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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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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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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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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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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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.

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2 CORRECT USE
2.1 DEVICE TYPES
A) TwinControl, turbine
B) TwinControl, cable with mains supply
2.2 TYPE OF USE
A) Systems with a turbine
The device is suitable for processing 2K liquid products such as paints and lacquers
in accordance with their classication into explosion classes IIA or IIB.
B) Systems with a mains power supply
The device is suitable for processing 2K 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.
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 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
A) Systems with a turbine
The system with turbine complies with Explosion Protection Directive 2014/34/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:
(See Explosion Protection Identication, Chapter 3)
The remote control (accessory) may be used along with a system with a turbine in
potentially explosive areas (zone 1, zone 2). The same applies to the 2A switchbox
(accessory).
B) Systems with a mains power supply
The system with mains power supply (cable) must not be operated in potentially explosive
areas (zone 0, 1, 2).
The remote control (accessory) may not be used along with a system with a mains power
supply (cable) in potentially explosive areas. The same applies to the 2A switchbox
(accessory).

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2.4 PROCESSIBLE WORKING MATERIALS
Low-viscosity to high-viscosity 2K lacquers (e.g., epoxy, PU, DD) with a pot life of more than 5 minutes.
- 2K water-based priming - 2K epoxy priming
- 2K solvent-based priming - 2K epoxy lacquers
- 2K PUR priming - 2K high-solid priming
- 2K PUR lacquers - 2K high-solid lacquers
- 2K products with acidic hardeners (only with TwinControl systems for acidic hardeners)
Solvent and water-based 2K products should not be processed using the same system.
Materials in direct contact with the products: see Chapter 5.5.1
NOTICE
Abrasive working materials and pigments!
Greater wear of product-wetted parts.
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 / 5.5.5 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.
TwinControl for acidic hardeners
Check products for compatibility:
see Chapter 5.5.1
Parts made of stainless steel 1.4404 are
labeled with "1.4404" (see example).
1.4404
B_07123
Designation "1.4404"
Example of hardener pump
WARNING
Acidic hardeners!
Risk of burns and injury for skin, tissue and organs.
Observe the lacquer manufacturer's safety data sheets and take prescribed safety
measures.
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 EXPLOSIONPROOF MARKING FOR DEVICES WITH TURBINES
– Turbines
As dened in the Directive 2014/34/EU (ATEX), the TwinControl control unit (turbine)
is suitable for use in potentially explosive areas.
Device type: TwinControl
Manufacturer: Wagner International AG
9450 Altstätten
Switzerland
Identication:
CE mark (European Communities)
Number of the notied body that is used by WAGNER in the production
monitoring phase (PTB Germany in this case)
Explosion-proof equipment
Device class II (not mining)
Category 2 device (suitable for zone 1)
Ex-atmosphere gas
Ex Electrical device corresponds to ignition protection type
Ignition protection type "Intrinsic safety" EN 60079-11, safety level "ia"
Device category (gas) IIB (ethylene, city gas)
Temperature class T4: maximum surface temperature 135°C; 275°F
Test center and year of issue
French abbreviation for "ATmosphères EXplosibles"
Certicate number
Special instructions exist for safe operation (see Chapter5.5.2.1).
Permissible ambient temperature range during operation:
Explosion protection identication and special notices regarding pumps
See operating manuals for pumps

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3.1.1 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 and tools against steel or rusty iron.
Do not drop the device or components and tools.
Ignition temperature of the pumped product
Check that the ignition temperature of the pumped product is higher than the max.
permissible surface temperature.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Operation without uid
Avoid running the pump so that it sucks in air (without uid inside). The air, combined
with the vapor of ammable uids, can generate internal areas with an explosion hazard.
Periodically check that the pumps are working smoothly, paying special attention to
the presence of air in the pumped uid, which may be caused by damaged packings.
Avoid operating the pump with damaged packing.
Ensure that the separating agent tank is lled with sucient separating agent.
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.
National regulations
Ensure that the national explosion prevention rules and regulations are observed
when setting up the device.

