Powder Tank 60L / 50L / 25L-D1

1 exhaust air hose 5 powder tank

2 powder injector PJ-D1 6 fluid air supply

3 suction system 7 fluid base

4 lid

Powder tanks 60L-D1, 50L-D1 and 25L-D1 are for holding paint powder and are available as accessories for the 2025 Digiflow G manual powder equipment. The powder tanks are designed for use in laboratories and low volume production in industry and trade.

The powder is conveyed out of the powder tank (5) via the injector (2) to the spraygun. A homogenous mixture of powder and air is created for the entire period of powder extraction by the supply of fluid air in the fluid base (7) of the powder tank.

1. Introduction

This technical manual contains information and hints for the service, repair and maintenance of the equipment. The observation of this manual is element of the warranty agreements.

Wagner powder systems are designed to meet the most stringent safety requirements. They can be operated in compliance with generally applicable safety codes and applicable national safety regulations.

Please pay particular attention to the parts marked by the following symbols. Follow the instructions exactly, in the interests of both your own safety and the correct functioning of the unit.

Warning

This symbol draws attention to the fact that if the operating instructions, working instructions, prescribed working sequences etc. are not followed exactly, this can lead to injury or even fatal accidents.

Caution

This warning indicates that if the operating instructions, working instructions, prescribed working sequences etc. are not followed exactly, this can lead to damage to the unit.

Hint

This symbol draws your attention to useful additional information and tips.

Wagner hereby declares that the unit described in these operating instructions has been designed and manufactured according to the provisions of EU Directive 89/392/EEC.
The following European standards have been applied:

EN 50014
EN 50050 EN 50053

The following German standards or guidelines have been applied:

ZH 1/443
VDMA 22371 part 1 VDE 0165

1.1 Safety Regulations

Warning

This equipment can be dangerous if it is not operated in accordance with this operating manual! There might be additional regulations to be observed, put into effect by governmental, state or other official agencies or local security (fire) departments!

The following rules must be observed in order to ensure a safe and efficient use of the equipment:

· Under no circumstance may persons with a cardiac pacemaker come close to the area between the tip of the spraygun and the workpiece to be coated!

· The user has to observe particularly the safety guidelines of the VdS or the local professional and security institutions. 2) 3) 6) 15)

· The user has to ensure that the medium value of the powder/air concentration does not exceed 50% of the LEL u ⁾ (maximum allowed concentration of powder in air). If the LEL is not known, the user should assume a value of 20 g/mł. 2) 3) 6)

· The main power connection for operation of the Wagner powder equipment must be electrically interlocked with the exhaust system of the powder coating booth. 2) 3) 6)

· In the event of faults or defects, repair work is to be performed at the user's discretion. 7)

· Repairs may only be carried out by specially trained personnel. 7)

· Repairs must never be performed in an explosion-hazard area. 7)

· The work area must have an electrostatically conductive floor (measured in accordance with DIN 51953). 2) 3) 6)

· All conductive parts in the work area must be electrostatically grounded (work area = 1.5 m at the sides, 2.5 m to the front and rear of every spray location or opening in the booth). 2) 3)

· All persons inside the work area must wear electrostatically conductive footwear. 2) 3)

· If gloves are used, they must be of antistatic material or have cut-out palm areas. 2) 3)

x) See paragraph 7. 1 "Applicable Safety Regulations and List of Sources"

HAZARD

PREVENTION

Electrostatic arcing may cause an explosion or fire. Mixtures of powder and air can explode or ignite causing property damage and/or severe injury.

Operator must be grounded. Grounding straps must be used when wearing rubber soled shoes.

Operator must be in contact with the spraygun handle; cut out palm section and trigger fingers of any work gloves to be used.

Operator must remove all metal objects from his or her person, which are not grounded.

The object being sprayed must be grounded.

All metal objects within the spray area must be grounded (including spray booth, part hangers, fire extinguishers, etc.).

Grounded conductive floor must be provided in spray area.

Turn off the Power Pack and unplug from outlet before flushing out the gun, cleaning or replacing parts on the gun such as changing tips.

Explosion or fire. Mixtures of powder and air can explode or ignite causing property damage and/or severe injury.

Exhaust and fresh air introduction must be provided to keep the air within the spray area free of accumulation of flammable atmosphere.

Smoking must not be allowed in spray area.

Fire extinguishing equipment must be present and in working order.

