WAGNER PROTEC 95-150 Installation instructions

PROTEC 95-150
PROTEC 72-200
PROTEC 60-240
Tiger 72-300
Icebreaker Piston Pumps
Protective Coating (PC)
Flow rate 150 cm3 – 300 cm3
Version 01/2020
B_07657

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VERSION 01/2020 ORDER NUMBER DOC2340282 IceBreaker 150-300 cm3
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 6
1.4 Service Manual 7
1.5 Continuous-ow heater operating manual 7
1.6 Abbreviations 7
1.7 Terminology for the Purpose of this Manual 7
2 CORRECT USE 8
2.1 Device Types 8
2.2 Type of Use 8
2.3 For Use in Potentially Explosive Areas 9
2.4 Processible Working Materials 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Identication "X" 10
3.3 Type plates 11
4 BASIC SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Equipment 12
4.1.2 A Safe Work Environment 12
4.1.3 Personnel Qualications 13
4.2 Safety Instructions for the Personnel 14
4.2.1 Personal Safety Equipment 14
4.2.2 Safe Handling of WAGNER Spray Devices 14
4.2.3 Grounding the Device 15
4.2.4 Product hose 16
4.2.5 Cleaning and Flushing 16
4.2.6 Touching Hot Surfaces 18
4.2.7 Maintenance and Repair 18
4.2.8 Protective and Monitoring Equipment 18
5 DESCRIPTION 19
5.1 Components 19
5.2 Mode of Operation 20
5.2.1 Air motor 20
5.2.2 Fluid section 20
5.3 Protective and monitoring equipment 21
5.4 Scope of delivery 21
5.5 Data 21
5.5.1 Materials of Paint-wetted Parts 21
5.5.2 Recommended Packings 21
5.5.3 Technical Data for PROTEC 22
5.5.4 Dimensions and Connections for PROTEC 95-150 and 72-200 23
5.5.5 Dimensions and Connections for PROTEC 60-240 24
5.5.6 Technical Data for Tiger 25
5.5.7 Dimensions and Connections for Tiger 26

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5.5.8 Volume Flow 28
5.5.9 Performance diagrams 29
5.6 Operating elements 48
5.6.1 Pressure Regulator Unit 48
5.7 Product Filter and Return Line 48
5.7.1 High-pressure lter (Option) 48
5.8 PC Air Filter Set (Option) 49
5.9 PC Heater Set (Option) 50
5.10 Feed Pump (Option) 51
6 ASSEMBLY AND COMMISSIONING 52
6.1 Training of Assembly/Commissioning Personnel 52
6.2 Storage Conditions 52
6.3 Installation Conditions 53
6.4 Transportation 53
6.5 Assembly and Installation 53
6.5.1 Ventilation of the Spray Booth 54
6.5.2 Air Supply Lines 54
6.5.3 Product supply lines 54
6.6 Grounding 55
6.7 Commissioning 57
7 OPERATION 58
7.1 Training the Operating Personnel 58
7.2 Emergency Stop 58
7.3 Tasks 58
7.4 Pressure Relief / Work Interruption 59
7.5 Basic Flushing 60
7.5.1 Filling with Working Product 61
8 CLEANING AND MAINTENANCE 61
8.1 Cleaning 61
8.1.1 Cleaning Personnel 61
8.1.2 Decommissioning and Cleaning 61
8.1.3 Long-term Storage 61
8.2 Maintenance 62
8.2.1 Maintenance Personnel 62
8.2.2 Safety instructions 62
8.2.3 Safety Checks and Maintenance Work 62
8.2.4 Emptying Pump 64
8.2.5 Filling the Empty Pump 65
8.2.6 Cleaning and Replacing the High-pressure Filter 66
9 TROUBLESHOOTING AND RECTIFICATION 67
10 REPAIR WORK 69
10.1 Repair Personnel 69
10.2 Repair Notes 69
10.3 Tools 70
10.4 Cleaning the Parts After Disassembly 70
10.5 Assembly of the Device 70

