WAGNER PM500 User manual

B_04200
Pneumatic Double
Diaphragm Pump PM500
Version 01/2013
Translation of the Original
Operating Manual

3
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
Contents
1 ABOUT THESE INSTRUCTIONS 5
1.1 Preface 5
1.2 Warnings, Notices and Symbols in these Instructions 5
1.3 Languages 6
1.4 Abbreviations in the Text 6
2 CORRECT USE 7
2.1 Device Types 7
2.2 Type of Use 7
2.3 Use in an Explosion Hazard Area 7
2.4 Safety Parameters 8
2.5 Processible Materials 8
2.6 Reasonably Foreseeable Misuse 9
2.7 Residual Risks 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Maximum Surface Temperature 10
4 GENERAL SAFETY INSTRUCTIONS 11
4.1 Safety Instructions for the Operator 11
4.1.1 Electrical Equipment 11
4.1.2 Personnel Qualications 11
4.1.3 Safe Work Environment 11
4.2 Safety Instructions for Sta 11
4.2.1 Safe Handling of WAGNER Spray Devices 12
4.2.2 Grounding the Unit 12
4.2.3 Material Hoses 12
4.2.4 Cleaning 13
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 13
4.2.6 Touching Hot Surfaces 13
4.2.7 Explosion Hazard 14
4.2.8 Noise Risk 14
4.2.9 Material Chemical Compatibility 14
4.2.10 Emergency Stop 14
4.2.11 Tightness Check 14
4.2.12 Maintenance 14
4.3 Use in Areas Subject to Explosion Hazards 15
4.3.1 Safety Regulations 15
4.3.2 Operation without Fluid 16
4.3.3 Maximum Surface Temperature 16
4.3.4 Maximum Surface Temperature - Exothermic Reactions 16
4.3.5 Connection Pipes 16
4.3.6 Pump Protection 16
5 DESCRIPTION 17
5.1 Areas of Application 17
5.2 Scope of Delivery 17

4
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
5.3 Data 18
5.3.1 Materials of the Fluid Transporting Parts 18
5.3.2 Technical Data 19
5.3.3 Dimensions and Connections 20
5.3.4 Performance Diagrams 21
5.4 Mode of Operation 22
6 ASSEMBLY AND COMMISSIONING 23
6.1 Transportation 23
6.2 Storage 23
6.3 Assembly 23
6.4 Grounding 27
6.5 Commissioning 29
6.5.1 Safety Regulations 29
6.5.2 Preliminary Operations 30
6.5.3 Unit Pressure Tightness Test 31
7 OPERATION 32
7.1 Operation 32
7.2 Ending Work 32
7.3 Storage Over Longer Periods of Time 32
8 TROUBLE SHOOTING AND RECTIFICATION 33
9 MAINTENANCE 35
9.1 Safety Instructions 36
9.2 Diaphragm Replacement (Preventive Maintenance) 36
9.3 Diaphragm Replacement (Due to Breakage) 38
9.4 Cleaning / Replacement of the Suction and Delivery Non-Return Valves 42
9.5 Replacement of the Reversing Valve 42
9.6 Material Hoses 43
9.7 Decommissioning 43
10 SPARE PARTS 44
10.1 How Can Spare Parts Be Ordered? 44
10.2 PM500 Pump 45
11 GUARANTEE AND CONFORMITY DECLARATIONS 48
11.1 Important Notes Regarding Product Liability 48
11.2 Warranty Claim 48
11.3 CE Declaration of Conformity 49
Contents

5
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
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
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 material damage.
Note - provides information about particular characteristics and how to proceed.
This information 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 information 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 information 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 information 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
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 operating and service
sta.
Operating and service personnel should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
This equipment can be dangerous if it is not operated according to the denitions in this
operating manual.
1.1 PREFACE

6
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
1.3 LANGUAGES
1.4 ABBREVIATIONS IN THE TEXT
Number of pieces
Position
Marking in the spare parts lists
Order No. Order No.
Double stroke
Materials:
Polytetrafluorethylene
Ethylene-propylene-diene monomer (rubber)
The operating manual is available in the following languages:
Language: Order No. Language: Order No.
German 2335746 English 2335747
Italian 2335748 French 2335750
Spanish 2335752

7
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
2 CORRECT USE
2.1 DEVICE TYPES
2.2 TYPE OF USE
2.3 USE IN AN EXPLOSION HAZARD AREA
Metallic versions (aluminum):
Pneumatic double diaphragm pumps with Order No.
U509.A0
U509.A0A
The device is suitable for processing liquid materials like paints and varnishes in accordance
with the classication into explosion classes IIA or IIB.
The pneumatic double diaphragm pumps can be employed in explosion hazard zones
(Zone 1).

