WAGNER PROTEC 2K Translation Of The Original Operating Manual
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WAGNER PROTEC 2K Translation Of The Original Operating Manual

WAGNER PROTEC 2K Translation Of The Original Operating Manual

2k system protective coating
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2K System
Protective Coating
Translation of the Original
Operating Manual
PROTEC 2K
Version 02/2016
B_05163

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Summary of Contents for WAGNER PROTEC 2K

  • Page 1 Translation of the Original Operating Manual PROTEC 2K Version 02/2016 2K System Protective Coating B_05163...

  • Page 3: Table Of Contents

    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 Device 4.2.3 Product Hoses 4.2.4 Cleaning and Flushing 4.2.5 Handling Hazardous Liquids, Varnishes and Paints 4.2.6...
  • Page 4 Data 5.5.1 Materials of Paint-wetted Parts 5.5.2 Recommended Packings 5.5.3 Technical Data 5.5.3.1 Technical Data for Entire System 5.5.3.2 Technical Data for PROTEC 2K Piston Pump 5.5.4 Dimensions and Weights 5.5.5 Volume fl ow 5.5.6 Performance Diagrams Flow Diagram 5.6.1...
  • Page 5 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Table of Contents Spraying Mode 7.4.1 Preparing 7.4.2 Circulating 7.4.3 2K Spraying 7.4.3.1 Pressure Drop 7.4.3.2 No-Load / Vent Pressure Relief/Work Interruption 7.5.1 Continuing after Work Interruption Intermediate Flushing 7.6.1 Intermediate Flushing with Flushing Pump 7.6.1.1 Relieving Flushing Pump...
  • Page 6 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Table of Contents ACCESSORIES 12.1 Conversion to other Mixing Ratios SPARE PARTS 13.1 How Can Spare Parts Be Ordered? 13.2 Overview 13.2.1 Basic Units 13.2.2 System Overview 13.2.3 Hoses 13.3 Trolley with Grounding, Return Line, and Air Inlet 13.3.1 2K Mechanism Trolley...

  • Page 7: About These Instructions

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 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 the operating and service personnel.

  • Page 8: Languages

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL LANGUAGES The operating manual is available in the following languages: Language Order No. Language Order No. Language Order No. German 2352823 English 2352824 French 2357841 Italian 2357842 Spanish 2357843 Russian 2359374...

  • Page 9: Terminology For The Purpose Of This Manual

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Materials Stainless steel Polyethylene Ultra-high molecular weight polyethylene Polytetrafl uorethylene PTFE with graphite PTFE Leather TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL Cleaning Manual cleaning of devices and device parts with cleaning agent...

  • Page 10: Correct Use

    WAGNER is not liable for any claims. WAGNER accepts no liability for any damage arising from incorrect use. Use the device only to work with the products recommended by WAGNER. Only operate the device as a whole. Do not perform unauthorized conversions or modifi cations to the device.

  • Page 11: Processible Working Materials

    Check if the fl uids and solvents used are compatible with the pump construction materials. For explanations of the models and construction materials, consult the data in Chapter 5.5 or contact a WAGNER service technician. Wear caused by abrasive working materials is not covered by the warranty. RECOMMENDED APPLICATION AREAS...

  • Page 12: Reasonably Foreseeable Misuse

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL REASONABLY FORESEEABLE MISUSE The forms of misuse listed below may result in physical injury or property damage: coating work pieces which are not grounded; performing unauthorized conversions or modifi cations to the device;...

  • Page 13: Identification

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL IDENTIFICATION CE EXPLOSION PROTECTION IDENTIFICATION As defi ned in Directive 94/9/EC (ATEX 95), the device is suitable for use in potentially explosive areas. CE mark (European Communities) Explosion-proof equipment Device class II (not mining)
  • Page 14 Lay all electrical cables with protection from mechanical damage, e.g., not near doors, routes used by industrial trucks etc. 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 15: Type Plate

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL TYPE PLATE The type plate consists of two parts. 1 Manufacturer J. Wagner AG 2 CE identifi cation Made in Switzerland CH 9450 Altstätten 3 System type 4 Serial number of system...

  • Page 16: General Safety Instructions

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 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...

  • Page 17: Safety Instructions For Staff

    In electrostatics application: Anyone fi tted with a pacemaker must not enter the high-voltage area! 4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or fl ushing agents: Never point the spray gun at people.

