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WAGNER IP 5000 Translation Of The Original Operating Manual Download Page 1

P_04342

P_04342

 

 

 

 

IP 5000

IP 5000-USD

Fresh Powder and Transfer Pump

Edition 08/2021

II 3D Ex tc IIIB T85°C Dc

Summary of Contents for IP 5000

Page 1: ...P_04342 P_04342 IP 5000 IP 5000 USD Fresh Powder and Transfer Pump Edition 08 2021 II 3D Ex tc IIIB T85 C Dc...

Page 2: ......

Page 3: ...and Equipment 11 4 1 2 A Safe Work Environment 12 4 1 3 Personnel Qualifications 12 4 2 Safety Instructions for the Personnel 13 4 2 1 Personal Safety Equipment 13 4 2 2 Safe Handling of WAGNER Powder...

Page 4: ...n 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...

Page 5: ...n 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 Sig...

Page 6: ...LS 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...

Page 7: ...41936 Danish 2396410 French 241943 Polish 2316573 Italian 241944 Romanian 2409919 Spanish 241945 Slovenian 2395395 Russian 2326214 Slovakian 2400611 Chinese 2384487 Czech 2302697 Swedish 2315185 Norwe...

Page 8: ...y 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 Sk...

Page 9: ...the following conditions Use the device only to work with the products recommended by WAGNER Do not deactivate safety fixtures Use only WAGNER original spare parts and accessories The operating person...

Page 10: ...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...

Page 11: ...eir supervision With open housings the mains voltage poses a danger Operate device in accordance with the safety regulations and electrotechnical regulations Do not disconnect any plug connections dur...

Page 12: ...ble system for suppressing fire and explosion must be installed The powder release must be electrically interlocked with the connected technical ventilation of the spray system Excess coating product...

Page 13: ...ures In particular wear safety goggles protective clothing and gloves as well as hand protection cream if necessary Use a mask or breathing apparatus if necessary For sufficient health and environment...

Page 14: ...rsons inside the working area are grounded e g that they are wearing static dissipative shoes Grounding cables must be checked regularly to ensure that they are serviceable see EN 60204 4 2 4 PRODUCT...

Page 15: ...be shut down and locked to prevent it from being switched back on Lock the compressed air supply and decompress the device Secure the device against being switched back on without authorization Use on...

Page 16: ...of the operating company Only repair and replace parts that are listed in the Chapters Accessories and Spare Parts and that are assigned to the device Do not use any defective components Before all w...

Page 17: ...0 POWDER PUMP 5 1 1 IP 5000 VERSION Front View Profile 1 2 4 5 6 7 P_04343 8 9 3 Designation 1 Control cabinet 2 Control panel 3 Cooling box for inlet valve air 4 Pressure regulator in the control cab...

Page 18: ...USD VERSION Front View Profile 5 6 7 2 1 4 P_04825 9 8 3 Designation 1 Control cabinet 2 Control panel 3 Cooling box for inlet valve air 4 Pressure regulator in the control cabinet 5 Powder inlet valv...

Page 19: ...ce are stored in the powder pump controller A cleaning recipe for cleaning suction and pressure hose is also stored in the controller The powder pump is equipped with an active inlet valve cooling for...

Page 20: ...unter 6 LED display Cleaning Time 7 Button Reduced Flow Rate 8 Button Full Flow Rate 9 Display for control via level monitoring 10 Fault display LED lights up 11 Pressure gauge for piston air The LEDs...

Page 21: ...lity The compressed air must meet the following quality requirements Quality Standard 6 5 2 according to ISO 8573 1 2010 6 5 2 particle density 5 mg m pressure dew point 7 C oil content 0 1 mg m Flow...

Page 22: ...in a reliable state after it is assembled and commissioned 6 2 STORAGE CONDITIONS Until the point of assembly the device must be stored in a dry location free from vibrations and with a minimum of dus...

