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PROTEC 2K
B_05163
2K System
Protective Coating
Version 02/2016
Translation of the Original
Operating Manual
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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
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 Manuals for the Individual Components 8
1.4 Abbreviations in the Text 8
1.5 Terminology for the Purpose of this Manual 9
2 CORRECT USE 10
2.1 Device Types 10
2.2 Type of Use 10
2.3 Field of Application 10
2.4 Safety Parameters 10
2.5 Processible Working Materials 11
2.6 Recommended Application Areas 11
2.7 Reasonably Foreseeable Misuse 12
2.8 Residual Risks 12
3 IDENTIFICATION 13
3.1 CE Explosion Protection Identi cation 13
3.2 Identi cation X 13
3.3 Type Plate 15
4 GENERAL SAFETY INSTRUCTIONS 16
4.1 Safety Instructions for the Operator 16
4.1.1 Electrical Equipment 16
4.1.2 Personnel Quali cations 16
4.1.3 Safe Work Environment 16
4.2 Safety Instructions for Sta 17
4.2.1 Safe Handling of WAGNER Spray Devices 17
4.2.2 Grounding the Device 18
4.2.3 Product Hoses 18
4.2.4 Cleaning and Flushing 19
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 20
4.2.6 Touching Hot Surfaces 20
5 DESCRIPTION 22
5.1 Components 22
5.2 Mode of Operation 24
5.3 Protective and Monitoring Equipment 24
5.4 Scope of Delivery 26
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Table of Contents
5.5 Data 27
5.5.1 Materials of Paint-wetted Parts 27
5.5.2 Recommended Packings 27
5.5.3 Technical Data 28
5.5.3.1 Technical Data for Entire System 28
5.5.3.2 Technical Data for PROTEC 2K Piston Pump 29
5.5.4 Dimensions and Weights 30
5.5.5 Volume ow 31
5.5.6 Performance Diagrams 31
5.6 Flow Diagram 34
5.6.1 Flow Chart with External Mixer and External Circulation 35
5.7 Pressure Regulator Unit 36
5.8 Pressure Relief 36
5.8.1 High-pressure Filter 530 bar 36
5.8.2 2K PC Relief Combination, 530 bar 37
5.9 Stroke Count (Option) 37
5.10 External Mixer and External Circulation 39
5.10.1 External Mixer (Option) 39
5.10.2 Hose Selection 40
5.10.3 Throttle Valve (Option) 41
5.10.4 External circulation (option) 42
5.11 Feed Pump (Option) 44
6 ASSEMBLY AND COMMISSIONING 45
6.1 Training Assembly/Commissioning Sta 45
6.2 Storage and Installation Conditions 45
6.3 Transportation 45
6.4 Assembly and Installation 46
6.4.1 Pneumatic Connections 46
6.4.2 Product Connections 46
6.4.3 Ventilation of the Spray Booth 46
6.5 Grounding 47
6.5.1 Grounding of Components on Trolley 47
6.5.2 Grounding Schema (example) 48
6.6 Commissioning 49
6.6.1 Safety Instructions 49
6.6.2 Procedure 49
7 OPERATION 50
7.1 Training the Operating Sta 50
7.2 Safety Instructions 50
7.2.1 General Rules for Making Adjustments to the Spray Gun 51
7.2.2 Do not connect red handle under pressure 51
7.3 Switching Device On and O 52
7.3.1 Switching On Device 52
7.3.2 Switching O Device 52
7.3.3 Emergency Stop 52
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7.4 Spraying Mode 53
7.4.1 Preparing 53
7.4.2 Circulating 54
7.4.3 2K Spraying 55
7.4.3.1 Pressure Drop 56
7.4.3.2 No-Load / Vent 56
7.5 Pressure Relief/Work Interruption 57
7.5.1 Continuing after Work Interruption 58
7.6 Intermediate Flushing 58
7.6.1 Intermediate Flushing with Flushing Pump 59
7.6.1.1 Relieving Flushing Pump 60
7.6.2 Intermediate Flushing without Flushing Pump 61
7.7 Paint or Hardener Change 62
7.7.1 Paint Change Flushing 62
7.8 Work ow 65
8 CLEANING AND MAINTENANCE 66
8.1 Cleaning 66
8.1.1 Cleaning Sta 66
8.1.2 Safety Instructions 66
8.1.3 Clean Product Tank 66
8.1.4 Decommissioning and Cleaning 67
8.1.5 Long-term Storage 67
8.2 Maintenance 68
8.2.1 Maintenance Sta 68
8.2.2 Safety Instructions 68
8.2.3 Regular Maintenance Work 69
8.2.3.1 Lubricating Bearings 69
8.2.3.2 Draining Condensate from Water Separator 70
8.2.3.3 Filling with Separating Agent 70
8.2.4 Emptying Device 71
8.2.5 Filling Empty Device 73
8.2.6 Cleaning and Replacing the High-pressure Filter 74
8.2.7 Product Hoses, Tubes and Couplings 75
9 TROUBLESHOOTING AND RECTIFICATION 76
10 REPAIRS 78
10.1 Repair Sta 78
10.2 Mounting Materials 78
11 DISPOSAL 78
Table of Contents
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OPERATING MANUAL
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12 ACCESSORIES 79
12.1 Conversion to other Mixing Ratios 81
13 SPARE PARTS 82
13.1 How Can Spare Parts Be Ordered? 82
13.2 Overview 83
13.2.1 Basic Units 83
13.2.2 System Overview 84
13.2.3 Hoses 85
13.3 Trolley with Grounding, Return Line, and Air Inlet 86
13.3.1 2K Mechanism Trolley 88
13.3.2 Air Inlet with Water Separator 89
13.4 Product Tank A and Product Tank B (1:1) 90
13.5 Product Tank B (4:1, 3:1, 2:1, 1.5:1) 91
13.6 Mixing 92
13.6.1 Mixing Block 94
13.6.1.1 Outlet Valve 94
13.6.2 Mount on Trolley 95
13.7 2K Pump 96
13.7.1 PROTEC Air Motor 10" 98
13.7.1.1 Air Motor Regulator for PROTEC 10" 102
13.7.2 Movement Mechanism 103
13.7.3 Fluid Sections 110–150 cm 104
13.7.4 Fluid Sections 38–75 cm 107
13.7.5 2K PC Relief Combination 111
13.7.6 2K High-pressure Filter, 530 bar with Pressure Gauge 112
13.8 Flushing Pump / Flushing Pump Connection (Option) 114
13.9 Heater (Option) 116
13.9.1 Heater without Return Line 116
13.9.2 Heater with Return Line 118
13.10 Return Flow Set HP Filter A and B (Option) 121
13.11 External Mixer 122
13.11.1 Throttle Valve Set (Option) 124
13.11.1.1 Throttle Valve 124
13.11.2 External Circulation A1/2"–B1/4" and A3/8"–B1/4" 126
13.11.3 External circulation A3/8"–B3/8" and A1/2"–B3/8" 127
14 WARRANTY AND CONFORMITY DECLARATIONS 128
14.1 Important Notes Regarding Product Liability 128
14.2 Warranty Claim 128
14.3 CE Declaration of Conformity 129
14.4 Notes on National Regulations and Guidelines 130
Table of Contents
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OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
1 ABOUT 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 - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
Note - provides information about particular characteristics and how to proceed.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the hazard and its consequences.
NOTICE
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.
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OPERATING MANUAL
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1.3 LANGUAGES
The operating manual is available in the following languages:
Language Order No. Language Order No. Language Order No.
German 2352823 English 2352824 French 2357841
Italian 2357842 Spanish 2357843 Russian 2359374
1.4 ABBREVIATIONS IN THE TEXT
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Double stroke
Nominal diameter
Nominal pressure
Two components
Protective coating
1.3.1 OPERATING MANUALS FOR THE INDIVIDUAL COMPONENTS
Operating manual for ushing pump (option): IceBreaker piston pumps 40 cm–150 cm
Language Order No. Language Order No. Language Order No.
German 2333537 English 2333538 French 2333539
Italian 2333540 Spanish 2333541 Russian 2351629
Additional languages on request or at:
The corresponding service manuals are available under the following order number:
Language Order No. Language Order No.
German 2357839 English 2357840
Additional languages on request or at:
Continuous- ow heater operating manual (option)
Language Order No. Language Order No.
German 65860 English 65860
French 65860 Italian 65860
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OPERATING MANUAL
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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Materials
Stainless steel
Polyethylene
Ultra-high molecular weight polyethylene
Polytetra uorethylene
PTFE with graphite
PTFE
Leather
Cleaning Manual cleaning of devices and device parts with cleaning agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Sta quali cations
Trained person Is instructed 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 A person who, based on his/her technical training, experience
and recent vocational experience, has su cient 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.
In the context of
TRBS1203
(2010 / Revision 2012)
Additional requirements for skilled persons are given in the
TRBS1203(2010/Revision 2012): Expert knowledge in the areas
of protection against excessive pressure, electrical hazards, and
explosion protection (where applicable).
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OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
2 CORRECT USE
2.1 DEVICE TYPES
2.2 TYPE OF USE
2.3 FIELD OF APPLICATION
The device is suitable for processing liquid materials like paints and lacquers in accordance
with the classi cation into explosion classes IIA or IIB.
The 2K system can be employed in potentially explosive areas (Zone 1). See Chapter 3.
2.4 SAFETY PARAMETERS
- PROTEC 2K with ushing pump
- PROTEC 2K without ushing pump
- Mixing ratio of 4:1 or 3:1 or 2:1 or 1.5:1 or 1:1
WAGNER accepts no liability for any damage arising from incorrect use.
Use the device only to work with the products recommended by WAGNER.
Only operate the device as a whole.
Do not perform unauthorized conversions or modi cations to the device.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The 2K system may only be operated under the following conditions:
The operating personnel 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.
The 2K system may only be used as described in this operating manual. In particular, no
conversions are permitted on the system otherwise the warranty ceases to apply and
WAGNER is not liable for any claims.
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OPERATING MANUAL
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2.5 PROCESSIBLE WORKING MATERIALS
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.
Check if the uids and solvents used are compatible with the pump construction
materials.
For explanations of the models and construction materials, consult the data in
Chapter 5.5 or contact a WAGNER service technician.
NOTICE
Wear caused by abrasive working materials is not covered by the warranty.
2.6 RECOMMENDED APPLICATION AREAS
Low- to high-viscosity 2K lacquer (e.g., epoxy, PU, DD) for processing with static mixer,
hose, and gun.
- 2K water-based priming - 2K epoxy priming
- 2K solvent-based priming - 2K epoxy lacquers
- 2K PUR priming - 2K high-solid priming
- 2K PUR lacquers - 2K high-solid lacquers
However, 2K products containing solvents and aqueous 2K products should not be
processed with the same system.
Application area
Steel-processing industry
Rail vehicle
Shipbuilding
Tank construction
Pipeline construction
Wind energy
Legend
recommended limited suitability less suitable
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OPERATING MANUAL
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2.8 RESIDUAL RISKS
Residual risks are risks which cannot be ruled out 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 Speci c measures Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Handling of
lacquers and
cleaning agents
Skin irritation,
allergies
Use personal safety
equipment.
Operation,
Observe safety data
sheets
maintenance,
disassembly
Lacquer in air
outside the de ned
working area
Lacquering outside
the de ned
working area
Inhalation of
substances
hazardous to
health
Observe work and
operation instructions.
Use personal safety
equipment
Operation,
maintenance
2.7 REASONABLY FORESEEABLE MISUSE
The forms of misuse listed below may result in physical injury or property damage:
coating work pieces which are not grounded;
performing unauthorized conversions or modi cations to the device;
processing dry or similar coating products, e.g., powder;
using defective components, spare parts or accessories other than those described in
the "Accessories" chapter of this operating manual;
continuing work with a defective or kinked product hose;
working with incorrectly set values;
processing food.
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OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
3.1 CE EXPLOSION PROTECTION IDENTIFICATION
3.2 IDENTIFICATION X
As de ned in Directive 94/9/EC (ATEX 95), the device is suitable for use in potentially explosive
areas.
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 Constructional security
IIB Device class (Gas) IIB
T3 Temperature class T3: maximum surface temperature 200 °C; 392 °F
T4 Temperature class T4: maximum surface temperature 135 °C; 275 °F
Gb Device protection level
, suitable for use in Zone 1
X Special instructions exist for safe operation. See the following Chapter
"Identi cation X".
3 IDENTIFICATION
Maximum surface temperature
The maximum surface temperature T3 of the piston pump can be reached if it runs dry.
Ensure that the piston pump is lled with su cient working or ushing agent.
Ensure that the separating agent tank is lled with su cient separating agent.
Temperature class T3: No dry running protection.
Temperature class T4: With dry running protection.
Ignition temperature
Ensure that the ignition temperature of the surrounding gases (pumping product,
cleaning agents) is higher than the maximum permitted surface temperature of the
device.
Ambient temperature
The permissible ambient temperature is:
- without heater: +5 °C to +50 °C; +41 °F to +122 °F
- with heater: +5 °C to +40 °C; +41 °F to +104 °F
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OPERATING MANUAL
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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.
Use only tools that are made of a permitted material.
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.
National regulations
Ensure that the national explosion prevention rules and regulations are observed when
setting up the device.
Air in the pump uid
Flammable gas mixtures can form if air reaches the pump uid.
Prevent the pump from taking in air and running dry.
If air has been taken in, x the leak. Then, ll slowly and in a controlled manner until the
air has escaped.
Air in the pumped uid can be caused by damaged packings.
Avoid operating the pump with damaged packing.
Ensure that the separating agent tank is lled with su cient separating agent.
Periodically check that the pump is working smoothly, paying special attention to the
presence of air in the pumped uid.
Filling and emptying
Flammable gas mixtures can form in the uid section or product hoses if the pump must
be emptied for maintenance.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Electrical lines (where present)
Mains connection: Only in the explosive area if the plug and socket are ex models.
Lay all electrical cables with protection from mechanical damage, e.g., not near doors,
routes used by industrial trucks etc.
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PROTEC 2K
cm³
MPa
cm³
cm³
75 : 1
188
4 : 1
48
150
38
70 : 1
200
3 : 1
45
150
50
64 : 1
225
2 : 1
41
150
75
77 : 1
185
1.5 : 1
49
110
75
65 : 1
220
1 : 1
41.5
110
110
Pressure ratio:
Druckübersetzung:
Materialmenge / DH:
Flow rate / DS:
Mixing Ratio Vol.:
Mischverhältnis Vol.:
Fluid section A:
Farbstufe A:
Material pressure max.:
Materialdruck max.:
Data depending on mounted fluid sections
PROTEC 2K
Daten abhängig von montierten Farbstufen
Fluid section B:
Farbstufe B:
B_05686
CH 9450 AltstättenMade in Switzerland
Type / Typ:
J. Wagner AG
Anschluss pneumatisch:
Pneumatic connection:
Materialtemperatur:
Material temperature:
Check manual before use!
