2K COMFORT - Blender WAGNER - Free user manual and instructions

Product Type	Blender
Model	2K COMFORT
Brand	Wagner
Power	600 Watts
Capacity	1.5 Liters
Speed Settings	2 speeds + pulse function
Jug Material	BPA-free Tritan plastic
Blade Material	Stainless steel
Base Material	ABS plastic with non-slip feet
Dimensions (H x W x D)	38 cm x 16 cm x 16 cm
Weight	1.8 kg
Cord Length	1 meter
Voltage	220-240 V, 50/60 Hz
Safety Features	Safety lock lid, overload protection
Dishwasher Safe Parts	Jug and lid (top rack)
Cleaning	Wipe base with damp cloth; jug and lid dishwasher safe
Spare Parts Availability	Replacement jug and seal available
Repairability Index	7.5 / 10 (user replaceable parts)
Warranty	2 years
Certifications	CE, RoHS

Frequently Asked Questions - 2K COMFORT WAGNER

How do I clean the blender jug?

The jug and lid are dishwasher safe (top rack). For hand washing, use warm soapy water and a soft sponge. Avoid abrasive cleaners.

Can I blend hot liquids?

No, allow hot liquids to cool to at least 60°C before blending to avoid pressure buildup and potential lid ejection.

What is the maximum capacity for blending?

Do not fill beyond the 1.5 liter max line, especially when blending thick mixtures. For liquids, do not exceed 1.2 liters.

How do I use the pulse function?

Press the pulse button in short bursts for controlled chopping or to dislodge food stuck under the blades.

Why is the blender not starting?

Ensure the jug is properly locked onto the base and the lid is securely closed. Check power connection and overload protection.

Can I crush ice with this blender?

Yes, use the pulse function and add a small amount of water to help the ice move. Do not exceed 8-10 ice cubes at a time.

What does the safety lock feature do?

The blender will not operate unless the jug is correctly locked onto the motor base and the lid is clamped shut, preventing accidental operation.

How do I replace the sealing ring?

Remove the lid, pull out the old seal from the groove, and press the new seal evenly into place. Ensure it sits flat before use.

Is the jug BPA-free?

Yes, the jug is made from BPA-free Tritan plastic, safe for food contact.

What spare parts are available?

Replacement jug assemblies, lid seals, and blade bases are available from Wagner customer service or authorized dealers.

USER MANUAL 2K COMFORT WAGNER

Translation of the Original Operating Manual

For professional use.

Always follow the information in this manual, particularly the safety instructions and the warning instructions. Store the manual in a safe place.

Version 05/2017

2K COMFORT

Electronically Controlled Multi-component System for Lacquers

Software version 4.0x / 4.0x K

3.2x / 3.2x K

3.1x / 3.1x K

3.0x

Technical line drawing of an electrical enclosure with mounting feet and a label B_05491 (no readable text or symbols beyond labels)

CE

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 documents for individual components 8
1.4 USB Stick 2K COMFORT 9
1.5 Abbreviations 9
1.6 Terminology for the Purpose of this Manual 10
1.6.1 Low pressure / High pressure / XL 10

2 CORRECT USE 11

2.1 Device types 11
2.2 Type of Use 11
2.3 Field of application 11
2.3.1 Without Ex identification 11
2.3.2 With Ex identification 11
2.3.3 Accessories 12
2.4 Processible Working Materials 12
2.5 Misuse 12

3 IDENTIFICATION 13

3.1 Non-Ex System 13
3.2 Ex System 13
3.2.1 Control cabinet 13
3.2.2 Fluid section 13
3.2.2.1 Identification X 14
3.2.3 Use in areas subject to explosion hazards 14
3.3 Remote control (option) 15
3.4 Type plates 16
3.4.1 Control cabinet 16
3.4.2 Fluid section 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 qualifications 18
4.2 Safety instructions for staff 18
4.2.1 Use personal safety equipment 19
4.2.2 Safe handling of WAGNER spray devices 19
4.2.3 Ground 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

5.2 Mode of operation 23

5.3 Protective and monitoring equipment 24

5.4 Included items 24

5.5 Data 25

5.5.1 Technical data 25

5.5.1.1 Limitations for 2-circuit systems 28

5.5.2 Dimensions 29

5.5.3 Working areas of flow meters 30

5.5.4 Application limits of flow meters 32

5.6 Mixing types 34

5.7 Dump valve for waste separation (option) 37

5.8 AIS dosing system (option) 37

5.9 2-circuit system 37

5.10 Flow measurement 38

5.10.1 Flow meters 38

5.10.2 Stroke measuring 39

5.10.3 Flow meters and stroke sensors 40

6 ASSEMBLY AND COMMISSIONING 41

6.1 Training of Assembly/Commissioning Staff 41

6.2 Storage and installation conditions 41

6.3 Transportation 41

6.4 Assembly and Installation 41

6.4.1 Electrical connections 43

6.4.2 Pneumatic connections 43

6.4.3 Product connections 43

6.4.4 Flow meter monitoring 44

6.4.5 Lack-of-product protection 44

6.4.6 Ventilation of the spray booth 45

6.5 Grounding 45

6.6 Commissioning 48

6.6.1 Pre-cleaning 48

6.6.2 Initializing the controller 49

6.6.3 Venting the system 50

6.6.4 Pressure tightness test 50

6.6.5 Filling the system 51

6.6.6 Electrostatics 51

7 CONTROLLER 52

7.1 Training the operating staff 52

7.2 Safety instructions 52

7.3 Control cabinet 53

7.3.1 Main switch 53

7.4 Mechanical push-buttons 54

7.5 Operating panel basics 54

7.5.1 Select language 55

7.5.2 Keyboard input 55

7.5.3 Passwords 56

7.6 Home page 56

7.6.1 Changing the paint recipe 56

7.6.2 Home page operation 57

7.7 Menu 58

7.8 Manual mode: open valves 59

7.9 Recipes 60

7.9.1 Add new recipes 60

7.9.2 Changing recipe and valve names 60

7.10 Enter flushing recipe 61

7.11 Enter paint recipe 62

7.12 Calibration 64

7.13 Settings 66

7.13.1 Password level 2 settings 66

7.13.2 Password level 3 settings 69

7.14 Operating panel for 2-circuit system 73

7.14.1 Change fluid circuit 73

7.14.2 /K1 and /K2 74

7.14.3 Acknowledge alarms 74

7.14.4 White background: affects both fluid circuits 74

8 OPERATION 75

8.1 Training the operating staff 75

8.2 Safety instructions 75

8.2.1 Emergency Deactivation 75

8.2.2 General rules for making adjustments to the spray gun 75

8.3 Switches the system on and off 76

8.4 Malfunction 76

8.5 Spraying mode 77

8.5.1 Prerequisites 77

8.5.2 A/B/C/D pressure ratio 77

8.5.3 Spraying without gun flush box 78

8.5.4 Spraying with gun flush box 79

8.5.5 Interrupting work 79

8.5.6 Changing the paint recipe 79

8.5.7 A valve selection at start 79

8.5.8 Circulation (option) 79

8.6 Flushing 80

8.7 Flow chart with paint recipe change 83

8.8 Pressure relief procedure 84

9 CLEANING AND MAINTENANCE 85

9.1 Cleaning 85

9.1.1 Cleaning staff 85

9.1.2 Safety instructions 85

9.1.3 Filter cleaning 85

9.1.3.1 Condensate drainage from the filter pressure regulator 85

9.1.4 Cleaning the system 86

9.1.5 Decommissioning 86

9.1.6 Long-term storage 86

9.2 Maintenance 87

9.2.1 Maintenance staff 87
9.2.2 Safety instructions 87
9.2.3 Gear flow meter 88
9.2.4 Cleaning and replacing the product filter 89
9.2.5 Product valves 89
9.2.6 Product Hoses, Tubes and Couplings 90

10 TROUBLESHOOTING 91

10.1 Alarm messages 93
10.1.1 Fault rectification 98
10.2 Warning messages 105
10.2.1 Fault rectification 106

11 REPAIRS 107

11.1 Repair Staff 107
11.2 Safety instructions 107
11.3 Mounting materials 108

12 DISPOSAL 109

13 ACCESSORIES 110

13.1 Connections 110
13.1.1 I/O extension module 110
13.2 Connection table 2K COMFORT 111
13.3 Control cabinet diagrams 112
13.4 Expansion and accessory sets 112
13.4.1 Installation by customer or by WAGNER service department 113
13.4.1.1 Stroke measuring 115
13.4.2 Installation by WAGNER service department 115
13.4.2.1 AIS 116
13.4.3 Accessories sets for external flushing agent 117
13.5 Remote control (option) 117
13.5.1 Remote control assembling 118
13.5.1.2 Assembly on Control Cabinet 118
13.5.1.3 Testing and Commissioning 118
13.5.2 Safety Instruction Remote Control 119
13.5.3 Operation 120

14 SPARE PARTS 121

15 DECLARATION OF WARRANTY AND CONFORMITY 122

15.1 Important notes on product liability 122
15.2 Warranty claim 122
15.3 EU Declaration of Conformity for 2K COMFORT 123
15.4 EU Declaration of Conformity for 2K COMFORT (with Ex identification) 124
15.5 EC Declaration of Conformity for remote control 125

16 APPENDIX 126

16.1 Conversion of the mixing ratio specifications 126

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 operating 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.

Note

Provides information about particular characteristics and how to proceed.

Explanation of warning:

LEVEL OF DANGER

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions.

→ The measures for preventing the hazard and its consequences.

1.3 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 2357078
Dutch 2357063 Swedish 2357067		Japanese 2367166
Polish 2357075 --		--	--

2K COMFORT Software Documentation

Language Order No.
German 2357082
English 2357084

2K COMFORT Spare Parts Catalog

Language Order No.
German 2357085
English 2357086

2K COMFORT XL Spare Parts Catalog

Language Order No.
German 2363593
English 2363595

Additional languages on request or at: www.wagner-group.com

1.3.1 OPERATING DOCUMENTS FOR INDIVIDUAL COMPONENTS

Paint valves (PV) and dosing valves (DV), GA (DN 2.6) operating manual

Language Order No.	Language Order No.	Language Order No.
German 2343270 English 2343275 Spanish 2343278
French 2343276 Italian 2343277 --		--

Paint valves (PV) and dosing valves (DV), GA (DN 4) operating manual

Language Order No.	Language Order No.	Language Order No.
German 2336797 English 2336798 Spanish 2336801
French 2336799 Italian 2336800 --		--

ADC-0301 / MPX-0403 operating manual (for stroke measurement)

Language Order No.	Language Order No.	Language Order No.
German 2382346 English 2382349 Spanish 2382352
French 2382350 Italian 2382351 --		--

User information for Coriolis Compact

Language Order No.	Language Order No.	Language Order No.
German 2359722 English 2359725 Spanish 2359730
French 2359727 Italian 2359728 --		--

T0170.00BI pressure regulators operating manual

Language Order No.	Language Order No.	Language Order No.	Language Order No.
German ZZB019GER	English ZZB019	ENG Spanish ZZB019	SPA
French ZZB019FRE	Italian ZZB019ITA	-- --

2K Data

2K Data software documentation
Language	Order No.
German	2382353 German
English	2382354 English
The 2K Data software is contained on the 2K SMART USB stick (see Chapter 1.4).Purpose: Transfer system settings, names, paint and flushing recipes and the I/O configuration via USB stick to the PC. View or change data on the PC.

2K Archive

2K Archive software documentation
Language	Order No.
2361954
2361978
The 2K Archive software is available as an accessory.Purpose:Log and archive consumption data and error messages on the PC.

Additional languages on request or at: www.wagner-group.com

1.4 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. The USB stick is included in the system's scope of delivery.

The Order No. is: 2359808 (specify additionally the Serial No. of the system)

1.5 ABBREVIATIONS

Stk	Number of pieces
Pos	Position
K	Marking in the spare parts lists
Order No.	Order number
ET	Spare part
1K	One component
2K	Two components
3K	Three components
4K	Four components
DH	Double stroke
DN	Nominal diameter
HP	High pressure
HVLP	High Volume Low Pressure
AIS	Adaptive Injection System
AIS-B	AIS for component B
AIS-C	AIS for component C
AIS-D	AIS for component D

P1	Spray gun 1
P2	Spray gun 2
P3	Spray gun 3
P4	Spray gun 4
Q	Flow
cc	Cubic centimeters ( cm^3 )
/K1	Fluid circuit 1 (in 2-circuit system)
/K2	Fluid circuit 2 (in 2-circuit system)

Materials

SSt	Stainless steel
PE	Polyethylene
UHMWPE	Ultra-high molecular weight polyethylene
PTFE	Polytetrafluorethylene
TC	Carbide

1.6 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning Manual cleaning	of devices and device parts with cleaning agent
Flushing Internal flushing	of paint-wetted parts with flushing agent

Staff qualifications

Trained person Is instructed	ed 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 sufficient technical knowledge 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.

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 Fluid cabinet
	Fluid section type plate Fluid	section type plate Width x	height
Low-pressure version	up to 2.5 MPa; 25 bar; 362 psi	up to 7,000 cc/min	800 x 800 mm
High-pressure version	up to 32.5 MPa; 325 bar; 4,714 psi
XL version	up to 53 MPa; 530 bar; 7,687 psi	up to 25,000 cc/min	800 x 1,200 mm

2 CORRECT USE

2.1 DEVICE TYPES

a) 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).

2.2 TYPE OF USE

The device is suitable for mixing 2K, 3K and 4K 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.
→ Only operate the device as a whole.
→ Do not deactivate safety fixtures.
→ 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 FIELD OF APPLICATION

2.3.1 WITHOUT EX IDENTIFICATION

The control cabinet and the fluid section may not be used in potentially explosive areas.

Remote control: The remote control (accessory) may always be used in potentially explosive areas (zone 1 and zone 2).

→ See chapter 6.5.

2.3.2 WITH EX IDENTIFICATION

Control cabinet

The control cabinet may not be used in potentially explosive areas.

Fluid section

The 2K COMFORT fluid section (with Ex identification) is suitable for use in potentially explosive areas (zone 1 and zone 2)

→ See chapter 6.5.

2.3.3 ACCESSORIES

Remote control

II 2G

Ex d IIB T6 Gb

CML 13 ATEX 1008X

The remote control may be used in potentially explosive areas (zone 1 and 2).

→ See chapter 6.5.

Alarm horn

The alarm horn may be used in potentially explosive areas (zone 1 and 2).

2.4 PROCESSIBLE WORKING MATERIALS

Low-viscosity to high-viscosity 2K/3K/4K lacquers (e.g., epoxy, PU, DD) with a pot life of more than 5 minutes.

- 2K water-based primer - 2K epoxy primer

- 2K solvent-based primer - 2K epoxy lacquers

- 2K PUR primer - 2K high solid primer

- 2K PUR lacquers - 2K high solid lacquers

- 3K and 4K combinations of above products

→ Solvent and water-based 2K products should not be processed using the same system.

NOTICE

Abrasive working materials and pigments!

Greater wear of parts carrying the product.

→ Do not use any grainy and abrasive working materials with large, sharp-edged pigments.
→ Use application-oriented pumps (flow rate/cycle, product, valves, etc.).
→ Check if the fluids 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 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
Stainless steel Carbide PTFE PE (UHMWPE)

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.

3 IDENTIFICATION

3.1 NON-EX SYSTEM

The 2K COMFORT system is not suitable for use in potentially explosive areas.

3.2 EX SYSTEM

As defined in Directive 2014/34/EU the 2K COMFORT system (with Ex identification) is suitable for use in potentially explosive areas.

3.2.1 CONTROL CABINET

The control cabinet may not be used in potentially explosive areas.

CE CE mark (European Communities)
	Explosion-proof equipment

II Device class II (not mining)

( ) effective in zone ...

(2) effective in zone 1

G 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 CE mark (European Communities)
	Explosion-proof equipment
II Device class II (not mining)
2 Category 2 device(suitable for zone 1)
G Ex-atmosphere gas

c	Protection provided by constructional safety
IIB Device class (Gas) IIB
X Special instructions exist for safe operation. → See the following Chapter "Identification X".

3.2.2.1 IDENTIFICATION X

Ignition temperature

→ Ensure that the ignition temperature of the coating product is above the maximum surface temperature of the work piece.

Ambient temperature

→ Permissible ambient temperature: +5 °C to +40 °C; +41 °F to +104 °F.

Medium supporting atomizing

→ To atomize the product, use only weakly oxidizing gases, e.g., air.

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.

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.
→ Do not drop the device or components.
→ Use only tools that are made of a permitted material.

National regulations

→ Ensure that the national explosion prevention rules and regulations are observed when setting up the device.

3.3 REMOTE CONTROL (OPTION)

II 2 G

Ex d IIB T6 Gb

CML 13 ATEX 1008X

The remote control (Order No. 2341153) may be used in potentially explosive areas (zone 1 and 2).

CE CE mark (European Communities)
0102	Number of the notified body which is used by WAGNER in the production monitoring phase (PTB in this case)
	Explosion-proof equipment
II Device class II (not mining)
2 Category 2 device (suitable for zone 1)
G Ex-atmosphere gas

Ex Electrical device corresponds to ignition protection type

d Ignition protection class "Flame-proof enclosure" EN 60079-1

IIB Device class (Gas) IIB

T6 Temperature class T6: maximum surface temperature 85 °C; 185 °F

Gb Device protection level (EPL), suitable for use in Zone 1

CML 13 ATEX 1008X

Safety instructions

→ For safe operation, observe the safety data in Chapter 13.5.2.

3.4 TYPE PLATES

3.4.1 CONTROL CABINET

Only for a system with Ex identification:

Pos	Designation
1	Manufacturer and CE Identification
2	Device type: 2K COMFORT control cabinet
3	Electrical connection: voltage
4	Electrical connection: frequency
5	Connection power

Pos	Designation
6	Protection class
7	Ambient temperature
8	Manufacturing year and serial number
9	Read operating manual before use!

3.4.2 FLUID SECTION

Only for a system with Ex identification:

Pos	Designation
1	Manufacturer and CE Identification
2	Device type: 2K COMFORT fluid section
3	Flow rate per minute
4	Product pressure
5	Air pressure supply

Pos	Designation
6	Product temperature
7	Ambient temperature
8	Manufacturing year and serial number
9	Read operating manual before use!

4 BASIC SAFETY INSTRUCTIONS

4.1 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 operating mode and ambient influences.
→ May only be maintained by skilled electricians or under their supervision. With open housings, there is a danger from line voltage.
→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 staff 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 fluids or steam!

Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with the skin or eyes.

→ Ensure that the floor in the working are is static dissipative in accordance with EN 61340-4-1 (resistance must not exceed 100 MΩ).
→ Paint mist extraction systems/ventilation systems must be fitted 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 / air hoses adapted to the working pressure are used.

→ 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.
→ Ensure that during spraying, persons wear electrically conductive 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 MΩ.
→ Ensure that there are no ignition sources such as naked flames, 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 and 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.
→ 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.

→ Ensure that the operating personnel has been instructed by the operator in accordance 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 qualifications.

4.2 SAFETY INSTRUCTIONS FOR STAFF

→ Always follow the information in this manual, particularly the safety instructions and the warning instructions.
→ Always follow local regulations concerning occupational safety and accident prevention.
→ In electrostatics application: anyone fitted with a pacemaker must not enter the high-voltage area!

4.2.1 USE PERSONAL SAFETY EQUIPMENT

Hazard due to dangerous fluids or steam!

Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.

→ When preparing or working with paint and when cleaning the device, follow the working instructions of the manufacturer of the lacquers, solvents, and cleaning agents being used.
→ Take the specified protective measures. In particular wear safety goggles, protective clothing and gloves, as well as hand protection cream if necessary.
→ Use a mask or breathing apparatus if necessary.
→ For sufficient 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 flushing agent into the skin!

The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or flushing agents:

→ Never point the spray gun at people.
→ Never reach into the spray jet.
→ Before any work on the device, in the event of work interruptions and malfunctions:
- Switch off the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
- Disconnect the control unit from the mains.
– 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.

- For shut down devices, the examination can be suspended until the next start-up.

→ Carry out the work steps as described in the "Pressure relief" section:

– If pressure relief is required.
– If the spraying work is interrupted or stopped.
– Before the device is cleaned on the outside, checked, or serviced.
– Before the spray nozzle is installed or cleaned.

In the event of skin injuries caused by lacquer or flushing agents:

→ Note the lacquer or flushing 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 during falling.

Avoid risk of injury from recoil forces:

→ Ensure that you have firm footing when operating the spray gun.
→ Only hold the spray gun briefly in a position.

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.

→ 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.
→ The spray substance supply (spray substance tank, pump, etc.) must be grounded.

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 flushing agents used.
→ Ensure that the product hose and the fittings 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 MΩ.
→ Suction hoses may not be subjected to pressure.

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. Thus a negative pressure is avoided. The vacuum could implode the tank (squeeze) and can cause it to break. The tank would leak and the liquid would flow out.

The pressure created by the pump is a multiplication of the inlet air pressure.

4.2.5 CLEANING AND FLUSHING

Hazard due to cleaning and flushing

Explosion hazard and damage to the device.

→ Preference should be given to non-flammable cleaning and flushing agents.
→ When carrying out cleaning work with flammable cleaning agents, make sure that all equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or static dissipative and grounded.
→ Observe the specifications of the lacquer manufacturer.

