WAGNER PROTEC GM 1-530, PROTEC GM 1-350 Translation Of The Original Operating Manual
Translation of the Original
Operating Manual
For professional use.
Always follow the information in this manual,
particularly the safety instructions and the warning
instructions. Store the manual in a safe place.
PROTEC GM 1-350
PROTEC GM 1-530
Airless manual gun
Version 07/2017
B_5040
VERSION 07/2017
ORDER NUMBER DOC 2349369
OPERATING MANUAL
Contents
1 ABOUT THESE INSTRUCTIONS 3
1.1 Preface 3
1.2 Warnings, Notices and Symbols in these Instructions 3
1.3 Languages 4
1.4 Abbreviations 4
1.5 Terminology for the Purpose of this Manual 4
2 CORRECT USE 5
2.1 Device type 5
2.2 Type of Use 5
2.3 For Use in Potentially Explosive Areas 5
2.4 Processible Working Materials 5
2.5 Misuse 5
3 IDENTIFICATION 6
3.1 Explosion protection identication 6
3.2 Identication "X" 6
3.3 Use in areas subject to explosion hazards 6
3.4 Example Type Plate: PROTEC GM 1-530 7
4 BASIC SAFETY INSTRUCTIONS 7
4.1 Safety instructions for the operator 7
4.2 Safety instructions for sta 8
5 DESCRIPTION 13
5.1 Components 13
5.2 Mode of operation 13
5.3 Safety xtures 13
5.4 Included items 14
5.5 Data 14
6 ASSEMBLY AND COMMISSIONING 15
6.1 Training of Assembly/Commissioning Sta 15
6.2 Storage conditions 15
6.3 Typical Airless Spraying System 15
6.4 Grounding 16
6.5 Lacquer Preparations 16
6.6 Commissioning 17
7 OPERATION 18
7.1 Training the operating sta 18
7.2 Work 18
8 CLEANING AND MAINTENANCE 22
8.1 Cleaning 22
8.2 Maintenance 23
9 TROUBLESHOOTING 27
10 REPAIR WORK 28
10.1 Repair Sta 28
11 DISPOSAL 28
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12 ACCESSORIES 29
12.1 Nozzle for nozzle holder PT-HD GM1 29
12.2 Nozzle for nozzle holder WAGNER Tip 7/8 UNF 30
12.3 Nozzle for anti-contact guard 7/8 UNF 30
13 SPARE PARTS 31
13.1 How to order spare parts? 31
13.2 Spare Parts List PROTEC GM 1-350/530 32
14 GUARANTEE AND CONFORMITY DECLARATIONS 34
14.1 Important notes on product liability 34
14.2 Warranty claim 34
14.3 EU Declaration of Conformity 35
1 ABOUT THESE INSTRUCTIONS
1.1 PREFACE
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device.
The operating manual is part of the device and must be available to the operating and
service personnel.
The device may only be operated by trained personnel and in compliance with this
operating manual.
Operating and service personnel should be instructed according to the safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this operating manual highlight particular dangers to users and to
the device and state measures for avoiding the hazard. These warning instructions fall into
the following categories:
DANGER
WARNING
CAUTION
Immediate risk of danger.
Non-observance will result in death or serious injury.
Potential risk.
Non-observance may result in death or serious injury.
Potentially hazardous situation.
Non-observance may result in minor injury.
Note
NOTICE
Potentially hazardous situation.
Non-observance may result in damage to property.
Provides information about particular characteristics and
how to proceed.
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Explanation of warning:
LEVEL OF DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The measures for preventing the hazard and its consequences.
1.3 LANGUAGES
The operating manual is available in the following languages:
Language Order No. Language Order No. Language Order No.
German 2348756 English 2349369 French 2355489
Italian 2355491 Spanish 2355493 Russian 2356564
Chinese 2356565 Swedish 2356566 Polish 2356567
Norwegian 2356568 Dutch 2356570 Finnish 2356571
Czech 2356572 Japanese 2358025 Turkish 2388104
Supplement for WAGNER Tip nozzle holder: Service manual:
Language Order No.
German, English, French, Spanish,
Italian, Dutch
1088951
Language Order No.
German 2355505
English 2355506
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order No. Order number Low-viscosity (LV) products
Spare part High-viscosity (HV) products
Marking in the spare parts lists Low air
Position Manual gun
Number of pieces AirCoat
Wrench size -- --
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning agent
Flushing Internal ushing with compressed air of parts carrying paint
Product pressure
generator
Sta qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks associated with
Electrically trained
person
Electrician Can assess the work assigned to him/her and detect possible hazards based on his/
Pump or pressure tank
improper behavior as well as the necessary protective devices and measures.
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.
her technical training, knowledge and experience in relevant provisions.
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Skilled person in
accordance with TRBS
1203
(2010/Revision 2012)
A person, who, based on his/her technical training, experience and recent vocational
experience, has sucient technical knowledge in the areas of explosion protection,
protection from pressure hazards and electric hazards (if applicable) 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.
2 CORRECT USE
2.1 DEVICE TYPE
Airless manual gun for manually coating work pieces.
2.2 TYPE OF USE
The spray gun is intended for atomizing liquid coating products under pressure (airless
process).
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Only operate the device as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
Follow the instructions in the operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device is suitable for use in potentially explosive areas as dened in Directive
2014/34/EU (ATEX), (see Explosion protection marking Chapter 3.1).
2.4 PROCESSIBLE WORKING MATERIALS
Top-coat lacquers, primer paints, corrosion protection, textured lacquers, lyes, staining
solvents, clear lacquers, separating agents, etc. with a solvent or water base. If you want
to spray working materials other than the aforementioned, please contact a WAGNER
representative.
