperature:

Temperatur Umgebung:

IP Code:

Schutzart:

Made in Switzerland

TwinControl

85-260 VAC 47-60 Hz

max. 40 W

+5 / +40 °C

IP 54

1 Manufacturer and CE mark 2 Device type: TwinControl 3 Year of manufacture 4 Serial number of system 5 Serial number of controller 6 Voltage 7 Maximum input power 8 Ambient temperature

9 Protection class 10 Dust-protected 11 Splash-proof 12 Do not dispose of used electrical equipment with

household refuse.

13 Read operating manual before use!

10 11

Check manual before use!

Vor Gebrauch Betriebsanleitung beachten!

B_06435

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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 inuences.

May only be maintained by skilled electricians or under their supervision. With open housings, the mains voltage poses a danger.

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 personnel 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 vapors!

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 area is static dissipative in accordance with EN61340-4-1 (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 hoses/air hoses adapted to the working pressure are used.

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Ensure that personal protective equipment (see Chapter 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 static dissipative 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 of 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.

Ensure that maintenance and safety checks are performed regularly. 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 qualications.

4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL

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: Danger due to high-voltage eld!

Danger to life.

Persons belonging to a risk group according to EMF guideline 2013/35/EU (e.g., carriers of active implants), must not enter the high-voltage area.

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4.2.1 PERSONAL SAFETY EQUIPMENT

Hazard due to dangerous uids or vapors!

Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.

When preparing or working with lacquer and when cleaning the device, follow the working instructions of the manufacturer of the lacquers, solvents and cleaning agents being used.

Take the specied protective measures, in particular wear safety goggles, protective clothing and gloves, as well as skin protection cream if necessary.

Use a mask or breathing apparatus if necessary. For sucient 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 lacquer or ushing agents:

Never point the spray gun at people. Never reach into the spray jet. Ensure that the working pressure does not exceed the maximum value shown on

the type plate. Before any work on the device, in the event of work interruptions and malfunctions:

– Switch o the energy and compressed air supply. – Relieve pressure from spray guns, high-pressure hoses and all devices. – Secure spray guns against actuation. – Disconnect the control unit from the mains. – In the event of functional faults: remedy the fault as described in the

"Troubleshooting" chapter.

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.

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 when falling.

Avoid risk of injury from recoil forces:

Ensure that you have ﬁrm footing when operating the spray gun.

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4.2.3 GROUNDING 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.

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 hoses 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 coecient. 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-ignitable 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 specications 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.

Never use chloride or halogenated solvents (such as trichloroethane and methylene chloride) with devices containing aluminium or galvanized/zinc-plated parts. They may react chemically thus producing an explosion danger.

Take measures for workplace safety (see Chapter 4.1.2). When commissioning or emptying the device, please note that:

– depending upon the coating product used, – depending on the flushing 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 heat-insulating, static dissipative 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.

Use only WAGNER original spare parts and accessories. Do not change or modify the device; if change is necessary, contact WAGNER. Only repair and replace parts that are listed in Chapter 13 or Chapter 14 and that are

assigned to the device. Do not use any defective components. Before all work on the device and in the event of work interruptions:

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, modied 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

B_02796

1:2

B_04563

Designation

1 Pneumatic pump for A-component 2 Flushing pump "S" 3 Pneumatic pump for B component 4 TwinControl control unit

B_02798

Designation

5 Frame 6 Mixing unit 7 Trolley 8 Wall mount

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5.1.1 TWINCONTROL FINISHING AND PROTECTIVE COATING

Depending on size, various suspensions are available for TwinControl systems:

TwinControl Finishing TwinControl Protective Coating (PC)

Small frame Large frame

Suspension

5-60*, 10-70, 28-40, 15-70, 15-150,

Pump A

Spraying procedure

* 5-60 not on trolley

5.2 MODE OF OPERATION

The TwinControl system consists of 5 function units: The pneumatically operated high-pressure pumps for A and B components and for ushing agents, the mixing unit and the control unit. The two product components are brought to high-pressure by the pumps and an adjustable, predened mixing ratio is intermixed in the static mixer, from where it is conveyed to the spray gun.

The system can be operated with one or more spray guns, depending on size and output. Various functions are controlled by the control unit, such as: ushing, pot life monitoring or mixing ratio.

21-110, 8-300, 3-600, 35-70, 35-150,

Small trolley Large trolley

Small wall

75-150, 55-200, 38-300, 72-300

48-110, 18-300, 8-600

Airless Airless

AirSpray

AirCoat

Basic principle

The lacquer ows continuously and the hardener is metered (injected) into the lacquer in portions in intermittent cycles with a slightly higher pressure.

Operation

The required mixing ratio is entered on the electronic controller, and the system can then be started by pressing the button on the electronic controller. This opens product valve A. The hardener valve B is then opened in pulses, and hardener is metered in according to requirements (mixing ratio).

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

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5.4 INCLUDED ITEMS

TwinControl systems consist of the following:

– pneumatic pump with stroke measurement for the A-component – pneumatic pump with stroke measurement for the B-component – pneumatic pump for ushing agent (versions without also possible) – control unit (turbine or cable connection) – frame or trolley or wall mount (wall mount not with PC) – static mixing unit (only with internal mixer) – diverse product valves

The system's scope of delivery also includes:

Description Order no.

Separating agent 250 ml; 250 cc 9992504 CE Declaration of Conformity Operating manual, in German 2339287 Operating manual in the local language TwinControl compact disc (CD, see Chapter 1.4) 2339342 Instruction sheet – transportation 2305117 Supplement for TwinControl with password protection 2304064

The delivery note shows the exact scope of delivery. Accessories: see Chapter 13.

See Chapter 15

See Chapter 1.3

5.5 TECHNICAL DATA

5.5.1 MATERIALS OF PAINTWETTED PARTS

Materials in direct contact with the products

TwinControl (without pumps) Stainless steel, FEP, HM, PA, PE, POM, PTFE Pumps

TwinControl systems for acidic hardeners:

– from B pump (input) to mixing head valve (output) 1.4404, 1.4408, 1.4571, FEP, HM, PE, PTFE – Mixing tube, additional 1.4301

See pump operating manuals (for order no., see Chapter1.3.1)

FEP = Fluorine elastomer HM = Carbide PA = Polyamide PE = polyethylene POM = Polyoxymethylene PTFE = Polytetrauorethylene

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5.5.2 CONTROL UNITS WITH TURBINES

Unit TwinControl control units with turbines

Minimum/maximum input air pressure MPa; bar; psi 0.6–0.8; 6–8; 87–116 Nominal air consumption NL/min 125

Permissible ambient temperature range

Protection class

Compressed air quality: free from oil and water

Explosion protection identication (see Chapter 3.1)

Rated safety data

°C +5 ... +40 °F +41 ... +104

Quality standard 7.5.4 according to ISO 8573.1, 2010

7: Particle concentration 5–10mg/m³ 5: Humidity: pressure dew point ≤ +7 °C 4: Oil content ≤ 5mg/m



Potentiometer connection A or B in Ex ia IIB type ignition protection

Connection of maximum values Unit Potentiometer A and B

Maximum high voltage

Maximum current

Maximum power

Maximum external capacity

Maximum external inductivity

The above-mentioned values for the maximum permissible external capacities and inductances are only valid as long as they do not occur simultaneously. If the external reactances are present simultaneously, the values are to be taken from the following table.

Maximum permissible external inductance 0.1 0.2 0.5 1 2 5 10 20

Maximum permissible external capacity

Remote control connection in Ex ia IIB type ignition protection

Connection of maximum values Unit Connection RC

Maximum high voltage

Maximum current

Maximum power

7.3 6 4.6 3.7 3.1 2.3 1.9 1.4

12.6

73.6

232

7.3

12.6

154

484

Maximum external capacity

Maximum external inductivity

Maximum permissible external inductance 0.1 0.2 0.5 1.0 2.0 5.0

Maximum permissible external capacity

7.3 5.9 4.4 3.5 2.7 1.8

7.3

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Service connection

Only for connection to relevant programming devices and only outside the potentially explosive area, or if an atmosphere not capable of explosion is present.

5.5.2.1 IDENTIFICATION X

1. The notices in the operating manual must be observed, particularly regarding grounding and connecting the potential equalization, and integrating the equipment into an existing system for potential equalization.

2. Opening the housing in environments with explosive gas atmospheres is not permitted.

3. Plugging in the service connector in explosive environments is not permitted, and may only be carried out by authorized maintenance personnel.

4. Maintenance and service tasks inside the housing may only be performed by authorized personnel.

5. No changes at the pressure regulator (inside the housing of the TwinControl controller) for the turbine or at the relief valves may be made.

6. A maintenance plan must be prepared for the controller (type TwinControl), or this controller must be integrated into an existing maintenance plan.

7. In order to prevent soiling inside the housing of the TwinControl controller, the integrity of the front lm must be checked at regular intervals. In the event of damage, the equipment must be removed from the Ex zone immediately and put out of operation, and repaired by WAGNER.

8. When designing and installing the compressed air system, it must be ensured that no explosive atmosphere can arise within the system.

9. Only WAGNER potentiometers may be connected to the potentiometer connections.

10. The remote control may only be used in an environment at risk of explosion if used along with a system with a turbine. The remote control cable must be laid securely and safely protected from damage. The maximum permitted cable length is 75 m; 246 ft.

11. If the complete TwinControl system is operated as part of a water varnish coating system connected to high voltage, the green-yellow ground cables must be removed and replaced with black cables with the same cross-section. Grounding symbols must be made unrecognizable.

12. The device does not comply with Chap. 6.3.12 of DIN EN 60079-11: 2007-08.

13. The device is suitable for overvoltage category II and may only be operated if all connections are inserted or provided with protective caps. Degree of pollution 3 for the environment is then permissible.

Permissible storage temperature: -20 °C; -4 °F ... +60 °C; +140 °F. Relative humidity (no dew) < 95%.

14. The 2A switchbox may only be used in an environment at risk of explosion if used along with a system with a turbine.

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5.5.3 CONTROL UNITS WITH MAINS POWER SUPPLY CABLE

Unit

Input voltage Input power Input frequency

Permissible ambient temperature range

Protection class

Quality standard 7.5.4 according to ISO 8573.1, 2010

Compressed air quality: free from oil and water

5.5.4 ENTIRE SYSTEM

Working areas Unit Limits

Inlet air pressure

Maximum permissible number of strokes by pumps in two-component operation

Maximum recommended strokes per minute of pumps in 2K operation

Maximum product pressure levels

without acidic

Product pH value

Product temperature

Ambient temperature

Relative humidity 10–95% (without condensation)

hardeners System for acidic hardeners:

Check products for compatibility (see Chapter 5.5.1)

Operation Assembly Storage

7: Particle concentration 5–10mg/m³ 5: Humidity: pressure dew point ≤ +7 °C 4: Oil content ≤ 5mg/m

/min. 30

/min. 20

TwinControl control units with cable

connection

maximum 40

+5 < Ta < +40

+41 < Ta < +104

0.6–0.8 6–8

87–116

see Chapter 5.5.5

3.5–9

+5 ... +60; +41 ... +140 +5 ... +40; +41 ... +104

0 ... +40; +32 ... +104

-20 ... +60; -4 ... +140

85–260

47-440

Minimum ow rate

The minimum ow rate depends on the pump size, mixing ratio, static mixer and setting for pressure and hardener valve stroke. Tests are required for volumes of less than 1 stroke a minute (of A or B).

WARNING

Exhaust air containing oil!

Risk of poisoning if inhaled.

Provide compressed air free from oil and water.

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Inputs / outputs and mixing ratio Unit for A-pump

5-60

28-40

15-70

15-150

EvoMotion

Puma

Puma TwinControl air inlet inch G 1/2" Mixer product outlet inch NPS 1/4 NPS 3/8 A/B mixing ratio volume 0.1:1–20:1 0.1:1–10:1 Dosing precision *

Inputs / outputs and mixing ratio Unit for A-pump

± 2

21-110

Puma

8-300

3-600

Puma

35-70

35-150

48-110

Leopard

Leopard TwinControl air inlet inch G 1/2" G 1" Mixer product outlet inch NPS 1/4 NPS 3/8 A/B mixing ratio volume 0.1:1–20:1 0.1:1–10:1 Dosing precision *

* The target mixing ratio at a precision level of ± 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 volume measuring sensors in accordance with Chapter 6.6.4.