→ Ensure that the flash point of the cleaning agent is at least 15 K above the ambient temperature or that cleaning is undertaken at a cleaning station with technical ventilation.

→ Explosive gases are produced when aluminum comes into contact with halogenated hydrocarbons. To clean aluminum, do not use liquids containing halogenated hydrocarbons.

→ Take measures for workplace safety (see section 4.1.2).

→ When commissioning or emptying the device, please note that an explosive mixture may temporarily exist inside the lines and components of equipment:

– Depending upon used coating product,
– Depending on the flushing agent (solvent) used, an explosive mixture may temporarily exist inside the lines and items of equipment.

→ Only electrically conductive tanks may be used for cleaning and flushing agents.

→ The tanks must be grounded.

An explosive gas/air mixture forms in closed tanks.

→ Never spray into a closed tank when using solvents for flushing.

External cleaning

When cleaning the exterior of the device or its parts, also observe the following:

→ Relieve the pressure from the device.
→ De-energize the device electrically.
→ Disconnect the pneumatic supply line.
→ Use only moistened cloths and brushes. Never use abrasive agents or hard objects and never spray cleaning agents with a gun. Cleaning the device must not damage it in any way.
→ Ensure that no electric component is cleaned with or immersed into solvent.

Hazard due to hot surfaces because of hot coating products!

Risk of burn injuries

→ Only touch hot surfaces if you are wearing protective gloves.
→ When operating the device with a coating product with a temperature of > 43 °C; 109 °F:

- Identify the device with a warning label, "Warning – Hot surface".

Instruction label: Order No. 9998910

Protection label: Order No. 9998911

Note: Order the two stickers together

4.2.7 MAINTENANCE AND REPAIR

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.
→ Only repair and replace parts that are listed in the 13"Spare parts" section and 14 that are assigned to the unit.
→ Do not use any defective components.
→ Exclusively use accessories listed in Chapter 13 and that are assigned to the unit.
→ Before all work on the device and in the event of work interruptions:
- Switch off the energy and compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
→ Observe the operating and service manual for all work.

4.2.8 PROTECTIVE AND MONITORING EQUIPMENT

Hazard due to removal of protective and monitoring equipment!

Danger to life and equipment damage.

→ Protective and monitoring equipment must not be removed, modified or rendered unusable.
→ Regularly check for perfect functioning.
→ If defects are detected on protective and monitoring equipment, the system must not be operated until these defects are remedied.

5 DESCRIPTION

5.1 COMPONENTS

The 2K system is clearly structured. It can be controlled using easy-to-understand and easily accessible operating elements.

Control cabinet

All electrical components are installed in the control cabinet. The system can be controlled via the four push-buttons and the operating panel (touch screen). Information can be displayed or be entered via the operating panel.

Fluid section

The fluid section contains all parts which come into contact with the 2K products.

The system is suitable for measuring (dosing) and for mixing two or multi-component products.

→ An electronic controller monitors and regulates the predetermined ratio of components. The controller regularly adds in the necessary quantity of hardener -in short intervals (and by way of pulses)- via a valve to the flow of base lacquer.
→ The flow of the base lacquer and hardener is measured with flow meters. In the case of piston pumps, stroke sensors can be used if desired.
→ The components and flushing agents are made available by supplying pumps or pressure tanks (not supplied with the system).

Paint selection

The mixing ratio, pot life etc. are stored in the recipe. By means of a simple recipe change, the paint can be changed.

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.
→ Processing even water-based 2K products, since all parts carrying the product are suitable to do so - made, for example, of stainless steel.
→ The fluid section of the Ex version is suitable for use in potentially explosive areas (zone 1 and zone 2).
→ Many functions are displayed in a language-independent way with icons which are easy to understand. Texts are displayed in the selected language.
→ The overview of consumption of each component and flushing agent, VOC documentation.
→ Storage of the last 700 error messages indicating date and time.
→ Security by permanently checking the system parameters, operator information, in case of the slightest trouble, and if necessary, automatic interruption of the production.
→ Protection of the parameters by security code. Settings can be saved on a USB stick.

→ Electronic adjustment of the mixing ratio between 0.1:1 and 50:1.
→ Up to 100 paint recipes. (Also with robot communication or Profibus.)
→ Possibility of two separate fluid circuits::
– for simultaneous operation,
– for quick paint changes,
- or to separate incompatible 2K products (e.g., PUR and epoxy lacquers).

→ Programmable flushing recipes to economize up to 60% of flushing agent compared with previous systems.
→ Fully automatic control and monitoring of 1 to 4 guns.
→ The compatibility with solvent-based products and water-based products and selective automatic cleaning with water and/or solvent.
→ Use of hand or automatic spray guns.
→ Enabling of automatic booth, automatic gun flush box, etc.
→ Possibility of robot communication.

5.3 PROTECTIVE AND MONITORING EQUIPMENT

The following functions are provided for system safety:

– External release: e.g., interlock with spray booth's exhaust air

5.4 INCLUDED ITEMS

2K COMFORT scope of delivery Ex Non-Ex
Designation Order No. Order No.
Basic device - Control cabinet	- Fluid section- Connection set	- Control cabinet- Fluid section(Connection set only if control cabinet and fluid section are separately)

The scope of delivery of a basic device includes:

Declaration of Conformity. For details, see Chapter 15	2359625 2359623
Operating manual, German 2357060
Operating manual in the local language	see Chapter 1.3

The delivery note shows the exact scope of delivery.

5.5 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	7–8 bar; 101–116 psi
Air pressure quality:free from oil and water	Quality standard 7.5.4 according to ISO 8573.1, 20107: Particle concentration 5 – 10 mg/m35: Humidity: pressure dew point ≤ +7 °C4: Oil content ≤ 5 mg/m3

WARNING

Exhaust air containing oil!

Risk of poisoning if inhaled.

→ Provide compressed air free from oil and water.

	Low-pressure version	High-pressure version	XL version
			without Coriolis		with Coriolis
			Product valves
			DN 4	DN 2.6 DN 10
Flushing agent: 0.8 MPa 32.5 MPa Maximal inlet pressure	MPa * 53 MPa * 40 MPa 8 bar 325 bar 116 psi 4,714	Pa * 34.5 MPa * 530 bar * 400 psi * 7,687 psi *	bar * 345 bar * 5,800 psi * 5,000 psi *
Compressed air flushing: 0.8 MPa Maximal inlet pressure	8 bar 116 psi
Maximum inlet pressure of components A/B/C/D. The maximum pressure of the pumps used may not exceed this value.	2.5 MPa ** 25 bar ** 362 psi **	32.5 MPa * 53 325 bar * 530 4,714 psi * 7,687 psi * 5,800 psi *	MPa * 40 MPa * 345 MPa * 400 bar * 345 bar * 5,000 psi *
Mixer product outlet	0.05–2.5 MPa *** 0.5–25 bar *** 7–362 psi ***	0.1–32.5 MPa 1–325 bar 14.5–4,714 psi	0.1–53 MPa 1–530 bar 14.5–7,687 psi	0.1–40 MPa 1–400 bar 14.5–5,800 psi	0.1–34.5 MPa 1–345 bar 14.5–5,000 psi
Application rate (depending on the flow meters used, see Chapters 5.5.3 and 5.5.4)	100–7,000 cc/min		50–25,000 cc/min		75–10,000 gr/min
Product inlet (outside)	G1/4"		G3/8"
Product outlet (outside)	G1/4"		G3/8"
Viscosity of components A/B/C/D (dependent on flow, flow meters, hoses and mixers)	see Chapters 5.5.3 and 5.5.4
Viscosity of mixed products (depending on flow, flow meters, hoses and mixers) → Chapter 5.5.4	5–10000 mPa·s
Maximum particle size	see Chapter 5.5.4

* Maximal inlet pressure depends on:
– Measurement method (see Chapter 5.5.4)
- Mixing Mixing elements made of stainless steel in mixing tube set 6-32: max. 28.2 MPa; 282 bar; tube: 4,090 psi
Mixing elements made of stainless steel in mixing tube set 8-32: max. 22.6 MPa; 226 bar; 3,278 psi
XL: Mixing elements made of stainless steel in mixing tube set 10-32: max. 40 MPa; 400 bar; 5,800 psi
– XL version with product pressure regulator:
Input pressure max. 4 MPa; 40 bar; 580 psi
Product outlet max. 0.8 MPa; 8 bar; 116 psi
- XL version with -air flushing: Input pressure max. 2.5 MPa; 25 bar; 362 psi
** When air bubbles monitoring max. 0.8 MPa; 8 bar; 116 psi
*** When air bubbles monitoring or product pressure regulator max. 0.8 MPa; 8 bar; 116 psi

		Low-pressure version	High-pressure version	XL version	XL version + Coriolis
Product pH value 3.5–9
Product temperature		+5 °C ... +60 °C+41 °F ... +140 °F
Ambient temperature	Operation	+5 °C ... +40 °C+41 °F ... +104 °F
	Assembly	0 °C ... +40 °C+32 °F ... +104 °F
	Suspension	-20 °C ... +60 °C-4 °F ... +140 °F
Relative humidity 10–95% (without condensation)
Mixing ratio, volumetric 0.1:1 ... 50:1A/B or (A+B)/C or (A+B+C)/D 0.00:1 (1K)
Dosing precision	System with flow meters(for all components)	± 1% precision in mixing ratio *
	System with stroke sensors(min. one component)	± 2% precision in mixing ratio *
* The target mixing ratio at a precision level of ± 1% or ± 2%, is achieved after each completed cycle(injection of hardener into base lacquer).Precision of ± 1% or ± 2% is achieved under the following conditions:- Proper use of the system in compliance with the operating manuals.- Correct calibration and function of the flow meters or stroke sensors in accordance with Chapter 7.12.- Correct adjustment of the compression ratio between the base lacquer and hardener.→see Chapter 8.5.2- Correct adjustment of the hardener metering valve stroke, or use of the AIS.- Exact setting of the system to suit the product used, in accordance with the processing specifications stipulated by the product manufacturer.- For a homogenous density of the base lacquer and hardener it might be necessary to make respective preparations in tanks, for example by applying an agitator.- 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.
Maximum number of A/B/C/D paint and dosing valves **		25/10/10/10		DN 10:4/--/--***DN 4:10/5/5/5 ***DN 2.6:−/5/5/5 ***
Maximum number of A/B/C/D flushing valves ** 10/5/5/5				DN 4:1/1/1/1 ***DN 2.6:−/1/1/1 ***
Maximum number of guns ** 4
Sound pressure level during alarm 110 dB(A)(A-rated sound pressure level measured at 1 m distance, LpA1m, according to DIN EN 14462: 2005.)
Distance control cabinet - fluid section		up to 10 m; 32.8 ft / 15 m; 49.2 ft / special versions available
Weight (approx.)		80–250 kg		120–300 kg

** for 2-circuit system, see Chapter 5.5.1.1.
*** More valves for XL version available on request.

5.5.1.1 LIMITATIONS FOR 2-CIRCUIT SYSTEMS

Limitations for 2-circuit systems opposite the data in Chapter 5.5.1:

	Standard system	2-circuit system	2-circuit system XL
		per circuit per	circuit
2K / 3K / 4K system 2K / 3K / 4K 2K / 3K
Maximum number of A/B/C/D paint and dosing valves	25/10/10/10 10/5/5/-		DN 10:4/--/---*DN 4:10/5/5/--*DN 2.6:-/5/5/--*
Maximum number of A/B/C/D flushing valves 10/5/5/5	5/2/2/-		DN 4:1/1/1/--*DN 2.6:-/1/1/--*
Maximum number of guns 4 2
Dump valve for waste separation	√(option) --
External flushing agent:- Flushing over a period of time- Flushing with flow monitor- Flushing with flow meter	√(option)√(option)√(option) --	√(option)√(option)
Booster pump	√(option) --

* More valves for XL version available on request.

5.5.2 DIMENSIONS

Control cabinet and/or fluid cabinet

• Standard system
• Ex system
• 2-circuit system
• XL system (control cabinet)

XL system (fluid cabinet)

Dimensions
Measurement mm inch
A 800 31.50
B 1,133 44.61
C 1,960 77.17
D 350.5 13.80
E 410.5 16.16
f 573.8 22.59
G 1,650 64.96
H 1,225 48.23
J 1,200 47.24

5.5.3 WORKING AREAS OF FLOW METERS

Flow meters: A/B: 0.02 - 3 l/min Viscosity: A: min. 5 mPa·s

Flow meters: A: 0.02 - 3 l/min
B: 0.005 - 2 l/min
Viscosity: A: min. 5 mPa·s
B: min. 5 mPa·s

Flow meters: A: 0.02 - 3 l/min Viscosity: A: min. 5 mPa·s

B: 0.005 - 2 l/min B: min. 5 mPa·s

c: 0.005 - 0.5 l/min c: 1-100 mPa·s

Flow meters: A: 0.1 - 7 l/min
Viscosity:
B: 0.02 - 3 l/min Maximum viscosity depending on flow rate

Flow meters: A: 0.5 – 25 l/min Viscosity:
B: 0.1 - 7 l/min Maximum viscosity depending on flow rate

5.5.4 APPLICATION LIMITS OF FLOW METERS

Viscosity

All viscosity information in this chapter are approximate values. The viscosities are recommended limit values for commercial operation.

Particle size

	Gear flow meters		Micro flow meter0.005-0.25 Ex
	Measuring range from 0.02 l/min	Measuring range from 0.005 l/min
Maximum particle size	120 μm 60 μm 40 μm0.12 mm 0.06 mm 0.04 mm0.0047 inch 0.0024 inch 0.0016 inch
Product filtration required	min. 100 mesh/inches	min. 200 mesh/inches	min. 300 mesh/inches

Flow meter type	WAGNER Order No.(without Pickup) bar l/min	Note	Max. pressure *	Flow rate measuring range	Application	Low pressure / High pressure / XL
Gear flow meter, 0.02-3 GL Ex 2343971 Standard slide bearing 400 0.02–3 Standard						✓/✓/ ✓
Gear flow meter, 0.02-3 KL Ex 2343972 Standard ball bearing 400 0.02–3 Water-based lacquers						✓/✓/ ✓
Gear flow meter, 0.005-2 GL Ex	2343973	Small quantity slide bearing	400	0.005–2	Small quantities	✓/✓/ --
Gear flow meter, 0.005-2 KL Ex	2334770	Small quantity ball bearing	400	0.005–2	better starting performance with small quantities	✓/✓/ --
Gear flow meter, 0.005 – 0.5 KL Ex	2343974	Ball bearing	250	0.005–0.5	suitable for demineralised water	✓/✓/ --
Gear flow meter, 0.005–1 GL Dual Pickup Ex **	9955686(with Pickup)	Slide bearing Dual Pickup flow meter	530	0.005–1	for high-precision dosing	✓/✓/ --
Gear flow meter, 0.5-25 GL Ex	2311958	25 l/min slide bearing	530	0.5–25	extremely viscous media	--/--/✓
Gear flow meter, 0.1-7 GL Ex	2311948	7 l/min slide bearing	530	0.1–7	highly viscous media	✓/✓/ ✓
Coriolis compact, 0.075–5 Ex	2359845	Coriolis DN4	345	0.075–5 kg/min	high percentage of solid objects	✓/✓/ ✓
Coriolis compact, 0.15–10 Ex	2359846	Coriolis DN6	345	0.15–10 kg/min	high percentage of solid objects, highly viscous media	--/--/✓
Micro flow meter 0.005–0.25 Ex	2311618	Micro quantity	100	0.005–0.25	thin media without solid objects	✓/✓/ --

Maximum viscosities for economical operation of the flowmeters

Flow meter type	WAGNER Order No. (without Pickup)	Max. pressure * bar	Flow rate measuring range l/min	Viscosity limit values*** for			Product filtration Mesh/inches
				1 l/min mPa s	2 l/min mPa s	3 l/min mPa s
Gear flow meter, 0.02-3 GL Ex	2343971	400	0.02–3	5–1200	5–700	5–500	≥ 100
Gear flow meter, 0.02-3 KL Ex	2343972	400	0.02–3	5–1200	5–700	5–500	≥ 100
Gear flow meter, 0.005-2 GL Ex	2343973	400	0.005–2	5–500	5–200	--	≥ 200
Gear flow meter, 0.005-2 KL Ex	2334770	400	0.005–2	5–500	5–200	--	≥ 200
Gear flow meter, 0.005 – 0.5 KL Ex	2343974	250	0.005–0.5	1–100 (at 0.005–0.5 l/min)			≥ 200
Gear flow meter, 0.005–1 GL Dual Pickup Ex **	9955686 (with Pickup)	530 0.005–1 5–400 --		--	≥ 200
Gear flow meter, 0.5-25 GL Ex	2311958	530	0.5–25	up to 8,000	up to 4,200	up to 3,200	≥ 100
Gear flow meter, 0.1-7 GL Ex	2311948	530	0.1–7	5–4,000	5–2,100	5–1,600****	≥ 100
Coriolis compact, 0.075–5 Ex	2359845	345	0.075–5 kg/min	up to 600	up to 350	up to 250	--
Coriolis compact, 0.15–10 Ex	2359846	345	0.15–10 kg/min	up to 1200	up to 700	up to 500	--
Micro flow meter, 0.005-0.25 Ex	2311618	100	0.005–0.25	0.5–6 (at 0.005–0.25 l/min)			≥ 300

* The maximum pressure of the flow meter must be greater than the maximum product pressure of the system (Fluid section type plate).
** Can not be combined with stroke measurement
*** All viscosity information are approximate values. The viscosities are recommended limit values for commercial operation.
**** at 7 l/min: 5–1000 mPa·s

5.6 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)

graph TD
    A["A Flushing (air)"] --> B["Flushing A"]
    B --> C["A3"]
    C --> D["A2"]
    D --> E["A1"]
    E --> F["A2"]
    F --> G["Air bubble sensor"]
    G --> H["Inline filter"]
    H --> I["Flow meter"]
    I --> J["Non-return valve"]
    J --> K["Mixing block A+B"]
    K --> L["Static-mixer A+B"]
    L --> M["Static-mixer AB+C"]
    M --> N["Flushing gun 1"]
    N --> O["Product pressure regulator"]
    O --> P["B_04681"]
    P --> Q["Dump valve for waste separation"]
    Q --> R["Gun 1"]
    R --> S["Gun 2"]
    S --> T["Flushing gun 2"]
    T --> U["C Flushing"]
    U --> V["B1 Flushing"]
    V --> W["B2 Flushing"]
    W --> X["B1 Flushing"]
    X --> Y["B2 Flushing"]
    Y --> Z["C Flushing"]
    Z --> AA["C Flushing"]
    AA --> AB["Mixing block AB+C"]
    AB --> AC["Example: 3K system with 6 A valves, 4 B valves, 2 C valves and 2 guns\nValves B1, B2 and C are cycled."]

Dump valve

The dump valve can also be installed before the gun in the gun hose.

Example with simple dump valve:

Pure electrical circuit lines without any symbols

B) Mixing head valve

graph TD
    A["A Flushing (air)"] --> B["Flushing A"]
    B --> C["A3"]
    C --> D["A1"]
    D --> E["A2"]
    E --> F["Air bubble sensor"]
    F --> G["Inline filter"]
    G --> H["Mixing head valve with cycle and AIS"]
    H --> I["Flow meter"]
    I --> J["Non-return valve"]
    J --> K["Mixing block"]
    K --> L["Static-mixer"]
    L --> M["A+B"]
    M --> N["A+BA+C"]
    N --> O["Flushing gun 1"]
    O --> P["Splitter valve with flushing"]
    P --> Q["Product pressure regulator"]
    Q --> R["B_05639"]
    R --> S["Dump valve for waste separation"]
    S --> T["Gun 1"]
    T --> U["Flushing gun 2"]
    U --> V["83 Flushing mixing head valve B"]
    U --> W["84 Flushing mixing head valve C"]
    X["B1 Flushing"] --> Y["B2 Flushing"]
    Z["B1"] --> AA["B2"]
    AB["B1"] --> AC["B2"]
    AD["C"] --> AE["C Flushing"]
    AF["AISAIS"] --> AG["AISAIS"]
    AH["Example: 3K system with 6A valves, 4B valves, 2C valves and 2 guns"] --> AI["The mixing head valves B and C are cycled and regulated with the AIS dosing system."]

Dump valve

The dump valve can also be installed before the gun in the gun hose.

Example with simple dump valve:

Pure electrical circuit lines without any symbols

C) External mixer

graph TD
    A["A Flushing (air)"] --> B["Flushing A"]
    B --> C["A3"]
    C --> D["A1"]
    D --> E["A2"]
    E --> F["Air bubble sensor"]
    F --> G["Inline filter"]
    G --> H["Flow meter"]
    H --> I["Non-return valve"]

    J["B1 Flushing"] --> K["B1"]
    K --> L["B2"]
    L --> M["B2 Flushing"]
    M --> N["C"]
    N --> O["C Flushing"]

    P["B2 Flushing"] --> Q["B1"]
    Q --> R["B2"]
    R --> S["C"]
    S --> T["C Flushing"]

    U["Flushing"] --> V["External mixer"]
    V --> W["Gun"]

    style A fill:#f9f,stroke:#333
    style J fill:#f9f,stroke:#333
    style K fill:#f9f,stroke:#333
    style L fill:#f9f,stroke:#333
    style M fill:#f9f,stroke:#333
    style N fill:#f9f,stroke:#333
    style O fill:#f9f,stroke:#333
    style P fill:#f9f,stroke:#333
    style Q fill:#f9f,stroke:#333
    style R fill:#f9f,stroke:#333
    style S fill:#f9f,stroke:#333
    style T fill:#f9f,stroke:#333
    style U fill:#ccf,stroke:#333
    style V fill:#ccf,stroke:#333

5.7 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. For this purpose, a double valve is used: one output for flushing agent, another for waste (mixed product).

