WAGNER TwinControl 18-40 ABS Translation Of The Original Operating Manual Download Page 40

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TwinControl

B_02804

B_02805

OPERATING MANUAL

EDITION 04/2010

PART NO. DOC393831

Pos from

Cable

A-Pump to frame

4 mm

; AWG11

B-Pump to frame

4 mm

; AWG11

Flushing pump to frame

4 mm

; AWG11

Control unit to frame

4 mm

; AWG11

Frame to the functional earth

4 mm

; AWG11

To the equipotential bond-
ing (operational earth)

5.7.1

EARTHING OF COMPONENTS ON FRAME OR CARRIAGE

Earth connections

View of rear side of system

Earth connection point on frame
View of operating side of system

Summary of Contents for TwinControl 18-40 ABS

Page 1: ...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 B_02795 II 2G Ex ia II B T4 X 0102 Translation of the original Opera...

Page 2: ......

Page 3: ...UCT LIABILITY AND WARRANTY 11 3 1 Important notes on product liability 11 3 2 Warranty 11 3 3 CE conformity 12 3 3 1 Devices with turbine 12 3 3 2 Devices with cable for mains connection 13 4 DESCRIPT...

Page 4: ...nd pressure tightness test 46 6 5 Pressure Relief Procedure 48 6 6 Filling the unit and calibration 50 6 6 1 Filling the unit 50 6 6 2 Calibration the unit 50 6 7 Flush system 51 6 8 General 52 6 9 Pa...

Page 5: ...NGLISH RENCH UTCH TALIAN 3PANISH ANISH 3WEDISH 370850 370851 370852 370853 370854 370855 370857 370856 This operating manual is available in the following languages Language Part No Language Part No L...

Page 6: ...NG This line warns of the hazard Possible consequences of failing to observe the warning instruc tions The signal word points out the hazard level The measures for preventing the hazard and its conseq...

Page 7: ...is a danger from line voltage Repairs and maintenance may only be carried out by skilled personnel Keep liquids away from the electrical components NSURE THAT THE mOOR OF THE WORKING AREA IS ANTI STA...

Page 8: ...Wagner service technician With shut down devices the examination can be by the next start Follow the Pressure Relief Procedure whenever you Are instructed to relieve pressure If the spraying work to...

Page 9: ...PERATURE 4O CLEAN USE ONLY SOLVENT FREE CLOTHS AND BRUSHES EVER USE HARD OBJECTS OR SPRAY ON CLEANING AGENTS A GUN N THE CASE OF START UP OR EMPTYING OF THE EQUIPMENT CAN BE PRESENT n EPENDING UPON U...

Page 10: ...E ARISING FROM INCORRECT USE 5SE THE UNIT ONLY TO WORK WITH THE MATERIALS RECOMMENDED BY 7 2 PERATE THE UNIT ONLY AS AN ENTIRE UNIT O NOT DEACTIVATE SAFETY EQUIPMENT 5SE ONLY 7 2 ORIGINAL SPARE PARTS...

Page 11: ...THE UNIT TO A LOCATION OTHER THAN THE ADDRESS OF THE PURCHASER 4HIS WARRANTY DOES NOT COVER DAMAGE CAUSED BY 5NSUITABLE OR IMPROPER USE FAULTY INSTALLATION OR COMMISSIONING BY THE PURCHASER OR A THIR...

Page 12: ...2004 108 EG 2002 95 EG 2002 96 EG Applied standards in particular DIN EN 1127 2008 02 DIN EN ISO 13732 1 2008 12 DIN EN 60079 14 2009 05 DIN EN ISO 12100 1 2004 04 DIN EN ISO 14121 2007 12 DIN EN 6100...

Page 13: ...ied version of TwinControl 5 60 18 40 28 40 35 70 48 110 35 150 70 75 150 72 300 150 72 300 ABS Cable with mains supply Complies with the following guidelines 2006 42 EG 2002 96 EG 2002 95 EG 2004 108...

Page 14: ...spraying system Spray gun blockage materials harden in the spraying system Flush the spray gun and paint supply with a suitable cleaning agent SIHI_0001_GB Low viscosity to high viscosity two compone...

Page 15: ...40 ABS Turbine Stand EM TC 1 Turbine 393179 28 40 AB Cable Stand no TC 1 Cable 393134 35 70 ABS Turbine Stand Leopard 35 70 Leopard 35 70 Puma 28 40 TC 1 Turbine 393132 35 70 ABS Turbine Wall 393135 3...