–

Correct adjustment of the compression ratio between the base lacquer and hardener in accordance

–

with Chapter 8.7. – Correct adjustment of the hardener dosing valve stroke, or use of the AIS. – Exact setting of the system to suit the product used, in accordance with the processing specications

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 specic operating conditions such as the permitted

product and ambient temperature, suitable viscosity and ow rate.

Regular maintenance has to be carried out by a qualied person (e.g., WAGNER service technician) in

–

accordance with Chapter 9.2.

2% is achieved under the following conditions:

18-300

Leopard

± 2

8-600

Jaguar

75-150

Jaguar

55-200

38-300

Jaguar

72-300

Tiger

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5.5.5 PUMPS

EvoMotion / Wildcat / Puma

5-60

10-70

18-40

28-40

15-70

15-150

21-110

8-300

3-600

Unit

Pump ratio 5:1 10:1 18:1 28:1 15:1 15:1 21:1 8:1 3:1 Volume ow per double stroke

Maximum product pressure on mixer**

Maximum product pressure at pump inlet

Product inlet (outside thread) M 36x2 G1½" Pump product outlet (outside thread) mm / M 24x1.5 Pump product outlet (inside thread) inch G 3/8" / Pump air inlet diameter (inside thread) inch / G 1/2"

Pump air inlet diameter mm; inch

Sound pressure level See operating manuals for pumps and valves

Leopard / Jaguar / Tiger

Pump ratio 35:1 35:1 48:1 18:1 8:1 75:1 55:1 38:1 72:1 Volume ow per double stroke (

Maximum product pressure on mixer**

Maximum product pressure at pump inlet

Product inlet (outside thread) M 36x2

Product inlet (inside thread) / / G 1½" / G 1½" Pump product outlet (outside thread) mm M 24x1.5 Pump air inlet diameter (inside thread) inch G 1/2" G 1" Sound pressure level See operating manuals for pumps and valves

) cm; cc 70 150 110 300 600 150 200 300 300

cm; cc 60 70 40 40 70 150 110 300 600

MPa 4.0 14.4 22.4 12 16.8 6.4 2.4

bar 40 144 224 120 168 64 24

psi 580 2089 3249 1740 2436 928 348

MPa 0.5 2.0 0.5

bar 5 20 5

psi 73 290 73

Unit

MPa 25.0 38.0 13.8 6.2 53 44 27 53

bar 250 380 138 62 530 440 270 530

psi 3626 5511 2000 900 7687 6382 3916 7687

MPa 2.0

bar 20

psi 290

EvoMotion

8.0;

0.31

Leopard

Wildcat

35-70

Leopard

Wildcat

35-150

Leopard

Puma

48-110

Leopard

18-300

Leopard

1½"

Puma

8-600

75-150

Jaguar

/ M 36x2 /

Puma

55-200

Jaguar

Puma

38-300

Jaguar

Puma

Tiger

72-300

** All high-pressure components must be designed in line with the highest maximum

pressure of the pumps used.

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5.5.6 DIMENSIONS

TwinControl on small frame

Pumps

A 860; 33.9 1205; 47.5 B 1551; 61.1

C 550; 21.7

Pump Jaguar

A 1015; 40.0 1428; 56.2 B 1655; 65.2

C 738; 29.1

EvoMotion, Wildcat, Puma,

Leopard

without

heater

mm; inch mm; inch

TwinControl on large frame

without

heater

mm; inch mm; inch

with heater

A + B

with heater

A + B

B_04488

TwinControl on large frame

Pump Tiger

without

heater

mm; inch mm; inch mm; inch

A 1015; 40.0 1428; 56.2 1616; 63.6

B 1715; 67.5 C 747; 29.4

with heater

A + B

double heater

on A side

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VERSION 10/2018 ORDER NUMBER DOC 2339321

TwinControl on wall

Type

28-40 15-70 15-150 21-110 8-300 3-600 35-70 35-150 48-110 18-300 8-600

mm; inch

A1 917; 36.1

1022;

40.2

1005;

39.6

1020;

40.2

1243; 48.9

1187;

46.7

1202;

47.3

C 512; 20.2

D 892; 35.1

E 238; 9.4 F 9; 0.35 G 909; 35.8

with heater

A2 1210; 47.6

B2 1114; 43.9 1243; 48.9

1187;

46.7

1202;

47.3

Without heater

1015;

40.0

1114;

43.9

1239; 48.8

1183;

46.6

1183;

46.6

1197;

47.1

1197;

47.1

With heater

B_04489

B_04490

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VERSION 10/2018 ORDER NUMBER DOC 2339321

TwinControl on small trolley

Pumps Wildcat, Puma, Leopard

without

heater

mm; inch mm; inch A 820; 32.3 899; 35.4 B 1787; 70.4

C 1225; 48.2 1243; 48.9

TwinControl on large trolley

Pumps Jaguar, Tiger

without

heater

mm; inch mm; inch A 1035; 40.8

B 1845; 72.6

C 1314; 51.7 1377; 54.2

with heater

A + B

with heater

A + B

5.5.7 WEIGHTS

Sample congurations Weight

Turbine Cable

Suspension Pumps

Frame 3x EvoMotion 5-60 87 192 86 190 Wall 3x EvoMotion 5-60 76 168 75 165 Frame 3x Puma 28-40 95 209 94 207 Frame 2x Leopard 35-70, 1x Puma 28-40 113 249 112 247 Frame 2x Leopard 48-110, 1x Puma 28-40 142 313 141 311 Trolley 2x Leopard 48-110, 1x Puma 28-40 159 351 158 349 Frame 2x Jaguar 75-150, 1x Leopard 35-70 198 437 197 434 Trolley 2x Jaguar 75-150, 1x Leopard 35-70 224 494 223 492 Frame 1x Tiger 72-300, 1x Jaguar 75-150, 1x Leopard 35-70 235 518 234 516 Frame 2x Tiger 72-300, 1x Leopard 35-70 264 582 263 580

kg lb kg lb

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5.6 OVERVIEW OF TWINCONTROL CONTROLLERS

Control

1 2 3 6 8 9 10

A-pumps = 5-60, 10-70, 28-40, 15-70, 15-150, 21-110, 35-70, 35-150

A-pumps = 48-110, 75-150, 55-200, 8-300, 38-300, 72-300, 3-600,18-300, 8-600

Circulation A, B × × × Circulation soft × × × GFB (gun ush box) (*) (*) × × (*) (*) AIS × × × × Flushing B × × × × External mixer × × × Automatic electrostatic system (**) (**) (**) (**) (**) Air ushing × × Product pressure regulator (low-pressure) × × × × × × × External horn × × × × × × × External release × × × × × × ×

× × × × × × ×

× × × ×

(*) GFB connection kit must be tted, order no. 2302563 (**) Automatic electrostatic system must be tted, order no. 2334530

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VERSION 10/2018 ORDER NUMBER DOC 2339321

1.0:1

5.7 PRINCIPLE DIAGRAM

5.7.1 CONTROLLER 1 / 9 / 10 FOR PUMPS 560 TO 35150

Use with A-pumps 5-60, 10-70, 28-40, 15-70, 15-150, 21-110, 35-70, 35-150 with single-acting product valves with spring reset.

Controllers 1 / 9 / 10 for turbine: The turbine generates the current from compressed air. Controller 1 for cable: Controller with electrical mains connection.

For dierences in controllers 1, 9 and 10: see Chapter 5.6

TwinControl Controllers 1 / 9 / 10 Turbine

1.0:1

TwinControl Controller 1 Cable

1.0:1

B_02764

AIS

AIS only with controller 9 or 10

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1.0:1

5.7.2 CONTROLLERS 2 / 3 / 6 / 8 FOR PUMPS 48110 TO 8600

Use with A-pumps 48-110, 75-150, 55-200, 8-300, 38-300, 72-300, 3-600,18-300, 8-600 with double-acting product valves.

Controllers 2 / 3 / 6 / 8 for turbine: The turbine generates the current from compressed air. Controllers 2 / 3 for cable: Controller with electrical mains connection.

For dierences in controllers 2, 3, 6 and 8: see Chapter 5.6

TwinControl Controllers 2 / 3 / 6 / 8 Turbine

1.0:1

Soft circulation only with controller 3, 6 or 8

TwinControl Controllers 2 / 3 Cable

1.0:1

Circulation soft

AIS

AIS only with controller 6 or 8

B_04464

Circulation soft

P1 P2

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5.8 OPERATING ELEMENTS AND CONTROL UNIT CONNECTIONS

Front side

The front side of the TwinControl control unit is the same on all 6 device variants.

128

126

129

127

125

124

109 110

111

112

113

114

SET

123

122

115

116

118

119

117

101

Designation

101 Push button [Start] 102 Push button [Stop] 103 Push button [Flush AB] 109 Alarm illuminated display 110 Pot life illuminated display 111 Service functions illuminated display 112 Calibration illuminated display 113 Totals illuminated display 114 Work illuminated display 115 Push button [Main menu selection] 116 Push button [Sub-menu selection] 117 A-component illuminated display 118 Start illuminated display 119 Alarm illuminated display 120 Flush AB illuminated display

102

120

TwinControl

121

B_02601

103

Designation

121 Push button [SET] 122 a) Push button [-]

b) Push button [Check for leaks] 123 Push button [+] 124 Display in the display unit 125 B-component illuminated display 126 Flushing agent A illuminated display 127 Circulation mode illuminated display

(option) 128 B-valve cycle LED 129 Flushing agent B illuminated display

Basic operating principles: see Chapter 7.3

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Rear side TwinControl control unit with turbine

132 142

131

130

May only be used when no explosive atmosphere is present.

B_02811

Rear side TwinControl control unit with cable connection

132 142

131

133134 135136 137

Wagner International AG

Made in Switzerland

CH 9450 Altstätten

Type / Typ:

TwinControl

Serial No unit:

Serie Nr. Anlage:

II 2 G

0102

Ex ia II B T4 ZELM 08 ATEX 0385 X +5°C < Ta < +40°C

+5°C < Ta < +40°C

Year of construction / Baujahr:

Serial No. controller:

Serie Nr. Steuerung:

Air pressure supply:

Luftdruckversorgung:

Ambient temperature:

Temperatur Umgebung:

IP Code:

Schutzart:

0.6 - 0.8 MPa

IP 54

6 - 8 bar

87 - 116 psi

+5 / +40 °C

Check manual before use!

Vor Gebrauch Betriebsanleitung beachten!

138137139

133136 140

Made in Switzerland Wagner International AG CH 9450 Altstätten

130

B_02812_a

Designation

130 Connection socket Service / TwinData 131 Connection for stroke measurement B /

sensor B

132 Connection for stroke measurement A /

sensor A 133 Silencer 134 Pressure relief valve 1 turbine 135 Pressure relief valve 2 turbine 136 Air inlet 137 Air outlet – Exhaust air

Type / Typ:

TwinControl

Year of construction / Baujahr:

Serial No unit.:

Serie Nr. Anlage:

Serial No. controller:

Serie Nr. Steuerung:

Voltage:

85-260 VAC 47-60 Hz

Spannung:

Line Power:

Eingangsleistung:

Ambient temperature:

Temperatur Umgebung:

IP Code:

IP 54

Schutzart:

max. 40 W

+5 / +40 °C

Check manual before use!

Vor Gebrauch Betriebsanleitung beachten!

