WAGNER PLASTCOAT 1030 User manual

Service manual
with electrical repair instructions
for electrically instructed persons
of the J. Wagner GmbH
PC 1030
2369648 B
08 / 2021

2
PC 1030
GB
Warning!
Mortar spraying machines develop high spraying pressures.
Attention − Danger of injury!
1Never reach into the spray jet with your ngers or hand!
Never point the spray lance at yourself or other persons!
Coating materials are caustic or irritating!
Protect your skin and eyes!
2The following points are to be observed in accordance with the operating
manual before every start-up:
1. Observe the permissible pressures.
2. Check all the connecting parts for leaks.
3Instructions for regular cleaning and maintenance of the machine are to be
observed strictly.
Observe the following point before any work on the machine and at every
working break:
1. Observe the curing time of the coating material.
2. Depressurize the spray lance and mortar hose.
3. Switch o the suction pump.
Ensure safety!

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PC 1030
CONTENTS
GB
Contents
SERVICE MANUAL
1 Safety regulations ______________________________4
2 Important information on product liability __________6
3 Technical data _________________________________6
4 Required tools and auxiliary material_______________6
5 Operating elements and displays on device _________6
6 Replacing the stator ____________________________7
6.1 Shaft seal _____________________________________8
7 Rotor replacement _____________________________8
8 Spare parts list Plast Coat 1030__________________ 10
8.1 Spare parts list frame _________________________ 12
9 Drive assembly Plast Coat 1030 _________________ 13
10 Spare parts list Controller ______________________ 14
11 Spare parts list New spray lances ________________ 16
12 Replacement of Seals and O-rings of the new Lance 18
ELECTRICAL REPAIR INSTRUCTIONS
1 Basic Principles ______________________________ 19
1.1 Electrically instructed person ___________________ 19
1.2 Skilled electrician for dened tasks ______________ 19
1.3 Legal foundations ____________________________ 19
1.4 Which tests must be performed _________________ 19
1.5 Five safety rules ______________________________ 20
1.6 Categorisation of protection classes _____________ 21
1.7 Explanation of electric variables and components __ 22
1.8 Explanation of electrical terms __________________ 22
2 Functional test work instructions ________________ 24
2.1 Functional test of cord set _____________________ 24
2.2 Functional test of capacitor ____________________ 24
2.3 Functional test of switches/buttons______________ 25
2.4 Functional test of earthing contact socket ________ 25
2.5 Functional test of the motor overcurrent
protection switch ____________________________ 25
2.6 Functional test of the threephase motor __________ 26
2.7 Functional test of AC motor ____________________ 26
3 Repair work instructions _______________________ 26
3.1 Replacing a cord set __________________________ 26
3.2 Replacing a 400 V cord set _____________________ 29
3.3 Replacing the capacitor _______________________ 27
3.4 Replacing switches/buttons ____________________ 27
3.5 Replacing the earthing contact socket ___________ 28
3.6 Replacing the motor protecting switch ___________ 28
3.7 Replacing the threephase motor ________________ 28
3.8 Replacing the AC motor _______________________ 29
4 Machine-specic documents ___________________ 30
4.1 Connection diagram PC 1030___________________ 30