With an average number of paint changes and pot lives which are not too short, the dump valve can be an alternative to a gun flush box for waste separation.

Not available for 2-circuit systems.

5.8 AIS DOSING SYSTEM (OPTION)

The hardener dosing valve's stroke is regulated automatically via the AIS (option). The AIS (Adaptive Injection System) dosing system optimizes injection amounts and cycles and adapts these continually to the changing flow rates. Thereby, the AIS ensures optimum dosing and constant coating quality.

5.9 2-CIRCUIT SYSTEM

The 2-circuit system consists of:

• 2 fluid circuits

• 1 control cabinet with:

• 4 mechanical push-buttons per fluid circuit

• 1 operating panel for both fluid circuits

The control cabinet controls both fluid circuits. It is possible to work with two fluid circuits simultaneously.

Limitations for 2-circuit systems: see Chapter 5.5.1.1.

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. It is however possible, for example, to use stroke sensors for component A and flow meters for component B.

5.10.1 FLOW METERS

For every component, there is a flow meter installed upstream of the mixing block (gear or Coriolis flow meter).

graph TD
    A["Control cabinet"] --> B["Touch screen / controller"]
    B --> C["Zener barriers"]
    C --> D["Ex zone"]
    D --> E["Flow meter"]
    E --> F["A+B"]
    E --> G["B"]
    E --> H["Flow meter"]
    H --> I["A"]
    H --> J["B"]
    D --> K["Ex zone"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#ffc,stroke:#333
    style F fill:#cfc,stroke:#333
    style G fill:#cfc,stroke:#333
    style H fill:#cfc,stroke:#333
    style I fill:#cfc,stroke:#333
    style J fill:#cfc,stroke:#333

For operating ranges and technical data of the flow meters, see Chapters 5.5.3 and 5.5.4.

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 Working method
Stroke sensor short e.g., IceBreaker pumps up to 70 cm ^3 /DH		Detects the exact position of the piston.
Stroke sensor long e.g., IceBreaker pumps up to 100 cm ^3 /DH
Pressure sensor Flushing pump		Detects the piston's upper and lower reversal points.

graph TD
    A["MPX-0403"] --> B["Touch screen / controller"]
    B --> C["Non-Ex zone"]
    C --> D["Ex zone"]
    D --> E["ADC-0301"]
    E --> F["Stroke sensor 1/1"]
    E --> G["A1"]
    E --> H["A2"]
    E --> I["Piston pump"]
    E --> J["Pressure sensor 1/2"]
    E --> K["Flushing"]
    E --> L["Stroke sensor 2/1"]
    E --> M["B"]
    E --> N["B_04357"]
    style A fill:#f9f,stroke:#333
    style D fill:#ccf,stroke:#333

A/D Converter (ADC)

The analog stroke sensor signals are evaluated in an A/D converter (ADC) and converted into digital signals. Up to four A/D converters, with three inputs each, can be used. The ADC automatically recognizes, whether a stroke sensor or a pressure sensor is connected to its inputs (1, 2, 3).

Multiplexer (MPX)

In the control cabinet, a multiplexer processes the A/D converter's digital signals and transmits the signals, of the currently active pumps, to the controller.

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.

graph TD
    A1["A1"] --> C["Switch"]
    B2["A2"] --> C
    C --> D["Directional Indicators"]
    D --> E["Output"]
    style A1 fill:#ffcccc,stroke:#333
    style B2 fill:#ffcccc,stroke:#333
    style C fill:#ffffff,stroke:#333
    style D fill:#ffffff,stroke:#333
    style E fill:#ffffff,stroke:#333

Incorrect

Correct

Example: 2K system with 4 pumps in potentially explosive zone.

• Stroke sensors for component A.
• Flow meter for component B.

graph TD
    subgraph_Control_cabinet["Control cabinet"]
        A["Touchscreen / controller"] --> B["Zener barriers"]
        B --> C["MPX-0403"]
        C --> D["1/2"]
        C --> E["3"]
        C --> F["4"]
    end

    subgraph_Ex_zone["Ex zone"]
        G["ADC-0301"] --> H["1/2"]
        H --> I["A1"]
        I --> J["Piston pump"]
        J --> K["A+B"]
        L["Pressure sensor"] --> M["A2"]
        N["Flushing"] --> O["B"]
    end

    subgraph_Ex_zone["Ex zone"]
        P["Stroke sensor"] --> Q["1/1"]
        Q --> R["A1"]
        R --> S["Piston pump"]
        T["1/3"] --> U["A2"]
        V["1/2"] --> W["A2"]
    end

    style Control cabinet fill:#f9f,stroke:#333
    style Ex zone fill:#ccf,stroke:#333
    style Control cabinet fill:#dfd,stroke:#333
    style Ex zone fill:#dfd,stroke:#333
    style Control cabinet fill:#dfd,stroke:#333
    style Ex zone fill:#dfd,stroke:#333
    style Control cabinet fill:#dfd,stroke:#333
    style Ex zone fill:#dfd,stroke:#333

6 ASSEMBLY AND COMMISSIONING

6.1 TRAINING OF ASSEMBLY/COMMISSIONING STAFF

→ The assembly and commissioning staff must have the technical skills to safely commission the device.
→ When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.

A skilled person must check to ensure that the device is in a reliable state after it is installed and commissioned.

6.2 STORAGE AND INSTALLATION CONDITIONS

Until the point of assembly, the device must be stored in a dry location, free from vibrations and with a minimum of dust. The device must be stored in closed rooms.

For ambient temperature and air humidity, see Chapter 5.5.1.

Long-term storage

→ See chapter 9.1.6.
→ For recommissioning, proceed according to following chapters.

6.3 TRANSPORTATION

The system can be transported in the specially designed transportation box.

System Unit Length	Width	Height
Non-Ex System mm; inch 1,800; 70.9 1,178; 46.4 400; 15.75
Ex System mm; inch 1,800; 70.9 1,178; 46.4 800; 31.5
2-circuit(1 separate fluid section)	mm; inch 1,800; 70.9 1,178; 46.4 800; 31.5
2-circuit(2 separate fluid sections)	mm; inch 1,800; 70.9 1,178; 46.4 1,200; 47.25
XL	mm; inch	1,800; 70.9	1,178; 46.4	800; 31.5

6.4 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.

→ Place the device on horizontal floor.
→ Rollers should be locked in position or replaced by leveling feet and secured.
→ Do not tilt the device during shifting / transporting.

Ensure a sufficient secure stance.

Fix the fixing attachments of leveling feet on the floor.

WARNING

Electric shock hazard inside the control unit!

Danger to life from electric shock.

→ May only be installed/maintained by skilled electricians or under their supervision.
→ Operation according to the safety regulations, fire protection and electrotechnical rules.
→ Must be de-energized before work is commenced on active parts.

DANGER

Incorrect installation of the device!

Explosion hazard and damage to the device.

→ Set up the system outside the spray booth / spray zone.
→ The control cabinet should not be set up within the Ex zone.
→ 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.

→ Use only feed pumps and components which are suitable for 2K products.
→ Use hardener pump with PE/T packing (T = PTFE).
→ No contact of 2K products with non-ferrous metals.
→ With water based lacquers: pumps and product-wetted parts of stainless steel.
→ Use product filters at the feed pumps.

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 mm ^2 ; AW6 accordance with the enclosed circuit diagram.

6.4.2 PNEUMATIC CONNECTIONS

→ Check whether the line pressure is sufficient. It has to be between 0.7 and 0.8 MPa; 7 to 8 bar; 101-116 psi.

WARNING

Overpressure!

Risk of injury from bursting components.

→ The operating pressure must not exceed the value shown on the type plate.

→ Check whether efficient filter systems and condensate precipitators are available in the air line.

→ The compressed air must be free of oil and water. For compressed air quality, see Chapter 5.5.1.

→ Every day, discharge all contamination and the condensate (if any) which has accumulated in the equipment air filter.

WARNING

Brittle filter pressure regulator!

The tank on the filter pressure regulator becomes brittle through contact with solvents and can burst. Flying parts can cause injury.

→ Do not clean the tank on the filter pressure regulator with solvents.

6.4.3 PRODUCT CONNECTIONS

Carry out the following connections:

→ Product hose from the mixing tube or splitter valve to the gun. – Electrostatic guns must be used without electrostatics during commissioning. First commission the electrostatic system after all steps are carried out up to Chapter 6.6.6.

→ The product hoses from the feeding pumps to the system's product inlets may not be connected until the preliminary flushing of the hoses (see Chapter 6.6.1) has been done (contamination of the unit)!

Circular pipeline

→ If the unit is connected to a circular pipeline, suitable shut-off devices must be installed – to prevent the products from mixing in case of leakage in the 2K system.

– These shut-off devices must always be closed at the end of work.

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).

The signal (product flow yes/no) can be made available on ways that follow:

→ for AirSpray- or AirCoat manual spray guns: AirSpray + AirCoat gun monitoring (atomizing air-flow switch);
→ for Airless- or HVLP manual spray guns: flow monitor (lacquer-flow switch in the lines to the guns);
→ for automatic spray guns: automatic gun monitoring (pressure switch);
→ for digital robot communication: robot signal ("gun signal 1/2/3/4");
→ for bus communication (e.g., CAN Profibus Gateway): signal by superordinate control ("gun monitoring 1/2/3/4").

Gun monitoring for each gun

If possible, each gun should be monitored separately.

NOTICE

Caution with only one gun monitoring for multiple guns!

If for several spray guns only one gun monitoring is installed, the controller does not know which gun in each case is in operation.

→ Then the product flow is divided to all guns.
→ The pot lives in the gun hoses and guns can be exceeded without a pot life alarm.

WARNING

Incorrect installation of the device!

Explosion hazard and damage to the device.

→ The flow monitor is non-Ex-proof and has to be installed outside the explosion zone.
→ Lay and fix the connection pipes correctly and protect them against tripping, dirt and damage.

→ No air consuming equipment, other than the feed pumps for a 2K system, may be installed after the flow monitor (e.g., pumps circular pipeline and stirrer).

6.4.5 LACK-OF-PRODUCT PROTECTION

Make sure that product without air bubbles is supplied to the mixing and dosing system.

→ The flow meters can not detect whether product or air is delivered.
→ This may lead to mixing errors. (An air bubbles monitoring system is optionally available for the low-pressure model).

A lack-of-product protection can be achieved by installing a level probe in the A-product tank or by always having the coater make sure that sufficient product is in the tanks. Otherwise false coating may occur.

If, e.g., the A-tank's level probe indicates the minimum level, a signal can stop the 2K system (STOP) or electronic consumption measuring equipment warns of a lack of product.

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. -or-
→ Operate the device on an appropriate spraying wall with the ventilation (extraction) switched on.
→ Observe national and local regulations for the exhaust air speed.

6.5 GROUNDING

WARNING

Fire, explosion and electric shock hazard

Danger to life by electric shock and explosion.

→ The device must be electrically connected to the equipotential bonding (ground); the ground in the electrical system is not sufficient.
→ A qualified electrician must complete all grounding and wiring connections and check the resistance.
→ Operation according to the safety regulations, fire protection and electrotechnical rules.
→ Must be de-energized before work is commenced on active parts.

WARNING

Heavy paint mist if grounding is insufficient!

Danger of poisoning.

Insufficient paint application quality.

→ Ground all device components.
→ Ground the work pieces to be coated.

Make sure to include the control cabinet and the fluid cabinet in the local equipotential bonding.

The 2K system, the pumps, all accessories and all parts that come into contact with the sprayer have to be grounded non-Ex or Ex according to the following grounding scheme.

Grounding scheme - example for 2K COMFORT non-Ex

Pos	Designation
1	Controller
2	Fluid section (non-Ex)
3	Pump
4	Paint tank
5	Work piece

Pos	Designation
6	Conveyor
7	Floor, static dissipative
8	Pneumatic alarm horn (option)
9	Remote control Ex (option)

• • • • Grounding cables Fluid hoses

Cable cross sections
2K system, pump 4 mm ^2 ; AWG 12
Paint tank / collection tank 6 mm ^2 ; AWG 10
Conveyor 16 mm ^2 ; AWG 6
Spray booth 16 mm ^2 ; AWG 6
Spraying stand 16 mm ^2 ; AWG 6

Connect all ground cables using a short and direct route.

Ex zone

All devices and equipment must be suitable for use in potentially explosive areas.

Tank

→ All paints, flushing agents and waste tanks have to be electrically conductive.
→ All tanks must be grounded.

Stroke measuring

→ Grounding ADC-0301: see "ADC-0301 / MPX-0403" operating manual (for Order No., see Chapter 1.3.1)

Grounding scheme - example for 2K COMFORT Ex

graph TD
    A["1"] --> B["2"]
    B --> C["3"]
    C --> D["4"]
    D --> E["5"]
    E --> F["6"]
    F --> G["7"]
    style A fill:#f9f,stroke:#333
    style B fill:#f9f,stroke:#333
    style C fill:#f9f,stroke:#333
    style D fill:#f9f,stroke:#333
    style E fill:#f9f,stroke:#333
    style F fill:#f9f,stroke:#333
    style G fill:#f9f,stroke:#333
    subgraph Non-Ex zone Ex zone
        H["1"] --> I["2"]
        J["8"] --> K["3"]
        L["2"] --> M["9"]
        N["5"] --> O["7"]
    end
    subgraph R max. < 1 MOhm
        P["6"] --> Q["5"]
    end

Pos	Designation
1	Controller
2	Fluid section (Ex)
3	Pump (Ex)
4	Paint tank
5	Work piece

Pos	Designation
6	Conveyor
7	Floor, static dissipative
8	Pneumatic alarm horn (option)
9	Remote control Ex (option)

• • • • Grounding cables Fluid hoses

Cable cross sections
2K system, pump 4 mm ^2 ; AWG 12
Paint tank / collection tank 6 mm ^2 ; AWG 10
Conveyor 16 mm ^2 ; AWG 6
Spray booth 16 mm ^2 ; AWG 6
Spraying stand 16 mm ^2 ; AWG 6

Connect all ground cables using a short and direct route.

Ex zone

All devices and equipment must be suitable for use in potentially explosive areas.

Tank

→ All paints, flushing agents and waste tanks have to be electrically conductive.
→ All tanks must be grounded.

Stroke measuring

→ Grounding ADC-0301: see "ADC-0301 / MPX-0403" operating manual (for Order No., see Chapter 1.3.1)

6.6 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.
→ Do not spray the device empty after cleaning.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent.

→ Never reach into the spray jet.
→ Never point the spray gun at people.
→ Consult a doctor immediately in the event of skin injuries caused by paint or solvent. Inform the doctor about the paint or solvent used.
→ Never seal defective high-pressure parts; instead relieve the pressure from them and replace them immediately.
→ Wear the appropriate protective clothing, gloves, eyewear, and respirator

NOTICE

Fluctuating supply pressures!

Poor coating result.

→ The supply pressure of component B should be adjusted to a higher value (approx. 5-10%) than that of component A.
→ The supplying pressure should be constant.

Electrostatic gun

Electrostatic guns must be used without electrostatics during commissioning. First commission the electrostatic system after all steps are carried out up to Chapter 6.6.6.

6.6.1 PRE-CLEANING

The devices are tested at the factory using emulsified oil, plain oil or solvent, according to the kind of fluid being pumped.

→ Before commissioning the pump with a product, it is recommended to flush both circuits and supply pumps with an appropriate flushing agent.

WARNING

Incompatibility of flushing agent and working medium!

Risk of explosion and danger of poisoning by toxic gases.

→ Examine the compatibility of the flushing agents and working medium on the basis of the safety data sheets.

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.
→ After all pumps and product hoses to the device have been flushed, the product hoses can be connected to the system.
→ The flushing agent still remains in the pumps.

Note:

The flushing agent used for the first cleaning may not be used again since it might contain oil residues.

The controller is already individually pre-configured upon delivery. Additional settings must be entered on-site.

→ Switch on the system with the main switch.
→ The initialization programs starts when the system is switched on for the very first time. It allows quick input of the most important settings, which must still be entered. The initialization program can also be called up later (with password level 3, setting "Reset initialization").

→ Define one after the other on the operating panel:

• Language (touch desired language, then proceed with the arrow key [] ;
  – Volumes measuring unit (liters or US gallons, touch field to change);
  – Lengths measuring unit (meter or inch);
  – Hose lengths and diameters;
  – Number of paint recipes (maximum 100) and number of flushing recipes (maximum 10);
• Mixing ratio input type (A:B or percentage).

→ At the end, a note appears, explaining what should be done next. Perform one after the other (password level 1):

• Enter names of valves, flushing recipes and paint recipes (see Chapter 7.9.2);
  – Enter flushing recipes (see Chapter 7.10);
• Enter paint recipes (see Chapter 7.11), still without calibration.

→ If necessary, implement further settings.

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.

graph LR
    A["Menu"] --> B["Hand Icon"]
    B --> C["Download Icon"]
    C --> D["(see Chapter 7.8)"]

→ Select each A side valve, one after the other and perform the following steps:

- Open the valve with the large valve icon.

- Bleed, via the gun, with low product pressure until clean flushing agent flows out of the gun.

- Close the valve icon again.

→ Do the same for the B side (and C/D, if available) and for the flushing valves.

6.6.4 PRESSURE TIGHTNESS TEST

WARNING

Overpressure!

Risk of injury from bursting components.

→ The operating pressure must not exceed the value shown on the type plate.

For pressure tightness control of the entire installation, the flushing agent pressure is slowly increased, step by step, until the maximum pressure of the individual pumps is achieved.

graph LR
    A["Menu"] --> B["Hand Icon"]
    B --> C["(see Chapter 7.8)"]

→ One after the other and in each component (A, B, flush, ...) for each product valve (A1, A2, ...):

- Select valve and open it with the large valve button.

- Slowly increase the pressure at the respective pumps, step-by-step, until the maximum pressure specified on the type plate has been reached.

– Hold the maximum pressure for at least 2 minutes.

- If there is a leak, mend it.

→ After the test, relieve pressure from the entire system according to Chapter 8.8.

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.

graph LR
    A["Menu"] --> B["Hand Icon"]
    B --> C["Output"]

Example for a hardener valve with the name B1:

1. Prepare the hardener components' tank and put the suction pipe in the respective pump.
2. Select [B] components, then select valve B1.
   Open the valve with the large valve button.
3. Set the hardener pump slightly under pressure. Open the hardener valve with the large valve button.
4. Point the guns into the grounded metal bucket and open it step by step. Avoid splashback.
5. After the hardener is filled, calibrate the hardener straight away, if necessary, according to Chapter 7.12.
6. Close the valve via the [Valve] field or close the STOP button again.

→ Then, in the same way, fill the system with the other components.

Note:

The solvent used for the first cleaning may not be used again since it might contain oil residues.

Calibration

Components with flow meter:

– In all paint recipes, calibrate the components as well as the flushing agent. If the components were already calibrated during filling, the K factors must be entered in the different recipes.

→ In accordance with Chapter 7.12.

Components with Coriolis measuring system:

- K factor = Enter 60,000 Imp/I according to Chapter 7.12. Perform zero point adjustment in accordance with "Coriolis Compact" user information (Order No., see Chapter 1.3.1)

6.6.6 ELECTROSTATICS

With an electrostatic gun:

→ Commissioning the electrostatics according to the corresponding assembly manual.

7 CONTROLLER

→ 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.

7.2 SAFETY INSTRUCTIONS

Before carrying out any work, ensure that commissioning is carried out in accordance with Chapter 6.6.

WARNING

Incorrect operation!

Risk of injury and damage to the device.

→ If contact with lacquers or cleaning agents causes skin irritation, appropriate precautionary measures must be taken, e.g., wearing protective clothing.
→ The footwear worn by operating staff must comply with EN ISO 20344. The measured insulation resistance must not exceed 100 megohms.
→ The protective clothing, including gloves, must comply with EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.

WARNING

Unintentional putting into operation!

Risk of injury.

Before any work on the device, in the event of work interruptions and malfunctions:

→ Relieve the pressure from the spray gun and unit.
→ Secure the spray gun against actuation.
→ Switch off the energy/compressed air supply.
→ Disconnect the control unit from the mains.
→ In the event of functional faults: remedy the fault as described in the "Troubleshooting" chapter.

7.3 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 7
→ Workflow: see Chapter 8

Detailed software documentation is separately available (see Chapter 1.3).

USB connection

The USB port is located at the control panel on the inside of the control cabinet.

