WAGNER EvoMotion 5-125 Translation Of The Original Operating Manual
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WAGNER EvoMotion 5-125 Translation Of The Original Operating Manual

Piston pump, delivery volume 125 cm3
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Version 01/2018
EvoMotion 5-125
Piston pump
Delivery volume 125 cm³
C_00116

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Summary of Contents for WAGNER EvoMotion 5-125

  • Page 1 Version 01/2018 EvoMotion 5-125 Piston pump Delivery volume 125 cm³ C_00116...

  • Page 3: Table Of Contents

    Electrical Devices and Equipment 4.1.2 A Safe Work Environment 4.1.3 Personnel Qualifications Safety Instructions for the Personnel 4.2.1 Personal Safety Equipment 4.2.2 Safe Handling of WAGNER Spray Devices 4.2.3 Grounding the Unit 4.2.4 Product hose 4.2.5 Cleaning and Flushing 4.2.6 Touching Hot Surfaces 4.2.7...
  • Page 4 VERSION 01/2018 ORDER NUMBER DOC 2316596 ASSEMBLY AND COMMISSIONING Training of Assembly/Commissioning Personnel Storage Conditions Installation Conditions Transportation Assembly and Installation 6.5.1 Ventilation of the Spray Booth 6.5.2 Air Supply Lines 6.5.3 Product supply lines Grounding Commissioning OPERATION Training the Operating Personnel Emergency Stop Tasks Pressure Relief/Work Interruption...
  • Page 5 VERSION 01/2018 ORDER NUMBER DOC 2316596 FUNCTION TEST AFTER REPAIR WORK DISPOSAL ACCESSORIES SPARE PARTS 14.1 How can spare parts be ordered? 14.2 Overview of the Components 14.3 Air motor M80 EM C60 14.4 Fluid section 125 14.4.1 Reversing valve 14.4.2 Pump air regulator GUARANTEE AND CONFORMITY DECLARATIONS 15.1...

  • Page 6: About These Instructions

    VERSION 01/2018 ORDER NUMBER DOC 2316596 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 7: Languages

    2316599 Spanish 2316600 Danish 2316602 Swedish 2316601 English 2316596 Additional languages on request or at: www.wagner-group.com ABBREVIATIONS Number of pieces Position Marking in the spare parts lists Order no. Order number Double stroke Two components Ultra high molecular weight polyethylene...

  • Page 8: Correct Use

    WAGNER explicitly prohibits any other use! The device may only be operated under the following conditions: Use the device only to work with the products recommended by WAGNER. Do not deactivate safety fixtures. Use only WAGNER original spare parts and accessories.

  • Page 9: Processible Working Materials

    VERSION 01/2018 ORDER NUMBER DOC 2316596 PROCESSIBLE WORKING MATERIALS Fluid materials like paints and lacquers. Application Water-based products Solvent-based products Low viscosity (<40 sec. DIN No. 4) Medium viscosity (40 to 60 sec. DIN No. 4) High viscosity (> 60 sec. DIN No. 4) UV - sensitive products Shear sensitive products Humidity sensitive products...

  • Page 10: Identification

    IDENTIFICATION EXPLOSION PROTECTION IDENTIFICATION As defined in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially explosive areas. Device types: EvoMotion 5-125 Piston Pump Manufacturer: Wagner International AG CH-9450 Altstätten, Switzerland European Communities Symbol for explosion protection...

  • Page 11: Type Plates

    Empty and fill the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings. TYPE PLATES Designation Manufacturer and CE Identification Wagner International AG Pump type CH-9450 ALTSTÄTTEN II 2 G Ex h IIB T3/T4 Gb X MADE IN SWITZERLAND...

  • Page 12: Basic Safety Instructions

    VERSION 01/2018 ORDER NUMBER DOC 2316596 BASIC 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 DEVICES AND EQUIPMENT Electric shock hazard! Danger to life from electric shock Prepare device in accordance with the local safety requirements with regard to the...

  • Page 13: Personnel Qualifications

    VERSION 01/2018 ORDER NUMBER DOC 2316596 Ensure that there are no ignition sources such as naked flames, sparks, glowing wires, or hot surfaces in the vicinity. No smoking. Ensure that the pipe joints, hoses, equipment parts and connections are permanently, technically leak-proof: - Periodic preventative maintenance and service (replacing hoses, checking tightness strength of the connections etc.).

