Page 1 For professional use. Version 05/2017 Always follow the information in this manual, particularly the safety instructions and the warning instructions. Store the manual in a safe place. 2K COMFORT Electronically Controlled Multi-component System for Lacquers Software version 4.0x / 4.0x K 3.2x / 3.2x K...
Page 3: Table Of Contents
Electrical devices and equipment 4.1.2 A safe work environment 4.1.3 Personnel qualifications Safety instructions for staff 4.2.1 Use personal safety equipment 4.2.2 Safe handling of WAGNER spray devices 4.2.3 Ground the unit 4.2.4 Product hoses 4.2.5 Cleaning and Flushing 4.2.6 Touching hot surfaces 4.2.7...
Page 4 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL DESCRIPTION Components Mode of operation Protective and monitoring equipment Included items Data 5.5.1 Technical data 5.5.1.1 Limitations for 2-circuit systems 5.5.2 Dimensions 5.5.3 Working areas of flow meters 5.5.4 Application limits of flow meters Mixing types Dump valve for waste separation (option) AIS dosing system (option)
Page 5 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Home page 7.6.1 Changing the paint recipe 7.6.2 Home page operation Menu Manual mode: open valves Recipes 7.9.1 Add new recipes 7.9.2 Changing recipe and valve names 7.10 Enter flushing recipe 7.11 Enter paint recipe 7.12 Calibration...
Page 6 Important notes on product liability 15.2 Warranty claim 15.3 EU Declaration of Conformity for 2K COMFORT 15.4 EU Declaration of Conformity for 2K COMFORT (with Ex identification) 15.5 EC Declaration of Conformity for remote control APPENDIX 16.1 Conversion of the mixing ratio specifications...
Page 7: About These Instructions
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL ABOUT THESE INSTRUCTIONS 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.
Page 8: Languages
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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...
Page 9: Usb Stick 2K Comfort
Additional languages on request or at: www.wagner-group.com USB STICK 2K COMFORT All operating documents specified above, as well as the accessory set's assembly manuals (with the description of the accessory's function) are also available as pdf files on a USB stick.
Page 10: Terminology For The Purpose Of This Manual
1.6.1 LOW PRESSURE / HIGH PRESSURE / XL These operating manual differentiates for purposes of illustration between 2K COMFORT low-pressure, high-pressure and XL version: Maximum product pressure Maximum flow rate...
Page 11: Correct Use
2K COMFORT b) 2K COMFORT (with Ex identification) The 2K COMFORT system is also available as a 2-circuit system (1 control cabinet, 2 fluid circuits). TYPE OF USE The device is suitable for mixing 2K, 3K and 4K liquid products such as paints and lacquers.
Page 12: Accessories
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...
Page 13: Identification
1 Ex-atmosphere gas 3.2.2 FLUID SECTION The 2K COMFORT system's fluid section (with Ex identification) is suitable for use in potentially explosive areas (zone 1 and zone 2). CE mark (European Communities) Protection provided by constructional safety...
Page 14: Use In Areas Subject To Explosion Hazards
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.
Page 15: Remote Control (Option)
The remote control (Order No. 2341153) may be used in potentially explosive areas (zone 1 and 2). CE mark (European Communities) Electrical device corresponds to ignition protection type 0102 Number of the notified body which is used by WAGNER in the Ignition protection class "Flame- production monitoring phase proof enclosure" EN 60079-1 (PTB in this case)
Page 16: Type Plates
Vor Gebrauch Betriebsanleitung beachten / Check manual before use! Designation Designation Manufacturer and CE Identification Protection class Device type: 2K COMFORT control cabinet Ambient temperature Electrical connection: voltage Manufacturing year and serial number Electrical connection: frequency Read operating manual before use! Connection power 3.4.2 FLUID SECTION...
Page 17: Basic Safety Instructions
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL BASIC SAFETY INSTRUCTIONS 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...
Page 18: Personnel Qualifications
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 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 MΩ.
Page 19: Use Personal Safety Equipment
– In the event of functional faults: remedy the fault as described in the "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.
Page 20: Ground The Unit
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 4.2.3 GROUND THE UNIT Hazard due to electrostatic charge! Explosion hazard and damage to the device. Friction, flowing 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.
Page 21: Cleaning And Flushing
