WAGNER VU 1 User manual

P_01790
VU 1/VU 2/VU 3
Reciprocator
Version 03/2020
II 3D IIIB T 135 °C IP54 0 °C ≤ Tamb ≤ +40 °C

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Table of Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 8
2 CORRECT USE 9
2.1 Device Type 9
2.2 Type of Use 9
2.3 For Use in Potentially Explosive Areas 9
2.4 Processible Working Materials 9
2.5 Misuse 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Permissible Device Combinations 10
4 BASIC SAFETY INSTRUCTIONS 11
4.1 Safety Instructions for the Operator 11
4.1.1 Electrical Devices and Equipment 11
4.1.2 A Safe Work Environment 12
4.1.3 Personnel Qualications 12
4.2 Safety Instructions for the Personnel 13
4.2.1 Personal Safety Equipment 13
4.2.2 Safe Handling of WAGNER Powder Spray Devices 13
4.2.3 Grounding the Device 14
4.2.4 Product Hoses 14
4.2.5 Electrical Connection Cables 15
4.2.6 Cleaning and Flushing 15
4.2.7 Maintenance and Repair 16
4.2.8 Protective and Monitoring Equipment 16
5 DESCRIPTION 17
5.1 Design of the VU 1 Reciprocator 17
5.2 Design of the VU 2 Reciprocator 18
5.3 Design of the VU 3 Reciprocator 19
5.4 Mode of Operation 20
5.5 Variants 20
5.6 Scope of Delivery 20
5.7 Data 21
5.7.1 Technical Data 21
5.7.2 VU 1 Dimensions 22
5.7.3 VU 2 Dimensions 23
5.7.4 VU 3 Dimensions 24
5.8 Accessories 24
6 ASSEMBLY AND COMMISSIONING 25
6.1 Training of Assembly/Commissioning Personnel 25
6.2 Storage Conditions 25
6.3 Installation Conditions 25

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6.4 Transportation 26
6.5 Assembly 27
6.6 Electrical Connection 29
6.6.1 MCS 1 Stand-alone/PrimaTech 29
6.6.2 Connecting 2 Reciprocators 30
6.6.3 Connecting 4 Reciprocators 31
6.6.4 Connecting the Reciprocator 32
6.6.5 Setting Up the Frequency Converter 34
6.7 Determination of the Number of Guns 34
6.8 Correct Number of Counterweights 35
6.8.1 VU 1 Reciprocator 35
6.8.2 VU 2 Reciprocator 36
6.8.3 VU 3 Reciprocator 36
6.9 Mounting the Additional Weights 38
6.10 Adjustment of the Upper and Lower Stops 39
6.11 VU 1 Gun Arrangement 40
6.11.1 Long Stroke Gun Arrangement for 2-4 Guns 40
6.11.2 Long Stroke Gun Arrangement for 5-8 Guns 40
6.11.3 Gun Arrangement in Multiple Levels 41
6.11.4 Gun Arrangement for Short Stroke Applications 41
6.12 VU 2 Gun Arrangement 42
6.12.1 Long Stroke Gun Arrangement for 2-4 Guns 42
6.12.2 Long Stroke Gun Arrangement for 5-6 Guns 42
6.12.3 Gun Arrangement for Short Stroke Applications 43
6.13 Grounding 44
6.13.1 Grounding the Powder Coating System 45
6.14 Safety Checks 45
7 OPERATION 46
7.1 Training the Operating Personnel 46
7.2 Tasks 46
7.3 Switching On the Reciprocator 46
7.4 Switching O the Reciprocator 46
7.4.1 Switching O in Normal Operation 46
7.4.2 Switching O the Reciprocator in the Event of Faults or Emergencies 46
8 CLEANING AND MAINTENANCE 47
8.1 Cleaning 47
8.1.1 Cleaning Personnel 47
8.1.2 Cleaning Procedures 47
8.2 Maintenance 47
8.2.1 Maintenance Personnel 47
8.2.2 Maintenance Instructions 47
8.2.3 Safety Checks and Maintenance Intervals 48
8.2.4 Maintenance Procedures 48
8.3 Checking and Adjusting the Belt Tension (Visual Inspection) 49
8.3.1 Checking the Belt Tension 49
8.3.2 Setting the Belt Tension 50
8.4 Checking and Adjusting the Belt Tension (Measuring Device) 55
8.4.1 Checking the Belt Tension 56
8.4.2 Setting the Belt Tension 56
8.5 Replace the Ball-Bearing Guides 57
8.6 Filling Up the Oil Tank of the Ball-Bearing Guides (Only VU1 and VU2) 58