Page 23: ...TION 08 2021 ORDER NUMBER DOC241936 IP 5000 6 4 ASSEMBLY EXAMPLE OF THE WAGNER POWDER CENTER Pump mounted to the side using fastening set accessory order no 241550 256 9 1600 P_00443 220 Measurements...

Page 24: ...der outlet 1 Maximum delivery head 5 m 16 4 ft 2 Surge damper 3 Suction Lance 4 Fresh powder 5 Target tank Suction side A Keep hose length as short as possible maximum 4 m 13 2 ft Use POE 12 powder ho...

Page 25: ...tion length maximum of 5 m 16 4 ft 2 Surge damper 3 Suction Lance 4 Fresh powder 5 Target tank Suction side A Keep hose length as short as possible maximum 4 m 13 2 ft Use POE 12 powder hose order no...

Page 26: ...DOC241936 IP 5000 6 6 ASSEMBLING THE POWDER PUMP 1 2 3 4 P_04344 Designation 1 Grounding screw 2 Plug connection 24 VDC and I O signals 3 Compressed air connection 4 Plug connection of external cleani...

Page 27: ...supply voltage and signal lines to upper part of plug in accordance with configuration plan see Chapter 13 1 5 Attach 24 VDC electric cable to the plug 2 and secure with safety clip 6 WARNING IP Code...

Page 28: ...locking nut 2 counterclockwise up to the stop 4 Press the O ring 1 into the groove again securing function Note Slide the powder hose onto the hose coupling as far as possible up to the stop 6 8 GROU...

Page 29: ...3 A Switch position 0 BigBag B Switch position 1 powder center Factory settings Operating mode powder center Pressure regulator 1 0 3 MPa 3 bar 43 5 psi Pressure regulator 2 0 3 MPa 3 bar 43 5 psi Pre...

Page 30: ...0 m 66 ft feed hose length 0 3 0 6 MPa 3 6 bar 43 5 87 psi for feeding from BigBag 20 50 m 66 164 ft feed hose length The precise setting of the blow out air is used to obtain an even powder flow Blow...

Page 31: ...00 6 9 3 PIN ASSIGNMENT IN THE CONTROL CABINET 6 5 4 3 2 P_04309 1 Designation 1 DIP switches 1 8 for setting see Chapter 7 5 1 2 LED display After run Level Controller 3 A button A button 4 Valve con...

Page 32: ...NG MODES The powder pump can be operated in two ways in conjunction with a powder center or BigBag used as a transfer pump 7 4 OPERATION WITH WAGNER POWDER CENTER The powder pump is controlled via the...

Page 33: ...cleaning off with cleaning box 6 on 3 off off 4 on set service interval 7 on 3 4 on set level controller time off 8 on 6 on standby deactivated off from software version 1 03 9 on SuperCenter Cleanin...

Page 34: ...play see Chapter 6 9 3 No powder is drawn in during the after run time 0 LED lights up function deactivated 1 LED lights up 3 pump cycles 2 LEDs light up 6 pump cycles 3 LEDs light up 9 pump cycles 4...

Page 35: ...ee Chapter 5 3 We recommend changing the pump and valve hoses when the fault display has appeared see Chapter 8 2 5 After replacing the hoses the cycle counter must be reset to zero see Chapter 7 6 Us...

Page 36: ...es 1 200 000 cycles have been executed 100 90 80 70 60 50 40 30 20 10 P_04311 After the display has changed to setting status the LED lights up at value 50 factory setting 2 000 000 with maximum 4 000...

Page 37: ...time 3 Minimum Internal LED display Function No LED lights up Function deactivated factory setting LED 1 lights up Signal 1 Pump on Signal 0 Pump off switch function LED 2 lights up Signal 1 Pump run...

Page 38: ...mp and valve hoses the cycle counter must be reset Auto 100 90 80 70 60 10 20 30 40 50 10 9 8 7 6 1 2 3 4 5 IP 5000 1 P_00036 2 3 Work steps 1 Switch powder pump off with ON OFF button 1 2 Press butto...

