WAGNER 2K COMFORT Original Operating Manual

− Mixing tube:

Mixing elements made of stainless steel in mixing tube set 6-32: max. 28.2 MPa; 282 bar;

4,090 psi

Mixing elements made of stainless steel in mixing tube set 8-32: max. 22.6 MPa; 226 bar;

3,278 psi

XL: Mixing elements made of stainless steel in mixing tube set 10-32: max. 40 MPa; 400 bar;

5,800 psi

− XL version with product pressure regulator:

Input pressure max. 4 MPa; 40 bar; 580 psi

Product outlet max. 0.8 MPa; 8 bar; 116 psi

− XL version with -air flushing: Input pressure max. 2.5 MPa; 25 bar; 362 psi

** When air bubbles monitoring max. 0.8 MPa; 8 bar; 116 psi

*** When air bubbles monitoring or product pressure regulator max. 0.8 MPa; 8 bar; 116 psi

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Product pH value

Product temperature

Ambient temperature

Operation

Assembly

Suspension

Lowpressure version

Highpressure version

XL version

3.5–9

+5 °C … +60 °C

+41 °F … +140 °F

+5 °C … +40 °C

+41 °F … +104 °F

0 °C … +40 °C

+32 °F … +104 °F

-20 °C … +60 °C

-4 °F … +140 °F

10–95% (without condensation)

0.1:1 … 50:1

0.00:1 (1K)

XL version +

Coriolis

Relative humidity

Mixing ratio, volumetric

A/B or (A+B)/C or (A+B+C)/D

Dosing precision

System with flow meters

(for all components)

System with stroke sensors

(min. one component)

± 1% precision in mixing ratio *

± 2% precision in mixing ratio *

* The target mixing ratio at a precision level of ± 1% or ± 2%, is achieved after each completed cycle

(injection of hardener into base lacquer).

Precision of 1% or ± 2% is achieved under the following conditions:

− Proper use of the system in compliance with the operating manuals.

− Correct calibration and function of the flow meters or stroke sensors in accordance with Chapter

− Correct adjustment of the compression ratio between the base lacquer and hardener.

see Chapter

accordance with Chapter 9 .

− Correct adjustment of the hardener metering valve stroke, or use of the AIS.

− Exact setting of the system to suit the product used, in accordance with the processing specifications stipulated by the product manufacturer.

− For a homogenous density of the base lacquer and hardener it might be necessary to make respective preparations in tanks, for example by applying an agitator.

− Correct use of the system in accordance with the specific operating conditions such as the permitted product and ambient temperature, permitted viscosity and flow rate.

− Regular maintenance has to be carried out by a qualified person (e.g., WAGNER Service Technician) in

Maximum number of A/B/C/D paint and dosing valves **

Maximum number of A/B/C/D flushing valves **

25/10/10/10

10/5/5/5

DN 10: 4/–/–/– ***

DN 4: 10/5/5/5 ***

DN 2.6: –/5/5/5 ***

DN 4: 1/1/1/1 ***

DN 2.6: –/1/1/1 ***

Maximum number of guns **

Sound pressure level during alarm

110 dB(A)

(A-rated sound pressure level measured at 1 m distance, LpA1m, according to DIN EN 14462: 2005.)

Distance control cabinet - fluid section

Weight (approx.) up to 10 m; 32.8 ft / 15 m; 49.2 ft / special versions available

80–250 kg 120–300 kg

** for 2-circuit system, see Chapter

5.5.1.1

*** More valves for XL version available on request.

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5.5.1.1 LIMITATIONS FOR 2-CIRCUIT SYSTEMS

Limitations for 2-circuit systems opposite the data in Chapter

5.5.1

2K / 3K / 4K system

Maximum number of A/B/C/D paint and dosing valves 25/10/10/10

Maximum number of A/B/C/D flushing valves

Maximum number of guns

Dump valve for waste separation

External flushing agent:

- Flushing over a period of time

- Flushing with flow monitor

- Flushing with flow meter

Booster pump

* More valves for XL version available on request.

Standard system

2K / 3K / 4K

10/5/5/5

(option)

2-circuit system per circuit

2-circuit system

XL per circuit

2K / 3K

10/5/5/–

DN 10: 4/–/–/– *

DN 4: 10/5/5/– *

DN 2.6: –/5/5/– *

5/2/2/–

DN 4: 1/1/1/– *

DN 2.6: –/1/1/– *

(option)

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5.5.2 DIMENSIONS

Control cabinet and/or fluid cabinet

− Standard system

− Ex system

− 2-circuit system

− XL system (control cabinet)

XL system (fluid cabinet)

H J

Measurement

E f

Dimensions mm

800

1,133

1,960

350.5

410.5

573.8

1,650

1,225

1,200 inch

31.50

44.61

77.17

13.80

16.16

22.59

64.96

48.23

47.24

B_05637

B_05669

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5.5.3 WORKING AREAS OF FLOW METERS

Flow meters: A/B: 0.02 – 3 l/min

0 5

[5:1]

Working area

Viscosity:

20 25 30 35

Mixing ratio (volumetric) A:B (0 = only A)

A: min. 5 mPa·s

B: min. 5 mPa·s

40 45 50

[50:1]

Flow meters: A: 0.02 – 3 l/min

B: 0.005 – 2 l/min

0 5

[5:1]

Working area

15 20 25

Viscosity:

A: min. 5 mPa·s

B: min. 5 mPa·s

Mixing ratio (volumetric) A:B (0 = only A)

40 45 50

[50:1]

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Flow meters: A: 0.02 – 3 l/min

B: 0.005 – 2 l/min c: 0.005 – 0.5 l/min

[5:1]

Working area

Max. amount A+B+C with corresponding mixing ratio

A:B, and

C = 0.25 l/min (for maximum value) or 5cc/min

(for minimum value)

Viscosity: A: min. 5 mPa·s

B: min. 5 mPa·s c: 1-100 mPa·s

20 25 30 35

Mixing ratio (volumetric) A:B (0 = only A)

40 45 50

[50:1]

Flow meters: A: 0.1 – 7 l/min

B: 0.02 – 3 l/min

[5:1]

Working area

Viscosity:

Maximum viscosity depending on flow rate

20 25 30 35

Mixing ratio (volumetric) A:B (0 = only A)

40 45 50

[50:1]

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Flow meters: A: 0.5 – 25 l/min

B: 0.1 – 7 l/min

Viscosity:

Maximum viscosity depending on flow rate

Working area

Standard

B_01660

Mixing ratio volumetric A:B [A:1] (0= only A)

5.5.4 APPLICATION LIMITS OF FLOW METERS

Viscosity

All viscosity information in this chapter are approximate values. The viscosities are recommended limit values for commercial operation.

Particle size

Maximum particle size

120 µm

Gear flow meters

Measuring range from 0.02 l/min

0.12 mm

0.0047 inch

Measuring range from 0.005 l/min

60 µm

0.06 mm

0.0024 inch

Micro flow meter

0.005-0.25 Ex

40 µm

0.04 mm

0.0016 inch

Product filtration required min. 100 mesh/inches min. 200 mesh/inches min. 300 mesh/inches

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5.6 MIXING TYPES

For mixing components A, B, C and D, three versions are available:

A) With mixing block (standard) B) With mixing head valve

A) Mixing block (standard)

C) With external mixer

A Flushing (air)

Flushing A

B1 Flushing

B2 Flushing

Example: 3K system with 6 A valves,

4 B valves, 2 C valves and 2 guns

Valves B1, B2 and C are cycled.

Air bubble sensor

Inline filter

Flow meter

Non-return valve

Mixing block A+B

Static-mixer A+B

C C Flushing

Mixing block AB+C

Static-mixer AB+C

Flushing gun 2 Flushing gun 1

Splitter valve with flushing

Product pressure regulator

Gun 2

B_04681

Dump valve for waste separation

Dump valve

The dump valve can also be installed before the gun in the gun hose.

Example with simple dump valve:

B_04685

Gun 1

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B) Mixing head valve

A Flushing (air)

Flushing A

B1 Flushing

B2 Flushing

Example: 3K system with 6 A valves, 4 B valves, 2 C valves and

2 guns

The mixing head valves B and C are cycled and regulated with the AIS dosing system.

Air bubble sensor

Inline filter

B1 B2

Mixing head valve with cycle and AIS

83 84

AIS

Flow meter

Non-return valve

Mixing block

Static-mixer

Flushing gun 1

Splitter valve with flushing

AIS

C Flushing

83 Flushing mixing head valve B

84 Flushing mixing head valve C

Flushing gun 2

Product pressure regulator

Gun 2

B_05639

Dump valve for waste separation

Dump valve

The dump valve can also be installed before the gun in the gun hose.

Example with simple dump valve:

B_04685

Gun 1

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C) External mixer

A Flushing (air)

Flushing A

B1 Flushing

B2 Flushing

Air bubble sensor

Inline filter

Flow meter

Non-return valve

Example: 3K system with 6 A valves,

4 B valves, 2 C valves and 2 guns

Valves B1, B2 and C are cycled.

C Flushing

Gun

Flushing

B_04683

External mixer

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5.7 DUMP VALVE FOR WASTE SEPARATION (OPTION)

In addition to the simple dump valve, there is also a dump valve for waste separation. When filling and when flushing, the system separates the flushing agent from the remaining product. For this purpose, a double valve is used: one output for flushing agent, another for waste (mixed product).

With an average number of paint changes and pot lives which are not too short, the dump valve can be an alternative to a gun flush box for waste separation.

Not available for 2-circuit systems.

5.8 AIS DOSING SYSTEM (OPTION)

The hardener dosing valve's stroke is regulated automatically via the AIS (option). The AIS

(Adaptive Injection System) dosing system optimizes injection amounts and cycles and adapts these continually to the changing flow rates. Thereby, the AIS ensures optimum dosing and constant coating quality.

5.9 2-CIRCUIT SYSTEM

The 2-circuit system consists of:

− 2 fluid circuits

− 1 control cabinet with:

− 4 mechanical push-buttons per fluid circuit

− 1 operating panel for both fluid circuits

The control cabinet controls both fluid circuits. It is possible to work with two fluid circuits simultaneously.

Limitations for 2-circuit systems: see Chapter 5.5.1.1

B_05641

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5.10 FLOW MEASUREMENT

The flow of components A, B, C and D can be measured as follows:

− with flow meters

− Gear flow meters

− Coriolis flow meters (contact-free)

− with stroke sensors (contact-free, from software version 4.0x / 4.0x K)

Only one measuring method can be used within a component. It is however possible, for example, to use stroke sensors for component A and flow meters for component B.

5.10.1 FLOW METERS

For every component, there is a flow meter installed upstream of the mixing block (gear or

Coriolis flow meter).

Non-Ex zone Ex zone

Example: 2K system with 4 pumps in potentially explosive zone

Control cabinet

Touch screen / controller

Zener barriers

Flushing

Flow meter

A+B

Flow meter

B_04356

For operating ranges and technical data of the flow meters, see Chapters 5.5.3

and

5.5.4

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5.10.2 STROKE MEASURING

For piston pumps, the flow can be measured contact-free with stroke sensors (from software version 4.0x / 4.0x K). For this, each pump must be equipped with a stroke sensor.

There are three types of stroke sensors:

Stroke sensor type Field of application

Stroke sensor short e.g., IceBreaker pumps up to 70 cm3/DH

Stroke sensor long e.g., IceBreaker pumps up to 100 cm3/DH

Working method

Detects the exact position of the piston.

Pressure sensor Flushing pump

Detects the piston's upper and lower reversal points.

Non-Ex zone Ex zone Example: 2K system with 4 pumps in potentially explosive zone

Control cabinet

Touch screen / controller

1/3

Stroke sensor

1/2

1/1

A1 Piston pump

2/1

Stroke sensor

Flushing

A+B

B_04357

A/D Converter (ADC)

The analog stroke sensor signals are evaluated in an A/D converter (ADC) and converted into digital signals. Up to four A/D converters, with three inputs each, can be used. The ADC automatically recognizes, whether a stroke sensor or a pressure sensor is connected to its inputs (1, 2, 3).

Multiplexer (MPX)

In the control cabinet, a multiplexer processes the A/D converter's digital signals and transmits the signals, of the currently active pumps, to the controller.

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5.10.3 FLOW METERS AND STROKE SENSORS

Flow meters and stroke sensor can be used simultaneously.

The following should be noted:

Only one measuring method can be used within a component.

As soon as stroke sensors are used, the flushing pump must be equipped with a pressure sensor.

B_04364

Incorrect

Correct

Example: 2K system with 4 pumps in potentially explosive zone.

− Stroke sensors for component A.

− Flow meter for component B.

Non-Ex zone Ex zone

Control cabinet

Touchscreen / controller

1/3

Stroke sensor

1/1

1/2

A1 Piston pump

Flushing

A+B

B_04363

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6 ASSEMBLY AND COMMISSIONING

6.1 TRAINING OF ASSEMBLY/COMMISSIONING STAFF

The assembly and commissioning staff must have the technical skills to safely commission the device.

When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.

A skilled person must check to ensure that the device is in a reliable state after it is installed and commissioned.

6.2 STORAGE AND INSTALLATION CONDITIONS

Until the point of assembly, the device must be stored in a dry location, free from vibrations and with a minimum of dust. The device must be stored in closed rooms.

For ambient temperature and air humidity, see Chapter

5.5.1

Long-term storage

See chapter 9.1.6

For recommissioning, proceed according to following chapters.

6.3 TRANSPORTATION

The system can be transported in the specially designed transportation box.

System

Non-Ex System

Ex System

2-circuit

(1 separate fluid section)

2-circuit

(2 separate fluid sections)

Unit mm; inch 1,800; 70.9

mm; inch mm; inch mm; inch mm; inch

Length

1,800; 70.9

Width

1,178; 46.4

Height

400; 15.75

800; 31.5

1,200; 47.25

800; 31.5

6.4 ASSEMBLY AND INSTALLATION

The mixing units are normally installed by WAGNER technicians directly or by their agents.

If this is not the case, the material has to be checked for damage on receipt of the system.

WARNING

Inclined ground!

Risk of accidents if the device rolls away/falls.

Place the device on horizontal floor.

Rollers should be locked in position or replaced by leveling feet and secured.

Do not tilt the device during shifting / transporting.

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B_05489

Ensure a sufficient secure stance.

Fix the fixing attachments of leveling feets on the floor.

WARNING

Electric shock hazard inside the control unit!

Danger to life from electric shock.

May only be installed/maintained by skilled electricians or under their supervision.

Operation according to the safety regulations, fire protection and electrotechnical rules.

Must be de-energized before work is commenced on active parts.

DANGER

Incorrect installation of the device!

Explosion hazard and damage to the device.

Set up the system outside the spray booth / spray zone.

The control cabinet should not be set up within the Ex zone.

Protect the control cabinet from extreme temperature and moisture changes as well as dirt.

The fluid section (non-Ex version) must not be installed in the explosion zone in the

2K COMFORT.