138141139

Designation

138 Grounding connection 139 Connections for control air

For connection numbers, see pneumatic diagram (Chapter 5.9)

140 Mains cable 141 Main switch 142 Remote control connection

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B_07283

5.9 PNEUMATIC DIAGRAM

5.9.1 TWINCONTROL 1

123

+ + + +

X Y

123

(option) (option)

1212

+ +

123

2 3

Control air

Mains air

Connection numbers for control unit 1 (on rear side)

Designation

1 Product valve A 2 Hardener valve B 3 Gun ush box (option) 4 Flushing valve air

6 External horn 10 Automatic electrostatic system (option) 12 Flushing 21 Changeover signal – pump A 22 Changeover signal – ushing pump 24 Changeover signal – pump B 25 External release

2 3

Further designations

Designation

+ Air supply

26 System compressed air monitoring AD Air regulator for operating pressure SD Control air pressure 0.6–0.8 MPa; 6–8 bar;

87–116 psi

MP Product pressure regulator, pneumatic

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VERSION 10/2018 ORDER NUMBER DOC 2339321

5.9.2 TWINCONTROL 2 / TWINCONTROL 3

1 1-

12345

(option)

213

123

+ + +

Mains air

123

1 2

Control air

123

(TwinControl 2: option)

12345

123

+ + + + +

123

3 3-

12345

B_07284

+ + +

123 123

123123

123

213

Connection numbers for control units 2 / 3, rear side

Designation

1 Product valve A 2 Hardener valve B

3 * Gun ush box

4 Flushing BS

5 * Circulation valve A, B

6 External horn 7 * Hardener valve, external mixer 8 * Air motor for spraying / air motor for soft

circulation A+B 10 Automatic electrostatic system (option) 12 Flushing AS

* TwinControl 2: Option

Connection numbers for control units 2 / 3, rear side

Designation

21 Changeover signal – pump A 22 Changeover signal – ushing pump A 23 Changeover signal – ushing pump B 24 Changeover signal – pump B 25 External release

Further designations

Designation

+ Air supply

26 System compressed air monitoring

SD Control air pressure 0.6–0.8 MPa; 6–8 bar;

87–116 psi

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B_07285

5.9.3 TWINCONTROL 6 / TWINCONTROL 8

1 1-

123

+ + +

Mains air

12345

123

1 2

Control air

12345

123

1 2

123

213

123

315

123

213

123

Connection numbers for control units 6 / 8, rear side

Designation

1 Product valve A 2 Hardener valve B

TwinControl 6: Flushing AS

TwinControl 8: Gun ush box

4 Flushing BS 5 Circulation valve A, B 6 External horn

TwinControl 6: Hardener valve, external mixer

TwinControl 8: Flushing AS

Air motor for spraying / air motor for soft

circulation A+B

AIS / control valve B

(for AIS assembly on large valves)

(internal)

213

(internal)

213

Connection numbers for control units 6 / 8, rear side

Designation

10 AIS / stepping motor B Z1 11 AIS / stepping motor B Z2 12 AIS / stepping motor B Z3 21 Changeover signal – pump A 22 Changeover signal – ushing pump A 23 Changeover signal – ushing pump B 24 Changeover signal – pump B 25 External release

Further designations

Designation

+ Air supply

26 System compressed air monitoring

SD Control air pressure 0.6–0.8 MPa; 6–8 bar;

87–116 psi

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B_07286

5.9.4 TWINCONTROL 9 / TWINCONTROL 10

From software version 4.2x

Only

TwinControl 10

153

TwinControl 9:

TwinControl 10:

TwinControl 9:

TwinControl 10:

7 4

Control air

(option)

Mains air

153

1 2 3

TwinControl 9:

TwinControl 10:

TwinControl 9:

TwinControl 10:

213

123

Connection numbers for control units 9 / 10, rear side

Designation

1 Product valve A 2 Hardener valve B 3 Gun ush box (option)

TwinControl 9: Stepping motor B Z1

TwinControl 10: Flushing air

6 External horn

TwinControl 9: Hardener valve, external mixer

TwinControl 10: --

TwinControl 9: --

TwinControl 10: Stepping motor B Z1

9 Stepping motor B Z2 10 Automatic electrostatic system (option) 11 Stepping motor B Z3 12 Flushing AS

Connection numbers for control units 9 / 10, rear side

Designation

21 Changeover signal – pump A 22 Changeover signal – ushing pump 24 Changeover signal – pump B 25 External release

Further designations

Designation

+ Air supply

26 System compressed air monitoring

AD Air regulator for operating pressure

Control air pressure 0.6–0.8 MPa; 6–8 bar;

87–116 psi TwinControl 10: Product pressure regulator,

pneumatic

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VERSION 10/2018 ORDER NUMBER DOC 2339321

5.10 LIST OF SERVICE FUNCTIONS

Software version V 4.0x / 4.1x / 4.2x

Unit Description

Filling

A B

Flushing recipes

F1 1 or 2 Denition (0=not used; 1=A product; 2=B product) Adjustable

up to 0-9999.9 Quantity Adjustable

F20 cc/sec Measuring unit (0=cc; 1=sec) Adjustable F31 F32 F33

System parameter

P6 min-1 Turbine frequency in revolutions per min (set value 38000 to 45000) Display

P7 Pot life reset

P100 0 or 1 Password (0 = no, 1 = yes) for level 1 Adjustable P101 Current software version Display P102 P103 P104 P105 P106 min Pot life post-alarm Adjustable P107 % of stroke Tolerance limit A for reversal point Adjustable P108 P109 P110 % of stroke Tolerance limit B for reversal point Adjustable P111 P112 P113

P114 0 or 1 Gun ush box (0 = no, 1 = yes) Adjustable P115 0 or 1 Manual leak inspection (0 = no, 1 = yes) Adjustable P116 mm/min Leak warning limit A Adjustable P117 mm/min Leak error limit A Adjustable P118 mm/min Leak warning limit B Adjustable P119 mm/min Leak error limit B Adjustable

/min. Running dry protection, pump A Adjustable /min. Running dry protection, pump B Adjustable /min. Max. number of double strokes – pump A where not hidden Adjustable /min. Max. number of double strokes – pump B where not hidden Adjustable

Mixed product in the hose Adjustable Volume A product from product valve to mixing block Adjustable Volume B product from product valve to mixing block Adjustable

Starting step for repetition Adjustable Final step for repetition Adjustable Number of repetitions Adjustable

Q Control Adjustable Actual value for Q Control Display Mixing tolerance Adjustable Actual value for mixing tolerance Display Actual value for position of stroke sensor A Display Actual value for position of stroke sensor B Display

Actual value reversal point stroke sensor A below Adjustable Actual value reversal point stroke sensor A above Adjustable

Actual value reversal point stroke sensor B below Adjustable Actual value reversal point stroke sensor B above Adjustable Measuring unit (0 = liters, 1 = US gallons, 2 = British gallons,

3 = conversion factor, can be set)

Adjustable

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VERSION 10/2018 ORDER NUMBER DOC 2339321

Software version V 4.0x / 4.1x / 4.2x

Unit Description

P120

P121

P122 0 or 1 Filling function with cycles of A (0 = o, 1 = on) Adjustable P123 sec 0.0–10.0s cycle duration of lling function Adjustable P124 P125 P126 0 or 1 Feed sequence (0 = AB, 1 = BA) Adjustable P127 P128 P129 P130 P131 min Time delay for alarm no. 18 ush program is not running (1-10 min) Adjustable P132

P133 P134 P135 P136 P137 0 or 1 0 = batch mode o; 1 = batch mode on Adjustable P138 0 or 1 Batch mode start via external signal (0 o, 1 = on) Adjustable P139 0 or 1 0 = normal start, 1 = If start is pressed for more than 2 sec,

P140 0 or 1 0 = emergency ushing o; 1 = emergency ushing on Adjustable P141 0 or 1 0 = No ushing after error message; 1 = Flushing after error message Adjustable P142 0 or 1 0 = Password for mixing ratio and batch mode quantity ;

P143 0 or 1 0 = ow monitoring o; 1 = ow monitoring on Adjustable P144 P145 P146 P147 0 or 1 Calibration of the components A and B with predened quantity Adjustable P148 P149

/min. Maximum double strokes of ushing pump A per min. Adjustable /min. Maximum double strokes of ushing pump B per min. Adjustable

cc/min. Minimum ow Adjustable cc/min. Maximum ow Adjustable

cc/min. Calibration quantity for component A Adjustable cc/min. Calibration quantity for component B Adjustable

Front display in mixing mode and/or if gun is closed: 0 = mixing ratio (MR); 1 = ow rate or pot life (F_P); 2 = job sum (JS); 3 = MR and F_P in turn; 4 = MR and JS in turn; 5 = F_P and JS in turn; 6 = MR and F_P and JS in turn.

Front display if [Stop] has been pressed: 0 = mixing ratio (MR); 1 = pot life only (P); 2 = job sum (JS); 3 = MR and P in turn; 4 = MR and JS in turn; 5 = P and JS in turn; 6 = MR and P and JS in turn.

0-100% of the cycle duration A-valve should be open Adjustable For 0-100% of the lling quantity, lling function should be on Adjustable

Password for level 1 Adjustable Password for level 2 Adjustable Password for level 3 Adjustable Password for level 4 Adjustable

1 = Save customer settings; 2 = Load customer settings; 3 = Load factory settings (only displayed in stop mode)

Number of A-cycles* 1000 for service message Adjustable Number of B-valve cycles* 1000 for service message Adjustable

separate lling of A and B will not be undertaken.

1 = No password for MR and batch mode quantity

Delay time until alarm, when ow is over the limit Adjustable

Adjustable

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VERSION 10/2018 ORDER NUMBER DOC 2339321

Software version V 4.0x / 4.1x / 4.2x

Unit Description

P150

P151 0 or 1 Calibration in mixing mode with predened quantity Adjustable P152 0 or 1 Start calibration in mixing mode with predened quantity via

P153 P154 P155

P156

Totals

P200 Liters Total A not zero adjustable Display P201 Liters Total A not zero adjustable x * 100,000 liters Display P202 Liters Total B not zero adjustable Display P203 Liters Total B not zero adjustable x * 100,000 liters Display P204 Liters Total for ushing A not zero adjustable Display P205 Liters Total for ushing B not zero adjustable Display P206 Cycles Number of A cycles zero adjustable Display P207 Cycles Number of A cycles * 100,000 zero adjustable Display P208 Cycles Number of A valve cycles not zero adjustable Display P209 Cycles Number of A cycles * 100,000 not zero adjustable Display P210 Cycles Number of B valve cycles zero adjustable Display P211 Cycles Number of B cycles * 100,000 zero adjustable Display P212 Cycles Number of B valve cycles not zero adjustable Display P213 Cycles Number of B cycles * 100,000 not zero adjustable Display

AIS

P300 Cycles Number of dosing valve cycles after the AIS has performed a

P301 % AIS warning limit (opening time of the dosing valve in percent) Adjustable P302 % AIS lower limit (opening time of the dosing valve in percent) Adjustable P303 % AIS upper limit (opening time of the dosing valve in percent) Adjustable P304 sec Valve > open, AIS open Adjustable P305 sec Repetition interval AIS open (for P304) Adjustable P306 Steps AIS open at stop Adjustable P307 cc/min AIS min ow Adjustable P308 % Current opening time of the dosing valve in percent Display P309 Steps Current AIS position. Start value = 1000 Display

cc/min. Calibration quantity for calibration in mixing mode Adjustable

0 = No calibration in mixing mode. Adjustable 1 = Calibration in mixing mode

(A-valve is in mixing block and is not opened). 2 = Calibration in mixing mode

(A-valve is not in mixing block and is opened).

Adjustable

external signal (0 = o, 1 = on)

0 = no circulation, 1 = soft circulation, 2 = circulation at operating pressure Adjustable Circulation A

0 = Product valve A remains closed during circulation. 1 = Product valve A opens during circulation.

Circulation B Adjustable 0 = Product valve B remains closed during circulation. 1 = Product valve B opens during circulation.

calculation (3–100)

Adjustable

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5.11 DRY RUNNING PROTECTION

In the event of hose rupture on the high-pressure side or idle running, due to lack of product, the pump runs too quickly. The system automatically closes the product valves and issues a fault message.

Prevention

Perform the daily maintenance work stated in Chapter 9.2. Ensure a sucient product supply at all times. In the case of unforeseen occurrences, immediately perform emergency stop in

accordance with Chapter 8.4.

5.12 HEATER OPTION

The electric, continuous-ow heater with explosion protection is downstream of the pump. The coating product can only be heated to maximum 80 °C. The continuous-ow heater is tted with a temperature limiter.

