Wagner SprayTech 40-15, 20-30 User Manual

Translation of the Original Operating Manual

Version 03/2013

Piston Pumps

Flow Rate 15 cm3 - 30 cm

II 2G IIB c T3 X

B_04119

VERSION 03/2013 ORDER NUMBER DOC 2310799

OPERATING MANUAL

Contents

1 ABOUT THIS OPERATING MANUAL 5

1.1 Preface 5

1.2 Warnings, Notices, and Symbols in this Operating Manual 5

1.3 Languages 6

1.4 Abbreviations in the Text 6

2 CORRECT USE 7

2.1 Device Types 7

2.2 Type of Use 7

2.3 Use in an Explosion Hazard Area 7

2.4 Safety Parameters 7

2.5 Processible Materials 8

2.6 Reasonably Foreseeable Misuse 8

2.7 Residual Risks 9

3 IDENTIFICATION 10

3.1 Explosion Protection Identi cation 10

3.2 Identi cation X 10

4 GENERAL SAFETY INSTRUCTIONS 11

4.1 Safety Instructions for the Operator 11

4.1.1 Electrical Equipment 11

4.1.2 Sta Quali cations 11

4.1.3 Safe Work Environment 11

4.2 Safety Instructions for Sta 12

4.2.1 Safe Handling of WAGNER Spray Devices 12

4.2.2 Grounding the Device 13

4.2.3 Material Hoses 13

4.2.4 Cleaning 14

4.2.5 Handling Hazardous Liquids, Varnishes, and Paints 14

4.2.6 Touching Hot Surfaces 14

4.3 Use in Areas Subject to Explosion Hazards 15

4.3.1 Safety Regulations 15

4.3.2 Operation without Fluid 15

5 DESCRIPTION 16

5.1 Field of Application 16

5.1.1 Correct Use 16

5.1.2 Processible Materials 16

5.2 Scope of Delivery 17

5.3 Data 17

5.3.1 Materials of Paint-wetted Parts 17

5.3.2 Technical Data 18

5.3.3 Measurements and Connections for FineFinish 40-15 20

5.3.4 Measurements and Connections for FineFinish 20-30 21

5.3.5 Performance Diagrams 22

5.4 Function 25

5.4.1 Pump 25

5.4.2 Pressure Regulator Unit 26

5.4.3 Safety and Motor Pressure Relief Valve 27

5.4.4 Return Valve 27

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Contents

6 ASSEMBLY AND COMMISSIONING 28

6.1 Transportation 28

6.2 Storage 28

6.3 Assembling the Pump 29

6.4 Grounding 30

6.5 Commissioning 32

6.5.1 Safety Instructions 32

6.5.2 Filling with Separating Agent 34

6.5.3 Basic Flushing 35

7 OPERATION 36

7.1 Filling with Working Material 36

7.2 Work 37

7.2.1 Spraying 37

7.2.2 Pressure Relief/Work Interruption 38

7.2.3 Decommissioning and Cleaning 39

7.3 Long-term Storage 40

8 TROUBLESHOOTING AND RECTIFICATION 41

9 MAINTENANCE 42

9.1 High-pressure Hoses 43

9.2 Decommissioning 43

10 ACCESSORIES 44

11 SPARE PARTS 47

11.1 How Can Spare Parts Be Ordered? 47

11.2 Overview of the Components 48

11.2.1 Components for FineFinish 40-15 48

11.2.2 Components for FineFinish 20-30 49

11.3 Air Motor 50

11.3.1 Reversing Valve 53

11.4 Fluid sections 54

11.4.1 Fluid Section 15 54

11.4.2 Fluid Section 30 56

11.5 Air Regulator Set 58

11.6 Air Regulator Set for AirCoat Air 59

11.7 Trolley, 4" 60

11.8 4-Wheel Trolley 61

12 3+2 YEARS GUARANTEE FOR PROFESSIONAL FINISHING 62

12.1 Scope of Guarantee 62

12.2 Guarantee Period and Registration 62

12.3 Handling 62

12.4 Exclusion of Guarantee 63

12.5 Additional Regulations 63

12.6 CE Declaration of Conformity 65

12.7 Reference to German Regulations and Guidelines 65

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1 ABOUT THIS OPERATING MANUAL