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11 FUNCTION TEST AFTER REPAIR WORK 70
12 DISPOSAL 71
13 ACCESSORIES 71
13.1 Accessories for Product Output 71
13.2 Accessories for Product Input 72
13.2.1 Suction hose 72
13.2.2 20 Liter Tank 73
13.3 Accessories for Trolley and Wall Mount 74
14 SPARE PARTS 75
14.1 How Can Spare Parts Be Ordered? 75
14.2 Overview of the PROTEC Components (For Version without Stroke Sensor) 75
14.3 Overview of the PROTEC TC Components (For Version with Stroke Sensor) 77
14.4 Overview of the Tiger Components (For Version without Stroke Sensor) 78
14.5 Overview of the Tiger TC Components (For Version with Stroke Sensor) 79
14.6 Air Motors 81
14.6.1 10" PROTEC Air Motor 81
14.6.2 Air Motor Regulator for PROTEC 81
14.6.3 12" Tiger Air Motor 81
14.6.4 Tiger Air Motor Regulator 81
14.6.5 Connection Sets (For Version without Stroke Sensor) 81
14.6.6 Connection Sets TC (For Version with Stroke Sensor) 81
14.6.7 Connection set, LM-FS 10 81
14.7 Fluid Sections 81
14.7.1 Fluid section 150 cm3 81
14.7.2 Fluid Section 200 cm3– 240 cm3 81
14.7.3 Fluid section 300 cm3 81
14.8 High-pressure lter 81
14.9 DN38 Suction Hose 81
14.10 PC Suction Tube 81
14.11 PC heavy duty trolley 81
14.11.1 PC air lter set 81
14.11.2 PC heater set 81
15 EU DECLARATION OF CONFORMITY 81

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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.
Notice 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.
1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2340281
Translation of the original operating manual
Language Order no. Language Order no.
English 2340282 Russian 2351798
French 2340285 Turkish 2386997
Italian 2340284 Japanese 2359824
Spanish 2340286 Dutch 2367470
Finnish 2391504 Swedish 2391503
Additional languages on request or at: www.wagner-group.com

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1.4 SERVICE MANUAL
The service manual is available in the following languages:
Language Order no. Language Order no.
German 2335993 English 2335994
Additional languages on request or at: www.wagner-group.com
1.5 CONTINUOUSFLOW HEATER OPERATING MANUAL
The operating manual Continuous-ow heater is available in the following languages:
Language Order no. Language Order no.
German 65860 English 65860
French 65860 Italian 65860
Additional languages on request or at: www.wagner-group.com
1.6 ABBREVIATIONS
Number of pieces Double stroke
Position DN Nominal diameter
Marking in the spare parts lists PN Nominal pressure
Order no. Order number Two components
Ultra-high molecular weight polyethylene PTFE
Polytetrauorethylene Stainless steel
PTFE with graphite polyethylene
: Heavy duty corrosion
protection
Leather
1.7 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 ushing agent.
Product pressure
generator
Pump or pressure tank.
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
accordance with TRBS
1203
(2010/Revision 2012)
A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the areas of explosion protection, protection
from pressure hazards and electric hazards (if applicable) 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.

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2 CORRECT USE
2.1 DEVICE TYPES
Pneumatic pump with spraypack:
PROTEC Tiger
95-150 72-300
72-200 --
60-240 --
2.2 TYPE OF USE
The device is suitable for processing liquid products like paints and lacquers:
– Non-ignitable products.
– Products in accordance with their classication in explosion class IIB.
WAGNER explicitly prohibits any other use!
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.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device can be employed in explosion hazard zones (Zone 1) (see Chapter 3).

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2.4 PROCESSIBLE WORKING MATERIALS
Fluid materials like paints and lacquers.
Application
Water-dilutable products
Solvent-based products
Primers
Epoxy and polyurethane lacquers, phenolic
lacquers
Underside protection, re protection materials
recommended limited suitability not suitable
NOTICE
Abrasive working materials and pigments!
Greater wear of product-wetted parts.
Use the application-oriented model (ow rate/cycle, product, valves, etc.) as
indicated in Chapter 5.5.
Check if the uids and solvents used are compatible with the pump construction
materials as indicated in Chapter 5.5.1.
Use suitable device combinations (packings, valves etc.)
Wear caused by abrasive working materials is not covered by the warranty.
Typical applications
Application
Steel-processing industry
Rail vehicle
Shipbuilding
Tank construction
Pipeline construction
Wind energy
recommended limited suitability not suitable
MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
No dry coating products, e.g., powder are processed.
no food, medicine or cosmetics are processed.
It is important to note that the device's materials are not food-safe.