  • Page 18: Grounding The Device

    VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL If needed, the liquid ejection devices must be checked by experts (e.g., WAGNER service technician) at least every 12 months to ensure they are safe for work in accordance with the DGUV regulation 100-500.

  • Page 19: Cleaning And Flushing

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 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.

  • Page 20: Handling Hazardous Liquids, Varnishes And Paints

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Only electrically conductive tanks may be used for cleaning and fl 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 fl ushing.
  • Page 21 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL...

  • Page 22: Description

    7 Circulation hose B 8 Product tank A 9 Product tank B 10 PROTEC 2K air motor 11 Air motor–fl uid section connection part (movement mechanism) with protection plates 12 Red handle: Spray on/off - Spray off : Upper position (as in illustration)
  • Page 23 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL B_05499...

  • Page 24: Mode Of Operation

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL MODE OF OPERATION The system is suitable for mixing of two-component products. Components A and B A 2K pump consisting of an air motor and two fl uid sections, feeds the two components A and B in a fi xed mixing ratio.
  • Page 25 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Brackets for circulation and return hoses The brackets prevent pressurized hoses from fl ying around. Always secure circulation and return hoses with the locking pin. B_05688 Overpressure protection for circulation valves Both circulation valves A (4) and B (5) for the internal return line are fi tted with an overpressure protection set to 63 MPa;...

  • Page 26: Scope Of Delivery

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL SCOPE OF DELIVERY 2K system comprising: - 2 fl uid sections - Air motor - Air pressure regulator for air motor - Movement mechanism - Sliding tables - Mixing unit - Optional: fl ushing pump...

  • Page 27: Data

    Product hoses A / B PA and FEP Option: Only FEP (see Chapter 13.2.3) PA = Polyamide FEP = Fluorinated ethylene propylene 5.5.2 RECOMMENDED PACKINGS WAGNER packings are manufactured in four diff erent materials: Product Color Leather dark brown PTFE with graphite black...

  • Page 28: Technical Data

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 5.5.3 TECHNICAL DATA 5.5.3.1 TECHNICAL DATA FOR ENTIRE SYSTEM Description Units PROTEC 2K Product inlet 27 liter tank Mixing product outlet External thread NPSM, 3/8" Product pH value 3.5–9 Maximum product viscosity...

  • Page 29: Technical Data For Protec 2K Piston Pump

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 5.5.3.2 TECHNICAL DATA FOR PROTEC 2K PISTON PUMP PROTEC PROTEC PROTEC PROTEC PROTEC 2K75- 2K70- 2K64- 2K77- 2K65- Description Units 150/38 150/50 150/75 110/75 110/110 Mixing ratio 4 : 1 3 : 1 2 : 1 1.5 : 1...

  • Page 30: Dimensions And Weights

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 5.5.4 DIMENSIONS AND WEIGHTS 832 mm 32.76 inch 1201 mm 47.28 inch 1710 mm 67.32 inch 235 mm 9.25 inch 187.5 mm 7.38 inch Transport box Internal dimensions 1220 x 850 x 1760 inch 48.03 x 33.46 x 69.29...

  • Page 31: Volume Flow

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 5.5.5 VOLUME FLOW WAGNER AL nozzles Volume fl ow* in l/min 7 MPa 10 MPa 15 MPa 20 MPa Maximum ranges for 70 bar 100 bar 150 bar 200 bar continuous operation...
  • Page 32 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL PROTEC 2K75-150/38 PROTEC 2K77-110/75 4 : 1 1.5 : 1 bar (MPa) Stroke frequency DH/min nl/min <psi> <scfm> 500 (50) 5000 <7250> <175> 400 (40) 4000 <5800> <140> 300 (30) 3000 <4350>...
  • Page 33 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL PROTEC 2K64-150/75 2 : 1 Stroke frequency DH/min bar (MPa) nl/min <psi> <scfm> 500 (50) 5000 <7250> <175> 400 (40) 4000 <5800> <140> 300 (30) 3000 <4350> <105> 200 (20) 2000 <2900>...

  • Page 34: Flow Diagram

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL FLOW DIAGRAM B_05183 A Fluid section A B Fluid section B 1 2K air pressure regulator 2 2K air ball valve 3 Blue handle: Circulation on/off 4 Circulation valve A with excess pressure...