Page 39: ...en changes to a blow out cycle The cleaning time can be set with the DIP switches see Chapter 7 5 1 In the case of powders that tend to sinter heavily or in the case of metallic powders repeat the cle...

Page 40: ...aning with cleaning box order no 241570 if necessary 3 Disconnect suction hose from the feed unit and connect to the cleaning box Check hose coupling for secure fit 4 Press the START STOP button and e...

Page 41: ...ht up 10 cleaning cycles 10 LEDs light up 11 cleaning cycles 8 1 7 PXM CLEANING PROCEDURE The powder pump cleaning procedure with use at a PXM powder center is described below To activate this functio...

Page 42: ...he device and in the event of work interruptions Switch off the energy and compressed air supply Relieve spray gun and device pressure Secure the spray gun against actuation Observe the operating and...

Page 43: ...Lock the compressed air supply and decompress the system To facilitate working on the pump it is advisable to detach the electrical and pneumatic connections at the control cabinet and place the compl...

Page 44: ...and valve housing 4 at the top of the pump body 5 9 Unscrew screws 2 on the lower valve block 10 Remove Y piece 3 and valve housing 4 at the bottom of the pump body 5 11 Remove old valve hoses 6 from...

Page 45: ...e hose flanges 9 at the top and bottom of the pump body 5 5 10 P_00011 15 Squeeze old pump hoses 10 lightly at the top and remove downwards from the pump body 5 P_00012 11 5 A 16 Carefully introduce n...

Page 46: ...4 17 Attach hose flange 9 to the bottom of the pump body 5 and fasten with screws 8 Do not damage the pump hoses Evenly tighten screws 8 crosswise 5 Nm 3 7 lb ft 18 Carefully screw connections 1 into...

Page 47: ...Remove plugs 4 pieces from the valves 12 21 Open the compressed air supply 22 Set blow out air on pressure regulator 13 to 0 MPa 0 bar 0 psi 23 Set piston air KV on pressure regulator 14 to 0 2 MPa 2...

Page 48: ...housing 4 and Y piece 3 to the top of the pump body 5 and fasten with screws 2 Evenly tighten screws 2 alternately crosswise 6 Nm 4 425 lb ft To facilitate assembly two longer screws order no 9907014...

Page 49: ...r hoses onto the upper and lower hose fitting and fasten with hose clips 30 Insert air lines into the upper and lower valve blocks 31 After successful execution of the tightness check and resetting of...

Page 50: ...ial number 1848 P_04349 P_04350 8 4 1 DISASSEMBLY I 0 0 P_00020 Work steps 1 Switch off the system 2 Switch off the main switch and protect against unauthorized restarting 3 Lock the compressed air su...

Page 51: ...MBER DOC241936 IP 5000 2 P_04329 3 4 1 6 Unscrew screws 4 on the lower valve block 7 Remove Y piece 3 and valve housing 2 at the bottom of the pump body 1 5 P_04331 8 Turn back connections 5 on the no...

Page 52: ...on the lower valve block and remove hose flange 6 from pump body 1 8 9 10 P_04334 10 Remove valves 10 AL1 and AL2 from the air connections 11 Unscrew air connections 8 out of the non return valve unit...

Page 53: ...steps 1 Screw in non return valve 12 up to stop in bushing 11 8 9 P_04336 2 Mount non return valve 9 with air connection 8 in control cabinet and screw them loosely together 6 1 7 P_04337 3 Attach hos...

Page 54: ...ctions in the hose bushing 6 with care 5 Evenly tighten screws 7 crosswise 5 Nm 3 7 lb ft 6 Screw the non return valve connections completely into the air connections in the hose bushing 6 AL1 AL2 P_0...

Page 55: ...sswise 6 Nm 4 43 lb ft Installation instructions To facilitate assembly two longer screws order no 9907014 can be used which must be replaced with the shorter screws when assembly is complete 10 Push...

Page 56: ...air or replacement of devices or parts of devices may only be performed outside the hazard area Malfunction Cause Solution Powder pump does not deliver No release by powder center Switch on ventilator...

