WAGNER TwinControl 35-70 Manual
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WAGNER TwinControl 35-70 Manual

WAGNER TwinControl 35-70 Manual

Electronically controlled 2k systems
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TwinControl

Electronically Controlled 2K Systems
Edition: 08/2020
Software version: Valid for systems with software version
V 4.xx

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Summary of Contents for WAGNER TwinControl 35-70

  • Page 1: Twincontrol

    TwinControl Electronically Controlled 2K Systems Edition: 08/2020 Software version: Valid for systems with software version V 4.xx...

  • Page 3: Table Of Contents

    Electrical Devices and Equipment 4.1.2 A Safe Work Environment 4.1.3 Personnel Qualifications Safety Instructions for the Personnel 4.2.1 Personal Safety Equipment 4.2.2 Safe Handling of WAGNER Spray Devices 4.2.3 Grounding the Device 4.2.4 Product Hoses 4.2.5 Cleaning and Flushing 4.2.6 Touching Hot Surfaces 4.2.7...
  • Page 4 TwinControl Electronically Controlled 2K Systems Table of Contents 5.7.1 Controller 1 / 9 / 10 for Pumps 5-60 to 35-150 5.7.2 Controllers 2 / 3 / 6 / 8 for Pumps 48-110 to 8-600 Operating Elements and Control Unit Connections Pneumatic Diagram 5.9.1 TwinControl 1...
  • Page 5 TwinControl Electronically Controlled 2K Systems Table of Contents Switching on the system Switching off the system Spraying mode Flushing Pressure Relief / Work Interruption 8.10 Automatic Electrostatic System Set for Electrostatic Gun GM 5000 (Option) 8.10.1 Commissioning and Settings 8.10.2 Paint filling 8.10.3 Spraying mode 8.10.4 Work interruption (STOP) 8.10.5 Flushing...
  • Page 6 TwinControl Electronically Controlled 2K Systems Table of Contents 13.3 Horn Alarm 13.4 Suction Hoses 13.5 Mixing hoses 13.6 13.7 Heater 13.8 Splitter valve 13.9 Product pressure regulator 13.10 Flushing Pressure Set 13.11 Additional Parts for Second Paint (2A) 13.12 Extension Cables 13.13 TC VM5000 Automatic Electrostatic System 13.14 Connection kit, GFB 13.15 Feed pump...

  • Page 7: About These Instructions

    TwinControl Electronically Controlled 2K Systems 1   About these instructions 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.

  • Page 8: Operating Manuals For The Individual Components

    2407458 Czech 2413915 Additional languages upon 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...

  • Page 9: Twincontrol Cd

    TwinControl Electronically Controlled 2K Systems 1   About these instructions 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...

  • Page 10: Terminology For The Purpose Of This Manual

    TwinControl Electronically Controlled 2K Systems 1   About these instructions TwinControl TC 1.4404 TwinControl for acidic hardeners Protective Coating: heavy duty corrosion protection High pressure 4-50 MPa; 40-500 bar; 580-7250 psi Highest pressure over 50 MPa; 500 bar; 7250 psi ESTA Electrostatically charged device Materials Stainless steel...

  • Page 11: Correct Use

    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: 4 Use the device only to work with the products recommended by WAGNER.

  • Page 12: Improper Use

    TwinControl Electronically Controlled 2K Systems 2   Correct Use – 2K products with acidic hardener (only with TwinControl systems for acidic hardeners) 4 Solvent and water-based 2K products should not be processed using the same system. Materials in direct contact with the products: see Chapter Materials of Paint-wetted Parts [8 25] NOTICE Abrasive working materials and pigments!

  • Page 13: Identification

    0102   II 2 G Ex ia IIB T4 ZELM 08 ATEX 0385 X +5 °C < Ta +40 °C European Communities 0102 Number of the notified body that is used by WAGNER in the production monitoring phase (PTB Germany in this case) Symbol for explosion protection Device class II...

  • Page 14: Identification For Devices With A Mains Power Supply

    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 European Communities Identification and special notices regarding pumps 4 See operating manuals for pumps...

  • Page 15: Type Plates

    TwinControl Electronically Controlled 2K Systems 3   Identification 3.3   TYPE PLATES TwinControl - Turbine Wagner International AG Made in Switzerland CH 9450 Altstätten Type / Typ: TwinControl Serial No unit.: Serie Nr. Anlage: II 2 G Ex ia II B T4 ZELM 08 ATEX 0385 X +5°C <...
  • Page 16 TwinControl Electronically Controlled 2K Systems 3   Identification TwinControl – Cable with mains supply Made in Switzerland Wagner International AG CH 9450 Altstätten Type / Typ: TwinControl Year of construction / Baujahr: Serial No unit.: Serie Nr. Anlage: Serial No. controller: Serie Nr.

  • Page 17: Basic Safety Instructions

    TwinControl Electronically Controlled 2K Systems 4   Basic Safety Instructions 4   BASIC SAFETY INSTRUCTIONS 4.1   SAFETY INSTRUCTIONS FOR THE OPERATOR 4 Keep this operating manual at hand near the device at all times. 4 Always follow local regulations concerning occupational safety and accident prevention regulations.

  • Page 18: Personnel Qualifications

    TwinControl Electronically Controlled 2K Systems 4   Basic Safety Instructions 4 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. 4 Ensure that during spraying, persons wear static dissipative gloves. The grounding takes place via the spray gun's handle or its trigger.

  • Page 19: Safe Handling Of Wagner Spray Devices

    4 In the event of functional faults, remedy the fault as described in the Troubleshooting chapter 4 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: Product Hoses

    TwinControl Electronically Controlled 2K Systems 4   Basic Safety Instructions 4 Wear static dissipative gloves when spraying. The grounding takes place via the spray gun's handle or its trigger. 4.2.4   Product Hoses Danger due to bursting of product hose! The product hose is under pressure and may cause dangerous injuries. 4 Ensure that the hose material is chemically resistant to the sprayed products and the flushing agents used.