Electrostatic arcing must be prevented. (See Electrostatic arcing)

Explosion or fire. Mixtures of powder and air can explode or ignite causing property damage and/or severe injury.

When cleaning the system, use only materials recommended by the coatings manufacturer. Be sure Power Pack is turned off and unplugged.

Avoid all ignition sources such as static electricity sparks, open flames such as pilot lights, hot objects such as cigarettes and sparks from connecting and disconnecting power cords and working light switches.

To prevent hazardous concentrations of flammable atmospheres, spray only in a properly ventilated spray booth.

Never operate spraygun unless ventilation fans are operating properly.

Check and follow all National, State and Local codes regarding air exhaust velocity requirements.

Ventilation must be maintained during the cleaning operation.

Toxic Substances: Some materials may be harmful if swallowed or come in contact with the skin.

Follow the requirements of the Material Safety Data Sheet supplied by the coatings manufacturer.

Exhaust and fresh air introduction must be provided within the spray area to keep the air free of high powder accumulations.

Wear a mask or respirator. Read all instructions for the mask to insure that it will provide the necessary protection against the inhalation of powder.

General

Read all instructions and safety precautions before operating.

Comply with all appropriate local, state and national codes governing ventilation, fire prevention, and operation of Electrostatic equipment usage.

The United States Government Safety Standards have been adopted under the Occupational Safety and Health Act. These standards, particularly the General Standards, Part 1910 and the Construction Standard, Part 1926, should be consulted.

NFPA Standard No. 33 is to be followed when setting up your spray area. Contact the National Fire Protection Association, Batterymarch Park, Quincy, Massachusetts, 02269 for more information.

Check with insurance company for additional requirements.

Use only identical replacement parts.

Personnel must be given training in accordance with the requirements of NFPA Standard No. 33 chapter 15.

It is the duty of all personnel responsible for the spray equipment operation and maintenance to read and understand all safety information furnished with this equipment.

1.2 General Safety Rules

· Keep your workplace well organized
A disorganized workplace creates a hazard.

· Store your tools carefully
Unused tools should be stored in a dry, locked room and out of the reach of unauthorized persons.

· Wear suitable work clothing

· Use breathing protection for work which produces powder.

· Take good care of the system
Keep the system clean to ensure that it works well and safely.

· Always remain alert
Watch your work. Proceed in a reasonable manner. Do not use tools when you lack concentration.

· Check your equipment for damage
Before using the system, carefully inspect slightly worn parts for proper operation. Check whether the moving parts operate properly, whether they jam and whether parts are damaged.

All parts must be properly assembled in order to ensure proper operation of the unit. Damaged parts should be repaired or replaced by a Wagner customer service.

Warning

For your own safety, use only accessories and equipment listed in the operating manual. The use of individual parts other than those recommended in the operating manual may create a hazard to personal safety.
Use only original Wagner replacement parts!

2. Preparing the powder tank for use

2.1 Assemble the powder tank and connect it

Hint

Before you begin assembling the manual powder system and starting it up, check to see that all components have been supplied for assembly.

Read and understand the operating instructions for the 2025 Digiflow G manual powder equipment.

Open spring clips B on lid A

Caution

The powder tank may only be filled to the half-way mark, because the volume of powder is increased by fluidizing.

powder tank 60L-D1: max. filling capacity 30 ... 35 kg powder
powder tank 50L-D1: max. filling capacity 20 ... 25 kg powder
powder tank 2 5L-D1: max. filling capacity 8 ... 12 kg powder

Lift lid A and half fill the powder tank with powder.
Replace lid A on the powder tank and secure it with spring clips B.
Connect grounding cable C to ground screw D.
Connect fluid air hose E to fluid air supply F.
Connect conveyor hose H and dosage air hose I to powder injector G.
Connect powder conveyor hose K.
Connect exhaust air hose L and lead it in the direction of the powder coating booth exhaust system.

2.2 Grounding the powder tank

In order to achieve a good powder coating and for security reasons, the powder tank must be properly grounded.

Attach grounding cable C to the ground screw on the manual powder equipment control unit.

Caution

Check to ensure that the grounding for the 2025 Digiflow G manual powder equipment is functioning properly.

2.3 How to carry out a change of color

Hint

All powder feeding parts should be blown through and cleaned from powder deposits with every interruption of work.

Use a separate powder tank for each color if you want to shorten the cleaning time for the manual powder equipment.

