WAGNER FlexControl 2K-FlexControl Paint Mixing System Operating manual
Below you will find brief information for Paint Mixing System FlexControl 2K-FlexControl. This manual provides a detailed guide for operating, repairing, and maintaining the WAGNER FlexControl 2K-FlexControl, a two-component paint mixing system designed for high-quality, reliable paint applications. This system features an electronic mixing ratio controller for precise mixing, ensuring consistent quality every time. It allows processing of both solvent-based and water-based 2K materials, making it versatile. The system is equipped with an automatic flushing system to minimize solvent waste, enhancing efficiency. The FlexControl 2K-FlexControl provides a range of functionalities including shot automatic mode, manual shot mode, and flushing cycles for optimal control over the mixing process. For added convenience, the system can be integrated into a supervisory system for remote diagnostics and error elimination. The system is designed for safe operation with built-in security measures and automatic parameter checking to ensure consistent quality and minimize potential risks.
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Translation of the original Operating manual 2K-FlexControl Edition 09/ 2009 Electronic mixing ratio controller for 2C paints "? EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL Contents 1 1.1 1.2 ABOUT THIS MANUAL Languages Warnings, notes and symbols in this manual 6 6 6 2 2.1 2.1.1 2.1.2 2.1.3 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.3 2.4 2.4.1 2.4.2 2.4.3 GENERAL SAFETY REGULATIONS Safety instructions for the operator Electrical equipment Personnel qualifications A safe work environment Safety instructions for personnel Safe handling of WAGNER spray units Earth the unit Material hoses Cleaning Handling hazardous liquids, varnishes and paints Touching hot surfaces Using in accordance with the instructions Field of application Explosion protection identification Maximum surface temperature Safety instructions 7 7 7 7 7 8 8 8 9 9 9 10 10 10 11 11 11 3 3.1 3.2 3.3 PRODUCT LIABILITY AND WARRANTY Important notes on product liability Warranty CE-Conformity 12 12 12 13 4 4.1 4.2 4.3 4.3.1 4.3.2 4.4 4.4.1 4.4.2 DESCRIPTION System presentation Processing materials Data Technical data Work area Functioning Measurement system Dialogue Human / Machine 14 14 15 15 15 17 18 18 19 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 TRANSPORT / INSTALLATION Transport Storage Installation Electrical connections Pneumatic connections Fluid connections Flow meter control Lack of product Ground the system Modem connection Printer connection 20 20 20 20 22 22 22 23 23 24 25 25 3 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL Contents 6 6.1 6.2 6.2.1 6.2.2 CONTROL UNIT Control elements Operating panel Operating level F1 Calibration level F2 26 26 26 26 29 6.2.3 6.3 6.4 6.5 Parameter-Level f3 Password Hand activating of the fluid valves Trouble shooting 30 33 33 34 7 7.1 7.2 7.3 7.4 7.5 7.6 START UP Preliminary washing and pressure tightness test Pressure relief procedure Filling the unit and calibration Start of painting Flush, colour change General informations 35 36 37 38 38 39 40 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 MAINTENANCE Unit cleaning Filter cleaning Condensate drainage from the filter-reducer Flow gear meter Material valves High pressure hose Control unit Dismantling 41 41 41 41 42 43 43 43 44 9 9.1 TROUBLE SHOOTING Faults and appropriate solutions 45 45 10 10.1 10.2 10.3 INSTALLATION OF ACCESSORIES Colour extension Gun control Conversion of different mixing proportion specification 46 46 46 47 11 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 SPARE PARTS How to order spare parts? Overview spare parts Basic unit 1 (1A, 1B) not to placed in a Ex-area Basic unit 2 (1A, 1B) Fluid part Ex proofed, Control part not Ex proofed Control cabinet, assy. Fluid cabinet, assy. - not Ex proofed Fluid cabinet, assy. - Ex proofed Atomizing air AirCoat dia 6 mm; 0.24 inch, in 2K unit Atomizing air, air gun dia 8 mm; 0.31 inch, in 2K unit Atomizing air, AirCoat dia 6 mm; 0.24 inch, in spray booth Atomizing air air gun dia 8 mm; 0.31 inch, in spray booth Gun control for Airless gun, not Ex proofed 384244/ 384270 49 49 51 53 54 55 57 59 61 62 63 64 65 4 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL Contents 11.13 11.14 11.15 11.16 11.17 11.18 11.19 11.20 11.21 11.22 11.23 11.24 11.25 11.26 11.27 11.27.1 11.28 11.29 11.30 11.31 11.32 11.33 11.34 11.35 11.36 11.37 11.38 11.39 11.40 11.41 11.42 11.43 11.44 11.45 11.46 11.47 11.48 11.49 Flow meters Robot communication 384254/ 384271 USA Stand, assy. Foot set Wheel set, assy. - 377120 Colour extension 2A Colour change valve assy. - 384103 Hardener extension 1B Hardener valve assy. - 384105 2 different solvent for hardener Material filter assy. - compact - 384110 Material filter assy. - with swivel joint - 139045 Air/ Solvent flush set for A, - maxi. 1 MPa; 10 bar; 145 psi, in 2K unit Mat. pressure regulator Set, pneum. 0.5 MPa; 0-5 bar; 72.5 psi, in spray booth Pressure regulator RV/ 1 stainless steel, with pneumatic remote control Technical data Material pressure regulator set 0-0.6 MPa; 0-87.02 psi in 2K unit Remote control Ex proofed, with 10 m; 32.8 ft cable Remote control pneumatic, without recipe, assy. - 377082 Manifold cabinet without recipe, assy. Remote control pneumatic without recipe, assy. Connection set without recipe, 10 m; 32.8 ft - 377963 Alarm horn - 384234 Alarm horn in spray booth - 384253 Release of automatic cabin - 384238 Teleservice with analog modem - 384215 Printer connection without printer Extension static mixer Atomizing air automatic dia 6 mm; 0.24 inch - 384219 Atomizing air automatic dia 8 mm; 0.31 inch - 384220 Electrostatic automatic - 384243 Set communication for gun flush box - 384235 Bulkhead holder (by more than 3 colours/ filters) Distribution set for 2 guns (2K / 3K operation) - 384249 Extension set 3K operation - not Ex proofed - 384223 Extension set 3K fluid part - Ex proofed Same detergent with A and B - 2302778 Adapter 65 65 66 66 67 68 69 70 71 73 74 74 75 76 77 78 79 80 81 82 84 85 85 86 87 87 88 89 90 90 91 91 92 93 94 96 98 98 12 12.1 12.2 TABLES / PARAMETERS Table hose volume System parameter 2K-FlexControl 99 99 100 13 CONNECTION DIAGRAMS - NOT EX PROOFED 102 14 CONNECTION DIAGRAMS - EX PROOFED 116 5 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 1 ABOUT THIS MANUAL 4HISOPERATINGMANUALCONTAINSINFORMATIONABOUTTHEOPERATIONREPAIRANDMAINTENANCE OFTHEUNIT !LWAYSFOLLOWTHESEINSTRUCTIONSWHENOPERATINGTHEUNIT 1.1 LANGUAGES This operating manual is available in the following languages: Language: Part No. Language: Part No. German 384860 English 384861 Dutch 384863 Italian 384864 Danish 384867 Swedish 384866 Norwegian 384869 Polish 384871 1.2 Language: French Spanish Finnish Part No. 384862 384865 384868 WARNINGS, NOTES AND SYMBOLS IN THIS MANUAL Warning instructions in this manual point out particular dangers to users and equipment and state measures for avoiding the hazard. These warning instructions fall into the following categories: Danger - imminent danger. Non-observance will result in death, serious injury and serious material damage. DANGER This line warns of the hazard! Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level. SIHI_0100_GB Warning - possible danger. Non-observance can result in death, serious injury and serious material damage. The measures for preventing the hazard and its consequences. WARNING This line warns of the hazard! Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level. SIHI_0103_GB Caution - a possibly hazardous situation. Non-observance can result in minor injury. The measures for preventing the hazard and its consequences. CAUTION This line warns of the hazard! Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level. The measures for preventing the hazard and its consequences. SIHI_0101_GB Caution - a possibly hazardous situation. Non-observance can cause material damage. SIHI_0102_GB CAUTION This line warns of the hazard! Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level. The measures for preventing the hazard and its consequences. Note - provide information on particular characteristics and how to proceed. 6 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 2 GENERAL SAFETY REGULATIONS 2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR +EEPTHESEOPERATINGINSTRUCTIONSTOHANDNEARTHEUNITATALLTIMES !LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN TION 2.1.1 ELECTRICAL EQUIPMENT Electrical plant and units 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. Must be operated in accordance with the safety regulations and electrotechnical regulations. Must be repaired immediately in the event of problems. Must be put out of operation if they pose a hazard. Must be de-energized before work is commenced on active parts. Inform staff about planned work, observe electrical safety regulations. To protect the electrical components, lay all of the various elements to a collective earthing point. It is thus absolutely necessary to attach the device correctly to a grounded voltage supply. With open housings, there is a danger from line voltage. Repairs and maintenance may only be carried out by skilled personnel. 2.1.2 PERSONNEL QUALIFICATIONS %NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS 2.1.3 A SAFE WORK ENVIRONMENT %NSURETHATTHEmOOROFTHEWORKINGAREAISANTISTATICINACCORDANCEWITH%.0ART eMEASUREMENTINACCORDANCEWITH$). %NSURETHATALLPERSONSWITHINTHEWORKINGAREAWEARANTISTATICSHOESEGSHOESWITH LEATHERSOLES %NSURETHATDURINGSPRAYINGPERSONSWEARANTISTATICGLOVESSOTHATTHEYAREEARTHED VIATHEHANDLEOFTHESPRAYGUN #USTOMERTOPROVIDEPAINTMISTEXTRACTIONUNITSCONFORMINGTOLOCALREGULATIONS %NSURETHATTHEFOLLOWINGCOMPONENTSOFASAFEWORKINGENVIRONMENTAREAVAILABLE n -ATERIALAIRHOSESADAPTEDTOTHEWORKINGPRESSURE n 0ERSONALSAFETYEQUIPMENTBREATHINGANDSKINPROTECTION %NSURETHATTHEREARENOIGNITIONSOURCESSUCHASNAKEDmAMEGLOWINGWIRESORHOT SURFACESINTHEVICINITY$ONOTSMOKE 4HEPLACEOFASSEMBLYISINACCORDANCEWITHTHEEXPLOSIONPREVENTIONTOSELECTNATIONAL RULESANDREGULATIONSCONSIDER %NSUREDBYTHEOPERATORTHETIGHTNESSEXAMINATIONBEFORESTARTUPDAILYAFTERREPAIRS ANDINREGULARINTERVALS n 4HEPIPEJOINTSITEMOFEQUIPMENTANDCONNECTIONSAREDURABLYTECHNICALLYCLOSE 7 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 2.2 SAFETY INSTRUCTIONS FOR PERSONNEL !LWAYSFOLLOWTHEINFORMATIONINTHESEINSTRUCTIONSPARTICULARLYTHEGENERALSAFETYIN STRUCTIONSANDTHEWARNINGINSTRUCTIONS !LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN TION 2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or cleaning agents: Never point the spray gun at people. Never reach into the spray jet. Before all work on the unit and in the event of work interruptions: – Secure the spray gun against actuation. – Relieve the pressure from the spray gun and unit. Ensured, that (in accordance with the guideline for liquid emitter (ZH 1/406 and BGR 500 Part 2 chap. 2.36) the liquid emitters are every 12 months to examine by experts (e.g. Wagner service technician). – With shut down devices the examination can be by the next start. Follow the «Pressure Relief Procedure» whenever you: – Are instructed to relieve pressure. – If the spraying work to be adjusted. – Stop spraying, clean check, or service the equipment. – Install or clean the spray nozzle. In the event of skin injuries caused by paint or cleaning agents: Note down the paint or cleaning agent that you have been using. Consult a doctor immediately. Avoid danger of injury through recoil forces: Ensure that you have a firm footing when operating the spray gun. Only hold the spray gun briefly in a position. 2.2.2 EARTH THE UNIT Electrostatic charges can occur on the unit due to the electrostatic charge and the flow speed involved in spraying.These can cause sparks and flames upon discharge. Ensure that the unit is always earthed. Earth the work pieces to be coated. Ensure that all persons inside the working area are earthed, e.g. that they are wearing antistatic shoes. When spraying, wear antistatic gloves to earth yourself via the spray gun handle. 