WAGNER TwinControl - User Manual

0102
TwinControl
Electronically Controlled 2K Systems
for Lacquers
Valid for systems with software version V 4.xx
Version 10/2018

WAGNER TwinControl Specifications

General

Brand	WAGNER
Model	TwinControl
Category	Mixer
Language	English

Summary

IDENTIFICATION

EXPLOSION-PROOF MARKING FOR DEVICES WITH TURBINES

Details ATEX identification for turbine units used in explosive areas.

USE IN AREAS SUBJECT TO EXPLOSION HAZARDS

BASIC SAFETY INSTRUCTIONS

SAFETY INSTRUCTIONS FOR THE OPERATOR

General safety instructions for the operator regarding the manual and local regulations.

ELECTRICAL DEVICES AND EQUIPMENT

Warns about electric shock hazards and necessary precautions.

A SAFE WORK ENVIRONMENT

Details hazards from fluids/vapors and requirements for a safe work environment.

PERSONNEL QUALIFICATIONS

SAFETY INSTRUCTIONS FOR THE PERSONNEL

PERSONAL SAFETY EQUIPMENT

SAFE HANDLING OF WAGNER SPRAY DEVICES

GROUNDING THE UNIT

CLEANING AND FLUSHING

MAINTENANCE AND REPAIR

PROTECTIVE AND MONITORING EQUIPMENT

CONTROL UNITS WITH TURBINES

IDENTIFICATION X

CONTROL UNITS WITH MAINS POWER SUPPLY (CABLE)

PUMPS

PRINCIPLE DIAGRAM

CONTROLLER 1; 9; 10 FOR PUMPS 5-60 TO 35-150

Shows the pneumatic principle diagram for controllers 1, 9, and 10.

CONTROLLERS 2; 3; 6; 8 FOR PUMPS 48-110 TO 8-600

OPERATING ELEMENTS AND CONTROL UNIT CONNECTIONS

PNEUMATIC DIAGRAM

TWINCONTROL 1

Provides the pneumatic diagram for TwinControl 1.

TWINCONTROL 2; TWINCONTROL 3

TWINCONTROL 6; TWINCONTROL 8

TWINCONTROL 9; TWINCONTROL 10

LIST OF SERVICE FUNCTIONS

LIST OF SERVICE FUNCTIONS (continued)

MAINTENANCE WORK ON THE PUMPS

ASSEMBLY AND COMMISSIONING

TRAINING OF ASSEMBLY;COMMISSIONING PERSONNEL

Specifies the required technical skills and safety awareness for personnel.

ASSEMBLY AND INSTALLATION

PNEUMATIC CONNECTIONS

GROUNDING

GROUNDING OF COMPONENTS ON FRAME OR TROLLEY

EXAMPLE OF GROUNDING SCHEME FOR TWINCONTROL WITH TURBINE

EXAMPLE OF GROUNDING SCHEME FOR TWINCONTROL WITH MAINS POWER CONNECTION (CABLE)

COMMISSIONING

PREPARATION BEFORE COMMISSIONING

Steps to prepare the system before commissioning, including grounding and connections.

BASIC FLUSHING AND PRESSURE TIGHTNESS TEST

BASIC FLUSHING AND PRESSURE TIGHTNESS TEST (continued)

REPLACING FLUSHING AGENT WITH WORKING MEDIA

REPLACING FLUSHING AGENT WITH WORKING MEDIA (continued)

CALIBRATING THE SYSTEM

METHOD OF CALIBRATION (SIMPLE PRACTICAL VARIANT)

OPERATING THE CONTROL UNIT

PASSWORD PROTECTION AND USER FUNCTIONS

BASIC FUNCTIONS FOR THE PAINTER

EXTENDED FUNCTIONS WITH PASSWORD PROTECTION

CALIBRATION

FLUSHING PROGRAMS

AIS

CHECK FOR LEAKS IN A AND B FLUID SECTION

BATCH MODE FILLING MODE

OPERATION

GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN

Safety rules for spray gun adjustments, warning about high-pressure spray.

MALFUNCTION

EMERGENCY DEACTIVATION

SWITCHING THE SYSTEM ON

SWITCHING THE SYSTEM ON (continued)

SWITCHING OFF THE SYSTEM

SPRAYING MODE

FLUSHING

PRESSURE RELIEF; WORK INTERRUPTION

PRESSURE RELIEF; WORK INTERRUPTION (continued)

AUTOMATIC ELECTROSTATIC SYSTEM SET FOR ELECTROSTATIC GUN GM5000 (OPTION)

PAINT FILLING

Safety precautions and procedure for paint filling with the electrostatic system.

SPRAYING MODE

REMOTE CONTROL AND ESTA REMOTE CONTROL (OPTION)

EXPLOSION PROTECTION

Conditions for using remote controls in potentially explosive areas.

TWINCONTROL REMOTE CONTROL

Installation and operation of the TwinControl remote control.

ESTA REMOTE CONTROL

CLEANING AND MAINTENANCE

CLEANING

General information about cleaning procedures and personnel.

SAFETY INSTRUCTIONS

Safety instructions to be followed before cleaning work.

CLEANING THE SYSTEM

MAINTENANCE

MAINTENANCE INSTRUCTIONS

General maintenance instructions and warnings about incorrect maintenance.

SAFETY CHECKS AND MAINTENANCE INTERVALS

EMPTYING SYSTEM

FILLING EMPTY SYSTEM

CLEANING OR REPLACING THE PRODUCT FILTER

ANGLED INLINE FILTER (530 BAR)

STRAIGHT INLINE FILTER (270 BAR)

HIGH-PRESSURE FILTER, 530 BAR

TROUBLESHOOTING

Fault display

Malfunction Remedy

System does not start up

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

System does not supply any product, pumps do not run

The 2 K product does not react correctly

Flow rate is too low

The system supplies product, but the spray pattern is inadequate

Flow rate is too high

ALARM MESSAGES AND FAULT RECTIFICATION

ALARM MESSAGES AND FAULT RECTIFICATION (continued)

REPAIRS

REPAIR PERSONNEL

REPAIR NOTES

General notes and warnings for maintenance and repair work.

SPARE PARTS