WAGNER TwinControl Installation instructions

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

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VERSION 10/2018 ORDER NUMBER DOC 2339321 .
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 Manuals for the Individual Components 8
1.4 TwinControl CD 9
1.5 Abbreviations 10
1.6 Terminology for the Purpose of this Manual 10
2 CORRECT USE 11
2.1 Device Types 11
2.2 Type of Use 11
2.3 For Use in Potentially Explosive Areas 11
2.4 Processible Working Materials 12
2.5 Misuse 12
3 IDENTIFICATION 13
3.1 Explosion-Proof Marking for Devices with Turbines 13
3.1.1 Use in Areas Subject to Explosion Hazards 14
3.2 Identication for Devices with a Mains Power Supply 15
3.3 Type Plates 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 the Personnel 18
4.2.1 Personal Safety Equipment 19
4.2.2 Safe Handling of WAGNER Spray Devices 19
4.2.3 Grounding 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
5 DESCRIPTION 23
5.1 Components 23
5.1.1 TwinControl Finishing and Protective Coating 24
5.2 Mode of Operation 24
5.3 Protective and Monitoring Equipment 24
5.4 Included Items 25
5.5 Technical Data 25
5.5.1 Materials of Paint-wetted Parts 25
5.5.2 Control Units with Turbines 26
5.5.3 Control Units with Mains Power Supply (Cable) 28
5.5.4 Entire System 28
5.5.5 Pumps 30
5.5.6 Dimensions 31
5.5.7 Weights 33

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VERSION 10/2018 ORDER NUMBER DOC 2339321 .
5.6 Overview of TwinControl Controllers 34
5.7 Principle Diagram 35
5.7.1 Controller 1 / 9 / 10 for Pumps 5-60 to 35-150 35
5.7.2 Controllers 2 / 3 / 6 / 8 for Pumps 48-110 to 8-600 36
5.8 Operating Elements and Control Unit Connections 37
5.9 Pneumatic Diagram 39
5.9.1 TwinControl 1 39
5.9.2 TwinControl 2 / TwinControl 3 40
5.9.3 TwinControl 6 / TwinControl 8 41
5.9.4 TwinControl 9 / TwinControl 10 42
5.10 List of Service Functions 43
5.11 Dry Running Protection 46
5.12 Heater (option) 46
5.13 AIS Dosing System (option) 46
5.14 Automatic Electrostatic System for Electrostatic Gun GM5000 (Option) 46
5.15 Connection Kit for Gun Flush Box (Option) 47
5.16 Feed Pump (Option) 47
5.16.1 EvoMotion 5-125 Feed Pump 48
5.17 Maintenance Work on the Pumps 48
6 ASSEMBLY AND COMMISSIONING 49
6.1 Training of Assembly/Commissioning Personnel 49
6.2 Storage and Installation Conditions 49
6.3 Transportation 50
6.4 Assembly and Installation 51
6.4.1 Pneumatic Connections 52
6.4.2 Product Connections 52
6.5 Grounding 53
6.5.1 Grounding of Components on Frame or Trolley 54
6.5.2 Example of Grounding Scheme for TwinControl with Turbine 55
6.5.3 Example of Grounding Scheme for TwinControl
with Mains Power Connection (Cable) 55
6.6 Commissioning 56
6.6.1 Preparation Before Commissioning 56
6.6.2 Basic Flushing and Pressure Tightness Test 57
6.6.3 Replacing Flushing Agent with Working Media 60
6.6.4 Calibrating the System 62
7 CONTROLLER 65
7.1 Training the Operating Personnel 65
7.2 Safety Instructions 65
7.3 Operating the Control Unit 66
7.3.1 Entering Numbers [SET] 67
7.4 Password Protection and User Functions 68
7.5 Basic Functions for the Painter 69
7.6 Extended Functions with Password Protection 70
7.6.1 Calibration 74
7.6.2 Flushing Programs 75
7.6.3 AIS 77
7.6.4 Check for Leaks in A and B Fluid Section 79
7.6.5 "Batch Mode" Filling Mode 80

