Translation of the Original Operating Manual

Version 03/2013

IceBreaker Piston Pumps 3

Flow Rate 40 cm

B_03900

VERSION 03/2013

ORDER NUMBER DOC 2303659

OPERATING MANUAL

Contents 1 1.1 1.2 1.3 1.4

ABOUT THIS OPERATING MANUAL Preface Warnings, Notices, and Symbols in this Operating Manual Languages Abbreviations in the Text

6 6 6 7 7

2 2.1 2.2 2.3 2.4 2.5 2.6 2.7

CORRECT USE Device Types Type of Use Use in an Explosion Hazard Area Safety Parameters Processible Materials Reasonably Foreseeable Misuse Residual Risks

8 8 8 8 8 9 9 10

3 3.1 3.2

IDENTIFICATION Explosion Protection Identification Identification X

11 11 11

4 4.1 4.1.1 4.1.2 4.1.3 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.3 4.3.1 4.3.2

GENERAL SAFETY INSTRUCTIONS Safety Instructions for the Operator Electrical Equipment Staff Qualifications Safe Work Environment Safety Instructions for Staff Safe Handling of WAGNER Spray Devices Grounding the Device Material Hoses Cleaning Handling Hazardous Liquids, Varnishes, and Paints Touching Hot Surfaces Use in Areas Subject to Explosion Hazards Safety Regulations Operation without Fluid

12 12 12 12 12 13 13 14 14 15 15 15 16 16 16

5 5.1 5.1.1 5.1.2 5.1.3 5.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6

DESCRIPTION Areas of Application Correct Use Processible Materials Recommended Application Areas Scope of Delivery Data Materials of Paint-wetted Parts Recommended Packings Technical Data Measurements and Connections Volume Flow Performance Diagrams

17 17 17 17 18 18 19 19 19 20 21 22 22

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Contents 5.4 5.4.1 5.4.2 5.4.3 5.4.3.1 5.4.3.2 5.4.4

Function Pump Pressure Regulator Unit High-pressure Filter (Option) High-pressure Filter (Option) Filter Relief Combination (Option) Stroke Count (Option)

24 24 25 25 25 26 26

6 6.1 6.2 6.3 6.4 6.5 6.5.1 6.5.2 6.5.3

ASSEMBLY AND COMMISSIONING Transportation Storage Assembling the Pump Grounding Commissioning Safety Instructions Filling with Separating Agent Basic Flushing

27 27 27 28 29 31 31 32 33

7 7.1 7.2 7.2.1 7.2.2 7.2.3 7.3

OPERATION Filling with Working Material Work Spraying Pressure Relief/Work Interruption Decommissioning and Cleaning Long-term Storage

34 34 35 35 35 36 36

8

TROUBLESHOOTING AND RECTIFICATION

37

9 9.1 9.2

MAINTENANCE High-pressure Hoses Decommissioning

38 39 39

10 10.1 10.1.2 10.1.3

ACCESSORIES Material Outlet Accessories Material Inlet Accessories Trolley, Rack, and Wall Mount Accessories

40 40 42 44

11 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11

SPARE PARTS How Can Spare Parts Be Ordered? Overview of the Components Air Motors Air Motor Regulators Fluid Sections Inlet Valve with Valve Depressor Relief Combination (up to 270 bar; 3916 psi) Paint Filter (up to 270 bar; 3916 psi) High-pressure Filter (up to 530 bar; 7687 psi) High-pressure Filter (up to 270 bar; 3916 psi) Trolley

45 45 46 47 51 52 55 56 57 58 60 62

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OPERATING MANUAL

Contents 12 12.1 12.2 12.3 12.4 12.5 12.6 12.7

3+2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING Scope of Guarantee Guarantee Period and Registration Handling Exclusion of Guarantee Additional Regulations CE Declaration of Conformity Reference to German Regulations and Guidelines

63 63 63 63 64 64 65 65

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1

ABOUT THIS OPERATING MANUAL

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 operating and service staff. Operating and service staff should be instructed according to the safety instructions. The device may only be operated in compliance with this operating manual. 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 THIS OPERATING MANUAL

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 Danger - immediate risk of danger. Non-observance will result in death or serious injury.

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level. The following are measures which can be taken to prevent the hazard and its consequences.

Warning - possible imminent danger. Non-observance may result in death or serious injury.

WARNING This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level. The following are measures which can be taken to prevent the hazard and its consequences.

Caution - a possibly hazardous situation. Non-observance may result in minor injury.

CAUTION This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level. The following are measures which can be taken to prevent the hazard and its consequences.

Notice - a possibly hazardous situation. Non-observance may result in material damage.

NOTICE This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level. The following are measures which can be taken to prevent the hazard and its consequences.

Note - provides information about particular characteristics and how to proceed.

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1.3

LANGUAGES

The operating manual is available in the following languages: Language Order No. Language Order No. German 2302505 English 2303659 Italian 2303663 Spanish 2303665 Danish 2303666 Swedish 2303667

Language French Dutch Portuguese

Order No. 2303661 2303662 2339146

The corresponding service instructions are available under the following order number: Language Order No. Language Order No. German 2335993 English 2335994

1.4

ABBREVIATIONS IN THE TEXT

Order No. No.

Number of pieces Position Marking in the spare parts lists Order number Order number (shortened form) Double stroke Stainless steel Two components

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2

CORRECT USE

2.1

DEVICE TYPES

Pneumatic pump with spraypack: 18-40

2.2

28-40

TYPE OF USE

The device is suitable for processing liquid materials such as paints and varnishes in accordance with their classification into explosion classes IIA or IIB.

2.3

USE IN AN EXPLOSION HAZARD AREA

The pneumatic pump can be employed in explosion hazard zones (Zone 1).

2.4

SAFETY PARAMETERS

WAGNER accepts no liability for any damage arising from incorrect use. Use the device only to work with the materials recommended by WAGNER. Only operate the device as a whole. Do not deactivate safety fixtures. Use only WAGNER original spare parts and accessories.

The pneumatic pump may only be operated under the following conditions: The operating staff must be trained on the basis of this operating manual. The safety regulations listed in this operating manual must be observed. The operating, maintenance, and repair information in this operating manual must be observed. The statutory requirements and accident prevention regulation standards in the country of use must be observed.

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2.5

PROCESSIBLE MATERIALS Fluid materials such as paints and varnishes.

NOTICE Abrasive materials and pigments! Greater wear of parts carrying the material. Use the application-oriented model (flow rate/cycle, material, valves, etc.) as indicated in Chapter 5.3.3. Check if the fluids and solvents used are compatible with the pump construction materials as indicated in Chapter 5.3.1.

2.6

REASONABLY FORESEEABLE MISUSE

The following is prohibited: coating work pieces which are not grounded, unauthorized conversions and modifications to the pneumatic pump, processing powder or similar coating materials, and using defective components, spare parts, or accessories other than those described in Chapter 10 of this operating manual. The forms of misuse listed below may result in health issues and/or material damage: use of powder as coating material and incorrectly set values for processing. Wagner pneumatic pumps are not designed for pumping food.

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2.7

RESIDUAL RISKS

Residual risks are risks which cannot be excluded even in the event of correct use. If necessary, warning and prohibition signs at the relevant points of risk indicate residual risks. Residual risk Source Consequences Skin contact with Handling of paints Skin irritations, paints and cleaning and cleaning agents agents allergies

Paint in air outside Painting outside the Inhalation of substances which the defined working defined working area are hazardous to area health

Specific measures Lifecycle phase Wear protective Operation, clothing Observe safety data maintenance, sheets disassembly Observe working Operation, and operating instructions maintenance

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3

IDENTIFICATION

3.1

EXPLOSION PROTECTION IDENTIFICATION

As defined in Directive 94/9/EC (ATEX 95), the device is suitable for use in areas where there is an explosion hazard.

