WAGNER TwinControl 35-70 ABS Translation Of The Original Operating Manual

Electronic mixing ratio controller for 2K paints

Translation of the original

Operating manual

TwinControl 5-60 ABS

TwinControl 18-40 ABS

TwinControl 28-40 ABS

TwinControl 35-70 ABS

TwinControl 48-110 ABS

TwinControl 35-150/70 ABS

TwinControl 75-150 ABS

TwinControl 72-300/150 ABS

TwinControl 72-300 ABS

Edition 04/2010

0102

II 2G Ex ia II B T4 X

B_02795

EDITION 04/2010

OPERATING MANUAL

Contents

PART NO. DOC393831

1.1 Languages

1.3

2

2.1

Warnings, notes and symbols in these instructions

GENERAL SAFETY INSTRUCTIONS

Safety instructions for the operator

2.1.3 A safe work environment

2.2 Safety instructions for staff

2.2.1 Safe handling of WAGNER spray units

2.2.2 Earth the unit

2.2.4 Cleaning

2.2.5 Handling hazardous liquids, varnishes and paints

2.2.6 Touching hot surfaces

2.4 Field of application

2.4.2 Systems with mains supply

3

3.1

PRODUCT LIABILITY AND WARRANTY

Important notes on product liability

3.2 Warranty

3.3 CE-conformity

3.3.1 Devices with turbine

3.3.2 Devices with cable for mains connection

4 DESCRIPTION

4.1 Fields of application, using in accordance with the instructions

4.2 Scope of delivery

4.3 Data

4.3.1 Basic units and components

4.3.3 Marking and rated data for devices with turbine

4.3.4 Weight of the basic units

4.3.5 Dimensions

4.4 Function

4.4.1 Design of TwinControl basic units

4.4.2 Principle diagram for basic units 18-40; 28-40; 35-70 and 35-150

4.4.3 Principle diagram for basic units 48-110; 75-150 and 72-300

4.4.4 Operator‘s controls on the control unit TwinControl 1 and 2

4.4.5 Service functions - Overview list

4.4.6 Pneumatic Diagram TwinControl 1

4.4.7 Pneumatic Diagram TwinControl 2

TwinControl .

8

8

7

8

9

9

9

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7

7

7

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10

10

10

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6

5

5

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28

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34

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22

25

25

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15

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18

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14

3

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Contents

5 TRANSPORT / INSTALLATION

5.1 Transport

5.2 Storage

5.3 Installation

5.7 Ground the System

5.7.1 Earthing of components on frame or carriage

5.7.2 Example of earthing scheme for basic unit with turbine

5.7.3 Example of earthing scheme for basic unit with cable

6

6.1

6.2

6.3

6.4

START-UP AND OPERATION

General rules for use of the spray system

Preparation of Start-up

Switching the unit on and off

Preliminary washing and pressure tightness test

6.5

6.6

Pressure Relief Procedure

Filling the unit and calibration

6.6.1 Filling the unit

6.6.2 Calibration the unit

6.8 General

6.9 Password protection and user functions

6.10 Brief description of the individual functions

6.10.1 Basic functions for the sprayer

6.10.2 Extended functions with password protection

7 MAINTENANCE

7.1 Cleaning the system

7.2

7.3

Cleaning the fi lters

Maintenance and Service

7.5 Dismantling

8.1

8.2

9

9.1

Faults and appropriate solutions

Conversion of different mixing proportion specifi cation

TABLES / PARAMETERS

Table hose volume

10 ACCESSORIES

11.1 How to order spare parts?

11.2 Where do you fi nd spare parts?

TwinControl .

51

52

53

54

48

50

50

50

54

55

42

42

43

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46

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60

60

61

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4

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

1

ABOUT THESE INSTRUCTIONS

4HISOPERATINGMANUALCONTAINSINFORMATIONONTHEOPERATIONREPAIRANDMAINTENANCEOF

THEUNIT

œ !LWAYSOBSERVETHESEINSTRUCTIONSWHENOPERATINGTHEUNIT

4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL

#OMPLIANCE WITH THESE INSTRUCTIONS CONSTITUTES AN INTEGRAL COMPONENT OF THE WARRANTY

AGREEMENT

1.1 LANGUAGES

This operating manual is available in the following languages:

Language: Part No.

Language:

German

Dutch

393830

2309946

English

Italian

Danish

Portuguese

2306233

2306235

Swedish

Polish

Part No.

393831

393834

2306234

2306104

Language:

French

Spanish

Finnish

Greek

Part No.

393832

393835

2304508

2309157

Spare parts to the TwinControl units and to the TwinControl accessories are to be found in the separately provided spare parts catalogue. The spare parts catalogue is available in the following languages:

Language

German

Part No.

393880

Language

English

Part No.

393881

Related operating instructions for the individual components.

Pneumatic pumps , EvoMotion Stainless steel

Language

German

Dutch

Danish

Portuguese

-

-

Part No.

ZZB021GER

ZZB021POR

Language

English

Italian

Swedish

Polish -

Part No.

ZZB021ENG

-

ZZB021ITA

Language

French

Spanish

Turkish

Greek -

Part No.

ZZB021FRE

-

ZZB021SPA

Pneumatic pumps Wildcat, Puma, Leopard and Jaguar:

Language:

German

Dutch

Danish

Portuguese

Part No.

367850

367853

367857

367859

Language:

English

Italian

Swedish

Polish

Part No.

367851

367854

367856

367864

Pneumatic pump Tiger:

,ANGUAGE

'ERMAN

0ART.O

,ANGUAGE

$UTCH

3PANISH

3WEDISH

0ART.O

370853

370855

370856

Language: Part No.

French 367852

Spanish

Turkish

Greek

367855

367858

2309490

5

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Colour valves FWV400, HDV400, GA400AL-D

,ANGUAGE

'ERMAN

0ART.O

,ANGUAGE

$UTCH

3PANISH

3WEDISH

0ART.O

384883

384885

384886

Colour valves FWV530 or HDV530

,ANGUAGE

'ERMAN

0ART.O

,ANGUAGE

$UTCH

3PANISH

3WEDISH

0ART.O

377983

377985

377986

1.2 CD TWINCONTROL

All operating documents specifi ed above are available also as pdf fi les on a Compact disk

(CD) and the CD are contained in the scope of delivery of an unit.

Order-No. is: 2307255.

1.3 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS

Warning instructions in this manual point out particular dangers to users and equipment and state measures for avoiding the hazard. These warning instructions fall into the following categories:

DANGER

Danger - imminent danger. Non-observance will result in death, serious injury and serious material damage.

This line warns of the hazard!

Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level.

œ The measures for preventing the hazard and its consequences.

SIHI_0100_GB

Warning - possible danger. Non-observance can result in death, serious injury and serious material damage.

SIHI_0103_GB

WARNING

This line warns of the hazard!

Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level.

œ The measures for preventing the hazard and its consequences.

Caution - a possibly hazardous situation. Non-observance can result in minor injury.

SIHI_0101_GB

CAUTION

This line warns of the hazard!

Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level.

œ The measures for preventing the hazard and its consequences.

Caution - a possibly hazardous situation. Non-observance can cause material damage.

SIHI_0102_GB

CAUTION

This line warns of the hazard!

Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level.

œ The measures for preventing the hazard and its consequences.

Note provide information on particular characteristics and how to proceed.

6

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

2

GENERAL SAFETY INSTRUCTIONS

2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR

œ +EEPTHESEOPERATINGINSTRUCTIONSTOHANDNEARTHEUNITATALLTIMES

œ !LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN

TION

2.1.1 ELECTRICAL EQUIPMENT

Electrical plant and units

œ To be provided in accordance with the local safety requirements with regard to the operating mode and ambient influences.

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

œ Must be operated in accordance with the safety regulations and electrotechnical regulations.

œ Must be repaired immediately in the event of problems.

œ Must be put out of operation if they pose a hazard.

œ Must be de-energized before work is commenced on active parts. Inform staff about planned work, observe electrical safety regulations.

œ To protect the electrical components, lay all of the various elements to a collective earthing point.

It is thus absolutely necessary to attach the device correctly to a grounded voltage supply.

œ With open housings, there is a danger from line voltage. Repairs and maintenance may only be carried out by skilled personnel.

œ Keep liquids away from the electrical components.

2.1.2 PERSONNEL QUALIFICATIONS

œ %NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS

2.1.3 A SAFE WORK ENVIRONMENT

œ %NSURETHATTHEmOOROFTHEWORKINGAREAISANTISTATICINACCORDANCEWITH%.0ART

eMEASUREMENTINACCORDANCEWITH$).

œ %NSURETHATALLPERSONSWITHINTHEWORKINGAREAWEARANTISTATICSHOESEGSHOESWITH

LEATHERSOLES

œ %NSURETHATDURINGSPRAYINGPERSONSWEARANTISTATICGLOVESSOTHATTHEYAREEARTHED

VIATHEHANDLEOFTHESPRAYGUN

œ #USTOMERTOPROVIDEPAINTMISTEXTRACTIONUNITSCONFORMINGTOLOCALREGULATIONS

œ %NSURETHATTHEFOLLOWINGCOMPONENTSOFASAFEWORKINGENVIRONMENTAREAVAILABLE n -ATERIALAIRHOSESADAPTEDTOTHEWORKINGPRESSURE n 0ERSONALSAFETYEQUIPMENTBREATHINGANDSKINPROTECTION

œ %NSURETHATTHEREARENOIGNITIONSOURCESSUCHASNAKEDmAMEGLOWINGWIRESORHOT

SURFACESINTHEVICINITY$ONOTSMOKE

œ 4HEPLACEOFASSEMBLYISINACCORDANCEWITHTHEEXPLOSIONPREVENTIONTOSELECTNATIONAL

RULESANDREGULATIONSCONSIDER

œ %NSUREDBYTHEOPERATORTHETIGHTNESSEXAMINATIONBEFORESTARTUPDAILY AFTERREPAIRS

ANDINREGULARINTERVALS n 4HEPIPEJOINTSITEMOFEQUIPMENTANDCONNECTIONSAREDURABLYTECHNICALLYCLOSE

7

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EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

2.2 SAFETY INSTRUCTIONS FOR STAFF

œ !LWAYSFOLLOWTHEINFORMATIONINTHESEINSTRUCTIONSPARTICULARLYTHEGENERALSAFETYIN

STRUCTIONSANDTHEWARNINGINSTRUCTIONS

œ !LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN

TION

2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS

The spray jet is under pressure and can cause dangerous injuries.

Avoid injection of paint or cleaning agents:

œ Never point the spray gun at people.

œ Never reach into the spray jet.

œ Before all work on the unit and in the event of work interruptions:

– Secure the spray gun against actuation.

– Relieve the pressure from the spray gun and unit.

œ Ensured, that (in accordance with the guideline for liquid emitter (ZH 1/406 and BGR

500 Part 2 chap. 2.36) the liquid emitters are every 12 months to examine by experts

(e.g. Wagner service technician).

– With shut down devices the examination can be by the next start.

œ Follow the «Pressure Relief Procedure» whenever you:

– Are instructed to relieve pressure.

– If the spraying work to be adjusted.

– Stop spraying, clean check, or service the equipment.

– Install or clean the spray nozzle.

In the event of skin injuries caused by paint or cleaning agents:

œ Note down the paint or cleaning agent that you have been using.

œ Consult a doctor immediately.

Avoid danger of injury through recoil forces:

œ Ensure that you have a firm footing when operating the spray gun.

œ Only hold the spray gun briefly in a position.

2.2.2 EARTH THE UNIT

Electrostatic charges can occur on the unit due to the electrostatic charge and the flow speed involved in spraying. These can cause sparks and flames upon discharge.

œ Ensure that the unit is always earthed.

œ Earth the work pieces to be coated.

œ Ensure that all persons inside the working area are earthed, e.g. that they are wearing antistatic shoes.

œ When spraying, wear antistatic gloves to earth yourself via the spray gun handle.