1.1 PREFACE

The operating manual contains information about safely operating, maintaining, cleaning and repairing the device. The operating manual is part of the device and must be available to operating and service sta . Operating and service sta should be instructed according to the safety instructions. The device may only be operated in compliance with this operating manual. This equipment can be dangerous if it is not operated according to the instructions in this operating manual.

1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL

Warning instructions in this operating manual highlight particular dangers to users and to the device and state measures for avoiding the hazard. These warning instructions fall into the following categories:

DANGER

Danger - immediate risk of danger.

Non-observance will result in death or serious injury.

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.

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The following are measures which can be taken to prevent the hazard and its consequences.

WARNING

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The following are measures which can be taken to prevent the hazard and its consequences.

CAUTION

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The following are measures which can be taken to prevent the hazard and its consequences.

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

This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level.

The following are measures which can be taken to prevent the hazard and its consequences.

NOTICE

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

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1.3 LANGUAGES

The operating manual is available in the following languages:

Language Order No. Language Order No.

German 2310798 English 2310799 French 2310800 Spanish 2310803 Italian 2310802 Dutch 2310801 Portuguese 2310804 Swedish 2310806 Danish 2310805

1.4 ABBREVIATIONS IN THE TEXT

Number of pieces Position Marking in the spare parts lists

Order No. Order No. No. Number

Double stroke Stainless steel Two components

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2 CORRECT USE

2.1 DEVICE TYPES

Pneumatic pump with spraypack:

2.2 TYPE OF USE

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

2.3 USE IN AN EXPLOSION HAZARD AREA

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

2.4 SAFETY PARAMETERS

WAGNER accepts no liability for any damage arising from incorrect use.

Use the device only to work with the materials recommended by WAGNER. Only operate the device as a whole. Do not deactivate safety  xtures. Use only WAGNER original spare parts and accessories.

The pneumatic pump may only be operated under the following conditions:

The operating sta must be trained on the basis of this operating manual. The safety regulations listed in this operating manual must be observed. The operating, maintenance, and repair information in this operating manual must

be observed. The statutory requirements and accident prevention regulation standards in the

country of use must be observed.

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2.5 PROCESSIBLE MATERIALS

Fluid materials such as paints and varnishes.

NOTICE

Abrasive materials and pigments!

Greater wear of parts carrying the material.

Use the application-oriented model ( ow rate/cycle, material, valves, etc.) as

indicated in Chapter 5.3.2.

Check if the  uids and solvents used are compatible with the pump construction

materials as indicated in Chapter 5.3.1.

2.6 REASONABLY FORESEEABLE MISUSE

The following is prohibited:

coating work pieces which are not grounded, unauthorized conversions and modi cations to the pneumatic pump, processing powder or similar coating materials, and using defective components, spare parts, or accessories other than those described

in Chapter 10 of this operating manual.

The forms of misuse listed below may result in health issues and/or material damage:

use of powder as coating material and incorrectly set values for processing.

Wagner pneumatic pumps are not designed for pumping food.

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2.7 RESIDUAL RISKS

Residual risks are risks which cannot be excluded even in the event of correct use. If necessary, warning and prohibition signs at the relevant points of risk indicate residual risks.

Residual risk Source Consequences Speci c measures Lifecycle phase

Skin contact with paints and cleaning agents

Paint in air outside the de ned working area

Handling of paints and cleaning agents

Painting outside the de ned working area

Skin irritations, Wear protective

clothing,

allergies Observe safety data

sheets

Inhalation of substances which are hazardous to health

Observe working and operating instructions

Operation,

maintenance,

disassembly Operation,

maintenance

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3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

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

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

3.2 IDENTIFICATION X

Maximum surface temperature

The maximum surface temperature of the piston pump can be reached if it runs dry.

