WAGNER IP 5000 Operational manual

P_04342
P_04342
IP 5000
IP 5000-USD
Fresh Powder and Transfer Pump
Edition 08/2021
II 3D Ex tc IIIB T85°C Dc

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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
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 USING IN ACCORDANCE WITH THE INSTRUCTIONS 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
3.3 Type Plate 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 IP 5000 Powder Pump 17
5.1.1 IP 5000 Version 17
5.1.2 IP 5000-USD Version 18
5.2 Functioning 19
5.3 Operating Elements on Control Cabinet 20
5.4 Extent of Delivery 20
5.5 Data 21
5.5.1 Technical Data 21
6 ASSEMBLY AND COMMISSIONING 22
6.1 Training of Assembly/Commissioning Personnel 22
6.2 Storage Conditions 22
6.3 Installation Conditions 22
6.4 Assembly Example of the WAGNER Powder Center 23

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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
6.5 Installation Recommendation 24
6.5.1 IP 5000 Version 24
6.5.2 IP 5000-USD Version 25
6.6 Assembling the Powder Pump 26
6.7 How to Handle the Hose Coupling 28
6.8 Grounding 28
6.9 Start Up 28
6.9.1 Commissioning in Connection with the Powder Center 30
6.9.2 Commissioning as Transfer Pump (BigBag) 30
6.9.3 Pin Assignment in the Control Cabinet 31
7 OPERATION 32
7.1 Training the Operating Personnel 32
7.2 Tasks 32
7.3 Operating Modes 32
7.4 Operation with WAGNER Powder Center 32
7.5 Setting Elements in the Control Cabinet 33
7.5.1 DIP Switch Functions 33
7.5.2 A+/A- Buttons 33
7.5.3 Function 1 "Use of Powder Center/BigBag" 34
7.5.4 Function 2 Recipe "Soft" 34
7.5.5 Function 3 "Set After-run Time" 34
7.5.6 Function 4 "Set Cleaning Time" 34
7.5.7 Function 6 "Set Service Interval" 35
7.5.8 Setting Example 36
7.5.9 Function 7 "Level Controller" 37
7.6 Cycle Counter 38
7.7 Conditions for Operating the Pump 38
8 CLEANING AND MAINTENANCE 39
8.1 Cleaning 39
8.1.1 Cleaning Personnel 39
8.1.2 Cleaning Procedures 39
8.1.3 Cleaning in Case of Paint Change 39
8.1.4 Internal Cleaning Procedure 39
8.1.5 External Cleaning Procedure 40
8.1.6 SuperCenter Cleaning Procedure 41
8.1.7 PXM Cleaning Procedure 41
8.2 Maintenance 42
8.2.1 Maintenance Personnel 42
8.2.2 Maintenance Instructions 42
8.2.3 Safety Checks and Maintenance Intervals 42
8.2.4 Maintenance Procedures 42
8.2.5 Changing Valve and Pump Hoses 43
8.3 Storage Conditions for Pump and Valve Hoses 49
8.4 Replacing the Non-return Valves 50
8.4.1 Disassembly 50
8.4.2 Assembly 53
9 TROUBLE SHOOTING AND SOLUTION 56
10 DISASSEMBLY AND DISPOSAL 57
10.1 Disassembly 57
10.2 Disposal 57

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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
11 ACCESSORIES 58
12 SPARE PARTS 61
12.1 How to Order Spare Parts 61
12.2 Powder Pump Spare Parts List 62
12.3 Control Cabinet Spare Parts List 64
12.4 Connecting Plug Spare Parts List 66
12.5 SN 600/14 Suction Lance Spare Parts List 67
12.6 SN 1500/14 Suction Lance Spare Parts List 68
12.7 External Cleaning Box Spare Parts List 69
13 CIRCUIT DIAGRAMS 70
13.1 Plug Assignment 70
13.2 Signal Sequence 71
13.2.1 Signal Sequence "Feeding Operation" 71
13.2.2 Signal Sequence "KPZ 2008 Cleaning" 71
13.2.3 Signal Sequence "PXM/PXS Standard Cleaning" 72
13.2.4 Signal Sequence "PXM/PXS Intensive Cleaning" 73
13.2.5 Signal Sequence "SuperCenter Cleaning" 74
13.3 Valve Assignment 75
13.4 Electrical Circuit Diagrams 76
13.5 Pneumatic Diagram 83
14 EU DECLARATION OF CONFORMITY 85