8

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EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

2.2.3 PAINT HOSES

œ %NSURETHATTHEHOSEMATERIALISCHEMICALLYRESISTANTTOTHESPRAYEDMATERIALS

œ %NSURETHATTHEMATERIALHOSEISSUITABLEFORTHEPRESSUREGENERATEDINTHEUNIT

œ %NSURETHATTHEFOLLOWINGINFORMATIONCANBESEENONTHEHIGHPRESSUREHOSE n -ANUFACTURER n 0ERMISSIBLEOPERATINGOVERPRESSURE n $ATEOFMANUFACTURE

œ 2OUTETHEHOSESAWAYFROM n 4HETRAFlCAREAS n 3HARPEDGES n -OVINGPARTS n (OTSURFACES

œ $ONOTUSETHEHOSESTOPULLTHEEQUIPMENT

4HEELECTRICALRESISTANCEOFTHECOMPLETEHIGHPRESSUREHOSEMUSTBELESSTHAN-/HM

2.2.4 CLEANING

œ "EFOREMAINTENANCEWORK n $EENERGIZETHESYSTEMELECTRICALLY n THEEQUIPMENTISTOSEPARATEFROMTHENET n DISCONNECTTHEPNEUMATICSUPPLYLINEAND n RELIEVETHEPRESSUREFROMTHEUNIT

œ %NSURETHATTHEmASHPOINTOFTHECLEANINGAGENTISATLEAST+ABOVETHEAMBIENTTEM

PERATURE

œ 4OCLEANUSEONLYSOLVENTFREECLOTHSANDBRUSHES.EVERUSEHARDOBJECTSORSPRAYON

CLEANINGAGENTSAGUN

œ )NTHECASEOFSTARTUPOREMPTYINGOFTHEEQUIPMENTCANBEPRESENT n $EPENDINGUPONUSEDCOATINGMATERIAL n ORCLEANINGSOLVENTS n EXPLOSIVEMIXTUREINSIDETHELINESANDITEMSOFEQUIPMENT

!NEXPLOSIVEGASAIRMIXTUREFORMSINCLOSEDCONTAINERS

œ 7HENCLEANINGUNITSWITHSOLVENTSNEVERSPRAYINTOACLOSEDCONTAINER

œ %ARTHTHECONTAINER

2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS

œ 7HENPREPARINGORWORKINGWITHPAINTANDWHENCLEANINGTHEUNITFOLLOWTHEWORK

INGINSTRUCTIONSOFTHEMANUFACTUREROFTHEPAINTSSOLVENTSANDCLEANINGAGENTSBEING

USED

œ 4AKE THE SPECIlED PROTECTIVE MEASURES IN PARTICULAR WEAR SAFETY GOGGLES PROTECTIVE

CLOTHINGANDGLOVESASWELLASHANDPROTECTIONCREAMIFNECESSARY

œ 5SEAMASKORBREATHINGAPPARATUSIFNECESSARY

œ &ORSUFlCIENTHEALTHANDENVIRONMENTALSAFETY/PERATETHEUNITINASPRAYBOOTHORON

ASPRAYINGWALLWITHTHEVENTILATIONEXTRACTION SWITCHEDON

œ 7EARSUITABLEPROTECTIVECLOTHINGWHENWORKINGWITHHOTMATERIALS

9

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

2.2.6 TOUCHING HOT SURFACES

œ 4OUCHHOTSURFACESONLYIFYOUAREWEARINGPROTECTIVEGLOVES

œ 7HENOPERATINGTHEUNITWITHACOATINGMATERIALWITHATEMPERATUREOF²#²&

)DENTIFYTHEUNITWITHAWARNINGLABELTHATSAYSu7ARNINGHOTSURFACEh

/RDER.O

)NFORMATIONLABEL

3AFETYLABEL

2.3 CORRECT USE

7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE

œ 5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2

œ /PERATETHEUNITONLYASANENTIREUNIT

œ $ONOTDEACTIVATESAFETYEQUIPMENT

œ 5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES

2.4 FIELD OF APPLICATION

2.4.1 SYSTEMS WITH TURBINE

The system with turbine complies with Explosion Protection Directive 94/9/EC (Atex) and can be used as a Category 2 device in Ex Zone 1.

It is designed with ignition protection type „Intrinsic safety“ and has the marking

0102

II 2G Ex ia II B T4 X.

2.4.2 SYSTEMS WITH MAINS SUPPLY

The system with mains supply must not be operated in potentially explosive areas (Zone

0, 1, 2).

10

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

3

PRODUCT LIABILITY AND WARRANTY

3.1 IMPORTANT NOTES ON PRODUCT LIABILITY

!SARESULTOFAN%#REGULATIONEFFECTIVEASFROM*ANUARYTHEMANUFACTURERSHALL

ONLYBELIABLEFORHISPRODUCTIFALLPARTSCOMEFROMHIMORAREAPPROVEDBYHIMANDIFTHE

DEVICESAREPROPERLYlTTEDOPERATEDANDMAINTAINED

)FOTHERMAKESOFACCESSORYANDSPAREPARTSAREUSEDTHEMANUFACTURER@SLIABILITYCOULDBE

FULLYORPARTIALLYNULLANDVOID

4HEUSAGEOFORIGINAL7!'.%2ACCESSORIESANDSPAREPARTSGUARANTEESTHATALLSAFETYRE

GULATIONSAREOBSERVED

3.2 WARRANTY

4HISUNITISCOVEREDBYOURWARRANTYONTHEFOLLOWINGTERMS

7EWILLATOURDISCRETIONREPAIRORREPLACEFREEOFCHARGEALLPARTSWHICHWITHINMONTHS

INSINGLESHIFTMONTHSINSHIFTORMONTHSINSHIFTOPERATIONFROMDATEOFRECEIPTBY

THE0URCHASERAREFOUNDTOBEWHOLLYORSUBSTANTIALLYUNUSABLEDUETOCAUSESPRIORTOTHE

SALEINPARTICULARFAULTYDESIGNDEFECTIVEMATERIALSORPOORWORKMANSHIP

4HETERMSOFTHEWARRANTYAREMETATOURDISCRETIONBYTHEREPAIRORREPLACEMENTOFTHE

UNITORPARTSTHEREOF4HERESULTINGCOSTSINPARTICULARSHIPPINGCHARGESROADTOLLSLABOUR

ANDMATERIALCOSTSWILLBEBORNEBYUSEXCEPTWHERETHESECOSTSAREINCREASEDDUETOTHE

SUBSEQUENTSHIPMENTOFTHEUNITTOALOCATIONOTHERTHANTHEADDRESSOFTHEPURCHASER

4HISWARRANTYDOESNOTCOVERDAMAGECAUSEDBY

5NSUITABLE OR IMPROPER USE FAULTY INSTALLATION OR COMMISSIONING BY THE PURCHASER OR A

THIRD PARTY NORMAL WEAR NEGLIGENT HANDLING DEFECTIVE MAINTENANCE UNSUITABLE COATING

PRODUCTS SUBSTITUTE MATERIALS AND THE ACTION OF CHEMICAL ELECTROCHEMICAL OR ELECTRICAL

AGENTSEXCEPTWHENTHEDAMAGEISATTRIBUTABLETOUS

!BRASIVE COATING PRODUCTS SUCH AS REDLEAD EMULSIONS GLAZES LIQUID ABRASIVES ZINC DUST

PAINTSANDSIMILARREDUCETHESERVICELIFEOFVALVESPACKINGSSPRAYGUNSNOZZLESCYLINDERS

PISTONSETC!NYWEARRESULTINGFROMTHEAFOREMENTIONEDCAUSESISNOTCOVEREDBYTHIS

WARRANTY

#OMPONENTSNOTMANUFACTUREDBY7AGNERARESUBJECTTOTHEWARRANTYTERMSOFTHEORIGI

NALMAKER

4HEREPLACEMENTOFAPARTDOESNOTEXTENDTHEWARRANTYPERIODOFTHEUNIT

4HEUNITSHOULDBEINSPECTEDIMMEDIATELYUPONRECEIPT

4OAVOIDLOSSWARRANTYANIYAPPARENTDEFECTSHOULDBENOTIlEDTOUSORTHEDEALERINWRI

TINGWITHINDAYSFROMDATEOFSALEOFTHEUNIT

4HERIGHTTOCOMMISSIONWARRANTYSERVICESTOATHIRDPARTYISRESERVED

7ARRANTYCLAIMSARESUBJECTTOPROOFOFPURCHASEBYSUBMITTINGANINVOICEORDELIVERYNOTE

)FANINSPECTIONlNDSDAMAGENOTCOVEREDBYTHEPRESENTWARRANTYTHEREPAIRWILLBECAR

RIEDOUTATTHEEXPENSEOFTHEPURCHASER

.OTETHATTHISWARRANTYDOESNOTINANYWAYRESTRICTLEGALLYENTITLEDCLAIMSORTHOSECONTRAC

TUALLYAGREEDTOINOURGENERALTERMSANDCONDITIONS

*7AGNER!'

11

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EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

3.3 CE-CONFORMITY

3.3.1 DEVICES WITH TURBINE

Herewith we declare that the supplied version of

5-60 18-40 28-40

TwinControl

35-70 48-110 35-150/70 75-150 72-300/150 72-300

ABS; Turbine

Complies with the following guidelines:

2006/42/EG 94/9/EG 2004/108/EG

2002/95/EG 2002/96/EG

Applied standards, in particular:

DIN EN 1127; 2008-02

DIN EN ISO 12100-1; 2004-04

DIN EN ISO 12100-2; 2004-04

DIN EN 12621; 2006-05

DIN EN ISO 13732-1; 2008-12

DIN EN ISO 14121; 2007-12

DIN EN 60079-0; 2010-03

DIN EN 60079-11; 2007-08

DIN EN 60079-14; 2009-05

DIN EN 61000-6-2; 2006-03

DIN EN 61000-6-4; 2007-09

EC type examination certifi cate:

Zelm 08 Atex 0385 X issued by the Zelm Ex Test and Certifi cation Body, D-38124 Braunschweig

(notifi ed body no. 0820)

Applied national technical standards and specifi cations, in particular:

BGR 500 Part 2 chap. 2.29, 2.36

BGR 104 TRBS 2153

EC quality certifi cate for the quality assurance system:

PTB 03 ATEX Q019 issued by the Federal Physical and Technical Institute (PTB), D-38116 Braunschweig

(notifi ed body 0102)

Marking:

0102

II 2G

Ex ia II B T4 X

ZELM 08 ATEX 0385 X

+5 ° C < Ta < +40 ° C

CE Certificate of Conformity

The certificate is enclosed with this product.The certificate of conformity can be reordered from your WAGNER representative, quoting the product and serial number.

Part number:

393916

12

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EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

3.3.2 DEVICES WITH CABLE FOR MAINS CONNECTION

Herewith we declare that the supplied version of

TwinControl

5-60 18-40 28-40 35-70 48-110 35-150/70

ABS; Cable with mains supply

75-150 72-300/150 72-300

Complies with the following guidelines

2006/42/EG 2002/96/EG

2002/95/EG 2004/108/EG

Applied standards, in particular:

DIN EN ISO 12100-1; 2004-04

DIN EN ISO 12100-2; 2004-04

DIN EN ISO 13732-1; 2008-12

DIN EN 14121; 2007-12

DIN EN 12621; 2006-05 DIN EN 61000-6-2; 2006-03

Applied national technical standards and specifi cations, in particular:

BGR 500 Part 2 chap. 2.29, 2.36

BGR 104

DIN EN 60204-1; 2002-06:

DIN EN 61000-6-4; 2007-09

TRBS 2153

Marking:

CE Certificate of Conformity

The certificate is enclosed with this product.The certificate of conformity can be reordered from your WAGNER representative, quoting the product and serial number.

Part number:

393915

13

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

4

DESCRIPTION

4.1 FIELDS OF APPLICATION, USING IN ACCORDANCE WITH THE INSTRUCTIONS

The TwinControl basic unit comprises 5 functional units: the pneumatically operated high-pressure pumps for

A and B components and for solvents, the mixing unit and the control unit. The two material components are brought to high pressure by the pumps and intermixed in an adjustable, predefi ned mixing ratio in the static mixer, from where it is conveyed to the gun. The system can be operated with one or more guns, depending on size and output. Various functions are controlled by the electronics in the control unit, such as: fl ushing, application life monitoring, mixing ratio, cutout in the event of line breakage. The application range is described in chapters 2.4.1 and 2.4.2, and the intended use is explained in 2.3.