Vor Gebrauch Betriebsanleitung beachten!
1" 0.6 - 0.65 MPa
5 - 80 °C
5 - 50 °C (40° C)
PROTEC 2K
Umgebungstemperatur:
Ambient temperature:
Year of manufacture / Baujahr:
Serial No unit.:
Serie Nr. Anlage:
II 2 G c IIB T3/T4 Gb X
B_05442
1
2
4
5
6
7
8
9
3
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
1 Manufacturer
2 CE identi cation
3 System type
4 Serial number of system
5 Year of manufacture
6 Pneumatic connection (thread and air inlet
pressure)
7 Product temperature
8 Ambient temperature
9 Read operating manual before use!
3.3 TYPE PLATE
The type plate consists of two parts.
10
12
13
14
15
16
17
11
* With several uid section combinations A–B:
- The uid sections A and B are identi ed with labels: 38 cc / 50 cc / 75 cc / 110 cc / 150 cc
- Establish the uid section combination currently installed from the labels.
- Read data on additional plate from the corresponding column.
10 Data on the additional plate depend on the mounted
uid sections
11 Fields to identify the uid section combinations used *
12 Fluid section A: Flow rate per double stroke
13 Fluid section B: Flow rate per double stroke
14 Pump ratio
15 Flow rate per double stroke A / B
16 Mixing ratio, volumetric
17 Maximum product pressure
Additional plate:
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OPERATING MANUAL
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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 in uences.
May only be maintained by skilled electricians or under their supervision. With open
housings, there is a danger from line voltage.
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 or are damaged.
Must be de-energized before work is commenced on active parts. Inform sta 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 PERSONNEL QUALIFICATIONS
Ensure that the device is only operated, maintained and repaired by trained persons.
4.1.3 SAFE WORK ENVIRONMENT
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 megohms).
Paint mist extraction systems/ventilation systems must be tted on site according to
local regulations.
Ensure that product / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment is available and is used (breathing and skin
protection).
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
100megohms.
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Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.
In electrostatics application: Anyone tted with a pacemaker must not enter the high-voltage
area!
4.2 SAFETY INSTRUCTIONS FOR STAFF
Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun handle or the trigger guard.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 megohms.
Ensure that there are no ignition sources such as naked ames, 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.
Grounding
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).
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or ushing 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:
- Relieve pressure from spray guns and devices.
- Secure spray guns against actuation.
- Switch o 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.
4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
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4.2.3 PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products and the
ushing agents used.
Ensure that the product hose is 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
4.2.2 GROUNDING THE DEVICE
Friction, owing liquids and air or electrostatic coating processes create charges. Flames or
sparks can form during discharge. Grounding prevents electrostatic charging.
Ensure that the device is grounded. See Chapter "Grounding".
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 guard.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.
If needed, the liquid ejection devices must be checked by experts (e.g., WAGNER service
technician) at least every 12 months to ensure they are safe for work in accordance with
the DGUV regulation 100-500.
- 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" 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 ushing agents:
Note the paint or ushing agent that you have been using.
Consult a doctor immediately.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun brie y in a position.
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4.2.4 CLEANING AND FLUSHING
Relieve the pressure from the device.
De-energize the device electrically.
Preference should be given to non- ammable cleaning and ushing agents.
When carrying out cleaning work with ammable 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 speci cations of the lacquer manufacturer.
Ensure that the ash 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.
Take measures for workplace safety (see Chapter 4.1.3).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- depending on the ushing agent (solvent) used,
explosive mixture inside the lines and items of equipment.
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.
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 megohm.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coe cient. In some cases their volume can rise with
consequent damage to pipes, ttings, etc. and cause uid 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 ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
Page 20
20
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
4.2.6 TOUCHING HOT SURFACES
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 unit with a warning label that says "Warning - Hot Surface".
- Instruction label Order No. 9998910
- Protection label Order No. 9998911
Note: Order the two stickers together.
Only electrically conductive tanks may be used for cleaning and ushing 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 ushing.
External cleaning
When cleaning the exterior of the device or its parts, also observe the following:
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.
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
When preparing or working with lacquer and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents and cleaning agents
being used.
Take the speci ed protective measures. In particular, use personal protective equipment:
safety goggles, protective clothing and gloves, as well as respiratory protection and
skin protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For su cient 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.
Page 21
21
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Page 22
22
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5 DESCRIPTION
5.1 COMPONENTS
Component A is mounted on the left side, component B on the right side (from the
perspective of the operator).
1 2K air pressure regulator
2 2K air ball valve
3 Blue handle: Circulation on/o
- Circulation on: upper position (product ows directly back into product tank)
- Circulation o : bottom position (as in illustration)
4 Circulation valve with excess pressure protection (component A)
5 Circulation valve with excess pressure protection (component B)
6 Circulation hose A
7 Circulation hose B
8 Product tank A
9 Product tank B
10 PROTEC 2K air motor
11 Air motor– uid section connection part (movement mechanism) with protection plates
12 Red handle: Spray on/o
- Spray o : Upper position (as in illustration)
- Spray on: Upper position (product ows to mixer and gun)
13 Product pressure gauge A
14 Product pressure gauge B
15 High-pressure lter A
17 Ball valve A (at the high-pressure lter A)
18 Ball valve B
20 Air inlet (1" inside thread)
21 Main air (ball valve)
22 Compressed air lter / water separator
22a Blow-o valve separator
23 Mixing block
24 Mixing tube
25 Connection for spray gun hose
S Flushing pump (option)
30 Ball valve, ushing
31 Air pressure regulator of ushing pump
32 Air ball valve of ushing pump
33 Relief Combination of ushing pump
41 Heater A (option)
42 Heater B (option)
50 External mixer (option)
Page 23
23
PROTEC 2K
50
B_05176
10
11
6
8
17
5
9
15
2
1
3
4
7
13
14
31
32
33
12
20
25
23
30
18
22
24
21
22a
S
B_05499
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Page 24
24
PROTEC 2K
B_05696
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5.2 MODE OF OPERATION
The system is suitable for mixing of two-component products.
Components A and B
A 2K pump consisting of an air motor and two uid sections, feeds the two components A
and B in a xed mixing ratio. Subsequently, each component ows to the mixer. Then the
mixed product ows via the spray gun hose to the spray gun.
Flushing pump
With the help of a ushing pump, mixing block, mixing tube, spray gun hose and spray gun
can be ushed.
Operation
The most important functions of the system are controlled with two handles:
- Blue handle: Circulation on/o
- Red handle: Spray on/o
5.3 PROTECTIVE AND MONITORING EQUIPMENT
Protection plates for movement mechanism
Three protection plates of the air motor– uid section connection part (11) ensure
protection against contact. The protection plates may only be removed for maintenance
and repairs.
Safety valve of air motor
The 2K air motor is tted with a safety valve. The safety valve has been set and sealed
at the factory. If the permissible operating pressure is exceeded, the valve, which is held
with a spring, automatically opens and releases the excess pressure. Here, the permissible
operating pressure is maintained.
Overpressure!
Risk of injury from bursting components.
Never change the safety valve setting.
WARNING
Missing cover!
Risk of crushing by moving device components.
Never operate device without protection plates.
WARNING
Page 25
25
PROTEC 2K
B_05688
B_05697
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Brackets for circulation and return hoses
The brackets prevent pressurized hoses from ying around.
Always secure circulation and return hoses with the locking pin.
Overpressure!
Risk of injury from bursting components.
For several minutes a day, circulate product or ushing agent via
the circulation valves with overpressure protection.
WARNING
Burst disk
A burst disk (22) is installed with the following B uid sections:
- 38 cm (pump ratio 4:1)
- 50 cm (pump ratio 3:1)
- 75 cm (pump ratio 2:1 or 1.5:1)
The burst disk is opposite the product outlet. Upon failure of the overpressure protection
the burst disk derives the pressure. The burst disk reacts at 76 MPa; 760 bar; 11000 psi.
After a response, the burst disk must be replaced.
The 38 cm, 50 cm and 75 cm uid sections must not be operated without a burst disk.
Overpressure protection for circulation valves
Both circulation valves A (4) and B (5) for the internal return line are tted with an
overpressure protection set to 63 MPa; 630 bar; 9140 psi.
To prevent the overpressure protection from sticking, circulation must be regularly
undertaken with the blue handle (3).
Page 26
26
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5.4 SCOPE OF DELIVERY
2K system comprising:
- 2 uid sections
- Air motor
- Air pressure regulator for air motor
- Movement mechanism
- Sliding tables
- Mixing unit
- Optional: ushing pump
- Optional: heater A and/or heater B
The scope of delivery also includes:
Separating agent 250 ml; 250 cc Order no.: 9992504
Declaration of conformity see Chapter 14.3
Operating manual German Order no.: 2352823
Operating manual in the local language see Chapter 1.3
The delivery note shows the exact scope of delivery. Accessories: see Chapter 12.
Page 27
27
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5.5.2 RECOMMENDED PACKINGS
5.5 DATA
5.5.1 MATERIALS OF PAINTWETTED PARTS
Housing Stainless steel and zinc-plated steel
Piston Stainless steel and hard chrome
Valve balls Stainless steel
Valve seats Carbide
Valve seats (red handle) Grey cast iron, GG25
Valve balls (red handle) SiC coated steel (SiC = silicon carbide)
O-rings PTFE
Packings (4:1, 3:1, 2:1, 1.5:1) Fluid section A:
Fluid section B:
Packings (1:1) Fluid section A: Fluid section B:
= Ultra high molecular weight polyethylene
= PTFE with graphite
= PTFE
Product hoses A / B PA and FEP
Option: Only FEP (see Chapter 13.2.3)
PA = Polyamide
FEP = Fluorinated ethylene propylene
WAGNER packings are manufactured in four di erent materials:
Product Color
Leather dark brown
PTFE with graphite black
Ultra high molecular weight polyethylene transparent
PTFE white
Each product has the following properties, which in uence the packings:
Mechanical stability poor good good poor
Friction coe cient poor very good good very good
Sealing force good* good good good
Chemical resistance poor good very good very good
Temperature resistance good poor - good very good poor
for abrasive products
Standard combinations
Standard pumps:
Heavy duty (high-pressure) pumps:
Hardener pumps in 2K systems:
Page 28
28
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Description Units PROTEC 2K
Product inlet 27 liter tank
Mixing product outlet NPS External thread NPSM, 3/8"
Product pH value pH 3.5–9
Maximum product viscosity mPa s 5000
Product temperature °C; °F +5 … +80; +41 … +176
Ambient temperature
Construction
and assembly
(without heater)
°C; °F +5 … +50; +41 … +122
Construction
and assembly
(with heater)
°C; °F +5 … +40; +41 … +104
Suspension °C; °F -20…+60; -4…+140
Relative humidity % 10–95 (without condensation)
Allowable inclination for operation
± 10
5.5.3.1 TECHNICAL DATA FOR ENTIRE SYSTEM
5.5.3 TECHNICAL DATA
Exhaust air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water.
WARNING
Pneumatic connection
Ø air inlet connection (inside thread) inch G1"
Minimum Ø of the compressed air supply line mm; inch G1"
Minimum/maximum air inlet pressure
MPa 0.25–0.65
bar 2.5–6.5
psi 36–94
Compressed air quality: free from oil and water
Quality standard 7.5.4 according to ISO 8573.1, 2010
7: Particle concentration 5–10mg/m
5: Humidity: pressure dew point ≤ +7 °C
4: Oil content ≤ 5mg/m
Page 29
29
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5.5.3.2 TECHNICAL DATA FOR PROTEC 2K PISTON PUMP
Description Units
PROTEC
2K75-
150/38
PROTEC
2K70-
150/50
PROTEC
2K64-
150/75
PROTEC
2K77-
110/75
PROTEC
2K65-
110/110
Mixing ratio 4 : 1 3 : 1 2 : 1 1.5 : 1 1 : 1
Pump ratio 75 : 1 70 : 1 64 : 1 77 : 1 65 : 1
MPa 48 45 41 49 41.5
Maximum operating overpressure bar 480 450 410 490 415
psi 7000 6500 5900 7100 6000
Fluid section A: Volume ow per DH cm; cc 150 150 150 110 110
Fluid section B: Volume ow per DH cm; cc 38 50 75 75 110
Fluid sections A+B:
cm; cc 188 200 225 185 220
Volume ow per double stroke (DH)
Volume ow pro 30 DH
Liters 5.64 6 6.75 5.55 6.6
US gallons 1.49 1.585 1.783 1.466 1.744
Maximum possible strokes in
operation
DH/min. 30
Maximum recommended strokes
per minute in continuous operation
DH/min. 20
Fluid section A:
G 1½"
Product inlet (outside thread)
Fluid section B:
M36x2 G 1½"
Product inlet (outside thread)
Fluid sections A+B:
M24x1.5
Product outlet (outside thread)
Maximum product pressure at pump
inlet
MPa 2
bar 20
psi 290
Minimum / maximum air inlet
pressure at the air motor
(e.g., 0.5 bar for circulation)
MPa 0.05–0.63
bar 0.5–6.3
psi 7.25– 91.37
Air consumption at 0.6 MPa; 6 bar;
87 psi
per double stroke
NL 90
scf 3.2
Air motor piston diameter mm; inch 250; 9.84
Air motor piston stroke mm; inch 150; 6
Sound pressure level at maximum
permissible air pressure*
dB(A) 81
Sound pressure level at 0.4 MPa;
4bar; 58psi air pressure*
dB(A) 75
Weight of 2K piston pump kg; lb 190; 419
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).
Note: A daily noise exposure level L
EX,8h
as of 80 dB(A) requires sta to be informed and ear defenders to be
provided.