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PC 1030
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SAFETY REGULATIONS
1 SAFETY REGULATIONS
The following sources are just a sample of those containing
safety requirements for mortar conveyors:
a) DIN EN 12001: 2004-05, Conveying, spraying and
placing machines for concrete and mortar - Safety
requirements; German version; German version EN
12001:2003
The following specications are to be observed in particular to
handle mortar spraying machines safely:
Usage of the mortar spraying machine
The mortar spraying machine PlastCoat 1030 may only be
used to process the coating materials described on page 38.
Any other usage is not allowed.
Proper usage also includes the observance of the operating
manual and the observance of the inspection and mainte-
nance conditions. Always keep the operating manual on hand
at the point of use of the mortar spraying machine.
The mortar spraying machine PlastCoat 1030 may only be op-
erated with a manometer. Only the mortar hose specied by
the manufacturer may be used.
Use only marked mortar hoses with at least 40 bars operating
pressure.
Protection of persons
In order to protect eyes, skin and the respiratory organs: Wear
safety goggles, protective clothing, gloves, possibly use
protective skin cream and respiratory equipment. Do
not decouple the mortar hose as long as it is under pressure.
Watch the manometer! Wear safety goggles! Do not point the
spray lance at persons!
In order to protect your ears wear ear protection.
Wear safety shoes when transporting the machine or working
with it.
People not needed to assist with machine installation, assem-
bly or operation, must keep away from the machine.
The PC 1030 is equipped with an EMERGENCY STOP switch
for emergencies.
Breathing masks
Make a breathing mask available to the processor in order to
protect against mineral dust. Refer to the regulations of the
German employer's liability insurance association ("Beruf-
sgenossenschaft") "Rules for the use of breathing masks"
(BGR 190) and "Processing coating materials" (BGV D25).
Connection to the mains network only via a special feed-
ing point, for example via a distribution board for con-
struction sites, with residual current protective device
with INF ≤30 mA.
Avoid soiling of the socket for the remote control at the
control unit.
Risk of injury from escaping material.
Before switching on, always check that the
material tap on the spray lance is closed.
Close material tap whenever stopping
work.
Never operate the mortar spraying ma-
chine if the rotor is exposed or if the con-
tainer has been removed.
Do not reach into the rotor when it is mov-
ing. Risk of crushing.
Caution if you have long hair. Only wear
close-tting clothes at work.
Do not insert objects or body parts
through the protective grid.
Risk of crushing when folding in the han-
dles, assembling the pump unit and con-
necting the mortar hose.
Cleaning and maintenance
Never decouple mortar hose or disassemble machine when
under pressure. Note pressure reading on pressure gauge.
When performing maintenance work, always switch o mor-
tar spraying machine, disconnect mains plug and ensure it
cannot be plugged back in by mistake.
Do not spray down the motor and control unit of the mortar
spraying machine with a water-jet, high-pressure cleaner or
high-pressure steam cleaner. Danger of short-circuits caused
by water ingressing.
Electrical equipment
Work on the machine’s electrical equipment may be carried
out only by a qualified electrician. The electrical equipment is
to be checked regularly. Eliminate faults such as loose connec-
tions or scorched cables.
Keep the label on the mortar spraying machine clean and
legible.
Whenever the machine is automatically
brought to a standstill or during power
failure, immediately move the selec-
tor switch to “A” to prevent the machine
starting back up again unintentionally.
There is a danger of injury.

5
PC 1030
Mortar hose
Danger of injury through leaking high-
pressure hose. Wear and tear and links as
well as usage that is not appropriate to the
purpose of the device can cause leakages
to form in the mortar hose. Liquid can be
injected into the skin through a leakage.
Mortar hoses must be checked thoroughly before they are
used.
Replace any damaged mortar hose immediately.
Never repair defective mortar hoses yourself!
Avoid sharp bends and folds: the smallest bending radius is
about 80 cm.
Do not drive over the mortar hose. Protect against sharp ob-
jects and edges.
Never pull on the mortar hose to move the device.
Do not twist the mortar hose.
Lay the mortar hose in such a way as to ensure that it cannot
be tripped over.
Only use WAGNER original-mortar hoses in
order to ensure functionality, safety and du-
rability.
The risk of damage rises with the age of the
mortar hose.
Wagner recommends replacing mortar hoses
after 6 years.
GB
SAFETY REGULATIONS

