WAGNER Basic 8000 Operational manual

Spray wall
Basic 8000
Translation of the Original Operating Manual
For professional use.
Always observe the information in this manual, particularly the safety
instructions and the warning instructions. Store the manual in a safe place. Edition: 07/2022

Operating manual Spray wall Basic 8000
Table of Contents
Order number 3305595 | Edition 07/2022 3
TABLE OF CONTENTS
1 About these Instructions 5
1.1 Preface 5
1.2 Warnings, Notices and Symbols in these Instructions 5
1.3 General Characters and Symbols 5
1.4 Languages 6
1.5 Abbreviations 6
1.6 Terminology for the Purpose of this Manual 6
2 Using in Accordance with the Instructions 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 For Use in Potentially Explosive Areas 8
2.4 Processible Working Materials 8
2.5 Misuse 8
3 Identification 9
3.1 CE identification 9
3.2 Type Plate 9
4 Basic Safety Instructions 10
4.1 Safety Instructions for the Operator 10
4.1.1 Electrical Devices and Equipment 10
4.1.2 A Safe Work Environment 10
4.1.3 Personnel Qualifications 11
4.2 Safety Instructions for the Personnel 11
4.2.1 Personal Safety Equipment 11
4.2.2 Safe Handling of WAGNER Powder Spray Devices 12
4.2.3 Grounding the Device 12
4.2.4 Product Hoses 13
4.2.5 Electrical Connection Cables 13
4.2.6 Cleaning and Flushing 13
4.2.7 Maintenance and Repair 14
4.2.8 Protective and Monitoring Equipment 15
4.2.9 Safety Features 15
5 Description 16
5.1 Components 16
5.1.1 Basic 8000 components 16
5.2 Extent of Delivery 17
5.3 Data 17
5.3.1 Technical Data 17
6 Assembly and Commissioning 18
6.1 Training of Assembly/Commissioning Personnel 18
6.2 Storage Conditions 18
6.3 Installation Conditions 18
6.4 Transportation 18
6.5 Delivery Condition of the Spray Wall 19
6.6 Assembly Sequence 19
6.7 First Commissioning 21
6.8 Grounding 21
6.8.1 Grounding the powder coating system 22
6.9 Fire detection and fire extinguishing measures 23

Operating manual Spray wall Basic 8000
Table of Contents
4 Order number 3305595 | Edition 07/2022
6.10 Safety Checks 23
6.10.1 Testing Before First Commissioning 23
6.11 Start Up 23
6.11.1 Operating and Display Elements 23
7 Operation 25
7.1 Training the Operating Personnel 25
7.2 Tasks 25
7.3 Switching on the System 25
7.4 Switching off the System 25
7.5 Performing a Paint Change 26
8 Cleaning and Maintenance 27
8.1 Cleaning 27
8.1.1 Cleaning Personnel 27
8.1.2 Cleaning Instructions 27
8.1.3 Cleaning Procedures 27
8.1.4 Setting the Cleaning Intervals 27
8.2 Maintenance 28
8.2.1 Maintenance Personnel 28
8.2.2 Maintenance Instructions 29
8.2.3 Safety Checks 29
8.2.4 Maintenance Procedures 29
8.2.5 Compressed Air Tank Maintenance 30
9 Inspections in Accordance with DIN EN 50177: 2009 31
9.1 Abbreviations 31
9.2 Overview Table 32
10 Troubleshooting and Rectification 34
11 Disassembly and Disposal 35
11.1 Disassembly 35
11.2 Disposal 35
12 Accessories 36
13 Spare Parts 37
13.1 How to Order Spare Parts 37
13.2 Notes on the Use of Spare Parts 37
13.3 Spare Parts List for Basic 8000 Spray Wall 38
13.4 Spare Parts List for Pressure Tank (Until 06/2021) 39
13.5 Spare Parts List for Pressure Tank (Starting 07/2021) 40
13.6 Spare Parts List for Air Diffuser (Until 06/2021) 40
13.7 Spare Parts List for Pneumatic Control Cabinet (Starting 07/2021) 41
13.8 Manual System Connection Set 41
14 Declaration of Conformity 43
14.1 CE Declaration of Conformity 43