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3.2 IDENTIFICATION FOR DEVICES WITH A MAINS POWER SUPPLY
, cable with mains power supply
The system with mains power supply (cable) must not be operated in potentially explosive
areas (zone 0, 1, 2).
The remote control (accessory) may not be used along with a system with a mains power
supply (cable) in potentially explosive areas.The same applies to the 2A switchbox (accessory).
Device type: TwinControl
Manufacturer: Wagner International AG
9450 Altstätten
Switzerland
Identication:
CE mark (European Communities)
Identication and special notices regarding pumps
See operating manuals for pumps

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3.3 TYPE PLATES
– Turbines
Check manual before use!
Vor Gebrauch Betriebsanleitung
beachten!
Year of construction / Baujahr:
Serial No. controller:
Serie Nr. Steuerung:
Air pressure supply:
Luftdruckversorgung:
IP Code:
Schutzart: IP 54
Ambient temperature:
Temperatur Umgebung:
0.6 - 0.8 MPa
6 - 8 bar
87 - 116 psi
+5 / +40 °C
CH 9450 Altstätten
TwinControl
Made in Switzerland
Type / Typ:
Wagner International AG
Serial No unit.:
Serie Nr. Anlage:
+5°C < Ta < +40°C
B_06434
3
4
5
6
7
8
9
12
2
1
13
10
11
II 2 G
Ex ia II B T4
ZELM 08 ATEX 0385 X
+5°C < Ta < +40°C
1 Manufacturer
2Device type: TwinControl
3 Serial number of system
4 CE identication
5 Year of manufacture
6 Serial number of controller
7 Air pressure supply
8 Ambient temperature
9 Protection class
10 Dust-protected
11 Splash-proof
12 Do not dispose of used electrical equipment with
household refuse.
13 Read operating manual before use!
– cable with mains power supply
Check manual before use!
Vor Gebrauch Betriebsanleitung
beachten!
Serial No. controller:
Serie Nr. Steuerung:
Voltage:
Spannung:
Line Power:
Eingangsleistung:
IP Code:
Schutzart:
85-260 VAC 47-60 Hz
max. 40 W
IP 54
Ambient temperature:
Temperatur Umgebung: +5 / +40 °C
CH 9450 Altstätten
TwinControl
Made in Switzerland
Type / Typ:
Wagner International AG
Serial No unit.:
Serie Nr. Anlage:
B_06435
4
5
6
7
8
9
3
1
13
10
11
12
Year of construction / Baujahr:
2
1 Manufacturer and CE mark
2Device type: TwinControl
3 Year of manufacture
4 Serial number of system
5 Serial number of controller
6 Voltage
7 Maximum input power
8 Ambient temperature
9 Protection class
10 Dust-protected
11 Splash-proof
12 Do not dispose of used electrical equipment with
household refuse.
13 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.
Alwaysfollowlocalregulations concerningoccupationalsafety andaccident 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, the mains voltage poses a danger.
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 personnel 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 vapors!
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 area is static dissipative in accordance with
EN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 hoses/air hoses adapted to the working pressure are used.

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VERSION 10/2018 ORDER NUMBER DOC 2339321 .
Ensure that personal protective equipment (see Chapter 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 static dissipative 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.
Ensure that the pipe joints, hoses, equipment parts and connections are permanently,
technically leak-proof:
– Periodic preventative maintenance and service (replacing hoses, checking
tightness strength of 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.
Ensure that maintenance and safety checks are performed regularly.
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.
Ensurethat theoperating personnelhas been instructedby theoperator inaccordance
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 THE PERSONNEL
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Alwaysfollowlocalregulationsconcerningoccupationalsafetyandaccidentprevention.
In electrostatics application: Danger due to high-voltage eld!
Danger to life.
Persons belonging to a risk group according to EMF guideline 2013/35/EU
(e.g., carriers of active implants), must not enter the high-voltage area.

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4.2.1 PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or vapors!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
When preparing or working with lacquer 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 skin 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 lacquer
or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Ensure that the working pressure does not exceed the maximum value shown on
the type plate.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy and compressed air supply.
– Relieve pressure from spray guns, high-pressure hoses and all devices.
– Secure spray guns against actuation.
– Disconnect the control unit from the mains.
– In the event of functional faults: remedy the fault as described in the
"Troubleshooting" chapter.
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.
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 when falling.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.

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VERSION 10/2018 ORDER NUMBER DOC 2339321 .
4.2.3 GROUNDING 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.
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 hoses 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.