WAGNER’s TOPFINISH Bell 2 with WACON Spray is a modular high-speed rotation atomisation system designed to make advanced coating technology more accessible. The solution combines high transfer efficiency, reduced material and air consumption, and an intuitive control concept, offering a flexible, future-proof option for both series production and changing manufacturing environments.
WAGNER is expanding its Bell family with the TOPFINISH Bell 2 and the WACON Spray control system, delivering a compact, modular solution that makes high-speed rotation atomisation easier to use than ever before. The combination of the TF Bell 2 high-speed rotation atomiser and the WACON Spray control unit creates a powerful package designed for both process-optimised series production and flexible manufacturing environments with frequently changing requirements.
High-speed rotation atomisation is regarded as one of the most demanding disciplines in surface technology. It combines extremely fine atomisation with very high transfer efficiency and fast working speeds. This technology is widely used in series production, such as automotive and plastic components, as well as in wood, furniture and glass coating. However, despite its advantages, high-speed rotation has often been restricted to high-end applications due to the expertise traditionally required for system planning, set-up and operation.
With the TF Bell 2 system, WAGNER aims to make high-speed rotation atomisation accessible beyond high-end applications. Reduced effort for set-up, operation, monitoring and maintenance means the solution is suitable not only for experienced users, but also for companies working with high-speed rotation technology for the first time. Together with existing atomisers such as the TF Bell 1 and ECH variants, WAGNER now offers a comprehensive bell portfolio that also covers special applications, including 2K coatings with integrated mixers or external charging for water-based coatings.
The TF Bell 2 operates with very low air and material consumption and can achieve a transfer efficiency of up to 90%, depending on material, flow rate and workpiece geometry. Newly developed air deflector rings with slot-shaped openings distribute air and material evenly, enabling particularly fine atomisation and consistent coating results. Bell cup size and serration can be tailored to the workpiece and coating material, while the spray jet width can be precisely adjusted from 80 to 800 millimetres.
An integrated high-voltage cascade with an output of 8 watts makes the TF Bell 2 suitable for common solvent-based applications as well as water-based paints with smaller paint kitchens of up to approximately 60 litres. For applications requiring higher power, such as larger water-based paint systems or wheel coating, an external cascade can be used as an alternative.
Different configurations are available to suit a wide range of production environments. The TF RobotBell 2 variant is designed for robot applications, while the TF Bell 2S is intended for linear axes, reciprocators and installations without movement technology. Thanks to its modular design, configurations without high voltage are also possible, for example when processing highly viscous materials. An adapter allows quick conversion from the bell to an airspray gun without changing hoses, making the system suitable for both automated series production and customer-specific applications.
A modular, expandable valve block enables the addition of a second colour. After flushing the first colour circuit, the next colour is immediately available, allowing colour changes within seconds. Robust valves ensure long service life, while an innovative quick-change system with strain relief simplifies hose and cable replacement. The removable three-part air deflector ring can be cleaned efficiently, supporting reliable operation over many years. A one-piece bell plate prevents paint build-up inside the bell and contributes to trouble-free coating.
Operation is simplified by the WACON Spray control system, which allows the TF Bell 2 to be commissioned quickly without prior programming. All relevant parameters, including turbine speed, bearing air, high voltage and shaping airs, are controlled centrally via a 7-inch touchscreen. Settings can be saved as recipes and recalled as required.
WACON Spray is designed as a modular control concept that can be adapted flexibly to different production environments. The stand-alone WACON Spray unit features a touchscreen and can be installed in a 19-inch rack or used as a desktop device. The WACON Extension box, without an HMI, and up to two WAMOD plug-in modules can be installed in either housing. These modules regulate high voltage, turbine speed and atomising air flow, with functionality ranging from basic to advanced features. Additional components can be added at any time with minimal installation effort via the WAGNER bus.
The system offers numerous interfaces for integration into external control systems, including digital and analogue inputs and outputs, as well as Profinet fieldbus. With additional function modules, more complex systems can be implemented, allowing control of up to four bells simultaneously. As an alternative, stand-alone WACAS function modules can be connected directly to higher-level control systems such as PLCs or robot controllers via modern fieldbuses. Their compact design makes them suitable for installation in robot arms or control cabinets with limited space.
Instead of conventional pressure control, WACON Spray uses innovative volumetric flow control for shaping air adjustment. This approach eliminates dependency on hose length or diameter, allowing recipes to be transferred between systems or remain unchanged after system modifications, improving process stability and saving time.
Overall, the TF Bell 2 system combines efficient high-speed rotation atomisation with an intelligent, modular control concept. It delivers excellent surface quality, reduces material and air consumption, and simplifies operation, servicing and integration into existing systems. With global certification and compliance with the latest safety standards, the solution is positioned as a future-proof option for high-performance coating applications.