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6

OPERATING MANUAL

VERSION 01/2013

ORDER NUMBER DOC 2335747

1.3 

LANGUAGES

1.4 

ABBREVIATIONS IN THE TEXT

Number of pieces
Position
Marking in the spare parts lists

Order No.

Order No.
Double stroke

Materials:

Polytetrafl uorethylene 
Ethylene-propylene-diene monomer (rubber)

The operating manual is available in the following languages:

Language:

Order No.

Language:

Order No.

German

2335746

English

2335747

Italian

2335748

French

2335750

Spanish

2335752

Summary of Contents for PM500

Page 1: ...B_04200 Pneumatic Double Diaphragm Pump PM500 Version 01 2013 Translation of the Original Operating Manual ...

Page 2: ......

Page 3: ...al Equipment 11 4 1 2 Personnel Qualifications 11 4 1 3 Safe Work Environment 11 4 2 Safety Instructions for Staff 11 4 2 1 Safe Handling of WAGNER Spray Devices 12 4 2 2 Grounding the Unit 12 4 2 3 Material Hoses 12 4 2 4 Cleaning 13 4 2 5 Handling Hazardous Liquids Varnishes and Paints 13 4 2 6 Touching Hot Surfaces 13 4 2 7 Explosion Hazard 14 4 2 8 Noise Risk 14 4 2 9 Material Chemical Compati...

Page 4: ...ION 32 7 1 Operation 32 7 2 Ending Work 32 7 3 Storage Over Longer Periods of Time 32 8 TROUBLE SHOOTING AND RECTIFICATION 33 9 MAINTENANCE 35 9 1 Safety Instructions 36 9 2 Diaphragm Replacement Preventive Maintenance 36 9 3 Diaphragm Replacement Due to Breakage 38 9 4 Cleaning Replacement of the Suction and Delivery Non Return Valves 42 9 5 Replacement of the Reversing Valve 42 9 6 Material Hose...

Page 5: ...consequences DANGER 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 WARNING 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 pre...

Page 6: ... Position Marking in the spare parts lists Order No Order No Double stroke Materials Polytetrafluorethylene Ethylene propylene diene monomer rubber The operating manual is available in the following languages Language Order No Language Order No German 2335746 English 2335747 Italian 2335748 French 2335750 Spanish 2335752 ...

Page 7: ...RD AREA Metallic versions aluminum Pneumatic double diaphragm pumps with Order No U509 A0 U509 A0A The device is suitable for processing liquid materials like paints and varnishes in accordance with the classification into explosion classes IIA or IIB The pneumatic double diaphragm pumps can be employed in explosion hazard zones Zone 1 ...

Page 8: ...se 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 NOTICE The operation of the pneumatic double diaphragm pump is only allowable under the following conditions The operating staff have previously been trained on the basis of this o...

Page 9: ...e disassembly Paint in air outside the defined working area Painting outside the defined working area Inhalation of substances which are hazardous to health Observe working and operating instructions Operation maintenance The following is prohibited coating work pieces which are not grounded unauthorized conversions and modifications to the device processing dry or similar coating materials and us...

Page 10: ...e 4 40 C 39 104 F As defined in the Directive 94 9 EC ATEX 95 the device is suitable for use in areas where there is an explosion hazard 4 C ambient temperature to 40 C European Communities Symbol for explosion protection Device class II Category 2 Zone 1 Ex atmosphere gas Explosion group Temperature class maximum surface temperature 135 C 275 F Ambient temperature 4 C to 40 C permissible ambient ...

Page 11: ...ve parts Inform staff about planned work Observe electrical safety regulations Ensure that the device is operated and repaired only by trained persons Makesurethatthefloorintheareawhereyouareworkingiselectrostaticallyconductive in accordance with EN 61340 4 1 Ensure that all persons within the working area wear electrostatically conductive shoes Ensurethatduringspraying personswearelectricallycond...

Page 12: ...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 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...

Page 13: ...e 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 Touch hot surfaces only if you are wearing protective gloves When operating the unit with a coating material with a temperature of 43 C 10...