8
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
2.4 SAFETY PARAMETERS
WAGNER accepts no liability for any damage arising from incorrect use.
Use the device only to work with the materials recommended by WAGNER.
Only operate the device as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
2.5 PROCESSIBLE MATERIALS
Fluid materials like paints and varnishes.
Abrasive materials and pigments!
Greater wear of parts carrying the material.
Use the application-oriented model (ow rate/cycle, material, valves, etc.) as
indicated in Chapter 5.3.2.
Check if the uids and solvents used are compatible with the pump construction
materials as indicated in Chapter 5.3.1.
NOTICE
The operation of the pneumatic double diaphragm pump is only allowable under the
following conditions:
The operating sta have previously been 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.

9
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
2.6 REASONABLY FORESEEABLE MISUSE
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be excluded 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
paints and cleaning
agents
Handling of paints
and cleaning agents
Skin irritations, Wear protective
clothing,
Operation,
allergies observe safety data
sheets
maintenance,
disassembly
Paint in air outside
the dened working
area
Painting outside the
dened working
area
Inhalation of
substances which
are hazardous to
health
Observe working
and operating
instructions
Operation,
maintenance
The following is prohibited:
coating work pieces which are not grounded,
unauthorized conversions and modications to the device,
processing dry or similar coating materials, and
using defective components and spare parts and accessories other than those
described in Chapter 10 of this operating manual.
The forms of misuse listed below may result in health issues and/or equipment damage:
use of powder as coating material and
incorrectly set values for processing.
Wagner double diaphragm pumps are not designed for pumping food.

10
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
3.2 MAXIMUM SURFACE TEMPERATURE
Maximum surface temperature: the same as the permissible material temperature.
Permissible material temperature: +4÷90 °C; +39÷194 °F
Permissible ambient temperature: +4÷40 °C; +39÷104 °F
As dened in the Directive 94/9/EC (ATEX 95), the device is suitable for use in areas where
there is an explosion hazard.
+4°C ambient temperature to +40°C
European Communities
Symbol for explosion protection
Device class II
Category 2 (Zone 1)
Ex-atmosphere gas
Explosion group
Temperature class: maximum surface temperature < 135 °C; 275 °F
Ambient temperature +4 °C to +40 °C: permissible ambient temperature area
Metallic versions (aluminum):
Pneumatic double diaphragm pumps with Order No.
U509.A0
U509.A0A

11
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL EQUIPMENT
4.1.2 PERSONNEL QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
4.2 SAFETY INSTRUCTIONS FOR STAFF
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
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.
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.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Ensure that the device is operated and repaired only by trained persons.
Make sure that the oor in the area where you are working is electrostatically conductive
in accordance with EN 61340-4-1.
Ensure that all persons within the working area wear electrostatically conductive shoes.
Ensure that during spraying, persons wear electrically conductive gloves. The grounding
takes place via the spray gun handle.
Paint mist extraction systems must be tted on site according to local regulations.
Ensure that the following components of a safe working environment are available:
– Material/air hoses adapted to the working pressure.
– Personal safety equipment (breathing and skin protection).
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires or
hot surfaces in the vicinity. Do not smoke.
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.

12
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
4.2.2 GROUNDING THE UNIT
4.2.3 MATERIAL HOSES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or cleaning 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:
- Switch o the energy/compressed air supply.
- Secure the spray gun against actuation.
- Relieve the pressure from the spray gun and device.
In the event of functional faults: remedy the fault as described in the "Trouble Shooting"
chapter.
The liquid emitters are to be checked for safe working conditions by an expert
(e.g. Wagner Service Technician) as often as necessary or at least every 12 months,
in accordance with the guidelines for liquid emitters (ZH 1/406 and BGR 500 Part 2
Chapter 2.36).
– For shut down devices, the examination can be suspended until the next start-up.
In the event of skin injuries caused by paint or cleaning agents:
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun briey in a position.
In order to avoid electrostatic charging of the device, the device must be grounded.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Ensure that the device is grounded for every spraying operation.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g. that they are wearing
electrostatically conductive shoes.
Wear electrostatically conductive gloves when spraying.The grounding takes place via
the spray gun handle.
Ensure that the hose material is chemically resistant to the sprayed materials.
Ensure that the material hose is suitable for the pressure generated in the device.
Make sure that the hoses are laid only in suitable places. In no case, should hoses be
laid in the following places:
- in high-traffic areas,
- on sharp edges,
- on moving parts or
- on hot surfaces
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the complete high pressure hose must be less than
1 MOhm.