Operating manual Spray wall Basic 8000
1 About these Instructions
Order number 3305595 | Edition 07/2022 5
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.
Info Provides information about particular characteristics and how to
proceed.
Explanation of warning notice:
WARNING
This notice warns you of a danger!
Possible consequences of not observing the warning notice.
4The measures for preventing the hazard and its consequences.
1.3 GENERAL CHARACTERS AND SYMBOLS
The characters and symbols in this operating manual indicate the following:
üRequirement that must be fulfilled before an action can be performed.
1. Step 1 of an action to be performed with several action steps.
4Second level action step
2. Step 2
ðIntermediate result of an action
ðResult of a complete action
4Action to be performed with an action step
1. Numbered list, first level
– Numbered list, second level

Operating manual Spray wall Basic 8000
1 About these Instructions
6 Order number 3305595 | Edition 07/2022
– Non-numbered list, first level
– Non-numbered list, second level
= cross-reference on page
♦ = wearing parts
⋆ = included in service set
● = not part of the standard equipment but available as a special accessory
1.4 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 3305594
Translation of the original operating manual
Language Order no. Language Order no.
English 3305595 Spanish 3311304
French 3305596 Slovakian 2306595
Italian 3305597 Czech 2417004
Danish 2444107
Additional languages upon request or at: www.wagner-group.com
1.5 ABBREVIATIONS
Order no. Order number
ET Spare part
K Marking in the spare parts lists
Pos Position
Stk Number of pieces
-- Item not available as spare part
/ Item does not exist
1.6 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning agent.
Flushing Internal flushing of paint-wetted parts with compressed air.

Operating manual Spray wall Basic 8000
1 About these Instructions
Order number 3305595 | Edition 07/2022 7
Personnel qualifications
Trained person Is instructed in the tasks assigned to him/her, the potential risks associ-
ated 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 neces-
sary 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 rele-
vant provisions.
Skilled person in
the context of
DGUV209‑052
A person who, based on his/her technical training, experience and re-
cent vocational experience, has sufficient technical knowledge in the
area of electrostatic coating and is familiar with the relevant and gener-
ally 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).

Operating manual Spray wall Basic 8000
2 Using in Accordance with the Instructions
8 Order number 3305595 | Edition 07/2022
2 USING IN ACCORDANCE WITH THE INSTRUCTIONS
2.1 DEVICE TYPE
Spray wall for powder coating work pieces.
2.2 TYPE OF USE
The Basic 8000 spray wall is the right choice when coating larger parts and features the
essential basic functions required in an economical system. Thanks to its construction, it is
ideal for integration in manual conveyor systems.
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
4Do not deactivate safety fixtures.
4Use only WAGNER original spare parts and accessories.
4The operating personnel must be trained on the basis of this operating manual.
4Follow the instructions in the operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The spray wall is not approved for operation in a potentially explosive atmosphere.
Info
The required minimum exhaust air volumetric flow, based on the quantity of powder
used and its ignitability, is to be adhered to by the operator. This must not exceed the
nominal exhaust air volumetric flow.
2.4 PROCESSIBLE WORKING MATERIALS
– Organic powder lacquers
– Metallic powder
Info
Contact your local WAGNER dealer and the lacquer manufacturer if you encounter
application problems.
2.5 MISUSE
Misuse can lead to physical injury and/or property damage! Special attention must be paid
that:
4No liquid coating products, e.g. solvents or water-based lacquers, are processed.
4No food, medicine or cosmetics are processed.