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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
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 241935
Translation of the original operating manual
Language Order no. Language Order no.
English 241936 Danish 2396410
French 241943 Polish 2316573
Italian 241944 Romanian 2409919
Spanish 241945 Slovenian 2395395
Russian 2326214 Slovakian 2400611
Chinese 2384487 Czech 2302697
Swedish 2315185 Norwegian 2413942
Portuguese 2343832 -- --
Hungarian 2338554 -- --
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
-- 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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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
2 USING IN ACCORDANCE WITH THE INSTRUCTIONS
2.1 DEVICE TYPE
Pneumatic feed pump for feeding powder lacquers.
2.2 TYPE OF USE
The IP 5000 powder pump is used to feed powder coating products from dierent
container types.
Application areas:
The IP 5000 powder pump is used to feed powder lacquers
– from original tanks (25 kg; 55.1 lbs)
– from BigBags (500 kg; 1102.3 lbs)
– as a transfer pump, e.g., to empty a powder container or to convey powder from one
tank to another
WARNING
Dust formation!
Danger of poisoning.
Danger due to escaping dust, contamination of the device and device components.
Only operate the device in conjunction with exhaust air equipment, for example a
suction device on the powder center.
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 device is suitable for use in potentially explosive areas (zone 22) in accordance with
Directive 2014/34/EU.
2.4 PROCESSIBLE WORKING MATERIALS
In principle all powder lacquers can be conveyed with the powder pump, for example
epoxy, polyester, mixed powders EP/PES/PUR.
However, inindividualcases theuse ofpowderswithspecialrecipes cancausemalfunctions,
which cannot be eliminated with the various pump recipes.
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
no liquid coating products, e.g., solvents or water-based lacquers are processed;
no food, medicine or cosmetics are processed.

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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
Device type: Powder feed pump
Manufacturer: Wagner International AG
9450 Altstätten
Switzerland
II 3D Ex tc IIIB T85°C Dc
CE: European Communities
Ex: Symbol for explosion protection
II: Device class II
3: Category 3
D: Ex-atmosphere dust
IIIB: Explosion group (dust group)
T85°C: Temperature class: maximum surface temperature < 85 °C; 185 °F
Dc: High safety level
3.2 PERMISSIBLE DEVICE COMBINATIONS
The IP 5000 powder pump can be used in the following WAGNER powder centers:
– PZ 2008 powder center
– SuperCenter 2012
– PXM powder center
– PXS powder center
3.3 TYPE PLATE
P_02570
2
1
3
4
5
Wagner International AG
CH-9450 Altstätten
II 3D Ex tc IIIB T85°C Dc
Typ:
Type:
Serie Nr./Baujahr:
Serial Nr./YB:
Spannung:
Voltage:
Eingangsleistung:
Line Power:
Made in Switzerland
Umgebungstemp.:
Ambient temperature:
Schutzklasse:
Prot Class:
IP 5000
IP 5000-USD
24V DC +/-20%
40W
+10°C Ta +50°C
IP 54
1 Serial number
2 Input voltage
3 Input power
4 Ambient temperature
5 Protection class

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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow applicable directives concerning occupational safety and accident
prevention regulations.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Danger of electric shock!
Danger to life from electric shock.
Prepare device in accordance with the applicable 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.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Do not disconnect any plug connections during operation.
Label plug connections with the warning "Do not disconnect under voltage".
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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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
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).
In the spray booth, coating may only be performed with correctly designed and
locked technical ventilation.
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.
Make sure that all people within the work area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 MΩ.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 MΩ.
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
A suitable system for suppressing re and explosion must be installed.
The powder release must be electrically interlocked with the connected technical
ventilation of the spray system.
Excess coating product (overspray) must be collected up safely.
Accumulations of powder in the spray booth are to be avoided. Set the parameters
of the oor cleaning and manually clean the spray booth as needed.
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 20 g/m³.
Ensure that maintenance and safety checks are performed regularly.
In case of defects, immediately shut down and repair the device or system before
switching it back on. Accumulations of powder are to be removed before switching
the system back on.
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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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always observe the information in this manual, particularly the safety instructions
and the warning instructions.
Always follow existing regulations concerning occupational safety and accident
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 protection, only operate the device with
technical 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.
– In the event of functional faults: remedy the fault as described in the
"Troubleshooting" chapter.
Carry out the work steps in accordance with the chapter on pressure relief in the
operating manual of the corresponding device:
– if pressure relief is required,
– if the coating work is interrupted or stopped,
– before the device is cleaned on the outside, checked, or serviced,
– before the spray nozzle is installed or cleaned.