  • Page 35: Flow Chart With External Mixer And External Circulation

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 5.6.1 FLOW CHART WITH EXTERNAL MIXER AND EXTERNAL CIRCULATION B_05689 50 External mixer (option) 60 + 64 External circulation (option for external mixer) 12 Red handle: Spray on/off 24 Static mixer 61 "External circulation"...

  • Page 36: Pressure Regulator Unit

    - for component B: 2K PC relief combination 5.8.1 HIGH-PRESSURE FILTER 530 BAR A WAGNER high-pressure fi lter is installed to ensure smooth operation. These have been developed especially for WAGNER pneumatic pumps. The fi lter inserts can be exchanged depending on the product to be used.

  • Page 37: Pc Relief Combination, 530 Bar

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 5.8.2 2K PC RELIEF COMBINATION, 530 BAR The component B is fi tted with a 2K PC relief combination. Fluid section B connection 53 MPa Product outlet 530 bar Return line 7687 psi Closed...
  • Page 38 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL...

  • Page 39: External Mixer And External Circulation

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 5.10 EXTERNAL MIXER AND EXTERNAL CIRCULATION 5.10.1 EXTERNAL MIXER (OPTION) The red handle (12) with mixing block and mixing tube is on an external frame rather than being on the trolley. The same applies to ball valve, fl ushing (30, option).

  • Page 40: Hose Selection

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 5.10.2 HOSE SELECTION Hose selection with external mixer The volume ratio of product hoses A and B should match the mixing ratio. If this is not the case, the hoses will respond to changes in pressure at diff erent speeds. One hose will reach the new pressure sooner than the other.

  • Page 41: Throttle Valve (Option)

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 5.10.3 THROTTLE VALVE (OPTION) Short-term mixing errors caused by too great a drop in pressure on the B side can be corrected with a throttle valve. Guideline for using a throttle valve: over-dimensioned B product hoses (see Chapter 5.10.2)

  • Page 42: External Circulation (Option)

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 5.10.4 EXTERNAL CIRCULATION (OPTION) With external circulation, the product can be circulated via the external mixer (50) and returned to the product tank. The external circulation consists of two parts: Two distributors (64) in the external mixer for connecting circulation hoses A and B.
  • Page 43 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Operation The blue handle (3) remains unchanged. The product can therefore be circulated internally on the trolley. The handle positions should be noted for the red handle (12) in the external mixer (see Chapter 5.10.1).

  • Page 44: Feed Pump (Option)

    Main pump The maximum product pressure at Feed pump the pump inlet of the PROTEC 2K fl uid sections may not be exceeded. B_05173 Protection of feed pump If the maximum pressure of the feed pump is lower than the maximum pressure of the main pump, this could be exceeded if the main pump malfunctions.

  • Page 45: Assembly And Commissioning

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL ASSEMBLY AND COMMISSIONING TRAINING ASSEMBLY/COMMISSIONING STAFF The assembly and commissioning staff must have the technical skills to safely commission the device. When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.

  • Page 46: Assembly And Installation

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL ASSEMBLY AND INSTALLATION WARNING Inclined ground! Risk of accidents if the device rolls away/falls. Place the device on horizontal fl oor. The wheels should be fi xed or replaced by levelling feet and secured.

  • Page 47: Grounding

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL GROUNDING WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic sparks. Clean the piston pump only with a damp cloth. Ground all device components. Ground the work pieces to be coated.

  • Page 48: Grounding Schema (Example)

    16 mm2; AWG 6 Spraying stand 16 mm2; AWG 6 Safe operation of the PROTEC 2K system is only guaranteed with a grounding connection. Connect all ground cables using a short and direct route. Ex zone All devices and equipment must be suitable for use in potentially explosive areas.

  • Page 49: Commissioning

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL COMMISSIONING 6.6.1 SAFETY INSTRUCTIONS Observe all safety regulations in accordance with Closed Chapter 4 and Chapter 7.2. Observe all safety regulations in accordance with Chapter 8.1.2 and Chapter 8.2.2. EMERGENCY STOP...

  • Page 50: Operation

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL OPERATION TRAINING THE OPERATING STAFF The operating staff must be qualifi ed to operate the entire system. The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.

  • Page 51: General Rules For Making Adjustments To The Spray Gun

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from fl ying parts. Ensure that the pump and suction system are always completely filled with fl ushing agent or working material.