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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device types: IceBreaker piston pump
PROTEC 95-150
PROTEC 72-200
PROTEC 60-240
Tiger 72-300
Manufacturer: Wagner International AG
CH-9450 Altstätten, Switzerland
European Communities
Symbol for explosion protection
Device class II
Category 2 (zone 1)
Ex-atmosphere gas
Explosion protection
Ignition protection for non-electrical devices
Explosion group
Maximum surface temperature < 200 °C; 392 °F (without drying protection
active)
Maximum surface temperature < 135 °C; 275 °F (with drying protection
active)
High safety level
There are special instructions to ensure safe operation.
See the following Chapter "Identication X".
3.2 IDENTIFICATION "X"
The maximum surface temperature corresponds to the permissible product temperature.
This and the permissible ambient temperature can be found in Chapter 5.5.3 and 5.5.6
(Technical data regarding the Jaguar, Tiger and PROTEC pumps).
Safe Handling of WAGNER Spray Devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
knocking or pushing metal against metal is to be avoided;
Do not drop the device or components.
Maximum surface temperature
The maximum surface temperature 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.
Ignition temperature of the coating product
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 range is: 5 °C to 50 °C; 41 °F to 122 °F.

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Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Electrostatic surface spraying
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.
Air in the pump uid
Ignitable gas mixtures can form if air enters 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
Ignitable gas mixtures can form in the uid section or product hoses if the pump must
be emptied for maintenance and/or repair purposes.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
3.3 TYPE PLATES
Designation
1 Manufacturer and CE identication
2 Pump type
3 Maximum product pressure
4 Pump ratio
5 Flow rate per double stroke
6 Maximum air inlet pressure
7 Maximum product temperature
8 Model year - serial number
9 Read the operating manual before use
1
2
4
5
6
7
8
9
3
B_06856
Pumpentyp / Pump type
Max. Materialdruck / Fluid pressure
Übersetzungsverhältnis / Ratio
Fördermenge DH / Delivery DS
Max. Luftdruck / Air pressure
Max. Temp. Material / Fluid
Baujahr - Serie Nr. / Year of manufacture - Serial No.
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
Wagner International AG
MADE IN SWITZERLAND
CH-9450 ALTSTÄTTEN
II 2 G Ex h IIB T3/T4 Gb X

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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.
Always follow local regulations 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 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.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
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. 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.
4.1.2 A SAFE WORK ENVIRONMENT
Danger due to dangerous uids or vapors!
Severe or fatal injuries due to explosion danger or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 M).
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 product hoses/air hoses adapted to the working pressure are used.
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 M.
Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun's handle or its trigger.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 M.
Ensure that there are no ignition sources such as naked ames, sparks, glowing
wires, or hot surfaces in the vicinity. No smoking.

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Ensure that the pipe joints, hoses, equipment parts and connections are
permanently, technically leak-proof:
- Periodic preventative maintenance and service (replacing hoses, checking tight-
ness strength of the 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.
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.
4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always observe the information in this manual, particularly the safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention regulations.
In electrostatics applications: anyone who belongs to a risk group according to EMF
Directive 2013/35/EU (e.g., those with active implants), must not enter the high-
voltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Danger due to dangerous uids or vapors!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
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 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 spray booth
or on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.

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4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Danger due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of
lacquer or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
− Secure the 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.
If necessary or at least every 12 months, the liquid ejection devices must be
checked for safe working conditions by an expert (e.g., WAGNER Service Technician)
in accordance with the guidelines for liquid ejection devices (ZH 1/406 and DGUV
100-500 Chapters 2.29 and 2.36).
− For shut-down devices, the check can be postponed until the next start-up.
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
Danger due to recoil forces!
Actuating the trigger can causes strong recoil forces. Thereby, the user can lose his
balance and injure himself when falling.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
4.2.3 GROUNDING THE DEVICE
Danger due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that all devices and tanks are grounded before each spraying process.
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's handle or its trigger.

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4.2.4 PRODUCT HOSE
Danger due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
Ensure that the hose material is chemically resistant to the sprayed products and
the ushing agents used.
Ensure that the product hose and the ttings are 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
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
− on hot surfaces
Ensure that the hoses are never run over by vehicles (e.g., fork lift trucks), 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.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 M.
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. In this way 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 input air pressure.

