2K COMFORT Translation of the Original

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2K COMFORT Translation of the Original | Manualzz
Translation of the Original
Operating Manual
2K COMFORT
Software version 3.0x
Electronically Controlled
Multi-component System
for Lacquers
Version 09/2015
B_05491
VERSION 09/2015
ORDER NUMBER DOC 2357061
OPERATING MANUAL
Table of Contents
1
1.1
1.2
1.3
1.3.1
1.4
1.5
1.6
ABOUT THESE INSTRUCTIONS
Preface
Warnings, Notices and Symbols in these Instructions
Languages
Operating Manuals for the Individual Components
2K COMFORT USB Stick
Abbreviations
Terminology for the Purpose of this Manual
7
7
7
8
8
9
10
10
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.4
2.5
2.6
2.7
CORRECT USE
Device Types
Type of Use
Field of Application
Non-Ex Version
Ex Version
Accessories
Safety Parameters
Processible Working Materials
Reasonably Foreseeable Misuse
Residual Risks
11
11
11
11
11
11
12
12
13
14
14
3
3.1
3.2
3.2.1
3.2.2
3.2.2.1
3.3
3.4
3.4.1
3.4.2
IDENTIFICATION
Non-Ex System
Ex System
Control Cabinet
Fluid Section
Identification X
Remote Control (Option)
Type Plates
Control Cabinet
Fluid Section
15
15
15
15
15
16
17
18
18
18
4
4.1
4.1.1
4.1.2
4.1.3
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
GENERAL SAFETY INSTRUCTIONS
Safety Instructions for the Operator
Electrical Equipment
Personnel Qualifications
Safe Work Environment
Safety Instructions for Staff
Safe Handling of WAGNER Spray Devices
Grounding the Device
Product Hoses
Cleaning and Flushing
Handling Hazardous Liquids, Varnishes and Paints
Touching Hot Surfaces
19
19
19
19
19
20
20
21
21
22
23
23
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OPERATING MANUAL
Table of Contents
5
5.1
5.2
5.3
5.4
5.4.1
5.4.2
5.4.3
5.4.4
5.5
5.6
5.7
DESCRIPTION
Design
Mode of Operation
Protective and Monitoring Equipment
Data
Technical Data
Measurements
Working Areas of Flow Meters
Application Limits of Flow Meters
Mixing Types
Dump Valve for Waste Separation (Option)
AIS Dosing System (Option)
24
24
24
25
26
26
28
29
31
32
34
34
6
6.1
6.2
6.3
6.4
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
6.5
6.6
6.6.1
6.6.2
6.6.3
6.6.4
6.6.5
6.6.6
ASSEMBLY AND COMMISSIONING
Training Assembly/Commissioning Staff
Storage and Installation Conditions
Transportation
Assembly and Installation
Electrical Connections
Pneumatic Connections
Product Connections
Flow Meter Monitoring
Lack-of-product Protection
Ventilation of the Spray Booth
Grounding
Commissioning
Preliminary Cleaning
Initializing the Controller
Venting the System
Pressure Tightness Test
Filling the System
Electrostatics
35
35
35
35
36
38
38
39
39
40
40
41
44
45
46
47
47
48
48
7
7.1
7.2
7.3
7.3.1
7.4
7.5
7.5.1
7.5.2
7.5.3
7.6
7.6.1
7.6.2
7.7
7.8
CONTROLLER
Training the Operating Staff
Safety Instructions
Control Cabinet
Main Switch
Mechanical Push-buttons
Operating Panel Basics
Select Language
Keyboard Input
Passwords
Home Page
Changing the Paint Recipe
Home Page Operation
Menu
Manual Mode: Opening Valves
49
49
49
50
50
51
51
52
52
53
53
53
54
55
56
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Table of Contents
7.9
7.9.1
7.9.2
7.10
7.11
7.12
7.13
7.13.1
7.13.2
Recipes
Add New Recipes
Change Recipe and Valve Names
Entering Flushing Recipe
Entering the Paint Recipe
Calibration
Settings
Settings Password Level 2
Settings Password Level 3
57
57
57
58
59
61
63
63
66
8
8.1
8.2
8.2.1
8.3
8.4
8.5
8.6
8.6.1
8.6.2
8.6.3
8.6.4
8.6.5
8.6.6
8.6.7
8.6.8
8.7
8.8
8.9
OPERATION
Training the Operating Staff
Safety Instructions
General Rules for Making Adjustments to the Spray Gun
Switching the System On and Off
Emergency Stop
Faults
Spraying Mode
Prerequisites
Pressure Ratio A/B/C/D
Spraying without Gun Flush Box
Spraying with Gun Flush Box
Interrupting Work
Changing the Paint Recipe
A Valve Selection during Start
Circulation (Option)
Flushing
Flow Chart with Paint Recipe Change
Pressure Relief
70
70
70
70
71
71
71
72
72
72
73
74
74
74
74
74
75
78
78
9
9.1
9.1.1
9.1.2
9.1.3
9.1.3.1
9.1.4
9.1.5
9.1.6
9.2
9.2.1
9.2.2
9.2.3
9.2.4
9.2.5
CLEANING AND MAINTENANCE
Cleaning
Cleaning Staff
Safety Instructions
Filter Cleaning
Condensate Drainage from the Filter Pressure Regulator
Cleaning the System
Decommissioning
Long-term Storage
Maintenance
Maintenance Staff
Safety Instructions
Gear Flow Meter
Product Valves
Product Hoses, Tubes and Couplings
80
80
80
80
81
81
81
82
82
83
83
83
84
85
86
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Table of Contents
10
10.1
10.1.1
10.2
10.2.1
TROUBLESHOOTING
Alarm Messages
Fault Rectification
Warning Messages
Fault Rectification
87
90
94
100
101
11
DISPOSAL
102
12
ACCESSORIES
12.1
Connections
12.1.1 I/O Extension Module
12.2
2K COMFORT Connection Table
12.3
Expansion and Accessory Sets
12.3.1 Installation by Custiomer or by WAGNER Service Department
12.3.2 Installation by WAGNER Service Department
12.3.2.1 AIS
12.3.3 Accessories Sets for External Flushing Agent
12.4
Remote Control (Option)
12.4.1 Remote Control Assembly
12.4.1.1 Software Settings
12.4.1.2 Assembly on Control Cabinet
12.4.1.3 Testing and Commissioning
12.4.2 Safety Instruction Remote Control
12.4.3 Operation
103
103
103
104
105
106
108
108
109
110
110
110
110
111
112
113
13
13.1
SPARE PARTS
How Can Spare Parts Be Ordered?
114
114
14
CONVERSION OF THE MIXING RATIO SPECIFICATIONS
115
15
15.1
15.2
15.3
15.4
15.5
15.5.1
15.6
DECLARATION OF WARRANTY AND CONFORMITY
Important Notes Regarding Product Liability
Warranty Claim
CE Declaration of Conformity 2K COMFORT (non-Ex version)
CE Declaration of Conformity 2K COMFORT (Ex version)
CE Declaration of Conformity of Remote Control
EC Type Examination Certificate of Remote Control
Notes on National Regulations and Guidelines
116
116
116
117
118
119
120
122
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OPERATING MANUAL
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 operating and service
staff.
The device may only be operated by trained staff and in compliance with this operating
manual. Operating and service personnel should be instructed according to the safety
instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2
WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this operating manual highlight particular dangers to users and to
the device and state measures for avoiding the hazard. These warning instructions fall into
the following categories:
DANGER
Danger - immediate risk of danger.
Non-observance will result in death or serious injury.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its consequences.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its consequences.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its consequences.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
NOTICE
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the danger and its consequences.
Note - provides information about particular characteristics and how to proceed.
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1.3
LANGUAGES
The 2K COMFORT Operating Manual is available in the following languages:
Language
Order No.
German
2357060
English
2357061
French
2357062
Spanish
2357065
Italian
2357064
2K COMFORT Software Documentation:
Language
Order No.
German
2357082
English
2357084
2K COMFORT Spare Parts Catalog:
Language
Order No.
German
2357085
English
2357086
Additional languages on request or at:
1.3.1
OPERATING MANUALS FOR THE INDIVIDUAL COMPONENTS
Operating manual
Language
German
French
Spanish
Paint valves (PV) and dosing valves (DV), GA (DN 2.6)
Order No.
Language
Order No.
2343270
English
2343275
2343276
Italian
2343277
2343278
Operating manual
Language
German
French
Spanish
Paint valves (PV) and dosing valves (DV), GA (DN 4)
Order No.
Language
Order No.
2343280
English
2343281
2343282
Italian
2343284
2343286
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OPERATING MANUAL
Coriolis mass flow meter operating manual
Language
German
French
Spanish
Order No.
2359722
2359727
2359730
Language
English
Italian
Order No.
2359725
2359728
Pressure regulator operating manual for lacquers T0170, T0180
Language
German
French
Spanish
Order No.
ZZB019GER
ZZB019FRE
ZZB019SPA
Language
English
Italian
Order No.
ZZB019ENG
ZZB019ITA
Software documentation for Comfort_Archive PC data archiving:
Language
German
English
Order No.
2361954
2361978
Additional languages on request or at:
1.4
2K COMFORT USB STICK
All operating documents specified above, as well as the accessory set's assembly manuals
(with the description of the accessory's function) are also available as pdf files on a
USB stick. The USB stick is included in the system's scope of delivery.
The Order No. is: 2359808. (Specify the system's article and serial number.)
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OPERATING MANUAL
1.5
ABBREVIATIONS
Order No.
HP
1.6
Number of pieces
Position
Marking in the spare parts lists
Order number
Spare part
One component
Two components
Three components
Four components
Double stroke
Nominal diameter
High pressure
Q
cc
AIS for component B
AIS for component C
AIS for component D
Flow
Cubic centimeters (cm3)
Materials
Stainless steel
Polyethylene
Ultra-high molecular weight
polyethylene
Polytetrafluorethylene
Carbide
TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Flushing
Staff qualifications
Trained person
Electrically trained
person
Electrician
Skilled person
In the context of
TRBS 1203
(2010 / Revision 2012)
Manual cleaning of devices and device parts with cleaning
agent
Internal flushing of paint-wetted parts with flushing agent
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.
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.
Can assess the work assigned to him/her and detect possible
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 sufficient technical
knowledge and is familiar with the relevant and generally
accepted rules of technology so that he/she can inspect and
assess the status of devices and coating systems based on
workplace safety.
Additional requirements for skilled persons are given in the
TRBS 1203 (2010/Revision 2012): Expert knowledge in the areas
of protection against excessive pressure, electrical hazards, and
explosion protection (where applicable).
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2
CORRECT USE
2.1
DEVICE TYPES
a) 2K COMFORT non-Ex version
b) 2K COMFORT Ex version
2.2
TYPE OF USE
The device is suitable for mixing 2K, 3K and 4K liquid products such as paints and lacquers.
2.3
FIELD OF APPLICATION
2.3.1
NON-EX VERSION
The control cabinet and the fluid section may not be used in potentially explosive areas.
Note: The remote control (accessory) may always be used in potentially explosive areas
(zone 1 and zone 2).
See Chapter 6.5.
2.3.2
EX VERSION
Control cabinet
The control cabinet may not be used in potentially explosive areas.
Fluid section
The FleXcontrol smart Ex fluid section is suitable for use in potentially explosive areas
(zone 1 and 2):
See Chapter 6.5.
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2.3.3
ACCESSORIES
Remote control
The remote control may be used in potentially explosive areas (zone 1 and 2).
See Chapter 6.5.
Alarm horn
The alarm horn may be used in potentially explosive areas (zone 1 and 2).
2.4
SAFETY PARAMETERS
The 2K system may only be used as described in this operating manual. In particular, no
conversions are permitted on the system otherwise the warranty ceases to apply and
WAGNER is not liable for any claims.
WAGNER accepts no liability for any damage arising from incorrect use.
Use the device only to work with the products recommended by WAGNER.
Only operate the device as a whole.
Do not perform unauthorized conversions or modifications to the device.
Do not deactivate safety fixtures.
Use only WAGNER original spare parts and accessories.
The 2K system may only be operated under the following conditions:
The operating staff must be trained on the basis of this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must be
observed.
The statutory requirements and accident prevention regulation standards in the
country of use must be observed.
The 2K system may only be operated if all parameters are set and all measurements / safety
checks are carried out correctly.
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2.5
PROCESSIBLE WORKING MATERIALS
Low-viscosity to high-viscosity 2K/3K/4K lacquers (e.g., epoxy, PU, DD) with a pot life of
more than 5 minutes.
-
2K water-based primer
2K solvent-based primer
2K PUR primer
2K PUR lacquers
2K epoxy primer
2K epoxy lacquers
2K high solid primer
2K high solid lacquers
3K and 4K combinations of above products
Solvent and water-based 2K products should not be processed using the same system.
Materials in direct contact with the products
- Stainless steel
- Carbide
- PTFE
- PE (UHMWPE)
NOTICE
Abrasive working materials and pigments!
Greater wear of parts carrying the product.
Do not use any grainy and abrasive working materials with large, sharp-edged
pigments.
Use application-oriented pumps (flow rate/cycle, product, valves, etc.).
Check if the fluids and solvents used are compatible with the pump construction
materials.
For explanations of the models and construction materials, consult the technical
data in Chapters 5.4.3 / 5.4.4 as well as the operating manuals for the pumps and
valves or contact a WAGNER service technician.
Wear caused by abrasive working materials is not covered by the warranty.
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OPERATING MANUAL
2.6
REASONABLY FORESEEABLE MISUSE
The forms of misuse listed below may result in physical injury or property damage:
coating work pieces which are not grounded;
unauthorized conversions or modifications to the 2K system,
processing dry or similar coating products, e.g., powder;
using defective components, spare parts or accessories other than those described in
the "Accessories" chapter of this operating manual;
continuing work with a defective or kinked product hose;
working with incorrectly set values;
processing food.
2.7
RESIDUAL RISKS
Residual risks are risks which cannot be ruled out even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk
Source
Consequences
Specific measures
Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Handling of
lacquers and
cleaning agents
Skin irritation,
allergies
Wear protective
clothing
Operation,
Lacquer in air
Lacquering outside
outside the defined the defined
working area
working area
Observe safety data maintenance,
sheets
disassembly
Inhalation of
Observe working
substances
and operating
hazardous to health instructions
Operation,
maintenance
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3
IDENTIFICATION
3.1
NON-EX SYSTEM
The 2K COMFORT system (non-Ex version) is not suitable for use in potentially explosive
areas.
3.2
EX SYSTEM
As defined in Directive 94/9/EC the 2K COMFORT system (Ex version) is suitable for use in
potentially explosive areas.
3.2.1
CONTROL CABINET
The control cabinet may not be used in potentially explosive areas.
CE
CE mark (European Communities)
Explosion-proof equipment
II
Device class II (not mining)
3.2.2
( )
(2)
G
effective in zone ...
effective in zone 1
Ex-atmosphere gas
FLUID SECTION
The 2K COMFORT Ex system's fluid section is suitable for use in potentially explosive areas
(zone 1 and zone 2).
CE mark (European Communities)
Explosion-proof equipment
Device class II (not mining)
Category 2 device (suitable for zone 1)
Ex-atmosphere gas
Device class (Gas) IIB
There are special notices for safe operation
See the following Chapter "Identification X".
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3.2.2.1
IDENTIFICATION X
Ignition temperature
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature of the work piece.
Ambient temperature
The permissible ambient temperature is: +5 °C to +40 °C; +41 °F to +104 °F.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
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 against steel or rusty iron.
Do not drop the device.
Use only tools that are made of a permitted material.
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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3.3
REMOTE CONTROL (OPTION)
The remote control (Order No. 2341153) may be used in potentially explosive areas
(zone 1 and 2).
CE
CE mark (European Communities)
0102 Number of the notified body which is used by WAGNER in the production monitoring
phase (PTB in this case)
Explosion-proof equipment
II
2
G
Device class II (not mining)
Category 2 device (suitable for zone 1)
Ex-atmosphere gas
Ex
d
IIB
T6
Gb
Electrical device corresponds to ignition protection type
Ignition protection class "Flame-proof enclosure" EN 60079-1
Device class (Gas) IIB
Temperature class T6: maximum surface temperature 85 °C; 185 °F
Device protection level
, suitable for use in Zone 1
CML 13 ATEX 1008X
CML Test center
13
Certificate's year of issue
ATEX French abbreviation for "ATmosphères EXplosibles"
1008 Certificate number
X
There are special notices for safe operation See the following section
"Identification X"
Identification X
For safe operation, observe the special notices in Chapter 12.4.2.
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3.4
TYPE PLATES
3.4.1
CONTROL CABINET
Only for an Ex System:
J. WAGNER AG
CH-9450 ALTSTÄTTEN
MADE IN SWITZERLAND
2K Comfort
II (2) G
Control unit
2
Gerätetyp / Type:
3
4
5
6
7
8
El. Anschluss Spannung / Connection voltage
El. Anschluss Frequenz / Connection frequency
Anschlussleistung / Connection Power
Schutzart / Protection class
Temperatur Umgebung / Ambient temperature
Serie Nr. / Serie No.
9
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
1
2
3
4
5
Manufacturer and CE Identification
Device type: 2K COMFORT control cabinet
Electrical connection: voltage
Electrical connection: frequency
Connection power
3.4.2
6
7
8
9
B_05486
1
Protection class
Ambient temperature
Year of manufacture - Serial number
Read operating manual before use!
FLUID SECTION
Only for an Ex System:
J. WAGNER AG
CH-9450 ALTSTÄTTEN
MADE IN SWITZERLAND
2K Comfort
II 2G IIB X
Fluid unit
2
Gerätetyp / Type:
3
4
5
6
7
8
Materialmenge pro Minute / Fluid volume per minute
Materialdruck / Fluid pressure
Luftdruckversorgung / Air pressure supply
Temperatur Material / Fluid temperature
Temperatur Umgebung / Ambient temperature
Serie Nr. / Serie No.
9
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
1
2
3
4
5
Manufacturer and CE Identification
Device type: 2K COMFORT fluid section
Flow rate per minute
Product pressure
Air pressure supply
6
7
8
9
B_05487
1
Product temperature
Ambient temperature
Year of manufacture - Serial number
Read operating manual before use!