4.1.1 PROCESSIBLE MATERIALS

Low-viscosity to high-viscosity two-component paints (e.g. epoxy, PU, DD) with an application life of more than 5 minutes.

CAUTION

Impurities in the spraying system!

Spray gun blockage, materials harden in the spraying system

œ Flush the spray gun and paint supply with a suitable cleaning agent.

SIHI_0001_GB

4.2 SCOPE OF DELIVERY

TwinControl basic units consist of the following materials

- Pneumatic pump with path measurement for A component

- Pneumatic pump with path measurement for B component

- Pneumatic pump for solvent (editions without also possible)

- Control unit (turbine or cable connection)

- Base frame or trolley or wall holder

- Static mixing unit

- Diverse material valves.

To the scope of delivery belong also

Separating fl uid 250 ml; 250 cc

Tool set PP3000

CE-Conformity

Operating manual German

Operating manual in the local language

Compact Disc TwinControl (CD)

Reference sheet Transport

Pneumatic scheme TwinControl

Part No. 9992504

Part No. 367840

Part No. see chapter 3.3.1 or 3.3.2

Part No. 393830

Part No. see chapter 1

Part No. 2307255

Part No. 2305117

Part No. 393901

The delivery note shows the exact scope of delivery.

Accessories see chapter 10.

14

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EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

4.3 DATA

4.3.1 BASIC UNITS AND COMPONENTS

Part

No.

Description:

TwinControl basic unit

393177 5-60 ABS Turbine Wall

393172 5-60 ABS Turbine Stand

393178 5-60 ABS Cable Wall

393176 5-60 ABS Cable Stand

393124 18-40 ABS Turbine Wall

393126 18-40 ABS Turbine Stand

393125 18-40 ABS Cable Wall

393127 18-40 ABS Cable Stand

393128 28-40 ABS Turbine Wall

393130 28-40 ABS Turbine Stand

393129 28-40 ABS Cable Wall

393131 28-40 ABS Cable Stand

393169 28-40 ABS Turbine Stand EM

393179 28-40 AB Cable Stand

393134 35-70 ABS Turbine Stand

393132 35-70 ABS Turbine Wall

393135 35-70 ABS Cable Stand

393133 35-70 AB Cable Wall

393164 35-70 AB Turbine Stand

393165 35-70 AB Turbine Stand V

393180 35-70 AB Cable Stand

393137 35-150/70 ABS Turbine Stand

393139 35-150/70 ABS Turbine Trolley

393138 35-150/70 ABS Cable Stand

393140 35-150/70 ABS Cable Trolley

393175 35-150/70 ABS Cable Stand EM

393146 48-110 ABS Turbine Stand

393170 48-110 ABS Turbine Stand EM

393148 48-110 ABS Turbine Trolley

393149 48-110 ABS Cable Trolley

393147 48-110 ABS Cable Stand

393174 48-110 ABS Cable Stand EM

393181 48-110 ABS Turbine Stand SZ

393168 48-110 AB Turbine Stand

A Pump B Pump

EvoMotion

5-60

EvoMotion

5-60

Flushing pump

EvoMotion

5-60

Control units

TC 1 Turbine

TC 1 Cable

Wildcat

18-40

Puma

28-40

Leopard

35-70

Wildcat

18-40

Puma

28-40

Leopard

35-70

Wildcat

18-40

Puma

28-40 no

Puma

28-40 no

TC 1 Turbine

TC 1 Cable

TC 1 Turbine

TC 1 Cable

TC 1 Turbine

TC 1 Cable

TC 1 Turbine

TC 1 Cable

TC 1 Turbine

TC 1 Cable

TC 1 Turbine

Leopard

35-150

TC 1 Cable

Puma

28-40 TC 2 Turbine

Leopard

48-110

Leopard

48-110 no

TC 2 Cable

TC 2 Turbine

TC 2 Cable

15

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Part

No.

Description:

TwinControl basic unit

393150 75-150 ABS Turbine Stand

393163 75-150 ABS Turbine Stand EM

393182 75-150 ABS Turbine Stand SZ

393152 75-150 ABS Turbine Trolley

393151 75-150 ABS Cable Stand

393153 75-150 ABS Cable Trolley

393154 72-300/150 ABS Turbine Stand

393183 72-300/150 ABS Turbine Stand SZ

393156 72-300/150 ABS Turbine Trolley

393166 72-300/150 AB Turbine Stand

393167 72-300/150 AB Turbine Stand -V

393155 72-300/150 ABS Cable Stand

393173 72-300/150 ABS Cable Stand EM

393157 72-300/150 ABS Cable Trolley

393158 72-300 ABS Turbine Stand

393160 72-300 ABS Turbine Stand

393159 72-300 ABS Cable Stand

393161 72-300 ABS Cable Trolley

A Pump

Jaguar

75-150

Tiger

72-300

B Pump Flushing pump

Jaguar

75-150

Tiger

72-300

Leopard

35-70

Control units

TC 2 Turbine

TC 2 Cable

TC 2 Turbine no

TC 2 Cable

Leopard

35-70 TC 2 Turbine

TC 2 Cable

Abbreviations

Code Description

GG TwinControl basic unit

SP TwinControl Spraypack

A Pneumatic pump for A component

B Pneumatic pump for B component

S Pneumatic pump for solvent

ST Control unit with inserted turbine

SK Control unit with electrical cable connection

Code Description

G Base frame with castors

T Mounted on trolley

W Wall mount

EM External mixer

OV Without fl ushing valve

SZ With soft circulation

Example type designations keys

Mode Type Main components Accessories

GG 72-300/150 A B S G SK EM SZ -

GG 48-110 A B W ST -

16

TwinControl .

EDITION 04/2010

OPERATING MANUAL

4.3.2 TECHNICAL DATA

PART NO. DOC393831

Description

Inlet air pressure min.

Inlet air pressure maxi.

Maxi. permissible number of strokes by pumps in two-component operation

Maxi. material pressure in mixer

Units

MPa; bar; psi

MPa; bar; psi

DS/ min

0.6; 6; 87

0.8; 8; 116

30

Maxi. Material pressure at inlet

Material outlet connection

MPa bar; psi

4

40

580

14.4

144

22.4

224

2089 3249

25.0

250

3626

MPa; bar; psi

Zoll; Inch G1/4 NPSM 1/4"

0.8; 8; 116

37.0

370

5366

53.0

530

7687

NPSM 3/8"

Air inlet connection

Material fl ow quantity of the mixing ratio 1:1

Material fl ow quantity of the mixing ratio 4:1

Material fl ow qty of the mixing ratio 10:1

Material fl ow qty of the mixing ratio 20:1 pH range of the material

Material Temperature

Ambient temperature

A/B mixing ratio volume

Ratio precision

Zoll; Inch l/ min l/ min l/ min l/ min pH

°C; °F

°C; °F

%

3.6

2.3

2.0

1.9

2.4

1.5

1.3

1.2

G 1/2"

4.2

2.6

5.0

4.1

5.6 10.1 11.2

2.3

2.2

0.1:1 – 20:1

4.7

4.6

± 2

6.6

3.5-9

3.6

3.7

9.0 13.5 18.0

4.9

+5 – +60; +41 - +140

+5 – +40; +41 - +104

G 1"

9.5

-

9.9

0,1:1 – 10:1

Sound pressure level at maxi. permissible air pressure

*

See operating manuals pumps and valves

Control units TwinControl with able connection

Input voltage

Input power

Input frequency

VAC

W

Hz

Control units TwinControl with turbine

Compressed air input maxi.

Nominal air consumption

Air pressure quality free of oil and water

MPa; bar; psi

NL/min

85 - 250 maxi. 40

47-440

0.5; 5; 73

125

(Quality standard 5.5.4 according ISO 8573.1)

5.5.4 = 40

μ m/ +7/ 5 mg/m 3

WARNING

Outgoing air containing oil!

Risk of poisoning if inhaled

œ Provide water-free and oil-free compressed air (quality standard

5.5.4 as per ISO 8573.1) 5.5.4 = 40 µm / +7 / 5 mg/m³.

SIHI_0023_GB

17

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

4.3.3 MARKING AND RATED DATA FOR DEVICES WITH TURBINE

Identifi cation

CE

102

Description

J. Wagner AG Company name

CH- 9450 Altstätten Address

CE mark with number of the notifi ed body that is used by us in the production monitoring phase (PTB in this case)

TwinControl

Serial No.

2007

II 2 G

Name of unit

Serial no. of device

Year of manufacture of device

Marking according to Directive 98//EC (Atex directive) [application area]

- II:

- 2:

Device group II, not mining

Category 2 (i.e. Zone 1)

Ex ia II B T4 X Marking according to standard(s) [equipment properties]

- Ex: Explosion-proof equipment

- ia:

- II:

Ignition protection type intrinsic safety, for Zone 0 and 1

Device group II, not mining

- B:

- T4:

- X:

Explosion group B, town gas, ethylene

Temperature class T4, 135 °C; 275 °F

Note special instructions for safety operation

ZELM 08 ATEX 0385 X Mark of notifi ed body, year of issue, issue of certifi cate (Atex), certifi cate number

+5 °C < Ta < +40 °C Permissible ambient temperature range

Rated safety data for connecting a potentiometer A or B with ignition protection type Ex ia IIB:

Connection of maximum values

Maxi. voltage

Maxi. current

Maxi. power

Maxi. External capacity

Maxi. External inductivity

U

0

[V]

I

0

[mA]

P

0

[mW]

C

0

[uF]

L

0

[mH]

Potentiometer A and B

12.6

73.6

232

7.3

26

The abovementioned values for the maximum permissible external capacities and inductances are only valid as long as they do not occur simultaneously.

If the external reactances are present simultaneously, the values are to be taken from the following table:

Maximum permissible external inductance L

0

[mH] 0.1

0.2

0.5

1

Maximum permissible external capacity C

0

2

[uF] 7.3

6 4.6

3.7

3.1

5 10

2.3

1.9

20

1.4

18

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Remote control connection with ignition protection type Ex ia IIB:

Connection of maximum values

Maxi. voltage

Maxi. current

Maxi. power

Maxi. External capacity

Maxi. External inductivity

U

0

[V]

I

0

[mA]

P

0

[mW]

C

0

[uF]

L

0

[mH]

Connection RC

12.6

154

484

7.3

6

The abovementioned values for the maximum permissible external capacities and inductances are only valid as long as they do not occur simultaneously.

If the external reactances are present simultaneously, the values are to be taken from the following table.

Maximum permissible external inductance L

0

[mH] 0.1

0.2

0.5

1.0

2.0

5.0

Maximum permissible external capacity C

0

[uF] 7.3

5.9

4.4

3.5

2.7

1.8

Service connection:

Only for connection to relevant programming devices and only outside the potentially explosive area.

Special conditions (X):

1. The information in the Operating Manual must be observed, particularly in respect of earthing and connecting the equipotential bonding, and integrating the equipment into an existing system for equipotential bonding.

2. Opening the housing in environments with explosive gas atmospheres is not permitted.

3. Plugging in the service connector in explosive environments is not permitted, and may only be carried out by authorized maintenance personnel.

4. Maintenance and service tasks inside the housing may only be performed by authorized personnel.

5. No changes in the pressure control valve (inside the housing of the TwinControl control unit) for the turbine or at the relief valves may be made.

6. A maintenance plan must be prepared for the TwinControl control unit, or this unit must be integrated into an existing maintenance plan.

7. In order to prevent soiling inside the housing of the TwinControl control unit, the integrity of the front fi lm must be checked at regular intervals. In the event of damage, the equipment must be removed from the Ex zone immediately and put out of operation, and repaired by Wagner.

8. When designing and installing the compressed air system, it must be ensured that no explosive atmosphere can arise within the system.