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VERSION 10/2018 ORDER NUMBER DOC 2339321 .
8 OPERATION 81
8.1 Training the Operating Personnel 81
8.2 Safety Instructions 81
8.2.1 General Rules for Making Adjustments to the Spray Gun 81
8.3 Malfunction 82
8.4 Emergency Deactivation 82
8.5 Switching the System On 83
8.6 Switching o the System 85
8.7 Spraying Mode 86
8.8 Flushing 87
8.9 Pressure Relief / Work Interruption 88
8.10 Automatic Electrostatic System Set for Electrostatic Gun GM5000 (Option) 90
8.10.1 Commissioning and Settings 90
8.10.2 Paint Filling 90
8.10.3 Spraying Mode 91
8.10.4 Work Interruption (Stop) 91
8.10.5 Flushing 91
8.11 Connection Kit for Gun Flush Box (Option) 91
8.12 Soft Circulation (Option) 92
8.13 External Mixers (Option) 93
8.13.1 Manual External Mixers DN2.6 and DN4 93
8.13.2 Manual External Mixer DN 8 93
8.14 Remote Control and ESTA Remote Control (Option) 94
8.14.1 Explosion Protection 94
8.14.2 TwinControl Remote Control 94
8.14.3 ESTA Remote Control 95
8.15 2A Switchbox for Second A-Pump (Option) 96
9 CLEANING AND MAINTENANCE 97
9.1 Cleaning 97
9.1.1 Cleaning Personnel 97
9.1.2 Safety Instructions 97
9.1.3 Filter Cleaning 97
9.1.4 Cleaning the System 98
9.1.5 Decommissioning 98
9.1.6 Long-term Storage 98
9.2 Maintenance 99
9.2.1 Maintenance Personnel 99
9.2.2 Maintenance Instructions 99
9.2.3 Safety Checks and Maintenance Intervals 100
9.2.4 Service Plug 100
9.2.5 Connections for Stroke Measurement 100
9.2.6 Turbine 100
9.2.7 Non-return Valves 101
9.2.8 Emptying System 101
9.2.9 Filling Empty System 101
9.2.10 Cleaning or Replacing the Product Filter 102
9.2.11 Product Hoses, Pipes and Couplings 104

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10 TROUBLESHOOTING 105
10.1 Alarm Messages and Fault Rectication 107
11 REPAIRS 110
11.1 Repair Personnel 110
11.2 Repair Notes 110
11.3 Assembly Aids 111
12 DISPOSAL 112
13 ACCESSORIES 113
13.1 Mixer 113
13.2 Remote Control 115
13.3 Horn Alarm 116
13.4 Suction Hoses 116
13.5 Mixing Hoses 117
13.6 AIS 117
13.7 Heater 118
13.8 Splitter Valve 120
13.9 Product Pressure Regulator 120
13.10 Flushing Pressure Set 120
13.11 Additional Parts for Second Paint (2A) 121
13.12 Extension Cables 122
13.13 TC VM5000 Automatic Electrostatic System 122
13.14 GFB Connection Kit 122
13.15 Feed Pump 123
13.16 AirCoat Regulator 123
13.17 Archiving Software 124
14 SPARE PARTS 125
14.1 Where Can Spare Parts Be Found? 125
14.2 Serial Number 125
14.3 Turbine 125
15 DECLARATION OF CONFORMITY 126
15.1 Devices with Turbines 126
15.2 Devices with Cable for Mains Power Supply 127
16 APPENDIX 128
16.1 Conversion of the Mixing Ratio Specications 128
16.2 Hose Volume Table 129

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VERSION 10/2018 ORDER NUMBER DOC 2339321 .
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 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.
Notice Provides information about particular characteristics and how
to proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.