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8.7 Lubricating the Ball-Bearing Guides with Grease 58
9 TROUBLESHOOTING AND RECTIFICATION 60
10 INSPECTIONS 61
11 DISASSEMBLY AND DISPOSAL 64
11.1 Disassembly 64
12 ACCESSORIES 65
12.1 Gun Base Support 65
12.2 Fastening Elements 66
12.3 VU1/VU 2 Gun Assemblies 67
12.4 VU 3 Spray Gun Assemblies 68
12.5 Controller Accessories (only VU1/VU 2) 68
12.6 CAN Bus Cable 69
12.7 RS 8 Roller Set (Only VU 1 and VU 2) 69
12.8 Grease Lubrication Maintenance Set 69
13 SPARE PARTS 71
13.1 How Can Spare Parts Be Ordered? 71
13.2 VU 1 Drive Unit 72
13.3 VU 2 Drive Unit 74
13.4 VU 3 Drive Unit 76
13.5 VU 1 Deection Unit 78
13.6 VU 2 Deection Unit 79
13.7 VU 3 Deection Unit 80
13.8 VU 1 Guide Unit 82
13.9 VU 2 Guide Unit 84
13.10 VU 3 Guide Unit 86
13.11 VU 1 Counterweight 87
13.12 VU 2 Counterweight 88
13.13 VU 3 Counterweight 89
13.14 VU 1 Reciprocator Column 90
13.15 VU 2 Reciprocator Column 92
13.16 VU 3 Reciprocator Column 93
13.17 VU 1 Wearing Part Sets 94
14 DECLARATION OF INCORPORATION 96
15 ELECTRICAL CONNECTION PLANS FOR VU 1/VU 2 97
16 ELECTRICAL CONNECTION PLANS FOR VU 3 99
17 INSTALLATION EXAMPLE AXIS SYSTEM ON VU 3 101
17.1 Components 101
17.2 U-Beam for Z-Axis Unit 102

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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.
Note: Provides information about particular characteristics and
how to proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a danger!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.

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1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2330731
Translation of the original operating manual
Language Order no. Language Order no.
English 2330732 Danish 2373600
French 2330733 Czech 2374441
Italian 2330734 Bulgarian 2392770
Spanish 2330735 Turkish 2401087
Russian 2336466 Romanian 2397438
Chinese 2336467 Slovakian 2400692
Dutch 2395096 Polish 2406134
Swedish 2372288 Portuguese 2392543
Hungarian 2340335 Finnish 2412414
Norwegian 2413802
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order no. Order number
Spare part
Marking in the spare parts lists
Position
Number of pieces
Figure
Sliding table (horizontal unit)
Reciprocator (vertical unit)
-- Item not available as spare part
/ Item does not exist

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1.5 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 compressed air
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 and
experience in relevant provisions.
Skilled person
in the context of
DGUV209-052
A person who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the area of electrostatic coating 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.
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).

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2 CORRECT USE
2.1 DEVICE TYPE
Reciprocator suitable for use in automatic powder coating systems.
2.2 TYPE OF USE
The VU 1/VU 2/VU 3 reciprocator serves to continuously move the powder spray guns,
attached to the gun mountings, up and down or to position them at a specic height.
The dierent types of gun mountings and their associated counterweights and fastening
elements are listed in chapter 12. The lifting and lowering speed and the lifting height
can be steplessly adjusted via the corresponding controller.
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.
Follow the instructions in the operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The VU 1/VU 2/VU 3 reciprocator can be used in areas subject to explosion hazards (Zone 22)
(see Explosion Protection Identication, Chapter 3.1).
In explosion hazard areas, only use approved explosion-proof electrical devices.
2.4 PROCESSIBLE WORKING MATERIALS
– types of powder that can be charged electrostatically;
– metallic powder.
Note:
Contact your localWAGNER 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:
liquid coating products, e.g., solvents or water-based lacquers are not processed;
no food, medicine or cosmetics are processed.