Switch the manual powder equipment off and secure it against being switched on again.
Separate grounding cable C from ground screw D on the powder tank.
Separate all air lines from powder injector G and the powder tank:
fluid air hose E, conveyor hose H, dosage air hose I and exhaust air hose L.
Separate powder feed hose K from powder injector G and the spraygun.
Pull powder injector G out of holder G1 and remove lid A on the powder tank.
Lift the powder tank out of the equipment trolley to clean it. Blow out the tank and the powder suction system thoroughly (suction if necessary).
Clean the powder tank and take particular care when cleaning the fluid base. Wipe everything over with a dry cloth.

Hint

Proper fluidizing is not possible if the fluid base is damaged and/or clogged.

Fill up the powder tank with new powder to the half-way mark only, and then again connect the powder tank as described in section 2.1.

3. Maintenance and cleaning

Caution

Maintenance, repair or replacement of the powder spray unit or its components may only be performed by trained personnel in a suitable location outside the hazard area.

Weekly cleaning of the manual powder system ensures trouble-free operation.

The wear parts of the powder injector must be checked and replaced if necessary.

Switch the manual powder equipment off and secure it against being switched on again.
Separate grounding cable C from ground screw D on the powder tank.
Separate all air lines from powder injector G and the powder tank:
fluid air hose E, conveyor hose H, dosage air hose I and exhaust air hose L.
Separate powder feed hose K from powder injector G and the spraygun.
Pull powder injector G out of holder G1 and remove lid A on the powder tank.
Lift the powder tank out of the equipment trolley to clean it. Blow out the tank and the powder suction system thoroughly (suction if necessary).
Clean the powder tank and wipe it over with a dry cloth.
Completely remove all residues of powder from the suction system.
Take particular care in cleaning the fluid base, check it for clogging or damage and replace it if necessary.

Caution

The quality of the compressed air must meet the requirements given in section
6. "Specification" so as to avoid premature soiling of the fluid base!

Check the powder injector for wear and replace worn parts where necessary.

A list of the wear and spare parts can be found in the operating instructions of the powder injector
PJ-D1.

4. Trouble shooting

Malfunction

Cause

Remedy

No powder output.

- The powder tank is empty.

- The powder hose is blocked.

- The powder suction system is plugged up in powder container.

- The feeding air hose is kinked.

- The powder hose is kinked.

- Refill powder tank.

- Blow through powder hose.

- Blow through powder suction system.

- Straighten hose or replace.

5. Spare parts lists and accessories

5.1 How to order

Faulty and useless parts are replaced according to our general delivery conditions. To ensure a correct spare part order and delivery, the following information is required:

billing address
delivery address
name of contact persons for further inquiries
way of delivery

Caution

To order any spare parts and for further information refer to the drawings mentioned in the spare parts list.

We can only accept liability for original Wagner spare parts supplied by the factory.

We wish to point out specifically that only Wagner original spare parts and accessories are tested and approved by Wagner. It is therefore possible that the installation and/or use of other products may detrimentally affect the design characteristics of the equipment and may therefore jeopardize their active and/or passive safety.

All liability and any guarantee is excluded for damage resulting from the use of spare parts and accessories from other manufacturers.

5.2 Spare parts list

powder tank 25L-D1 part no. 0265 031
powder tank 50L-D1 part no. 0265 032
powder tank 60L-D1 part no. 0265 033

Item.

Part No.

Description

1

0263 375

tank 60L

1

0264 211

tank 50L

1

0264 212

tank 25L

2

0264 215

base housing

3

0264 381

lid

4

0264 382 *

fluid base

5

9971 527

seal (10x5)

6

9994 703

spring clip (lift = 7,6 mm)

7

- **

filister head screw (M3x5)

8

9992 270

threaded connection

9

0184 336

hose nipple

10

- **

hex nut (BM 16x1,5)

11

9982 058 *

exhaust air hose (Powder hose 17x3)

12

0241 296 *

powder injector PJ-D1

13

0241 279 *

injector connection assembly (with O-ring)

14

- **

knurled nut (M6)

15

- **

washer (A 6,4)

16

0241 276

ground cable assembly

17

- **

star washer

19

0241 376

cable coupling

20

0263 357*

suction tube (60L-D1)

20

0264 421 *

suction tube (50L-D1)

20

0264 420 *

suction tube (25L-D1)

21

8324 008

seal (6x6)

24

9971 178 *

O-ring (16x2; included in item 13)

27 0263 404
valve (Ø 1,3)

28 9998 553
double hose socket

* wear part
** no wear part (just for information); not available as spare part!

