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Translation of the Original Operating Manual Version 01/2013 Piston Pumps Flow Rate 15 cm3 II 2G IIB c T3 X B_04119 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL Contents 1 1.1 1.2 1.3 1.4 ABOUT THESE INSTRUCTIONS Preface Warnings, Notices and Symbols in these Instructions Languages Abbreviations in the Text 5 5 5 6 6 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 CORRECT USE Device Types Type of Use Use in an Explosion Hazard Area Safety Parameters Processible Materials Reasonably Foreseeable Misuse Residual Risks 7 7 7 7 7 8 8 9 3 3.1 3.2 IDENTIFICATION Explosion Protection Identification Identification X 10 10 10 4 4.1 4.1.1 4.1.2 4.1.3 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.3 4.3.1 4.3.2 GENERAL SAFETY INSTRUCTIONS Safety Instructions for the Operator Electrical Equipment Personnel Qualifications Safe Work Environment Safety Instructions for Staff Safe Handling of WAGNER Spray Devices Grounding the Device Material Hoses Cleaning Handling Hazardous Liquids, Varnishes and Paints Touching Hot Surfaces Use in Areas Subject to Explosion Hazards Safety Regulations Operation without Fluid 11 11 11 11 11 12 12 13 13 14 14 14 15 15 15 5 5.1 5.1.1 5.1.2 5.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.4 5.4.1 5.4.2 5.4.3 5.4.4 DESCRIPTION Field of Application Correct Use Processible Materials Scope of Delivery Data Materials of Wetted Parts Technical Data Measurements and Connections Performance Diagrams Function Pump Pressure Regulator Unit Safety and Motor Pressure Relief Valve Return Valve 16 16 16 16 17 17 17 17 19 20 21 21 22 23 23 3 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 6 6.1 6.2 6.3 6.4 6.5 6.5.1 6.5.2 6.5.3 ASSEMBLY AND COMMISSIONING Transportation Storage Assembling the Pump Grounding Commissioning Safety Instructions Filling with Separating Fluid Basic Cleaning 24 24 24 25 26 28 28 30 31 7 7.1 7.2 7.2.1 7.2.2 7.2.3 7.3 OPERATION Filling with Working Material Work Spraying Pressure Relief / Work Interruption Decommissioning and Cleaning Long-term Storage 32 32 33 33 34 35 35 8 TROUBLE SHOOTING AND RECTIFICATION 36 9 9.1 9.2 MAINTENANCE High-pressure Hoses Decommisioning 38 39 39 10 ACCESSORIES 40 11 11.1 11.2 11.3 11.3.1 11.4 11.5 11.6 11.7 11.8 SPARE PARTS How Can Spare Parts Be Ordered? Overview of Components Air Motor Reversing Valve Fluid Section 15 Air Regulator Set for EvoMotion 40-15 Air Regulator Set for AirCoat Air Trolley, 4" 4-Wheel Trolley 44 44 45 46 49 50 52 53 54 55 12 12.1 12.2 12.3 12.4 WARRANTY AND CONFORMITY DECLARATIONS Important Notes Regarding Product Liability Warranty Claim CE Declaration of Conformity Reference to German Regulations and Guidelines 56 56 56 57 57 4 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 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 operating and service staff. Operating and service personnel 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 definitions 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 device and state measures for avoiding the hazard. These warning instructions fall into the following categories: DANGER This information warns you of a hazard! Danger - immediate risk of danger. Possible consequences of not observing the warning instructions. The signal word indicates the hazard level. Non-observance will result in death or serious injury. The measures consequences. Warning - possible imminent danger. Non-observance may result in death or serious injury. the hazard and its WARNING for preventing the hazard and its CAUTION This information warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level. The measures consequences. Notice - a possibly hazardous situation. Non-observance may result in material damage. preventing This information warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level. The measures consequences. Caution - a possibly hazardous situation. Non-observance may result in minor injury. for for preventing the hazard and its NOTICE This information 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. Note - provides information about particular characteristics and how to proceed. 5 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 1.3 LANGUAGES The operating manual is available in the following languages: Language Order No. Language German 2333557 English French 2333559 Spanish Italian 2333560 1.4 Order No. 2333558 2333561 ABBREVIATIONS IN THE TEXT Order No. No. Number of pieces Position Marking in the spare parts lists Order number Number Double stroke Stainless steel Two components 6 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 2 CORRECT USE 2.1 DEVICE TYPES Pneumatic pump with spraypack 40-15 2.2 TYPE OF USE The device is suitable for processing liquid materials like paints and varnishes in accordance with the classification into explosion classes IIA or IIB. 2.3 USE IN AN EXPLOSION HAZARD AREA The pneumatic pump can be employed in explosion hazard zones (Zone 1). 2.4 SAFETY PARAMETERS WAGNER accepts no liability for any damage arising from incorrect use. Use the device only to work with the materials recommended by WAGNER. Only operate the device as a whole. Do not deactivate safety fixtures. Use only WAGNER original spare parts and accessories. The pneumatic pump may only be operated under the following conditions: The operating staff must be trained on the basis of this operating manual. The safety regulations listed in this operating manual must be observed. The operating, maintenance and repair information in this operating manual must be observed. The statutory requirements and accident prevention regulation standards in the country of use must be observed. 7 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 2.5 PROCESSIBLE MATERIALS Fluid materials like paints and varnishes. NOTICE Abrasive materials and pigments! Greater wear of parts carrying the material. Use the application-oriented model (flow rate/cycle, material, valves, etc.) as indicated in Chapter 5.3.2. Check if the fluids and solvents used are compatible with the pump construction materials as indicated in Chapter 5.3.1. 