  • Page 21: Touching Hot Surfaces

    TwinControl Electronically Controlled 2K Systems 4   Basic Safety Instructions 4 Never use chloride or halogenated solvents (such as trichloroethane and methylene chloride) with devices containing aluminium or galvanized/zinc-plated parts. They may react chemically thus producing an explosion danger. 4 Take measures for workplace safety. 4 It should be noted that when the device is put into operation or emptied: depending on the coating product used, depending on the rinsing agent (solvent) used, there may briefly be a mixture inside the pipes and equipment which can ignite.

  • Page 22: Protective And Monitoring Equipment

    TwinControl Electronically Controlled 2K Systems 4   Basic Safety Instructions 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel.

  • Page 23: Description

    TwinControl Electronically Controlled 2K Systems 5   Description 5   DESCRIPTION 5.1   COMPONENTS B_07720 Pneumatic pump for A-component Flushing pump [S] Pneumatic pump for B component TwinControl control unit Frame Mixing unit Trolley Wall mount 5.1.1   TwinControl Finishing and Protective Coating Depending on size, various suspensions are available for TwinControl systems: Order number 2339321 | Edition 08/2020...

  • Page 24: Mode Of Operation

    TwinControl Electronically Controlled 2K Systems 5   Description TwinControl Finishing TwinControl Protective Coating (PC) Suspension Small frame Large frame small trolley large trolley small wall Pump A 5-60*, 10-70, 28-40, 21-110, 95-150, 72-200, 60-240 26-200, 3-600, 35-70, 35-150, 48-110, 8-600 Spraying procedure Airless Airless AirSpray...

  • Page 25: Technical Data

    TwinControl Electronically Controlled 2K Systems 5   Description Description Order no. Separating agent 250 ml; 250 cc 9992504 CE Declaration of Conformity See Chapter Declaration of Conformity [8 129] Operating manual, in German 2339287 Operating manual in the local language See Chapter Languages [8 7] TwinControl compact disc (CD, see Chapter 2339342 TwinControl CD [8 9])
  • Page 26 TwinControl Electronically Controlled 2K Systems 5   Description Unit TwinControl control units with turbines IP Code IP 54 Compressed air quality: free Quality standard 7.5.4 in accordance with ISO 8573.1, 2010 from oil and water 7: Particle concentration 5–10 mg/m 5: Humidity: Pressure condensation point ≤ +7 °C 4: Oil content ≤...

  • Page 27: Control Units With Mains Power Supply (Cable)

    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 may only be used in an environment at risk of explosion if used along with a system with a turbine.

  • Page 28: Entire System

    TwinControl Electronically Controlled 2K Systems 5   Description 5.5.4   Entire System Working areas Unit Limits Input air pressure 0.6–0.8 6–8 87–116 Maximum permissible number of strokes by pumps in DH/min two-component operation Maximum recommended strokes per minute of DH/min pumps in 2K operation Maximum product pressure levels see Chapter Pumps [8 29]...

  • Page 29: Pumps

    – Correct use of the system in accordance with the specific operating conditions such as the permitted product and ambient temperature, suitable viscosity and flow rate. – Regular maintenance has to be carried out by a qualified person (e.g., WAGNER service technician) in accordance with Chapter Maintenance [8 100]. 5.5.5   Pumps...
  • Page 30 TwinControl Electronically Controlled 2K Systems 5   Description EvoMotion / Wildcat / Puma Unit Pump air inlet diameter (inside thread) inch G 1/2" Pump air input diameter 8.0; inch 0.31 Sound pressure level See operating manuals for pumps and valves Leopard / Protec / (Jaguar) / Tiger Unit Pump ratio 35:1...

  • Page 31: Dimensions

    TwinControl Electronically Controlled 2K Systems 5   Description 5.5.6   Dimensions B_04488 TwinControl on small frame Pumps EvoMotion, Wildcat, Puma, Leopard without with heater heater A + B mm; inch mm; inch 860; 33.9 1205; 47.5 1551; 61.1 550; 21.7 TwinControl on large frame Pump Protec without...
  • Page 32 TwinControl Electronically Controlled 2K Systems 5   Description Without heater B_04489 With heater B_04490 TwinControl on wall Type mm; inch 917; 36.1 1022; 40.2 1005; 39.6 1243; 48.9 1202; 47.3 1015; 40.0 1239; 48.8 1183; 46.6 1197; 47.1 512; 20.2 892; 35.1 238;...
  • Page 33 TwinControl Electronically Controlled 2K Systems 5   Description TwinControl on wall Type with heater 1210; 47.6 1114; 43.9 1243; 48.9 1202; 47.3 1114; 43.9 1239; 48.8 1183; 46.6 1197; 47.1 TwinControl on small trolley Pumps Wildcat, Puma, Leopard without with heater heater A + B mm;...

  • Page 34: Weights

    TwinControl Electronically Controlled 2K Systems 5   Description TwinControl on large trolley Pumps Protec without with heater heater A + B mm; inch mm; inch 1035; 40.8 1845; 72.6 1314; 51.7 1377; 54.2 5.5.7   Weights Sample configurations Weight Suspension Pumps Turbine Cable Frame 3x EvoMotion 5-60...

  • Page 35: Principle Diagram

    TwinControl Electronically Controlled 2K Systems 5   Description (**) Automatic electrostatic system must be installed, order no. 2334530 5.7   PRINCIPLE DIAGRAM 5.7.1   Controller 1 / 9 / 10 for Pumps 5-60 to 35-150 Use with A-pumps 5-60, 10-70, 28-40, 21-110, 35-70, 35-150 with single-acting product valves with spring reset.