Page 57: ...work 10 2 DISPOSAL NOTICE Do not dispose of used electrical equipment with household refuse In accordance with European Directive 2012 19 EU on the disposal of used electrical equipment and its imple...

Page 58: ..._00440 Consists of suspension bracket for wall mounting 2 rubber buffers 241555 Surge damper P_01034 for use in theWAGNER circulating powder center reduced dust formation 265110 Suction device IP 5000...

Page 59: ...241570 External cleaning box P_00449 3313075 Pump rack IP 5000 P_00499 390955 Hose take up D10 D12 not electrically conductive P_01035 2305866 Hose take up D10 D12 electrically conductive P_01035 235...

Page 60: ...der no Designation 9987135 Hose holder for POE 12 and POE 14 powder hoses P_00474 2301253 Thread adapter P_00924 2305865 for the seating of a complete coupling 2310700 Powder hose POE 12 2312126 Powde...

Page 61: ...the following spare parts lists Wearing parts Wearing parts are not included in the warranty terms Included in service set Note These parts are not covered by warranty terms Not part of standard equi...

Page 62: ...62 EDITION 08 2021 ORDER NUMBER DOC241936 IP 5000 12 2 POWDER PUMP SPARE PARTS LIST P_04347 1 8 11 7 9 6 5 4 10 3 2 10 4 6 11 9...

Page 63: ...Hose flange outlet valve 4 2 2301449 Valve housing 5 2 2312058 Service set valve hose D15 x 25 x 74 2 hoses 6 2 241489 Y block 7 2 241541 Hose fitting D30 x 41 8 2 241237 Non return valve up to seria...

Page 64: ...ER NUMBER DOC241936 IP 5000 12 3 CONTROL CABINET SPARE PARTS LIST P_04348 1 3 5 2 12 17 18 10 25 26 13 14 19 6 9 7 8 4 15 20 21 24 16 11 23 11 22 27 Note With the IP 5000 USD the control cabinet is ar...

Page 65: ...valve 9 2 9943158 Non return valve 10 1 241234 Double ejector 11 2 2334272 Pressure regulator 12 1 9943159 Pressure regulator 13 1 9943160 Pressure gauge 14 1 9974242 O ring 15 4 9910903 Hexagon nut...

Page 66: ...RTS LIST 1 2 3 4 5 6 P_00024 7 Order no Designation 1 1 9956254 Externally mounted housing 2 1 9956253 Pin insert 10 pin 3 1 9956252 Bushing insert 10 pin 4 1 9906029 Socket cap screw 5 1 241545 Gromm...

Page 67: ...S LIST 1 2 4 5 3 P_00448 X 30 6 Measurement X order no 2301550 582 mm Order no Designation 1 1 265412 Fluid ring 2 1 2301098 Crown M18x1 5 3 1 2353080 Coupling piece complete 4 1 9992260 Coupling plug...

Page 68: ...TS LIST 1 2 4 5 3 P_01033 X 30 6 Measurement X order no 2301548 1518 mm Order no Designation 1 1 265412 Fluid ring 2 1 2304065 Suction head 3 1 2353080 Coupling piece complete 4 1 9992260 Coupling plu...

Page 69: ...R NUMBER DOC241936 IP 5000 12 7 EXTERNAL CLEANING BOX SPARE PARTS LIST 1 2 3 P_00438 Order no Designation 1 1 9956234 Solenoid valve EVP 342 2 1 9943158 Non return valve d10 3 1 390954 Coupling piece...

Page 70: ...P_04316 XST 9 PIN Assignment Function Plug 1 Device voltage supply 2 Device grounding 3 Release 24 V signal 4 Powder pump START STOP 24 V ON 0 V OFF 5 Cleaning ON OFF 6 Level controller output 24V 7 L...