13
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
4.2.4 CLEANING
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
4.2.6 TOUCHING HOT SURFACES
De-energize the device electrically.
Disconnect the pneumatic supply line.
Relieve the pressure from the device.
Ensure that the flash point of the cleaning agent is at least 5 K above the ambient
temperature.
To clean, use cloths and brushes moistened with solvent. Never use hard objects or
spray on cleaning agents with a gun.
An explosive gas/air mixture forms in closed containers.
When cleaning devices with solvents, never spray into a closed container.
Ground the container.
When preparing or working with paint and when cleaning the unit, follow the working
instructions of the manufacturer of the paints, solvents and cleaning agents being
used.
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 a 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 materials.
Touch hot surfaces only if you are wearing protective gloves.
When operating the unit with a coating material with a temperature of > 43 °C; 109.4 °F:
- Identify the device with a warning sticker "Warning - hot surface".
Order No.
9998910 Instruction sticker
9998911 Protection sticker
Note: Order the two stickers together.
Several liquids have a high expansion coecient. In some cases its volume can rise with
consequent damage to hoses, ttings and cause uid leakage.
When the pump sucks liquid from a closed container, ensure that air or suitable gas can
enter the container to avoid a vacuum being generated in the container itself. Thus a
negative pressure is avoided. The vacuum could implode the container (squeeze) and can
cause it to break. The container would leak and the liquid would ow out.
The pressure ratio is 1:1. Therefore the pressure generated by the pump is equal to the
input air pressure.

14
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
4.2.8 NOISE RISK
4.2.9 MATERIAL CHEMICAL COMPATIBILITY
4.2.10 EMERGENCY STOP
4.2.11 TIGHTNESS CHECK
4.2.12 MAINTENANCE
Make sure that the pump's construction materials are chemically compatible with the uid
to be pumped. A wrong choice can cause harm to persons (as a result of the inuence of
harmful products and products which irritate skin) as well as polluting the environment,
along with premature damage to the pump and its hoses.
To quickly stop the unit in case of an emergency, close the air cut-o valve or the pressure
regulator to interrupt the air supply to the pump’s motor. The cut-o valve is not supplied
with the pump. It must be provided and properly installed by the user.
Caution:The pneumatic pumps' delivery circuits can remain pressurized, even when the air
cut-o valve is closed.
When using the pump after a long period of inactivity, check tightness of all parts subject
to pressure.
Depending on the type of use and the substances used, the user has to check for the
presence of deposits on the pump as well as check its cleanliness at regular intervals and
the state of wear of the components and proper operation of the pump assembly.
The operation must be carried out in conformity with what is written in this manual.
4.2.7 EXPLOSION HAZARD
Never use chloride or halogenated solvents (such as trichloroethane and methylene
chloride) with units containing aluminium or galvanized and zinc-plated parts. They may
react chemically thus producing an explosion danger.
Read the classication and information leaet concerning the product and solvent to be
used.
In some working conditions, the pump can be particularly noisy: for example when the
compressed air supply is high and when there is no pressure or a very low pressure in the
pumped uid (free ow operation). In these cases, all personnel working next to the pump
shall wear adequate individual protections and/or use valves and seats in plastic material,
provided the working conditions and the compatibility with the pumped uid allow it.

15
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
4.3.1 SAFETY REGULATIONS
4.3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS
Only the pneumatic double diaphragm metallic pumps (aluminium) can be used in
explosion hazard zones. The following safety regulations must be observed and followed.
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.
Ignition temperature of the pumped material
Check that the ignition temperature of the pumped material is higher than the max.
allowable surface temperature.
Medium supporting atomizing
To atomize the material, use only weakly oxidizing gases, e.g. air.
Surface spraying, electrostatic
Do not spray system parts with electrostatic.
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.