8 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 2.2.3 MATERIAL HOSES %NSURETHATTHEHOSEMATERIALISCHEMICALLYRESISTANTTOTHESPRAYEDMATERIALS %NSURETHATTHEMATERIALHOSEISSUITABLEFORTHEPRESSUREGENERATEDINTHEUNIT %NSURETHATTHEFOLLOWINGINFORMATIONCANBESEENONTHEHIGHPRESSUREHOSE n -ANUFACTURER n 0ERMISSIBLEOPERATINGOVERPRESSURE n $ATEOFMANUFACTURE 2OUTETHEHOSESAWAYFROM n 4HETRAFlCAREAS n 3HARPEDGES n -OVINGPARTS n (OTSURFACES $ONOTUSETHEHOSESTOPULLTHEEQUIPMENT 4HEELECTRICALRESISTANCEOFTHECOMPLETEHIGHPRESSUREHOSEMUSTBELESSTHAN-/HM 2.2.4 CLEANING "EFOREMAINTENANCEWORK n $EENERGIZETHESYSTEMELECTRICALLY n THEEQUIPMENTISTOSEPARATEFROMTHENET n DISCONNECTTHEPNEUMATICSUPPLYLINEAND n RELIEVETHEPRESSUREFROMTHEUNIT %NSURETHATTHEmASHPOINTOFTHECLEANINGAGENTISATLEAST+ABOVETHEAMBIENTTEM PERATURE 4OCLEANUSEONLYSOLVENTFREECLOTHSANDBRUSHES.EVERUSEHARDOBJECTSORSPRAYON CLEANINGAGENTSAGUN )NTHECASEOFSTARTUPOREMPTYINGOFTHEEQUIPMENTCANBEPRESENT n $EPENDINGUPONUSEDCOATINGMATERIAL n ORCLEANINGSOLVENTS n EXPLOSIVEMIXTUREINSIDETHELINESANDITEMSOFEQUIPMENT !NEXPLOSIVEGASAIRMIXTUREFORMSINCLOSEDCONTAINERS 7HENCLEANINGUNITSWITHSOLVENTSNEVERSPRAYINTOACLOSEDCONTAINER %ARTHTHECONTAINER 2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS 7HENPREPARINGORWORKINGWITHPAINTANDWHENCLEANINGTHEUNITFOLLOWTHEWORK INGINSTRUCTIONSOFTHEMANUFACTUREROFTHEPAINTSSOLVENTSANDCLEANINGAGENTSBEING USED 4AKE THE SPECIlED PROTECTIVE MEASURES IN PARTICULAR WEAR SAFETY GOGGLES PROTECTIVE CLOTHINGANDGLOVESASWELLASHANDPROTECTIONCREAMIFNECESSARY 5SEAMASKORBREATHINGAPPARATUSIFNECESSARY &ORSUFlCIENTHEALTHANDENVIRONMENTALSAFETY/PERATETHEUNITINASPRAYBOOTHORON ASPRAYINGWALLWITHTHEVENTILATIONEXTRACTIONSWITCHEDON 7EARSUITABLEPROTECTIVECLOTHINGWHENWORKINGWITHHOTMATERIALS 9 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 2.2.6 TOUCHING HOT SURFACES 4OUCHHOTSURFACESONLYIFYOUAREWEARINGPROTECTIVEGLOVES 7HENOPERATINGTHEUNITWITHACOATINGMATERIALWITHATEMPERATUREOF²#²& )DENTIFYTHEUNITWITHAWARNINGLABELTHATSAYSu7ARNINGHOTSURFACEh /RDER.O )NFORMATIONLABEL 3AFETYLABEL 2.3 USING IN ACCORDANCE WITH THE INSTRUCTIONS 7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE 4HEmUID CABINETISSUITABLEFORMIXINGOFmUIDCOMPONENTSMATERIALS#OATINGOR AUXILIARYMATERIALSOFTHESURFACETECHNIQUEASWELLASEQUIVALENTMATERIALS /PERATEONLYTHEENTIREUNIT $ONOTDEACTIVATESAFETYlXTURES 5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES 2.4 FIELD OF APPLICATION 4HOSE.OT%XVARIANTHAVETOBESETUPOUTSIDEOFTHEHAZARDOUSAREA )TISTHESAMEWITHTHE%XVARIANTFORTHEELCONTROLCABINET 4HEmUIDCABINETOFTHE%XPROOFEDVERSIONISEQUIPPEDWITHINTRINSICALLYSAFEmOWGEAR METERS n !CCGUIDELINE%'!TEX))' n )NIGNITEPROTECTIONCLASS%%XIB))"4 n 7ITHHOUSINGPROTECTIONCLASS)0 n !ND%XPNEUMATICSVALVESACCGUIDELINE%'!TEX))' n )NIGNITEPROTECTIONCLASS%%XM))4AND%%XE))4 n 7ITHHOUSINGPROTECTIONCLASS)0 ANDTHUSSUITABLEFORUSEINHAZARDOUSLOCATIONSZONE 10 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 2.4.1 EXPLOSION PROTECTION IDENTIFICATION !SDElNEDINTHE$IRECTIVE#%!4%8THEUNITISSUITABLEFORUSEINAREASWHERE THEREISANEXPLOSIONHAZARD ))'))"8 #% %X )) ' ))" 8 #OMMUNAUTÏS%UROPÏENNES 3YMBOLFOREXPLOSIONPROTECTION 5NITCLASS)) #ATEGORY:ONE %XATMOSPHEREGAS %XPLOSIONCLASS 3PECIALIDENTIlCATION 2.4.2 MAXIMUM SURFACE TEMPERATURE X: The maximum surface temperature corresponds to the permissible material temperature. This and the permissible ambient temperature can be found in the Technical Data. 2.4.3 SAFETY INSTRUCTIONS 3AFEHANDLINGOF7!'.%2SPRAYUNITS 4HEMAXIMUMSURFACETEMPERATUREOFTHEPISTONPUMPCANBEREACHEDIFITRUNSDRY %NSURETHATTHEPISTONPUMPISlLLEDWITHSUFlCIENTWORKINGORCLEANINGMEDIUM %NSURETHATTHESEPARATINGAGENTCONTAINERISlLLEDWITHSUFlCIENTSEPARATINGAGENT -ECHANICALSPARKSCANFORMIFTHEUNITCOMESINTOCONTACTWITHMETAL )NANEXPLOSIVEATMOSPHERE $ONOTKNOCKORPUSHTHEUNITAGAINSTSTEELORRUSTYIRON $ONOTDROPTHEUNIT 5SEONLYTOOLSTHATAREMADEOFAPERMITTEDMATERIAL )GNITIONTEMPERATUREOFTHECOATINGMATERIAL %NSURETHATTHEIGNITIONTEMPERATUREOFTHECOATINGMATERIALISABOVETHEMAXIMUM SURFACETEMPERATURE -EDIUMSUPPORTINGATOMIZING 4OATOMIZETHEMATERIALUSEONLYWEAKLYOXIDIZINGGASESEGAIR 3URFACESPRAYINGELECTROSTATIC $ONOTSPRAYUNITPARTSWITHELECTROSTATICEGELECTROSTATICSPRAYGUN #LEANING )F THERE ARE DEPOSITS ON THE SURFACES THE UNIT MAY FORM ELECTROSTATIC CHARGES &LAMES OR SPARKSCANFORMIFTHEREISADISCHARGE 2EMOVEDEPOSITSFROMTHESURFACESTOMAINTAINCONDUCTIVITY 5SEONLYADAMPCLOTHTOCLEANTHEUNIT 11 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 3 PRODUCT LIABILITY AND WARRANTY 3.1 IMPORTANT NOTES ON PRODUCT LIABILITY !SARESULTOFAN%#REGULATIONEFFECTIVEASFROM*ANUARYTHEMANUFACTURERSHALL ONLYBELIABLEFORHISPRODUCTIFALLPARTSCOMEFROMHIMORAREAPPROVEDBYHIMANDIFTHE DEVICESAREPROPERLYlTTEDOPERATEDANDMAINTAINED )FOTHERMAKESOFACCESSORYANDSPAREPARTSAREUSEDTHEMANUFACTURER@SLIABILITYCOULDBE FULLYORPARTIALLYNULLANDVOID 4HEUSAGEOFORIGINAL7!'.%2ACCESSORIESANDSPAREPARTSGUARANTEESTHATALLSAFETYRE GULATIONSAREOBSERVED 3.2 WARRANTY 4HISUNITISCOVEREDBYOURWARRANTYONTHEFOLLOWINGTERMS 7EWILLATOURDISCRETIONREPAIRORREPLACEFREEOFCHARGEALLPARTSWHICHWITHINMONTHS INSINGLESHIFTMONTHSINSHIFTORMONTHSINSHIFTOPERATIONFROMDATEOFRECEIPTBY THE0URCHASERAREFOUNDTOBEWHOLLYORSUBSTANTIALLYUNUSABLEDUETOCAUSESPRIORTOTHE SALEINPARTICULARFAULTYDESIGNDEFECTIVEMATERIALSORPOORWORKMANSHIP 4HETERMSOFTHEWARRANTYAREMETATOURDISCRETIONBYTHEREPAIRORREPLACEMENTOFTHE UNITORPARTSTHEREOF4HERESULTINGCOSTSINPARTICULARSHIPPINGCHARGESROADTOLLSLABOUR ANDMATERIALCOSTSWILLBEBORNEBYUSEXCEPTWHERETHESECOSTSAREINCREASEDDUETOTHE SUBSEQUENTSHIPMENTOFTHEUNITTOALOCATIONOTHERTHANTHEADDRESSOFTHEPURCHASER 4HISWARRANTYDOESNOTCOVERDAMAGECAUSEDBY 5NSUITABLE OR IMPROPER USE FAULTY INSTALLATION OR COMMISSIONING BY THE PURCHASER OR A THIRD PARTY NORMAL WEAR NEGLIGENT HANDLING DEFECTIVE MAINTENANCE UNSUITABLE COATING PRODUCTS SUBSTITUTE MATERIALS AND THE ACTION OF CHEMICAL ELECTROCHEMICAL OR ELECTRICAL AGENTSEXCEPTWHENTHEDAMAGEISATTRIBUTABLETOUS !BRASIVE COATING PRODUCTS SUCH AS REDLEAD EMULSIONS GLAZES LIQUID ABRASIVES ZINC DUST PAINTSANDSIMILARREDUCETHESERVICELIFEOFVALVESPACKINGSSPRAYGUNSNOZZLESCYLINDERS PISTONSETC!NYWEARRESULTINGFROMTHEAFOREMENTIONEDCAUSESISNOTCOVEREDBYTHIS WARRANTY #OMPONENTSNOTMANUFACTUREDBY7AGNERARESUBJECTTOTHEWARRANTYTERMSOFTHEORIGI NALMAKER 4HEREPLACEMENTOFAPARTDOESNOTEXTENDTHEWARRANTYPERIODOFTHEUNIT 4HEUNITSHOULDBEINSPECTEDIMMEDIATELYUPONRECEIPT 4OAVOIDLOSSWARRANTYANIYAPPARENTDEFECTSHOULDBENOTIlEDTOUSORTHEDEALERINWRI TINGWITHINDAYSFROMDATEOFSALEOFTHEUNIT 4HERIGHTTOCOMMISSIONWARRANTYSERVICESTOATHIRDPARTYISRESERVED 7ARRANTYCLAIMSARESUBJECTTOPROOFOFPURCHASEBYSUBMITTINGANINVOICEORDELIVERYNOTE )FANINSPECTIONlNDSDAMAGENOTCOVEREDBYTHEPRESENTWARRANTYTHEREPAIRWILLBECAR RIEDOUTATTHEEXPENSEOFTHEPURCHASER .OTETHATTHISWARRANTYDOESNOTINANYWAYRESTRICTLEGALLYENTITLEDCLAIMSORTHOSECONTRAC TUALLYAGREEDTOINOURGENERALTERMSANDCONDITIONS *7AGNER!' 12 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 3.3 CE-CONFORMITY Herewith we declare that the supplied version of FlexControl basic equipment 1A 1B Ex 384002 Complies with the following guidelines: 98/37/EG 94/9/EG 73/23/EWG 89/336/EWG Applied standards, in particular: DIN EN ISO 12100-1 (EN 292-1) DIN EN ISO 12100-2 (EN 292-2) DIN EN 563 DIN EN 1127 prEN 1953 DIN EN ISO 13463 EN 50014 EN 50020 EN 50081-2 EN 50082-2 EN 60204-1 Applied national technical standards and specifications, in particular: BGV D 25 (VBG 23) BRG 104 BGR 132 (ZH 1/200) Marking: II (2) G; II 2G IIB X CE Certificate of Conformity The certificate is enclosed with this product.The certificate of conformity can be reordered from your WAGNER representative, quoting the product and serial number. Part number: FlexControl 384920 13 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 4 DESCRIPTION 4.1 SYSTEM PRESENTATION ➞ Wagner has developed mixing units in various fields for 2-component paints applications. ➞ The 2K-FlexControl was developed to meet the growing demand for low until middle high pressure 27 MPa; 270 bar; 3916 psi 2-component dosing units. This increasing demand is not only for quan-tity but also particularly, for an increase in quality. Naturally, because these products are used in various branches of industry, processing equipment is required which can guaranty consistent quality. ➞ Conceived in this mind, the 2K-FlexControl offers, among other things, to its user: – Processing also of water-based 2K materials, since all material-touching are manufactured in stainless steel materials. – The fluid cabinet of the Ex proofed version is equipped with intrinsically safe – flow gear meters (acc. guide line 94/9/EC (Atex, II 2 G) – in ignite protection class EEx ib IIB T4 with housing protection class IP65 – and Ex-pneumatics valves (acc. guide line 94/9/EC (Atex, II 2 G) – in ignite protection class EEx m II T4 and EEx e II T6 with housing protection class IP65 and thus suitable for use in hazardous locations (zone 1). ➞ The announcements of the functions are language independently represented with simple symbols. ➞ Siemens SPS S7-CPU. ➞ The consumption synthesis of the product and the solvent. ➞ Clear plant attitude in the flow chart on the fluid cabinet. ➞ The possibility of operating control from the inside of a closed spray booth by a remote control. ➞ The electronic precision in dosing.. ➞ Security by permanently checking the system parameters which, on the slightest trouble, inform the user and automatically suspends the production. ➞ The protection of parameters by security code and the system backup on eprom memory. ➞ The possibility of integration in a supervision system (RS232 or MPI-Bus). ➞ The electronic adjustment of the mixing ratio between 1:1 and 20:1. ➞ The possibility to use up to 5 compatible A products, 2 B products and 1 C product. ➞ An automatic flushing system of the products circuits which permit to save up to 60% of solvent compared with the previous systems. ➞ The compatibility with solvent based products and water based products, with selective water and/ or solvent automatic cleaning. ➞ The using of hand or automatic spray guns. ➞ Possibility of remote diagnostics and an elimination of errors with software problems by means of modem ➞ Printer connection, signal from spray booth, automatic gun flush unit etc. are available. Contact Wagner for further informations. 14 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 4.2 PROCESSING MATERIALS ➞ Material in contact with products: – Stainless steel – Hard metal – Teflon – Viton – POM 2K material on solvent base or water base. However do not processed solvent basic and aqueous basic 2K materials with the same system. CAUTION Abrasive materials and pigments! Greater wear of the parts carrying the material Do not use any grainy and abrasive materials with large, sharp-edged pigments. Use suitable combinations of devices (packages, valves etc.). SIHI_0011_GB So caused wear is not covered by the warranty. 4.3 DATA 4.3.1 TECHNICAL DATA Pressure: 0.5-0.8 MPa 5-8 bar 73-116 psi Inlet air pressure WARNING Outgoing air containing oil! Risk of poisoning if inhaled Provide water-free and oil-free compressed air (quality standard 5.5.4 as per ISO 8573.1) 5.5.4 = 40 μm / +7 / 5 mg/m³. SIHI_0023_GB 15 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL High pressure version: 27 MPa 270 bar 3915 psi Inlet solvent (maxi.) A-B products (maxi.) Outlet mixed products (maxi.) Low pressure version 0.8 MPa; 8 bar 116 psi Inlet Solvent (maxi.) 0.5 MPa; 5 bar 73 psi Inlet Air pressure flushing (maxi.) 2.5 MPa; 25 bar 362 psi Inlet A-B products (maxi.) 0.05-0.5 MPa 0.5-5 bar 7-73 psi Outlet Mixed product 0.5 MPa; 5 bar; 73 psi due to material pressure regulator M16x1.5 Material inlet (out) M16x1.5 Material outlet (out) 100-3000 cc/min Mixed product outlet Mixed product 20-2000 mPas Product viscosity A-B 120 Micron Fluid filtration required, min. 100 mesh 3.5 to 9 Material pH value +5 °C - +40 °C +41 °F - +104 °F Material temperature +5 °C - +40 °C +41 °F - +104 °F Environment temperature 0.1:1 to 20:1 A/B mixing ratio vol. (1K too) for 3K (A+B) / C mixing ratio vol. ± 1% Ratio precision 5 Maxi. number of A product 2 Maxi. number of B product 2 Maxi. number of solvent for B approx. 60 kg; 132.3 lbs Weight Dimension: h 1730 mm; 68.1 inch w 450 mm; 17.7 inch d 510 mm; 20 inch Control and fluid cabinet on stand 16 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL h 1000 mm; 39.37 inch Control and fluid cabinet wall mount w 450 mm; 17.7 inch d 270 mm; 10.63 inch 110 dBA * Sound level by alarm * A rated sound pressure level measured at 1m distance according to DIN EN ISO 3746-1995. Electrical supply: Chap. 14.2 4.3.2 see electrical circuit diagram 16A – 115 / 230VAC (50 / 60 Hz) + PE WORK AREA Flow ratio mixed material A+B [L/min] Work area FlexControl Work area "? Mixing ratio volume A:B [A:1] (0= only A) 17 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 4.4 FUNCTIONING 4.4.1 MEASUREMENT SYSTEM The system is composed of two or three circuits ; a master circuit (A product) and a slave circuit (B product). ➞ The control unit controls and adjusts the given mixing proportion, as over a pneumatic valve in short intervals the necessary hardener quantity is added to the continuous flow of the master lacquer. ➞ The flow rate of master lacquer and hardeners are measured by gear flow meter. The materials (components and solvents) are made available by supplying pumps or receivers (not supplied with the system). CAUTION Constant supply pressures! Poor coating results The supply pressure of the component B must be adjust to a higher value (appr. 10%) than that the component A. The supplying pressure should be constant. SIHI_0056_GB # Mixing bloc !"