Operating manual Spray wall Basic 8000
3 Identification
Order number 3305595 | Edition 07/2022 9
3 IDENTIFICATION
3.1 CE IDENTIFICATION
The spray wall is not approved for operation in a potentially explosive atmosphere.
Device type: Basic 8000
Manufacturer: Wagner International AG
9450 Altstätten
Switzerland
3.2 TYPE PLATE
Wagner International AG
9450 Altstätten
Switzerland
Designed by WAGNER Switzerland, assembled byWAGNER Germany
Bezeichnung der Serie oder des Typs
Designation of the series or type
Baujahr/Year of manufacture
Seriennummer/Serial number
Bestimmungsgemässe Verwendung
Intended use
Bezeichnung der Maschine
Designation of the machine
Betriebsart/Operating mode
Installierte Leistung
Installed power
Maximale Grösse der Werkstücke
Maximum size of workpieces
Erforderlicher Mindest-Abluftvolumenstrom
bei 20 °C
Required minimum extract air volume flow
at 20 °C
Maximale Menge des Beschichtungspulvers
(g/min) bei UEG
Maximum quantity of coating powder
introduced (g/min) at LEL
Spannung/Voltage
Frequenz/Frequency
Gesamte Öffnungsfläche
Total opening area
Druckluftversorgung
Compressed air supply
Druckluftbedarf
Compressed air requirements
Basic 8000
Sprühwand für elektrostatische
Pulverbeschichtung
Spray wall for electrostatic
powder coating
Manuelle Beschichtung durch
Bedienperson vor der Sprühwand
Manual coating by operator in front
of the spray wall
6 kW
30 % der gesamten Öffnungsfläche
(1.3 m²)
30 % of total opening area (1.3 m²)
8000 m³/h
maximal 1330 g/min bei UEG 20 g/m³
maximum 1330 g/min at LEL 20 g/m³
230V/400 V
50 Hz
4.4 m²
6.5–8.0 bar
30 Nm³/h
1
2
3
4
5
6
7
9
10
8
11
12
13
14
15
16
P_05376
1 Manufacturer, CE/UKCA identification 9 Maximum size of work pieces
2 Designation of the machine 10 Minimum exhaust air volume flow
3 Designation of the series or type 11 Maximum powder quantity
4 Year of manufacture 12 Voltage
5 Serial number 13 Frequency
6 Using in Accordance with the Instruc-
tions
14 Total opening area
7 Operating mode 15 Compressed air supply
8 Installed power 16 Air consumption

Operating manual Spray wall Basic 8000
4 Basic Safety Instructions
10 Order number 3305595 | Edition 07/2022
4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4Keep this operating manual at hand near the device at all times.
4Always follow existing regulations concerning occupational safety and accident
prevention regulations.
4.1.1 Electrical Devices and Equipment
Danger of electric shock!
Danger to life from electric shock:
4Place and operate device in accordance with the existing safety requirements with
regard to the operating mode and ambient influences.
4May only be maintained by skilled electricians or under their supervision. With open
housings, the mains voltage poses a danger.
4Operate device in accordance with the safety regulations and electrotechnical
regulations.
4Do not disconnect any plug connections during operation.
4Label plug connections with the warning "Do not disconnect when energized".
4Must be repaired immediately in the event of problems.
4Decommission if device poses a danger or is damaged.
4Must be de-energized before work is commenced.
4Secure the device against being switched back on without authorization.
4Inform personnel about planned work.
4Observe electrical safety regulations.
4Ground all devices to a common grounding point.
4Only operate the device with a properly installed socket with a protective ground wire
connection.
4Keep liquids away from electrical devices.
4.1.2 A Safe Work Environment
Danger due to falling parts!
Serious or life-threatening injuries due to falling parts.
4Ensure sufficient, safe dimensioning of the customer-provided work piece suspension.
Danger due to dust formation!
Severe or fatal injuries due to explosion danger or inhalation, swallowing or contact with the
skin or eyes.
4The floor of the work area must be electrostatically conductive (measurement in
accordance with EN1081:2018+A1:2020 or EN61340-4-1:2004+A1:2015).
4In the spray booth, coating may only be performed with correctly designed and locked
technical ventilation.
4Make sure that grounding and potential equalization of all system parts is reliably and
permanently in effect and that they withstand the loads to be expected (e.g.
mechanical, corrosion).