Lay and fix the connecting cable correctly and protect it against tripping, dirt and traffic.

Use only feed pumps and components which are suitable for 2K products.

Use hardener pump with PE/T packing (T = PTFE).

No contact of 2K products with non-ferrous metals.

With water based lacquers: pumps and product-wetted parts of stainless steel.

Use product filters at the feed pumps.

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6.4.1 ELECTRICAL CONNECTIONS

An electric connection cable with plug is standardly provided.

When exchanging the connection cable, please observe the following:

Carry out the electrical connections and the grounding inside the control unit using a 3-wire cable of 1.5 mm2; in accordance with the enclosed circuit diagram.

6.4.2 PNEUMATIC CONNECTIONS

Check whether the line pressure is sufficient. It has to be between 0.7 and 0.8 MPa;

7 to 8 bar; 101-116 psi.

WARNING

Overpressure!

Risk of injury from bursting components.

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

Check whether efficient filter systems and condensate precipitators are available in the air line.

The compressed air must be free of oil and water. For compressed air quality, see

Chapter 5.5.1

Every day, discharge all contamination and the condensate (if any) which has accumulated in the equipment air filter.

WARNING

Brittle filter pressure regulator!

The tank on the filter pressure regulator becomes brittle through contact with solvents and can burst. Flying parts can cause injury.

Do not clean the tank on the filter pressure regulator with solvents.

6.4.3 PRODUCT CONNECTIONS

Carry out the following connections:

Product hose from the mixing tube or splitter valve to the gun.

− Electrostatic guns must be used without electrostatics during commissioning.

First commission the electrostatic system after all steps are carried out up to

Chapter 6.6.6

The product hoses from the feeding pumps to the system's product inlets may not be connected until the preliminary flushing of the hoses (see Chapter

6.6.1

) has been done (contamination of the unit)!

Circular pipeline

If the unit is connected to a circular pipeline, suitable shut-off devices must be installed

− to prevent the products from mixing in case of leakage in the 2K system.

− These shut-off devices must always be closed at the end of work.

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6.4.4 FLOW METER MONITORING

For safe operation it is necessary for the 2K system to receive a signal, when the gun is open and there is 2K product flow. Otherwise for example no B product is added when the

A flow meter is blocked, although A product continues flowing through the leakage in the flow meter (possibly not visible).

The signal (product flow yes/no) can be made available on ways that follow: for AirSpray- or AirCoat manual spray guns: AirSpray + AirCoat gun monitoring

(atomizing air-flow switch); for Airless- or HVLP manual spray guns: flow monitor (lacquer-flow switch in the lines to the guns); for automatic spray guns: automatic gun monitoring (pressure switch); for digital robot communication: robot signal ("gun signal 1/2/3/4"); for bus communication (e.g., CAN Profibus Gateway): signal by superordinate control

("gun monitoring 1/2/3/4").

Gun monitoring for each gun

If possible, each gun should be monitored separately.

NOTICE

Caution with only one gun monitoring for multiple guns!

If for several spray guns only one gun monitoring is installed, the controller does not know which gun in each case is in operation.

Then the product flow is divided to all guns.

The pot lives in the gun hoses and guns can be exceeded without a pot life alarm.

WARNING

Incorrect installation of the device!

Explosion hazard and damage to the device.

The flow monitor is non-Ex-proof and has to be installed outside the explosion zone.

Lay and fix the connection pipes correctly and protect them against tripping, dirt and damage.

No air consuming equipment, other than the feed pumps for a 2K system, may be installed after the flow monitor (e.g., pumps circular pipeline and stirrer).

6.4.5 LACK-OF-PRODUCT PROTECTION

Make sure that product without air bubbles is supplied to the mixing and dosing system.

The flow meters can not detect whether product or air is delivered.

This may lead to mixing errors. (An air bubbles monitoring system is optionally available for the low-pressure model).

A lack-of-product protection can be achieved by installing a level probe in the A-product tank or by always having the coater make sure that sufficient product is in the tanks.

Otherwise false coating may occur.

If, e.g., the A-tank's level probe indicates the minimum level, a signal can stop the 2K system

(STOP) or electronic consumption measuring equipment warns of a lack of product.

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The lack-of-product protection with level probe is not supplied with the 2K system and has to be realized on-site.

6.4.6 VENTILATION OF THE SPRAY BOOTH

WARNING

Toxic and/or flammable vapor mixtures!

Risk of poisoning and burns.

Operate the device in a spray booth approved for the working materials.

-or-

Operate the device on an appropriate spraying wall with the ventilation (extraction) switched on.

Observe national and local regulations for the exhaust air speed.

6.5 GROUNDING

WARNING

Fire, explosion and electric shock hazard

Danger to life by electric shock and explosion.

The device must be electrically connected to the equipotential bonding (ground); the ground in the electrical system is not sufficient.

A qualified electrician must complete all grounding and wiring connections and check the resistance.

Operation according to the safety regulations, fire protection and electrotechnical rules.

Must be de-energized before work is commenced on active parts.

WARNING

Heavy paint mist if grounding is insufficient!

Danger of poisoning.

Insufficient paint application quality.

Ground all device components.

Ground the work pieces to be coated.

Make sure to include the control cabinet and the fluid cabinet in the local equipotential bonding.

The 2K system, the pumps, all accessories and all parts that come into contact with the sprayer have to be grounded non-Ex or Ex according to the following grounding scheme.

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Grounding scheme - example for 2K COMFORT non-Ex

Non-Ex zone Ex zone

R max.

< 1 MOhm

4 7

B_04657

Designation

1 Controller

2 Fluid section (non-Ex)

3 Pump

4 Paint tank

5 Work piece

Grounding cables

Designation

6 Conveyor

7 Floor, static dissipative

Pneumatic alarm horn (option)

Remote control Ex (option)

Fluid hoses

Cable cross sections

2K system, pump

Paint tank / collection tank

Conveyor

Spray booth

Spraying stand

4 mm2; AWG 12

6 mm2; AWG 10

16 mm2; AWG 6

Connect all ground cables using a short and direct route.

Ex zone

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

Tank

All paints, flushing agents and waste tanks have to be electrically conductive.

All tanks must be grounded.

Stroke measuring

Grounding ADC-0301: see "ADC-0301 / MPX-0403" operating manual (for Order No.,

see Chapter 1.3.1

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Grounding scheme - example for 2K COMFORT Ex

Non-Ex zone

Ex zone

B_04656

4 7

Designation

1 Controller

2 Fluid section (Ex)

3 Pump (Ex)

4 Paint tank

5 Work piece

Grounding cables

Designation

Conveyor

Floor, static dissipative

Pneumatic alarm horn (option)

Remote control Ex (option)

Fluid hoses

Cable cross sections

2K system, pump

Paint tank / collection tank

Conveyor

Spray booth

Spraying stand

4 mm2; AWG 12

6 mm2; AWG 10

16 mm2; AWG 6

Connect all ground cables using a short and direct route.

Ex zone

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

Tank

All paints, flushing agents and waste tanks have to be electrically conductive.

All tanks must be grounded.

Stroke measuring

Grounding ADC-0301: see "ADC-0301 / MPX-0403" operating manual (for Order No.,

see Chapter 1.3.1

commission the electrostatic system after all steps are carried out up to Chapter 6.6.6

R max.

< 1 MOhm

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6.6 COMMISSIONING

WARNING

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

Danger to life from flying parts.

Ensure that the device is always completely filled with flushing agent or working medium.

Do not spray the device empty after cleaning.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent.

Never reach into the spray jet.

Never point the spray gun at people.

Consult a doctor immediately in the event of skin injuries caused by paint or solvent.

Inform the doctor about the paint or solvent used.

Never seal defective high-pressure parts; instead relieve the pressure from them and replace them immediately.

Wear the appropriate protective clothing, gloves, eyewear, and respirator

NOTICE

Fluctuating supply pressures!

Poor coating result.

The supply pressure of component B should be adjusted to a higher value (approx. 5-10%) than that of component A.

The supplying pressure should be constant.

Electrostatic gun

Electrostatic guns must be used without electrostatics during commissioning. First

6.6.1 PRE-CLEANING

The devices are tested at the factory using emulsified oil, plain oil or solvent, according to the kind of fluid being pumped.

Before commissioning the pump with a product, it is recommended to flush both circuits and supply pumps with an appropriate flushing agent.

WARNING

Incompatibility of flushing agent and working medium!

Risk of explosion and danger of poisoning by toxic gases.

Examine the compatibility of the flushing agents and working medium on the basis of the safety data sheets.

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Pre-cleaning

Before the product hoses are connected to the system, they should be flushed, together with the corresponding pumps, with the flushing agent to be used.

Unless this preliminary flushing is executed, the flow meters can already be clogged due to contamination during the first flow through!

For preliminary cleaning of the pumps, carefully follow the corresponding pump instructions.

After all pumps and product hoses to the device have been flushed, the product hoses can be connected to the system.

The flushing agent still remains in the pumps.

Note:

The flushing agent used for the first cleaning may not be used again since it might contain oil residues.

6.6.2 INITIALIZING THE CONTROLLER

The controller is already individually pre-configured upon delivery. Additional settings must be entered on-site.

Switch on the system with the main switch.

The initialization programs starts when the system is switched on for the very first time. It allows quick input of the most important settings, which must still be entered.

The initialization program can also be called up later (with password level 3, setting

"Reset initialization").

Define one after the other on the operating panel:

− Language (touch desired language, then proceed with the arrow key );

− Volumes measuring unit (liters or US gallons, touch field to change);

− Lengths measuring unit (meter or inch);

− Hose lengths and diameters;

− Number of paint recipes (maximum 100) and number of flushing recipes

(maximum 10);

− Mixing ratio input type (A:B or percentage).

At the end, a note appears, explaining what should be done next. Perform one after the other (password level 1):

− Enter names of valves, flushing recipes and paint recipes (see Chapter

7.9.2

);

− Enter flushing recipes (see Chapter 7.10

);

− Enter paint recipes (see Chapter

7.11

), still without calibration.

If necessary, implement further settings.

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6.6.3 VENTING THE SYSTEM

First bleed the system via the gun with little product pressure:

Prepare a grounded metal bucket, that is suitable to collect all products to be disposed of.

Menu (see Chapter

)

Select each A side valve, one after the other and perform the following steps:

− Open the valve with the large valve icon.

− Bleed, via the gun, with low product pressure until clean flushing agent flows out of the gun.

− Close the valve icon again.

Do the same for the B side (and C/D, if available) and for the flushing valves.

6.6.4 PRESSURE TIGHTNESS TEST

WARNING

Overpressure!

Risk of injury from bursting components.

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

For pressure tightness control of the entire installation, the flushing agent pressure is slowly increased, step by step, until the maximum pressure of the individual pumps is achieved.

Menu (see Chapter

After the test, relieve pressure from the entire system according to Chapter 8.8

)

One after the other and in each component (A, B, flush, ...) for each product valve

(A1, A2, ...):

− Select valve and open it with the large valve button.

− Slowly increase the pressure at the respective pumps, step-by-step, until the maximum pressure specified on the type plate has been reached.

− Hold the maximum pressure for at least 2 minutes.

− If there is a leak, mend it.

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6.6.5 FILLING THE SYSTEM

NOTICE

Interchange of the two components A and B!

Device damage by hardened product.

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

Menu (see Chapter

)

Example for a hardener valve with the name B1:

1. Prepare the hardener components' tank and put the suction pipe in the respective pump.

2. Select [B] components, then select valve B1.

Open the valve with the large valve button.

3. Set the hardener pump slightly under pressure. Open the hardener valve with the large valve button.

4. Point the guns into the grounded metal bucket and open it step by step. Avoid splashback.

5. After the hardener is filled, calibrate the hardener straight away, if necessary, according to Chapter

In accordance with Chapter 7.12

6. Close the valve via the [Valve] field or close the STOP button again.

Then, in the same way, fill the system with the other components.

Note:

The solvent used for the first cleaning may not be used again since it might contain oil residues.

Calibration

Components with flow meter:

− In all paint recipes, calibrate the components as well as the flushing agent.

If the components were already calibrated during filling, the K factors must be entered in the different recipes.

Components with Coriolis measuring system:

− K factor = Enter 60 ,000 Imp/l according to Chapter

Perform zero point adjustment in accordance with "Coriolis Compact" user information

(Order No., see Chapter

Basic operating principles: see Chapter 7

)

6.6.6 ELECTROSTATICS

With an electrostatic gun:

Commissioning the electrostatics according to the corresponding assembly manual.

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7 CONTROLLER

7.1 TRAINING THE OPERATING STAFF

The operating staff must be qualified to operate the entire system.

The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.

Before work commences, the operating staff must receive appropriate system training.

7.2 SAFETY INSTRUCTIONS

Before carrying out any work, ensure that commissioning is carried out in accordance with

Chapter

6.6

WARNING

Incorrect operation!

Risk of injury and damage to the device.

If contact with lacquers or cleaning agents causes skin irritation, appropriate precautionary measures must be taken, e.g., wearing protective clothing.

The footwear worn by operating staff must comply with EN ISO 20344. The measured insulation resistance must not exceed 100 megohms.

The protective clothing, including gloves, must comply with EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.

WARNING

Unintentional putting into operation!

Risk of injury.

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

Relieve the pressure from the spray gun and unit.

Secure the spray gun against actuation.

Switch off the energy/compressed air supply.

Disconnect the control unit from the mains.

In the event of functional faults: remedy the fault as described in the "Troubleshooting" chapter.

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7.3 CONTROL CABINET

There are four push-buttons and an operating panel (touch screen) for the system controller in the control cabinet. The touchscreen and the push-buttons can be used to communicate with the controller.

Initialization program for commissioning: see Chapter

6.6.2

Workflow: see Chapter

Detailed software documentation is separately available (see Chapter 1.3

USB connection

The USB port is located at the control panel on the inside of the control cabinet.

Standard system of the control cabinet 2-circuit system of the control cabinet

B_05490

Designation

1 Control cabinet

2 Operating panel (touchscreen)

3 Mechanical push-buttons

3a Mechanical push-buttons, Circuit 1

3b Mechanical push-buttons, Circuit 2

4 Main switch

7.3.1 MAIN SWITCH

The main switch, on the right side of the control cabinet, switches the controller on and off.

When switched off, all valves close automatically.

Switching the system on and off: see Chapter

8.3

B_05641

2-circuit system

It is possible to work with two fluid circuits simultaneously. The operation of both fluid circuits is at any time immediately possible with mechanical push-buttons (3a or 3b).

The operating panel can be switched at any time quickly from one fluid circuit to the other.

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7.4 MECHANICAL PUSH-BUTTONS

The system's basic functions are controlled by four mechanical push-buttons:

START STOP Flushing RECIPE CHANGE

Starts spraying mode.

Flashes green during filling.

Lights up green as soon as the system is ready for spraying. The AirCoat air is activated (option).