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4
GENERAL 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 EQUIPMENT
Electrical devices and equipment
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient influences.
May only be maintained by skilled electricians or under their supervision. With open
housings, there is a danger from line voltage.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard or are damaged.
Must be de-energized before work is commenced on active parts. Inform staff 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
PERSONNEL QUALIFICATIONS
Ensure that the device is only operated, maintained and repaired by trained persons.
4.1.3
SAFE WORK ENVIRONMENT
Ensure that the floor in the working area is static dissipative in accordance with
EN 61340-4-1 (resistance must not exceed 100 megohms).
Paint mist extraction systems/ventilation systems must be fitted on site according to
local regulations.
Ensure that product / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment 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 megohms.
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Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun handle.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 megohms.
Ensure that there are no ignition sources such as naked flames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
Ensure that the pipe joints, hoses, equipment parts and connections are permanently,
technically leak-proof:
- Periodic preventative maintenance and service (replacing hoses, checking tightness
strength and connections, etc.)
- Regular monitoring of leaks and defects via visual inspection and odor testing, e.g.,
daily before commissioning, at the end of work or weekly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
Grounding
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).
4.2
SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
In electrostatics application: Anyone fitted with a pacemaker must not enter the
high-voltage area!
4.2.1
SAFE HANDLING OF WAGNER SPRAY DEVICES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or flushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before all work on the device, in the event of work interruptions and functional faults:
- Relieve pressure from spray guns and devices.
- Secure spray guns against actuation.
- Switch off the energy/compressed air supply.
- Disconnect the control unit from the mains.
- In the event of functional faults, remedy the fault as described in the "Troubleshooting"
chapter.
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If needed, the liquid ejection devices must be checked by experts (e.g., WAGNER service
technician) at least every 12 months to ensure they are safe for work in accordance with
the DGUV regulation 100-500.
- For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure Relief" chapter:
- If pressure relief is required.
- If the spraying work is interrupted or stopped.
- Before the device is cleaned on the outside, checked or serviced.
- Before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by paint or flushing agents:
Note the paint or flushing agent that you have been using.
Consult a doctor immediately.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun briefly in a position.
4.2.2
GROUNDING THE DEVICE
Friction, flowing liquids and air or electrostatic coating processes create charges. Flames or
sparks can form during discharge. Grounding prevents electrostatic charging.
Ensure that the device is grounded. See chapter "Grounding".
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.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.
4.2.3
PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products and the
flushing agents used.
Ensure that the product hose is 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
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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,
- at 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.
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 megohm.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coefficient. In some cases their volume can rise with
consequent damage to pipes, fittings, etc. and cause fluid 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 flow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
4.2.4
CLEANING AND FLUSHING
Relieve the pressure from the device.
De-energize the device electrically.
Preference should be given to non-flammable cleaning and flushing agents.
When carrying out cleaning work with flammable 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 specifications of the paint manufacturer.
Ensure that the flash 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.
Take measures for workplace safety (see Chapter 4.1.3).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- depending on the flushing agent (solvent) used,
explosive mixture inside the lines and items of equipment.
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Only electrically conductive tanks may be used for cleaning and flushing 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 flushing.
External cleaning
When cleaning the exterior of the device or its parts, also observe the following:
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.
4.2.5
HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
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 specified protective measures. In particular, use personal protective equipment:
safety goggles, protective clothing and gloves, as well as respiratory protection and
skin protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sufficient 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.
4.2.6
TOUCHING HOT SURFACES
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109 °F: identify the unit with a warning label that says "Warning - Hot Surface".
- Instruction label
Order no. 9998910
- Protection label
Order no. 9998911
Note: Order the two stickers together.
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5
DESCRIPTION
5.1
DESIGN
The 2K system is clearly structured. It can be controlled using easy-to-understand and
easily accessible operating elements.
Control cabinet
All electrical components are installed in the control cabinet. The system can be controlled
via the four push-buttons and the operating panel (touch screen). Information is displayed
or can be entered via the operating panel.
Fluid section
The fluid section contains all parts which come into contact with the 2K products.
5.2
MODE OF OPERATION
The system is suitable for measuring (dosing) and for mixing two or multi-component
products.
An electronic controller monitors and regulates the predetermined ratio of components.
The controller regularly adds in the necessary quantity of hardener -in short intervals
(and by way of pulses)- via a valve to the flow of base lacquer.
The flow of the base lacquer and hardener is measured with flow meters.
The components and flushing agents are made available by supplying pumps or
pressure tanks (not supplied with the system).
Paint selection
The mixing ratio, pot life etc. are stored in the recipe. By means of a simple recipe change,
the paint can be changed.
Further characteristics and areas of application
For low to medium pressure (32.5 MPa; 325 bar; 4,714 psi).
Modular structure - can be combined as required by the customer.
Electronic dosing precision guarantees consistent quality.
Processing even water-based 2K products, since all parts carrying the product are
suitable to do so - made, for example, of stainless steel.
The fluid section of the Ex version is suitable for use in potentially explosive areas
(zone 1 and zone 2).
Many functions are displayed in a language-independent way with icons which are
easy to understand. Texts are displayed in the selected language.
The overview of consumption of each component and flushing agent, VOC
documentation.
Storage of the last 700 error messages indicating date and time.
Security by permanently checking the system parameters, operator information, in
case of the slightest trouble, and if necessary, automatic interruption of the production.
Protection of the parameters by security code. Settings can be saved on a USB stick.
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Electronic adjustment of the mixing ratio between 0.1:1 and 50:1.
Up to 100 paint recipes. (Also with robot communication or Profibus.)
Programmable flushing recipes to economize up to 60% of flushing agent compared
with previous systems.
Fully automatic control and monitoring of 1 to 4 guns.
The compatibility with solvent-based products and water-based products and
selective automatic cleaning with water and/ or solvent.
Use of hand or automatic spray guns.
Enabling of automatic booth, automatic gun flush box, etc.
Possibility of robot communication.
5.3
PROTECTIVE AND MONITORING EQUIPMENT
The following functions are provided for system safety:
- External release: e.g. interlock with spray booth's exhaust air
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5.4
DATA
5.4.1
TECHNICAL DATA
Electrical
100-240 VAC / 120-350 VDC / 50-60 Hz + PE
60 W / 0.3 A
See electrical circuit diagram (delivered together with the system)
Pneumatic
Compressed air Inlet
Compressed air quality:
free from oil and water
0.7-0.8 MPa; 7-8 bar; 101-116 psi
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/m3
WARNING
Exhaust air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water.
Low pressure High pressure
version
version
Flushing agent:
0.8 MPa
32.5 MPa
Maximal inlet pressure
8 bar
325 bar
116 psi
4,714 psi
Compressed air flushing:
0.8 MPa
Maximal inlet pressure
8 bar
-116 psi
2.5 MPa
32.5 MPa
Maximum inlet pressure of components A/B/C/D.
The maximum pressure of the pumps used may not
25 bar
325 bar
exceed this value.
362 psi
4,714 psi
Mixer product outlet
0.05–0.8 MPa 0.1–32.5 MPa
(0.8 MPa; 8 bar; 116 psi due to product pressure regulator)
0.5–8 bar
1–325 bar
7–116 psi
14.5–4,714 psi
Application rate (depending on the flow meters used,
100-7,000 cc/min
see Chapters 5.4.3 and 5.4.4)
Product inlet (outside)
G1/4"
Product outlet (out)
G1/4"
Viscosity of components A/B/C/D
see Chapters 5.4.3 and 5.4.4
(dependent on flow, flow meters, hoses and mixers)
Viscosity of mixed products (depending on flow, flow
20–10,000 mPa·s
meters, hoses and mixers) Chapter 5.4.4
Maximum particle size
See Chapter 5.4.4
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Low pressure High pressure
version
version
Maximum particle size
120 μm
Product filtration required, min. 100 mesh/inch
0.12 mm
For flow meters from 0.005: min. 300 mesh/inch
0.0047 inch
Product pH value
3.5–9
+ 5 °C … + 60 °C
Product temperature
+41 °F … + 140 °F
+ 5 °C … + 40 °C
Operation
+41 °F … + 104 °F
0 °C … + 40 °C
Ambient temperature
Assembly
+32 °F … + 104 °F
-20 °C … + 60 °C
Suspension
-4 °F … + 140 °F
10–95%
Relative humidity
(without condensation)
Mixing ratio, volumetric
0.1:1 - 50:1
A/B or (A+B) /C
0.00:1 (1K)
Dosing precision
± 1% precision in mixing ratio
Maximum number of components A/B/C/D
25/10/10/10
Maximum quantity of flushing agent for A/B/C/D
10/5/5/5
Maximum number of guns
4
Sound pressure level during alarm
110 dB(A)
(A-rated sound pressure level measured at 1 m distance, LpA1m, according to
DIN EN 14462: 2005.)
up to 10 m; 32.8 ft / 15 m; 49.2 ft
Distance control cabinet - fluid section
Special versions available
*
The target mixing ratio at a precision level of ± 1% is achieved after each completed
cycle (injection of hardener into base paint).
Precision of 1% is achieved under the following conditions:
- Proper use of the system in compliance with the operating manuals.
- Correct calibration and function of the flow meters in accordance with Chapter 7.12.
- Correct adjustment of the compression ratio between the base lacquer and hardener.
See Chapter 8.6.2
- Correct adjustment of the hardener metering valve stroke, or use of the AIS.
- Exact setting of the system to suit the product used, in accordance with the processing
specifications 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 specific operating conditions such as
the permitted product and ambient temperature, permitted viscosity and flow rate.
- Regular maintenance has to be carried out by a qualified person (e.g., WAGNER Service
Technician) in accordance with Chapter 9.
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5.4.2
MEASUREMENTS
mm
inch
800
31.50
1,133
44.61
1,960
77.17
350.5
13.80
410.5
16.16
573.8
22.59
A
F
E
D
C
B
B_05637
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5.4.3
WORKING AREAS OF FLOW METERS
Flow-mixed product A+B [l/min]
Working area for standard flow meter
Working area
Standard
"?
Mixing ratio volumetric A:B [A:1] (0= only A)
Flow-mixed product A+B [l/min]
Working area for small quantity flow meter
Working area
Small quantity
"?
Mixing ratio volumetric A:B [A:1] (0= only A)
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Flow-mixed product A+B [l/min]
Working area for flow meter A = 25 L/min; B = 7 L/min and Coriolis NW8
Working area
Standard
"?
Mixing ratio volumetric A:B [A:1] (0= only A)
Flow-mixed product A+B [l/min]
Working area for flow meter A = 7 L/min; B = 7 L/min
Working area
Small quantity
"?
Mixing ratio volumetric A:B [A:1] (0= only A)
30
2302932
2334771
2311959
2311949
2312234
2301268
9956278
Gear flow meter 0.005-2 GL Ex
Gear flow meter 0.005-2 KL Ex
Gear flow meter 0.5-25 GL Ex
Gear flow meter 0.1-7 GL Ex
Coriolis compact 0.075-5 Ex
Coriolis compact 0.15-10 Ex
Micro flow meter 0.005-0.25 Ex
Micro quantity
Standard slide bearing
Standard ball bearing
Small quantity slide
bearing
Small quantity ball
bearing
25 l/min (FC+ XL) slide
bearing
7 l/min (FC+ XL) slide
bearing
Coriolis NW4
Coriolis NW6 (FC+ XL)
100
350
350
400
400
400
400
bar
400
400
highly viscous media
extremely viscous media
better starting performance with
small quantities
Small quantities
Standard
Water-based lacquers
Application
Maximum viscosity per flow rate
1 l/min
2 l/min
3 l/min
mPa s
mPa s
mPa s
1,200
700
500
1,200
700
500
500
200
-500
200
-8,000
4,200
3,200
4,000
2,100
1,600
600
350
250
1,200
700
500
5 at 0.0025 - 0.25 l/min
high percentage of solid objects
high percentage of solid objects,
highly viscous media
0.0025-0.25 thin media without solid objects
0.075 - 5
0.15 - 10
0.1 - 7
0.5 - 25
0.005 - 2
0.005 - 2
Flow rate
measuring
range
l/min
0.02 - 3.0
0.02 - 3.0
Particle size: product filtration required, min. 100 mesh/inch. For flow meters from 0.005: min. 300 mesh/inch.
Overview of maximum viscosities for economical operation of the flowmeters
Max.
Flow rate
WAGNER
pressure
measuring range
Flow meter type
Order No.*
bar
l/min
Gear flow meter 0.02-3 GL Ex
2302929
400
0.02 - 3.0
Gear flow meter 0.02-3 KL Ex
2302927
400
0.02 - 3.0
Gear flow meter 0.005-2 GL Ex
2302932
400
0.005 - 2
Gear flow meter 0.005-2 KL Ex
2334771
400
0.005 - 2
Gear flow meter 0.5-25 GL Ex
2311959
400
0.5 - 25
Gear flow meter 0.1-7 GL Ex
2311949
400
0.1 - 7
Coriolis compact 0.075-5 Ex
2312234
350
0.075 - 5
Coriolis compact 0.15-10 Ex
2301268
350
0.15 - 10
Micro flow meter 0.005-0.25 Ex
9956278
100
0.0025-0.25
* Order No. for flow meter as a spare part, without fittings etc.
2302929
2302927
Note
Max.
pressure
5.4.4
Gear flow meter 0.02-3 GL Ex
Gear flow meter 0.02-3 KL Ex
Flow meter type
WAGNER
Order No.*
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APPLICATION LIMITS OF FLOW METERS
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5.5
MIXING TYPES
For mixing components A, B, C and D, three versions are available:
A) With mixing block (standard)
B) With mixing head valve
C) With external mixer
A) Mixing block (standard)
Example: 3K system with 6 A valves,
4 B valves, 2 C valves and 2 guns
Flushing A (air)
Flushing B1
Valves B1, B2 and C are cycled.
Flushing A
Flushing B2
A3
A4
A1
A2
B2
B1
C Flushing
C
Air bubble sensor
Inline filter
Flow meter
Non-return valve
Mixing block AB+C
Mixing block A+B
Static-mixer A+B
Static-mixer AB+C
Flushing gun 1
Flushing gun 2
Splitter valve with flushing
Gun 2
Product pressure regulator
B_04681
Dump valve for waste
separation
Dump valve
The dump valve can also be installed before the
gun in the gun hose.
Gun 1
Example with simple dump valve:
B_04685
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B) Mixing head valve
Example: 3K system with 6 A valves,
4 B valves, 2 C valves and 2 guns
The mixing head valves B and C
are cycled and regulated with the
AIS dosing system.
A Flushing (air)
B1 Flushing
B2 Flushing
A Flushing
A3
A4
B2
B1
A1
C Flushing
C
A2
Air bubble sensor
Inline filter
Mixing head valve with
cycles and AIS
83
83 Flushing mixing head valve B
84
AIS
AIS
84 Flushing mixing head valve C
Flow meter
Non-return valve
Mixing block
Static-mixer
Flushing gun 1
Flushing gun 2
Splitter valve with flushing
Gun 2
Product pressure regulator
B_05639
Dump valve for
waste separation
Gun 1
Dump valve
The dump valve can also be installed before the gun in the gun hose.
Example with simple dump valve:
B_04685
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C) External mixer
Example: 3K system with
6 A valves, 4 B valves,
2 C valves and 2 guns
Valves B1, B2 and C are
cycled.
A Flushing (air)
B1 Flushing
A Flushing
B2 Flushing
A4
A3
B1
A1
B2
A2
C
C Flushing
Air bubble sensor
Gun
Inline filter
Flushing
Flow meter
Non-return valve
B_04683
External mixer
5.6
DUMP VALVE FOR WASTE SEPARATION (OPTION)
In addition to the simple dump valve, there is also a dump valve for waste separation.
When filling and when flushing, the system separates the flushing agent from the
remaining product. For this purpose, a double valve is used: one output for flushing agent,
another for waste (mixed product).
With an average number of paint changes and pot lives which are not too short, the dump
valve can be an alternative to a gun flush box for waste separation.
5.7
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 flow rates. Thereby, the AIS ensures optimum
dosing and constant coating quality.
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6
ASSEMBLY AND COMMISSIONING
6.1
TRAINING ASSEMBLY/COMMISSIONING STAFF
The assembly and commissioning staff must have the technical skills to safely undertake
commissioning.
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 before commissioning.
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 specifications
of temperatures and relative humidity, see, technical data (Chapter 5.5.3).
Long-term storage
See Chapter 9.1.6.
For recommissioning, proceed according to following chapters.
6.3
TRANSPORTATION
The system can be transported in the specially designed transportation box.
Inner dimensions in mm; inch
Length
Width
Height
180; 7
118; 4.65
82.5; 3.25
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WARNING
Inclined ground!
Risk of accidents if the device rolls away/falls.
Place the device on horizontal floor.
Rollers should be locked in position or replaced by leveling feet
and secured.
Do not tilt the device during shifting / transporting.
B_05489
Ensure a sufficient secure stance.
The fixing attachments of leveling feet
should be locked to base.
6.4
ASSEMBLY AND INSTALLATION
The mixing units are normally installed by WAGNER technicians directly or by their agents.
If this is not the case, the material has to be checked for damage on receipt of the system.
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, fire protection
and electrotechnical rules.
Must be de-energized before work is commenced on active
parts.
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WARNING
Toxic and/or flammable vapor mixtures!
Risk of poisoning and burns.
Operate the device in a spray booth approved for the working
materials.
– or –
Operate the device on an appropriate spraying wall with the
ventilation (extraction) switched on.
Observe national and local regulations for the exhaust air speed.
DANGER
Incorrect installation of the device!
Explosion hazard and damage to the device.
Set up the system outside the spray booth / spray zone.
The control cabinet should not be set up within the Ex zone.
Protect the control cabinet from extreme temperature and
moisture changes as well as dirt.
The 2K COMFORT fluid section (non-Ex version) may not be
installed in the explosion zone.
Lay and fix the connecting cable correctly and protect it against
tripping, dirt and traffic.
WARNING
Inclined ground!
Risk of accidents if the device rolls away/falls.
Place the device on horizontal floor.