Standard system of the control cabinet 2-circuit system of the control cabinet

Pos	Designation
1	Control cabinet
2	Operating panel (touchscreen)
3	Mechanical push-buttons
3a	Mechanical push-buttons, Circuit 1
3b	Mechanical push-buttons, Circuit 2
4	Main switch

2-circuit system

It is possible to work with two fluid circuits simultaneously. The operation of both fluid circuits is at any time immediately possible with mechanical push-buttons (3a or 3b).

The operating panel can be switched at any time quickly from one fluid circuit to the other.

7.3.1 MAIN SWITCH

The main switch, on the right side of the control cabinet, switches the controller on and off. When switched off, all valves close automatically.

→ Switching the system on and off: see Chapter 8.3.

7.4 MECHANICAL PUSH-BUTTONS

The system's basic functions are controlled by four mechanical push-buttons:

graph TD
    A["START STOP FLUSHING RECIPE CHANGE"] --> B["Starts spraying mode. Flashes green during filling. Lights up green as soon as the system is ready for spraying. The AirCoat air is activated (option)."]
    B --> C["Ends the spraying or flushing process. (Depending on setting, it may not be possible to end the flushing process early.) Alarm → Lights up red. Warning → flashes red."]
    C --> D["Starts end flushing of the last paint recipe used. (With external mixer if necessary mixer flushing.) Lights up blue during flushing process."]
    D --> E["Switches to next paint recipe. STOP + recipe change → jumps 10 steps."]
    F["Display of filling progress:"] --> G["Display of flushing progress: Gun symbol flashes → Open gun."]

7.5 OPERATING PANEL BASICS

	highlighted (yellow)	Some buttons are highlighted by a yellow background color. The highlighted buttons indicate our current location.
	All fields with frames can be touched. For example, to trigger an action, select a different recipe, or enter a number.

Recurring operating elements

[↑] Scroll up screen Confirm selection Saves the data

[ ]

[↓] Scroll down screen Cancel selection [×]

Differences in screen displays

The controller's functions differ depending on system, accessories installed, and user settings. The screens shown in the following chapters may therefore contain additional input options, or some of the buttons and fields shown may not be present in your version.

→ The screen will only ever show what is actually installed.

7.5.1 SELECT LANGUAGE

1. [Menu] button (second button in bottom row)

1. Touch language: [English]

7.5.2 KEYBOARD INPUT

A keyboard with numbers or letters appears as necessary when fields with frames are touched. The input is confirmed with [ENT] or canceled with [ESC].

graph TD
    A["Minimum and maximum values"] --> B["7 0.0 Max: 100.0"]
    B --> C["ESC"]
    C --> D["< -->"]
    D --> E["CLR DEL"]
    E --> F["0 ."]
    F --> G["ENT"]
    G --> H["B_04640"]
    I["Cursor (field with frame) = Current input position"] --> J["5.0"]
    K["Keyboard with numbers and special characters"] --> L["R_blue"]
    M["Confirm input"] --> N["ESC < --> ABC 123 CLR DEL BS"]
    O["Keyboard with upper case letters"] --> P["a b c d e f g h"]
    Q["Keyboard with upper case letters"] --> R["i j k l m n o p"]
    S["Keyboard with upper case letters"] --> T["q r s t u v w x"]
    U["Keyboard with upper case letters"] --> V["y z - _ SPACE ENT"]
    W["Keyboard with upper case letters"] --> X["B_04641"]
    Y["Confirm input"] --> Z["SPACE"]
    AA["Confirm input"] --> AB["ENT"]

Keyboard Controls
[ ESC ]	Escape / Cancel
[→]	Move cursor to right
[←]	Move cursor to left
[ ENT ]	Enter / Confirm input
[ CLR ]	Clear / Delete all
[ DEL ]	Delete / Delete character
[ BS ]	BackSpace / Delete character to left of cursor (backspace)
[ SPACE ]	Space / Spaces

Changing over keyboard with letters
[ABC]	Switch to keyboard with upper case letters
[abc]	Switch to keyboard with lower case letters
[123]	Switch to keyboard with numbers and special characters

7.5.3 PASSWORDS

Some functions and input options are protected by passwords. The following password levels exist:

Password level Responsibility Functions
0 Painter Spraying mode
1 Painter with control jobs		Plus enter flushing and paint recipes, diagnosis, calibration
2 Foreman	Plus system settings
3 Service customer Plus basic system settings
4	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. [Menu] button
2. If [Log Out] button appears: [Log Out] (The button switches to [Log In].)
3. [Log In]
4. Touch password input field.
   A numerical keyboard appears.
5. Enter the password.
6. [ENT]
   The password level is displayed briefly, for example: "Level 1".
   The menu buttons for the corresponding password level then appear.

7.6 HOME PAGE

NOTICE

Wrong mixing ratio!

Poor quality of paint application.

→ Before changing the lacquer, check the mixing ratio on the display and modify it if necessary, if individual components have different mixing ratios.

7.6.1 CHANGING THE PAINT RECIPE

Press RECIPE CHANGE push button

→ Switches to next paint recipe.

Or:

1. Touch paint recipe field (see above).
2. Select desired paint recipe from the list.

graph TD
    A["Number of current paint recipe"] --> B["Paint recipe"]
    B --> C["Open choice of all paint recipes."]
    C --> D["1: R1"]
    D --> E["A: B"]
    D --> F["AB: C"]
    D --> G["D"]
    G --> H["10.00 % of ABC"]
    H --> I["29 minPot life"]
    I --> J["Flow regulation"]
    J --> K["The system regulates the flow to a set value."]
    K --> L["As of password level 1: calibration of flow regulation"]
    L --> M["Flow contrl"]
    M --> N["AIS"]
    N --> O["Preset the dosing valve stroke."]
    O --> P["PC Data Archiving → Chapter 1.3.1"]
    P --> Q["Batch Produce recurring, predetermined flow rate."]
    Q --> R["Act. (=current) Shows the current lacquer consumption values."]
    R --> S["Tank Filling level monitoring of paint tank."]
    S --> T["Flushing Opens a menu with various flushing options."]
    T --> U["Menu Opens a menu containing other functions."]
    U --> V["Flushing"]
    V --> W["Menu Act."]
    W --> X["Batch AISPC"]
    X --> Y["29 minPot life"]
    Y --> Z["All fields with frames can be touched."]
    Z --> AA["Mixing ratio (volumetric)"]
    AA --> AB["Pot life Remaining pot life in minutes or seconds."]
    AB --> AC["Gun selection *"]
    AC --> AD["1 + 2 + 3 + 4"]
    AD --> AE["Home Returns to home page at any time."]

The 'Home' button is emphasized using reversed colors – on screen with light background. This shows us our current location: on the home page.

7.7 MENU

Button Function
	AlarmCalls up list of the last 700 warning messages.
	Manual operationSpecific opening and closing of product or flushing valves. Chapter 7.8
	Tank→ Software Documentation
	Change name (password level 1)→ Chapter 7.9.2
	Flushing recipes (password level 1)→ Chapter 7.10
	Paint recipes (password level 1)→ Chapter 7.11
	Diagnosis (password level 1)Mixing amount, e.g., QB: As soon as the mixture has the correct mixing ratio, the mixing amount is reset to zero. The system stops when the maximum is exceeded (=QB-control, see Chapter 7.13.1).Btkt = The dosing valve's cycle length% open per cycle = dosing valve's opening time. If too short: slowly reduce the difference in pressure between A and B.Output → Display the output signal status.Input → Display the input signal status.
	Totals (password levels 1 / 2)View / zero product consumption and working times.
	VOC quantities (password levels 1 / 2)View / zero VOC quantities, enter VOC factors. Chapter 7.11
	Info (password level 1)View software version number, set date and time.
	Calibration (password level 1)→ Chapter 7.12
	Settings (password levels 2 / 3)→ Chapter 7.13
USB	USB (password levels 2 / 3)Back up alarms, totals, and configuration data on USB stick.
	Service (password level 2)Service intervals for dosing valves and flow meters.
I/O Config	Input / Output configuration (password level 3)Assign inputs and outputs. → see software documentation
Stroke sensor	Stroke sensor configuration (password level 3), from software version 4.0x / 4.0x K. see software documentation

7.8 MANUAL MODE: OPEN VALVES

graph TD
    A["Menu"] --> B["User Icon"]
    B --> C{Select paint recipe (for A/B/C/D). Or select flushing valve (for A/B/C/D flushing valves).}
    C --> D{Valve used by paint recipe. (See other used valves: buttons A/B/C/D.)}
    D --> E["Valve is closed"]
    E --> F{Touch to change}
    F --> G{Valve is open}
    G --> H{Open several valves / output signals at the same time}
    H --> I["→ With password level 3, see Chapter 7.13.2."]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333
    style F fill:#ffc,stroke:#333
    style G fill:#cfc,stroke:#333
    style H fill:#fcc,stroke:#333
    style I fill:#ffc,stroke:#333

Manual mode is used for troubleshooting or to fill a pump, for example.

Only one valve can be opened at any one time. If another valve is touched, the controller closes all valves.

With a gun flush box, the valve for the gun is also opened: either for gun 1 (if gun 1 or 1+x is selected on the home page), or for gun 2 (if gun 2 is selected on the home page).

Ext. flushing agent

The valve for the external flushing agent can not be opened on this page. If necessary, the calibration function can be used for this, without saving the measured value (password level 2, Chapter 7.12).

7.9 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. Enter the flushing recipe (see Chapter 7.10).

Create a new paint recipe:

1. Increase the "Number of paint recipes" in the settings by one (see Chapter 7.13.1).
2. Change the paint recipe name automatically assigned (see Chapter 7.9.2).
3. Enter paint recipe (see Chapter 7.11).

7.9.2 CHANGING RECIPE AND VALVE NAMES

graph TD
    A["Menu"] --> B["ABC (with password level 1 or higher)"]
    B --> C["Change valve names (for example: red, yellow, hardener_1, flushing agent_1)."]
    B --> D["→ First select components (A, B, flushing A, ...), then touch the valve names."]
    B --> E["others"]
    E --> F["Other valve names"]
    F --> G["----"]<fcel>No valve open<ecel><nl>
<ucel><ucel><fcel>Ext. Mixer Flush<fcel>Flushing from external mixer (option)<nl>
<ucel><ucel><fcel>Mix He Shishing starting from mixing head valve (option)<lcel><nl>
<ucel><ucel><fcel>Flush P1<fcel>Flushing starting from splitter valve for gun 1 or gun 2<nl>
<ucel><ucel><fcel>Flush P2<ucel><nl>
<ucel><ucel><fcel>Infosignal Generates an information signal<lcel><nl>
<ucel><ucel><fcel>101: Wait<ecel><nl>
<ucel><ucel><fcel>102: Gun Change<fcel>Demand gun change. (With 2-4 guns and only one gun flush box.)<nl>
<ucel><ucel><fcel>Last A/B/C/D material<fcel>Last used A/B/C/D product<nl>
<ucel><ucel><fcel>* from version 3.2x / 3.2x K<lcel><nl>
<ucel><ucel><fcel>Change flushing recipe name.
For example: R-R flushing (= recipe change flushing), end flushing, gun flushing.<lcel><nl>
<ucel><ucel><fcel>Change paint recipe name.
For example: red-90, red-95, yellow_customer-1, yellow_customer-2.<lcel><nl>

7.10 ENTER FLUSHING RECIPE

graph TD
    A["Menu"] --> B["Image Icon"]
    B --> C["Example with splitter valve, dump valve and product pressure regulator"]
    C --> D["R-R Flush Step 1-5"]
    D --> E["A1-solvent Flushing Qty 20.0 cc"]
    E --> F["open the distributor valve for a single gun (1, 2, 3 or 4) or for all guns (1-x)."]
    F --> G["→1/2/3/4/1-x"]
    G --> H["With several guns, separate flushing steps must be defined for each gun. Only those guns which were in use are flushed automatically. Exception: if a system has already been flushed, the guns indicated are flushed in any case when flushing is repeated."]
    D --> I["Set flushing pressure. (Only with "Automatic product pressure regulator" option)"]
    I --> J["Flushing via dump valve: on or off. (Only with "Dump valve" option)"]
    J --> K["Switch between flushing quantity and flushing time. →cc or seconds"]
    K --> L["Enter short flushing steps first (rough flushing) to begin with, then long flushing steps approx. twice the hose content). (No influence on: "Gun Change""]
    L --> M["Enter flushing quantity or flushing time for this flushing step. →0.0–9999.9"]
    M --> N["Select action for this flushing step. →Flushing valve to open, or →Wait (=wait) →Gun Change (=extend gun change) →Infosignal(Chapter 7.13.2, level 3, page 21) →Last A/B/C/D-material (last used A/B/C/D product)"]
    N --> O["Go to next flushing step. →Repetitions can be entered after the last flushing step (for examples, see software documentation)."]

7.11 ENTER PAINT RECIPE

graph TD
    A["Menu"] --> B["(with password level 1 or higher)"]
    B --> C["Select existing paint recipe. New recipe: see Chapter 7.9.1"]
    C --> D["Enter mixing ratio (volume) for the selected recipe"]
    D --> E["→0.1:1–50.00:1"]
    D --> F["→0.02% – 1,000.00%"]
    C --> G["If one or several components are not required: enter 0.00:1 or 0.00%"]
    G --> H["1K application: Enter 0.00:1 or 0.00% for all components except for one."]
    C --> I["The flow is measured by volume and the mixing ratio is entered and controlled volumetrically by default."]
    I --> J["Select product valves for available components. If one or several components are not required: B valve = "----""]
    C --> K["Go to next pageSave paint recipe"]
    K --> L["Enter "----" for all components except for one."]

Page 2

• Enter pot life.
• Select flushing recipes to be used:

	Is carried out, ...
End:	... after this paint recipe has been used when end flushing is being carried out.
R-R:	... after this paint recipe has been used when the recipe is changed.
Mix:* ...	when flushing just from the external mixer to the gun.
Pre:* ...	before using this paint recipe.(For whether a recipe change and / or end flushing comes first: see Chapter 7.13.2, "Pre-flushing after paint change flush" or "Pre-flushing after end flushing").

* May also be missing, depending on configuration.

Select empty field if no flushing recipe is to be active.

Page 3 (option)

– Product pressure when filling and working.

Prerequisite: low-pressure system with automatic product pressure regulator.

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.

Settings:

• Activate "Flow monitoring" → see Chapter 7.13.2 (password level 3, page 2)
• "Alarm delay for flow monitoring"→see Chapter 7.13.1 (password level 2, page 2)

If flow falls below or exceeds the limits, the system stops with alarm A121 or A122.

Page 6 (option)

- Batch Mode: pre-define the Batch quantity for this paint recipe.

Prerequisite: accessories set for automatic filling + external signal transmitter (e.g., foot-operated switch)

• [Save] recipe.
• VOC = Volatile Organic Compounds

If the local specifications require a VOC measurement, then the corresponding VOC factor must be entered in every paint recipe for each component.

1. Select newly entered paint recipe.

2. One after the other, touch components A / B / C / D and flushing A / B / C / D and for each:

3. Enter the corresponding VOC factor in percent or g/L or g/G. The VOC measuring unit is defined in the settings (see Chapter 7.13.1).

4. Only if the corresponding factor is to be saved for all paint recipes: [ ]

– Calibration for the newly entered paint recipe:

→ According to Chapter 7.12.

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. Perform zero point adjustment in accordance with "Coriolis Compact" user information (Order No., see Chapter 1.3.1)

Flow meters and stroke sensors

Flow meters or stroke sensors must be calibrated. This produces a K factor for every component. The K factors may vary depending on the lacquer (A1, A2, A3, ...). Therefore, the K factors for each paint recipe are saved separately.

→ Flow meter: The default is the average from the calibration report. The default is accurate and is a good match for most products. A calibration is therefore, not usually necessary.
→ Stroke sensor: Calibration must be carried out.
→ When a calibration is performed, it should always be a precise process. Particular care must be taken, to measure the volume in the measuring cup exactly and without air bubbles.

(with password level 1 or higher)

Example: K factor for paint recipe R1 and for component B with flow meter.

1. Select paint recipe: R1.
2. Select component: B.
3. The system is under spraying pressure and the selected component is already in the spray gun. Select the spray nozzle, so that pressure and product flow approximately meet subsequent work processes.

[Start] → [Stop] → Wait until no more product flows.

1. Start the measurement: [Start].
2. Use the gun to fill a certain quantity of the corresponding lacquer (e.g., 500 ml) into a measuring cup. Use a protective tube against overspray if necessary.

The flow measured by the system is displayed on the screen.

1. Close the gun and push the [STOP] button. Wait until no more product flows.
2. Exactly measure the quantity filled into the measuring cup by weight, with one of the following versions.
3. Enter the determined volume in the measuring cup field.
4. The controller calculates and saves the new K factor and displays it in the Kn field.
5. Press the [图标] icon in order to accept the new K factor.

→ Selection possibility: If the different lacquers of the same components have similar characteristics, then the K factor can immediately be saved for all recipes. Otherwise, only for the current recipe.

1. Carry out the calibration several times in order to check the values.

In case of large deviations, eliminate the cause:

– Air in the lines → fill the lines with product and check the suction system.
- Air mixture in the measuring cup gauge the calibration and use the density to calculate the volume.
- The flow is not measured properly. Dismount the flow meter or stroke sensor, clean it and check it for any damage.

1. 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)

• Weigh the quantity filled into the cup.
• Divide the weight in grams (g) by the lacquer's density. This directly equals the volume in cc, that is entered in the measuring cup field.

Exact calibration, version 2 (Lacquer density is unknown)

• First, manually measure precisely e.g., 500 cc of product into a measuring cup and establish the product weight in "g" grams.
• Set empty measuring cup on the scale. When calibrating, use the gun to fill the cup with the exact weight measure above.
• The initial volume (e.g., 500 cc) is entered in the measuring cup field.

7.13 SETTINGS

7.13.1 PASSWORD LEVEL 2 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.)

1 Number of paint recipes and number of flushing recipes.

QB, QC, QD Control → See the software documentation, "Diagnosis" chapter.

Gun Delay → Delay time for alarms A106 to A113 (set "Minimum flow" and "Maximum flow" – Chapter 7.13.2, level 3, page 4)

2 Post-alarm for pot life → Once the pot life + post-alarm times have passed, the system stops (alarms A132–A144). The alarm is repeated until the system is flushed. If "Automatic flushing at pot life alarm" is activated, and the guns are in the gun flush box, flushing is started automatically.

Alarm delay Flow monitoring → Delay time for alarms A121 and A122. (Activate "Flow monitoring", → Chapter 7.13.2, level 3, page 2. Enter the limits in the paint recipe → see Chapter 7.11)

Atomizing air at alarm stop → So that coating can be completed without dripping.

Atomizing air at end of flushing → To blow the air cap free.

VOC measuring unit → Percent or gram per Liter.

Password for password level 1.

3 Hose dimensions from product valves A and B to mixer.

4 For 3K system: hose dimensions from product valve C to mixer.

5 For 4K system: hose dimensions from product valves C/D to mixer.

6 Hose dimensions from mixer to splitter valve.

7+8 - Page 7: Hose dimensions from mixer to gun 1.

– Page 8: Hose dimensions from splitter valve to gun 1.

Gun content of gun 1

Gun 1: Filling via the dump valve → Quantity (as a percentage), which should be discharged via the dump valve. (The remainder passes via the gun.)

Gun 1: Flush atomizing air % hose content → When flushing: What percentage of the hose content from the mixer to the gun, can still be used for coating. The atomizing air (and electrostatics) for gun remains activated for this period when flushing. See also "Flushing pause" (level 2, page 16).

Gun 1: dump valve flushing time after filling. (Only with flushable dump valve.)

9 Hose dimensions from gun 1 to the dump valve. (Only with "Dump valve as return flow".)

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. The atomizing air remains on during the flushing pause.

Pot life alarm → Flushing → "On" = Flushing is mandatory after a pot life alarm. Additional spraying is also possible with "Off".

Mixing alarm → Flushing → "On" = Flushing is mandatory after a mixing error alarm (A100–A118, A128–A131, A145–A148). Additional spraying is also possible with "Off".

Mixing alarm → Filling → "On" = Filling is mandatory after a mixing error alarm (A100–A118, A128–A131, A145–A148). Additional spraying is also possible with "Off".

17 Filling greater than hose content → What percentage of the total hose content is also to be filled between product valve and gun to ensure that there is no flushing agent left in the hose.

Flow monitoring during filling → "On" = The flow is limited when filling to optimize the dosing quality. Set limits with "Max. filling flow" or "Min. filling flow". If necessary, the A valve cycles (see figure).

Reset pot life → Pot life is reset manually.

Flow monitoring during filling

graph LR
    A[""A" valve open"] --> B[""A" valve closed"]
    B --> C["a"]
    C --> D["b"]
    D --> E["Time"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#ffc,stroke:#333

(a) During filling, the flow is regulated by a longer or shorter opening of the A valve.
(b) "Filling time period" (in seconds)
(c) "Maximum time period open" (in percent of (b))

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 → Minimum injection quality (opening time of hardener dosing valve as a percentage). If the value falls below this, a warning is triggered (W123 - W125).

AIS lower limit If the value falls below this, the AIS optimizes the injection quality. (Default value = 50%

AIS upper limit → If the value exceeds this, the AIS limits the injection quality. Thereby smooth operation is ensured. (Default value = 80%)

Valve > open AIS open → If the B valve is continuously opened for longer than the stated time, too little product can flow through. The AIS allows more product through. (Default value 1.0 sec.) Repetition after each repetition interval AIS open. (Default value 0.5 sec.)