Page 16: ...V 393155 72 300 150 ABS Cable Stand Leopard 35 70 TC 2 Cable 393173 72 300 150 ABS Cable Stand EM 393157 72 300 150 ABS Cable Trolley 393158 72 300 ABS Turbine Stand Tiger 72 300 TC 2 Turbine 393160...

Page 17: ...1 4 NPSM 3 8 Air inlet connection Zoll Inch G 1 2 G 1 Material flow quantity of the mixing ratio 1 1 l min 3 6 2 4 4 2 6 6 9 0 13 5 18 0 Material flow quantity of the mixing ratio 4 1 l min 2 3 1 5 2...

Page 18: ...g B Explosion group B town gas ethylene T4 Temperature class T4 135 C 275 F X Note special instructions for safety operation ZELM 08 ATEX 0385 X Mark of notified body year of issue issue of certificat...

Page 19: ...using 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 maintenan...

Page 20: ...ck 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...

Page 21: ...able Base frame 112 247 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...

Page 22: ...3 5 DIMENSIONS TwinControl ABS turbine or cable mounted on the wall Type 5 60 18 40 28 40 35 70 mm inch A 917 36 B 1061 42 C 509 20 D 892 35 E 238 10 F 9 0 35 TwinControl ABS turbine or cable mounted...

Page 23: ...nControl B_02800 A B C OPERATING MANUAL EDITION 04 2010 PART NO DOC393831 TwinControl ABS turbine or cable mounted on the base frame Type 75 150 72 300 72 300 150 mm inch A 1015 40 0 B 1655 65 2 C 735...

Page 24: ...O DOC393831 TwinControl ABS turbine or cable mounted on the trolley Type 48 110 35 150 70 mm inch A 820 32 28 B 1769 69 65 C 1227 48 31 TwinControl ABS turbine or cable mounted on the trolley Type 75...

Page 25: ...her 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...

Page 26: ...ntrol Control unit 1 Cable 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...

Page 27: ...2 Turbine TwinControl Control unit 2 Cable 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 w...

Page 28: ...ons 112 Luminous display Calibrate 113 Luminous display Totals 114 Luminous display Works 115 Push button main menu selection 116 Push button sub menu selection 117 Luminous display A component 118 Lu...

Page 29: ...Serial No controller Serie Nr Steuerung Voltage Spannung Line Power Eingangsleistung Prot Class Schutzklasse 85 260 VAC 47 60 Hz max 40 W IP 54 Ambient temperature Temperatur Umgebung 5 40 C CH 9450...

Page 30: ...ce adjustable P5 Actual value mixing tolerance Display P6 DS min Protection of dry running pump A adjustable P7 DS min Protection of dry running pump B adjustable P8 DS min Maxi number of double strok...

Page 31: ..._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 adjustable P36 0 or 1 Feed function with pulses of A 0 off 1 on adjustable P37...

Page 32: ...mber of B valve 100000 cycles resetable Display P59 Cycles Number of B valve cycles not resetable Display P60 Cycles Number of B valve 100000 cycles not resetable Display P61 0 99999 Number of A valve...

Page 33: ...Change over signal Pump A Change over signal flushing pump Change over signal Pump B External release Flush Air Option Gun flush box Hardener valve B Flush Material valve A No Description 0 Air supply...

Page 34: ...GRAM TWINCONTROL 2 Change over signal Pump A Change over signal flushing pump Change over signal Pump B External release ES 1 Numbers Electrical schematic Option Air motor B Flush BS Option Gun flush...

Page 35: ...r by placing feet to be replaced and secured When shifting transport do not tilt the unit SIHI_0052_GB The complete system can be safely transported in a wooden crate The dimensions of the transportat...

Page 36: ...TORAGE 7HEN STORING THE UNIT PLACE IT IN A CLOSED AND DRY ENVIRONMENT UNTIL UNTIL F THE EQUIPMENT IS NOT GOING TO BE USED FOR A LONG TIME LUBRICATE IT BY SUCKING EMULSIlED OIL OR PLAIN OIL FROM THE FE...

Page 37: ...e department or by an expert representative When removing from the packaging check the system parts for pos sible transport damage WARNING Toxic and or flammable vapor mixtures Risk of poisoning and b...