9. Only Wagner potentiometers may be connected to the potentiometer connections.

10. The remote control cable must be laid securely and safely protected from damage.

The remote control may be used in potentially explosive environments; the maximum permitted cable length is 75 m; 246 ft.

19

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

11. If the complete TwinControl system is operated as part of a water varnish coating system connected to high voltage, the green-yellow earth cables must be removed and replaced with black cables with the same cross-section. Earthing symbols must be made unrecognizable.

12. The device does not comply with chap. 6.3.12 of DIN EN 60079-11: 2007-08.

13. The device is suitable for over voltage Category II and may only be operated if all connections are inserted or provided with protective caps. Degree of Pollution 3 for the environment is then permissible.

Permissible storage temperature: -40 ° C; 104 ° F ... +80 ° C; +176 ° F.

Relative humidity (no bedewing) < 95%.

20

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

4.3.4 WEIGHT OF THE BASIC UNITS

Part No.

Description

393172 TwinControl 5-60 ABS Turbine Base frame

393176 TwinControl 5-60 ABS Cable Base frame

393177 TwinControl 5-60 ABS Turbine Wall

393178 TwinControl 5-60 ABS Cable Wall

393124 TwinControl 18-40 ABS Turbine Wall

393125 TwinControl 18-40 ABS Cable Wall

393126 TwinControl 18-40 ABS Turbine Base frame

393127 TwinControl 18-40 ABS Cable Base frame

393128 TwinControl 28-40 ABS Turbine Wall

393129 TwinControl 28-40 ABS Cable Wall

393130 TwinControl 28-40 ABS Turbine Base frame

393131 TwinControl 28-40 ABS Cable Base frame

393132 TwinControl 35-70 ABS Turbine Wall

393133 TwinControl 35-70 ABS Cable Wall

393134 TwinControl 35-70 ABS Turbine Base frame

393135 TwinControl 35-70 ABS Cable Base frame

393137 TwinControl 35-150/70 ABS Turbine Base frame

393138 TwinControl 35-150/70 ABS Cable Base frame

393139 TwinControl 35-150/70 ABS Turbine Trolley

393140 TwinControl 35-150/70 ABS Cable Trolley

393146 TwinControl 48-110 ABS Turbine Base frame

393147 TwinControl 48-110 ABS Cable Base frame

393148 TwinControl 48-110 ABS Turbine Trolley

393149 TwinControl 48-110 ABS Cable Trolley

393150 TwinControl 75-150 ABS Turbine Base frame

393151 TwinControl 75-150 ABS Cable Base frame

393152 TwinControl 75-150 ABS Turbine Trolley

393153 TwinControl 75-150 ABS Cable Trolley

393154 TwinControl 72-300/150 ABS Turbine Base frame

393155 TwinControl 72-300/150 ABS Cable Base frame

393156 TwinControl 72-300/150 ABS Turbine Trolley

393157 TwinControl 72-300/150 ABS Cable Trolley

393158 TwinControl 72-300 ABS Turbine Base frame

393159 TwinControl 72-300 ABS Cable Base frame

393160 TwinControl 72-300 ABS Turbine Trolley

393161 TwinControl 72-300 ABS Cable Trolley

Weight in kg Weight in lb

87 192

86

76

75

190

168

165

95

94

113

112

198

197

224

223

142

141

159

158

235

234

264

263

209

207

249

247

582

580

437

434

494

492

313

311

351

349

518

516

21

TwinControl .

EDITION 04/2010

OPERATING MANUAL

4.3.5 DIMENSIONS

PART NO. DOC393831

TwinControl ABS turbine or cable mounted on the base frame

5-60 18-40 28-40 35-70

Type

35-150/70 48-110

A

B

C mm; inch

875; 34.5

1577; 62

550; 22

A

A

D

B_02799

C

B_02801

C

TwinControl ABS turbine or cable mounted on the wall

5-60 18-40

Type

28-40 35-70

A

B

C

D mm; inch

917; 36

1061; 42

509; 20

E

F

892; 35

238; 10

9; 0.35

22

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

TwinControl .

A

B_02800

TwinControl ABS turbine or cable mounted on the base frame

Type

A

B

C

75-150 72-300

72-300/150 mm; inch

1015; 40.0

1655; 65.2

735; 28.94

C

23

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

TwinControl .

A C

B_02822

TwinControl ABS turbine or cable mounted on the trolley

Type 48-110 35-150/70

A

B

C mm; inch

820; 32.28

1769; 69.65

1227; 48.31

TwinControl ABS turbine or cable mounted on the trolley

Type 75-150 72-300/150 72-300

A

B

C mm; inch

1035; 40.80

1829; 72.00

1314; 51.70

24

5

6

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

4.4 FUNCTION

Basic principle:

The paint fl ows continuously and the hardener is metered or injected into the paint in portions in intermittent cycles with a slightly higher pressure.

Description:

The required mixing ratio is entered on the electronic control, and the system can then be started by pressing the button on the electronic control. This opens material valve A. The hardener valve B is then opened in pulses, and hardener metered-in according to requirement.

4.4.1 DESIGN OF TWINCONTROL BASIC UNITS

1 Pump for A component

2 Solvent pump „S“

3 Pump for B component

4 Control unit TwinControl

6 Stand

7 Mixing unit

8 Trolley

9 Mounting for wall

8

4

1

2

3

B_02796

1:2

7

B_02797

B_02798

25

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

4.4.2 PRINCIPLE DIAGRAM FOR BASIC UNITS 18-40; 28-40; 35-70 AND 35-150

Control unit 1 Turbine:

This control, which generates current from compressed air with a turbine, is suitable for all systems with pumps from 18-40 to 35-150 with single-acting material valves with spring reset.

Control unit 1 Cable:

This control with electrical mains connection is suitable for all systems with pumps from

18-40 to 35-150 with single-acting material valves with spring reset.

TwinControl

Control unit 1 Turbine or TwinControl

Control unit 1 Cable

S

B

A

B_02764

P1

26

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

4.4.3 PRINCIPLE DIAGRAM FOR BASIC UNITS 48-110; 75-150 AND 72-300

Control unit 2 Turbine:

This control, which generates current from compressed air with a turbine, is suitable for all systems with pumps from 48-110 to 72-300 with double-acting material valves.

Control unit 2 Cable:

This control with electrical mains connection is suitable for all systems with pumps from

48-110 to 72-300 with double-acting material valves.

TwinControl

Control unit 2 Turbine or TwinControl

Control unit 2 Cable

S

B

A

B_02745

P1

P2

27

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

4.4.4 OPERATOR‘S CONTROLS ON THE CONTROL UNIT TWINCONTROL 1 AND 2

The front of the TwinControl control unit is the same on all 4 device variants.

129

128 126

127 125 124

109

110

111

112

113

114

A B

B

A

B

A

123

122

SET

TwinControl

115 116

117

118

101

119

102

120

103

114

115

116

117

118

119

110

111

112

113

101

102

103

109

Push button „Start“

Push button „Stop“

Push button „Flushing AB“

Luminous display Alarm

Luminous display pot life

Luminous display Service functions

Luminous display Calibrate

Luminous display Totals

Luminous display Works

Push button main menu selection

Push button sub menu selection

Luminous display A component

Luminous display Start

Luminous display Alarm

121

B_02601

120

121

122

123

124

125

126

127

128

129

Luminous display Flushing AB

Push button SET a) Push button „-“ b) Push button „Check for leaks“

Push button „+“

Display

Luminous display B component

Luminous display Solvent A

Luminous display circulation operation

(Option)

B-valve cycle display

Luminous display Solvent B

28

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Rear wall TwinControl Control unit 1 and 2 with Turbine

132 142 134 136 135

A

Made in Switzerland

J. Wagner AG

CH 9450 Altstätten

TwinControl Type / Typ:

Serial No unit.:

Serie Nr. Anlage:

B

131

130

0102

II 2 G

Ex ia II B T4 X

ZELM 08 ATEX 0385 X

Y ear of construction / Baujahr:

Serial No. controller:

Serie Nr. Steuerung:

Air pressure supply:

Luftdruckversorgung:

0.6 - 0.8 MPa

6 - 8 bar

87 - 116 psi

Ambient temperature:

Temperatur Umgebung:

Prot. Class:

Schutzklasse:

IP 54

+5 / +40 °C

B_02811

139

137 133

Check manual before use!

Vor Gebrauch Betriebsanleitung beachten!

137 138

Rear wall TwinControl Control unit 1 and 2 with cable connection

132 142 134 136 135 140 133

A

J. Wagner AG

CH 9450 Altstätten

Made in Switzerland

B

131

130

134

135

136

137

130

131

132

133

Type / Typ:

Prot. Class:

Schutzklasse:

TwinControl

Serial No unit.:

Serie Nr. Anlage:

Serial No. controller:

Serie Nr. Steuerung:

Voltage:

Spannung:

85-260 VAC 47-60 Hz

Line Power:

Eingangsleistung:

Ambient temperature:

Temperatur Umgebung: max. 40 W

+5 / +40 °C

IP 54

B_02812

139

Service connection socket

Connection for stroke measurement B

Connection for stroke measurement A

Silencer

Pressure relief valve 1 Turbine

Pressure relief valve 2 Turbine

Air inlet

Air outlet exhaust air

138

139

140

141

142

Check manual before use!

Vor Gebrauch Betriebsanleitung beachten!

141 138

Earth connection

Connections for controlled air

(for hose connections see pneumatic diagrams)

Power cable

Main switch

Remote control

29

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

4.4.5 SERVICE FUNCTIONS - OVERVIEW LIST

Item

AB

A

B

SA

SA will fl ash

SB

SB will fl ash

SA + SB will fl ash

Unit cc cc cc

Description

Software version: B3.30 and C3.30

Mixed material in the hose

Volume A material from material valve to mixing block

Volume B material from material valve to mixing block cc

0-200 sec or cc cc

Flushing quantity on A side

Time SA valve (solvent) is open during air - solvent fl ush

2 Flushing quantity on A side

Flushing quantity on B side

0-200 sec or cc

Time SB valve (air) is open during air - solvent fl ush

2 Flushing quantity on B side

0-200 Number of repetitions during air - solvent fl ush

P18

P19

P20

P21

P3

P4

P5

P6

P0

P1

P2

Confi guration level 3

0 or 1 Password (0 = no, 1 = yes) for level 1 cc cc

%

%

Actual Software version

Q Control

Value Q Control

Mixing tolerance

Actual value mixing tolerance

DS/min Protection of dry running pump A

P7

P8

DS/min

DS/min

Protection of dry running pump B

Maxi. number of double strokes pump A where not masked

P9 DS/min Maxi. number of double strokes pump B where not masked

P10 0-99999 ml Quantity of material when fl ushing on A side

P14

P15

P16

P17

P11 0-99999 ml Quantity of material when fl ushing on B side

P12 min Pot life alarm delay

P13 % from stroke

Tolerance limit A reverse point

ADC

ADC

ADC

% from stroke

Actual value Reverse point stroke sensor A down

Actual value Reverse point stroke sensor A up

Actual value Position stroke sensor A

Tolerance limit B reverse point

P22

ADC

ADC

Actual value Reverse point stroke sensor B down

Actual value Reverse point stroke sensor B up

ADC Actual value Position stroke sensor B

0,1,2,3 Unit of measurement (0 = Liter, 1 = US Gallon, 2 = UK Gallon,

3 = conversion factors is adjustable)

0 or 1 Gun Flush Box (GFB) (0 = no, 1 = yes)

TwinControl .

adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable

Display adjustable

Display adjustable

Display adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable

Display adjustable adjustable adjustable

Display adjustable adjustable

30

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

P30

P31

P32

P33

P34

P35

P23

P24

P25

P26

P27

P28

P29

P41

P42

P43

P44

P45

P46

P47

P36

P37

P38

P39

P40

P48

P49

Software version: B3.30 and C3.30

0 or 1 Manually leakage check up (0 = no, 1 = yes) mm/min Warning tolerance for leakage A mm/min Fault tolerance for leakage A mm/min Warning tolerance for leakage B mm/min Fault tolerance for leakage B