European Communities Symbol for explosion protection Device class II Category 2 (Zone 1) Ex-atmosphere gas Explosion group Constructional safety Temperature class: maximum surface temperature < 200 °C; 392 °F Special Notes (see Chapter 3.2)

3.2

IDENTIFICATION X

Maximum surface temperature The maximum surface temperature of the piston pump can be reached if it runs dry. Ensure that the piston pump is filled with sufficient working or flushing agent. Ensure that the separating agent container is filled with sufficient separating agent. Ignition temperature of the coating material Ensure that the ignition temperature of the coating material is above the maximum surface temperature. Ambient temperature The permissible ambient temperature is: +5 °C to +60 °C; +41 °C to 140 °F. Medium supporting atomizing To atomize the material, use only weakly oxidizing gases, e.g. air.

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4

GENERAL 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 EQUIPMENT

Electrical devices and equipment To be provided 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. Must be operated in accordance with the safety regulations and electrotechnical regulations. Must be repaired immediately in the event of problems. Must be decommissioned if they pose a hazard. Must be de-energized before work is commenced on active parts. Inform staff about planned work. Observe electrical safety regulations.

4.1.2

STAFF QUALIFICATIONS

Ensure that the device is operated and repaired only by trained persons.

4.1.3

SAFE WORK ENVIRONMENT

Ensure that the floor in the working area is electrically conductive in accordance with EN 61340-4-1 (resistance must not exceed 100 Mohm). Ensure that all persons within the working area wear electrostatically conductive shoes. Footwear must comply with EN 20344. The measured insulation resistance must not exceed 100 Mohm. Ensure that during spraying, persons wear electrically conductive gloves. The grounding takes place via the spray gun handle. If protective clothing is worn, including gloves, it has to comply with EN 1149-5. The measured insulation resistance must not exceed 100 Mohm. Paint mist extraction systems must be fitted on site according to local regulations. Ensure that the following components of a safe working environment are available: – Material/air hoses adapted to the working pressure. – Personal safety equipment (breathing and skin protection). Ensure that there are no ignition sources such as naked flames, sparks, glowing wires, or hot surfaces in the vicinity. Do not smoke.

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4.2

SAFETY INSTRUCTIONS FOR STAFF

Always follow the information in these instructions, particularly the general safety instructions and the warning instructions. Always follow local regulations concerning occupational safety and accident prevention.

4.2.1

SAFE HANDLING OF WAGNER SPRAY DEVICES

The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or cleaning agents: Never point the spray gun at people. Never reach into the spray jet. Before all work on the device, in the event of work interruptions and functional faults: – Switch off the energy/compressed air supply. – Relieve the pressure from the spray gun and device. – Secure the spray gun against actuation. – In the event of functional faults: remedy the fault as described in the "Troubleshooting" chapter. The liquid emitters are to be checked for safe working conditions by an expert (e.g. Wagner Service Technician) as often as necessary or at least every 12 months, in accordance with the guidelines for liquid emitters (ZH  1/406 and BGR  500 Part  2 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/Work Interruptions” chapter: – 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 paint or cleaning agents: Note down the paint or cleaning agent that you have been using. Consult a doctor immediately. Avoid danger of injury through recoil forces: Ensure that you have firm footing when operating the spray gun. Only hold the spray gun briefly in a position.

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4.2.2

GROUNDING THE DEVICE

In order to avoid electrostatic charging of the device, the device must be grounded. Friction, flowing liquids, and air or electrostatic coating processes create charges. Flames or sparks can form during discharge. Ensure that the device is grounded for every spraying operation. Ground the work pieces to be coated. Ensure that all persons inside the working area are grounded, e.g. that they are wearing electrostatically conductive shoes. Wear electrostatically conductive gloves when spraying. The grounding takes place via the spray gun handle.

4.2.3

MATERIAL HOSES

Ensure that the hose material is chemically resistant to the sprayed materials. Ensure that the material hose is suitable for the pressure generated in the device. Ensure that the following information can be seen on the high-pressure hose: - Manufacturer - Permissible operating overpressure - Date of manufacture Make sure that the hoses are laid only in suitable places. In no case, should hoses be laid in the following places: – in high-traffic areas, – on sharp edges, – on moving parts, or – on hot surfaces Make sure that the hoses are never used to pull or move the equipment. The electrical resistance of the complete high-pressure hose must be less than 1 Mohm. 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 container, ensure that air or suitable gas can enter the container to avoid a vacuum being generated. The vacuum could implode the container (squeeze) and can cause it to break. The container would leak and the liquid would flow out. The pressure created by the pump is a multiplication of the inlet air pressure.

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4.2.4

CLEANING

De-energize the device electrically. Disconnect the pneumatic supply line. Relieve the pressure from the device. Ensure that the flash point of the cleaning agent is at least 5 K above the ambient temperature. To clean, use cloths and brushes moistened with solvent. Never use hard objects or spray on cleaning agents with a gun. Preferably, non-combustible cleaning agents should be used. An explosive gas/air mixture forms in closed containers. When cleaning devices with solvents, never spray into a closed container. Only use electrically conductive containers for cleaning liquids. The containers must be grounded.

4.2.5

HANDLING HAZARDOUS LIQUIDS, VARNISHES, AND PAINTS

When preparing or working with paint and when cleaning the device, follow the working instructions of the manufacturer of the paints, 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 a 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 materials.

4.2.6

TOUCHING HOT SURFACES

Only touch hot surfaces if you are wearing protective gloves. When operating the device with a coating material with a temperature of > 43 °C; 109.4 °F: - Identify the device with a warning label "Warning - hot surface". Order No. 9998910 Instruction label 9998911 Protection sticker Note: Order the two stickers together.

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4.3

USE IN AREAS SUBJECT TO EXPLOSION HAZARDS

The pneumatic pump may be used in areas subject to explosion hazards. The following safety regulations must be observed and followed.

4.3.1

SAFETY REGULATIONS

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 against steel or rusty iron. Do not drop the device. Only use tools that are made of a permitted material. Ignition temperature of the pumped material Check that the ignition temperature of the pumped material is higher than the max. allowable surface temperature. Medium supporting atomizing To atomize the material, 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. Only use a damp cloth to clean the device.

4.3.2

OPERATION WITHOUT FLUID

Avoid running the pump so that it sucks in air (without fluid inside). The air, combined with the vapor of flammable fluids, can generate internal areas with an explosion hazard. Periodically check that the pump is working smoothly, paying special attention to the presence of air in the pumped fluid, which may be caused by damaged packings. Avoid operating the pump with damaged packings. Ensure that the separating agent container is filled with sufficient separating agent.

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5

DESCRIPTION

5.1

AREAS OF APPLICATION

5.1.1

CORRECT USE

The pneumatic piston pump is suitable for processing liquid materials according to Chapter 5.1.2.

5.1.2

PROCESSIBLE MATERIALS

Application Water-dilutable materials Solvent-based varnish and paints Primers Epoxy and polyurethane paints and varnish, phenolic paints and varnish Liquid plastics Wax-based underside protection Chemically aggressive materials that attack carbide seats Legend recommended

limited suitability

less suitable

NOTICE Abrasive materials and pigments! Greater wear of parts carrying the material. Use suitable combinations of devices (packings, valves, etc.).

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5.1.3

RECOMMENDED APPLICATION AREAS

Application Furniture industry Kitchen manufacturers Joinery Window factories Steel-processing industry Construction of vehicles Shipbuilding Legend recommended

5.2

limited suitability

less suitable

SCOPE OF DELIVERY

Pneumatic piston pump Consists of: - Fluid section - Air motor - Connection elements - Air pressure regulator for air motor The scope of delivery also includes: Separating agent 250 ml; 250 cc Conformity certificate Operating manual, German Operating manual in the local language

Order No.: see Order No.: see

9992504 Chapter 12 2302505 Chapter 1

The delivery note shows the exact scope of delivery. Accessories: see Chapter 10.