Ensure that the piston pump is  lled with su cient working or  ushing agent. Ensure that the separating agent container is  lled with su cient separating agent.

Ignition temperature of the coating material

Ensure that the ignition temperature of the coating material is above the maximum

surface temperature.

Ambient temperature

The permissible ambient temperature is: +5 °C to +60 °C; +41 °C to 140 °F.

Medium supporting atomizing

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

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4 GENERAL SAFETY INSTRUCTIONS

4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR

Keep this operating manual at hand near the unit 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. Must be operated in accordance with the safety regulations and electrotechnical

regulations. Must be repaired immediately in the event of problems. Must be decommissioned if they pose a hazard. Must be de-energized before work is commenced on active parts. Inform sta about

planned work. Observe electrical safety regulations.

4.1.2 STAFF QUALIFICATIONS

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

4.1.3 SAFE WORK ENVIRONMENT

Ensure that the  oor in the working area is electrically conductive in accordance with

EN61340-4-1 (resistance must not exceed 100 Mohm). Ensure that all persons within the working area wear electrostatically conductive shoes.

Footwear must comply with EN 20344. The measured insulation resistance must not

exceed 100 Mohm. Ensure that during spraying, persons wear electrically conductive gloves. The grounding

takes place via the spray gun handle. If protective clothing is worn, including gloves, it has to comply with EN1149-5. The

measured insulation resistance must not exceed 100 Mohm. Paint mist extraction systems must be  tted on site according to local regulations. Ensure that the following components of a safe working environment are available:

– Material/air hoses adapted to the working pressure. – Personal safety equipment (breathing and skin protection).

Ensure that there are no ignition sources such as naked  ames, sparks, glowing wires,

or hot surfaces in the vicinity. Do not smoke.

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4.2 SAFETY INSTRUCTIONS FOR STAFF

Always follow the information in these instructions, particularly the general safety

instructions and the warning instructions.

Always follow local regulations concerning occupational safety and accident

prevention.

4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES

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

Never point the spray gun at people. Never reach into the spray jet.

Before all work on the device, in the event of work interruptions and functional faults: – Switch o the energy/compressed air supply. – Relieve the pressure from the spray gun and device. – Secure the spray gun against actuation. – In the event of functional faults: remedy the fault as described in the " Troubleshooting"

chapter.

The liquid emitters are to be checked for safe working conditions by an expert

(e.g. Wagner Service Technician) as often as necessary or at least every 12 months, in accordance with the guidelines for liquid emitters (ZH1/406 and BGR500 Part 2 Chapter2.36).

– For shut down devices, the examination can be suspended until the next commissioning.

Carry out the work steps as described in the "Pressure Relief/Work Interruptions"

chapter: – if pressure relief is required. – if the spraying work is interrupted or stopped. – before the device is cleaned on the outside, checked, or serviced. – before the spray nozzle is installed or cleaned. In the event of skin injuries caused by paint or cleaning agents:

Note down the paint or cleaning agent that you have been using. Consult a doctor immediately.

Avoid danger of injury through recoil forces:

Ensure that you have ﬁrm footing when operating the spray gun. Only hold the spray gun brie y in a position.

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4.2.2 GROUNDING THE DEVICE

In order to avoid electrostatic charging of the device, the device must be grounded. Friction,  owing liquids, and air or electrostatic coating processes create charges. Flames or sparks can form during discharge.

Ensure that the device is grounded for every spraying operation. Ground the work pieces to be coated. Ensure that all persons inside the working area are grounded, e.g. that they are wearing

electrostatically conductive shoes.

Wear electrostatically conductive gloves when spraying. The grounding takes place via

the spray gun handle.