Liter

Liter

Total A not resettable

Total A not resettable x * 100000 Liter

Liter

Liter

Liter

Liter

Total B not resettable

Total B not resettable x * 100000 Liter

Total A fl ush not resettable

Total B fl ush not resettable min-1 Turbine frequency in revolutions per min (set value 38000 to 45000)

0-6 Front announcement in the mixing process respectable if the gun is closed:

0 = Mixing ratio (MV);

1 = Flow Rate or Pot life (F_P);

2 = Job sum (JS);

3 = MV and F_P alternating;

4 = MV and JS alternating;

5 = F_P and JS alternating;

6 = MV and F_P and JS alternating)

0 or 1 Feed function with pulses of A (0 = off, 1 = on) sec 0.0 - 10.0s cycle duration of feed function

% 0-100% of the cycle duration A valve should be open

% 0-100% of the feed quantity feed function should be on

0 or 1 Flushing sequence (0 = AB, 1 = BA)

0 or 1 Material sequence at fl ush start (0 = AB, 1 = BA)

0 or 1 Feed sequence (0 = AB, 1 = BA)

0-9999 Password for level 1

0-9999 Password for level 2

0-9999 Password for level 3 min Time delay for alarm No. 18 (1-10)

1,2,3

0,1,2

0.1

1 = Save customer settings;

2 = Load customer settings

3 = Load factory settings (in stop mode visible only)

0 = No calibration in mixing mode

1 = Calibration in mixing mode (A valve will not open)

2 = Calibration in mixing mode (A valve will open)

0 = Flush volume in cc;

1 = fl ush volume in sec adjustable adjustable adjustable adjustable adjustable

Display

Display

Display

Display

Display

Display

Display adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable

31

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

P51

P52

P57

P58

P59

P60

P53

P54

P55

P56

P61

P62

P63

P64

P68

P69

P70

P65

P66

P67

P50 0-6

Software version: B3.30 and C3.30

Display after stop is pressed:

0 = Mixing ratio (MV);

1 = Pot life only (P);

2 = Job sum (JS);

3 = MV and P alternating;

4 = MV and JS alternating;

5 = P and JS alternating;

6 = MV and P and JS alternating

Maximal double stroke fl ush pump A per minute 0-999

DS/min

0-999

DS/min

Maximal double stroke fl ush pump B per minute

Cycles Number of A valve cycles resetable

Cycles Number of A valve * 100000 cycles resetable

Cycles Number of A valve cycles not resetable

Cycles Number of A valve * 100000 cycles not resetable

Cycles Number of B valve cycles resetable

Cycles Number of B valve * 100000 cycles resetable

Cycles Number of B valve cycles not resetable

Cycles Number of B valve * 100000 cycles not resetable

0-99999 Number of A valve * 1000 cycles for service message

0-99999 Number of B valve * 1000 cycles for service message

0 or 1 0 = Shot Mode off

1 = Shot Mode on

0 or 1 0 = Normal Start

1 = If start is pressed more than 2 sec, fi lling separately A and B will

not be done

0 or 1 0 = No fl ushing after error message

1 = Flushing after error message

0 or 1 0 = Password for mixing ratio and Shot Mode quantity

1 = No password for mixing ratio and Shot Mode quantity

0 or 1 0 = Flow-rate monitoring off

1 = Flow-rate monitoring on

0-99999 cc/min

0-99999 cc/min

Minimum fl ow rate

Maximum fl ow rate

0.0-20.0 s Delay time until alarm when fl ow is outside limit adjustable adjustable adjustable

Display

Display

Display

Display

Display

Display

Display

Display adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable adjustable

32

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

4.4.6 PNEUMATIC DIAGRAM TWINCONTROL 1

Material valve A Flush

1

Flush Air Hardener valve B

1 5 1 1

Option

Gun fl ush box

2 0 2 0 -

Pneumatic horn external

12

2

1

1 3

12

2

5

1 3

12

2

1 5

1 3

12

2

1 1

1 3

12

2

14

2 0

1 3

4 2

5 1 3

12

2 4

2

1 3

12

2

1

No.

0

1

3

5

6

Description

Air supply

Material valve A

Change over signal Pump A

Flushing valve

Change over signal fl ushing pump

11 Hardener valve B

13 Change over signal Pump B

15 Flushing valve Air

20 Gun fl ush box

22 External release

24 Pneumatic horn external

3

1

Change over signal Pump A

2 3

1 3

1

Change over signal Pump B

2 3

6

1

Change over signal fl ushing pump

2 3

2 2

1

External release

2 3

B_02815

33

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

4.4.7 PNEUMATIC DIAGRAM TWINCONTROL 2

12

Material valve A

2

1

1 3

1

14

+

1

1

4

1 -

2

1 -

5 1 3

12

2

5

1 3

+

Flush AS

5

12

Hardener valve B

Option

Air motor B

2

12

1 2 1

Flush BS

1 5 1 1 1 1 -

1 1

4

1 1 -

2

14

1 1

2

1 1

1 3

+

5 1 3

12

4 2

14

1 2 Nr 5

5 1 3

2

1 3

12

+

2

1 5

1 3

+

12

Option

Gun fl ush box

2 0

2

1 3

14

2 0

4

2 0 -

2

5 1 3

12

Pneumatic horn external

2 4

2

1 3

No.

+

1

3

5

6

11

12

ES 1 = Numbers Electrical schematic

Description

Air supply

Material valve A

Change over signal Pump A

Flushing valve AS

Change over signal fl ushing pump

Hardener valve B

Air motor B

13 Change over signal Pump B

15 Flushing valve B

20 Gun fl ush Box

22 External release

24 Pneumatic horn external

Change over signal Pump A

3

1

ES 9

2 3

Change over signal fl ushing pump

1

6 ES 7

2 3

1 3

Change over signal Pump B

1

ES 10

2 3

2 2

External release

1

ES 5

2 3

B_02814

34

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

5

TRANSPORT / INSTALLATION

5.1 TRANSPORT

The complete system can be safely transported in a wooden crate.

The dimensions of the transportation crate can be determined with the help of the data of the dimensions in chapter 4.3.5 and the weights of the basic equipments are in chapter

4.3.4 to be found.

When lifting the system, always make sure that it remains in balance.

Basic units mounted on base frame.

A

A xxx kg xxxx lb

B_02820

SIHI_0052_GB

WARNING

Inclined surface!

Risk of accidents if the unit rolls away/falls

œ Place the unit on horizontal soil.

œ The wheels must be fixed or by placing feet to be replaced and secured.

œ When shifting/transport do not tilt the unit.

35

EDITION 04/2010

OPERATING MANUAL

Basic units mounted on trolley

PART NO. DOC393831 xxx kg xxxx lb

TwinControl .

xxx kg xxxx lb

B_02823 B_02825

B_02824

5.2 STORAGE

7HENSTORINGTHEUNITPLACEITINACLOSEDANDDRYENVIRONMENT²#UNTIL²#²&

UNTIL²&

œ )F THE EQUIPMENT IS NOT GOING TO BE USED FOR A LONG TIME LUBRICATE IT BY SUCKING

EMULSIlEDOILORPLAINOIL FROMTHEFEEDINGPUMPS

œ 7HEN RESUMING WORK OPERATION PROCEED AS DESCRIBED IN #HAP uPRELIMINARY

OPERATIONSv

36

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

5.3 INSTALLATION

The system is installed and commissioned by the Wagner Service department or by an expert representative. When removing from the packaging, check the system parts for possible transport damage.

WARNING

Electric shock haza rd inside the controller!

Danger to life from electric shock

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

œ Are operated in accordance with the safety regulations, fire and electro-technical rules.

œ The voltage is switched off before work is begun on active components.

SIHI_0045_GB

WARNING

Toxic and/or flammable vapor mixtures!

Risk of poisoning and burns

œ Operate the unit in a spraying booth approved for the working materials.

-or-

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

œ Observe national and local regulations for the outgoing air speed.

SIHI_0028_GB

WARNING

Inclined surface!

Risk of accidents if the unit rolls away/falls

œ Place the unit on horizontal soil.

œ The wheels must be fixed or by placing feet to be replaced and secured.

œ When shifting/transport do not tilt the unit.

SIHI_0052_GB

37

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

5.4 PNEUMATIC CONNECTIONS

➞ Check whether the line pressure is suffi cient. It has to lie between 0.5-0.8 MPa; 5-8 bar;

73-116 psi.

WARNING

Overpressure!

Risk of injury bursting components

œ The operating pressure must never exceed the value shown on the plate.

SIHI_0054_GB

œ #HECKWHETHEREFlCIENTlLTERSYSTEMSANDCONDENSATEPRECIPITATORSAREAVAILABLEON

THEAIRLINE

œ %VERY DAY DISCHARGE ALL IMPURITIES AND THE CONDENSATE IF ANY ACCUMULATED IN THE

EQUIPMENTAIRlLTER

WARNING

Brittle filter pressure regulator!

The container on the filter pressure regulator becomes brittle through contact with solvents and can burst

Flying parts can cause injury

œ Do not clean the container on the pressure regulator with solvent.

SIHI_0014_GB

38

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

5.5 FLUID CONNECTIONS

-> Connection of the hose for the cleaning agent (solvent) from the solvent pump via the suction unit into the container.

5.6 ENSURING SUFFICIENT MATERIAL

In the event of hose breakage on the high pressure side or idle running due to lack of material, the system switches the pumps off automatically.

5.7 GROUND THE SYSTEM

WARNING

Fire, explosion and electric shock hazard!

Danger to life from electric shock and explosion

œ The unit must be electrically connected to a true earth ground; the ground in the electrical system is not sufficient.

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

œ Must be operated in accordance with the safety regulations, fire and electrotechnical regulations.

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

SIHI_0057_GB

WARNING

Heavy paint mist if earthing is insufficient!

Risk of poisoning

Insufficient paint application quality

œ Earth all unit components.

œ Earth the workpieces being painted.

SIHI_0003_GB

39

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

5.7.1 EARTHING OF COMPONENTS ON FRAME OR CARRIAGE

View of rear side of system

TwinControl .

2 Earth connections

4

1

3

Pos from

1

2

3

A-Pump to frame

B-Pump to frame

Flushing pump to frame

Cable

4 mm 2 ; AWG11

4 mm 2 ; AWG11

4 mm 2 ; AWG11

4 Control unit to frame 4 mm 2 ; AWG11

5 Frame to the functional earth 4 mm 2 ; AWG11

B_02804

5

To the equipotential bonding (operational earth)

Earth connection point on frame

View of operating side of system

B_02805

40

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

5.7.2 EXAMPLE OF EARTHING SCHEME FOR BASIC UNIT WITH TURBINE

TwinControl .

‡

†

„

…

A

W

‰

B

…

ˆ

Legend

3 TwinControl Frame

4 Paint container

5 Work piece

6 Conveyor

7 Floor conductive

8 Water container

R max. < 1 MOhm

B_02746

Cable cross sections

TwinControl Frame

Water container

Conveyor

4 mm 2 ; AWG11

6 mm 2 ; AWG10

16 mm 2 ; AWG5

Cable cross sections

Spray booth

Spraying stand

16 mm 2 ; AWG5

16 mm 2 ; AWG5

5.7.3 EXAMPLE OF EARTHING SCHEME FOR BASIC UNIT WITH CABLE

Basic unit with cable and mains current connection

Not Ex-Zone

Ex-Zone 1 and 2

‡

†

„

…

A

W

‰

B

…

Legend

3 TwinControl Frame

4 Paint container

5 Work piece

6 Conveyor

7 Floor conductive

8 Water container

ˆ

R max. < 1 MOhm

B_02803

41

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

6

START-UP AND OPERATION

6.1 GENERAL RULES FOR USE OF THE SPRAY SYSTEM

Observe general safety instructions in chapter 2.

The operating documents provided by Wagner for the pneumatic pumps and other system components should be read through carefully. The appropriate operating manual are available on the Wagner CD as pdf fi le.