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5.3

DATA

5.3.1

MATERIALS OF PAINT-WETTED PARTS

Housing Stainless steel Piston Stainless steel and hard chrome Valve balls Stainless steel Valve seats Carbide O-rings Teflon Packings Standard = Ultra high molecular weight polyethylene = Teflon (PTFE) with graphite

5.3.2

RECOMMENDED PACKINGS

WAGNER packings are manufactured in four different materials: Material Color Leather dark brown Teflon (PTFE) with graphite black Ultra high molecular weight polyethylene transparent Teflon (PTFE) white Each material has the following properties, which influence the packings: Mechanical stability Friction coefficient Sealing force Chemical resistance Temperature resistance

poor poor good* poor good

good very good good good poor - good

good good good very good very good

poor very good good very good poor

for abrasive materials Standard combinations Standard pumps: Heavy-duty (high-pressure) pumps: Hardener pumps in 2K systems:

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5.3.3

TECHNICAL DATA

Description Pump ratio Volume flow per double stroke Maximum operating overpressure

Maximum possible strokes in operation Maximum recommended strokes per minute in continuous operation Minimum/maximum air inlet pressure

Ø air inlet connection (inside thread) Minimum Ø of the compressed air supply line Air consumption at 0.6 MPa; 6 bar; 87 psi per double stroke Air motor piston diameter Air motor piston stroke Sound pressure level at maximum permissible air pressure* Sound pressure level at 0.6 MPa; 6 bar; 87 psi air pressure* Sound pressure level at 0.4 MPa; 4 bar; 58 psi air pressure* Material inlet (outside thread) Material outlet (outside thread) Weight Material pH value Maximum material pressure at pump inlet

Material temperature Ambient temperature Allowable inclination for operation

Units cm3; cc MPa bar psi /min

18 : 1 40 14.4 144 2089

28 : 1 40 22.4 224 3249 60

/min

40

MPa bar psi inch mm; inch nl scf mm; inch mm; inch

5.3 0.19 80; 3.2 75; 3

8.3 0.29 100; 4 75; 3

dB(A)

77

78

dB(A)

74

74

dB(A)

69

69

mm mm kg; lb pH MPa bar psi

0.25-0.8 2.5-8 36-116 G 1/2" 9; 0.35

M 36x2 M 24x1.5 15; 33 16; 35 3.5 ÷ 9 2 20 290 +5 ÷ +80; +41 ÷ +176 +5 ÷ +60 ; +41 ÷ +140 ± 10

* A-rated sound pressure level measured at 1-m distance, LpA1m, according to DIN EN 14462: 2005. Reference measurements have been made by SUVA (Swiss accident insurance institute).

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5.3.4

MEASUREMENTS AND CONNECTIONS

S H I

Wall mount

R

G/2 P

G

O

Q

C

T

B

B_03902

D

M

H

G

J

L1 L2 (E)

mm; inch mm; inch 722; 28.4 169; 6.7 ~ 321; 12.6 261.5; 10.3 460.5; 18.1 134; 5.3 182; 7.2 80; 3.2 ø 25; ø 1 M6 M36x2 M24x1.5 G3/8" G1/2" G1/4" 106; 4.2 96.5; 3.8 ø 9; ø 0.35 ø 7; ø 0.28 149; 5.9 55; 2.2

A

A B C D E F G H I J K L1 L2 M N O P Q R S T

N

F

K B_03901

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5.3.5

VOLUME FLOW

Wagner AL nozzles

inch 0.007 0.009 0.011 0.013 0.015 0.017 0.019 0.021 0.023 0.025 0.027

mm 0.18 0.23 0.28 0.33 0.38 0.43 0.48 0.53 0.58 0.64 0.69

Spray angle 40° 20-30-40-50-60° 10-20-30-40-50-60° 10-20-30-40-50-60-80° 10-20-30-40-50-60-80° 20-30-40-50-60-70° 20-30-40-50-60-70-80° 20-40-50-60-80° 20-40-50-60-70-80° 20-40-50-60-80° 20-40-50-60-80°

Volume flow* in l/min at at at 7 MPa 10 MPa 15 MPa 70 bar 100 bar 150 bar 1015 psi 1450 psi 2175 psi 0.1650 0.2000 0.2400 0.2060 0.2500 0.3090 0.2950 0.3450 0.4260 0.4530 0.5280 0.6600 0.5770 0.6720 0.8130 0.7310 0.7860 1.0640 0.9260 1.0920 1.3700 1.1430 1.3600 1.6900 1.3700 1.5900 2.0100 1.6200 1.9100 1.8300

Maximum ranges for continuous operation at 50 DS/min

Wildcat 18-40 Puma 28-40

Volume flow refers to water.

PERFORMANCE DIAGRAMS

Stroke frequency Example

/min

Material pressure bar (MPa) psi

B

AR

BAR

AR

BAR

B

AR

BAR

B

Air consumption nl/min

5.3.6

"?

Water delivery rate l/min

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Diagram for WILDCAT 18-40 Stroke frequency

/min NLMIN

BAR-0A PSI



















SCFM

 

!

Material pressure



" " #



#

 



 

"?

Air consumption

!  



 











LMIN













GPM

Water delivery rate A = 8 bar; 0.8 MPa; 116 psi air pressure B = 6 bar; 0.6 MPa; 87 psi air pressure C = 4 bar; 0.4 MPa; 58 psi air pressure

Diagram for PUMA 28-40 Stroke frequency

/min NLMIN

BAR-0A 

















 

!



!



 

"



"



Material pressure

SCFM

 

 

#

#

 







  "?



Air consumption

PSI

 











LMIN













GPM

Water delivery rate A = 8 bar; 0.8 MPa; 116 psi air pressure B = 6 bar; 0.6 MPa; 87 psi air pressure C = 4 bar; 0.4 MPa; 58 psi air pressure

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5.4 FUNCTION 5.4.1 PUMP

1 2

1 2 3 4 5 6 7 8 9 10 11

Control housing with integrated silencer Air pressure regulator Ball valve Air motor Compressed air inlet Mounting flange Separating agent cup Material outlet Fluid section Material inlet Grounding connection

4 3

11

6

5 7

9 8

B_03906

10

Function principle The piston pump is driven with compressed air (2). This compressed air moves the air piston up and down in the air motor (4) and it also moves the associated pump piston up and down in the fluid section (9). In the control housing (1), the air pressure is redirected at the end of each stroke with the help of the reversing valve. The working material is sucked up during the upwards stroke and is continuously conveyed towards the material outlet (8) in both stroke directions. Air motor (4) The air motor with its pneumatic reverse (1) does not require pneumatic oil. The compressed air is fed to the motor via the air pressure regulator (2) and the ball valve (3). The air motor is fitted with a safety valve. The safety valve has been set and sealed at the factory. In case of pressures over and above the permissible operating pressure, the valve, which is held with a spring, automatically opens and releases the excess pressure.

WARNING Overpressure! Risk of injury from bursting components. Never change the safety valve setting. Fluid section (9) The fluid section has been designed as a piston pump with exchangeable ball valves. The hard chrome-plated pump piston runs in two fixed packings which are self-adjusting by means of a pressure spring, thus resulting in a long service life. Between the air motor and the fluid section there is a separating agent cup (7) for holding the separating agent.

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5.4.2 1 2 3 4 5

PRESSURE REGULATOR UNIT

Pressure regulator Ball valve Pressure gauge Compressed air inlet AirCoat regulator (option)

Pneumatic pump Puma 28-40 AirCoat

1 2

5 4

3 B_03909

Positions of the ball valve 1 Closed: working pressure in the air motor will be relieved (control pressure is still present). 2 Closed: the air motor may still be under pressure. 3 Open: working position

Pneumatic pump Puma 28-40 Airless

1

2 3 B_03907

5.4.3

HIGH-PRESSURE FILTER (OPTION)

So that the complete pressure relief of the pump can be performed (see Chapter 7.2.2), a high-pressure filter with a return line or a relief combination, is mandatory.

5.4.3.1

up to 530 bar; 7687 psi

HIGH-PRESSURE FILTER (OPTION)

1

To ensure problem-free operation it is recommended that a WAGNER high-pressure filter be used. These have been developed especially for WAGNER pneumatic pumps. The filter inserts can be exchanged depending on the material to be used. The respective high-pressure filters and their inserts for the device can be found in the accessories list.

