Electrical Connection Cables 4.2.6 Cleaning and Flushing 4.2.7 Maintenance and Repair 4.2.8 Protective and Monitoring Equipment DESCRIPTION Design of the IP 5000 Powder Pump 5.1.1 IP 5000 Version 5.1.2 IP 5000-USD Version Functioning Operating Elements on Control Cabinet Extent of Delivery Data 5.5.1...
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Commissioning as Transfer Pump (BigBag) 6.9.3 Pin Assignment in the Control Cabinet OPERATION Training the Operating Personnel Tasks Operating Modes Operation with WAGNER Powder Center Setting Elements in the Control Cabinet 7.5.1 DIP Switch Functions 7.5.2 A+/A- Buttons 7.5.3 Function 1 "Use of Powder Center/BigBag"...
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 ACCESSORIES SPARE PARTS 12.1 How to Order Spare Parts 12.2 Powder Pump Spare Parts List 12.3 Control Cabinet Spare Parts List 12.4 Connecting Plug Spare Parts List 12.5 SN 600/14 Suction Lance Spare Parts List 12.6...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 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.
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 LANGUAGES The operating manual is available in the following languages: Original operating manual Language Order no. German 241935 Translation of the original operating manual Language Order no. Language Order no. English 241936 Danish...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL Cleaning Cleaning Manual cleaning of devices and device parts with cleaning agent Flushing Internal flushing of paint-wetted parts with compressed air Personnel qualifications 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.
DEVICE TYPE Pneumatic feed pump for feeding powder lacquers. TYPE OF USE The IP 5000 powder pump is used to feed powder coating products from different container types. Application areas: The IP 5000 powder pump is used to feed powder lacquers –...
Temperature class: maximum surface temperature < 85 °C; 185 °F High safety level PERMISSIBLE DEVICE COMBINATIONS The IP 5000 powder pump can be used in the following WAGNER powder centers: – PZ 2008 powder center – SuperCenter 2012 – PXM powder center –...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 BASIC SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual at hand near the device at all times. Always follow applicable directives concerning occupational safety and accident prevention regulations. 4.1.1 ELECTRICAL DEVICES AND EQUIPMENT Danger of electric shock! Danger to life from electric shock.
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 4.1.2 A SAFE WORK ENVIRONMENT Danger due to dust formation! Severe or fatal injuries due to explosion danger or inhalation, swallowing or contact with the skin or eyes. The floor in the working area must be electrostatically conductive (measurements according to EN 1081 and EN 61340-4-1).
Use a mask or breathing apparatus if necessary. For sufficient health and environmental protection, only operate the device with technical ventilation (extraction) switched on. 4.2.2 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES Danger due to dust formation! Do not point spray guns at people.
Danger due to damaged product hoses! The product hose may cause dangerous injuries. Use only an original WAGNER powder hose. Make sure that the hoses are laid only in suitable places. Hoses should not be laid in the following places under any circumstances: –...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 4.2.5 ELECTRICAL CONNECTION CABLES Risk caused by improperly laid cables! Risk of injury and damage to the device. Properly lay connection cables and check them regularly. Immediately replace damaged connection cables. Ensure that no work is ever performed with a damaged connection cable.
Danger due to improper maintenance and repair! Danger to life and equipment damage. Only a WAGNER service center or a specially trained person may carry out repairs and replace parts. Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel.
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 DESCRIPTION DESIGN OF THE IP 5000 POWDER PUMP 5.1.1 IP 5000 VERSION Front View Profile P_04343 Designation 1 Control cabinet 2 Control panel 3 Cooling box for inlet valve air 4 Pressure regulator (in the control cabinet)
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 5.1.2 IP 5000-USD VERSION Front View Profile P_04825 Designation 1 Control cabinet 2 Control panel 3 Cooling box for inlet valve air 4 Pressure regulator (in the control cabinet) 5 Powder inlet valve...
The powder pump is equipped with an active inlet valve cooling for gentle powder feeding. Mode of operation: The IP 5000 powder pump is a vacuum-assisted peristaltic pump. Feeding occurs by means of two pump hoses. The pump hoses are reciprocally sealed by pressure. Through generation of a vacuum, the pump hose is opened again and the powder is fed.