Also observe the operating instructions for the components mounted on site.

CAUTION

Constant supply pressures!

Poor coating results

œ The supply pressure of the component B must be adjust to a higher value (appr. 10%) than that the component A.

œ The supplying pressure should be constant.

SIHI_0056_GB

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent

œ Never reach into the spray jet.

œ Never point the spray gun at peole.

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

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

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

SIHI_0059_GB

WARNING

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

Danger to life from flying parts

œ Ensure that the unit is always completely filled with cleaning agent or working medium.

œ Do not spray the unit empty after cleaning.

SIHI_0058_GB

42

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

6.2 PREPARATION OF START-UP

The following points should be noted before commissioning:

➞ Ensure earthing of the unit and all other conductive parts inside the work area.

➞ Connect spray gun without nozzle with high-pressure hose to the mixing unit and secure with safety catch.

➞

Check that all material-conveying connections are correctly connected.

➞

Check that all air-conveying connections are correctly connected in accordance with the pneumatic diagram provided.

➞

Visually check acceptable pressure of all system components.

➞

Check level of release agent in the pumps and top up if necessary.

➞ Provide a material container for A and B components, a container for fl ushing agent and an empty container for return fl ow.

➞ Connect the system to the air supply.

SIHI_0137_GB

CAUTION

Magnetic fields!

Danger of damage to electronic devices and magnetic data carriers

œ Make sure that electronic devices and magnetic data carriers are removed from the danger area.

43

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

6.3 SWITCHING THE UNIT ON AND OFF

2.

3.

TwinControl .

1.

A

A+S

B+S

Return

B_02832

Example of TwinControl system ready for spraying

S

B

44

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

1.

2.

off

TwinControl .

off on

B_02835

1. Switch on air supply

3.

on

B_02836

2. Switch on control air

Remark: control air drives turbine, electronic is powered by turbine on

3. Turn on main switch

Remark:

Valid only for TwinControl with cable off

B_02837

Emergency Stop

In the case of unforeseen occurrences

1. Switch off air supply (1)

2. Hold electrically conductive part of the gun against the metal container and trigger until no further pressure is present.

3. Secure gun

4. Provide collection container and open return valve for A- and B-component and fl ushing agent pump. Close all valves again after pressure relief.

45

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

6.4 PRELIMINARY WASHING AND PRESSURE TIGHTNESS TEST

The units are tested in the factory with emulsifying oil, pure oil or solvent.

Possible residues must be fl ushed out of the circuits with a solvent (cleaning agent) before commissioning.

WARNING

Incompatibility of cleaning agent and working medium!

Risk of explosion and danger of poisoning by toxic gasses

œ Check the compatibility of cleaning agent and working medium in accordance with safety data sheets.

SIHI_0060_GB

Always carry out precleaning and the pressurisation test:

- before putting the new system into operation for the fi rst time

- before using the system again after prolonged storage

- before servicing the system.

Please note:

- Do not insert the nozzle into the gun yet. Gun secured.

- Keep the pump pressure as low as possible during fl ushing.

- Operating instructions for the individual components must be known.

Procedure:

1. Connect compressed air supply.

2. Connect cleaning agent to all 3 pumps. Provide and earth an empty container.

3. Set a low pressure (approx. 0.5 MPa; 5 bar; 73 psi) on the pressure controllers for the 3 pumps.

4. First of all, vent and clean the fl ushing pump with the cleaning agent via the return ball valve.

„Start“, open. Close return ball valve of the fl ushing pump and release the gun, point into the earthed empty bucket and trigger. When clean solvent emerges, close the gun and secure.

6. Gradually increase pressure in the fl ushing pump with the pressure controller until maximum pressure is reached. Maintain the pressure for 3 minutes and check all connection points for leaks.

A B

B

A

B

A

SET

TwinControl

B_02744

46

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

7. Relieve pressure of fl ushing agent circuit. Close return ball valve of fl ushing pump and turn compressed air controller down. Release the gun and trigger, holding the metal part of the gun against the bucket and pointing it into the earthed bucket, until no further pressure is present.

8. Secure gun with trigger guard. Close the fl ushing valves by pressing „Stop“.

9. Vent pump A in the same way.

10. Select pump A component „A“. Press „Start“.

11. Close return ball valve of pump A and release the gun, point into the earthed empty bucket and trigger. When clean solvent emerges, close the gun and secure.

12. Gradually increase pressure in pump A with the pressure controller until maximum pressure is reached. Maintain the pressure for 3 minutes and check all connection points of the A-material circuit for leaks.

13. Press „Stop“ on the TwinControl control unit.

14. Relieve pressure of A-material circuit and turn off compressed air controller. Release the gun and trigger, holding the metal part of the gun against the bucket and pointing it into the earthed bucket, until no further pressure is present.

15. Secure gun with trigger guard.

16. Select pump B component „B“. Press „Start“.

17. Vent pump B in the same way.

WARNING

Overpressure!

Risk of injury bursting components

œ The operating pressure must never exceed the value shown on the plate.

SIHI_0054_GB

18. Close return ball valve of pump B and release the gun, point into the earthed empty bucket and trigger. When clean solvent emerges, close the gun and secure.

19. Gradually increase pressure in pump B with the pressure controller until maximum pressure is reached. Maintain the pressure for 3 minutes and check all connection points of the B-material circuit for leaks.

20. Press „Stop“ on the TwinControl control unit.

21. Relieve pressure of B-material circuit and turn off compressed air controller. Release the gun and trigger, holding the metal part of the gun against the bucket and pointing it into the earthed bucket, until no further pressure is present.

22. Secure gun with trigger guard.

47

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

6.5 PRESSURE RELIEF PROCEDURE

The pressure must always be relieved

- when the spraying tasks are fi nished

- before servicing the system

- before carrying out cleaning tasks on the system

- before moving the system to another location

- if something needs to be checked on the system

- if the nozzle is removed from the gun.

Please read the general safety instructions in chapter 2.

SIHI_0059_GB

Procedure:

1. Secure the gun.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent

œ Never reach into the spray jet.

œ Never point the spray gun at peole.

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

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

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

2. Press „Stop“ on the

TwinControl control unit.

A B

B

A

B

A

BP

SET

TwinControl

B_02744

AL4

3. Close air valves on the pumps for A-, Bcomponent and solvent.

BL7

AP

B_02631

LL10

LP

48

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

4. Release the gun

5. Hold electrically conductive part of the gun against the metal container and trigger until no further pressure is present.

TwinControl .

BD AD container and open return ball valve for A- and Bcomponent and fl ushing agent pump.

Close all valves again after pressure relief.

B3

BV8

B5

A3

AV7

A5

LP

L2

B_02633

LV9

L4

49

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

6.6 FILLING THE UNIT AND CALIBRATION

WARNING

Do not exchange the two components A and B!

Equipment damage by hardened paint

œ Mark unit parts and paint container, so that the components A and B are not exchanged.

SIHI_0061_GB

6.6.1 FILLING THE UNIT

➞ Using the same procedure as for fi lling the system with cleaning agent, the main material is now conveyed into the A-circuit and the hardening material into the Bcircuit in circulation mode.

6.6.2 CALIBRATION THE UNIT

➞

The system is volumetrically calibrated in the factory, therefore it does not have to be calibrated with the material. However, if a calibration is required, proceed as follows:

A B

B

A

B

A

A B

B

A

B

A

SET

TwinControl

B_02744

SET

TwinControl

B_02744

1. The material to be calibrated is fi rst of all conveyed manually as far as the gun.

2. Set the pump pressure to 0.5 MPa; 5 bar; 73 psi and select the nozzle so that the material fl ow volume corresponds to the subsequent production process.

3. Start the calibration process for the A side with the [Start] key.

4. A minimum of 5 pump double strokes are discharged into a measuring cup with the gun (use protective sleeve against over spray if necessary).

5. Press button [STOP]

6. The quantity discharged into the measuring cup in cm 3 is entered by pressing [SET] and „+“ „-“ and confi rmed by pressing [SET].

Attention: The calibration process can be interrupted without saving by pressing the

Stop button.

7. The control has now calculated and saved the new K-factor and displays it.

50

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

8. Repeat the calibration in order to check it.

Large deviations may be due to the following error causes :

- There is air in the lines -> Fill lines with material and check suction system.

- High proportion of air bubbles in the material in the measuring cup -> Determine material weight with scale and calculate the volume based on the density.

9. Calibrate the B component in the same way as the A component.

10. The K-factor can be entered directly for the fl ushing pump. The value corresponds to cm 3 per double stroke.

11. Flush the system.

6.7 FLUSH SYSTEM

Flushing must always be carried out

- before prolonged work interruptions

- at the end of work

- before expiry of the application life

- before a material change.

DANGER

Exploding gas/ air mixture!

Danger to life from flying parts and burns

œ Never spray into a closed container.

œ Earth the container.

SIHI_0008_GB

➞

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

Note : Before the spray nozzle is removed, the pressure (see section. 6.4) has to be released.

➞ Wear protective eye wear.

➞ Set the fl ushing agent pressure as low as possible for fl ushing.

Procedure:

1. Press the Stop button.

2. Press the Flush button. Open gun carefully and spray into an earthed container. Flush until clean fl ushing agent emerges. Repeat fl ushing cycle if necessary or adjust fl ushing quantity in fl ushing program. Adjust fl ushing pressure at the fl ushing pump so that the desired fl ushing effect is achieved.

51

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent

œ Never reach into the spray jet.

œ Never point the spray gun at peole.

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

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

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

SIHI_0059_GB

6.8 GENERAL

➞ The fl ushing agent pressure for A and B and the material pressure for the A and B components must always be present on the device during operation.

➞ Make sure that the nozzle is inserted in the gun when feeding the material hose. The fl ushing process must always be performed without the nozzle in the gun.

➞ It is important that the level in the A and B material containers and in the fl ushing material container is checked visually, in order to prevent unintended interruptions in the spray process.

52

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

6.9 PASSWORD PROTECTION AND USER FUNCTIONS

Level 0 Painter

Function:

Start, Stop, fl ush, (option circulate)

“+” “-”

(P0=0)

Press “+” and “-” simultaneously, SET, Password Level 1, SET

“+” “-”,

(P0=1)

Level 1 Painter with control job

Function:

Start, Stop, fl ush, (option circulate)

View only:

Job quantity, total quantity, calibration value, pot life time, latest alarm, mixed material in hose, fi ll quantity A, B, fl ush quantity A, B

“+” “-”,

(P0=0)

“+” “-”,

(P0=1)

Press “+” and “-” simultaneously, SET, Password Level 2, SET

Level 2 Boss

Function:

Start, Stop, fl ush, (option circulate)

View and change:

Job quantity, total quantity, mixed material in hose, fi ll quantity A, B, fl ush quantity A, B, mixing ratio, pot life time.

View only: calibration value, alarms

“+” “-”,

Press “+” and “-” simultaneously, SET, Password Level 3, SET

Level 3 Service

Function:

Start, Stop, fl ush, (option circulate)

View and change:

Job quantity, total quantity, mixed material in hose, fi ll quantity A, B, fi ll quantity A, B, calibration value, alarms, mixing ratio, pot life time.

View and change: parameter P0 to P99.

Exceptions:

The parameters P13, P14, P15, P17, P18 and P19 can be seen only.

“+” “-”,

The passwords, which are set by Wagner with the distribution of the equipment, are not contained for safety reasons in the manual. The valid passwords are communicated to the customer separately.

53

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

6.10 BRIEF DESCRIPTION OF THE INDIVIDUAL FUNCTIONS

Description of the press buttons:

Change numbers. Set -> „+“ (higher) or „-“ (smaller)

Save numbers -> Set

Terminate data input -> Push button „Stop“

Main menu -> 2 x Push button „Stop“

If the indication „OFF“ appears after making an entry in the display, then the input authorisation must be enabled.