# !" if use 2 hardener Static mixer Flush valve Flow meter Colour valve Flow meter Check valve Flush air Flow meter Mixing bloc Hardener valve Colour valve Check valve "? ! Flush valve " 18 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 4.4.2 DIALOGUE HUMAN / MACHINE A substantial characteristic of the 2K-FlexControl is the simple and clear operation. With few clearly inserted operating elements the unit can be controlled. Control cabinet Switch ON/ OFF Fluid cabinet Colour change button FlowDiagram Button start / stop / flush "? Push button for valve A and B Control cabinet In the control cabinet all electrical components are installed. The unit can be controlled by the push buttons and the operating panel. Information from an into the unit are possible by the operating panel. Fluid panel In the fluid cabinet are all parts installed, which are in contact with the fluid. On the door there is a flow diagrams with pneumatic switches for colour changes and manual open of the valves. 19 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 5 TRANSPORT / INSTALLATION 5.1 TRANSPORT The system is transportable by a euro-pallet. h 600 mm; 23.62 inch l 1200 mm; 47.24 inch d 800 mm; 31.49 inch Weight:approx. 60 kg; 132 lbs WARNING Inclined surface! Risk of accidents if the unit rolls away/falls Place the unit on horizontal soil. The wheels must be fixed or by placing feet to be replaced and secured. When shifting/transport do not tilt the unit. SIHI_0052_GB 5.2 STORAGE Place the unit in a closed and dry environment (+5 °C to +40 °C; +41 °F to +104 °F). ➞ If the equipment is not going to be used for a long time, lubricate it by sucking emulsified oil (or plain oil) from the feeding pumps. ➞ When resuming work operation, proceed as described in Chap. „preliminary operations”. 5.3 INSTALLATION Mixing units are installed by WAGNER technicians directly or by their agents. If this is not the case, verify that the material has not been damaged. WARNING Electric shock hazard inside the controller! Danger to life from electric shock May only be installed/maintained by skilled electricians or under their supervision. Are operated in accordance with the safety regulations, fire and electro-technical rules. The voltage is switched off before work is begun on active components. SIHI_0045_GB 20 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL WARNING Toxic and/or flammable vapor mixtures! Risk of poisoning and burns Operate the unit in a spraying booth approved for the working materials. -or Operate the unit on an appropriate spraying wall with the ventilation (extraction) switched on. Observe national and local regulations for the outgoing air speed. SIHI_0028_GB DANGER Incorrect installation of the unit! Risk of explosion and equipment damage Place the control unit inclusive fluid cabinet outside the spray booth /spray zone and the explosion zone. Protect the control unit from extreme temperature, moisture changes and dirt. Lay and fix the connecting cable correctly and protect against fall down and passage traffic. SIHI_0053_GB WARNING Inclined surface! Risk of accidents if the unit rolls away/falls Place the unit on horizontal soil. The wheels must be fixed or by placing feet to be replaced and secured. When shifting/transport do not tilt the unit. SIHI_0052_GB ➞ ➞ ➞ ➞ ➞ Use only feed pumps etc, which are suitable for 2C materials. Use hardener pump with PE-Teflon package. No product contact with copper alloy. Pumps etc by water based paint in stainless steel. Use material filters at the feed pumps 21 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 5.4 ELECTRICAL CONNECTIONS An electrical lead with plug is according to standard intended. With exchange that of lead must be considered the following: ➞ Carry out the electrical connection and the grounding inside the control unit using a 3 wire cable of AWG16; please refer to the enclosed electric diagram Chap. 12. 5.5 PNEUMATIC CONNECTIONS ➞ Make sure the pressure distribution line is suitable, considering that the normal working pressure is 0.5-0.8 MPa; 5-8 bar; 73 to 116 psi. WARNING Overpressure! Risk of injury bursting components The operating pressure must never exceed the value shown on the plate. SIHI_0054_GB ➞ Make sure efficient filters and condensate separators have been installed on the air line. ➞ Every day, discharge all impurities and the condensate (if any) accumulated in the equipment at filter. WARNING Brittle filter pressure regulator! The container on the filter pressure regulator becomes brittle through contact with solvents and can burst Flying parts can cause injury Do not clean the container on the pressure regulator with solvent. SIHI_0014_GB 5.6 FLUID CONNECTIONS Make sure to connect what follows: ➞ Material hose from the line mixer to the user’s device. ➞ The material hoses from the feeding pumps to the unit must not be connected until the preliminary flushing has been done! 22 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 5.7 FLOW METER CONTROL For save operation it is necessary that the 2K-FlexControl get the information, whether the gun is open and there is a material flow. If not, in case of blocking of the A- flow meter B-material is not proportioned, although A material can flow through the leakage in the flow meter (eve. not visible)! The external signal can be different according to the application: ➞ In case of an automatic gun, there is a pressure meter to connect the pneumatic signal of device opening. ➞ A contact can also be connected to the terminals available in the control unit. ➞ In case of an AirCoat manual gun, a flow meter kit shall be installed on the atomizing air circuit ➞ In case of Airless- or HVLP manual guns, a flow monitor shall be installed on the air pressure supply of the fading pumps. WARNING Incorrect installation of the unit! Risk of explosion and equipment damage The flow monitor is not Ex-proved and must be installed outside the Ex-area. Lay and fix the connecting cable correctly and protect against fall down and passage traffic. SIHI_0055_GB ➞ It is not allowed to install other air consumption equipment (p.e. pumps for ring pipes or stirrer) as the feeding pumps for one 2K unit after the flow monitor. 5.8 LACK OF PRODUCT It is to be guaranteed that product without bubbles is supplied to the mixing and proportioning plant 2K-FlexControl. ➞ The A-gear flow meter does not detect whether material or air is delivered. ➞ The control will therefore the „a-amount of air“ the necessary B-hardener to itproportions. A lack of material protection can be managed, as in the A-product container is attached a level sensor or that the painter always made sure that sufficient product is in the containers, otherwise it can come it to false coating. E.g. if the level sensor of the A-container displays the minimum, a signal can stop the 2KFlexControl (STOP). The lack of material protection is not contained in the 2K-FlexControl and is build-laterally manages to become. 23 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 5.9 GROUND THE SYSTEM WARNING Fire, explosion and electric shock hazard! Danger to life from electric shock and explosion The unit must be electrically connected to a true earth ground; the ground in the electrical system is not sufficient. A qualified electrician must complete all grounding and wiring connections and check the resistance. Must be operated in accordance with the safety regulations, fire and electrotechnical regulations. Must be de-energized before work is commenced on active parts. SIHI_0057_GB WARNING Heavy paint mist if earthing is insufficient! Risk of poisoning Insufficient paint application quality Earth all unit components. Earth the workpieces being painted. SIHI_0003_GB The 2C-equipement, the pumps and all parts involved in the spray process have to be earthed according to the scheme bellow. Earthing schema (example) Non-hazardous area Conveyor Hazardous area FlexControl Controller FlexControl Fluid (explosion-proof design) Object Pumps R max. < 1 MOhm Paint container B_00430 Floor conductive 24 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL Cable cross sections 2C equipment, pumps Paint container Conveyor Spray booth Spraying stand 5.10 4 mm2; AWG 11 6 mm2; AWG 10 16 mm2; AWG 5 16 mm2; AWG 5 16 mm2; AWG 5 MODEM CONNECTION The modem is attached over a two-wire line (a, b) to an analog telephone connection. The two-wire line will install over the cable coubling into the electric cabinet; ➞ acc. electrical connection diagram. In order to prevent an unintentional selecting into the control cabinet, the telephone connection should be plugged off with the modem after each use 5.11 PRINTER CONNECTION ➞ The printer (parallel) is attached over the printer cable, consisting of a PC/PPI cable, a Gender Changer and a converter cable to the control cabinet. ➞ The PC/PPI cable is connected by the D-Sub coupling with the electric cabinet with the control. The converter cable is attached to the printer. In order to have a right communication between control and printer, the DIP_switches must be correctly adjusted with the PC/PPI cable and with the converter cable. Switch-number PC/PPI cable - position Converter cable - position 1 0 on 2 1 off 3 0 on 4 1 off 5 1 off 6 0 on 7 - off 8 - off Expression: One prints out during an error message or when zeroing the sums on level 1. During an error message the date and the time as well as the kind of the error message are printed. If the sums zero are set, these are first still printed out. Also the date and the time, the mixing proportion as well as the C-factors are printed out with. 25 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 6 CONTROL UNIT 6.1 CONTROL ELEMENTS Turn / off: ➞ Turn the start switch to position on and the control unit will start – Turn it to off and – the control unit is switched of. Push button start / stop / flush: ➞ Push the start button and the automatic mix control has started, – the stop light flashes during filling the hose with mixed 2K material. – After filling the green start light is on ➞ Stop the automatic mix control with the stop button. ➞ Button flush starts the automatic flush program. The stop light flashes during flushing, after that the light it off. 6.2 OPERATING PANEL The 2C unit can be controlled by the operating panel. There are four levels: ➞ Operating level ➞ Calibration level ➞ Parameter level ➞ Configuration level. Data input: ➞ Press ENTER and the cursor goes to the first input field of the current page. ➞ Press ENTER again and the cursor jumps to the next input field. ➞ With the key arrow values can be changed. Push again ENTER to save the new value. 6.2.1 OPERATING LEVEL F1 ➞ After the software start up the operating level is on the display. ➞ With the key arrow you switch to four different pages. Push F1 in any other level and you always come to the operating level. 26 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL Page 1 Desired mixed ratio Remaining pot life time Key arrow "? Actual mixing ratio F1 F2 F3 F4 Enter button In the first page of the operating level ➞ The mixing ratio can be chosen by volume A:B = xx,x :1. (to change the mixing ratio a password is required - level 3). ➞ You see the actual mixing ratio (act) as well as the remaining pot life time (T) in minutes. Page 2 Quantity A "? Quantity B Quantity A+B In the 2. page of the operating level ➞ You see the fluid quantity used since the last reset. ➞ Push the stop button 3 seconds and this quantities are reseted. Page 3 Fluid flow A "? Fluid flow A+B Fluid flow B In the 3. page of the operating level ➞ You see the actual fluid flow of the components in milli litre per minute. 27 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL Page 4 "? In the 4. page of the operating level ➞ You see the flush quantity used during flushing. ➞ Push the stop button 3 seconds and this quantity are reseted. Page 5 Mode selection "? In the 5. page (Option) The following mode are possible: ➞ 0 (off ) = Shot automatic is not active ➞ 1 (auto) = Shot automatic is active ➞ 2 (man) = Manual shot mode, manual shots are possible Automatic mode If mode 1 is selected, press arrow button until the following page appears. Target quantity "? Actual quantity Enter the target quantity at „shot size“. The 2C unit only brings material as long as the shot signal is on. As soon as the target quantity is actived, all valves close and material flow stops. The next shot cycle starts only, if the shot signal is interrupted and again on. The shot signal must be on until the target material is spent, if it is interrupted during the shot cycle, also the material flow is stopped. The shot cycle will continue when the shot signal is again on. 28 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL Manual mode If mode 2 is selected, press arrow button until the following page appears. Actual quantity "? The target size „shot size“ is in this mode relevant. The 2C unit will feed material as long as the shot signal is on. The delivered quantity is displayed at “act Shot size”. 