WAGNER PROTEC 2K Operational manual

PROTEC 2K
B_05163
2K System
Protective Coating
Version 02/2016
Translation of the Original
Operating Manual

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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Table of Contents
1 ABOUT THESE INSTRUCTIONS 7
1.1 Preface 7
1.2 Warnings, Notices and Symbols in these Instructions 7
1.3 Languages 8
1.3.1 Operating Manuals for the Individual Components 8
1.4 Abbreviations in the Text 8
1.5 Terminology for the Purpose of this Manual 9
2 CORRECT USE 10
2.1 Device Types 10
2.2 Type of Use 10
2.3 Field of Application 10
2.4 Safety Parameters 10
2.5 Processible Working Materials 11
2.6 Recommended Application Areas 11
2.7 Reasonably Foreseeable Misuse 12
2.8 Residual Risks 12
3 IDENTIFICATION 13
3.1 CE Explosion Protection Identication 13
3.2 Identication X 13
3.3 Type Plate 15
4 GENERAL SAFETY INSTRUCTIONS 16
4.1 Safety Instructions for the Operator 16
4.1.1 Electrical Equipment 16
4.1.2 Personnel Qualications 16
4.1.3 Safe Work Environment 16
4.2 Safety Instructions for Sta 17
4.2.1 Safe Handling of WAGNER Spray Devices 17
4.2.2 Grounding the Device 18
4.2.3 Product Hoses 18
4.2.4 Cleaning and Flushing 19
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 20
4.2.6 Touching Hot Surfaces 20
5 DESCRIPTION 22
5.1 Components 22
5.2 Mode of Operation 24
5.3 Protective and Monitoring Equipment 24
5.4 Scope of Delivery 26

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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
Table of Contents
5.5 Data 27
5.5.1 Materials of Paint-wetted Parts 27
5.5.2 Recommended Packings 27
5.5.3 Technical Data 28
5.5.3.1 Technical Data for Entire System 28
5.5.3.2 Technical Data for PROTEC 2K Piston Pump 29
5.5.4 Dimensions and Weights 30
5.5.5 Volume ow 31
5.5.6 Performance Diagrams 31
5.6 Flow Diagram 34
5.6.1 Flow Chart with External Mixer and External Circulation 35
5.7 Pressure Regulator Unit 36
5.8 Pressure Relief 36
5.8.1 High-pressure Filter 530 bar 36
5.8.2 2K PC Relief Combination, 530 bar 37
5.9 Stroke Count (Option) 37
5.10 External Mixer and External Circulation 39
5.10.1 External Mixer (Option) 39
5.10.2 Hose Selection 40
5.10.3 Throttle Valve (Option) 41
5.10.4 External circulation (option) 42
5.11 Feed Pump (Option) 44
6 ASSEMBLY AND COMMISSIONING 45
6.1 Training Assembly/Commissioning Sta 45
6.2 Storage and Installation Conditions 45
6.3 Transportation 45
6.4 Assembly and Installation 46
6.4.1 Pneumatic Connections 46
6.4.2 Product Connections 46
6.4.3 Ventilation of the Spray Booth 46
6.5 Grounding 47
6.5.1 Grounding of Components on Trolley 47
6.5.2 Grounding Schema (example) 48
6.6 Commissioning 49
6.6.1 Safety Instructions 49
6.6.2 Procedure 49
7 OPERATION 50
7.1 Training the Operating Sta 50
7.2 Safety Instructions 50
7.2.1 General Rules for Making Adjustments to the Spray Gun 51
7.2.2 Do not connect red handle under pressure 51
7.3 Switching Device On and O 52
7.3.1 Switching On Device 52
7.3.2 Switching O Device 52
7.3.3 Emergency Stop 52

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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
7.4 Spraying Mode 53
7.4.1 Preparing 53
7.4.2 Circulating 54
7.4.3 2K Spraying 55
7.4.3.1 Pressure Drop 56
7.4.3.2 No-Load / Vent 56
7.5 Pressure Relief/Work Interruption 57
7.5.1 Continuing after Work Interruption 58
7.6 Intermediate Flushing 58
7.6.1 Intermediate Flushing with Flushing Pump 59
7.6.1.1 Relieving Flushing Pump 60
7.6.2 Intermediate Flushing without Flushing Pump 61
7.7 Paint or Hardener Change 62
7.7.1 Paint Change Flushing 62
7.8 Workow 65
8 CLEANING AND MAINTENANCE 66
8.1 Cleaning 66
8.1.1 Cleaning Sta 66
8.1.2 Safety Instructions 66
8.1.3 Clean Product Tank 66
8.1.4 Decommissioning and Cleaning 67
8.1.5 Long-term Storage 67
8.2 Maintenance 68
8.2.1 Maintenance Sta 68
8.2.2 Safety Instructions 68
8.2.3 Regular Maintenance Work 69
8.2.3.1 Lubricating Bearings 69
8.2.3.2 Draining Condensate from Water Separator 70
8.2.3.3 Filling with Separating Agent 70
8.2.4 Emptying Device 71
8.2.5 Filling Empty Device 73
8.2.6 Cleaning and Replacing the High-pressure Filter 74
8.2.7 Product Hoses, Tubes and Couplings 75
9 TROUBLESHOOTING AND RECTIFICATION 76
10 REPAIRS 78
10.1 Repair Sta 78
10.2 Mounting Materials 78
11 DISPOSAL 78
Table of Contents

