WAGNER Wildcat 18-40 Betriebshandbuch

Wildcat 10-70 / 18-40

Puma 28-40 / 15-70

Puma 21-110 / 15-150

Leopard 35-70

Leopard 35-150 / 48-110

Jaguar 75-150

IceBreaker Piston Pumps

Flow rate 40 cm3 – 150 cm3

Version 08/2018

B_06985

VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 cm3

Contents

1 ABOUT THESE INSTRUCTIONS 6

1.1 Preface 6

1.2 Warnings, Notices and Symbols in these Instructions 6

1.3 Languages 6

1.4 Service Manual 7

1.5 Abbreviations 7

1.6 Terminology for the Purpose of this Manual 7

2 CORRECT USE 8

2.1 Device Types 8

2.1.1 Pneumatic Pumps and Their Spraypacks 8

2.1.2 Special Versions for Acidic Hardeners and Their Spraypacks 8

2.2 Type of Use 8

2.3 For Use in Potentially Explosive Areas 8

2.4 Processible Working Materials 8

2.4.1 Special Versions for Acidic Hardeners 9

2.5 Misuse 9

3 IDENTIFICATION 10

3.1 Explosion Protection Identication 10

3.2 Identication "X" 10

3.3 Type plates 11

4 BASIC SAFETY INSTRUCTIONS 12

4.1 Safety Instructions for the Operator 12

4.1.1 Electrical Devices and Equipment 12

4.1.2 A Safe Work Environment 12

4.1.3 Personnel Qualications 13

4.2 Safety Instructions for the Personnel 13

4.2.1 Personal Safety Equipment 13

4.2.2 Safe Handling of WAGNER Spray Devices 14

4.2.3 Grounding the Unit 14

4.2.4 Product hose 15

4.2.5 Cleaning and Flushing 16

4.2.6 Touching Hot Surfaces 16

4.2.7 Maintenance and Repair 17

4.2.8 Protective and Monitoring Equipment 17

5 DESCRIPTION 18

5.1 Components 18

5.2 Mode of Operation 18

5.2.1 Air motor 18

5.2.2 Fluid section 18

5.3 Protective and monitoring equipment 19

5.4 Included Items 19

5.5 Data 19

5.5.1 Materials of Paint-wetted Parts 19

5.5.2 Recommended Packings 20

5.5.3 Technical Data for Wildcat and Puma 21

5.5.4 Measurements and Connections for Wildcat and Puma 22

VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 cm3

5.5.5 Technical Data for Leopard and Jaguar 23

5.5.6 Measurements and Connections for Leopard and Jaguar 24

5.5.7 Volume Flow 25

5.5.8 Performance diagrams 25

5.6 Operating elements 28

5.6.1 Pressure Regulator Unit 28

5.7 Product Filter and Return Line 28

5.7.1 High-pressure Filter (Option) 28

5.7.2 Relief Combination and Inline Filter up to 270 Bar (Option) 29

5.8 Stroke Count (Option) 29

5.9 Feed Pump (Option) 30

6 ASSEMBLY AND COMMISSIONING 31

6.1 Training of Assembly/Commissioning Personnel 31

6.2 Storage Conditions 31

6.3 Installation Conditions 31

6.4 Transportation 31

6.5 Assembly and Installation 32

6.5.1 Ventilation of the Spray Booth 33

6.5.2 Air Supply Lines 33

6.5.3 Product supply lines 33

6.6 Grounding 33

6.7 Commissioning 35

7 OPERATION 36

7.1 Training the Operating Personnel 36

7.2 Emergency Stop 36

7.3 Tasks 36

7.4 Pressure Relief/Work Interruption 37

7.5 Basic Flushing 38

7.6 Filling with Working Material 38

8 CLEANING AND MAINTENANCE 39

8.1 Cleaning 39

8.1.1 Cleaning Personnel 39

8.1.2 Decommissioning and Cleaning 39

8.1.3 Long-term Storage 39

8.2 Maintenance 40

8.2.1 Maintenance Personnel 40

8.2.2 Maintenance Instructions 40

8.2.3 Safety Checks and Maintenance Intervals 41

8.2.4 Emptying Pump 43

8.2.5 Filling the Empty Pump 44

8.2.6 Cleaning and Replacing the Filter 45

9 TROUBLESHOOTING AND RECTIFICATION 47

10 REPAIR WORK 48

10.1 Repair Personnel 48

10.2 Repair Notes 48

10.3 Tools 48

10.4 Cleaning the Parts After Disassembly 49

10.5 Assembly of the Device 49

VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 cm3

11 FUNCTION TEST AFTER REPAIR WORK 50

12 DISPOSAL 50

13 ACCESSORIES 52

13.1 Wildcat and Puma Pumps 52