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4.2.5 CLEANING AND FLUSHING
Danger due to cleaning and ushing!
Explosion hazard and damage to the device.
Preference should be given to non-ignitable 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.
Never use chloride or halogenated solvents (such as trichloroethane and methylene
chloride) with devices containing aluminium or galvanized/zinc-plated parts. They
may react chemically thus producing an explosion danger.
Take measures for workplace safety (see Chapter 4.1.2).
When commissioning or emptying the device, please note that:
−depending upon the coating product used,
−depending on the ushing agent (solvent) used.
an explosive mixture may temporarily exist inside the lines and components of
equipment.
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:
Relieve the pressure from the device.
De-energize the device electrically.
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 spray gun. Cleaning the device must not
damage it in any way.
Ensure that no electric component is cleaned with or immersed into solvent.
4.2.6 TOUCHING HOT SURFACES
Danger due to hot surfaces because of hot coating products!
Risk of burn injuries
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 device with a warning label "Warning – hot surface".
Order no.
9998910 instruction label
9998911 protection label
Note: Order the two stickers together.

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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 13 and Chapter 14 that are
assigned to the device.
Do not use any defective components.
Exclusively use accessories listed in Chapter 13 and that are assigned to the unit.
Before all work on the device and in the event of work interruptions:
− Relieve the pressure from the spray gun, high-pressure hoses and all devices.
− Secure the spray gun against actuation.
− Switch o the energy and compressed air supply.
− Disconnect the control unit from the mains.
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 COMPONENTS
B_07646
10
9
8
7
5
3
2
1
4
11
6
Designation
1 Control housing with integrated silencer
2 Air pressure regulator
3 Ball valve
4 Air motor
5 Compressed air input
6 Mounting ange
7 Separating agent cup
8 Product output
9 Fluid section
10 Product input
11 Grounding connection
5.2 MODE OF OPERATION
The piston pump is driven with compressed air (2). This compressed air moves the air
piston up and down in the air motor (4) and it also moves the associated pump piston up
and down in the uid section (9).
In the control housing (1), the air pressure is redirected at the end of each stroke with the
help of the reversing valve. The working material is sucked up during the upwards stroke
and is continuously conveyed towards the product outlet (8) in both stroke directions.
5.2.1 AIR MOTOR
The air motor (4) with its pneumatic reverse (1) does not require pneumatic oil.
The compressed air is fed to the motor via the air regulator (2) and the ball valve (3).
The air motor (4) is tted with a safety valve in accordance with Chapter 5.3.
5.2.2 FLUID SECTION
The uid section (9) has been designed as a piston pump with exchangeable ball valves.
The hard chrome-plated pump piston runs in two xed packings which are self-adjusting
by means of a pressure spring, thus resulting in a long service life.
Between the air motor (4) and the uid section (9) there is a separating agent cup (7) for
holding the separating agent.

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VERSION 01/2020 ORDER NUMBER DOC2340282 IceBreaker 150-300 cm3
5.3 PROTECTIVE AND MONITORING EQUIPMENT
WARNING
Overpressure!
Danger to life from bursting device components.
Never change the safety valve setting.
The air motor is tted with a safety valve. The safety valve has been set and sealed at the
factory. In case of pressures over and above the permissible operating pressure, the valve,
which is held with a spring, automatically opens and releases the excess pressure.
5.4 SCOPE OF DELIVERY
Consists of:
– Fluid section
– Air motor
– Connection elements
– Air pressure regulator for air motor
The standard equipment includes:
Order no. Designation
1 9992504 Separating agent 250 ml; 250 cc
1 see Chapter 15 Declaration of Conformity
1 2340281 Operating manual, in German
1 see Chapter 1.3 Operating manual in the local language
The delivery note shows the exact scope of delivery. Accessories: see Chapter 13.

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VERSION 01/2020 ORDER NUMBER DOC2340282 IceBreaker 150-300 cm3
5.5 DATA
5.5.1 MATERIALS OF PAINTWETTED PARTS
Paint-wetted part Product
Housing Stainless steel
Piston Stainless steel and hard chrome
Valve balls Stainless steel
Valve seats Carbide
O-rings PTFE
Packings Standard
= Ultra high molecular weight polyethylene
= PTFE with graphite
5.5.2 RECOMMENDED PACKINGS
WAGNER packings are manufactured in four dierent materials:
Product Color
Leather dark brown
PTFE with graphite black
Ultra high molecular weight polyethylene transparent
PTFE white
Each product has the following properties, which inuence the packings:
Designation
Mechanical stability poor good good poor
Friction coecient poor very good good very good
Sealing force good* good good good
Chemical resistance poor good very good very good
Temperature resistance good poor - good very good poor
for abrasive products
Standard combinations
Standard pumps:
Heavy duty (high-pressure) pumps:
Hardener pumps in 2K systems: