WAGNER TwinControl Original Operating Manual

TwinControl

Electronically Controlled 2K Systems
for Lacquers

Valid for systems with software version V 4.xx

Version 10/2018

0102

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

1

Made in Switzerland

Type / Typ:

2

Serial No unit.:

3

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!

12

10
11

4

Year of construction / Baujahr:

5

Serial No. controller:

6

Serie Nr. Steuerung:

Air pressure supply:

7

Luftdruckversorgung:

Ambient temperature:

8

Temperatur Umgebung:

IP Code:

9

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

.

13

B_06434

Check manual before use!

Vor Gebrauch Betriebsanleitung
beachten!

– cable with mains power supply

1

Wagner International AG
CH 9450 Altstätten

Type / Typ:

2

3

Year of construction / Baujahr:

Serial No unit.:

4

Serie Nr. Anlage:

Serial No. controller:

5

Serie Nr. Steuerung:

Voltage:

6

Spannung:

Line Power:

7

Eingangsleistung:

Ambient temperature:

8

Temperatur Umgebung:

IP Code:

9

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!

13

12

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:

– 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.

.

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

4

1

2

3

B_02796

.

8

1:2

7

6

5

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

26

12.6

154

484

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 1.0 2.0 5.0

Maximum permissible external capacity

7.3 5.9 4.4 3.5 2.7 1.8

7.3

6

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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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VERSION 10/2018 ORDER NUMBER DOC 2339321

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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VERSION 10/2018 ORDER NUMBER DOC 2339321

Inputs / outputs and mixing ratio Unit for A-pump

5-60

28-40

15-70

15-150

EvoMotion

Puma

Puma

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

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

G

1½"

Puma

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.

30