13.1.1 Product Outlet and Miscellaneous 52

13.1.2 Product inlet 54

13.1.3 Trolley, Frame and Wall Mount Accessories 56

13.2 Leopard and Jaguar Pumps 58

13.2.1 Product Outlet and Miscellaneous 58

13.2.2 Product inlet 60

13.2.3 Trolley and Wall Mount 62

14 SPARE PARTS 63

14.1 How can spare parts be ordered? 63

14.2 Overview of the Components 64

14.3 Air Motors 68

14.3.1 Wildcat, Puma and Leopard Air Motors 68

14.3.2 Wildcat and Puma Air Motor Regulators 71

14.3.3 Leopard Air Motor Regulator 72

14.3.4 Jaguar Air Motor 73

14.3.5 Jaguar Air Motor Regulator 76

14.4 Connection Sets 77

14.4.1 Connection Sets for 40–70 cm377

14.4.2 Connection Sets for 110–150 cm378

14.5 Fluid Sections 80

14.5.1 Fluid Sections 40 cm3 80

14.5.2 Fluid Sections 70 cm3 82

14.5.3 Fluid Sections 110 cm3 84

14.5.4 Fluid Sections 150 cm386

14.6 Inlet Valve with Valve Depressor 88

14.7 Relief Combination 270 Bar 88

14.8 Straight Inline Filter, 270 bar 89

14.9 Angled Inline Filter, 530 Bar 89

14.10 High-pressure Filter, 270 Bar 90

14.11 High-pressure Filter, 530 Bar 92

14.12 AirCoat Regulator and AirCoat Filter Regulator 94

14.13 Trolley for Wildcat, Puma and Leopard 95

14.14 Trolley for Leopard 48-110 and Jaguar 96

15 EU DECLARATION OF CONFORMITY 97

VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 cm3

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 risk.

Non-observance can result in death or serious injury.

CAUTION Potentially hazardous situation.

Non-observance may result in minor injury.

NOTICE Potentially hazardous situation.

Non-observance may result in damage to property.

Notice Provides information about particular characteristics and how to

proceed.

Explanation of warning notice:

LEVEL OF DANGER

This notice warns you of a hazard!

Possible consequences of not observing the warning notice.

The measures for preventing the hazard and its consequences.

1.3 LANGUAGES

The operating manual is available in the following languages:

Original operating manual

Language Order No.

German 2333537

Translation of the original operating manual

Language Order No. Language Order No.

French 2333539 English 2333538

Spanish 2333541 Italian 2333540

Japanese 2338088 Russian 2351629

Dutch 2367552 Hungarian 2352104

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

VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 cm3

1.4 SERVICE MANUAL

The service manual is available in the following languages:

Language Order No. Language Order No.

German 2335993 English 2335994

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

1.5 ABBREVIATIONS

Number of pieces Stainless steel

Position Polyethylene

Marking in the spare parts lists Ultra-high molecular weight polyethylene

Order No. Order number Polytetrauorethylene

Double stroke PTFE with graphite

DN Nominal diameter PTFE

PN Nominal pressure Leather

Two components -- --

1.6 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 ushing agent.

Product pressure

generator

Pump or pressure tank.

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,

experience and knowledge of the relevant provisions.

Skilled person in

accordance with TRBS

1203

(2010/Revision 2012)

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

and recent vocational experience, has sucient technical

knowledge in the areas of explosion protection, protection

from pressure hazards and electric hazards (if applicable) and

is familiar with the relevant and generally accepted rules of

technology so that he/she can inspect and assess the status of

devices and coating systems based on workplace safety.

VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 cm3

2 CORRECT USE

2.1 DEVICE TYPES

2.1.1 PNEUMATIC PUMPS AND THEIR SPRAYPACKS

Wildcat Puma Leopard Jaguar

10-70 28-40 35-70 75-150

18-40 15-70 35-150 --

-- 21-110 48-110 --

-- 15-150 -- --

2.1.2 SPECIAL VERSIONS FOR ACIDIC HARDENERS AND THEIR SPRAYPACKS

Wildcat Leopard

10-70 (TC 1.4404) 35-70 (TC 1.4404)

2.2 TYPE OF USE

The device is suitable for processing liquid products like paints and lacquers:

– Non-ignitable products.

– Products in accordance with their classication in explosion class IIB.

WAGNER explicitly prohibits any other use!

The device may only be operated under the following conditions:

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

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.

2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS

The device can be employed in explosion hazard zones (Zone 1) (see Chapter 3).

2.4 PROCESSIBLE WORKING MATERIALS

Fluid materials like paints and lacquers.

Application

Water-dilutable products

Solvent-based lacquers and paints

Primers

Epoxy and polyurethane lacquers, phenolic

lacquers

Liquid plastics

Wax-based underside protection

Chemically aggressive products that attack

carbide seats

Special versions for 2K products:

Wildcat 10-70 TC and Leopard 35-70 TC -- -- -- --

recommended limited suitability not suitable -- not compatible with 2K products

VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 cm3

NOTICE

Abrasive working materials and pigments!

Greater wear of product-wetted parts.

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

indicated in Chapter 5.5.

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

materials as indicated in Chapter 5.5.1.

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

Wear caused by abrasive working materials is not covered by the warranty.

Typical applications

Fields of application

Furniture industry

Kitchen manufacturers

Joinery

Window factories

Steel-processing industry

Construction of vehicles

Shipbuilding

recommended limited suitability not suitable

2.4.1 SPECIAL VERSIONS FOR ACIDIC HARDENERS

WARNING

Acidic hardeners!

Risk of burns and injury for skin, tissue and organs.

Observe the lacquer manufacturer's safety data sheets and take prescribed safety

measures.

Special versions:

Wildcat 10-70 TC and Leopard 35-70 TC

Check products for compatibility: see Chapter 5.5.1.

Parts made of stainless steel 1.4404 are labeled with

"1.4404" (see example).

Further information about operation with acidic

hardeners can be found in the operating manual for the

entire system.

1.4404

B_06427

Maximum pressure

for the uid

section's output

Designation "1.4404"

Example of hardener pump

2.5 MISUSE

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

Special attention must be paid that:

No dry coating products, e.g., powder are processed.

no food, medicine or cosmetics are processed.

It is important to note that the device's materials are not food-safe.

VERSION 08/2018 ORDER NUMBER DOC 2333538 IceBreaker 40-150 cm3

3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially

explosive areas.

Device types: IceBreaker Piston Pump

Wildcat 10-70, Wildcat 18-40

Puma 28-40, Puma 15-70, Puma 21-110, Puma 15-150

Leopard 35-70, Leopard 35-150, Leopard 48-110

Jaguar 75-150

Manufacturer: Wagner International AG

CH-9450 Altstätten, Switzerland

European Communities

Symbol for explosion protection

Device class II

Category 2 (zone 1)

Ex-atmosphere gas

Explosion protection

Ignition protection for non-electrical devices

Explosion group

Maximum surface temperature < 200 °C; 392 °F (without drying protection

active)

Maximum surface temperature < 135 °C; 275 °F (with drying protection

active)

High safety level

There are special instructions to ensure safe operation.

See the following Chapter "Identication X".

3.2 IDENTIFICATION "X"

The maximum surface temperature corresponds to the permissible product temperature.

This and the permissible ambient temperature can be found in Chapter 5.5.3 and 5.5.5

(technical data regarding the Wildcat, Puma, Leopard and Jaguar pumps).

Safe Handling of WAGNER Spray Devices

Mechanical sparks can form if the device comes into contact with metal.

In an explosive atmosphere:

knocking or pushing metal against metal is to be avoided;

Do not drop the device or components.

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 tank is lled with sucient separating agent.

Ignition temperature of the coating product

Ensure that the ignition temperature of the surrounding gases (pumping product,

cleaning agents) is higher than the maximum permitted surface temperature of the

device.

Ambient temperature

The permissible ambient temperature range is: 5 °C to 50 °C; 41 °F to 122 °F.

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