WAGNER 2K COMFORT Installation instructions

Translation of the Original
Operating Manual
2K COMFORT
Electronically Controlled
Multi-component System for
Lacquers
Software version 4.0x / 4.0x K
3.2x / 3.2x K
3.1x / 3.1x K
3.0x
For professional use.
Always follow the information in this manual,
particularly the safety instructions and the warning
instructions. Store the manual in a safe place.
Version 05/2017
B_05491

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VERSION 05/2017 ORDER NUMBER DOC 2357061
Table of Contents
1 ABOUT THESE INSTRUCTIONS 7
1.1 Preface 7
1.2 Warnings, Notices and Symbols in these Instructions 7
1.3 Languages 8
1.3.1 Operating documents for individual components 8
1.4 USB Stick 2K COMFORT 9
1.5 Abbreviations 9
1.6 Terminology for the Purpose of this Manual 10
1.6.1 Low pressure / High pressure / XL 10
2 CORRECT USE 11
2.1 Device types 11
2.2 Type of Use 11
2.3 Field of application 11
2.3.1 Without Ex identication 11
2.3.2 With Ex identication 11
2.3.3 Accessories 12
2.4 Processible Working Materials 12
2.5 Misuse 12
3 IDENTIFICATION 13
3.1 Non-Ex System 13
3.2 Ex System 13
3.2.1 Control cabinet 13
3.2.2 Fluid section 13
3.2.2.1 Identication X 14
3.2.3 Use in areas subject to explosion hazards 14
3.3 Remote control (option) 15
3.4 Type plates 16
3.4.1 Control cabinet 16
3.4.2 Fluid section 16
4 BASIC SAFETY INSTRUCTIONS 17
4.1 Safety instructions for the operator 17
4.1.1 Electrical devices and equipment 17
4.1.2 A safe work environment 17
4.1.3 Personnel qualications 18
4.2 Safety instructions for sta 18
4.2.1 Use personal safety equipment 19
4.2.2 Safe handling of WAGNER spray devices 19
4.2.3 Ground the unit 20
4.2.4 Product hoses 20
4.2.5 Cleaning and Flushing 21
4.2.6 Touching hot surfaces 22
4.2.7 Maintenance and repair 22
4.2.8 Protective and monitoring equipment 22

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5 DESCRIPTION 23
5.1 Components 23
5.2 Mode of operation 23
5.3 Protective and monitoring equipment 24
5.4 Included items 24
5.5 Data 25
5.5.1 Technical data 25
5.5.1.1 Limitations for 2-circuit systems 28
5.5.2 Dimensions 29
5.5.3 Working areas of ow meters 30
5.5.4 Application limits of ow meters 32
5.6 Mixing types 34
5.7 Dump valve for waste separation (option) 37
5.8 AIS dosing system (option) 37
5.9 2-circuit system 37
5.10 Flow measurement 38
5.10.1 Flow meters 38
5.10.2 Stroke measuring 39
5.10.3 Flow meters and stroke sensors 40
6 ASSEMBLY AND COMMISSIONING 41
6.1 Training of Assembly/Commissioning Sta 41
6.2 Storage and installation conditions 41
6.3 Transportation 41
6.4 Assembly and Installation 41
6.4.1 Electrical connections 43
6.4.2 Pneumatic connections 43
6.4.3 Product connections 43
6.4.4 Flow meter monitoring 44
6.4.5 Lack-of-product protection 44
6.4.6 Ventilation of the spray booth 45
6.5 Grounding 45
6.6 Commissioning 48
6.6.1 Pre-cleaning 48
6.6.2 Initializing the controller 49
6.6.3 Venting the system 50
6.6.4 Pressure tightness test 50
6.6.5 Filling the system 51
6.6.6 Electrostatics 51
7 CONTROLLER 52
7.1 Training the operating sta 52
7.2 Safety instructions 52
7.3 Control cabinet 53
7.3.1 Main switch 53
7.4 Mechanical push-buttons 54
7.5 Operating panel basics 54
7.5.1 Select language 55
7.5.2 Keyboard input 55
7.5.3 Passwords 56