Ends the spraying or flushing process.

(Depending on setting, it may not be possible to end the flushing process early.)

Alarm Lights up red.

Warning Flashes red.

Starts end flushing of the last paint recipe used. (With external mixer if necessary mixer flushing.)

Lights up blue during flushing process.

Switches to next paint recipe.

STOP + recipe change jumps 10 steps.

Display of filling progress:

Display of flushing progress:

Gun symbol flashes Open gun.

7.5 OPERATING PANEL BASICS

Some buttons are highlighted by a yellow background color. The highlighted buttons indicate our current location.

highlighted (yellow)

All fields with frames can be touched. For example, to trigger an action, select a different recipe, or enter a number.

Recurring operating elements

Scroll up screen

Scroll down screen

Confirm selection

Cancel selection

Saves the data

Differences in screen displays

The controller's functions differ depending on system, accessories installed, and user settings. The screens shown in the following chapters may therefore contain additional input options, or some of the buttons and fields shown may not be present in your version.

The screen will only ever show what is actually installed.

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7.5.1 SELECT LANGUAGE

1. [Menu] button (second button in bottom row)

3. Touch language: [English]

7.5.2 KEYBOARD INPUT

A keyboard with numbers or letters appears as necessary when fields with frames are touched. The input is confirmed with [ ENT ] or canceled with [ ESC ].

Minimum and maximum values

Cursor (field with frame) =

Current input position

Keyboard with numbers and special characters

Min:

Max:

5.0

R_blue

Cancel input

B_04640

Confirm input

Keyboard Controls

Cancel

Move cursor to right

Move cursor to left

Confirm input

Delete all

Delete character

Delete character to left of cursor (backspace)

Spaces

B_04641

Keyboard with upper case letters

Confirm input

Changing over keyboard with letters

Switch to keyboard with upper case letters

Switch to keyboard with lower case letters

Switch to keyboard with numbers and special characters

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7.5.3 PASSWORDS

Some functions and input options are protected by passwords. The following password levels exist:

Password level

Responsibility

Painter

Painter with control jobs

Foreman

Service customer

WAGNER Service

Department

Functions

Spraying mode

Plus enter flushing and paint recipes, diagnosis, calibration

Plus system settings

Plus basic system settings

−

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

Password input

1. [Menu] button

2. If [Log Out] button appears: [Log Out] ( The button switches to [Log In].)

3. [Log In]

4. Touch password input field.

A numerical keyboard appears.

5. Enter the password.

6. [ENT]

The password level is displayed briefly, for example: "Level 1".

The menu buttons for the corresponding password level then appear.

7.6 HOME PAGE

NOTICE

Wrong mixing ratio!

Poor quality of paint application.

Before changing the lacquer, check the mixing ratio on the display and modify it if necessary, if individual components have different mixing ratios.

7.6.1 CHANGING THE PAINT RECIPE

Press RECIPE CHANGE push button

Switches to next paint recipe.

Or:

1. Touch paint recipe field (see above).

2. Select desired paint recipe from the list.

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7.6.2 HOME PAGE OPERATION

Number of current paint recipe

All fields with frames can be touched.

Paint recipe

Opens choice of all paint recipes.

Mixing ratio (volumetric)

Pot life

Remaining pot life in minutes or seconds.

Gun selection

A : B

AB : C

D

Pot life

Gun of ABC min

Flow regulation

The system regulates the flow to a set value.

As of password level 1: calibration of flow regulation

Flushing

Opens a menu with various flushing options.

Act.

Menu

Opens a menu containing other functions.

Batch PC

Tank

Filling level monitoring of paint tank.

AIS

Flow contrl

B_05461

AIS

Preset the dosing valve stroke.

PC Data Archiving

Chapter 1.3.1

Act.

(=current)

Shows the current lacquer consumption values.

Batch

Produce recurring, predetermined flow rate.

Home

Returns to home page at any time.

The 'Home' button is emphasized using reversed colors – on screen with light background. This shows us our current location: on the home page.

* Only present with corresponding setting (with password level 3, see

Chapter 7.13.2

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7.7 MENU

Button Function

Alarm

Calls up list of the last 700 warning messages.

Manual operation

Specific opening and closing of product or flushing valves. Chapter

exceeded (=QB-control, see Chapter 7.13.1

Tank

Software Documentation

USB

I/O

Config

Stroke sensor

Change name (password level 1)

Chapter 7.9.2

Flushing recipes (password level 1)

Chapter 7.10

Paint recipes (password level 1)

Chapter 7.11

Diagnosis (password level 1)

Mixing amount, e.g., QB : As soon as the mixture has the correct mixing ratio, the mixing amount is reset to zero. The system stops when the maximum is

Btkt = The dosing valve's cycle length

% open per cycle = dosing valve's opening time. If too short: slowly reduce the difference in pressure between A and B.

Output Display the output signal status.

Input Display the input signal status.

Totals (password levels 1 / 2)

View / zero product consumption and working times.

VOC quantities (password levels 1 / 2)

View / zero VOC quantities, enter VOC factors. Chapter

7.11

Info (password level 1)

View software version number, set date and time.

Calibration (password level 1)

Chapter 7.12

Settings (password levels 2 / 3)

Chapter 7.13

USB (password levels 2 / 3)

Back up alarms, totals, and configuration data on USB stick.

Service (password level 2)

Service intervals for dosing valves and flow meters.

Input / Output configuration (password level 3)

Assign inputs and outputs. see software documentation

Stroke sensor configuration (password level 3), from software version 4.0x /

4.0x K. see software documentation

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7.8 MANUAL MODE: OPEN VALVES

Menu Select paint recipe (for A/B/C/D).

Or select flushing valve (for A/B/C/D flushing valves).

Valve used by paint recipe.

(See other used valves: buttons A/B/C/D.)

Current flow

Flow rate since the valve was last opened

Set product pressure.

(Only with

"Automatic product pressure regulator" option, see Chapter

Q

Vjob

cc / min

cc bar

Leak inspec.

The buttons with reversed colors show our current location:

Select component

A/B/C/D.

Displays list of A/B/

C/D flushing valves.

Manual operation

Output

Valves

Status of selected valve

Leak inspection

(only for piston pumps with stroke sensor)

see software documentation

Valve is closed

Touch to change

Valve is open

Open several valves / output signals at the same time

With password level 3,

see Chapter 7.13.2

Manual mode is used for troubleshooting or to fill a pump, for example.

Only one valve can be opened at any one time. If another valve is touched, the controller closes all valves.

With a gun flush box, the valve for the gun is also opened: either for gun 1 (if gun 1 or 1+x is selected on the home page), or for gun 2 (if gun 2 is selected on the home page).

Ext. flushing agent

The valve for the external flushing agent can not be opened on this page. If necessary, the calibration function can be used for this, without saving the measured value (password level 2, Chapter

1. Increase the "Number of flushing recipes" in the settings by one (see Chapter 7.13.1

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7.9 RECIPES

7.9.1 ADD NEW RECIPES

Create a new flushing recipe:

2. Change the flushing recipe's automatically assigned name (see Chapter

7.9.2

3. Enter the flushing recipe (see Chapter 7.10

Create a new paint recipe:

1. Increase the "Number of paint recipes" in the settings by one (see Chapter 7.13.1

2. Change the paint recipe name automatically assigned (see Chapter

7.9.2

3. Enter paint recipe (see Chapter 7.11

7.9.2 CHANGING RECIPE AND VALVE NAMES

Menu ABC (with password level 1 or higher) others

Change valve names (for example: red, yellow, hardener_1, flushing agent_1).

First select components (A, B, flushing A, ...), then touch the valve names.

Other valve names

No valve open

Flushing from external mixer

(option)

Flushing starting from mixing head valve (option)

Flushing starting from splitter valve for gun 1 or gun 2

Generates an information signal

Wait

Demand gun change. (With 2-4 guns and only one gun flush box.)

Last used A/B/C/D product

* from version 3.2x / 3.2x K

Change flushing recipe name .

For example: R-R flushing (= recipe change flushing), end flushing, gun flushing.

Change paint recipe name .

For example: red-90, red-95, yellow_customer-1, yellow_ customer-2.

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7.10 ENTER FLUSHING RECIPE

Select existing flushing recipe.

(New flushing recipe: see Chapter 7.9.1

Current flushing step for input on this page.

Define total number of flushing steps for this recipe.

1–16

Example with splitter valve, dump valve and product pressure regulator

Select action for this flushing step.

Flushing valve to open, or

(=wait)

(=extend gun change)

(Chapter

(For whether a recipe change and / or end flushing comes first: see Chapter 7.13.2

, level 3, page 21)

(last used A/B/C/D product)

Step

Flushing Qty

20.0 bar

Enter flushing quantity or flushing time for this flushing step.

0.0–9999.9

Enter short flushing steps first (rough flushing) to begin with, then long flushing steps (approx. twice the hose content).

(No influence on: " ")

B_05202

Switch between flushing quantity and flushing time.

cc or seconds

Opens the distributor valve for a single gun (1, 2, 3 or 4) or for all guns (1-x).

1 / 2 / 3 / 4 / 1-x

With several guns, separate flushing steps must be defined for each gun.

Only those guns which were in use are flushed automatically.

Exception: if a system has already been flushed, the guns indicated are flushed in any case when flushing is repeated.

Set flushing pressure.

(Only with "Automatic product pressure regulator" option)

Flushing via on or off.

(Only with "Dump valve" option) dump valve :

Go to next flushing step

Repetitions can be entered after the last flushing step

(for examples, see software documentation).

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7.11 ENTER PAINT RECIPE

Menu (with password level 1 or higher)

Select existing paint recipe.

New recipe: see Chapter

7.9.1

A : B

AB : C

D of ABC

Enter mixing ratio (volume) for the selected recipe

0.1:1–50.00:1

0.02% – 1,000.00%

If one or several components are not required: enter 0.00:1 or 0.00%.

1K application: Enter 0.00:1 or 0.00% for all components except for one.

The flow is measured by volume and the mixing ratio is entered and controlled volumetrically by default.

Save paint recipe.

Go to next page

B_05476

Select product valves for available components.

If one or several components are not required:

B valve = "---------"

1K application: Enter "---------" for all components except for one.

Page 2

− Enter pot life .

− Select flushing recipes to be used:

Is carried out, ...

End : ... after this paint recipe has been used when end flushing is being carried out.

R-R : ... after this paint recipe has been used when the recipe is changed.

Mix : * ... when flushing just from the external mixer to the gun.

Pre : * ... before using this paint recipe.

, "Pre-flushing after paint change flush" or "Pre-flushing after end flushing").

* May also be missing, depending on configuration.

Select empty field if no flushing recipe is to be active.

Page 3 (option)

− Product pressure when filling and working.

Prerequisite: low-pressure system with automatic product pressure regulator.

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Page 4 (option)

− Flow regulation : pre-define flow set value for this paint recipe.

Settings: "Flow regulation" see Chapter

(password level 3, page 19)

Page 5 (option)

− Flow monitoring : enter minimum and maximum flow in cc/min. (For example, with robot applications to monitor nozzle wear and nozzle blockages.)

Prerequisite: gun monitoring or flow monitor.

Settings:

− Activate "Flow monitoring" see Chapter

(password level 3, page 2)

− "Alarm delay for flow monitoring" see Chapter

(password level 2, page 2)

If flow falls below or exceeds the limits, the system stops with alarm A121 or A122.

Page 6 (option)

− Batch Mode : pre-define the Batch quantity for this paint recipe.

Prerequisite: accessories set for automatic filling + external signal transmitter

(e.g., foot-operated switch)

− Save recipe.

− VOC = Volatile Organic Compounds

If the local specifications require a VOC measurement, then the corresponding VOC factor must be entered in every paint recipe for each component.

1. Select newly entered paint recipe.

2. One after the other, touch components A / B / C / D and flushing A / B / C / D and for each:

− Enter the corresponding VOC factor in percent or g/L or g/G. The VOC measuring unit is defined in the settings (see Chapter

According to Chapter 7.12

− Only if the corresponding factor is to be saved for all paint recipes:

− Calibration for the newly entered paint recipe:

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7.12 CALIBRATION

Coriolis measuring system : K factor = 60, 000 Imp/L

1. Enter "60, 000" in the Kn field in all paint recipes for components with Coriolis measuring system and then save.

2. Perform zero point adjustment in accordance with "Coriolis Compact" user information

(Order No., see Chapter

)

Flow meters and stroke sensors

Flow meters or stroke sensors must be calibrated. This produces a K factor for every component. The K factors may vary depending on the lacquer (A1, A2, A3, ...). Therefore, the K factors for each paint recipe are saved separately.

Flow meter: The default is the average from the calibration report. The default is accurate and is a good match for most products. A calibration is therefore, not usually necessary.

Stroke sensor : Calibration must be carried out.

When a calibration is performed, it should always be a precise process. Particular care must be taken, to measure the volume in the measuring cup exactly and without air bubbles.

Menu (with password level 1 or higher)

Example : K factor for paint recipe and for component B with flow meter.

1. Select paint recipe: .

2. Select component: B.

3. The system is under spraying pressure and the selected component is already in the spray gun. Select the spray nozzle, so that pressure and product flow approximately meet subsequent work processes.

[Start] [Stop] Wait until no more product flows.

4. Start the measurement: [Start].

5. Use the gun to fill a certain quantity of the corresponding lacquer (e.g., 500 ml) into a measuring cup. Use a protective tube against overspray if necessary.

The flow measured by the system is displayed on the screen.

6. Close the gun and push the [STOP] button. Wait until no more product flows.

7. Exactly measure the quantity filled into the measuring cup by weight, with one of the following versions.

8. Enter the determined volume in the measuring cup field.

9. The controller calculates and saves the new K factor and displays it in the Kn field.

10. Press the [ ] icon in order to accept the new K factor.

Selection possibility: If the different lacquers of the same components have similar characteristics, then the K factor can immediately be saved for all recipes.

Otherwise, only for the current recipe.

11. Carry out the calibration several times in order to check the values.

In case of large deviations, eliminate the cause:

− Air in the lines fill the lines with product and check the suction system.

− Air mixture in the measuring cup gauge the calibration and use the density to calculate the volume.

− The flow is not measured properly. Dismount the flow meter or stroke sensor, clean it and check it for any damage.

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12. In all paint recipes, calibrate all components.

With identical flow meters (identical components) and identical lacquers or lacquers with similar characteristics, the K factor can be taken over: Enter the value directly in the Kn field and then save.

Exact calibration, version 1 (Lacquer density is known)

− Weigh the quantity filled into the cup.

− Divide the weight in grams (g) by the lacquer's density. This directly equals the volume in cc, that is entered in the measuring cup field.

Exact calibration, version 2 (Lacquer density is unknown)

− First, manually measure precisely e.g., 500 cc of product into a measuring cup and establish the product weight in "g" grams.

− Set empty measuring cup on the scale. When calibrating, use the gun to fill the cup with the exact weight measure above.