6.2.2 CALIBRATION LEVEL F2 It is not possible to do the calibration while the unit is in operation mode. Stop the unit before you can go in calibration level. ➞ With F2 you come into the calibration level, password is required. ➞ After that you are asked, which flow meter you want to calibrate. ➞ Enter 1 at CAL TYP to calibrate flow meter A – Enter 2 for flow meter B. Input field for flow meter type "? Calibrate procedure Quantity checked through the gun Quantity measured from flow meter "? The flow meter must be calibrated with the actual used fluid for a precise volume measurement. (The control unit calculates the calibration factor of the flow meter then automatically). Therefore proceed as follows: ➞ The unit is filled with 2C paint and the fluid is under pressure and the chosen fluid is already on the gun. – In the display appears the actual volume (Vact) and the set volume (Vset) of the chosen flow meter, both set to zero at the begin of calibration. ➞ Now a certain amount of fluid shall be filled in a measuring cup trough the gun. (e.g. 200 mL) – Now you see the quantity measured from flow meter in the display at „Vact“. 29 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL ➞ Quantify now the fluid amount in the measuring cup and enter in mL at „Vset“ and confirm with enter. – If you want to leave the calibration mode without calibration, press F2, and do not press Enter ! ➞ The control unit has now calculated the new calibration value and set the display to zero. ➞ Repeat now the calibration. ➞ When calibration is finished, push F2 to come again to the calibration start page, where you are asked, which flow meter you want to calibrate. ➞ Make sure the other fluid is on the gun before you start the calibration with the other fluid ➞ Frequent calibration of flow meter is required for a perfect quality of mixed fluid. ➞ New calibration must be done at relevant viscosity change or generally every 1 to 2 month. Press F1 to come to operating level. 6.2.3 PARAMETER-LEVEL F3 Push F3 to come to the parameter level. Enter the password and you come to the first page. Push arrow button to change pages. Page 1 "? In the first page of the parameter level 3 ➞ you find the values for the control cycle. ➞ In the second line the real value is shown during production. The standard setting is: – Btol= 1.0% Bqc= 150 ml ➞ Increase value Bqc at high flow rate. Page 2 Pot life control Pot life set value Pot life alarm delay "? Quantity of mixed fluid in hose 30 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL In the 2. page of the parameter level 3 ➞ Enter the pot life time in minutes at „TMIXset“. ➞ Enter the quantity of mixed fluid in milli liter in the hose at „VOL MIX“. ➞ When the unit is started, first of all the quantity „VOL MIX“ must flow trough the hose (filling) until mixed material is in the gun and ready to spray. – The red stop lamp is flashing during this process. ➞ The pot life control starts to count backwards after the unit has been started with the button „Start”. – The pot life time will be set to the set value, every time the flow quantity (VOL MIX) is over. – The stop lamp will be on and the display shows „flush!”, as soon as the pot life time has come to zero. ➞ The pot life time will be set to the set value, if you continue to spray or flush the unit. ➞ The pot life alarm can be delayed for the time (Ta). The pot life alarm comes again after this time, if nothing happens. C-factor of flow meter A "? C-factor of flow meter B Gun delay Page 3 In the 3. page of the parameter level 3 ➞ You see the calibration value KA and KB which were calculated at the calibration procedure. ➞ You may also change these values here. (Pulse/Liter) The gun delay (Tgun) in seconds is used to super wise the A flow meter. ➞ The unit stops if the A flow meter is blocked and the gun is open more then time Tgun, the unit will stop. Page 4 "? In the 4. page of the parameter level 3 ➞ Bqm is a value for the control cycle, set point: 0.2. 31 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL Page 5 "? In the 5. page of the parameter level 3 ➞ Here the operation mode is asked. – HP means high pressure up to 27 MPa; 270 bar; 3916 psi – LP (air) means low pressure up to 0.6 MPa; 6 bar; 87 psi High pressure HP 1. Step 2. Step 3. Step "? 4. Step 5. Step ➞ Define your flush program in this mask. – Enter zero, if you want to skip a step. ➞ Start the flush program with the button „Flush”. – The Stop lamp is flashing until it is finished. Low pressure LP "? 1. Step 2. Step 3. Step "? 4. Step Hose filling without air 5. Step Hose filling without air ➞ With the mode of operation low pressure – In 2. step will flush alternately with solvent and air. ➞ On the last mask the cycle time for solvent and air is to be entered. "? Time interval for solvent A Time interval for air 32 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL Page 6 Activate the Shot automatic The shot is used for a constant batch volume. The desired volume must be entered into the controller. The operator or a robot starts the short cycle. The material flow stops automatically, when the desired volume is delivered. The electronic control guarantees for a precision volume. The shot process can be interrupted and resumed. Manual mode is possible too. Select „shot mode“ "? ➞ Activate or deactivate the shot automatic with the function „shot mode“. ➞ 1 (on) = the Shot automatic is activated ➞ 0 (off ) = the Shot automatic is deactivated 6.3 PASSWORD The calibration level 2 and the parameter level 3 are protected by passwords. ➞ These passwords can be changed in the program level 4 from a Wagner engineer. – The basic setting is for level 2 = 22 and for level 3 = 33. 6.4 HAND ACTIVATING OF THE FLUID VALVES Press the push button on the fluid part to open the fluid valve A or B. B A "? 33 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL ➞ The flush valve can be activated by the control unit. – If a valve is open, the stop lamp is flashing. ➞ Push the stop button to close it again. – Shift F1 = open flush valve A – Shift F2 = open flush valve B – Shift F3 = open air flush valve Note The ESC- key will not be used. If it is erroneously pressed, appears „password enter - password ****“ Press in this case simply again the ESC- key. 6.5 TROUBLE SHOOTING ➞ If there is a disturbance, the fault appears on the display: – The stop lamp is on and the unit stops. – The fault can be reseted with the stop button. See trouble shooting to find the reason for it. See Chap. 8 34 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 7 START UP CAUTION Constant supply pressures! Poor coating results The supply pressure of the component B must be adjust to a higher value (appr. 10%) than that the component A. The supplying pressure should be constant. SIHI_0056_GB 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 peole. 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. Wear the appropriate protective clothing, gloves, eyewear, and respirator. SIHI_0059_GB WARNING Gas mixtures can explode if there is an incompletely filled unit! Danger to life from flying parts Ensure that the unit is always completely filled with cleaning agent or working medium. Do not spray the unit empty after cleaning. SIHI_0058_GB 35 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 7.1 PRELIMINARY WASHING AND PRESSURE TIGHTNESS TEST The equipment is tested at the factory using emulsified oil, plain oil or solvent, according to the kind of fluid being pumped. ➞ Before starting up the pump with the product, it is recommended to wash both circuits and feeding pumps with a proper solvent. WARNING Incompatibility of cleaning agent and working medium! Risk of explosion and danger of poisoning by toxic gasses Check the compatibility of cleaning agent and working medium in accordance with safety data sheets. SIHI_0060_GB 1. Preliminary flushing The material hoses must not be connected to the 2K-FlexControl until they are with the suitable solvent flushed together with the pumps ➞ Otherwise flowmeter can be plugged all ready with the first solvent flow due to contamination in the material hose or pump! ➞ For pumps preliminary washing, carefully follow there corresponding instruction. ➞ After all pumps and material hoses to the 2K-FlexControl has been flushed, the material hose can be connected to the 2K-FlexControl. ➞ The solvent still remains in the pumps. 2. Bleeding the system First bleed every circuit through the gun with little pump until clean solvent flows out the gun ➞ A and B components can be opened by pushing the button on fluid cabinet. ➞ The flush valve A is activated with the command „Shift F1“ on digital display of the control cabinet and closed again by pushing the stop-button. – As indication that the valve is open the stop light will flash. ➞ The flush valve B is activated with the command „Shift F2“ on digital display of the control cabinet and closed again by pushing – As indication that the valve is open the stop light will flash. 3. Pressure tightness test ➞ For pressure tightness control of the total installation gradually increase solvent pressure circuit by circuit until you reach the maximum pressure of the pumps. 36 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL WARNING Overpressure! Risk of injury bursting components The operating pressure must never exceed the value shown on the plate. SIHI_0054_GB ➞ Carefully examine the total installation for leakage – Hold the maximum pressure 2 minutes. – If there is a leakage, fix it. After inspection turn off air supply of all pumps, open the gun and circulation valve of all pumps to discharge the whole solent pressure. Note The solvent used for the first washing can not be used again since it could contain oil residues. 7.2 PRESSURE RELIEF PROCEDURE The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you: ➞ Are instructed to relieve the pressure ➞ Stop spraying ➞ Check or service any of the system equipment ➞ Install or clean the spray tip 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 peole. 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. Wear the appropriate protective clothing, gloves, eyewear, and respirator. SIHI_0059_GB 37 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL Pressure Relief Procedure for the hole system: 1. Set the operator switch to [STOP] 2. Relieve fluid and air pressure at the component and solvent feed pumps or pressure pots, as explained in their separate instruction manuals. 3. If using an electrostatic gun, make sure the electrostatic power is turned off. 4. Set the operator switch to [START] 5. Hold a metal part of the spray gun firmly to the side of a grounded metal pail, and trigger the gun to relieve fluid pressure. 6. Set the operator switch to [STOP] 7.3 FILLING THE UNIT AND CALIBRATION WARNING Do not exchange the two components A and B! Equipment damage by hardened paint Mark unit parts and paint container, so that the components A and B are not exchanged. SIHI_0061_GB 1. Prepare the hardener container, carry the solvent out the pump and fill it with hardener. 2. Set the hardener pump a little on pressure. Open the hardener valve with push button on fluid door, open the gun and hold it over a container suitable for washing solvent. 3. After the first filling with hardener the B flow meter has to be calibrated. See chap. 6.2 4. After that do it the same way with the A component. 7.4 START OF PAINTING ➞ Adjust the main component pressure according to the required flow rate, keeping in mind that B-component pressure must be higher (5 until 10%) than spraying pressure. ➞ Start the automatic cycle by pushing the [Start] button. ➞ Keep the spray gun open over a container suitable for washing solvent (waste container). – 2C fluid starts to flow and B-component is proportioned to the A component. ➞ Wait until the hose is filled with mixed 2C material. – This procedure is indicated by the flashing stop lamp. – As soon as this procedure is finished, flashing stops. – The green start lamp is on. – Only after filling correctly mixed fluid leaves the gun. 38 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL ➞ Now you can start with the painting. ➞ The fluid flow rate depends: – On fluid pressure – Cross section – Hose length – Nozzle and – The fluid viscosity. ➞ During production the B-valve shall operate every 1-3 seconds depending on the flow rate. ➞ The frequency can be optimized by the pressure adjustment of the hardener pump or by the stroke length of the hardener valve. With the push button [Stop] the automatic cycle can be stopped. All fluid valves are closed. 7.5 FLUSH, COLOUR CHANGE DANGER Exploding gas/ air mixture! Danger to life from flying parts and burns Never spray into a closed container. Earth the container. SIHI_0008_GB ➞ Follow the «Pressure Relief Procedure» on Chap. 7.2 whenever you are instructed to relieve the pressure. ➞ If you are using a high pressure gun, remove the spray tip before purging. – Relieve pressure before removing the spray tip. ➞ Wear protective eye wear. ➞ Use the lowest possible fluid pressure when purging. 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 peole. 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. Wear the appropriate protective clothing, gloves, eyewear, and respirator. SIHI_0059_GB 39 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL WARNING Discharge of the elektrostatic in atmospheres containing solvents! Fire and explosion hazard Turn off the electrostatics on an electrostatic gun before purging or before placing the gun in the Gun Flush Box. SIHI_0062_GB 1. Flush The unit is flushed at colour changes, longer interruptions or at work end. For that reason the unit must be stopped by the push button Stop, then start the flush program with the push button Flush. ➞ Keep the open gun in a suitable container until the flush program is completed. The stop light flashes during the flush program is running, after that all valves close. ➞ If the flushing is insufficient, flush a second time and adjust the flush program. (see chap. 6.3) 2. Colour change If the 2C unit has got more A components, choose the requested colour by the pneumatic switch on the fluid panel door. ➞ It must to be paid attention that only one A-component is preselected. WARNING Wrong mixing ratio! Poor surface quality Before change the color, check the mixing ratio on the display and, if necessarily change, if individual components have different mixing ratio. SIHI_0063_GB 3. Hardener change If the option 2 hardeners is installed, the correct hardener must be selected in each case to the A-component with the hardener selector switch. 7.6 GENERAL INFORMATIONS ➞ The pressure for solvent A and B must be on while the FlexControl is in use. ➞ If the unit is connected to a circular paint system, suitable valves must be placed in – Between to avoid mixing in case of leakage in the FlexControl. – These valves must be closed after work. 40 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 8 MAINTENANCE WARNING Incorrect maintenance/repair! Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup tions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and unit. - Secure the spray gun against actuation. Observe the operating and service instructions when carrying out all work. SIHI_0004_GB ➞ In accordance with the guideline for liquid emitter (ZH 1/406 and BGV D 15): – The liquid emitters are with need, at least however every 12 months to examine by experts (e.g. Wagner service technician) for their work-safe condition. – With shut down devices the examination can be suspended up to next start-up. 8.1 UNIT CLEANING ➞ A cleaned unit makes an easy localization of any leakage and quick repair. 8.2 FILTER CLEANING ➞ Refer to the corresponding manual to clean the filters on the supplying pumps and in the spray gun. 8.3 CONDENSATE DRAINAGE FROM THE FILTER-REDUCER ➞ Frequently drain the condensate that may accumulate in the air filter. – Make sure the water level in the filter cup never reaches the maxi. level marked on the cup itself. 41 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 8.4 FLOW GEAR METER ➞ The washing of the A flow meter will made through the automatic flushing procedure [Flushing]. ➞ If the single parts have to be cleaned, the equipment should be disassembled. 3 5 1 2 5 7 10 11 "? 1. Remove the electronic sensor (1) from the flow meter. – The sensor can be removed by loosening the screws from the holes (10) without removing the cover (11). 2. Unscrew the screws (2) - two opposite screws should be left in by two turns. 3. Take the cover (3) off the flow meter carefully parallel. – If necessary, knock softly on the cover with a plastic hammer, so that it separates. – The separation of the cover must be done parallel, so that the internal parts are not stressed. – For this reason do not use screwdrivers as levers. 4. Remove the screws which has been left screwed at the previous point. 5. Remove the cover, the gear wheels (7) and the shafts (5). – Mostly it is a dirt particle in the flow meter, which caused the problem. – If the parts cannot be easy removed, put the flow meter into suitable solvent. – Remove the parts afterwards without any force! – It is not important that the gear wheels turn on the shaft, is this not the case, it is not a suitable flowmeter for the used fluid. ➞ Call Wagner-Service for further information. Re assembly After the flowmeter has been cleaned shafts and gears have been assembled, check that the gears turn easily, even if you easily press with your finger against the shafts. 1. Assembly the cover again parallel in the correct position according to the reference pins. ➞ These pins must never be removed from the flow meter body. 42 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 2. Tighten the screws with 15 Nm; 11.06 lbft. 3. Using a short jet of compressed air, maximum 0.1 MPa; 1 bar; 14.5 psi and listen if the gears turn. 4. Assemble the electronic sensor again. and do not interchange A and B sensor. 8.5 MATERIAL VALVES Control the leakage (air or fluid discharge) out of the leakage hole of the Colour change valve in regular time intervals (one time per week). ➞ By air leakage: change rod sealing ➞ By fluid leakage: tighten or change the sealing ➞ Check the leakage of valve seats in regular time intervals, do a pressure test in accordance with chap. 7.1) 8.6 HIGH PRESSURE HOSE The lifetime of the fluid hoses is even with appropriate handling reduced due to environmental influences. ➞ The lifetime of the fluid hoses is even with appropriate handling reduced due to environmental influences. ➞ As precaution fluid hose should be replaced after a specified period by the plant operator. 8.7 CONTROL UNIT If with the main switch is turned off, the process dates remain in the internal eprom. ➞ Existing parameters must be teached in after a software update don by a flash (see parameter list 6.3). ➞ This is not necessary if the update is don by a modem. DANGER Bursting hose, bursting threaded joints! Danger to life from injection of material Ensure that the hose material is chemically resistant. Ensure that the spray gun, threaded joints and material hose between the unit and the spray gun is suitable for the pressure generated in the unit. Ensure that the following information can be seen on the highpressure hose: - Manufacturer - Permissible operating pressure - Date of manufacture. SIHI_0029_GB 43 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 8.8 DISMANTLING When the equipment must be scraped, please make a different disposal of the materials. The following materials have been used: ➞ Steel ➞ Aluminium ➞ Rubber ➞ Plastic ➞ Tungsten carbide Fluids (paints, adhesives, sealers, solvents) shall be disposed according to the valid specific standards. 44 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 9 TROUBLE SHOOTING In case of a fault, the reason is shown on the display, ➞ the stop lamp is on, ➞ the horn sounds (optional) and the unit stops. ➞ Confirm the fault with the push button Stop. In case of a alarm it is also important, from which work routine an fault was generated. 9.1 FAULTS AND APPROPRIATE SOLUTIONS Flush! The pot life is over, continue to spray or flush. AThere is more than 15 seconds (e.g. Gun delay Tgn in Chap. 6.3) atomizing air flow without fluid flow. – Or the flow meter is blocked due to contamination. – If there is a fluid flow, the LED must be on, otherwise it is blocked (open and clean it see point 8.) – Or the A-component is smaller than the minimum limit BThe quantity of B is too few. – It is too less B pumped for the selected mixing ratio is needed, – Increase the hardener pressure. – The stroke on the B valve is too short, untwist the adjustment screw a few. – It could also be that the B container is empty or the flow meter is blocked. (LED is not on although there is a fluid flow.) A+ The flow rate of A fluid is more than the maximum limit of the flow meter (0.8 gpm). – Reduce flow rate. B+ The flow rate of B fluid is more than the maximum limit of the flow meter (0.8 gpm). – Reduce flow rate. gun control Even though there is a fluid flow on the A side there is no open gun signal within 50 seconds. – The gun control sensor may be defect resp. there is no signal. – Repair or replace it. 45 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 10 INSTALLATION OF ACCESSORIES WARNING Electric shock hazard inside the controller! Danger to life from electric shock May only be installed/maintained by skilled electricians or under their supervision. Are operated in accordance with the safety regulations, fire and electro-technical rules. The voltage is switched off before work is begun on active components. SIHI_0045_GB 10.1 COLOUR EXTENSION Each unit must be ordered including all desired accessories, which are then installed. ➞ Is is possible to install later a colour extension from a Wagner serviceman. Follow the corresponding instruction. Order-no. 384125 Colour extension 2A 10.2 GUN CONTROL Statements for the Airless spray gun control system ➞ For the manually Airless- or HVLP gun is the following gun control system used. – In order to detect the blocking of the flow meter, the flow of material can be checked indirectly over the air consumption of the feed pumps – A flow sensor is suitable for it where the switch point can be adjust. It must not be connected any other air consumers (e.g. pumps for ring circuit system, agitator, etc.) than the feed pumps for the 2K-FlexControl (colour, hardener and solvent). Flow monitor "? Piston pump/ Air motor Colour 4 Colour 3 Colour 2 Colour 1 Hardener Solvent 46 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL Adjustment in the control of the 2K-FlexControl: ➞ Adjust the T gun (alarm delay approx. 20 seconds) so that there is no alarm if the gun will be closed. See Chap. 6.3 Adjustment of the flow switch not Ex proofed ➞ The flow sensor must be adjusted locally in accordance with enclosed operating instruction by IFM. ➞ Adjust with normal operation of the feed pumps – The maximum (page 9) flow and – The minimum flow when feed pumps are turned off (page 10). ➞ Afterwards the switching point can be adjusted (suggestion: 3) (page 11). Electric connection: ➞ See electrical schematic ➞ Installation of the flow switch: – In accordance with enclosed operating instruction of IFM (page 5-6). WARNING Incorrect installation of the unit! Risk of explosion and equipment damage The flow monitor is not Ex-proved and must be installed outside the Ex-area. Lay and fix the connecting cable correctly and protect against fall down and passage traffic. SIHI_0055_GB 10.3 CONVERSION OF DIFFERENT MIXING PROPORTION SPECIFICATION It is very important that the data sheets of the paint supplier are available, so that the correct mixing ratio can be entered. ➞ Some paint supplier indicate the mixing ratio by weight, others by volume. ➞ Since the flow meter measure volumetric, we need the specification in volume. #ONVERSIONOFMIXINGPROPORTIONOFGRAVIMETRICALLYINVOLUMETRIC &OREXAMPLE PARTSBYWEIGHT#OMP!AND PARTSBYWEIGHT#OMP" OR G#OMP! G #OMP" OR PARTSBYWEIGHT OR BYWEIGHT!GRAV"GRAV 4HE DENSITY OR SPEC VOLUME MUST OF THE COMPONENTS ! AND " ADMITS TO BE OR BE BEFOREHANDDETERMINED 47 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL $ENSITY 0! 0" 7EIGHT ! 6OLUME ! 7EIGHT " 6OLUME " GR CM GR CM GR CM GR CM +G , +G , -IXINGRATIO !GRAV -VOL!VOLÁ"VOL 0 "GRAV Á ! GR " GR -VOL Á GR GR CM 0 Á CM OTHERVOLMIXINGPROPORTIONSPECIFICATIONS PARTSBYVOLUME#OMP! PARTSBYVOLUME#OMP" 48 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11 SPARE PARTS 11.1 HOW TO ORDER SPARE PARTS? !LWAYSSUPPLYTHEFOLLOWINGINFORMATIONTOENSUREDELIVERYOFTHERIGHTSPAREPART 0ART.UMBERDESCRIPTIONANDQUANTITY 4HEQUANTITYNEEDNOTBETHESAMEASTHENUMBERGIVENINTHEu1UANTITYhCOLUMN4HIS NUMBERMERELYINDICATESHOWMANYOFTHERESPECTIVEPARTSAREUSEDINEACHSUBASSEMBLY 4HEFOLLOWINGINFORMATIONISALSOREQUIREDTOENSURESMOOTHPROCESSINGOFYOURORDER !DDRESSFORTHEINVOICE !DDRESSFORDELIVERY .AMEOFTHEPERSONTOBECONTACTEDINTHEEVENTOFANYQUERIES 4YPEOFDELIVERYREQUIREDAIRFREIGHTORMAILSEAROUTEOROVERLANDROUTEETC -ARKSINSPAREPARTSLISTS .OTETOCOLUMNu+hINTHEFOLLOWINGSPAREPARTSLISTS U 7EARINGPARTS .OTE.OLIABILITYISASSUMEDFORWEARINGPARTS L .OTPARTOFSTANDARDEQUIPMENTAVAILABLEHOWEVERASADDITIONALEXTRA WARNING Incorrect maintenance/repair! Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup tions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and unit. - Secure the spray gun against actuation. Observe the operating and service instructions when carrying out all work. SIHI_0004_GB 49 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 50 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.2 Point OVERVIEW SPARE PARTS Part No. Description 11.3 384001 ◆ Basic unit 1 (1A, 1B) not to be placed in a Ex-area 11.3 384003 ◆ Basic unit 1 (1A, 1B) not to be placed in a Ex-area AMERICA 11.4 384002 ◆ Basic Unit 2 (1A, 1B) fluid part Ex proofed, control part not Ex proofed 11.5 ◆ Control cabinet assy. 11.6 ◆ Fluid cabinet assy. - not Ex proofed 11.7 ◆ Fluid cabinet assy. - Ex proofed 11.8 384209 ◆ Atomizing air supply AirCoat dia 6 mm; 0.24 inch in 2K unit 11.9 384218 ◆ Atomizing air supply air gun dia 8 mm; 0.31 inch in 2K unit 11.10 384228 ◆ Atomizing air supply dia 6 mm; 0.24 inch on spray booth 11.11 384229 ◆ Atomizing air supply air gun dia 8 mm; 0.31 inch on spray booth 11.12 384244 ◆ Gun control for Airless gun, not Ex proofed 11.12 384270 ◆ Gun control for Airless gun, not Ex proofed AMERICA ◆ Flow meter 11.13 11.14 384284 ◆ Robot communication (24VDC) 11.14 384271 ◆ Robot communication (24VDC) AMERICA 11.15 384206 11.16 9998888 Foot set ( 4 piece needed for each stand) 11.17 377120 Wheel set (incl. 4 wheels for stand) assy. 11.18 384125 Colour extension 2A 11.19 384103 Colour change valve assy. 11.20 384226 ◆ Hardener extension 1B 11.21 384105 11.22 384246 ◆ 2 different solvent for hardener 11.23 384110 Material filter, assy., compact 11.24 139045 Material filter, assy., rotary 11.25 384208 ◆ Air/solvent flush set for A, maxi. 1 MPa; 10 bar; 145 psi in 2K unit 11.26 384127 11.27 3823733 Stand assy. Hardener dosing valve assy. Material pressure regulator set, pneum. 0-0.6 MPa; 0-6 bar; 0-87.02 psi in spray booth RV/ 1 Stainless steel pressure regulator with pneumatic remote control 11.28 384214 ◆ Material pressure regulator set 0.05-0.5 MPa; 0.5-5 bar; 7.25-72.5 psi in 2K unit 11.29 384217 ◆ Remote control Ex proofed with cable 10 m; 32.80 ft 11.30 377082 ◆ Remote control, pneumatic, without recipe, assy. 11.31 ◆ Manifold cabinet without recipe, assy. 11.32 ◆ Remote control, pneumatic, without recipe, assy. 11.33 377963 ◆ Connection set without recipe, 10 m; 32.80 ft 11.34 384234 ◆ Alarm horn 11.35 384253 ◆ Alarm horn in spray booth ◆ Can be ordered only with new equipment and not individually 51 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL Point Part No. Description 11.36 384238 ◆ Release of automatic cabin 11.36 384272 ◆ Release of automatic cabin AMERICA 11.37 384215 ◆ Teleservice with analog modem 11.38 384216 ◆ Printer connection without printer 11.39 384237 11.40 384219 ◆ Atomizing air automatic dia 6 mm; 0.24 inch (no air during filling and flushing) 11.41 384220 ◆ Atomizing air automatic dia 8 mm; 0.31 inch (no air during filling and flushing) 11.42 384243 ◆ Electrostatic Automatic 11.42 384273 11.43 384235 ◆ Set communication for gun flush box 11.44 384358 ◆ Bulkhead holder (a must if the FlexControl is has more than 3 colours and filters) 11.45 384249 ◆ Double valve for 2 guns (2K/ 3K operation) 11.46 384223 ◆ Extension set 3K operation - not Ex proofed 11.46 384277 ◆ Extension set 3K operation - not Ex proofed AMERICA 11.47 384224 ◆ Extension set 3K - fluid part Ex proofed 11.48 11.49 2302778 Extension static mixer Electrostatic Automatic AMERICA Same solvent A and B Adapter ◆ Can be ordered only with new equipment and not individually 52 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.3 Pos BASIC UNIT 1 (1A, 1B) NOT TO PLACED IN A EX-AREA K Qty Part No. Description in chapter 1 1 Control cabinet assy. 11.5 2 1 Fluid cabinet 1A 1B, assy. 11.6 3 1 384334 Profile 2 electric / pneumatic 4 8 9900318 Cheese head screw 5 8 9921501 Spring ring 6 1 384344 Profile 2 electric / pneumatic "? 53 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.4 Pos BASIC UNIT 2 (1A, 1B) FLUID PART EX PROOFED, CONTROL PART NOT EX PROOFED K Qty Part No. Description in chapter 1 1 Control cabinet assy. 11.5 2 1 Fluid cabinet 1A 1B, assy. 11.7 3 2 384344 Profile 2 electric/ pneumatic 4 2 384334 Profile 2 electric/ pneumatic 5 8 9921501 Spring ring 6 8 9900318 Cheese head screw 7 2 9935057 Blind rivet nut 8 1 9982072 Hose 1 m; 3.28 ft 9 1 9992290 Fitting Y, plug-in 10 1 9982062 Hose, blue 1 m; 3.28 ft 11 1 384111 Filter pressure reducing valve 1/4 assy. 12 2 9920104 Washer A4.3 13 2 9906004 Cheese head screw 14 1 3151777 Reducing, straight 15 1 384239 Connecting set assy., 10 m; 32.80 ft "? "? 54 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.5 Pos CONTROL CABINET, ASSY. K Qty Part No. Description 1 1 384331 Electro cabinet 2 1 384930 Spare part Simatic 3 1 3125139 Text Display 4 1 3155322 LED-element green 5 1 3155321 LED-element red 6 1 9955176 Power pack 7 1 9951115 Fuse, slow-acting 8 4 9956021 3/2 way valve Matrix 9 8 9971183 O-ring 10 2 9956095 Zener barriers (only in Ex version) 10 1 3 2 8 9 7 B_00383 6 5 4 WARNING Electric shock hazard inside the controller! Danger to life from electric shock May only be installed/maintained by skilled electricians or under their supervision. Are operated in accordance with the safety regulations, fire and electro-technical rules. The voltage is switched off before work is begun on active components. SIHI_0045_GB 55 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 56 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.6 Pos FLUID CABINET, ASSY. - NOT EX PROOFED K Qty Part No. Description 1 2 104376 Lock screw 2 2 123446 Double connector 3 5 350499 Screw-in socket 4 2 384115 Return valve, assy. 5 3 384116 Swivel assy. 6 2 7 1 384103 Colour change valve, assy. 8 1 384105 Hardener dosing valve assy. 9 1 384111 Filter pressure reducing valve 1/4 10 2 384323 Plug 11 1 384326 Mixing block 12 1 384340 Fluid cabinet 13 1 384911 Mixing pipe assy. 14 4 9943062 Base valve 15 2 9943071 Actuating piece 16 2 9943072 Actuating piece 17 1 9987084 Hose line 18 7 9990157 Pipe elbow union 90 degrees 19 2 9991785 Or-valve 20 2 9992290 Fitting Y plug-in 21 1 9992298 Cross piece 22 2 9992723 Fitting, straight 23 10 9992724 Screw in angle 24 1 9998066 Clamping profile edge protector 1.2 m; 3.93 ft 25 1 9998420 Pipe clamp 26 1 2302977 Pick-up assy. Flowmeter assy. (see chap. 11.13) 26a 1 384401 Cable with plug for Pick-up 27 1 9998788 Screw-in screw connection, straight 28 1 104618 Double connector 29 1 3151777 Reducing straight 384805 Sticker 30 31 2 9900329 Cheese head screw with hexagon 32 2 9900335 Cheese head screw with hexagon M5x50 33 2 9900353 Cheese head screw with hexagon M4x12 34 2 9907218 Cheese head screw with hexagon 35 4 9999161 Plug 57 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL Pos K Qty Part No. Description 36 2 9913053 Hexagon setting nut 37 6 9913054 Hexagon setting nut 38 2 9920806 Washer 39 2 9920101 Washer 40 2 9920104 Washer 41 1 384555 Nipple M16 NPS 1/4" 42 4 384556 Nipple M16 NPS 3/8" 35 15 19 30 16 14 20 12 5 4 6 2 18 21 23 8 34 37 36 10 1 17 24 26 11 27 38 25 13 7 32 3 40 33 39 31 3 42 B_00397 29 9 28 41 WARNING Incorrect maintenance/repair! Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup tions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and unit. - Secure the spray gun against actuation. Observe the operating and service instructions when carrying out all work. SIHI_0004_GB 58 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.7 FLUID CABINET, ASSY. - EX PROOFED Pos K Qty Part No. Description 1 2 104376 Lock screw 2 2 123446 Double socket 3 5 350499 Screw-in socket 4 2 384115 Return check valve assy. 5 3 384116 Swivel part, assy. 6 1 384103 Colour change valve, assy. 7 1 384105 Hardener dosing valve, assy. 9 2 384323 Plug 10 1 384326 Mixing block 11 1 384340 Fluid cabinet 5A 12 1 384911 Mixing pipe, assy. 13 4 9943062 Basic valve 3/2 14 2 9943071 Actuating piece 15 2 9943072 Actuating piece 16 1 9987084 High pressure hose 17 7 9990157 Pipe elbow union 90 degrees 18 2 9991785 Or-valve 19 2 9992290 Y connection, plug-in 20 2 9992724 Angle screwing in connection 21 1 9998420 Pipe clamp 22 2 2302977 Pick-up assy. 23 1 9998788 Screw-in screw connection, straight 24 1 104618 Double connection WARNING Incorrect maintenance/repair! Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup tions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and unit. - Secure the spray gun against actuation. Observe the operating and service instructions when carrying out all work. SIHI_0004_GB 59 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL Pos K Qty Part No. Description 5 9982072 Hose 27 1 384353 Plate to valve Ex proofed 28 1 9956064 3/2 way valve with spoil Atex 29 1 9956065 Clamp socket 30 5 9999231 Connection plug 31 2 Flow meter (see chap. 11.13) 27 29 28 14 15 13 11 19 18 7 9 1 31 B_00398 30 16 2 10 23 5 6 20 3 17 4 22 21 12 24 60 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.8 ATOMIZING AIR AIRCOAT DIA 6 MM; 0.24 INCH, IN 2K UNIT Pos K Qty Part No. Description 384209 Atomizing air supply NW6 mm; 0.24 inch in unit with monitoring 1 1 115313 Filter reducing valve 2 1 9998677 Pressure gauge 0-1 MPa; 0-10 bar; 0-145 psi 3 1 377088 Flow monitor assembly 4 2 9906005 Cheese head screw with hexagon M4x35 5 2 9992199 Angle screwing in connection swivelling 6 1 9981938 Hose 2.8 m; 9.19 ft 7 1 9992166 Fitting, straight 8 2 9994627 Double nipple 9 3 9950615 Cable tie 12 2 9998354 Angle screwing in connection 13 1 3102587 Bulkhead connection SCM-1/4 Festo 9 12 6 3 1 5 4 7 13 8 5 8 12 2 B_01875 61 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.9 Pos ATOMIZING AIR, AIR GUN DIA 8 MM; 0.31 INCH, IN 2K UNIT K Qty Part No. Description 384218 Atomizing air NW 8 mm; 0.31 inch in 2K unit with monitoring 1 1 115096 Pressure control valve 2 2 9970148 Sealing ring 3 2 9985685 Reducing piece 4 1 3304972 Screw connection, straight 5 2 9999208 Angle screwing in connection 6 1 9998725 Pressure gauge 0-1 MPa; 0-10 bar; 0-145 psi 7 1 377288 Flow monitor assembly 8 2 9956046 Grommet 9 1 9987076 Air hose, black 10 m; 32.80 ft 10 3 9950615 Cable tie short 12 2 9994627 Double connector 13 1 3102587 Bulkhead connection 16 2 9906005 Cheese head screw with hexagon 17 2 9999359 Screw in angle 10 17 12 5 9 7 1 16 13 4 6 3 5 12 17 2 8 B_01876 62 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.10 ATOMIZING AIR, AIRCOAT DIA 6 MM; 0.24 INCH, IN SPRAY BOOTH Pos K Qty Part No. Description 384228 Atomizing air NW 6 mm; 0.24 inch in spray booth with monitoring 1 1 115313 Filter reducing valve 2 1 9998677 Pressure gauge 0-1 MPa; 0-10 bar; 0-145 psi 3 1 9998781 Mounting set 4 1 377088 Flow monitor assembly 5 2 9906005 Cheese head screw with hexagon 6 2 9992199 Angle screw-in connection, straight 7 1 9981938 Hose 10 m; 32.80 ft 8 1 9992166 Screw connection, straight 9 1 9994627 Double nipple 10 3 9950615 Cable tie 12 2 9998354 Angle screwing in connection 10 12 7 4 1 6 5 8 3 9 12 2 6 B_01877 63 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.11 ATOMIZING AIR AIR GUN DIA 8 MM; 0.31 INCH, IN SPRAY BOOTH Pos K Qty Part No. Description 384229 Atomizing air NW 8 mm; 0.31 inch in spray booth with monitoring 1 1 115096 Pressure regulator valve 2 1 115999 Fastening set 3 2 9970148 Sealing ring 4 2 9985685 Reducing nipple 5 1 3304972 Screw connection, straight 6 1 9999208 Angle screwing in connection 7 1 9998725 Pressure gauge D50 mm; 1.97 inch, 1 MPa; 10 bar; 145 psi 8 1 377088 Flow monitor assembly 9 2 9956046 Grommet 10 1 9987076 Air hose, black 10 m; 32.80 ft 11 1 9970149 Sealing ring 12 1 9994627 Double nipple 13 3 9950615 Cable tie 14 1 9998987 Screw-in screw connection, straight 16 2 9906005 Cheese head screw with hexagon 17 2 9999359 Angle screwing in connection 18 1 9999357 Connection straight 18 13 2 17 3 1 6 10 8 16 4 5 7 4 11 14 12 12 3 9 B_01878 64 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.12 GUN CONTROL FOR AIRLESS GUN, NOT EX PROOFED 384244/ 384270 Pos Qty Part No. Description 1 K 1 9955834 Flow monitor 2 1 9955835 Cable 10 m; 32.80 ft 3 1 9955836 Adapter G1/2“ 4 1 9955242 Plug (only for 384270) AMERICA "? 11.13 FLOW METERS Pos K Qty Part No. Description 1 2302978 Flow meter with plain bearing 0.02-3 l/min 2 2302976 Flow meter with ball bearing 0.02-3 l/min 3 2302980 Flow meter with plain bearing 0.05-2 l/min 4 2308798 O-ring for item 1 and 2 "? 