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7.6 Home page 56
7.6.1 Changing the paint recipe 56
7.6.2 Home page operation 57
7.7 Menu 58
7.8 Manual mode: open valves 59
7.9 Recipes 60
7.9.1 Add new recipes 60
7.9.2 Changing recipe and valve names 60
7.10 Enter ushing recipe 61
7.11 Enter paint recipe 62
7.12 Calibration 64
7.13 Settings 66
7.13.1 Password level 2 settings 66
7.13.2 Password level 3 settings 69
7.14 Operating panel for 2-circuit system 73
7.14.1 Change uid circuit 73
7.14.2 /K1 and /K2 74
7.14.3 Acknowledge alarms 74
7.14.4 White background: aects both uid circuits 74
8 OPERATION 75
8.1 Training the operating sta 75
8.2 Safety instructions 75
8.2.1 Emergency Deactivation 75
8.2.2 General rules for making adjustments to the spray gun 75
8.3 Switches the system on and o 76
8.4 Malfunction 76
8.5 Spraying mode 77
8.5.1 Prerequisites 77
8.5.2 A/B/C/D pressure ratio 77
8.5.3 Spraying without gun ush box 78
8.5.4 Spraying with gun ush box 79
8.5.5 Interrupting work 79
8.5.6 Changing the paint recipe 79
8.5.7 A valve selection at start 79
8.5.8 Circulation (option) 79
8.6 Flushing 80
8.7 Flow chart with paint recipe change 83
8.8 Pressure relief procedure 84
9 CLEANING AND MAINTENANCE 85
9.1 Cleaning 85
9.1.1 Cleaning sta 85
9.1.2 Safety instructions 85
9.1.3 Filter cleaning 85
9.1.3.1 Condensate drainage from the lter pressure regulator 85
9.1.4 Cleaning the system 86
9.1.5 Decommissioning 86
9.1.6 Long-term storage 86

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9.2 Maintenance 87
9.2.1 Maintenance sta 87
9.2.2 Safety instructions 87
9.2.3 Gear ow meter 88
9.2.4 Cleaning and replacing the product lter 89
9.2.5 Product valves 89
9.2.6 Product Hoses, Tubes and Couplings 90
10 TROUBLESHOOTING 91
10.1 Alarm messages 93
10.1.1 Fault rectication 98
10.2 Warning messages 105
10.2.1 Fault rectication 106
11 REPAIRS 107
11.1 Repair Sta 107
11.2 Safety instructions 107
11.3 Mounting materials 108
12 DISPOSAL 109
13 ACCESSORIES 110
13.1 Connections 110
13.1.1 I/O extension module 110
13.2 Connection table 2K COMFORT 111
13.3 Control cabinet diagrams 112
13.4 Expansion and accessory sets 112
13.4.1 Installation by customer or by WAGNER service department 113
13.4.1.1 Stroke measuring 115
13.4.2 Installation by WAGNER service department 115
13.4.2.1 AIS 116
13.4.3 Accessories sets for external ushing agent 117
13.5 Remote control (option) 117
13.5.1 Remote control assembling 118
13.5.1.2 Assembly on Control Cabinet 118
13.5.1.3 Testing and Commissioning 118
13.5.2 Safety Instruction Remote Control 119
13.5.3 Operation 120
14 SPARE PARTS 121
15 DECLARATION OF WARRANTY AND CONFORMITY 122
15.1 Important notes on product liability 122
15.2 Warranty claim 122
15.3 EU Declaration of Conformity for 2K COMFORT 123
15.4 EU Declaration of Conformity for 2K COMFORT (with Ex identication) 124
15.5 EC Declaration of Conformity for remote control 125
16 APPENDIX 126
16.1 Conversion of the mixing ratio specications 126

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1 ABOUT THESE INSTRUCTIONS
1.1 PREFACE
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device.
The operating manual is part of the device and must be available to the operating and
service personnel.
The device may only be operated by trained personnel and in compliance with this
operating manual.
Operating and service personnel should be instructed according to the safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this operating manual highlight particular dangers to users and to
the device and state measures for avoiding the hazard. These warning instructions fall into
the following categories:
DANGER Immediate risk of danger.
Non-observance will result in death or serious injury.
WARNING Potential risk.
Non-observance may result in death or serious injury.
CAUTION Potentially hazardous situation.
Non-observance may result in minor injury.
NOTICE Potentially hazardous situation.
Non-observance may result in damage to property.
Note Provides information about particular characteristics and how
to proceed.
Explanation of warning:
LEVEL OF DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The measures for preventing the hazard and its consequences.