  • Page 36: Operating Elements And Control Unit Connections

    TwinControl Electronically Controlled 2K Systems 5   Description Controllers 2 / 3 / 6 / 8 for turbine: The turbine generates the current from compressed air. Controllers 2 / 3 for cable: Controller with electrical mains connection. For differences in controllers 2, 3, 6 and 8: see Chapter 5.6 1.0:1 1.0:1 1.0:1...
  • Page 37 TwinControl Electronically Controlled 2K Systems 5   Description 128 126 127 125 TwinControl B_02601 101 Push button [Start] 102 Push button [Stop] 103 Push button [Flush AB] 109 Alarm illuminated display 110 Pot life illuminated display 111 Service functions illuminated display 112 Calibration illuminated display 113 Totals illuminated display 114 Work illuminated display...
  • Page 38 TwinControl Electronically Controlled 2K Systems 5   Description Wagner International AG Made in Switzerland CH 9450 Altstätten Type / Typ: TwinControl Serial No unit: Serie Nr. Anlage: II 2 G 0102 Ex ia II B T4 ZELM 08 ATEX 0385 X +5°C <...

  • Page 39: Pneumatic Diagram

    TwinControl Electronically Controlled 2K Systems 5   Description 5.9   PNEUMATIC DIAGRAM 5.9.1   TwinControl 1 B_07283 Connection numbers for control unit 1 (at rear) Designation Product valve A Hardener valve B Gun flush box (option) Flushing valve air External horn Automatic electrostatic system (option) Flushing Changeover signal –...

  • Page 40: Twincontrol 2 / Twincontrol

    TwinControl Electronically Controlled 2K Systems 5   Description Further designations Designation Air supply System compressed air monitoring Air regulator for operating pressure Control air pressure 0.6–0.8 MPa; 6–8 bar; 87–116 psi Product pressure regulator, pneumatic 5.9.2   TwinControl 2 / TwinControl 3 B_07284 Connection numbers for control units 2/3 at rear Designation...

  • Page 41: Twincontrol 6 / Twincontrol

    TwinControl Electronically Controlled 2K Systems 5   Description Designation Air motor for spraying / air motor for soft circulation A+B Automatic electrostatic system (option) Flushing AS Changeover signal – pump A Changeover signal – flushing pump A Changeover signal – flushing pump B Changeover signal –...

  • Page 42: Twincontrol 9 / Twincontrol

    TwinControl Electronically Controlled 2K Systems 5   Description Connection numbers for control units 6/8 at rear Designation Product valve A Hardener valve B TwinControl 6: AS flushing TwinControl 8: gun flush box Flushing BS Circulation valve A, B External horn TwinControl 6 external mixer hardener valve TwinControl 8: AS flushing Air motor for spraying / air motor for soft circulation A+B AIS / control valve B (for AIS assembly on large valves)
  • Page 43 TwinControl Electronically Controlled 2K Systems 5   Description TwinControl 9: TwinControl 9: TwinControl 10: TwinControl 10: TwinControl 9: TwinControl 9: TwinControl 10: TwinControl 10: Connection numbers for control units 9/10 at rear Designation Product valve A Hardener valve B Gun flush box (option) TwinControl 9: stepping motor B Z1 TwinControl 10: air flushing External horn...

  • Page 44: List Of Service Functions

    TwinControl Electronically Controlled 2K Systems 5   Description Further designations Designation Air supply System compressed air monitoring Air regulator for operating pressure Control air pressure 0.6–0.8 MPa; 6–8 bar; 87–116 psi TwinControl 10: Product pressure regulator, pneumatic 5.10   LIST OF SERVICE FUNCTIONS Software version V 4.0x / 4.1x / 4.2x Unit Description...
  • Page 45 TwinControl Electronically Controlled 2K Systems 5   Description P110 % of stroke Tolerance limit B for reversal point Adjustable P111 Actual value reversal point stroke sensor B below Adjustable P112 Actual value reversal point stroke sensor B above Adjustable P113 0, 1, 2, 3 Measuring unit (0 = liters, 1 = US gallons, 2 = British gallons, 3 = Con- Adjustable version factor, adjustable)
  • Page 46 TwinControl Electronically Controlled 2K Systems 5   Description P143 0 or 1 0 = flow monitoring off; 1 = flow monitoring on Adjustable P144 0-99999 cc/min Minimum flow Adjustable P145 0-99999 cc/min Maximum flow Adjustable P146 0.0-20.0 s Delay time until alarm if flow is outside of limits. Adjustable P147 0 or 1...

  • Page 47: Dry Running Protection

    TwinControl Electronically Controlled 2K Systems 5   Description P300 Cycles Number of dosing valve cycles after the AIS has performed a calcula- Adjustable tion (3–100) P301 AIS warning limit (opening time of the dosing valve in percent) Adjustable P302 AIS lower limit (opening time of the dosing valve in percent) Adjustable P303 AIS upper limit (opening time of the dosing valve in percent)

  • Page 48: Connection Kit For Gun Flush Box (Option)

    TwinControl Electronically Controlled 2K Systems 5   Description The automatic electrostatic system transmits the approval signal from a TwinControl system (as of version 4.03) to a VM 5000 control unit. If the electrostatic system for the gun may be switched on (after filling), the TwinControl system transmits the pneumatic approval signal to the pressure switch.

  • Page 49: Evomotion 5-125 Feed Pump

    TwinControl Electronically Controlled 2K Systems 5   Description 2. The pressure-relief valve must be cleaned regularly and after each activation: Flush with solvent. 5.16.1   EvoMotion 5-125 feed pump B_07208 Use with Protective Coating systems with pumps 95-150, 72-200. With these pumps, the maximum product pressure at the pump inlet is 2 MPa;...