2.6 REASONABLY FORESEEABLE MISUSE The following is prohibited: coating work pieces which are not grounded, unauthorized conversions and modifications to the pneumatic pump, processing dry 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 equipment damage: use of powder as coating material and incorrectly set values for processing. Wagner pneumatic pumps are not designed for pumping food. 8 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 2.7 RESIDUAL RISKS Residual risks are risks which cannot be excluded even in the event of correct use. If necessary, warning and prohibition signs at the relevant points of risk indicate residual risks. Residual risk Source Consequences Skin contact with Handling of paints Skin irritations, paints and cleaning and cleaning agents agents allergies Paint in air outside Painting outside the Inhalation of substances which the defined working defined working area are hazardous to area health Specific measures Lifecycle phase Wear protective Operation, clothing, observe safety data maintenance, sheets disassembly Observe working Operation, and operating instructions maintenance 9 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 3 IDENTIFICATION 3.1 EXPLOSION PROTECTION IDENTIFICATION As defined in the 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 security Temperature class: maximum surface temperature < 200 °C; 392 °F Special Notes (see Chapter 3.2) 3.2 IDENTIFICATION X Maximum surface temperature The maximum surface temperature of the piston pump can be reached if it runs dry. Ensure that the piston pump is filled with sufficient working or flushing agent. Ensure that the separating fluid container is filled with sufficient separating fluid. 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. 10 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 4 GENERAL SAFETY INSTRUCTIONS 4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention. 4.1.1 ELECTRICAL EQUIPMENT Electrical devices and equipment To be provided in accordance with the local safety requirements with regard to the operating mode and ambient influences. May only be maintained by skilled electricians or under their supervision. Must be operated in accordance with the safety regulations and electrotechnical regulations. Must be repaired immediately in the event of problems. Must be decommissioned if they pose a hazard. Must be de-energized before work is commenced on active parts. Inform staff about planned work. Observe electrical safety regulations. 4.1.2 PERSONNEL QUALIFICATIONS Ensure that the device is operated and repaired only by trained persons. 4.1.3 SAFE WORK ENVIRONMENT Ensure that the floor in the working area is electrically conductive in accordance with EN 61340-4-1 (Resistance must not exceed 100 MOhm). Ensure that all persons within the working area wear electrostatically conductive shoes. Footwear must comply with EN 20344. The measured insulation resistance may 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 may not exceed 100 MOhm. Paint mist extraction systems must be fitted on site according to local regulations. Ensure that the following components of a safe working environment are available: – Material/air hoses adapted to the working pressure. – Personal safety equipment (breathing and skin protection). Ensure that there are no ignition sources such as naked flames, sparks, glowing wires or hot surfaces in the vicinity. Do not smoke. 11 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 4.2 SAFETY INSTRUCTIONS FOR STAFF Always follow the information in these instructions, particularly the general safety instructions and the warning instructions. Always follow local regulations concerning occupational safety and accident prevention. 4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or cleaning agents: Never point the spray gun at people. Never reach into the spray jet. Before all work on the device, in the event of work interruptions and functional faults: – Switch off the energy/compressed air supply. – Relieve the pressure from the spray gun and device. – Secure the spray gun against actuation. In the event of functional faults: remedy the fault as described in the "Trouble Shooting" chapter. The liquid emitters are to be checked for safe working conditions by an expert (e.g. Wagner Service Technician) as often as necessary or at least every 12 months, in accordance with the guidelines for liquid emitters (ZH 1/406 and BGR 500 Part 2 Chapter 2.36). – For shut down devices, the examination can be suspended until the next start-up. Carry out the work steps as described in the "Pressure Relief / Work Interruptions" chapter: – if pressure relief is required. – if the spraying work is interrupted or stopped. – before the device is cleaned on the outside, checked or serviced. – before the spray nozzle is installed or cleaned. In the event of skin injuries caused by paint or cleaning agents: Note down the paint or cleaning agent that you have been using. Consult a doctor immediately. Avoid danger of injury through recoil forces: Ensure that you have firm footing when operating the spray gun. Only hold the spray gun briefly in a position. 12 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 4.2.2 GROUNDING THE DEVICE In order to avoid electrostatic charging of the device, the device must be grounded. Friction, flowing liquids and air or electrostatic coating processes create charges. Flames or sparks can form during discharge. Ensure that the device is grounded for every spraying operation. Ground the work pieces to be coated. Ensure that all persons inside the working area are grounded, e.g. that they are wearing electrostatically conductive shoes. Wear electrostatically conductive gloves when spraying. The grounding takes place via the spray gun handle. 4.2.3 MATERIAL HOSES Ensure that the hose material is chemically resistant to the sprayed materials. Ensure that the material hose is suitable for the pressure generated in the device. Ensure that the following information can be seen on the high pressure hose: – Manufacturer – Permissible operating overpressure – Date of manufacture Make sure that the hoses are laid only in suitable places. In no case, should hoses be laid in the following places: – in high traffic areas, – on sharp edges, – on moving parts or – on hot surfaces. Make sure that the hoses are never used to pull or move the equipment. The electrical resistance of the complete high pressure hose must be less than 1 MOhm. Several liquids have a high expansion coefficient. In some cases their volume can rise with consequent damage to pipes, fittings, etc. and cause fluid leakage. When the pump sucks liquid from a closed container, ensure that air or suitable gas can enter the container to avoid a vacuum being generated 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 flow out. The pressure created by the pump is a multiplication of the inlet air pressure. 13 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 4.2.4 CLEANING De-energize the device electrically. Disconnect the pneumatic supply line. Relieve the pressure from the device. Ensure that the flash point of the cleaning agent is at least 5 K above the ambient temperature. To clean, use cloths and brushes moistened with solvent. Never use hard objects or spray on cleaning agents with a gun. Preferably, non-combustible cleaning agents should be used. An explosive gas/air mixture forms in closed containers. When cleaning devices with solvents, never spray into a closed container. Only use electrically conductive containers for cleaning liquids. The containers must be grounded. 