B_03908

2

Closed

Open 3

1 2 3

Fluid section connection Material outlet Return line

up to 270 bar; 3916 psi 1

Open (Return line)

Preferred filter installation position

2

Closed (Spraying) B_03910

3

B_04064

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5.4.3.2

FILTER RELIEF COMBINATION (OPTION)

Instead of the standard high-pressure filter the lower-cost filter relief combination can be used if only a small volume of material is to be processed. Use: in pumps up to 28-40. 1 You will find the relief combination and the suitable filter inserts in the accessories list. 1 2 3 4 5

2 4

Fluid section connection Relief combination Return line Paint filter Material outlet

5.4.4

3 5 B_04330

STROKE COUNT (OPTION)

Each air motor has a 1/8" air connection with which the air pressure in the lower air motor chamber can be measured. This signal can be used for counting the strokes in an external control, for example. The pressure signal corresponds to the set working air pressure and is available during the complete upwards stroke of the pump. If both of the signal flanks are evaluated, the upper and lower reversal point can be determined. A 4/2-mm; 0.16/0.08-inch air hose is used as an air signal line.

1 2 3 4

Order No. 9998675 9999066 9982072 9943049

Designation Threaded plug Angle screw-in connection Air hose (per meter) Pneumatic pre-selection counter

2

4

3 1 B_03703

B_03912

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6

ASSEMBLY AND COMMISSIONING

6.1

TRANSPORTATION

The pump can be moved on a trolley (4"-trolley) or manually without lifting equipment or a crane.

Only pumps without trolleys may be lifted by the ring nut or lifting eye bolt (see accessories) and transported short distances.

B_04065

6.2

STORAGE

Store the pump in a closed and dry environment. Thoroughly clean the pump, if a long-term decommissioning is planned. When resuming pump operation, proceed as described in the following sections.

WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic sparks. Only use a damp cloth to clean the pump.

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6.3

ASSEMBLING THE PUMP

Notice This pump can be used as part of a spraying system for Airless or AirCoat applications. The individual components are shown in the accessories, or can be arranged with a spraypack configurator. The nozzles must be selected according to the gun operating manual. Procedure: a) Mount pump (1) on stand, trolley (6), or wall mount. b) Mount the AirCoat regulator (7) with an AirCoat system. c) Mount high-pressure filter (3) or filter relief combination. d) Mount suction system (5). e) Mount return tube (4) or return hose. f ) Connect high-pressure hose and gun (2) as laid down in the operating manual for the gun.

2 AirCoat system

Airless system 2

6

7

5

1

5

1 6

3

3

4 4

B_03914

B_03915

WARNING Inclined ground! Risk of accidents if the device rolls away/falls. Position the trolley with the piston pump horizontally. If the surface is inclined, position the feet of the trolley towards the gradient. Secure the trolley.

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6.4

GROUNDING

WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic sparks. Only use a damp cloth to clean the piston pump. Ground all device components. Ground the work pieces to be coated.

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.

Grounding scheme (example) Conveyor

Work piece

Spraying stand

R max < 1 MΩ

Paint container B_00304

Floor, electrostatically conductive

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OPERATING MANUAL

The grounding connection is mandatory with the IceBreaker Pumps. Cable cross sections Pump Paint container Conveyor Booth Spraying stand

4 mm2; 6 mm2; 16 mm2; 16 mm2; 16 mm2;

Procedure: 1. Screw on grounding cable with eye. 2. Clamp the grounding cable clip to a grounding connection on site. 3. Ground the material (paint) container to an on-site grounding connection. 4. Ground the other parts of the system to an on-site grounding connection. 16 mm2; B_03916

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OPERATING MANUAL

6.5

COMMISSIONING

6.5.1

SAFETY INSTRUCTIONS

Before carrying out any work, the following points must be observed in accordance with the operating manual: - Observe all safety regulations in accordance with Chapter 4. - Carry out commissioning properly.

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.

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 outgoing air speed.

WARNING Gas mixtures can explode if the pump is not completely filled! Danger to life from flying parts. Ensure that the pump and suction system are always completely filled with flushing agent or working medium. Do not spray the device empty after cleaning.

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OPERATING MANUAL

Before every start-up, the following points should be observed as laid down in the operating manual: - Secure gun with safety clip. - Check the permissible pressures. - Check all connecting parts for leaks. - Check hoses for damage. It should be ensured that the device is in the following state before carrying out any work on it: - The pressure should be released from the pump and high-pressure hose with gun. - The gun should be secured with the safety clip. - The air supply should be interrupted.

Closed

2

Open

EMERGENCY STOP In case of unforeseen occurrences the ball valve (2) should be closed immediately and the return valve (3) opened. Open B_03917

3

6.5.2

FILLING WITH SEPARATING AGENT

NOTICE Piston pump runs dry! High wear/damage to the packings. Paint or solvent can escape if the seals are dry. Ensure that the separating agent container is filled with sufficient separating agent. Filling level 1 cm; 0.4 inch under the cup edge.

Place the supplied separating agent into the separating agent cup. Filling level: 1 cm; 0.4 inch under the cup edge Separating agent: Order No. 9992504 Notice Maximum permissible inclination of pump for moving, transportation, etc. after filling it with separating agent ± 30°. The pump must be vertical during operation.

B_03918

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OPERATING MANUAL

6.5.3 1. 2. 3. 4. 5. 6.

7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

BASIC FLUSHING

1 Place empty container (5) under return tube (4). Closed Place suction hose (7) in the container 2 with flushing agent (6). Adjust the pressure regulator (1) to Open approx. 0.05 MPa; 0.5 bar; 7.25 psi. Open return valve (3). Slowly open the ball valve (2). Adjust the air pressure on the pressure 3 regulator (1) so that the pump runs smoothly. 4 Rinse the system until clean flushing agent flows into the container (5). Close ball valve (2). Close return valve (3). 5 Point the gun, without nozzle, into container (5) and open it. B_03919 Slowly open the ball valve (2). Rinse until clean flushing agent flows from the gun. Close ball valve (2). When there is no pressure remaining in the system, close the gun. Secure the gun. Dispose of the contents of the container (5) according to the local regulations.

7

6

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OPERATING MANUAL

7 7.1

OPERATION FILLING WITH WORKING MATERIAL

1

Closed 2

Open

7

3 4

5

6 B_03919

1. Place empty container (5) under return tube (4). 2. Place suction hose (7) in the container with working material (6). Note: If the pump is equipped with a rigid suction system, it should only be dipped in into the working material up to the middle of the inlet housing at the maximum! 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Adjust the pressure regulator (1) to approx. 0.05 MPa; 0.5 bar; 7.25 psi. Open return valve (3). Slowly open the ball valve (2). Adjust the air pressure on the pressure regulator (1) so that the pump runs smoothly. Close ball valve (2) as soon as pure working material starts coming from the return tube (4). Close return valve (3). Point the gun, without nozzle, into container (5) and open it. Slowly open the ball valve (2). Close ball valve (2) as soon as pure working material starts coming from the gun. When there is no pressure remaining in the system, close the gun. Secure the gun. Dispose of the contents of the container (5) according to the local regulations.

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7.2

WORK

7.2.1

SPRAYING

1

closed 1. Secure gun and place nozzle in the gun. 2. Slowly open the ball valve (2). 3. Set required working pressure on the pressure regulator (1). 4. Optimize the spraying results as laid down in the gun instructions. 5. Start work process.

2

open

7

3 4

5

6 B_03919

7.2.2 1. 2. 3. 4. 5

PRESSURE RELIEF/WORK INTERRUPTION

Close gun. Close ball valve (2). Release the system by opening the gun. Close and secure gun. Open and close the return valve to completely depressurize the system.

If the system has been used with 2K materials:

NOTICE Hardened working material in the spraying system when 2K material is processed! Destruction of pump and injection system. Follow the manufacturer‘s processing rules, particularly regarding the pot life. Flush thoroughly before the end of the pot life. The pot life is decreased by warmth.

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7.2.3

DECOMMISSIONING AND CLEANING

Notice The device should be cleaned for maintenance purposes. Ensure that no remaining material dries and sticks. Procedure: 1. Work interruption -> carry out the steps in Chapter 7.2.2. 2. Basic flushing -> carry out the steps in Chapter 6.5.3. 3. Maintain the gun according to the operating manual. 4. Clean and check the suction system and the suction filter. 5. When using a high-pressure filter: clean and check filter insert and filter housing. 6. Clean the outside of the system.