  • Page 50: Maintenance Work On The Pumps

    TwinControl Electronically Controlled 2K Systems 5   Description NOTICE Maximum product pressure at pump inlet Damage to pump and seals. 4 Operate feed pump 5-125 at maximum 0.4 MPa; 4 bar; 58 psi air pressure. 5.17   MAINTENANCE WORK ON THE PUMPS NOTICE Hardened working product in the spraying system! Destruction of the spraying system.

  • Page 51: Assembly And Commissioning

    TwinControl Electronically Controlled 2K Systems 6   Assembly and Commissioning 6   ASSEMBLY AND COMMISSIONING 6.1   TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL 1. The assembly and commissioning personnel must have the technical skills to safely commission the device. 2. When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.

  • Page 52: Assembly And Installation

    4 Do not tilt the device when pushing/during transport. 6.4   ASSEMBLY AND INSTALLATION The system is installed and commissioned by the WAGNER service department or by an expert representative. When removing from the packaging, check the system parts for possible transport damage.

  • Page 53: Pneumatic Connections

    TwinControl Electronically Controlled 2K Systems 6   Assembly and Commissioning WARNING Danger of electric shock inside the control unit! Danger to life from electric shock. 4 May only be installed/maintained by skilled electricians or under their supervision. 4 Operation according to the safety regulations, fire protection and electrotechnical rules.

  • Page 54: Product Connections

    TwinControl Electronically Controlled 2K Systems 6   Assembly and Commissioning WARNING Brittle pressure regulator with filter! The tank on the pressure regulator with filter becomes brittle through contact with solvents and can burst. Flying parts can cause injury. 4 Do not clean the tank on the pressure regulator with filter using solvent. 6.4.2 ...
  • Page 55 TwinControl Electronically Controlled 2K Systems 6   Assembly and Commissioning J. Wagner AG Made in Switzerland CH 9450 Altstätten Type / Typ: TwinControl Serial No unit.: Serie Nr. Anlage: 0102 II 2 G Ex ia II B T4 X ZELM 08 ATEX 0385 X +5°C <...

  • Page 56: Grounding Scheme Example For Twincontrol With Turbine

    TwinControl Electronically Controlled 2K Systems 6   Assembly and Commissioning 6.5.2   Grounding Scheme example for TwinControl with Turbine Ex-Zone 1 und 2 Ex-Zone 1 and 2 TwinControl R max. < 1 MOhm B_07731 TwinControl frame Paint tank Work piece Conveyor Floor, static dissipative Flushing agent tank Remote Control (Option) 10 Horn (option)

  • Page 57: Basic Flushing And Pressure Tightness Test

    TwinControl Electronically Controlled 2K Systems 6   Assembly and Commissioning 2. Connect spray gun without nozzle with high-pressure hose to the mixing unit and secure with safety clip. 3. Check hoses for damage. 4. Check that all product-conveying connections are correctly connected. 5.
  • Page 58 TwinControl Electronically Controlled 2K Systems 6   Assembly and Commissioning 2. Connect compressed air supply. Switch the system on. 3. Place the suction hoses of the three pumps in a grounded metal tank with flushing agent. Use a separate, grounded, metal tank for each pump. Provide and ground an additional, empty metal tank.
  • Page 59 TwinControl Electronically Controlled 2K Systems 6   Assembly and Commissioning – Flush until the hose content has been emptied and clean flushing agent comes out. – Close and secure the spray gun. – Gradually increase pressure in pump B with the pressure regulator until maximum pressure is reached.

  • Page 60: Replacing Flushing Agent With Working Media

    TwinControl Electronically Controlled 2K Systems 6   Assembly and Commissioning 6.6.3   Replacing Flushing Agent with Working Media NOTICE Interchange of the two components A and B! Device damage due to hardened product. 4 Label device components and paint tank so that the components A and B are not mixed up.

  • Page 61: Calibrating The System

    TwinControl Electronically Controlled 2K Systems 6   Assembly and Commissioning – Open return valve of pump B. As soon as pure working product comes out, close return valve again. – Select component [B] in sub-menu and press [Start]. – Point the spray gun (preferably without nozzle) into the grounded metal tank. Release the spray gun safety and open carefully.
  • Page 62 TwinControl Electronically Controlled 2K Systems 6   Assembly and Commissioning 8. Repeat the calibration in order to check it. Large deviations may be due to the following error causes: – Air in the lines. Fill the lines with product and check the suction system. –...
  • Page 63 TwinControl Electronically Controlled 2K Systems 6   Assembly and Commissioning 1000 610.00 TwinControl TwinControl 1000 610.00 B_07738 e.g., weigh out 500 cm3 (= 0.5 liter) of A-prod- Set calibration A on the control unit. uct. Once 610 g has been discharged, enter 500 on Tubing to protect against overspray the control unit and confirm with [SET].

  • Page 64: Controller

    TwinControl Electronically Controlled 2K Systems 7   Controller 7   CONTROLLER 7.1   TRAINING THE OPERATING PERSONNEL 1. The operating personnel must be qualified to operate the entire system. 2. The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.
  • Page 65 TwinControl Electronically Controlled 2K Systems 7   Controller TwinControl B_07739 Alarm Pot life Tasks Main menu Sub-menu Display Setting buttons [Flush] button [Stop] button 10 [Start] button 11 Menu selection buttons Base position When switched on, the control unit is in its base position. The three lamps "Work", "A" and "B"...

  • Page 66: Entering Numbers [Set]

    TwinControl Electronically Controlled 2K Systems 7   Controller [Stop] button Device status Function of [Stop] button Program running Terminates active program. Resets all valves to origi- nal status. Program not running Returns to base position Setting input [SET] Terminates input without saving Alarm Acknowledges alarm.