16
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
4.3.2 OPERATION WITHOUT FLUID
4.3.3 MAXIMUM SURFACE TEMPERATURE
4.3.4 MAXIMUM SURFACE TEMPERATURE  EXOTHERMIC REACTIONS
4.3.5 CONNECTION PIPES
4.3.6 PUMP PROTECTION
Avoid running the pump sucking air (without uid inside). The air, combined with the
vapor of ammable uids, can generate internal areas with an explosion hazard.
Periodically check that the pump is working regularly, paying special attention to the
presence of air in the pumped uid, which may be caused by a breakage in the pump.
Avoid operating the pump with damaged diaphragms.
The maximum surface temperature of the pump depends on the temperature of the
pumped uid, that must not exceed the values indicated in the "Technical Data" chapter.
Fluids incompatible with the pump’s materials or particularly reactive mixtures of products
with several components may cause exothermic reactions and develop dangerous
temperatures or pressure.
Connection pipes must be made of conductive material and properly grounded.
If the pumping uids contain solid particles, install a lter on the intake circuit. This
prevents particles, that are large enough to damage the internal parts of the pump, from
entering. Refer to the Technical Data chapter to verify the maximum size of solids that can
be pumped.
Keep metal surfaces clean. Electric conductivity of the surfaces is essential for explosion
protection.
Frequently clean the equipment so as to prevent insulating substance residue from
accumulating.
Do not use rusted parts or metal tools that may cause sparks of a mechanical origin inside
the explosion hazard area.

17
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
5 DESCRIPTION
5.1 AREAS OF APPLICATION
5.2 SCOPE OF DELIVERY
Abrasive materials and pigments!
Greater wear of parts carrying the material.
Use the application-oriented model (ow rate/cycle, material, valves, etc.) as
indicated in Chapter 5.3.2.
Check if the uids and solvents used are compatible with the pump construction
materials as indicated in Chapter 5.3.1.
NOTICE
- Diaphragm pump
CE Conformity see Chapter 11
Operating manual, German Order No.: 2335746
Operating manual for other languages see Chapter 1
The delivery note shows the exact scope of delivery.

18
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
5.3 DATA
5.3.1 MATERIALS OF THE FLUID TRANSPORTING PARTS
Order No. Pump body Diaphragm Diaphragm disc Valve seat Valve ball O-rings
U509.A0 Aluminum PTFE Stainless steel Stainless steel Stainless steel EPDM
U509.A0A Aluminum,
nickel coated
PTFE Stainless steel Stainless steel Stainless steel EPDM
Positions of the individual parts: see spare parts list.
Outgoing air containing oil!
Risk of poisoning if inhaled.
Air motor switching problems.
Provide compressed air free from oil and water
(Quality Standard 5.5.4 according to ISO 8573.1)
5.5.4 = 40 μm / +7 / 5 mg/m³.
WARNING

19
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
Description Unit
Wetted parts materials
Aluminum Aluminum, nickel coated
Transmission ratio 1:1
Flow volume per double stroke (DH) cm³ 500
cc
Maximum operating pressure MPa 1.0
bar 10
psi 145
Maximum possible speed DH/min 150
Maximum ow rate l/min 75
(free ow - ooded inlet) GPM 19.8
Minimum air inlet pressure MPa 0.2
bar 2.0
psi 29
Maximum air inlet pressure MPa 1.0
bar 10
psi 145
Air inlet connection (male) BSP(R) 1/4"
Maximum suction height (1) m 6.0
ft 19.5
Maximum solid body size mm 3.5
inches 0.14
Sound pressure equivalent
40 cycles/min. (feeding 6 bar) (2) dB(A) 81
Fluid connections
(inlet & outlet bush) BSP(G) 1"
Weight kg 13.8
lb 30.5
Maximum material pressure at the
pump's inlet
MPa 0.1
bar 1
psi 14.5
Material temperature °C +4 ÷ 90
°F +39 ÷ 194
Ambient temperature °C +4 ÷ +40
°F +39 ÷ +104
Allowable inclination for operation 10°
(1) Start condition: Empty pump / dry valves
(2) LqA (10s)
5.3.2 TECHNICAL DATA

20
D
C
AB
F
H
J
K
B_04201
E
G
J
OPERATING MANUAL
VERSION 01/2013 ORDER NUMBER DOC 2335747
5.3.3 DIMENSIONS AND CONNECTIONS
mm; inch
344; 13.54
210; 8.27
359; 14.13
279; 10.98
200; 7.87
120; 4.72
250; 9.84
150; 5.90
G1" F
G1/4"