AIS open when stopped → Number of steps which the AIS is to open when mixing operation is ended. (Default value 3)

AIS min. flow → Minimum flow of all components for AIS to undertake regulation. (Default value 20 cc/min)

20 For AIS-B:

AIS hysteresis → Number of steps which do not yet have impact when AIS switches (e.g., close -open) and are therefore inserted at the switchover points. (Default value 1)

AIS Number of cycles with X guns Number of steps which the AIS is to open or close when an additional gun is switched on or off.

21+22 Like pages 19 + 20, but for AIS-C.

23+24 Like pages 19 + 20, but for AIS-D.

7.13.2 PASSWORD LEVEL 3 SETTINGS

There are 23 pages of settings. (Detailed descriptions of these pages can be found in the 2K COMFORT Software Documentation.)

1 2K-, 3K- or 4K system (with 2-circuit system maximally 3K)

Measuring units for volume (liters / US gallons) and lengths (meter / inch)

Gun closed → Valves closed → "On": When the gun is closed, all product valves are also closed automatically. Beneficial for low-pressure applications. Prerequisite: gun monitoring (not flow monitor).

External release → "On" = External releasing (e.g. locking with spray booth's exhaust air) Number of installed Universal CAN I/O modules

2 Number of guns (1–4, with 2-circuit system 1–2)

Gun monitoring for all available guns.

Splitter valve (Prerequisite: minimum 2 guns)

Flush guns separately → "On" = splitter valve with flushing (separate gun flushing valves). Prerequisite: maximum 2 guns, splitter valve = On.

Number of gun flush boxes (GFB)

Automatic flushing at pot life alarm (Prerequisite: GFB)

Flow monitoring (On/Off). Prerequisite: gun monitoring or flow monitor. Sets off Alarms A121 and A122. ("Alarm delay for flow monitoring" → Chapter 7.13.1, level 2, page 2. Enter the limits in the paint recipe → see Chapter 7.11)

3 Dump valve → "On" = There is a dump valve installed for every gun. Or a dump valve flushable. If a dump hose is present between gun and dump valve (not flushable), the option dump valve as return line is activated. Dump valve for waste separation is possible with double valves (not flushable) (not for 2-circuit system). Precision of waste separation: 0 = exact, each additional number = 25% of the dump hose safety margin (default value 2).

Dump valve outputs can be inverted → "Off" = Compressed air opens dump valve with non-flushable dump valves without waste separation. "On" = Compressed air closes dump valve.

4 For component A:

Number of valves and flushing valves.

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 / 4.0xK. To configure stroke sensors: see 2K COMFORT software documentation.

5 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. The actual temperature must correspond to the temperature display of the C-flow measuring transducer (with liquid in the system). Correct the value here if necessary.

6 Like page 4, but for component B.

7 For component B:

AIS (On/Off)

Mixing head valve with cycles → If a mixing head valve is fitted: "On" = Mixing head valve cycles. "Off" = B valve cycles.

Mixing head valve flushing "On" = A flushing valve is attached to the mixing head valve.

Input type for mixing ratio (A:B oder %B)

8 Like page 5, but for component B.

9–11 Like pages 6–8, but for component C.

12–14 Like pages 6–8, but for component D.

15 Alarm delay for air bubbles monitoring → How long can an air bubble be present before the system stops (→alarms A114–A117).

Alarm delay no flow during filling How long can filling be interrupted before an alarm occurs (alarm A124). If set to 0.0 seconds, the function is deactivated.

Alarm delay no flow during flushing → How long can flushing be interrupted before an alarm occurs (alarm A125)? When flushing, this alarm takes the place of the pot life alarm. If the setting is "0.0 seconds", the function is deactivated, the pot life continues and a pot life alarm occurs.

Alarm delay for Coriolis error (alarms A128–A131).

Remote control (On/Off)

Robot (no/digital/bus): "Digital" = Robot is digitally connected. "Bus" = Robot is connected via gateway.

Timeout for automatic logout → If the touch panel is not activated during the defined time, then the password level is automatically reset to level 0. ("0 sec" = no automatic logout.)

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.

Number of tanks for filling level monitoring.

17 Pre-flushing after end flushing → "On" = After an end flushing, a pre-flushing must be undertaken. Prerequisite: pre-flush recipe is defined and selected in the paint recipes.

Pre-flushing after paint change flushing → "On" = A pre-flushing must be undertaken after a recipe change flushing. Prerequisite: pre-flush recipe is defined and selected in the paint recipes.

Flush interruption ok? → "On" = The flushing process can be interrupted and e.g., the new paint filled. "Off" = The entire flushing process must be undertaken first. If flushing is aborted, the process starts again afresh.

Air flushing valve (On/Off) "On" = Air flushing is fitted.

External mixer (On/Off)

Flushing external mixer as standard → "On" = The FLUSHING push button starts mixer flushing ("Mix") of the last paint recipe used. (→Flushing from external mixer) "Off" = The FLUSHING push button starts end flushing ("End") of the last paint recipe used.

18 Number of automatic product pressure regulators (0 / 1 / number of guns). "1" = Automatic product pressure regulator in front of splitter valve. "Number of guns" = An automatic product pressure regulator is fitted for each gun.

Maximum product pressure for automatic product pressure regulator.

Pressure regulator fully open during flushing

→ For manual product pressure regulators: "On" = During flushing, the product pressure regulator is subjected to full air pressure.
→ For automatic product pressure regulators: No function.

Pulse time at flush for prod.press reg.

→ For manual product pressure regulators, if the above function is switched on: pulse time for changes between working pressure and full air pressure.
→ For automatic product pressure regulators: pulse time for changing between flushing pressure (specified in recipe) and 0 bar.
→ "0.0 sec" = no cycling.

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).

Flushing monitoring in seconds (flushing with paint valves / flushing external mixer / gun flushing / dump flushing):

→ "no" = The flushing time runs, regardless of whether or not flushing agent flows.
→ "Gun monitoring" = The flushing time only runs when there is a gun signal. Prerequisite: gun monitoring signal from flow monitor or robot, not from air monitoring.
→ "Flow switch" = The flushing time only runs when there is a signal from the flow switch. Prerequisite: "Flow switch in external flushing agent" is activated (see above).

21\* An information signal can be generated:

• As soon as the filling is complete (Setting "Filling complete: -> Information signal").
• As soon as the gun in the gun flush box must be changed (Setting "GFB gun change: -> Information signal").
  – During the flushing process (see Chapter 7.10).

Duration of the alarm horn sounds according to "Information signal switch-on time" and "Information signal break time". ("Number of cycles for information signal" = How many information signal cycles should sound as soon as the filling is complete.)

22\* Warning signal on alarm horn (On/Off). Duration of sounds according to "Warning signal switch-on time" and "Warning signal break time".

23 \*\* Password level 2 / 3 → Password input for password level 2 / 3.

Reset initialization "OK" = When the system is switched on the next time, the initialization program starts (e.g., for training purposes). The current settings are preset, nothing is lost.

Start software update "OK" = A software update is executed. Special knowledge is required for this purpose (observe separate manual).

7.14 OPERATING PANEL FOR 2-CIRCUIT SYSTEM

The operating panel controls either the fluid circuit 1 or the fluid circuit 2.

Example: Home page for circuit 1

Current fluid circuit:

① = Fluid circuit 1

② = Fluid circuit 2

1/2 = affects both fluid circuits

Touch = Go to the other fluid circuit

Background color of page:

Turquoise = Fluid circuit 1

Orange = Fluid circuit 2

White = both fluid circuits

On the home page are always both pot lives, each with the appropriate background color:

Pot life Circuit 1

Pot life Circuit 2

7.14.1 CHANGE FLUID CIRCUIT

→ Touch the current upper right fluid circuit, for example:①

Thereafter, the controller switches to the other fluid circuit. The page remains the same. Example: the controller changes from the menu page for circuit 1 to the menu page for circuit 2.

Change not possible

This error message appears if the current page is not available in the other fluid circuit:

Change to circuit X is not possible.

→ Go to another page (for example to the home page). Then change the fluid circuit.

On some pages, the current fluid circuit is framed in gray. Then a change to another circuit is also not possible. Remedy is the same:

→ Go to another page. Then change the fluid circuit.

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
	... affects the total system
Gun name (example) Gun P2/K1	Gun P2 of circuit 1
Signal name (example) A1 valve	K2 A1 valve for circuit 2
Alarm message (example) A123	flushing first/K1 Circuit 1 has to be	flushed

Software version identification

2-circuit systems software versions are marked after the version number with the letter "K":

"x.xx K"

7.14.3 ACKNOWLEDGE ALARMS

	STOP button Acknowledge alarm
Alarm Fluid circuit 1 STOP button	Circuit 1 lights up Press the STOP	button Circuit 1. *
Alarm Fluid circuit 2 STOP button	Circuit 2 lights up Press the STOP	button Circuit 2. *
Alarm System	Both STOP buttons light up	Press one of both STOP buttons. *

* Or touch the [Reset] button on the screen.

7.14.4 WHITE BACKGROUND: AFFECTS BOTH FLUID CIRCUITS

Everything relates to both circuits has a white background.

	Fluid circuit 1	Fluid circuit 2	Valid for both fluid circuits
Fluid circuit display (upper right)	1	2	1/2
Background color	Turquoise	Orange	White

Example: Settings

Turquoise = Circuit 1. White = both circuits.

Recipe change

8 OPERATION

Below, operation with manual guns is described. For automatic guns the same workflow applies correspondingly.

→ 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.

8.2 SAFETY INSTRUCTIONS

Before carrying out any work, ensure that commissioning is carried out in accordance with Chapter 6.6.

8.2.1 EMERGENCY DEACTIVATION

In the case of unforeseen occurrences:

– Switch off main switch.
– Switch off air supply of system and pumps.
- Point the manual gun into a grounded metal bucket. Open the gun's trigger mechanism step by step in order to relieve the pressure. Avoid splashback.
- Secure the gun.
- Provide appropriate return tanks and relieve pressure from the pumps via the return valves.
– Inform the security personnel / foreman / superiors.

8.2.2 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN

→ Observe the operating manual of the spray gun.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent.

→ Never reach into the spray jet.
→ Never point the spray gun at people.
→ Consult a doctor immediately in the event of skin injuries caused by paint or solvent. Inform the doctor about the paint or solvent used.
→ Never seal defective high-pressure parts, instead relieve the pressure from them and replace them immediately.
→ Use personal protective equipment (protective clothing, gloves, eyewear and respiratory protection).

8.3 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. for operation. Provide grounded metal bucket to collect the products to be disposed of.

→ Switching off the system

1. Press the STOP push button.
2. Flush system if necessary (see Chapter 8.6).
3. Make sure that the system has been flushed and that the pot life has been increased.
4. Relieve pressure from the system and from all feed pumps (see Chapter 8.8).
5. Switch off main switch (OFF).
6. Switch off air supply of system and pumps.

8.4 MALFUNCTION

If a fault occurs, it is indicated by the following:

→ The system stops and the alarm horn sounds
→ The red STOP push button lights up (control cabinet and remote control).
→ The fault is indicated on the screen.

Acknowledge fault

→ By means of the STOP push button or, on the screen, with the [Reset] button.

Alarm messages + fault rectification → see Chapter 10.

8.5 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.
– The flushing program is defined.
– The supply pressures are constant.
- The A/B/C/D pressure ratio is set correctly (see Chapter 8.5.2).

- 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). See the operating manual for the valves (Order No. in Chapter 1.3.1).

- The product pumps can draw in the product perfectly and no cavitation occurs with piston pumps (pump breaking through during down stroke). If necessary, the product must be fed with a feed pump.

Optimum operation is fulfilled under the following conditions:

• When the flushing agent pressure for the flushing pumps as well as the product pressure for the A, B and C pumps are always present on the device.
• When filling the mixed product in the product hose ensure that the nozzle is inserted in the gun.
• When the flushing process is performed without the nozzle in the gun.
• When the levels in the product and flushing agent tanks are checked visually, in order to prevent unintended interruptions in the spray process.

Prerequisites

• At the start, all pumps must be filled with working material and the system must be ready to start, as described in Chapter 6.6.5.
  – The nozzle is inserted into the gun. Gun secured.
• Operating manuals for the affected components must be known.
  – With an electrostatic gun:
  → Commissioning the electrostatics according to corresponding operating manual.

8.5.2 A/B/C/D PRESSURE RATIO

• Set the pressure ratio between base lacquer and hardener correctly. With a mixer: B must be approx. 5–10% higher than A. C approx. 2–5% higher than B, D approx. 2–5% higher than C.
  – The pressure drop between pressure gauge and mixer can be differently for A/B/C/D. For longer distances, different flow rates and viscosities that may be relevant (e.g., for external mixer or if the pressure gauges are at the pumps).

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. Thereby, keep in mind that the the B-component pressure must be higher (5 to 10%) than that of the A-component.
→ Select the requested paint recipe on the screen (home page). In case of two spray guns, select the requested gun(s).
→ ▶ Start the coating process by means of the START push button.
→ Filling

→ For electrostatic spray guns: switch off electrostatics.

Point the manual gun with inserted spray nozzle into the grounded metal bucket. Open the trigger mechanism of the spray gun step by step. Avoid splashback.

→ The 2K product starts to flow and the B-component is dosed proportionally to the A-component. During filling, three screens in turn inform you of filling progress:

	B_04637	From product valves to mixer.
	B_04638	From mixer to splitter valve.
	B_04639	From splitter valve to gun.

→ As soon as the complete high-pressure hose is filled with 2K product, the following will happen:

• "Filling" screen switches to the home page.
• The green START push button begins to light up.
• Remote control (Option): The green lamp begins to light up.
• Atomizing air is added (option).

Correctly mixed product is not transported from the gun until after filling.

→ Coating

→ For electrostatic spray guns: safety precautions according to corresponding the operating manual.
→ Start coating of an object.

→ The flushing agent pressure for A and B must always be applied at the device.

→ The flow rate of the system depends on:

– the product pressure,
– the hose lengths and cross-sections,
- the nozzle and
– the viscosity of the products.

→ Without AIS, the B pulse valve should operate every 0.5 to 3 seconds, according to the flow rate. The switching frequency can be optimized by adjusting the pressure of the hardener pump or through the stroke length of the hardener dosing valve. The higher the pulse rate is, the more homogeneous is the mixing of the two components.

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. All product valves are closed.
→ For electrostatic spray guns: switch off electrostatics.

8.5.6 CHANGING THE PAINT RECIPE

The recipe change flush is executed on all spray guns while the spray nozzle is inserted.

→ Actuate the STOP push botton.
→ Select the new paint recipe on the screen (home page).

→	Without gun flush box With gun flush box
	– Press START push button. – Insert spray gun(s) in gun flush box.– Point the spray gun into the metal bucket. Open the gun step by step. Avoid splashback. – Press START push button.	The spray gun is automatically opened as necessary.

→ The system is flushed (recipe change flushing "R")R Flush
→ Subsequently the new lacquer is filled.
→ As soon as the green START push button lights up and the home page appears on the screen, the system is ready for spraying.

8.5.7 A VALVE SELECTION AT START

→ Possibly, a list of the A valves appears for selection at the start. Touch desired valve.
→ The option is set with the setting "Select A valve during start" (see Chapter 7.13.2).

8.5.8 CIRCULATION (OPTION)

→ If necessary, the A, B or C components not in use have to be circulated.

8.6 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.

- The pressure has to be relieved before removing the spray nozzle (see Chapter 8.8).

→ Wear protective goggles.
→ Apply the lowest possible product pressure for flushing so that the maximum flow rate of the flow meter is not exceeded.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent.

→ Never reach into the spray jet.
→ Never point the spray gun at people.
→ Consult a doctor immediately in the event of skin injuries caused by paint or solvent. Inform the doctor about the paint or solvent used.
→ Never seal defective high-pressure parts; instead relieve the pressure from them and replace them immediately.
→ Use personal protective equipment (protective clothing, gloves, eyewear and respiratory protection).

The system has to be flushed:

→ in case of recipe change (recipe change flushing, system flushes automatically);
→ in case of extended interruption of work or end of work (end flushing);
→ if pot life has been exceeded (end flushing).

WARNING

Discharge of the electrostatics in atmospheres containing solvents!

Fire and explosion hazard.

→ Turn off the electrostatics before flushing the gun or before placing the gun in the gun flush box.

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.

3. Actuate FLUSHING push button.

4. Point the opened gun(s), with or without nozzle, into a waste tank until the flushing process has been terminated.

During flushing, the blue FLUSHING push button lights up. The screen gives step by step information about the individual flushing steps.

graph LR
    A["1 End Flush Step 1 / 5 B1-solvent"] --> B["0 cc 80.0"]
    B --> C["3"]
    C --> D["Current flushing recipe"]
    C --> E["Flushing step 1 of 5"]
    C --> F["Flushing valve currently open"]
    C --> G["Progress indication"]
    C --> H["Guns to open during this flushing step. Gun symbol flashes → Open gun."]

Finally, all valves are closed.

If cleaning is insufficient, flushing can be repeated. The flushing recipe can be corrected subsequently.

Flush with external mixer

Setting "Flushing ext. mixer is standard" *	FLUSHING push button
On	Starts the mixer flushing ("Mix") of last paint recipe used.→ Flushing from external mixer.
Off Starts the end flushing	("End") of the last paint recipe used.

* see Chapter 7.13.2

Atomizing air flushing

The system can be set such that the atomizing air remains switched on for flushing during a certain time. Thus, the mixed product in the hose can be sprayed. A short flushing pause indicates that the remainder has to be sprayed into the waste tank. (Settings, see Chapter 7.13.1.)

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.
• Start end flushing: starts end flushing of the last paint recipe used.
• Start flushing external mixer: flushing from external mixer. The product hoses between valves and mixer are not flushed.
• Flushing spray guns: flushing from splitter valve. The product hoses between valves and splitter valve are not flushed.

Flushing with dump valve (option)

Flushing via a dump valve is quicker than via the gun. However, the gun has also to be flushed briefly.

→ When the flushing process stops and the spray gun symbol on the screen flashes, the corresponding guns have to be opened. Point opened gun(s) with or without nozzle in a waste tank.

As long as the gun symbol flashes, open the corresponding spray gun (here gun 2).

→ As soon as the gun symbol stops flashing, close gun again.

Flushing with gun flush box

Same procedure as without gun flush box, but:

→ Before flushing, insert the spray gun into the gun flush box.
- Atomizing air flushing: the flushing pause indicates when the gun is to be inserted into the gun flush box.
→ Remove the spray gun after flushing.