  • Page 67: Basic Functions For The Painter

    Exceptions: Parameters P107, P108, P109, P110, P111, P112, P308 and P309 can be viewed only. The passwords, which are set by WAGNER at the time of the device delivery, are not contained in the operating manual for safety reasons. The valid passwords are communicated to the customer separately.

  • Page 68: Extended Functions With Password Protection

    TwinControl Electronically Controlled 2K Systems 7   Controller Flushing TwinControl B_07744 The flushing program runs automatically. The flushing program needs to have been defined in advance under service level 3 (with password protection). Also refer to flushing stages F1 to F33 in the service functions list in Chapter 5.10 and how to define the flushing program in Chapter 7.6.2.
  • Page 69 TwinControl Electronically Controlled 2K Systems 7   Controller Displays job total B in cm TwinControl B_07785 – Only convey flushing agent A (START / STOP) Displays job total for flushing agent A in cm TwinControl B_07786 – Only convey flushing agent B (START / STOP) Displays job total flushing agent B in cm Valid for: –...
  • Page 70 TwinControl Electronically Controlled 2K Systems 7   Controller TwinControl B_07789 – Total amount flushing A Set to "0": Press [SET] push button > 2 seconds. Display in liters. TwinControl B_07790 – Total amount flushing B Set to "0": Press [SET] push button > 2 seconds. Display in liters.
  • Page 71 TwinControl Electronically Controlled 2K Systems 7   Controller TwinControl B_07793 – Circulation of A and B components (only possible if option available) Service (password entry required for P100) TwinControl B_07794 – Content of spray hose with mixed material [cm TwinControl B_07795 –...

  • Page 72: Calibration

    TwinControl Electronically Controlled 2K Systems 7   Controller Totals P200 - P213 (Also see Chapter 5.10) – Change from P0 to P1...P2, ... with [+] button. Return with [-] button. 7.6.1   Calibration (Password entry required for P100) TwinControl B_07429 Calibrate A [Start] ->...

  • Page 73: Flushing Programs

    TwinControl Electronically Controlled 2K Systems 7   Controller TwinControl B_07432 Calibrate flushing B Direct input in cm /DH of the flushing pump 7.6.2   Flushing Programs Flushing program mode TwinControl B_07433 The flushing steps can be defined in the mode shown under parameters F1 to F20. Enter flushing program 4 Press [SET] during program step F1 (to F20).
  • Page 74 TwinControl Electronically Controlled 2K Systems 7   Controller Step F Actions Quantity Unit 0.0-9999.9 cc/sec 0.0-9999.9 cc/sec 0.0-9999.9 cc/sec 0.0-9999.9 cc/sec 0.0-9999.9 cc/sec 0.0-9999.9 cc/sec 0.0-9999.9 cc/sec 0.0-9999.9 cc/sec 0.0-9999.9 cc/sec 0.0-9999.9 cc/sec ** With repeated flushing (2 instances of flushing one after another), flushing steps "F1" and "F2" are only performed the first time.

  • Page 75: Ais

    TwinControl Electronically Controlled 2K Systems 7   Controller Step F Action Value Unit Remarks Start of repetition from step 4 End of repetition at step 5 Number of repetitions from step 4 to 5 = 10x for Puma 28-40 Step F Action Value Unit...
  • Page 76 TwinControl Electronically Controlled 2K Systems 7   Controller AIS settings (password level 4) Parameter Explanation Unit Values Default value P305 Repetition interval: For the above function (P304), 0.5-25.0 the AIS undertakes a step every x seconds until the valve cycles again. P306 Number of steps which the AIS is to open when mix- Steps...

  • Page 77: Check For Leaks In A And B Fluid Section

    Observe for 3 minutes in spray mode with gun open: If the AIS position (P309) is continually counting up or down in the same direction without the opening time of the dosing valve (P308) changing, the AIS is not working. Contact the WAGNER service department. Check AIS stepping motor Check whether the AIS stepping motor works: 1.

  • Page 78: Batch Mode" Filling Mode

    TwinControl Electronically Controlled 2K Systems 7   Controller 2. Press [-] push button for three seconds. Leakage error messages See Chapter Alarm messages and fault rectification [8 110]. 7.6.5   "Batch Mode" filling mode The Batch Mode setting allows a recurring and pre-defined flow rate to be discharged via the gun or via an external valve.

  • Page 79: Operation

    8.2   SAFETY INSTRUCTIONS The operating documents for the pneumatic pumps and other system components should be read through carefully. The appropriate operating manuals are available on the WAGNER CD as PDF files. Also observe the operating manuals for the components mounted on site.

  • Page 80: Emergency Deactivation

    TwinControl Electronically Controlled 2K Systems 8   Operation 4 The alarm display lights up (control unit and remote control). 4 A fault is indicated on the display. Acknowledge fault 4 With the [Stop] button. Alarm messages and fault rectification see Chapter Alarm messages and fault rectification [8 110].

  • Page 81: Switching On The System

    TwinControl Electronically Controlled 2K Systems 8   Operation 8.5   SWITCHING ON THE SYSTEM B_07764 Return line Example of TwinControl system ready for spraying Order number 2339321 | Edition 08/2020...

  • Page 82: Switching Off The System

    TwinControl Electronically Controlled 2K Systems 8   Operation B_07765 1. Switch on the main air supply. Switch on control air. Note: For control units with turbines, the turbines are powered by control air which switches on the electronics. For a system with a product pressure regulator: switch on the work air. For a TwinControl cable variant: Turn on main switch on the control unit.

