WAGNER TwinControl 5-60 ABS Operational 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
B_02795
II 2G Ex ia II B T4 X
0102
Translation of the original
Operating manual
Electronic mixing ratio
controller for 2K paints
Edition 04/2010
3
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
Contents
1 ABOUT THESE INSTRUCTIONS 5
1.1 Languages 5
1.2 CD TwinControl 6
1.3 Warnings, notes and symbols in these instructions 6
2 GENERAL SAFETY INSTRUCTIONS 7
2.1 Safety instructions for the operator 7
2.1.1 Electrical equipment 7
2.1.2 Personnel qualifications 7
2.1.3 A safe work environment 7
2.2 Safety instructions for staff 8
2.2.1 Safe handling of WAGNER spray units 8
2.2.2 Earth the unit 8
2.2.3 Paint hoses 9
2.2.4 Cleaning 9
2.2.5 Handling hazardous liquids, varnishes and paints 9
2.2.6 Touching hot surfaces 10
2.3 Correct use 10
2.4 Field of application 10
2.4.1 Systems with Turbine 10
2.4.2 Systems with mains supply 10
3 PRODUCT 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 DESCRIPTION 14
4.1 Fields of application,using in accordance with the instructions 14
4.1.1 Processible materials 14
4.2 Scope of delivery 14
4.3 Data 15
4.3.1 Basic units and components 15
4.3.2 Technical data 17
4.3.3 Marking and rated data for devices with turbine 18
4.3.4 Weight of the basic units 21
4.3.5 Dimensions 22
4.4 Function 25
4.4.1 Design of TwinControl basic units 25
4.4.2 Principle diagram for basic units 18-40; 28-40; 35-70 and 35-150 26
4.4.3 Principle diagram for basic units 48-110; 75-150 and 72-300 27
4.4.4 Operator‘s controls on the control unit TwinControl 1 and 2 28
4.4.5 Service functions - Overview list 30
4.4.6 Pneumatic Diagram TwinControl 1 33
4.4.7 Pneumatic Diagram TwinControl 2 34
4
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
Contents
5 TRANSPORT / INSTALLATION 35
5.1 Transport 35
5.2 Storage 36
5.3 Installation 37
5.4 Pneumatic connections 38
5.5 Fluid connections 39
5.6 Ensuring sufficient material 39
5.7 Ground the System 39
5.7.1 Earthing of components on frame or carriage 40
5.7.2 Example of earthing scheme for basic unit with turbine 41
5.7.3 Example of earthing scheme for basic unit with cable 41
6 START-UP AND OPERATION 42
6.1 General rules for use of the spray system 42
6.2 Preparation of Start-up 43
6.3 Switching the unit on and off 44
6.4 Preliminary washing and 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 Password protection and user functions 53
6.10 Brief description of the individual functions 54
6.10.1 Basic functions for the sprayer 54
6.10.2 Extended functions with password protection 55
7 MAINTENANCE 60
7.1 Cleaning the system 60
7.2 Cleaning the filters 60
7.3 Maintenance and Service 61
7.4 High pressure hose 62
7.5 Dismantling 62
8 TROUBLE SHOOTING 63
8.1 Faults and appropriate solutions 64
8.2 Conversion of different mixing proportion specification 68
9 TABLES / PARAMETERS 69
9.1 Table hose volume 69
10 ACCESSORIES 70
11 SPARE PARTS 76
11.1 How to order spare parts? 76
11.2 Where do you find spare parts? 77
5
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
1 ABOUT THESE INSTRUCTIONS
1.1 LANGUAGES
4HISOPERATINGMANUALCONTAINSINFORMATIONONTHEOPERATIONREPAIRANDMAINTENANCEOF
THEUNIT
!LWAYSOBSERVETHESEINSTRUCTIONSWHENOPERATINGTHEUNIT
4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL
#OMPLIANCE WITH THESE INSTRUCTIONS CONSTITUTES AN INTEGRAL COMPONENT OF THE WARRANTY
AGREEMENT
Pneumatic pumps Wildcat, Puma, Leopard and Jaguar:
Language: Part No. Language: Part No. Language: Part No.