The wheels should be fixed or replaced by levelling feet and
secured.
Do not tilt the device during shifting / transporting.
Use only feed pumps and components which are suitable for 2K products.
Use hardener pump with PE/T packing (T = PTFE).
No contact of 2K products with non-ferrous metals.
With water-based lacquers: pumps and product-wetted parts of stainless steel.
Use product filters at the feed pumps.
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6.4.1
ELECTRICAL CONNECTIONS
An electric connection cable with plug is standardly provided.
When exchanging the connection cable, please observe the following:
Carry out the electrical connections and the grounding inside the control unit using
a 3-wire cable of 1.5 mm²; AWG16 in accordance with the enclosed circuit diagram.
6.4.2
PNEUMATIC CONNECTIONS
Check whether the line pressure is sufficient. It has to be between 0.7 and 0.8 MPa;
7 to 8 bar; 101-116 psi.
WARNING
Overpressure!
Risk of injury from bursting components.
The operating pressure must not exceed the value shown on
the type plate.
Check whether efficient filter 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/m3
Every day, discharge all contamination and the condensate (if any) which has
accumulated in the equipment air filter.
WARNING
Brittle filter pressure regulator!
The tank on the filter pressure regulator becomes brittle through
contact with solvents and can burst.
Flying parts can cause injury.
Do not clean the tank on the filter pressure regulator with solvents.
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6.4.3
PRODUCT CONNECTIONS
Carry out the following connections:
Product hose from the mixing tube or splitter valve to the gun.
- Electrostatic guns must be used without electrostatics during commissioning.
First commission the electrostatic system after all steps are carried out up to
Chapter 6.6.6.
The product hoses from the feeding pumps to the system's product inlets may not
be connected until the preliminary flushing of the hoses (see Chapter 6.6.1) has been
completed (contamination of the unit)!
Circular pipeline
If the unit is connected to a circular pipeline, suitable shut-off devices must be
installed
– to prevent the products from mixing in case of leakage in the 2K system.
– These shut-off devices must always be closed at the end of work.
6.4.4
FLOW METER MONITORING
For safe operation it is necessary for the 2K system to receive a signal, when the gun is
open and there is 2K product flow. Otherwise for example no B product is added when the
A flow meter is blocked, although A product continues flowing through the leakage in the
flow meter (possibly not visible).
The signal (product flow yes/no) can be made available on ways that follow:
for AirSpray- or AirCoat manual spray guns: AirSpray + AirCoat gun monitoring
(atomizing air-flow switch);
for Airless- or HVLP manual spray guns: flow monitor (lacquer-flow switch in the lines
to the guns);
for automatic spray guns: automatic gun monitoring (pressure switch);
for digital robot communication: robot signal ("gun signal 1/2/3/4");
for bus communication (e.g., CAN Profibus Gateway): signal by superordinate control
("gun monitoring 1/2/3/4").
Gun monitoring for each gun
If possible, each gun should be monitored separately.
Caution with only one gun monitoring for multiple guns
If for several spray guns only one gun monitoring is installed, the controller does not know
which gun in each case is in operation. Then the product flow is divided to all guns. The pot
lives in the gun hoses and guns can be exceeded without a pot life alarm.
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WARNING
Incorrect installation of the device!
Explosion hazard and damage to the device.
The flow monitor is not Ex-proof and has to be installed outside
the explosion zone.
Lay and fix the connection pipes correctly and protect them
against tripping, dirt and damage.
No air consuming equipment, other than the feed pumps for a 2K system, may be
installed after the flow monitor (e.g., pumps circular pipeline and stirrer).
6.4.5
LACK-OF-PRODUCT PROTECTION
Make sure that product without air bubbles is supplied to the mixing and dosing system.
The flow meters can not detect whether product or air is delivered.
This may lead to mixing errors. (An air bubbles monitoring system is optionally
available for the low-pressure model)
A lack-of-product protection can be achieved by installing a level probe in the A-product
tank or by always having the coater make sure that sufficient product is in the tanks.
Otherwise false coating may occur.
If, e.g., the A-tank's level probe indicates the minimum level, a signal can stop the 2K system
(STOP) or electronic consumption measuring equipment warns of a lack of product.
The lack-of-product protection with level probe is not supplied with the 2K system and has
to be realized on-site.
6.4.6
VENTILATION OF THE SPRAY BOOTH
Observe the safety instructions in Chapter 4.1.3.
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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6.5
GROUNDING
WARNING
Fire, explosion and electric shock hazard
Danger to life by electric shock and explosion.
The device must be electrically connected to the equipotential
bonding (ground); the ground in the electrical system is not
sufficient.
A qualified electrician must complete all grounding and wiring
connections and check the resistance.
Operation according to the safety regulations, fire protection
and electrotechnical rules.
Must be de-energized before work is commenced on active parts.
WARNING
Heavy paint mist if grounding is insufficient!
Danger of poisoning.
Insufficient paint application quality.
Ground all device components.
Ground the work pieces to be coated.
Make sure to include the control cabinet and the fluid cabinet in the local equipotential
bonding.
The 2K system, the pumps, all accessories and all parts that come into contact with the
sprayer have to be grounded non-Ex or Ex according to the following grounding scheme.
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Grounding scheme - example for 2K COMFORT non-Ex
6
Non-Ex zone
Ex zone
8
1
5
9
3
2
R max.
< 1 MOhm
4
Legend
Grounding cables
1 Controller
2 Fluid section (non-Ex)
3 Pump
4 Paint tank
5 Work piece
7
6
7
8
9
B_04657
Fluid hoses
Conveyor
Floor, static dissipative
Pneumatic alarm horn (option)
Remote control Ex (option)
Cable cross sections
2K system, pump
Paint tank / collection tank
Conveyor
Spray booth
Spraying stand
4 mm2; AWG 12
6 mm2; AWG 10
16 mm2; AWG 6
16 mm2; AWG 6
16 mm2; AWG 6
Connect all ground cables using a short and direct route.
Ex zone
All devices and equipment must be suitable for use in potentially explosive areas.
Tank
All paints, flushing agents and waste tanks have to be electrically conductive.
All tanks must be grounded.
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Grounding scheme - example for 2K COMFORT Ex
6
Non-Ex zone
Ex zone
1
8
2
5
9
3
R max.
< 1 MOhm
B_04656
Legend
Grounding cables
1 Controller
2 Fluid section (Ex)
3 Pump (Ex)
4 Paint tank
5 Work piece
4
7
6
7
8
9
Fluid hoses
Conveyor
Floor, static dissipative
Pneumatic alarm horn (option)
Remote control Ex (option)
Cable cross sections
2K system, pump
Paint tank / collection tank
Conveyor
Spray booth
Spraying stand
4 mm2; AWG 12
6 mm2; AWG 10
16 mm2; AWG 6
16 mm2; AWG 6
16 mm2; AWG 6
Connect all ground cables using a short and direct route.
Ex zone
All devices and equipment must be suitable for use in potentially explosive areas.
Tank
All paints, flushing agents and waste tanks have to be electrically conductive.
All tanks must be grounded.
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6.6
COMMISSIONING
WARNING
Gas mixtures can explode if there is an incompletely filled device!
Danger to life from flying parts.
Ensure that the device is always completely filled with flushing
agent or working medium.
Do not spray the device empty after cleaning.
WARNING
High pressure spray jet!
Danger to life from injecting paint or solvent.
Never reach into the spray jet.
Never point the spray gun at people.
Consult a doctor immediately in the event of skin injuries caused
by paint or solvent. Inform the doctor about the paint or solvent
used.
Never seal defective high-pressure parts, instead relieve the
pressure from them and replace them.
Wear the appropriate protective clothing, gloves, eyewear and
respiratory protection.
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.
Electrostatic gun
Electrostatic guns must be used without electrostatics during commissioning.
First commission the electrostatic system after all steps are carried out up to
Chapter 6.6.6.
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6.6.1
PRELIMINARY CLEANING
The devices are tested at the factory using emulsified oil, plain oil or solvent, according to
the kind of fluid being pumped.
Before commissioning the pump with a product, it is recommended to flush both
circuits and supply pumps with an appropriate flushing agent.
WARNING
Incompatibility of flushing agent and working medium!
Risk of explosion and danger of poisoning by toxic gases.
Examine the compatibility of the flushing agents and working
medium on the basis of the safety data sheets.
Preliminary cleaning
Before the product hoses are connected to the system, they should be flushed, together
with the corresponding pumps, with the flushing agent to be used.
Unless this preliminary flushing is executed, the flow meters can already be clogged
due to contamination during the first flow through!
For preliminary cleaning of the pumps, carefully follow the corresponding pump
instructions.
After all pumps and product hoses to the device have been flushed, the product hoses
can be connected to the system.
The flushing agent still remains in the pumps.
Note: The flushing agent used for the first cleaning may not be used again since it might
contain oil residues.
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6.6.2
INITIALIZING THE CONTROLLER
The controller is already individually pre-configured upon delivery. Additional settings
must be entered on-site.
Switch on the system with the main switch.
The initialization programs starts when the system is switched on for the very first
time. It allows quick input of the most important settings, which must still be entered.
The initialization program can also be called up later (with password level 3, setting
"Re-set initialization")
Define one after the other on the operating panel:
- Language (touch desired language, then proceed with the arrow key
);
- Volumes measuring unit (liters or US gallons, touch field to change);
- Lengths measuring unit (meter or inch);
- Hose lengths and diameters;
- Number of paint recipes (maximum 100) and number of flushing recipes (maximum 10);
- Mixing ratio input type (A:B or percentage).
At the end, a note appears, explaining what should be done next. Perform one after the
other (password level 1):
- Enter names of valves, flushing recipes and paint recipes (see Chapter 7.9.2);
- Enter flushing recipes (see Chapter 7.10);
- Enter paint recipes (see Chapter 7.11), still without calibration.
If necessary, implement further settings.
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6.6.3
VENTING THE SYSTEM
First bleed the system via the gun with little product pressure:
Prepare a grounded metal bucket, that is suitable to collect all products to be disposed of.
(see Chapter 7.8)
Menu
Select each A side valve, one after the other and perform the following steps:
- Open the valve with the large valve icon.
- Bleed, via the gun, with low product pressure until clean flushing agent flows out of
the gun.
- Close the valve icon again.
Do the same for the B side (and C/D, if available) and for the flushing valves.
6.6.4
PRESSURE TIGHTNESS TEST
For pressure tightness control of the entire installation, the flushing agent pressure is
slowly increased, step by step, until the maximum pressure of the individual pumps is
achieved.
WARNING
Overpressure!
Risk of injury from bursting components.
The operating pressure must not exceed the value shown on
the type plate.
Menu
(see Chapter 7.8)
One after the other and in each component (A, B, flush, ...) for each product valve
(A1, A2, ...):
– Select valve and open it with the large valve button.
– Slowly increase the pressure at the respective pumps, step-by-step, until the
maximum pressure specified on the type plate has been reached.
– Hold the maximum pressure for at least 2 minutes.
– If there is a leak, mend it.
After the test, relieve pressure from the entire system according to Chapter 8.9.
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6.6.5
FILLING THE SYSTEM
NOTICE
Interchange of the two components A and B!
Device damage by hardened product.
Label device components and paint tank so that the components A and B are not
mixed up.
(see Chapter 7.8)
Menu
Example for a hardener valve with the name B1:
1. Prepare the hardener components' tank and put the suction pipe in the respective pump.
2. Select [B] components, then select valve B1.
Open the valve with the large valve button.
3. Set the hardener pump slightly under pressure. Open the hardener valve with the large
valve button.
4. Point the guns into the grounded metal bucket and open it step by step. Avoid splashback.
5. After the hardener is filled, calibrate the hardener straight away, if necessary, according
to Chapter 7.12.
6. Close the valve via the [Valve] field or close the STOP button again.
Then, in the same way, fill the system with the other components.
Note: The solvent used for the first cleaning may not be used again since it might contain
oil residues.
Calibrating the flow meters
In all paint recipes, calibrate the components as well as the flushing agent.
If the components were already calibrated during filling, the K factors must be entered in
the different recipes.
According to Chapter 7.12.
6.6.6
ELECTROSTATICS
With an electrostatic gun:
Commissioning the electrostatics according to the corresponding assembly manual.
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7
CONTROLLER
7.1
TRAINING THE OPERATING STAFF
The operating staff must be qualified and fit to operate the entire system.
The operating staff 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 staff must receive appropriate system training.
7.2
SAFETY INSTRUCTIONS
Before carrying out any work, the following points must be observed in accordance with
the operating manual:
Observe all safety regulations in accordance with Chapter 4.
Carry out commissioning 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 staff 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:
Relieve the pressure from the spray gun and unit.
Secure the spray gun against actuation.
Switch off the energy/compressed air supply.
Disconnect the control unit form the network.
In the event of functional faults: remedy the fault as described in
the "Troubleshooting" chapter.
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7.3
CONTROL CABINET
There are four push-buttons and an operating panel (touch screen) for the system
controller in the control cabinet. The touchscreen and the push-buttons can be used to
communicate with the controller.
Initialization program for commissioning: see Chapter 6.6.2
Basic operating principles: see Chapter 7
Workflow: see Chapter 8
Detailed software documentation is separately available (see Chapter 1.3).
USB connection
The USB port is at the control panel on the inside of the control cabinet.
Control cabinet
Operating panel
(Touchscreen)
Main switch
Mechanical push-buttons
0
549
B_0
7.3.1
MAIN SWITCH
The main switch, on the right side of the control cabinet, switches the controller on and off.
When switched off, all valves close automatically.
Switching the system on and off: see Chapter 8.3.
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7.4
MECHANICAL PUSH-BUTTONS
The basic functions for each circuit are controlled by four mechanical push-buttons:
R
START
STOP
Starts spraying mode.
FLUSHING
Ends the spraying
or
flushing process.
Flashes green during
(Depending
on setting,
filling.
it may not be possible to
Lights up green as soon
end the flushing process
as the system is ready for
early.)
spraying. The AirCoat air
Alarm Lights up red.
is activated (option).
Warning Flashes red.
Starts end flushing of
the last paint recipe
used. (With external
mixer if necessary mixer
flushing.)
Switches to next paint
recipe.
STOP + recipe change
jumps 10 steps.
Lights up blue during
flushing process.
Display of flushing
progress:
Display of filling
progress:
Gun symbol flashes
7.5
RECIPE CHANGE
Open gun.
OPERATING PANEL BASICS
highlighted (yellow)
Some buttons are highlighted by a yellow background color.
The highlighted buttons indicate our current location.
All fields with frames can be touched. For example, to trigger an
action, select a different recipe, or enter a number.
Recurring operating elements
Scroll up screen
Scroll down screen
Confirm selection
Cancel selection
Saves the data
Differences in screen displays
The controller's functions differ depending on system, accessories installed, and user
settings. The screens shown in the following chapters may therefore contain additional
input options, or some of the buttons and fields shown may not be present in your version.
The screen will only ever show what is actually installed.
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7.5.1
SELECT LANGUAGE
1. [Menu] button (second button in bottom row)
2.
3. Touch language: [English]
7.5.2
KEYBOARD INPUT
A keyboard with numbers or letters appears as necessary when fields with frames are touched. The input is
confirmed with [ ENT ] or canceled with [ ESC ].
Min:
Max:
Keyboard with
numbers and special
characters
Cursor (field with frame) =
Current input position
Minimum and
maximum values
5.0
R_blue
Cancel input
B_04640
Confirm input
B_04641
Keyboard with upper
case letters
Keyboard Controls
Cancel
Move cursor to right
Move cursor to left
Confirm input
Delete all
Delete character
Delete character to left of
cursor (backspace)
Space
Confirm input
Changing over keyboard with letters
Switch to keyboard with upper case letters
Switch to keyboard with lower case letters
Switch to keyboard with numbers and
special characters
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7.5.3
PASSWORDS
Some functions and input options are protected by passwords. The following password
levels exist:
Password level
Responsibility
Functions
0
Painter
Spraying mode
1
Painter with control jobs
Plus enter flushing and paint recipes,
diagnosis, calibration
2
Foreman
Plus system settings
3
Service customer
Plus basic system settings
4
Service WAGNER
The passwords, which are set by WAGNER at the time of the equipment delivery, are not
contained in the manual for safety reasons. The valid passwords are communicated to the
customer separately.
Password input
1. [Menu] button
2. If [Log Out] button appears: [Log Out] ( The button switches to [Log In].)
3. [Log In]
4. Touch password input field.
A numerical keyboard appears.
5. Enter the password.
6. [ENT]
The password level is displayed briefly, for example: "Level 1".
The menu buttons for the corresponding password level then appear.
7.6
HOME PAGE
NOTICE
Wrong mixing ratio!
Poor quality of paint application.
Before changing the lacquer, check the mixing ratio on the display and modify it if
necessary, if individual components have different mixing ratios.
7.6.1
R
Or:
CHANGING THE PAINT RECIPE
Press RECIPE CHANGE push-button
Switches to next paint recipe.
1. Touch paint recipe field (see above).
2. Select desired paint recipe from the list.
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7.6.2
HOME PAGE OPERATION
All fields with frames can be touched.
Number of current paint recipe
Mixing ratio (volumetric)
Pot life
Remaining pot life in minutes or seconds.
Paint recipe
Opens choice of all
paint recipes.
Gun selection
Flow regulation
The system regulates the flow to a set
value.
A:B
AB : C
of ABC
D
Pot life
As of password level 1:
calibration of flow regulation
min
B_05460
Gun
Menu
Act.
Batch
PC
AIS
Flow
contrl
B_05461
Flushing
Opens a menu with
various flushing options.
Tank
Filling level monitoring
of paint tank
AIS
Preset the dosing valve
stroke.
PC data archiving
Chapter 1.3.1
Menu
Opens a menu containing
other functions.
Act. (=current)
Shows the current lacquer
consumption values.
Home
Returns to home page at any time.
The 'Home' button is emphasized using reversed colors
– on screen with light background. This shows us our
current location: on the home page.
Batch
Produce recurring,
predetermined quantity of
product.
* Only present with corresponding
setting (with password level 3,
see Chapter 7.13.2).
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7.7
MENU
Button
Function
Alarm
Calls up list of the last 700 warning messages.