  • Page 83: Spraying Mode

    TwinControl Electronically Controlled 2K Systems 8   Operation B_07761 3. Switch off the control air. Note: For control units with turbines, the turbines are powered by control air. 4. For a system with a product pressure regulator: Switch off the work air. B_07762 5.
  • Page 84 TwinControl Electronically Controlled 2K Systems 8   Operation – AIS is used. Or without AIS: If the dosing valve (B-side) is set using the valve stroke such that as many cycles are undertaken as possible (depending on flow rate and mixing ratio every 0.5–2 seconds).

  • Page 85: Flushing

    TwinControl Electronically Controlled 2K Systems 8   Operation NOTICE Fluctuating supply pressures! Poor coating result. 4 The supply pressure of component B should be adjusted to a higher value (approx. 5-10%) than that of component A. 4 The supply pressures should be constant. 8.8 ...

  • Page 86: Pressure Relief / Work Interruption

    TwinControl Electronically Controlled 2K Systems 8   Operation Cleaning the system see Chapter Cleaning the system [8 99] 8.9   PRESSURE RELIEF / WORK INTERRUPTION The pressure must always be relieved: – after the spraying tasks are finished, – before servicing or repairing the spraying system, –...
  • Page 87 TwinControl Electronically Controlled 2K Systems 8   Operation TwinControl B_07767 (Example for A-components) Closed Open Open (return flow) Closed (spraying) ð With password level 1: Only convey A component or only convey B component. ð Press [Start]. ð Place grounded metal tank for return product under the return tube of the respective pump.
  • Page 88 TwinControl Electronically Controlled 2K Systems 8   Operation ð Repeat step 3 for all A and B pumps. 4. Flush mixed product from step 3. ð Press [Flush]. B_07769 ð Point the spray gun (preferably without nozzle) into the grounded metal tank for return product.

  • Page 89: Automatic Electrostatic System Set For Electrostatic Gun Gm 5000 (Option)

    TwinControl Electronically Controlled 2K Systems 8   Operation ð Point the spray gun into the grounded metal tank for return product. ð Release and open spray gun to relieve the pressure. Avoid splashback. ð When no further overpressure is detected, close and secure the spray gun. B_07770 Splitter valve ð...

  • Page 90: Commissioning And Settings

    TwinControl Electronically Controlled 2K Systems 8   Operation 4 Switch off the electrostatic system. 1. Paint filling 4 The electrostatic system is enabled. 2. Spraying mode 3. Work Interruption (Stop) 4 Switch off the electrostatic system. 4 Switch off the electrostatic system. 4.

  • Page 91: Work Interruption (Stop)

    TwinControl Electronically Controlled 2K Systems 8   Operation 2. Switch on the electrostatics on the VM 5000 control unit manually as described in the VM 5000 operating manual. 3. Perform spraying mode as described in this operating manual (TwinControl). Ensure that the electrostatics has been set correctly on the GM 5000 gun as described in the GM 5000 and VM 5000 operating instructions.
  • Page 92 TwinControl Electronically Controlled 2K Systems 8   Operation Example, soft circulation Leopard B_07773 Circulation valve GA 400 Working pressure Circulation pressure Soft circulation setting Via password level 4 where pos. "P154" P154 = 1. 0 = no circulation, 1 = soft circulation, 2 = circulation at operating pressure Separate settings for A and B components P155 = 1 A-component circulating (product valve A opens when circulating)

  • Page 93: External Mixers (Option)

    TwinControl Electronically Controlled 2K Systems 8   Operation 8.13   EXTERNAL MIXERS (OPTION) 8.13.1   Manual External Mixers DN2.6 and DN4 5-60, 10-70, 28-40, 15-70, For A-pumps: 15-150, 21-110, 35-70, 35-150 A, B and S components Inputs: Spray on/off Switches A+B: Flushing on/off Switch S: B_07774 A+B (open position)

  • Page 94: Remote Control And Esta Remote Control (Option)

    TwinControl Electronically Controlled 2K Systems 8   Operation B_07775 A+B (open position) AS (closed position) BS (closed position) Spraying mode Handle A+B open, ball valves AS and BS closed. Flushing mode 1. Close handle A+B 2. Carry out flushing process in accordance with Chapter Flushing [8 85] Note: ð...

  • Page 95: Twincontrol Remote Control

    TwinControl Electronically Controlled 2K Systems 8   Operation 8.14.2   TwinControl Remote Control Installation Connect the remote control to the control unit: Insert the cable into the RC connection (remote control, see Chapter Operating Elements and Control Unit Connections [8 36]). Several cables can be connected together up to a maximum length of 75 m; 246 ft. The cable must be installed permanently and protected from mechanical damage.
  • Page 96 TwinControl Electronically Controlled 2K Systems 8   Operation 24 8 20 1 TwinControl B_07777 Outside ESTA area ESTA area completely electrostatically charged TwinControl control unit Functional potential equalization Electrical cable Reversing box ESTA remote control C1 (1) Product valve A C2 (3) Gun flush box (option) C3 (5) Circulation (option) C4 (6) Alarm C5 Air supply...

  • Page 97: Switchbox For Second A-Pump (Option)

    TwinControl Electronically Controlled 2K Systems 8   Operation Made in Switzerland Type / Typ: TwinControl Check manual before use! Vor Gebrauch Betriebsanl beachten! B_04537 View from the rear of system Control unit Reversing box Functional potential equalization Electrical cable Hose connections to ESTA remote control 8.15 ...
  • Page 98 TwinControl Electronically Controlled 2K Systems 8   Operation Switching over pump 1. [Stop]. 2. [Flush] --> Hold gun in a grounded tank, carefully open and hold until clean flushing agent comes out. 3. Turn switchbox switch up to stop. 4. Filling and spraying according to Chapter Spraying mode [8 83]. Always turn switch up to stop.

