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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 3 VERSION 09/2015 ORDER NUMBER DOC 2357061 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 4 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 5 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 6 VERSION 09/2015 ORDER NUMBER DOC 2357061 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. 7 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 8 VERSION 09/2015 ORDER NUMBER DOC 2357061 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.) 9 VERSION 09/2015 ORDER NUMBER DOC 2357061 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). 10 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 11 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 12 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 13 VERSION 09/2015 ORDER NUMBER DOC 2357061 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 14 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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". 15 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 16 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 17 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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! 18 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 19 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 20 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 21 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 22 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 23 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 24 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 25 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 26 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 27 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 28 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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) 29 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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.* VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL APPLICATION LIMITS OF FLOW METERS 31 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 32 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 33 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 34 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 35 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 36 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 37 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 38 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 39 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 40 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 41 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 42 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 43 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 44 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 45 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 46 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 47 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 48 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 49 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 50 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 51 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 7.5.1 SELECT LANGUAGE 1. [Menu] button (second button in bottom row) 2. 3. Touch language: [English] 7.5.2 KEYBOARD INPUT A keyboard with numbers or letters appears as necessary when 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 52 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 53 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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). 54 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 55 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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). 56 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 57 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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). 58 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 59 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 60 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 61 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 62 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 63 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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) 64 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 65 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 66 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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.) 67 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 68 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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). 69 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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). 70 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 71 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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). 72 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 73 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 74 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 75 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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.) 76 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 77 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 78 VERSION 09/2015 ORDER NUMBER DOC 2357061 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. 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. 79 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 80 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 81 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 82 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 83 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 84 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 85 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 86 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 87 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 88 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 89 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 90 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 91 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 92 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 93 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 94 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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.) 95 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 96 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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). 97 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 98 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 99 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 10.2.1 100 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 101 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 102 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 103 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 104 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 105 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 106 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 107 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 108 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 109 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 110 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 111 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 112 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 113 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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. 114 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 115 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 116 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 117 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 118 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 119 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 120 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 14.1 121 VERSION 09/2015 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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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