Page 38: ...he filter pressure regulator becomes brittle through contact with solvents and can burst Flying parts can cause injury Do not clean the container on the pressure regulator with sol vent SIHI_0014_GB H...

Page 39: ...tem is not sufficient A qualified electrician must complete all grounding and wiring connections and check the resistance Must be operated in accordance with the safety regulations fire and electrotec...

Page 40: ...to frame 4 mm2 AWG11 3 Flushing pump to frame 4 mm2 AWG11 4 Control unit to frame 4 mm2 AWG11 5 Frame to the functional earth 4 mm2 AWG11 To the equipotential bond ing operational earth 5 7 1 EARTHING...

Page 41: ...Floor conductive 8 Water container Cable cross sections TwinControl Frame 4 mm2 AWG11 Water container 6 mm2 AWG10 Conveyor 16 mm2 AWG5 Cable cross sections Spray booth 16 mm2 AWG5 Spraying stand 16 m...

Page 42: ...ppr 10 than that the component A The supplying pressure should be constant SIHI_0056_GB WARNING High pressure spray jet Danger to life from injecting paint or solvent Never reach into the spray jet Ne...

Page 43: ...onnect 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 conveyi...

Page 44: ...44 TwinControl A B S A S B S B_02832 2 3 1 OPERATING MANUAL EDITION 04 2010 PART NO DOC393831 Example of TwinControl system ready for spraying Return 6 3 SWITCHING THE UNIT ON AND OFF...

Page 45: ...on main switch Remark Valid only for TwinControl with cable Emergency Stop In the case of unforeseen occurrences 1 Switch off air supply 1 2 Hold electrically conductive part of the gun against the m...

Page 46: ...he system Please note Do not insert the nozzle into the gun yet Gun secured Keep the pump pressure as low as possible during flushing Operating instructions for the individual components must be known...

Page 47: ...rial 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 i...

Page 48: ...ver seal defective high pressure parts instead relieve the pressure from them and replace Wear the appropriate protective clothing gloves eyewear and respirator SIHI_0059_GB The pressure must always b...

Page 49: ...3831 4 Release the gun 5 Hold electrically conductive part of the gun against the metal container and trigger until no further pressure is present 6 Secure gun 7 Provide collection container and open...

Page 50: ...ated with the material However if a calibration is required proceed as follows 1 The material to be calibrated is first of all conveyed manually as far as the gun 2 Set the pump pressure to 0 5 MPa 5...

Page 51: ...flying parts and burns Never spray into a closed container Earth the container SIHI_0008_GB 6 7 FLUSH SYSTEM Flushing must always be carried out before prolonged work interruptions at the end of work...

Page 52: ...re from them and replace Wear the appropriate protective clothing gloves eyewear and respirator SIHI_0059_GB 6 8 GENERAL The flushing agent pressure for A and B and the material pressure for the A and...

Page 53: ...sh option circulate 6 9 PASSWORD PROTECTION AND USER FUNCTIONS Press and simultaneously SET Password Level 1 SET Press and simultaneously SET Password Level 2 SET Press and simultaneously SET Password...

Page 54: ...on frequency Display see chapter 4 4 5 P35 Automatic stop in case of error Alarm LED on Stop LED on Error code is displayed Flushing The flushing program runs automatically B valve to mixing block A v...

Page 55: ...cm3 Manual mode Totals Only convey B component START STOP Displays job total B in cm3 Only convey flushing circuit A START STOP Displays job total flushing agent A in cm3 Valid only for models 48 110...

Page 56: ...UAL EDITION 04 2010 PART NO DOC393831 Total amount A To Re Set 0 Press SET push button 2 seconds Display in liter Total amount B To Re Set 0 Press SET push button 2 seconds Display in liter Total amou...

Page 57: ...tart open gun discharge approx 5 dou ble strokes at spray pressure close gun Set input measured value in measuring cup in cm3 Set Abort with Stop button Calibration B Start open gun discharge approx 5...

Page 58: ...A A B_02744 B A SET TwinControl B B A A B_02744 OPERATING MANUAL EDITION 04 2010 PART NO DOC393831 Content of spray hose with mixed material cm3 Quantity material valve A up to mixing block cm3 Quant...

Page 59: ...o 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 Fault messages Display of last 28 error messages View with Circulation of A and B co...

Page 60: ...y gun and unit Secure the spray gun against actuation Observe the operating and service instructions when carrying out all work 7 2 CLEANING THE FILTERS In accordance with the guideline for liquid spr...