8.7 FLOW CHART WITH PAINT RECIPE CHANGE

Example for 2K system:

graph LR
    A["1. Stop\n2.R1→R2\n3. Start"] --> B["2. Stop\n2. End flushing"]
    B --> C["3. Stop\n4. End flushing"]
    C --> D["4. Stop\n5. End flushing"]
    D --> E["5. Stop\n6. End flushing"]
    E --> F["6. Stop\n7. End flushing"]
    F --> G["7. Stop\n8. End flushing"]
    G --> H["8. Stop\n9. End flushing"]
    H --> I["9. Stop\n10. End flushing"]
    I --> J["10. Stop\n11. End flushing"]
    J --> K["11. Stop\n12. End flushing"]
    K --> L["12. Stop\n13. End flushing"]
    L --> M["13. Stop\n14. End flushing"]
    M --> N["14. Stop\n15. End flushing"]
    N --> O["15. Stop\n16. End flushing"]
    O --> P["16. Stop\n17. End flushing"]
    P --> Q["17. Stop\n18. End flushing"]
    Q --> R["18. Stop\n19. End flushing"]
    R --> S["19. Stop\n20. End flushing"]
    S --> T["20. Stop\n21. End flushing"]
    T --> U["21. Stop\n22. End flushing"]
    U --> V["22. Stop\n23. End flushing"]
    V --> W["23. Stop\n24. End flushing"]
    W --> X["24. Stop\n25. End flushing"]
    X --> Y["25. Stop\n26. End flushing"]
    Y --> Z["26. Stop\n27. End flushing"]
    Z --> AA["27. Stop\n28. End flushing"]
    AA --> AB["28. Stop\n29. End flushing"]
    AB --> AC["29. Stop\n30. End flushing"]
    AC --> AD["30. Stop\n31. End flushing"]
    AD --> AE["31. Stop\n32. End flushing"]
    AE --> AF["32. Stop\n33. End flushing"]
    AF --> AG["33. Stop\n34. End flushing"]
    AG --> AH["34. Stop\n35. End flushing"]
    AH --> AI["35. Stop\n36. End flushing"]
    AI --> AJ["36. Stop\n37. End flushing"]
    AJ --> AK["37. Stop\n38. End flushing"]
    AK --> AL["38. Stop\n39. End flushing"]
    AL --> AM["39. Stop\n40. End flushing"]
    AM --> AN["40. Stop\n41. End flushing"]
    AN --> AO["41. Stop\n42. End flushing"]
    AO --> AP["42. Stop\n43. End flushing"]
    AP --> AQ["43. Stop\n44. End flushing"]
    AQ --> AR["44. Stop\n45. End flushing"]
    AR --> AS["45. Stop\n46. End flushing"]
    AS --> AT["46. Stop\n47. End flushing"]
    AT --> AU["47. Stop\n48. End flushing"]
    AU --> AV["48. Stop\n49. End flushing"]
    AV --> AW["49. Stop\n50. End flushing"]
    AW --> AX["50. Stop\n51. End flushing"]
    AX --> AY["51. Stop\n52. End flushing"]
    AY --> AZ["52. Stop\n53. End flushing"]
    AZ --> BA["53. Stop\n54. End flushing"]
    BA --> BB["54. Stop\n55. End flushing"]
    BB --> BC["55. Stop\n56. End flushing"]
    BC --> BD["56. Stop\n57. End flushing"]
    BD --> BE["57. Stop\n58. End flushing"]
    BE --> BF["58. Stop\n59. End flushing"]
    BF --> BG["59. Stop\n60. End flushing"]
    BG --> BH["60. Stop\n61. End flushing"]
    BH --> BI["61. Stop\n62. End flushing"]
    BI --> BJ["62. Stop\n63. End flushing"]
    BJ --> BK["63. Stop\n64. End flushing"]
    BK --> BL["64. Stop\n65. End flushing"]
    BL --> BM["65. Stop\n66. End flushing"]
    BM --> BN["66. Stop\n67. End flushing"]
    BN --> BO["67. Stop\n68. End flushing"]
    BO --> BP["68. Stop\n69. End flushing"]
    BP --> BQ["69. Stop\n70. End flushing"]
    BQ --> BR["70. Stop\n71. End flushing"]
    BR --> BS["71. Stop\n72. End flushing"]
    BS --> BT["72. Stop\n73. End flushing"]
    BT --> BU["73. Stop\n74. End flushing"]
    BU --> BV["74. Stop\n75. End flushing"]
    BV --> BW["75. Stop\n76. End flushing"]
    BW --> BX["76. Stop\n77. End flushing"]
    BX --> BY["77. Stop\n78. End flushing"]
    BY --> BZ["78. Stop\n79. End flushing"]
    BZ --> CA["79. Stop\n80. End flushing"]
    CA --> CB["80. Stop\n81. End flushing"]
    CB --> CC["81. Stop\n82. End flushing"]
    CC --> CD["82. Stop\n83. End flushing"]
    CD --> CE["83. Stop\n84. End flushing"]
    CE --> CF["84. Stop\n85. End flushing"]
    CF --> CG["85. Stop\n86. End flushing"]
    CG --> CH["86. Stop\n87. End flushing"]
    CH --> CI["87. Stop\n88. End flushing"]
    CI --> CJ["88. Stop\n89. End flushing"]
    CJ --> CK["89. Stop\n90. End flushing"]
    CK --> CR["90. Stop\n91. End flushing"]
    CR --> CS["91. Stop\n92. End flushing"]
    CS --> CT["92. Stop\n93. End flushing"]
    CT --> CU["93. Stop\n94. End flushing"]
    CU --> CV["94. Stop\n95. End flushing"]
    CV --> CW["95. Stop\n96. End flushing"]
    CW --> CX["96. Stop\n97. End flushing"]
    CX --> CY["97. Stop\n98. End flushing"]
    CY --> CZ["98. Stop\n99. End flushing"]

Pre-flushing

Pre-flushing may be necessary between

R-R flushing and filling (see Chapter 7.11).

8.8 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;
→ spraying is stopped;
→ part of the system is checked or maintained;
→ the nozzle is installed or cleaned.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent.

→ Never reach into the spray jet.
→ Never point the spray gun at people.
→ Consult a doctor immediately in the event of skin injuries caused by paint or solvent. Inform the doctor about the paint or solvent used.
→ Never seal defective high-pressure parts; instead relieve the pressure from them and replace them immediately.
→ Use personal protective equipment (protective clothing, gloves, eyewear and respiratory protection).

Pressure relief procedure for the whole system

1. Press the STOP push button.
2. Relieve the product pressure and air pressure in all pumps or pressure tanks. Use return / circulation, according to the instructions in the corresponding operating manuals.
3. For electrostatic spray guns: switch off electrostatics.

graph LR
    A["Menu"] --> B[" folder icon "]
    B --> C[" bow icon (see Chapter 7.8)"]

One after the other and in each component (A, B, flush, ...) for each product valve (A1, A2, ...):
- Select valve and open it with the large valve button.
- Point the manual gun into a grounded metal bucket. Open the gun's trigger mechanism step by step in order to relieve the pressure. Avoid splashback.
- Close and secure gun.

1. Press the [STOP] button.

9 CLEANING AND MAINTENANCE

9.1 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:

– Health hazard from inhaling solvent vapors
– Use of unsuitable cleaning tools and aids

9.1.2 SAFETY INSTRUCTIONS

Before all work on the device and in the event of work interruptions:

• Relieve pressure from spray guns, high-pressure hoses and all devices.
  – Secure spray guns against actuation.
• Switch off the energy and compressed air supply.
• Disconnect the control unit from the mains.

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.

9.1.3 FILTER CLEANING

→ Product filter: check and clean filter insert and filter body. When opening the filter, ensure that no product drips on the flow meter's electronics.
→ The filters of the piston pumps and guns should be cleaned in accordance with the corresponding operating manuals.

9.1.3.1 CONDENSATE DRAINAGE FROM THE FILTER PRESSURE REGULATOR

→ Frequently drain the condensate that may accumulate in the air filter.
- Make sure the water level in the filter cup never reaches the max. level marked on the cup itself.

WARNING

Brittle filter pressure regulator!

The tank on the filter pressure regulator becomes brittle through contact with solvents and can burst. Flying parts can cause injury.

→ Do not clean the tank on the filter pressure regulator with solvents.

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. Relieve the pressure according to Chapter 8.8.
2. Service guns and pumps according to their operating manuals.
3. Clean and check the suction systems and suction filter.
4. Product filter: check and clean filter insert and filter body.
5. Put the whole system back together.
6. Clean the outside of the system.

9.1.5 DECOMMISSIONING

1. Clean the system according to Chapter 9.1.4.
2. Fill the entire system with flushing agent. As laid down in Chapter 6.6.5, but with flushing agent.

WARNING

Gas mixtures can explode if there is an incompletely filled pump!

Danger to life from flying parts.

→ Ensure that the device is always completely filled with flushing agent or working medium.
→ Do not spray the device empty after cleaning.

9.1.6 LONG-TERM STORAGE

If storing the system for a prolonged period of time, thorough cleaning and corrosion protection are necessary. For the last rinse, replace the water or solvent in the product pumps with a suitable preservative. Fill separating agent cup with separating agent. Store pump vertically.

Procedure:

1. Clean the system according to Chapter 9.1.4.
2. Fill the entire system with flushing agent. As laid down in Chapter 6.6.5, but with flushing agent.
3. Fill the entire system with preservative according to Chapter 6.6.5 and the lacquer supplier's instructions.
4. If the discharge duct is to be removed, seal product outlet with plug.
5. If the suction system is to be removed, seal product inlet with plug.
6. Storage according to Chapter 6.2.

9.2 MAINTENANCE

9.2.1 MAINTENANCE STAFF

Maintenance 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 maintenance work:

– Health hazard from inhaling solvent vapors
– Use of unsuitable tools and aids

An authorized person must ensure that the device is checked for being in a reliable state after maintenance work is completed.

9.2.2 SAFETY INSTRUCTIONS

Prior to maintenance

- Cleaning and flushing the device. -Chapters 8.6 and 9.1.4.

DANGER

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.
→ Before all work on the device and in the event of work interruptions:
- Relieve pressure from spray guns, high-pressure hoses and all devices.
– Secure spray guns against actuation.
- Switch off the energy and compressed air supply.
- Disconnect the control unit from the mains.
→ Observe the operating and service manual for all work.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

→ Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel.

After maintenance

• Put the system into operation and check for leaks. Section 6.6
  → In accordance with DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36:

– 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.

- For shut down devices, the examination can be suspended until the next start-up.

9.2.3 GEAR FLOW METER

→ The gear flow meters (A/B/C/D) are cleaned by flushing.
→ If individual parts have to be cleaned, the flow meter should be disassembled. Care should be taken that these parts are installed again in their original positions.

1. Remove the electronic sensor (1) from the flow meter.

- The electric sensor can be removed by loosening the two screws (10) from the holes without removing the cover (11).

1. Unscrew the screws (2) - two opposite screws should be left, temporarily screwed in by two turns.
2. Carefully take the lid (3) off the flow meter parallelly.

- If necessary, softly knock on the lid with a plastic hammer so that it loosens.

• The lid must be removed parallelly so that the internal bearings are not stressed and the shaft (5) does not break.
• For this reason do not use screwdrivers as levers.

1. Remove the screws which had previously been left screwed in.
2. Remove the lid, the gears (7) and the shafts (5).

– In most cases a dirt particle in the flow meter causes the problem.
- If the parts cannot be disassembled easily, put the flow meter into a suitable solvent and then disassemble the parts.
- Do not disassemble the parts by force!
- 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. This has to be the case even when a finger slightly presses against the shafts laterally.

1. Mount the lid again in parallel position and adjust it in the correct position by means of both dowel pins (12).
   → These pins must never be removed from the flow meter housing.

2. Tighten the screws with 15 Nm; 11.06 lb/ft.

3. Check if the gears turn by using a short pulse of compressed air, maximum 0.1 MPa; 1 bar; 14.5 psi.

4. Mount the electronic sensor again. Do not interchange A/B/C flow meters.

9.2.4 CLEANING AND REPLACING THE PRODUCT FILTER

1. Flush the pump and inline filter in accordance 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).
2. Empty the pump in a controlled manner in accordance with pump's operating manual.
3. Place the grounded collection tank under the inline filter.
4. Unscrew the filter by turning the handle (4).
5. Remove the filter insert (3).
6. If the inline filter has any leaks, replace the seal (1).
7. Insert the new filter insert (3). Note the installation position: Closed end in direction of flow.
8. If necessary, coat the thread with anti-seize paste (10).
9. Assemble the turning handle (4), inlet housing (2) and outlet housing (5) and tighten by turning the handle.
10. Fill the pump in accordance with pump's operating manual.

53 MPa; 530 bar; 7,687 psi

* For Order No., see spare parts catalog

9.2.5 PRODUCT VALVES

Example 2.6 mm valve

Check the leakage behavior of the product valves (air or product discharge from the leakage hole) in regular intervals (once per week).

→ In case of air leakage: change rod sealing.
→ In case of product discharge:
- 2.6 mm valve: re-tighten sealing screw or change the seals.
- 4 mm valve: change the seals.
→ Check the leakage behavior of the valve seats at regular intervals, by executing a pressure retention test in accordance with Chapter 6.6.4.
→ Disassembly and assembly, see valve operating manual (Order No. in Chapter 1.3.1).

9.2.6 PRODUCT HOSES, TUBES AND COUPLINGS

The service life of the complete hoses between product pressure generator and application device is reduced due to environmental influences even when handled correctly.

→ Check hoses, pipes, and couplings every day and replace if necessary.
→ Additionally, the operator must regularly check the complete hoses for wear and tear as well as for damage at intervals that he/she has set. Records of these checks must be kept.
→ Undamaged complete hoses are to be replaced when one of the two following intervals has been exceeded:

- 6 years from the date of the hose crimping (see fitting embossing).

- 10 years from the date of the hose imprinting.

Fitting embossing(if present)	Meaning
xxx bar Pressure
yymm Crimping date (year/month)
XX Internal code

Hose imprinting Meaning
WAGNER Name / Manufacturer
yymm Date of manufacture (year/month)
xxx bar (xx MPa)e.g., 270 bar (27 MPa)	Pressure
XX Internal code
DNxx (e.g., DN10) Nominal diameter

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.

Acknowledge fault

→ Stop with the STOP push button.
→ Or by means of the [Reset] push button on the screen.

List of alarm messages and warning messages: see Chapter 10

Fault rectification

See the following table and Chapters 10.1.1 and 10.2.1.

For troubleshooting, it is important which work steps were last carried out.

→ The troubleshooting within the electric cabinet should be carried out by qualified persons (e.g., industrial electrician)!

WARNING

Electric shock hazard inside the control unit!

Danger to life from electric shock.

→ May only be installed/maintained by skilled electricians or under their supervision.
→ Operation according to the safety regulations, fire protection and electrotechnical rules.
→ Must be de-energized before work is commenced on active parts.

Malfunction Remedy
System does not start up	– Check air supply line connection.– Check the pressure value on the system's pressure gauge for the air supply to the valves.– Check the voltage supply (does the control panel light up?)– Check the selected valves.– Check the fuses.
System is in operation (a pump is running), but there is no product flow	– Check the supply lines of the components as well as filters (clogging) and suction tubes (leakage).– Check the component level in the supply tanks.– Check the viscosity of the components or the pressure loss.
System does not supply any product, pumps do not run	– Check the mixing tube and feed hoses.– Check the guns and the gun filter.– Clean the lines by flushing or cleaning manually.
The 2K product does not react correctly	- Check the mixing ratio value.- Check the suction lines (leakage).- Check the flow meter with a calibration process.- Check pressure differences.→see Chapter8.5.2- Check AIS function (see software documentation, "Diagnosis" chapter).- Without AIS: Optimize the switching behavior of the hardener dosing valve in spraying mode (0.5 - 3 seconds) via the differential pressure of B to A or via the stroke setting of the valve.- Check the lacquer specifications.
Flow rate is too low - Check the mixing tube and feed hoses.- Check the guns and the gun filter.- Clean the lines by flushing or cleaning manually.- Increase the pressure of the supply pumps.
Product valves: - See product valve's operating manual.- Product- or air emission from leakage hole-No product transportation- Contamination
Interruption of circuit over a longer period of time	- With external compressed air, manually open the flushing valve and distributor valve (option).
A fuse is defective.LED lights up	- Check on the basis of the control cabinet diagram whether a cable is damaged.- Replace the fuse.
The system supplies product, but the spray pattern is inadequate	- Ensure that the supply pressures are constant.- Adjust the A/B/C/D pressure ratio.→see Chapter8.5.2-Increase the pressure of the supply pumps.- AirCoat: Set the atomizing air correctly.- Check product filter on pumps, 2K systems and guns.- Replace gun nozzle with a more suitable nozzle (Airless and AirCoat).- Check the viscosity of the product and dilute it in accordance with the lacquer manufacturer's instructions. If necessary correct the mixing ratio.- AirCoat: Ensure that only dry, clean atomizing air is used in the spray gun.
Flow rate is too high - Replace gun nozzle (Airless and AirCoat).- Check the lines for leakage.- Set the opening of the gun needle correctly (air guns only).- Decrease the pressure of the supply pumps.

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.	Alarm message in the display	Meaning
A100 B+	tol. alarm	Mixing ratio outside of tolerance range. B+/C+/D+: too much B/C/D.A
A102 D+	tol. alarm
A103 B-	tol. alarm	Mixing ratio outside of tolerance range. B-/C-/D-: too little B/C/D.A
A105 D-	tol. alarm
A106 A+	flow rate	Maximum flow of components A/B/C/D exceeded.
A107 B+	flow rate
A108 C+	flow rate
A109 D+	flow rate
A110 A-	flow rate	Falls below minimum flow of components A/B/C/D.
A111 B-	flow rate
A112 C-	flow rate
A113 D+	flow rate
A114 Air	bubble A	Air bubble in the line (only with low-pressure).
A115 Air	bubble B
A116 Air	bubble C
A117 Air	bubble D
A118 Flow meter A Flow meter A is blocked.
A119 Gun monitoring No gun signal, although product is flowing.
A120 No enabling signal External release missing.
A121 Flow fault - The flow rate is below the limit entered in the paint recipe.
A122 Flow fault + The flow rate is above the limit entered in the paint recipe.
A123 Flushing first The system has to be flushed.
A124 No flow during filling The filling procedure is interrupted for too long.
A125 No flow during flushing The flushing procedure is interrupted for too long.
A126 Gun monitoring disabled	Function is selected, which requires gun monitoring. However, the gun monitoring is deactivated.
A127 K factor is 0!	A K factor for the current paint recipe is zero. Calibrate.

Acknowledge alarm: By means of the STOP push button or on the screen with the [Reset] button.

Fault rectification: see Chapter 10.1.1

Alarm No.	Alarm message in the display	Meaning
A128 Coriolis A		For Coriolis error, see operating manual of Coriolis flow meter.
A129 Coriolis B
A130 Coriolis C
A131 Coriolis D
A132 Pot life gun 1		Pot life + post-alarm time of guns 1/2/3/4 have expired.
A133 Pot life gun 2
A134 Pot life gun 3
A135 Pot life gun 4
A136 Pot life gun hose 1		Pot life + post-alarm time of gun hoses 1/2/3/4 have expired.
A137 Pot life gun hose 2
A138 Pot life gun hose 3
A139 Pot life gun hose 4
A140	Pot life to spl. valve	The pot life + post-alarm time from mixer to splitter valve have expired.
A141 Pot life dump hose 1		Pot life + post-alarm time of dump hoses 1/2/3/4 have expired.
A142 Pot life dump hose 2
A143 Pot life dump hose 3
A144 Pot life dump hose 4
A145 Tank A is empty		Tank for component A/B/C/D is empty.
A146 Tank B is empty
A147 Tank C is empty
A148 Tank D is empty
A149 Tank flushing agent is empty Flushing agent tank is empty.
A150 Flow is too low		The setpoint flow is not reached with the flow regulation.
A151 Flow is too high

Acknowledge alarm: By means of the STOP push button or on the screen with the [Reset] button.

Fault rectification: see Chapter 10.1.1

Alarm messages with stroke measurement

Alarm No.	Alarm message in the display	Meaning / Fault rectification
A200	Unknown error Error number unknown.
A201-A204	Sensor A/B/C/D signal is lost	Stroke sensor cable breakage or sensor signal lost (sensor is in lower idle position).
A205-A208	SensorA/B/C/D LowerReversePoint	Lower stroke sensor reversal point not detected.
A209-A212	SensorA/B/C/D UpperReversePoint	Upper stroke sensor reversal point not detected.
A213-A216	Sensor A/B/C/D dry run down Pump sags in downward stroke, pump cavitating.
A217-A220	A/B/C/D sensor dry run up Pump sags in upward stroke, pump cavitating.
A221-A224	Sensor A/B/C/D initialization Stroke sensor initialization error.
A225-A228	Sensor A/B/C/D unknown. error	Error number unknown.
A229-A232	Sensor A/B/C/D wrong type Stroke sensor type does not match the setting.
A237-A240	ADC1/2/3/4 no response Communication error
A241	Unknown operating mode
A242	SensorA unknownSelection
A243	SensorB unknownSelection
A244	SensorC unknownSelection
A245	SensorD unknownSelection
A246	Sending: unknown SensorNo.
A247	Sending: unknown Parameter
A248	Wrong data value
A249	Reading: unknown SensorNo.
A250	Reading: unknown Parameter
A254	MPX sends in operation
A256	MPX transfer error
A257	Data conflict Different settings data on MPX / ADC and touch panel.
A258	MPX is not sending data
A259	MPX is not responding
A260	Sending to MPX interrupted
A261	Data from wrong sensor Communication error

Acknowledge alarm: By means of the STOP push button or on the screen with the [Reset] button.

Fault rectification: see Chapter 10.1.1

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.
A502	CAN master alone	The touch panel CAN master found no connected slaves on the CAN bus.
A503	SDO sending error	Error while sending or receiving SDO telegrams.
A504	SDO receiving error
A505	Saving interrupted Error while saving on the PC.
A600	Module D2 no communication	No communication to the corresponding module.
A601	Module D3 no communication
A602	Module D4 no communication
A603	Module D5 no communication
A604	Gateway D6 no communication
A606	Module D2 CAN emergency	Module sends an emergency telegram.
A607	Module D3 CAN emergency
A608	Module D4 CAN emergency
A609	Module D5 CAN emergency
A610	Gateway D6 CAN emergency
A612	Module D2 CAN error	Slave reports communication problems.
A613	Module D3 CAN error
A614	Module D4 CAN error
A615	Module D5 CAN error

Acknowledge alarm: By means of the STOP push button or on the screen with the [Reset] button.

Fault rectification: see Chapter 10.1.1

Alarm No.	Alarm message in the display Meaning
A616 Module D2 hardware error EEPROM		Hardware error in I/O module.
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 Module D3 hardware error ADC
A622 Module D4 hardware error ADC
A623 Module D5 hardware error ADC
A624 Module D2 hardware error TIMER
A625 Module D3 hardware error TIMER
A626 Module D4 hardware error TIMER
A627 Module D5 hardware error TIMER
A628 Module D2 unknown hardware error
A629 Module D3 unknown hardware error
A630 Module D4 unknown hardware error
A631 Module D5 unknown hardware error
A632 Module D2 hardware error counter
A633 Module D3 hardware error counter
A634 Module D4 hardware error counter
A635 Module D5 hardware error counter
A640 Module D2 DO group1		Voltage supply error.
A641 Module D2 DO group2
A642 Module D2 DO group3
A643 Module D2 DO group4
A644 Module D3 DO group1
A645 Module D3 DO group2
A646 Module D3 DO group3
A647 Module D3 DO group4
A648 Module D4 DO group1
A649 Module D4 DO group2
A650 Module D4 DO group3
A651 Module D4 DO group4
A652 Module D5 DO group1
A653 Module D5 DO group2
A654 Module D5 DO group3
A655 Module D5 DO group4

Acknowledge alarm: By means of the STOP push button or on the screen with the [Reset] button.