Page 71: ...1SIGNAL SEQUENCE FEEDING OPERATION Signal I1 O1 P_04317 0V 24V 1 2 1 State 1 OFF 2 ON 13 2 2SIGNAL SEQUENCE KPZ 2008 CLEANING DIP switch 7 is set to off Signal I2 P_04318 1 2 1 0V 24V Cleaning ends au...

Page 72: ...MBER DOC241936 IP 5000 13 2 3SIGNAL SEQUENCE PXM PXS STANDARD CLEANING DIP switch 7 is set to on P_04325 low low T1 1 2 3 T1 200 ms 4 Description 1 I2 Cleaning on off 2 I4 Level controller input 3 O2...

Page 73: ...P 5000 13 2 4SIGNAL SEQUENCE PXM PXS INTENSIVE CLEANING DIP switch 7 is set to on 1 2 3 T1 200 ms 4 P_04326 low low T 0 ms T T1 Description 1 I2 Cleaning on off 2 I4 Level controller input 3 O2 Cleani...

Page 74: ...R NUMBER DOC241936 IP 5000 13 2 5SIGNAL SEQUENCE SUPERCENTER CLEANING DIP switch 7 is set to on 1 2 3 4 P_04327 low low Description 1 I2 Cleaning on off 2 I4 Level controller input 3 O2 Cleaning in pr...

Page 75: ...936 IP 5000 13 3 VALVE ASSIGNMENT Inlet valve 1 Pump tube 1 Piston valve 1 Vacuum valve 1 Blow out valve 1 Outlet valve 1 Inlet valve 2 Pump tube 2 Piston valve 2 Vacuum valve 2 Blow out valve 2 Outle...

Page 76: ...PLAN4 P C WAG IP5000 0241608A Controller version Bxxx Project name Installation place ce Project manager Remarks Yellow_green Grounding Blue Control voltage DC Red Mains voltage Black Brown Orange Yel...

Page 77: ...77 EDITION 08 2021 ORDER NUMBER DOC241936 IP 5000 P_00029 Cause Location Side Side name Cover Volume Cover Table of Contents Grounding Valves Powder center connection Cleaning box connection...

Page 78: ...78 EDITION 08 2021 ORDER NUMBER DOC241936 IP 5000 P_00030 Supply Release Display Display...

Page 79: ...79 EDITION 08 2021 ORDER NUMBER DOC241936 IP 5000 P_00031...

Page 80: ...80 EDITION 08 2021 ORDER NUMBER DOC241936 IP 5000 P_00032...

Page 81: ...81 EDITION 08 2021 ORDER NUMBER DOC241936 IP 5000 P_00033 Powder center...

Page 82: ...82 EDITION 08 2021 ORDER NUMBER DOC241936 IP 5000 P_00034 Cleaning box...

Page 83: ...PNEUMATIC DIAGRAM 1 2 1 1 2 12 1 2 2 1 3 2 1 3 12 12 1 2 4bar 2 1 2 1 2 1 12 1 2 12 3 1 2 12 3 1 2 12 1 2 2 1 3 12 12 1 2 12 3 1 2 12 3 1 2 AV 1 AV 2 EV 1 AL 1 VK 1 KV 1 EV 2 AL 2 VK 2 KV 2 2 3 4 5 6...

Page 84: ...escription 1 EV1 inlet valve 1 2 AL1 blow out valve 1 3 VK1 vacuum valve 1 4 KV1 piston valve 1 5 AV 1 outlet valve 1 6 EV 2 inlet valve 2 7 AL2 blow out valve 2 8 VK2 vacuum valve 2 9 KV2 piston valv...

Page 85: ...N ISO 4414 2010 EN IEC 60079 0 2018 EN ISO 13732 1 2008 EN 60079 31 2014 EN 14462 2015 EN IEC 61000 6 2 2019 EN 1127 1 2019 EN IEC 61000 6 4 2019 Applied national technical standards and specification...

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Page 88: ...ts powder wagner group com www wagner group com CERTI F I E D Order no 241936 Edition 08 2021 Document No 11057356 Version G...

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