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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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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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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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
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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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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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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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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.

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2.5 PROCESSIBLE WORKING MATERIALS
Abrasive working materials and pigments!
Greater wear of parts carrying the product.
Do not use any grainy and abrasive working materials with large, sharp-edged
pigments.
Check if the uids and solvents used are compatible with the pump construction
materials.
For explanations of the models and construction materials, consult the data in
Chapter 5.5 or contact a WAGNER service technician.
NOTICE
Wear caused by abrasive working materials is not covered by the warranty.
2.6 RECOMMENDED APPLICATION AREAS
Low- to high-viscosity 2K lacquer (e.g., epoxy, PU, DD) for processing with static mixer,
hose, and gun.
- 2K water-based priming - 2K epoxy priming
- 2K solvent-based priming - 2K epoxy lacquers
- 2K PUR priming - 2K high-solid priming
- 2K PUR lacquers - 2K high-solid lacquers
However, 2K products containing solvents and aqueous 2K products should not be
processed with the same system.
Application area
Steel-processing industry
Rail vehicle
Shipbuilding
Tank construction
Pipeline construction
Wind energy
Legend
recommended limited suitability less suitable

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2.8 RESIDUAL RISKS
Residual risks are risks which cannot be ruled out even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk Source Consequences Specic measures Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Handling of
lacquers and
cleaning agents
Skin irritation,
allergies
Use personal safety
equipment.
Operation,
Observe safety data
sheets
maintenance,
disassembly
Lacquer in air
outside the dened
working area
Lacquering outside
the dened
working area
Inhalation of
substances
hazardous to
health
Observe work and
operation instructions.
Use personal safety
equipment
Operation,
maintenance
2.7 REASONABLY FORESEEABLE MISUSE
The forms of misuse listed below may result in physical injury or property damage:
coating work pieces which are not grounded;
performing unauthorized conversions or modications to the device;
processing dry or similar coating products, e.g., powder;
using defective components, spare parts or accessories other than those described in
the "Accessories" chapter of this operating manual;
continuing work with a defective or kinked product hose;
working with incorrectly set values;
processing food.

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3.1 CE EXPLOSION PROTECTION IDENTIFICATION
3.2 IDENTIFICATION X
As dened in Directive 94/9/EC (ATEX 95), the device is suitable for use in potentially explosive
areas.
CE CE mark (European Communities)
Explosion-proof equipment
II Device class II (not mining)
2 Category 2 device (suitable for zone 1)
G Ex-atmosphere gas
C Constructional security
IIB Device class (Gas) IIB
T3 Temperature class T3: maximum surface temperature 200 °C; 392 °F
T4 Temperature class T4: maximum surface temperature 135 °C; 275 °F
Gb Device protection level , suitable for use in Zone 1
X Special instructions exist for safe operation. See the following Chapter
"Identication X".
3 IDENTIFICATION
Maximum surface temperature
The maximum surface temperature T3 of the piston pump can be reached if it runs dry.
Ensure that the piston pump is lled with sucient working or ushing agent.
Ensure that the separating agent tank is lled with sucient separating agent.
Temperature class T3: No dry running protection.
Temperature class T4: With dry running protection.
Ignition temperature
Ensure that the ignition temperature of the surrounding gases (pumping product,
cleaning agents) is higher than the maximum permitted surface temperature of the
device.
Ambient temperature
The permissible ambient temperature is:
- without heater: +5 °C to +50 °C; +41 °F to +122 °F
- with heater: +5 °C to +40 °C; +41 °F to +104 °F

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Safe handling of WAGNER spray devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the device against steel or rusty iron.
Do not drop the device.
Use only tools that are made of a permitted material.
Surface spraying, electrostatics
Do not spray device parts using electrostatic equipment.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the device.
National regulations
Ensure that the national explosion prevention rules and regulations are observed when
setting up the device.
Air in the pump uid
Flammable gas mixtures can form if air reaches the pump uid.
Prevent the pump from taking in air and running dry.
If air has been taken in, x the leak. Then, ll slowly and in a controlled manner until the
air has escaped.
Air in the pumped uid can be caused by damaged packings.
Avoid operating the pump with damaged packing.
Ensure that the separating agent tank is lled with sucient separating agent.
Periodically check that the pump is working smoothly, paying special attention to the
presence of air in the pumped uid.
Filling and emptying
Flammable gas mixtures can form in the uid section or product hoses if the pump must
be emptied for maintenance.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Electrical lines (where present)
Mains connection: Only in the explosive area if the plug and socket are ex models.
Lay all electrical cables with protection from mechanical damage, e.g., not near doors,
routes used by industrial trucks etc.