The temperature is set using the temperature regulator. The coating product temperature can be read o the thermometer on the coating product output.

For description, see heater operating manual.

5.13 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.

Prerequisite: control unit 6, 8, 9 or 10. AIS sets including conversion for control units 1 / 2 see Chapter 13.6.

5.14 AUTOMATIC ELECTROSTATIC SYSTEM FOR ELECTROSTATIC GUN GM5000 OPTION

The TC VM5000 automatic electrostatic system serves as an additional safety device for the safe use of the TwinControl 2K system with a GM5000 electrostatic gun.

However, the user has a duty to proceed in compliance with the instructions in Chapter 8.10. The automatic electrostatic system transmits the approval signal from a TwinControl

system (as of version 4.03) to a VM 5000 control unit. If the electrostatic system for the gun may be switched on (after lling), the TwinControl system transmits the pneumatic approval signal to the pressure switch. The pressure switch switches at a set pressure of, e.g., 2 bar. The pressure switch is connected to the VM 5000 control unit via the interface cable. The remote control function must be set in the VM 5000.

Control for the automatic electrostatic system: For installation possibilities in the TwinControl control units, see Chapter 5.6.

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B_06776

B_06777

5.15 CONNECTION KIT FOR GUN FLUSH BOX OPTION

The GFB connection kit is used as a link between the TwinControl system and a gun ush box. The installed connection kit records the following test functions:

- is a gun used in the gun ush box,

- is the GFB lid closed,

- is the gun in the gun ush box for ushing open.

The GFB connection kit is included in the control units 3 and 8. For installation possibilities in other control units, see Chapter 5.6.

5.16 FEED PUMP OPTION

A feed pump can be used with high-viscosity products or longer feed lines.

Dimensioning of the feed pump

The piston pumps pump the working product to the product output with up and down strokes but only draw in new product on the up stroke. The feed pump therefore has to pump twice the volumetric ow.

The maximum product pressure at the pump inlet of the TwinControl pump must not be exceeded.

Feed pump

Main pump

Protection of feed pump

If the maximum pressure of the feed pump is lower than the maximum pressure of the main pump, this could be exceeded if the main pump malfunctions. The feed pump and connection line must therefore be protected from excessive overpressure. An overpressure valve must then be installed between the feed pump and main pump.

Observe the ow direction during installation.

The pressure-relief valve must be cleaned regularly and after each activation: Flush with solvent.

Feed pump

Pressure relief valve

Main pump

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5.16.1 EVOMOTION 5125 FEED PUMP

Use with protective coating systems with pumps 75-150, 55-200, 38-300, 72-300. With these pumps, the maximum product pressure at the pump inlet is 2 MPa; 20 bar; 290 psi. With a pump ratio of 5:1, the inlet air pressure of the feed pump must be limited to 0.4 MPa; 4 bar; 58 psi.

EvoMotion 5-125 Unit Values

Pump ratio 5:1 Volume ow per double stroke Maximum possible strokes in operation Inlet air pressure* MPa; bar; psi 0.2–0.8; 2–8; 28–116 Maximum operating overpressure* MPa; bar; psi 4; 40; 581

* Observe the information below:

cm; cc 125

/min. 60

NOTICE

Maximum product pressure at pump inlet

Damage to pump and seals.

Operate feed pump 5-125 at maximum 0.4 MPa; 4 bar; 58 psi air pressure.

B_07208

5.17 MAINTENANCE WORK ON THE PUMPS

NOTICE

Hardened working product in the spraying system!

Destruction of the spraying system.

Ensure that no mixed product is in the system during maintenance work.

For maintenance work on the pumps, proceed as follows:

Flush and clean the system. Chapter 9.1.4

2. Close and secure spray guns.

3. Consecutively for each pump. – Switch o the compressed air supply (close ball valve). – TwinControl control unit: Select "Work" in main menu. Select the respective

components (e.g., "A") in the sub-menu and push [Start].

– Relieve the respective pump of pressure in accordance with pump's operating

manual. – Carry out desired work in accordance with pump's operating manual. – Relieve the pump of pressure in accordance with pump's operating manual. – TwinControl control unit: [Stop] – TwinControl control unit: [Flush]

4. Close and secure spray guns.

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6 ASSEMBLY AND COMMISSIONING

6.1 TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL

The assembly and commissioning personnel 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 5.5.4.

Long-term Storage

See Chapter 9.1.6.

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B_02820

6.3 TRANSPORTATION

The complete system can be safely transported in a wooden crate. The dimensions of the transport crate can be dened with the help of the information on device dimensions in Chapter 5.5.6. Weights for sample congurations can be found in Chapter 5.5.7.

When lifting the system, always make sure that it remains balanced.

Devices mounted on frame

xxx kg xxxx lb

Device mounted on trolley

xxx kg xxxx lb

B_02823

xxx kg xxxx lb

B_02825

B_02824

WARNING

Inclined ground!

Risk of accidents if the device rolls away/falls.

Place the device on horizontal oor. The rollers should be xed or replaced by leveling feet and secured. Do not tilt the device when pushing/during transport.

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6.4 ASSEMBLY AND INSTALLATION

The system is installed and commissioned by the WAGNER service department or by an expert representative. When removing from the packaging, check the system parts for possible transport damage.

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.

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.

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6.4.1 PNEUMATIC CONNECTIONS

Check whether the line pressure is sucient. It must be between 0.6–0.8 MPa; 6–8 bar; 87–116 psi.

WARNING

Overpressure!

Risk of injury from bursting components.

The operating pressure must not exceed the value shown on the type plate.

Check whether ecient lter systems and condensate precipitators are available in the air line.

The compressed air must be free of oil and water. Quality standard 7.5.4 according to ISO 8573.1, 2010 must be observed:

7: Particle concentration 5–10mg/m³ 5: Humidity: pressure dew point ≤ +7 °C 4: Oil content ≤ 5mg/m

Every day, discharge all impurities and the condensate (if any) accumulated in the system 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.

6.4.2 PRODUCT CONNECTIONS

Fit suction systems in accordance with operating manuals for pumps. Connect high-pressure hose and gun to the TwinControl mixer unit as laid down in

the operating manual for the gun.

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6.5 GROUNDING

DANGER

Discharge of electrostatically charged components in atmospheres containing solvents!

Explosion hazard from electrostatic sparks or ames.

Ground all device components. Ground the work pieces to be coated.

WARNING

Danger due to re, explosion and electric shock hazard!

Danger to life through electric shock and explosion.

The device must be connected to the potential equalization (ground); the ground in the electrical system is not sucient.

A qualied 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 insucient!

Danger of poisoning. Insucient paint application quality.

Ground all device components. Ground the work pieces to be coated.

Ex zone

All devices and equipment must be suitable for use in potentially explosive areas.

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VERSION 10/2018 ORDER NUMBER DOC 2339321

6.5.1 GROUNDING OF COMPONENTS ON FRAME OR TROLLEY

View of rear side of system

J. Wagner AG

Made in Switzerland

CH 9450 Altstätten

Type / Typ:

TwinControl

Serial No unit.:

Serie Nr. Anlage:

II 2 G

0102

Ex ia II B T4 X

ZELM 08 ATEX 0385 X +5°C < Ta < +40°C +5°C < Ta < +40°C

Year of construction / Baujahr:

Serial No. controller:

Serie Nr. Steuerung:

0.6 - 0.8 MPa

Air pressure supply:

6 - 8 bar

Luftdruckversorgung:

87 - 116 psi

Ambient temperature:

+5 / +40 °C

Temperatur Umge

Prot. Class:

Schutzklasse:

Grounding connections

On the potential equalization (signal ground)

B_04536

Connect all grounding cables using a short and direct route.

from - to Line

1 A-pump on frame 4 mm; AWG 12 2 B-pump on frame 4 mm; AWG 12 3 Flushing pump on frame 4 mm; AWG 12 4 Control unit on frame 4 mm; AWG 12

2A switchbox (option) or reversing box

(ESTA remote control, option) on control

4 mm; AWG 12

unit

6 Frame to signal ground 4 mm; AWG 12

Grounding connection point on frame. View of operating side of system.

B_02805

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Cable cross-sections

TwinControl frame 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

6.5.2 EXAMPLE OF GROUNDING SCHEME FOR TWINCONTROL WITH TURBINE

Ex zone 1 and 2







TwinControl







R max. < 1 MOhm

B_04532





A B

Legend Grounding cables Fluid hoses

3 TwinControl frame 5 Work piece 7 Floor, static dissipative 9 Remote control (option) 4 Paint tank 6 Conveyor 8 Flushing agent tank 10 Horn (option)

6.5.3 EXAMPLE OF GROUNDING SCHEME FOR TWINCONTROL WITH MAINS POWER CONNECTION CABLE





Non-Ex zone



Ex zone 1 and 2









A B

Legend Grounding cables Fluid hoses

3 TwinControl frame 5 Work piece 7 Floor, static dissipative 9 Remote control (option) 4 Paint tank 6 Conveyor 8 Flushing agent tank 10 Horn (option)



TwinControl





R max. < 1 MOhm

B_04533

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6.6 COMMISSIONING

6.6.1 PREPARATION BEFORE COMMISSIONING

Make sure that the device and all other conductive parts within the work area are grounded.

Connect spray gun without nozzle with high-pressure hose to the mixing unit and secure with safety clip.

Check hoses for damage. Check that all product-conveying connections are correctly connected. Check all connections for leaks. Check that all connections carrying air are connected correctly according to the

pneumatic diagrams in Chapter 5.9. Visually check the permissible pressures for all the system components. Check level of separating agent in the pumps and top up separating agent if

necessary. Provide and ground a product tank for A and B components, a tank for ushing

agent and an empty tank for return ow. Connect the system to the air supply.

NOTICE

Magnetic elds!

Danger of damage to electronic devices and magnetic data carriers.

Ensure that electronic devices and magnetic data carriers are removed from the danger area.

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6.6.2 BASIC FLUSHING AND PRESSURE TIGHTNESS TEST

The devices are tested in the factory with emulsifying oil, pure oil or solvent. Possible residues must be ushed out of the circuits with a solvent (ushing agent) before commissioning.

WARNING

Incompatibility of ushing agent and working media!

Risk of explosion and danger of poisoning by toxic gases.

Examine the compatibility of the ushing and cleaning agents and working media on the basis of the safety data sheets.

Always carry out basic ushing and the pressure tightness test:

– before putting the new system into operation for the rst time (pumps are empty); – before using the system again after prolonged storage; – before servicing the system.

WARNING

Overpressure!

Risk of injury from bursting components.

The operating pressure must not exceed the value shown on the type plate.

Please note:

– Do not insert the nozzle into the gun yet. Gun secured. – Keep the pump pressure as low as possible during ushing. – Operating manuals for the aected components must be read and understood.

Process

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Connect compressed air supply. Switch the system on.

3. Place the suction hoses of the three pumps in a grounded metal tank with ushing agent. Use a separate, grounded, metal tank for each pump. Provide and ground an additional, empty metal tank.

4. Place grounded metal tanks for return product under the return tube of each of the pumps.

5. Close the pressure regulator of all of the pumps (0 MPa; 0 bar; 0 psi).

6. Select "Work" in main menu.

7. Flushing and pressure tightness test for pump A:

7.1. Open return valve of pump A.

7.2. Slowly open ball valve of pump A.

7.3. Slowly turn up the air pressure on the pressure regulator of pump A. Only turn up the air pressure until the pump is running normally (approx. 0–0.05MPa; 0–0.5 bar; 0–7.25 psi). Be ready to switch from air to ushing agent and prevent back spray.

7.4. Close the ball valve of pump A again as soon as clean ushing agent comes out.

7.5. Close the return valve of pump A again.

7.6. In sub-menu, select component "A"

and press [Start].

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7.7. Point the spray gun (preferably without nozzle) into the grounded metal tank for return product and open carefully.

7.8. Slowly open ball valve of pump A. Be ready to switch from air to ushing agent and prevent back spray.

7.9. Flush until the hose content has been emptied and clean ushing agent comes out.

7.10. Close and secure the spray gun.

7.11. Gradually increase pressure in pump A with the pressure regulator until maximum pressure is reached. Maintain the pressure for 3 minutes and check all connection points of the A-product circuit for leaks.