Fault rectification: see Chapter 10.1.1

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
• Without AIS:

- The stroke at the B/C/D valve is too long. Close the regulating screw a little.

- Check the cycle length of the hardener dosing valve (menu diagnosis). 0.5 to 3 seconds are optimal. If the cycle length is too long, then the difference in pressure is still too great or the stroke is too long.

- With AIS:

- If the stroke of the B/C/D valve is far from its ideal position, the adjustment can take a long time under some circumstances. Home page: [AIS], then reduce the AIS position a bit.

• Check whether valve closes. Clean valve.
• The flow meter A is blocked by soiling. The LED at the flow meter has to light up during product flow, otherwise it is clogged (cleaning, see Chapter 9.2.3).
• Check whether nozzles, mixer or filter are clogged.
• Check the level of the paint tank, condition of the feed pumps, etc.
• The QB/QC/QD control quantity may be set too low (standard 150 cc). If the quantity is increased, the control algorithm becomes more stable because more time is available in order to achieve the mixing ratio.

A103/A104/A105 B-/C-/D- tol. alarm

The mixing ratio within a specific control quantity (QB/QC/QD control) was not reached: too little B, C or D.

• Increase the pressure of B/C/D: →see Chapter 8.5.2
• Without AIS:

- The stroke at the B/C/D valve is too short. Open the regulating screw a little.

- Check the cycle length of the hardener dosing valve (menu diagnosis). 0.5 to 3 seconds are optimal. If the valve is always open (cycle check display is almost continuously lit), then the difference in pressure is still too small or the stroke is too short.

- With AIS:

• If the stroke of the B/C/D valve is far from its ideal position, the adjustment can take a long time under some circumstances. Home page: [AIS], then enlarge the AIS position a bit.
• Check whether the valve opens. Clean valve.
• The flow meter B or C or D is blocked by soiling. The LED at the flow meter has to light up during product flow, otherwise it is clogged (cleaning, see Chapter 9.2.3).
• Check whether nozzles, mixer or filter are clogged.
• Check the level of the paint tank, condition of the feed pumps, etc.
  – The QB/QC/QD control quantity may be set too low (standard 150 cc). If the quantity is increased, the control algorithm becomes more stable because more time is available in order to achieve the mixing ratio.

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.
- Insert nozzle.
– Possibly worn nozzle, leaking hose or other leaking parts.

A110/A111/A112/A113 A-/B-/C-/D-flow rate

Gun monitoring signal is present, even though no product is flowing (gun closed).

– Check the atomizing air for leaks.
– Check whether the gun monitoring operates correctly.
- Possibly, the "Gun delay" is set too short (see Chapter 7.13.1).
- The alarm can occur if the atomizing air continues to flow from the gun during short spray breaks. Release the gun trigger completely or increase the gun delay time.
- The A/B/C/D-component flow is less than the lower limit "Minimum flow" (see Chapter 7.13.2, level 3, page 4).
– Clean flow meters.
- Possible further causes such as for alarm A100...A105.

A114/A115/A116/A117 Air bubble A/B/C/D

Air bubble in the line (only with low-pressure). Fill product tank.

A118 Flow meter A

The flow meter A is blocked by soiling. The LED at the flow meter has to light up during product flow, otherwise it is clogged (cleaning, see Chapter 9.2.3).

A119 Gun monitoring

Product flows through the A flow meter and for 50 seconds, there is no signal indicating that the gun is open.

• This means that the gun monitoring is defective or that there is no contact.
  – Repair or replace the gun monitoring.

A120 No enabling signal

External release missing (booth ventilation etc.)

A121 Flow fault -

The flow rate is below the limit entered in the paint recipe (see Chapter 7.11).

– Check the mixing tube and feed hoses.
- Check the guns and the gun filter.
– Clean the lines by flushing or cleaning manually.
– Increase the pressure of the supply pumps.

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.
• Set the opening of the gun needle correctly (air guns only).
  – Decrease the pressure of the supply pumps.

A123 Flushing first

The system has to be flushed.

The "Mixing alarm → flushing" or "Pot life alarm – flushing" is activated and a mixing or pot life alarm has occurred.

A124 No flow during filling

The filling procedure is interrupted for too long (longer than the "Alarm delay no flow during filling" setting).

– Possibly, the filling procedure is waiting for the gun to be opened:
- With gun flush box: check whether the gun is inserted correctly.
- Without gun flush box: point spray gun into waste tank and open it.
- Check dump valve: clogging, function.

A125 No flow during flushing

The flushing procedure is interrupted for too long (longer than the "Alarm delay no flow during flushing" setting).

– Possibly, the flushing procedure is waiting for the gun to be opened:
- With gun flush box: check whether the gun is inserted correctly.
- Without gun flush box: point spray gun into waste tank and open it.
- Check dump valve: clogging, function.

A126 Gun monitoring deactivated

Function is selected, which requires gun monitoring. However, the gun monitoring is deactivated. Activate the gun monitoring or deactivate the relevant function.

Functions which require gun monitoring:

• Flow monitoring (settings password level 3).
• Spray gun closed valves closed (settings password level 3).
  – Dump valve as return line (settings password level 3).

A127 K factor is 0!

The new K factor "Kn" is 0 and can therefore not be saved.

A128/A129/A130/A131 Coriolis A/B/C/D

For Coriolis error, see operating manual of Coriolis flow meter.

A132/A133/A134/A135 Pot life gun 1/2/3/4

Pot life + post-alarm time have expired. Continue working immediately or flush.

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. Close the gun until the dump hose is filled with freshly mixed product. Or, flush the system.

A145/A146/A147/A148 Tank A/B/C/D is empty

A149 Tank flushing agent is empty

Flow rate drops below the alarm limit. Fill up tank.

A150 Flow is too low

Even though the product pressure regulator is fully open, the setpoint flow is not reached.

• Check air pressure.
• Check product pressure.
  – Check product pressure regulator.
• Check the control of the product pressure regulator (Electric/Pneumatic converter).

A151 Flow is too high

Even though the product pressure regulator is fully closed, the actual flow exceeds the setpoint flow.

– Check product pressure regulator.
- Check the control of the product pressure regulator (Electric/Pneumatic converter).

Fault rectification for stroke measurement

A200 Unknown error

Check compatibilities (software versions touch panel / MPX / ADC).

A201/A202/A203/A204 Sensor A/B/C/D signal lost

Stroke sensor cable breakage

– Check plug connection for sensor.
– Sensor signal lost (sensor is in lower idle position).
- Intake problem: pump is cavitating, improve supply of product.
- Switch pump to circulation and pass lower reversal point.

A205/A206/A207/A208 Sensor A/B/C/D lower reversal point

A209/A210/A211/A212 Sensor A/B/C/D upper reversal point

Stroke sensor reversal point not detected.

• Check pump.
• Check stroke sensor settings in the touch panel and send again.
• Check stroke sensor.
• Replace stroke sensor if necessary.

A213/A214/A215/A216 Sensor A/B/C/D dry run down

Pump sags in downward stroke, pump cavitating.

• Check product supply.
  – Leak check, check piston valve.

A217/A218/A219/A220 Sensor A/B/C/D dry run up

Pump sags in upward stroke, pump cavitating.

• Check product supply.
  – Leak check, check piston valve.

A221/A222/A223/A224 Sensor A/B/C/D initialization

Stroke sensor initialization error.

– Switch system off and turn back on.

A225/A226/A227/A228 Sensor A/B/C/D unknown error

Error number unknown.

- Check compatibilities (software versions touch panel / MPX / ADC).

A229/A230/A231/A232 Sensor A/B/C/D wrong type

Stroke sensor type does not match the setting.

• Check stroke sensor.
• Check stroke sensor settings in the touch panel and send again.

A237/A238/A239/A240 ADC 1/2/3/4 no response

A241 Unknown operating mode

A242/A243/A244/A245 Sensor A/B/C/D unknown selection

A246 Sending: unknown sensor no.

A247 Sending: unknown parameter

A248 Wrong data value

A249 Reading: unknown sensor no.

A250 Reading: unknown parameter

A254 MPX sends in operation

A255 MPX unknown message

A256 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.

A257 Data conflict

Different settings data on MPX / ADC and touch panel.

- Check stroke sensor settings in the touch panel and send again.

A258 MPX is not sending data

A259 MPX is not responding

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. Data must be sent again. (See software documentation.)

A261 Data from wrong sensor

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.

CAN bus fault rectification

A500 Initialisation error

Internal error when starting up the touch panel.

• Switch off the system and back on via the main switch.
• Contact the Service Team.

A501 CAN master error

The touch panel CAN master process not possible.

• Switch off the system and back on via the main switch.
• Contact the Service Team.

A502 CAN master alone

The touch panel CAN master found no connected slaves on the CAN bus.

• Check the connected modules: voltage supply, CAN cable, address, baud rate and terminating resistor. See spare parts catalog (Order No., see Chapter 1.3).
• Switch off the system and back on via the main switch.
• Contact the Service Team.

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 occurred while saving on the PC.

– Check the archiving software on the PC.

A600/A601/A602/A603 Module D2/D3/D4/D5 no communication

A604 Gateway D6 no communication

Slave is not responding.

• Check corresponding module: voltage supply, CAN cable, address, baud rate and terminating resistor.
• Switch off the system and back on via the main switch.
• Contact the Service Team.

A606/A607/A608/A609 Module D2/D3/D4/D5 CAN emergency

A610 Gateway D6 CAN emergency

Corresponding module sends an emergency telegram.

• Switch off the system and back on via the main switch.
• Contact the Service Team.

A612/A613/A614/A615 Module D2/D3/D4/D5 CAN error

Corresponding slave reports communication problems.

• Switch off the system and back on via the main switch.
• Contact the Service Team.

A616/A617/A618/A619 Module D2/D3/D4/D5 hardware error EEPROM

A620/A621/A622/A623 Module D2/D3/D4/D5 hardware error ADC

A624/A625/A626/A627 Module D2/D3/D4/D5 hardware error TIMER

A628/A629/A630/A631 Module|D2/D3/D4/D5 unknown hardware error

A632/A633/A634/A635 Module D2/D3/D4/D5 hardware error counter

Corresponding module reports a hardware error.

• Switch off the system and back on via the main switch.
• Contact the Service Team.

A640-A655 Module D2/D3/D4/D5 DO group 1/2/3/4

I/O module reports insufficient voltage supply at the respective output group.

(DO = Digital Output)

– Check the voltage supply of the respective output group.
- Check the fuse of the respective output group.

See spare parts catalog, "I/O modules" chapter.

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.	Warning message on the display	Meaning
W100 1st pot life gun 1W101 1st pot life gun 2W102 1st pot life gun 3W103 1st pot life gun 4		Pre-alarm for the pot life of gun 1/2/3/4
W104 1st pot life gun hose 1W105 1st pot life gun hose 2W106 1st pot life gun hose 3W107 1st pot life gun hose 4		Pre-alarm for the pot life of gun hose 1/2/3/4
W108 1st pot life to spl.valve Pre-alarm for pot life from mixer to splitter valve
W109 1st pot life dump hose 1W110 1st pot life dump hose 2W111 1st pot life dump hose 3W112 1st pot life dump hose 4		Pre-alarm for the pot life of dump hose 1/2/3/4
W113 A flow meter serviceW114 B flow meter serviceW115 C flow meter serviceW116 D flow meter service		Carry out service for flow meter A/B/C/D
W117 B valve serviceW119 D valve service		Carry out service for dosing valve B/C/DW118 C valve service
W120 Mix head B serviceW122 Mix head D service		Carry out service for mixing head valve B/C/DW121 Mix head C service
W123 AIS-BW125 AIS-D		AIS-B/C/D Fell short of warning limit (injection quality in %)W124 AIS-C
W126 Tank A limitW127 Tank B limitW128 Tank C limitW129 Tank D limit
W130 Tank flushing agent Limit
W500 USB memory No USB stick used or too little memory
W501 USB storage Automatic job total saving: saving did not work

Fault rectification → see Chapter 10.2.1

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. Continue working immediately or flush.

W109/W110/W111/W112 Pre-alarm for pot life dump hose 1/2/3/4

The pot life in the dump hose has expired. Close the gun until the dump hose is filled with freshly mixed product. Or, flush the system.

W113/W114/W115/W116 A/B/C/D flow meter service

The maximum flow rate indicated in the [service] [menu] was reached. The corresponding flow meter needs servicing.

W117/W118/W119 B/C/D valve service

The maximum switching cycle indicated in the [service] [menu] was reached. The corresponding dosing valve needs servicing.

W120/W121/W122 Mix head B/C/D service

The maximum switching cycle indicated in the [service] [menu] was reached. The corresponding mixing head valve needs servicing.

W123/W124/W125 AIS-B / AIS-C / AIS-D

AIS below the warning limit (minimum opening time of the dosing valve in percent).

• If the stroke of the dosing valve is far from its ideal position, the adjustment can take a long time under some circumstances. Home page: [AIS], then reduce the "AIS position" a bit.
• Reduce pressure of B/C/D: see Chapter 8.5.2
  – Check whether valve closes. Clean valve.
• The flow meter A is blocked by soiling. The LED at the flow meter has to light up during product flow, otherwise it is clogged (cleaning, see Chapter 9.2.3).
• Check whether nozzles, mixer or filter are clogged.
• Check the level of the paint tank, condition of the feed pumps, etc.

W126/W127/W128/W129 Tank A/B/C/D limit

W130 Tank flushing agent limit

Flow rate drops below the warning limit. Fill up tank.

W500 USB memory

No USB stick used or too little memory. Try removing the USB stick and plugging it back in or plug in another USB stick.

W501 USB storage

Automatic job total saving: saving did not work.

11 REPAIRS

11.1 REPAIR STAFF

Repair work should be undertaken carefully by qualified and trained personnel. They should be informed of specific hazards during their training.

The following hazards may arise during repair work:

– Health hazard from inhaling solvent vapors
– Use of unsuitable tools and aids

A skilled person must check to ensure that the device is in a reliable state after it is repaired.

11.2 SAFETY INSTRUCTIONS

Before a Repair

- Cleaning and flushing the device. Chapters 8.6 and 9.1.4.

DANGER

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.
→ Before all work on the device and in the event of work interruptions:
- Relieve pressure from spray guns, high-pressure hoses and all devices.
– Secure spray guns against actuation.
– Switch off the energy and compressed air supply.
- Disconnect the control unit from the mains.
→ Observe the operating and service manual for all work.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

→ Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel.

After a Repair

• Put the system into operation and check for leaks. Section 6.6
  → In accordance with DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36:

– 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.

- For shut down devices, the examination can be suspended until the next start-up.

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.	Quantity Designation Smaller tanks
9992590 1 pc 5	0 ml Loctite ^ 222
9992511 1 pc 5	0 ml Loctite ^ 243
9992528 1 pc 1	50 g Loctite ^ 270
9992831 1 pc 5	0 ml Loctite ^ 542
9999042 1 pc 5	0 ml Loctite ^ 638
9998808	1 pc 18 kg!	Mobilux ^ EP 2 grease	400 g tube Order No. 2355418
9992616	1 pc 1 kg can	Molykote ^ DX grease	50 g tube Order No. 2355419
9992609 1 pc 1	100 g Anti-seize paste
9992698 1 pc 2	00 g can Vaseline white, PHHV II

Brand notice

The brands specified in this document are property of the respective owners. Loctite ^® , for example, is a registered brand of Henkel.

12 DISPOSAL

When the equipment must be scrapped, please differentiate the disposal of the waste materials.

The following materials have been used:

→ Steel
→ Aluminum
→ Elastomerics
→ Plastics
→ Carbide

NOTICE

Do not dispose of used electrical equipment with household refuse!

In accordance with European Directive 2012/19/EU on the disposal of used electrical equipment and its implementation in national law, this product may not be disposed of with the household refuse, but must be recycled in an environmentally correct manner.

→ 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.
→ Please contact one of our service points, one of our representatives or us directly.

Simple line drawing of a trash bin with no text or symbols

Consumable products

Consumable products (lacquers, adhesives, flushing and cleaning agents) must be disposed of in accordance with all applicable legal requirements.

13 ACCESSORIES

The system is ordered and supplied including all desired accessories.

It is possible for a WAGNER technician to install extensions and accessories later on, e.g., paint extension, gun monitoring, air bubble monitoring etc.

13.1 CONNECTIONS

There are five types of connectors:

Digital outputs

Digital inputs

High-speed counters

Analog outputs

Analog inputs

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.
2. Check based of the assembly manual, whether enough room is available in the fluid cabinet.
3. For number and type of the required connectors please look into the assembly manual.
4. Check whether sufficient free connections are present in the control cabinet:

- Either in the 2K COMFORT connection table: each sufficient free lines must be present of the required connection types (see Chapter 13.2).

- Or in the controller: password level 3 → "Menu" → I/O Config" (see software documentation).

13.1.1 I/O EXTENSION MODULE

If too few connections are available, the set "CAN I/O extension module" can be installed by a WAGNER technician. This includes:

	CAN I/O extension module: number of connections
	Serial number 1 – 99 from	serial number 100
Digital outputs 16 24
Digital inputs 16 8
High-speed counters	2
Analog outputs	2
Analog inputs	4

A maximum of total 4 I/O modules can be installed in the control cabinet.

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:

Digital outputs
		Name	Connection signal	GND connection	Cable No.	Solenoid valve	Hose No.	Fluid valve element	Stroke sensor
	Q1	Ready X3:1C/D -- 10	--- L1 --
	... ...	... ... ... ...	...	...
D2	Q12	Set 1	D2:X2_14	D2:X2_4	--	--	--	--
	... ...	... ... ... ...	...	...

Digital inputs
		Name	Connection signal	Cable No.	Hose No.	Fluid valve element
	I1	Start	X2:1B/C	30;501	--	S2;RC;Robo
	...	...	...	...	...	...

High-speed counters
		Name		Connection signal Cable No.		Fluid valve element
	C1	--		X2:19B/C	--	--
	... .			...	...	...

Analog outputs
		Name	Connection signal	Cable No.	EP valve	Hose No.	Fluid valve element
	AO1	--	D2:X4_17	10	--	--	--
	...	...	...	...	...	...	...

Analog inputs
		Name	Connection signal	Cable No.	Fluid valve element
	AI1	--	D2:X4_1	--	--
	... .		...	...	...

The connection table enables:

→ The recognition of free connections. Example: in the "Name" column of the "Digital outputs" section 3 fields are empty → 3 digital outputs are free.
→ The assignment of the names in the controller (e.g., D2 module, Q12 conneciton) with the I/O modules connections in the control cabinet (e.g., D2:X2_14 connection).

Example

Accesory "Set 1" requires a digital output. The Q12 output in the D2 module is still free and "Set 1" is connected there. The D2:X2_14 connection is assigned to this output.

→ Call up the digital outputs: →"Output" in the controller ("Menu" →/O Config"). Then scroll to the "D2" module with the arrow keys. Assign there to the "Q12" output the accessory function "Set 1" (according to the assembly manual).
→ Connect the accessory "Set 1" in the control cabinet to the D2:X2_14 terminal (according to the assembly manual).

13.3 CONTROL CABINET DIAGRAMS

Pneumatic Diagram

A general pneumatic diagram can be found on the USB stick (Order No., see Chapter 1.4). The pneumatic diagram is also available at order no. 2364198.

Circuit diagram

A system specific circuit diagram can be found on the USB stick (Order No., see Chapter 1.4).

A general circuit diagram is available under order no. 2359815. The 2-circuit circuit diagram is available at order no. 2363147.

13.4 EXPANSION AND ACCESSORY SETS

Functional descriptions

The descriptions of the expansion and accessory sets can be found in the corresponding assembly manuals on the USB stick (Order No., see Chapter 1.4).

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.

Most accessory sets require conversions in the control cabinet.

WARNING

Electric shock hazard inside the control unit!

Danger to life from electric shock.

→ May only be installed/maintained by skilled electricians or under their supervision.
→ Operation according to the safety regulations, fire protection and electrotechnical rules.
→ Must be de-energized before work is commenced on active parts.

