WAGNER PM500 Operating Manual
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WAGNER PM500 Operating Manual

WAGNER PM500 Operating Manual

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

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Summary of Contents for WAGNER PM500

  • Page 1 Translation of the Original Operating Manual Version 01/2013 Pneumatic Double Diaphragm Pump PM500 B_04200...

  • Page 3: Table Of Contents

    Safety Instructions for the Operator 4.1.1 Electrical Equipment 4.1.2 Personnel Qualifi cations 4.1.3 Safe Work Environment Safety Instructions for Staff 4.2.1 Safe Handling of WAGNER Spray Devices 4.2.2 Grounding the Unit 4.2.3 Material Hoses 4.2.4 Cleaning 4.2.5 Handling Hazardous Liquids, Varnishes and Paints 4.2.6...
  • Page 4 Cleaning / Replacement of the Suction and Delivery Non-Return Valves Replacement of the Reversing Valve Material Hoses Decommissioning SPARE PARTS 10.1 How Can Spare Parts Be Ordered? 10.2 PM500 Pump GUARANTEE AND CONFORMITY DECLARATIONS 11.1 Important Notes Regarding Product Liability 11.2 Warranty Claim 11.3 CE Declaration of Conformity...

  • Page 5: About These Instructions

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL ABOUT THESE INSTRUCTIONS 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 operating and service staff .

  • Page 6: Languages

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL LANGUAGES 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 ABBREVIATIONS IN THE TEXT Number of pieces Position Marking in the spare parts lists Order No.

  • Page 7: Correct Use

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL CORRECT USE DEVICE TYPES Metallic versions (aluminum): Pneumatic double diaphragm pumps with Order No. U509.A0 U509.A0A TYPE OF USE The device is suitable for processing liquid materials like paints and varnishes in accordance with the classifi cation into explosion classes IIA or IIB.

  • Page 8: Safety Parameters

    OPERATING MANUAL 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 fi xtures.

  • Page 9: Reasonably Foreseeable Misuse

    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. RESIDUAL RISKS Residual risks are risks which cannot be excluded even in the event of correct use.

  • Page 10: Identification

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL IDENTIFICATION EXPLOSION PROTECTION IDENTIFICATION Metallic versions (aluminum): Pneumatic double diaphragm pumps with Order No. U509.A0 U509.A0A As defi ned in the Directive 94/9/EC (ATEX 95), the device is suitable for use in areas where there is an explosion hazard.

  • Page 11: General Safety Instructions

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS 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 infl uences.

  • Page 12: Safe Handling Of Wagner Spray Devices

    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).

  • Page 13: Cleaning

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL Several liquids have a high expansion coeffi cient. In some cases its volume can rise with consequent damage to hoses, fi ttings and cause fl 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.

  • Page 14: Explosion Hazard

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING 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 classifi cation and information leafl et concerning the product and solvent to be used.

  • Page 15: Use In Areas Subject To Explosion Hazards

    The following safety regulations must be observed and followed. 4.3.1 SAFETY REGULATIONS 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.

  • Page 16: Operation Without Fluid

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL 4.3.2 OPERATION WITHOUT FLUID Avoid running the pump sucking air (without fl uid inside). The air, combined with the vapor of fl ammable fl 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 fl uid, which may be caused by a breakage in the pump.

  • Page 17: Description

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL DESCRIPTION AREAS OF APPLICATION NOTICE Abrasive materials and pigments! Greater wear of parts carrying the material. Use the application-oriented model (fl ow rate/cycle, material, valves, etc.) as indicated in Chapter 5.3.2. Check if the fl uids and solvents used are compatible with the pump construction materials as indicated in Chapter 5.3.1.

  • Page 18: Data

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL 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, PTFE Stainless steel Stainless steel Stainless steel EPDM...

  • Page 19: Technical Data

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL 5.3.2 TECHNICAL DATA Description Unit Wetted parts materials Transmission ratio Flow volume per double stroke (DH) cm³ Maximum operating pressure Maximum possible speed DH/min Maximum fl ow rate l/min (free fl ow - fl ooded inlet) 19.8 Minimum air inlet pressure Maximum air inlet pressure...

  • Page 20: Dimensions And Connections

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL 5.3.3 DIMENSIONS AND CONNECTIONS B_04201 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"...