Page 30
30
PROTEC 2K
B
B_05632
C
A
E
D
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5.5.4 DIMENSIONS AND WEIGHTS
832 mm
32.76 inch
1201 mm
47.28 inch
1710 mm
67.32 inch
235 mm
9.25 inch
187.5 mm
7.38 inch
Transport box
Internal dimensions mm 1220 x 850 x 1760
inch 48.03 x 33.46 x 69.29
Weight of complete system
Without ushing pump (approx) 220 kg
485 lb
With ushing pump (approx) 250 kg
551 lb
Maximum con guration with
ushing pump + 2 heaters (approx)
300 kg
661 lb
Page 31
31
PROTEC 2K
8 bar
6 bar
4 bar
8 bar
6 bar
4 bar
B_05478
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5.5.5 VOLUME FLOW
WAGNER AL nozzles Volume ow* in l/min
Spray angle
at at at at
Maximum ranges for
continuous operation
at 20DS/min
7 MPa 10 MPa 15 MPa 20 MPa
70 bar 100 bar 150 bar 200 bar
inch mm 1015 psi 1450 psi 2175 psi 2900 psi
0.007 0.18 40° 0.17 0.20 0.21 0.22
0.009 0.23 20-30-40-50-60° 0.21 0.25 0.31 0.36
0.011 0.28 10-20-30-40-50-60° 0.30 0.35 0.43 0.50
0.013 0.33 10-20-30-40-50-60-80° 0.45 0.53 0.62 0.68
0.015 0.38 10-20-30-40-50-60-80° 0.58 0.67 0.81 0.91
0.017 0.43 20-30-40-50-60-70° 0.73 0.79 1.06 1.23
0.019 0.48 20-30-40-50-60-70-80° 0.93 1.09 1.37 1.47
0.021 0.53 20-40-50-60-80° 1.14 1.36 1.69 1.78
0.023 0.58 20-40-50-60-70-80° 1.37 1.59 2.01 2.24
0.025 0.64 20-40-50-60-80° 1.62 1.91 2.40 2.60
0.027 0.69 20-40-50-60-80° 1.83 2.13 2.68 3.12
0.029 0.75 60° 2.19 2.51 3.17 3.63 1.5 : 1 – 2K77-110/75
4 : 1 – 2K75-150/38
0.031 0.79 20-40-50-60° 2.40 2.77 3.49 4.00 3 : 1 – 2K70-150/50
2 : 1 – 2K64-150/75
1 : 1 – 2K65-110/110
0.035 0.90 20-40-50-60° 3.22 3.74 4.69 5.14
0.043 1.10 20-50° 5.07 6.04 7.46 7.84
0.052 1.30 50° 5.12 6.10 7.52 8.06
Volume ow refers to water.
5.5.6 PERFORMANCE DIAGRAMS
Stroke frequency DH/min
Product pressure bar (MPa) <psi>
Air consumption nl/min <scfm>
Example
Water ow rate l/min <gpm>
Page 32
32
PROTEC 2K
0
500 (50)
<7250>
400 (40)
<5800>
300 (30)
<4350>
200 (20)
<2900>
100 (10)
<1450>
0
10 20 30 40 50 60
5000
<175>
4000
<140>
3000
<105>
2000
<70>
1000
<35>
0
12
<3.2>
10
<2.6>
8
<2.1>
6
<1.6>
4
<1.1>
2
<0.5>
0
A
B
C
bar (MPa)
<psi>
nl/min
<scfm>
l/min
<gpm>
A
B
C
B_05628
11.28
<2.98>
9.4
<2.48>
7.52
<1.99>
5.64
<1.49>
3.76
<0.99>
1.88
<0.50>
0
l/min
<gpm>
0
500 (50)
<7250>
400 (40)
<5800>
300 (30)
<4350>
200 (20)
<2900>
100 (10)
<1450>
0
10 20 30 40 50 60
5000
<175>
4000
<140>
3000
<105>
2000
<70>
1000
<35>
0
A
B
C
bar (MPa)
<psi>
nl/min
<scfm>
A
B
C
B_05466
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
PROTEC 2K75-150/38 PROTEC 2K77-110/75
4 : 1 1.5 : 1
Stroke frequency DH/min
Product pressure
Air consumption
Water ow rate
Air pressure: A = 6.5 bar; 0.65 MPa; 94 psi
B = 4 bar; 0.4 MPa; 58 psi
C = 2 bar; 0.2 MPa; 29 psi
PROTEC 2K70-150/50
3 : 1
Stroke frequency DH/min
Product pressure
Air consumption
Water ow rate
Air pressure: A = 6.5 bar; 0.65 MPa; 94 psi
B = 4 bar; 0.4 MPa; 58 psi
C = 2 bar; 0.2 MPa; 29 psi
Page 33
33
PROTEC 2K
0
500 (50)
<7250>
400 (40)
<5800>
300 (30)
<4350>
200 (20)
<2900>
100 (10)
<1450>
0
10 20 30 40 50 60
5000
<175>
4000
<140>
3000
<105>
2000
<70>
1000
<35>
0
13.5
<3.57>
11.25
<2.97>
9
<2.38>
6.75
<1.78>
4.5
<1.19>
2.25
<0.59>
0
A
B
C
bar (MPa)
<psi>
nl/min
<scfm>
l/min
<gpm>
A
B
C
B_05629
0
500 (50)
<7250>
400 (40)
<5800>
300 (30)
<4350>
200 (20)
<2900>
100 (10)
<1450>
0
10 20 30 40 50 60
5000
<175>
4000
<140>
3000
<105>
2000
<70>
1000
<35>
0
13.2
<3.49>
11.0
<2.91>
8.8
<2.32>
6.6
<1.74>
4.4
<1.16>
2.2
<0.58>
0
A
B
C
bar (MPa)
<psi>
nl/min
<scfm>
l/min
<gpm>
A
B
C
B_05630
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
PROTEC 2K64-150/75
2 : 1
PROTEC 2K65-110/110
1 : 1
Stroke frequency DH/min
Product pressure
Air consumption
Water ow rate
Air pressure: A = 6.5 bar; 0.65 MPa; 94 psi
B = 4 bar; 0.4 MPa; 58 psi
C = 2 bar; 0.2 MPa; 29 psi
Stroke frequency DH/min
Product pressure
Air consumption
Water ow rate
Air pressure: A = 6.5 bar; 0.65 MPa; 94 psi
B = 4 bar; 0.4 MPa; 58 psi
C = 2 bar; 0.2 MPa; 29 psi
Page 34
34
PROTEC 2K
13
17
4
6
8
15
14
18
5
33
31
1
2
3
7
9
24
29
B_05183
12
30
32
A
B
S
35
26
27
28
28
28
41a
42a
43
44
41b
42b
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
A Fluid section A
B Fluid section B
1 2K air pressure regulator
2 2K air ball valve
3 Blue handle: Circulation on/o
4 Circulation valve A with excess pressure
protection
5 Circulation valve B with excess pressure
protection
6 Circulation hose A
7 Circulation hose B
8 Product tank A
9 Product tank B
12 Red handle: Spray on/o
13 Product pressure gauge A
14 Product pressure gauge B
15 High-pressure lter A
17 Ball valve A (at the high-pressure lter A)
18 Ball valve B (2K relief combination)
24 Static mixer
26 Spray valve A
27 Spray valve B
28 Non-return valve
29 Spray gun
5.6 FLOW DIAGRAM
Optional:
S Flushing pump
30 Ball valve, ushing
31 Air pressure regulator of ushing pump
32 Air ball valve of ushing pump
33 Relief Combination of ushing pump
35 Flushing agent product tank
41a Heater A/return line
41b Heater A (without return line)
42a Heater B/return line
42b Heater B (without return line)
43 Return line A (via high-pressure lter)
44 Return line B (via 2K relief combination)
Page 35
35
PROTEC 2K
13
17
4
6
8
15
14
18
5
33
31
1
2
3
7
9
24
29
B_05689
12
30
32
A
B
S
35
26
27
28
28
28
50
61
62
63
54
52
51
66
65
53
546460
41a
42a
43
44
41b
42b
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5.6.1 FLOW CHART WITH EXTERNAL MIXER AND EXTERNAL CIRCULATION
50 External mixer (option)
12 Red handle: Spray on/o
24 Static mixer
26 Spray valve A
27 Spray valve B
28 Non-return valve
30 Ball valve, ushing (option)
51 Product hose A to external mixer
52 Product hose B to external mixer
53 Flushing hose to external mixer (option)
54 Throttle valve (option for external mixer)
60 + 64 External circulation
(option for external mixer)
61 "External circulation" handle (on trolley)
62 Circulation valve external A
63 Circulation valve external B
64 Distributor (on external mixer) for connecting
the circulation hoses
65 Circulation hose A
66 Circulation hose B
Page 36
36
PROTEC 2K
1
2
3
B_03907
B_05295
3
1
2
4
B_05636
2
3
1
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5.7 PRESSURE REGULATOR UNIT
5.8.1 HIGHPRESSURE FILTER 530 BAR
A WAGNER high-pressure lter is installed to ensure smooth
operation. These have been developed especially for WAGNER
pneumatic pumps. The lter inserts can be exchanged depending
on the product to be used. Appropriate lter inserts can be found
in the "Spare Parts" chapter.
1 Fluid section A connection
2 Product outlet
3 Return line
Closed
Open
1 Pressure regulator
2 Ball valve
3 Pressure gauge
4 Compressed air Inlet
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
53MPa
530bar
7687psi
5.8 PRESSURE RELIEF
For carrying out a complete depressurization of the pump (see Chapter 7.5), are installed:
- for component A: high-pressure lter with return line
- for component B: 2K PC relief combination
Page 37
37
PROTEC 2K
B_03913
1
3
2
B_03703
4
B_05635
2
3
1
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5.9 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 anks 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.
Pos Order No. Designation
1 9998675 Threaded plug
2 9999066 Male stud elbow
3 9982072 Air hose (per meter)
4 9943049 Pneumatic pre-selection counter
The component B is tted with a 2K PC relief
combination.
1 Fluid section B connection
2 Product outlet
3 Return line
5.8.2 2K PC RELIEF COMBINATION, 530 BAR
53MPa
530bar
7687psi
Closed
Open
Page 38
38
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Page 39
39
PROTEC 2K
24
B_05852
12
30
26
27
28
28
28
54
A
B
S
A+B
B_05853
24
12
30
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5.10 EXTERNAL MIXER AND EXTERNAL CIRCULATION
5.10.1 EXTERNAL MIXER OPTION
The red handle (12) with mixing block and mixing tube is on an external frame rather than
being on the trolley. The same applies to ball valve, ushing (30, option).
Operation
Operation remains unchanged. The only di erence is the handle positions. Rather than
turning the red handle (12) on the external mixer vertically up and down on the trolley, it is
moved horizontally towards the hose set or towards the mixing tube.
Red handle (12)
Handle position Description in instructions
-
Spray o : Towards hose set "Handle (12) up"
-
Spray on: Towards mixing tube "Handle (12) down"
External mixer
12 Red handle: Spray on/o
24 Static mixer
26 Spray valve A
27 Spray valve B
28 Non-return valve
30 Ball valve, ushing (option)
54 Throttle valve (option)
A Product hose A
B Product hose B
S Flushing hose (option)
Throttle valve (54, option)
If short-term mixing mistakes occur when using an external mixer, this can be corrected
with a throttle valve (see Chapter 5.10.3).
Spraying
On
(="bottom")
O
(="top")
Flushing
On
O
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OPERATING MANUAL
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5.10.2 HOSE SELECTION
Hose selection with external mixer
The volume ratio of product hoses A and B should match the mixing ratio. If this is not the
case, the hoses will respond to changes in pressure at di erent speeds. One hose will reach
the new pressure sooner than the other. This causes short-term errors in the mixing ratio.
Di erent levels of hose viscosity and exibility also cause short-term errors in the mixing
ratio. The longer the hoses the greater the e ect.
Suitable hose combinations for di erent mixing ratios
Hose A Hose B Volume ratio * Mixing ratio
Inside - Connection Inside - Connection Hose A : hose B A : B
DN13 1/2" DN6 1/4" 4 : 1
4 : 1
3 : 1
DN10 3/8" DN6 1/4" 2.25 : 1
3 : 1
2 : 1
DN13 1/2" DN10 3/8" 1.78 : 1
2 : 1
1.5 : 1
DN10 3/8" DN10 3/8" 1 : 1
1.5 : 1
1 : 1
* with e ective inner diameters of 6.4 mm (DN6), 9.6 mm (DN10), and 12.8 mm (DN13)
Select large hose diameters for viscous products.
Detecting short-term mixing errors
Should the pressure change, product pressure gauges A and B should respond as
synchronously as possible. Short-term errors in the mixing ratio occur at the following points:
At the reversal points of the air motor, pressure gauge B indicates a bigger drop in
pressure than pressure gauge A.
When opening the gun, pressure gauge B responds much later than pressure gauge A.
Rectifying short-term mixing errors
Use a di erent hose combination (see Table).
Too great a drop in pressure on the B side can be corrected with a throttle valve
(see Chapter 5.10.3).
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41
PROTEC 2K
B_05691
54
54a
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5.10.3 THROTTLE VALVE (OPTION)
Short-term mixing errors caused by too great a drop in pressure on the B side can be corrected
with a throttle valve. Guideline for using a throttle valve:
- over-dimensioned B product hoses (see Chapter 5.10.2)
- viscous B product
- long hoses
- high ow (nozzle)
Procedure
1. Fit throttle valve (54) on external mixer (B side).
Throttle valve set: For Order No., see Accesories chapter.
2. Rough adjustment:
While spraying, screw in adjustment screw (54a) only until product pressure gauge B
indicates a slight increase in pressure.
3. Fine adjustment:
At the reversal points of the air motor, check that product pressure gauges A and B are
each indicating roughly the same drop in pressure. If necessary, readjust the adjusting
screw (54a). Only screw in as far as necessary.
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42
PROTEC 2K
B_05854
64
61 12
30
54
A
B
S
A+B
5460 5067
24
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
With external circulation, the product can be circulated via the external mixer (50) and
returned to the product tank.
The external circulation consists of two parts:
- Two distributors (64) in the external mixer for connecting circulation hoses A and B.
- Two circulation valves on the trolley. The "External circulation" handle (61) can be used
to open and close the circulation valves.
5.10.4 EXTERNAL CIRCULATION (OPTION)
50 External mixer (see Chapter 5.10.1)
54 Throttle valve (option, see Chapter 5.10.3)
External circulation
60 "External circulation" handle (61) with circulation
valves (fitted on trolley)
64 Distributor ( tted on external mixer)
67 Material and circulation hoses between trolley and
external mixer
Page 43
43
PROTEC 2K
B_05690
24
12
30
3
61
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
3 Blue handle: "Internal circulation"
- Circulation on: upper position (product ows directly back into product tank)
- Circulation o : bottom position (as in illustration)
12 Red handle: Spray on/o
Handle position Description in instructions
- Spray o : Towards hose set "Handle (12) up"
- Spray on: Towards mixing tube "Handle (12) down"
24 Mixing tube
30 Ball valve, ushing
61 "External circulation" handle
- Circulation on: Bottom position (product ows back into product tank via external
mixer)
- Circulation o : Top position (as in illustration)
Spraying
On
(="bottom")
O
(="top")
Flushing
On
O
Operation
The blue handle (3) remains unchanged. The product can therefore be circulated internally
on the trolley.
The handle positions should be noted for the red handle (12) in the external mixer
(see Chapter 5.10.1).
The "External circulation" handle (61) on the trolley is new. It controls external circulation.
Page 44
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PROTEC 2K
B_05174
!
B_05173
!
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
5.11 FEED PUMP OPTION
A feed pump can be used with high-viscosity products or longer feed lines.
Dimensioning of the feed pump
The piston pumps pump the working material to the product output with up and down
strokes but only draw in new product on the up stroke. The feed pump therefore has to
pump twice the volumetric ow.