4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS When preparing or working with paint and when cleaning the device, follow the working instructions of the manufacturer of the paints, solvents and cleaning agents being used. Take the specified protective measures. In particular, wear safety goggles, protective clothing and gloves, as well as hand protection cream if necessary. Use a mask or a breathing apparatus if necessary. For sufficient health and environmental safety: Operate the device in a spray booth or on a spraying wall with the ventilation (extraction) switched on. Wear suitable protective clothing when working with hot materials. 4.2.6 TOUCHING HOT SURFACES Touch hot surfaces only if you are wearing protective gloves. When operating the device with a coating material with a temperature of > 43 °C;109.4 °F: - Identify the device with a warning sticker "Warning - hot surface". Order No. 9998910 Instruction sticker 9998911 Protection sticker Note: Order the two stickers together. 14 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 4.3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS The pneumatic pump may be used in areas subject to explosion hazards. The following safety regulations must be observed and followed. 4.3.1 SAFETY REGULATIONS Safe handling of WAGNER spray devices Mechanical sparks can form if the device comes into contact with metal. In an explosive atmosphere: Do not knock or push the device against steel or rusty iron. Do not drop the device. Use only 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, electrostatic Do not spray system parts with electrostatic. 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. 4.3.2 OPERATION WITHOUT FLUID Avoid running the pump sucking air, without fluid inside. The air, combined with the vapor of flammable fluids, can generate internal areas with an explosion hazard. Periodically check that the pump is working regularly, paying special attention to the presence of air in the pumped fluid, which may be caused by damaged packings. Avoid operating the pump with damaged packing. Ensure that the separating fluid container is filled with sufficient separating fluid. 15 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 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 the material transporting parts. Use suitable combinations of devices (packings, valves etc.) 16 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 5.2 SCOPE OF DELIVERY Pneumatic piston pump consisting of: - Fluid section - Air motor - Connection elements Separating fluid 250 ml Declaration of conformity Operating manual, German Operating manual in the local language Order No.: 9992504 see Chapter 12 Order No.: 2333557 see Chapter 1 The delivery note shows the exact scope of delivery. Accessories: see Chapter 10. 5.3 DATA 5.3.1 MATERIALS OF WETTED PARTS Pump housing Piston Valve balls Valve seats Static seals Packings Stainless steel Stainless steel Stainless steel Stainless steel PTFE PE / T = Ultra high molecular weight polyethylene Teflon (PTFE) 5.3.2 TECHNICAL DATA Description Pump ratio Volume flow per double stroke (DH) Maximum operating pressure Maximum possible strokes in operation Minimum / maximum air inlet pressure Ø air inlet connection (inside thread) Minimum Ø of the compressed air supply line Air consumption at 0.6 MPa; 6 bar; 87 psi per double stroke Units 40:1 15 25.0 250 3626 60 0.2-0.8 2-8 28-116 8.0 0.31 9.0 0.35 3.9 0.14 17 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL Description Air motor piston diameter Units 80 3.15 60 2.4 Air motor piston stroke Sound pressure level at maximum permissible air pressure* 72 Sound pressure level at 0.6 MPa; 6 bar; 87 psi air pressure* 69 Sound pressure level at 0.4 MPa; 4 bar; 58 psi air pressure* 65 Material inlet (outside thread) M36x2 Material outlet (outside thread) Weight Material pH value Maximum material pressure at pump inlet Material temperature Ambient temperature Allowable inclination for operation * pH NPS 1/4" 9 19.8 3.5 ÷ 9 2 20 90 +5 ÷ +80 (+41 ÷ +176) +5 ÷ +60 (+41 ÷ +140) ± 10 A rated sound pressure level measured at 1 m distance, LpA1m, according to DIN EN 14462: 2005. 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 according to ISO 8573.1) 5.5.4 = 40 μm / +7 / 5 mg/m³. 18 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 5.3.3 MEASUREMENTS AND CONNECTIONS A B C D E F1 F2 G H1 H2 I J K L M N O P Q R S T B H1 A L H2 K 4.09 4.27 24.45 10.89 5.28 G 1/4" NPS 1/4" M36x2 G 1/4" 8 210 207 86 7 182 80 106 96.5 ø9 ø7 149 ø 25 0.31 8.27 8.15 3.39 0.28 7.17 3.15 4.17 3.8 ø 0.35 ø 0.28 5.87 ø1 I E J 104 108.5 621 276.5 134 F1 F2 Wall mount S T C N Q O D R G M M/ 2 P B_04120 19 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 5.3.4 PERFORMANCE DIAGRAMS Example Stroke frequency /min Air consumption nl/min <scfm> B AR BAR Material pressure bar (MPa) psi AR B BAR AR B BAR "? Water delivery rate l/min <gpm> Diagram EvoMotion 40-15 Stroke frequency bar (MPa) /min nl/min <psi> <scfm> 300 (30) 0 <4350> 10 20 30 40 50 60 <11> A A 240 (24) 240 <8> <3480> 180 180 (18) <6> <2610> C C 120 (12) 120 <4> <1740> 60 (6) 60 <870> <2> 0 0 C_00054 0.15 0.30 0.45 0.60 <0.04> <0.08> <0.12> <0.16> 0.75 Air consumption B B Material pressure 300 0 0.90 l/min <0.20> <0.24> <gpm> Material flow - water A = 8 bar; 0.8 MPa; 116 psi air pressure B = 6 bar; 0.6 MPa; 87 psi air pressure C = 4 bar; 0.4 MPa; 58 psi air pressure 20 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 5.4 FUNCTION 5.4.1 PUMP 1 11 2 Air motor Air inlet Mounting flange 8 Separating fluid 3 container 5 Material outlet 4 9 6 Fluid section 8 7 Material inlet 10 13 8 Grounding connection 12 6 9 Reversing valve 5 10 Safety valve 14 (air motor ventilation) 11 Air pressure regulator 12 Ball valve B_04121 13 Air outlet to the reversing valve 7 7 14 Air inlet into the reversing valve Function principle The piston pump is driven with compressed air (11). This compressed air moves the air piston up and down in the air motor (1) and it also moves the associated pump piston up and down in the fluid section (6). At the end of each stroke, the compressed air is redirected by a reversing valve (9). The working material is sucked up during the upwards stroke and is continuously conveyed towards the material outlet (5) in both stroke directions. 