The LEDs also light up when the pump is switched off with "ON/OFF" button 1 (serves for 24 VDC voltage monitoring). EXTENT OF DELIVERY Order no. Designation 241004 IP 5000 powder pump 2386088 IP 5000-USD powder pump The standard equipment includes: 241942 Declaration of Conformity...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 ASSEMBLY AND COMMISSIONING TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL The assembly and commissioning personnel 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.
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 ASSEMBLY EXAMPLE OF THE WAGNER POWDER CENTER Pump mounted to the side using fastening set (accessory order no. 241550). P_00443 Measurements in mm...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 INSTALLATION RECOMMENDATION 6.5.1 IP 5000 VERSION P_04306 Designation A Suction side (powder inlet) B Pressure side (powder outlet) 1 Maximum delivery head 5 m; 16.4 ft 2 Surge damper 3 Suction Lance 4 Fresh powder...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 6.5.2 IP 5000-USD VERSION P_04826 Designation A Suction side (powder inlet) B Pressure side (powder outlet) 1 Suction length, maximum of 5 m; 16.4 ft 2 Surge damper 3 Suction Lance 4 Fresh powder...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 ASSEMBLING THE POWDER PUMP P_04344 Designation 1 Grounding screw 2 Plug connection 24 VDC and I/O signals 3 Compressed air connection 4 Plug connection of external cleaning box (accessory order no. 241570)
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 The powder pump is fixed next to the feed tank, for example the powder center or BigBag. P_04307 Work steps: 1. Mount the powder pump at installation location (fastening set order no. 241550, available as an accessory).
Slide the powder hose onto the hose coupling as far as possible (up to the stop)! GROUNDING For safety reasons the system must be properly grounded. WAGNER recommends the use of a copper cable of at least 4 mm² with sufficient mechanical stability.
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 P_04308 Designation 1 Pressure regulator 1 2 Pressure regulator 2 3 Pressure regulator 3 A Switch position "0" (BigBag) B Switch position "1" (powder center) Factory settings: Operating mode: powder center Pressure regulator 1: 0.3 MPa;...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 6.9.1 COMMISSIONING IN CONNECTION WITH THE POWDER CENTER Work steps: 1. Set pressure on pressure regulator 1 (piston air KV) in the control cabinet (factory setting 0.3 MPa; 3 bar; 43.5 psi). Setting value: –...
– in conjunction with a powder center or BigBag – used as a transfer pump OPERATION WITH WAGNER POWDER CENTER The powder pump is controlled via the powder center controller. The powder pump is operated via the powder center touch screen (from PZ 2005).
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 SETTING ELEMENTS IN THE CONTROL CABINET 7.5.1 DIP SWITCH FUNCTIONS Function No. Switch No. 8 Explanation 1 on = use of powder center* (hose lengths < 20 m) 1 off = use of BigBag* (hose lengths >...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 7.5.3 FUNCTION 1 "USE OF POWDER CENTER/BIGBAG" The setting to powder center or BigBag is dependent on the distance from the pump to the target tank. Note: For rising heights above 3 m; 9.9 ft select the "BigBag" setting.
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 7.5.7 FUNCTION 6 "SET SERVICE INTERVAL" The service interval display is a useful auxiliary function for trouble-free operation of the pump. The factory settings are based on empirical values and are to be considered as non-binding guide values.
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 7.5.8 SETTING EXAMPLE The "Powder center" operating mode is activated in the example. 4 LEDs light up on the display, which means that another 800 000 pump cycles can be executed until the fault message appears (factory setting 2 000 000 cycles - 800 000 possible cycles = 1 200 000 cycles have been executed).
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 7.5.9 FUNCTION 7 "LEVEL CONTROLLER" The level controller serves to guarantee a consistent filling level in the powder tank. For this purpose an external level probe is connected, which sends the relevant signal to the powder pump controller.
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 CYCLE COUNTER The powder pump is equipped with a cycle counter, which triggers a warning signal (fault LED flashes) after reaching a set number of pump cycles, prompting replacement of the valve and pump hoses.
The cleaning intervals should be adapted by the operator depending on the level of use and if necessary the level of soiling. If in doubt, we recommend contacting WAGNER's specialist personnel. 8.1.3 CLEANING IN CASE OF PAINT CHANGE In the case of a paint change, all powder feeding parts must be thoroughly cleaned.
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 8.1.5 EXTERNAL CLEANING PROCEDURE WARNING Bursting powder hose! Risk of injury and damage to the device. The powder hose may be loaded with a maximum pressure of 0.6 MPa; 6 bar; 87 psi.
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 8.1.6 SUPERCENTER CLEANING PROCEDURE The powder pump cleaning procedure, if used at a SuperCenter, is described below. To activate this function, the DIP switch 7 must be set to "on" (see Chapter 7.5.1).
Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a specially 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 device.
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 8.2.5 CHANGING VALVE AND PUMP HOSES P_00020 Work steps: 1. Switch off the system. 2. Switch off the main switch and protect against unauthorized restarting. 3. Lock the compressed air supply and decompress the system.
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 P_00008 7. Unscrew screws 2 on the upper valve block. 8. Remove Y-piece 3 and valve housing 4 at the top of the pump body 5. 9. Unscrew screws (2) on the lower valve block.
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 P_00010 13. Unscrew screws 8 on the upper and lower hose flange 9. 14. Remove hose flanges 9 at the top and bottom of the pump body 5. P_00011 15. Squeeze old pump hoses 10 lightly at the top and remove downwards from the pump body 5.
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 View from top P_00013 The pump hoses must not be mounted twisted (observe ridges A). Press hose collar at the top and bottom against the wall with your fingers. P_00014 17. Attach hose flange 9 to the bottom of the pump body 5 and fasten with screws 8.
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 Tightness check: The tightness check is not essential and should be performed only by qualified personnel. P_04346 20. Remove plugs (4 pieces) from the valves 12. 21. Open the compressed air supply. 22. Set blow-out air on pressure regulator 13 to 0 MPa; 0 bar; 0 psi.
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 P_00008 27. Fit upper valve housing 4 and Y-piece 3 to the top of the pump body 5 and fasten with screws 2. Evenly tighten screws (2) alternately crosswise. (6 Nm; 4.425 lb ft).
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 P_00015 28. Fit lower valve housing (4) and Y-piece (3) to the bottom of the pump body (5) and fasten with screws (2). Evenly tighten screws (2) alternately crosswise. (6 Nm; 4.425 lb ft).
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 REPLACING THE NON-RETURN VALVES Non-return valve 241237 Non-return valve 2409407 (up to serial number 1847) (up to serial number 1848) P_04349 P_04350 8.4.1 DISASSEMBLY P_00020 Work steps: 1. Switch off the system. 2. Switch off the main switch and protect against unauthorized restarting.
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 P_04329 6. Unscrew screws (4) on the lower valve block. 7. Remove Y-piece (3) and valve housing (2) at the bottom of the pump body (1). P_04331 8. Turn back connections (5) on the non-return valves up to stop.
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 P_04333 9. Unscrew screws (7) on the lower valve block and remove hose flange (6) from pump body (1). P_04334 10. Remove valves (10) (AL1 and AL2) from the air connections. 11. Unscrew air connections (8) out of the non-return valve units (9) and dismount non-return valves.
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 8.4.2 ASSEMBLY P_04335 Work steps: 1. Screw in non-return valve (12) up to stop in bushing (11). P_04336 2. Mount non-return valve (9) with air connection (8) in control cabinet and screw them loosely together.
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 4. Loosely screw the non-return valve connections into the air connections in the hose bushing (6) with care. 5. Evenly tighten screws 7 crosswise (5 Nm; 3.7 lb ft). 6. Screw the non-return valve connections completely into the air connections in the hose bushing (6).
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 P_04338 8. Fit lower valve housing (2) and Y-piece (3) to the bottom of the pump body (1) and fasten with screws (4). 9. Evenly tighten screws (4) alternately crosswise. (6 Nm; 4.43 lb ft).
WAGNER devices, protective systems and safety, monitoring and control equipment may only be serviced/repaired as defined in Directive 2014/34/EC (ATEX) by trained WAGNER service personnel or skilled persons in accordance with TRBS 1203! Note national regulations! Service, repair or replacement of devices or parts of devices may only be performed...
WAGNER or one of our dealers will take back your used WAGNER electric or electronic equipment and will dispose of it for you in an environmentally-friendly way.