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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
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 spray booth must be grounded.
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.
WARNING
Bursting powder hose!
Risk of injury and damage to the device.
The powder hose may be loaded with a maximum pressure of 0.6 MPa; 6 bar; 87 psi.

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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
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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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
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 specially trained person may carry out repairs and
replace parts.
Repair or replacement of devices or parts of devices are only allowed to be performed
outside the hazard area by qualied personnel.
Use only WAGNER original spare parts and accessories.
WAGNER assumes no liability for changes to the product made by the operating
company without the knowledge of WAGNER. Any adjustments to the documentation
and the market release are the responsibility of the operating company.
Only repair and replace parts that are listed in the Chapters "Accessories" and "Spare Parts"
and 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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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
5 DESCRIPTION
5.1 DESIGN OF THE IP 5000 POWDER PUMP
5.1.1 IP 5000 VERSION
Front View Prole
1
2
4
5
6
7
P_04343
89
3
Designation
1 Control cabinet
2 Control panel
3 Cooling box for inlet valve air
4 Pressure regulator (in the control cabinet)
5 Powder inlet valve
6 Pump body
7 Powder outlet valve
8 Pump tube 1
9 Pump tube 2

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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
5.1.2 IP 5000USD VERSION
Front View Prole
5
6
7
2
1
4
P_04825
98
3
Designation
1 Control cabinet
2 Control panel
3 Cooling box for inlet valve air
4 Pressure regulator (in the control cabinet)
5 Powder inlet valve
6 Pump body
7 Powder outlet valve
8 Pump tube 1
9 Pump tube 2

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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
5.2 FUNCTIONING
The powder pump can be operated in two ways:
– Automatic mode, for example on a WAGNER powder center
– Manual mode for commissioning or non-automatically controlled feeding tasks
If used in a WAGNER powder center, the powder pump is controlled via the powder
center controller. The 24V supply to the powder pump is provided via the powder center.
Two recipes for full or reduced performance are stored in the powder pump controller.
A cleaning recipe for cleaning suction and pressure hose is also stored in the controller.
The powder pump is equipped with an active inlet valve cooling for gentle powder feeding.
Mode of operation:
The IP 5000 powder pump is a vacuum-assisted peristaltic pump. Feeding occurs by means of
two pump hoses. The pump hoses are reciprocally sealed by pressure. Through generation of
a vacuum, the pump hose is opened again and the powder is fed. The reciprocal control of the
two pump hoses produces an even powder ow under optimal conditions.
1
2
3
P_00003
Designation
1Inlet Valve
2 Pump hose
3 Outlet valve

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EDITION 08/2021 ORDER NUMBER DOC241936 IP 5000
5.3 OPERATING ELEMENTS ON CONTROL CABINET
Auto
100
90
80
70
60
10
20
30
40
50
10
9
8
7
6
1
2
3
4
5
IP 5000
14
6
109 11
P_00006
87
3
5
2
Designation
1 Button: "ON/OFF"
2 LED ashes if no release has been issued by the powder center.
The buttons are then locked.
3 Button: "Cleaning ON/OFF"
4 Button: "START / STOP" (manual operations)
5 LED display: "Service Interval" (cycle counter) *
6 LED display: "Cleaning Time" *
7 Button: "Reduced Flow Rate"
8 Button: "Full Flow Rate"
9 Display for control via level monitoring
10 Fault display (LED lights up)
11 Pressure gauge for piston air
The LEDs also light up when the pump is switched o with "ON/OFF" button 1
(serves for 24 VDC voltage monitoring).
5.4 EXTENT OF DELIVERY
Order no. Designation
1 241004 IP 5000 powder pump
1 2386088 IP 5000-USD powder pump
The standard equipment includes:
1 241942 Declaration of Conformity
1 241935 Operating manual, in German
1 see Chapter 1.3 Operating manual in local language
For special versions the delivery note applies.