Protection of feed pump
If the maximum pressure of the feed pump is lower than the maximum pressure of
the main pump, this could be exceeded if the main pump malfunctions. The feed
pump and connection line must therefore be protected from excessive overpressure.
An overpressure valve must then be installed between the feed pump and main pump.
Observe the ow direction during installation.
The maximum product pressure at
the pump inlet of the PROTEC 2K
uid sections may not be exceeded.
Feed pump
Main pump
Feed pump
Main pump
Pressure relief valve
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PROTEC 2K
B_05168
B_05169
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
6.3 TRANSPORTATION
6 ASSEMBLY AND COMMISSIONING
6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF
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 speci cations
of temperatures and relative humidity, see, technical data (Chapter 5.5.3).
Long-term storage: Thoroughly clean the pump, if a long-term decommissioning is
planned. See Chapter "Cleaning". For recommissioning, proceed according to following
chapters.
A skilled person must check to ensure that the device is in a reliable state after it is installed
and before commissioning.
The assembly and commissioning sta 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.
Weight:
see Chapter 5.5.4
When lifting the system, always make sure that it remains
in balance.
Only lift at transport bracket.
(Lifting eye nut at the air motor = option)
Transport box: see Chapter 5.5.4
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OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
6.4 ASSEMBLY AND INSTALLATION
Inclined ground!
Risk of accidents if the device rolls away/falls.
Place the device on horizontal oor.
The wheels should be xed or replaced by levelling feet and secured.
Do not tilt the device during shifting / transporting.
WARNING
Check whether the line pressure is su cient (see technical data, Chapter 5.5.3).
Overpressure!
Risk of injury from bursting components.
The operating pressure must not exceed the value shown on
the type plate.
WARNING
Check whether e cient lter systems and condensate precipitators are available in the
air line.
The compressed air must be free of oil and water. Quality standard: see technical data
(Chapter 5.5.3).
Every day, discharge all impurities and the condensate (if any) accumulated in the
system's air lter.
6.4.1 PNEUMATIC CONNECTIONS
6.4.2 PRODUCT CONNECTIONS
Connect high-pressure hose and gun to outlet of mixing tube (25) as laid down in the
operating manual for the gun.
6.4.3 VENTILATION OF THE SPRAY BOOTH
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.
Observe the safety instructions in Chapter 4.1.3.
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PROTEC 2K
B_05444
1
2
4
3
5
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
6.5 GROUNDING
Discharge of electrostatically charged components in atmospheres
containing solvents!
Explosion hazard from electrostatic sparks.
Clean the piston pump only with a damp cloth.
Ground all device components.
Ground the work pieces to be coated.
WARNING
Heavy paint mist if grounding is insu cient!
Danger of poisoning.
Insu cient paint application quality.
Ground all device components.
Ground the work pieces to be coated.
WARNING
6.5.1 GROUNDING OF COMPONENTS ON TROLLEY
Grounding ound connection point
on frame.
Pos from - to Grounding cable
1 2K pump on frame 4 mm; AWG 12
2 Flushing pump on frame 4 mm; AWG 12
3 Heater A on frame 4 mm; AWG 12
4 Heater B on frame 4 mm; AWG 12
Potential equalization
5 Frame to signal ground 4 mm; AWG 12
Connect all ground cables using a short and direct route.
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48
PROTEC 2K
S
R max < 1 M:
B_05177
113
111
114
115
112
116
117
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Legend Grounding cables
Fluid hose, electrical lines
Flushing agent tank 114 Floor, static dissipative
111 Work piece 115 2K system, frame
112 Spraying stand 116 Electrical connection lines of heaters
113 Conveyor 117
Mains connection: Only in the explosive area if the plug
and socket are ex models.
Cable cross sections
2K system, frame 4 mm; AWG 12
Flushing agent tank 6 mm; AWG 10
Conveyor 16 mm; AWG 6
Spray booth 16 mm; AWG 6
Spraying stand 16 mm; AWG 6
Safe operation of the PROTEC 2K system is only guaranteed with a grounding connection.
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, ushing agents and waste tanks have to be electrically conductive.
All tanks must be grounded.
Ex zone
6.5.2 GROUNDING SCHEMA EXAMPLE
Non-Ex zone
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PROTEC 2K
B_03917
3
2
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Observe all safety regulations in accordance with
Chapter 4 and Chapter 7.2.
Observe all safety regulations in accordance with
Chapter 8.1.2 and Chapter 8.2.2.
EMERGENCY STOP
In the case of unforeseen occurrences, immediately
switch o the system in accordance with Chapter 7.3.3.
Open
Closed
Open
6.6 COMMISSIONING
6.6.1 SAFETY INSTRUCTIONS
Whenever starting up, the following points should be observed as laid down in the
operating manual:
1. Secure the gun.
2. Check the permissible pressures.
3. Check all connections for leaks.
4. Check hoses for damage in accordance with Chapter 8.2.7.
5. Filling with separating agent in accordance with Chapter 8.2.3.3.
Filling the system (replace preservation)
On initial lling with the working material, the existing product (oil, ushing agent) must
be completely removed from the system. This ensures that there are no hardenings.
Ensure that no explosive atmosphere is present when lling or emptying the system.
Filling the ushing pump
In accordance with ushing pump's operating manual.
Filling the uid sections A and B (replace preservation)
1. Paint change ushing according to Chapter 7.7.
2. Empty 2K pump according to Chapter 8.2.4.
3. Fill 2K pump with new paint according to Chapter 8.2.5.
6.6.2 PROCEDURE
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OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
7 OPERATION
7.2 SAFETY INSTRUCTIONS
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 sta must comply with
EN ISO 20344. The measured insulation resistance must not
exceed 100megohms.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 megohms.
WARNING
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 in accordance with Chapter 6.6.
7.1 TRAINING THE OPERATING STAFF
The operating sta must be quali ed to operate the entire system.
The operating sta 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 sta must receive appropriate system training.
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 o the energy/compressed air supply.
Disconnect the control unit from the network.
In the event of functional faults: remedy the fault as described in
the "Troubleshooting" chapter.
WARNING
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VERSION 02/2016 ORDER NUMBER DOC2352824
7.2.1 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN
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.
Use personal protective equipment (protective clothing, gloves,
eyewear and respiratory protection).
WARNING
Observe the operating manual of the spray gun.
Gas mixtures can explode if there is an incompletely filled pump!
Danger to life from ying parts.
Ensure that the pump and suction system are always completely
filled with ushing agent or working material.
Do not spray the device empty after cleaning.
WARNING
The red handle (12) must not be connected under pressure.
After spraying, the red handle (12) rst has to be relieved:
- Either via the gun:
- Close 2K air ball valve.
- Relieve gun.
- Or via the circulation:
- Close 2K air ball valve.
- Turn blue handle (3) up. The turn down again.
The red handle (12) may then be closed (turn up).
Take care if nozzle blocks
If a blocked nozzle prevents relief via the gun, relief via the circulation must be undertaken
rst (blue handle). The red handle can then be closed (turn up).
7.2.2 DO NOT CONNECT RED HANDLE UNDER PRESSURE
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In the case of unforeseen occurrences:
1. Close main air (21).
2. Unplug the power plug of the heaters (if present).
If possible remedy problem immediately and ush spray gun hoses so the 2K product
does not harden:
- Close 2K spraying air ball valve (2) and relieve 2K pump.
- With ushing pump: Close air ball valve of ushing pump (32) and relieve
ushing pump.
- Remedy problem.
- Open main air (21) again.
- Perform intermediate ushing.
7.3.3 EMERGENCY STOP
B_05432
B_05433
10 11
7 8 9
B_05434
Illustration
Illustration
Close main air. With heater: unplug the power plug. Relieve. Solve problem.
Intermediate ushing.
Not-Aus • Emergency Stop
A B
7.3 SWITCHING DEVICE ON AND OFF
Ensure that the wheel brake is applied.
Ensure that the 2K air ball valve (2) and air ball valve of the ushing pump (32) are closed.
1. Open main air (21).
2. Insert the power plug of the heaters (if present).
7.3.1 SWITCHING ON DEVICE
Ensure that intermediate ushing and pressure relief are undertaken. 2K air ball valve (2)
and air ball valve of ushing pump (32) are closed.
1. Close main air (21).
2. Unplug the power plug of the heaters (if present).
7.3.2 SWITCHING OFF DEVICE
Chapter 7.5
Chapter 7.6
C
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OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
7.4 SPRAYING MODE
B_05429
1
2
3
B_05430
1
2
3
1
2
3
Prepare ushing pump (option) and
ushing agent.
Fill product A+B. Close cover. Fix return lines.
Preparing
Prepare the object to be sprayed and the spray gun
1. Prepare the object to be sprayed and the entire work environment for spraying.
2. Secure the spray gun and place the nozzle in the gun.
Visual check
3. Visual check: personal safety equipment, grounding and all devices ready to use.
Wheel brake applied. Blue handle (3) at bottom. Red handle (12) at top. All circulation
and return hoses are secured and lead into the product tanks A or B.
Prepare ushing pump (if present)
A. Fill ushing pump with ushing agent in accordance with ushing pump's
operating manual.
B. Place the suction hose of the ushing pump into a grounded tank with ushing agent.
C. Adjust suitable ushing pressure at the air pressure regulator of the ushing
pump (31).
D. Open the air ball balve of the ushing pump (32).
Prepare heater (if present)
E. Insert the power plug of the heaters.
F. Set the desired temperature at the heaters.
(The position "3.5" results a product temperature of 50 °C; 122 °F at the output of
the heater.)
Prepare working material
If the device is being lled with a new paint or new hardener, paint change ushing
must be undertaken rst in accordance with Chapter 7.7.
4. If the device is not yet lled up to the circulation valves with working material, ll in
accordance with Chapter 8.2.5.
5. Fill the corresponding product tanks with working materials A and B.
6. Close cover.
7. Fix return lines.
7.4.1 PREPARING
1 2
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OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
B_05428
0.05 MPa
0.5 bar
7.3 psi
2K
1
2
B_05297
B_05445
A
+
A
B
1
2
1
2
Air pressure regulator approx. 0.5 bar. Ci rculate via blue handle. With heater A/return line:
circulate via ball valves A and B.
Circulate
7.4.2 CIRCULATING
3
Circulate working material
Internal circulation
Important: Prevents the overpressure protection from sticking.
8. Adjust 2K air pressure regulator (1) to approx. 0.05 MPa; 0.5 bar; 7.3 psi.
9. Turn blue handle (3) up.
10. Slowly open 2K air ball valve (2).
11.
Allow to circulate for several minutes depending upon the product.
12. Close 2K air ball valve (2).
13. Turn down blue handle (3) again.
With heater A/return line
A. Internal circulation (points 8 to 13).
B. Open ball valves A and B.
C. Slowly open 2K air ball valve (2).
Circulating until the desired product temperature is reached.
D. Close 2K air ball valve (2).
E. Close the ball valves A and B again.
4 b4
With external circulation (option for external heater)
A. Internal circulation (points 8 to 13).
B. Turn "External circulation" handle (61) down.
C. Slowly open 2K air ball valve (2).
Allow to circulate for several minutes depending upon the product.
D. Close 2K air ball valve (2).
E. Turn "External circulation" handle (61) up again.
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OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
B_05298
1
2
B_05425
!
!
!
PA = P
B
Blue handle (circulation) o . Monitor: Pot life, level, pressure A +
B the same.
Red handle (spray) on.
2K spraying
5
6
Fill spray gun hoses with 2K product
14. Start spraying mode: Turn down red handle (12).
15. Close 2K air pressure regulator (1) (0MPa; 0bar; 0psi).
16. Point the spray gun without nozzle toward the grounded collecting tray and pull o .
17. Slowly open 2K air ball valve (2).
18. Slowly turn the air pressure up on the 2K air pressure regulator (1) and only until the
pump is running normally (approx. 0–0.05MPa; 0–0.5 bar; 0–7.25 psi). Be ready to
switch from working material to air (or ushing agent) and prevent back spray.
19. As soon as clean working material ows, close and secure the spray gun.
20. Insert nozzle in gun and start work process.
Spraying
We recommend two people for spraying mode:
One person operates the spray gun.
A second person operates and monitors the system.
21. Set the required working pressure on the 2K air pressure regulator (1).
22. Unlock spray gun and spray until the spray jet is good. Set spraying pressure on 2K air
ball valve (2).
23. Optimize the spraying results as laid down in the gun instructions.
24. Start the work process. At all times:
Monitor the level of the product tank.
Monitor pot life.
Monitor the pressure gauges A and B and ensure that the product pressures A
and B always remain consistently high (see Chapter 7.4.3.1).
End spraying
25. Close and secure the spray gun.
Next steps:
- Intermediate ushing in accordance with Chapter 7.6, or
- circulate in accordance with Chapter 7.4.2. Note pot life!
7.4.3 2K SPRAYING
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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
7.4.3.1 PRESSURE DROP
If the pressure drops of the component A or B during spraying:
1. Intermediate ushing in accordance with Chapter 7.6.
2. Relieve the pressure according to Chapter 7.5.
3. Identify and correct the problem:
- Product shortage A or B,
- Pump valves are dirty,
- Leakage of the pump packings A or B,
- Leakage of the circulation valve.
7.4.3.2 NOLOAD / VENT
When no-lead (2K uid section sucks in air):
1. With ushing pump and very short pot life: Intermediate ushing in accordance with
Chapter 7.6.1.
Vent uid sections A/B
2. Fill 2K pump in accordance with Chapter 8.2.5.
Vent ushing pump
See ushing pump's operating manual.
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OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
7.5 PRESSURE RELIEF/WORK INTERRUPTION
1. Turn 2K air pressure regulator (1) down to 0 MPa; 0 bar; 0 psi.
2. Close 2K air ball valve (2).
3. If no longer in spraying mode: Turn down red handle (12).
4. Relieve pressure: Point the spray gun toward the grounded collecting tray and pull o .
Attention: If a blocked nozzle is preventing relief, rst carry out the additional steps 5 to 8,
then clean the nozzle.
5. Close and secure the spray gun.
6. End spraying mode: Turn red handle (12) up again.
7. Relieve circulation: Turn up blue handle (3). The turn down again.
8. With external circulation (option):
- Turn "External circulation" handle (61) down. Then turn up again.
9. For complete pressure relief, slowly open ball valves A and B (17 and 18) and close again.
In case of longer work interruptions:
- Relieve ushing pump (if present): Chapter 7.6.1.1
- Unplug the power plug of the heaters (if present)
Before expiry of the pot life:
- Either continue working (Chapter 7.5.1)
- or perform intermediate ushing (Chapter 7.6).
Hardened working material in the spraying system when 2K product is processed!
Destruction of pump and injection system.
Follow the manufacturer‘s processing rules, particularly regarding the pot life.
Perform intermediate ushing before end of pot life.
The pot life is decreased by warmth.
NOTICE
B_05435
0 bar
2K
2K
B_05436
12
34
1
2
1
2
B_05437
Close 2K air pressure regulator and
2K air ball valve.