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Several liquids have a high expansion coefficient. In some cases their volume can rise with consequent damage to pipes, fittings, etc. and cause fluid leakage. When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can enter the tank.
Page 22: Touching Hot Surfaces
Hazard due to improper maintenance and repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Do not change or modify the device; if change is necessary, contact WAGNER.
Page 23: Description
Further characteristics and areas of application For low to medium pressure (32.5 MPa; 325 bar; 4714 psi). 2K COMFORT XL for high-pressure (53 MPa; 530 bar; 7687 psi). Modular structure - can be combined as required by the customer. Electronic dosing precision guarantees consistent quality.
Page 24: Protective And Monitoring Equipment
Possibility of robot communication. PROTECTIVE AND MONITORING EQUIPMENT The following functions are provided for system safety: – External release: e.g., interlock with spray booth's exhaust air INCLUDED ITEMS 2K COMFORT scope of delivery Non-Ex Designation Order No. Order No. Basic device...
Page 25: Data
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL DATA 5.5.1 TECHNICAL DATA Electrical Voltage and frequency range 100–240 VAC / 120–350 VDC / 50–60 Hz + PE Power consumption 60 W / 0.3 A See electrical circuit diagram (delivered together with the system). Pneumatic Compressed air Inlet 0.7–0.8 MPa;...
Page 26 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL XL version without Coriolis High- Low-pressure pressure Product valves version with Coriolis version DN 2.6 DN 4 DN 10 Flushing agent: 0.8 MPa 32.5 MPa * 53 MPa * 40 MPa * 34.5 MPa * 8 bar 325 bar *...
Page 27 − Correct use of the system in accordance with the specific operating conditions such as the permitted product and ambient temperature, permitted viscosity and flow rate. − Regular maintenance has to be carried out by a qualified person (e.g., WAGNER Service Technician) in accordance with Chapter 9.
Page 28: Limitations For 2-Circuit Systems
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 5.5.1.1 LIMITATIONS FOR 2-CIRCUIT SYSTEMS Limitations for 2-circuit systems opposite the data in Chapter 5.5.1: 2-circuit system 2-circuit system Standard system per circuit per circuit 2K / 3K / 4K system 2K / 3K / 4K 2K / 3K DN 10: 4/–/–/–...
Page 29: Dimensions
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 5.5.2 DIMENSIONS Control cabinet and/or fluid cabinet XL system (fluid cabinet) − Standard system − Ex system − 2-circuit system − XL system (control cabinet) B_05669 B_05637 Dimensions Measurement inch 31.50 1,133 44.61 1,960 77.17...
Page 30: Working Areas Of Flow Meters
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 5.5.3 WORKING AREAS OF FLOW METERS Flow meters: A/B: 0.02 – 3 l/min Viscosity: A: min. 5 mPa·s min. 5 mPa·s Working area [5:1] [50:1] Mixing ratio (volumetric) A:B (0 = only A) Flow meters: A: 0.02 –...
Page 31 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Flow meters: Viscosity: A: 0.02 – 3 l/min A: min. 5 mPa·s 0.005 – 2 l/min min. 5 mPa·s 0.005 – 0.5 l/min 1-100 mPa·s Working area Max. amount A+B+C with corresponding mixing ratio A:B, and C = 0.25 l/min (for maximum value) or 5cc/min (for minimum value)
Page 32: Application Limits Of Flow Meters
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Flow meters: Viscosity: A: 0.5 – 25 l/min 0.1 – 7 l/min Maximum viscosity depending on flow rate Working area Standard B_01660 Mixing ratio volumetric A:B [A:1] (0= only A) 5.5.4 APPLICATION LIMITS OF FLOW METERS Viscosity All viscosity information in this chapter are approximate values.
Page 33: Version 05/2017 Order Number Doc
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL...
Page 34: Mixing Types
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL MIXING TYPES For mixing components A, B, C and D, three versions are available: A) With mixing block (standard) B) With mixing head valve C) With external mixer A) Mixing block (standard) Example: 3K system with 6 A valves, A Flushing (air) 4 B valves, 2 C valves and 2 guns...
Page 35 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL B) Mixing head valve A Flushing (air) Example: 3K system with 6 A valves, 4 B valves, 2 C valves and B1 Flushing 2 guns B2 Flushing Flushing A The mixing head valves B and C are cycled and regulated with the AIS dosing system.
Page 36 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL C) External mixer Example: 3K system A Flushing (air) with 6 A valves, B1 Flushing 4 B valves, 2 C valves and 2 guns Flushing A Valves B1, B2 and C are B2 Flushing cycled.
Page 37: Dump Valve For Waste Separation (Option)
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL DUMP VALVE FOR WASTE SEPARATION (OPTION) In addition to the simple dump valve, there is also a dump valve for waste separation. When filling and when flushing, the system separates the flushing agent from the remaining product.