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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
Device type: VU 1/VU 2/VU 3 reciprocator
Manufacturer: J. Wagner GmbH
88677 Markdorf
Germany
II 3D IIIB T 135 °C IP54 0 °C ≤ Tamb ≤ +40 °C
Ex: Symbol for explosion protection
II: Device class II
3: Category 3
D: Ex-atmosphere dust
IIIB: Explosion group (dust group)
T 135 °C Temperature class (T < 135 °C)
IP 54 IP Code
Tamb Permissible ambient temperature
3.2 PERMISSIBLE DEVICE COMBINATIONS
WARNING
Incorrect use!
Risk of injury and damage to the device.
Only connect the reciprocator to original WAGNER devices.
The reciprocator type seriesVU 1, VU 2 andVU 3 can be controlled with the following controllers:
– MCS 1 movement control module (stand-alone operation)
– ProTech S
– ProTech M (not for VU 3)
– PrimaTech CCM with MCS 1 movement control module
The reciprocator type series VU 1,VU 2 and VU 3 can be combined with the following devices:
– Only VU 1/VU 2: Sliding units of the type series HU 1-xxxx, HU 1-xxxx M, RS 8-xxxx
– PEA-C4, PEA-T3 type series guns
– Only VU 1/VU 3: Z-axes
For this purpose, the notices regarding the correct gun arrangement in Chapter 6.11 and
Chapter6.12 are to be observed!
– Further devices can be combined depending on the project specics.
Please determine permissibility within the framework of the project.

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4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Alwaysfollowlocal regulationsconcerningoccupationalsafetyandaccidentprevention
regulations.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Danger of electric shock!
Danger to life from electric shock.
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, the mains voltage poses a danger.
Operatedevicein accordancewith thesafetyregulationsandelectrotechnicalregulations.
Must be repaired immediately in the event of problems.
Decommission if device poses a danger or is damaged.
Must be de-energized before work is commenced. Secure the device against being
switched back on without authorization. Inform personnel about planned work.
Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground
wire connection.
Keep liquids away from electrical devices.

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4.1.2 A SAFE WORK ENVIRONMENT
Danger due to dust formation!
Severe or fatal injuries due to explosion danger or inhalation, swallowing or contact with
the skin or eyes.
The oor in the working area must be electrostatically conductive
(measurements according to EN 1081 and EN 61340-4-1).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system
parts are reliable and continuous and can withstand the expected stress
(e.g., mechanical stress, corrosion).
Ensure that personal protective equipment (see Chapter 4.2.1) is available and is used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 megohms.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 megohms.
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. No smoking.
Maintain sucient quantities of suitable re extinguishers and ensure that they are
serviceable.
The powder release must be electronically interlocked with the powder spray system
exhaust equipment.
Excess coating product (overspray) must be collected up safely.
The operating company must ensure that an average concentration of powder lacquer
in the air does not exceed 50% of the lower explosion limit
(LEL = max. permitted concentration of powder to air). If no reliable LEL value is available,
the average concentration must not exceed 10 g/m³.
Ensure that maintenance and safety checks are performed regularly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Danger due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in accordance
with the operating manual and the operating instructions. The device must only
be operated, maintained and repaired by trained personnel. Refer to the operating
instructions for information about the required personnel qualications.

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4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always observe the information in this manual, particularly the safety instructions
and the warning instructions.
Alwaysfollow localregulations concerning occupational safety andaccident prevention
regulations.
In electrostatics applications: Persons belonging to a risk group according to EMF
guideline 2013/35/EU (e.g., carriers of active implants), must not enter the high-voltage
area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Danger due to dust formation!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
Observe the processing regulations laid down by the manufacturer of the powder
lacquer being used, when preparing or processing the powder.
Take note of the manufacturer’s notication and the relevant environmental protection
regulations when disposing of powder lacquers.
Take the specied protective measures. 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 sucient health and environmental safety: Operate the device in a powder coating
booth or on a spraying wall with the ventilation (extraction) switched on.
4.2.2 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
Danger due to dust formation!
Do not point spray guns at people.
Do not spray device parts using electrostatic equipment.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve pressure on powder spray gun and device.
– Secure the powder spray gun against actuation.
– Disconnect the control unit from the mains.
– Inthe eventof functional faults:remedy thefault asdescribedin the "Troubleshooting"
chapter.

