WAGNER IP 5000 Betriebshandbuch

P_04342

IP 5000

IP 5000-USD

Fresh Powder and Transfer Pump

Edition 08/2021

II 3D Ex tc IIIB T85°C Dc

EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000

Table of Contents

1 ABOUT THESE INSTRUCTIONS 6

1.1 Preface 6

1.2 Warnings, Notices and Symbols in these Instructions 6

1.3 Languages 7

1.4 Abbreviations 7

1.5 Terminology for the Purpose of this Manual 8

2 USING IN ACCORDANCE WITH THE INSTRUCTIONS 9

2.1 Device Type 9

2.2 Type of Use 9

2.3 For Use in Potentially Explosive Areas 9

2.4 Processible Working Materials 9

2.5 Misuse 9

3 IDENTIFICATION 10

3.1 Explosion Protection Identication 10

3.2 Permissible Device Combinations 10

3.3 Type Plate 10

4 BASIC SAFETY INSTRUCTIONS 11

4.1 Safety Instructions for the Operator 11

4.1.1 Electrical Devices and Equipment 11

4.1.2 A Safe Work Environment 12

4.1.3 Personnel Qualications 12

4.2 Safety Instructions for the Personnel 13

4.2.1 Personal Safety Equipment 13

4.2.2 Safe Handling of WAGNER Powder Spray Devices 13

4.2.3 Grounding the Device 14

4.2.4 Product Hoses 14

4.2.5 Electrical Connection Cables 15

4.2.6 Cleaning and Flushing 15

4.2.7 Maintenance and Repair 16

4.2.8 Protective and Monitoring Equipment 16

5 DESCRIPTION 17

5.1 Design of the IP 5000 Powder Pump 17

5.1.1 IP 5000 Version 17

5.1.2 IP 5000-USD Version 18

5.2 Functioning 19

5.3 Operating Elements on Control Cabinet 20

5.4 Extent of Delivery 20

5.5 Data 21

5.5.1 Technical Data 21

6 ASSEMBLY AND COMMISSIONING 22

6.1 Training of Assembly/Commissioning Personnel 22

6.2 Storage Conditions 22

6.3 Installation Conditions 22

6.4 Assembly Example of the WAGNER Powder Center 23

EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000

6.5 Installation Recommendation 24

6.5.1 IP 5000 Version 24

6.5.2 IP 5000-USD Version 25

6.6 Assembling the Powder Pump 26

6.7 How to Handle the Hose Coupling 28

6.8 Grounding 28

6.9 Start Up 28

6.9.1 Commissioning in Connection with the Powder Center 30

6.9.2 Commissioning as Transfer Pump (BigBag) 30

6.9.3 Pin Assignment in the Control Cabinet 31

7 OPERATION 32

7.1 Training the Operating Personnel 32

7.2 Tasks 32

7.3 Operating Modes 32

7.4 Operation with WAGNER Powder Center 32

7.5 Setting Elements in the Control Cabinet 33

7.5.1 DIP Switch Functions 33

7.5.2 A+/A- Buttons 33

7.5.3 Function 1 "Use of Powder Center/BigBag" 34

7.5.4 Function 2 Recipe "Soft" 34

7.5.5 Function 3 "Set After-run Time" 34

7.5.6 Function 4 "Set Cleaning Time" 34

7.5.7 Function 6 "Set Service Interval" 35

7.5.8 Setting Example 36

7.5.9 Function 7 "Level Controller" 37

7.6 Cycle Counter 38

7.7 Conditions for Operating the Pump 38

8 CLEANING AND MAINTENANCE 39

8.1 Cleaning 39

8.1.1 Cleaning Personnel 39

8.1.2 Cleaning Procedures 39

8.1.3 Cleaning in Case of Paint Change 39

8.1.4 Internal Cleaning Procedure 39

8.1.5 External Cleaning Procedure 40

8.1.6 SuperCenter Cleaning Procedure 41

8.1.7 PXM Cleaning Procedure 41

8.2 Maintenance 42

8.2.1 Maintenance Personnel 42

8.2.2 Maintenance Instructions 42

8.2.3 Safety Checks and Maintenance Intervals 42

8.2.4 Maintenance Procedures 42

8.2.5 Changing Valve and Pump Hoses 43

8.3 Storage Conditions for Pump and Valve Hoses 49

8.4 Replacing the Non-return Valves 50

8.4.1 Disassembly 50

8.4.2 Assembly 53

9 TROUBLE SHOOTING AND SOLUTION 56

10 DISASSEMBLY AND DISPOSAL 57

10.1 Disassembly 57

10.2 Disposal 57

EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000

11 ACCESSORIES 58

12 SPARE PARTS 61

12.1 How to Order Spare Parts 61

12.2 Powder Pump Spare Parts List 62

12.3 Control Cabinet Spare Parts List 64

12.4 Connecting Plug Spare Parts List 66

12.5 SN 600/14 Suction Lance Spare Parts List 67

12.6 SN 1500/14 Suction Lance Spare Parts List 68

12.7 External Cleaning Box Spare Parts List 69

13 CIRCUIT DIAGRAMS 70

13.1 Plug Assignment 70

13.2 Signal Sequence 71

13.2.1 Signal Sequence "Feeding Operation" 71

13.2.2 Signal Sequence "KPZ 2008 Cleaning" 71

13.2.3 Signal Sequence "PXM/PXS Standard Cleaning" 72

13.2.4 Signal Sequence "PXM/PXS Intensive Cleaning" 73

13.2.5 Signal Sequence "SuperCenter Cleaning" 74

13.3 Valve Assignment 75

13.4 Electrical Circuit Diagrams 76

13.5 Pneumatic Diagram 83

14 EU DECLARATION OF CONFORMITY 85

EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000

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 manual highlight particular dangers to users and to the

device and state measures for avoiding the hazard. These warning instructions fall into

the following categories:

DANGER Immediate risk of danger.