1 2 3 4 Air motor The air motor (1) with its pneumatic reverse (9) does not require pneumatic oil. The compressed air is fed to the motor via an air regulator (11) and the ball valve (12). The air motor is to be equipped with a safety valve (10) in accordance with Chapter 5.4.3. The safety valve (10) has been set and sealed at the factory. In case of pressures over and above the permissible operating pressure, the valve, which is held with a spring, automatically opens and releases the excess pressure. WARNING Overpressure! Risk of injury from bursting components. Never change the safety valve setting. Fluid section (6) The fluid section has been designed as a piston pump with exchangeable ball valves. The pump piston runs in two fixed packings which are self-adjusting by means of a pressure spring, thus resulting in a long service life. Between the air motor and the fluid section there is a separating fluid cup (4) for holding the separating fluid. 21 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 5.4.2 1 2 3 4 5 6 7 PRESSURE REGULATOR UNIT Pressure regulator Ball valve Pressure gauge (air inlet pressure) Pressure gauge for AirCoat air (option) Compressed air inlet Pressure regulator AirCoat (option) Safety and motor pressure relief valve 2 3 1 4 2 6 7 3 1 5 7 5 B_04122 Ball valve positions: 1 2 Open: working position Closed: The air motor can still be under pressure. open 1 2 closed B_04123 22 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 5.4.3 SAFETY AND MOTOR PRESSURE RELIEF VALVE Safety valve The safety valve (10) has been factory adjusted so as to ensure that if pressure exceeds the permitted operating pressure, the valve, which is held with a spring, automatically opens and releases the excess pressure. As well as handling pressure limits, the valve is also used as a pressure relief valve for the air motor. 10 Pressure relief of the air motor: 1 2 10 Close ball valve (2). Pull back the ring on the safety valve (10) and hold it there until the pressure in the air motor has been equalized. 2 B_04124 WARNING Overpressure! Risk of injury from bursting components. Never change the safety valve setting. 5.4.4 RETURN VALVE So that the complete pressure relief of the pump can be performed (see Chapter 7.2.2), the installation of a return valve is mandatory. The suitable return valves (ball valves), return pipes and hoses for the device can be found in the accessories list. 1 2 3 Material outlet Return valve Material return line 2 1 B_04075 3 23 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 6 ASSEMBLY AND COMMISSIONING 6.1 TRANSPORTATION The pump can be moved on a trolley or manually without lifting equipment. 6.2 STORAGE Store the pump in a closed and dry environment. Thoroughly clean the pump, if a long-term decommissioning is planned. When resuming pump operation, proceed as described in the following sections. WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic sparks. Clean the pump only with a damp cloth. 24 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 6.3 ASSEMBLING THE PUMP Note This pump can be used as part of a spraying system for Airless or AirCoat applications. Individual supplement components for this pump can be found in the Wagner Accessories Catalogue, or can be put together with the Spraypack Configurator. The nozzles must be selected according to the gun instructions. In the case of spraypack orders, the pumps (1) are already pre-mounted on a trolley (6) or on a stand at the factory. Example: Airless System 3 6 1 2 8 4 Procedure: 1 2 3 4 5 6 Mount pump (1) on stand, trolley (6) or wall mount. Mount an AirCoat system with the pressure regulator (7) and secure the thread at the air inlet to the pump (1) with Loctite 270. Mount suction system (5). Mount the return valve (8) for pressure relief or material circulation. Mount return tube (4) or return hose. Connect the high pressure hose (2) and gun (3) in accordance with the gun operating manual. 5 B_04076 Example: AirCoat System 7 3 1 6 2 8 4 5 B_04077 WARNING Inclined ground! Risk of accidents if the device rolls away/falls. 25 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 6.4 GROUNDING WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic sparks. Clean the piston pump only with a damp cloth. WARNING Heavy paint mist if grounding is insufficient! Danger of poisoning. Insufficient paint application quality. Ground all device components. Ground the work pieces to be coated. Grounding scheme (example) Conveyor Note for the sprayer Safety shoes and gloves, if used, must be electrostatically conductive. Work piece Spraying stand R max < 1 MΩ Paint container B_00304 Floor, electrostatically conductive 26 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL Cable cross sections Pump Paint container Conveyor Spray booth Spraying stand Procedure: 1 2 3 4 Screw on grounding cable with eye. Clamp the grounding cable clip to a grounding connection on site. Ground the material (paint) container to an on-site grounding connection. Ground the other parts of the system to an on-site grounding connection. Grounding cable B_04127 27 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 6.5 COMMISSIONING 6.5.1 SAFETY INSTRUCTIONS Before carrying out any work, the following points must be observed in accordance with the operating manual: - Observe all safety regulations in accordance with Chapter 4. - Carry out commissioning properly. WARNING High pressure spray jet! Danger to life from injecting paint or solvent. Never reach into the spray jet. Never point the spray gun at people. Consult a doctor immediately in the event of skin injuries caused by paint or solvent. Inform the doctor about the paint or solvent used. Never seal defective high pressure parts, instead relieve the pressure from them and replace them. WARNING Toxic and/or flammable vapor mixtures! Risk of poisoning and burns Operate the device in a spray booth approved for the working materials. -orOperate the device on an appropriate spraying wall with the ventilation (extraction) switched on. Observe national and local regulations for the outgoing air speed. WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from flying parts. Ensure that the pump and suction system are always completely filled with flushing agent or working medium. Do not spray the device empty after cleaning. 28 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL Before every start-up, the following points should be observed as laid down in the operating manual: - Check the permissible pressures. - Check all connections for leaks. - Check hoses for damage. It should be ensured that the device is in the following state before carrying out any work on it: - Interrupt the air supply (2). - Depressurize the air motor (pull the ring on the safety valve (10)). - Relieve the pressure from the fluid section. 