7.12. Relieve pressure of A-product-circuit:

– Relieve air pressure in accordance with the operating manual for pump A. – Slowly open the return valve of pump A. When no further overpressure is

detected, close the return valve again. – Point the spray gun into the grounded metal tank for return product. – Release and open spray gun to relieve the pressure. Avoid splashback. – When no further overpressure is detected, close and secure the spray gun.

7.13. Close product valve by pressing [Stop].

8. Flushing and pressure tightness test for pump B:

8.1. Open return valve of pump B.

8.2. Slowly open ball valve of pump B.

8.3. Slowly turn up the air pressure on the pressure regulator of pump B. Only turn up the air pressure until the pump is running normally (approx. 0–0.05MPa; 0–0.5 bar; 0–7.25 psi). Be ready to switch from air to ushing agent and prevent back spray.

8.4. Close the ball valve of pump B again as soon as clean ushing agent comes out.

8.5. Close the return valve of pump B again.

8.6. Select component "B" in sub-menu

8.7. Point the spray gun (preferably without nozzle) into the grounded metal tank for return product and open carefully.

8.8. Slowly open ball valve of pump B. Be ready to switch from air to ushing agent and prevent back spray.

8.9. Flush until the hose content has been emptied and clean ushing agent comes out.

8.10. Close and secure the spray gun.

8.11. Gradually increase pressure in pump B with the pressure regulator until maximum pressure is reached. Maintain the pressure for 3 minutes and check all connection points of the B-product circuit for leaks.

8.12. Relieve pressure of B-product circuit:

and press [Start].

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– Relieve air pressure in accordance with the operating manual for pump B. – Slowly open the return valve of pump B. When no further overpressure is

8.13. Close product valve by pressing [Stop].

9. Flushing and pressure tightness test for ushing pump:

9.1. Open return valve of ushing pump.

9.2. Slowly open the ball valve of the ushing pump.

9.3. Slowly turn the air pressure up on the pressure regulator of the ushing pump. Only turn up the air pressure until the pump is running normally (approx. 0–0.05MPa; 0–0.5 bar; 0–7.25 psi). Be ready to switch from air to ushing agent and prevent back spray.

9.4. Close the ball valve of the ushing pump again as soon as clean ushing agent comes out.

9.5. Close return valve of ushing pump again.

9.6. In sub-menu, select ushing valve AS:

and press [Start].

9.7. Point the spray gun (preferably without nozzle) into the grounded metal tank for return product and open carefully.

9.8. Slowly open the ball valve of the ushing pump. Be ready to switch from air to ushing agent and prevent back spray.

9.9. Flush until the hose content has been emptied and clean ushing agent comes out.

9.10. Close and secure the spray gun.

9.11. Gradually increase pressure in the ushing pump with the pressure regulator until maximum pressure is reached. Maintain the pressure for 3 minutes and check all connection points for leaks.

9.12. Relieve pressure of ushing agent circuit:

– Relieve air pressure in accordance with the operating manual for ushing

pump.

– Slowly open return valve of ushing pump. When no further overpressure

is detected, close the return valve again. – Point the spray gun into the grounded metal tank for return product. – Release and open spray gun to relieve the pressure. Avoid splashback. – When no further overpressure is detected, close and secure the spray gun.

9.13. Close ushing valve by pressing [Stop].

9.14. If there is a separate B ushing valve (controller 2 or 3): Select ushing valve BS in the sub-menu

and then repeat steps 9.7 to 9.13.

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6.6.3 REPLACING FLUSHING AGENT WITH WORKING MEDIA

NOTICE

Interchange of the two components A and B!

Device damage due to hardened product.

Label device components and paint tank so that the components A and B are not mixed up.

Prerequisites

At the start, all pumps should be lled with ushing agent just as after basic ushing

–

6.6.2).

– Do not insert the nozzle into the gun yet. Gun secured. – Operating manuals for the aected components must be read and understood.

Process

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Connect compressed air supply. Switch the system on.

3. Place the suction hoses of the three pumps in the respective grounded metal tanks: – ushing agent for the ushing pumps – master product for pump A – hardener product for pump B

4. Place grounded metal tanks for return product under the return tubes of pumps A

and B.

5. Set a low pressure (approx. 0.05 MPa; 0.5 bar; 7 psi) on the pressure regulators for the

three pumps.

6. Select "Work" in main menu.

7. Filling pump A:

7.1. Open return valve of pump A.

7.2. Slowly open ball valve of pump A.

7.3. Close the ball valve of pump A again as soon as pure working product comes out.

7.4 Close the return valve of pump A again.

7.5. In sub-menu, select component "A"

7.6. Point the spray gun (preferably without nozzle) into the grounded metal tank for return product and open carefully.

7.7. Slowly open ball valve of pump A.

7.8. Close the ball valve of pump A again as soon as pure working product without air inclusions comes out.

7.9. Close and secure the spray gun.

and press [Start].

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7.10. Relieve pressure of A-product-circuit: – Relieve air pressure in accordance with the operating manual for pump A. – Slowly open the return valve of pump A. When no further overpressure is

7.11. Close product valve by pressing [Stop].

8. Filling pump B:

8.1. Open return valve of pump B. As soon as pure working product comes out, close return valve again.

8.2. Select component "B" in sub-menu

8.3. Point the spray gun (preferably without nozzle) into the grounded metal tank. Release the spray gun safety and open carefully. Flush until the hose content is emptied and pure working product, without air inclusions, comes out. Close and secure the spray gun.

8.4. Relieve pressure of B-product circuit:

– Relieve air pressure in accordance with the operating manual for pump B. – Slowly open the return valve of pump B. When no further overpressure is

8.5. Close product valve by pressing [Stop].

9. Dispose of the contents of the waste tanks according to the local regulations. The system is ready to start. Continue with calibration (Chapter6.6.4) or spraying

10. (Chapter8.7). If not continuing with work straight away, ush the system (Chapter 8.8).

and press [Start].

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6.6.4 CALIBRATING THE SYSTEM

Calibrating A-component Calibrating B-component

SET

TwinControl

B_02744

SET

TwinControl

B_02744

The system is volumetrically calibrated in the factory, therefore it does not have to be calibrated with the product. However, if a calibration is required, proceed as follows:

1. The product to be calibrated is rst conveyed manually as far as the gun.

2. Set the pump pressure to 0.5 MPa; 5 bar; 73 psi and select the nozzle so that the product ow rate corresponds to the subsequent production process.

3. Start the calibration process for the A-side with the [Start] button.

4. A minimum of 5 pump double strokes are discharged into a measuring cup via the gun (use tubing to protect against overspray if necessary). The ow rate measured by the controller is shown on the display.

5. Press the [STOP] button.

The quantity discharged into the measuring cup in cm

is entered by pressing [SET] and [+] [-] and

conrmed by pressing [SET]. Interrupting process: The calibration process can be interrupted without saving by pressing the [Stop]

button.

7. The controller has now calculated and saved the new K-factor and displays it.

8. Repeat the calibration in order to check it. Large deviations may be due to the following error causes:

– air in the lines – large proportion of air bubbles in product in measuring cup

Fill the lines with product and check the suction system.

Determine product weight with

scale and calculate the volume based on the density.

9. Calibrate the B-component in the same way as the A-component.

10. The K factor can be entered directly for the ushing pump (in cm

per double stroke).

11. Flush system.

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6.6.4.1 METHOD OF CALIBRATION SIMPLE PRACTICAL VARIANT

Manually measure precisely e.g., 500 cm

of A-product into a measuring cup and

determine the product weight in "g" grams. Note: For pumps with more than 150 cm

/ a greater product reference quantity

must be specied. Rule of thumb: At least 3 double strokes of the pump.

2. The product to be calibrated is rst conveyed manually as far as the gun.

3. Set the pump pressure to 0.5 MPa; 5 bar; 73 psi and select the nozzle so that the product ow rate corresponds to the subsequent production process.

4. Set calibration from A-side on control unit.

5. Start the calibration process for the A-side with the [Start] button.

Use the gun to add the weight in "g" indicated above for 500 cm

of A-product into a

measuring cup (use tubing to protect against overspray if necessary). The ow rate measured by the controller is shown on the display.

7. Press the [STOP] button.

Enter the preselected reference amount in "cm

" (500 = example) by pressing [SET]

and [+] [-] and conrm by pressing [SET]. Interrupting process: The calibration process can be interrupted without saving by pressing the [Stop] button.

9. The controller has now calculated and saved the new K-factor and displays it.

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1000

900

800

700

600

500

400

300

200

100

e.g., weigh out 500 cm3 (= 0.5 liter) of A-product.

610.00

Set calibration A on the control unit.

Tubing to protect against overspray

1000

900

800

700

600

500

400

300

200

100

SET

TwinControl

SET

TwinControl

Once 610 g has been discharged, enter 500 on the control unit and conrm with [SET].

B_03751

610.00

Use gun to convey the 610 g of A-product measured above into tank.

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7 CONTROLLER

7.1 TRAINING THE OPERATING PERSONNEL

The operating personnel must be qualied 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 personnel 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 100megohms.

The protective clothing, including gloves, must comply with ENISO 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:

Switch o the energy and compressed air supply. Relieve pressure from spray guns, high-pressure hoses and all devices. Secure spray guns against actuation. 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 OPERATING THE CONTROL UNIT

For the meaning of all symbols/illuminated displays: see Chapter 5.8

Main menu Sub-menu Display

Alarm

Pot life

Tasks

SET

TwinControl

B_02744

Setting buttons [Flush] button [Stop] button [Start] button Menu selection buttons

Base position

When switched on, the control unit is in its base position. The three lamps "Work", "A" and "B" are illuminated in the base position. Depending on system status, other lamps might light up or ash.

Returning to base position

Press the [Stop] button once or twice.

Triggering action

1. Main menu selection (depending on personal authorization)

2. Sub-menu selection

3. [Start] or [Flush]

[Start] button

Main menu Sub-menu Function of the [Start] button

A + B Start of work cycle A A-valve opens B B-valve opens Flushing agent A A-ushing-valve opens

– With separate A and B ushing hoses

Tasks

Flushing agent B

ushing valve opens

– If only one ush hose is connected directly to

mixer

[Start] button has no function

Circulation operating mode

Circulation of A and B product

(option)

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[Stop] button

Device status Function of [Stop] button

Program running

Terminates active program. Resets all valves to original

status. Program not running Returns to base position Setting input [SET] Terminates input without saving Alarm

Acknowledges alarm Fault rectication (Chapter 10)

Alarm

If there is a malfunction, the systems stops and the alarm display lights up. An error code appears on the display.

Acknowledge with [Stop] button Fault rectication in accordance with Chapter 10

Pot life

– Pot life display lights up – Pot life display ashing

Pot life running.

Display shows the remaining pot life.

Display in the display unit

–

When working in accordance with system parameter P120 (see Chapter5.10). After pressing [Stop] button in accordance with system parameter P121

–

(see Chapter5.10).

7.3.1 ENTERING NUMBERS SET

Changing and saving numbers

To change numbers To save numbers

[SET], [+] (higher) or [-] (lower) Terminate data input [Stop] button

[SET] Into main menu 2x [Stop] button

If the indication "OFF" appears after making an entry in the display, then the input authorization must be enabled.

SET

TwinControl

B_02744

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7.4 PASSWORD PROTECTION AND USER FUNCTIONS

Level 0 Painter Functions:

Start, stop, ush, (option - circulate)

Press [+] and [-] at the same time ->[SET] ->Password level 1 ->[SET]

Level 1 Painter with control jobs Functions:

Start, stop, ush, (option - circulate)

View only:

Job quantities, total quantities, calibration values, pot life, last alarm, mixed quantity in hose, lling quantity A, B, ushing quantity A, B

Press [+] and [-] at the same time ->[SET] ->Password level 2 ->[SET]

Level 2 Foreman Functions:

Start, stop, ush, (option - circulate)

View or change:

Job quantities, total quantities, mixed product in hose, lling quantity A, B, ushing quantity A, B, mixing ratio, pot life.