  • Page 99: Cleaning And Maintenance

    TwinControl Electronically Controlled 2K Systems 9   Cleaning and Maintenance 9   CLEANING AND MAINTENANCE 9.1   CLEANING 9.1.1   Cleaning Personnel Cleaning work should be undertaken regularly and carefully by qualified and trained personnel. They should be informed of specific hazards during their training. The following hazards may arise during cleaning work: –...

  • Page 100: Decommissioning

    TwinControl Electronically Controlled 2K Systems 9   Cleaning and Maintenance 7. Product change: If necessary, remove, clean and check the pump inlet housing. If necessary, also remove, clean and check the fluid section. 8. Clean the outside of the system. 9. Fully assemble the system. 10.

  • Page 101: Maintenance Instructions

    DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.

  • Page 102: Service Plug

    Yearly or as required 4 In accordance with DGUV regulation 100-500, Chapters 2.29 and 2.36: ð The liquid ejection devices should be checked by an expert (e.g., WAGNER service technician) for their safe working conditions as required and at least every 12 months.

  • Page 103: Emptying The System

    TwinControl Electronically Controlled 2K Systems 9   Cleaning and Maintenance 4 The pressure-relief valve must be cleaned regularly and after each activation: Flush with solvent. 9.2.8   Emptying the system 1. Visual check: personal safety equipment, grounding and all devices ready to use. 2.

  • Page 104: Cleaning Or Replacing The Product Filter

    TwinControl Electronically Controlled 2K Systems 9   Cleaning and Maintenance 9.2.10   Cleaning or replacing the product filter 9.2.10.1   Angled Inline Filter (530 bar) 53 MPa 530 bar 7687 psi B_07113 Flow direction * For order no., see spare parts catalog. 1. Flush the pump and inline filter in accordance with Chapter Maintenance Work on the Pumps [8 50] and with pump's operating manual.
  • Page 105 TwinControl Electronically Controlled 2K Systems 9   Cleaning and Maintenance 1. Flush the pump and inline filter in accordance with Chapter Maintenance Work on the Pumps [8 50] and with pump's 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 106 TwinControl Electronically Controlled 2K Systems 9   Cleaning and Maintenance 53 MPa 530 bar 7687 psi B_07757 Loctite® 542 * Mobilux® EP2 * Filter identification Anti-seize paste * * For order no., see spare parts catalog. 1. Flush the pump and high-pressure filter in accordance with Chapter Maintenance Work on the Pumps [8 50] and with pump's operating manual.

  • Page 107: Product Hoses, Pipes And Couplings

    TwinControl Electronically Controlled 2K Systems 9   Cleaning and Maintenance 6. Unscrew the union nut (A) and lift slightly so that it does not get dirty in the next step. 7. Remove the filter housing (B) with the union nut (A). The cone spring (E) remains in the filter housing (B).
  • Page 108 TwinControl Electronically Controlled 2K Systems 9   Cleaning and Maintenance 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 Order number 2339321 | Edition 08/2020...

  • Page 109: Troubleshooting

    TwinControl Electronically Controlled 2K Systems 10   Troubleshooting 10   TROUBLESHOOTING Fault display If a fault occurs, it is indicated by the following: 1. The horn sounds and the system stops. 2. The alarm display lights up (control unit and remote control). 3.

  • Page 110: Alarm Messages And Fault Rectification

    TwinControl Electronically Controlled 2K Systems 10   Troubleshooting Malfunction Remedy The 2K product does not 1. Check the mixing ratio value. react correctly 2. Check the suction lines (leakage). 3. Check the stroke sensors by carrying out a calibration. 4. Check the differential pressure between B and A (B approx. 5-10% higher than A).
  • Page 111 TwinControl Electronically Controlled 2K Systems 10   Troubleshooting Code Meaning Cause Fault rectification No authorization Unauthorized input Release authorization Shortage of the B- Too little B-component in the mix- Increase air pressure for B pump or component ture. reduce for A. Without AIS: Increase length of stroke of timing valve in B-product.
  • Page 112 Check product supply. Leak check, pump cavitating. check piston valve. Alarm password The software is not enabled. Enter software password. WAGNER AG password (only possi- ble on PC). Incorrectly adjusted Turbine speed too low. Check turbine. Adjust air pressure air pressure (WAGNER technician).
  • Page 113 TwinControl Electronically Controlled 2K Systems 10   Troubleshooting Code Meaning Cause Fault rectification EEPROM alarm Reading or writing to the EEPROM Contact WAGNER service depart- is not possible. ment. ADC alarm Reading the potentiometer values Contact WAGNER service depart- is not possible. ment.

  • Page 114: Repairs

    DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.

  • Page 115: Assembly Aids

    4 WAGNER devices, protective systems and safety, monitoring and control equipment may only be serviced/repaired as defined in Directive 2014/34/EC (ATEX) by trained WAGNER service personnel or skilled persons in accordance with TRBS 1203! Note national regulations! 4 Service, repair or replacement of devices or parts of devices may only be performed outside the hazard area! 11.3 ...

  • Page 116: Disposal

    4 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 117: Accessories

    TwinControl Electronically Controlled 2K Systems 13   Accessories 13   ACCESSORIES 13.1   MIXER Order no. Designation 2338297 Manual, external mixer DN 2.6 For A-pumps 5-60, 10-70, 28-40, 21-110, 35-70, 35-150 B_02977 2339620 Automatic, external mixer DN 2.6 For A-pumps 5-60, 10-70, 28-40, 21-110, 35-70, 35-150 Prerequisite: Controller 3, 6 or 9 B_04512 2338298...
  • Page 118 TwinControl Electronically Controlled 2K Systems 13   Accessories Order no. Designation 2339628 Circulation G3/8" for automatic, external mixer DN4 B_04497 2338300 Manual, external mixer DN 8 For A-pumps 48-110, 3-600, 60-240 (270 bar), 8-600, 75-150, 55-200, 60-240 B_02978 2338301 Circulation for manual, external mixer DN8 B_04485 Order number 2339321 | Edition 08/2020...