− The initial volume (e.g., 500 cc) is entered in the measuring cup field.

Flow quantity measured by the system.

Select paint recipe (for A/B/C/D).

Or select flushing valve (for A/B/C/D flushing valves).

Valve used by paint recipe.

Kn

K

0 bar

0 0 cc cc

Imp/L

Start

Enter pressure at which calibration takes place.

(Only with "Automatic product pressure regulator" option.)

B others

Select component A/B/C/D.

Displays list of A/B/C/D flushing valves.

Calibrate external flushing agent.

K = Current K factor for selected component

(A, B, ...).

Is saved in the selected paint recipe.

B_05458

Replaces the current K factor (K) for the selected component (A, B, ...) with the new K factor (Kn).

Depending on selection in the query which appears:

either only in the selected paint recipe,

or in all paint recipes.

Kn = Newly calculated K factor

Input of quantity calculated with measuring cup and scale.

Start measurement

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7.13 SETTINGS

7.13.1 PASSWORD LEVEL 2 SETTINGS

Level 2

There are 24 pages of settings. Depending on configuration, pages may be jumped.

The page numbers with a gray background always appear, the others are optional. (Detailed descriptions of these pages can be found in the 2K COMFORT Software Documentation.)

1 Number of paint recipes and number of flushing recipes .

QB, QC, QD Control See the software documentation, "Diagnosis" chapter.

Gun Delay Delay time for alarms A106 to A113 (set "Minimum flow" and "Maximum flow" Chapter

"Flow monitoring", Chapter 7.13.2

, level 3, page 4)

2 Post-alarm for pot life Once the pot life + post-alarm times have passed, the system stops (alarms A132–A144). The alarm is repeated until the system is flushed.

If "Automatic flushing at pot life alarm" is activated, and the guns are in the gun flush box, flushing is started automatically.

Alarm delay Flow monitoring Delay time for alarms A121 and A122. (Activate

, level 3, page 2. Enter the limits in the paint

recipe see Chapter 7.11

Atomizing air at alarm stop So that coating can be completed without dripping.

Atomizing air at end of flushing To blow the air cap free.

VOC measuring unit Percent or gram per Liter.

Password for password level 1.

3 Hose dimensions from product valves A and B to mixer.

4 For 3K system: hose dimensions from product valve C to mixer.

5 For 4K system: hose dimensions from product valves C/D to mixer.

6 Hose dimensions from mixer to splitter valve.

7+8 − Page 7: Hose dimensions from mixer to gun 1.

− Page 8: Hose dimensions from splitter valve to gun 1.

Gun content of gun 1

Gun 1: Filling via the dump valve Quantity (as a percentage), which should be discharged via the dump valve. (The remainder passes via the gun.)

Gun 1: Flush atomizing air % hose content When flushing: What percentage of the hose content from the mixer to the gun, can still be used for coating. The atomizing air (and electrostatics) for gun remains activated for this period when flushing.

See also "Flushing pause" (level 2, page 16).

Gun 1: dump valve flushing time after filling. (Only with flushable dump valve.)

9 Hose dimensions from gun 1 to the dump valve. (Only with "Dump valve as return flow".)

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10+11 Like pages 8 + 9, but for gun 2.

12+13 Like pages 8 + 9, but for gun 3.

14+15 Like pages 8 + 9, but for gun 4.

16 The flushing pause indicates that with "Atom.air on flush % of hose volume" the remainder must be sprayed into the waste tank. The atomizing air remains on during the flushing pause.

Pot life alarm Flushing "On" = Flushing is mandatory after a pot life alarm.

Additional spraying is also possible with "Off".

Mixing alarm Flushing "On" = Flushing is mandatory after a mixing error alarm

(A100–A118, A128–A131, A145–A148). Additional spraying is also possible with "Off".

Mixing alarm Filling "On" = Filling is mandatory after a mixing error alarm

(A100–A118, A128–A131, A145–A148). Additional spraying is also possible with "Off".

17 Filling greater than hose content What percentage of the total hose content is also to be filled between product valve and gun to ensure that there is no flushing agent left in the hose.

Flow monitoring during filling "On" = The flow is limited when filling to optimize the dosing quality. Set limits with "Max. filling flow" or "Min. filling flow". If necessary, the A valve cycles (see figure).

Reset pot life Pot life is reset manually.

Flow monitoring during filling c

"A" valve open a

"A" valve closed b

(a) During filling, the flow is regulated by a longer or shorter opening of the A valve.

(b) "Filling time period" (in seconds)

Time

B_06130

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18 Save Start/Stop totals USB stick "On": Start/Stop totals are written continuously to a USB stick (USB stick must be plugged in).

PC data archiving "On": Data are archived continuously on PC. (Operating manual for PC data archiving, see Chapter

Alarms A121 and A122. ("Alarm delay for flow monitoring" Chapter 7.13.1

)

19 For AIS-B:

AIS warning limit Minimum injection quality (opening time of hardener dosing valve as a percentage). If the value falls below this, a warning is triggered (W123 -

W125).

AIS lower limit If the value falls below this, the AIS optimizes the injection quality.

(Default value = 50%)

AIS upper limit If the value exceeds this, the AIS limits the injection quality.

Thereby smooth operation is ensured. (Default value = 80%)

Valve > open AIS open If the B valve is continuously opened for longer than the stated time, too little product can flow through. The AIS allows more product through. (Default value 1.0 sec.) Repetition after each repetition interval AIS open .

(Default value 0.5 sec.)

AIS open when stopped Number of steps which the AIS is to open when mixing operation is ended. (Default value 3)

AIS min. flow Minimum flow of all components for AIS to undertake regulation.

(Default value 20 cc/min)

20 For AIS-B:

AIS hysteresis Number of steps which do not yet have impact when AIS switches

(e.g., close open) and are therefore inserted at the switchover points. (Default value

AIS Number of cycles with X guns Number of steps which the AIS is to open or close when an additional gun is switched on or off.

21+22 Like pages 19 + 20, but for AIS-C.

23+24 Like pages 19 + 20, but for AIS-D.

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7.13.2 PASSWORD LEVEL 3 SETTINGS

Level 3

There are 23 pages of settings. (Detailed descriptions of these pages can be found in the

2K COMFORT Software Documentation.)

1 2K , 3K or 4K system (with 2-circuit system maximally 3K)

Measuring units for volume (liters / US gallons) and lengths (meter / inch)

Gun closed Valves closed "On": When the gun is closed, all product valves are also closed automatically. Beneficial for low-pressure applications. Prerequisite: gun monitoring (not flow monitor).

External release "On" = External releasing (e.g. locking with spray booth's exhaust air)

Number of installed Universal CAN I/O modules

2 Number of guns (1–4, with 2-circuit system 1–2)

Gun monitoring for all available guns.

Splitter valve (Prerequisite: minimum 2 guns)

Flush guns separately "On" = splitter valve with flushing (separate gun flushing valves). Prerequisite: maximum 2 guns, splitter valve = On.

Number of gun flush boxes (GFB)

Automatic flushing at pot life alarm (Prerequisite: GFB)

Flow monitoring (On/Off). Prerequisite: gun monitoring or flow monitor. Sets off

, level 2,

page 2. Enter the limits in the paint recipe see Chapter 7.11

)

3 Dump valve "On" = There is a dump valve installed for every gun. Or a dump valve flushable.

If a dump hose is present between gun and dump valve (not flushable), the option dump valve as return line is activated. Dump valve for waste separation is possible with double valves (not flushable) (not for 2-circuit system). Precision of waste separation : 0 = exact, each additional number = 25% of the dump hose safety margin (default value 2).

Dump valve outputs can be inverted "Off" = Compressed air opens dump valve with non-flushable dump valves without waste separation.

"On" = Compressed air closes dump valve.

4 For component A:

Number of valves and flushing valves.

Minimum and maximum flow . Sets off Alarms A106 to A113. (Delay time "Gun Delay"

see Chapter

− During the flushing process (see Chapter 7.10

, level 2, page 1)

Air bubbles monitoring (On/Off)

Coriolis flow meter

Flow measurement with stroke sensors (On/Off), from software version 4.0x / 4.0x K.

To configure stroke sensors: see 2K COMFORT software documentation.

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5 Only for Coriolis:

Density area lower and upper value. The actual density must correspond to the density display of the C-flow measuring transducer (with liquid in the system).

Correct the value here if necessary.

Temperature range lower and upper value. The actual temperature must correspond to the temperature display of the C-flow measuring transducer (with liquid in the system). Correct the value here if necessary.

6 Like page 4, but for component B.

7 For component B:

AIS (On/Off)

Mixing head valve with cycles If a mixing head valve is fitted: "On" = Mixing head valve cycles. "Off" = B valve cycles.

Mixing head valve flushing "On" = A flushing valve is attached to the mixing head valve.

Input type for mixing ratio (A:B oder %B)

8 Like page 5, but for component B.

9–11 Like pages 6–8, but for component C.

12–14 Like pages 6–8, but for component D.

15 Alarm delay for air bubbles monitoring How long can an air bubble be present before the system stops ( alarms A114–A117).

Alarm delay no flow during filling How long can filling be interrupted before an alarm occurs (alarm A124). If set to 0.0 seconds, the function is deactivated.

Alarm delay no flow during flushing How long can flushing be interrupted before an alarm occurs (alarm A125)? When flushing, this alarm takes the place of the pot life alarm. If the setting is "0.0 seconds", the function is deactivated, the pot life continues and a pot life alarm occurs.

Alarm delay for Coriolis error (alarms A128–A131).

Remote control (On/Off)

Robot (no/digital/bus): "Digital" = Robot is digitally connected. "Bus" = Robot is connected via gateway.

Timeout for automatic logout If the touch panel is not activated during the defined time, then the password level is automatically reset to level 0. ("0 sec" = no automatic logout.)

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16 Batch Mode Allows a recurring and pre-defined flow rate to be discharged

(see software documentation).

Measuring unit for pot life minutes or seconds. (Change recipes accordingly after changeovers!)

Booster pump (Off / A-side / Mix-side)

A valve selection at start "On": After starting, a prompt appears asking which A valve is to be used for the selected recipe.

Number of tanks for filling level monitoring.

17 Pre-flushing after end flushing "On" = After an end flushing, a pre-flushing must be undertaken. Prerequisite: pre-flush recipe is defined and selected in the paint recipes.

Pre-flushing after paint change flushing "On" = A pre-flushing must be undertaken after a recipe change flushing. Prerequisite: pre-flush recipe is defined and selected in the paint recipes.

Flush interruption ok?

"On" = The flushing process can be interrupted and e.g., the new paint filled. "Off" = The entire flushing process must be undertaken first. If flushing is aborted, the process starts again afresh.

Air flushing valve (On/Off) "On" = Air flushing is fitted.

External mixer (On/Off)

Flushing external mixer as standard "On" = The FLUSHING push button starts mixer flushing ("Mix") of the last paint recipe used. ( Flushing from external mixer)

"Off" = The FLUSHING push button starts end flushing ("End") of the last paint recipe used.

18 Number of automatic product pressure regulators (0 / 1 / number of guns). "1" =

Automatic product pressure regulator in front of splitter valve. "Number of guns" =

An automatic product pressure regulator is fitted for each gun.

Maximum product pressure for automatic product pressure regulator.

Pressure regulator fully open during flushing

For manual product pressure regulators: "On" = During flushing, the product pressure regulator is subjected to full air pressure.

For automatic product pressure regulators: No function.

Pulse time at flush for prod.press reg.

For manual product pressure regulators, if the above function is switched on: pulse time for changes between working pressure and full air pressure.

For automatic product pressure regulators: pulse time for changing between flushing pressure (specified in recipe) and 0 bar.

"0.0 sec"= no cycling.

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19 Flow regulation (On/Off).

P (proportional-)part and I (integral-)part of controller.

Number of flow measurements , which are included in the calculation.

Time period between the flow measurements.

20 Flow meter in external flushing agent (On/Off).

Flow switch in external flushing agent (On/Off).

Flushing monitoring in seconds (flushing with paint valves / flushing external mixer

/ gun flushing / dump flushing):

"no" = The flushing time runs, regardless of whether or not flushing agent flows.

"Gun monitoring" = The flushing time only runs when there is a gun signal.

Prerequisite: gun monitoring signal from flow monitor or robot, not from air monitoring.

"Flow switch" = The flushing time only runs when there is a signal from the flow switch. Prerequisite: "Flow switch in external flushing agent" is activated (see above).

21 * An information signal can be generated:

− As soon as the filling is complete (Setting "Filling complete: -> Information signal").

− As soon as the gun in the gun flush box must be changed (Setting "GFB gun change:

-> Information signal").

Duration of the alarm horn sounds according to "Information signal switch-on time" and "Information signal break time". ("Number of cycles for information signal" =

How many information signal cycles should sound as soon as the filling is complete.)

22 * Warning signal on alarm horn (On/Off). Duration of sounds according to "Warning signal switch-on time“ and "Warning signal break time".

23 ** Password level 2 / 3 Password input for password level 2 / 3.

Reset initialization "OK" = When the system is switched on the next time, the initialization program starts (e.g., for training purposes). The current settings are preset, nothing is lost.

Start software update "OK" = A software update is executed. Special knowledge is required for this purpose (observe separate manual).

* from version 3.2x / 3.2x K

** Page 21 until version 3.1x / 3.1x K

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7.14 OPERATING PANEL FOR 2-CIRCUIT SYSTEM

The operating panel controls either the fluid circuit 1 or the fluid circuit 2.

Example: Home page for circuit 1

Current fluid circuit:

= Fluid circuit 1

= Fluid circuit 2

1/2 = affects both fluid circuits

Touch = Go to the other fluid circuit

A : B

AB : C

Gun

Background color of page:

Turquoise = Fluid circuit 1

Orange = Fluid circuit 2

White = both fluid circuits

Pot life min min

Menu Act.

Batch PC

On the home page are always both pot lives, each with the appropriate background color:

Pot life Circuit 1

Pot life Circuit 2

7.14.1 CHANGE FLUID CIRCUIT

Touch the current upper right fluid circuit, for example:

Thereafter, the controller switches to the other fluid circuit. The page remains the same.

Example: the controller changes from the menu page for circuit 1 to the menu page for circuit 2.

Change not possible

This error message appears if the current page is not available in the other fluid circuit:

Change to circuit X is not possible.

Go to another page (for example to the home page). Then change the fluid circuit.

On some pages, the current fluid circuit is framed in gray. Then a change to another circuit is also not possible. Remedy is the same:

Go to another page. Then change the fluid circuit.

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7.14.2 /K1 AND /K2

Names and alarm messages, which refer to a specific fluid circuit, are marked with "/K1" or "/K2".