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4.2.3 GROUNDING THE DEVICE
Danger due to electrostatic charge!
Explosion hazard and damage to the device.
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the device.
Flames or sparks can form during discharge.
Correct grounding of the entire coating system prevents electrostatic charges:
Ensure that all devices and tanks are grounded before each coating process.
All of the system's conductive elements, such as oors, walls, ceilings, protective
grating, transport equipment, work pieces, powder tanks, automatic moving devices
or construction parts etc. in the spray area, with the exception of parts which carry
high voltage during operation, must be connected to the grounding system.
Parts of the booth must be grounded in accordance with EN 12981.
Ensure that all persons 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 HOSES
Danger due to damaged product hoses!
The product hose may cause dangerous injuries.
Use only an original WAGNER powder hose.
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
– in high-traffic areas,
– on sharp edges,
– on moving parts or
– on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses
are never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Ensure that no work is ever performed with a damaged hose.
Make sure that the hoses are never used to pull or move the device.

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4.2.5 ELECTRICAL CONNECTION CABLES
Risk caused by improperly laid cables!
Risk of injury and damage to the device.
Properly lay connection cables and check them regularly.
Immediately replace damaged connection cables.
Ensure that no work is ever performed with a damaged connection cable.
Do not lay connection cables on routes used by product handling vehicles and not
through doors/gates.
Do not route connection cables near aisles or walkways in order to avoid tripping.
4.2.6 CLEANING AND FLUSHING
Danger due to cleaning and ushing!
Explosion hazard and damage to the device.
Before starting cleaning or any other manual work, the high voltage in the spray area
must 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 only electrically conducting and grounded tanks for cleaning uids.
Preference should be given to non-ignitable cleaning uids.
If ignitable cleaning uids are used, all parts carrying high voltage must be discharged
to a discharge energy of less than 0.24 mJ, once the high voltage has been switched
o, before they can be reached. Most ignitable solvents have an ignition energy of
around 0.24 mJ or 60 nC.
The cleaning agent's ash point must be at least 15 K above the ambient temperature.
Note the details provided by the powder lacquer manufacturer.
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used
for getting rid of dust build-up.
Take measures for workplace safety (see Chapter 4.1.2).

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4.2.7 MAINTENANCE AND REPAIR
Danger due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Use only WAGNER original spare parts and accessories.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in Chapter 12 and Chapter 13 that are
assigned to the device.
Do not use any defective components.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve pressure on powder spray gun and device.
– Secure the powder spray gun against actuation.
Observe the operating and service manual for all work.
4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
Danger due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.

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5 DESCRIPTION
5.1 DESIGN OF THE VU 1 RECIPROCATOR
P_01791
1
2
3
4
5
8
7
6
Designation
1 Stand
2 Upper stop
3 Gun mounting carriage
4 Counterweight carriage
5 Drive belt
6 Lower stop
7 Electronic switchbox
8 Motor with gear unit

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5.2 DESIGN OF THE VU 2 RECIPROCATOR
1
2
5
3
4
76
8
P_02863
Designation
1 Stand
2 Upper stop
3 Gun mounting carriage
4 Counterweight carriage
5 Drive belt
6 Lower stop
7 Electronic switchbox
8 Motor with gear unit

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5.3 DESIGN OF THE VU 3 RECIPROCATOR
P_04287
1
2
3
4
5
8
7
6
Designation
1 Stand
2 Upper stop
3 Gun mounting carriage
4 Counterweight carriage
5 Drive belt
6 Lower stop
7 Electronic switchbox
8 Motor with gear unit

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5.4 MODE OF OPERATION
The device carrier on lifting unit 3 is moved up and down by drive belt 5 and the motor
with gear unit 8.
Lifting speed, reversal point or position are all controlled by the central control unit.
Position control is carried out by frequency converter and path measurement via incremental
position encoder.
5.5 VARIANTS
Order no. Designation
2327615 Reciprocator, VU 1-1800 (height of stroke 1800 mm; 70.87 inches)
2327616 Reciprocator, VU 1-2400 (height of stroke 2400 mm; 94.49 inches)
2327617 Reciprocator, VU 1-3000 (height of stroke 3000 mm; 118.11 inches)
2363696 Reciprocator, VU 2-1800 (height of stroke 1800 mm; 70.87 inches)
2363695 Reciprocator, VU 2-2400 (height of stroke 2400 mm; 94.49 inches)
2411131 Reciprocator, VU 3-2000 (height of stroke 2000 mm; 78.74 inches)
5.6 SCOPE OF DELIVERY
Order no. Designation
1see Chapter 5.5 VU 1/VU 2/VU 3 reciprocator
The standard equipment includes:
1see Chapter 14 Declaration of incorporation
1 2330731 Operating and assembly manual, German
1see Chapter 1.3 Operating and assembly manual in the local language