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PC 1030
GB
2 IMPORTANT INFORMATION ON
PRODUCT LIABILITY
An EU directive valid since 01.01.1990 species that the manu-
facturer is only liable for his products if all the parts originate
from the manufactured or are approved by him, and if the
units are mounted and operated properly. If accessories or
spare parts from third parties are used, liability can be partially
or completely inapplicable. In extreme cases the responsible
authorities can prohibit the use of the entire unit (German in-
dustrial employer’s liability insurance association and factory
inspectorate).
With original WAGNER accessories and spare parts, compli-
ance with all safety regulations is guaranteed.
POWER
ERROR
SPEED
R
A
F
2 1
4
3
5
TECHNICAL DATA/ REQUIRED TOOLS/ OPERATING ELEMENTS
3 TECHNICAL DATA
PlastCoat 1030
Voltage: 230 V~, 50/60 Hz
Fusing: 16 A time-lag
Device supply cable: 5 m long, 3 x 2.5 mm2
Motor output P1: 2.3 kW
Max. convey capacity (water): 10, 15, 20 l/min
(depending on the rotor/
stator)
Max. operating pressure: 40 bar
Max. granular size: K6 mm
Dimensions L x W x H: 1150 x 550 x 620 mm
Container capacity: 50 l
Weight (PlastCoat 1030): 60 kg
Weight (Spray lance): 2.1 kg
Max. tyre pressure: 2.5 bar
Degree of protection: IP 54
Max. sound pressure level: 70 dB (A)*
Atomizing air connection: Rapid action coupling
DN 7.2 mm
Max. atomizing air pressure: 10 bar
Minimum required compressed
air volume: 320 l/min
Max. mortar hose length: 40 m (and 2.5 m hose
whip)
Max. delivery height: 20 m
* Place of measurement: 1 m distance from unit and 1.60 m
above reverberant oor.
4 REQUIRED TOOLS AND AUXILIARY
MATERIAL
Designation Order no.
Pump sliding means 9992824
Loctite 243 9992511
5 OPERATING ELEMENTS AND
DISPLAYS ON DEVICE
1 Delivery volume controller 0-10
2 Selector switch for operating mode
3 Indicator light (Error)
4 Operating light (Power)
5 EMERGENCY STOP switch
A
R
F
“A”position = automatic
Basic setting for control with an automatic
spray lance
A
R
F
“F”position = manual activation
Switches on the mortar spraying machine.
This setting is required for:
• disassembling the pump unit
A
R
F
“R” position = reverse gear
This setting is required for:
• relieving pressure on the mortar hose
• assembling the pump unit

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PC 1030 GB
6 REPLACING THE STATOR
REPLACING THE STATOR
Clean the outlet unit
Clean the outlet unit (4) with a jet of water and a suitable bot-
tle brush.
Clean the container (7) with a jet of water and a suitable brush.
Clean the protective grid with a radiator brush.
Also clean the rotor (6) and stator (5) thoroughly with water
and, if necessary, using a brush.
Then spray rotor (6) and stator (5) and with a suitable pump
lubricant.
Keep the thread of the pump housing and the pump tube
clean so that leaking after the assembly is avoided.
Dismantling
Mortar spraying machine must be depres-
surised.
If necessary, set the selector switch briey
to “R” (reverse).
Watch the manometer ––> 0 bar.
Wear safety goggles.
Disconnect external controls. Disassembly
may only be carried out by the person
who controls the machine.
Never operate mortar spraying machine
with an exposed rotor.
Do not reach into the rotor when it is mov-
ing. Risk of crushing.
Caution if you have long hair. Only wear
close-tting clothes at work.
• Move selector switch (g. 14, 1) to “A” and set delivery vol-
ume controller (2) to„0“.
• Disconnect mains plug.
• Loosen the star screws (3) and remove the outlet unit (4).
• Set delivery volume controller (2) to 1 or 2.
• Connect mains plug to mains power supply.
• Move the selector switch (1) to position „F“. As soon as the
stator (5) is released from the rotor (6), set the selector
switch to„A“.
• Remove the stator (5) completely.
• Disconnect mains plug.
Mounting
If the machine is down for a longer period of
time, the stator can become set at the rotor.
Therefore, if the stator has been in storage for
a longer period of time, do not mount it until
you are about to begin work.
Assembly, see chapter 6.2.2
POWER
ERROR
SPEED
R
A
F
21
4
3