  • Page 14: Safe Handling Of Wagner Spray Devices

    "Troubleshooting" chapter. If necessary, or at least every 12 months, the liquid ejection devices must be checked for safe working conditions by an expert (e.g. WAGNER service technician) in accordance with the guidelines for liquid ejection devices (DGUV 100-500 Chapters 2.29 and 2.36).

  • Page 15: Product Hose

    VERSION 01/2018 ORDER NUMBER DOC 2316596 4.2.4 PRODUCT HOSE Hazard due to bursting of product hose! The product hose is under pressure and may cause dangerous injuries. Ensure that the hose material is chemically resistant to the sprayed products and the flushing agents used.

  • Page 16: Cleaning And Flushing

    VERSION 01/2018 ORDER NUMBER DOC 2316596 4.2.5 CLEANING AND FLUSHING Hazard due to cleaning and flushing! Explosion hazard and damage to the device. Preference should be given to non-ignitable cleaning and flushing agents. When carrying out cleaning work with flammable cleaning agents, make sure that all equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or static dissipative and grounded.

  • Page 17: Maintenance And Repair

    4.2.7 MAINTENANCE AND REPAIR Hazard due to improper maintenance and repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Use only WAGNER original spare parts and accessories.

  • Page 18: Description

    VERSION 01/2018 ORDER NUMBER DOC 2316596 DESCRIPTION COMPONENTS Designation 1 Air motor 2 Reversing valve 3 Silencer 4 Air inlet 5 Product inlet 6 Grounding connection 7 Mounting flange 8 Fluid section 9 Air pressure regulator (option) 10 Ball valve (option) 11 Safety valve (option) 12 Spacer (separating fluid tank) 13 Product outlet...

  • Page 19: Protective And Monitoring Equipment

    VERSION 01/2018 ORDER NUMBER DOC 2316596 PROTECTIVE AND MONITORING EQUIPMENT 5.3.1 SAFETY VALVE WARNING Overpressure! Danger to life from bursting device components. Never change the safety valve setting. The air motor is fitted with a safety valve. The safety valve (11) has been set and sealed at the factory.

  • Page 20: Included Items

    Stainless steel Static seals EPDM Sealing packages PE/ T = Ultra high molecular weight polyethylene Polytetrafluorethylene (PTFE) 5.5.2 RECOMMENDED PACKINGS WAGNER packings for this device: Product Color Ultra high molecular weight transparent polyethylene PTFE white Each product has the following properties, which influence the packings:...

  • Page 21: Technical Data

    VERSION 01/2018 ORDER NUMBER DOC 2316596 5.5.3 TECHNICAL DATA Description Unit Pump ratio Volume flow per double stroke (DH) Maximum operating overpressure Maximum possible strokes in operation 0.2–0.8 Minimum/maximum air inlet pressure 2–8 28–116 Quality standard 7.5.4 according to ISO 8573.1, 2010 7: Particle concentration 5 – 10 mg/m³...

  • Page 22: Dimensions And Connections

    VERSION 01/2018 ORDER NUMBER DOC 2316596 5.5.4 DIMENSIONS AND CONNECTIONS 126.5 1338.5 52.7 944.5 37.2 0.31 G1/2“ 4.33 0.43 B_03460 * On-site: possible wall mount fixing...

  • Page 23: Performance Diagrams

    ORDER NUMBER DOC 2316596 5.5.5 PERFORMANCE DIAGRAMS Example Stroke frequency 8 bar 6 bar 4 bar B_00301 Product flow - water l/min <gpm> EvoMotion 5-125 stainless steel Stroke frequency bar (MPa) nl/min <psi> <scfm> 40 (4) <11> <580> 30 (3) <440>...

  • Page 24: Operating Elements

    VERSION 01/2018 ORDER NUMBER DOC 2316596 OPERATING ELEMENTS 5.6.1 PRESSURE REGULATOR UNIT     geschlossen  B_06876 Designation Open: working position 1 Ball valve Closed: The air motor may still be under pressure. 2 Safety valve 3 Pressure regulator 4 Pressure gauge (air inlet pressure) 5 Compressed air inlet...