Page 14: ...all parts subject to pressure Depending on the type of use and the substances used the user has to check for the presence of deposits on the pump as well as check its cleanliness at regular intervals and the state of wear of the components and proper operation of the pump assembly The operation must be carried out in conformity with what is written in this manual 4 2 7 EXPLOSION HAZARD Never use c...

Page 15: ...e 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 sy...

Page 16: ...ed the values indicated in the Technical Data chapter Fluids incompatible with the pump s materials or particularly reactive mixtures of products with several components may cause exothermic reactions and develop dangerous temperatures or pressure Connection pipes must be made of conductive material and properly grounded If the pumping fluids contain solid particles install a filter on the intake ...

Page 17: ...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 NOTICE Diaphragm pump CE Conformity see Chapter 11 Operating manual German Order No 2335746 Operating manual for other languages see Chapter 1 The delivery note shows the exact scope of d...

Page 18: ...PTFE Stainless steel Stainless steel Stainless steel EPDM U509 A0A Aluminum nickel coated PTFE Stainless steel Stainless steel Stainless steel EPDM Positions of the individual parts see spare parts list 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 m...

Page 19: ...Pa 0 2 bar 2 0 psi 29 Maximum air inlet pressure MPa 1 0 bar 10 psi 145 Air inlet connection male BSP R 1 4 Maximum suction height 1 m 6 0 ft 19 5 Maximum solid body size mm 3 5 inches 0 14 Sound pressure equivalent 40 cycles min feeding 6 bar 2 dB A 81 Fluid connections inlet outlet bush BSP G 1 Weight kg 13 8 lb 30 5 Maximum material pressure at the pump s inlet MPa 0 1 bar 1 psi 14 5 Material t...

Page 20: ...A B F H J K B_04201 E G J OPERATING MANUAL VERSION 01 2013 ORDER NUMBER DOC 2335747 5 3 3 DIMENSIONS AND CONNECTIONS mm inch 344 13 54 210 8 27 359 14 13 279 10 98 200 7 87 120 4 72 250 9 84 150 5 90 G1 F G1 4 ...

Page 21: ...RATING MANUAL VERSION 01 2013 ORDER NUMBER DOC 2335747 5 3 4 PERFORMANCE DIAGRAMS Example Material pressure bar MPa psi Material flow volume water l min gpm Air consumption nl min scfm Diagram PM500 Material pressure Material flow volume water A 6 bar 0 6 MPa 87 psi air pressure B 5 bar 0 4 MPa 58 psi air pressure C 4 bar 0 4 MPa 58 psi air pressure Air consumption The chart above refers to the al...

Page 22: ...ducing the diaphragm s movement and consequently causing one of the pumping chambers P to empty as a result of volume decrease while at the same time the other chamber P sucks the fluid in as a result of volume increase A series of four non return valves C prevents the liquid from flowing back thus producing the suction and delivery phases in each pumping chamber and generating the pumping effect ...

Page 23: ... least once a week that there are no air and or liquid leaks 6 1 TRANSPORTATION The pump may be moved manually without lifts and cranes 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 Dischargeofelectrostaticallychargedcomponentsinatmospheres containingsolv...

Page 24: ...pump to rigid pipes For pumps installed in areas subject to explosion hazards all hoses and pipes must be made of conductive material and must be grounded Install a suction filter on the suction hose This prevents particles that are large enough to damage the internal parts of the pump from entering Refer to the Technical Data chapter to verify the maximum size of solids that can be pumped Air suc...

Page 25: ...can be run with non lubricated air Air pressure quality 5 5 4 40 μm 7 5 mg m Reversing valve The pump s reversing valve does not need any lubrication Safety valve The PM500 models are equipped with a safety valve that opens when the maximum allowed value of compressed air supply is exceeded Non return valve If the pump has been installed on a higher level than the liquid to be pumped it is recomme...

Page 26: ...e installed after the filter pressure regulator 4 so that the air supply 3 for the pilot valves is not interrupted The control of the on off valve can be made locally or remotely B_04207 1 2 3 4 Installation of the air cut off valve 1 for the emergency stop For the PM500 double diaphragm pump an external air cut off valve 1 must be installed before the filter pressure regulator 4 for the emergency...