Gun name (example)

Signal name (example)

Alarm message (example)

Name / Alarm message

…/K1

…/K2

…

Gun P2/K1

A1 valve/K2

A123 flushing first/K1

Meaning

… Circuit 1

… Circuit 2 affects the total system

Gun P2 of circuit 1

A1 valve for circuit 2

Circuit 1 has to be flushed

Software version identification

2-circuit systems software versions are marked after the version number with the letter "K":

"x.xx K"

7.14.3 ACKNOWLEDGE ALARMS

STOP button

Alarm Fluid circuit 1

Alarm Fluid circuit 2

Alarm System

* Or touch the [Reset] button on the screen.

Acknowledge alarm

STOP button Circuit 1 lights up Press the STOP button Circuit 1. *

STOP button Circuit 2 lights up Press the STOP button Circuit 2. *

Both STOP buttons light up Press one of both STOP buttons. *

7.14.4 WHITE BACKGROUND: AFFECTS BOTH FLUID CIRCUITS

Everything relates to both circuits has a white background.

Fluid circuit 1 Fluid circuit 2

Fluid circuit display (upper right)

Background color Turquoise Orange

Example: Settings

Turquoise = Circuit 1. White = both circuits.

2K, 3K or 4K

1

Measuring unit volume

Liters

Measuring unit length

Meters

Gun closed Valves closed

Off

External release

Off

Number of universal CAN I/O modules

Recipe change

1

2

7 : R7

3 : R3

Valid for both fluid circuits

1/2

White

Recipe change

1/2

Menu Level 2 Level 3

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8 OPERATION

Below, operation with manual guns is described. For automatic guns the same workflow applies correspondingly.

8.1 TRAINING THE OPERATING STAFF

The operating staff must be qualified to operate the entire system.

The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.

Before work commences, the operating staff must receive appropriate system training.

8.2 SAFETY INSTRUCTIONS

Before carrying out any work, ensure that commissioning is carried out in accordance with

Chapter

6.6

8.2.1 EMERGENCY DEACTIVATION

In the case of unforeseen occurrences:

− Switch off main switch.

− Switch off air supply of system and pumps.

− Point the manual gun into a grounded metal bucket. Open the gun's trigger mechanism step by step in order to relieve the pressure. Avoid splashback.

− Secure the gun.

− Provide appropriate return tanks and relieve pressure from the pumps via the return valves.

− Inform the security personnel / foreman / superiors.

8.2.2 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN

Observe the operating manual of the spray gun.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent.

Never reach into the spray jet.

Never point the spray gun at people.

Consult a doctor immediately in the event of skin injuries caused by paint or solvent.

Inform the doctor about the paint or solvent used.

Never seal defective high-pressure parts, instead relieve the pressure from them and replace them immediately.

Use personal protective equipment (protective clothing, gloves, eyewear and respiratory protection).

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8.3 SWITCHES THE SYSTEM ON AND OFF

Switching the system on

1. Turn red-yellow main switch on the right side of the control cabinet to ON. The software is started.

2. Turn on the air supply of the system and of all feed pumps. Prepare feed pumps, lacquer tank etc. for operation. Provide grounded metal bucket to collect the products to be disposed of.

Switching off the system

1. Press the STOP push button.

2. Flush system if necessary (see Chapter 8.6

3. Make sure that the system has been flushed and that the pot life has been increased.

4. Relieve pressure from the system and from all feed pumps (see Chapter 8.8

5. Switch off main switch (OFF).

6. Switch off air supply of system and pumps.

8.4 MALFUNCTION

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

The system stops and the alarm horn sounds

The red STOP push button lights up (control cabinet and remote control).

The fault is indicated on the screen.

Acknowledge fault

By means of the STOP push button or, on the screen, with the [Reset] button.

Alarm messages + fault rectification see Chapter

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8.5 SPRAYING MODE

8.5.1 PREREQUISITES

Optimum painting results are obtained if:

− The system parameters are set correctly.

− Product data such as the mixing ratio and pot life correspond to the working material.

− The flushing program is defined.

− The supply pressures are constant.

− The A/B/C/D pressure ratio is set correctly (see Chapter 8.5.2

− AIS is used.

Or without AIS: If the dosing valve (B side) is set using the valve stroke such that as many cycles are undertaken as possible (depending on flow rate and mixing ratio every

0.5 - 2 seconds). See the operating manual for the valves (Order No. in Chapter

The option is set with the setting "Select A valve during start" (see Chapter 7.13.2

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

Optimum operation is fulfilled under the following conditions:

− When the flushing agent pressure for the flushing pumps as well as the product pressure for the A, B and C pumps are always present on the device.

− When filling the mixed product in the product hose ensure that the nozzle is inserted in the gun.

− When the flushing process is performed without the nozzle in the gun.

− When the levels in the product and flushing agent tanks are checked visually, in order to prevent unintended interruptions in the spray process.

Prerequisites

− At the start, all pumps must be filled with working material and the system must be ready to start, as described in Chapter

6.6.5

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

− Operating manuals for the affected components must be known.

− With an electrostatic gun:

Commissioning the electrostatics according to corresponding operating manual.

8.5.2 A/B/C/D PRESSURE RATIO

− Set the pressure ratio between base lacquer and hardener correctly. With a mixer:

B must be approx. 5–10% higher than A. C approx. 2–5% higher than B, D approx. 2–5% higher than C.

− The pressure drop between pressure gauge and mixer can be differently for A/B/C/D.

For longer distances, different flow rates and viscosities that may be relevant (e.g., for external mixer or if the pressure gauges are at the pumps).

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8.5.3 SPRAYING WITHOUT GUN FLUSH BOX

Provide grounded metal bucket to collect the products to be disposed of.

Insert spray nozzle into manual gun.

The product pressure of the components is set depending on the required product flow rate. Thereby, keep in mind that the the B-component pressure must be higher

(5 to 10%) than that of the A-component.

Select the requested paint recipe on the screen (home page). In case of two spray guns, select the requested gun(s).

Start the coating process by means of the START push button.

Filling

For electrostatic spray guns: switch off electrostatics.

Point the manual gun with inserted spray nozzle into the grounded metal bucket.

Open the trigger mechanism of the spray gun step by step. Avoid splashback.

The 2K product starts to flow and the B-component is dosed proportionally to the

A-component. During filling, three screens in turn inform you of filling progress:

B_04637

From product valves to mixer.

From mixer to splitter valve.

B_04638

B_04639

From splitter valve to gun.

As soon as the complete high-pressure hose is filled with 2K product, the following will happen:

− "Filling" screen switches to the home page.

− The green START push button begins to light up.

− Remote control (Option): The green lamp begins to light up.

− Atomizing air is added (option).

Correctly mixed product is not transported from the gun until after filling.

Coating

For electrostatic spray guns: safety precautions according to corresponding the operating manual.

Start coating of an object.

The flushing agent pressure for A and B must always be applied at the device.

The flow rate of the system depends on:

− the product pressure,

− the hose lengths and cross-sections,

− the nozzle and

− the viscosity of the products.

Without AIS, the B pulse valve should operate every 0.5 to 3 seconds, according to the flow rate. The switching frequency can be optimized by adjusting the pressure of the hardener pump or through the stroke length of the hardener dosing valve. The higher the pulse rate is, the more homogeneous is the mixing of the two components.

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8.5.4 SPRAYING WITH GUN FLUSH BOX

Same procedure as in Chapter

8.5.3

, however:

before actuating the START push button, insert the spray gun into the gun flush box.

Remove the spray gun after filling.

8.5.5 INTERRUPTING WORK

The STOP push button stops the coating process. All product valves are closed.

For electrostatic spray guns: switch off electrostatics.

8.5.6 CHANGING THE PAINT RECIPE

The recipe change flush is executed on all spray guns while the spray nozzle is inserted.

Actuate the STOP push botton.

Select the new paint recipe on the screen (home page).

Without gun flush box

− Press START push button.

− Point the spray gun into the metal bucket. Open the gun step by step.

Avoid splashback.

With gun flush box

− Insert spray gun(s) in gun flush box.

The spray gun is automatically opened as necessary.

− Press START push button.

The system is flushed (recipe change flushing "

Subsequently the new lacquer is filled.

").

As soon as the green START push button lights up and the home page appears on the screen, the system is ready for spraying.

8.5.7 A VALVE SELECTION AT START

Possibly, a list of the A valves appears for selection at the start. Touch desired valve.

8.5.8 CIRCULATION (OPTION)

If necessary, the A, B or C components not in use have to be circulated.

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8.6 FLUSHING

DANGER

Exploding gas / air mixture!

Danger to life from flying parts and burns.

Never spray into a closed tank.

Ground the tank.

If a high-pressure gun is used, remove the spray nozzle before flushing.

− The pressure has to be relieved before removing the spray nozzle (see Chapter 8.8

Wear protective goggles.

Apply the lowest possible product pressure for flushing so that the maximum flow rate of the flow meter is not exceeded.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent.

Never reach into the spray jet.

Never point the spray gun at people.

Consult a doctor immediately in the event of skin injuries caused by paint or solvent.

Inform the doctor about the paint or solvent used.

Never seal defective high-pressure parts; instead relieve the pressure from them and replace them immediately.

Use personal protective equipment (protective clothing, gloves, eyewear and respiratory protection).

The system has to be flushed: in case of recipe change (recipe change flushing, system flushes automatically); in case of extended interruption of work or end of work (end flushing); if pot life has been exceeded (end flushing).

WARNING

Discharge of the electrostatics in atmospheres containing solvents!

Fire and explosion hazard.

Turn off the electrostatics before flushing the gun or before placing the gun in the gun flush box.

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End flushing

The FLUSHING push button normally starts the end flushing of the last paint recipe used.

1. Stopping the system.

2. For electrostatic spray guns: switch off electrostatics.

Actuate FLUSHING push button.

4. Point the opened gun(s), with or without nozzle, into a waste tank until the flushing process has been terminated.

During flushing, the blue FLUSHING push button lights up. The screen gives step by step information about the individual flushing steps.

Step

Current flushing recipe

Flushing step 1 of 5

Flushing valve currently open

Progress indication

Guns to open during this flushing step.

Gun symbol flashes Open gun.

Finally, all valves are closed.

If cleaning is insufficient, flushing can be repeated. The flushing recipe can be corrected subsequently.

Flush with external mixer

Setting "Flushing ext. mixer is standard" *

FLUSHING push button

Off

* see Chapter 7.13.2

Starts the mixer flushing ("Mix") of last paint recipe used.

Flushing from external mixer.

Starts the end flushing ("End") of the last paint recipe used.

Atomizing air flushing

The system can be set such that the atomizing air remains switched on for flushing during a certain time. Thus, the mixed product in the hose can be sprayed. A short flushing pause indicates that the remainder has to be sprayed into the waste tank. (Settings, see

Chapter

R-R flushing and filling (see Chapter 7.11

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Start other flushing recipes

For electrostatic spray guns: switch off electrostatics.

On the screen's home page.

Depending on the configuration, various selection possibilities appear:

− Manual flushing: select a recipe from the list of all recipes.

− Start end flushing : starts end flushing of the last paint recipe used.

− Start flushing external mixer : flushing from external mixer. The product hoses between valves and mixer are not flushed.

− Flushing spray guns : flushing from splitter valve. The product hoses between valves and splitter valve are not flushed.

Flushing with dump valve (option)

Flushing via a dump valve is quicker than via the gun. However, the gun has also to be flushed briefly.

When the flushing process stops and the spray gun symbol on the screen flashes, the corresponding guns have to be opened. Point opened gun(s) with or without nozzle in a waste tank.

Step

As long as the gun symbol flashes, open the corresponding spray gun (here gun 2).

As soon as the gun symbol stops flashing, close gun again.

Flushing with gun flush box

Same procedure as without gun flush box, but:

Before flushing, insert the spray gun into the gun flush box.

− Atomizing air flushing: the flushing pause indicates when the gun is to be inserted into the gun flush box.

Remove the spray gun after flushing.

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8.7 FLOW CHART WITH PAINT RECIPE CHANGE

Example for 2K system:

Spraying with paint recipe

Mixed product

Recipe change flushing

R-R Flushing

Filling

Spraying with paint recipe

A+B

Filling

Mixed product End flushing

1. Stop

3. Start

Filling of A and B up to mixing block separately

1. Stop

2. End flushing

Filling the spray hose with mixed products

Pre-flushing

Pre-flushing may be necessary between

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8.8 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 steps in this chapter whenever: you are instructed to relieve the pressure; spraying is stopped; part of the system is checked or maintained; the nozzle is installed or cleaned.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent.

Never reach into the spray jet.

Never point the spray gun at people.

Consult a doctor immediately in the event of skin injuries caused by paint or solvent.

Inform the doctor about the paint or solvent used.

Never seal defective high-pressure parts; instead relieve the pressure from them and replace them immediately.

Use personal protective equipment (protective clothing, gloves, eyewear and respiratory protection).

Pressure relief procedure for the whole system

1. Press the STOP push button.

2. Relieve the product pressure and air pressure in all pumps or pressure tanks. Use return

/ circulation, according to the instructions in the corresponding operating manuals.

3. For electrostatic spray guns: switch off electrostatics.

4. Menu

(see Chapter 7.8

1. Relieve the pressure according to Chapter 8.8

One after the other and in each component (A, B, flush, ...) for each product valve (A1, A2, ...):

− Select valve and open it with the large valve button.

− Point the manual gun into a grounded metal bucket. Open the gun's trigger mechanism step by step in order to relieve the pressure. Avoid splashback.

− Close and secure gun.

5. Press the [STOP] button.

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9 CLEANING AND MAINTENANCE

9.1 CLEANING

9.1.1 CLEANING STAFF

Cleaning work should be undertaken regularly and carefully by qualified and trained staff.

They should be informed of specific hazards during their training.

The following hazards may arise during cleaning work:

− Health hazard from inhaling solvent vapors

− Use of unsuitable cleaning tools and aids

9.1.2 SAFETY INSTRUCTIONS

Before all work on the device and in the event of work interruptions:

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

− Secure spray guns against actuation.

− Switch off the energy and compressed air supply.

− Disconnect the control unit from the mains.

If there are deposits on the surfaces, the device may form electrostatic charges. Flames or sparks can form during discharge.

Remove deposits from the surfaces to maintain conductivity.

Use only a damp cloth to clean the device.

9.1.3 FILTER CLEANING

Product filter: check and clean filter insert and filter body. When opening the filter, ensure that no product drips on the flow meter's electronics.

The filters of the piston pumps and guns should be cleaned in accordance with the corresponding operating manuals.

9.1.3.1 CONDENSATE DRAINAGE FROM THE FILTER PRESSURE REGULATOR

Frequently drain the condensate that may accumulate in the air filter.

− Make sure the water level in the filter cup never reaches the max. level marked on the cup itself.

WARNING

Brittle filter pressure regulator!

The tank on the filter pressure regulator becomes brittle through contact with solvents and can burst. Flying parts can cause injury.

Do not clean the tank on the filter pressure regulator with solvents.

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9.1.4 CLEANING THE SYSTEM

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

A cleaned system allows an easy localization of any leakage and quick repair.