3
6
5
7
7

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PC 1030
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7 ROTOR REPLACEMENT FIG. 7
• Loosen xing screw (1) and remove old rotor (6).
• Fit new rotor with new xing screw.
• Glue xing screw with Loctite 243.
Note: use Loctite 243 only.
ROTOR REPLACEMENT
6.1 SHAFT SEAL
Check the seals on the PC 1030 every month.
• Move selector switch (g. 16, 1) to “A” and set delivery vol-
ume controller (2) to„0“.
• Disconnect mains plug.
• Loosen the star screws (3) and remove the outlet unit (4).
• Set delivery volume controller (2) to 1 or 2.
• Connect mains plug to mains power supply.
• Move the selector switch (1) to position „F“. As soon as the
stator (5) is released from the rotor (6), set the selector
switch to„A“.
• Remove the stator (5) completely.
• Disconnect mains plug.
•Pull out the two locking pins (7) and remove the anti-twist
lock (8).
• Remove the ange (9) with a 17-wrench.
• Remove the container (10).
• Check the seal (11) and replace if necessary.
• Clean the shaft seal (12).
•Check the rotor (6) and replace if necessary (see chapter
9.5).
POWER
ERROR
SPEED
R
A
F
2
1
4
3

3
6
5
7
8
8
9
10
11
12
16


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PC 1030 GB

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PC 1030
8 SPARE PARTS LIST FOR PLASTCOAT 1030
ITEM ORDER NO. DESIGNATION
19990368 Star knob nut (2) 2 0342314 Sealing 32305009 Coupling complete 42313 540 Pressure gauge complete 52373608 Outlet unit cpl. 6348315 Pump casing 72361120 Anti-twist lock for stator 82368779 Catch (2) 99900247 Hexagon head screw (2) 10 9921507 Spring washer (2) 11 2360857 Retaining plate for stator 12 2360707 Rubber seal, ange 13 2357594 Receptacle
ITEM ORDER NO. DESIGNATION
14 348316 Rotor 15 348324 Screw (2) 16 2360651 Feeder shaft 17 2360706 Rubber seal, motor 18 9921501 Spring washer (4) 19 9900313 Cylinder head screw (4) 20 9910708 Cap nut (4) 21 2310491 Connecting bolt (2) 22 2373606 Controller PC-1030 complete 23 2365723 Label PC 1030 (2) 24 2364373 Rating Label PC-1030
The number in brackets gives the total quan- tity of a component in the assembly. The order number corresponds to one piece. Therefore, please also specify the quantity that you require when ordering.
GB
SPARE PARTS LIST FOR PLASTCOAT 1030

11
PC 1030
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
171819
20
21
22
23
24
(25+5
Nm)
Explanation (xNm) indicates torque
(25+5Nm)
(25+5Nm)
GB
SPARE PARTS ILLUSTRATION

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PC 1030
GB
1
2
2
3
4
5
6
ITEM ORDER NO. DESIGNATION
13142039 Ring nut M12
23069013 Square head plug
32367604 Guide pulley
4348349 Wheel
59994902 Wheel cap
62309787 Protective cap
8.1 SPARE PARTS LIST FRAME
SPARE PARTSLIST FRAME

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PC 1030
9 DRIVE ASSEMBLY PLAST COAT 1030
GB
DRIVE ASSEMBLY PLAST COAT 1030

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PC 1030
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SPARE PARTS LIST CONTROLLER
10 SPARE PARTS LIST CONTROLLER
Front view
1
2/3
6
7Emergency
Stop
8
9
4
ITEM ORDER NO. DESIGNATION
1 2362391
2365766
Mains cable assy. (EU)
Mains cable assy. (China)
2 2362393
2308410
Potentiometer assy.
32315 462 Control knob for potentiometer
4 2315416
2308475
Switch
62313 743 Emergency stop switch
72313 481 Signal lamp (green)
ITEM ORDER NO. DESIGNATION
82313 482 Signal lamp (red)
92316 781 Adhesive label (front)
10 2313 485 Coupler plug six-pole
11 2313 486 Coupler plug three-pole
12 2311 685 Cap
13 2316 783 Adhesive label (back)
14 2313 823 Female receptacle
Back view
Right view
14
10
11
12
electric /
pneumatic
connector
remote
control
connector
2316 783
13