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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
12 ACCESSORIES 79
12.1 Conversion to other Mixing Ratios 81
13 SPARE PARTS 82
13.1 How Can Spare Parts Be Ordered? 82
13.2 Overview 83
13.2.1 Basic Units 83
13.2.2 System Overview 84
13.2.3 Hoses 85
13.3 Trolley with Grounding, Return Line, and Air Inlet 86
13.3.1 2K Mechanism Trolley 88
13.3.2 Air Inlet with Water Separator 89
13.4 Product Tank A and Product Tank B (1:1) 90
13.5 Product Tank B (4:1, 3:1, 2:1, 1.5:1) 91
13.6 Mixing 92
13.6.1 Mixing Block 94
13.6.1.1 Outlet Valve 94
13.6.2 Mount on Trolley 95
13.7 2K Pump 96
13.7.1 PROTEC Air Motor 10" 98
13.7.1.1 Air Motor Regulator for PROTEC 10" 102
13.7.2 Movement Mechanism 103
13.7.3 Fluid Sections 110–150 cm 104
13.7.4 Fluid Sections 38–75 cm 107
13.7.5 2K PC Relief Combination 111
13.7.6 2K High-pressure Filter, 530 bar with Pressure Gauge 112
13.8 Flushing Pump / Flushing Pump Connection (Option) 114
13.9 Heater (Option) 116
13.9.1 Heater without Return Line 116
13.9.2 Heater with Return Line 118
13.10 Return Flow Set HP Filter A and B (Option) 121
13.11 External Mixer 122
13.11.1 Throttle Valve Set (Option) 124
13.11.1.1 Throttle Valve 124
13.11.2 External Circulation A1/2"–B1/4" and A3/8"–B1/4" 126
13.11.3 External circulation A3/8"–B3/8" and A1/2"–B3/8" 127
14 WARRANTY AND CONFORMITY DECLARATIONS 128
14.1 Important Notes Regarding Product Liability 128
14.2 Warranty Claim 128
14.3 CE Declaration of Conformity 129
14.4 Notes on National Regulations and Guidelines 130
Table of Contents

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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
1 ABOUT THESE INSTRUCTIONS
Warning instructions in this operating 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 - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
Note - provides information about particular characteristics and how to proceed.
This notice 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.
DANGER
This notice 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 notice 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.
CAUTION
This notice 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.
NOTICE
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.

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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
1.3 LANGUAGES
The operating manual is available in the following languages:
Language Order No. Language Order No. Language Order No.
German 2352823 English 2352824 French 2357841
Italian 2357842 Spanish 2357843 Russian 2359374
1.4 ABBREVIATIONS IN THE TEXT
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Double stroke
Nominal diameter
Nominal pressure
Two components
Protective coating
1.3.1 OPERATING MANUALS FOR THE INDIVIDUAL COMPONENTS
Operating manual for ushing pump (option): IceBreaker piston pumps 40 cm–150 cm
Language Order No. Language Order No. Language Order No.
German 2333537 English 2333538 French 2333539
Italian 2333540 Spanish 2333541 Russian 2351629
Additional languages on request or at:
The corresponding service manuals are available under the following order number:
Language Order No. Language Order No.
German 2357839 English 2357840
Additional languages on request or at:
Continuous-ow heater operating manual (option)
Language Order No. Language Order No.
German 65860 English 65860
French 65860 Italian 65860

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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Materials
Stainless steel
Polyethylene
Ultra-high molecular weight polyethylene
Polytetrauorethylene
PTFE with graphite
PTFE
Leather
Cleaning Manual cleaning of devices and device parts with cleaning agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Sta 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 A person who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge 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.
In the context of
TRBS1203
(2010 / Revision 2012)
Additional requirements for skilled persons are given in the
TRBS1203(2010/Revision 2012): Expert knowledge in the areas
of protection against excessive pressure, electrical hazards, and
explosion protection (where applicable).

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PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
2 CORRECT USE
2.1 DEVICE TYPES
2.2 TYPE OF USE
2.3 FIELD OF APPLICATION
The device is suitable for processing liquid materials like paints and lacquers in accordance
with the classication into explosion classes IIA or IIB.
The 2K system can be employed in potentially explosive areas (Zone 1). See Chapter 3.
2.4 SAFETY PARAMETERS
- PROTEC 2K with ushing pump
- PROTEC 2K without ushing pump
- Mixing ratio of 4:1 or 3:1 or 2:1 or 1.5:1 or 1:1
WAGNER accepts no liability for any damage arising from incorrect use.
Use the device only to work with the products recommended by WAGNER.
Only operate the device as a whole.
Do not perform unauthorized conversions or modications to the device.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The 2K system may only be operated under the following conditions:
The operating personnel must be trained on the basis of this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must be
observed.
The statutory requirements and accident prevention regulation standards in the country
of use must be observed.
The 2K system may only be used as described in this operating manual. In particular, no
conversions are permitted on the system otherwise the warranty ceases to apply and
WAGNER is not liable for any claims.