WARNING Brittle filter pressure regulator! The container on the filter pressure regulator becomes brittle through contact with solvents and can burst. Flying parts can cause injury. Do not clean the container on the filter pressure regulator with solvents. 7. Put the whole system back together. 8. Check the level of the separating agent -> Chapter 6.5.2. 9. Fill the system with flushing agent as laid down in Chapter 7.1 "Filling with Working Material".

WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from flying parts. Ensure that the pump and suction system are always completely filled with flushing agent or working medium. Do not spray the device empty after cleaning.

7.3

LONG-TERM STORAGE

When storing the device for longer periods of time, it is necessary to thoroughly clean it and protect it from corrosion. Replace the water or solvent in the material pump with a suitable preservative, fill separating agent cup with separating agent. Procedure: 1. Carry out points 1 through 9 in Chapter 7.2.3 “Decommissioning and Cleaning”. 2. Flush with preservative according Chapter 6.5.3.

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8

TROUBLESHOOTING AND RECTIFICATION

Problem The pump does not work

Cause Air motor does not work or stops.

No pressure indication on the pressure gauge (air pressure regulator defective). Spray nozzle is clogged.

Poor spray pattern Irregular operation of material pump: spray jet collapses (pulsation)

Insufficient compressed air supply. Filter insert in spray gun or high-pressure filter is clogged. Fluid section or high-pressure hose are blocked (e.g. 2K material hardened). Grease in spool and sleeve assembly. Pump stops at the stroke end occasionally. See gun instructions. Viscosity is too high. Spraying pressure is too low.

Remedy Open and close ball valve on the pressure regulator unit or briefly disconnect compressed air supply. Disconnect compressed air supply briefly or repair or change pressure regulator. Clean the nozzle according to the instructions. Check compressed air supply. Clean the parts and use a suitable working material. Dismount and clean fluid section, replace high-pressure hose. Degrease spool and sleeve assembly. Check detent element (see service manual).

Thin spraying material. Increase air inlet pressure. Use a smaller nozzle. Valves are clogged. Clean material pump, if necessary leave to soak in flushing agent. Foreign body in suction valve. Dismount suction valve housing, clean, and check valve seat. Diameter of compressed air line too Assemble a larger supply line small. -> Technical data, Chapter 5.3.3 Valves, packings, or pistons are worn Replace the parts. out. Control air filter or work air filter is Check filter and clean it if necessary. clogged. The pump runs smoothly The suction system's union nut is Tighten union nut. but does not suck up any loose; the pump is taking in air. material Suction filter is clogged. Clean filter. Ball in suction or piston valve is Clean with flushing agent sticking. (if necessary vent device). Pump runs when the gun Packings, valves, or pistons are worn Replace the parts. is closed out. Air motor is iced up There is a lot of condensation water Install a water separator. in the air supply. If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service Center.

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9

MAINTENANCE

WARNING 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 device. Before all work on the device and in the event of work interruptions: - Disconnect the control unit from the mains. - Relieve the pressure from the spray gun and device. - Secure the spray gun against actuation. Observe the operating manual and service instructions at all times when carrying out work. 1. Check the level of separating agent in the separating agent cup every day, and top up if necessary. 2. Check and clean the high-pressure filter every day or as required. 3. Each decommissioning procedure should be carried out as laid down in Chapter 7.2.3. 4. Check hoses, pipes, and couplings every day and replace if necessary. In accordance with the guideline for liquid emitters (ZH  1/406 and BGR  500 Part  2 Chapter 2.36): - The liquid emitters should be checked by an expert (e.g. Wagner service technician) for their safe working conditions as required and at least every 12 months. - If devices have been decommissioned, the examination can be suspended until the next start-up. The service instructions are available in German and English. For order number see Chapter 1.

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9.1

HIGH-PRESSURE HOSES

The service life of the fluid hoses is reduced due to environmental influences even when handled correctly. Check hoses, pipes, and couplings every day and replace if necessary. As a precaution, fluid hoses should be replaced after a period specified by the operator.

DANGER Bursting hose, bursting threaded joints! Danger to life from injection of material. Ensure that the hose material is chemically resistant to the sprayed materials. Ensure that the spray gun, threaded joints, and material hose between the device and the spray gun are suitable for the pressure generated in the device. Ensure that the following information can be seen on the high-pressure hose: - Manufacturer - Permissible operating pressure - Date of manufacture

9.2

DECOMMISSIONING

When the equipment must be scrapped, please differentiate the disposal of the waste materials. The following materials have been used: Steel Aluminum Elastomers Plastics Carbide The consumable materials (paints, adhesives, sealers, solvents) must be disposed of according to the valid specific standards.

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10 ACCESSORIES 10.1

MATERIAL OUTLET ACCESSORIES

Accessories list Designation A Piston pump PE/TG A Piston pump PE/T 1 Separating agent 250 ml; 250 cc 2 Grounding cable 3 m; 9.8 ft 3 Lifting eye bolt 4 AirCoat regulator 5 AirCoat filter regulator, complete 6 HP filter DN10-PN270-SSt, complete 7 HP filter DN12-PN530-SSt, complete 9 Filter relief combination 10 Paint filter DN6-PN270-G1/4"-1/4"NPS-SSt 12 Adapter G1/4"-NPS1/4" 13 Adapter G3/8"-NPS1/4" 14 Adapter G3/8"-NPS 3/8" 15 Return tube DN6-G1/4"-100mm-PA 16 Circulation hose DN6-PN310-G1/4"-1.8m-PA 17 Circulation hose DN6-PN310-G1/4"-2.8m-PA 18 Return hose DN6-PN310-G1/4"-PA 19 Plug-in nipple with hose connector DN13 20 Plug-in nipple with quick-release coupling DN13 21 Quick release coupling with hose connector DN 13 22 Plug-in nipple with quick-release coupling DN10 23 Quick release coupling with hose connector DN 10 24 Regulator lock 25 Ball valve DN7-PN10-G1/4-R1/4-CB 26 Loctite, 542 50 ml; 50 cc Wearing part

Order No. Order No. 2329456 2329467 2329458 2329469 9992504 236219 9907133 2328611 2333478 2329024 2329025 367135 2329978 2332619 2332621 2332620 2331752 2331017 2331014 2329046 9985619 9998813 9998812 9998810 9998811 2334956 2335815 9992831

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OPERATING MANUAL

3

24

A

2 22 20 23 19

21 9

5

6

270 bar

1

7 530 bar

270 bar

x

y 4

13

y

12 14

10

B_04098

16/17 25 15 y 26

18

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OPERATING MANUAL

10.1.2

MATERIAL INLET ACCESSORIES

For trouble-free intake, use hoses which are as short as possible. The maximum hose length is dependent upon the viscosity of the material, the suction height, and the nominal diameter of the hose. Accessories list Designation A Piston pump PE/TG A Piston pump PE/T 1 Top reservoir set, 5 l for piston pump 2 Suction elbow for top reservoir SSt Suction hose DN16-SSt, complete 3 4 Suction hose DN25-SSt, complete 5 LP hose fitting DN25-M36-SSt 6 LP hose DN25-PN10-EPDM (per meter) 7 LP hose DN25-PN10-PE (per meter) 8 LP hose fitting DN16-M36-SSt 9 LP hose DN16-PN10-EPDM (per meter) 10 LP hose DN16-PN10-PE (per meter) 11 Suction pipe DN16-SSt, complete 12 Suction pipe DN25-SSt, complete 13 Suction elbow DN25-SSt 14 Suction pipe DN25-200L-SSt, complete 15 Bung adapter DN25-G2" 16 Suction pipe DN25-30L-SSt, complete 17 Suction filter DN16-18mesh-SSt 18 Suction filter DN25-18mesh-SSt 19 Inlet valve with valve depressor Wearing part

Order No. Order No. 2329456 2329467 2329458 2329469 2332169 2323225 2324110 2324116 2325408 2323474 2323595 2325390 2323329 2323597 2324158 2323239 2324247 2324238 2315163 2324241 2323396 2323325 2329689

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OPERATING MANUAL

19

11

DN16

12

DN25

9

16

8

DN

13 10

8

6 25

5

DN

13

16

DN

7

25

DN

5 3 15

1

4

200L

30L

16

14

DN16

DN25 2

B_03921

17

18

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VERSION 03/2013

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OPERATING MANUAL

10.1.3

TROLLEY, RACK, AND WALL MOUNT ACCESSORIES

Accessories list Designation A Piston pump PE/TG A Piston pump PE/T 1 Trolley 4", complete 2 Rack 4", complete 3 Wall mount 4", complete Wearing part

Order No. Order No. 2329456 2329467 2329458 2329469 2325901 2332374 2332143

3 1

2

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OPERATING MANUAL

11 SPARE PARTS 11.1

HOW CAN SPARE PARTS BE ORDERED?