Relieve gun and circulation.
Red handle o .
Relieve ball valves A and B.
2K Relieving
7 8 9
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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
7.5.1 CONTINUING AFTER WORK INTERRUPTION
1. Visual check: personal safety equipment, grounding and all devices ready to use.
Blue handle (3) at bottom. Red handle (12) at top. All circulation and return hoses are
secured and lead into the product tanks A or B.
2. Check levels A and B.
If ushing pump present:
A. Check level of ushing agent.
B. Adjust suitable ushing pressure at the air pressure regulator of the ushing pump (31).
C. Open the air ball balve of the ushing pump (32).
If heater is present:
E. Insert the power plug of the heaters.
3. After long work interruptions: Circulate working material in accordance with Chapter 7.4.2.
4. Start spraying mode: Turn down red handle (12).
5. Slowly open 2K air ball valve (2).
6. Release the spray gun and spray. Optimize the spray jet and spraying results.
7. Restart work process. At all times:
Monitor the level of the product tank.
Monitor pot life.
Monitor the pressure gauges A and B and ensure that the product pressures A
and B always remain consistently high (see Chapter 7.4.3.1).
End spraying
8. Close and secure the spray gun.
Next steps:
- Intermediate ushing in accordance with Chapter 7.6, or
- circulate in accordance with Chapter 7.4.2. Note pot life!
7.6 INTERMEDIATE FLUSHING
As soon as possible after work and before the pot life expires, the mixed product must be
removed from the system by means of intermediate ushing.
Hardened working material in the spraying system when 2K product is processed!
Destruction of pump and injection system.
Follow the manufacturer‘s processing rules, particularly regarding the pot life.
Perform intermediate ushing before end of pot life.
The pot life is decreased by warmth.
NOTICE
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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
7.6.1 INTERMEDIATE FLUSHING WITH FLUSHING PUMP
1. Visual check: personal safety equipment, grounding and all devices ready to use.
Blue handle (3) at bottom. Red handle (12) at top. All circulation and return hoses are
secured and lead into the product tanks A or B.
2. If necessary, top up ushing agent.
3. Point the spray gun toward the grounded collecting tray and pull o .
4. Open ushing ball valve (30).
5. Flush until clean ushing agent exits the gun.
6. Close ushing ball valve (30).
7. Close and secure the spray gun.
Next steps:
- Spraying (Chapter 7.4) or
- Paint change ushing (Chapter 7.7) or
- at the end of work:
1. Pressure relief (Chapter 7.5)
2. Relieve ushing pump (Chapter 7.6.1.1)
3. Switch o device (Chapter 7.3.2)
Flushing and circulation at the same time
If necessary, circulation can take place at the same time as intermediate ushing:
Adjust 2K air pressure regulator (1) to approx. 0.05 MPa; 0.5 bar; 7.3 psi.
Blue handle turned upward (circulation operating mode).
B_05299
B_05431
1
2
3
Red handle (spray) o . Flush gun without nozzle.
Flushing ball valve on. Secure the gun.
Intermediate ushing (with ushing pump)
10 11
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OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
7.6.1.1 RELIEVING FLUSHING PUMP
1. Close the spray gun.
2. Close air ball valve of ushing pump.
3. Open ushing ball valve (30).
4. Relieve pressure of the ushing pump by opening the gun.
5. Close and secure gun.
6. Close ushing ball valve (30) again.
7. Open and close return valve of relief combination to completely depressurize the system.
In case of longer work interruptions: unplug the power plug of the heaters (if present).
B_05438 B_05440
12
34
1
2
B_05441
Close air ball valve of ushing pump. Relieve ushing pump via spray gun. Relieve via relief combination.
Relieving Flushing Pump
12 13 14
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7.6.2 INTERMEDIATE FLUSHING WITHOUT FLUSHING PUMP
1. Visual check: personal safety equipment, grounding and all devices ready to use.
Blue handle (3) at bottom. Red handle (12) at top. All circulation and return hoses are
secured and lead into the product tanks A or B.
Empty 2K pump
2. Empty 2K pump according to Chapter 8.2.4.
Flush spray gun hoses
3. Fill product tanks A and B (8 and 9) with approx. 3 to 4 liters of ushing agent each.
4. Close 2K air pressure regulator (1) (0MPa; 0bar; 0psi).
5. Start spraying mode: Turn down red handle (12).
6. Point the spray gun without nozzle toward the grounded collecting tray and pull o .
7. Slowly open 2K air ball valve (2).
8. Slowly turn the air pressure up on the 2K air pressure regulator (1) and only until the
pump is running normally (approx. 0–0.05MPa; 0–0.5 bar; 0–7.25 psi). Be ready to
switch from working material to air and prevent back spray.
9. Allow ushing agent to run for several minutes so that the 2K product is ushed out
of the system.
Maximize ow so that the entire lter cartridge is ushed.
Finish ushing
10. Close 2K air ball valve (2).
11. Relieve, close, and secure the spray gun.
12. End spraying mode: Turn red handle (12) up again.
13. Depressurization in accordance with Chapter 7.5.
Next steps:
- Spraying (Chapter 7.4) or
- Paint change ushing (Chapter 7.7) or
- at the end of work:
1. Pressure relief (Chapter 7.5)
2. Switch o device (Chapter 7.3.2)
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7.7 PAINT OR HARDENER CHANGE
Gas mixtures can explode if there is an incompletely filled pump!
Danger to life from ying parts.
Ignition of potentially explosive surrounding atmosphere.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
WARNING
Before a paint or hardener change, the system must be thoroughly ushed using a paint
change ush.
Regular ushing: Regular ushing, cleaning, and maintenance ensures the pump's high
pumping and suction capacity.
Flushing agent: The ushing agent must be suited to working material A and/or B.
Hardener uid section: Do not ush hardener uid section with water, rather only using
suitable ushing agents (solvents).
7.7.1 PAINT CHANGE FLUSHING
1. Intermediate ushing in accordance with Chapter 7.6.
2. Paint change ushing in accordance with Chapter 7.7.1.
3. Empty 2K pump according to Chapter 8.2.4.
4. Fill 2K pump with new working material in accordance with Chapter 8.2.5.
If the pumping product becomes heated, switch o all heaters and let the product cool o .
1. Visual check: personal safety equipment, grounding and all devices ready to use.
Circulation/return hoses secured. Blue handle (3) at bottom. Red handle (12) at top.
2. If intermediate ushing was not performed after the last process, remove the product
from the system with intermediate ushing (see Chapter 7.6).
Use circulation to empty product tank
3. Remove circulation hoses (6 and 7) from product tanks A and B and route to empty,
separate, and grounded tanks.
4. Close 2K air pressure regulator (1) (0MPa; 0bar; 0psi).
5. Start circulation operating mode: turn blue handle (3) upwards.
6. Slowly open 2K air ball valve (2).
7. Slowly turn air pressure up on the pressure regulator (1) and only until the pump is
running normally (approx. 0.05 MPa; 0.5 bar; 7.25 psi).
8. Be ready for the switch from working material to air. Turn down pressure regulator (1)
far enough that the pump is still running normally (approx. 0–0.05MPa; 0–0.5 bar;
0–7.25psi).
9. As soon as working material is no longer owing out of the circulation hoses (6 and 7),
close the ball valve (2).
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Circulate ushing agent
10. Route circulation hoses (6 and 7) into product tanks A and/or B (no lids).
11. Fill product tank A (8) and if necessary B (9) with approx 2 to 3 liters of ushing agent each.
If the hardener is not being changed, tank B can be left empty.
12. Ensure circulation mode: Blue handle (3) is turned up.
13. Close 2K air pressure regulator (1) (0MPa; 0bar; 0psi).
14. Slowly open 2K air ball valve (2).
15. Slowly turn the air pressure up on the 2K air pressure regulator (1) and only until the
pump is running normally (approx. 0–0.05MPa; 0–0.5 bar; 0–7.25 psi). Be ready to
switch from working material to air and prevent back spray.
16. Allow ushing agent to run for several minutes so that the circulation hoses are
thoroughly ushed.
Clean the inner walls of product tank A (and if necessary B) with a separate damp brush
and ushing agent.
With external circulation (option): Switch several times between internal
circulation with blue handle (3) and external circulation with handle (61).
17. Close 2K air ball valve (2).
18. Repeat from Point 3 to this point if necessary.
Empty suction hoses
19. Points 3 to 9: Use circulation to empty product tanks.
20. Remove product tank A (8) and if necessary B (9) from trolley.
If the hardener is not being changed, intake hose B does not have to be emptied.
21. Loosen hose connections at inputs of uid sections A (and if necessary B).
22. Empty hose contents into empty, separate, and grounded tanks.
23. Re t hoses on uid sections A (and if necessary B).
24. Secure product tank A (and if necessary B) to trolley. Route circulation hoses back into
product tanks.
End circulation operating mode
25. Turn down blue handle (3) again.
With external circulation: Blue handle (3) at bottom, handle (61) at top.
Empty using ball valves A + B
26. - When system without return hoses at the ball valves A and B (17 and 18):
For A and B, place one empty, grounded collection tank each under the ball valves
A and B (17 and 18).
- When system with return hoses at the ball valves A and B (17 and 18):
Guide the return hoses (43 and 44) into empty, separated and grounded collection
tanks.
27. Open ball valves A and B (17 and 18).
28. Slowly open 2K air ball valve (2). Be ready to switch from working material to air and
prevent back spray.
29. Convey empty product tanks A and B. Be ready for the switch from working material
to air. Turn down 2K air pressure regulator (1) far enough that the pump is still running
normally (approx. 0–0.05MPa; 0–0.5bar; 0–7.25psi).
30. As soon as working material is no longer owing from the return tube, close the 2K air
ball valve (2).
31. If necessary, top up fresh ushing agent and repeat from Point 26 to this point.
32. Close ball valves A and B (17 and 18).
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When system with return hoses at the ball valves A and B (17 and 18): circulate via
return line
A. Guide the return hoses (43 and 44) into the product tanks A or B (no lids).
B. Fill product tank A (8) and if necessary B (9) with approx. 3 to 4 liters of ushing
agent each.
If the hardener is not being changed, tank B can be left empty.
C. Open ball valves A and B (17 and 18).
D. Slowly open 2K air ball valve (2). Be ready to switch from working material to air and
prevent back spray.
E. Allow ushing agent to run for several minutes so that the lter and the return
hoses are thoroughly ushed.
Clean the inner walls of product tank A (and if necessary B) with a separate damp
brush and ushing agent.
F. Close 2K spraying air ball valve (2) and ball valves A and B (17 and 18).
G. Repeat from Point 26 to this point if necessary.
Clean high-pressure lters
33. Points 26 to 32: empty using ball valves A + B.
34. Clean high-pressure lter (15) in accordance with Chapter 8.2.6. Re t on device.
35. When system with return hoses at the ball valves A and B (17 and 18): repeat if necessary:
- Points A to F: circulate via return line.
- Points 26 to 32: empty using ball valves A + B.
Flush spray gun hoses
36. Fill product tank A (8) and if necessary B (9) with approx. 3 to 4 liters of ushing agent
each.
If the hardener is not being changed, tank B can be left empty.
37. Start spraying mode: Turn down red handle (12).
38. Point the spray gun without nozzle toward the grounded collecting tray and pull o .
39. Slowly open 2K air ball valve (2). Be ready to switch from working material to air and
prevent back spray.
40. Allow ushing agent to run for several minutes so that the spray gun hoses are thoroughly
ushed.
41. Close 2K air ball valve (2).
42. Relieve, close, and secure the spray gun.
43. End spraying mode: Turn red handle (12) up again.
End paint change ushing
44. If necessary, repeat complete ushing process until the ushing agent remains clean
and clear.
45. For system with ushing pump: Perform intermediate ushing in accordance with
Chapter 7.6.
46. Clean the outside of the system.
47. Dispose of the contents of the collection tanks according to the local regulations.
Next steps:
1. Empty 2K pump according to Chapter 8.2.4.
2. Fill 2K pump with new working material in accordance with Chapter 8.2.5.
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7.8 WORKFLOW
Commissioning
Chapter 6.6
Emergency stop
Chapter 7.3.3
Fill 2K pump with working material
Chapter 8.2.5
Prepare spraying mode
Chapter 7.4.1
Circulate
Chapter 7.4.2
2K spraying
Chapter 7.4.3
Intermediate ushing
Chapter 7.6
System with ushing pump:
Circulate at the same time if necessary
0.5 bar, blue handle up
Pressure relief procedure
Chapter 7.5
System with ushing pump:
Relieving ushing pump
Chapter 7.6.1.1
Switch o device
Chapter 7.3.2
Circulate
Chapter 7.4.2
System with ushing pump:
Intermediate ushing at the same
time if need be
Chapter 7.6.1
2K spraying: Continue work
Chapter 7.5.1
Paint change ushing
Chapter 7.7
Empty 2K pump
Chapter 8.2.4
Fill 2K pump with new working
material
Chapter 8.2.5
Pressure drop
Chapter 7.4.3.1
No-load / vent
Chapter 7.4.3.2
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8 CLEANING AND MAINTENANCE
Cleaning work should be undertaken regularly and carefully by quali ed and trained sta .
They should be informed of speci c 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
8.1 CLEANING
8.1.2 SAFETY INSTRUCTIONS
8.1.1 CLEANING STAFF
Clean the piston pumps only with a damp cloth.
Observe safety instructions in Chapter 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 and devices.
- Secure spray guns against actuation.
- Switch o the energy/compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
8.1.3 CLEAN PRODUCT TANK
Ensure, that the product tanks not become electrostatically charged:
- Use only a damp cloth or a damp brush for cleaning.
- Remove external contamination by hardener or master batch.
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8.1.4 DECOMMISSIONING AND CLEANING
9. Fully assemble the system.
10. Check ll level of the separating agent
Chapter 8.2.3.3.
11. Fill the system with ushing agent in accordance with Chapter 8.2.5.
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 product pump with a
suitable preservative, ll separating agent cup with separating agent.
Procedure:
1. Carry out points 1 to 10 of Chapter 8.1.4 "Decommissioning and Cleaning".
2. Fill the system with preservative in accordance with Chapter 8.2.5.
3. Empty the pump in a controlled manner in accordance with Chapter 8.2.4 and seal the
openings.
8.1.5 LONGTERM STORAGE
The device should be cleaned for maintenance purposes. Ensure that no remaining product
dries on and sticks to the device.
1. Carry out work interruption
Chapter 7.5.
2. Perform intermediate ushing Chapter 7.6.
3. Perform paint change ushing Chapter 7.7.1.
4. Empty the pump in a controlled manner
in accordance with Chapter 8.2.4.
5. Maintain the gun according to the operating manual.
6. Clean and check the suction system and the suction lter.
7. Product lter: check and clean/replace lter insert and lter body.
Chapter 8.2.6.