Page 27: ...nveyor Work piece Spraying stand 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 WARNING Dischargeofelectrostaticallychargedcomponentsinatmospheres containingsolvents Explosion hazard from electrostatic sparks Clean the pump only with a damp cloth WARNING ...

Page 28: ...tory with PM500 pumps Procedure 1 Remove the crimp connection delivered with the pump 2 Crimp the grounding cable on the terminal and screw it back onto the pump s foot 3 Ground the material paint container to a local ground connection 4 Ground the other parts of the system to a local ground connection ...

Page 29: ... 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 or Operate the...

Page 30: ...Check if the air cut off valve is open Press the actuation button on one end of the reversing valve until the reversing valve switches over The air flows out audibly Turn the pressure regulator knob clockwise until the pump starts Don t let the pump run too quickly while suctioning Preliminary cleaning The pump was tested with oil or other fluids depending on the model Before use it is necessary t...

Page 31: ...h the pump for 2 or 3 minutes 6 5 3 UNIT PRESSURE TIGHTNESS TEST Close the material delivery valve once the pump is primed Gradually increase the pressure until reaching the maximum allowed value for the pump and the devices connected to it Ensure that no air or liquid escapes Opened Opened Closed Delivery Discharge Return line Air ...

Page 32: ...ies the material while the material delivery valve is open Change the air pressure with the air pressure regulator in order to achieve the desired amount or material pressure Drawn in air In case air accidentally flows into the pump suction inlet the air pressure must immediately be reduced to avoid the pump working at an excessive speed Stopping the pump To stop the pump simply close the material...

Page 33: ...fully clean the filter No fluid is available at the pump s inlet Check the fluid level in the tank or container The suction pipe is clogged or leaking possibility of sucking air in from the atmosphere Check the suction pipe Replace it if necessary The material flow is suspended The suction pipe is partially clogged Check the suction pipe Replace it if necessary Cavitation air bubbles in the liquid...

Page 34: ...the air cut off valve is closed The material delivery valve or the delivery manifold leaks Check the material delivery valve and the seals of the delivery manifold Dirty or worn out non return valves in the delivery and suction manifold Clean the non return valves and replace them if they are worn If the problem is not listed above consult your WAGNER Service Center ...

Page 35: ...equired and at least every 12 months For shut down devices the examination can be suspended until the next start up 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 Catalogue chapter and that are assigned to the device Be...

Page 36: ...the fluids involved Close the compressed air supply and release the pressure from the pump and pipes connected to it Depending on the operation disconnect the material and air side connection pipes Remove the pump from the base or support it is fastened to Turn the pump upside down over a container suitable for collecting any liquid it may contain After the pump has been reassembled and reinstalle...

Page 37: ...tral nut and remove the first diaphragm The diaphragm is composed of two layers the material side and the air side d Clean the parts and replace the first diaphragm and the shaft s O rings e Remount the diaphragm cover f Repeat steps b to e for the opposite side of the pump g Remount the suction and delivery manifolds Apply the right torques according to the directions in Chapter 10 2 ...

Page 38: ... fluid must be checked Mark the coupled parts diaphragm covers manifold covers with a felt tip pen so as to make subsequent reassembly easier a Remove the suction and delivery manifolds b Unscrew the mounting screws from the two diaphragm covers and remove the diaphragm covers c Remove the reversing valve 1 d With the help of two wrenches located opposite each other or hexagonal socket spanner and...

Page 39: ...the second diaphragm f Remove the inner diaphragm cover 3 g Remove the shaft 4 from the motor block h Dismount the fast discharge valves 5 then remove their gaskets i Clean all parts and check their condition Replace defective parts j Check the internal cylindrical area of the motor It must be clean and smooth without any scratches k Check the sliding shoes 6 two halves for wear and replace if nec...

Page 40: ... on the motor block with the appertaining seals and shaft guide bushing n Insert the spring 9 in the cross hole of the shaft and grease it at the ends o Put the two halves of the sliding shoe on the shaft make sure to keep the steps 10 opposite each other p Insert the shaft with the sliding shoe into the motor block making sure that the steps 10 are each aligned in the direction of the drillings 1...