  • Page 52: Switching Device On And Off

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL SWITCHING DEVICE ON AND OFF 7.3.1 SWITCHING ON DEVICE Ensure that the wheel brake is applied. Ensure that the 2K air ball valve (2) and air ball valve of the fl ushing pump (32) are closed.

  • Page 53: Spraying Mode

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL SPRAYING MODE 7.4.1 PREPARING Prepare the object to be sprayed and the spray gun 1. Prepare the object to be sprayed and the entire work environment for spraying. 2. Secure the spray gun and place the nozzle in the gun.

  • Page 54: Circulating

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 7.4.2 CIRCULATING Circulate working material Internal circulation Important: Prevents the overpressure protection from sticking. 8. Adjust 2K air pressure regulator (1) to approx. 0.05 MPa; 0.5 bar; 7.3 psi. 9. Turn blue handle (3) up.

  • Page 55: Spraying

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 7.4.3 2K SPRAYING Fill spray gun hoses with 2K product 14. Start spraying mode: Turn down red handle (12). 15. Close 2K air pressure regulator (1) (0 MPa; 0 bar; 0 psi). 16. Point the spray gun without nozzle toward the grounded collecting tray and pull off .

  • Page 56: Pressure Drop

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 7.4.3.1 PRESSURE DROP If the pressure drops of the component A or B during spraying: 1. Intermediate fl ushing in accordance with Chapter 7.6. 2. Relieve the pressure according to Chapter 7.5.

  • Page 57: Pressure Relief/Work Interruption

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL PRESSURE RELIEF/WORK INTERRUPTION 1. Turn 2K air pressure regulator (1) down to 0 MPa; 0 bar; 0 psi. 2. Close 2K air ball valve (2). 3. If no longer in spraying mode: Turn down red handle (12).

  • Page 58: Continuing After Work Interruption

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 7.5.1 CONTINUING AFTER WORK INTERRUPTION 1. Visual check: personal safety equipment, grounding and all devices ready to use. Blue handle (3) at bottom. Red handle (12) at top. All circulation and return hoses are secured and lead into the product tanks A or B.

  • Page 59: Intermediate Flushing With Flushing Pump

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 7.6.1 INTERMEDIATE FLUSHING WITH FLUSHING PUMP 1. Visual check: personal safety equipment, grounding and all devices ready to use. Blue handle (3) at bottom. Red handle (12) at top. All circulation and return hoses are secured and lead into the product tanks A or B.

  • Page 60: Relieving Flushing Pump

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 7.6.1.1 RELIEVING FLUSHING PUMP 1. Close the spray gun. 2. Close air ball valve of fl ushing pump. 3. Open fl ushing ball valve (30). 4. Relieve pressure of the fl ushing pump by opening the gun.

  • Page 61: Intermediate Flushing Without Flushing Pump

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 7.6.2 INTERMEDIATE FLUSHING WITHOUT FLUSHING PUMP 1. Visual check: personal safety equipment, grounding and all devices ready to use. Blue handle (3) at bottom. Red handle (12) at top. All circulation and return hoses are secured and lead into the product tanks A or B.

  • Page 62: Paint Or Hardener Change

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL PAINT OR HARDENER CHANGE 1. Intermediate fl ushing in accordance with Chapter 7.6. 2. Paint change fl ushing in accordance with Chapter 7.7.1. 3. Empty 2K pump according to Chapter 8.2.4.
  • Page 63 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Circulate fl ushing agent 10. Route circulation hoses (6 and 7) into product tanks A and/or B (no lids). 11. Fill product tank A (8) and if necessary B (9) with approx 2 to 3 liters of fl ushing agent each.
  • Page 64 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL When system with return hoses at the ball valves A and B (17 and 18): circulate via return line A. Guide the return hoses (43 and 44) into the product tanks A or B (no lids).

  • Page 65: Workflow

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL WORKFLOW Commissioning Emergency stop Chapter 6.6 Chapter 7.3.3 Pressure drop Chapter 7.4.3.1 Fill 2K pump with working material No-load / vent Chapter 8.2.5 Chapter 7.4.3.2 Prepare spraying mode Chapter 7.4.1 Circulate Chapter 7.4.2...

  • Page 66: Cleaning And Maintenance

    DANGER Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.

  • Page 67: Decommissioning And Cleaning

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 8.1.4 DECOMMISSIONING AND CLEANING The device should be cleaned for maintenance purposes. Ensure that no remaining product dries on and sticks to the device. 1. Carry out work interruption Chapter 7.5.