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1.3 LANGUAGES
The 2K COMFORT Operating Manual is available in the following languages:
Language Order No. Language Order No. Language Order No.
German 2357060 English 2357061 Spanish 2357065
French 2357062 Italian 2357064 Chinese 2357078
Dutch 2357063 Swedish 2357067 Japanese 2367166
Polish 2357075 -- -- -- --
2K COMFORT Software Documentation
Language Order No.
German 2357082
English 2357084
2K COMFORT Spare Parts Catalog 2K COMFORT XL Spare Parts Catalog
Language Order No. Language Order No.
German 2357085 German 2363593
English 2357086 English 2363595
Additional languages on request or at: www.wagner-group.com
1.3.1 OPERATING DOCUMENTS FOR INDIVIDUAL COMPONENTS
Paint valves (PV) and dosing valves (DV), GA (DN 2.6) operating manual
Language Order No. Language Order No. Language Order No.
German 2343270 English 2343275 Spanish 2343278
French 2343276 Italian 2343277 -- --
Paint valves (PV) and dosing valves (DV), GA (DN 4) operating manual
Language Order No. Language Order No. Language Order No.
German 2336797 English 2336798 Spanish 2336801
French 2336799 Italian 2336800 -- --
ADC-0301 / MPX-0403 operating manual (for stroke measurement)
Language Order No. Language Order No. Language Order No.
German 2382346 English 2382349 Spanish 2382352
French 2382350 Italian 2382351 -- --
User information for Coriolis Compact
Language Order No. Language Order No. Language Order No.
German 2359722 English 2359725 Spanish 2359730
French 2359727 Italian 2359728 -- --

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T0170.00BI pressure regulators operating manual
Language Order No. Language Order No. Language Order No.
German ZZB019GER English ZZB019ENG Spanish ZZB019SPA
French ZZB019FRE Italian ZZB019ITA -- --
2K Data 2K Archive
2K Data software documentation 2K Archive software documentation
Language Order No. Language Order No.
German 2382353 German 2361954
English 2382354 English 2361978
The 2KData software is contained on the
2KSMART USB stick (see Chapter 1.4).
Purpose: Transfer system settings, names, paint
and ushing recipes and the I/O conguration
via USB stick to the PC. View or change data on
the PC.
The 2KArchive software is available as an accessory.
Purpose:
Log and archive consumption data and error messages
on the PC.
Additional languages on request or at: www.wagner-group.com
1.4 USB STICK 2K COMFORT
All operating documents specied above, as well as the accessory set's assembly manuals
(with the description of the accessory's function) are also available as pdf les on a USB
stick. The USB stick is included in the system's scope of delivery.
The Order No. is: 2359808 (specify additionally the Serial No. of the system)
1.5 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part
One component
Two components
Three components
Four components
Double stroke
Nominal diameter
HP High pressure
AIS for component B
AIS for component C
AIS for component D
Spray gun 1
Spray gun 2
Spray gun 3
Spray gun 4
QFlow
cc Cubic centimeters (cm3)
Fluid circuit 1 (in 2-circuit system)
Fluid circuit 2 (in 2-circuit system)
Materials
Stainless steel
Polyethylene
Ultra-high molecular weight polyethylene
Polytetrauorethylene
Carbide

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1.6 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Sta qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as
well as the necessary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person in
accordance with TRBS
1203
(2010/Revision 2012)
A person who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge and is familiar with the relevant and generally
accepted rules of technology so that he/she can inspect and
assess the status of devices and coating systems based on
workplace safety.
1.6.1 LOW PRESSURE / HIGH PRESSURE / XL
These operating manual dierentiates for purposes of illustration between 2K COMFORT
low-pressure, high-pressure and XL version:
Maximum product pressure Maximum ow rate Fluid cabinet
Fluid section type plate, Ex Fluid section type plate,
Ex Width x height
Low-pressure version up to 2.5 MPa; 25 bar; 362 psi up to 7,000 cc/min 800 x 800 mm
High-pressure version up to 32.5 MPa; 325 bar; 4,714 psi
XL version up to 53 MPa; 530 bar; 7,687 psi up to 25,000 cc/min 800 x 1,200 mm

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2 CORRECT USE
2.1 DEVICE TYPES
a) 2K COMFORT
b) 2K COMFORT (with Ex identication)
The 2K COMFORT system is also available as a 2-circuit system (1 control cabinet, 2 uid circuits).
2.2 TYPE OF USE
The device is suitable for mixing 2K, 3K and 4K liquid products such as paints and lacquers.
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Only operate the device as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
Follow the instructions in the operating manual.
2.3 FIELD OF APPLICATION
2.3.1 WITHOUT EX IDENTIFICATION
The control cabinet and the uid section may not be used in potentially explosive areas.
Remote control: The remote control (accessory) may always be used in potentially
explosive areas (zone 1 and zone 2).
See chapter 6.5.
2.3.2 WITH EX IDENTIFICATION
Control cabinet 
The control cabinet may not be used in potentially explosive areas.
Fluid section 
The 2K COMFORT uid section (with Ex identication) is suitable for use in potentially
explosive areas (zone 1 and zone 2)
See chapter 6.5.

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2.3.3 ACCESSORIES
Remote control
The remote control may be used in potentially explosive areas (zone 1 and 2).
See chapter 6.5.
Alarm horn
The alarm horn may be used in potentially explosive areas (zone 1 and 2).
2.4 PROCESSIBLE WORKING MATERIALS
Low-viscosity to high-viscosity 2K/3K/4K lacquers (e.g., epoxy, PU, DD) with a pot life of
more than 5 minutes.
− 2K water-based primer − 2K epoxy primer
− 2K solvent-based primer − 2K epoxy lacquers
− 2K PUR primer − 2K high solid primer
− 2K PUR lacquers − 2K high solid lacquers
− 3K and 4K combinations of above products
Solvent and water-based 2K products should not be processed using the same
system.
NOTICE
Abrasive working materials and pigments!
Greater wear of parts carrying the product.
Do not use any grainy and abrasive working materials with large, sharp-edged
pigments.
Use application-oriented pumps (ow rate/cycle, product, valves, etc.).
Check if the uids and solvents used are compatible with the pump construction
materials.
For explanations of the models and construction materials, consult the technical
data in Chapters 5.5.4 as well as the operating manuals for the pumps and valves or
contact a WAGNER service technician.
Wear caused by abrasive working materials is not covered by the warranty.
Materials in direct contact with the products
Stainless steel Carbide PTFE PE (UHMWPE)
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
No dry coating products, e.g. powder are processed;
No food, medicine or cosmetics are processed.

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3 IDENTIFICATION
3.1 NONEX SYSTEM
The 2K COMFORT system is not suitable for use in potentially explosive areas.
3.2 EX SYSTEM
As dened in Directive 2014/34/EU the 2K COMFORT system (with Ex identication) is
suitable for use in potentially explosive areas.
3.2.1 CONTROL CABINET

The control cabinet may not be used in potentially explosive areas.
CE CE mark (European Communities)
Explosion-proof equipment
II Device class II (not mining)
() eective in zone ...
(2) eective in zone 1
G Ex-atmosphere gas
3.2.2 FLUID SECTION

The 2K COMFORT system's uid section (with Ex identication) is suitable for use in potentially
explosive areas (zone 1 and zone 2).
CE CE mark (European Communities)
Explosion-proof equipment
II Device class II (not mining)
2 Category 2 device
(suitable for zone 1)
G Ex-atmosphere gas
Protection provided by
constructional safety
IIB Device class (Gas) IIB
X Special instructions exist for safe
operation. See the following
Chapter "Identication X".

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3.2.2.1 IDENTIFICATION X
Ignition temperature
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature of the work piece.
Ambient temperature
Permissible ambient temperature: +5 °C to +40 °C; +41 °F to +104 °F.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Surface spraying, electrostatics
Do not spray device parts using electrostatic equipment.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the device.
3.2.3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS
Safe handling of WAGNER spray devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the device or components against steel or rusty iron.
Do not drop the device or components.
Use only tools that are made of a permitted material.
National regulations
Ensure that the national explosion prevention rules and regulations are observed
when setting up the device.

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3.3 REMOTE CONTROL OPTION
 
The remote control (Order No. 2341153) may be used in potentially explosive areas (zone 1 and 2).
CE CE mark (European Communities)
0102 Number of the notied body
which is used by WAGNER in the
production monitoring phase
(PTB in this case)
Explosion-proof equipment
II Device class II (not mining)
2 Category 2 device (suitable for
zone 1)
G Ex-atmosphere gas
Ex Electrical device corresponds to
ignition protection type
d Ignition protection class "Flame-
proof enclosure" EN 60079-1
IIB Device class (Gas) IIB
T6 Temperature class T6: maximum
surface temperature 85 °C; 185 °F
Gb Device protection level ,
suitable for use in Zone 1
CML 13 ATEX 1008X
ATEX certicate number
Safety instructions
For safe operation, observe the safety data in Chapter 13.5.2.