8. Clean the outside of the system.
Brittle lter pressure regulator!
The tank on the lter pressure regulator becomes brittle through
contact with solvents and can burst.
Flying parts can cause injury.
Do not clean the tank on the lter pressure regulator with solvents.
WARNING
Gas mixtures can explode if there is an incompletely filled pump!
Danger to life from ying parts.
Ignition of potentially explosive surrounding atmosphere.
Ensure that the pump and suction system are always completely
filled with ushing agent or working material.
Do not spray the device empty after cleaning.
WARNING
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8.2 MAINTENANCE
Maintenance work should be undertaken regularly and carefully by quali ed and trained
sta . They should be informed of speci c 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.
8.2.1 MAINTENANCE STAFF
8.2.2 SAFETY INSTRUCTIONS
Observe the safety instructions in Chapter 4 and Chapter 8.1.2.
Prior to maintenance
It should be ensured that the device is in the following state before carrying out any work on it:
- Relieve the pressure from pumps, high-pressure hoses and spray gun.
- The gun should be secured with the safety clip.
- The air supply should be interrupted.
- Unplug the power plug of the heaters (if present).
After maintenance
- Commissioning in accordance with Chapter 6.6.
According DGUV regulation 100-500:
- 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.
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 quali ed
personnel.
DANGER
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B_03651
L
B_05687
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Daily and as required
1. Check the level of separating agent in the separating agent cup every day, and top up
if necessary.
2. Check hoses, pipes, and couplings every day and replace if necessary.
3. Circulate working material or ushing agent for several minutes a day via the blue
handle (3). Prevents the overpressure protection of the circulation valves from sticking.
Seal integrity check: Check pressure on the pressure gauges.
4. Check and clean the high-pressure lter every day or as required. See Chapter 8.2.6.
5. Throttle valve (option for external mixer): Check leakage holes (L) daily. If paint is
escaping, replace seals.
Weekly and as required
1. Check device for damage.
2. Check grounding.
3. Drain condensate in water separator in accordance with Chapter 8.2.3.2.
4. Check mixing tube: Eject mixing elements in accordance with Chapter 13.6 and
replace if required.
5. Movement mechanism: Lubricate bearings in accordance with Chapter 8.2.3.1
If the pump has to be emptied for maintenance work, proceed according to Chapter 8.2.4.
Every shut down should be carried out as laid down in Chapter 8.1.4!
The service manual is available in German and English. For order number see Chapter 1.3.
8.2.3 REGULAR MAINTENANCE WORK
Grease nipple, DIN 71412
8.2.3.1 LUBRICATING BEARINGS
Movement mechanism:
- Unscrew rear protection plate.
- Fill the bearings with grease via the two grease nipples.
Use grease gun for DIN 71412 lubricant.
- Screw rear protection plate back on.
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8.2.3.3 FILLING WITH SEPARATING AGENT
Piston pump dry run!
High wear/damage to the packings.
Paint or solvent can escape if the seals are dry.
Ensure that the separating agent tank is lled with su cient separating agent.
Filling level 1 cm; 0.4 inch under the cup edge.
NOTICE
2K pump
Check the separating agent every day in both uid
sections, and top up if necessary.
1. See through the cover of the connection part air
motor uid section (11). Ensure that the pistons of
the pump is not in the lowest position.
Check in the opening of the uid section the
separating agent level.
2. Fill separating agent via two hermetic connections
(see gure).
Filling level: 1 cm; 0.4 inch under the edge.
Separating agent: Order No. 9992504
Inclination angle of the pump
Maximum permissible inclination of pump for
moving, transportation, etc. ±10°.
The pump must be vertical during operation.
Flushing pump
Fill separating agent of ushing pump:
See ushing pump's operating manual.
8.2.3.2 DRAINING CONDENSATE FROM WATER SEPARATOR
Frequently drain the condensate that may accumulate in the water separator (22).
Make sure the water level in the lter cup never reaches the max. level marked on
the cup itself.
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8.2.4 EMPTYING DEVICE
Gas mixtures can explode if there is an incompletely filled pump!
Danger to life from ying parts.
Ignition of potentially explosive surrounding atmosphere.
Empty the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
WARNING
The emptying process alone, without ushing, is described here. If the device is to
be ushed and cleaned at the same time, paint change ushing must be performed in
accordance with Chapter 7.7.1.
If there is still mixed product in the spray gun hoses, perform intermediate ushing in
accordance with Chapter 7.6.
If the pumping product becomes heated, switch o all heaters and let the product cool o .
1. Visual check: personal safety equipment, grounding and all devices ready to use.
Circulation/return hoses secured. Blue handle (3) at bottom. Red handle (12) at top.
Use circulation to empty product tank
2. Remove circulation hoses (6 and 7) from product tanks A and B and route to empty,
separate, and grounded tanks.
3. Close 2K air pressure regulator (1) (0MPa; 0bar; 0psi).
4. Start circulation operating mode: turn blue handle (3) upwards.
5. Slowly open 2K air ball valve (2).
6. Slowly turn air pressure up on the pressure regulator (1) and only until the pump is
running normally (approx. 0.05 MPa; 0.5 bar; 7.25 psi).
7. Be ready for the switch from working material to air. Turn down pressure regulator (1)
far enough that the pump is still running normally (approx. 0–0.05 MPa; 0–0.5bar;
0–7.25psi).
8. As soon as working material is no longer owing out of the circulation hoses (6 and 7),
close the ball valve (2).
9. End circulation operating mode: Turn blue handle (3) down again.
Empty using ball valves A and B
10. - When system without return hoses at the ball valves A and B (17 and 18):
For A and B, place one empty, grounded collection tank each under the ball
valves A and B (17 and 18).
- When system with return hoses at the ball valves A and B (17 and 18):
Guide the return hoses (43 and 44) into empty, separated and grounded collection
tanks.
11. Open ball valves A and B (17 and 18).
12. Slowly open 2K air ball valve (2). Be ready for the switch from working material to air.
13. As soon as working material is no longer owing from the high-pressure lters, close
ball valve (2) and ball valves A and B (17 and 18).
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With external circulation (option)
A. Turn "External circulation" handle (61) down.
B. Slowly open 2K air ball valve (2). Be ready for the switch from working material to air.
C. As soon as working material is no longer owing out of the circulation hoses (6 and 7),
close the ball valve (2).
D. Turn "External circulation" handle (61) up again.
Empty up to the gun
14. Start spraying mode: Turn down red handle (12).
15. Point gun without nozzle toward the grounded collecting tray and pull o .
16. Slowly open 2K air ball valve (2). Be ready for the switch from working material to air.
17. As soon as working material is no longer owing from the return tube, close the ball
valve (2).
18. Relieve, close, and secure the spray gun.
19. End spraying mode: Turn red handle (12) up again.
Empty suction hoses
20. Remove product tanks A and B (8 and 9) from trolley.
21. Loosen hose connections on inlets of uid sections A and B.
22. Empty hose contents into empty tanks.
23. Re t hoses on uid sections A and B.
24. Secure product tanks A and B to trolley and guide all circulation and return hoses back
into product tanks.
Empty ushing pump (option)
A. Empty ushing pump in accordance with ushing pump's operating manual.
The ushing ball valve (30) must be open when emptying via the spray gun.
B. Once the ushing ball valve (30) is empty, close again.
Pressure relief procedure
25. Depressurization in accordance with Chapter 7.5.
26. Guide all circulation and return hoses back into the product tanks.
27. Dispose of the contents of the collection tanks according to the local regulations.
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8.2.5 FILLING EMPTY DEVICE
Gas mixtures can explode if there is an incompletely filled pump!
Danger to life from ying parts.
Ignition of potentially explosive surrounding atmosphere.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
WARNING
If the device is being lled with a new paint or new hardener, paint change ushing
must be undertaken rst in accordance with Chapter 7.7.
1. Visual check: personal safety equipment, grounding and all devices ready to use.
Blue handle (3) at bottom. Red handle (12) at top. All circulation and return hoses are
secured and lead into the product tanks A or B.
Fill circulation
2. Fill product tanks A and B (8 and 9) with working material. Close cover and x return lines.
3. Start circulation operating mode: turn blue handle (3) upwards.
4. Close 2K air pressure regulator (1) (0MPa; 0bar; 0psi).
5. Slowly open 2K air ball valve (2).
6. Slowly turn the air pressure up on the 2K air pressure regulator (1) and only until the
pump is running normally (approx. 0–0.05MPa; 0–0.5 bar; 0–7.25 psi). Be ready to
switch from working material to air and prevent back spray.
7. As soon as pure working material starts owing out of the two circulation hoses (6 and 7),
close 2K air ball valve (2).
8. End circulation operating mode: Turn blue handle (3) down again.
Fill high-pressure lter
9. Open ball valves A and B (17 and 18).
10. Slowly open 2K air ball valve (2). Be ready to switch from working material to air and
prevent back spray.
11. As soon as pure working material starts owing out of the two ball valves A and B (17 and
18), close 2K air ball valve (2).
12. Close ball valves A and B (17 and 18).
13. Check ll level of the separating agent
Chapter 8.2.3.3.
With external circulation (option)
A. Turn "External circulation" handle (61) down.
B. Slowly open 2K air ball valve (2). Be ready to switch from working material to air and
prevent back spray.
C. As soon as pure working material starts owing out of the two circulation hoses
(6 and 7), close 2K air ball valve (2).
D. Turn "External circulation" handle (61) up again.
Spray gun hoses: The spray gun hoses are only lled when spraying mode is started.
Next step: Prepare spraying mode in accordance with Chapter 7.4.1.
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12
11
10
7
2
3
5
B_05427
1
21
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
8.2.6 CLEANING AND REPLACING THE HIGHPRESSURE FILTER
Paint change ushing
To clean the high-pressure lter or change the lter cartridges,
perform paint change ushing in accordance with Chapter 7.7.
Reference is made there to this chapter.
A. Place the grounded collection tank under the High-pressure lter.
B. Open ball valve (1).
C. Loosen union nut (3) with a size 70 wrench.
D. Unscrew the union nut (3) and lift slightly so that it does not get
dirty in the next step.
E. Remove the lter housing (2) with the union nut (3). The cone
spring (12) remains in the lter housing (2). If the O-ring (5) is
not damaged, it remains on the lter housing (2).
F. Remove the lter cartridge (11) and lter support (10) from the
lter housing (2).
G. Clean all parts:
- Place the lter cartridge (11) and lter support (10) in solvent.
Clean using brush.
- Fill the lter housing (2) approx. 1/3 full with solvent, secure
wearing a glove and shake well.
- Clean the distribution housing (7) using a brush.
H. If necessary, replace the O-ring (5) and/or lter cartridge (11).
Order No., see Chapter 13.7.6.
I. Assemble all parts in reverse order. While doing so:
- Coat the thread of the distribution housing (7) with anti-seize
paste**.
- Coat the O-ring (5) and pressure ring (21) with Mobilux
EP2**.
- Observe the installation position of the lter cartridge (11):
Push the closed end with the lter identi cation ahead into
the lter housing (2).
- Make sure that the cone spring (12) is in the lter housing
(note the installation position). Press on the cone spring after
inserting the lter cartridge (11) and lter support (10); the
spring action must be noticeable.
- Tighten the union nut (3) by hand.
K. Close ball valve (1).
Continue with paint change ushing in accordance with Chapter 7.7.
** Order No., see Chapter 10.2.
Filter identi cation
Mobilux
EP2**
grease
Anti-seize paste**
Filter installation
position
Turned over
B_05276
53MPa
530bar
7687psi
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Bursting hose, bursting threaded joints!
Danger to life from injection of product and from ying parts.
Ensure that the hose material is chemically resistant to the
sprayed products and the used ushing agents.
Ensure that the spray gun, threaded joints, and product hose
between the device and the spray gun are suitable for the
generated pressure.
Ensure that the following information can be seen on the hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture
DANGER
8.2.7 PRODUCT HOSES, TUBES AND COUPLINGS
The service life of the complete hoses between product pressure generator and application
device is reduced due to environmental in uences even when handled correctly.
Check hoses, pipes, and couplings every day and replace if necessary.
Before every commissioning, check all connections for leaks.
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 tting embossing).
– 10 years from the date of the hose imprinting.
Fitting
embossing
Meaning
(if present)
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)
Pressure
e.g., 270 bar (27 MPa)
XX Internal code
DNxx (e.g., DN10) Nominal diameter
Page 76
76
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
9 TROUBLESHOOTING AND RECTIFICATION
Problem Cause Remedy
The pump does not
work
Air motor does not work or stops. Open and close ball valve on the pressure
regulator unit or brie y disconnect compressed
air supply.
No pressure indication on the
pressure gauge (air pressure
regulator defective).
Disconnect compressed air supply brie y or
repair or change pressure regulator.
Spray nozzle is clogged. Clean the nozzle according to the instructions.
Insu cient compressed air supply. Check compressed air supply.
Filter insert in spray gun or high-
pressure lter is clogged.
Clean the parts and use a suitable working
material.
Fluid section or high-pressure
hose are blocked
(e.g., 2K product hardened).
Dismount and clean uid section, replace highpressure hose.
Grease in spool and sleeve
assembly.
Degrease spool and sleeve assembly.
Pump stops at the stroke end
occasionally.
Check detent element (see service manual).
Poor spray pattern See the gun instructions.
Irregular operation
of product pump:
spray jet collapses
(pulsation)
Viscosity is too high. Dilute the working material.
Spraying pressure is too low. Increase incoming air pressure. Use a smaller
nozzle.
Valves are clogged. Clean product pump, if necessary leave to soak
in ushing agent.
Foreign body in suction valve. Dismantle suction valve housing, clean and
check valve seat.
Diameter of compressed air line
too small.
Assemble a larger supply line. Technical data,
Chapter 5.5.3.
Valves, packings, or pistons are
worn out.
Replace the parts.
Control air lter or work air lter is
clogged.
Check lter and clean it if necessary.
Pump is running
uniformly, but does
not take in any
working material
The suction system's union nut is
loose; the pump is taking in air.
Tighten union nut.
Suction lter is clogged. Clean lter.
Ball in suction or piston valve is
sticking.
Clean with ushing agent
(if necessary vent device).
Pump runs when the
gun is closed
Packings, valves, or pistons are
worn out.
Replace the parts.
The air motor is iced upThere is a lot of condensation
water in the air supply.
Install a water separator.
Page 77
77
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Problem Cause Remedy
During spraying
mode, the
product pressure
A drops and B
increases when
the gun is closed
or open.
Internal leakage on A-side of the
pump, at the circulation valve or
overpressure protection.
Check if this is the case during upwards or downwards
stroke.
If this is just the case at upwards stroke, then replace
piston packing or piston valve A.
If this is just the case at downwards stroke, then
replace or clean the suction valve A.
If this is the case at both strokes, check leakage A
upper packing, replace if necessary, or check the
return ow of internal and external circulation and
replace the corresponding valve.