  • Page 68: Maintenance

    - Commissioning in accordance with Chapter 6.6. According DGUV regulation 100-500: - The liquid ejection devices should be checked by an expert (e.g., WAGNER service technician) for their safe working conditions as required and at least every 12 months. - For shut down devices, the examination can be suspended until the next start-up.

  • Page 69: Regular Maintenance Work

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 8.2.3 REGULAR MAINTENANCE WORK Daily and as required 1. Check the level of separating agent in the separating agent cup every day, and top up if necessary. 2. Check hoses, pipes, and couplings every day and replace if necessary.

  • Page 70: Draining Condensate From Water Separator

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 8.2.3.2 DRAINING CONDENSATE FROM WATER SEPARATOR Frequently drain the condensate that may accumulate in the water separator (22). Make sure the water level in the fi lter cup never reaches the max. level marked on the cup itself.

  • Page 71: Emptying Device

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 8.2.4 EMPTYING DEVICE WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from fl ying parts. Ignition of potentially explosive surrounding atmosphere. Empty the device slowly and in a controlled manner.
  • Page 72 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL With external circulation (option) A. Turn "External circulation" handle (61) down. B. Slowly open 2K air ball valve (2). Be ready for the switch from working material to air. C. As soon as working material is no longer fl owing out of the circulation hoses (6 and 7), close the ball valve (2).

  • Page 73: Filling Empty Device

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 8.2.5 FILLING EMPTY DEVICE WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from fl ying parts. Ignition of potentially explosive surrounding atmosphere. Empty and fi ll the device slowly and in a controlled manner.

  • Page 74: Cleaning And Replacing The High-Pressure Filter

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 8.2.6 CLEANING AND REPLACING THE HIGH-PRESSURE FILTER Paint change fl ushing Filter installation To clean the high-pressure fi lter or change the fi lter cartridges, position perform paint change fl ushing in accordance with Chapter 7.7.

  • Page 75: Product Hoses, Tubes And Couplings

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 8.2.7 PRODUCT HOSES, TUBES AND COUPLINGS DANGER Bursting hose, bursting threaded joints! Danger to life from injection of product and from fl ying parts. Ensure that the hose material is chemically resistant to the sprayed products and the used fl ushing agents.

  • Page 76: Troubleshooting And Rectification

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL TROUBLESHOOTING AND RECTIFICATION Problem Cause Remedy The pump does not Air motor does not work or stops. Open and close ball valve on the pressure work regulator unit or briefl y disconnect compressed air supply.
  • Page 77 Air emission from leakage hole. The throttle valve must not be operated with Leakage compressed air. Air emission at valve cover. If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service Center.

  • Page 78: Repairs

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL REPAIRS 10.1 REPAIR STAFF Repair work must be carried out carefully and by qualifi ed and trained personnel. They should be informed of specifi c hazards during their training. The repairs must be carried out in accordance with the corresponding service manual.

  • Page 79: Accessories

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL ACCESSORIES Order No. Description Remarks 2352831 Set of 2K PC Including Leopard 35-70 piston pump. fl ushing pumps For details, see Chapter 13.8. 2359293 Attachment kit for For connecting to an external fl ushing pump.
  • Page 80 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Order No. Description Remarks 2353092 External mixer Frame and fi ttings for conversion: 2K PC Red handle, mixing block, and mixing tube are converted from trolley into external mixer. For details, see Chapters 5.10.1 and 13.11.

  • Page 81: Conversion To Other Mixing Ratios

    OPERATING MANUAL 12.1 CONVERSION TO OTHER MIXING RATIOS The PROTEC 2K system can be subsequently converted to a diff erent mixing ratio. For this, depending on the conversion, one or more of the following sets are required: Order No. Conversion set 2352830 Fluid section A 150 cm³...

  • Page 82: Spare Parts

    DANGER Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.

  • Page 83: Overview

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.2 OVERVIEW 13.2.1 BASIC UNITS 1.5:1 Pos System component Order No. ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ Trolley, air motor, 2K mechanism, mixing Fluid section A ✓ ✓ ✓ ✓ ✓ ✓...