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VERSION 10/2018 ORDER NUMBER DOC 2339321 .
1.3 LANGUAGES
The TwinControl operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2339287
Translation of the original operating manual
Language Order no. Language Order no. Language Order no.
English 2339321 Spanish 2339330 Romanian 2372826
French 2339322 Italian 2339323 Polish 2396599
Japanese 2344161 Turkish 2386987 -- --
Additional languages on request or at: www.wagner-group.com
Spare parts for the TwinControl systems and TwinControl accessories are to be found in two separate spare
parts catalogs. The catalogs are available in the following languages:
Spare parts catalog for TwinControl Finishing
(Small frame / small trolley / small wall):
Language Order no. Language Order no.
German 2339290 English 2339331
Spare parts catalog for TwinControl Protective Coating (PC)
(Large frame / large trolley):
Language Order no. Language Order no.
German 2339293 English 2339332
TwinControl CD: see Chapter 1.4
1.3.1 OPERATING MANUALS FOR THE INDIVIDUAL COMPONENTS
EvoMotion 5-60 operating manual
Language Order no. Language Order no. Language Order no.
German 2333562 English 2333563 Spanish 2333566
French 2333564 Italian 2333565 -- --
Operating manual
Wildcat 10-70, 18-40 / Puma 28-40, 15-70, 21-110, 15-150 / Leopard 35-70, 35-150, 48-110
Language Order no. Language Order no. Language Order no.
German 2333537 English 2333538 Spanish 2333541
French 2333539 Italian 2333540 -- --
Operating manual Puma 8-300, 3-600 / Leopard 18-300, 8-600 / Jaguar 38-300
Language Order no. Language Order no. Language Order no.
German 2333547 English 2333548 Spanish 2333551
French 2333549 Italian 2333550 -- --
Operating manual Jaguar 75-150, 55-200 / Tiger 72-300
Language Order no. Language Order no. Language Order no.
German 2340281 English 2340282 Spanish 2340286
French 2340285 Italian 2340284 -- --

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Operating manual EvoMotion 5-125 (Accessory, use as feed pump)
Language Order no. Language Order no. Language Order no.
German 2316595 English 2316596 Spanish 2316600
French 2316597 Italian 2316599 -- --
Operating manual Paint and dosing valves DN 2.6 (for valves PV 400, DV 400, GA 400DV)
Language Order no. Language Order no. Language Order no.
German 2343270 English 2343275 Spanish 2343278
French 2343276 Italian 2343277 -- --
Operating manual Paint valve PV 100-DN4
Language Order no. Language Order no. Language Order no.
German 2343280 English 2343281 Spanish 2343286
French 2343282 Italian 2343284 -- --
Operating manual Paint and dosing valves PV 530, DV 530
Language Order no. Language Order no. Language Order no.
German 2372892 English 2372893 Spanish 2372900
French 2372895 Italian 2372897 -- --
Operating manual Automatic Airless spray gun GA 400AL (for valve GA 400AL / soft circulation)
Language Order no. Language Order no. Language Order no.
German 350939 English 350941 Spanish 350949
French 350946 Italian 350948 -- --
Continuous-ow heater operating manual
Language Order no. Language Order no. Language Order no.
German 65860 English 65860 Dutch 65860
French 65860 Italian 65860 Danish 65860
Product pressure regulator operating manual
Language Order no. Language Order no. Language Order no.
German ZZB019GER English ZZB019ENG Spanish ZZB019SPA
French ZZB019FRE Italian ZZB019ITA -- --
1.4 TWINCONTROL CD
All operating documents specied previously are also available as PDF les on a compact
disk (CD). The CD is included in the system's scope of delivery.
The order no. is: 2339342

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VERSION 10/2018 ORDER NUMBER DOC 2339321 .
1.5 ABBREVIATIONS
Abbreviations in the text
Number of pieces TC 1.4404 TwinControl for acidic hardeners
Position Protective coating: heavy duty corrosion protection
Marking in the spare parts lists HP High pressure 4-50 MPa; 40-500 bar; 580-7,250 psi
Order no. Order number HPP Highest pressure over 50 MPa; 500 bar; 7,250 psi
Double stroke ESTA Electrostatically charged device
Nominal diameter Materials
Two components Stainless steel
Fluorine elastomer
GFB Gun ush box Polyamide
TwinControl Polytetrauorethylene
Abbreviations in the text and control unit
A component Mixing ratio
B component Job total
Flushing agent Pot life
Flushing on A-side Flow rate / pot life
Flushing on B side -- --
1.6 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning agent.
Flushing Internal ushing of paint-wetted parts with ushing agent.
Personnel 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
in the areas of explosion protection, protection from pressure
hazards and electric hazards (if applicable) 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.