  • Page 25: Assembly And Commissioning

    VERSION 01/2018 ORDER NUMBER DOC 2316596 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.

  • Page 26: Assembly And Installation

    A variety of supplemental components for this pump can be found in the WAGNER liquid coating or accessories catalogues. So that the pump can be separated from the rest of the system, the correct product valve must be mounted in the product line.

  • Page 27: Ventilation Of The Spray Booth

    VERSION 01/2018 ORDER NUMBER DOC 2316596 6.5.1 VENTILATION OF THE SPRAY BOOTH Operate the device in a spray booth approved for the working materials. - or - Operate the device on an appropriate spraying wall with the ventilation (extraction) switched on. Observe national and local regulations for the exhaust air speed.
  • Page 28 VERSION 01/2018 ORDER NUMBER DOC 2316596 Grounding scheme (example) Ex zone Conveyor Spraying stand Work piece R max < 1 MΩ Product tank Floor, static dissipative B_00304 Part / workstation Cable cross sections Pump 4 mm ; AWG 12 Product tank 6 mm ;...

  • Page 29: Commissioning

    VERSION 01/2018 ORDER NUMBER DOC 2316596 COMMISSIONING WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from flying parts. Ensure that the pump and suction system are always completely filled with flushing agent or working medium. Do not spray the device empty after cleaning.

  • Page 30: Operation

    VERSION 01/2018 ORDER NUMBER DOC 2316596 OPERATION TRAINING THE OPERATING PERSONNEL The operating personnel must be qualified to operate the entire system. The operating personnel must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures. Before work commences, the operating personnel must receive appropriate system training.

  • Page 31: Tasks

    VERSION 01/2018 ORDER NUMBER DOC 2316596 TASKS closed open B_06877 Ensure that: commissioning was carried out in accordance with Chapter 6.7. 1. Visual check: personal safety equipment, grounding and all devices ready to use. 2. Close the valve (3). 3. Slowly open the ball valve (2). 4.

  • Page 32: Pressure Relief/Work Interruption

    VERSION 01/2018 ORDER NUMBER DOC 2316596 PRESSURE RELIEF/WORK INTERRUPTION The pressure must always be relieved when: − after the spraying tasks are finished, − before servicing or repairing the spraying system, − before carrying out cleaning tasks on the spraying system, −...

  • Page 33: Basic Flushing

    VERSION 01/2018 ORDER NUMBER DOC 2316596 BASIC FLUSHING Regular flushing Regular flushing, cleaning and maintenance ensures the pump's high pumping and extraction capacity. The cleaning and flushing agents used must be compatible with the working material. WARNING Incompatibility of flushing / cleaning agent with the working medium! Risk of explosion and danger of poisoning by toxic gases.

  • Page 34: Cleaning And Maintenance

    VERSION 01/2018 ORDER NUMBER DOC 2316596 CLEANING AND MAINTENANCE CLEANING 8.1.1 CLEANING PERSONNEL Cleaning work should be undertaken regularly and carefully by qualified and trained personnel. They should be informed of specific hazards during their training. The following hazards may arise during cleaning work: −...

  • Page 35: 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. 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 unit.

  • Page 36: Safety Checks And Maintenance Intervals

    Yearly or as required In accordance with DGUV regulation 100-500 Chapter 2.29 and 2.36: – 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.
  • Page 37 Fitting embossing Meaning xxx bar Pressure yymm Crimping date (year/month) Internal code Hose imprinting Meaning Wagner Name / Manufacturer yymm Date of manufacture (year/month) xxx bar (xx MPa) Pressure e.g., 270 bar (27 MPa) Internal code DNxx (e.g., DN10) Nominal diameter...

  • Page 38: Emptying Pump

    VERSION 01/2018 ORDER NUMBER DOC 2316596 8.2.4 EMPTYING PUMP WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from flying parts. Ignition of potentially explosive surrounding atmosphere. Empty pump slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

  • Page 39: Filling The Empty Pump

    VERSION 01/2018 ORDER NUMBER DOC 2316596 8.2.5 FILLING THE EMPTY PUMP WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from flying parts. Ignition of potentially explosive surrounding atmosphere. Fill the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

  • Page 40: Troubleshooting And Rectification

    Air motor is iced up. There is a lot of condensation water Install a water separator. in the air supply. If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service Center.