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PC 1030 GB

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PC 1030
GB
SPARE PARTS LIST OF SPRAY LANCE
11 SPARE PARTS LIST NEW PNEUMATIC AND AUTOMATIC SPRAYLANCE
2334 115, 2334 116
ITEM PART NO. DESIGNATION
2334 115 Automatic spray lance
2334 116 Pneumatic spray lance
2322 199 Complete spray head
(composed of positions 1-6)
1 2321 045 Union nut 2 0342 350 Sealing washer 3 0268 781 Texture tip 8 (standard) 4 2343 086 Material tube for spray lance 5 2322 194 Air hose of spray head * 6 2322 488 O-ring 25 x 2,5 7 2323 764 Housing component, left 8 2319 220 Lever 9 2322 363 Magnet 10 2319 228 Turn restrictor 11 9999 360 Retaining ring 12 2336 552 O-ring 30x 2,8 (2 pcs) 13 2322 179 Slide bush 14 2319 230 Closing cylinder 15 2336 553 O-ring 20x 2,5 (2 pcs) 16 2334 155 Lance body 17 2319 231 Seal washer 18 2319 233 O-Ring 20,29 x 2,62 19 2320 770 Hose connection 20 3156 823 Cable tting
(Automatic version only)
21 0348 216 Reed sensor, cpl.
(Automatic version only)
22 2329 900 Air hose * 23 2336 554 Oval-head screw (2) 24 2324 716 Hand-grip 25 2323 782 Housing component, right 26 2336 221 Stoppers (2)
* Glue with Loctite 243

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PC 1030 GB
SPARE PARTS LIST OF SPRAY LANCE
1
2
3
4
5
6
7
8
9
10
11
12
13
13
14
15
16
17
1819
2021
22
23 24 25 26

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PC 1030
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12 REPLACEMENT OF SEALS AND ORINGS OF THE NEW LANCE
2338828 Assembly tools for the new PC lance
Content of the kit
1, 2 Guiding tools for inserting the closing cylinder
3 Inserting tool for the seal 2319 231
Assembly of the closing cylinder and new o-rings
Attention! The inside of the lance body
must be clean. Otherwise it‘s possible that
the closing cylinder can‘t be assembled.
1. Insert both guiding tools (1 and 2) in the front and back side
of the lance body (4). Make sure that these parts are in line
with the shape of the closing cylinder.
2. Lubricate closing cylinder (5) and all seals and o-rings.
3. Insert the closing cylinder (5) with the help of the guiding
tools (1 and 2) into the lance body. Attention: Avoid dam-
age to the o-rings due to the sharp edges.
4. Fully press the closing cylinder to the bottom of the lance
body with the help of a bench vice.
5. Countersink the slide bush (6) with the help of a hammer and
a chisel until the groove for the retaining ring is visible.
6. Secure the closing cylinder with the retaining ring (7).
7. Insert the seal washer (8) with the inserting tool (3) into the
lance body.
8. Lubricate o-Ring (9) and insert it into the hose connection
(10). Insert the hose connection completely into the lance
body.
9. Secure the thread with Loctite 243 (blue).
1 2 3
4
5
6
7
8
9
10
REPLACEMENT OF SEALS AND O-RINGS OF THE NEW LANCE