View only: calibration values, alarms

Press [+] and [-] at the same time ->[SET] ->Password level 3 ->[SET]

Level 3 Service customer Functions:

Start, stop, ush, (option - circulate)

View or change:

Job quantities, total quantities, mixed product in hose, lling quantity A, B, ushing quantity A, B, calibration value, alarms, mixing ratio, pot life.

View and change parameters from P0 to P7.

Password = xxxx

Press [+] and [-] at the same time ->[SET] ->Password level 4 ->[SET]

Level 4 Service Functions:

Start, stop, ush, (option - circulate)

View or change:

Job quantities, total quantities, mixed product in hose, lling quantity A, B, ushing quantity A, B, calibration value, alarms, mixing ratio, pot life.

View and change parameters from P0 to P309. Exceptions: Parameters P107, P108, P109, P110, P111, P112, P308 and P309 can be

viewed only.

The passwords, which are set by WAGNER at the time of the device delivery, are not contained in the operating manual for safety reasons. The valid passwords are communicated to the customer separately.

Password = xxxx

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7.5 BASIC FUNCTIONS FOR THE PAINTER

Base position

System is ready to start [Start] button-> system starts mixing

System is mixing

Pot life LED ashing -> pot life running Work LED ashing -> lling Work LED illuminated -> system ready to spray B-valve cycle display -> ashes in B-valve cycle Display -> See Chapter5.10 -> P120

Automatic stop in case of error

Alarm illuminated display on Stop illuminated display on Error code is displayed

Flushing

The ushing program runs automatically. The ushing program must have been dened in advance under service level 3 (with password protection). Also refer to ushing steps F1 to F33 in the service functions list in Chapter 5.10 and how to dene the ushing program in Chapter 7.6.2.

Emergency ushing

If the ushing button is pressed for 3 seconds or more, only the steps involving ushing agent are undertaken (actions 3 or 4).

SET

TwinControl

B_02744

SET

TwinControl

B_02744

SET

TwinControl

B_02744

SET

TwinControl

B_02744

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7.6 EXTENDED FUNCTIONS WITH PASSWORD PROTECTION

Adjusting the mixing ratio

Press [SET] -> change value with + - push button. Press [SET] again to conrm new value (Cancel with STOP push button).

Manual operation / job quantities

– Only convey A-component

(START / STOP). Displays job total A in cm

– Only convey B-component

(START / STOP). Displays job total B in cm

– Only convey ushing agent A

(START/STOP) Displays job total for ushing agent A in cm

– Only convey ushing agent B

(START/STOP) Displays job total ushing agent B in cm

Valid for:

– types 48-110, 75-150, 72-300, 55-200, 38-300, 8-300,

3-600, 18-300, 8-600

– or when separate ushing agent B is available.

SET

TwinControl

B_02744

SET

TwinControl

B_02744

SET

TwinControl

B_02744

SET

TwinControl

B_02744

SET

TwinControl

B_02744

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Total quantities

– Total amount A

Set to "0": Press [SET] push button > 2 seconds. Display in liters.

– Total amount B

Set to "0": Press [SET] push button > 2 seconds. Display in liters.

– Total amount ushing A

Set to "0": Press [SET] push button > 2 seconds. Display in liters.

– Total amount ushing B

Set to "0": Press [SET] push button > 2 seconds. Display in liters.

SET

TwinControl

B_02744

SET

TwinControl

B_02744

SET

TwinControl

B_02744

SET

TwinControl

B_02744

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B_02744

Pot life

Setting the pot life. set [SET] with [+] [-], [SET].

Error messages

Display of last 28 error messages. View with ±.

SET

TwinControl

B_02744

SET

TwinControl

Circulation of A and B components

(only possible if option available)

SET

TwinControl

B_02744

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Service (password entry required for P100)

–

Content of spray hose with mixed product

– Quantity from product valve A to mixing block

– Quantity from product valve B to mixing block

– Parameter

Service parameters P0 - P7 Conguration parameters P100 - P154 Totals P200 - P213 (Also see Chapter 5.10)

Change from P0 to P1...P2, ... with [+] button. Return with [-] button.

SET

TwinControl

B_02744

SET

TwinControl

B_02744

SET

TwinControl

B_02744

SET

TwinControl

B_02744

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7.6.1 CALIBRATION

(Password entry required for P100)

Calibrate A

[Start] -> Open gun -> With spray pressure, pump out around 5double strokes into measuring cup ->Gun closed -> [SET] -> Enter measurement in measuring cup in cm

-> [SET]

(Cancel with [Stop] button)

Calibrate B

[Start] -> Open gun -> With spray pressure, pump out around 5double strokes into measuring cup ->Gun closed -> [SET] -> Enter measurement in measuring cup in cm

-> [SET]

(Cancel with [Stop] button)

Calibration Flushing A

Direct input in cm

/ of ushing pump

Calibrate ushing B

Direct input in cm

/ of ushing pump

SET

TwinControl

B_02744

SET

TwinControl

B_02744

SET

TwinControl

B_02744

SET

TwinControl

B_02744

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7.6.2 FLUSHING PROGRAMS

Flushing program mode

The ushing steps can be dened in the mode shown under parameters F1 to F20.

Enter ushing program

– Press [SET] during program step F1 (to F20). A appears on the left to enter the action.

Use [+] or [-] button to select the value. For input values, see description of action in

Table 2. – Press [SET]. – Enter the amount using the [+] or [-] button. – Press [SET]. – Enter the measuring unit cc (= ml) or sec using the [+] or [-] button. – Press [SET] (the measuring unit displayed is saved). – The [+] or [-] button takes you to the next program step (F2 or Fx).

Table 1: ushing steps

Step F Actions Quantity Unit

Table 2: actions

Action Description of action

0 No activity 1 Product A 2 Product B 3 Flushing A 4 Flushing B 5 Wait time

SET

TwinControl

B_02744

Table 3: repetitions

Step F Step Description

F31 ** 3-20 Start repetition F32 ** 3-20 End repetition

F33 1-200 Number of repetitions

** F31 must be smaller than F32.

* With repeated ushing (2 instances of ushing one after another), ushing steps

"F1" and "F2" are only performed the rst time. During the second ushing cycle, the ushing program starts from step "F3".

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Display in the display unit

When the programmed ushing program is called up by pressing the [Flush] push button on the control unit and is running, each of the individual steps is shown briey on the display.

Examples of ushing programs

for EvoMotion 5-60

Step F Action Value Unit Remarks

Product A (press 10cc of A-product into spray hose) Product B (press 10cc of B-product into spray hose) Flushing A (press mixed product out of the spray hose) Flushing A (solvent for solvent-air ushing) Flushing B (air for solvent-air ushing) Flushing A (ll spray hose with ushing agent again) Start of repetition from step 4 End of repetition at step 5 Number of repetitions from step 4 to 5 = 10x

for Puma 28-40

Step F Action Value Unit Remarks

Product A (press 10cc of A-product into spray hose) Product B (press 10cc of B-product into spray hose) Flushing A (ush product hose with 200 cc)

for Leopard 48-110

Step F Action Value Unit Remarks

Product A Product B Flushing B (ush 200 cc on B-side) Flushing A (ush 200 cc on A-side)

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7.6.3 AIS

Prerequisite: AIS system

The AIS (Adaptive Injection System) automatically regulates the dosing valve stroke. A stepping motor increases or decreases the stroke in steps.

AIS settings (password level 4)

Parameter Explanation Unit Values Default

Number of dosing valve cycles after the AIS has performed

G300

G301

G302

G303

G304

G305

G306

G307

a calculation. Note: When starting the mixing mode, the AIS must wait for these cycles, before the adjustment can begin.

Warning limit: Minimum injection quality (opening time of the dosing valve in percent). If the value falls below this, a warning is triggered (code 97).

Lower injection quality limit (opening time of dosing valve as a percentage). If the value falls below this, the AIS optimizes the injection quality.

Upper injection quality limit (opening time of dosing valve as a percentage). If the value falls below this, the AIS limits the injection quality. Thereby smooth operation is ensured.

If the dosing valve is continuously opened for longer than the stated time, then too little product ows through. The AIS allows more product through.

Repetition interval: For the above function (P304), the AIS undertakes a step every x seconds until the valve cycles again.

Number of steps which the AIS is to open when mixing operation is ended.

Minimum ow of all components for AIS to undertake regulation.

Cycles 3–100 3

% 0–100 10

% 0–100 50

% 0–100 60

sec 0.5–25.0 1.5

Steps 0–20 5

cc/min 5–1000 100

AIS Information (view only, password level 4)

Parameter Explanation

G308 Current opening time of the dosing valve in percent (0–100%)

Current AIS position. The start value (after pressing the START push button) is 1000. Each step

G309

of the stepping motor changes the value by 1. A number greater than 1000 increases the ow rate. A number less than 1000 decreases the ow rate.

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Presetting dosing valve stroke (from password level 2) Depending on the starting position, some time may be needed to reach the optimum

stroke (AIS position). This alignment time can be reduced with an appropriate manual presetting. The dosing valve stroke can be manually preset, if product B ows (not ushing agent B):

- Main menu "Work", submenu "A+B", START

- Main menu "Work", submenu "B", START

- Main menu "Work", submenu "Circulation operating mode", START

- Main menu "Calibration", submenu "B", START

- During a ushing step with product B

Procedure

Preset dosing valve stroke when product B ows:

1. Main menu "Work" (see gure)

2. Press push button [-] or [+] several times until the product ow is approximately correct.

+ increases the ow – decreases the ow

Note: Do not press the SET button.

SET

TwinControl

B_02744

In the event of mixing problems:

Checking AIS function

Observe for 3 minutes in spray mode with gun open: If the AIS position (P309) is continually counting up or down in the same direction without the opening time of the dosing valve (P308) changing, the AIS is not working. Contact the WAGNER service department.

Check AIS stepping motor

Check whether the AIS stepping motor works:

1. Main menu "Work", submenu "B", START

2. Press push button [-] until the product ow stops.

If the stepping motor does not react:

- Check connections.

- Contact the WAGNER service department.

AIS error messages

Error code 97: see Chapter 10.1.

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7.6.4 CHECK FOR LEAKS IN A AND B FLUID SECTION

Leak testing setting

Via password level 4 where pos. "P115" P115 = 1.

Sensitivity settings

Leak warning limit A (mm/min) Leak error limit A (mm/min) Leak warning limit B (mm/min) Leak error limit B (mm/min)

Leak testing for one stroke direction

1. [Stop]. Secure the gun. Close all return valves.

2. Pumps A and B: Set pressure regulator to working pressure.

3. Press [-] push button for three seconds. A-pump and B-pump (including circulation valves) are

checked for leaks for 10 seconds. During the check, the display counts from 10 to 0 and the LED displays for A and B ash alternately. Any leakage is indicated by an error message.

SET

TwinControl

B_02744

Changing stroke direction

4. Pumps A and B: Set pressure regulator to zero.

5. Place grounded metal tanks for return product under the return tubes of pumps A and B.

6. Pumps A and B: Briey open each return valve. As soon as the stroke direction audibly switches over, close valve.

Leak testing for the other stroke direction

7. Pumps A and B: Set pressure regulator to working pressure.

8. Press [-] push button for three seconds.

Leakage error messages

See Chapter 10.1.

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7.6.5 "BATCH MODE" FILLING MODE

The Batch Mode setting allows a recurring and pre-dened ow rate to be discharged via the gun or via an external valve.

Batch Mode setting

Via password level 4 where pos. "P137" P137 = 1.

Other settings for the Batch quantity to be displayed:

Parameter pos. "P120" and "P121" must be set to one of the following values:

(job sum) or (MR and JS in turn) or (P and JS in turn) or (MR and JS and P in turn).

Access for changing the Batch quantity

1.) Via password level 2 or

2.) Via parameter pos. "P142" P142 = 1 (no password protection for MR and Batch quantity).

Changing the Batch quantity

"Total" illuminated display must be ashing. Press [Set] -> the current set value is displayed. Use the [+] or [-] button to select the set value. Use [SET] to save the new set value.