German 367850 English 367851 French 367852
Dutch 367853 Italian 367854 Spanish 367855
Danish 367857 Swedish 367856 Turkish 367858
Portuguese 367859 Polish 367864 Greek 2309490
Pneumatic pump Tiger:
,ANGUAGE 0ART.O ,ANGUAGE 0ART.O
'ERMAN %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. Language: Part No.
German 393830 English 393831 French 393832
Dutch 2309946 Italian 393834 Spanish 393835
Danish 2306233 Swedish 2306234 Finnish 2304508
Portuguese 2306235 Polish 2306104 Greek 2309157
Related operating instructions for the individual components.
Pneumatic pumps , EvoMotion Stainless steel
Language Part No. Language Part No. Language Part No.
German ZZB021GER English ZZB021ENG French ZZB021FRE
Dutch - Italian ZZB021ITA Spanish ZZB021SPA
Danish - Swedish - Turkish -
Portuguese ZZB021POR Polish - Greek -
Spare parts to the TwinControl units and to the TwinControl accessories are to be found in the separately pro-
vided spare parts catalogue.The spare parts catalogue is available in the following languages:
Language Part No. Language Part No.
German 393880 English 393881
6
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
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 follo-
wing categories:
Danger - imminent danger. Non-observance will result
in death, serious injury and serious material damage.
Warning - possible danger. Non-observance can result
in death, serious injury and serious material damage.
Caution - a possibly hazardous situation. Non-obser-
vance can result in minor injury.
Note - provide information on particular characteristics and how to proceed.
Caution - a possibly hazardous situation. Non-obser-
vance can cause material damage.
SIHI_0100_GB
DANGER
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 consequences.
SIHI_0103_GB
WARNING
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 consequences.
SIHI_0101_GB
CAUTION
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 consequences.
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.
The measures for preventing the hazard and its consequences.
Colour valves FWV400, HDV400, GA400AL-D
,ANGUAGE 0ART.O ,ANGUAGE 0ART.O
'ERMAN %NGLISH
&RENCH $UTCH
)TALIAN 3PANISH
$ANISH 3WEDISH
384880 384881
384882 384883
384884 384885
384887 384886
Colour valves FWV530 or HDV530
,ANGUAGE 0ART.O ,ANGUAGE 0ART.O
'ERMAN %NGLISH
&RENCH $UTCH
)TALIAN 3PANISH
$ANISH 3WEDISH
377980 377981
377982 377983
377984 377985
377987 377986
1.2 CD TWINCONTROL
All operating documents specified above are available also as pdf files on a Compact disk
(CD) and the CD are contained in the scope of delivery of an unit.
Order-No. is: 2307255.
7
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
2 GENERAL SAFETY INSTRUCTIONS
+EEPTHESEOPERATINGINSTRUCTIONSTOHANDNEARTHEUNITATALLTIMES
!LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
2.1.3 A SAFE WORK ENVIRONMENT
Electrical plant and units
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient influences.
May only be maintained by skilled electricians or under their supervision.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be put out of operation if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform staff about
planned work, observe electrical safety regulations.
To protect the electrical components, lay all of the various elements to a collective
earthing point.
It is thus absolutely necessary to attach the device correctly to a grounded voltage
supply.
With open housings,there is a danger from line voltage. Repairs and maintenance may
only be carried out by skilled personnel.
Keep liquids away from the electrical components.
%NSURETHATTHEmOOROFTHEWORKINGAREAISANTISTATICINACCORDANCEWITH%.0ART
eMEASUREMENTINACCORDANCEWITH$).
%NSURETHATALLPERSONSWITHINTHEWORKINGAREAWEARANTISTATICSHOESEGSHOESWITH
LEATHERSOLES
%NSURETHATDURINGSPRAYINGPERSONSWEARANTISTATICGLOVESSOTHATTHEYAREEARTHED
VIATHEHANDLEOFTHESPRAYGUN
#USTOMERTOPROVIDEPAINTMISTEXTRACTIONUNITSCONFORMINGTOLOCALREGULATIONS
%NSURETHATTHEFOLLOWINGCOMPONENTSOFASAFEWORKINGENVIRONMENTAREAVAILABLE
n -ATERIALAIRHOSESADAPTEDTOTHEWORKINGPRESSURE
n 0ERSONALSAFETYEQUIPMENTBREATHINGANDSKINPROTECTION
%NSURETHATTHEREARENOIGNITIONSOURCESSUCHASNAKEDmAMEGLOWINGWIRESORHOT
SURFACESINTHEVICINITY$ONOTSMOKE
4HEPLACEOFASSEMBLYISINACCORDANCEWITHTHEEXPLOSIONPREVENTIONTOSELECTNATIONAL
RULESANDREGULATIONSCONSIDER
%NSUREDBYTHEOPERATORTHETIGHTNESSEXAMINATIONBEFORESTARTUPDAILYAFTERREPAIRS
ANDINREGULARINTERVALS
n 4HEPIPEJOINTSITEMOFEQUIPMENTANDCONNECTIONSAREDURABLYTECHNICALLYCLOSE
%NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS
2.1.2 PERSONNEL QUALIFICATIONS
2.1.1 ELECTRICAL EQUIPMENT
8
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
2.2 SAFETY INSTRUCTIONS FOR STAFF
!LWAYSFOLLOWTHEINFORMATIONINTHESEINSTRUCTIONSPARTICULARLYTHEGENERALSAFETYIN
STRUCTIONSANDTHEWARNINGINSTRUCTIONS
!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:
Never point the spray gun at people.
Never reach into the spray jet.
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.
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.
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:
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
Ensure that you have a firm footing when operating the spray gun.
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.
Ensure that the unit is always earthed.
Earth the work pieces to be coated.
Ensure that all persons inside the working area are earthed, e.g. that they are wearing
antistatic shoes.
When spraying, wear antistatic gloves to earth yourself via the spray gun handle.
9
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
2.2.3 PAINT HOSES
%NSURETHATTHEHOSEMATERIALISCHEMICALLYRESISTANTTOTHESPRAYEDMATERIALS
%NSURETHATTHEMATERIALHOSEISSUITABLEFORTHEPRESSUREGENERATEDINTHEUNIT
%NSURETHATTHEFOLLOWINGINFORMATIONCANBESEENONTHEHIGHPRESSUREHOSE
n -ANUFACTURER
n 0ERMISSIBLEOPERATINGOVERPRESSURE
n $ATEOFMANUFACTURE
2OUTETHEHOSESAWAYFROM
n 4HETRAFlCAREAS
n 3HARPEDGES
n -OVINGPARTS
n (OTSURFACES
$ONOTUSETHEHOSESTOPULLTHEEQUIPMENT
4HEELECTRICALRESISTANCEOFTHECOMPLETEHIGHPRESSUREHOSEMUSTBELESSTHAN-/HM
2.2.4 CLEANING
"EFOREMAINTENANCEWORK
n $EENERGIZETHESYSTEMELECTRICALLY
n THEEQUIPMENTISTOSEPARATEFROMTHENET
n DISCONNECTTHEPNEUMATICSUPPLYLINEAND
n RELIEVETHEPRESSUREFROMTHEUNIT
%NSURETHATTHEmASHPOINTOFTHECLEANINGAGENTISATLEAST+ABOVETHEAMBIENTTEM
PERATURE
4OCLEANUSEONLYSOLVENTFREECLOTHSANDBRUSHES.EVERUSEHARDOBJECTSORSPRAYON
CLEANINGAGENTSAGUN
)NTHECASEOFSTARTUPOREMPTYINGOFTHEEQUIPMENTCANBEPRESENT
n $EPENDINGUPONUSEDCOATINGMATERIAL
n ORCLEANINGSOLVENTS
n EXPLOSIVEMIXTUREINSIDETHELINESANDITEMSOFEQUIPMENT