Consists of: – suspension bracket for wall mounting – 2 rubber buffers P_00440 241555 Surge damper – for use in the WAGNER circulating powder center – reduced dust formation P_01034 265110 Suction device, IP 5000 2301550 Suction lance, SN600/14 for powder center...
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ORDER NUMBER DOC241936 Order no. Designation 241565 Parking station P_00447 241570 External cleaning box P_00449 3313075 Pump rack, IP 5000 P_00499 390955 Hose take-up, D10-D12, not electrically conductive P_01035 2305866 Hose take-up, D10-D12, electrically conductive P_01035 2353080 Coupling piece, electrically conductive...
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 Order no. Designation 9987135 Hose holder for POE 12 and POE 14 powder hoses 2301253 Thread adapter 2305865 – for the seating of a complete coupling P_00924 2310700 Powder hose, POE 12 2312126...
DANGER Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a specially trained person may carry out repairs and replace parts. Use only WAGNER original spare parts and accessories. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the device.
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 12.2 POWDER PUMP SPARE PARTS LIST P_04347...
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 Order no. Designation 2312057 Service set pump hose D33 x 401 (2 hoses) 2301442 Hose flange inlet valve 241486 Hose flange outlet valve 2301449 Valve housing 2312058 Service set valve hose D15 x 25 x 74 (2 hoses)
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 12.3 CONTROL CABINET SPARE PARTS LIST 17/18 10/25/26 13/14 15/20 P_04348 Note: With the IP 5000-USD, the control cabinet is arranged rotated by 180°.
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IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 Order no. Designation 360931 PCB display, complete ET (Note installation direction for USD variant) 2305520 Print, complete IP 5000 ET 360458 Ribbon cable, Flex-Flat 8-pin 241526 Blowing out box 9943152 Double 3/2-way valve 9943157...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 12.5 SN 600/14 SUCTION LANCE SPARE PARTS LIST ∅30 P_00448 Measurement X order no. 2301550 582 mm Order no. Designation 265412 Fluid ring 2301098 Crown, M18x1.5 2353080 Coupling piece, complete 9992260 Coupling plug...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 12.6 SN 1500/14 SUCTION LANCE SPARE PARTS LIST ∅30 P_01033 Measurement X order no. 2301548 1518 mm Order no. Designation 265412 Fluid ring 2304065 Suction head 2353080 Coupling piece, complete 9992260 Coupling plug...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 13 CIRCUIT DIAGRAMS 13.1 PLUG ASSIGNMENT XST 9 P_04316 Assignment Function Plug Device voltage supply Device grounding Release (+24 V signal) Powder pump START/STOP +24 V = ON; 0 V = OFF Cleaning ON/OFF...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 13.2 SIGNAL SEQUENCE 13.2.1 SIGNAL SEQUENCE "FEEDING OPERATION" Signal I1/O1 P_04317 State 1 OFF 2 ON 13.2.2 SIGNAL SEQUENCE "KPZ 2008 CLEANING" DIP switch 7 is set to "off". Signal I2 P_04318 Cleaning ends automatically...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 13.2.3 SIGNAL SEQUENCE "PXM/PXS STANDARD CLEANING" DIP switch 7 is set to "on". T1=200 ms P_04325 Description 1 I2 Cleaning on/off 2 I4 Level controller input 3 O2 Cleaning in process 4 Start...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 13.2.4 SIGNAL SEQUENCE "PXM/PXS INTENSIVE CLEANING" DIP switch 7 is set to "on". 0 ms < T < T1 T1=200 ms P_04326 Description 1 I2 Cleaning on/off 2 I4 Level controller input 3 O2 Cleaning in process...
IP 5000 EDITION 08/2021 ORDER NUMBER DOC241936 13.2.5 SIGNAL SEQUENCE "SUPERCENTER CLEANING" DIP switch 7 is set to "on". P_04327 Description 1 I2 Cleaning on/off 2 I4 Level controller input 3 O2 Cleaning in process 4 Start cleaning...
II 3D Ex tc IIIB T85°C Dc EU Declaration of Conformity The EU Declaration 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:...
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Order no. 241936 Edition 08/2021 ts-powder@wagner-group.com www.wagner-group.com...
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