Manual operation
Specific opening and closing of product or flushing valves.
Chapter 7.8
Tank
Software Documentation
Change name (password level 1)
Chapter 7.9.2
Flushing recipes (password level 1)
Chapter 7.10
Paint recipes (password level 1)
Chapter 7.11
Diagnosis (password level 1)
Mixing amount, e.g., QB: As soon as the mixture has the correct mixing ratio,
the mixing amount is reset to zero. The system stops when the maximum is
exceeded (=QB-control, see Chapter 7.13.1).
Btkt = The dosing valve's cycle length
% open per cycle = dosing valve's opening time. If too short: slowly reduce
the difference in pressure between A and B.
Output Display the output signal status.
Input Display the input signal status.
Totals (password levels 1 / 2)
View / zero product consumption and working times.
VOC quantities (password levels 1 / 2)
View / zero VOC quantities, enter VOC factors.
Chapter 7.11
Info (password level 1)
View software version number, set date and time.
Calibration (password level 1)
Chapter 7.12
Settings (password levels 2 / 3)
Chapter 7.13
USB
USB (password levels 2 / 3)
Back up alarms, totals, and configuration data on USB stick.
Service (password level 2)
Service intervals for dosing valves and flow meters.
I/O
Config
Input / Output configuration (password level 3)
Assign inputs and outputs. See software documentation
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7.8
MANUAL MODE: OPENING VALVES
Menu
Select paint recipe (for A/B/C/D).
Or select flushing valve (for A/B/C/D flushing valves).
The buttons with reversed colors show our
current location:
Valve used by paint recipe.
(See other used valves: buttons A/B/C/D.)
A
B
Current flow
Q
Vjob
cc / min
cc
bar
Quantity of product
since the valve was
last opened
Select component
A/B/C/D.
C
D
A
B
Displays list of A/B/
C/D flushing valves.
C
Menu
Output
Manual operation
Valves
Status of selected valve
B_05237
D
Set product pressure.
(Only with "automatic product
pressure regulator" option,
see Chapter 7.13.2.)
Valve is closed
Touch to change
Valve is open
Open several valves / output
signals at the same time
With password level 3,
see Chapter 7.13.2.
Manual mode is used for troubleshooting or to fill a pump, for example.
Only one valve can be opened at any one time. If another valve is touched, the controller
closes all valves.
With a gun flush box, the valve for the gun is also opened: either for gun 1 (if gun 1 or 1+x
is selected on the home page), or for gun 2 (if gun 2 is selected on the home page).
External flushing agent: The valve for the external flushing agent can not be opened on
this page. If necessary, the calibration function can be used for this, without saving the
measured value (password level 2, Chapter 7.12).
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7.9
RECIPES
7.9.1
ADD NEW RECIPES
Create a new flushing recipe:
1. Increase the "Number of flushing recipes" in the settings by one (see Chapter 7.13.1).
2. Change the flushing recipe name automatically assigned (see Chapter 7.9.2).
3. Enter the flushing recipe (see Chapter 7.10).
Create a new paint recipe:
1. Increase the "Number of paint recipes" in the settings by one (see Chapter 7.13.1).
2. Change the paint recipe name automatically assigned (see Chapter 7.9.2).
3. Enter paint recipe (see Chapter 7.11).
7.9.2
Menu
CHANGE RECIPE AND VALVE NAMES
ABC
(with password level 1 or higher)
Change valve names (for example: red, yellow,
hardener_1, flushing agent_1).
First select components (A, B, flushing A, ...), then
touch the valve names.
others
Other valve names
No valve open
Flushing starting from external
mixer (option)
Flushing starting from mixing
head valve (option)
Flushing starting from splitter
valve for gun 1 or gun 2
Wait
Demand gun change.
(With 2-4 guns and only one gun
flush box.)
Change flushing recipe name.
For example: R-R flushing (= recipe change flushing),
end flushing, gun flushing.
Change paint recipe name.
For example: red-90, red-95, yellow_customer-1,
yellow_customer-2.
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7.10
ENTERING FLUSHING RECIPE
Menu
Select existing flushing recipe.
(New flushing recipe: see Chapter 7.9.1)
Current flushing step for input on this page.
Define total number of flushing steps for this recipe.
1 - 16
Example with splitter valve,
dump valve and product
pressure regulator
Select action for this flushing step.
Flushing valve to open, or
(=wait)
(=extend gun change)
Step
Flushing Qty
Enter flushing quantity or flushing time for
this flushing step.
0.0 - 9999.9
Enter short flushing steps first (rough
flushing) to begin with, then long flushing
steps (approx. twice the hose content).
(No influence on: "
")
20.0
bar
Menu
B_05202
Opens the distributor valve for a
single gun (1, 2, 3 or 4) or for all
guns (1-x).
1 / 2 / 3 / 4 / 1-x
With several guns, separate flushing steps
must be defined for each gun.
Only those guns which were in use are
flushed automatically.
Exception: if a system has already been
flushed, the guns indicated are flushed in
any case when flushing is repeated.
Switch between flushing quantity
and flushing time.
cc or seconds
Set flushing pressure.
(Only with "automatic
product pressure
regulator" option)
Flushing via dump valve:
on or off.
(Only with "dump valve"
option)
Go to next flushing
step.
Repetitions can
be entered after the
last flushing step (for
examples, see software
documentation).
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7.11
ENTERING THE PAINT RECIPE
Menu
(with password level 1 or higher)
Select existing paint recipe.
New recipe: see Chapter 7.9.1
Enter mixing ratio (volume) for the selected
recipe
0.1:1 - 50.00:1
0.02% - 1000.00%
If one or several components are not required:
enter 0.00:1 or 0.00%.
A:B
AB : C
D
1K application: enter 0.00:1 or 0.00% for all
components except for one.
The flow is measured by volume and the mixing
ratio is entered and controlled volumetrically by
default.
of ABC
Select product valves for available components.
Menu
B_05476
Save paint recipe.
Go to next page
If one or several components are not required:
B valve = "---------"
1K application: enter "---------" for all components
except for one.
Page 2
- Enter pot life.
- Select flushing recipes to be used:
Is carried out, ...
End:
... after this paint recipe has been used when end flushing is being
carried out.
R-R:
... after this paint recipe has been used when the recipe is changed.
Mix: * ... when flushing just from the external mixer to the gun.
Pre: *
... before using this paint recipe.
(For whether a recipe change and / or end flushing comes first:
see Chapter 7.13.2, "Pre-flushing after paint change flush" or
"Pre-flushing after end flushing").
* May also be missing, depending on configuration.
Select empty field if no flushing recipe is to be active.
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Page 3 (option)
- Product pressure when filling and working.
Prerequisite: low-pressure system with automatic product pressure regulator.
Page 4 (option)
- Flow regulation: pre-define flow set value for this paint recipe.
Settings: "Flow regulation" see Chapter 7.13.2 (password level 3, page 19)
Page 5 (option)
- Flow monitoring: enter minimum and maximum flow in cc/min. (For example, with
robot applications to monitor nozzle wear and nozzle blockages.)
Prerequisite: gun monitoring or flow monitor.
Settings:
- Activate "Flow monitoring" Chapter 7.13.2 (password level 3, page 2)
- "Alarm delay flow monitoring" Chapter 7.13.1 (password level 2, page 2)
If flow falls below or exceeds the limits, the system stops with alarm A121 or A122.
Page 6 (option)
- Batch Mode: pre-define the Batch quantity for this paint recipe.
Prerequisite: Accessories set for automatic filling + external signal transmitter (e.g., footoperated switch)
-
Save recipe.
- VOC = Volatile Organic Compounds
If the local specifications require a VOC measurement, then the corresponding VOC factor
must be entered in every paint recipe for each component.
Menu
1. Select newly entered paint recipe.
2. One after the other, touch components A / B / C / D and
flushing A / B / C / D and for each:
- Enter the corresponding VOC factor in percent or
g/L or g/G. The VOC measuring unit is defined in the
settings (see Chapter 7.13.1).
- Only if the corresponding factor is to be saved for all
paint recipes:
- Calibration of the flow meters for the newly entered paint recipe:
According to Chapter 7.12.
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7.12
CALIBRATION
The flow of components A/B/C/D is measured with flow meters. The test equipment must
be calibrated. This produces a K factor for every component.
The K factors may vary depending on the lacquer (A1, A2, A3, ...). Therefore, the K factors for
each paint recipe are saved separately.
The default is the average from the calibration report. The default is accurate and is a good
match for most products. A calibration is therefore, not usually necessary.
If calibration is repeated, it should be a precise process. Particular care must be taken, to
measure the volume in the measuring cup exactly and without air bubbles.
Menu
(with password level 1 or higher)
Example: K factor for the paint recipe
and for component B.
1. Select paint recipe: .
2. Select component: B.
3. The system is under spraying pressure and the selected component is already in the
spray gun. Select the spray nozzle, so that pressure and product flow approximately
meet subsequent work processes.
[Start] [Stop] Wait until no more product flows.
4. Start the measurement: [Start].
5. Use the gun to fill a certain quantity of the corresponding lacquer (e.g., 500 ml) into a
measuring cup. Use a protective tube against overspray if necessary.
The flow measured by the system is displayed on the screen.
6. Close the gun and push the [STOP] button. Wait until no more product flows.
7. Exactly measure the quantity filled into the measuring cup by weight, with one of the
following versions.
8. Enter the determined volume in the measuring cup field.
9. The controller calculates and saves the new K factor and displays it in the Kn field.
10. Press the [ ] icon in order to accept the new K factor.
Selection possibility: If the different lacquers of the same components have similar
characteristics, then the K factor can immediately be saved for all recipes. Otherwise,
only for the current recipe.
11. Carry out the calibration several times in order to check the values.
In case of large deviations, eliminate the cause:
- Air in the lines fill the lines with product and check the suction system.
- Air mixture in the measuring cup gauge the calibration and use the density to
calculate the volume.
- The flow is not measured properly. Dismount the flow meter or stroke sensor,
clean it and check it for any damage.
12. In all paint recipes, calibrate all components.
With identical flow meters (identical components) and identical lacquers or lacquers
with similar characteristics, the K factor can be taken over: Enter the value directly in
the Kn field and then save.
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Exact calibration, version 1 (Lacquer density is known)
– Weigh the quantity filled into the cup.
– Divide the weight in grams (g) by the lacquer's density. This directly equals the volume
in cc, that is entered in the measuring cup field.
Exact calibration, version 2 (Lacquer density is unknown)
– First, manually measure precisely e.g., 500 cc of product into a measuring cup and
establish the product weight in "g" grams.
– Set empty measuring cup on the scale. When calibrating, use the gun to fill the cup with
the exact weight measure above.
– The initial volume (e.g., 500 cc) is entered in the measuring cup field.
Flow quantity measured by the system.
Valve used by paint recipe.
Select paint recipe (for A/B/C/D).
Or select flushing valve (for A/B/C/D flushing valves).
Enter pressure at which calibration takes place.
(only with "automatic product pressure regulator" option)
A
B
C
D
0 bar
0 cc
0 cc
Imp/L
Imp/L
Kn
K
Menu
Select component A/B/C/D.
A
B
C
D
Displays list of A/B/C/D flushing
valves.
others
Calibrate external flushing agent.
Start
B_05458
K = Current K factor for selected component
(A, B, ...).
Is saved in the selected paint recipe.
Replaces the current K factor (K) for the selected
component (A, B, ...) with the new K factor (Kn).
Depending on selection in the query which
appears:
either only in the selected paint recipe,
or in all paint recipes.
Kn = Newly calculated K factor
Input of quantity calculated with measuring
cup and scale.
Start measurement
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7.13
SETTINGS
7.13.1
SETTINGS PASSWORD LEVEL 2
Menu
Level 2
There are 24 pages of settings. Depending on configuration, pages may be jumped.
The page numbers with a gray background always appear, the others are optional. (Detailed
descriptions of these pages can be found in the 2K COMFORT Software Documentation.)
1. Number of paint recipes and number of flushing recipes.
QB, QC, QD Control
See the software documentation, "Diagnosis" chapter.
Gun Delay Delay time for alarms A106 to A113 (set "Minimum flow" and "Maximum
flow" Chapter 7.13.2, level 3, page 4)
2. Post-alarm for pot life Once the pot life + post-alarm times have passed, the
system stops (alarms A132–A144). The alarm is repeated until the system is flushed.
If "Automatic flushing at pot life alarm" is activated, and the guns are in the gun
flush box, flushing is started automatically.
Alarm delay Flow monitoring Delay time for alarms A121 and A122. (Activate
"Flow monitoring", Chapter 7.13.2, level 3, page 2. Enter the limits in the paint
recipe See Chapter 7.11.)
Atomizing air at alarm stop
So that coating can be completed without dripping.
Atomizing air at end of flushing
VOC measuring unit
To blow the air cap free.
Percent or gram per Liter.
Password for password level 1.
3. Hose dimensions from product valves A and B to mixer.
4. For 3K system: hose dimensions from product valve C to mixer.
5. For 4K system: hose dimensions from product valves C/D to mixer.
6. Hose dimensions from mixer to splitter valve.
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7.+8. - Page 7: Hose dimensions from mixer to gun 1.
- Page 8: Hose dimensions from splitter valve to gun 1.
Gun content of gun 1
Gun 1: Filling via the dump valve Quantity (as a percentage), which should be
discharged via the dump valve. (The remainder passes via the gun.)
Gun 1: Flush atomizing air % hose content When flushing: What percentage
of the hose content from the mixer to the gun, can still be used for coating.
The atomizing air (and electrostatics) for gun 1 remains activated for this period
when flushing. See also "Flush pause" (level 2, page 16).
Gun 1: dump valve flushing time after filling. (Only with flushable dump valve.)
9. Hose dimensions from gun 1 to the dump valve. (Only with "Dump valve as return
flow".)
10.+11. Like pages 8 + 9, but for gun 2.
12.+13. Like pages 8 + 9, but for gun 3.
14.+15. Like pages 8 + 9, but for gun 4.
16. The flush pause indicates that with "Atom.air on flush % of hose volume" the
remainder must be sprayed into the waste tank. The atomizing air remains on during
the flush pause.
Pot life alarm Flushing "On" = Flushing is mandatory after a pot life alarm.
Additional spraying is also possible with "Off ".
Mixing alarm Flushing "On" = Flushing is mandatory after a mixing error alarm
(A100–A118, A128–A131, A145–A148). Additional spraying is also possible with
"Off ".
Mixing alarm Filling "On" = Filling is mandatory after a mixing error alarm
(A100–A118, A128–A131, A145–A148). Additional spraying is also possible with
"Off ".
17. Filling greater than hose content What percentage of the total hose content is
also to be filled between product valve and gun to ensure that there is no flushing
agent left in the hose.
Flow monitoring during filling "On" = The flow is limited when filling to optimize
the dosing quality. Set limits with Max. filling flow or min. filling flow. If necessary,
the A valve cycles with the filling time interval.
Reset pot life
Pot life is reset manually.
18. Save Start/Stop totals USB stick "On": Start/Stop totals are written continuously
to a USB stick (USB stick must be plugged in).
PC data archiving "On": Data are archived continuously on PC.
(Operating manual for PC data archiving see Chapter 1.3.1)
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19. For AIS-B:
AIS warning limit Minimum injection quality (opening time of hardener dosing
valve as a percentage). If the value falls below this, a warning is triggered (W123 - W125).
AIS lower limit If the value falls below this, the AIS optimizes the injection quality.
(Default value = 50%)
AIS upper limit
If the value exceeds this, the AIS limits the injection quality.
Thereby smooth operation is ensured. (Default value = 80%)
Valve > open AIS open If the B valve is continuously opened for longer than
the stated time, too little product can flow through. The AIS allows more product
through. (Default value 1.0 sec.) Repetition after each repetition interval AIS open.
(Default value 0.5 sec.)
AIS open when stopped Number of steps which the AIS is to open when mixing
operation is ended. (Default value 3)
AIS min. flow Minimum flow of all components for AIS to undertake regulation.
(Default value 20 cc/min)
20. For AIS-B:
AIS hysteresis
Number of steps which do not yet have impact when AIS
switches (e.g., close open) and are therefore inserted at the changeover points.
(Default value 1)
AIS Number of cycles with X guns Number of steps which the AIS is to open or
close when an additional gun is switched on or off.
21.+22. Like pages 19 + 20, but for AIS-C.
23.+24. Like pages 19 + 20, but for AIS-D.
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7.13.2
SETTINGS PASSWORD LEVEL 3
Menu
Level 3
There are 21 pages of settings. (Detailed descriptions of these pages can be found in the
2K COMFORT Software Documentation.)
1. 2K, 3K or 4K system
Measuring units for volume (liters / US gallons) and lengths (meter / inch)
Gun closed Valves closed "On": When the gun is closed, all product valves are
also closed automatically. Beneficial for low-pressure applications. Prerequisite: gun
monitoring (not flow monitor).
External release
"On" = External release (e.g., locking with spray booth's exhaust air)
Number of installed Universal CAN I/O modules
2. Number of guns
Gun monitoring for all available guns.
Splitter valve (Prerequisite: minimum 2 guns)
Flush guns separately "On" = splitter valve with flushing (separate gun flushing
valves). Prerequisite: maximum 2 guns, splitter valve = On.
Number of gun flush boxes (GFB)
Automatic flushing at pot life alarm (Prerequisite: GFB)
Flow monitoring (On/Off ). Prerequisite: Gun monitoring or flow monitor. Sets off
Alarms A121 and A122. ("Alarm delay for flow monitoring" Chapter 7.13.1, level 3,
page 2. Enter the limits in the paint recipe See Chapter 7.11.)
3. Dump valve "On" = There is a dump valve installed for every gun. Or a dump valve
flushable. If a dump hose is present between gun and dump valve (not flushable), the
option dump valve as return line is activated. Dump valve for waste separation is
possible with double valves (not flushable). Precision of waste separation: 0 = exact,
each additional number = 25% of the dump hose safety margin (default value 2).
Dump valve outputs can be inverted "Off " = Compressed air opens dump valve
with non-flushable dump valves without waste separation. "On" = Compressed air
closes dump valve.
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4. For component A:
Number of valves and flushing valves.