Operation

Press [Start].

SET

TwinControl

B_02744

Note:

If lling has not yet taken place, it is undertaken automatically. Filling complete -> System at Stop. Press [Start] again. The system is running and shifts to Stop when the target quantity is reached. The operating cycle can be repeated any number of times.

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8 OPERATION

Below, operation with manual guns is described. For automatic guns, the same workow applies correspondingly.

8.1 TRAINING THE OPERATING PERSONNEL

The operating personnel must be qualied 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 personnel must receive appropriate system

training.

8.2 SAFETY INSTRUCTIONS

The operating documents for the pneumatic pumps and other system components should be read through carefully. The appropriate operating manuals are available on the WAGNER CD as PDF les.

Also observe the operating manuals for the components mounted on site.

Automatic electrostatic system

The automatic electrostatic system tted for the GM 5000 electrostatic gun may only be released in spraying mode. Always follow the instructions in the operating manual.

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 media. Do not spray the device empty after cleaning.

8.2.1 GENERAL RULES FOR MAKING ADJUSTMENTS TO 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. Wear the appropriate protective clothing, gloves, eyewear, and respirator

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8.3 MALFUNCTION

If a fault occurs, it is indicated by the following:

The system stops and the alarm horn sounds The alarm display lights up (control unit and remote control). A fault is indicated on the display.

Acknowledge fault

With the [Stop] button.

Alarm messages + fault rectication

see Chapter 10.1.

8.4 EMERGENCY DEACTIVATION

In the case of unforeseen occurrences, immediately:

1. Switch o air supply.

2. Vent air motors for all pumps.

3. Provide grounded metal tanks for return product. Relieve pressure from all the pumps via the return valves.

4. Point the spray gun into the grounded metal tank for return product. Release and open spray gun to relieve the pressure. Avoid splashback.

5. When no further overpressure is detected, close and secure the spray gun.

O

Closed

Open

B_04458

B_04457

4. 5.

B_04459

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8.5 SWITCHING THE SYSTEM ON

2. 3.

A+S B+S

Return line

B_04505

Example of TwinControl system ready for spraying

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1. Switch on air supply.

2. Switch on control air.

Note:

For control units with turbines, the turbines are powered by control air and the electronics thereby switched on.

3. For a system with a product pressure regulator: Switch on the work air.

O

B_02835

O

4. For a TwinControl cable variant: Turn on main switch on the control unit.

B_02836

O

B_02837

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8.6 SWITCHING OFF THE SYSTEM

Carry out ushing in accordance with Chapter 8.8.

2. Relieve pressure according to Chapter 8.9.

3. Switch o control air.

Note:

For control units with turbines, the turbines are powered by control air.

4. For a system with a product pressure regulator: Switch of the work air.

5. Switch o air supply.

O

B_07212

O

B_07211

6. For a TwinControl cable variant: Switch o main switch on control unit.

7. Relieve compressed air pressure between main switch and pumps:

– Flushing pump A: Open air ball valve – Flushing pump A: Open and close relief valve – Flushing pump A: Close air ball valve

O

B_07213

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8.7 SPRAYING MODE

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 product;

− the ushing program is dened;

− the supply pressures are constant;

− the pressure regulator for the A pump and B pump are set correctly. A is always around 10% lower than B;

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 A and B can draw in the product perfectly and no cavitation occurs (pump breaking through during down stroke). If necessary, the product must be fed with a feed pump.

Optimum operation is fullled under the following conditions:

− The ushing agent pressure for A and B is always present on the device, and the product pressure for the A and B pumps.

− When lling the mixed product in the product hose, ensure that the nozzle is inserted in the gun.

− The ushing process is performed without the nozzle in the gun.

− The level in the A and B product tanks and in the ushing product tank is checked visually, in order to prevent unintended interruptions in the spray process.

Prerequisites

At the start, all pumps must be lled with working product and the system must be

− ready to start, as described in Chapter 6.6.3.

− The nozzle is inserted into the gun. Gun secured.

− Operating manuals for the aected components must be read and understood.

Process

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. If necessary, use [Stop] to move control unit into base position.

3. Press [Start] button on control unit.

4. Filling process: Pull the trigger on the gun with nozzle and spray into waste bucket. The green start lamp on the control unit ashes during lling.

5. Fill until the green start lamp is lit up continuously and no more ushing agent or unmixed product comes out (Only mixed product should come out).

6. Start the coating process right away and perform without interruption if possible. Bear in mind the pot life of product at all times.

7. If necessary, adjust air pressure levels of high-pressure pumps. The hardener pressure should be slightly higher than that of the A-component.

Once spraying work is complete, perform ushing (Chapter 8.8) and/or pressure relief

8. (Chapter 8.9).

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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 supply pressures should be constant.

8.8 FLUSHING

The system's ushing program ushes the hoses between the mixer and gun and removes any mixed product present.

Flushing must always be carried out:

− before prolonged work interruptions and before the end of work;

− before expiry of the pot life;

− before a product change.

WARNING

Incompatibility of ushing agent and working media!

Risk of explosion and danger of poisoning by toxic gases.

Examine the compatibility of the ushing and cleaning agents and working media on the basis of the safety data sheets.

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 8.9).

−

Wear protective goggles.

Set the ﬂushing agent pressure as low as possible for ﬂushing.

Process

1. Press [Stop] on the control unit.

2. Press ]Flush] on the control unit.

3. Point the spray gun (preferably without nozzle) into the grounded metal tank for return product.

4. Release the spray gun safety and open carefully.

5. Flush until clean ushing agent comes out and the ushing program is complete.

6. Close and secure the spray gun.

Display in the display unit

While the ushing program is underway, the individual steps and entered data are shown on the display.

Insucient ushing aect

If necessary adjust the ushing pressure on the ushing pump. If necessary, adapt the ushing program.

See "Dening Flushing Program" in Chapter 7.6.2. Check suitability of ushing agent for the master and hardener materials used.

Note manufacturer's recommendations for use.

Cleaning the system

See Chapter 9.1.4

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B_02744

8.9 PRESSURE RELIEF / WORK INTERRUPTION

The pressure must always be relieved:

– after the spraying tasks are nished, – before servicing or repairing the spraying system, – before carrying out cleaning tasks on the spraying system, – before moving the spraying system to another location, – before something must be checked on the spraying system, – before the nozzle or the lter is removed from the spray gun.

Procedure (password level 1 is required)

1. Close and secure the spray gun.

2. Press [Stop].

3. Relieve all A and B pumps of pressure:

– Relieve air pressure in accordance with

the respective operating manual.

– With product pressure regulator (option):

Ensure that the product pressure regulator is open.

– With password level 1:

Only convey A-components, or only convey B-components

– Press [Start].

– Place grounded metal tank for return

product under the return tube of the

respective pump. – Open the return valve slowly. – When no further overpressure is

detected, close the return valve.

Closed

Open

SET

TwinControl

Open

B_04458

(Example for A-components)

B_02744

Open

(Return line)

Closed

(Spraying)

SET

TwinControl

– Point the spray gun into the grounded

metal tank for return product. – Release and open spray gun to relieve

the pressure. Avoid splashback. – When no further overpressure is detected,

close and secure the spray gun. – Press [Stop].

– Repeat step 3 for all A and B pumps.

B_04462

B_07295

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SET

4. Flush mixed product from step 3. – Press [Flush]. – Point the spray gun (preferably without nozzle) into the grounded

metal tank for return product. – Release the spray gun safety and open carefully. – Flush until clean ushing agent comes out and the ushing

program is complete. – Close and secure the spray gun. – With splitter valve: Switch splitter valve over and repeat step 4

for the second gun.

5. Relieve all ushing pumps of pressure: – Relieve air pressure in accordance with the respective operating

manual.

– With product pressure regulator (option): Ensure that the product

pressure regulator is open.

– With password level 1:

Only convey ushing agent A, or only convey ushing agent B

– Press [Start].

– Place grounded metal tank for return product under the return

tube of the respective pump. – Open the return valve slowly. – When no further overpressure is detected, close the return valve. – Point the spray gun into the grounded metal tank for return product. – Release and open spray gun to relieve the pressure.

Avoid splashback. – When no further overpressure is detected, close and secure the

spray gun. – With splitter valve: Switch splitter valve over and relieve the pressure

from the second gun as well. – Press [Stop]. – With two ushing pumps: Repeat step 5 for ushing pump B.

6. Switch o air supply.

B_07112

Splitter valve

SET

TwinControl

B_02744

Closed

B_07295

Splitter valve

Mains air

(Example for ushing agent A)

Open

B_07296

7. Relieve air pressure between main cock and pump: – Open the air ball valve of ushing pump A. – Place grounded metal tank for return product under the return

tube of ushing pump A. – Open the return valve slowly. – When no further overpressure is detected, close the return valve. – Close air ball valve of ushing pump A again.

O

B_04457

8. Note: Control air pressure is still present.

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8.10 AUTOMATIC ELECTROSTATIC SYSTEM SET FOR ELECTROSTATIC GUN GM5000 OPTION

The TC VM5000 automatic electrostatic system set serves as an additional safety device for the safe use of the TwinControl 2K system with a GM 5000 electrostatic gun. However, the operator has a duty to proceed in compliance with the following instructions.

Four possible operating states of the TwinControl system:

1. Paint lling

2. Spraying mode

3. Work interruption (stop)

4. Flushing

8.10.1 COMMISSIONING AND SETTINGS

Perform commissioning and parameter settings as described in the operating manuals for the electrostatic guns and control units.

Settings on the pressure switch

The pressure sensor is set to the lower switching point of 2 bar at the factory. If the switching point setting needs to be adjusted, proceed as described in the assembly manual for the automatic electrostatic system set (order no. 2334831).

Switch o the electrostatic system. The electrostatic system is enabled. Switch o the electrostatic system. Switch o the electrostatic system.

Settings on the VM5000 control unit

Device conguration settings must be undertaken on the VM 5000 control unit. Please follow the safety instructions and instructions in the VM 5000 operating manual. Undertake the device conguration settings in the VM 5000:

C11: Set remote enable to on.

Function test

After commissioning, a function test is required in accordance with the assembly manual for the automatic electrostatic system set, order no. 2334831.

8.10.2 PAINT FILLING

Safety precautions:

Before product can be lled with the TwinControl system, the electrostatic system on the VM 5000 control unit must be switched o manually. This ensures that under no circumstances will solvent be sprayed if the electrostatic system is switched on. The electrostatic system can cause ignitable solvent-air mixtures to explode.

1. Switch o the electrostatic system on the VM 5000 control unit manually as described in the VM 5000 operating manual.

2. Perform product lling as described in this operating manual (TwinControl). The "Work" illuminated display ashes during lling.

3. When the lling process is complete, the illuminated display "Work" is lit up continuously.

Attention:

It must be ensured that the lling quantity is set correctly on the system. At the end of the lling process, the product hose must be lled with product that can be sprayed up to the end of the gun nozzle. In other words, product that can be sprayed (without solvent) must come out of the gun nozzle.

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8.10.3 SPRAYING MODE

Safety precautions:

Before spraying mode with electrostatic system can be started, it must be checked whether product, that can be sprayed (without solvent), is coming out of the gun nozzle.

1. Press and release the trigger of the spray gun and check that product, that can be sprayed (without solvent), is coming out of the gun nozzle. Perform the paint lling procedure, if necessary, and set the correct lling quantity.

2. Switch on the electrostatic system on the VM 5000 control unit manually as described in the VM 5000 operating manual.

3. Perform spraying mode as described in this operating manual (TwinControl). Ensure that the electrostatic system has been set correctly on the GM 5000 spray gun as described in the GM 5000 and VM 5000 operating instructions.

8.10.4 WORK INTERRUPTION STOP

1. Switch o the electrostatic system on the VM 5000 control unit manually as described in the VM 5000 operating manual.

Relieve pressure according to Chapter 8.9.

8.10.5 FLUSHING

Safety precautions

Before the TwinControl system is ushed, the electrostatic system on the VM 5000 control unit must be switched o manually. This ensures that under no circumstances will solvent be sprayed if the electrostatic system is switched on. The electrostatic system can cause ignitable solvent-air mixtures to explode.