Page 38: Flow Measurement
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 5.10 FLOW MEASUREMENT The flow of components A, B, C and D can be measured as follows: − with flow meters − Gear flow meters − Coriolis flow meters (contact-free) − with stroke sensors (contact-free, from software version 4.0x / 4.0x K) Only one measuring method can be used within a component.
Page 39: Stroke Measuring
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 5.10.2 STROKE MEASURING For piston pumps, the flow can be measured contact-free with stroke sensors (from software version 4.0x / 4.0x K). For this, each pump must be equipped with a stroke sensor. There are three types of stroke sensors: Stroke sensor type Field of application...
Page 40: Flow Meters And Stroke Sensors
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 5.10.3 FLOW METERS AND STROKE SENSORS Flow meters and stroke sensor can be used simultaneously. The following should be noted: Only one measuring method can be used within a component. As soon as stroke sensors are used, the flushing pump must be equipped with a pressure sensor.
Page 41: Assembly And Commissioning
1,178; 46.4 800; 31.5 ASSEMBLY AND INSTALLATION The mixing units are normally installed by WAGNER technicians directly or by their agents. If this is not the case, the material has to be checked for damage on receipt of the system. WARNING Inclined ground! Risk of accidents if the device rolls away/falls.
Page 42 Protect the control cabinet from extreme temperature and moisture changes as well as dirt. The fluid section (non-Ex version) must not be installed in the explosion zone in the 2K COMFORT. Lay and fix the connecting cable correctly and protect it against tripping, dirt and traffic.
Page 43: Electrical Connections
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 6.4.1 ELECTRICAL CONNECTIONS An electric connection cable with plug is standardly provided. When exchanging the connection cable, please observe the following: Carry out the electrical connections and the grounding inside the control unit using a 3-wire cable of 1.5 mm2;...
Page 44: Flow Meter Monitoring
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 6.4.4 FLOW METER MONITORING For safe operation it is necessary for the 2K system to receive a signal, when the gun is open and there is 2K product flow. Otherwise for example no B product is added when the A flow meter is blocked, although A product continues flowing through the leakage in the flow meter (possibly not visible).
Page 45: Ventilation Of The Spray Booth
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL The lack-of-product protection with level probe is not supplied with the 2K system and has to be realized on-site. 6.4.6 VENTILATION OF THE SPRAY BOOTH WARNING Toxic and/or flammable vapor mixtures! Risk of poisoning and burns. Operate the device in a spray booth approved for the working materials.
Page 46 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Grounding scheme - example for 2K COMFORT non-Ex Non-Ex zone Ex zone R max. < 1 MOhm B_04657 Designation Designation Controller Conveyor Fluid section (non-Ex) Floor, static dissipative Pump Pneumatic alarm horn (option)
Page 47 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Grounding scheme - example for 2K COMFORT Ex Non-Ex zone Ex zone R max. < 1 MOhm B_04656 Designation Designation Controller Conveyor Fluid section (Ex) Floor, static dissipative Pump (Ex) Pneumatic alarm horn (option)
Page 48: Commissioning
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL COMMISSIONING WARNING Gas mixtures can explode if there is an incompletely ﬁlled device! Danger to life from flying parts. Ensure that the device is always completely filled with flushing agent or working medium.
Page 49: Initializing The Controller
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Pre-cleaning Before the product hoses are connected to the system, they should be flushed, together with the corresponding pumps, with the flushing agent to be used. Unless this preliminary flushing is executed, the flow meters can already be clogged due to contamination during the first flow through! For preliminary cleaning of the pumps, carefully follow the corresponding pump instructions.
Page 50: Venting The System
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 6.6.3 VENTING THE SYSTEM First bleed the system via the gun with little product pressure: Prepare a grounded metal bucket, that is suitable to collect all products to be disposed of. (see Chapter 7.8) Menu Select each A side valve, one after the other and perform the following steps: −...
Page 51: Filling The System
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 6.6.5 FILLING THE SYSTEM NOTICE Interchange of the two components A and B! Device damage by hardened product. Label device components and paint tank so that the components A and B are not mixed up.