  • Page 21: Performance Diagrams

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL 5.3.4 PERFORMANCE DIAGRAMS Example Material fl ow volume - water l/min <gpm> Diagram PM500 bar (MPa) nl/min <psi> <scfm> 10 (1.0) <145> <26.9> 8.0 (0.8) <10.7> <116> 6.0 (0.6) <8.0> <87> 4.0 (0.4) <5.4>...

  • Page 22: Mode Of Operation

    (C) prevents the liquid from fl owing back, thus producing the suction and delivery phases in each pumping chamber, and generating the pumping eff ect. The PM500 models are equipped with a safety valve that opens when the maximum allowed value of compressed air supply is exceeded.

  • Page 23: Assembly And Commissioning

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL ASSEMBLY AND COMMISSIONING TRANSPORTATION The pump may be moved manually, without lifts and cranes. STORAGE Store the pump in a closed and dry environment. Thoroughly clean the pump, if a long-term decommissioning is planned. When resuming pump operation, proceed as described in the following sections.
  • Page 24 VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL Material delivery valve Material hose Delivery manifold Material return valve Air pressure regulator Safety valve Air cut-off valve Suction hose Suction manifold Air suction fi lter B_04205 Material connection: Connect the pump's suction hose (on the underside) to the suction manifold. Connect it to the material hose's delivery manifold (on the upper side).
  • Page 25 Reversing valve: The pump's reversing valve does not need any lubrication. Safety valve: The PM500 models are equipped with a safety valve that opens when the maximum allowed value of compressed air supply is exceeded. Non-return valve: If the pump has been installed on a higher level than the liquid to be pumped, it is...
  • Page 26 OPERATING MANUAL Installation of the air cut-off valve (1) for the emergency stop: For the PM500 double diaphragm pump, an external air cut-off valve (1) must be installed before the fi lter pressure regulator (4) for the emergency stop is installed.

  • Page 27: Grounding

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL GROUNDING WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic sparks. Clean the pump only with a damp cloth. WARNING Heavy paint mist if grounding is insuffi cient! Danger of poisoning.

  • Page 28: Version 01/2013 Order Number Doc

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL The grounding connection is mandatory with PM500 pumps. B_04208 Procedure: 1. Remove the crimp connection delivered with the pump. 2. Crimp the grounding cable on the terminal and screw it back onto the pump’s foot.

  • Page 29: Commissioning

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL COMMISSIONING 6.5.1 SAFETY REGULATIONS Before carrying out any work, the following points must be observed in accordance with the operating instructions: - Observe all safety regulations in accordance with Chapter 4. - Carry out commissioning properly. WARNING High pressure spray jet! Danger to life from injecting paint or solvent.

  • Page 30: Preliminary Operations

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL 6.5.2 PRELIMINARY OPERATIONS Preliminary cleaning The pump was tested with oil or other fl uids, depending on the model. Before use, it is necessary to fl ush the pump once using an adequate solvent. Ensure that: - The pressure regulator knob is turned fully counterclockwise (0 bar pressure).

  • Page 31: Unit Pressure Tightness Test

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL Close the return valve, if installed. Discharge Closed (Return line) Opened Delivery Opened B_04212 Let the solvent fl ow through the pump for 2 or 3 minutes. 6.5.3 UNIT PRESSURE TIGHTNESS TEST Close the material delivery valve, once the pump is primed.

  • Page 32: Operation

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL OPERATION OPERATION Suctioning: Make sure that the air pressure regulator knob is turned fully counterclockwise (0 bar pressure). Open the compressed air and material delivery valve, then increase the air pressure until the pump starts.

  • Page 33: Trouble Shooting And Rectification

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL TROUBLE SHOOTING AND RECTIFICATION Problem Cause Remedy Pump does not work. The air motor does not work or Turn the pressure regulator knob clockwise stops. to a minimum of 2 bar. Press the actuation button on one end of the reversing valve until the reversing valve switches over.
  • Page 34 Clean the non-return valves and replace continues to run even in the delivery and suction manifold. them if they are worn. if the air cut-off valve is closed. If the problem is not listed above, consult your WAGNER Service Center.

  • Page 35: Maintenance

    In accordance with the guideline for liquid emitters (ZH 1/406 and BGR  500 Part  2 Chapter 2.36): - The liquid emitters should be checked by an expert (e.g. Wagner service technician) for their safe working conditions as required and at least every 12 months.