11.14 ROBOT COMMUNICATION 384254/ 384271 USA This operation must be selected, if a robot control or any other control unit activates the spray gun. The following signals are possible (relay for potential separation are in the FlexControl cabinet): ➞ From the robot to the FlexControl (always 24VDV): – Gun open (this signal is necessary to run the FlexControl) – Stop (will bring the FlexControl in stop mode) – Start (will start the FlexControl) – Flush (will start the flush program) ➞ From the FlexControl to the robot (all potential free contacts): – Ready (FlexControl is ready to spray) – Error (FlexControl is not ready, one of all error has stopped the FlexControl) – Flushing (FlexControl is in the flushing procedure) 65 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.15 STAND, ASSY. Pos K Qty Part No. Description 389094 Stand, assy. 4 9998888 Foot 4 9910105 Hexagon nut Qty Part No. Description 4 9998888 Foot set B_00386 11.16 FOOT SET Pos 1 K "? 66 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.17 WHEEL SET, ASSY. - 377120 Pos K Qty Part No. Description 1 2 9994946 Castor single 2 2 9994947 Castor with double stop "? 67 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.18 COLOUR EXTENSION 2A Pos K Qty Part No. Description 1 1 384103 Colour change valve assy. 2 2 350499 Screwed connector 3 2 9990157 Pipe elbow union 90 degrees 4 6 9992724 Screw in angle 5 1 9974164 O-ring 6 1 384329 Filling part 7 4 9900336 Cheese head screw 8 2 9943072 Control knob 9 2 9943062 Base valve 3/2 10 1 9982072 Hose 1 m; 3.28 ft 11 2 9992290 Fitting Y plug-in 12 2 34077 Lock nut assy. 4 9 11 8 6 1 5 2 10 3 B_00402 7 12 68 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.19 COLOUR CHANGE VALVE ASSY. - 384103 Pos K 1 Qty Part No. Description 2 350482 Compression spring 2 ✭ 2 350485 Sealing screw 3 ✭ 2 350486 Sealing collar 4 ✭ 2 350487 Pressure piece 2 350490 Clamping nut AL 5 6 ✭ 2 350491 Pressure ring 7 ✭ 2 384120 Valve rod assy., mounted 8 1 ** 9 2 384345 Piston 10 Valve housing, premounted 2 9913014 Hexagon nut 11 ✭ 12 9923513 Spring plate 12 ✭ 2 9974065 O-ring 13 ✭ 2 9974187 O-ring 384912 Service-set ✭ Included in service set ** The valve box can‘t be ordered as a spare part, but only the whole colour change valve. "? WARNING Incorrect maintenance/repair! Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup tions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and unit. - Secure the spray gun against actuation. Observe the operating and service instructions when carrying out all work. SIHI_0004_GB 69 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.20 HARDENER EXTENSION 1B Pos K Qty Part No. Description 1 1 384105 Hardener dosing valve assy. 2 2 350499 Screwed connector 3 2 9990157 Pipe elbow union 90 degrees 4 2 9992724 Screw in angle 5 1 9974164 O-ring 6 1 384329 Filling part 7 4 9900336 Cheese head screw 8 1 9943072 Control knob 9 1 9943130 Base valve 5/2 10 1 9982072 Hose 1 m; 3.28 ft 11 2 9992290 Fitting Y plug-in 12 1 34077 Lock nut assy. 13 1 384810 Sticker 2B 9 11 13 8 5 10 6 2 12 1 3 B_00403 4 7 70 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.21 HARDENER VALVE ASSY. - 384105 Pos K Qty Part No. Description 1 1 384103 Colour change valve, assy. 2 1 9913058 Hexagon nut 3 1 9907250 Hexagon head screw 4 1 389064 Separating fluid supply 4 3 2 1 B_00385 71 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL Separating fluid supply Pos K Qty Part No. Description 1 389064 Separating fluid supply 1 1 389444 One-way syringe 2 1 9950615 Cable tie 3 1 9982079 Hose D6 4 1 9999057 Plug-in connection, straight 5 1 9999125 Elbow hose connection 2 1 3 (Length 22-23 mm; 0.86-0.90 inch) 5 3 (Length 29-30 mm; 1.14-1.18 inch) 4 B_02359 72 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.22 2 DIFFERENT SOLVENT FOR HARDENER Pos K Qty Part No. Description 1 1 9999265 Pneumatic valve 5/2 2 5 9992724 Screw in angle 3 2 9992290 Connection Y pluggable Note ➞ If the option hardener extension is selected and there are two different solvent to flush hardener side, this option must be selected. ➞ The solvent will be at the same time changed as the hardener is switched to the other. "? 73 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.23 MATERIAL FILTER ASSY. - COMPACT - 384110 Pos K Qty Part No. Description 1 1 34383 Filter insert red 200 mesh 2 1 43590 Compression spring 3 1 71319 Fitting piece 4 1 179456 Nipple 5 1 9970123 Sealing ring 6 1 384313 Housing "? 11.24 MATERIAL FILTER ASSY. - WITH SWIVEL JOINT - 139045 Pos K Qty Part No. Description 1 34383 Filter insert red (200 mesh) 1 43235 Filter insert yellow (100 mesh) 1 34377 Filter insert white (50 mesh) 1 89323 Filter insert green (30 mesh) "? 74 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.25 AIR/ SOLVENT FLUSH SET FOR A, - MAXI. 1 MPA; 10 BAR; 145 PSI, IN 2K UNIT Pos K Qty Part No. Description 1 1 115313 Filter reducing valve 2 1 9998677 Pressure gauge 0-1 MPa; 0-10 bar; 0-145 psi 3 2 9992103 Fitting L, plug-in 4 1 9998694 Return check valve 5 2 9992106 Fitting, straight plug-in 6 1 9981938 Hose 0.3 m; 0.98 ft 7 1 9992199 Fitting L, plug-in 8 1 384103 Colour change valve assy. 9 1 350499 Screwed connector 10 1 9990157 Pipe elbow union 90 degrees 11 2 9992724 Screw in angle 12 1 9974164 O-ring 13 1 384329 Filling part 14 4 9900336 Cheese head screw 15 1 9982072 Hose 1 m; 3.28 ft 16 1 9956021 3/2 way valve Matrix 17 1 34077 18 2 9907229 Cheese head screw 19 2 9971183 O-ring 20 1 9994627 Double connector 21 1 3102587 Bulkhead connection Lock nut assy. "? 75 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.26 Pos MAT. PRESSURE REGULATOR SET, PNEUM. 0.5 MPA; 0-5 BAR; 72.5 PSI, IN SPRAY BOOTH K Qty Part No. Description 1 1 104376 Lock screw 2 1 115313 Filter reducing valve 3 1 115378 Connector R3/8 4 1 118482 Reducing nipple 5 1 350271 Double nipple 6 1 T0170.00BI 7 1 9982072 Hose 1 m; 3.28 ft 8 3 9985559 Reducing nipple 9 1 9998253 Screw in angle 8-1/4 10 1 9998677 Pressure gauge 0-1 MPa; 0-10 bar; 0-145 psi 11 1 9998781 Mounting set 12 4 9999066 Angle screwing in connection Pressure regulator 0-0.5 MPa; 0-5 bar; 0-72.5 psi "? 76 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.27 PRESSURE REGULATOR RV/ 1 STAINLESS STEEL, WITH PNEUMATIC REMOTE CONTROL Pos K Qty 1 Part No. Description T0170.00BI Pressure regulator RV/ 1 stainless steel, with pneumatic remote control 2 A588.03 Diaphragm disk Product 3 A590.03 Diaphragm disk Air 4 Body Guide Ball ◆✭ 5 6 ◆✭ 7 ◆✭ 10 ◆✭ 11 Shoving rod B563.01 Upper reducer valve body T6007.00A Complete ball seat body 8 9 B391.03 12 B620.03B Lower reducer valve body G725.05 PTFE paint pressure reducer diaphragm G726.06 Paint pressure reducer diaphragm H285.03 Spring K316.62 Nut ◆✭ K811.03 Ball 16 ◆✭ L118.06A O-ring 17 ◆✭ L148.06 O-ring 14 15 Ball seat 3826024 Spare parts kit comprising at pos. 5,7,9,11,14,16 and 17 ◆ = Wearing part ✭ = Included in service set 3826024 3.5 Nm; 2.58 lbft 12 6 10 3 7 9 8 2 1 5 16 15 17 14 11 B_00427 4 77 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.27.1 TECHNICAL DATA Material used: Regulation part Stainless steel Area that comes in contact with the product Product diaphragm PTFE Lock ball Stainless steel Lock seat Tungsten carbide Capacity With fluids having a viscosity of 45 mPa.s Corresponding to about 20 s. Ford 4 Inlet pressure 0.5 MPa; 5 bar; 72.5 psi Outlet pressure "? Flow rate l/min. Maximal air connection 2.5 MPa; 25 bar; 362.59 psi Maximal inlet pressure control air 0.5 MPa; 5 bar; 72.5 psi Maximal outlet pressure 0.5 MPa; 5 bar; 72.5 psi Regulation field 0-0.5 MPa; 0-5 bar; 0-72.5 psi Product inlet connection (gas) 3/8“ Spring Product outlet connection (gas) 1/4“ Slot Pressure gauge connection (gas) 1/4“ Slot Air inlet connection (gas) 1/8“ Slot Dimensions (*) Diameter 75 mm; 2.95 inch Height 83 mm; 3.26 inch Note Pneumatic remote control (*) Dimensions are not binding 78 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.28 Pos MATERIAL PRESSURE REGULATOR SET 0-0.6 MPA; 0-87.02 PSI IN 2K UNIT K Qty Part No. Description 1 1 104376 Lock screw 2 1 115378 Connector R3/8 3 1 118482 Reducing nipple 4 1 123459 Pressure gauge socket 5 1 350271 Double nipple 6 1 T0170.00BI 7 1 9982072 Hose 1 m; 3.28 ft 8 2 9985559 Reducing nipple 9 1 9991920 Pressure regulator 0-1 MPa; 10 bar; 145 psi 10 1 9992290 Fitting Y, plug-in 11 1 9998677 Pressure gauge 0-1 MPa; 10 bar; 145 psi 12 3 9999066 Angle screwing in connection Material pressure regulator "? 79 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.29 REMOTE CONTROL EX PROOFED, WITH 10 M; 32.8 FT CABLE Pos K Qty Part No. Description 1 1 384375 Cable kit Remote control 2 1 377077 Remote control 3 1 9955978 Chassis-socket 16-pol "? 80 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.30 REMOTE CONTROL PNEUMATIC, WITHOUT RECIPE, ASSY. - 377082 Pos K Qty Part No. Description 1 1 Chap. 11.31 Manifold cabinet without recipe assy. 2 1 Chap. 11.32 Remote control pneumatic without recipe 3 1 377963 Connection set without recipe 1 3 2 B_00434 Non hazardous area Hazardous area 81 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.31 MANIFOLD CABINET WITHOUT RECIPE, ASSY. Pos K Qty Part No. Description 1 8 364331 Seal 2 1 377478 Cabinet manifold assy. 3 1 384314 Housing 4 1 3108160 End plate 2.5 mm² 5 1 3110841 Cross link 2.5 mm² 6 1 3156825 Cable coupling ST-M20x1.5 7 1 3156833 Jam nut GMP-GL-M 20x1.5 8 1 3156835 Jam nut GMP-GL-M 32x1.5 9 1 9900224 Hexagon screw M6x25 10 4 9900318 Cheese head screw M8x20 11 8 9900334 Cheese head screw M4x8 12 2 9900338 Cheese head screw M6x30 13 2 9900365 Cheese head screw M4x25 14 2 9907220 Hexagon head drill screw St3.5x13 15 4 9907229 Cheese head screw M3x40 16 2 9910102 Hexagon nut M6 17 4 9920102 Washer A8.4 18 4 9920103 Washer A6.4 19 1 9921502 Spring ring A6 20 1 9922 017 Serrated lock washer A6.4 21 1 9950344 Mounting rail 90 mm; 3.54 inch 22 2 9955327 Holder End piece 23 1 9955959 4-Lead earthed lead term 24 2 9955974 4-Wire-basic-terminal 25 2 9956021 3/2 way valve MATRIX 26 2 9956029 Triple deck diode terminal block 27 1 9956034 End plate 28 1 9956038 Triple deck terminal block 29 3 9956080 Pressure switch 30 1 9956083 2 way comb jumper 31 1 9956084 Cable coupling M32x1.5 32 3 9970149 Sealing ring 33 4 9971183 O-ring 5x1 34 1 9998090 Screw-in screw connection, straight 35 1 9998614 Schott-plug in straight D6 mm; 0.24 inch 36 2 9998868 Wall holder 82 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL Pos K Qty Part No. Description 37 3 9999266 Screw connection 38 2 9999267 Pipe clamp 39 1 377503 Cable 11 m; 36.08 ft 40 1 9955979 Cable switch 10 36 2 14 19 18 16 21 7 26 28 4 5 23 24 34 1 11 29 17 8 20 30 22 27 38 18 12 32 6 38 37 3 33 13 25 15 9 31 35 39 40 B_00456 83 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.32 REMOTE CONTROL PNEUMATIC WITHOUT RECIPE, ASSY. Pos K Qty Part No. Description 1 1 377479 Cabinet pneumatic without recipe, assy. 2 1 377884 Sticker for remote control 3 1 3156835 Jam nut M32x1.5 4 1 9900224 Hexagon screw M6x25 5 4 9900318 Cheese head screw M8x20 6 2 9910102 Hexagon nut M6 7 4 9920102 Washer A8.4 8 2 9920103 Washer A6.4 9 1 9921502 Spring ring A6 10 1 9922017 Serrated lock washer A6.4 11 1 9943031 Optical display red 12 1 9943032 Optical display green 13 3 9943062 Basic valve 3/2 14 3 9943071 Control knob 15 1 9956084 Cable coupling M32x1.5 16 6 9992724 Screw in angle D4-M5 17 2 9992725 Screw in angle D4-G1/8“ 18 2 9998868 Wall holder 5 3 6 18 9 8 17 11 12 10 7 1 4 B_00433 15 16 13 14 2 84 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.33 CONNECTION SET WITHOUT RECIPE, 10 M; 32.8 FT - 377963 Pos Qty Part No. Description 1 K 2 9956042 Cable lug with isolation 2 2 9955709 Lettering No. 1 3 2 9955711 Lettering No. 3 4 2 9955712 Lettering No. 4 5 2 9955713 Lettering No. 5 6 2 9955714 Lettering No. 6 7 2 9955715 Lettering No. 7 8 3 9950615 Cable tie 9 6 9982072 Hose DA 4 / DI 2.5, 11 m; 36.09 ft ; 10 1 9953412 Strand spool 1.5 mm , 11 m; 36.09 ft 11 1 9982016 Protective hose d40x1.4, 10.5 m; 34.45 ft 12 1 9998461 Textile tape 50 mm; 1.97 inch, 0.01 m; 0.39 inch 2 11.34 ALARM HORN - 384234 Pos K Qty Part No. Description 1 1 9956051 Alarm horn 2 1 384376 Cable kit 3 1 9910208 Hexagon nut with clamp 4 2 9920102 Washer 5 1 9956068 Time relay "? 85 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.35 ALARM HORN IN SPRAY BOOTH - 384253 Pos K Qty Part No. Description 1 1 R037.00 Pneumatic horn 2 1 9943023 One way restrictor 3 1 9956021 3/2 way valve MATRIX 4 1 9956026 Grommet 5 2 9971183 O-ring 6 2 9907229 Cheese head screw "? 86 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.36 RELEASE OF AUTOMATIC CABIN - 384238 Pos K Qty Part No. Description 2 1 9955956 Contactor clamp 3 1 9955957 End plate "? 11.37 TELESERVICE WITH ANALOG MODEM - 384215 Pos K Qty Part No. Description 1 384373 Cable kit for teleservice 2 1 9955327 Holder End piece 3 1 9955960 3 conductor double level clamp 4 1 9955947 Modem 5 1 9955961 End plate "? 