Page 52: Controller
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL CONTROLLER TRAINING THE OPERATING STAFF The operating staff must be qualified to operate the entire system. The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures. Before work commences, the operating staff must receive appropriate system training.
Page 53: Control Cabinet
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL CONTROL CABINET There are four push-buttons and an operating panel (touch screen) for the system controller in the control cabinet. The touchscreen and the push-buttons can be used to communicate with the controller. Initialization program for commissioning: see Chapter 6.6.2 Basic operating principles: see Chapter...
Page 54: Mechanical Push-Buttons
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL MECHANICAL PUSH-BUTTONS The system's basic functions are controlled by four mechanical push-buttons: START STOP Flushing RECIPE CHANGE Starts spraying mode. Ends the spraying Starts end flushing of Switches to next paint or flushing process. the last paint recipe recipe.
Page 55: Select Language
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 7.5.1 SELECT LANGUAGE 1. [Menu] button (second button in bottom row) 3. Touch language: [English] 7.5.2 KEYBOARD INPUT A keyboard with numbers or letters appears as necessary when fields with frames are touched.
Page 56: Passwords
Plus basic system settings WAGNER Service − Department The passwords, which are set by WAGNER at the time of the equipment delivery, are not contained in the manual for safety reasons. The valid passwords are communicated to the customer separately. Password input 1.
Page 57: Home Page Operation
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 7.6.2 HOME PAGE OPERATION All fields with frames can be touched. Number of current paint recipe Mixing ratio (volumetric) Pot life Paint recipe Remaining pot life in minutes or seconds. Opens choice of all paint recipes.
Page 58: Menu
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL MENU Button Function Alarm Calls up list of the last 700 warning messages. Manual operation Specific opening and closing of product or flushing valves. Chapter Tank Software Documentation Change name (password level 1) Chapter 7.9.2 Flushing recipes (password level 1)
Page 59: Manual Mode: Open Valves
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL MANUAL MODE: OPEN VALVES Menu Select paint recipe (for A/B/C/D). Or select flushing valve (for A/B/C/D flushing valves). Valve used by paint recipe. The buttons with reversed colors show our (See other used valves: buttons A/B/C/D.) current location: Current flow Select component...
Page 60: Recipes
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL RECIPES 7.9.1 ADD NEW RECIPES Create a new flushing recipe: 1. Increase the "Number of flushing recipes" in the settings by one (see Chapter 7.13.1). 2. Change the flushing recipe's automatically assigned name (see Chapter 7.9.2). 3.
Page 61: Enter Flushing Recipe
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 7.10 ENTER FLUSHING RECIPE Menu Select existing flushing recipe. (New flushing recipe: see Chapter 7.9.1) Current flushing step for input on this page. Define total number of flushing steps for this recipe. 1–16 Example with splitter valve, dump valve and product...
Page 62: Enter Paint Recipe
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 7.11 ENTER PAINT RECIPE (with password level 1 or higher) Menu Enter mixing ratio (volume) for the selected Select existing paint recipe. recipe New recipe: see Chapter 7.9.1 0.1:1–50.00:1 0.02% – 1,000.00% If one or several components are not required: enter 0.00:1 or 0.00%.
Page 63 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Page 4 (option) − Flow regulation: pre-define flow set value for this paint recipe. Settings: "Flow regulation" see Chapter 7.13.2 (password level 3, page 19) Page 5 (option) − Flow monitoring: enter minimum and maximum flow in cc/min. (For example, with robot applications to monitor nozzle wear and nozzle blockages.) Prerequisite: gun monitoring or flow monitor.
Page 64: Calibration
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 7.12 CALIBRATION Coriolis measuring system: K factor = 60, 000 Imp/L 1. Enter "60, 000" in the Kn field in all paint recipes for components with Coriolis measuring system and then save. 2.
Page 65 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 12. In all paint recipes, calibrate all components. With identical flow meters (identical components) and identical lacquers or lacquers with similar characteristics, the K factor can be taken over: Enter the value directly in the Kn field and then save. Exact calibration, version 1 (Lacquer density is known) −...
Page 66: Settings