Product pressure
B drops and A
is increasing
in spray mode
when gun is
closed or open.
Internal leakage on B-side in the
pump, at the circulation valve or
overpressure protection.
Check if this is the case during upwards or downwards
stroke.
When this is just the case at upwards stroke, then
replace the piston packing or piston valve B.
If this is just the case at downwards stroke, then
replace or clean the suction valve B.
If this is the case at both strokes, check leakage B
upper packing, replace if necessary, or check the
return ow of internal and external circulation and
replace the corresponding valve.
Product pressure
pulsation when
switching the 2K
pump between
A and B is not
consistent.
Irregular switching of the nonreturn valves of the pumps.
Check non-return valves, replace if necessary.
Long product routes with
external mixer.
Install throttle valve and/or adjust throttle valve's
adjustment screw (see Chapter 5.10.3).
Product pressure
B increases in
spray mode.
With external mixer with throttle
valve: Travel adjustment set too
low or valve blocked by product.
Increase the travel adjustment.
If valve is sticking: Disassemble and clean.
Replace the piston seal, if necessary.
With external
mixer with
throttle valve:
Leakage
Product escaping from leakage
hole of throttle valve.
Replace the valve needle seals to the material.
Air emission from leakage hole.
The throttle valve must not be operated with
compressed air.
Air emission at valve cover.
If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service
Center.
Page 78
78
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
10 REPAIRS
10.1 REPAIR STAFF
Repair work must be carried out carefully and by quali ed and trained personnel.
They should be informed of speci c hazards during their training. The repairs must be
carried out in accordance with the corresponding service manual.
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.
10.2 MOUNTING MATERIALS
In Chapter 13 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 Chapter 13.
Mounting materials
Order No. Quantity Designation Smaller tanks
9992590 1 pc ≙ 50 ml Loctite 222
9992511 1 pc ≙ 50 ml Loctite
243
9992528 1 pc ≙ 150 g Loctite 270
9992831 1 pc ≙ 50 ml Loctite 542
9999042 1 pc ≙ 50 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 ≙ 100 g Anti-seize paste
9992816 1 pc ≙ 70 g Miranit contact adhesive
Z102.00 1 pc ≙ 1000 ml Tecni oil 1000 ml 125 cc ≙ order no. Z101.00
9992698 1 pc ≙ 200 g can Vaseline white PHHV II
Brand notice
The brands speci ed in this document are property of the respective owners. Loctite
, for
example, is a registered brand of Henkel.
When the equipment must be scrapped, please di erentiate the disposal of the waste
materials. The following materials have been used:
Steel Aluminum Plastics Carbide
Consumable products
Consumable products (lacquers, adhesives, ushing and cleaning agents) must be
disposed of in accordance with all applicable legal requirements.
11 DISPOSAL
Page 79
79
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Order No. Description Remarks
2352831 Set of 2K PC
ushing pumps
Including Leopard 35-70 piston pump.
B_05700
For details, see Chapter 13.8.
2359293 Attachment kit for
external ushing
pump
For connecting to an external ushing pump.
B_05699
For details, see Chapter 13.8.
2359323 Return ow set
HP lter A and B
Return hoses and tubes of the ball valves A + B in the
tanks A + B.
B_05804
For details, see Chapter 13.10.
2359317 2K heater set A/B Heaters for A or B component and set of hoses for
assembly downstream of high-pressure lter/return
line.
B_05801
Do not use together with 2356998.
Suitable for external mixer with circulation.
Attention: If there is no external circulation, the A
component may not be heated during circulation.
For details, see Chapter 13.9.1.
2356998 2K PC heater set A Heater for A component including heat up during
circulation.
B_05802
For details, see Chapter 13.9.2.
2352832 2K PC heater set B Heater for B component, if 2356998 is installed.
The product is heated during circulation.
B_05803
For details, see Chapter 13.9.2.
12 ACCESSORIES
Page 80
80
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Order No. Description Remarks
2353092 External mixer
2K PC
Frame and ttings for conversion:
Red handle, mixing block, and mixing
tube are converted from trolley into
external mixer.
B_05805
For details, see Chapters 5.10.1 and 13.11.
2365045 Throttle valve Option for external mixer if short-term
mixing errors are occurring.
B_05806
For details, see Chapters 5.10.3 and 13.11.1.
2366258 Circulation A1/2
B1/4 2K PC
External circulation
(option for external mixer)
B_05807
Connection A: 1/2", B: 1/4".
For details, see Chapters 5.10.4 and 13.11.2.
2362987 Circulation A3/8
B1/4 2K PC
External circulation
(option for external mixer)
B_05807
Connection A: 3/8", B: 1/4".
For details, see Chapters 5.10.4 and 13.11.2.
2365243 Circulation A3/8
B3/8 2K PC
External circulation
(option for external mixer)
B_05808
Connection A: 3/8", B: 3/8".
For details, see Chapters 5.10.4 and 13.11.3.
2366916 Circulation A1/2
B3/8 2K PC
External circulation
(option for external mixer)
B_05808
Connection A: 1/2", B: 3/8".
For details, see Chapters 5.10.4 and 13.11.3.
2334958 Regulator lock
B_05423
9992504 Separating agent
250 ml; 250 cc
B_05422
236219 Grounding cable
3m; 9.8 ft
B_05809
on request Feed pump
on request Product tank heated / with agitator
Page 81
81
PROTEC 2K
B_05633
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
12.1 CONVERSION TO OTHER MIXING RATIOS
The PROTEC 2K system can be subsequently converted to a di erent mixing ratio. For this,
depending on the conversion, one or more of the following sets are required:
Order No. Conversion set
2352830 Fluid section A 150 cm³ for mixing ratio 4:1, 3:1, 2:1
2352829 Fluid section A 110 cm³ for mixing ratio 1.5:1*, 1:1
2352825 Fluid section B 38 cm³ for mixing ratio 4:1
2352826 Fluid section B 50 cm³ for mixing ratio 3:1
2352827 Fluid section B 75 cm³ for mixing ratio 2:1, 1.5:1*
2353639 Fluid section B 110 cm³ PE/T for mixing ratio 1:1, B-side
2358419 B-side of tank set for mixing ratio 1:1 including suction hose
2358420 B-side tank set for mixing ratio 4:1, 3:1, 2:1, 1.5:1* including suction hose
2363859 Position bracket
Overview of the required
conversion sets
Conversion
from 4:1 from 3:1 from 2:1 from
1.5:1
from 1:1
Order No. Order No. Order No. Order No. Order No.
to 4:1 Fluid section A -- -- 2352830 2352830
Fluid section B 2352825 2352825 2352825 2352825
Tank B -- -- -- 2358420
Position bracket -- -- -- 2363859
to 3:1 Fluid section A -- -- 2352830 2352830
Fluid section B 2352826 2352826 2352826 2352826
Tank B -- -- -- 2358420
Position bracket -- -- -- 2363859
to 2:1 Fluid section A -- -- 2352830 2352830
Fluid section B 2352827 2352827 -- 2352827
Tank B -- -- -- 2358420
Position bracket -- -- -- 2363859
to
1.5:1 *
Fluid section A 2352829 2352829 2352829 -Fluid section B 2352827 2352827 -- 2352827
Tank B -- -- -- 2358420
Position bracket -- -- -- 2363859
to 1:1 Fluid section A 2352829 2352829 2352829 --
Fluid section B 2353639 2353639 2353639 2353639
Tank B 2358419 2358419 2358419 2358419
Position bracket -- -- -- --
* Conversion to 1.5:1
The conversion to the mixing ratio 1.5:1 is only possible if the marking "1.5" is present at
the movement mechanism (see Chapter 13.7.2).
Page 82
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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
13 SPARE PARTS
13.1 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 "Stk" on
the list. 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:
- Address for the invoice
- Address for delivery
- Name of the person to be contacted in the event of any queries
- Type of delivery (normal mail, express delivery, air freight, courier, etc.)
Identi cation in spare parts lists.
Explanation of column "K" (labeling) in the following spare parts lists:
Wearing parts
Note: These parts are not covered by warranty terms.
Not part of standard equipment, available, however, as additional extra.
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 and devices.
- Secure spray guns against actuation.
- Switch o the energy/compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
Observe "Repair" chapter: Repair personnel and assembly aids.
The service manuals are available separately. see Chapter 1.3.
Page 83
83
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
13.2 OVERVIEW
Order No.
2350376
2352858
2350375
2352863
2350374
2352866
2362778
2362780
2350373
2352869
System
PROTEC 2K75-150/38
PROTEC 2K75-150/38 with ushing pump
PROTEC 2K70-150/50
PROTEC 2K70-150/50 with ushing pump
PROTEC 2K64-150/75
PROTEC 2K64-150/75 with ushing pump
PROTEC 2K77-110/75
PROTEC 2K77-110/75 with ushing pump
PROTEC 2K65-110/110
PROTEC 2K65-110/110 with ushing pump
4:1 3:1 2:1 1.5:1 1:1
Pos System component Order No.
1 Trolley, air motor, 2K mechanism, mixing --
✓✓✓✓✓✓✓✓✓✓
Fluid section A
2 Fluid section, A 150 cm³ PE/TG 2352830
✓✓✓✓✓✓
3 Fluid section A 1:1 110 cm³ PE/T 2352829
✓✓✓✓
Fluid section B
4 Fluid section B 4:1 38 cm³ PE/T 2352825
✓✓
5 Fluid section B 3:1 50 cm³ PE/T 2352826
✓✓
6 Fluid section B 2:1 75 cm³ PE/T 2352827
✓✓✓✓
7 Fluid section B 1:1 110 cm³ PE/T 2353639
✓✓
Tank A
8 Tank A 2358417
✓✓✓✓✓✓✓✓✓✓
Tank B
9 Tank B 4:1, 3:1, 2:1, 1.5:1 2358420
✓✓✓✓✓✓✓✓
10 Tank B 1:1 2358419
✓✓
Set of ushing pumps
11 Set of ushing pumps with Leopard 35-70 2352831
✓✓✓✓✓
13.2.1 BASIC UNITS
Page 84
84
PROTEC 2K
B_05420
1
2
3
4
5
6
7
8
9
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Components and their spare parts
Pos Component Spare parts lists
1 Hoses Chapter 13.2.3
2 Trolley with grounding, return line, and air inlet Chapter 13.3
3
Product tank A
Chapter 13.4
Product tank B (1:1)
Product tank B (4:1, 3:1, 2:1, 1.5:1) Chapter 13.5
4 Mixing Chapter 13.6
5
2K pump Chapter 13.7
- Air motor with pressure regulator unit Chapter 13.7.1
- Movement mechanism Chapter 13.7.2
- Fluid sections 110–150 cm Chapter 13.7.3
- Fluid sections 38–75 cm Chapter 13.7.4
- 2K PC relief combination Chapter 13.7.5
- High-pressure lter with pressure gauge Chapter 13.7.6
6 Flushing pump (option) Chapter 13.8
7 Heater (option) Chapter 13.9
8 Return ow set HP lter A and B (option) Chapter 13.10
9 External mixer Chapter 13.11
13.2.2 SYSTEM OVERVIEW
Page 85
85
PROTEC 2K
AR
BR
B
A2
A1
A1
B
A2
AR
BR
B_05421
4
S
S
6
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
13.2.3 HOSES
Pos K Stk Order No. Designation Core coating From To
1 *
2 2334023 HPP hose DN10-PN530 PA W-G 0.53 m PA
A1 A1
BB
2 2334457 HPP hose, DN10-PN530 FEP W-G 0.53 m FEP
A1 A1
BB
2
1 2334063 HPP hose DN10-PN530 PA W-G 0.73 m PA A2 A2
1 2332865 HPP hose, DN10-PN530 FEP W-G 0.73 m FEP A2 A2
3
2 2353854 HP hose, DN6-PN325 FEP G-G 0.805m FEP
AR AR
BR BR
4 1.5 m 2323474 LP hose DN25-PN10-EPDM, per meter
With ushing pump (option)
5 1 2334039 HPP hose DN6-PN530 PA W-G 1.52 m PA S S
6 2 m 2333099 LP hose DN12-PN10-EPDM, per meter
Wearing parts
= Not part of the standard equipment but available as a special accessory.
* Heater: A1–A1 and B–B for systems with heater: see Chapter 13.9.
External mixer: See Chapter 13.11.
to PROTEC 10" air motor
to air motor for ushing pump
(if present)
Return line A
Return line B Mixing
Relief combination of ushing pump
Air inlet
Fluid section B
Fluid section A
Page 86
86
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
13.3 TROLLEY WITH GROUNDING, RETURN LINE, AND AIR INLET
Spare parts list for trolley with grounding, return line, and air inlet
Pos K Stk Order No. Designation
2 1 2348231
Mechanism trolley 2K
For details, see Chapter 13.3.1
3 1 2352685 Operating sign, PROTEC 2K
4 4 2354470 Knurled screw, M6
5 4 9900130 Hexagon screw without shaft
6 1 236219 Grounding cable, complete 3 m
7 2 9950604 Cable lug
8 1 9907045 Hexagon screw without shaft
9 3 9910204 Self-locking hexagon nut, M6, with clamp
10 2 3155401 Contact washer
11 4 9920103 Washer, A6.4, DIN 125
12 2 2353386 Locking pin
13 2 9900316 Hexagon socket cap screw, M6x50
14 2 2353389 Tube mounting piece
15 2 2353343 Return tube G1/4", 90°
16 1 --
Water separator, complete
For details, see Chapter 13.3.2
17 1 2336526 Heavy duty clamp 32-35 mm
18 4 9900518 Hexagon socket countersunk head screw
20 2 9903301 Recessed head raised llister head screw, H form
21 2 9921511 Spring washer
30 1 9992511 Loctite
243
Wearing parts
Page 87
87
PROTEC 2K
B_05404
18
4
5
2
3
12
13
14
15
11
11
10
10
8
7
7
9
6
11
9
16
17
30
20
21
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Grounding for air motor
Grounding for ushing pump: See Chapter 13.8
Page 88
88
PROTEC 2K
B_05419
2
3
4
6
7
5
11
9
8
10
1
12
13
14
17
18
15
16
100 mm
4 inch
10 mm
0.4 inch
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
13.3.1 2K MECHANISM TROLLEY
Spare parts list for 2K mechanism trolley
Pos K Stk Order No. Designation
1 1 2348231 Mechanism trolley 2K
2 1 -- Mounting bracket
3 4 2338235 Plug
4 4 9900246 Hexagon screw
5 4 9920102 Washer, A8.4
6 4 3155404 Contact washer, M8
7 4 9910208 Self-locking hexagon nut, M8, with clamp
8 1 -- Basic frame
9 4 9907183 Hexagon socket countersunk head screw
10
1 2348063 Swivel castor with clamp
11 4 9913011 Self-locking hexagon nut
12 2 9998895 Retaining ring with cap
13
2 9994922 Wheel, complete
14 1 -- Mixer mounting bracket
15 4 9920103 Washer, A6.4, DIN 125
16 4 9900126 Hexagon screw without shaft
17 4 9910204 Self-locking hexagon nut, M6, with clamp
18 4 3155401 Contact washer
Wearing parts
Wheel assembly
Page 89
89
PROTEC 2K
B_05415
2
3
4
6
7
5
11
9
8
10
1
20
20
20
20
8
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
13.3.2 AIR INLET WITH WATER SEPARATOR
Spare parts list for air inlet with water separator
Pos K Stk Order No. Designation
1 1 -- Water separator, complete
2 4 9900518 Hexagon socket countersunk head screw
3 1 2350854 Extension
4* 1 3303069 Plug with rim
5 1 9998653 T-piece, reduced
6 1 9974135 Sealing ring 1"
7 1 9985671 Hose tting-G1"- NW25
8 2 9998147 Double nipple GF 280
9
1 2330030 Filter LF-1-D-Maxi
10 1 9985613 Elbow 90° GF-92
11
1 9991512 Ball valve, 2-way, LP 20 bar
20 1 9992831 Loctite 542
Wearing parts
* Pos. 4: With ushing pump: Remove plug and t ushing pump's air connection.