Procedure:

2. Service guns and pumps according to their operating manuals.

3. Clean and check the suction systems and suction filter.

4. Product filter: check and clean filter insert and filter body.

5. Put the whole system back together.

6. Clean the outside of the system.

9.1.5 DECOMMISSIONING

1. Clean the system according to Chapter 9.1.4

2. Fill the entire system with flushing agent. As laid down in Chapter 6.6.5

, but with flushing agent.

WARNING

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

Danger to life from flying parts.

Ensure that the device is always completely filled with flushing agent or working medium.

Do not spray the device empty after cleaning.

9.1.6 LONG-TERM STORAGE

If storing the system for a prolonged period of time, thorough cleaning and corrosion protection are necessary. For the last rinse, replace the water or solvent in the product pumps with a suitable preservative. Fill separating agent cup with separating agent.

Store pump vertically.

Procedure:

1. Clean the system according to Chapter 9.1.4

2. Fill the entire system with flushing agent. As laid down in Chapter 6.6.5

, but with flushing agent.

3. Fill the entire system with preservative according to Chapter 6.6.5

and the lacquer supplier's instructions.

4. If the discharge duct is to be removed, seal product outlet with plug.

5. If the suction system is to be removed, seal product inlet with plug.

6. Storage according to Chapter

6.2

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9.2 MAINTENANCE

9.2.1 MAINTENANCE STAFF

Maintenance work should be undertaken regularly and carefully by qualified and trained staff. They should be informed of specific hazards during their training.

The following hazards may arise during maintenance work:

− Health hazard from inhaling solvent vapors

− Use of unsuitable tools and aids

An authorized person must ensure that the device is checked for being in a reliable state after maintenance work is completed.

9.2.2 SAFETY INSTRUCTIONS

Prior to maintenance

− Cleaning and flushing the device. Chapters

8.6

and

9.1.4

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts.

Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.

Before all work on the device and in the event of work interruptions:

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

− Secure spray guns against actuation.

− Switch off the energy and compressed air supply.

− Disconnect the control unit from the mains.

Observe the operating and service manual for all work.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel.

After maintenance

− Put the system into operation and check for leaks. Section 6.6

In accordance with DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36:

− The liquid ejection devices should be checked by an expert (e.g., WAGNER service technician) for their safe working conditions as required and at least every 12 months.

− For shut down devices, the examination can be suspended until the next start-up.

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9.2.3 GEAR FLOW METER

The gear flow meters (A/B/C/D) are cleaned by flushing.

If individual parts have to be cleaned, the flow meter should be disassembled. Care should be taken that these parts are installed again in their original positions.

5 1. Remove the electronic sensor (1) from the flow meter.

− The electric sensor can be removed by loosening the two screws (10) from the holes without removing the cover (11).

2. Unscrew the screws (2) - two opposite screws should be left, temporarily screwed in by two turns.

3. Carefully take the lid (3) off the flow meter parallelly.

− If necessary, softly knock on the lid with a plastic hammer so that it loosens.

− The lid must be removed parallelly so that the internal bearings are not stressed and the shaft (5) does not break.

− For this reason do not use screwdrivers as levers.

B_04655

4. Remove the screws which had previously been left screwed in.

5. Remove the lid, the gears (7) and the shafts (5).

− In most cases a dirt particle in the flow meter causes the problem.

− If the parts cannot be disassembled easily, put the flow meter into a suitable solvent and then disassemble the parts.

− Do not disassemble the parts by force!

− It is important that the gears turn on the shaft, if they don't, the flow meter is not suitable for the lacquer.

Contact WAGNER Service Department for further information.

Assembly

After cleaning the gear flow meter and assembling the shafts and gears into the housing, check whether they turn easily, without any obstruction. This has to be the case even when a finger slightly presses against the shafts laterally.

1. Mount the lid again in parallel position and adjust it in the correct position by means of both dowel pins (12).

These pins must never be removed from the flow meter housing.

2. Tighten the screws with 15 Nm; 11.06 lb/ft.

3. Check if the gears turn by using a short pulse of compressed air, maximum 0.1 MPa;

1 bar; 14.5 psi.

4. Mount the electronic sensor again. Do not interchange A/B/C flow meters.

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9.2.4 CLEANING AND REPLACING THE PRODUCT FILTER

1. Flush the pump and inline filter in accordance with pump's operating manual. Flush using the gun so that the flushing agent flows through the inline filter. Maximize the flow (remove the nozzle, open the dosing valve if necessary).

2. Empty the pump in a controlled manner in accordance with pump's operating manual.

3. Place the grounded collection tank under the inline filter.

4. Unscrew the filter by turning the handle (4).

5. Remove the filter insert (3).

6. If the inline filter has any leaks, replace the seal (1).

7. Insert the new filter insert (3). Note the installation position:

Closed end in direction of flow.

8. If necessary, coat the thread with anti-seize paste (10).

9. Assemble the turning handle (4), inlet housing (2) and outlet housing (5) and tighten by turning the handle.

10. Fill the pump in accordance with pump's operating manual.

53 MPa; 530 bar; 7,687 psi

Flow dir ection

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* For Order No., see spare parts catalog

9.2.5 PRODUCT VALVES

Example 2.6 mm valve

Leakage hole

Rod seal

(pneumatic O-ring)

Product sealings

Sealing screw

Check the leakage behavior of the product valves

(air or product discharge from the leakage hole) in regular intervals (once per week).

In case of air leakage: change rod sealing.

In case of product discharge:

− 2.6 mm valve: re-tighten sealing screw or change the seals.

− 4 mm valve: change the seals.

Check the leakage behavior of the valve seats at regular intervals, by executing a

pressure retention test in accordance with Chapter 6.6.4.

Disassembly and assembly, see valve operating manual (Order No. in Chapter 1.3.1

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9.2.6 PRODUCT HOSES, TUBES AND COUPLINGS

The service life of the complete hoses between product pressure generator and application device is reduced due to environmental influences even when handled correctly.

Check hoses, pipes, and couplings every day and replace if necessary.

Additionally, the operator must regularly check the complete hoses for wear and tear as well as for damage at intervals that he/she has set. Records of these checks must be kept.

Undamaged complete hoses are to be replaced when one of the two following intervals has been exceeded:

− 6 years from the date of the hose crimping (see fitting embossing).

− 10 years from the date of the hose imprinting.

Fitting embossing

(if present) xxx bar yymm

Hose imprinting

WAGNER yymm xxx bar (xx MPa) e.g., 270 bar (27 MPa)

DNxx (e.g., DN10)

Meaning

Pressure

Crimping date (year/month)

Internal code

Meaning

Name / Manufacturer

Date of manufacture (year/month)

Pressure

Internal code

Nominal diameter

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10 TROUBLESHOOTING

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

The system stops.

The alarm horn sounds.

Control cabinet: The red STOP push button lights up.

The fault is indicated on the screen.

Remote control (option): The red LED STOP lights up.

Acknowledge fault

Stop with the STOP push button.

Or by means of the [Reset] push button on the screen.

List of alarm messages and warning messages: see Chapter

Fault rectification

See the following table and Chapters 10.1.1

and

10.2.1

For troubleshooting, it is important which work steps were last carried out.

The troubleshooting within the electric cabinet should be carried out by qualified persons (e.g., industrial electrician)!

WARNING

Electric shock hazard inside the control unit!

Danger to life from electric shock.

May only be installed/maintained by skilled electricians or under their supervision.

Operation according to the safety regulations, fire protection and electrotechnical rules.

Must be de-energized before work is commenced on active parts.

Malfunction

System does not start up

System is in operation

(a pump is running), but there is no product flow

System does not supply any product, pumps do not run

Remedy

− Check air supply line connection.

− Check the pressure value on the system's pressure gauge for the air supply to the valves.

− Check the voltage supply (does the control panel light up?)

− Check the selected valves.

− Check the fuses.

− Check the supply lines of the components as well as filters (clogging) and suction tubes (leakage).

− Check the component level in the supply tanks.

− Check the viscosity of the components or the pressure loss.

− Check the mixing tube and feed hoses.

− Check the guns and the gun filter.

− Clean the lines by flushing or cleaning manually.

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Malfunction

The 2K product does not react correctly

Flow rate is too low

Product valves:

− Product- or air emission from leakage hole

− No product transportation

− Contamination

Interruption of circuit over a longer period of time

A fuse is defective.

LED lights up

The system supplies product, but the spray pattern is inadequate

Flow rate is too high

Remedy

− Check the mixing ratio value.

− Check the suction lines (leakage).

− Check the flow meter with a calibration process.

− Check pressure differences. see Chapter

− Check AIS function (see software documentation, "Diagnosis" chapter).

− Without AIS: Optimize the switching behavior of the hardener dosing valve in spraying mode (0.5 - 3 seconds) via the differential pressure of B to A or via the stroke setting of the valve.

− Check the lacquer specifications.

− Check the mixing tube and feed hoses.

− Check the guns and the gun filter.

− Clean the lines by flushing or cleaning manually.

− Increase the pressure of the supply pumps.

− See product valve's operating manual.

− With external compressed air, manually open the flushing valve and distributor valve (option).

− Check on the basis of the control cabinet diagram whether a cable is damaged.

− Replace the fuse.

− Ensure that the supply pressures are constant.

− Adjust the A/B/C/D pressure ratio. see Chapter

− Increase the pressure of the supply pumps.

− AirCoat: Set the atomizing air correctly.

− Check product filter on pumps, 2K systems and guns.

− Replace gun nozzle with a more suitable nozzle (Airless and AirCoat).

− Check the viscosity of the product and dilute it in accordance with the lacquer manufacturer's instructions. If necessary correct the mixing ratio.

− AirCoat: Ensure that only dry, clean atomizing air is used in the spray gun.

− Replace gun nozzle (Airless and AirCoat).

− Check the lines for leakage.

− Set the opening of the gun needle correctly (air guns only).

− Decrease the pressure of the supply pumps.

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10.1 ALARM MESSAGES

In the case of an alarm message, the system stops. The alarm horn sounds.

The red STOP push button lights up (control cabinet and remote control).

The fault is indicated on the screen.

Alarm No. Alarm message in the display Meaning

A100 B+ tol. alarm

A101 C+ tol. alarm

A102 D+ tol. alarm

Mixing ratio outside of tolerance range. B+/C+/D+: too much B/C/D.

A103 B– tol. alarm

A104 C– tol. alarm

A105 D– tol. alarm

A106 A+ flow rate

Mixing ratio outside of tolerance range. B–/C–/D–: too little B/C/D.

A107 B+ flow rate

A108 C+ flow rate

A109 D+ flow rate

A110 A– flow rate

A111 B– flow rate

A112 C– flow rate

A113 D+ flow rate

A114 Air bubble A

Maximum flow of components A/B/C/D exceeded.

Falls below minimum flow of components A/B/C/D.

A115 Air bubble B

A116 Air bubble C

A117 Air bubble D

A118 Flow meter A

A119 Gun monitoring

A120 No enabling signal

A121 Flow fault –

A122 Flow fault +

A123 Flushing first

A124 No flow during filling

A125 No flow during flushing

A126

A127

Gun monitoring disabled

K factor is 0!

Air bubble in the line (only with low-pressure).

Flow meter A is blocked.

No gun signal, although product is flowing.

External release missing.

The flow rate is below the limit entered in the paint recipe.

The flow rate is above the limit entered in the paint recipe.

The system has to be flushed.

The filling procedure is interrupted for too long.

The flushing procedure is interrupted for too long.

Function is selected, which requires gun monitoring. However, the gun monitoring is deactivated.

A K factor for the current paint recipe is zero. Calibrate.

Acknowledge alarm : By means of the STOP push button or on the screen with the [Reset] button.

Fault rectification:

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Alarm No. Alarm message in the display Meaning

A128 Coriolis A

A129 Coriolis B

A130 Coriolis C

For Coriolis error, see operating manual of Coriolis flow meter.

A131 Coriolis D

A132 Pot life gun 1

A133 Pot life gun 2

A134 Pot life gun 3

Pot life + post-alarm time of guns 1/2/3/4 have expired.

A135 Pot life gun 4

A136 Pot life gun hose 1

A137 Pot life gun hose 2

A138 Pot life gun hose 3

A139 Pot life gun hose 4

Pot life + post-alarm time of gun hoses 1/2/3/4 have expired.

A140 Pot life to spl. valve

A141 Pot life dump hose 1

A142 Pot life dump hose 2

A143 Pot life dump hose 3

A144 Pot life dump hose 4

A145 Tank A is empty

A146 Tank B is empty

A147 Tank C is empty

The pot life + post-alarm time from mixer to splitter valve have expired.

Pot life + post-alarm time of dump hoses 1/2/3/4 have expired.

Tank for component A/B/C/D is empty.

A148 Tank D is empty

A149 Tank flushing agent is empty Flushing agent tank is empty.

A150 Flow is too low

A151 Flow is too high

The setpoint flow is not reached with the flow regulation.

Acknowledge alarm : By means of the STOP push button or on the screen with the [Reset] button.

Fault rectification:

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Alarm messages with stroke measurement

Alarm No. Alarm message in the display Meaning / Fault rectification

A200 Unknown error

A201–

A204

Sensor A/B/C/D signal is lost

A205–

A208

SensorA/B/C/D

LowerReversePoint

Error number unknown.

Stroke sensor cable breakage or sensor signal lost

(sensor is in lower idle position).

Lower stroke sensor reversal point not detected.

A209–

A212

A213–

A216

A217–

A220

A221–

A224

A225–

A228

A229–

A232

SensorA/B/C/D

UpperReversePoint

A/B/C/D sensor dry run up

Sensor A/B/C/D initialization

Sensor A/B/C/D unknown. error

Sensor A/B/C/D wrong type

A237–

A240

ADC1/2/3/4 no response

A241 Unknown operating mode

A242 SensorA unknownSelection

A243 SensorB unknownSelection

A244 SensorC unknownSelection

A245 SensorD unknownSelection

A246 Sending: unknown SensorNo.

A247 Sending: unknown Parameter

Upper stroke sensor reversal point not detected.

Sensor A/B/C/D dry run down Pump sags in downward stroke, pump cavitating.

Pump sags in upward stroke, pump cavitating.

Stroke sensor initialization error.

Error number unknown.

Stroke sensor type does not match the setting.

Communication error

A248 Wrong data value

A249 Reading: unknown SensorNo.

A250 Reading: unknown Parameter

A254 MPX sends in operation

A255 MPX unknown message

A256 MPX transfer error

A257 Data conflict

A258 MPX is not sending data

A259 MPX is not responding

Communication error

Different settings data on MPX / ADC and touch panel.

Communication error

A260

A261

Sending to MPX interrupted

Data from wrong sensor

The sending of settings data to the MPX and ADC was not terminated.

Communication error

Acknowledge alarm : By means of the STOP push button or on the screen with the [Reset] button.