There are 24 pages of settings. Depending on configuration, pages may be jumped. The page numbers with a gray background always appear, the others are optional. (Detailed descriptions of these pages can be found in the 2K COMFORT Software Documentation.) Number of paint recipes and number of flushing recipes.
Page 67 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 10+11 Like pages 8 + 9, but for gun 2. 12+13 Like pages 8 + 9, but for gun 3. 14+15 Like pages 8 + 9, but for gun 4. 16 The flushing pause indicates that with "Atom.air on flush % of hose volume" the remainder must be sprayed into the waste tank.
Page 68 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 18 Save Start/Stop totals USB stick "On": Start/Stop totals are written continuously to a USB stick (USB stick must be plugged in). PC data archiving "On": Data are archived continuously on PC. (Operating manual for PC data archiving, see Chapter 1.3.1) 19 For AIS-B: AIS warning limit...
Page 69: Password Level 3 Settings
Minimum and maximum flow. Sets off Alarms A106 to A113. (Delay time "Gun Delay" see Chapter 7.13.1, level 2, page 1) Air bubbles monitoring (On/Off ) Coriolis flow meter Flow measurement with stroke sensors (On/Off ), from software version 4.0x / 4.0x K. To configure stroke sensors: see 2K COMFORT software documentation.
Page 70 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Only for Coriolis: Density area lower and upper value. The actual density must correspond to the density display of the C-flow measuring transducer (with liquid in the system). Correct the value here if necessary. Temperature range lower and upper value.
Page 71 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 16 Batch Mode Allows a recurring and pre-defined flow rate to be discharged (see software documentation). Measuring unit for pot life minutes or seconds. (Change recipes accordingly after changeovers!) Booster pump (Off / A-side / Mix-side) A valve selection at start "On": After starting, a prompt appears asking which A valve is to be used for the selected recipe.
Page 72 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 19 Flow regulation (On/Off ). P- (proportional-)part and I- (integral-)part of controller. Number of flow measurements, which are included in the calculation. Time period between the flow measurements. 20 Flow meter in external flushing agent (On/Off ). Flow switch in external flushing agent (On/Off ).
Page 73: Operating Panel For 2-Circuit System
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 7.14 OPERATING PANEL FOR 2-CIRCUIT SYSTEM The operating panel controls either the fluid Current fluid circuit: circuit 1 or the fluid circuit 2. = Fluid circuit 1 = Fluid circuit 2 Example: Home page for circuit 1 1/2 = affects both fluid circuits Touch...
Page 74: K1 And /K2
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 7.14.2 /K1 AND /K2 Names and alarm messages, which refer to a specific fluid circuit, are marked with "/K1" or "/K2". Name / Alarm message Meaning …/K1 … Circuit 1 …/K2 … Circuit 2 …...
Page 75: Operation
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL OPERATION Below, operation with manual guns is described. For automatic guns the same workflow applies correspondingly. TRAINING THE OPERATING STAFF The operating staff must be qualified to operate the entire system. The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.
Page 76: Switches The System On And Off
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL SWITCHES THE SYSTEM ON AND OFF Switching the system on 1. Turn red-yellow main switch on the right side of the control cabinet to ON. The software is started. 2. Turn on the air supply of the system and of all feed pumps. Prepare feed pumps, lacquer tank etc.
Page 77: Spraying Mode
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL SPRAYING MODE 8.5.1 PREREQUISITES Optimum painting results are obtained if: − The system parameters are set correctly. − Product data such as the mixing ratio and pot life correspond to the working material. −...
Page 78: Spraying Without Gun Flush Box
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 8.5.3 SPRAYING WITHOUT GUN FLUSH BOX Provide grounded metal bucket to collect the products to be disposed of. Insert spray nozzle into manual gun. The product pressure of the components is set depending on the required product flow rate.
Page 79: Spraying With Gun Flush Box
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 8.5.4 SPRAYING WITH GUN FLUSH BOX Same procedure as in Chapter 8.5.3, however: before actuating the START push button, insert the spray gun into the gun flush box. Remove the spray gun after filling. 8.5.5 INTERRUPTING WORK The STOP push button stops the coating process.
Page 80: Flushing
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL FLUSHING DANGER Exploding gas / air mixture! Danger to life from flying parts and burns. Never spray into a closed tank. Ground the tank. If a high-pressure gun is used, remove the spray nozzle before flushing. −...