Always supply the following information to ensure delivery of the right spare part: Order number, designation, and quantity The quantity need not be the same as the number given in the quantity column " " on the lists. This number merely indicates how many of the respective parts are used in each component. The following information is also required to ensure smooth processing of your order: - Billing address - Delivery address - Name of the person to be contacted in the event of any queries - Type of delivery (normal mail, express delivery, air freight, courier, etc.) Identification in spare parts lists Explanation of column " " (labeling) in the following spare parts lists: Wearing parts Note: No liability is assumed for wearing parts. Not part of the standard equipment but available as a special accessory.

WARNING Incorrect maintenance/repair! Risk of injury and equipment damage. Have repairs and part replacements carried out only by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and device. - Secure the spray gun against actuation. Observe the operating manual and service instructions at all times when carrying out work.

The service instructions are available separately. See Chapter 1.

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OPERATING MANUAL

11.2

OVERVIEW OF THE COMPONENTS

Designation 1 Piston pump 2 Fluid section 3 Air motor 4 Spring 5 Coupling 9 Grounding cable, complete 10 Molykote DX grease Tightening torque for air motor/fluid section

Order No. Order No. Order No. Order No. 2329456 2329458 2329467 2329469 2329641 2329643 2329641 2329643 2329613 2329617 367530 367529 2329613 236219 367530 9992616 25 Nm; 18 lbft

3

10

1

9 5 4

Tightening torque pos. 2 and 3 2

B_03926

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OPERATING MANUAL

11.3

AIR MOTORS

WARNING Incorrect maintenance/repair! Risk of injury and equipment damage. Have repairs and part replacements carried out only by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and device. - Secure the spray gun against actuation. Observe the operating manual and service instructions at all times when carrying out work. Air motor spare parts list Designation 1 Air motor 2 Flange 3 Piston rod 4 Cylinder pipe 5 Compressed air pipe 6 Control air pipe 8 Plug 9 Outlet seal 10 Connecting part 11 Silencer 12 Hood 13 Compressed air filter 14 Control air filter 15 Fluid warning label 16 Shoulder screw 17 Sound deadening pad 18 Cotter pin 23 Filter holder 25 Throttle 28 O-ring 29 Rod seal 30 Pilot valve Spool and sleeve assembly, complete 31 32 Permaglide bushing 33 Complete piston = Wearing part = Included in service set

1 1 1 1 1 1 2 2 1 1 1 1 1 1 2 1 2 1 1 6 2 2 1 1 1

Order No. Order No. 2329613 2329617 367316 367302 366303 367303 367304 367305 367307 L414.06C 367309 367310 367311 367313 367314 2332082 367318 367319 367320 367324 9971123 9974217 369290 9943080 9962018 9998663 9998661

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OPERATING MANUAL

69 49 16

10-15 Nm; 7-11 lbft

109 12 46

15 4 71 72

17

106

41

20-25 Nm; 15-19 lbft 49 16

5 6 39 36 41 51 40 Nm; 30 lbft 53 33

110 11 110

1

43 42 2-3 Nm; appr. 2 lbft 55

107

106 110 108

29

110

9 57 35 31

56 10 40 18 30 44 45

53 (LEOPARD)

28 75 47

13 8

75

8 37 74

81

32

47

54 48

100

25 14 23 37

3

36

29

30

34 60 61 59 58 109 2 52 50 25 Nm; 19 lbft 108

B_03927

110

Pressure regulator (pos. 100), for details see Chapter 11.3.2

Do not dismount the piston (pos. 81).

Pos. 53 (LEOPARD): lower washer only for LEOPARD pump.

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Air motor spare parts list Designation 34 Seal wiper ring 35 Safety valve 36 O-ring 37 O-ring 39 O-ring 40 O-ring 41 O-ring 42 O-ring 43 O-ring 44 Threaded plug 45 Threaded plug 46 WAGNER label 47 Threaded plug 48 Control housing 49 Washer 50 Hexagon screw 51 Hexagon nut 52 Washer 53 Washer 54 SFS screw 55 Socket cap screw M6x16 56 Washer 57 Sealing ring 58 Base 59 Clamping bracket 60 Socket cap screw 61 Spring washer 69 Drive fastener 71 IceBreaker label 72 Warning label 74 Detent element, complete ISO 1/2 75 Damper ISO 1/2 81 Spool and sleeve assembly ISO1 or ISO 2 100 Pressure regulator unit, complete 106 Loctite 222 50ml; 50cc 107 Loctite, 243 50 ml; 50 cc 108 Loctite, 542 50 ml; 50 cc 109 Molykote DX grease 110 Beacon grease Service set = Wearing part = Included in service set

1 1 2 2 2 2 2 1 1 1 1 1 2 1 2 3 1 3 1 2 3 3 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1

Order No. Order No. 9974090 368288 9974115 9974084 9974085 9974089 9974095 9971448 9974097 9974098 9998674 9998274 2330369 2330370 9998675 367315 9925033 9900225 9910101 9920106 9920107 9907126 9900325 9920103 9970149 9952668 9952667 9900701 9921505 9998718 2330382 2332077 368038 368313 9943097 2328606 9992590 9992511 9992831 9992616 9998808 366995 367995

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OPERATING MANUAL

11.4

AIR MOTOR REGULATORS

6

10

9

14

2

8

14 14 1

7

4 12

13 6 3

11

6

7

12

13

B_03935

12

5

Air motor regulator spare parts list Designation 1 Pressure regulator unit 4", complete Pressure regulator valve 4" 2 3 Pressure gauge 0-10 bar (d40) 4 Distribution piece 4" 5 Hexagon socket head cap screw 6 Hexagon socket head cap screw O-ring 7 8 O-ring 9 O-ring 10 Edge ball valve 4" 11 Screw plug 12 Molykote DX grease 13 Loctite, 542 50 ml; 50 cc 14 Beacon grease = Wearing part = Included in service set

1 1 1 1 2 4 2 1 1 1 1 1 1 1

Order No. 2328606 2309972 9998677 2309744 9907039 9900316 9974166 9971313 9971137 2310635 9904407 9992616 9992831 9998808

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11.5

FLUID SECTIONS

WARNING Incorrect maintenance/repair! Risk of injury and equipment damage. Have repairs and part replacements carried out only by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and device. - Secure the spray gun against actuation. Observe the operating manual and service instructions at all times when carrying out work.

Fluid sections spare parts list Designation 1 1 Fluid section 2 1 Pipe 3 1 Cylinder 4 1 Inlet housing 40 5 1 Piston 6 1 Valve screw 7 1 Ball guide, inlet 8 1 Connecting flange 9 1 Valve seat, inlet 10 1 Valve seat, outlet 11 1 Snap ring flange 12 2 Snap ring half 13 1 Securing ring 16 1 Support ring 17 1 Pressure ring 18 1 Support ring 19 1 Pressure ring 100 1 Packing PE/TG, complete (small) 101 1 Packing PE/T, complete (small) 20 2 Sealing collar TG (small) 20 2 Sealing collar T (small) = Wearing part = Included in service set = Special accessories

40 cm3

40 cm3

Order No. 2329641

Order No. 2329643 367502 367503 2322467 367505 367506 367507 367501 367509 367510 367511 367512 367513 367516 367517 367518 367519

115805 123219 123398 123426

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OPERATING MANUAL

32

31 39

60 5

53

45 60

8

43 28 10 6

60 44

51 1

52 25 Nm; 18 lbft

60

16 21 20 21 20 21 17 40

25

100 101

11 111

50

60

13 46 51 25

60

62

3

61

70

70 Nm +10 Nm 52 lbft + 7 lbft

12

2

100 Nm 74 lbft

61

41 19 23 22 23 22 23 18

40 Nm/ 30 lbft

7 42 27 9 103 104

4

60 61

71 B_03929

Tighten pos. 4 by hand on block. Use a standard spanner only if necessary. In this case use a spanner to hold pos. 3.