4.2.3 MATERIAL HOSES

Ensure that the hose material is chemically resistant to the sprayed materials. Ensure that the material hose is suitable for the pressure generated in the device.

Ensure that the following information can be seen on the high-pressure hose: – Manufacturer – Permissible operating overpressure – Date of manufacture

Make sure that the hoses are laid only in suitable places. In no case, should hoses be laid

in the following places: – in high-trafﬁc areas, – on sharp edges, – on moving parts, or – on hot surfaces

Make sure that the hoses are never used to pull or move the equipment.

The electrical resistance of the complete high-pressure hose must be less than 1 Mohm. Several liquids have a high expansion 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 container, ensure that air or suitable gas can enter the container to avoid a vacuum being generated in the container itself. Thus a negative pressure is avoided. The vacuum could implode the container (squeeze) and can cause it to break. The container would leak and the liquid would  ow out. The pressure created by the pump is a multiplication of the inlet air pressure.

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4.2.4 CLEANING

De-energize the device electrically.

Disconnect the pneumatic supply line.

Relieve the pressure from the device.

Ensure that the ﬂash point of the cleaning agent is at least 5 K above the ambient

temperature.

To clean, use cloths and brushes moistened with solvent. Never use hard objects or

spray on cleaning agents with a gun.

Preferably, non-combustible cleaning agents should be used.

An explosive gas/air mixture forms in closed containers.

When cleaning devices with solvents, never spray into a closed container.

Only use electrically conductive containers for cleaning liquids.

The containers must be grounded.

4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES, AND PAINTS

When preparing or working with paint and when cleaning the device, follow the

working instructions of the manufacturer of the paints, solvents, and cleaning agents being used.

Take the speci ed protective measures. In particular, wear safety goggles, protective

clothing, and gloves, as well as hand protection cream if necessary. Use a mask or a breathing apparatus if necessary. For 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 materials.

4.2.6 TOUCHING HOT SURFACES

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

- Identify the device with a warning label "Warning - hot surface".

Order No.

9998910 Instruction label 9998911 Protection sticker

Note: Order the two stickers together.

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4.3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS

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

4.3.1 SAFETY REGULATIONS

Safe handling of WAGNER spray devices

Mechanical sparks can form if the device comes into contact with metal. In an explosive atmosphere:

Do not knock or push the unit against steel or rusty iron. Do not drop the device. Only use tools that are made of a permitted material.

Ignition temperature of the pumped material

Check that the ignition temperature of the pumped material is higher than the max.

allowable surface temperature.

Medium supporting atomizing

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

Surface spraying, electrostatics

Do not spray device parts using electrostatic equipment.

Cleaning

If there are deposits on the surfaces, the device may form electrostatic charges. Flames or sparks can form during discharge.

Remove deposits from the surfaces to maintain conductivity. Only use a damp cloth to clean the device.

4.3.2 OPERATION WITHOUT FLUID

Avoid running the pump so that it sucks in air (without  uid inside). The air, combined with the vapor of  ammable  uids, can generate internal areas with an explosion hazard. Periodically check that the pump is working smoothly, paying special attention to the presence of air in the pumped  uid, which may be caused by damaged packings.

Avoid operating the pump with damaged packings. Ensure that the separating agent container is  lled with su cient separating agent.

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5 DESCRIPTION

5.1 FIELD OF APPLICATION

5.1.1 CORRECT USE

The pneumatic piston pump is suitable for conveying and processing (AirCoat technique) liquid materials in accordance with Chapter 5.1.2.

5.1.2 PROCESSIBLE MATERIALS

Application

Water-based materials Solvent-based materials Low viscosity (<40 sec. DIN No. 4) Medium viscosity (40 to 60 sec. DIN No. 4) High viscosity ( >60 sec. DIN No. 4) UV - sensitive materials Shear sensitive materials Humidity sensitive materials

Legend

recommended limited suitability less suitable

NOTICE

Abrasive materials and pigments!