Page 81 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL End flushing The FLUSHING push button normally starts the end flushing of the last paint recipe used. 1. Stopping the system. 2. For electrostatic spray guns: switch off electrostatics. Actuate FLUSHING push button. 4.
Page 82 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Start other flushing recipes For electrostatic spray guns: switch off electrostatics. On the screen's home page. Depending on the configuration, various selection possibilities appear: − Manual flushing: select a recipe from the list of all recipes. −...
Page 83: Flow Chart With Paint Recipe Change
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL FLOW CHART WITH PAINT RECIPE CHANGE Example for 2K system: Spraying with paint recipe Spraying with paint recipe Recipe change flushing Mixed Mixed product R-R Flushing Filling Filling Filling product End flushing 1.
Page 84: Pressure Relief Procedure
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL PRESSURE RELIEF PROCEDURE The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. To reduce the risk of an injury from injection, splashing fluid or moving parts, follow the steps in this chapter whenever: you are instructed to relieve the pressure;...
Page 85: Cleaning And Maintenance
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL CLEANING AND MAINTENANCE CLEANING 9.1.1 CLEANING STAFF Cleaning work should be undertaken regularly and carefully by qualified and trained staff. They should be informed of specific hazards during their training. The following hazards may arise during cleaning work: −...
Page 86: Cleaning The System
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 9.1.4 CLEANING THE SYSTEM The system should be cleaned for maintenance purposes. Ensure that no remaining product dries on and sticks to the device. A cleaned system allows an easy localization of any leakage and quick repair. Procedure: 1.
Page 87: Maintenance
Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.
Page 88: Gear Flow Meter
− It is important that the gears turn on the shaft, if they don't, the flow meter is not suitable for the lacquer. Contact WAGNER Service Department for further information. Assembly After cleaning the gear flow meter and assembling the shafts and gears into the housing, check whether they turn easily, without any obstruction.
Page 89: Cleaning And Replacing The Product Filter
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 9.2.4 CLEANING AND REPLACING THE PRODUCT FILTER 1. Flush the pump and inline filter in accordance with pump's 53 MPa; 530 bar; 7,687 psi operating manual. Flush using the gun so that the flushing agent flows through the inline filter. Maximize the flow (remove the nozzle, open the dosing valve if necessary).
Page 90: Product Hoses, Tubes And Couplings
Meaning (if present) xxx bar Pressure yymm Crimping date (year/month) Internal code Hose imprinting Meaning WAGNER Name / Manufacturer yymm Date of manufacture (year/month) xxx bar (xx MPa) Pressure e.g., 270 bar (27 MPa) Internal code DNxx (e.g., DN10) Nominal diameter...
Page 91: Troubleshooting
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 10 TROUBLESHOOTING If a fault occurs, it is indicated by the following: The system stops. The alarm horn sounds. Control cabinet: The red STOP push button lights up. The fault is indicated on the screen. Remote control (option): The red LED STOP lights up.
Page 92 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Malfunction Remedy The 2K product does − Check the mixing ratio value. not react correctly − Check the suction lines (leakage). − Check the flow meter with a calibration process. − Check pressure differences. see Chapter 8.5.2 −...
Page 93: Alarm Messages
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 10.1 ALARM MESSAGES In the case of an alarm message, the system stops. The alarm horn sounds. The red STOP push button lights up (control cabinet and remote control). The fault is indicated on the screen. Alarm No.
Page 94 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Alarm No. Alarm message in the display Meaning A128 Coriolis A A129 Coriolis B For Coriolis error, see operating manual of Coriolis flow meter. A130 Coriolis C A131 Coriolis D A132 Pot life gun 1 A133 Pot life gun 2 Pot life + post-alarm time of guns 1/2/3/4 have expired.
Page 95 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Alarm messages with stroke measurement Alarm No. Alarm message in the display Meaning / Fault rectification A200 Unknown error Error number unknown. A201– Stroke sensor cable breakage or sensor signal lost Sensor A/B/C/D signal is lost A204 (sensor is in lower idle position).