Fault rectification:

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CAN I/O modules alarm messages

Alarm No. Alarm message in the display

A500 Initialisation error

A501 CAN master error

A502 CAN master alone

A503 SDO sending error

A504 SDO receiving error

A505 Saving interrupted

A600 Module D2 no communication

A601 Module D3 no communication

A602 Module D4 no communication

A603 Module D5 no communication

A604 Gateway D6 no communication

A606 Module D2 CAN emergency

A607 Module D3 CAN emergency

A608 Module D4 CAN emergency

A609 Module D5 CAN emergency

A610 Gateway D6 CAN emergency

A612 Module D2 CAN error

A613 Module D3 CAN error

A614 Module D4 CAN error

A615 Module D5 CAN error

Meaning

Internal error when starting up the touch panel.

The touch panel CAN master process not possible.

The touch panel CAN master found no connected slaves on the CAN bus.

Error while sending or receiving SDO telegrams.

Error while saving on the PC.

No communication to the corresponding module.

Module sends an emergency telegram.

Slave reports communication problems.

Acknowledge alarm : By means of the STOP push button or on the screen with the [Reset] button.

Fault rectification:

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Alarm No. Alarm message in the display

A616 Module D2 hardware error EEPROM

A617 Module D3 hardware error EEPROM

A618 Module D4 hardware error EEPROM

A619 Module D5 hardware error EEPROM

A620 Module D2 hardware error ADC

A621 Module D3 hardware error ADC

A622 Module D4 hardware error ADC

A623 Module D5 hardware error ADC

A624 Module D2 hardware errror TIMER

A625 Module D3 hardware errror TIMER

A626 Module D4 hardware errror TIMER

A627 Module D5 hardware errror TIMER

A628 Module D2 unknown hardware error

A629 Module D3 unknown hardware error

A630 Module D4 unknown hardware error

A631 Module D5 unknown hardware error

A632 Module D2 hardware error counter

A633 Module D3 hardware error counter

A634 Module D4 hardware error counter

A635 Module D5 hardware error counter

A640 Module D2 DO group1

A641 Module D2 DO group2

A642 Module D2 DO group3

A643 Module D2 DO group4

A644 Module D3 DO group1

A645 Module D3 DO group2

A646 Module D3 DO group3

A647 Module D3 DO group4

A648 Module D4 DO group1

A649 Module D4 DO group2

A650 Module D4 DO group3

A651 Module D4 DO group4

A652 Module D5 DO group1

A653 Module D5 DO group2

A654 Module D5 DO group3

A655 Module D5 DO group4

Meaning

Hardware error in I/O module.

Voltage supply error.

Acknowledge alarm : By means of the STOP push button or on the screen with the [Reset] button.

Fault rectification:

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10.1.1 FAULT RECTIFICATION

A100/A101/A102 B+/C+/D+ tol. alarm

The mixing ratio within a specific control quantity (QB/QC/QD control) was not reached: too much B, C or D.

− Reduce pressure of B/C/D: see Chapter

− Without AIS:

− The stroke at the B/C/D valve is too long. Close the regulating screw a little.

− Check the cycle length of the hardener dosing valve (menu diagnosis).

0.5 to 3 seconds are optimal. If the cycle length is too long, then the difference in pressure is still too great or the stroke is too long.

− With AIS:

− If the stroke of the B/C/D valve is far from its ideal position, the adjustment can take a long time under some circumstances. Home page: [AIS], then reduce the

AIS position a bit.

− Check whether valve closes. Clean valve.

− The flow meter A is blocked by soiling. The LED at the flow meter has to light up during product flow, otherwise it is clogged (cleaning, see Chapter

− Check whether nozzles, mixer or filter are clogged.

− Check the level of the paint tank, condition of the feed pumps, etc.

− The QB/QC/QD control quantity may be set too low (standard 150 cc). If the quantity is increased, the control algorithm becomes more stable because more time is available in order to achieve the mixing ratio.

A103/A104/A105 B–/C–/D– tol. alarm

The mixing ratio within a specific control quantity (QB/QC/QD control) was not reached: too little B, C or D.

− Increase the pressure of B/C/D: see Chapter

− Without AIS:

− The stroke at the B/C/D valve is too short. Open the regulating screw a little.

− Check the cycle length of the hardener dosing valve (menu diagnosis). 0.5 to

3 seconds are optimal. If the valve is always open (cycle check display is almost continuously lit), then the difference in pressure is still too small or the stroke is too short.

− With AIS:

− If the stroke of the B/C/D valve is far from its ideal position, the adjustment can take a long time under some circumstances. Home page: [AIS], then enlarge the AIS position a bit.

− Check whether the valve opens. Clean valve.

− The flow meter B or C or D is blocked by soiling. The LED at the flow meter has to light up during product flow, otherwise it is clogged (cleaning, see Chapter

The flow is greater than the upper limit of the flow meter "Maximum flow" (see Chapter 7.13.2

− Check whether nozzles, mixer or filter are clogged.

− Check the level of the paint tank, condition of the feed pumps, etc.

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A106/A107/A108/A109 A+/B+/C+/D+ flow rate

, level 3, page 4).

− The flow rate has to be reduced.

− Insert nozzle.

− Possibly worn nozzle, leaking hose or other leaking parts.

A110/A111/A112/A113 A–/B–/C–/D– flow rate

Gun monitoring signal is present, even though no product is flowing (gun closed).

− Check the atomizing air for leaks.

− Check whether the gun monitoring operates correctly.

− Possibly, the "Gun delay" is set too short (see Chapter

− The alarm can occur if the atomizing air continues to flow from the gun during short spray breaks. Release the gun trigger completely or increase the gun delay time.

− The A/B/C/D-component flow is less than the lower limit "Minimum flow"

(see Chapter

, level 3, page 4).

− Clean flow meters.

− Possible further causes such as for alarm A100…A105.

A114/A115/A116/A117 Air bubble A/B/C/D

Air bubble in the line (only with low-pressure). Fill product tank.

A118 Flow meter A

The flow meter A is blocked by soiling. The LED at the flow meter has to light up during product flow, otherwise it is clogged (cleaning, see Chapter

The flow rate is below the limit entered in the paint recipe (see Chapter 7.11

A119 Gun monitoring

Product flows through the A flow meter and for 50 seconds, there is no signal indicating that the gun is open.

− This means that the gun monitoring is defective or that there is no contact.

− Repair or replace the gun monitoring.

A120 No enabling signal

External release missing (booth ventilation etc.)

A121 Flow fault –

− Check the mixing tube and feed hoses.

− Check the guns and the gun filter.

− Clean the lines by flushing or cleaning manually.

− Increase the pressure of the supply pumps.

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A122 Flow fault +

The flow rate is above the limit entered in the paint recipe (see Chapter 7.11

− Replace gun nozzle (Airless and AirCoat).

− Check the lines for leakage.

− Set the opening of the gun needle correctly (air guns only).

− Decrease the pressure of the supply pumps.

A123 Flushing first

The system has to be flushed.

The "Mixing alarm flushing" or "Pot life alarm flushing" is activated and a mixing or pot life alarm has occurred.

A124 No flow during filling

The filling procedure is interrupted for too long (longer than the "Alarm delay no flow during filling" setting).

− Possibly, the filling procedure is waiting for the gun to be opened:

− With gun flush box: check whether the gun is inserted correctly.

− Without gun flush box: point spray gun into waste tank and open it.

− Check dump valve: clogging, function.

A125 No flow during flushing

The flushing procedure is interrupted for too long (longer than the "Alarm delay no flow during flushing" setting).

− Possibly, the flushing procedure is waiting for the gun to be opened:

− With gun flush box: check whether the gun is inserted correctly.

− Without gun flush box: point spray gun into waste tank and open it.

− Check dump valve: clogging, function.

A126 Gun monitoring deactivated

Function is selected, which requires gun monitoring. However, the gun monitoring is deactivated. Activate the gun monitoring or deactivate the relevant function.

Functions which require gun monitoring:

− Flow monitoring (settings password level 3).

− Spray gun closed valves closed (settings password level 3).

− Dump valve as return line (settings password level 3).

A127 K factor is 0!

The new K factor "Kn" is 0 and can therefore not be saved.

A128/A129/A130/A131 Coriolis A/B/C/D

For Coriolis error, see operating manual of Coriolis flow meter.

A132/A133/A134/A135 Pot life gun 1/2/3/4

Pot life + post-alarm time have expired. Continue working immediately or flush.

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A136/A137/A138/A139 Pot life gun hose 1/2/3/4

Pot life + post-alarm time have expired. Continue working immediately or flush.

A140 Pot life up to splitter valve

Pot life + post-alarm time have expired. Continue working immediately or flush.

A141/A142/A143/A144 Pot life dump hose 1/2/3/4

Pot life + post-alarm time in dump hose have expired. Close the gun until the dump hose is filled with freshly mixed product. Or, flush the system.

A145/A146/A147/A148 Tank A/B/C/D is empty

A149 Tank flushing agent is empty

Flow rate drops below the alarm limit. Fill up tank.

A150 Flow is too low

Even though the product pressure regulator is fully open, the setpoint flow is not reached.

− Check air pressure.

− Check product pressure.

− Check product pressure regulator.

− Check the control of the product pressure regulator (Electric/Pneumatic converter).

A151 Flow is too high

Even though the product pressure regulator is fully closed, the actual flow exceeds the setpoint flow.

− Check product pressure regulator.

− Check the control of the product pressure regulator (Electric/Pneumatic converter).

Fault rectification for stroke measurement

A200 Unknown error

Check compatibilities (software versions touch panel / MPX / ADC).

A201/A202/A203/A204 Sensor A/B/C/D signal lost

Stroke sensor cable breakage

− Check plug connection for sensor.

− Sensor signal lost (sensor is in lower idle position).

− Intake problem: pump is cavitating, improve supply of product.

− Switch pump to circulation and pass lower reversal point.

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A205/A206/A207/A208 Sensor A/B/C/D lower reversal point

A209/A210/A211/A212 Sensor A/B/C/D upper reversal point

Stroke sensor reversal point not detected.

− Check pump.

− Check stroke sensor settings in the touch panel and send again.

− Check stroke sensor.

− Replace stroke sensor if necessary.

A213/A214/A215/A216 Sensor A/B/C/D dry run down

Pump sags in downward stroke, pump cavitating.

− Check product supply.

− Leak check, check piston valve.

A217/A218/A219/A220 Sensor A/B/C/D dry run up

Pump sags in upward stroke, pump cavitating.

− Check product supply.

− Leak check, check piston valve.

A221/A222/A223/A224 Sensor A/B/C/D initialization

Stroke sensor initialization error.

− Switch system off and turn back on.

A225/A226/A227/A228 Sensor A/B/C/D unknown error

Error number unknown.

− Check compatibilities (software versions touch panel / MPX / ADC).

A229/A230/A231/A232 Sensor A/B/C/D wrong type

Stroke sensor type does not match the setting.

− Check stroke sensor.

− Check stroke sensor settings in the touch panel and send again.

A237/A238/A239/A240 ADC 1/2/3/4 no response

A241 Unknown operating mode

A242/A243/A244/A245 Sensor A/B/C/D unknown selection

A246

A247

Sending: unknown sensor no.

Sending: unknown parameter

A248

A249

Wrong data value

Reading: unknown sensor no.

A250

A254

A255

A256

Reading: unknown parameter

MPX sends in operation

MPX unknown message

MPX transfer error

Communication errors between the touch panel, MPX multiplexer and A/D converter ADC.

− Check cable with plug.

− Check compatibilities (software versions touch panel / MPX / ADC).

− If this occurs repeatedly, contact the WAGNER Service Department.

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A257 Data conflict

Different settings data on MPX / ADC and touch panel.

− Check stroke sensor settings in the touch panel and send again.

A258

A259

MPX is not sending data

MPX is not responding

Communication errors between the touch panel, MPX multiplexer and A/D converter ADC.

− Check cable with plug.

− Check compatibilities (software versions touch panel / MPX / ADC).

− If this occurs repeatedly, contact the WAGNER Service Department.

A260 Sending to MPX interrupted

The sending of settings data to the MPX and ADC was not terminated. Data must be sent again. (See software documentation.)

A261 Data from wrong sensor

Communication errors between the touch panel, MPX multiplexer and A/D converter ADC.

− Check cable with plug.

− Check compatibilities (software versions touch panel / MPX / ADC).

− If this occurs repeatedly, contact the WAGNER Service Department.

CAN bus fault rectification

A500 Initialisation error

Internal error when starting up the touch panel.

− Switch off the system and back on via the main switch.

− Contact the Service Team.

A501 CAN master error

The touch panel CAN master process not possible.

− Switch off the system and back on via the main switch.

− Contact the Service Team.

A502 CAN master alone

The touch panel CAN master found no connected slaves on the CAN bus.

− Check the connected modules: voltage supply, CAN cable, address, baud rate and terminating resistor. See spare parts catalog (Order No., see Chapter

1.3

− Switch off the system and back on via the main switch.

− Contact the Service Team.

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A503

A504

SDO sending error

SDO receiving error

Error while sending or receiving SDO telegrams.

− Switch off the system and back on via the main switch.

− Contact the Service Team.

A505 Saving interrupted

An error occured while saving on the PC.

− Check the archiving software on the PC.

A600/A601/A602/A603

A604

Module D2/D3/D4/D5 no communication

Gateway D6 no communication

Slave is not responding.

− Check corresponding module: voltage supply, CAN cable, address, baud rate and terminating resistor.

− Switch off the system and back on via the main switch.

− Contact the Service Team.

A606/A607/A608/A609

A610

Module D2/D3/D4/D5 CAN emergency

Gateway D6 CAN emergency

Corresponding module sends an emergency telegram.

− Switch off the system and back on via the main switch.

− Contact the Service Team.

A612/A613/A614/A615 Module D2/D3/D4/D5 CAN error

Corresponding slave reports communication problems.

− Switch off the system and back on via the main switch.

− Contact the Service Team.

A616/A617/A618/A619

A620/A621/A622/A623

A624/A625/A626/A627

A628/A629/A630/A631

A632/A633/A634/A635

Module D2/D3/D4/D5 hardware error EEPROM

Module D2/D3/D4/D5 hardware error ADC

Module D2/D3/D4/D5 hardware error TIMER

Module D2/D3/D4/D5 unknown hardware error

Module D2/D3/D4/D5 hardware error counter

Corresponding module reports a hardware error.

− Switch off the system and back on via the main switch.

− Contact the Service Team.

A640–A655 Module D2/D3/D4/D5 DO group 1/2/3/4

I/O module reports insufficient voltage supply at the respective output group.

(DO = Digital Output)

− Check the voltage supply of the respective output group.

− Check the fuse of the respective output group.

See spare parts catalog, "I/O modules" chapter.

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10.2 WARNING MESSAGES

In the case of warning messages, the system does not stop, work can be continued.

The red STOP push button blinks (control cabinet and remote control).

The fault is indicated on the screen.