  • Page 84: System Overview

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.2.2 SYSTEM OVERVIEW Components and their spare parts Pos Component Spare parts lists Hoses Chapter 13.2.3 Trolley with grounding, return line, and air inlet Chapter 13.3 Product tank A Chapter 13.4 Product tank B (1:1) Product tank B (4:1, 3:1, 2:1, 1.5:1)

  • Page 85: Hoses

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.2.3 HOSES Order No. Designation Core coating From 2334023 HPP hose DN10-PN530 PA W-G 0.53 m 2334457 HPP hose, DN10-PN530 FEP W-G 0.53 m 2334063 HPP hose DN10-PN530 PA W-G 0.73 m 2332865 HPP hose, DN10-PN530 FEP W-G 0.73 m...

  • Page 86: Trolley With Grounding, Return Line, And Air Inlet

    Spare parts list for trolley with grounding, return line, and air inlet Order No. Designation Mechanism trolley 2K 2348231 For details, see Chapter 13.3.1 2352685 Operating sign, PROTEC 2K 2354470 Knurled screw, M6 9900130 Hexagon screw without shaft 236219 Grounding cable, complete 3 m...
  • Page 87 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Grounding for fl ushing pump: See Chapter 13.8 Grounding for air motor B_05404...

  • Page 88: Mechanism Trolley

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.3.1 2K MECHANISM TROLLEY Spare parts list for 2K mechanism trolley Order No. Designation 2348231 Mechanism trolley 2K Mounting bracket 2338235 Plug 9900246 Hexagon screw 9920102 Washer, A8.4 3155404 Contact washer, M8...

  • Page 89: Air Inlet With Water Separator

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.3.2 AIR INLET WITH WATER SEPARATOR Spare parts list for air inlet with water separator Order No. Designation Water separator, complete 9900518 Hexagon socket countersunk head screw 2350854 Extension 3303069 Plug with rim...

  • Page 90: Product Tank A And Product Tank B (1:1)

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.4 PRODUCT TANK A AND PRODUCT TANK B (1:1) Spare parts list for product tanks A and B (1:1) Tank A Tank B (1:1) Designation Order No. Order No. Tank, complete...

  • Page 91: Product Tank B (4:1, 3:1, 2:1, 1.5:1)

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.5 PRODUCT TANK B (4:1, 3:1, 2:1, 1.5:1) Mixing ratio 4:1 / 3:1 / Spare parts list for product tank B (4:1, 3:1, 2:1, 1.5:1) 2:1 / 1.5:1 Designation Order No.

  • Page 92: Mixing

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.6 MIXING Spare parts list for mixing Order No. Designation Mixing, complete 2350342 Handle, blue 2325554 Fillister head screw, M6x12 2352612 Locating screw 9999500 Helical spring, air 2349800 Switching bracket, complete...
  • Page 93 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Remove the mixing elements: The mixing elements are discharged with an iron stick in the lower part of the mixing tube through the socket in direction of the arrow (see fi gure) against the direction of fl ow.

  • Page 94: Mixing Block

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.6.1 MIXING BLOCK Spare parts list for mixing block Order No. Designation 2357789 Mixing block, complete 3676419 Fitting DF-MM-R3/8"-G3/8"-PN530-SSt 2349779 Mixing block 2323718 Fitting-PF-M-R1/4-530 bar-SSt 2324032 Screw plug 2357787 Outlet valve, complete (for details see Chapter 13.6.1.1)

  • Page 95: Mount On Trolley

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.6.2 MOUNT ON TROLLEY Spare parts list for mixing Order No. Designation Mixing, complete For details, see Chapter 13.6. 2345254 Hexagon socket cylinder head screw 9900316 Hexagon socket cap screw, M6x50...

  • Page 96: 2K Pump

    Fluid section A. For details, see Chapter 13.7.3 Fluid section B. For details, see Chapters 13.7.3 or 13.7.4 2K PC relief combination. For details, see Chapter 13.7.5 2358553 HP fi lter, PROTEC 2K. For details, see Chapter 13.7.6 2329019 Fitting-EF-FM-G1 1/2-G1 1/2-PN25-TG 2336489 Fitting DF-MM-G1½"-Rd55x1/6-PN25-CS...
  • Page 97 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 70 Nm; 51.6 lbft 70 Nm; 51.6 lbft 2 present with 1:1 ratio. B_05405...