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Fluid sections spare parts list 21 103 104 22 22 23 25 27 28 31 32 39 40 41 42 43 44 45 46 50 51 52 53 60 61 62 70 71

3 1 1 2 2 3 2 1 1 1 2 6 1 1 1 1 1 1 1 3 6 3 3 1 1 1 1 1 1 1

Designation Sealing collar PE (small) Packing PE/TG, complete (large) Packing PE/T, complete (large) Sealing collar TG (large) Sealing collar T (large) Sealing collar PE (large) O-ring O-ring O-ring Separating agent cup Coupling cover O-ring Wave spring (small) Wave spring (large) Ball (large) Ball (small) O-ring O-ring O-ring Hexagon screw Washer Hexagon screw Connecting tube Mobilux EP 2 grease Anti-seize paste tube Molykote DX grease Fitting SF-MM-G3/8"-M24-PN530-SSt Sealing sleeve Service set PE/TG Service set PE/T

40 cm3

40 cm3

Order No. 123427 367991

Order No. 123427 367992

367522 367900 367523

367523 367525 367527 367528 367531 367532 9974089 9998669 9998670 9941513 9941518 9974094 9974093 9974106 9907124 9920106 9900225 367306 9998808 9992609 9992616 2329922 2329898 367990

367994

111 1 Valve seat set 40 stainless steel 2331582 = Wearing part = Included in service set = Special accessories Note on pos. 111: Valve seat set 40 stainless steel consisting of: pos. 28, 10, 27, 9, but in stainless steel version.

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OPERATING MANUAL

11.6

INLET VALVE WITH VALVE DEPRESSOR

2 3 4 5 1 6

7

B_04331

Designation 1 2 3 4 5 6 7 8

1 1 1 1 1 1 1 1 Wearing part

Inlet valve with valve depressor Ball guide, inlet Ball O-ring Valve seat, inlet Inlet housing Valve tappet, complete Sealing sleeve

8

Order No. for 40-cm3 fluid section 2329689 367507 9941513 367527 367509 2329412 368037 2329898

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OPERATING MANUAL

11.7

RELIEF COMBINATION (UP TO 270 BAR; 3916 PSI)

3 7 2

3

9

7

6

1

7

4 8

100 Nm 74 lbft

5

B_04068

1 2 3 4 5 6 7 8 9

1 1 2 1 1 1 1 1 1 Wearing part

Order No. 2329023 2324549 2323718 169248 2324552 3204611 9992831 9992616 9992609

Designation Relief combination Relief housing Hexagon plug Relief valve, complete Outlet pipe Fitting-DF-MM-G1/4"-G1/4"-PN530-SSt Loctite, 542 50 ml; 50 cc Molykote DX grease Anti-seize paste tube

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11.8

PAINT FILTER (UP TO 270 BAR; 3916 PSI)

2 3

4

5 6

1 7

8 8 B_04329

1 2 3 4 5

6 7 8

1 1 1 1 1

Order No. 2329978 2329940 9970123 43590 34383 43235 34377 89323 -2310575 9992609

Designation Paint filter DN6-PN270-G1/4"-1/4"NPS-SSt Fitting piece G1/4" Sealing ring Pressure spring Filter insert * * 200-mesh filter insert (red) * 100-mesh filter insert (yellow) * 50-mesh filter insert (white) * 30-mesh filter insert (green) Housing Fitting-DF-MM-M16x1.5-1/4"NPS-PN530-SSt Anti-seize paste tube

1 1 1 Wearing part = Not part of the standard equipment but available as a special accessory.

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11.9

HIGH-PRESSURE FILTER (UP TO 530 BAR; 7687 PSI)

90 Nm; 66 lbft 3

23

34

Tighten pos. 3 by hand

2

21

35

5 12 Identification of the filter

1 11

10 36 36 140 Nm 103 lbft

7 34

4

34 13 20 33

20 Stainless steel

Carbon steel

34

B_03934

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1 2 3 4 5 7 10 11

1 1 1 1 1 1 1 1

Ball valve version in: Stainless steel Carbon steel Designation Order No. Order No. HP filter DN12-PN530, complete 2329025 2335334 Filter housing 2324542 Union nut 2324543 Fitting-DF-MM-G1/2-G3/8-PN530-SSt 2330780 O-ring 9955863 Distribution housing for ball valve 2324670 Filter support 9894245 Filter cartridge * * Filter cartridge 200 295721 * Filter cartridge 100 3514068 * Filter cartridge 50 3514069 * Filter cartridge 20 291564 Cone spring 3514058 Fitting-DF-MM-R3/8-R1/4-PN530-SSt 2328291 Ball valve 2330156 9998679 Pressure ring d45 2325562 Hexagon plug 2323718 Double connector 3204611 2325826 Loctite 542 50 ml; 50 cc 9992831 Mobilux EP 2 grease 9998808 Anti-seize paste tube 9992609

12 1 13 1 1 20 21 1 23 1 33 1 34 1 35 1 36 1 = Wearing part = Not part of the standard equipment but available as a special accessory.

WARNING 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 Catalogue" chapter and that are assigned to the device. Before all work on the device and in the event of work interruptions: - Disconnect the control unit from the mains. - Relieve the pressure from the spray gun and device. - Secure the spray gun against actuation. Observe the operating manual and service instructions at all times when carrying out work.

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11.10 HIGH-PRESSURE FILTER (UP TO 270 BAR; 3916 PSI) 90 Nm; 66 lbft

3

23

34

Tighten pos. 3 by hand

2

21

35

5 12

1

Identification of the filter 11

10

37 36

8 140 Nm; 103 lbft

7

4 34

36 13

B_04069

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1 2 3 4 5 7 8 10 11

1 1 1 1 1 1 1 1 1

Ball valve version in: Designation HD filter DN10-PN270 SSt, complete Filter housing Union nut Reducing double nipple with 2x60° O-ring Distribution housing Relief valve Filter support Filter cartridge * * Filter cartridge 200 * Filter cartridge 100 * Filter cartridge 50 * Filter cartridge 20 Cone spring Outlet pipe Pressure ring d45 Hexagon plug Loctite 542 50 ml; 50 cc Mobilux EP 2 grease Anti-seize paste tube Molykote DX grease

Stainless steel Order No. 2329024 2324542 2324543 2325826 9955863 2324544 169248 9894245 295721 3514068 3514069 291564 3514058 2324552 2325562 2323718 9992831 9998808 9992609 9992616

12 1 13 1 21 1 23 1 34 1 35 1 36 1 37 1 = Wearing part = Not part of the standard equipment but available as a special accessory.

WARNING 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 Catalogue" chapter and that are assigned to the device. Before all work on the device and in the event of work interruptions: - Disconnect the control unit from the mains. - Relieve the pressure from the spray gun and device. - Secure the spray gun against actuation. Observe the operating manual and service instructions at all times when carrying out work.

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11.11 TROLLEY

15 5

17 10

2

13 14

4

9 5

16 6

Distance

3

1

7 8

A B

11

Designation 1 1 Trolley, complete 2 1 Stand, left, 4"-6" (welded) 3 1 Stand, right, 4"-6" (welded) 4 4 Hexagon screw DIN931 M6x75 5 6 Self-locking hexagon nut, M6 6 2 Wheel, D250 7 4 Washer 8 4 Cotter pin 9 1 Wheel axle 4"-6" 10 2 Connecting part 4"-6" 11 2 Tube plug, ribbed 12 2 Saddle feet for round tubes 13 2 Plug 14 4 Hexagon screw 15 1 Wall mount 16 2 Hexagon screw without shaft M6x55 17 2 Handle = Wearing part

12

B_03932

Order No. 2325901 --9907140 9910204 2304440 340372 9995302 -367943 ---9900218 2332143 3061695 9998747

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12 3+2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING 12.1

SCOPE OF GUARANTEE

All Wagner professional colour application devices (hereafter referred to as products) are carefully inspected, tested, and subject to strict checks under Wagner quality assurance. Wagner exclusively issues extended guarantees to commercial or professional users (hereafter referred to as “customer”) who have purchased the product in an authorized specialist shop, and which relate to the products listed on the Internet at www.wagner-group.com/profi-guarantee. The buyer’s claim for liability for defects from the purchase agreement with the seller and statutory rights are not impaired by this guarantee. We provide a guarantee in that we decide whether to replace or repair the product or individual parts, or take the device back and reimburse the purchase price. The costs for materials and working hours are our responsibility. Replaced products or parts become our property.