10 closed 10 2 open C_00157 B_04124 EMERGENCY STOP In the case of unforeseen occurrences the ball valve (2) should be closed immediately. Open the safety valve (10) and relieve the material-conveying parts completely of pressure via the return valve (3). 2 3 B_04078 29 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 6.5.2 FILLING WITH SEPARATING FLUID NOTICE Piston pump dry run! High wear/damage to the packages. Paint or solvent can escape if the seals are dry. Ensure that the separating fluid container is filled with sufficient separating fluid. Fill level 1 cm; 0.4 inch under the pot edge. Pour the supplied separating fluid into the intended opening. Filling level: 1 cm; 0.4 inch under the cup edge Separating fluid: See accessories. Note Maximum permissible inclination of pump for moving, transportation etc. after filling it with separating fluid ± 30°. The pump must be vertical during operation. B_04130 30 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 6.5.3 BASIC CLEANING Before each basic flushing, the nozzle must be removed from the pistol. The data in the gun's operating manual are to be observed. With AirCoat systems, carry out the basic flushing of the system without atomizing air (8). 1 2 3 4 5 6 7 8 9 10 11 12 13 Place empty container (5) under return pipe (4). Place suction hose (7) in the container with flushing agent (6). Open return valve (3). Slowly open the ball valve (2). Adjust the air pressure on the pressure regulator (1) so that the pump runs smoothly. Flush the system until clean flushing agent flows into the container (5). Close ball valve (2). Close return valve (3). Point the gun (9), without nozzle, into container (5) and open it. Slowly open the ball valve (2). Flush until clean flushing agent flows from the gun. Close ball valve (2). Relieve the system pressure, either by opening the return valve (3) or via the trigger on the gun (9). 14 When there is no pressure remaining in the system, close the gun (9) or the return valve (3). 15 Secure the gun. 16 Dispose of the contents of the container (5) according to the local regulations. closed 1 8 2 open 7 3 4 6 9 5 B_04079 31 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 7 7.1 OPERATION FILLING WITH WORKING MATERIAL Note: Before each filling, the nozzle must be removed from the pistol. The data in the gun's operating manual are to be observed. In case of AirCoat systems, carry out the filling of the system without atomizing air (8). 1 2 3 4 5 6 7 8 9 10 11 12 13 Place empty container (5) under return pipe (4). Place suction hose (7) in the container with working material (6). Open return valve (3). Slowly open the ball valve (2). Adjust the air pressure on the pressure regulator (1) so that the pump runs smoothly. Spray until clean working material flows into the container (5). Close ball valve (2). Close return valve (3). Point the gun (9), without nozzle, into container (5) and open it. Slowly open the ball valve (2). Spray until clean working material flows from the gun (9). Close ball valve (2). Relieve the system pressure, either by opening the return valve (3) or via the trigger on the gun (9). 14 When there is no pressure remaining in the system, close the gun (9) or the return valve (3). 15 Secure the gun. 16 Dispose of the contents of the container (5) according to the local regulations. 32 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 7.2 WORK 7.2.1 SPRAYING System example for the AirCoat procedure closed 8 1 2 open 9 7 3 4 6 5 B_04080 1 2 3 4 5 6 Secure the gun and insert the nozzle into the gun. Close return valve (3). Slowly open the ball valve (2). Set required working pressure on the pressure regulator (1). Optimize the spraying results according to the data in the gun operating manual. Start work process. 33 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 7.2.2 PRESSURE RELIEF / WORK INTERRUPTION Pressure relief of the material 1 Close the spray gun. 2 Close ball valve (2). 3 Relieve the system pressure, either by opening the gun or by opening the return valve (3). 4 Close and secure gun. 5 Open and close the return valve (3) to completely depressurize the system. Pressure relief of the air (in case of longer work interruptions) 1 Carry out pressure relief of the material (as mentioned above). 2 Ensure that the ball valve (2) is closed. 3 Pull back the ring on the safety valve (10) and hold it there until the pressure in the air motor has been equalized. 10 10 2 B_04124 If the system has been used with 2-component materials: NOTICE Hardened material in the spraying system when 2-component material is processed! Destruction of pump and injection system. Follow the manufacturer‘s processing rules, particularly regarding the pot life. Flush thoroughly before the end of the pot life. The pot life is decreased by warmth. 34 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 7.2.3 DECOMMISSIONING AND CLEANING Note The device should be cleaned for maintenance purposes. Ensure that no remaining material dries and sticks. Procedure: 1 Carry out pressure relief of the material and air -> Chapter 7.2.2. 2 Basic cleaning -> carry out the steps in Chapter 6.5.3. 3 Maintain the gun according to the operating manual. 4 Clean and check the suction system and the suction filter. 5 Clean the outside of the system. WARNING Brittle filter pressure regulator! The container on the filter pressure regulator becomes brittle through contact with solvents and can burst. Flying parts can cause injury. Do not clean the container on the filter pressure regulator with solvent. 6 Put the whole system back together. 7 Check the level of the separating fluid -> Chapter 6.5.2. 8 Fill the system with flushing agent according to Chapter 5.2.4 "Filling with Working Material". WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from flying parts. Ensure that the pump and suction system are always completely filled with flushing agent or working medium. Do not spray the device empty after cleaning. 7.3 LONG-TERM STORAGE When storing the device for longer periods of time, it is necessary to thoroughly clean it and protect it from corrosion. Replace the water or solvent in the material pump with a suitable preservative, fill separating fluid cup with separating fluid. Procedure: 1 Chapter 7.2.3 "Decommissioning and Cleaning", perform points 1 to 7. 2 Flushing with preserving agent according to Chapter 6.5.3. 