  • Page 98: Protec Air Motor 10

    Hexagon screw without shaft 9900122 Hexagon screw without shaft 9900150 Shoulder ring 369324 Lifting eye nut 369325 Washer 9925034 WAGNER PROTEC 10 label 2353725 Hood 9 369311 Velcro fastener adhesive part 9999151 Velcro fastener coating part 9999152 Sound deadening pad 9 369319...
  • Page 99 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 140 Nm; 103 lbft 40 Nm; 30 lbft 70 Nm; 52 lbft 10 Nm; 7 lbft ≤ 4 Nm; ≤ 3 lbft 42 43 35 41 40 Nm; 30 lbft Grease all O-rings with Mobilux EP2 (pos.
  • Page 100 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL PROTEC 10" air motor spare parts list Stk Designation Order No. Silencer 9 369310 O-ring 9974165 Socket cap screw; hexagon socket, M8X35 9900314 Washer 8.4 9925029 Connecting part 9 369309 Sound deadening pad 9/12"...
  • Page 101 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL PROTEC 10" air motor spare parts list Stk Designation Order No. Tube 10 2347029 O-ring 9971004 Compressed air tube 10 2347257 Type plate PP3000 Warning label 2332077 Fluid warning label 2332082...

  • Page 102: Air Motor Regulator For Protec 10

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.7.1.1 AIR MOTOR REGULATOR FOR PROTEC 10" B_03937 Spare parts list for air motor regulator for PROTEC 10" Stk Designation Order No. Pressure regulator unit, complete Pressure regulator valve 9–10" 2309974...

  • Page 103: Movement Mechanism

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.7.2 MOVEMENT MECHANISM Spare parts list for movement mechanism Order No. Designation Movement mechanism 2352569 O-ring 9907075 Hexagon socket cylinder head screw 2349530 Air motor plate 2349535 Spacer shaft 2357784 Guide shaft...

  • Page 104: Fluid Sections 110-150 Cm3

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.7.3 FLUID SECTIONS 110–150 CM3  A component B component 150 cm3 110 cm3 110 cm3 Spare parts list for fl uid section 110–150 cm3 Stk Designation Order No. Order No. Order No.
  • Page 105 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Press in pin Apply a little grease 70 Nm ±10 Nm 52 lbft ±7 lbft 100 Nm 74 lbft 160 Nm 118 lbft Apply a little grease B_05411...
  • Page 106 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL A component B component 150 cm3 110 cm3 110 cm3 Spare parts list for fl uid section 110–150 cm3 Stk Designation Order No. Order No. Order No. O-ring 368527 Valve seat inlet 70/150 TC...

  • Page 107: Fluid Sections 38-75 Cm3

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.7.4 FLUID SECTIONS 38–75 CM3  B component 38 cm3 50 cm3 75 cm3 Spare parts list for fl uid sections 38–75 cm3 Stk Designation Order No. Order No. Order No. Fluid section...
  • Page 108 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL B component 38 cm3 50 cm3 75 cm3 Spare parts list for fl uid sections 38–75 cm3 Stk Designation Order No. Order No. Order No. Piston 2353724 2353723 2353721 Wave spring (small)
  • Page 109 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Press in pin 4:1 + 3:1: 40 Nm; 30 lbft 2:1: 60 Nm; 44 lbft Apply a little grease 100 Nm 80 Nm 74 lbft 59 lbft 4:1 + 3:1: 40 Nm; 30 lbft...
  • Page 110 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL...

  • Page 111: 2K Pc Relief Combination

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.7.5 2K PC RELIEF COMBINATION Spare parts list for 2K PC relief combination Order No. Designation Relief combination 2K PC 2350040 Pressure gauge 0-750 bar 9970153 Pressure gauge seal 1/4" 2361702 Exhaust distributor M501.00...

  • Page 112: 2K High-Pressure Filter, 530 Bar With Pressure Gauge

    2K HIGH-PRESSURE FILTER, 530 BAR WITH PRESSURE GAUGE Spare parts list for 2K high-pressure fi lter, 530 bar with pressure gauge Ball valve version in: Stainless steel Stk Designation Order No. HP fi lter, PROTEC 2K 2358553 Pressure gauge 0-750 bar 2350040 Pressure gauge seal 1/4"...
  • Page 113 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Pos 2: Screw in pressure gauge by hand until stop is reached, then turn 1/4  revolution with open-end wrench. Thereafter continue turning the pressure gauge only to align. 140 Nm Do not turn back.