12.2

GUARANTEE PERIOD AND REGISTRATION

The guarantee period amounts to 36 months. For industrial use or equal wear, such as shift operations in particular, or in the event of rentals, it amounts to 12 months. Systems driven by petrol or air are also guaranteed for a 12 month period. The guarantee period begins with the day of delivery by the authorized specialist shop. The date on the original purchase document is authoritative. For all products bought in authorized specialist shops from 02/01/2009 the guarantee period is extended to 24 months providing the buyer of these devices registers in accordance with the following conditions within 4 weeks of the day of delivery by the authorized specialist shop. Registration can be completed on the Internet at www.wagner-group.com/profi-guarantee. The guarantee certificate is valid as confirmation, as is the original purchase document that carries the date of the purchase. Registration is only possible if the buyer agrees to the data that is entered during registration being stored. When services are carried out under guarantee the guarantee period for the product is neither extended nor renewed. Once the guarantee period has expired, claims made against the guarantee or from the guarantee can no longer be enforced.

12.3

HANDLING

If defects can be seen in the materials, processing, or performance of the device during the guarantee period, guarantee claims must be made immediately, or at the latest within a period of 2 weeks. The authorized specialist shop that delivered the device is entitled to accept guarantee claims. Guarantee claims may also be made to the service centers named in the operating manual. The product has to be sent without charge or presented together with the original purchase document that includes details of the purchase date and the name of the product. In order to claim for an extension to the guarantee, the guarantee certificate must be included. The costs as well as the risk of loss or damage to the product in transit or by the center that accepts the guarantee claims or who delivers the repaired product, are the responsibility of the customer.

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12.4

EXCLUSION OF GUARANTEE

Guarantee claims cannot be considered - for parts that are subject to wear and tear due to use or other natural wear and tear, as well as defects in the product that are a result of natural wear and tear, or wear and tear due to use. This includes in particular cables, valves, packings, nozzles, cylinders, pistons, means-carrying housing components, filters, pipes, seals, rotors, stators, etc. Damage due to wear and tear that is caused in particular by sanded coating materials, such as dispersions, plasters, putties, adhesives, glazes, quartz foundation. - in the event of errors in devices that are due to non-compliance with the operating instructions, unsuitable or unprofessional use, incorrect assembly and/or commissioning by the buyer or by a third party, utilization other than is intended, abnormal ambient conditions, unsuitable coating materials, the influence of chemical, electrochemical, or electrical agents, unsuitable operating conditions, operation with the incorrect mains voltage supply/frequency, overload, or defective servicing or care and/or cleaning. - for errors in the device that have been caused by using accessory parts, additional components, or spare parts that are not original Wagner parts. - for products to which modifications or additions have been carried out. - for products where the serial number has been removed or is illegible. - for products to which attempts at repairs have been carried out by unauthorized persons. - for products with slight deviations from the target properties, which are negligible with regard to the value and usability of the device. - for products that have been partially or fully taken apart.

12.5

ADDITIONAL REGULATIONS

The above guarantees apply exclusively to products that have been bought from authorized specialist shops in the EU, CIS, Australia and are used within the reference country. If an inspection finds damage not covered by the present guarantee, repairs are carried out at the expense of the buyer. The above regulations manage the legal relationship to us concludingly. Additional claims, in particular for damages and losses of any type, which occur as a result of the product or its use, are excluded from the product liability act except with regard to the area of application. Claims for liability for defects to the specialist trader remain unaffected. German law applies to this guarantee. The contractual language is German. In the event that the meaning of the German and a foreign text of this guarantee deviate from one another, the meaning of the German text has priority.

J. Wagner GmbH Professional Finishing Division Otto Lilienthal Strasse 18 88677 Markdorf Germany

Wagner professional guarantee (As of 02/01/2009)

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12.6

CE DECLARATION OF CONFORMITY

Herewith we declare that the supplied version of pneumatic pumps and their spraypacks:

18-40

28-40

comply with the following guidelines: 2006/42/EC 94/9/EC Applied standards, in particular: DIN EN ISO 12100: 2011 DIN EN ISO 13732-1: 2008 DIN EN 809: 2012 DIN EN 14462: 2010 DIN EN ISO 4413: 2011 DIN EN 12621: 2011 DIN EN ISO 4414: 2011 DIN EN 1127-1: 2011

DIN EN 13463-1: 2009 DIN EN 13463-5: 2011 DIN EN ISO 80079-34: 2012

Applied national technical standards and specifications, in particular: Part 2 Chapter 2.29 and Chapter 2.36 Identification:

EC Certificate of Conformity The CE certificate 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: 2302304

12.7

REFERENCE TO GERMAN REGULATIONS AND GUIDELINES Part 2, Chapter 2.36 Working with Liquid Ejection Devices Part 2, Chapter 2.29 Working with Coating Materials Explosion protection rules Avoiding ignition risks Equipment for cleaning work pieces with solvents Guidelines for liquid ejection devices Painting rooms and equipment Plant Safety Ordinance

Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they can be found on the Internet.

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66

ED

FI

CERT

I

A

J. Wagner Ges.m.b.H. Ottogasse 2/20 2333 Leopoldsdorf Austria Tel. +43/ 2235 / 44 158 Fax +43/ 2235 / 44 163 [email protected]

DK

Wagner Spraytech Scandinavia A/S Helgeshøj Allé 28 2630 Taastrup Denmark Tel. +45/43/ 27 18 18 Fax +45/43/ 43 05 28 [email protected]

GB

Wagner Spraytech (UK) Limited The Coach House 2 Main Road Middleton Cheney OX17 2ND Great Britain UK helpline +44/1295 714200 Fax +44/1295 710100 [email protected]

B

Wagner Spraytech Benelux b.v. Veilinglaan 56-58 1861 Meise-Wolvertem Belgium Tel. +32/2/269 46 75 Fax +32/2/269 78 45 [email protected]

E

Wagner Spraytech Iberica S.A. P.O. Box 132, Crta. N-340 08750 Molins de Rey Barcelona, Spain Tel. +34/93/6800028 Fax +34/93/66800555 [email protected]

I

Wagner Colora S.r.l Via Italia, 34 I- 20060 Gessate (MI) Italy Tel. +39/ 02 959292 1 Fax +39/ 02 95780187 [email protected]

CH

J. Wagner AG Industriestrasse 22 9450 Altstätten Switzerland Tel. +41/71 / 7 57 22 11 Fax +41/71 / 7 57 22 22 [email protected]

F

NL Wagner France S.a.r.l 12 Avenue des Tropiques Z.A. de Courtaboeuf 91978 Les Ulis Cedex France Tel. +33 825 011 111 Fax +33 (0) 1 69 81 72 57 [email protected]

Wagner Spraytech Benelux b.v. De Heldinnenlaan 200, 3543 MB Utrecht Netherlands Tel. +31/ 30/241 41 55 Fax +31/ 30/241 17 87 [email protected]

D

J. Wagner GmbH Otto-Lilienthal-Straße 18 D-88677 Markdorf Postfach 11 20 D-88669 Markdorf Germany Tel. +49 / 75 44 / 505 -1664 Fax +49 / 75 44 / 505 -1155 [email protected] www.wagner-group.com

CZ

Wagner, spol. s r.o. Nedasovská str. 345 155 21 Prague 5 -Zlicín Czech Republic Tel. +42/ 2 / 579 50 412 Fax +42/ 2 / 579 51 052 [email protected]

Wagner Spraytech Scandinavia A/S Helgeshøj Allé 28 2630 Taastrup Denmark Tel. +45/43/ 21 18 18 Fax +45/43/ 43 05 28 [email protected]

S

www.wagner-group.com Subject to changes and errors.