A B

B

A

B

A

SET

TwinControl

B_02744 6.10.1 BASIC FUNCTIONS FOR THE SPRAYER

Basic setting

System is ready to start

„Start“ button-> system starts mixing

A B

B

A

B

A

SET

TwinControl

B_02744

System is mixing

Pot life LED fl ashing -> pot life running

Work LED fl ashing -> preload

Work LED illuminated -> system ready to spray

B-valve cycle display -> injection frequency

Display -> see chapter 4.4.5 -> P35.

A B

B

A

B

A

SET

TwinControl

B_02744

Automatic stop in case of error

Alarm LED on

Stop LED on

Error code is displayed

A B

B

A

B

A

SET

TwinControl

B_02744

Flushing

The fl ushing program runs automatically. B valve to mixing block, A valve to mixing block, A fl ushing quantity, B fl ushing quantity. Display of quantities and A/B fl ushing side during fl ushing.

The fl ushing sequence A/B or B/A can be selected (P 40

->see list of service functions, chap. 4.4.5).

A B

B

A

B

A

SET

TwinControl

B_02744

54

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

6.10.2 EXTENDED FUNCTIONS WITH PASSWORD PROTECTION

Adjusting the mixing ratio

Press SET -> change value with + - push button.

Press SET again to confi rm new value

(Abort with STOP push button)

A B

B

A

B

A

TwinControl .

SET

TwinControl

B_02744

Manual mode / Totals

Only convey A component

(START / STOP).

Displays job total A in cm 3 .

A B

B

A

B

A

SET

TwinControl

B_02744

Manual mode / Totals

Only convey B component

(START / STOP).

Displays job total B in cm 3 .

A B

B

A

B

A

SET

TwinControl

B_02744

Only convey fl ushing circuit A

(START / STOP)

Displays job total fl ushing agent A in cm 3 .

Valid only for models 48-110, 75-150, 72-300

A B

B

A

B

A

SET

TwinControl

B_02744

Only convey fl ushing circuit B

(START / STOP)

Displays job total fl ushing agent B in cm 3 .

Valid only for models 48-110, 75-150, 72-300

A B

B

A

B

A

SET

TwinControl

B_02744

55

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Total amount A

To Re-Set „0“: Press „SET“ push button > 2 seconds.

Display in liter.

A B

B

A

B

A

TwinControl .

SET

TwinControl

B_02744

Total amount B

To Re-Set „0“: Press „SET“ push button > 2 seconds.

Display in liter.

A B

B

A

B

A

SET

TwinControl

B_02744

Total amount fl ushing circuit A

To Re-Set „0“: Press „SET“ push button > 2 seconds.

Display in liter.

A B

B

A

B

A

SET

TwinControl

B_02744

Total amount fl ushing circuit B

Set to „0“: Press „SET“ push button > 2 seconds.

Display in liter.

A B

B

A

B

A

SET

TwinControl

B_02744

56

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Calibration (Password entry required for PO)

Calibration A

Start: -> open gun -> discharge approx. 5 double strokes at spray pressure -> close gun -> Set

-> input measured value in measuring cup in cm 3 -> Set

(Abort with Stop button)

A B

B

A

B

A

TwinControl .

SET

TwinControl

B_02744

Calibration B

Start: -> open gun -> discharge approx. 5 double strokes at spray pressure -> close gun -> Set

-> input measured value in measuring cup in cm 3 -> Set

(Abort with Stop button)

A B

B

A

B

A

SET

TwinControl

B_02744

Calibration Flushing A

Direct input in cm 3 / double stroke of fl ushing pump

A B

B

A

B

A

SET

TwinControl

B_02744

Calibration Flushing B

Direct input in cm 3 / double stroke of fl ushing pump

A B

B

A

B

A

SET

TwinControl

B_02744

57

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Service (Password entry required for PO)

Content of spray hose with mixed material

[cm 3 ]

A B

B

A

B

A

TwinControl .

SET

TwinControl

B_02744

Quantity material valve A up to mixing block

[cm 3 ]

A B

B

A

B

A

SET

TwinControl

B_02744

Quantity material valve B up to mixing block

[cm 3 ]

A B

B

A

B

A

SET

TwinControl

B_02744

Flushing quantity on A side

[cm 3 ]

A B

B

A

B

A

SET

TwinControl

B_02744

Flushing quantity on B side

[cm 3 ]

A B

B

A

B

A

SET

TwinControl

B_02744

58

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Service

Service parameters P0 - P70

Confi guration parameters P100 - P148

(see also section 4.4.5)

Change from P0 to P1..P2... with „+“-button.

Return with „-“-button

Pot life

Set the pot life [min].

Set, „+“ „-“ adjust, set.

A B

B

A

B

A

A B

B

A

B

A

TwinControl .

SET

TwinControl

B_02744

SET

TwinControl

B_02744

Fault messages

Display of last 28 error messages.

View with ±.

A B

B

A

B

A

SET

TwinControl

B_02744

Circulation of A and B component

(only possible if option available)

A B

B

A

B

A

SET

TwinControl

B_02744

Check for leaks in A and B colour stage

Press „-“ push-button > 3 seconds - the A and B pumps are checked for leaks during a 10 second period. Any leakage is indicated by an error message. During the check, the display counts from 10 to 0 and the LED displays for A and B fl ash alternately.

A B

B

A

B

A

SET

TwinControl

B_02744

59

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

7

MAINTENANCE

WARNING

Incorrect maintenance/repair!

Risk of injury and damage to the equipment

œ Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center.

œ Before all work on the unit and in the event of work interruptions:

- Switch off the energy/compressed air supply.

- Relieve the pressure from the spray gun and unit.

- Secure the spray gun against actuation.

œ Observe the operating and service instructions when carrying out all work.

SIHI_0004_GB

œ In accordance with the guideline for liquid spray devices (ZH 1/406 and BGR 500 Part

2, chap. 2.36):

– The occupational safety state of the liquid spray devices is to be inspected as required, however at least every 12 months by an expert (e.g. Wagner service technician).

– In case of non-operative units the test can be postponed until the next start-up.

7.1 CLEANING THE SYSTEM

œ !CLEANEDUNITMAKESANEASYLOCALIZATIONOFANYLEAKAGEANDQUICKREPAIR

7.2 CLEANING THE FILTERS

œ 2EFERTOTHECORRESPONDINGMANUALTOCLEANTHElLTERSONTHESUPPLYINGPUMPSANDIN

THESPRAYGUN

60

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

7.3 MAINTENANCE AND SERVICE

WARNING

Service plug!

Risk of explosion

œ Do connect the service plug if a potentially explosive gas atmosphere may be present.

SIHI_05050_ENG

Connectors A and B on the back of the device serve for connecting the potentiometer and may be inserted and removed even during operation.

WARNING

Maintenance and service tasks!

Risk of explosion

œ Maintenance and service tasks inside the housing may only be performed by trained Wagner staff, and only in the absence of any potentially explosive gas atmosphere.

SIHI_05051_ENG

61

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

7.4 HIGH PRESSURE HOSE

The lifetime of the fluid hoses is even with appropiate handling reduced due to enviromental influences.

œ Frequent view and occasional functional test is recommended.

œ As precaution fluid hose should be replaced after a specified period by the plant operator.

DANGER

Bursting hose, bursting threaded joints!

Danger to life from injection of material

œ Ensure that the hose material is chemically resistant.

œ Ensure that the spray gun, threaded joints and material hose between the unit and the spray gun is suitable for the pressure generated in the unit.

œ Ensure that the following information can be seen on the highpressure hose:

- Manufacturer

- Permissible operating pressure

- Date of manufacture.

SIHI_0029_GB

7.5 DISMANTLING

7HENTHEEQUIPMENTMUSTBESCRAPEDPLEASEMAKEADIFFERENTDISPOSALOFTHEMATERIALS

4HEFOLLOWINGMATERIALSHAVEBEENUSED

œ 3TEEL

œ !LUMINIUM

œ 2UBBER

œ 0LASTIC

œ 4UNGSTENCARBIDE

&LUIDSPAINTSADHESIVESSEALERSSOLVENTS SHALLBEDISPOSEDACCORDINGTOTHEVALIDSPECIlC

STANDARDS

62

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

8

TROUBLE SHOOTING

If a fault occurs, it is indicated:

➞ the horn sounds and the system stops. An error code appears on the display.

➞ the fault is acknowledged with the [Stop] button.

If the alarm signal sounds, it is advantageous to be able to determine which operating situation has caused the error. Troubleshooting can be carried out in accordance with the list in chapter 8.1.

➞ Faults caused by a defect in the control box may only be remedied by a trained expert

(e.g. workshop electrician)!

WARNING

Electric shock haza rd inside the controller!

Danger to life from electric shock

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

œ Are operated in accordance with the safety regulations, fire and electro-technical rules.

œ The voltage is switched off before work is begun on active components.

SIHI_0045_GB

63

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

8.1 FAULTS AND APPROPRIATE SOLUTIONS

Code Cause

Off No authorisation

11 Shortage of the B component

12 B Excess

15 Pot life

16 Compressed air supply

Software version: B3.30 and C3.30

Description of faults

Unauthorised input

Too little B component in the mixture

Too much B component in the mixture

Troubleshooting

Enable authorisation

- Increase air pressure for B pump or reduce for A

- Increase travel of timing valve in B material

- Reduce air pressure for B pump

- Decrease travel of timing valve in B material

- Flush or continue operation The pot life is over

Compressed air supply less than

0.4 MPa; 4 bar; 58 psi

- Increase compressed air supply

17

18

20

21

External release

Flushing problem

Sensor A down

Sensor B down

The external release is not present - Actived external release

Flush program is non-operational - Compressed air for A and B material pump open

- Open gun, check the gun fl ush box

Stroke sensor A cable breakage or sensor signal lost (sensor is in lower idle position)

Stroke sensor B cable breakage or sensor signal lost (sensor is in lower idle position)

- Switch A pump to circulation and pass lower reversal point

- Check plug connection sensor A

- Switch B pump to circulation and pass lower reversal point

- Check plug connection sensor B

24 Initialisation Sensor A Initialisation error Stroke sensor A Switch off unit and turn back on

25 Initialisation Sensor B Initialisation error Stroke sensor B Switch off unit and turn back on

26 Reverse points

Sensor A

27 Reverse points

Sensor B

Stroke sensor A

Problem stroke point

Stroke sensor B

Problem stroke point

Set greater tolerance limit for reversal point A and calibrate A

Set greater tolerance limit for reversal point B and calibrate B

30 Downward speed A Pump A sags in downward stroke Check material supply

31 Downward speed B Pump B sags in downward stroke Check material supply

32 Upward speed A

33 Upward speed B

40 Alarm Password

Pump A sags in upward stroke

Pump B sags in upward stroke

The software is not enabled

41 Wrongly adjusted air pressure

42 Wrongly adjusted air pressure

61 Warning Leakage A up

62 Warning Leakage A down

Turbine speed to low

Turbine speed to high

The A colour stage has a slight leak in the upward stroke

The A colour stage has a slight leak in the downward stroke

Check material supply

Check material supply

Enter software password

Wagner AG password

(only possible on PC)

Adjust air pressure

(Wagner technician)

Adjust air pressure

(Wagner technician)

Schedule an inspection of the A colour stage

Schedule an inspection of the A colour stage

64

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Code Cause

64 Alarm Leakage A down

65 Warning Leakage B up

66 Warning Leakage B down

Software version: B3.30 and C3.30

Description of faults Troubleshooting

63 Alarm Leakage A up The A colour stage has a large leak in the upward stroke

The leak in the A pump in the downward stroke exceeds the error limit

The B colour stage has a slight leak in the upward stroke

The B colour stage has a slight leak in the downward stroke

67 Alarm Leakage B up The B colour stage has a large leak in the upward stroke

Carry out inspection of the A colour stage

Carry out inspection of the A colour stage

Schedule an inspection of the B colour stage

Schedule an inspection of the B colour stage

Carry out inspection of the B colour stage

68 Alarm Leakage B down

The leak in the B pump in the downward stroke exceeds the error limit

A-material pump is too fast

Carry out inspection of the B colour stage

Stroke rate throttle 70 Number of strokes from A pump too high

71 Number of strokes from B pump too high

B-material pump is too fast Stroke rate throttle

72 Number of strokes from A fl ushing pump too high

73 Number of strokes from B fl ushing pump too high

80 A-valve worn out

A-fl ushing pump is too fast

B-fl ushing pump is too fast

A-valve has too many cycles

Stroke rate throttle

Stroke rate throttle

Revision of A-valve

81 B-valve worn out

90 Alarm EEPROM

B-valve has too many cycles Revision of B-valve

91

92

93

Alarm ADC

Alarm K factor

Pump A

Alarm K factor

Pump B

Reading or writing to the EEPROM is not possible

Reading the potentiometer values is not possible

The current k factor is outside the valid range

The current k factor is outside the valid range

Contact Wagner Service

Contact Wagner Service

Recalibrate pump

Check range setting of pump

Recalibrate pump

Check range setting of pump

65

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Code Cause

Software version: B3.30 and C3.30

Description of faults Troubleshooting

Check nozzle and pump pressure 94 Flow rate is too high The current fl ow is above the set value

95 Flow rate is too low The current fl ow is below the set value

Check nozzle and pump pressure

96 Gun signal missing The gun signal is not present Check gun monitoring

66

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

TwinControl .