35 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 8 TROUBLE SHOOTING AND RECTIFICATION Problem Pump does not work. Cause Air motor does not work or stops. No pressure indication on the pressure gauge (pressure regulator defective). Spray nozzle is clogged. Insufficient compressed air supply. Filter insert in spray gun is clogged. Fluid section or high pressure hose are blocked (e.g., two-component material hardened). Sometimes, the pump stops at a switching point. Poor spray pattern. Irregular pump operation: spray jet collapses (pulsation). See gun instructions. Viscosity is too high. Spraying pressure is too low. Valves are clogged. Foreign body in suction valve. Diameter of compressed air line too small. Valves, packings or pistons are worn out. Pressure regulator filter is clogged. The pump runs evenly, The suction system's union nut is does not however, loose; the pump is taking in air. suck up material. Suction filter is clogged. Ball in suction or piston valve is stuck. Pump runs when the Packings, valves or pistons are worn gun is closed. out. Air motor is iced up. There is a lot of condensation water in the air supply. Remedy Open and close ball valve on the pressure regulator unit or briefly disconnect compressed air supply. Disconnect compressed air supply briefly or repair or replace pressure regulator. Clean the nozzle according to the instructions. Check compressed air supply. Clean the parts and use a suitable working material. Dismount and clean fluid section, replace high pressure hose. Press the starter on the reversing valve and restart the pump. Clean the slide on the reversing valve carefully and if necessary lubricate it with a light layer of oil. Thin spraying material. Increase incoming air pressure. Use a smaller nozzle. Clean pump, if necessary leave it to soak in cleaning agent. Dismount suction valve housing, clean and check valve seat. Assemble a larger incoming line -> Technical Data, Chapter 5.3.2. Replace the parts. Check filter and clean it if necessary. Tighten union nut. Clean filter. Clean balls and valve seats. Replace the parts. Install a water separator. If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service Center. 36 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 37 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 9 MAINTENANCE WARNING Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare Parts" chapter and that are assigned to the device. Before all work on the device and in the event of work interruptions: - Disconnect the control unit from the mains. - Relieve the pressure from the spray gun and device. - Secure the spray gun against actuation. Always follow the operating and service instructions at all times when carrying out work. 1 2 3 4 Check the level of separating fluid in the separating fluid cup every day, and top up if necessary. Check and clean the high pressure filter every day or as required (if available). Every decommissioning should be carried out as laid down in Chapter 7.2.3! Check hoses, pipes and couplings every day and replace if necessary. In accordance with the guideline for liquid emitters (ZH 1/406 and BGR 500 Part 2 Chapter 2.36): - The liquid emitters should be checked by an expert (e.g. Wagner service technician) for their safe working conditions as required and at least every 12 months. - For shut down devices, the examination can be suspended until the next start-up. 38 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 9.1 HIGH-PRESSURE HOSES The service life of the fluid hoses is, even with appropriate handling, reduced due to environmental influences. Check hoses, pipes and couplings every day and replace if necessary. As a precaution fluid hoses should be replaced after a period specified by the plant operator. DANGER Bursting hose, bursting threaded joints! Danger to life from injection of material. Ensure that the hose material is chemically resistant to the sprayed materials. Ensure that the spray gun, threaded joints and material hose between the device and the spray gun are suitable for the pressure generated in the device. Ensure that the following information can be seen on the high pressure hose: - Manufacturer - Permissible operating pressure - Date of manufacture 9.2 DECOMMISIONING When the equipment must be scrapped, please differentiate the disposal of the waste materials. The following materials have been used: Steel Aluminum Elastomerics Plastics Carbide The consumable materials (paints, adhesives, sealers, solvents) must be disposed of according to the valid specific standards. 39 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 10 ACCESSORIES EvoMotion 40-15 accessories 1 2 3 4 5 Order No. 2329450 T6145.00A 236219 9992504 9992505 Designation EvoMotion 40-15 PE/T AirCoat regulator set Grounding cable, complete 3 m; 9.8 ft Separating fluid 250 ml Separating fluid 500 ml Material outlet accessories 11 12 13 14 Order No. 2334488 2334472 2331752 2329046 Designation Ball valve R1/4"-G1/4"-PN350-SSt Ball valve R1/4"-G1/4"-PN350-CS Return pipe DN6-G1/4"-100mm-PA Return hose DN6-PN310-G1/4"-PA Material inlet accessories Order No. 15 2324158 16 2324110 17 2323225 2332169 18 19 2323396 Wearing part Designation Suction pipe DN16-SSt, complete Flex suction hose DN16-SSt, complete Suction elbow for top reservoir SSt Top reservoir set, 5 l for piston pump Suction filter DN16-18mesh-SSt 40 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 3 x 2 x 1 11 4/5 12 13 14 18 15 16 17 19 B_04081 41 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL Trolley, rack and wall bracket accessories 21 22 23 24 Order No. 2332143 2332374 T6196.00 2325901 Designation Wall mount, 4", complete 4-leg stand Trolley, 4 wheels Trolley, 4", complete 21 22 23 24 B_04113 42 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 43 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 11 SPARE PARTS 11.1 HOW CAN SPARE PARTS BE ORDERED? Always supply the following information to ensure delivery of the right spare part: Order number, designation and quantity The quantity need not be the same as the number given in the quantity column " " on the list. This number merely indicates how many of the respective parts are used in each module. 