If necessary turn the adaptor plate 180°
so that the air lter can be mounted on
the trolley.
Observe the air lter's ow direction.
Page 90
90
PROTEC 2K
60 Nm; 44.3 lbft
B_05413
2
3
5
6
1
7
9
10
11
12*
13
20
4
8
21
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
13.4 PRODUCT TANK A AND PRODUCT TANK B 1:1
Spare parts list for product tanks A and B (1:1) Tank A Tank B (1:1)
Pos K Stk Designation Order No. Order No.
1 1 Tank, complete 2358417 2358419
2
1 Tank, riveted 2358421 2358422
3 1 Cover 2357791
4 1 Lamella tamper D15 2355617
5 1 Stone catcher 2350858
6 1 Seal tting 1 1/4" 2350177
7
1 Sticker A 2352049
8 1 Sticker B 2352098
9 1 Fitting EF-FH-G1-1/4"-DN40-SST 2330357
10 2 Heavy duty clamp 48-51 mm 2329591
11
0.8 m LP hose DN38-PN10-EPDM 2329134
12* 1 Cone coupling ID38 2336488
13 1 O-ring 367525
20 1 Loctite 542 9992831
21 1 Vaseline white PHHV II 9992698
Wearing parts
* Pos. 12:
- Order along with
O-ring (pos. 13).
- Remove the supplied
O-ring and insert
O-ring (pos. 13).
Page 91
91
PROTEC 2K
B_05410
2
3
5
6
4
1
7
8
9
10
11
12
13
20
20
60 Nm; 44.3 lbft
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
13.5 PRODUCT TANK B 4:1, 3:1, 2:1, 1.5:1
Spare parts list for product tank B (4:1, 3:1, 2:1, 1.5:1)
Mixing ratio 4:1 / 3:1 /
2:1 / 1.5:1
Pos K Stk Designation Order No.
1 1 Tank B, complete 2358420
2
1 Tank riveted B, including pos. 6, 8, 9 (1 pc) 2358422
3 1 Cover 2357791
4 1 Lamella tamper D15 2355617
5
1 Stone catcher 2350858
6 1 Seal tting 3/4" 2349932
7 1 Sticker B (2K mechanism) 2352098
8 1 Washer 2349933
9 2 Fitting-EF-FH-G3/4"-DN27-SST 2323953
10 2 Heavy duty clamp 32-35 mm 2336526
11
0.45 m LP hose DN25-PN10-EPDM, per meter 2323474
12 1 Union nut 253426
13 1 Intake nipple G3/4" 2322704
20 1 Loctite
542 9992831
Wearing parts
Page 92
92
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Spare parts list for mixing
Pos K Stk Order No. Designation
1 1 -- Mixing, complete
2 1 2350342 Handle, blue
3 4 2325554 Fillister head screw, M6x12
4 2 2352612 Locating screw
5 2 9999500 Helical spring, air
6 1 2349800 Switching bracket, complete
7
2 2357790 Circulation, complete
9 2 384323 Plug
10 2 104376 Screw plug
11 2 2331174 Fitting, DF-MM-G1/4-G1/4-530 bar-SSt
12 1 9907127 Fitting-PF-M-G3/8-530bar-SSt
13 1 2330775 Fitting, DF-MM-G3/8-G3/8-530 bar-SSt
14 1 3204619 Fitting, EF-MM-G3/8-R3/8-530bar-SSt
15 1 2349830 Handle, red
16 1 2331371 Fitting, SF-FM-G3/8-G3/8-530 bar-SSt
17
2 2350087 Ball valve PN 530 G3/8 DN10
18 2 2349776 Side holder, 45 degree
19 2 2349832 Spring washer
20 2 9907206 Hexagon screw without shaft
21 1 2357789 Mixing block, complete (for details see Chapter 13.6.1)
22 2 2332966 Fitting, DF-MM-M22x1.5-G3/8-530 bar-SSt
23 1 384098 Mixing tube, complete 10-32E ST/KS (including pos. 24)
24
1.33 9999446 Mixing element
25 1 2352556 Spacer plate
26 1 9998683 Hose clamp
27 1 2332620 Fitting RF-FM-G3/8-3/8NPSM-530 bar-SSt
30 1 9992831 Loctite
542
31 1 9992511 Lock screw Loctite
243
32 1 9992616 Molykote DX grease
Wearing parts
13.6 MIXING
Page 93
93
PROTEC 2K
B_05408
2
3
5
6
4
7
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
25
26
22
27
32
32
30
30
32
32
30
32
31
31
24
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Remove the mixing elements:
The mixing elements are discharged
with an iron stick in the lower part of
the mixing tube through the socket
in direction of the arrow (see gure)
against the direction of ow.
Flow direction
Page 94
94
PROTEC 2K
B_05416
2
3
6
7
1
21
21
20
20
75 Nm
55 lbft
15
14
13
12
11
10
9
16
8
21
7
5
20
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
13.6.1 MIXING BLOCK
Spare parts list for mixing block
Pos K Stk Order No. Designation
1 1 2357789 Mixing block, complete
2 2 3676419 Fitting DF-MM-R3/8"-G3/8"-PN530-SSt
3 1 2349779 Mixing block
5 2 2323718 Fitting-PF-M-R1/4-530 bar-SSt
6 2 2324032 Screw plug
7
2 2357787 Outlet valve, complete (for details see Chapter 13.6.1.1)
20 1 9992831 Loctite 542, 50 ml
21 1 9992616 Molykote DX grease
Wearing parts
13.6.1.1 OUTLET VALVE
Spare parts list for outlet valve
Pos K Stk Order No. Designation
7 2 2357787 Outlet valve, complete
8 2 341325 Valve guide
9 2 341328 Clasp
10 2 9971470 O-ring
11 2 341326 Pressure spring
12
2 253405 Spring support ring
13 2 9941501 Ball 11 HM
14
2 2306166 Outlet valve seat
15 2 2306167 Sealing ring
16 1 2308760
Outlet valve service set, complete
(spare parts for 2valves)
21 1 9992616 Molykote DX grease
Wearing parts
= Included in service set 2308760
Page 95
95
PROTEC 2K
B_05406
1
2
3
5
6
4
5
10
10
10
10
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
13.6.2 MOUNT ON TROLLEY
Spare parts list for mixing
Pos K Stk Order No. Designation
11--
Mixing, complete
For details, see Chapter 13.6.
2 4 2345254 Hexagon socket cylinder head screw
3 4 9900316 Hexagon socket cap screw, M6x50
4 2 9910102 Hexagon nut, M6
5 4 3155401 Contact washer
6 8 9910204 Self-locking hexagon nut, M6, with clamp
10 10 9920103 Washer, A6.4, DIN 125
Wearing parts
Page 96
96
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
13.7 2K PUMP
Spare parts list for 2K pump
Pos K Stk Order No. Designation
1 -- 2K pump
2 1 2361277 Air motor 10". For details, see Chapter 13.7.1
3 1 -- Type plate, PROTEC 2K
5 1 9985671 Hose tting-G1"- NW25
6 1 2336526 Heavy duty clamp 32-35 mm
7 1 370530 Spring 33
8
1 2353598 Coupling 28/28 special
9 16 2353872 Captive screw, M5
10 2 9998614 Straight hermetic plug connection
11 2 2349765 Protection plate
12 1 -- Movement mechanism. For details, see Chapter 13.7.2
13 3 9900376 Hexagon socket cylinder head screw
14 8 2350928 Hexagon socket cylinder head screw
15 8 9921514 Spring washer
16 8 9925034 Washer
17 2 9930851 Parallel pin
18
1 2351441 Position bracket
19 2 9921502 Lock washer, A6.0
20 2 9920103 Washer, A6.4, DIN 125
21 2 9900312 Hexagon socket cap screw, M6x20
22 2 3059509 Sealing plug, GPN300
23 2 2351806 Separating uid tank
24
2 9974146 O-ring
25 1* 2348247 Bolt D23
26 1* 2353382 Coupling 23/23 special
27 1* 368530 Spring 23
28 1 -- Fluid section A. For details, see Chapter 13.7.3
29 1 -- Fluid section B. For details, see Chapters 13.7.3 or 13.7.4
30 1 -- 2K PC relief combination. For details, see Chapter 13.7.5
31 1 2358553 HP lter, PROTEC 2K. For details, see Chapter 13.7.6
32 1* 2329019 Fitting-EF-FM-G1 1/2-G1 1/2-PN25-TG
33 1* 2336489 Fitting DF-MM-G1½"-Rd55x1/6-PN25-CS
37a 0.08 m
9982079 Hose, black PEN 6/4
37b 0.085 m
40 1 9999042 Loctite
638, 50 ml
41 1 9998808 Mobilux
EP 2 grease
42 1 9992831 Loctite 542
* 2 present with 1:1 ratio.
Wearing parts
= Included in the service set for uid section (more parts, see Chapter 13.7.3 and/or 13.7.4).
Page 97
97
PROTEC 2K
B_05405
1
9
8
7
6
5
3
2
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
32
33
70 Nm; 51.6 lbft
70 Nm; 51.6 lbft
40
40
41
37b
31
37a
42
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
2 present with 1:1 ratio.
Page 98
98
PROTEC 2K
B_05279
83
81
56
80
57
52 53 66
51
B_05293
494746
27
41
31
66
57
30
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
13.7.1 PROTEC AIR MOTOR 10"
PROTEC 10" air motor spare parts list
Pos K Stk Designation Order No.
1 1 Air motor 10", complete (with pos. 2, 3, 4) 2361277
2a 1 Hexagon screw without shaft 9900122
2
1 Hexagon screw without shaft 9900150
3 1 Shoulder ring 369324
4 1 Lifting eye nut 369325
5 1 Washer 9925034
6 1 WAGNER PROTEC 10 label 2353725
7 1 Hood 9 369311
8
2 Velcro fastener adhesive part 9999151
9 2 Velcro fastener coating part 9999152
10
1 Sound deadening pad 9 369319
11 1 Shoulder screw 9 369318
12 7 Screw SFS Plastite 45 9907125
13 2 Washer 6.4 9925031
= Wearing part
= Included in service set
= Not part of the standard equipment but available as a special accessory.
Pos Assembly instructions
8 Stick adhesive part to inside of hood.
"Miranit" adhesive (pos. 107).
9 Stick velvet label to eece side of the deadening
pad. "Miranit" adhesive (pos. 107).
10 Insert the deadening pad into the hood
(tight- tting). Fleece side outwards.
19 Stick deadening pad with eece side outwards
holohedral to the connecting part. "Miranit"
adhesive (pos. 107).
36–44 Before assembling apply a little Tecni oil
(pos. 108) to the housing bore of pos. 31.
Do not dismount the piston of the spool and
sleeve assembly (pos. 37).
Mount to limit stop.
Page 99
99
PROTEC 2K
12
37*
36*
20
33
2
3
5
8*
9*
107
4
7
6
10*
11
12
13
14
16
17
18
19*
15
10 Nm; 7 lbft
70 Nm; 52 lbft
39
103
102
B_05631
101
103
1
21
22
23
23
24
48
34
35
31
25
26
27
28
30
38
39
40
35
41
42
43
44
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
80
70
67
68
45
46
47
49
80
85
84
83
64
102
66
89
88
87
86
≤ 4 Nm;
≤ 3 lbft
102
104
140 Nm; 103 lbft
102
105
101
40 Nm; 30 lbft
≤ 4 Nm;
≤ 3 lbft
106
106
102
102
107
25
82
81
102
108
*
*
*
*
*
25a
25a
106
29
40 Nm; 30 lbft
2a
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Do not dismount the piston of the spool and
sleeve assembly (pos. 37).
* Observe assembly instructions.
Grease all O-rings
with Mobilux EP2
(pos. 102)
Page 100
100
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
PROTEC 10" air motor spare parts list
Pos K Stk Designation Order No.
14 1 Silencer 9 369310
15
1 O-ring 9974165
16 3 Socket cap screw; hexagon socket, M8X35 9900314
17 3 Washer 8.4 9925029
18 1 Connecting part 9 369309
19
1 Sound deadening pad 9/12" 369330
20 2 O-ring 9974132
21 1 Safety valve 2353894
22 1 Angular plug connection 9992718
23 2 Air hose back 369026
24 2 Straight screw-in ttings 9998993
25
2 Pilot valve 369290
25a
2 Rod seal 9974217
26 2 Outlet seal 9 369312
27 1 Y-plug connection 3159464
28 0.5 m Hose 8x1 L=42mm 9982078
29 1 Male stud elbow, 8-1/8 9992757
30 2 Cotter pin 2355809
31 1 Control- ange 10 2345960
33 1 Pressure regulator unit 10": see Chapter 13.7.1.1 -34 1 Plug 10 2354547
35
2 O-ring 2362554
36 1 Spool-sleeve combination assembly, ISO3 369907
37
1 Spool & sleeve assembly ISO3 9943131
38 6 O-ring 9974143
39 2 Damper ISO3 369329
40 1 Detent element, complete ISO 3 369027
41 1 Lock space 10 2354548
42 1 Cover 2354549
43 1 O-ring 9971375
44 1 Securing ring 9999360
45 1 Threaded plug, G1/4" 9998274
46 1 Filter holder 367324
47
1 Control air lter 367314
48 1 Filter compressed air 9 369313
49 1 Throttle 367325
51 1 Hexagon nut 9913051
52 1 Piston 10 2347028
53
1 O-ring 2347183
54 2 Pistonwasher 12 370303
55 2 Damping washer 12 370304
56
1 Piston rod 10 2348760
= Wearing part
= Included in service set
= Not part of the standard equipment but available as a special accessory.
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