!NEXPLOSIVEGASAIRMIXTUREFORMSINCLOSEDCONTAINERS
7HENCLEANINGUNITSWITHSOLVENTSNEVERSPRAYINTOACLOSEDCONTAINER
%ARTHTHECONTAINER
2.2.5 HANDLING HAZARDOUS LIQUIDS,VARNISHES AND PAINTS
7HENPREPARINGORWORKINGWITHPAINTANDWHENCLEANINGTHEUNITFOLLOWTHEWORK
INGINSTRUCTIONSOFTHEMANUFACTUREROFTHEPAINTSSOLVENTSANDCLEANINGAGENTSBEING
USED
4AKE THE SPECIlED PROTECTIVEMEASURES IN PARTICULAR WEARSAFETY GOGGLES PROTECTIVE
CLOTHINGANDGLOVESASWELLASHANDPROTECTIONCREAMIFNECESSARY
5SEAMASKORBREATHINGAPPARATUSIFNECESSARY
&ORSUFlCIENTHEALTHANDENVIRONMENTALSAFETY/PERATETHEUNITINASPRAYBOOTHORON
ASPRAYINGWALLWITHTHEVENTILATIONEXTRACTIONSWITCHEDON
7EARSUITABLEPROTECTIVECLOTHINGWHENWORKINGWITHHOTMATERIALS
10
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
2.2.6 TOUCHING HOT SURFACES
4OUCHHOTSURFACESONLYIFYOUAREWEARINGPROTECTIVEGLOVES
7HENOPERATINGTHEUNITWITHACOATINGMATERIALWITHATEMPERATUREOF²#²&
)DENTIFYTHEUNITWITHAWARNINGLABELTHATSAYSu7ARNINGHOTSURFACEh
/RDER.O
)NFORMATIONLABEL
3AFETYLABEL
2.3 CORRECT USE
2.4 FIELD OF APPLICATION
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2
/PERATETHEUNITONLYASANENTIREUNIT
$ONOTDEACTIVATESAFETYEQUIPMENT
5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES
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).
11
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
3 PRODUCT LIABILITY AND WARRANTY
3.1 IMPORTANT NOTES ON PRODUCT LIABILITY
3.2 WARRANTY
!SARESULTOFAN%#REGULATIONEFFECTIVEASFROM*ANUARYTHEMANUFACTURERSHALL
ONLYBELIABLEFORHISPRODUCTIFALLPARTSCOMEFROMHIMORAREAPPROVEDBYHIMANDIFTHE
DEVICESAREPROPERLYlTTEDOPERATEDANDMAINTAINED
)FOTHERMAKESOFACCESSORYANDSPAREPARTSAREUSEDTHEMANUFACTURER@SLIABILITYCOULDBE
FULLYORPARTIALLYNULLANDVOID
4HEUSAGEOFORIGINAL7!'.%2ACCESSORIESANDSPAREPARTSGUARANTEESTHATALLSAFETYRE
GULATIONSAREOBSERVED
4HISUNITISCOVEREDBYOURWARRANTYONTHEFOLLOWINGTERMS
7EWILLATOURDISCRETIONREPAIRORREPLACEFREEOFCHARGEALLPARTSWHICHWITHINMONTHS
INSINGLESHIFTMONTHSINSHIFTORMONTHSINSHIFTOPERATIONFROMDATEOFRECEIPTBY
THE0URCHASERAREFOUNDTOBEWHOLLYORSUBSTANTIALLYUNUSABLEDUETOCAUSESPRIORTOTHE
SALEINPARTICULARFAULTYDESIGNDEFECTIVEMATERIALSORPOORWORKMANSHIP
4HETERMSOFTHEWARRANTYAREMETATOURDISCRETIONBYTHEREPAIRORREPLACEMENTOFTHE
UNITORPARTSTHEREOF4HERESULTINGCOSTSINPARTICULARSHIPPINGCHARGESROADTOLLSLABOUR
ANDMATERIALCOSTSWILLBEBORNEBYUSEXCEPTWHERETHESECOSTSAREINCREASEDDUETOTHE
SUBSEQUENTSHIPMENTOFTHEUNITTOALOCATIONOTHERTHANTHEADDRESSOFTHEPURCHASER
4HISWARRANTYDOESNOTCOVERDAMAGECAUSEDBY
5NSUITABLE OR IMPROPER USE FAULTY INSTALLATION OR COMMISSIONING BY THE PURCHASER OR A
THIRDPARTY NORMALWEARNEGLIGENTHANDLINGDEFECTIVE MAINTENANCEUNSUITABLECOATING
PRODUCTS SUBSTITUTE MATERIALS AND THE ACTION OF CHEMICAL ELECTROCHEMICAL OR ELECTRICAL
AGENTSEXCEPTWHENTHEDAMAGEISATTRIBUTABLETOUS
!BRASIVECOATING PRODUCTSSUCHAS REDLEADEMULSIONSGLAZES LIQUIDABRASIVES ZINCDUST
PAINTSANDSIMILARREDUCETHESERVICELIFEOFVALVESPACKINGSSPRAYGUNSNOZZLESCYLINDERS