Minimum and maximum flow. Sets off Alarms A106 to A113. (Delay time "Gun Delay"
see Chapter 7.13.1, level 2, page 1)
Air bubbles monitoring (On/Off )
Coriolis flow meter
5. Only for Coriolis:
Density area lower and upper value. The actual density must correspond to the
density display of the C-flow measuring transducer (with liquid in the system).
Correct the value here if necessary.
Temperature range lower and upper value. The actual temperature must
correspond to the temperature display of the C-flow measuring transducer
(with liquid in the system). Correct the value here if necessary.
6. Like page 4, but for component B.
7. For component B:
AIS (On/Off )
Mixing head valve with cycles If a mixing head valve is fitted: "On" = Mixing head
valve cycles. "Off " = B valve cycles.
Mixing head valve flushing
valve.
"On" = A flushing valve is attached to the mixing head
Input type for mixing ratio (A:B oder %B)
8. Like page 5, but for component B.
9.–11.
Like pages 6–8, but for component C.
12.–14. Like pages 6–8, but for component D.
15. Alarm delay for air bubbles monitoring How long can an air bubble be present
before the system stops ( alarms A114–A117).
Alarm delay no flow during filling How long can filling be interrupted before an
alarm occurs (alarm A124). If set to 0.0 seconds, the function is deactivated.
Alarm delay no flow during flushing How long can flushing be interrupted
before an alarm occurs (alarm A125)? When flushing, this alarm takes the place of
the pot life alarm. If the setting is "0.0 seconds", the function is deactivated, the pot
life continues and a pot life alarm occurs.
Alarm delay for Coriolis error (alarms A128–A131).
Remote control (On/Off )
Robot (no/digital/bus): "Digital" = Robot is digitally connected. "Bus" = Robot is
connected via gateway.
Timeout for automatic logout
If the touch panel is not activated during
the defined time, then the password level is automatically reset to level 0.
("0 sec" = no automatic logout.)
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16. Batch Mode
Allows a recurring and pre-defined quantity of product to be
discharged (see software documentation).
Measuring unit for pot life
changeovers!)
minutes or seconds. (Change recipes accordingly after
Booster pump (Off / A-side / Mix-side)
A valve selection at start "On": After starting, a prompt appears asking which
A valve is to be used for the selected recipe.
Number of tanks for filling level monitoring.
17. Pre-flushing after end flushing "On" = After an end flushing, a pre-flushing must
be undertaken. Prerequisite: Pre-flush recipe is defined and selected in the paint
recipes.
Pre-flushing after paint change flushing
"On" = A pre-flushing must be
undertaken after a recipe change flushing. Prerequisite: Pre-flush recipe is defined
and selected in the paint recipes.
Flush interruption ok?
"On" = Flushing process can be interrupted and e.g.,
the new paint filled. "Off " = The entire flushing process must be undertaken first. If
flushing is aborted, the process starts again afresh.
Air flushing valve (On/Off ) "On" = Air flushing is fitted.
External mixer (On/Off )
Flushing external mixer as standard "On" = The FLUSHING push-button starts
mixer flushing ("Mix") of the last paint recipe used. ( Flushing from external mixer)
"Off " = The FLUSHING push-button starts end flushing ("End") of the last paint recipe
used.
18. Number of automatic product pressure regulators (0 / 1 / number of guns).
"1" = Automatic product pressure regulator in front of splitter valve.
"Number of guns" = An automatic product pressure regulator is fitted for each gun.
Maximum product pressure for automatic product pressure regulator.
Pressure regulator fully open during flushing
For manual product pressure regulators: "On" = During flushing, the product
pressure regulator is subjected to full air pressure.
For automatic product pressure regulators: No function.
Pulse time at flush for prod.press reg.
For manual product pressure regulators, if the above function is switched on:
pulse time for changes between working pressure and full air pressure.
For automatic product pressure regulators: pulse time for changing between
flushing pressure (specified in recipe) and 0 bar.
"0.0 sec"= no cycling.
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19 Flow regulation (On/Off ).
P- (proportional-)part and I- (integral-)part of controller.
Number of flow measurements, which are included in the calculation.
Time period between the flow measurements.
20. Flow meter in external flushing agent (On/Off ).
Flow switch in external flushing agent (On/Off ).
Flushing monitoring in seconds (flushing with paint valves / flushing external mixer
/ gun flushing / dump flushing):
"no" = The flushing time runs, regardless of whether or not flushing agent flows.
"Gun monitoring" = Flushing time only runs when there is a gun signal.
Prerequisite: gun monitoring signal from flow monitor or robot, not from air
monitoring.
"Flow switch" = The flushing time only runs when there is a signal from the
flow switch. Prerequisite: "Flow switch in external flushing agent" is activated
(see above).
21. Password level 2 / 3
Password input for password level 2 / 3.
Reset initialization "OK" = When the system is switched on the next time, the
initialization program starts (e.g., for training purposes). The current settings are
preset, nothing is lost.
Start software update "OK" = A software update is executed. Special knowledge is
required for this purpose (observe separate manual).
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8
OPERATION
Below, operation with manual guns is described. For automatic guns the same workflow
applies correspondingly.
8.1
TRAINING THE OPERATING STAFF
The operating staff must be qualified and fit to operate the entire system.
The operating staff 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 staff must receive appropriate system training.
8.2
SAFETY INSTRUCTIONS
Observe the safety instructions in Chapter 4 and Chapter 7.2.
8.2.1
GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN
Observe spray gun operating manual.
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.
Use personal protective equipment (protective clothing, gloves,
eyewear and respiratory protection).
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8.3
SWITCHING THE SYSTEM ON AND OFF
Switching the system on
1. Turn red-yellow main switch on the right side of the control cabinet to ON.
The software is started.
2. Turn on the air supply of the system and of all feed pumps. Prepare feed pumps,
lacquer tank etc. for operation. Provide grounded metal bucket to collect the
products to be disposed of.
Switching off the system
1. Press the STOP push-button.
2. Flush system if necessary (see Chapter 8.7).
3. Make sure that the system has been flushed and that the pot life has been increased.
4. Relieve pressure from the system and from all feed pumps (see Chapter 8.9).
5. Switch off main switch (OFF).
6. Switch off air supply of system and pumps.
8.4
EMERGENCY STOP
In the case of unforeseen occurrences:
– Switch off main switch.
– Switch off air supply of system and pumps.
– Point the manual gun into a grounded metal bucket. Open the gun's trigger
mechanism step by step in order to relieve the pressure. Avoid splashback.
– Secure the gun.
– Provide appropriate return tanks and relieve pressure from the pumps via the return
valves.
– Inform the security personnel / foreman / superiors.
8.5
FAULTS
If a fault occurs, it is indicated by the following:
The system stops and the alarm horn sounds
The red STOP push-button lights up (control cabinet and remote control).
The fault is indicated on the screen.
Acknowledge fault
By means of the STOP push-button or, on the screen, with the [Reset] button.
Alarm messages + fault rectification
see Chapter 10.
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8.6
SPRAYING MODE
8.6.1
PREREQUISITES
Optimum painting results are obtained if:
- The system parameters are set correctly.
- Product data such as the mixing ratio and pot life correspond to the working material.
- The flushing program is defined.
- The supply pressures are constant.
- The A/B/C/D pressure ratio is set correctly (see Chapter 8.6.2).
- AIS is used.
Or without AIS: If the dosing valve (B side) is set using the valve stroke such that as
many cycles are undertaken as possible (depending on flow rate and mixing ratio every
0.5 - 2 seconds). See operating manual for valves (Order No. in Chapter 1.3.1).
- The product pumps can draw in the product perfectly and no cavitation occurs with
piston pumps (pump breaking through during down stroke). If necessary, the product
must be fed with a feed pump.
Optimum operation is fulfilled under the following conditions:
- When the flushing agent pressure for the flushing pumps as well as the product pressure
for the A, B and C pumps are always present on the device.
- When filling the mixed product in the product hose ensure that the nozzle is inserted
in the gun.
- When the flushing process is performed without the nozzle in the gun.
- When the levels in the product and flushing agent tanks are checked visually, in order to
prevent unintended interruptions in the spray process.
Prerequisites
- At the start, all pumps must be filled with working material and the system must be
ready to start, as described in Chapter 6.6.5.
- The nozzle is inserted into the gun. Gun secured.
- Operating manuals for the affected components must be known.
- With an electrostatic gun:
Commissioning the electrostatics according to corresponding operating manual.
8.6.2
PRESSURE RATIO A/B/C/D
- Set the pressure ratio between base lacquer and hardener correctly. With a mixer:
B must be approx. 5–10% higher than A. C approx. 2–5% higher than B, D approx. 2–5%
higher than C.
- The pressure drop between pressure gauge and mixer can be differently for A/B/C/D.
For longer distances, different flow rates and viscosities that may be relevant (e.g., for
external mixer or if the pressure gauges are at the pumps).
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8.6.3
SPRAYING WITHOUT GUN FLUSH BOX
Provide grounded metal bucket to collect the products to be disposed of.
Insert spray nozzle into manual gun.
The product pressure of the components is set depending on the required product flow
rate. Thereby, keep in mind that the the B-component pressure must be higher (5 to
10%) than that of the A-component.
Select the requested paint recipe on the screen (home page). In case of two spray guns,
select the requested gun(s).
Start the coating process by means of the START push-button.
Filling
For electrostatic spray guns: switch off electrostatics.
Point the manual gun with inserted spray nozzle into the grounded metal bucket. Open
the trigger mechanism of the spray gun step by step. Avoid splashback.
The 2K product starts to flow and the B-component is dosed proportionally to the
A-component. During filling, three screens in turn inform you of filling progress:
B_04637
B_04638
B_04639
From product valves to mixer.
From mixer to splitter valve.
From splitter valve to gun.
As soon as the complete high-pressure hose is filled with 2K product, the following will
happen:
the "Filling" screen switches to the home page.
The green START push-button begins to light up.
Remote control (Option): The green lamp begins to light up.
Atomizing air is added (option).
Correctly mixed product is not transported from the gun until after filling.
Coating
For electrostatic spray guns: safety precautions according to corresponding the
operating manual.
Start coating of an object.
The flushing agent pressure for A and B must always be applied at the device.
The flow rate of the system depends on:
the product pressure,
the hose lengths and cross-sections,
the nozzle and
the viscosity of the products.
Without AIS, the B pulse valve should operate every 0.5 to 3 seconds, according to the
flow rate. The switching frequency can be optimized by adjusting the pressure of the
hardener pump or through the stroke length of the hardener dosing valve. The higher
the pulse rate is, the more homogeneous is the mixing of the two components.
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8.6.4
SPRAYING WITH GUN FLUSH BOX
Same procedure as in Chapter 8.6.3, however:
before actuating the START push-button, insert the spray gun into the gun flush box.
Remove the spray gun after filling.
8.6.5
INTERRUPTING WORK
The STOP push-button stops the coating process. All product valves are closed.
For electrostatic spray guns: switch off electrostatics (see Chapter 12.5.4).
8.6.6
CHANGING THE PAINT RECIPE
The recipe change flush is executed on all spray guns while the spray nozzle is inserted.
Actuate the STOP push botton.
Select the new paint recipe on the screen (home page).
Without gun flush box
With gun flush box
– Press START push-button.
– Insert spray gun(s) in gun flush box.
The spray gun is automatically opened
as necessary.
– Point the spray gun into the metal
bucket. Open the gun step by step.
Avoid splashback.
– Press START push-button.
The system is flushed (recipe change flushing "
").
Subsequently the new lacquer is filled.
As soon as the green START push-button lights up and the home page appears on the
screen, the system is ready for spraying.
8.6.7
A VALVE SELECTION DURING START
Possibly, a list of the A valves appears for selection at the start. Touch desired valve.
The option is set with the setting "Select A valve during start" (see Chapter 7.13.2).
8.6.8
CIRCULATION (OPTION)
If necessary, the A, B or C-components not in use have to be circulated.
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8.7
FLUSHING
DANGER
Exploding gas / air mixture!
Danger to life from flying parts and burns.
Never spray into a closed tank.
Ground the tank.
If a high-pressure gun is used, remove the spray nozzle before flushing.
The pressure has to be relieved before removing the spray nozzle (see Chapter 8.9).
Wear protective goggles.
Apply the lowest possible product pressure for flushing so that the maximum flow rate
of the flow meter is not exceeded.
WARNING
High pressure spray jet!
Danger to life from injecting paint or solvent.
Never reach into the spray jet.
Never point the spray gun at people.
Consult a doctor immediately in the event of skin injuries caused
by paint or solvent. Inform the doctor about the paint or solvent
used.
Never seal defective high-pressure parts, instead relieve the
pressure from them and replace them.
Wear the appropriate protective clothing, gloves, eyewear and
respiratory protection.
The system has to be flushed:
in case of recipe change (recipe change flushing, system flushes automatically);
in case of extended interruption of work or end of work (end flushing);
if pot life has been exceeded (end flushing).
WARNING
Discharge of the electrostatics in atmospheres containing solvents!
Fire and explosion hazard.
Turn off the electrostatics before flushing the gun or before
placing the gun in the gun flush box.
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End flushing
The FLUSHING push-button normally starts the end flushing of the last paint recipe used.
1. Stopping the system.
2. For electrostatic spray guns: switch off electrostatics.
3.
Actuate FLUSHING push-button.
4. Point the opened gun(s), with or without nozzle, into a waste tank until the flushing
process has been terminated.
During flushing, the blue FLUSHING push-button lights up. The screen gives step by
step information about the individual flushing steps.
1
Current flushing recipe
Step
Flushing step 1 of 5
Flushing valve currently open
Progress indication
3
B_05236
Guns to open during this flushing step.
Gun symbol flashes Open gun.
Finally, all valves are closed.
If cleaning is insufficient, flushing can be repeated. The flushing recipe can be corrected
subsequently.
Flush with external mixer
Setting "Flush ext. mixer
is standard" -*
FLUSHING push-button
On
Starts the mixer flushing ("Mix") of last paint recipe used.
Flushing from external mixer.
Off
* see Chapter 7.13.2
Starts the end flushing ("End") of the last paint recipe used.
Atomizing air flushing
The system can be set such that the atomizing air remains switched on for flushing during
a certain time. Thus, the mixed product in the hose can be sprayed. A short flushing
pause indicates that the remainder has to be sprayed into the waste tank. (Settings see
Chapter 7.13.1.)
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Start other flushing recipes
For electrostatic spray guns: switch off electrostatics.
On the screen's home page.
Depending on the configuration, various selection possibilities appear:
- Manual flushing: select a recipe from the list of all recipes.
- Start end flushing: starts end flushing of the last paint recipe used.
- Start flushing external mixer: flushing from external mixer. The product hoses between
valves and mixer are not flushed.
- Flushing spray guns: flushing from splitter valve. The product hoses between valves
and splitter valve are not flushed.
Flushing with dump valve (option)
Flushing via a dump valve is quicker than via the gun. However, the gun has also to be
flushed briefly.
When the flushing process stops and the spray gun symbol on the screen flashes, the
corresponding guns have to be opened. Point opened gun(s) with or without nozzle
in a waste tank.
1
Step
As long as the gun symbol flashes,
open the corresponding spray gun
(here gun 2).
B_05236
2
As soon as the gun symbol stops flashing, close gun again.
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8.8
FLOW CHART WITH PAINT RECIPE CHANGE
Example for 2K system:
Spraying with paint recipe
Spraying with paint recipe
Recipe change flushing
Mixed
product
R-R Flushing
A
Filling
B
Filling
Filling of A and B up to
mixing block separately
1. Stop
2.
3. Start
A+B
Filling
Mixed
product
End flushing
1. Stop
2. End flushing
Filling the spray hose with mixed
products
Pre-flushing
Pre-flushing may be necessary between
R-R flushing and filling (see Chapter 7.11).
8.9
PRESSURE RELIEF
The system pressure must be manually relieved to prevent the system from starting or
spraying accidentally.
To reduce the risk of an injury from injection, splashing fluid or moving parts, follow the
steps in this chapter whenever:
you are instructed to relieve the pressure;
spraying is stopped;
part of the system is checked or maintained;
the nozzle is installed or cleaned.
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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.
Wear the appropriate protective clothing, gloves, eyewear and
respiratory protection.
Pressure relief procedure for the whole system
1. Press the STOP push-button.
2. Relieve the product pressure and air pressure in all pumps or pressure tanks. Use return /
circulation, according to the instructions in the corresponding operating manuals.
3. For electrostatic spray guns: switch off electrostatics.
4. Menu
(see Chapter 7.8)
One after the other and in each component (A, B, flush, ...) for each product valve
(A1, A2, ...):
- Select valve and open it with the large valve button.
- Point the manual gun into a grounded metal bucket. Open the gun's trigger
mechanism step by step in order to relieve the pressure. Avoid splashback.
- Close and secure gun.
5. Press the [STOP] button.
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9
CLEANING AND MAINTENANCE
9.1
CLEANING
9.1.1
CLEANING STAFF
Cleaning work should be undertaken regularly and carefully by qualified and trained staff.
They should be informed of specific hazards during their training.
The following hazards may arise during cleaning work:
- Health hazard from inhaling solvent vapors
- Use of unsuitable cleaning tools and aids
9.1.2
SAFETY INSTRUCTIONS
Use only a damp cloth to clean the device.
Observe safety instructions in Chapter 4.
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may
carry out repairs and replace parts.
Only repair and replace parts that are listed in the Chapter
"Spare parts" and that are assigned to the unit.
Before all work on the device and in the event of work interruptions:
- Relieve pressure from spray guns and devices.
- Secure spray guns against actuation.
- Switch off the energy/compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating manual and service manuals at all times
when carrying out work.
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9.1.3
FILTER CLEANING
Product filter: Check and clean filter insert and filter housing. When opening the filter,
ensure that no product drips on the flow meter's electronics.
The filters of the piston pumps and guns should be cleaned in accordance with the
corresponding operating manuals.
9.1.3.1
CONDENSATE DRAINAGE FROM THE FILTER PRESSURE REGULATOR
Frequently drain the condensate that may accumulate in the air filter.
Make sure the water level in the filter cup never reaches the max. level marked on
the cup itself.