  • Page 36: Safety Instructions

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL SAFETY INSTRUCTIONS Prior to maintenance and cleaning measures note: Wear protective clothing and use specifi c protection devices with regard to the nature of the fl uids involved. Close the compressed air supply and release the pressure from the pump and pipes connected to it.
  • Page 37 VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL b) Unscrew the mounting screws from only one of the diaphragm covers. c) Unscrew the central nut and remove the fi rst diaphragm. The diaphragm is composed of two layers: the material side and the air side. 20 Nm 14.8 lbft 25 Nm...

  • Page 38: Diaphragm Replacement (Due To Breakage)

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL DIAPHRAGM REPLACEMENT (DUE TO BREAKAGE) If the diaphragms are replaced as a result of breakage, all the internal parts of the motor must be cleaned and the condition of the seals and reversing valve, which may have been damaged by contact with the pump fl uid, must be checked.
  • Page 39 VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL e) Clamp the end of the shaft released from the diaphragm in a bench vice (with soft jaws to avoid damaging it). Dismount the central nut from the opposite end of the shaft.
  • Page 40 VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL In the following assembly instructions, apply the right torques, greases and glues according to Chapter 10.2! m) Mount one internal diaphragm cover (8) on the motor block, with the appertaining seals and shaft guide bushing. 5.9 lbft B_04221 n) Insert the spring (9) in the cross hole of the shaft, and grease it at the ends.
  • Page 41 VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL q) Rotate the shaft, so that the gap (12) between the two halves of the sliding shoe is aligned with the air connection hole (13). Note: The gap (12) needs to be vertical, when the pump is in the operating position. B_04224 r) Hold the end of the shaft (without inner diaphragm cover) in a bench vice (with soft jaws to avoid damage).

  • Page 42: Cleaning / Replacement Of The Suction And Delivery Non-Return Valves

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL CLEANING / REPLACEMENT OF THE SUCTION AND DELIVERY NON-RETURN VALVES a) Remove the suction and delivery manifold. b) Remove the seals, seats and balls from the diaphragm covers and the manifold's housings. c) Check the condition of wear of the ball guide/stops inside the diaphragm cover and manifold.

  • Page 43: Material Hoses

    VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL MATERIAL HOSES The lifetime of the fl uid hoses is, even with appropriate handling, reduced due to environmental infl uences. Check hoses, pipes and couplings every day and replace if necessary. As a precaution fl uid hoses should be replaced after a period specifi ed by the plant operator.

  • Page 44: Spare Parts

    Incorrect maintenance/repair! Risk of injury and equipment damage. Have repairs and part replacements be carried out only by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 45: Pm500 Pump

    ORDER NUMBER DOC 2335747 OPERATING MANUAL 10.2 PM500 PUMP PM500 U509.A0 U509.A0A Order No. Order No. Designation U509.A0 U509.A0A DDP PM500 paint A327.22 Diaphragm disc A328.01 Motor block A330.04 Piston bushing A331.01 Discharger fl ange A337.08 Sliding shoe block (set) A414.04 Bleed Screw A673.03...
  • Page 46 VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL 20 Nm; 14.8 lbft 5 Nm; 3.7 lbft 2 Nm; 1.5 lbft 5 Nm; 3.7 lbft 45 12 19 36 18 22 1 42 17 8 Nm; 5.9 lbft 20 Nm; 35 31 14.8 lbft 20 Nm;...
  • Page 47 VERSION 01/2013 ORDER NUMBER DOC 2335747 OPERATING MANUAL PM500 U509.A0 U509.A0A Order No. Order No. Designation L126.06 O-ring L151.06 O-ring L107.06 O-ring L123.06 O-ring L116.06 O-ring L127.06 O-ring L408.06 Gasket, DI.18 L415.06 Outlet seal M033.07 Cover 1" M M209.04 Nipple with adjusting collar, 1/4 M218.04...

  • Page 48: Guarantee And Conformity Declarations

    The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with.

  • Page 49: Ce Declaration Of Conformity

    II 2G IIB T4 +4°C Tamb +40°C EC Certifi cate of Conformity The CE certifi cate of conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order No.:...
  • Page 50 DK- 8600 Silkeborg Telephone: +32 (0)2 269 4675 Telephone: +45 70 200 245 Telefax: +32 (0)2 269 7845 Telefax: +45 86 856 027 E-Mail: info@wsb-wagner.be / HP www.wsb-wagner.eu E-Mail info@wagner-industri.com United Kingdom France WAGNER Spraytech (UK) Ltd. J. WAGNER France S.A.R.L.
  • Page 52 Order No. 2335747 People's Republic of China Phone Telefax Germany Phone Telefax E-mail...

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