Page 41: ...nner diaphragm cover v Mount the second diaphragm with the relevant seals and O rings Align the diaphragm s holes with the holes in the inner diaphragm cover and insert three screws as on the other side Screw on the diaphragm s central nut w Mount the first external diaphragm cover first remove the three screws then secure it with all six screws Mount the second external diaphragm cover in the sam...

Page 42: ...alls and seats for excessive wear Clean or replace the components e Clean the contact surfaces of the manifolds and the diaphragm cover and mount the components Apply the right torque according to the directions in Chapter 10 2 It is recommended that the static seals be replaced when reassembling 9 4 CLEANING REPLACEMENT OF THE SUCTION AND DELIVERY NON RETURN VALVES 9 5 REPLACEMENT OF THE REVERSIN...

Page 43: ...anger 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 WARNING 9 7 DECOMMISSIONING When the equipment must be scrapped please differentiate the disposal of the waste materials The foll...

Page 44: ...ARNING 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 Billing addr...

Page 45: ...d 15 1 F146 21 F146 01 Delivery manifold 16 2 G702 05 PM 500 PTFE Diaphragm white 17 2 G705 06 PM 500 Diaphragm Motor black 18 6 G709 07 M Valve Screw 19 1 H209 03 Spring 20 2 H505 07 Silencer 21 8 K106 62 Allen screw M8x75 SS 22 6 K107 62 TCEI Screw M6x20 23 2 K118 03 Screw M5x40 24 4 K131 62 Screw M5x20 25 10 K146 62 Screws M8x45 26 2 K166 62 Screw M4x50 27 4 9900386 Hexagon socket cylinder head...

Page 46: ...43 29 34 9 45 12 18 22 1 42 17 16 42 1 13 34 10 49 25 54 48 56 26 50 57 542 542 222 222 20 Nm 14 8 lbft 542 5 Nm 3 7 lbft 27 2 Nm 1 5 lbft 542 5 Nm 3 7 lbft 542 20 Nm 14 8 lbft 28 60 8 Nm 5 9 lbft 35 31 20 Nm 14 8 lbft 25 Nm 18 4 lbft 542 222 32 61 49 222 222 30 OPERATING MANUAL VERSION 01 2013 ORDER NUMBER DOC 2335747 ...

Page 47: ... 04 T nipple FFM 1 4 50 1 M225 04 Quick fitting D M 1 4 X 4 51 1 M239 00 Nipple D MF 1 4 52 1 M303 00 Quick fitting L M5X4 53 2 M336 00 Plug in nipple rotating 54 1 P124 00M Filter regulator CZ 1 4 55 1 P498 00 Reversing valve P 1 SP NUM 56 1 P903 00 Pressure gauge 010 1 8X52 57 1 S424 07 Hose control MT 0 330 58 1 S426 07 Hose MT 0 400 59 1 Y622 00A Cable lug 60 1 Z510 00 Adhesive label grounding...

Page 48: ...on 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 electric...

Page 49: ... 2011 DIN EN 809 2012 DIN EN ISO 4413 2011 DIN EN ISO 4414 2011 DIN EN 12621 2011 DIN EN 1127 1 2011 DIN EN ISO 13463 1 2009 DIN EN ISO 13732 1 2008 DIN EN 14462 2010 Applied national technical standards and specifications in particular BGR 500 part 2 Chapter 2 29 and Chapter 2 36 TRBS 2153 Labeling EC Certificate of Conformity The CE certificate of conformity is enclosed with this product If need...

Page 50: ... wagner france fr Netherlands WSB Finishing Equipment B V De Heldinnenlaan 200 NL 3543 MB Utrecht Telephone 31 0 30 241 4155 Telefax 31 0 30 241 1787 E Mail info wsb wagner nl HP www wsb wagner eu Italy WAGNER COLORA S r l Via Fermi 3 I 20875 Burago di Molgora MB Telephone 39 039 625021 Telefax 39 039 6851800 E Mail info wagnercolora com Japan WAGNER Spraytech Ltd 2 35 Shinden Nishimachi J Daito S...

Page 51: ......

Page 52: ...Order No 2335747 People s Republic of China Phone Telefax Germany Phone Telefax E mail ...

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