WARNING
Brittle filter pressure regulator!
The tank on the filter pressure regulator becomes brittle through
contact with solvents and can burst.
Flying parts can cause injury.
Do not clean the tank on the filter pressure regulator with solvents.
9.1.4
CLEANING THE SYSTEM
The system should be cleaned for maintenance purposes. Ensure that no remaining
product dries on and sticks to the device.
A cleaned system enables simple localization of any leaks and quick repairs.
Procedure:
1. Relieve the pressure according to Chapter 8.9.
3. Service guns and pumps according to their operating manuals.
4. Clean and check the suction systems and suction filter.
5. Product filter: Check and clean filter insert and filter housing.
6. Put the whole system back together.
7. Clean the outside of the system.
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9.1.5
DECOMMISSIONING
1. Clean the system according to Chapter 9.1.4.
2. Fill the entire system with flushing agent. As defined in Chapter 6.6.5 but with
flushing agent.
WARNING
Gas mixtures can explode if there is an incompletely filled pump!
Danger to life from flying parts.
Ensure that the pump and suction system are always completely
filled with flushing agent or working medium.
Do not spray the device empty after cleaning.
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:
1. Clean the system according to Chapter 9.1.4.
2. Fill the entire system with flushing agent. As defined in Chapter 6.6.5 but with
flushing agent.
3. Fill the entire system with preservative according to Chapter 6.6.5 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.
6. Storage according to Chapter 6.2.
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9.2
MAINTENANCE
9.2.1
MAINTENANCE STAFF
Maintenance work should be undertaken regularly and carefully by qualified and trained
staff. They should be informed of specific hazards during their training.
The following hazards may arise during maintenance work:
- Health hazard from inhaling solvent vapors
- Use of unsuitable tools and aids
An authorized person must ensure that the device is checked for being in a reliable state
after maintenance work is completed.
9.2.2
SAFETY INSTRUCTIONS
Observe the safety instructions in Chapter 4 and Chapter 9.1.2.
Prior to maintenance
It should be ensured that the device is in the following state before carrying out any work
on it:
- Cleaning and flushing the device Chapter 9.1.4.
- Relieve the pressure from pumps, high-pressure hoses, and spray guns.
- The guns should be secured with the safety clip.
- The air supply should be interrupted.
After maintenance
- Put the system into operation and check for leaks.
Chapter 6.6.
According DGUV regulation 100-500:
- 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.
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 qualified
personnel.
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9.2.3
GEAR FLOW METER
The gear flow meters (A/B/C/D) are cleaned by flushing.
If individual parts have to be cleaned, the flow meter should be disassembled.
Care should be taken that these parts are installed again in their original positions.
5
3
12
7
2
5
1
11
10
B_04655
1. Remove the electronic sensor (1) from the flow meter.
– The electric sensor can be removed by loosening the two screws (10) from the
holes without removing the cover (11).
2. Unscrew the screws (2) - two opposite screws should be left, temporarily screwed in
by two turns.
3. Carefully take the lid (3) off the flow meter parallelly.
– If necessary, softly knock on the lid with a plastic hammer so that it loosens.
– The lid must be removed parallelly so that the internal bearings are not stressed
and the shaft (5) does not break.
– For this reason do not use screwdrivers as levers.
4. Remove the screws which had previously been left screwed in.
5. Remove the lid, the gears (7) and the shafts (5).
– In most cases a dirt particle in the flow meter causes the problem.
– If the parts cannot be disassembled easily, put the flow meter into a suitable solvent
and then disassemble the parts.
– Do not disassemble the parts by force!
– It is important that the gears turn on the shaft, if they don't, the flow meter is not
suitable for the lacquer.
Contact WAGNER Service for further information.
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Assembly:
After cleaning the gear flow meter and assembling the shafts and gears into the housing,
check whether they turn easily, without any obstruction. This has to be the case even when
a finger slightly presses against the shafts laterally.
1. Mount the lid again in parallel position and adjust it in the correct position by means
of both dowel pins (12).
These pins must never be removed from the flow meter housing.
2. Tighten the screws with 15 Nm; 11.06 lb/ft.
3. Check if the gears turn by using a short pulse of compressed air, maximum 0.1 MPa;
1 bar; 14.5 psi.
4. Mount the electronic sensor again. Do not interchange A/B/C flow meters.
9.2.4
PRODUCT VALVES
Check the leakage behavior of the product valves (air or product discharge from the
leakage hole) in regular intervals (once per week).
In case of air leakage: change rod sealing.
In case of product discharge:
– 2.6 mm valve: Re-tighten sealing screw or change the seals.
– 4 mm valve: Change the seals.
Check the leakage behavior of the valve seats at regular intervals, by executing a
pressure retention test in accordance with Chapter 6.7.4.
Disassembly and assembly, see valve operating manual (Order No. in Chapter 1.3.1).
Example 2.6 mm valve
Leakage hole
Rod seal
(pneumatic O-ring)
Product sealings
Sealing screw
B_04679
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9.2.5
PRODUCT HOSES, TUBES AND COUPLINGS
DANGER
Bursting hose, bursting threaded joints!
Danger to life from injection of product and from flying parts.
Ensure that the hose material is chemically resistant to the
sprayed products and the used flushing agents.
Ensure that the spray gun, threaded joints, and product hose
between the device and the spray gun are suitable for the
generated pressure.
Ensure that the following information can be seen on the hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture.
The service life of the complete hoses between product pressure generator and application
device is reduced due to environmental influences even when handled correctly.
Check hoses, pipes, and couplings every day and replace if necessary.
Before every commissioning, check all connections for leaks.
Additionally, the operator must regularly check the complete hoses for wear and tear
as well as for damage at intervals that he/she has set. Records of these checks must
be kept.
Undamaged complete hoses are to be replaced when one of the two following
intervals has been exceeded:
– 6 years from the date of the hose crimping (see fitting embossing).
– 10 years from the date of the hose imprinting.
Fitting
embossing
(if present)
Hose imprinting
Meaning
Meaning
WAGNER
Name/Manufacturer
xxx bar
Pressure
yymm
Date of manufacture
(year/month)
yymm
Crimping date
(year/month)
xxx bar (xx MPa)
Pressure
e.g., 270 bar (27 MPa)
XX
Internal code
XX
Internal code
DNxx (e.g., DN10)
Nominal diameter
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10 TROUBLESHOOTING
If a fault occurs, it is indicated by the following:
The system stops.
The alarm horn sounds.
Control cabinet: The red STOP push-button lights up.
The fault is indicated on the screen.
Remote control (option): The red LED STOP lights up.
Acknowledge fault
Stop with the STOP push-button.
Or by means of the [Reset] push-button on the screen.
List of alarm messages and warning messages
See Chapter 10.
Fault rectification
See the following table and Chapters 10.1.1 and 10.2.1.
For troubleshooting, it is important which work steps were last carried out.
The troubleshooting within the electric cabinet should be carried out by qualified
persons (e.g., industrial electrician)!
WARNING
Electric shock hazard inside the control unit!
Danger to life from electric shock.
May only be installed/maintained by skilled electricians or
under their supervision.
Operation according to the safety regulations, fire protection
and electrotechnical rules.
Must be de-energized before work is commenced on active
parts.
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Malfunction
System does not start up
System is in operation
(a pump is running), but
there is no product flow
System does not supply
any product, pumps do
not run
The 2K product does not
react correctly
Flow rate is too low
Lacquer loss from the
bleed bore of a product
valve
Interruption of circuit
over a longer period of
time
A fuse is defective.
LED lights up
Remedy
Check air supply line connection.
Check the pressure value on the system's pressure gauge for the air supply to
the valves.
Check the voltage supply (does the control panel light up?)
Check the selected valves.
Check the fuses.
Check the supply lines of the components as well as filters (clogging) and
suction tubes (leakage).
Check the component level in the supply tanks.
Check the viscosity of the components or the pressure loss.
Check the mixing tube and feed hoses.
Check the guns and the gun filter.
Clean the lines by flushing or cleaning manually.
Check the mixing ratio value.
Check the suction lines (leakage).
Check the flow meter with a calibration process.
Check pressure differences. See Chapter 8.6.2
Check AIS function (see software documentation, "Diagnosis" chapter).
Without AIS: Optimize the switching behavior of the hardener dosing valve in
spraying mode (0.5 - 3 seconds) via the differential pressure of B to A or via the
stroke setting of the valve.
Check the lacquer specifications.
Check the mixing tube and feed hoses.
Check the guns and the gun filter.
Clean the lines by flushing or cleaning manually.
Increase the pressure of the supply pumps.
Replace the valve needle seal, check the valve needle and housing for damage
and if necessary replace the entire valve.
With external compressed air, manually open the flushing valve and distributor
valve (option).
- Check on the basis of the control cabinet diagram whether a cable is damaged.
Replace the fuse.
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Malfunction
The system supplies
product, but the spray
pattern is inadequate
Flow rate is too high
Remedy
Ensure that the supply pressures are constant.
Adjust the A/B/C/D pressure ratio. See Chapter 8.6.2
Increase the pressure of the supply pumps.
AirCoat: Set the atomizing air correctly.
Check product filter on pumps, 2K systems and guns.
Replace gun nozzle with a more suitable nozzle (Airless and AirCoat).
Check the viscosity of the product and dilute it in accordance with the lacquer
manufacturer's instructions. If necessary correct the mixing ratio.
AirCoat: Ensure that only dry, clean atomizing air is used in the spray gun.
Replace gun nozzle (Airless and AirCoat).
Check the lines for leakage.
Set the opening of the gun needle correctly (air guns only).
Decrease the pressure of the supply pumps.
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10.1
ALARM MESSAGES
In the case of an alarm message, the system stops. The alarm horn sounds.
The red STOP push-button lights up (control cabinet and remote control).
The fault is indicated on the screen.
Alarm No. Alarm message in the
display
A100
B+ tol. Alarm
A101
C+ tol. Alarm
A102
D+ tol. Alarm
A103
B– tol. Alarm
A104
C– tol. Alarm
A105
D– tol. Alarm
A106
A+ flow rate
A107
B+ flow rate
A108
C+ flow rate
A109
D+ flow rate
A110
A– flow rate
A111
B– flow rate
A112
C– flow rate
A113
D+ flow rate
A114
Air bubble A
A115
Air bubble B
A116
Air bubble C
A117
Air bubble D
A118
Flow meter A
A119
Gun monitoring
A120
No enabling signal
A121
Flow fault –
A122
Flow fault +
A123
Flushing first
A124
No flow during filling
A125
No flow during flushing
A126
Gun monitoring disabled
A127
K factor is 0!
Meaning
Mixing ratio outside of tolerance range. B+/C+/D+:
too much B/C/D.
Mixing ratio outside of tolerance range. B–/C–/D–:
too little B/C/D.
Maximum flow of components A/B/C/D exceeded.
Falls below minimum flow of components A/B/C/D.
Air bubble in the line (only with low-pressure).
Flow meter A is blocked.
No gun signal, although product is flowing.
External release missing.
The flow rate is below the limit entered in the paint recipe.
The flow rate is above the limit entered in the paint recipe.
The system has to be flushed.
The filling procedure is interrupted for too long.
The flushing procedure is interrupted for too long.
Function is selected, which requires gun monitoring. However, the
gun monitoring is deactivated.
A K factor for the current paint recipe is zero. Calibrate.
Acknowledge alarm: By means of the STOP push-button or on the screen with the [Reset] button.
Fault rectification: see Chapter 10.1.1
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Alarm No. Alarm message in the
display
A128
Coriolis A
A129
Coriolis B
A130
Coriolis C
A131
Coriolis D
A132
Pot life gun 1
A133
Pot life gun 2
A134
Pot life gun 3
A135
Pot life gun 4
A136
Pot life gun hose 1
A137
Pot life gun hose 2
A138
Pot life gun hose 3
A139
Pot life gun hose 4
A140
Pot life to spl. valve
A141
A142
A143
A144
A145
A146
A147
A148
A149
A150
A151
Pot life dump hose 1
Pot life dump hose 2
Pot life dump hose 3
Pot life dump hose 4
Tank A is empty
Tank B is empty
Tank C is empty
Tank D is empty
Tank flushing agent is empty
Flow is too low
Flow is too high
Meaning
For Coriolis error, see operating manual of Coriolis flow meter.
Pot life + post-alarm time of guns 1/2/3/4 have expired.
Pot life + post-alarm time of gun hoses 1/2/3/4 have expired.
The pot life + post-alarm time from mixer to splitter valve have
expired.
Pot life + post-alarm time of dump hoses 1/2/3/4 have expired.
Tank for component A/B/C/D is empty.
Flushing agent tank is empty.
The setpoint flow is not reached with the flow regulation.
The setpoint flow is not reached with the flow regulation.
Acknowledge alarm: By means of the STOP push-button or on the screen with the [Reset] button.
Fault rectification: see Chapter 10.1.1
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CAN I/O modules alarm messages
Alarm No. Alarm message in the display
A500
Initialisation error
A501
CAN master error
A502
CAN master alone
A503
A504
A505
A600
A601
A602
A603
A604
A606
A607
A608
A609
A610
A612
A613
A614
A615
SDO sending error
SDO receive error
Saving interrupted
Module D2 no communication
Module D3 no communication
Module D4 no communication
Module D5 no communication
Gateway D6 no communication
Module D2 CAN emergency
Module D3 CAN emergency
Module D4 CAN emergency
Module D5 CAN emergency
Gateway D6 CAN emergency
Module D2 CAN error
Module D3 CAN error
Module D4 CAN error
Module D5 CAN error
Meaning
Internal error when starting up the touch panel.
The touch panel CAN master process not possible.
The touch panel CAN master found no connected
slaves on the CAN bus.
Error while sending or receiving SDO telegrams.
Error while saving on the PC
No communication to the corresponding module.
Module sends an emergency telegram.
Slave reports communication problems.
Acknowledge alarm: By means of the STOP push-button or on the screen with the [Reset] button.
Fault rectification: see Chapter 10.1.1
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Alarm No.
A616
A617
A618
A619
A620
A621
A622
A623
A624
A625
A626
A627
A628
A629
A630
A631
A632
A633
A634
A635
A640
A641
A642
A643
A644
A645
A646
A647
A648
A649
A650
A651
A652
A653
A654
A655
Alarm message in the display
Module D2 hardware error EEPROM
Module D3 hardware error EEPROM
Module D4 hardware error EEPROM
Module D5 hardware error EEPROM
Module D2 hardware error ADC
Module D3 hardware error ADC
Module D4 hardware error ADC
Module D5 hardware error ADC
Module D2 hardware errror TIMER
Module D3 hardware errror TIMER
Module D4 hardware errror TIMER
Module D5 hardware errror TIMER
Module D2 unknown hardware error
Module D3 unknown hardware error
Module D4 unknown hardware error
Module D5 unknown hardware error
Module D2 hardware error counter
Module D3 hardware error counter
Module D4 hardware error counter
Module D5 hardware error counter
Module D2 DO group1
Module D2 DO group2
Module D2 DO group3
Module D2 DO group4
Module D3 DO group1
Module D3 DO group2
Module D3 DO group3
Module D3 DO group4
Module D4 DO group1
Module D4 DO group2
Module D4 DO group3
Module D4 DO group4
Module D5 DO group1
Module D5 DO group2
Module D5 DO group3
Module D5 DO group4
Meaning
Hardware error in I/O module.
Voltage supply error.
Acknowledge alarm: By means of the STOP push-button or on the screen with the [Reset] button.
Fault rectification: see Chapter 10.1.1
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10.1.1
FAULT RECTIFICATION
A100/A101/A102 B+/C+/D+ tol. Alarm
The mixing ratio within a specific control quantity (QB/QC/QD control) was not reached:
too much B, C or D.
- Reduce pressure of B/C/D: see Chapter 8.6.2
- Without AIS:
- The stroke at the B/C/D valve is too long. Close the regulating screw a little.
- Check the cycle length of the hardener dosing valve (menu
diagnosis). 0.5 to
3 seconds are optimal. If the cycle length is too long, then the difference in pressure is
still too great or the stroke is too long.
- With AIS:
- If the stroke of the B/C/D valve is far from its ideal position, the adjustment can take a
long time under some circumstances. Home page: [AIS], then reduce the AIS position
a bit.
- Check whether valve closes. Clean valve.
- The flow meter A is blocked by soiling. The LED at the flow meter has to light up during
product flow, otherwise it is clogged (cleaning, see Chapter 9.2.3).
- Check whether nozzles, mixer or filter are clogged.
- Check the level of the paint tank, condition of the feed pumps, etc.
- The QB/QC/QD control quantity may be set too low (standard 150 cc). If the quantity is
increased, the control algorithm becomes more stable because more time is available in
order to achieve the mixing ratio.
A103/A104/A105 B–/C–/D– tol. Alarm
The mixing ratio within a specific control quantity (QB/QC/QD control) was not reached:
too little B, C or D.
- Increase the pressure of B/C/D: see Chapter 8.6.2
- Without AIS:
- The stroke at the B/C/D valve is too short. Open the regulating screw a little.
- Check the cycle length of the hardener dosing valve (menu diagnosis). 0.5 to 3 seconds
are optimal. If the valve is always open (cycle check display is almost continuously lit),
then the difference in pressure is still too small or the stroke is too short.
- With AIS:
- If the stroke of the B/C/D valve is far from its ideal position, the adjustment can take
a long time under some circumstances. Home page: [AIS], then enlarge the AIS
position a bit.
- Check whether the valve opens. Clean valve.
- The flow meter B or C or D is blocked by soiling. The LED at the flow meter has to light up
during product flow, otherwise it is clogged (cleaning, see Chapter 9.2.3).
- Check whether nozzles, mixer or filter are clogged.
- Check the level of the paint tank, condition of the feed pumps, etc.
- The QB/QC/QD control quantity may be set too low (standard 150 cc). If the quantity is
increased, the control algorithm becomes more stable because more time is available in
order to achieve the mixing ratio.
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A106/A107/A108/A109 A+/B+/C+/D+ flow rate
The flow is greater than the upper limit of the flow meter "Maximum flow" (see Chapter 7.13.2,
level 3, page 4).
- The flow rate has to be reduced.
- Insert nozzle.
- Possibly worn nozzle, leaking hose or other leaking parts.
A110/A111/A112/A113 A–/B–/C–/D– flow rate
Gun monitoring signal is present, even though no product is flowing (gun closed).
- Check the atomizing air for leaks.
- Check whether the gun monitoring operates correctly.
- Possibly, the "Gun delay" is set too short (see Chapter 7.13.1).
- The alarm can occur if the atomizing air continues to flow from the gun during short
spray breaks. Release the gun trigger completely or increase the gun delay time.
- The A/B/C/D-component flow is less than the lower limit "Minimum flow" (see Chapter 7.13.2,
level 3, page 4).
- Clean flow meters.
- Possible further causes such as for alarm A100…A105.
A114/A115/A116/A117 Air bubble A/B/C/D
Air bubble in the line (only with low-pressure). Fill product tank.
A118
Flow meter A
The flow meter A is blocked by soiling. The LED at the flow meter has to light up during
product flow, otherwise it is clogged (cleaning, see Chapter 9.2.3).
A119
Gun monitoring
Product flows through the A flow meter and for 50 seconds, there is no signal indicating
that the gun is open.
- This means that the gun monitoring is defective or that there is no contact.
- Repair or replace the gun monitoring.
A120
No enabling signal
External release missing (booth ventilation etc.)
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A121
Flow fault –
The flow rate is below the limit entered in the paint recipe (see Chapter 7.11).
- Check the mixing tube and feed hoses.
- Check the guns and the gun filter.
- Clean the lines by flushing or cleaning manually.
- Increase the pressure of the supply pumps.
A122
Flow fault +
The flow rate is above the limit entered in the paint recipe (see Chapter 7.11).
- Replace gun nozzle (Airless and AirCoat).
- Check the lines for leakage.
- Set the opening of the gun needle correctly (air guns only).
- Decrease the pressure of the supply pumps.
A123
Flushing first
The system has to be flushed.
The "Mixing alarm flushing" or "Pot life alarm
life alarm has occurred.
flushing" is activated and a mixing or pot
A124
No flow during filling
The filling procedure is interrupted for too long (longer than the "Alarm delay no flow
during filling" setting).
- Possibly, the filling procedure is waiting for the gun to be opened:
- With gun flush box: check whether the gun is inserted correctly.
- Without gun flush box: point spray gun into waste tank and open it.
- Check dump valve: Clogging, function.
A125
No flow during flushing
The flushing procedure is interrupted for too long (longer than the "Alarm delay no flow
during flushing" setting).
- Possibly, the flushing procedure is waiting for the gun to be opened:
- With gun flush box: check whether the gun is inserted correctly.
- Without gun flush box: point spray gun into waste tank and open it.
- Check dump valve: Clogging, function.
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A126
Gun monitoring deactivated
Function is selected, which requires gun monitoring. However, the gun monitoring is deactivated.
Activate the gun monitoring or deactivate the relevant function.
Functions which require gun monitoring:
- Flow monitoring (settings password level 3).
- Spray gun closed valves closed (settings password level 3).
- Dump valve as return line (settings password level 3).
A127
K factor is 0!
The new K factor "Kn" is 0 and can therefore not be saved.
A128/A129/A130/A131 Coriolis A/B/C/D
For Coriolis error, see operating manual of Coriolis flow meter.
A132/A133/A134/A135 Pot life gun 1/2/3/4
Pot life + post-alarm time have expired. Continue working immediately or flush.
A136/A137/A138/A139 Pot life gun hose 1/2/3/4
Pot life + post-alarm time have expired. Continue working immediately or flush.
A140
Pot life up to splitter valve
Pot life + post-alarm time have expired. Continue working immediately or flush.
A141/A142/A143/A144 Pot life dump hose 1/2/3/4
Pot life + post-alarm time in dump hose have expired. Close the gun until the dump hose
is filled with freshly mixed product. Or, flush the system.
A145/A146/A147/A148 Tank A/B/C/D is empty
A149
Tank flushing agent is empty
Flow rate drops below the alarm limit. Fill up tank.
A150
Flow is too low
Even though the product pressure regulator is fully open, the setpoint flow is not reached.
- Check air pressure.
- Check product pressure.
- Check product pressure regulator.
- Check the control of the product pressure regulator (Electric/Pneumatic converter).
A151
Flow is too high
Even though the product pressure regulator is fully closed, the actual flow exceeds the
setpoint flow.
- Check product pressure regulator.
- Check the control of the product pressure regulator (Electric/Pneumatic converter).
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A500
Initialisation error
Internal error when starting up the touch panel.
- Switch the system off and back on via the main switch.
- Contact the Service Team.
A501
CAN master error
The touch panel CAN master process not possible.
- Switch the system off and back on via the main switch.
- Contact the Service Team.
A502
CAN master alone
The touch panel CAN master found no connected slaves on the CAN bus.
- Check the connected modules: voltage supply, CAN cable, address, baud rate and
terminating resistor. See spare parts catalog, "I/O modules" chapter.
- Switch the system off and back on via the main switch.
- Contact the Service Team.
A503
SDO sending error
A504
SDO receiving error
Error while sending or receiving SDO telegrams.
- Switch the system off and back on via the main switch.
- Contact the Service Team.
A505
Saving interrupted
An error occured while saving on the PC.
- Check the archiving software on the PC
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A600/A601/A602/A603
Module D2/D3/D4/D5 no communication
A604
Gateway D6 no communication
Slave is not responding.
- Check corresponding module: voltage supply, CAN cable, address, baud rate and
terminating resistor.
- Switch the system off and back on via the main switch.
- Contact the Service Team.
A606/A607/A608/A609
Module D2/D3/D4/D5 CAN emergency
A610
Gateway D6 CAN emergency
Corresponding module sends an emergency telegram.
- Switch the system off and back on via the main switch.
- Contact the Service Team.
A612/A613/A614/A615
Module D2/D3/D4/D5 CAN error
Corresponding slave reports communication problems.
- Switch the system off and back on via the main switch.
- Contact the Service Team.
A616/A617/A618/A619
Module D2/D3/D4/D5 hardware error EEPROM
A620/A621/A622/A623
Module D2/D3/D4/D5 hardware error ADC
A624/A625/A626/A627
Module D2/D3/D4/D5 hardware error TIMER
A628/A629/A630/A631
Module D2/D3/D4/D5 unknown hardware error
A632/A633/A634/A635
Module D2/D3/D4/D5 hardware error counter
Corresponding module reports a hardware error.
- Switch the system off and back on via the main switch.
- Contact the Service Team.
A640–A655
Module D2/D3/D4/D5 DO group 1/2/3/4
I/O module reports insufficient voltage supply at the respective output group.
(DO = Digital Output)
- Check the voltage supply of the respective output group.
- Check the fuse of the respective output group.
See spare parts catalog, "I/O modules" chapter.
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10.2
WARNING MESSAGES
In the case of warning messages, the system does not stop, work can be continued.
The red STOP push-button blinks (control cabinet and remote control).
The fault is indicated on the screen.
Alarm No. Warning message on the
display
W100
1st pot life gun 1
W101
1st pot life gun 2
W102
1st pot life gun 3
W103
1st pot life gun 4
W104
1st pot life gun hose 1
W105
1st pot life gun hose 2
W106
1st pot life gun hose 3
W107
1st pot life gun hose 4
W108
1st pot life to spl.valve
W109
1st pot life dump hose 1
W110
1st pot life dump hose 2
W111
1st pot life dump hose 3
W112
1st pot life dump hose 4
W113
A flow meter service
W114
B flow meter service
W115
C flow meter service
W116
D flow meter service
W117
B valve service
W118
C valve service
W119
D valve service
W120
Mix Head B service
W121
Mix Head C service
W122
Mix Head D service
W123
AIS-B
W124
AIS-C
W125
AIS-D
W126
Tank A limit
W127
Tank B limit
W128
Tank C limit
W129
Tank D limit
W130
Tank flushing agent limit
W500
USB memory
W501
USB storage
Fault rectification
Meaning
Pre-alarm for the pot life of gun 1/2/3/4
Pre-alarm for the pot life of gun hose 1/2/3/4
Pre-alarm for pot life from mixer to splitter valve
Pre-alarm for the pot life of dump hose 1/2/3/4
Carry out service for flow meter A/B/C/D
Carry out service for dosing valve B/C/D
Carry out service for mixing head valve B/C/D
AIS-B/C/D Fell short of warning limit (injection quality in %)
No USB stick used or too little memory
Automatic job total saving: Saving did not work
see Chapter 10.2.1
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10.2.1
FAULT RECTIFICATION
W100/W101/W102/W103
Pre-alarm for the pot life of gun 1/2/3/4
Pot life has expired. Continue working immediately or flush.
W104/W105/W106/W107
Pre-alarm for pot life gun hose 1/2/3/4
Pot life has expired. Continue working immediately or flush.
W108
Pre-alarm for pot life from mixer to splitter valve
Pot life has expired. Continue working immediately or flush.
W109/W110/W111/W112
Pre-alarm for pot life dump hose 1/2/3/4
The pot life in the dump hose has expired. Close the gun until the dump hose is filled with
freshly mixed product. Or, flush the system.
W113/W114/W115/W116
A/B/C/D flow meter service
The maximum flow rate indicated in the [service] [menu] was reached.
The corresponding flow meter needs servicing.
W117/W118/W119
B/C/D valve service
The maximum switching cycle indicated in the [service]
The corresponding dosing valve needs servicing.
[menu] was reached.
W120/W121/W122
Mix Head B/C/D service
The maximum switching cycle indicated in the [service] [menu] was reached.
The corresponding mixing head valve needs servicing.
W123/W124/W125
AIS-B / AIS-C / AIS-D
AIS below the warning limit (minimum opening time of the dosing valve in percent).
- If the stroke of the dosing valve is far from its ideal position, the adjustment can take a
long time under some circumstances. Home page: [AIS], then reduce the "AIS position"
a bit.
- Reduce pressure of B/C/D: see Chapter 8.6.2
- Check whether valve closes. Clean valve.
- The flow meter A is blocked by soiling. The LED at the flow meter has to light up during
product flow, otherwise it is clogged (cleaning, see Chapter 9.2.3).
- Check whether nozzles, mixer or filter are clogged.
- Check the level of the paint tank, condition of the feed pumps, etc.
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W126/W127/W128/W129 Tank A/B/C/D limit
W130
Tank flushing agent limit
Flow rate drops below the warning limit. Fill up tank.
W500
USB memory
No USB stick used or too little memory. Try removing the USB stick and plugging it back in
or plug in another USB stick.
W501
USB storage
Automatic job total saving: Saving did not work.
11 DISPOSAL
When the equipment must be scrapped, please differentiate the disposal of the waste
materials.
The following materials have been used:
Steel
Aluminum
Elastomerics
Plastics
Carbide
NOTICE
Do not dispose of used electrical equipment with household
refuse!
In accordance with European Directive 2002/96/EC on the disposal
of used electrical equipment and its implementation in national
law, this product may not be disposed of with the household refuse,
but must be recycled in an environmentally correct manner.
WAGNER or one of our dealers will take back your used WAGNER
electric or electronic equipment and will dispose of it for you in an
environmentally-friendly way. Please contact one of our service
points, one of our representatives or us directly to arrange this.
Consumable products
Consumable products (lacquers, adhesives, flushing and cleaning agents) must be
disposed of in accordance with all applicable legal requirements.
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12 ACCESSORIES
The system is ordered and supplied including all desired accessories.
It is possible for a WAGNER technician to install extensions and accessories later on, e.g.,
paint extension, gun monitoring, air bubble monitoring etc.
12.1
CONNECTIONS
There are five types of connectors:
Digital outputs Digital inputs High-speed counters Analog outputs Analog inputs
Before the installation of an accessory set, it must be checked whether enough room in the
fluid cabinet and enough connections in the control cabinet are available:
1. Open on the 2K COMFORT USB stick (see Chapter 1.4) the assembly manual of the
required set.
2. Check based of the assembly manual, whether enough room is available in the fluid
cabinet.
3. For number and type of the required connectors please look into the assembly manual.
4. Check whether sufficient free connections are present in the control cabinet:
- Either in the 2K COMFORT connection table: each sufficient free lines must be present
of the required connection types (see Chapter 12.2).
- Or in the controller: password level 3 "Menu" "I/O Config"
(see software documentation).
12.1.1
I/O EXTENSION MODULE
If too few connections are available, an "CAN I/O extension module set" can be installed by
a WAGNER technician. This includes:
- 16 digital outputs
- 8 digital inputs
- 2 high-speed counters
- 2 analog outputs
- 4 analog inputs
A maximum of total 4 I/O modules can be installed in the control cabinet.
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12.2
2K COMFORT CONNECTION TABLE
The "2K COMFORT connection table" is delivered together with the system and must be
adapted for each conversion. It is available on the USB stick (see Chapter 1.4).
The table is divided into five sections:
…
Q1 Ready
… …
D2
Name
Q12
… …
Digital outputs
Connection
GND
signal
connection
X3:1C/D
-…
…
D2:X2_14
…
Cable
No.
10
…
D2:X2_4
…
Solenoid
Fluid valve
Hose No.
valve
element
--L1
…
…
…
-…
-…
-…
-…
Digital inputs
…
Name
I1
…
Start
…
Connection signal
Cable No.
Hose No.
X2:1B/C
…
30;501
…
-…
Fluid valve
element
S2;RC;Robo
…
High-speed counters
…
Name
Connection signal
Cable No.
X2:19B/C
…
-…
C1 -… …
Fluid valve
element
-…
Analog outputs
…
Name
AO1 -… …
D2:X4_17
…
Name
…
Connection signal
AI1 -… …
Assignment in the controller
(touch panel)
Analog inputs
Connection signal
D2:X4_1
…
Connection in the control
cabinet
Cable
No.
10
…
EP valve Hose No.
-…
Cable No.
-…
-…
Fluid valve
element
-…
Fluid valve element
-…
Valve name in the circuit
diagram
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The connection table enables:
The recognition of free connections. Example: in the "Name" column of the "Digital
outputs" section 3 fields are empty 3 digital outputs are free.
The assignment of the names in the controller (e.g., D2 module, Q12 conneciton)
with the I/O modules connections in the control cabinet (e.g., D2:X2_14 connection).
Example
Accesory "Set 1" requires a digital output. The Q12 output in the D2 module is still free and
"Set 1" is connected there. The D2:X2_14 connection is assigned to this output.
Call up the digital outputs:
"Output" in the controller ("Menu"
"I/O Config").
Then scroll to the "D2" module with the arrow keys . Assign there to the "Q12" output
the accessory function "Set 1" (according to the assembly manual).
Connect the accessory "Set 1" in the control cabinet to the D2:X2_14 terminal (according
to the assembly manual).
12.3
EXPANSION AND ACCESSORY SETS
Functional descriptions
The descriptions of the expansion and accessory sets can be found in the corresponding
assembly manuals on the USB stick (Order No. see Chapter 1.4).
Installation
Have expansion and accessory sets be installed only by specially trained staff or a
WAGNER service center.
Carry out each installation according to the corresponding assembly manual.
Installation in an ex-proof system
Installation in WAGNER devices, protective systems, safety, control and regulation fixtures
in the sense of the 94/9/EC Directive (ATEX) may only be undertaken by trained WAGNER
service staff or persons qualified in accordance with TRBS 1203 (2010).
Observe TRBS 1201 Parts 1 and 3, Plant Safety Ordinance (BetrSichV.).
National regulations should also be noted.
Electric shock hazard inside the control unit!
Most accessory sets require conversions in the control cabinet.
May only be installed/maintained by skilled electricians or under their supervision.
Operation according to the safety regulations, fire protection and electrotechnical rules.
Must be de-energized before work is commenced on active parts.
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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, fire protection
and electrotechnical rules.
Must be de-energized before work is commenced on active
parts.
12.3.1
INSTALLATION BY CUSTIOMER OR BY WAGNER SERVICE DEPARTMENT
Expansion and accessory sets
Order No. Name
Ex
NonHighLowEx pressure pressure
2358991
Valve set paint/flush, high-pressure DN 2.6
(for 1–2 A-components)
x
x
x
--
2358992
Valve set paint/flush, low-pressure DN 4
(for 1–2 A-components)
x
x
--
x
2362624
Valve set supplement for air flushing (A-component)
x
x
--
x
2358994
Valve set dosing/flushing DN 2.6, 400 bar TC, non-Ex
(for 1–2 B/C/D-components, if component is already
present. Valve seat of carbide)
--
x
x
x
2358995
Valve set dosing/flushing DN 2.6, 400 bar SSt, non-Ex
(for 1–2 B/C/D-components, if component is already
present. Valve seat of stainless steel)
--
x
x
x
Valve set flushing Ex, for 1–2 B/C/D-components:
Use one of the above two sets 2358994 or 2358995.
For flushing these sets are also suitable for use in
potentially explosive areas.
x
--
x
x
2359046
High-pressure splitter valve DN 2.6
x
x
x
--
2359052
Low-pressure splitter valve DN 4
x
x
--
x
2359066
High-pressure splitter valve DN 2.6 with flushing connection
x
x
x
--
2359054
Low-pressure splitter valve DN 4 with flushing connection
x
x
--
x
2359041
Splitter valve: 2 to 3-4 DN 2.6
x
x
x
--
2359042
Splitter valve: 2 to 3-4 DN 4
x
x
--
x
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Expansion and accessory sets
Order No. Name
Ex
NonHighLowEx pressure pressure
2359033
Gun monitoring for AirSpray + AirCoat DN 8 in fluid cabinet,
non-Ex
--
x
x
x
2359035
Gun monitoring for AirSpray + AirCoat DN 8 in fluid cabinet,
Ex
x
--
x
x
2359031
Gun monitoring for AirSpray + AirCoat DN 8 in spray booth,
non-Ex
--
x
x
x
2357092
Gun monitoring for AirSpray + AirCoat DN 8 in spray booth,
Ex
x
--
x
x
2359030
Gun monitoring for automatic gun (pressure switch)
x
x
x
x
2359023
Automatic atomizer air system
x
x
x
x
2359022
Control of gun flush box
x
x
x
x
2341153
Remote control with cable 15 m; 49 ft (see Chapter 12.4)
x
x
x
x
x
x
x
x
2343063
Extension cable 15 m; 49 ft for remote control
Lengthen to a maximum of 2 times 15 m; 49 ft. (Total 45 m; 147 ft.)
2360731
Dump valve set, not flushable
x
x
x
x
2360732
Dump valve set, flushable
x
x
x
x
2343061
Dump valve for waste separation (flushable)
x
x
x
x
2359109
Product pressure regulator, 8 bar manual
x
x
--
x
2360992
External release, pneumatic
x
x
x
x
392030
Ex alarm horn, spray booth
x
x
x
x
2362637
PC data archiving
Prerequisite: network connection of the 2K COMFORT
system by WAGNER Service department
x
x
x
x
2359045
Profibus module
x
x
x
x
2362638
Control for booster pump
x
x
x
--
2360730
Output expansion CAN I/O
x
x
x
x
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12.3.2
INSTALLATION BY WAGNER SERVICE DEPARTMENT
Expansion and accessory sets
Order No. Name
Ex
Non- HighLowEx pressure pressure
2358996
Valve set dosing DN 2.6, 400 bar TC, Ex
(for 1–2 B/C/D-components, if component is already present.
Valve seat of carbide)
x
--
x
x
2362622
Valve set dosing DN 2.6, 400 bar SSt, Ex
(for 1–2 B/C/D-components, if component is already present.
Valve seat of stainless steel)
x
--
x
x
2360926
Installation material 3K
x
x
x
x
2359024
Flow monitor lacquer, non-Ex
--
x
x
x
2359025
Flow monitor lacquer, Ex
x
--
x
x
2359110
Product pressure regulator, digital (controllable)
x
x
--
x
2359111
Air bubbles monitoring, non-Ex
--
x
x
x
2359112
Air bubbles monitoring, Ex
x
--
x
x
2362636
Automatic electrostatic system set for GM 5000 manual gun
x
x
x
x
2360940
Automatic electrostatic system set for automatic gun
x
x
x
x
12.3.2.1
AIS
AIS accessories sets
Name
AIS basic set
additionally, if yet no mixing head valve is present: [A] or [B]
[A] Added component with flow meter:
Mixing head cycle for flow meter
[B] Added component with Coriolis:
Mixing head cycle for Coriolis
additionally, if length of connection set <15m:
Double 3/2-way valve
additionally, if length of connection set >15m:
Connection dosing, EX
Cable, length = 4 x length of connection set + 4 m
Connection plate, EX i
Double 3/2-way valve
Ex
Stk
Non-Ex
Order No.
Order No.
1
2359016
1
2360953
1
2360954
2
9956145
4*
m
1
2
2356618
9956160
2356898
--
---9956145
* 3 pieces, if mixing head valve is already present
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12.3.3
ACCESSORIES SETS FOR EXTERNAL FLUSHING AGENT
External flushing agent can be used for:
- Mixing head cycle
- External mixer
- Splitter valve, flushable
- Dump valve, flushable
- Dump valve for waste separation
The external flushing can be done in three ways. Optionally, an accessory set is required
(installed by the WAGNER Service department):
Flushing mode
Flushing recipe
specification
Meaning
Flushing over a
period of time
Flushing time
Flushing time runs,
if the flushing valves
are open.
Flushing with flow
monitor
Flushing time
Flushing with flow
meter
Flushing quantity Precise flushing
quantity is used.
Flushing time runs,
if flushing agent
flows.
Accessory set
Ex
Non-Ex
--
--
Flow monitor lacquer, Ex,
Order No. 2359025
Flow monitor
lacquer, non-Ex,
Cable, Order No. 9956160, Order No. 2359024
length = Distance control
cabinet–flow monitor +
2m
not subsequently orderable
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12.4
REMOTE CONTROL (OPTION)
The remote control can be operated in the EX area, allowing the following functions to
be controlled: start; stop; flushing and recipe change. In addition, a signal display for the
current recipe and displays for the operating status (Filling, Ready and Alarm) can be
installed.
Designation
Remote control
Magnetic pin, complete
Order No.
2341153
2342917
Extension cable 15 m; 49 ft for remote control
Maximum extension of 2 times 15 m; 49 ft. (Total 45 m; 147 ft.)
12.4.1
2343063
REMOTE CONTROL ASSEMBLY
12.4.1.1
SOFTWARE SETTINGS
Log in as the administrator (Level 3 password).
Set the remote control option to ON.
Menu
12.4.1.2
Level 3
Parameter
Setting
Remote control
ON
ASSEMBLY ON CONTROL CABINET
Observe safety instructions in Chapter 12.4.2
1. Before connecting the remote control or an extension cable, de-energize the device.
In other words, switch off the main switch and unplug the power plug.
2. Plug the plug on the underside of the control cabinet into the socket intended for it.
3. Ground the remote control's ground wire.
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12.4.1.3
TESTING AND COMMISSIONING
Make sure that the commands and signals described in Chapter 12.4.3 are being
transmitted. To do this, activate and check the various functions on the control cabinet
and remote control in turn.
Function
Impact on control cabinet
Impact on remote control
Start
Green push-button lights up
START LED lights up
Stop
Red push-button lights up
STOP LED lights up
Flushing
Blue push-button lights up
FLUSH LED lights up
Recipe change
The recipe is changed on the The display in the center of the
display. The recipe displayed remote control changes the
matches that of the remote number (counting upward).
control.
The impacts are always the same regardless of whether the function is activated on the
remote control or control cabinet. Activate all functions on remote control and control
cabinet at least once.
Carry out commissioning and parameter settings according to the operating manual and
the 2K COMFORT software manual.
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12.4.2
SAFETY INSTRUCTION REMOTE CONTROL
The installation must be carried out in accordance with Chapter 12.4.1. The following safety
instructions must be observed:
Do not open housing under voltage.
Open housing only in the absence of a potentially explosive atmospheres.
The gap distance from cover-housing bottom to fixed obstacles must be at least 3 cm;
1.2 inches.
The remote control must be securely assembled, the line must be laid firmly and
with protection from mechanical damage. (For example not laid in the area of aisles
or walkways, not on driveways from product handling vehicles, not through doors/
gates.)
The first attachment point of the line should be no more than 30 cm; 12 inch away
from the housing.
Extension cable: lengthen to a maximum of 2 times 15 m; 49 ft. (Total 45 m; 147 ft.)
The plug connectors of remote control and extension cable must be located in
non-potentially explosive areas.
Grounding: ground the housing via a separate line (cross-section 4 mm²; 0.0062 sq in),
connect on the local equipotential bonding (see grounding schemas in Chapter 6.5).
Warning: Any repair by a repair shop according to EN 60079-19 is not possible due to
flame path gaps smaller than the maximum permitted by EN 60079-1.
Contact the WAGNER service center in Markdorf (Germany) if a repair is necessary.
NOTICE
Magnetic fields!
Danger of damage to electronic devices and magnetic data carriers.
Ensure that electronic devices and magnetic data carriers are
removed from the danger area of the magnetic pin.
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12.4.3
OPERATION
The same four functions as on the control cabinet are on the remote control: START, STOP,
FLUSHING and RECIPE CHANGE.
The functions are identical, with the following two exceptions.
On the remote control:
– the functions will be activated with a magnetic pin.
– the green START LED flashes during filling.
Upon enabling a function these yellow LED lights up as
a confirmation.
RECIPE CHANGE
FleXcontrol
Smart
FLUSHING
R
Field of activity
magnetic pen
START
Flashes during filling.
STOP
B_04684
DANGER
Magnetic fields!
Danger to life from malfunction of heart pacemakers.
Make sure that persons with pacemakers:
Do not use the device.
Do not linger in the area of the magnetic pin.
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13 SPARE PARTS
Spare parts catalog
Order No. See Chapter 1.3.
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may
carry out repairs and replace parts.
Only repair and replace parts that are listed in the Chapter
"Spare parts" and that are assigned to the unit.
Before all work on the device and in the event of work interruptions:
- Relieve pressure from spray guns and devices.
- Secure spray guns against actuation.
- Switch off the energy/compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating manual and service manuals at all times
when carrying out work.
13.1
HOW CAN SPARE PARTS BE ORDERED?
Always supply the following information to ensure delivery of the right spare part:
Order number, designation and quantity
The quantity need not be the same as the number given in the quantity column "Stk"
on the list. This number merely indicates how many of the respective parts are used in
each component.
The following information is also required to ensure smooth processing of your order:
- Address for the invoice
- Address for delivery
- Name of the person to be contacted in the event of any queries
- Type of delivery (normal mail, express delivery, air freight, courier, etc.)
Identification in spare parts lists.
Explanation of column "K" (labeling) in the following spare parts lists:
Wearing parts
Note: These parts are not covered by warranty terms.
Not part of standard equipment, available, however, as additional extra.
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14 CONVERSION OF THE MIXING RATIO SPECIFICATIONS
It is very important that the data sheets of the paint supplier are available, so that the
correct mixing ratio can be entered.
Some lacquer manufacturers state the mixing ratio by weight, others by volume or
ratio.
Since the gear flow meter measures volumetrically, we need the specification in
volume.
Conversion of mixing proportion from gravimetric to volumetric:
Example:
10 Parts of component A by weight and
1
Parts of component B by weight
or
10g Component A
1g Component B
or
parts by weight 10:1
or
10:1 per weight (A gravimetric : B gravimetric)
The density or specific volume of the components A and B must be known or be
determined beforehand.
Density:
G
PA =
A
V
0.15 gr
=
A
G
PB =
V
B
gr
Kg
= 1.5
0.1 cm3
cm3
0.1 gr
=
= 1.5
gr
Kg
= 1
0.1 cm3
cm3
B
L
= 1
L
Mixing ratio:
Agrav.
Mvol = Avol ÷ Bvol =
P
Bgrav.
÷
A
10gr
Mvol =
gr
1.5
cm3
÷
1 gr
1
gr
P
B
= 6.67 ÷ 1
cm3
Other volumetric mixing ratio specifications:
667 Parts of component A by volume
1 Parts of component B by volume
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15 DECLARATION OF WARRANTY AND CONFORMITY
15.1
IMPORTANT NOTES REGARDING PRODUCT LIABILITY
As a result of an EC regulation effective from January 1, 1990, the manufacturer shall only
be liable for his product if all parts originate from him or are approved by him, and if the
devices are properly mounted, operated and maintained.
The manufacturer will not be held liable or will only be held partially liable if third-party
accessories or spare parts have been used.
With genuine WAGNER accessories and spare parts, you have the guarantee that all safety
regulations are complied with.
15.2
WARRANTY CLAIM
Full warranty is provided for this device:
We will at our discretion repair or replace free of charge all parts which within 24 months
in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by
the purchaser are found to be wholly or substantially unusable due to causes prior to the
sale, in particular faulty design, defective materials or poor workmanship.
The type of warranty provided is such that the device or individual components of the
device are either replaced or repaired as we see fit. The resulting costs, in particular
shipping charges, road tolls, labour and material costs will be borne by us except where
these costs are increased due to the subsequent shipment of the device to a location other
than the address of the purchaser.
We do not provide warranty for damage that has been caused or contributed to for the
following reasons:
Unsuitable or improper use, faulty assembly or commissioning by the purchaser or a
third party, normal wear, negligent handling, defective maintenance, unsuitable coating
products, substitute products and the influence of chemical, electrochemical or electrical
agents, except when the damage is attributable to us.
Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust
paints and so forth reduce the service life of valves, packings, spray guns, nozzles, cylinders,
pistons etc. Wear and tear due to such causes are not covered by this warranty.
Components that have not been manufactured by WAGNER are subject to the original
warranty of the manufacturer.
Replacement of a component does not extend the period of warranty of the device.
The device should be inspected immediately upon receipt. To avoid losing the warranty,
we or the supplier company are to be informed in writing about obvious faults within
14 days upon receipt of the device.
We reserve the right to have the warranty compliance met by a contracting company.
The services provided by this warranty are dependent on evidence being provided in the
form of an invoice or delivery note. If the examination discovers that no warranty claim
exists, the costs of repairs are charged to the purchaser.
It is clearly stipulated that this warranty claim does not represent any constraint on statutory
regulations or regulations agreed to contractually in our general terms and conditions.
J. Wagner AG
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15.3
CE DECLARATION OF CONFORMITY 2K COMFORT (NON-EX VERSION)
Herewith we declare that the supplied version of
2K COMFORT (non-Ex version)
complies with the following provisions applying to it:
- 2006/42/EC
- 2006/95/EC
- 2004/108/EC
- 2011/65/EU
- 2002/96/EC
Applied standards, in particular:
+B: 2006
+B1: 2008
- DGUV regulation 100-500
Identification:
EC Certificate of Conformity
The CE certificate of conformity is enclosed with this product. If needed, further copies
can be ordered through your WAGNER dealer by specifying the product name and serial
number.
Order number:
2K COMFORT (non-Ex version): 2359623
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15.4
CE DECLARATION OF CONFORMITY 2K COMFORT (EX VERSION)
Herewith we declare that the supplied version of
2K COMFORT (Ex version)
complies with the following provisions applying to it:
- 2006/42/EC
- 94/9/EC
- 2004/108/EC
- 2011/65/EU
- 2002/96/EC
Applied standards, in particular:
- DIN EN 61000-6-1: 2007
+B: 2006
- DIN EN 61000-6-3: 2007 +A1: 2011 +B1: 2012
+B1: 2008
- DGUV regulation 100-500
Identification:
EC Certificate of Conformity
The CE certificate of conformity is enclosed with this product. If needed, further copies
can be ordered through your WAGNER dealer by specifying the product name and serial
number.
Order number:
2K COMFORT (Ex version): 2359625
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15.5
CE DECLARATION OF CONFORMITY OF REMOTE CONTROL
Herewith we declare that the supplied version of
- 2K COMFORT remote control
complies with the following provisions applying to it:
- 94/9/EC
- 2004/108/EC
- 2002/95/EC
- 2002/96/EC
Applied standards, in particular:
-
Identification:
EC Certificate of Conformity
The CE certificate of conformity is enclosed with this product. If needed, further copies
can be ordered through your WAGNER dealer by specifying the product name and serial
number.
Order number:
Remote control: 2343991
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15.5.1
EC TYPE EXAMINATION CERTIFICATE OF REMOTE CONTROL
EC Type Examination Certificate
1
CML 13ATEX1008X Issue 1
Equipment intended for use in Potentially Explosive Atmospheres Directive 94/9/EC
2
Equipment
Flex Control Smart Remote Control Unit
3
Manufacturer
4
Address
J Wagner AG
Industriestrasse 22
Alstatten
9450
Switzerland
5
The equipment [component] is specified in the schedule of this certificate and the documents
to which it refers.
6
Certification Management Limited, Notified Body Number 2503 in accordance with Article 9 of
Directive 94/9/EC, certifies that this equipment has been found to comply with the Essential
Health and Safety Requirements relating to the design and construction of equipment intended
for use in potentially explosive atmospheres given in Annex II to the Directive.
The examination and test results are recorded in the confidential reports listed in Section 12.
7
If an ‘X’ suffix appears after the certificate number, it indicates that the equipment is subject to
conditions of safe use (affecting correct installation or safe use). These are specified in
Section 14.
8
This EC Type Examination certificate relates only to the design and construction of the
specified equipment or component. Further requirements of Directive 94/9/EC Article 8 apply
to the manufacture of the equipment or component and are separately certified.
9
Compliance with the Essential Health and Safety Requirements, with the exception of those
listed in the confidential report, has been demonstrated through compliance with the following
documents:
EN 60079-0:2012
10
EN 60079-1:2007
The equipment shall be marked with the following:
II 2 G
This certificate shall only be copied
in its entirety and without change
1 of 2
M D Shearman
Managing Director
B_04695
Ex d IIB T6 Gb
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CML 13ATEX1008X
Issue 1
11
Description
The Flex Control Smart remote control Unit is an instrument remote control unit located in the
hazardous area, connected via a cable and gland to an electronics cabinet situated in a safe area.
The remote control unit consists of a separately certified flameproof instrument housing with a floated
glass window and internal electronics.
Ratings:
24 V, 0.375 A
The following separately certified component flameproof instrument housing is utilised with the
equipment:
Enclosure Type
XD-ILwin
ATEX Certificate No.
FTZÚ 03ATEX 0207U
Marking
Ex d IIC Gb
Standards
EN 60079-0:2009
EN 60079-1:2007
Assessment has been carried out where applicable on this component enclosure to address the
differing requirements of EN 60079-0:2012, for which the equipment is certified.
12
Document history and Evaluation Reports
Issue
Date
Report
Notes
1
11 Nov 2013
R42A/00
First issue
Note: Drawings that describe the equipment or component are listed in the Annex.
13
Conditions of manufacture
None.
14
Special Conditions for Safe Use (Conditions of Certification)
The following conditions relate to safe installation and/or use of the equipment.
The maximum design gaps of the flameproof joints are smaller than the maximum
permitted gaps according to the standard. Verified values of the design gaps are
mentioned in the instructions.
This certificate shall only be copied
in its entirety and without change
2 of 2
B_04696
14.1
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15.6
NOTES ON NATIONAL REGULATIONS AND GUIDELINES
Plant Safety Ordinance
Electrical systems and equipment
Painting rooms and equipment
Electrostatic coating
Equipment for cleaning work pieces with solvents
DGUV regulation 100-500 Operating working materials
g)
Avoidance of ignition dangers due to electrostatic charges
h)
Guidelines for liquid ejection devices
i)
Checking working materials and systems which require monitoring
Part 1:
Checking systems in areas subject to explosion hazards and checking of work
stations in areas subject to explosion hazards
Part 3:
Repairs to devices, protective systems, safety, control and regulation fixtures,
in the sense of the 94/9/EC Directive - Determination of checking necessity
according to § 14 sec. 6 BetrSichV (Industrial Safety Regulations)
Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they can be found on the Internet.
122
ED
FI
CERT
I
Order No.
Edition
2357061
09/2015
Germany
Phone
Telefax
E-mail
Switzerland
Document No. 11175321
Version A
Phone
Telefax
More contact addresses on the internet at:
Company/Locations/WAGNER worldwide
Subject to changes without notice

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