1. Switch o the electrostatic system on the VM 5000 control unit manually as described in the VM 5000 operating manual.

2. Briey press and release the trigger of the GM 5000 spray gun and check that the electrostatic system has been switched o.

Carry out ushing in accordance with Chapter 8.8. The "Flushing" illuminated display lights up during ushing.

8.11 CONNECTION KIT FOR GUN FLUSH BOX OPTION

Software settings and tests

1. Attach the compressed air and increase slowly to the desired value. Switch on the voltage supply. Watch out for compressed air leaks!

Set parameter P114 in accordance with Chapter 7.6 (GFB = 1, yes).

2. For system parameters, see Chapter 5.10.

3. Insert a gun into the gun ush box and lock the cover. The trigger mechanism of the gun ush box may not be operated now, i.e., is

4. depressurized at connection no. 3 and at no. 3- is pressurized (see Chapter 5.8 and 5.9).

5. Press the "ushing" button or allow the TwinControl to undercut the pot life. As soon as the pot life alarm is triggered, electro-pneumatic valve no. 3 is actuated. The trigger mechanism of the gun ush box is now operated, i.e., is pressurized at connection no. 3 and is depressurized at no. 3-.

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8.12 SOFT CIRCULATION OPTION

Systems with soft circulation can

Working pressure

automatically circulate the A and/or B component. During circulation, the pumps run at the preset, reduced circulation pressure.

Circulation valve

GA 400

B_04516

B_04507

Soft circulation setting

Via password level 4 where pos. "P154" P154 = 1. 0 = no circulation, 1 = soft circulation, 2 = circulation at operating pressure

Separate settings for A and B components

A-component circulating (product valve A opens when circulating) A-component not circulating (product valve A remains closed) B-component circulating (product valve B opens when circulating) B-component not circulating (product valve B remains closed)

Circulation pressure

Example, soft circulation Leopard

Starting circulation

1. Press the [STOP] button.

2. If necessary, place return hoses in the corresponding product tanks.

3. Select circulation mode:

4. [Start]

Ending circulation

[Stop]

circulation stops and pressure returns to operating pressure.

Maintenance

Check valves regularly for leaks (leakage testing in Chapter 7.6.4). If the valves are leaking, some of the product will ow back to the product tank and the mixing ratio will no longer be right.

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8.13 EXTERNAL MIXERS OPTION

8.13.1 MANUAL EXTERNAL MIXERS DN2.6 AND DN4

For A-pumps: 5-60, 10-70, 28-40, 15-70, 15-150,

21-110, 35-70, 35-150

Inputs: A, B and S components Switches A+B: Spray on/o Switch S: Flushing on/o

(open position)

Spraying mode

Switches A+B open, switch S closed.

Flushing mode

1. Close switches A+B

2. Open switch S Perform ushing in accordance with Chapter 8.8

4. Close switch S

A+B

(closed position)

B_04506

8.13.2 MANUAL EXTERNAL MIXER DN 8

For A-pumps: 48-110, 8-300, 3-600, 18-300,

8-600, 75-150, 38-300, 72-300

Inputs: A, B and S components Handle A+B: Spray on/o Ball valve AS: Flushing on/o for A-side Ball valve BS: Flushing on/o for B-side

Spraying mode

Handle A+B open, ball valves AS and BS closed.

Flushing mode

1. Close handle A+B Perform ushing in accordance with Chapter 8.8

2. Please note:

– rst ush B-side for 5 seconds

(ball valve BS open, AS closed),

– then ush A-side until the ushing process

is complete (ball valve AS open, BS closed).

3. Close ball valves AS and BS

B_04504

(closed position)

A+B

(open position)

(closed position)

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B_04500

8.14 REMOTE CONTROL AND ESTA REMOTE CONTROL OPTION

If the control unit cannot be accessed directly from the workplace, the remote control is used for the basic functions: start, stop, ush and circulate.

The ESTA remote control is used with electrostatically charged systems.

8.14.1 EXPLOSION PROTECTION

The remote control may not be used along with a system with a mains power supply (cable) in potentially explosive areas.

The TwinControl remote control may be used along with a system with a turbine in potentially explosive areas (zone 1, zone 2) (see Chapter 2.3).

8.14.2 TWINCONTROL REMOTE CONTROL

Installation

Connect the remote control to the control unit: Insert the cable into the RC (remote control) connection (see Chapter 5.8). Several cables can be connected together up to a maximum length of 75 m; 246 ft. The cable must be installed permanently and protected from mechanical damage. The rst xing point must be no more than 20 cm from the cable gland.

Operation

[Start], [Stop] and [Flush AB] buttons: Same as the corresponding buttons on the control unit. [Circulation] button: Circulation valves A and B are opened.

Illuminated displays:

Filling Circulation Ready Alarm Flush AB

TwinControl

Buttons:

[Flush] [Stop] [Start] [Circulation]

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8.14.3 ESTA REMOTE CONTROL

Installation

Pneumatic lines: Connect remote control with control unit and reversing box as shown. Electric cable: Connect reversing box to control unit (for RC connection, see Chapter 5.8).

completely electrostatically charged

(1) Product valve A

TwinControl control unit

(3) Gun ush box (option) (5) Circulation (option) (6) Alarm Air supply

Functional potential equalization

(30) Circulation (option) (31) Start (32) Stop

Electrical

cable

Reversing

box

(33) Flush

Functional potential equalization

The functional potential equalization connection must have little induction and be short (see diagram).

ESTA area

Outside ESTA area

ESTA remote

24 8 20 1

control

30 31

32 33

TwinControl

33203224311308

B_04499

Operation

[Start], [Stop] and [Flush AB] buttons: Same as the corresponding buttons on the control unit.

[Circulation] button: Circulation valves A and B are opened.

B_04537

Made in Switzerland

Type / Typ:

TwinControl

Check manual before use!

Vor Gebrauch Betriebsanl beachten!

View of rear of system:

1 Control unit 2 Reversing box 3 Functional potential equalization 4 Electrical cable 5 Hose connections to ESTA remote control

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8.15 2A SWITCHBOX FOR SECOND APUMP OPTION

TwinControl

B_04508

If two dierent colors are to be used in turn, a second A-pump can be installed. A 2A switchbox is used to switch between pumps A1 and A2. The switchbox switches the following pump signals over and forwards them to the control unit:

– Product valve A (pneumatic) – Changeover signal – pump A (pneumatic) – Stroke measurement A / sensor A (electric)

Prerequisites

– Pumps A1 and A2 must be the same (model and size). – Hose from product valve A1 or A2 to mixing block: same diameter and length. – Same hardener and same mixing ratio for components A1 and A2. – Soft circulation is not possible. – External mixer on request.

Grounding

The switchbox must be grounded. The stroke measurement cables may be extended by 5 meters.

Explosion protection

Explosion protection is retained for systems with turbines, even with the 2A switchbox.

Switching over pump

1. [Stop].

2. [Flush] --> Hold gun in a grounded tank, carefully open and hold until clean ushing agent comes out.

3. Turn switchbox switch up to stop.

Filling and spraying according to Chapter 8.7.

Always turn switch up to stop. The center position will result in a fault message (code 20: sensor A at bottom).

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9 CLEANING AND MAINTENANCE

9.1 CLEANING

9.1.1 CLEANING PERSONNEL

Cleaning work should be undertaken regularly and carefully by qualied and trained personnel. They should be informed of specic hazards during their training.

The following hazards may arise during cleaning work:

– risk to health 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:

− Switch o the energy and compressed air supply.

− Relieve pressure from spray guns, high-pressure hoses and all devices.

− Secure spray guns against actuation.

− Disconnect the control unit from the mains.

9.1.3 FILTER CLEANING

For information on cleaning the product lter see Chapter 9.2.10.

9.1.3.1 CONDENSATE DRAINAGE FROM THE FILTER PRESSURE REGULATOR

Frequently drain the condensate that may accumulate in the pneumatic lter.

– Make sure the water level in the lter cup never reaches the max. level marked

on the cup.

WARNING

Brittle lter pressure regulator!

Flying parts can cause injury. The tank on the lter pressure regulator becomes brittle through contact with solvents

and can burst.

Do not clean the tank on the lter pressure regulator with solvents.

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9.1.4 CLEANING THE SYSTEM

The system must be cleaned to change products and for maintenance purposes. Ensure that no remaining product dries on and sticks to the device.

A cleaned system allows leaks to be found easily and measures to be taken quickly.

Procedure

Carry out the basic ushing: Chapter 6.6.2.

1. Carry out work interruption: Chapter 8.9.

2. Empty system in a controlled manner: Chapter 9.2.8.

4. Service spray gun in accordance to its operating instructions.

5. Clean and check the suction systems including the suction lter. Remove product lter. Clean and check the lter inserts and lter housing.

6. See Chapter 9.2.10.

7. Product change: If necessary, remove, clean and check the pump inlet housing. If necessary, also remove, clean and check the uid section.

8. Clean the outside of the system.

9. Fully assemble the system.

10. Check the level of the separating agent: see pump operating manuals. Always carry out basic ushing and the pressure tightness test: Chapter 6.6.2.

11.

WARNING

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from ying parts.

Ensure that the device, pumps and suction systems are always completely lled with ushing agent or working media.

Do not spray the device empty after cleaning.

9.1.5 DECOMMISSIONING

Clean the system according to Chapter 9.1.4. Fill the entire system with ushing agent. As laid down in Chapter 6.6.3, but with

2. ushing agent.

9.1.6 LONGTERM 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

Clean the system according to Chapter 9.1.4. Fill the entire system with ushing agent. As laid down in Chapter 6.6.3, but with

ushing agent. Fill the entire system with preservative according to Chapter 6.6.3 and the lacquer

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.

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9.2 MAINTENANCE

9.2.1 MAINTENANCE PERSONNEL

Maintenance work should be undertaken regularly and carefully by qualied and trained personnel. They should be informed of specic hazards during their training.

The following hazards may arise during maintenance work:

− risk to health 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 MAINTENANCE INSTRUCTIONS

WARNING

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.

Use only WAGNER original spare parts and accessories. 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:

− Switch o the energy and compressed air supply.

− Relieve pressure from spray guns, high-pressure hoses and all devices.

− Secure spray guns against actuation.

− Disconnect the control unit from the mains. Observe the operating and service manual for all work.

Prior to Maintenance

–

Flush and clean the system. Chapter 9.1.4 Switch o the system. Chapter 8.6

–

After maintenance

Carry out safety checks in accordance with Chapter 9.2.3.

–

Put the system into operation and check for leaks as described in Chapter 6.6.

– – Have the system checked for safe condition by an authorized person.

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 qualied personnel.

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9.2.3 SAFETY CHECKS AND MAINTENANCE INTERVALS

Every day

Check grounding: see Chapter 6.5 Check hoses, tubes and couplings: see Chapter 9.2.11 Check the level of separating agent in the separating agent cup and top up if necessary. Check and clean the product lter or replace it as required: Chapter9.2.10

Weekly

Check system for damage. Check non-return valves: Chapter 9.2.7 Clean product lter: Chapter 9.2.10 Clean pneumatic lter: Chapter 9.1.3.1 Product valves: Check air or product emission from the leakage holes according to

the respective operating manual. Check the function of the safety xtures (see Chapter 5.3):

– External release – Pumps and accessories: Check protective and monitoring equipment in

accordance with the respective operating manuals.

Yearly or as required

In accordance with DGUV regulation 100-500 Chapter 2.29 and 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.

9.2.4 SERVICE PLUG

WARNING

Service plug!

Explosion hazard.

Do not connect the service plug if a potentially explosive gas atmosphere could be present.

9.2.5 CONNECTIONS FOR STROKE MEASUREMENT

Plug connectors A and B on the rear side of the device are used to connect the potentiometers and may be inserted and removed, even during operation (lines are intrinsically safe).

9.2.6 TURBINE

When replacing the turbine, attention should be paid to the "TC Turbine Set" assembly manual with order no. 2320883.

When replacing the generator, attention should be paid to the "TC Generator Conversion Set" assembly manual with order no. 2336796.

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