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.) Identification in spare parts lists Explanation of column "K" (labeling) in the following spare parts lists: Wearing parts Note: No liability is assumed for wearing parts. Not part of standard equipment, available, however, as additional extra. WARNING Incorrect maintenance/repair! Risk of injury and damage to the device. Have repairs and part replacements be carried out only by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and device. - Secure the spray gun against actuation. Always follow the operating and service instructions at all times when carrying out work. 44 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 11.2 OVERVIEW OF COMPONENTS 1 2 3 4 5 6 7 8 9 10 11 12 13 1 1 1 1 1 2 1 4 4 3 3 1 1 Order No. 2329450 2329635 U3B08018060 A359.71A E516.71A 9900353 2332394 9920106 9900330 3055157 H115.62 T6140.00A 9998253 Designation EvoMotion 40-15 PE/T Fluid section 15 PE/T EM Air motor M80 EM Spacer Safety fixture spacer Hexagon socket cylinder head screw Holder plate Washer Hexagon socket cylinder head screw Hexagon nut with clamp Tie rod Pump air regulator set Screwing in angle 8-1/4 13 3 12 7 20 Nm; 14.7 lbft 8 9 4 1 6 5 11 2 10 30 Nm; 22.1 lbft B_04135 45 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 11.3 AIR MOTOR WARNING Incorrect maintenance/repair! Risk of injury and damage to the device. Have repairs and part replacements be carried out only by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and device. - Secure the spray gun against actuation. Always follow the operating and service instructions at all times when carrying out work. Air motor spare parts list EM M80 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 1 2 1 1 1 2 1 1 1 1 1 2 1 1 1 Order No. U3B08018060 F132.91C L108.06 D608.81 3055157 9920106 G903.06 L413.06 A164.01 L802.08 L110.06 D404.12 L109.06 A408.12 T616.00C P498.00KNE Designation Air motor EM M80 Motor flange, upper, M50 EM O-ring Cylinder motor Hexagon nut with clamp Washer Steamer Gasket DE 80 Motor piston Sliding ring O-ring Piston rod, M80 EM O-ring Air tube, M80 EM Motor flange, complete M80 EM, at bottom Reversing valve ISO N/1 (spare parts list, see Chapter 11.3.1.) Grounding, complete Rod seal Sensor below, M80 Lock washer for shaft Washer Pilot valve Screw in angle Silencer Reducing nipple 17 1 367258 18 1 L403.06 19 1 T703.00 20 2 K606.02 21 1 A160.01A 22 1 369290 23 1 9992757 24 2 H505.07 25 1 M432.00 = Wearing part = Included in service set = Not part of the standard equipment but available as an accessory. 46 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 30 Nm; 22 lbft 28 2 3 29 4 5 35 Nm; 25.8 lbft 6 30 7 29 8 29 9 13 30 4.5 Nm; 3.3 lbft 7 14 29 11 1 10 29 13 3 29 17 16 15 27 24 19 22 20 Nm; 14.7 lbft 27 29 25 18 23 12 Installation instructions: Mount piston rod (12) always from bottom to top via the rod seal (18). 20 B_03431 21 20 47 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL Air motor spare parts list EM M80 27 28 29 30 1 4 1 1 Order No. 9992831 9907241 9998808 9998157 Designation Loctite 542 Hexagon socket cylinder head screw Grease mobilux EP 2 Loctite 480 1 T910.00 Service set EM Air motor M80 = Wearing part = Included in service set = Not part of the standard equipment but available as an accessory. WARNING Incorrect maintenance/repair! Risk of injury and damage to the device. Have repairs and part replacements be carried out only by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and device. - Secure the spray gun against actuation. Always follow the operating and service instructions at all times when carrying out work. 48 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 11.3.1 REVERSING VALVE 4 1 2 3 B_03139 Spare parts list for the reversing valve, 40-15 1 2 3 4 1 6 1 2 Order No. P498.00 9971123 P521.00 P520.00 Designation Reversing valve O-ring Reversing valve gasket Steamer 49 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 11.4 FLUID SECTION 15 30 Nm; 22.1 lbft 24 29 8 36 22 2.5 Nm; 1.84 lbft 2 25 30 26 30 3 9 25 26 4 23 20 30 10 27 28 31 27 11 28 30 27 28 5 27 1 28 27 28 27 21 12 6 35 33 13 7 14 19 15 30 10 17 34 35 16 31 B_03445 18 32 50 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL Spare parts list for fluid section 15 No. 1 1 2329635 2 1 A661.12 3 1 K617.03 4 1 A662.12 1 T9037.00E 5 6 1 H204.03 7 1 A658.03 8 1 H203.03 9 1 T9038.00E 10 2 L107.06 11 1 B534.03 12 1 T6157.00I 13 1 A170.03 1 K801.03 14 15 1 A169.03 16 1 K803.03 1 K601.03 17 18 1 2323838 19 1 9992831 20 1 A171.03 21 1 A172.03 22 1 A411.03 23 1 A410.03 24 1 T6158.00 25 2 G101.05 26 2 G101.08E 6 G104.05 27 28 5 G104.08E 29 1 9900136 30 1 9998808 1 9992609 31 32 1 2329898 33 1 B0461.03A 34 1 2323718 35 1 9992528 36 1 9992590 Designation Fluid section 15 SS PE/T EM Connecting flange 15 Snap ring Snap ring flange 15 Packing PE/T 13/25 Spring, upper Tube 15 Spring Packing PE/T 18/29 O-ring Cylinder 15 Pump Rod 15 SS Support spring Ball Valve screw 15 Ball Securing ring Inlet housing 15 Loctite 542 Support ring, outside Support ring, inside Support ring, inside Support ring, outside Connector Sealing collar T 18/29 Sealing collar PE 18/29 Sealing collar T 13/25 Sealing collar PE 13/25 Hexagon screw without shaft Grease mobilux EP 2 Anti-sieze paste Sealing sleeve Fitting-DF-MM-R1/4"-1/4" NPS-PN350 Hexagon plug Loctite 270 Loctite 222 1 T9039.00E Service set EM 15 PE/T = Wearing part = Included in service set = Not part of the standard equipment but available as an accessory. 51 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 11.5 AIR REGULATOR SET FOR EVOMOTION 40-15 14 14 9 14 5 14 4 8 1 13 2 14 10 3 11 12 B_04117 1 1 2 2 3 1 4 1 5 1 8 1 9 1 10 1 11 1 12 0.32 m 13 1 14 1 = Wearing part Order No. T6140.00A 9906026 9998677 9985682 9998039 M101.00 P484.00C1 M297.00 9992743 9982078 P124.00M 9992831 Designation Pump air regulator set Hexagon socket cylinder head screw Pressure gauge 0-1 MPa; 0-10 bar; 0-145 psi (d40) Reducer Screw-in connection's elbow Ball valve, FM Safety valve 1/4" T-connection Threaded fitting, straight Hose, black AD8 x 1.25 (0.32 m; 1.05 ft. long) Filter regulator CZ 1/4 Loctite 542 52 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 11.6 AIR REGULATOR SET FOR AIRCOAT AIR 7 6 4 7 5 1 3 7 2 B_03436 1 1 2 1 3 1 4 1 5 1 6 1 7 1 = Wearing part Order No. T6145.00A 9998677 9992129 9998719 9985694 P123.00 9992528 Designation AirCoat regulator set Pressure gauge 0-1 MPa; 0-10 bar; 0-145 psi (d40) Elbow with taper Detachable double nipple T-piece Air pressure regulator, 1/4" Loctite 270 53 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 11.7 TROLLEY, 4" 15 5 17 10 2 13 14 4 9 5 16 6 3 1 7 8 A Distance 11 12 Designation 1 1 Trolley, complete 2 1 Stand left 4" (welded) 3 1 Stand right 4" (welded) 4 4 Hexagon screw DIN931 M6x75 5 6 Self-locking hexagon nut M6 6 2 Wheel, D250 7 4 Washer 8 4 Cotter pin 9 1 Wheel axle 4" 2 Connecting part 4" 10 11 2 Tube plug, ribbed 12 2 Saddle feet for round tubes 13 2 Plug 14 4 Hexagon bolt 15 1 Wall mount 16 2 Hexagon screw without shaft M6x55 17 2 Handle = Wearing parts B_04074 Order No. 2325901 --9907140 9910204 2304440 340372 9995302 -367943 ---9900218 2332143 3061695 9998747 54 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 11.8 4-WHEEL TROLLEY 4 12 3 2 8 13 5 1 6 10 9 11 7 B_03439 1 1 2 5 3 1 4 1 5 1 6 1 7 4 8 4 9 4 4 10 11 4 12 4 13 2 14 4 = Wearing part 14 Order No. T6196.00 9910204 E3107.92B E3107.92C H009.62 