  • Page 114: Flushing Pump / Flushing Pump Connection (Option)

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.8 FLUSHING PUMP / FLUSHING PUMP CONNECTION (OPTION) Attachment Set of fl ushing Spare parts list for fl ushing pump / fl ushing pump connection kit for external pumps fl ushing pump K Designation Order No.
  • Page 115 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL R1/4" G1/4" G1/4" B_05418 * Flow direction...

  • Page 116: Heater (Option)

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.9 HEATER (OPTION) 13.9.1 HEATER WITHOUT RETURN LINE Suitable for external mixer with circulation. - A-side: If there is no external circulation, the A component may not heat up during circulation.
  • Page 117 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Heater on trolley Grounding: see Chapter 6.5.1 Heater for B component Heater for A component Thermometer is mounted at the heater output (above). B_05499 Hose connections for heater A B_05554 Hose connections for heater B...

  • Page 118: Heater With Return Line

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.9.2 HEATER WITH RETURN LINE Heater spare parts list Heater A Heater B Designation Order No. Order No. 2K PC heater set 2356998 2352832 Heater Ex A 32, 1-circuit (for details and spare parts, see the 65021 operating manual, continuous-fl ow heater, Order No.
  • Page 119 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 30 * 14 15 Fluid section output B component: Pos 8 on circulation valve) Grounding of frame (see Chapter 6.5.1) to the grounding connection of heater B_05640 * Grease all stainless steel connections with Molykote .
  • Page 120 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL...

  • Page 121: Return Flow Set Hp Filter A And B (Option)

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.10 RETURN FLOW SET HP FILTER A AND B (OPTION) B_05551 Spare parts list for "return fl ow set HP fi lter A/B" Order No. Designation 2359323 Return fl ow set HP fi lter A/B 2353343 Return tube G1/4", 90°...

  • Page 122: External Mixer

    Spare parts list for "External mixer 2K PC" Order No. Designation 2353092 External mixer 2K PC 2365814 Frame for external mixer Protec 2K 2360983 Spacer plate for mixing tube mount 2360974 Spacer plate mixing block 9900316 Hexagon socket cylinder head screw...
  • Page 123 PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL Red handle with ball valves, mixing block, and mixing tube: For spare parts, see Chapter 13.6 1/2" connection A (pos 14) * 3/8" connection A (pos 12) 3/8" connection B (pos 12) 1/4"...

  • Page 124: Throttle Valve Set (Option)

    2342204 Sealing ring at front 2342205 Support ring = Wearing part = Included in service set. = Not part of the standard equipment but available as a special accessory. ** = The valve housing can only be ordered from the WAGNER Service Department.
  • Page 125 = Included in service set. = Not part of the standard equipment but available as a special accessory. ** = The valve housing can only be ordered from the WAGNER Service Department. The throttle valve must not be operated with compressed air.

  • Page 126: External Circulation A1/2"-B1/4" And A3/8"-B1/4

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.11.2 EXTERNAL CIRCULATION A1/2"–B1/4" AND A3/8"–B1/4" Spare parts list for external circulation A1/2"–B1/4" and A3/8"–B1/4" A1/2"–B1/4" A3/8"–B1/4" Stk Designation Order No. Order No. Circulation set A3/8 B1/4 2K PC 2366258 2362987...

  • Page 127: External Circulation A3/8"-B3/8" And A1/2"-B3/8

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 13.11.3 EXTERNAL CIRCULATION A3/8"–B3/8" AND A1/2"–B3/8" Spare parts list for external circulation A3/8"–B3/8" and A1/2"–B3/8" A3/8"–B3/8" A1/2"–B3/8" Stk Designation Order No. Order No. Circulation set A3/8 B3/8 2K PC 2365243 2366916...

  • Page 128: Warranty 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 129: Ce Declaration Of Conformity

    T4: With dry running protection. 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 number:...

  • Page 130: Notes On National Regulations And Guidelines

    PROTEC 2K VERSION 02/2016 ORDER NUMBER DOC2352824 OPERATING MANUAL 14.4 NOTES ON NATIONAL REGULATIONS AND GUIDELINES Plant Safety Ordinance Painting rooms and equipment Equipment for cleaning work pieces with solvents DGUV regulation 100-500 Operating working materials Avoidance of ignition dangers due to electrostatic charges...
  • Page 132 Order No. 2352824 Edition 02/2016 Germany Phone Telefax E-mail Switzerland Phone Telefax More contact addresses on the internet at: Company/Locations/WAGNER worldwide Subject to changes without notice...

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