Greater wear of parts carrying the material.

Use suitable combinations of devices (packings, valves, etc.)

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5.2 SCOPE OF DELIVERY

Pneumatic piston pump consisting of:

- Fluid section

- Air motor

- Connection elements

Separating agent 250 ml Order No.: 9992504 Conformity certi cate GM2000W see Chapter 12 Operating manual, German Order No.: 2310798 Operating manual in the local language see Chapter 1

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

5.3 DATA

5.3.1 MATERIALS OF PAINTWETTED PARTS

Pump housing Stainless steel Piston Stainless steel Valve balls Stainless steel Valve seats Stainless steel Static seals Packings

Ultra high molecular weight polyethylene

PTFE

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5.3.2 TECHNICAL DATA

Description Units

Pump ratio 40:1 Volume  ow per double stroke cm; cc 15 30

Maximum operating overpressure MPa 25.0 16.0

bar 250 160

psi 3626 2320 Maximum possible strokes in operation /min 60 60 Minimum/maximum air inlet pressure MPa 0.2-0.8

bar 2-8

psi 28-116 Ø air inlet connection (inside thread) mm 8.0

inch 0.31

Minimum Ø of the compressed air supply line mm 9.0

inch 0.35

Air consumption at 0.6 MPa; 6 bar; 87 psi per double stroke nl 3.9

scf 0.14 Air motor piston diameter mm 80

inch 3.15

Air motor piston stroke mm 60

inch 2.4

Sound pressure level at maximum permissible air pressure* dB(A) 72 Sound pressure level at 0.6 MPa; 6 bar; 87 psi air pressure* dB(A) 69 Sound pressure level at 0.4 MPa; 4 bar; 58 psi air pressure* dB(A) 65 Material inlet (outside thread) mm M36x2 Material outlet (outside thread) inch NPS 1/4"

Weight kg 9 11

lb 19.8 24.7 Material pH value pH 3.5 ÷ 9 Maximum material pressure at pump inlet MPa 2

bar 20

psi 90

Material temperature

Ambient temperature +5 ÷ +60

Allowable inclination for operation ± 10

20:1

+5 ÷ +80

+41 ÷ +176

+41 ÷ +140

* A-rated sound pressure level measured at 1 m distance, LpA1m, in accordance with DIN EN 14462: 2005.

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WARNING

Outgoing air containing oil!

Risk of poisoning if inhaled. Air motor switching problems.

Provide compressed air free from oil and water

(Quality Standard 5.5.4 in accordance with ISO 8573.1)

5.5.4 = 40 m / +7 / 5 mg/m³.

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5.3.3 MEASUREMENTS AND CONNECTIONS FOR FINEFINISH 4015

mm inch

A 104 4.09 B 108.5 4.27 C 621 24.45 D 276.5 10.89

E 134 5.28 F1 G 1/4" F2 NPS 1/4"

G M36x2 H1 G 1/4" H2 8 0.31

I 210 8.27

J 207 8.15

K 86 3.39

L 7 0.28

M 182 7.17

N 80 3.15

O 106 4.17

P 96.5 3.8

Q ø 9 ø 0.35

R ø 7 ø 0.28

S 149 5.87 T ø 25 ø 1

Wall mount

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5.3.4 MEASUREMENTS AND CONNECTIONS FOR FINEFINISH 2030

mm inch

A 104 4.09 B 108.5 4.27 C 643 25.3 D 201 7.91

E 134.5 5.3 F1 G 3/8" F2 NPS 1/4"

G M36x2 H1 G 1/4" H2 8 0.31

I 210 8.27

J 207 8.15

K 80 3.15

L 7 0.28

M 182 7.17

N 80 3.15

O 106 4.17

P 96.5 3.8

Q ø 9 ø 0.35

R ø 7 ø 0.28

S 149 5.87 T ø 25 ø 0.98

Wall mount

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