Page 61: ...gas atmo sphere may be present SIHI_05051_ENG WARNING Maintenance and service tasks Risk of explosion Maintenance and service tasks inside the housing may only be performed by trained Wagner staff and...

Page 62: ...the high pressure hose Manufacturer Permissible operating pressure Date of manufacture 7 4 HIGH PRESSURE HOSE 7HEN THE EQUIPMENT MUST BE SCRAPED PLEASE MAKE A DIFFERENT DISPOSAL OF THE MATERIALS 4HE...

Page 63: ...The voltage is switched off before work is begun on active com ponents SIHI_0045_GB If a fault occurs it is indicated the horn sounds and the system stops An error code appears on the display the faul...

Page 64: ...wer idle position 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 bac...

Page 65: ...e B pump in the downward stroke exceeds the error limit Carry out inspection of the B colour stage 70 Number of strokes from A pump too high A material pump is too fast Stroke rate throttle 71 Number...

Page 66: ...use Description of faults Troubleshooting 94 Flow rate is too high The current flow is above the set value Check nozzle and pump pressure 95 Flow rate is too low The current flow is below the set valu...

Page 67: ...67 TwinControl OPERATING MANUAL EDITION 04 2010 PART NO DOC393831...

Page 68: ...METER MEASURE VOLUMETRIC WE NEED THE SPECIlCATION IN VOLUME ONVERSION OF MIXING PROPORTION OF GRAVIMETRICALLY IN VOLUMETRIC OR EXAMPLE PARTS BY WEIGHT OMP AND PARTS BY WEIGHT OMP OR G OMP G OMP OR PA...

Page 69: ...69 TwinControl I 6OL I 6OL MM M MM M OPERATING MANUAL EDITION 04 2010 PART NO DOC393831 9 TABLES PARAMETERS 9 1 TABLE HOSE VOLUME Di Inside diameter hose L Hose length Vol Material volume in the hose...

Page 70: ...NG MANUAL EDITION 04 2010 PART NO DOC393831 10ACCESSORIES Part No Description 2306526 Mixer external pneumatic NW 2 6 NW6 KS 2307749 Mixer external pneumatic NW 2 6 NW10 GXP 2307030 Mixer external man...

Page 71: ...Vor Gebrauch Betriebsanleitung beachten B A B_02981 Serial No controller Serie Nr Steuerung Voltage Spannung Line Power Eingangsleistung Prot Class Schutzklasse 85 260 VAC 47 60 Hz max 40 W IP 54 Ambi...

Page 72: ...8 OPERATING MANUAL EDITION 04 2010 PART NO DOC393831 Part No Description 2307080 Circulation soft Tiger 2308874 Remote control TwinControl 2303255 Heater set A or B for TwinControl to 35 150 2302813 H...

Page 73: ...G MANUAL EDITION 04 2010 PART NO DOC393831 Part No Description 2302461 Heater set B for TwinControl 48 110 to 75 150 2303256 Heater set A for TwinControl 72 300 2303257 Heater set B for TwinControl 72...

Page 74: ...FB 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 e...

Page 75: ...75 TwinControl OPERATING MANUAL EDITION 04 2010 PART NO DOC393831...

Page 76: ...LOWING INFORMATION TO ENSURE DELIVERY OF THE RIGHT SPARE PART 0ART UMBER DESCRIPTION AND QUANTITY 4HE QUANTITY NEED NOT BE THE SAME AS THE NUMBER GIVEN IN THE u1UANTITYh COLUMN 4HIS NUMBER MERELY INDI...

Page 77: ...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 find Spare parts ca...

Page 78: ...rielles wagner france fr 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 info wsb wagner nl Italy WAGNER COLORA S r l...

Page 79: ......

Page 80: ...RMANY 7 2 MB TTO ILIENTHAL 3TR 0OSTFACH ARKDORF 4ELEPHONE 4ELEFAX AIL SERVICE STANDARD WAGNER GROUP COM 3WITZERLAND 7 2 NDUSTRIESTRASSE 0OSTFACH LTST TTEN 4ELEPHONE 4ELEFAX AIL REP CH WAGNER GROUP CH...

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WAGNER TwinControl 18-40 ABS, Translation Of The Original Operating Manual

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Summary of Contents for TwinControl 18-40 ABS

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