67

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

8.2 CONVERSION OF DIFFERENT MIXING PROPORTION SPECIFICATION

)TISVERYIMPORTANTTHATTHEDATASHEETSOFTHEPAINTSUPPLIERAREAVAILABLESOTHATTHECOR

RECTMIXINGRATIOCANBEENTERED

œ 3OMEPAINTSUPPLIERINDICATETHEMIXINGRATIOBYWEIGHTOTHERSBYVOLUME

œ 3INCETHEmOWMETERMEASUREVOLUMETRICWENEEDTHESPECIlCATIONINVOLUME

#ONVERSIONOFMIXINGPROPORTIONOFGRAVIMETRICALLYINVOLUMETRIC

&OREXAMPLE

PARTSBYWEIGHT#OMP!AND

PARTSBYWEIGHT#OMP"

OR G#OMP!

G #OMP"

OR PARTSBYWEIGHT

OR BYWEIGHT!GRAV"GRAV

œ 4HE DENSITY OR SPEC VOLUME MUST OF THE COMPONENTS ! AND " ADMITS TO BE OR BE

BEFOREHANDDETERMINED

$ENSITY

0

!

7EIGHT

!

6OLUME

!

GR

CM

GR

CM

+G

,

0

"

7EIGHT

"

6OLUME

"

GR

CM

GR

CM

-IXINGRATIO

!GRAV

-VOL!VOLÁ"VOL

0

!

Á

"GRAV

0

"

-VOL

GR

GR

Á

GR

Á

GR

CM CM

OTHERVOLMIXINGPROPORTIONSPECIFICATIONS

PARTSBYVOLUME#OMP!

PARTSBYVOLUME#OMP"

+G

,

68

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

9

TABLES / PARAMETERS

9.1 TABLE HOSE VOLUME

Di = Inside diameter hose

L = Hose length

Vol = Material volume in the hose

$I

;MM=

,

;M=

6OL

;,=

$I

;MM=

,

;M=

6OL

;,=

TwinControl .

69

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

10

ACCESSORIES

Part No.

Description

2306526 Mixer external pneumatic

NW 2.6/ NW6 KS

TwinControl .

B_02977

2307749 Mixer external pneumatic

NW 2.6/ NW10 GXP

B_02977

2307030 Mixer external manual

NW8/ NW10 VA

B_02978

2307031 Circulation mixer

NW8 external

B_02979

70

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

-

Part No.

-

Description

Control connection circulation soft

Control unit with turbine

Re-tooled devices in the exchange available

A

B

Control connection circulation soft

Control unit with cable

Re-tooled devices in the exchange available

B_02980

A

B

B_02981

2307131 Circulation soft Leopard

Made in Switzerland

Type / Typ:

J. Wagner AG

CH 9450 Altstätten

TwinControl

Serial No unit.:

Serie Nr. Anlage:

0102

II 2 G

Ex ia II B T4 X

ZELM 08 ATEX 0385 X ear of construction / Baujahr:

Serial No. controller:

Serie Nr. Steuerung:

Air pressure supply:

Luftdruckversorgung:

0.6 - 0.8 MPa

6 - 8 bar

87 - 116 psi

Ambient temperature:

Temperatur Umgebung:

Prot. Class:

Schutzklasse:

+5 / +40 °C

IP 54

Check manual before use!

Vor Gebrauch Betriebsanleitung beachten!

J. Wagner AG

CH 9450 Altstätten

Made in Switzerland

Type / Typ: TwinControl

Serial No unit.:

Serie Nr. Anlage:

Serial No. controller:

Serie Nr. Steuerung:

Voltage:

Spannung:

85-260 VAC 47-60 Hz

Line Power:

Eingangsleistung:

Ambient temperature:

Temperatur Umgebung: max. 40 W

+5 / +40 °C

Prot. Class:

Schutzklasse:

IP 54

Check manual before use!

Vor Gebrauch Betriebsanleitung beachten!

B_02981

2307028 Circulation soft Jaguar

B_02983

71

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Part No.

Description

2307080 Circulation soft Tiger

TwinControl .

2308874 Remote control TwinControl

B_02984

B_02985

2303255 Heater set A or B for TwinControl to 35-150

2302813 Heater set A for TwinControl

48-110 to 75-150

B_02986

B_02988

72

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Part No.

Description

2302461 Heater set B for TwinControl

48-110 to 75-150

TwinControl .

B_02987

2303256 Heater set A for TwinControl

72-300

2303257 Heater set B for TwinControl

72-300

2303278 Heater set A double for TwinControl

72-300

B_02989

B_02990

B_02991

73

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Part No.

Description

2302563 Connecting set GFB 1

The connecting set Gun Flush

Box 1 can be used together with a TwinControl equipment with the control unit type 1.

The connecting set Gun Flush

Box 1 is necessary as link between the TwinControl equipment and a Gun Flush Box

(GFB).

TwinControl .

B_03116

2306085 Gun distributor

B_02992

2312343 Set

External pneumatic horn

B_03128

2309015 Archiving software TwinControl V3

74

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

TwinControl .

75

PART NO. DOC393831

TwinControl .

EDITION 04/2010

OPERATING MANUAL

11

SPARE PARTS

11.1 HOW TO ORDER SPARE PARTS?

!LWAYSSUPPLYTHEFOLLOWINGINFORMATIONTOENSUREDELIVERYOFTHERIGHTSPAREPART

0ART.UMBERDESCRIPTIONANDQUANTITY

4HEQUANTITYNEEDNOTBETHESAMEASTHENUMBERGIVENINTHEu1UANTITYhCOLUMN4HIS

NUMBERMERELYINDICATESHOWMANYOFTHERESPECTIVEPARTSAREUSEDINEACHSUBASSEMBLY

4HEFOLLOWINGINFORMATIONISALSOREQUIREDTOENSURESMOOTHPROCESSINGOFYOURORDER

!DDRESSFORTHEINVOICE

!DDRESSFORDELIVERY

.AMEOFTHEPERSONTOBECONTACTEDINTHEEVENTOFANYQUERIES

4YPEOFDELIVERYREQUIREDAIRFREIGHTORMAILSEAROUTEOROVERLANDROUTEETC

-ARKSINSPAREPARTSLISTS

.OTETOCOLUMNu+hINTHEFOLLOWINGSPAREPARTSLISTS

U 7EARINGPARTS

.OTE.OLIABILITYISASSUMEDFORWEARINGPARTS

L .OTPARTOFSTANDARDEQUIPMENTAVAILABLEHOWEVERASADDITIONALEXTRA

WARNING

Incorrect maintenance/repair!

Risk of injury and damage to the equipment

œ Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center.

œ Before all work on the unit and in the event of work interruptions:

- Switch off the energy/compressed air supply.

- Relieve the pressure from the spray gun and unit.

- Secure the spray gun against actuation.

œ Observe the operating and service instructions when carrying out all work.

SIHI_0004_GB

76

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

11.2 WHERE DO YOU FIND SPARE PARTS?

Spare parts to the TwinControl basic equipments, to whose components and to the

TwinControl accessories are in a separate spare parts catalogue to fi nd. Spare parts catalogues are available in the languages German and English.

Part No.

Description

393880 Spare parts catalogue TwinControl German

393881 Spare parts catalogue TwinControl English

2307255 Compact disk (CD) TwinControl

Further spare parts to TwinControl components, which are not represented in the spare parts catalogue, fi nd you on the Compact disk (CD) in the appropriate manuals.

77

TwinControl .

EDITION 04/2010

OPERATING MANUAL

PART NO. DOC393831

Germany

J. WAGNER GmbH

Otto-Lilienthal-Str. 18

Postfach 1120

D- 88677 Markdorf

Telephone: +49 7544 5050

Telefax: +49 7544 505200

E-Mail: [email protected]

Belgium

WAGNER Spraytech Benelux BV

Veilinglaan 58

B- 1861 Wolvertem

Telephone: +32 (0)2 269 4675

Telefax: +32 (0)2 269 7845

E-Mail: [email protected]

United Kingdom

WAGNER Spraytech (UK) Ltd.

Haslemere Way

Tramway Industrial Estate

GB- Banbury, OXON OX16 8TY

Telephone: +44 (0)1295 265 353

Telefax: +44 (0)1295 269861

E-Mail: [email protected]

Netherlands

WAGNER SPRAYTECH Benelux BV

Zonnebaan 10

NL- 3542 EC Utrecht

Telephone: +31 (0) 30 241 4155

Telefax: +31 (0) 30 241 1787

E-Mail: [email protected]

Japan

WAGNER Spraytech Ltd.

2-35, Shinden Nishimachi

J- Daito Shi, Osaka, 574-0057

Telephone: +81 (0) 720 874 3561

Telefax: +81/ (0) 720 874 3426

E-Mail: [email protected]

Sweden

WAGNER Industrial Solutions Scandinavia

Skolgatan 61

SE- 568 31 Skillingaryd

Telephone: +46 (0) 370 798 30

Telefax: +46 (0) 370 798 48

E-Mail: [email protected]

Czechoslovakia

WAGNER s.r.o.

Nedasovská Str. 345

15521 Praha 5 - Zlicin

Telephone: +42 (0) 2 579 50 412

Telefax: +42 (0)2 579 51 052

E-Mail: [email protected]

Switzerland

J. WAGNER AG

Industriestrasse 22

Postfach 663

CH- 9450 Altstätten

Telephone: +41 (0)71 757 2211

Telefax: +41 (0)71 757 2222

E-Mail: [email protected]

Denmark

WAGNER Industrial Solution Scandinavia

Viborgvej 100, Skærgær

DK- 8600 Silkeborg

Telephone: +45 70 200 245

Telefax: +45 86 856 027

E-Mail [email protected]

France

J. WAGNER France S.A.R.L.

Parc de Gutenberg - Bâtiment F8

8, Voie la Cardon

F- 91127 Palaiseau-Cedex

Telephone: +33 1 825 011 111

Telefax: +33 1691 946 55

E-Mail: [email protected]

Italy

WAGNER COLORA S.r.l

Via Fermi, 3

I- 20040 Burago di Molgora (MI)

Telephone: +39 039 625021

Telefax: +39 039 6851800

E-Mail: [email protected]

Austria

J. WAGNER GmbH

Otto-Lilienthal-Str. 18

Postfach 1120

D- 88677 Markdorf

Telephone: +49 (0) 7544 5050

Telefax: +49 (0) 7544 505200

E-Mail: [email protected]

Spain

WAGNER Spraytech Iberica S.A.

Ctra. N- 340, Km. 1245,4

E- 08750 Molins de Rei (Barcelona)

Telephone: +34 (0) 93 680 0028

Telefax: +34 (0) 93 668 0156

E-Mail: [email protected]

USA

WAGNER Systems Inc.

300 Airport Road, unit 1

Elgin, IL 60123 USA

Telephone: +1 630 503 2400

Telefax: +1 630 503 2377

E-Mail: [email protected]

78

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