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PC 1030
ELECTROTECHNICAL REPAIR INSTRUCTIONS: BASIC PRINCIPLES
GB
1
BASIC PRINCIPLES
1.1 ELECTRICALLY INSTRUCTED PERSON
In order to carry out work on electrical systems and equipment, a person must at least have training as an electrically instructed
person.
However, an electrically instructed person is not authorised to autonomously set up, modify or repair electrical systems and
equipment. Such tasks may only be performed under the direction and supervision of a skilled electrician.
The electrically instructed person must be trained on all systems and equipment. This training is carried out by the senior skilled
electrician, who highlights the hazards and special features. The senior skilled electrician also ensures that the requirements and
guidelines in respect of UVV, VDE and EN standards have been complied with.
All electrically instructed persons must receiving training at least once a year on the hazards, safe handling and correct conduct
in relation to electrical systems.
Documents and work instructions must also be made available to electrically instructed persons. These must relate to the exact
machine type and indicate potential hazards and special features. The work instructions must include safe and correct replace-
ment of a connecting cable, for example.
1.2 SKILLED ELECTRICIAN FOR DEFINED TASKS
In order to autonomously carry out work on electrical systems and equipment, a person must have training as a skilled electrician
for dened tasks.
However, the skilled electrician for dened tasks must also, like the electrically instructed person, be trained on all systems and
equipment. This training is carried out by the senior skilled electrician, who highlights the hazards and special features. The
senior skilled electrician also ensures that the requirements and guidelines in respect of UVV, VDE and EN standards have been
complied with.
It is also necessary for a responsible skilled electrician to assume professional responsibility.
1.3 LEGAL FOUNDATIONS
Once a system and its equipment has been repaired, modied or set up, it must not constitute any hazard for users and their
environment. To ensure that safety can still be guaranteed, an annual inspection is required for mobile systems and equipment.
1.4 WHICH TESTS MUST BE PERFORMED
A test in accordance with the guidelines of BGV A3 must
be performed and veried. This test must be performed on all electrical
equipment, even if "only" a mechanical repair has been carried out.

20
PC 1030
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ELECTROTECHNICAL REPAIR INSTRUCTIONS: BASIC PRINCIPLES
Contents of BGV A3: The test as per BGV A3 is divided into a visual and a metrological test.
Visual inspection: - Protective conductors (protection class I )
- Insulating parts
- Housing
- Connecting cables
- Typeplate
- Machine-specic components
Metrological test: - Short-circuit test
- Protective conductor resistance (RSL)
- Equivalent leakage current (IEA)
- Insulation resistance (Riso)
- Functional test
Attention! If one of the above-specied criteria cannot be fullled, then the test is considered a failure.
If the customer refuses the necessary repair, he must be informed in writing to this eect. Clear reference must
be made to the fact that safe operation of the system cannot be assured. This must be counter-signed by the
operating company.
You must full this obligation as you, as an expert, will be required to produce evidence in the event of dama-
ge.
1.5 FIVE SAFETY RULES
The Five Safety Rules are more than just rules. They are the precondition for working on electrical systems and appliances. Please
take these rules seriously - they are essential for your safety.
Isolation
Isolation means all-pole disconnection of a system from live parts.
All live cables must be disconnected at all poles at the place of work before starting work. This can be done by means of main
switches, expert removal of fuses, disconnection of plug connectors etc.
Protecting against restarting
In order to prevent inadvertent restarting of a system on which work is being carried out, restarting must be prevented reliably
and safely. For example the unscrewed fuse elements can be replaced with lockable disabling elements or circuit-breakers can be
masked with adhesive lm. A "Please do not switch on - work in progress" sign can also be affixed. For appliances which are con-
nected to the network by a plug connector, it is sufficient to store the unplugged connector on the machine in such a way that it
cannot be mixed up with another connector. In addition, the connector must always be kept in the worker's immediate vicinity.
Verication of safe isolation from the supply
Verication of safe isolation from the supply in low-voltage networks, i.e. systems with operating voltages below 1000 V, must
only be carried out using devices or equipment suitable for this purpose. A two-pole measuring instrument must be used. The
voltage detectors used must comply with the respective rated voltage and must be tested before and after verication of safe
isolation from the supply. I.e. the function of the detectors must be tested on a reliable live source.