  • Page 119: Remote Control

    TwinControl Electronically Controlled 2K Systems 13   Accessories 13.2   REMOTE CONTROL Order no. Designation 2308874 TwinControl remote control includes 15 m; 49 ft. ca- ble. Maximum permissible cable length: 75 m; 246 ft. Please note: If used in a system with a mains power supply (cable) ->...

  • Page 120: Suction Hoses

    TwinControl Electronically Controlled 2K Systems 13   Accessories 13.4   SUCTION HOSES Order no. Designation 2324110 Suction hose DN16-SSt complete for: – EvoMotion 5-60 – Wildcat 10-70, 18-40 – Puma 28-40, 21-110 – Leopard 35-70 B_04472 2324116 Suction hose DN25-SSt complete for: –...

  • Page 121: Ais

    TwinControl Electronically Controlled 2K Systems 13   Accessories Order no. Designation 2312390 Mixing hose 32 G1/4 " 2312393 Mixing hose 96 G1/4 " 2312396 Mixing hose 32 G1/4 " 2312399 Mixing hose 96 G1/4 " 2312402 Mixing hose 32 G3/8 " 2312405 Mixing hose 96 G3/8...

  • Page 122: Heater

    TwinControl Electronically Controlled 2K Systems 13   Accessories 13.7   HEATER Order no. Designation 2338290 Heater set A or B for TwinControl pumps 5-60, 10-70, 28-40, 21-110, 35-70, 35-150 B_04476 2338294 Heater set A or B for TwinControl pumps 3-600, 48-110, 60-240, 8-600; and for 95-150 (without trolley) B_04477 2338291...

  • Page 123: Splitter Valve

    TwinControl Electronically Controlled 2K Systems 13   Accessories Order no. Designation 2338293 Heater set A, B trolley for TwinControl pump 95-150 (with trolley) B_04480 2338295 Double parallel heater set for TwinControl pumps 72-200 (without trolley), 60-240 (without trolley) B_04481 2338296 Twin serial heater set for TwinControl pumps 72-200 (without trolley), 60-240 (without trolley) B_04482...

  • Page 124: Product Pressure Regulator

    TwinControl Electronically Controlled 2K Systems 13   Accessories 13.9   PRODUCT PRESSURE REGULATOR Order no. Designation 2315965 Product pressure regulator set 0.8 MPa; 8 bar; 116 psi, pneumatic (including flushing pressure set). For low pressure systems. B_06282 2315994 Product pressure regulator set 0.8 MPa; 8 bar; 116 psi, mechanical For low-pressure systems.

  • Page 125: Extension Cables

    TwinControl Electronically Controlled 2K Systems 13   Accessories Order no. Designation 2341205 Expansion set 2A-HM1 (TC) for TwinControl A-pumps 28-40, 35-70, 31-110 2340707 Expansion set 2A-HM1-ND (TC) for TwinControl A- pumps 5-60, 10-70 2341006 Expansion set 2A-HM2 (TC) for TwinControl A-pumps 21-110, 35-150 Extension 2A (for systems without a heater), switchbox 2A incl.

  • Page 126: Tc Vm5000 Automatic Electrostatic System

    TwinControl Electronically Controlled 2K Systems 13   Accessories 13.13   TC VM5000 AUTOMATIC ELECTROSTATIC SYSTEM Order no. Designation 2334530 Automatic electrostatic system The TC VM5000 automatic electrostatic system set serves as an additional safety device for the safe use of the TwinControl 2K system with a GM5000 electrostatic gun. Prerequisite: Controller 1, 2, 3, 9 or 10 13.14 ...

  • Page 127: Aircoat Regulator

    TwinControl Electronically Controlled 2K Systems 13   Accessories 13.16   AIRCOAT REGULATOR Order no. Designation 2328611 AirCoat regulator For A-pumps: Wildcat, Puma, Leopard, Protec B_04501 2336769 AirCoat regulator 5-60 For A-pump EvoMotion 5-60 B_06431 13.17   ARCHIVING SOFTWARE Order no. Designation 2317811 TwinData RS-232 archiving soft- ware consisting of: RS232 –...

  • Page 128: Spare Parts

    DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.

  • Page 129: Declaration Of Conformity

     II 2 G Ex ia IIB T4 ZELM 08 ATEX 0385 X +5 °C < Ta +40 °C 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. 4 Order number: 393916...

  • Page 130: Devices With Cable For Mains Power Supply

    Identification: EC Declaration of Conformity The EC 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. 4 Order number: 393915 Order number 2339321 | Edition 08/2020...

  • Page 131: Appendix

    TwinControl Electronically Controlled 2K Systems 16   Appendix 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. 1. Some lacquer manufacturers state the mixing ratio by weight, others by volume or ratio.
  • Page 132 TwinControl Electronically Controlled 2K Systems 16   Appendix [mm] [mm] 0.06 0.39 0.09 0.59 0.13 0.79 12.5 0.16 12.5 0.98 0.19 1.18 0.25 1.57 0.31 1.96 0.38 2.36 3.14 0.63 3.93 0.57 0.15 0.85 1.13 12.5 0.25 12.5 1.41 0.29 0.39 2.26 0.49 2.83...
  • Page 133 TwinControl Electronically Controlled 2K Systems 16   Appendix Order number 2339321 | Edition 08/2020...
  • Page 134 TwinControl Electronically Controlled 2K Systems 16   Appendix Order number 2339321 | Edition 08/2020...
  • Page 136 Order number 2339321 Edition 08/2020 More contact addresses on the internet at: www.wagner-group.com Subject to changes without notice...

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