6. Specification

Description	Tank 60L-D1	Tank 50L-D1	Tank 25L-D1
tank weight	approx. 10 kg	approx. 9.6 kg	approx. 7.5 kg
effective volume	60 l	50 l	25 l
max. filling capacity	30 ... 35 kg powder	20 ... 25 kg powder	8 ... 12 kg powder
fluid air pressure	1 ...2 bar	1 ...2 bar	1 ...2 bar
air consumption	5 ... 8 Nm³/h	5 ... 8 Nm³/h	5 ... 8 Nm³/h

Compressed air quality according to ISO 8573.1:

residual water content in compressed air:

max. 1.3 g H2O/Nm3 at a dew point of 7 °C

residual oil content in compressed air:

max. 0.01 mg oil/Nm3

residual dust content in compressed air:

max. 1 mg dust/Nm3

Ambient conditions:

If low temperature powders are used, the ambient temperature may have to be lower than
30 °C.

Hint

Volume measures
All volume indications (m³/h) are Nm³/h. (Norm cubic meters per hour). One cubic meter of a gas at 0 °C and 1.013 bar is called norm cubic meter.
1 Nm3/h = 35.3 ft3/h

7. Supplement

7.1 Applicable Safety Regulations and List of Sources

1)

EN 50050
DIN VDE 0745
part 100

Electrostatic manual powder coating equipment

(published by
VDE-Verlag, Berlin)

2)

EN 50053 – 2
DIN VDE 0745
part 200

Selection, installation and use of electrostatic spraying equipment, manual electrostatic equipment for powder

(published by
VDE-Verlag, Berlin)

3)

ZH 1/443

Electrostatic powder coating with manual powder coating equipment

(published by
C. Heymanns-Verlag,
Cologne)

4)

EX-RL / ZH 1/10

Guidelines for explosion protection

(published by
C. Heymanns-Verlag,
Cologne)

5)

VDE 0165

Installation of electrical equipment in explosion-hazard areas

(published by
VDE-Verlag, Berlin)

EN 50014

Electrical equipment for explosion-hazard areas

(published by
VDE-Verlag, Berlin)

6)

VDMA 24371
part 1

Guidelines for electrostatic coating using synthetic resin powders

(published by
Beuth-Verlag, Berlin)

7)

ELEX V

Regulation for electrical systems in
explosion-hazard areas

(published by
VDE-Verlag, Berlin)

8)

VDE 0134

Instructions for first aid in case of accident

(published by
Beuth-Verlag, Berlin)

9)

VDS 2093

Association of insurance companies

(Riehlerstr. 36
50668 Cologne)

7.2 Warranty

What is covered by this warranty:

Faulty parts are replaced according to our general delivery conditions.

Within the applicable warrant period, Wagner will repair or replace, defective parts without charge if such parts are returned with transportation charges prepaid to the nearest authorized service center. If Wagner is unable to repair this product so as to conform to this limited warranty after a reasonable number of attempts, Wagner will provide, either a replacement for this product or a full refund of the purchase price of this product.

These remedies are the sole and exclusive remedies available for breach of express and implied warranties.

What is not covered by this warranty:

This warranty does not cover any damage or defects:

Caused by use or installation of repair or replacement parts or accessories not manufactured by Wagner,
Caused by repair performed by anyone other than a Wagner authorized service center, or
Caused by or related to abrasion, corrosion, abuse, misuse, negligence, accident, normal wear, faulty installation or tampering in a manner which impairs normal operation.

Limitation of remedies:

IN NO CASE SHALL WAGNER BE LIABLE FOR ANY INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES OR LOSS, INCLUDING TRANSPORTATION COSTS, WHETHER SUCH DAMAGES ARE BASED UPON A BREACH OF EXPRESS OR IMPLIED WARRANTIES, BREACH OF CONTRACT, NEGLIGENCE, STRICT TORT, OR ANY OTHER LEGAL THEORY.

Disclaimer of implied warranties:

THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

No ability to transfer:

This warranty is extended to the original purchaser only and is not transferable.

Your rights under state law:

Some states do not allow limitations on how long an implied warranty lasts or the exclusion of incidental or consequential damages, so the above limitation and exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.