Page 96 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL CAN I/O modules alarm messages Alarm No. Alarm message in the display Meaning A500 Initialisation error Internal error when starting up the touch panel. A501 CAN master error The touch panel CAN master process not possible. The touch panel CAN master found no connected A502 CAN master alone...
Page 97 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL Alarm No. Alarm message in the display Meaning A616 Module D2 hardware error EEPROM A617 Module D3 hardware error EEPROM A618 Module D4 hardware error EEPROM A619 Module D5 hardware error EEPROM A620 Module D2 hardware error ADC A621...
Page 98: Fault Rectification
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 10.1.1 FAULT RECTIFICATION A100/A101/A102 B+/C+/D+ tol. alarm The mixing ratio within a specific control quantity (QB/QC/QD control) was not reached: too much B, C or D. − Reduce pressure of B/C/D: see Chapter 8.5.2 −...
Page 99 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL A106/A107/A108/A109 A+/B+/C+/D+ flow rate The flow is greater than the upper limit of the flow meter "Maximum flow" (see Chapter 7.13.2, level 3, page 4). − The flow rate has to be reduced. −...
Page 100 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL A122 Flow fault + The flow rate is above the limit entered in the paint recipe (see Chapter 7.11). − Replace gun nozzle (Airless and AirCoat). − Check the lines for leakage. −...
Page 101 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL A136/A137/A138/A139 Pot life gun hose 1/2/3/4 Pot life + post-alarm time have expired. Continue working immediately or flush. A140 Pot life up to splitter valve Pot life + post-alarm time have expired. Continue working immediately or flush. A141/A142/A143/A144 Pot life dump hose 1/2/3/4 Pot life + post-alarm time in dump hose have expired.
Page 102 MPX transfer error Communication errors between the touch panel, MPX multiplexer and A/D converter ADC. − Check cable with plug. − Check compatibilities (software versions touch panel / MPX / ADC). − If this occurs repeatedly, contact the WAGNER Service Department.
Page 103 Communication errors between the touch panel, MPX multiplexer and A/D converter ADC. − Check cable with plug. − Check compatibilities (software versions touch panel / MPX / ADC). − If this occurs repeatedly, contact the WAGNER Service Department. A260 Sending to MPX interrupted The sending of settings data to the MPX and ADC was not terminated.
Page 104 VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL A503 SDO sending error A504 SDO receiving error Error while sending or receiving SDO telegrams. − Switch off the system and back on via the main switch. − Contact the Service Team. A505 Saving interrupted An error occured while saving on the PC.
Page 105: Warning Messages
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 10.2 WARNING MESSAGES In the case of warning messages, the system does not stop, work can be continued. The red STOP push button blinks (control cabinet and remote control). The fault is indicated on the screen. Alarm No.
Page 106: Fault Rectification
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 10.2.1 FAULT RECTIFICATION W100/W101/W102/W103 Pre-alarm for the pot life of gun 1/2/3/4 Pot life has expired. Continue working immediately or flush. W104/W105/W106/W107 Pre-alarm for pot life gun hose 1/2/3/4 Pot life has expired. Continue working immediately or flush. W108 Pre-alarm for pot life from mixer to splitter valve Pot life has expired.
Page 107: Repairs
Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.
Page 108: Mounting Materials
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 11.3 MOUNTING MATERIALS In the spare parts catalog the order numbers for device spare parts can be found, as well as for wearing parts such as seals. Use torques, greases and glues in accordance with the spare parts catalog. Mounting materials Order No.
Page 109: Disposal
WAGNER or one of our dealers will take back your used WAGNER electric or electronic equipment and will dispose of it for you in an environmentally-friendly way.
Page 110: Accessories
Before the installation of an accessory set, it must be checked whether enough room in the fluid cabinet and enough connections in the control cabinet are available: 1. Open on the 2K COMFORT USB stick (see Chapter 1.4) the assembly manual of the required set.
Page 111: Connection Table 2K Comfort
OPERATING MANUAL 13.2 CONNECTION TABLE 2K COMFORT The "2K COMFORT connection table" is delivered together with the system and must be adapted for each conversion. It is available on the USB stick (see Chapter 1.4). The table is divided into five sections:...
Page 112: Control Cabinet Diagrams
Assembly Have expansion and accessory sets be installed only by specially trained staff or a WAGNER service center. Carry out each assembly according to the corresponding assembly manual. A skilled person must check to ensure that the device is in a reliable state after it is mounted.