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PROTEC 2K
cm³
MPa
cm³
cm³
75 : 1
188
4 : 1
48
150
38
70 : 1
200
3 : 1
45
150
50
64 : 1
225
2 : 1
41
150
75
77 : 1
185
1.5 : 1
49
110
75
65 : 1
220
1 : 1
41.5
110
110
Pressure ratio:
Druckübersetzung:
Materialmenge / DH:
Flow rate / DS:
Mixing Ratio Vol.:
Mischverhältnis Vol.:
Fluid section A:
Farbstufe A:
Material pressure max.:
Materialdruck max.:
Data depending on mounted fluid sections PROTEC 2K
Daten abhängig von montierten Farbstufen
Fluid section B:
Farbstufe B:
B_05686
CH 9450 AltstättenMade in Switzerland
Type / Typ:
J. Wagner AG
Anschluss pneumatisch:
Pneumatic connection:
Materialtemperatur:
Material temperature:
Check manual before use!
Vor Gebrauch Betriebsanleitung beachten!
1" 0.6 - 0.65 MPa
5 - 80 °C
5 - 50 °C (40° C)
PROTEC 2K
Umgebungstemperatur:
Ambient temperature:
Year of manufacture / Baujahr:
Serial No unit.:
Serie Nr. Anlage:
II 2 G c IIB T3/T4 Gb X
B_05442
1
2
4
5
6
7
8
9
3
OPERATING MANUAL
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1 Manufacturer
2 CE identication
3 System type
4 Serial number of system
5 Year of manufacture
6 Pneumatic connection (thread and air inlet
pressure)
7 Product temperature
8 Ambient temperature
9 Read operating manual before use!
3.3 TYPE PLATE
The type plate consists of two parts.
10
12
13
14
15
16
17
11
*With several uid section combinations A–B:
- The uid sections A and B are identied with labels: 38 cc / 50 cc / 75 cc / 110 cc / 150 cc
- Establish the uid section combination currently installed from the labels.
- Read data on additional plate from the corresponding column.
10 Data on the additional plate depend on the mounted
uid sections
11 Fields to identify the uid section combinations used *
12 Fluid section A: Flow rate per double stroke
13 Fluid section B: Flow rate per double stroke
14 Pump ratio
15 Flow rate per double stroke A / B
16 Mixing ratio, volumetric
17 Maximum product pressure
Additional plate:

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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident prevention.
4.1.1 ELECTRICAL EQUIPMENT
Electrical devices and equipment
To be provided 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, there is a danger from line voltage.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard or are damaged.
Must be de-energized before work is commenced on active parts. Inform sta 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.
4.1.2 PERSONNEL QUALIFICATIONS
Ensure that the device is only operated, maintained and repaired by trained persons.
4.1.3 SAFE WORK ENVIRONMENT
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 megohms).
Paint mist extraction systems/ventilation systems must be tted on site according to
local regulations.
Ensure that product / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment is available and is used (breathing and skin
protection).
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.

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Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.
In electrostatics application: Anyone tted with a pacemaker must not enter the high-voltage
area!
4.2 SAFETY INSTRUCTIONS FOR STAFF
Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun handle or the trigger guard.
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.
Ensure that the pipe joints, hoses, equipment parts and connections are permanently,
technically leak-proof:
- Periodic preventative maintenance and service (replacing hoses, checking tightness
strength and connections, etc.)
- Regular monitoring of leaks and defects via visual inspection and odor testing, e.g.,
daily before commissioning, at the end of work or weekly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
Grounding
Make sure that the ground and potential equalization of all system parts are performed
reliably and continuously and can withstand the expected stress (e.g., mechanical
stress, corrosion).
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before all work on the device, in the event of work interruptions and functional faults:
- Relieve pressure from spray guns and devices.
- Secure spray guns against actuation.
- Switch o the energy/compressed air supply.
- Disconnect the control unit from the mains.
- In the event of functional faults, remedy the fault as described in the "Troubleshooting"
chapter.
4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES

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4.2.3 PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products and the
ushing agents used.
Ensure that the product hose is suitable for the pressure generated.
Ensure that the following information can be seen on the high-pressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture
4.2.2 GROUNDING THE DEVICE
Friction, owing liquids and air or electrostatic coating processes create charges. Flames or
sparks can form during discharge. Grounding prevents electrostatic charging.
Ensure that the device is grounded. See Chapter "Grounding".
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are wearing
static dissipative shoes.
Wear static dissipative gloves when spraying. The grounding takes place via the spray
gun handle or the trigger guard.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.
If needed, the liquid ejection devices must be checked by experts (e.g.,WAGNER service
technician) at least every 12 months to ensure they are safe for work in accordance with
the DGUV regulation 100-500.
- For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure Relief" chapter:
- If pressure relief is required.
- If the spraying work is interrupted or stopped.
- Before the device is cleaned on the outside, checked or serviced.
- Before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by paint or ushing agents:
Note the paint or ushing agent that you have been using.
Consult a doctor immediately.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun briey in a position.

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4.2.4 CLEANING AND FLUSHING
Relieve the pressure from the device.
De-energize the device electrically.
Preference should be given to non-ammable cleaning and ushing agents.
When carrying out cleaning work with ammable cleaning agents, make sure that all
equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or
static dissipative and grounded.
Observe the specications of the lacquer manufacturer.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical
ventilation.
Take measures for workplace safety (see Chapter 4.1.3).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- depending on the ushing agent (solvent) used,
explosive mixture inside the lines and items of equipment.
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.
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 megohm.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coecient. In some cases their volume can rise with
consequent damage to pipes, ttings, etc. and cause uid leakage.
When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can
enter the tank. Thus a negative pressure is avoided. The vacuum could implode the tank
(squeeze) and can cause it to break. The tank would leak and the liquid would ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.

20
PROTEC 2K
OPERATING MANUAL
VERSION 02/2016 ORDER NUMBER DOC2352824
4.2.6 TOUCHING HOT SURFACES
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C; 109 °F:
identify the unit with a warning label that says "Warning - Hot Surface".
- Instruction label Order No. 9998910
- Protection label Order No. 9998911
Note: Order the two stickers together.
Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
Never spray into a closed tank when using solvents for ushing.
External cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects and
never spray cleaning agents with a gun. Cleaning the device must not damage it in any
way.
Ensure that no electric component is cleaned with or immersed into solvent.
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
When preparing or working with lacquer and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents and cleaning agents
being used.
Take thespeciedprotectivemeasures.Inparticular,usepersonalprotectiveequipment:
safety goggles, protective clothing and gloves, as well as respiratory protection and
skin protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient 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 products.