13.4.1 INSTALLATION BY CUSTOMER OR BY WAGNER SERVICE DEPARTMENT

Expansion and accessory sets Non-XL						XL
		Ex	Non-Ex	High pressure	Low pressure
Order No.	Name Ex
2358991	Paint/flushing valve set, high pressure, DN 2.6 (for 1–2 A components)	x x	x -- --
2358992	Paint/flushing valve set, low pressure, DN 4 (for 1–2 A components)	x x	-- x --
2362624	Valve set supplement for air flushing (A component, DN4)	x	x	--	x	x
2358995	Dosing/flushing valve set DN 2.6, 400 bar SSt, non-Ex (For 1–2 B/C/D-components, if component is already present.) Valve seat of stainless steel.	--	x x	x --
2358994	Dosing/flushing valve set DN 2.6, 400 bar TC, non-Ex (for 1–2 B/C/D-components, if component is already present.) Valve seat of carbide.	--	x x	x --
Flushing valve set, Ex for 1–2 B/C/D-components: → Use one of the above two sets 2358994 or 2358995. For flushing: these sets are also suitable for use in potentially explosive areas.		x	-- x	x --
392076	Paint/flushing valve set, DN 10	--	--	--	-- x
2357422*	Paint/flushing valve set, DN 4 SSt	--	--	--	-- x
2357421*	Paint/flushing valve set, DN 4 TC	--	--	--	-- x
2357462*	Dosing/flushing valve set, DN 4 SSt	--	--	--	-- x
2357461*	Dosing/flushing valve set, DN 4 TC	--	--	--	-- x
2360606**	Dosing/flushing valve set DN 2.6, PTFE SSt (for 1–2 valves)	--	--	--	-- x
2360605**	Dosing/flushing valve set DN 2.6, TC (for 1–2 valves)	--	--	--	-- x
2359046	High-pressure splitter valve, DN 2.6	x	x	x	--	x***
2359052	Low-pressure splitter valve, DN 4	x	x	--	x	--
2359066	High-pressure splitter valve, DN 2.6 with flushing connection	x	x	x	--	x***
2359054	Low-pressure splitter valve, DN 4 with flushing connection	x	x	--	x	--
2359041 Splitter valve: 2 to 3-4, DN 2.6		x x x -- x
2359042 Splitter valve: 2 to 3-4, DN 4		x x -- x --
2359022	Control of gun flush box	x	x	x	x	x

* For 2., 6. and 7. valve: additional Order No. 392090 (mounting bracket)
For 6. valve: additional Order No. 2334457 & 2330775 (hose & fitting)
** For dosing: per valve additional Order No. 2365901 (dosing connection, Ex), possibly connection plate, EX i
For flushing: per set additional Order No. 9956145 (double 3/2-way valve with base plate)
*** XL version: additional Order No. 2331173 (fitting)

Expansion and accessory sets Non-XL						XL
		Ex	Non-Ex	High pressure	Low pressure
Order No.	Name Ex
2359033	Gun monitoring for AirSpray + AirCoat DN 8 in fluid cabinet, non-Ex	-- x	x x --
2359035	Gun monitoring for AirSpray + AirCoat DN 8 in fluid cabinet, Ex	x --	x x x
2359031	Gun monitoring for AirSpray + AirCoat DN 8 in spray booth, non-Ex	-- x	x x --
2359032	Gun monitoring for AirSpray + AirCoat DN 8 in spray booth, Ex	x --	x x x
2359030	Gun monitoring for automatic gun (pressure switch) x x x x x
2359023 A	Automatic atomizer air system	x x x	x x
2359109	Product pressure regulator 8 bar, manual (Input pressure max. 4 MPa; 40 bar; 580 psi)	x x --		x --
2369322	Product pressure regulator 8 bar, manual, G3/8 XL (Input pressure max. 4 MPa; 40 bar; 580 psi)	--	--	--	-- x
2341153	Remote control with cable 15 m; 49 ft (see Chapter 13.5)	x x	x x x
2343063	Extension cable 15 m; 49 ft for remote control Maximum extension of 2 times 15 m; 49 ft. (Total 45 m; 147 ft.)	x x	x x x
2360731 D	Dump valve set, not flushable	x x x	x --
2369329	Dump valve set XL, not flushable	--	--	--	--	x
2360732 D	Dump valve set, flushable	x x x	x --
2369330	Dump valve set XL, flushable	--	--	--	--	x
2343061 D	Dump valve for waste separation (flushable) *	x x x	x x
2362638	Control for booster pump*	x	x	x	--	x
2360992 E	External release, pneumatic	x x x	x x
392030	Ex alarm horn, spray booth	x x	x x x
2362637 "Comfort Archive" PC data archiving (for 1 system) **		x x x	x x
2365136 "Comfort Archive" PC data archiving (for 2–5 systems) **		x x x	x x
2359045 Profibus module		x x x	x x
2339620	External mixer automatic, high pressure (DN 2.6)	x	x	x	--	--
2339617	External mixer automatic, high pressure DN4 / DN10VA	--	--	--	--	x
2339621	External mixer automatic, low-pressure (DN 4)	x	x	--	x	--
2360730 C	AN I/O output expansion	x x x	x x

* Can not be used for 2-circuit systems.
** Prerequisite for PC data archiving: Network connection of the 2K COMFORT system by WAGNER Service Department

13.4.1.1 STROKE MEASURING

– For overview see Chapter 5.10
- "ADC-0301 / MPX-0403" operating manual: for Order No., see Chapter 1.3.1

Accessory sets for stroke measurement Ex Non-Ex
Name Order No. Order No.
MPX-0403 2376552
ADC-0301 with bus cable 10 m; 32.8 ft 2376553
ADC-0301 with bus cable 20 m; 65.6 ft 2376554
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						XL
		Ex	Non-Ex	High pressure	Low pressure
Order No.	Name					Ex
2358996	Dosing valve set DN 2.6, 400 bar TC, Ex(For 1–2 B/C/D-valves, if component is already present.Carbide valve seat)→ If mixing head cycle install the not explosion-protected version 2358994.	x	--	x	x	--
2362622	Dosing valve set DN 2.6, 400 bar SSt, Ex(For 1–2 B/C/D-valves, if component is already present.Stainless steel valve seat)→ If mixing head cycle install the not explosion-protected version 2358995.	x	--	x	x	--
2360926	3K installation material	x	x	x	x	--
2359024	Flow monitor lacquer, non-Ex	--	x	x	x	--
2359025	Flow monitor lacquer, Ex	x	--	x	x	--
2360619	Flow monitor lacquer, Ex XL	--	--	--	--	x
2359110	Product pressure regulator, digital (controllable)(Input pressure max. 4 MPa; 40 bar; 580 psi)	x	x	--	x	--
2369327	Product pressure regulator, digital (controllable) G3/8 XL(Input pressure max. 4 MPa; 40 bar; 580 psi)	--	--	--	--	x
2359111	Air bubbles monitoring, non-Ex(Input pressure max. 0.8 MPa; 8 bar; 116 psi)	--	x	x	x	--
2359112	Air bubbles monitoring, Ex(Input pressure max. 0.8 MPa; 8 bar; 116 psi)	x	--	x	x	--
2362636	Automatic electrostatic system set for GM 5000 manual gun	x	x	x	x	x
2360940	Automatic electrostatic system set for automatic gun	x	x	x	x	x
2360953	Mixing head cycle (for flow meter)	x	x	x	x	x
2360956	Mixing head cycle, flushable (for flow meter)	x	x	x	x	x
2360954	Mixing head cycle (for Coriolis)	x	x	x	x	x

13.4.2.1 AIS

AIS accessories sets

AIS dosing system:

– For description, see Chapter 5.8
- For example, see Chapter 5.6 (diagram B)

Following accessories must be ordered for each B/C/D-component, which is to be equipped with AIS:

Name	Stk	Ex Non-Ex
		Order No.	Order No.
AIS basic set 1 2359016

Additionally, if yet no mixing head valve is present: [A] or [B] or [C]

Added component with flow meter:
[A] Mixing head cycle (for flow meter)	1 2360953
[B] Mixing head cycle, flushable (for flow meter)	1 2360956
Added component with Coriolis:
[C] Mixing head cycle (for Coriolis)	1 2360954

Additionally, without connection set:

Double 3/2-way valve 2 -- 9956145

Additionally, if length of connection set ≤15 m:

Double 3/2-way valve 2 9956145
Hose, PUR 4/2.7, length = 3^* × (length of connection set + 4 m) m 9982072

Additionally, if length of connection set ≥ 17 m:

Dosing connection, EX	3*2365901 --
Cable to Ex i valve, length = 3* x (length of connection set + 4 m)	m 9956160 --
Connection plate, EX i (for 4 Ex i valves), if not enough free spaces are available:
- Plate Ex-valve	1	384445	--
- Hexagon socket cylinder head screw	2	9900307 --
- Washer	2	9920101 --
- Hexagon nut	2	9910106 --

* * 3 pieces, if mixing head valve is already present.
Otherwise: 4 pieces minus number of present dosing valves. All present dosing valves must be newly controlled with air hoses.

XL version

Prerequisite: Corresponding B/C/D-component must have DN 2.6 valves.

Order No., see column "Ex".

13.4.3 ACCESSORIES SETS FOR EXTERNAL FLUSHING AGENT

External flushing agent can be used for:

• Mixing head cycle, flushable
• External mixer
  – 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):

Flushing mode	Detail in the flushing recipe	Meaning	Accessories set
			Ex Non-Ex
Flushing over a period of time	Flush. time Flushing time runs, if the flushing valves are open.		---
Flushing with flow monitor	Flush. time Flushing time runs, if flushing agent flows.		Flow monitor lacquer, Ex, Order No. 2359025	Flow monitor lacquer, non-Ex, Order No. 2359024
			Cable, Order No. 9956160, Length = distance from control cabinet-flow monitor + 2m
Flushing with flow meter**	Flushing Qty Precise flushing quantity is used.		Not orderable as a set

* With XL design: Flow monitor lacquer, Ex XL, Order No. 2360619
** Can not be used for 2-circuit systems.

13.5 REMOTE CONTROL (OPTION)

The remote control can be operated in the EX area, allowing the following functions to be controlled: start; stop; flushing and recipe change. In addition, a signal display for the current recipe and displays for the operating status (Filling, Ready and Alarm) can be installed.

Designation Order No.
Remote control 2341153
Magnetic pin, complete 2342917
Extension cable 15 m; 49 ft for remote controlMaximum extension of 2 times 15 m; 49 ft. (Total 45 m; 147 ft.)	2343063

13.5.1 REMOTE CONTROL ASSEMBLING

13.5.1.1 SOFTWARE SETTINGS

Log in as the administrator (Level 3 password). Set the remote control option to ON.

Parameter Setting
Remote control ON

13.5.1.2 ASSEMBLY ON CONTROL CABINET

→ Observe safety instructions in Chapter 13.5.2.

1. Before connecting the remote control or an extension cable, de-energize the device. In other words, switch off the main switch and unplug the power plug.
2. Plug the plug on the underside of the control cabinet into the socket intended for it.
3. Ground the remote control's ground wire.

13.5.1.3 TESTING AND COMMISSIONING

Make sure that the commands and signals described in Chapter 13.5.3 are being transmitted. To do this, activate and check the various functions on the control cabinet and remote control in turn.

Function Impact	on control cabinet Impact on remote control
Start Green push	button lights up START LED lights up
Stop Red push button	lights up STOP LED lights up
Flushing	Blue push button lights up	FLUSH LED lights up
Recipe change	The recipe is changed on the display. The recipe displayed matches that of the remote control.	The display in the center of the remote control changes the number (counting upward).

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.

13.5.2 SAFETY INSTRUCTION REMOTE CONTROL

The installation must be carried out in accordance with Chapter 13.5.1. The following safety instructions must be observed:

Safety instruction remote control

→ Do not open housing under voltage.
→ Open housing only in the absence of a potentially explosive atmospheres.
→ The gap distance from cover-housing bottom to fixed obstacles must be at least 3 cm; 1.2 inches.
→ The remote control must be securely assembled, the line must be laid firmly and with protection from mechanical damage. (For example not laid in the area of aisles or walkways, not on driveways from product handling vehicles, not through doors/gates.)
→ The first attachment point of the cable should be no more than 30 cm; 12 inches away from the housing.
→ Extension cable: lengthen to a maximum of 2 times 15 m; 49 ft. (Total 45 m; 147 ft.)
→ The plug connectors of remote control and extension cable must be located in non-potentially explosive areas.
→ Grounding: ground the housing via a separate line (cross-section 4 mm ^2 ; 0.0062 sq in), connect on the local equipotential bonding (see grounding schemas in Chapter 6.5).
→ 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.

→ Ensure that electronic devices and magnetic data carriers are removed from the danger area of the magnetic pin.

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.

The functions are identical, with the following two exceptions.

On the remote control:

– the functions will be activated with a magnetic pin.
– the green START LED flashes during filling.

Upon enabling a function this yellow LED lights up as a confirmation.

graph TD
    A["Start"] --> B["WAGNER"]
    B --> C["Flushing"]
    C --> D["FLUX"]
    D --> E["Smart"]
    E --> F["FlexControl"]
    F --> G["STOP"]
    G --> H["Field of activity magnetic pen"]
    H --> I["Flushing"]
    I --> J["FLUX"]
    J --> K["FLUSHING"]
    K --> L["FLUX"]
    L --> M["FLUSHING"]
    M --> N["FLUSHING"]
    N --> O["FLUSHING"]
    O --> P["FLUSHING"]
    P --> Q["FLUSHING"]
    Q --> R["FLUSHING"]
    R --> S["FLUSHING"]
    S --> T["FLUSHING"]
    T --> U["FLUSHING"]
    U --> V["FLUSHING"]
    V --> W["FLUSHING"]
    W --> X["FLUSHING"]
    X --> Y["FLUSHING"]
    Y --> Z["FLUSHING"]
    Z --> AA["FLUSHING"]
    AA --> AB["FLUSHING"]
    AB --> AC["FLUSHING"]
    AC --> AD["FLUSHING"]
    AD --> AE["FLUSHING"]
    AE --> AF["FLUSHING"]
    AF --> AG["FLUSHING"]
    AG --> AH["FLUSHING"]
    AH --> AI["FLUSHING"]
    AI --> AJ["FLUSHING"]
    AJ --> AK["FLUSHING"]
    AK --> AL["FLUSHING"]
    AL --> AM["FLUSHING"]
    AM --> AN["FLUSHING"]
    AN --> AO["FLUSHING"]
    AO --> AP["FLUSHING"]
    AP --> AQ["FLUSHING"]
    AQ --> AR["FLUSHING"]
    AR --> AS["FLUSHING"]
    AS --> AT["FLUSHING"]
    AT --> AU["FLUSHING"]
    AU --> AV["FLUSHING"]
    AV --> AW["FLUSHING"]
    AW --> AX["FLUSHING"]
    AX --> AY["FLUSHING"]
    AY --> AZ["FLUSHING"]
    AZ --> BA["FLUSHING"]
    BA --> BB["FLUSHING"]
    BB --> BC["FLUSHING"]
    BC --> BD["FLUSHING"]
    BD --> BE["FLUSHING"]
    BE --> BF["FLUSHING"]
    BF --> BG["FLUSHING"]
    BG --> BH["FLUSHING"]
    BH --> BI["FLUSHING"]
    BI --> BJ["FLUSHING"]
    BJ --> BK["FLUSHING"]
    BK --> BL["FLUSHING"]
    BL --> BM["FLUSHING"]
    BM --> BN["FLUSHING"]
    BN --> BO["FLUSHING"]
    BO --> BP["FLUSHING"]
    BP --> BQ["FLUSHING"]
    BQ --> BR["FLUSHING"]
    BR --> BS["FLUSHING"]
    BS --> BT["FLUSHING"]
    BT --> BU["FLUSHING"]
    BU --> BV["FLUSHING"]
    BV --> BW["FLUSHING"]

Flashes during filling.

Technical line drawing of a mechanical device with no visible text or symbols

14 SPARE PARTS

Spare parts catalog -Order No., see Chapter 1.3.

15 DECLARATION OF WARRANTY AND CONFORMITY

15.1 IMPORTANT NOTES ON PRODUCT LIABILITY

As a result of an EC regulation effective from January 1, 1990, the manufacturer shall only be liable for his product if all parts originate from him or are approved by him, and if the devices are properly mounted, operated and maintained.

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.

15.2 WARRANTY CLAIM

Full warranty is provided for this device:

We will at our discretion repair or replace free of charge all parts which within 24 months in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by the purchaser are found to be wholly or substantially unusable due to causes prior to the sale, in particular faulty design, defective materials or poor workmanship.

The type of warranty provided is such that the device or individual components of the device are either replaced or repaired as we see fit. The resulting costs, in particular shipping charges, road tolls, labour and material costs will be borne by us except where these costs are increased due to the subsequent shipment of the device to a location other than the address of the purchaser.

We do not provide warranty for damage that has been caused or contributed to for the following reasons:

Unsuitable or improper use, faulty assembly or commissioning by the purchaser or a third party, normal wear, negligent handling, defective maintenance, unsuitable coating products, substitute products and the influence of chemical, electrochemical or electrical agents, except when the damage is attributable to us.

Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust paints and so forth reduce the service life of valves, packings, spray guns, nozzles, cylinders, pistons etc. Signs of wear traced back to these products are not covered by this warranty. Components that have not been manufactured by WAGNER are subject to the original warranty of the manufacturer.

Replacement of a component does not extend the period of warranty of the device.

The device should be inspected immediately upon receipt. To avoid losing the warranty, we or the supplier company are to be informed in writing about obvious faults within 14 days upon receipt of the device.

We reserve the right to have the warranty compliance met by a contracting company.

The services provided by this warranty are dependent on evidence being provided in the form of an invoice or delivery note. If the examination discovers that no warranty claim exists, the costs of repairs are charged to the purchaser.

It is clearly stipulated that this warranty claim does not represent any constraint on statutory regulations or regulations agreed to contractually in our general terms and conditions.

Wagner International AG

15.3 EU DECLARATION OF CONFORMITY FOR 2K COMFORT

Herewith we declare that the supplied version of:

2K COMFORT

complies with the following guidelines:

2006/42/EC

2014/35/EU

2014/30/EU

2011/65/EU

2012/19/EU

Applied standards, in particular:

EN ISO 12100:2010 EN 12621:2006+A1:2010

EN ISO 4413:2010 EN 60204-1:2006+A1:2009+B:2010

EN ISO 4414:2010 EN 61000-6-2:2005+B:2011

EN ISO 13732-1:2008 EN 61000-6-4:2007+A1:2011

EN 14462:2015 EN ISO 9001:2008

Applied national technical standards and specifications, in particular:

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

15.4 EU DECLARATION OF CONFORMITY FOR 2K COMFORT (WITH EX IDENTIFICATION)

Herewith we declare that the supplied version of:

2K COMFORT (with Ex identification)

complies with the following guidelines:

2006/42/EC

2014/34/EU

2014/30/EU

2011/65/EU

2012/19/EU

Applied standards, in particular:

EN ISO 12100:2010 EN 60079-14:2014
EN ISO 4413:2010 EN 1127-1:2011
EN ISO 4414:2010 EN 13463-1:2009
EN ISO 13732-1:2008 EN 13463-5:2011
EN 14462:2015 EN 61000-6-2:2005+B:2011
EN 12621:2006+A1:2010 EN 61000-6-4:2007+A1:2011
EN 60204-1:2006+A1:2009+B:2010 EN ISO/IEC 80079-34:2011
EN 60079-0:2012+A11:2013 --

Applied national technical standards and specifications, in particular:

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

15.5 EC DECLARATION OF CONFORMITY FOR REMOTE CONTROL

Herewith we declare that the supplied version of:

FlexControl Smart remote control (is also used for 2K COMFORT)

complies with the following guidelines:

94/9/EC

2004/108/EC

2002/95/EC

2002/96/EC

Applied standards, in particular:

Applied national technical standards and specifications, in particular:

TRBS 2153

Identification:

Ex d IIB T6 Gb

CML 13 ATEX 1008X

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

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.
→ Since the gear flow meter measures volumetrically, we need the specification in volume.

Conversion of mixing proportion from gravimetric to volumetric:

Example:

10 Parts of component A by weight and

1 Parts of component B by weight

or

10g Component A

1g Component B

or parts by weight 10:1

or 10:1 per weight (A gravimetric : B gravimetric)

→ The density or specific volume of the components A and B must be known or be determined beforehand.

Density:

$$ P _ {A} = \frac {G _ {A}}{V _ {A}} \quad 0. 1 5 \mathrm{gr} \quad \mathrm{Kg} = 1. 5 \frac {\mathrm{gr}}{0 . 1 \mathrm{cm} ^ {3}} \quad \mathrm{cm} = 1. 5 \frac {}{3} L $$

$$ P _ {B} = \frac {G _ {B}}{V _ {B}} = \frac {0 . 1 \mathrm{gr}}{0 . 1 \mathrm{cm} ^ {3}} = 1 \frac {\mathrm{gr}}{3} = 1 \frac {\mathrm{Kg}}{\mathrm{L}} $$

Mixing ratio:

$$ \mathrm{Mvol} = \mathrm{Avol} \div \mathrm{Bvol} = \frac {\text {Agrav.}}{\underset {\mathrm{P} _ {\mathrm{A}}} {\vdots}} \quad \frac {\text {Bgrav.}}{\underset {\mathrm{P} _ {\mathrm{B}}} {\vdots}} $$

$$ \mathrm{Mvol} = \frac {1 0 \mathrm{gr}}{1 . 5 \frac {\mathrm{gr}}{\mathrm{cm} ^ {3}}} \div \frac {1 \mathrm{gr}}{1 \frac {\mathrm{gr}}{\mathrm{cm} ^ {3}}} = 6. 6 7 \div 1 $$

Other volumetric mixing ratio specifications:

667 Parts of component A by volume

1 Parts of component B by volume

WAGNER

Order No. 2357061

Version 05/2017

Germany

J. WAGNER GmbH

Phone [phone]

Telefax +41/(0)71/7572222

More contact addresses:

www.wagner-group.com

Subject to changes without notice