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2K COMFORT
WAGNER 2K COMFORT User Manual
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T
ransla
tion of the Original
Operating Manual
2K C
OMFORT
Electronically Contr
olled
Multi-
component S
ystem f
or
Lacquers
Soft
ware v
ersion
4.0x / 4.0x K
3.2x / 3.2x K
3.1x / 3.1x K
3.0x
F
or professional use
.
Always f
ollow the information in this manual
,
particular
ly the safety instructions and the warning
instructions. Store the manual in a saf
e place.
V
ersion 05/2017
B_05491
2
Table of Contents
Default Chapter
3
Table of Contents
3
1 About These Instructions
7
Preface
7
Warnings, Notices and Symbols in These Instructions
7
Languages
8
Operating Documents for Individual Components
8
USB Stick 2K COMFORT
9
Abbreviations
9
Terminology for the Purpose of this Manual
10
Low Pressure / High Pressure / XL
10
2 Correct Use
11
Device Types
11
Type of Use
11
Field of Application
11
Without Ex Identification
11
With Ex Identification
11
Accessories
12
Processible Working Materials
12
Misuse
12
3 Identification
13
Non-Ex System
13
Ex System
13
Control Cabinet
13
Fluid Section
13
Use in Areas Subject to Explosion Hazards
14
Identification X
14
Remote Control (Option)
15
Type Plates
16
Control Cabinet
16
Fluid Section
16
4 Basic Safety Instructions
17
Safety Instructions for the Operator
17
Electrical Devices and Equipment
17
A Safe Work Environment
17
Personnel Qualifications
18
Safety Instructions for Staff
18
Use Personal Safety Equipment
19
Safe Handling of WAGNER Spray Devices
19
Ground the Unit
20
Product Hoses
20
Cleaning and Flushing
21
Touching Hot Surfaces
22
Maintenance and Repair
22
Protective and Monitoring Equipment
22
5 Description
23
Components
23
Mode of Operation
23
Protective and Monitoring Equipment
24
Included Items
24
Data
25
Technical Data
25
Limitations for 2-Circuit Systems
28
Dimensions
29
Working Areas of Flow Meters
30
Application Limits of Flow Meters
32
Version 05/2017 Order Number Doc
33
Mixing Types
34
Dump Valve for Waste Separation (Option)
37
AIS Dosing System (Option)
37
2-Circuit System
37
Flow Measurement
38
Flow Meters
38
Stroke Measuring
39
Flow Meters and Stroke Sensors
40
6 Assembly and Commissioning
41
Training of Assembly/Commissioning Staff
41
Storage and Installation Conditions
41
Transportation
41
Assembly and Installation
41
Electrical Connections
43
Pneumatic Connections
43
Product Connections
43
Flow Meter Monitoring
44
Lack-Of-Product Protection
44
Ventilation of the Spray Booth
45
Grounding
45
Commissioning
48
Pre-Cleaning
48
Initializing the Controller
49
Venting the System
50
Pressure Tightness Test
50
Filling the System
51
Electrostatics
51
7 Controller
52
Training the Operating Staff
52
Safety Instructions
52
Control Cabinet
53
Main Switch
53
Mechanical Push-Buttons
54
Operating Panel Basics
54
Select Language
55
Keyboard Input
55
Passwords
56
Home Page
56
Changing the Paint Recipe
56
Home Page Operation
57
Menu
58
Manual Mode: Open Valves
59
Recipes
60
Add New Recipes
60
Changing Recipe and Valve Names
60
Enter Flushing Recipe
61
Enter Paint Recipe
62
Calibration
64
Settings
66
Password Level 2 Settings
66
Password Level 3 Settings
69
Operating Panel for 2-Circuit System
73
Change Fluid Circuit
73
K1 and /K2
74
Acknowledge Alarms
74
White Background: Affects both Fluid Circuits
74
8 Operation
75
Training the Operating Staff
75
Safety Instructions
75
Emergency Deactivation
75
General Rules for Making Adjustments to the Spray Gun
75
Switches the System on and off
76
Malfunction
76
Spraying Mode
77
Prerequisites
77
A/B/C/D Pressure Ratio
77
Spraying Without Gun Flush Box
78
Spraying with Gun Flush Box
79
Interrupting Work
79
Changing the Paint Recipe
79
A Valve Selection at Start
79
Circulation (Option)
79
Flushing
80
Flow Chart with Paint Recipe Change
83
Pressure Relief Procedure
84
9 Cleaning and Maintenance
85
Cleaning
85
Cleaning Staff
85
Safety Instructions
85
Filter Cleaning
85
Condensate Drainage from the Filter Pressure Regulator
85
Cleaning the System
86
Decommissioning
86
Long-Term Storage
86
Maintenance
87
Maintenance Staff
87
Safety Instructions
87
Gear Flow Meter
88
Cleaning and Replacing the Product Filter
89
Product Valves
89
Product Hoses, Tubes and Couplings
90
10 Troubleshooting
91
Alarm Messages
93
Fault Rectification
98
Warning Messages
105
Fault Rectification
106
11 Repairs
107
Repair Staff
107
Safety Instructions
107
Mounting Materials
108
12 Disposal
109
13 Accessories
110
Connections
110
I/O Extension Module
110
Connection Table 2K COMFORT
111
Control Cabinet Diagrams
112
Expansion and Accessory Sets
112
Installation by Customer or by WAGNER Service Department
113
Stroke Measuring
115
Installation by WAGNER Service Department
115
Ais
116
Accessories Sets for External Flushing Agent
117
Remote Control (Option)
117
Remote Control Assembling
118
Assembly on Control Cabinet
118
Testing and Commissioning
118
Safety Instruction Remote Control
119
Operation
120
14 Spare Parts
121
15 Declaration of Warranty and Conformity
122
Important Notes on Product Liability
122
Warranty Claim
122
EU Declaration of Conformity for 2K COMFORT
123
EU Declaration of Conformity for 2K COMFORT (with Ex Identification)
124
EC Declaration of Conformity for Remote Control
125
16 Appendix
126
Conversion of the Mixing Ratio Specifications
126
4
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WAGNER 2K COMFORT Specifications
General
Brand
WAGNER
Model
2K COMFORT
Category
Control Systems
Language
English
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