Note:
Contact your local WAGNER dealer and the lacquer manufacturer if you encounter
application problems.
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
No dry coating products, e.g. powder are processed;
Do not process food, medicine or cosmetics.
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device type: Airless manual gun
Manufacturer: Wagner International AG
CH-9450 Altstätten, Switzerland
II 2G X
CE European Communities
Ex Symbol for explosion protection
II Device class II
2 Category 2 (Zone 1)
G Ex-atmosphere gas
X Special notes (see Chapter 3.2)
3.2 IDENTIFICATION "X"
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature (85°C; 185°F).
Ambient temperature
Permissible ambient temperature: +5 °C to +40 °C; +41 °F to +104 °F.
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.
3.3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS
Safe handling of WAGNER spray devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the device or components and tools against steel or rusty iron.
Do not drop the device or components and tools.
National regulations
Ensure that the national explosion prevention rules and regulations are observed
when setting up the device.
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3.4 EXAMPLE TYPE PLATE: PROTEC GM 1530
Designation
1 Wagner International AG
2 Serial number
3 Production date (month/year)
4 Spray gun designation
5 Maximum product pressure
6 Maximum product temperature
KEEP CLEAR OF TIP
7 * Keep clear of nozzle
8 * Maximum product pressure
7
53 MPa 7700 psi
8
9 * Injection hazard
INJECTION HAZARD
10 Warning
9
11 Skin injection hazard/Read
instruction manual
12 Fire and explosion hazard/read
operating manual
13 "Warning – Hot surface!"
WARNING
10
SKIN INJECTION HAZARD
11
READ INSTRUCTION MANUAL
FIRE AND EXPLOSION HAZARD
12
READ INSTRUCTION MANUAL
* For nozzle holder PT-HD GM1
4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
II 2G X
Wagner Int. AG
1
CH-9450 Altstaetten
2
Serial-No. XXXXX
3
SWISS MADE
MM/JJ
4
5
MAX WPR
530 bar
7700 psi
PROTEC
GM 1-530
B_06752
MAX TEMP
85 °C
185 °F
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Electric shock hazard!
Danger to life from electric shock
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, there is a danger from line voltage.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if it poses a hazard or is damaged.
Must be de-energized before work is commenced. Inform 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.
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4.1.2 A SAFE WORK ENVIRONMENT
Hazard due to dangerous uids or steam!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working are is static dissipative in accordance
withEN61340-4-1 (resistance must not exceed 100 MΩ).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g. mechanical
stress, corrosion).
Ensure that product / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment (see Chapter 4.2.1) is available and is
used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 MΩ.
Ensure that during spraying, persons wear electrically conductive gloves. The
grounding takes place via the spray gun handle or the trigger.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 MΩ.
Ensure that there are no ignition sources such as naked 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 of the connections etc.).
- Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g., daily before commissioning, at the end of work or weekly.
In the event of defects, immediately bring the device or system to a stop and
arrange to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Hazard due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.
4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
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4.2.1 USE PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or steam!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
When preparing or working with paint and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents, and cleaning
agents being used.
Take the specied protective measures. In particular wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient health and environmental safety: Operate the device in a spray booth
or on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.
4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Hazard due to injection of lacquer or ushing agent into the skin!
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 any work on the device, in the event of work interruptions and malfunctions:
- Relieve the pressure from the spray gun and device.
- Secure the spray gun 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.
If needed, the liquid ejection devices must be checked by experts (e.g., WAGNER
service technician) at least every 12 months for their work-safe condition in
accordance with DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36.
– For shut down devices, the examination can be suspended until the next start-
up.
Carry out the work steps as described in the "Pressure relief" 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 lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
Danger due to recoil forces!
Actuating the trigger can causes strong recoil forces. Thereby the user can lose his
balance and injure himself during falling.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
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4.2.3 GROUND THE UNIT
Hazard due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that all devices and tanks are grounded before each spraying process.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
Wear static dissipative gloves when spraying. The grounding takes place via the
spray gun handle or the trigger.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.
4.2.4 PRODUCT HOSES
Hazard due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
Ensure that the hose material is chemically resistant to the sprayed products and
the ushing agents used.
Ensure that the product hose and the ttings are suitable for the pressure
generated.
Ensure that the following information can be seen on the high-pressure hose:
- Manufacturer
– Permissible operating pressure
- Date of manufacture
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
- in high-traffic areas,
- at sharp edges,
- on moving parts or
- on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the
hoses are never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Ensure that no work is ever performed with a damaged hose.
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 MΩ.
Suction hoses may not be subjected to pressure.
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4.2.5 CLEANING AND FLUSHING
Hazard due to cleaning and ushing
Explosion hazard and damage to the device.
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 specications 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.
Explosive gases are produced when aluminum comes into contact with
halogenated hydrocarbons. To clean aluminum, do not use liquids containing
halogenated hydrocarbons.
Take measures for workplace safety (see Chapter 4.1.2).
When commissioning or emptying the device, please note that an explosive
mixture may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- depending on the ushing agent (solvent) used,
an explosive mixture may temporarily exist inside the lines and items of equipment.
Only electrically conductive tanks may be used for cleaning and 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:
Relieve the pressure from the device.
De-energize the device electrically.
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects
and never spray cleaning agents with a gun. Cleaning the device must not damage
it in any way.
Ensure that no electric component is cleaned with or immersed into solvent.
4.2.6 TOUCHING HOT SURFACES
Hazard due to hot surfaces because of hot coating products!
Risk of burn injuries
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109 °F:
- Identify the device with a warning label "Warning – hot surface".
Order No.
9998910 Instruction label
9998911 Protection label
Note: Order the two stickers together.
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