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3.4 TYPE PLATES
3.4.1 CONTROL CABINET
OnlyforasystemwithExidentication:
MADE IN SWITZERLAND
CH-9450 ALTSTÄTTEN
B_05486
II (2) G
3
4
5
6
7
8
9
2
1
El. Anschluss Spannung / Connection voltage
El. Anschluss Frequenz / Connection frequency
Anschlussleistung / Connection Power
Schutzart / Protection class
Temperatur Umgebung / Ambient temperature
Baujahr - Serie Nr. / Year of manufacture - Serial No.
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
Gerätetyp / Type: 2K Comfort Control unit
Wagner International AG
Designation
1 Manufacturer and CE Identication
2 Device type: 2K COMFORT control cabinet
3 Electrical connection: voltage
4 Electrical connection: frequency
5 Connection power
Designation
6 Protection class
7 Ambient temperature
8 Manufacturing year and serial number
9 Read operating manual before use!
3.4.2 FLUID SECTION
Onlyfor a systemwith Ex identication:
MADE IN SWITZERLAND
CH-9450 ALTSTÄTTEN
Gerätetyp / Type: 2K Comfort Fluid unit
B_06264
II 2G c IIB X
3
4
5
6
7
8
9
2
1
Materialmenge pro Minute / Fluid volume per minute
Materialdruck / Fluid pressure
Luftdruckversorgung / Air pressure supply
Temperatur Material / Fluid temperature
Temperatur Umgebung / Ambient temperature
Baujahr - Serie Nr. / Year of manufacture - Serial No.
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
Wagner International AG
Designation
1 Manufacturer and CE Identication
2 Device type: 2K COMFORT uid section
3 Flow rate per minute
4 Product pressure
5 Air pressure supply
Designation
6 Product temperature
7 Ambient temperature
8 Manufacturing year and serial number
9 Read operating manual before use!

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4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Electric shock hazard!
Danger to life from electric shock
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, there is a danger from line voltage.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if it poses a hazard or is damaged.
Must be de-energized before work is commenced. Inform sta about planned work.
Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground
wire connection.
Keep liquids away from electrical devices.
4.1.2 A SAFE WORK ENVIRONMENT
Hazard due to dangerous uids or steam!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working are is static dissipative in accordance
withEN61340-4-1 (resistance must not exceed 100 M).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g. mechanical
stress, corrosion).
Ensure that product / air hoses adapted to the working pressure are used.

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Ensure that personal protective equipment (see section 4.2.1) is available and is
used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 M.
Ensure that during spraying, persons wear electrically conductive gloves.The grounding
takes place via the spray gun handle or the trigger.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 M.
Ensure that there are no ignition sources such as naked ames, sparks, glowing
wires, or hot surfaces in the vicinity. No smoking.
Ensurethatthepipe joints,hoses,equipment partsand connectionsarepermanently,
technically leak-proof:
–Periodic preventative maintenance and service (replacing hoses, checking
tightness strength and connections, etc.)
–Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g., daily before commissioning, at the end of work or weekly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Hazard due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.
4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.
In electrostatics application: anyone tted with a pacemaker must not enter the high-
voltage area!

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4.2.1 USE PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or steam!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
When preparing or working with paint and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents, and cleaning
agents being used.
Take the specied protective measures. In particular wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient health and environmental safety: Operate the device in a spray booth or
on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.
4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Hazard due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint
or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
– Disconnect the control unit from the mains.
–Intheeventoffunctionalfaults:remedythefaultasdescribedinthe"Troubleshooting"
section.
If needed, the liquid ejection devices must be checked by experts (e.g., WAGNER
service technician) at least every 12 months for their work-safe condition in
accordance with DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36.
– For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure relief" section:
– If pressure relief is required.
– If the spraying work is interrupted or stopped.
– Before the device is cleaned on the outside, checked, or serviced.
– Before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
Danger due to recoil forces!
Actuating the trigger can causes strong recoil forces. Thereby the user can lose his balance
and injure himself during falling.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun briey in a position.

20
OPERATING MANUAL
VERSION 05/2017 ORDER NUMBER DOC 2357061
4.2.3 GROUND THE UNIT
Hazard due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges.
Flames or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that all devices and tanks are grounded before each spraying process.
Make sure that the ground and potential equalization of all system parts are performed
reliably and continuously and can withstand the expected stress (e.g., mechanical
stress, corrosion).
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
Wear static dissipative gloves when spraying. The grounding takes place via the spray
gun handle or the trigger.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.
4.2.4 PRODUCT HOSES
Hazard due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
Ensure that the hose material is chemically resistant to the sprayed products and the
ushing agents used.
Ensure that the product hose and the ttings are suitable for the pressure generated.
Ensure that the following information can be seen on the high-pressure hose:
– Manufacturer
– Permissible operating pressure
– Date of manufacture
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
– in high traffic areas,
– on sharp edges,
– on moving parts or
– on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses
are never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Ensure that no work is ever performed with a damaged hose.
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 M.
Suction hoses may not be subjected to pressure.