PISTONSETC!NYWEARRESULTINGFROMTHEAFOREMENTIONEDCAUSESISNOTCOVEREDBYTHIS
WARRANTY
#OMPONENTSNOTMANUFACTUREDBY7AGNERARESUBJECTTOTHEWARRANTYTERMSOFTHEORIGI
NALMAKER
4HEREPLACEMENTOFAPARTDOESNOTEXTENDTHEWARRANTYPERIODOFTHEUNIT
4HEUNITSHOULDBEINSPECTEDIMMEDIATELYUPONRECEIPT
4OAVOIDLOSSWARRANTYANIYAPPARENTDEFECTSHOULDBENOTIlEDTOUSORTHEDEALERINWRI
TINGWITHINDAYSFROMDATEOFSALEOFTHEUNIT
4HERIGHTTOCOMMISSIONWARRANTYSERVICESTOATHIRDPARTYISRESERVED
7ARRANTYCLAIMSARESUBJECTTOPROOFOFPURCHASEBYSUBMITTINGANINVOICEORDELIVERYNOTE
)FANINSPECTIONlNDSDAMAGENOTCOVEREDBYTHEPRESENTWARRANTYTHEREPAIRWILLBECAR
RIEDOUTATTHEEXPENSEOFTHEPURCHASER
.OTETHATTHISWARRANTYDOESNOTINANYWAYRESTRICTLEGALLYENTITLEDCLAIMSORTHOSECONTRAC
TUALLYAGREEDTOINOURGENERALTERMSANDCONDITIONS
*7AGNER!'
12
TwinControl .
II 2G
Ex ia II B T4 X
ZELM 08 ATEX 0385 X
+5 °C < Ta < +40 °C
0102
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
3.3 CE-CONFORMITY
3.3.1 DEVICES WITH TURBINE
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
Herewith we declare that the supplied version of
TwinControl
5-60 18-40 28-40 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 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 61000-6-2; 2006-03
DIN EN ISO 12100-2; 2004-04 DIN EN 60079-0; 2010-03 DIN EN 61000-6-4; 2007-09
DIN EN 12621; 2006-05 DIN EN 60079-11; 2007-08
EC type examination certificate:
Zelm 08 Atex 0385 X issued by the Zelm Ex Test and Certification Body, D-38124 Braunschweig
(notified body no.0820)
Applied national technical standards and specifications, in particular:
BGR 500 Part 2 chap. 2.29, 2.36 BGR 104 TRBS 2153
EC quality certificate for the quality assurance system:
PTB 03 ATEX Q019 issued by the Federal Physical and Technical Institute (PTB), D-38116 Braunschweig
(notified body 0102)
Marking:
13
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
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:
3.3.2 DEVICES WITH CABLE FOR MAINS CONNECTION
393915
Herewith we declare that the supplied 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/EG
Applied standards, in particular:
DIN EN ISO 12100-1; 2004-04 DIN EN ISO 13732-1; 2008-12 DIN EN 60204-1; 2002-06:
DIN EN ISO 12100-2; 2004-04 DIN EN 14121; 2007-12 DIN EN 61000-6-4; 2007-09
DIN EN 12621; 2006-05 DIN EN 61000-6-2; 2006-03
Applied national technical standards and specifications, in particular:
BGR 500 Part 2 chap. 2.29, 2.36 BGR 104 TRBS 2153
Marking:
14
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
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, predefined 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: flushing, ap-
plication 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
CAUTION
Impurities in the 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-component paints (e.g.epoxy, PU, DD) with an applica-
tion life of more than 5 minutes.