H1156.62 R204.07 3155404 9920106 R120.00F 9900311 9900389 9900309 3055157 Designation Trolley, 4 wheels Hexagon nut with clamp Stand, right Stand, left Spray gun hook Stand pin Plug Contact washer, M08 Washer Wheel Hexagon socket cylinder head screw Hexagon socket cylinder head screw Hexagon socket cylinder head screw Hexagon nut with clamp 55 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 12 WARRANTY AND CONFORMITY DECLARATIONS 12.1 IMPORTANT NOTES REGARDING PRODUCT LIABILITY As a result of an EC regulation effective from January 1, 1990, the manufacturer shall only be liable for his product if all parts originate from him or are approved by him, and if the devices are properly mounted, operated and maintained. The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with. 12.2 WARRANTY CLAIM Full warranty is provided for this device: We will at our discretion repair or replace free of charge all parts which within 36 months in single-shift, 18 months in double-shift or 9 months in triple-shift operation from date of receipt by the purchaser are found to be wholly or substantially unusable due to causes prior to the sale, in particular faulty design, defective materials or poor workmanship. The type of warranty provided is such that the device or individual components of the device are either replaced or repaired as we see fit. The resulting costs, in particular shipping charges, road tolls, labour and material costs will be borne by us except where these costs are increased due to the subsequent shipment of the device to a location other than the address of the purchaser. We do not provide warranty for damage that has been caused or contributed to for the following reasons: Unsuitable or improper use, faulty installation or commissioning by the purchaser or a third party, normal wear, negligent handling, defective maintenance, unsuitable coating products, substitute materials and the action of chemical, electrochemical or electrical agents, except when the damage is attributable to us. Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust paints and so forth reduce the service life of valves, packings, spray guns, nozzles, cylinders, pistons etc. Wear and tear due to such causes are not covered by this warranty. Components that have not been manufactured by WAGNER are subject to the original warranty of the manufacturer. Replacement of a component does not extend the period of warranty of the device. The device should be inspected immediately upon receipt. To avoid losing the warranty, we or the supplier company are to be informed in writing about obvious faults within 14 days upon receipt of the device. We reserve the right to have the warranty compliance met by a contracting company. The services provided by this warranty are dependent on evidence being provided in the form of an invoice or delivery note. If the examination discovers that no warranty claim exists, the costs of repairs are charged to the purchaser. It is clearly stipulated that this warranty claim does not represent any constraint on statutory regulations or regulations agreed to contractually in our general terms and conditions. J. Wagner AG 56 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL 12.3 CE DECLARATION OF CONFORMITY Herewith we declare that the supplied version of pneumatic pumps and their spraypacks comply with the following guidelines: 2006/42/EC 94/9/EC Applied standards, in particular: Applied national technical standards and specifications, in particular: Part 2 Chapter 2.29 and Chapter 2.36 Labeling: II 2G IIB c T3 X EC Certificate of Conformity The CE certificate of conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order number: 2312813 12.4 REFERENCE TO GERMAN REGULATIONS AND GUIDELINES Part 2, Chapter 2.36 "Working with Liquid Ejection Devices" Part 2, Chapter 2.29 "Working with Coating Materials" Explosion protection rules Avoiding ignition risks Equipment for cleaning work pieces with solvents Guidelines for liquid ejection devices Painting rooms and equipment Plant Safety Ordinance Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they can be found on the Internet. 57 VERSION 01/2013 ORDER NUMBER DOC 2333558 OPERATING MANUAL Germany J. WAGNER GmbH Otto-Lilienthal-Str. 18 Postfach 1120 D- 88677 Markdorf Telephone: +49 7544 5050 Telefax: +49 7544 505200 E-Mail: [email protected] Switzerland J. WAGNER AG Industriestrasse 22 Postfach 663 CH- 9450 Altstätten Telephone: +41 (0)71 757 2211 Telefax: +41 (0)71 757 2222 E-Mail: [email protected] Belgium WSB Finishing Equipment Veilinglaan 56/58 B- 1861 Wolvertem Telephone: +32 (0)2 269 4675 Telefax: +32 (0)2 269 7845 E-Mail: [email protected] / HP www.wsb-wagner.eu Denmark WAGNER Industrial Solution Scandinavia Viborgvej 100, Skærgær DK- 8600 Silkeborg Telephone: +45 70 200 245 Telefax: +45 86 856 027 E-Mail [email protected] United Kingdom WAGNER Spraytech (UK) Ltd. Haslemere Way Tramway Industrial Estate GB- Banbury, OXON OX16 8TY Telephone: +44 (0)1295 265 353 Telefax: +44 (0)1295 269861 E-Mail: [email protected] France J. WAGNER France S.A.R.L. Parc de Gutenberg - Bâtiment F8 8, Voie la Cardon F- 91127 Palaiseau-Cedex Telephone: +33 1 825 011 111 Telefax: +33 1691 946 55 E-Mail: [email protected] Netherlands WSB Finishing Equipment B.V. De Heldinnenlaan 200 NL- 3543 MB Utrecht Italy WAGNER COLORA S.r.l Via Fermi, 3 I- 20875 Burago di Molgora (MB) Telephone: +31 (0) 30 241 4155 Telefax: +31 (0) 30 241 1787 E-Mail: [email protected] / HP www.wsb-wagner.eu Telephone: +39 039 625021 Telefax: +39 039 6851800 E-Mail: [email protected] Japan WAGNER Spraytech Ltd. 2-35, Shinden Nishimachi J- Daito Shi, Osaka, 574-0057 Telephone: +81 (0) 720 874 3561 Telefax: +81/ (0) 720 874 3426 E-Mail: [email protected] Austria J. WAGNER GmbH Otto-Lilienthal-Str. 18 Postfach 1120 D- 88677 Markdorf Telephone: +49 (0) 7544 5050 Telefax: +49 (0) 7544 505200 E-Mail: [email protected] Sweden WAGNER Industrial Solutions Scandinavia Skolgatan 61 SE- 568 31 Skillingaryd Telephone: +46 (0) 370 798 30 Telefax: +46 (0) 370 798 48 E-Mail: [email protected] Spain WAGNER Spraytech Iberica S.A. Ctra. N- 340, Km. 1245,4 E- 08750 Molins de Rei (Barcelona) Telephone: +34 (0) 93 680 0028 Telefax: +34 (0) 93 668 0156 E-Mail: [email protected] Czechoslovakia WAGNER s.r.o. Nedasovská Str. 345 15521 Praha 5 - Zlicin Telephone: +42 (0) 2 579 50 412 Telefax: +42 (0)2 579 51 052 E-Mail: [email protected] USA WAGNER Systems Inc. 300 Airport Road, unit 1 Elgin, IL 60123 USA Telephone: +1 630 503 2400 Telefax: +1 630 503 2377 E-Mail: [email protected] 58 ED FI CERT I Order No. Germany Phone Telefax E-mail Switzerland Phone Telefax 2333558
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