Page 113: Installation By Customer Or By Wagner Service Department
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 13.4.1 INSTALLATION BY CUSTOMER OR BY WAGNER SERVICE DEPARTMENT Expansion and accessory sets Non-XL Non- High pressure pressure Order No. Name Paint/flushing valve set, high pressure, DN 2.6 2358991 (for 1–2 A components)
Page 114 External mixer automatic, high pressure DN4 / DN10VA 2339621 External mixer automatic, low-pressure (DN 4) 2360730 CAN I/O output expansion * Can not be used for 2-circuit systems. ** Prerequisite for PC data archiving: Network connection of the 2K COMFORT system by WAGNER Service Department...
Page 115: Stroke Measuring
ADC-0301 with bus cable 50 m; 164 ft 2376555 Stroke sensor 1 2305981 Stroke sensor 2 2305982 Pressure switch 2351041 13.4.2 INSTALLATION BY WAGNER SERVICE DEPARTMENT Expansion and accessory sets Non-XL Non- High pressure pressure Order No. Name Dosing valve set DN 2.6, 400 bar TC, Ex (For 1–2 B/C/D-valves, if component is already present.
Page 116: Ais
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 13.4.2.1 AIS AIS accessories sets AIS dosing system: − For description, see Chapter − For example, see Chapter (diagram B) Following accessories must be ordered for each B/C/D-component, which is to be equipped with AIS: Non-Ex Name...
Page 117: Accessories Sets For External Flushing Agent
− Splitter valve, flushable − Dump valve, flushable − Dump valve for waste separation The external flushing can be done in three ways. Optionally, an accessory set is required (installed by the WAGNER Service Department): Accessories set Detail in the Flushing mode...
Page 118: Remote Control Assembling
The impacts are always the same regardless of whether the function is activated on the remote control or control cabinet. Activate all functions on remote control and control cabinet at least once. Carry out commissioning and parameter settings according to the operating manual and the 2K COMFORT software manual.
Page 119: Safety Instruction Remote Control
Warning: Any repair by a repair shop according to EN 60079-19 is not possible due to flame path gaps smaller than the maximum permitted by EN 60079-1. Contact the WAGNER service center in Markdorf (Germany) if a repair is necessary. NOTICE Magnetic fields! Danger of damage to electronic devices and magnetic data carriers.
Page 120: Operation
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 13.5.3 OPERATION DANGER Magnetic fields! Danger to life from malfunction of heart pacemakers. Make sure that persons with pacemakers: Do not use the device. Do not enter in the area of the magnetic pin. The same four functions as on the control cabinet are on the remote control: START, STOP, FLUSHING and RECIPE CHANGE.
Page 121: Spare Parts
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 14 SPARE PARTS Spare parts catalog Order No., see Chapter 1.3.
Page 122: Declaration Of Warranty And Conformity
The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with.
Page 123: Eu Declaration Of Conformity For 2K Comfort
DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36 Identification: EU Declaration of Conformity The EU Declaration of Conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order number: 2359623...
Page 124: Eu Declaration Of Conformity For 2K Comfort (With Ex Identification)
DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36 TRGS 727 Identification: EU Declaration of Conformity The EU Declaration of Conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order number: 2359625...
Page 125: Ec Declaration Of Conformity For Remote Control
Applied national technical standards and specifications, in particular: TRBS 2153 Identification: EU Declaration of Conformity The EU Declaration of Conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order number: 2343991...
Page 126: Appendix
VERSION 05/2017 ORDER NUMBER DOC 2357061 OPERATING MANUAL 16 APPENDIX 16.1 CONVERSION OF THE MIXING RATIO SPECIFICATIONS It is very important that the data sheets of the paint supplier are available, so that the correct mixing ratio can be entered. Some lacquer manufacturers state the mixing ratio by weight, others by volume or ratio.
Page 128 Order No. 2357061 Version 05/2017 Germany Phone Telefax E-mail ts-liquid@wagner-group.com Switzerland Phone Telefax More contact addresses: www.wagner-group.com Subject to changes without notice...

WAGNER 2K COMFORT Original Operating Manual

1 About These Instructions

2 Correct Use

3 Identification

4 Basic Safety Instructions

5 Description

6 Assembly and Commissioning

7 Controller

8 Operation

9 Cleaning and Maintenance

10 Troubleshooting

11 Repairs

12 Disposal

13 Accessories

14 Spare Parts

15 Declaration of Warranty and Conformity

16 Appendix

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Summary of Contents for WAGNER 2K COMFORT

Table of Contents