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 fluid 250 ml; 250 cc Part No. 9992504
Tool set PP3000 Part No.367840
CE-Conformity Part No. see chapter 3.3.1 or 3.3.2
Operating manual German Part No. 393830
Operating manual in the local language Part No. see chapter 1
Compact Disc TwinControl (CD) Part No.2307255
Reference sheet Transport Part No. 2305117
Pneumatic scheme TwinControl Part No. 393901
The delivery note shows the exact scope of delivery.
Accessories see chapter 10.
15
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
4.3 DATA
4.3.1 BASIC UNITS AND COMPONENTS
Part
No.
Description:
TwinControl basic unit
A Pump B Pump Flushing
pump
Control
units
393177 5-60 ABS Turbine Wall
EvoMotion
5-60
EvoMotion
5-60
EvoMotion
5-60
TC 1 Turbine
393172 5-60 ABS Turbine Stand
393178 5-60 ABS Cable Wall TC 1 Cable
393176 5-60 ABS Cable Stand
393124 18-40 ABS Turbine Wall
Wildcat
18-40
Wildcat
18-40
Wildcat
18-40
TC 1 Turbine
393126 18-40 ABS Turbine Stand
393125 18-40 ABS Cable Wall TC 1 Cable
393127 18-40 ABS Cable Stand
393128 28-40 ABS Turbine Wall
Puma
28-40
Puma
28-40
Puma
28-40
TC 1 Turbine
393130 28-40 ABS Turbine Stand
393129 28-40 ABS Cable Wall TC 1 Cable
393131 28-40 ABS Cable Stand
393169 28-40 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 35-70 ABS Cable Stand TC 1 Cable
393133 35-70 AB Cable Wall
393164 35-70 AB Turbine Stand
no TC 1 Turbine
393165 35-70 AB Turbine Stand V
393180 35-70 AB Cable Stand TC 1 Cable
393137 35-150/70 ABS Turbine Stand
Leopard
35-150
Puma
28-40
TC 1 Turbine
393139 35-150/70 ABS Turbine Trolley
393138 35-150/70 ABS Cable Stand
TC 1 Cable393140 35-150/70 ABS Cable Trolley
393175 35-150/70 ABS Cable Stand EM
393146 48-110 ABS Turbine Stand
Leopard
48-110
Leopard
48-110
TC 2 Turbine393170 48-110 ABS Turbine Stand EM
393148 48-110 ABS Turbine Trolley
393149 48-110 ABS Cable Trolley
TC 2 Cable393147 48-110 ABS Cable Stand
393174 48-110 ABS Cable Stand EM
393181 48-110 ABS Turbine Stand SZ TC 2 Turbine
393168 48-110 AB Turbine Stand no TC 2 Cable
16
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
Part
No.
Description:
TwinControl basic unit
A Pump B Pump Flushing
pump
Control
units
393150 75-150 ABS Turbine Stand
Jaguar
75-150
Jaguar
75-150
Leopard
35-70
TC 2 Turbine
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 TC 2 Cable
393153 75-150 ABS Cable Trolley
393154 72-300/150 ABS Turbine Stand
Tiger
72-300
TC 2 Turbine
393183 72-300/150 ABS Turbine Stand SZ
393156 72-300/150 ABS Turbine Trolley
393166 72-300/150 AB Turbine Stand no
393167 72-300/150 AB Turbine Stand -V
393155 72-300/150 ABS Cable Stand
Leopard
35-70
TC 2 Cable393173 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 72-300 ABS Turbine Stand
393159 72-300 ABS Cable Stand TC 2 Cable
393161 72-300 ABS Cable Trolley
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
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 - - -
Code Description
G Base frame with castors
T Mounted on trolley
W Wall mount
EM External mixer
OV Without flushing valve
SZ With soft circulation
17
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
4.3.2 TECHNICAL DATA
SIHI_0023_GB
WARNING
Outgoing air containing oil!