87 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.38 PRINTER CONNECTION WITHOUT PRINTER Pos K Qty Part No. Description 1 1 9955941 D-Sub cable 2 1 3125137 PC/ PPI cable 3 1 9956015 Interface-converter cable 4 1 9956016 Mini Gender-Changer 5 1 9955995 Profibus Module 6 1 9955977 D-Sub socket 7 2 9907223 Fastening screw 8 1 9952405 Ferrite core ring "? 88 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.39 EXTENSION STATIC MIXER Pos K Qty Part No. Description 1 1 104618 Double connector 2 1 384352 Connection connector 3 1 384911 Mixing pipe, assy. "? 89 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.40 ATOMIZING AIR AUTOMATIC DIA 6 MM; 0.24 INCH - 384219 Pos K Qty Part No. Description 1 1 9950967 Solenoid valve 5/2 2 1 9998253 Screw in angle 8-1/4 3 1 9981938 Hose 0.05 m; 1.97 inch 4 1 377507 Cable 5 1 9955818 Mains socket 6 1 9998254 Screw-in screw connection, straight "? 11.41 ATOMIZING AIR AUTOMATIC DIA 8 MM; 0.31 INCH - 384220 Pos K Qty Part No. Description 1 1 9950967 Solenoid valve 5/2 2 1 9999208 Screw in angle 8-1/4 3 1 9981985 Hose 0.05 m; 1.97 inch 4 1 377507 Cable 5 1 9955818 Mains socket 6 1 9998987 Screw-in screw connection, straight 4 2 6 3 5 1 B_00396 90 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.42 ELECTROSTATIC AUTOMATIC - 384243 Pos K Qty Part No. Description 1 1 350025 Adapter box assy. 2 2 9955956 Relay "? 11.43 SET COMMUNICATION FOR GUN FLUSH BOX - 384235 Pos K Qty Part No. Description 1 2 9950385 Fastening elements 2 2 9956026 Grommet 3 1 9956029 Triple deck diode terminal block 4 1 9982018 Hose 0.04 m; 1.57 inch 5 1 9999227 Solenoid valve 6 3 9999231 Connection 7 1 9992290 Y-Connection "? 91 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 11.44 Pos BULKHEAD HOLDER (BY MORE THAN 3 COLOURS/ FILTERS) K Qty Part No. Description 1 1 384349 Bulkhead holder 2 x 9987084 Material hose Teflon L=500 2 x 9987115 Hardener hose Teflon L=650 3 4 9910102 Hexagon nut 4 4 9925048 Spring ring 5 8 9920103 Washer 6 4 9900325 Cheese head screw with hexagon 7 1 384350 Bulkhead fastener "? 92 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.45 DISTRIBUTION SET FOR 2 GUNS (2K / 3K OPERATION) - 384249 Pos 1 2 3 4 5 6 7 8 9 10 11 12 13 K Qty 1 1 3 2 1 2 2 2 6 2 2 2 1 Part No. 384103 104376 350499 9990157 9987084 9900335 9921517 9910106 9992724 9992290 9943062 9943072 384323 Description Colour change valve assy. Lock screw Screwed connector Pipe elbow union 90 degrees High pressure hose Cheese head screw Spring ring Hexagon nut Screw in angle Fitting Y, plug-in Base valve 3/2 Control knob Plug 9 11 12 10 2 13 6 7 8 5 4 3 1 B_00413 WARNING Incorrect maintenance/repair! Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup tions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and unit. - Secure the spray gun against actuation. Observe the operating and service instructions when carrying out all work. SIHI_0004_GB 93 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.46 EXTENSION SET 3K OPERATION - NOT EX PROOFED - 384223 Pos K Qty Part No. Description 1 1 384115 Return check valve assy. 2 1 Flow meter, assy. (see chap. 11.13) 3 1 2302977 Pick-up assy. 3a 1 384401 Cable with plug for Pick-up 4 1 384116 Swivel part, assy. 5 2 9990157 Pipe elbow union 90 degrees 6 2 350499 Screwed connector 7 1 350062 GA 400AL-D 8 1 357470 Swivel part, assy. 9 1 117206 Swivel part, assy. 10 1 384326 Mixing block 11 1 9998788 Screw-in screw connection, straight 12 1 384911 Mixing pipe assy. 13 1 104618 Double connection 14 1 9998420 Pipe clamp 15 2 9900338 Cheese head screw 16 4 9925031 Washer 17 4 9910204 Hexagon nut with clamp 18 2 9900316 Cheese head screw 19 1 9987115 High pressure hose 20 1 9943071 Control knob 21 1 9991785 Or-valve 22 1 9943062 Base valve 3/2 23 1 9992290 Connection Y, plug-in 24 2 9992724 Screw in angle 25 1 9999066 Angle screwing in connection 26 1 9956029 Triple deck diode terminal block 27 1 9956021 3/2 way valve MATRIX 28 2 9955718 Cable screwing 29 2 9956026 Grommet 30 2 9971183 O-ring 31 2 9907229 Cheese head screw 32 1 350489 Seal 94 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL WARNING Incorrect maintenance/repair! Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup tions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and unit. - Secure the spray gun against actuation. Observe the operating and service instructions when carrying out all work. SIHI_0004_GB 25 18 23 21 29 7 20 32 22 24 8 9 31 4 27 2 30 3 26 1 28 10 6 5 11 17 16 14 12 15 19 13 B_00400 95 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.47 EXTENSION SET 3K FLUID PART - EX PROOFED Pos K Qty Part No. Description 1 1 384115 2 1 3 1 2302977 Pick-up assy. 4 2 384116 Swivel part, assy. 5 2 9990157 Pipe elbow union 90 degrees 6 2 350499 Screwed connector 7 1 350062 GA 400AL-D 8 1 357470 Swivel part, assy. Return check valve assy. Flow meter, assy. (see chap. 11.13) 9 1 384326 Mixing block 10 1 9998788 Screw-in screw connection, straight 11 1 384911 Mixing pipe, assy. 12 1 104618 Double connection 13 1 9998420 Pipe clamp 14 2 9900338 Cheese head screw 15 4 9925031 Washer 16 4 9910204 Hexagon nut with clamp 17 2 9900316 Cheese head screw 18 1 9987115 High pressure hose 19 1 9943071 Control knob 20 1 9991785 Or-valve 21 1 9943062 Base valve 22 1 9992290 Connection Y, plug-in 23 2 9992724 Screw in angle 24 1 9999066 Angle screwing in connection 25 1 9956026 Grommet 26 1 384353 Plate to valve Ex proofed 27 1 9956064 3/2 way valve with winding Atex 28 1 9956065 Terminal box 29 1 9956029 Triple deck diode terminal block 30 1 9951115 Fuse, slow-acting 31 1 9956095 Zener barriers 32 1 117206 Swivel part, assy. 96 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL WARNING Incorrect maintenance/repair! Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup tions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and unit. - Secure the spray gun against actuation. Observe the operating and service instructions when carrying out all work. SIHI_0004_GB 20 31 30 22 24 17 29 7 23 25 8 6 5 21 32 19 27 9 28 18 2 10 3 1 16 15 11 26 13 14 12 4 B_00401 97 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 11.48 SAME DETERGENT WITH A AND B - 2302778 Pos K Qty Part No. Description 1 1 9987084 Material hose Teflon L=500 mm; 19.69 inch 2 1 377093 Circulation connector Part No. Description 384555 Adapter M16 inside to NPS 1/4" outside 384556 Adapter M16 inside to NPS 3/8" outside 384559 Adapter M16 inside to G1/4" outside 377342 Adapter M16 inside to G3/8" outside 11.49 ADAPTER Pos K Qty 98 EDITION 09 /2009 FLEXCONTROL PART.-NO. DOC384861 OPERATING MANUAL 12 TABLES / PARAMETERS 12.1 TABLE HOSE VOLUME Di = Inside diameter hose L = Hose length Vol = Material volume in the hose $I , 6OL $I , 6OL ;MM= ;M= ;,= ;MM= ;M= ;,= 99 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 12.2 SYSTEM PARAMETER 2K-FLEXCONTROL Level Parameter Basic setting F1 A:B 1,0:1 F3 Btol= 1.0 % Bqc= 150 mL TMIXset 180 min Ta 5 min VOL MIX= 150 mL KA 11000 P/L KB 11000 P/L Tgn 5s Bqm= 0,200 mL FLUSHING 1 1=HP, 2=LP High pressure (HP) B 5s A 100 mL B 3s A 400 mL B 0s Customer setting Remarks Low pressure (LP) B 5s A 20 s B 0s A end 400 mL B end 0s Shot Mode 0 (off ) Solvent/air Tkt F4 solv= 2,0 s air= 2,0 s A - 5 mL B - 5 mL C - 5 mL A+ 3000 m L B+ 3000 m L C + 3000 m L Code Level 2 22 Code Level 3 33 number of B valves 1 100 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL Level Parameter Basic setting F4 Komp C? 0 (off ) Printer? 0 (off ) Gun flush box? 0 (off ) Save? 0 Customer setting Remarks Save after Start-up! 101 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL "? 13 CONNECTION DIAGRAMS - NOT EX PROOFED 102 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 103 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 104 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 105 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 106 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 107 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 108 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 109 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 110 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 111 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 112 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 113 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 114 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 115 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL 14 CONNECTION DIAGRAMS - EX PROOFED 116 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 117 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 118 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 119 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 120 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 121 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 122 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 123 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 124 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 125 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 126 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 127 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 128 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL "? OPERATING MANUAL 129 EDITION 09 /2009 PART.-NO. DOC384861 FLEXCONTROL OPERATING MANUAL Germany J. WAGNER GmbH Otto-Lilienthal-Str. 18 Postfach 1120 D- 88677 Markdorf Telephone: +49 7544 5050 Telefax: +49 7544 505200 E-Mail: [email protected] Switzerland J. WAGNER AG Industriestrasse 22 Postfach 663 CH- 9450 Altstätten Telephone: +41 (0)71 757 2211 Telefax: +41 (0)71 757 2222 E-Mail: [email protected] Belgium WAGNER Spraytech Benelux BV Veilinglaan 58 B- 1861 Wolvertem Telephone: +32 (0)2 269 4675 Telefax: +32 (0)2 269 7845 E-Mail: [email protected] Denmark WAGNER Industrial Solution Scandinavia AB Viborgvej 100, Skoergoer DK- 8600 Silkeborg Telephone: +45 702 00245 Telefax: +45 868 56027 E-Mail [email protected] United Kingdom WAGNER Spraytech (UK) Ltd. Haslemere Way Tramway Industrial Estate GB- Banbury, OXON OX16 8TY Telephone: +44 (0)1295 265 353 Telefax: +44 (0)1295 269861 E-Mail: [email protected] France J. WAGNER France S.A.R.L. Parc de Gutenberg - Bâtiment F8 8, Voie la Cardon F- 91127 Palaiseau-Cedex Telephone: +33 1 825 011 111 Telefax: +33 1691 946 55 E-Mail: [email protected] Netherlands WAGNER SPRAYTECH Benelux BV Zonnebaan 10 NL- 3542 EC Utrecht Italy WAGNER COLORA S.r.l Via Fermi, 3 I- 20040 Burago di Molgora (MI) Telephone: +31 (0) 30 241 4155 Telefax: +31 (0) 30 241 1787 E-Mail: [email protected] Telephone: +39 039 625021 Telefax: +39 039 6851800 E-Mail: [email protected] Japan WAGNER Spraytech Ltd. 2-35, Shinden Nishimachi J- Daito Shi, Osaka, 574-0057 Telephone: +81 (0) 720 874 3561 Telefax: +81/ (0) 720 874 3426 E-Mail: [email protected] Austria J. WAGNER GmbH Otto-Lilienthal-Str. 18 Postfach 1120 D- 88677 Markdorf Telephone: +49 (0) 7544 5050 Telefax: +49 (0) 7544 505200 E-Mail: [email protected] Sweden WAGNER Industrial Solutions Scandinavia AB Skolgaten 61 SE- 56831 Skillingaryd Telephone: +46 (0) 421 500 20 Telefax: +46 (0) 370 798 48 E-Mail: [email protected] Spain WAGNER Spraytech Iberica S.A. Ctra. N- 340, Km. 1245,4 E- 08750 Molins de Rei (Barcelona) Telephone: +34 (0) 93 680 0028 Telefax: +34 (0) 93 668 0156 E-Mail: [email protected] Czechoslovakia WAGNER s.r.o. Nedasovská Str. 345 15521 Praha 5 - Zlicin Telephone: +42 (0) 2 579 50 412 Telefax: +42 (0)2 579 51 052 E-Mail: [email protected] USA WAGNER Systems Inc. 300 Airport Road, unit 1 Elgin, IL 60123 USA Telephone: +1 630 503 2400 Telefax: +1 630 503 2377 E-Mail: [email protected] 130 ED FI CERT I /RDERNUMBER 384861 'ERMANY *7!'.%2'MB( /TTO,ILIENTHAL3TR 0OSTFACH $-ARKDORF 4ELEPHONE 4ELEFAX %-AILSERVICESTANDARD WAGNERGROUPCOM 3WITZERLAND *7!'.%2!' )NDUSTRIESTRASSE 0OSTFACH #(!LTSTËTTEN 4ELEPHONE 4ELEFAX %-AILREPCH WAGNERGROUPCH WWWWAGNERGROUPCOM
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Key Features
- Electronic mixing ratio control
- Automatic flushing system
- Solvent and water based 2K materials processing
- Shot automatic mode
- Manual shot mode
- Integration with supervisory system
- Security measures and parameter checking
Frequently Answers and Questions
What types of paint materials can I use with the FlexControl 2K-FlexControl?
This system can handle both solvent-based and water-based 2K materials. However, do not process solvent-basic and aqueous-basic 2K materials with the same system.
How do I change the mixing ratio on the FlexControl 2K-FlexControl?
A password is required to change the mixing ratio. You can adjust this on level 3 of the operating panel.
What is the purpose of the automatic flushing system?
The automatic flushing system helps to minimize solvent waste and ensure clean lines and components between paint changes.
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