Alarm No. Warning message on the display Meaning

W100 1st pot life gun 1

W101 1st pot life gun 2

Pre-alarm for the pot life of gun 1/2/3/4

W102 1st pot life gun 3

W103 1st pot life gun 4

W104 1st pot life gun hose 1

W105 1st pot life gun hose 2

Pre-alarm for the pot life of gun hose 1/2/3/4

W106 1st pot life gun hose 3

W107 1st pot life gun hose 4

W108 1st pot life to spl.valve

Pre-alarm for pot life from mixer to splitter valve

W109 1st pot life dump hose 1

W110 1st pot life dump hose 2

W111 1st pot life dump hose 3

W112 1st pot life dump hose 4

W113 A flow meter service

W114 B flow meter service

W115 C flow meter service

W116 D flow meter service

Pre-alarm for the pot life of dump hose 1/2/3/4

Carry out service for flow meter A/B/C/D

W117 B valve service

W118 C valve service

W119 D valve service

W120 Mix head B service

W121 Mix head C service

W122 Mix head D service

W123 AIS-B

W124 AIS-C

W125 AIS-D

W126 Tank A limit

W127 Tank B limit

W128 Tank C limit

W129 Tank D limit

W130 Tank flushing agent Limit

W500 USB memory

W501 USB storage

Carry out service for dosing valve B/C/D

Carry out service for mixing head valve B/C/D

AIS-B/C/D Fell short of warning limit (injection quality in %)

No USB stick used or too little memory

Automatic job total saving: saving did not work

Fault rectification

see Chapter 10.2.1

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10.2.1 FAULT RECTIFICATION

W100/W101/W102/W103 Pre-alarm for the pot life of gun 1/2/3/4

Pot life has expired. Continue working immediately or flush.

W104/W105/W106/W107 Pre-alarm for pot life gun hose 1/2/3/4

Pot life has expired. Continue working immediately or flush.

W108 Pre-alarm for pot life from mixer to splitter valve

Pot life has expired. Continue working immediately or flush.

W109/W110/W111/W112 Pre-alarm for pot life dump hose 1/2/3/4

The pot life in the dump hose has expired. Close the gun until the dump hose is filled with freshly mixed product. Or, flush the system.

W113/W114/W115/W116 A/B/C/D flow meter service

The maximum flow rate indicated in the [service] [menu] was reached. The corresponding flow meter needs servicing.

W117/W118/W119 B/C/D valve service

The maximum switching cycle indicated in the [service] [menu] was reached.

The corresponding dosing valve needs servicing.

W120/W121/W122 Mix head B/C/D service

The maximum switching cycle indicated in the [service] [menu] was reached.

The corresponding mixing head valve needs servicing.

W123/W124/W125 AIS-B / AIS-C / AIS-D

AIS below the warning limit (minimum opening time of the dosing valve in percent).

− If the stroke of the dosing valve is far from its ideal position, the adjustment can take a long time under some circumstances. Home page: [AIS], then reduce the "AIS position" a bit.

− Reduce pressure of B/C/D: see Chapter

− Check whether valve closes. Clean valve.

− The flow meter A is blocked by soiling. The LED at the flow meter has to light up during product flow, otherwise it is clogged (cleaning, see Chapter

− Put the system into operation and check for leaks. Section 6.6

− Check whether nozzles, mixer or filter are clogged.

− Check the level of the paint tank, condition of the feed pumps, etc.

W126/W127/W128/W129 Tank A/B/C/D limit

W130 Tank flushing agent limit

Flow rate drops below the warning limit. Fill up tank.

W500 USB memory

No USB stick used or too little memory. Try removing the USB stick and plugging it back in or plug in another USB stick.

W501 USB storage

Automatic job total saving: saving did not work.

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11 REPAIRS

11.1 REPAIR STAFF

Repair work should be undertaken carefully by qualified and trained personnel. They should be informed of specific hazards during their training.

The following hazards may arise during repair work:

− Health hazard from inhaling solvent vapors

− Use of unsuitable tools and aids

A skilled person must check to ensure that the device is in a reliable state after it is repaired.

11.2 SAFETY INSTRUCTIONS

Before a Repair

− Cleaning and flushing the device. Chapters

8.6

and

9.1.4

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts.

Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.

Before all work on the device and in the event of work interruptions:

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

− Secure spray guns against actuation.

− Switch off the energy and compressed air supply.

− Disconnect the control unit from the mains.

Observe the operating and service manual for all work.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel.

After a Repair

In accordance with DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36:

− The liquid ejection devices should be checked by an expert (e.g., WAGNER service technician) for their safe working conditions as required and at least every 12 months.

− For shut down devices, the examination can be suspended until the next start-up.

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11.3 MOUNTING MATERIALS

In the spare parts catalog the order numbers for device spare parts can be found, as well as for wearing parts such as seals.

Use torques, greases and glues in accordance with the spare parts catalog.

Mounting materials

Order No.

9992590

9992511

9992528

9992831

9999042

9998808

9992616

9992609

9992698

Quantity

1 pc ≙ 50 ml

1 pc ≙ 150 g

1 pc ≙ 50 ml

1 pc ≙ 18 kg!

1 pc ≙ 1 kg can

1 pc ≙ 100 g

1 pc ≙ 200 g can

Designation

Loctite® 222

Loctite® 243

Loctite® 270

Loctite® 542

Loctite® 638

Mobilux® EP 2 grease

Molykote® DX grease

Anti-seize paste

Vaseline white, PHHV II

Smaller tanks

400 g tube

50 g tube ≙

≙ Order No. 2355418

Order No. 2355419

Brand notice

The brands specified in this document are property of the respective owners. Loctite®, for example, is a registered brand of Henkel.

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12 DISPOSAL

When the equipment must be scrapped, please differentiate the disposal of the waste materials.

The following materials have been used:

Steel

Aluminum

Elastomerics

Plastics

Carbide

NOTICE

Do not dispose of used electrical equipment with household refuse!

In accordance with European Directive 2012/19/EU on the disposal of used electrical equipment and its implementation in national law, this product may not be disposed of with the household refuse, but must be recycled in an environmentally correct manner.

WAGNER or one of our dealers will take back your used WAGNER electric or electronic equipment and will dispose of it for you in an environmentally-friendly way.

Please contact one of our service points, one of our representatives or us directly.

Consumable products

Consumable products (lacquers, adhesives, flushing and cleaning agents) must be disposed of in accordance with all applicable legal requirements.

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13 ACCESSORIES

The system is ordered and supplied including all desired accessories.

It is possible for a WAGNER technician to install extensions and accessories later on, e.g., paint extension, gun monitoring, air bubble monitoring etc.

13.1 CONNECTIONS

There are five types of connectors:

Digital outputs Digital inputs High-speed counters Analog outputs Analog inputs

Before the installation of an accessory set, it must be checked whether enough room in the fluid cabinet and enough connections in the control cabinet are available:

1. Open on the 2K COMFORT USB stick (see Chapter 1.4

) the assembly manual of the

required set.

2. Check based of the assembly manual, whether enough room is available in the fluid cabinet.

3. For number and type of the required connectors please look into the assembly manual.

4. Check whether sufficient free connections are present in the control cabinet:

− Either in the 2K COMFORT connection table: each sufficient free lines must be present of the required connection types (see Chapter

13.2

− Or in the controller: password level 3 "Menu" "I/O Config"

(see software documentation).

13.1.1 I/O EXTENSION MODULE

If too few connections are available, the set "CAN I/O extension module" can be installed by a WAGNER technician. This includes:

Digital outputs

Digital inputs

High-speed counters

Analog outputs

Analog inputs

CAN I/O extension module: number of connections

Serial number 1 – 99 from serial number 100

A maximum of total 4 I/O modules can be installed in the control cabinet.

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13.2 CONNECTION TABLE 2K COMFORT

The "2K COMFORT connection table" is delivered together with the system and must be

adapted for each conversion. It is available on the USB stick (see Chapter 1.4

The table is divided into five sections:

Name

Q1 Ready

… …

Q12

… …

Connection signal

X3:1C/D

…

Digital outputs

GND connection

-10

… …

D2:X2_14

…

D2:X2_4

…

Hose No.

…

Fluid valve element

…

Stroke sensor

…

I1 Start

… …

Name

Digital inputs

Connection signal Cable No.

X2:1B/C

…

30;501

…

Hose No.

…

Fluid valve element

S2;RC;Robo

…

C1 --

… …

AO1 --

… …

AI1 --

… …

Name

High-speed counters

Connection signal

X2:19B/C

…

Analog outputs

Connection signal Cable No. EP valve Hose No.

D2:X4_17

…

Analog inputs

Connection signal Cable No.

D2:X4_1 --

… …

Cable No.

…

Fluid valve element

…

Fluid valve element

…

Fluid valve element

…

Assignment in the controller (touch panel)

Connection in the control cabinet

Valve name in the circuit diagram

The connection table enables:

The recognition of free connections. Example: in the "Name" column of the "Digital outputs" section 3 fields are empty 3 digital outputs are free.

The assignment of the names in the controller (e.g., D2 module, Q12 conneciton) with the I/O modules connections in the control cabinet (e.g., D2:X2_14 connection).

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Example

Accesory "Set 1" requires a digital output. The Q12 output in the D2 module is still free and

"Set 1" is connected there. The D2:X2_14 connection is assigned to this output.

Call up the digital outputs: "Output" in the controller ("Menu" "I/O Config").

Then scroll to the "D2" module with the arrow keys . Assign there to the "Q12" output the accessory function "Set 1" (according to the assembly manual).

Connect the accessory "Set 1" in the control cabinet to the D2:X2_14 terminal

(according to the assembly manual).

13.3 CONTROL CABINET DIAGRAMS

Pneumatic Diagram

A general pneumatic diagram can be found on the USB stick (Order No., see Chapter 1.4

The pneumatic diagram is also available at order no. 2364198.

Circuit diagram

A system specific circuit diagram can be found on the USB stick (Order No., see Chapter 1.4

A general circuit diagram is available under order no. 2359815. The 2-circuit circuit diagram is available at order no. 2363147.

13.4 EXPANSION AND ACCESSORY SETS

Functional descriptions

The descriptions of the expansion and accessory sets can be found in the corresponding

assembly manuals on the USB stick (Order No., see Chapter 1.4

Assembly

Have expansion and accessory sets be installed only by specially trained staff or a

WAGNER service center.

Carry out each assembly according to the corresponding assembly manual.

A skilled person must check to ensure that the device is in a reliable state after it is mounted.

Most accessory sets require conversions in the control cabinet.

WARNING

Electric shock hazard inside the control unit!

Danger to life from electric shock.

May only be installed/maintained by skilled electricians or under their supervision.

Operation according to the safety regulations, fire protection and electrotechnical rules.

Must be de-energized before work is commenced on active parts.

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13.4.1 INSTALLATION BY CUSTOMER OR BY WAGNER SERVICE DEPARTMENT

Expansion and accessory sets

Order No. Name

2358991

Paint/flushing valve set, high pressure, DN 2.6

(for 1–2 A components) x x

2358992

Paint/flushing valve set, low pressure, DN 4

(for 1–2 A components) x x

2362624 Valve set supplement for air flushing (A component, DN 4) x x

2358995

2358994

Dosing/flushing valve set DN 2.6, 400 bar SSt, non-Ex

(For 1–2 B/C/D-components, if component is already present.) Valve seat of stainless steel.

Dosing/flushing valve set DN 2.6, 400 bar TC, non-Ex

(for 1–2 B/C/D-components, if component is already present.) Valve seat of carbide.

Flushing valve set, Ex for 1–2 B/C/D-components:

Use one of the above two sets 2358994 or 2358995.

For flushing: these sets are also suitable for use in potentially explosive areas.

-x x x

392076 Paint/flushing valve set, DN 10

2357422 * Paint/flushing valve set, DN 4 SSt

2357421 * Paint/flushing valve set, DN 4 TC

2357462 * Dosing/flushing valve set, DN 4 SSt

2357461 * Dosing/flushing valve set, DN 4 TC

2360606 ** Dosing/flushing valve set DN 2.6, PTFE SSt (for 1–2 valves) ---

2360605 ** Dosing/flushing valve set DN 2.6, TC (for 1–2 valves) ---

2359046 High-pressure splitter valve, DN 2.6

2359052 Low-pressure splitter valve, DN 4

2359066 High-pressure splitter valve, DN 2.6 with flushing connection x

2359054 Low-pressure splitter valve, DN 4 with flushing connection x x x x x x x

2359041 Splitter valve: 2 to 3-4, DN 2.6

2359042 Splitter valve: 2 to 3-4, DN 4

2359022 Control of gun flush box x x x x x x

Non-XL

High pressure

Low pressure x

-x x x

-x

-x x x x x

-x x

-x

* For 2., 6. and 7. valve: additional Order No. 392090 (mounting bracket)

For 6. valve: additional Order No. 2334457 & 2330775 (hose & fitting)

** For dosing: per valve additional Order No. 2365901 (dosing connection, Ex), possibly connection plate, EX i

For flushing: per set additional Order No. 9956145 (double 3/2-way valve with base plate)

*** XL version: additional Order No. 2331173 (fitting)

-x

-x x ***

-x ***

-x x x x x x x

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Expansion and accessory sets

Order No. Name

-x x --

Non-XL

High pressure

Low pressure

Ex x x -x x x

2359030 Gun monitoring for automatic gun (pressure switch)

2359023 Automatic atomizer air system

-x x -x x x x x x x x x x

-x x x x x

---

2341153 Remote control with cable 15 m; 49 ft (see Chapter 13.5

− For overview see Chapter 5.10

x x

2343063

Extension cable 15 m; 49 ft for remote control

Maximum extension of 2 times 15 m; 49 ft. (Total 45 m; 147 ft.)

2360731 Dump valve set, not flushable x x x x

2369329 Dump valve set XL, not flushable

2360732 Dump valve set, flushable

2369330 Dump valve set XL, flushable

2343061 Dump valve for waste separation (flushable) *

-x

2362638 Control for booster pump *

2360992 External release, pneumatic x x x x

392030 Ex alarm horn, spray booth x x

2362637 "Comfort Archive" PC data archiving (for 1 system) ** x x

2365136 "Comfort Archive" PC data archiving (for 2–5 systems) ** x x

2359045 Profibus module

2339620 External mixer automatic, high pressure (DN 2.6) x x x x

2339617 External mixer automatic, high pressure DN4 / DN10VA ---

2339621 External mixer automatic, low-pressure (DN 4) x x

2360730 CAN I/O output expansion x x

-x x x x x x x x x

-x x

-x

* Can not be used for 2-circuit systems.

** Prerequisite for PC data archiving: Network connection of the 2K COMFORT system by WAGNER Service

Department x x x x

-x x

-x x x

-x

-x x x x x x x x

-x

-x x x

-x x

-x x x

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13.4.1.1 STROKE MEASURING

− "ADC-0301 / MPX-0403" operating manual: for Order No., see Chapter