Risk of poisoning if inhaled
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.
Description Units
5-60 ABS
18-40 ABS
28-40 ABS
35-70 ABS
35-150/70 ABS
48-110 ABS
75-150 ABS
72-300/150 ABS
72-300 ABS
Inlet air pressure min. MPa; bar; psi 0.6; 6; 87
Inlet air pressure maxi. MPa; bar; psi 0.8; 8; 116
Maxi. permissible number of strokes by
pumps in two-component operation DS/ min 30
Maxi. material pressure in mixer MPa
bar;
psi
4
40
580
14.4
144
2089
22.4
224
3249
25.0
250
3626
37.0
370
5366
53.0
530
7687
Maxi. Material pressure at inlet MPa; bar; psi 0.8; 8; 116
Material outlet connection Zoll; Inch G1/4 NPSM 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 2.6 5.0 4.1 5.6 10.1 11.2
Material flow qty of the mixing ratio 10:1 l/ min 2.0 1.3 2.3 4.7 3.6 4.9 9.5 9.9
Material flow qty of the mixing ratio 20:1 l/ min 1.9 1.2 2.2 4.6 3.7 -
pH range of the material pH 3.5-9
Material Temperature °C; °F +5 – +60; +41 - +140
Ambient temperature °C; °F +5 – +40; +41 - +104
A/B mixing ratio volume 0.1:1 – 20:1 0,1:1 – 10:1
Ratio precision % ± 2
Sound pressure level at maxi.permissible air
pressure *See operating manuals pumps and valves
Control units TwinControl with able connection
Input voltage VAC 85 - 250
Input power W maxi. 40
Input frequency Hz 47-440
Control units TwinControl with turbine
Compressed air input maxi. MPa; bar; psi 0.5; 5; 73
Nominal air consumption NL/min 125
Air pressure quality free of oil and water (Quality standard 5.5.4 according ISO 8573.1)
5.5.4 = 40 μm/ +7/ 5 mg/m3
18
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
4.3.3 MARKING AND RATED DATA FOR DEVICES WITH TURBINE
Identification Description
J.Wagner AG Company name
CH- 9450 Altstätten Address
CE102 CE mark with number of the notified body that is used by us in the production
monitoring phase (PTB in this case)
TwinControl Name of unit
Serial No. Serial no. of device
2007 Year of manufacture of device
II 2 G Marking according to Directive 98//EC (Atex directive) [application area]
-
Explosion-proof equipment
- II: Device group II, not mining
- 2: Category 2 (i.e. Zone 1)
- G: Gases
Ex ia II B T4 X Marking according to standard(s) [equipment properties]
- Ex: Explosion-proof equipment
- ia: Ignition protection type intrinsic safety, for Zone 0 and 1
- II: Device group II, not mining
- 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 certificate (Atex), certificate 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 Potentiometer A and B
Maxi. voltage U0[V] 12.6
Maxi. current I0[mA] 73.6
Maxi. power P0[mW] 232
Maxi. External capacity C0[uF] 7.3
Maxi. External inductivity L0[mH] 26
The abovementioned values for the maximum permissible external capacities and induct-
ances 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 L0[mH] 0.1 0.2 0.5 1 2 5 10 20
Maximum permissible external capacity C0[uF] 7.3 6 4.6 3.7 3.1 2.3 1.9 1.4
19
TwinControl .
OPERATING MANUAL
EDITION 04/2010 PART NO. DOC393831
Remote control connection with ignition protection type Ex ia IIB:
Connection of maximum values Connection RC
Maxi. voltage U0[V] 12.6
Maxi. current I0[mA] 154
Maxi. power P0[mW] 484
Maxi. External capacity C0[uF] 7.3
Maxi. External inductivity L0[mH] 6
The abovementioned values for the maximum permissible external capacities and induct-
ances 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 L0 [mH] 0.1 0.2 0.5 1.0 2.0 5.0
Maximum permissible external capacity C0 [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 theTwinControl 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 film 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.
20
TwinControl .
OPERATING MANUAL
EDITION 04/2010 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%.
This manual suits for next models
8
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