Non-observance will result in death or serious injury.

WARNING Potential danger.

Non-observance may result in death or serious injury.

CAUTION Potentially dangerous situation.

Non-observance may result in minor injury.

NOTICE Potentially dangerous situation.

Non-observance may result in damage to property.

Note: Provides information about particular characteristics and

how to proceed.

Explanation of warning notice:

LEVEL OF DANGER

This notice warns you of a danger!

Possible consequences of not observing the warning notice.

The measures for preventing the hazard and its consequences.

EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000

1.3 LANGUAGES

The operating manual is available in the following languages:

Original operating manual

Language Order no.

German 241935

Translation of the original operating manual

Language Order no. Language Order no.

English 241936 Danish 2396410

French 241943 Polish 2316573

Italian 241944 Romanian 2409919

Spanish 241945 Slovenian 2395395

Russian 2326214 Slovakian 2400611

Chinese 2384487 Czech 2302697

Swedish 2315185 Norwegian 2413942

Portuguese 2343832 -- --

Hungarian 2338554 -- --

Additional languages on request or at: www.wagner-group.com

1.4 ABBREVIATIONS

Order no. Order number

Spare part

Marking in the spare parts lists

Position

Number of pieces

-- Item not available as spare part

/ Item does not exist

EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000

1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning

Cleaning Manual cleaning of devices and device parts with cleaning agent

Flushing Internal ushing of paint-wetted parts with compressed air

Personnel qualications

Trained person Is instructed in the tasks assigned to him/her, the potential risks

associated with improper behavior as well as the necessary

protective devices and measures.

Electrically trained

person

Is instructed by an electrician about the tasks assigned to him/her,

the potential risks associated with improper behavior as well as

the necessary protective devices and measures.

Electrician Can assess the work assigned to him/her and detect possible

hazards based on his/her technical training, knowledge and

experience in relevant provisions.

Skilled person in the

context of

DGUV 209-052

A person who, based on his/her technical training, experience

and recent vocational experience, has sucient technical

knowledge in the area of electrostatic coating 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.

Additional requirements for skilled persons can also be found

in TRBS1203(2010/amendment 2012): Expert knowledge in

the areas of protection against excessive pressure, electrical

hazards, and explosion protection (where applicable).

EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000

2 USING IN ACCORDANCE WITH THE INSTRUCTIONS

2.1 DEVICE TYPE

Pneumatic feed pump for feeding powder lacquers.

2.2 TYPE OF USE

The IP 5000 powder pump is used to feed powder coating products from dierent

container types.

Application areas:

The IP 5000 powder pump is used to feed powder lacquers

– from original tanks (25 kg; 55.1 lbs)

– from BigBags (500 kg; 1102.3 lbs)

– as a transfer pump, e.g., to empty a powder container or to convey powder from one

tank to another

WARNING

Dust formation!

Danger of poisoning.

Danger due to escaping dust, contamination of the device and device components.

Only operate the device in conjunction with exhaust air equipment, for example a

suction device on the powder center.

The device may only be operated under the following conditions:

Use the device only to work with the products recommended by WAGNER.

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 (zone 22) in accordance with

Directive 2014/34/EU.

2.4 PROCESSIBLE WORKING MATERIALS

In principle all powder lacquers can be conveyed with the powder pump, for example

epoxy, polyester, mixed powders EP/PES/PUR.

However, inindividualcases theuse ofpowderswithspecialrecipes cancausemalfunctions,

which cannot be eliminated with the various pump recipes.

2.5 MISUSE

Misuse can lead to physical injury and/or property damage!

Special attention must be paid that:

no liquid coating products, e.g., solvents or water-based lacquers are processed;

no food, medicine or cosmetics are processed.

EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000

3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

Device type: Powder feed pump

Manufacturer: Wagner International AG

9450 Altstätten

Switzerland

II 3D Ex tc IIIB T85°C Dc

CE: European Communities

Ex: Symbol for explosion protection

II: Device class II

3: Category 3

D: Ex-atmosphere dust

IIIB: Explosion group (dust group)

T85°C: Temperature class: maximum surface temperature < 85 °C; 185 °F

Dc: High safety level

3.2 PERMISSIBLE DEVICE COMBINATIONS

The IP 5000 powder pump can be used in the following WAGNER powder centers:

– PZ 2008 powder center

– SuperCenter 2012

– PXM powder center

– PXS powder center

3.3 TYPE PLATE

P_02570

Wagner International AG

CH-9450 Altstätten

II 3D Ex tc IIIB T85°C Dc

Typ:

Type:

Serie Nr./Baujahr:

Serial Nr./YB:

Spannung:

Voltage:

Eingangsleistung:

Line Power:

Made in Switzerland

Umgebungstemp.:

Ambient temperature:

Schutzklasse:

Prot Class:

IP 5000

IP 5000-USD

24V DC +/-20%

40W

+10°C Ta +50°C

IP 54

1 Serial number

2 Input voltage

3 Input power

4 Ambient temperature

5 Protection class

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