  • Page 41: Repairs

    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. 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 unit.

  • Page 42: Cleaning The Parts After Disassembly

    VERSION 01/2018 ORDER NUMBER DOC 2316596 10.4 CLEANING THE PARTS AFTER DISASSEMBLY WARNING Incompatibility of cleaning agent with the working medium! Risk of explosion and danger of poisoning by toxic gases. Examine the compatibility of the cleaning agents and working media on the basis of the safety data sheets.

  • Page 43: Function Test After Repair Work

    VERSION 01/2018 ORDER NUMBER DOC 2316596 11 FUNCTION TEST AFTER REPAIR WORK After all repairs, the device must be checked for safe condition before recommissioning. The necessary scope of inspection and testing depends on the repair carried out and must be documented by the repair personnel.

  • Page 44: Accessories

    VERSION 01/2018 ORDER NUMBER DOC 2316596 13 ACCESSORIES B_06864 Order no. Designation U1B05125D Piston pump 9992504 Separating agent 250 ml; 250 cc 9992505 Separating agent 500 ml; 500 cc T6140.00 Air regulator 236219 Grounding cable 3 m; 9.8 ft 2368149 Connection set DN20 3m 3201040 Fitting-DF-MM-R1/2-R1/2-PN50-SSt 2328382...

  • Page 45: 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. 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 unit.

  • Page 46: Overview Of The Components

    VERSION 01/2018 ORDER NUMBER DOC 2316596 14.2 OVERVIEW OF THE COMPONENTS 10 11 7 Nm; 5.1 lbft 20 Nm; 14.7 lbft B_03468...
  • Page 47 VERSION 01/2018 ORDER NUMBER DOC 2316596 Order no. Designation U1B05125D EvoMotion 5-125 PE/T 1 U3B08018060A Air motor M80 EM C60 U2B125FC Fluid section 125 St PE/T A112.62 Protection - connecting piece A111.02 Connecting piece M/P 9920106 Washer 9900342 Hexagon socket cylinder head screw...

  • Page 48: Air Motor M80 Em C60

    VERSION 01/2018 ORDER NUMBER DOC 2316596 14.3 AIR MOTOR M80 EM C60 30 Nm; 22.1 lbft 35 Nm; 25.8 lbft 4.5 Nm; 3.3 lbft 20 Nm; 14.7 lbft Installation instructions: Mount piston rod (12) always from bottom to top by the assigned rod seal (18).
  • Page 49 VERSION 01/2018 ORDER NUMBER DOC 2316596 Order no. Designation U3B08018060A Air motor M80 EM C60 F132.91C Motor flange, upper, M80 EM L108.06 O-ring D608.81 Cylinder motor 3055157 Hexagon nut with clamp 9992757 Threaded elbow fitting G903.06 Damper L413.06 Seal DE 80 A164.01 Motor piston L802.08...

  • Page 50: Fluid Section 125

    VERSION 01/2018 ORDER NUMBER DOC 2316596 14.4 FLUID SECTION 125 18 Nm; 13.2 lbft B_03470...
  • Page 51 VERSION 01/2018 ORDER NUMBER DOC 2316596 Order no. Designation U2B125FC Fluid section 125 St PE/T F142.21 Spacer MP L136.06 O-ring T971.00E Packing PE/T 36/50 H212.03 Spring, upper A645.01 Washer A644.12 Cylinder flange 9907079 Hexagon socket cylinder head screw D114.42A Pump rod D36 G609.08 Seal A646.03...

  • Page 52: Reversing Valve

    VERSION 01/2018 ORDER NUMBER DOC 2316596 14.4.1 REVERSING VALVE B_03139 Order no. Designation P498.00 Reversing valve, complete 9971123 O-ring P521.00 Valve seal P520.00 Damper = Wearing parts 14.4.2 PUMP AIR REGULATOR B_06880 Order no. Designation T6140.00 Set - pump air regulator M101.00 Ball valve, FM 9998039...

  • Page 53: 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 54: Eu Declaration Of Conformity

    DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36 Identification: 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: 2312813...
  • Page 56 Order no. 2316596 Edition 01/2018 ts-liquid@wagner-group.com www.wagner-group.com...

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