WAGNER EvoMotion 5-125 Original Operating Manual
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WAGNER EvoMotion 5-125 Original Operating Manual

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C_00116
Piston Pump
EvoMotion 5-125
Translation of the original operating manual
 
 II 2 G Ex h IIB T3/T4 Gb X
For professional use.
Always observe the information in this manual, particularly the safety
instructions and the warning instructions. Store the manual in a safe place.
Edition: 03/2021

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  • Page 1 C_00116 Piston Pump EvoMotion 5-125 Translation of the original operating manual    II 2 G Ex h IIB T3/T4 Gb X For professional use. Always observe the information in this manual, particularly the safety instructions and the warning instructions. Store the manual in a safe place. Edition: 03/2021...

  • Page 3: Table Of Contents

    Operating manual Piston Pump EvoMotion 5-125 Table of Contents TABLE OF CONTENTS About these instructions Preface Warnings, Notices and Symbols in these Instructions General Characters and Symbols Languages Abbreviations Terminology for the Purpose of this Manual Correct Use Device type...
  • Page 4 Operating manual Piston Pump EvoMotion 5-125 Table of Contents Troubleshooting and Rectification Repairs 10.1 Repair Personnel 10.2 Repair Notes 10.3 Tools 10.4 Cleaning the Parts after Disassembly 10.5 Assembly of the Device Function Test after Repair Work Disposal 12.1 Device 12.2...

  • Page 5: About These Instructions

    Operating manual Piston Pump EvoMotion 5-125 1   About these instructions 1   ABOUT THESE INSTRUCTIONS 1.1   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 6: Languages

    Operating manual Piston Pump EvoMotion 5-125 1   About these instructions – Non-numbered list, first level – Non-numbered list, second level = cross-reference on page ♦ = wearing parts ⋆ = included in service set ● = not part of the standard equipment but available as a special accessory 1.4 ...
  • Page 7 Operating manual Piston Pump EvoMotion 5-125 1   About these instructions Personnel qualifications Trained person Is instructed in the tasks assigned to him/her, the potential risks associ- ated with improper behavior as well as the necessary protective devices and measures. Electrically...

  • Page 8: Correct Use

    WAGNER explicitly prohibits any other use! The device may only be operated under the following conditions: 4 Use the device only to work with the materials recommended by WAGNER. 4 Do not deactivate safety fixtures. 4 Use only WAGNER original spare parts and accessories.

  • Page 9: Misuse

    Operating manual Piston Pump EvoMotion 5-125 2   Correct Use NOTICE Abrasive working materials and pigments! Greater wear of product-wetted parts. 4 Use the application-oriented model (flow rate/cycle, product, valves, etc.) as indicated in the Chapter Technical Data. 4 Check if the fluids and solvents being used are compatible with the pump construction materials as indicated in the Chapter Materials of Paint-wetted Parts.

  • Page 10: Identification

    Operating manual Piston Pump EvoMotion 5-125 3   Identification 3   IDENTIFICATION 3.1   EXPLOSION PROTECTION IDENTIFICATION As defined in Directive 2014/34/EU (ATEX), the device is suitable for use in potentially explosive areas. Device type EvoMotion 5-125 Piston Pump Manufacturer Wagner International AG 9450 Altstätten Switzerland  ...

  • Page 11: Type Plate

    Operating manual Piston Pump EvoMotion 5-125 3   Identification Electrostatic surface spraying 4 Do not spray device parts using electrostatic equipment. Cleaning If there are deposits on the surfaces, the device may form electrostatic charges. Flames or sparks can form during discharge.

  • Page 12: Basic Safety Instructions

    Operating manual Piston Pump EvoMotion 5-125 4   Basic Safety Instructions 4   BASIC SAFETY INSTRUCTIONS 4.1   SAFETY INSTRUCTIONS FOR THE OPERATOR 4 Keep this operating manual at hand near the device at all times. 4 Always follow existing regulations concerning occupational safety and accident prevention regulations.

  • Page 13: Safety Instructions For The Personnel

    Operating manual Piston Pump EvoMotion 5-125 4   Basic Safety Instructions 4 Ensure that all persons within the working area wear static dissipative shoes. Footwear must comply with EN 20344. The measured insulation resistance must not exceed 100 MΩ. 4 Ensure that during spraying, persons wear static dissipative gloves. The grounding takes place via the spray gun's handle or its trigger.
  • Page 14 4 In the event of functional faults, remedy the fault as described in the Troubleshooting chapter 4 If needed, the liquid ejection devices must be checked by experts (e.g., WAGNER service technician) at least every 12 months for their work-safe condition in accordance with DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36.
  • Page 15 Operating manual Piston Pump EvoMotion 5-125 4   Basic Safety Instructions 4 Wear static dissipative gloves when spraying. The grounding takes place via the spray gun's handle or its trigger. 4.2.4   Product Hoses Danger due to bursting of product hose! The product hose is under pressure and may cause dangerous injuries.
  • Page 16 Danger due to improper maintenance and repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel.
  • Page 17 Operating manual Piston Pump EvoMotion 5-125 4   Basic Safety Instructions 4 Do not use any defective components. 4 Before all work on the device and in the event of work interruptions: 4 Relieve the pressure from the spray gun, product hoses and all devices.

  • Page 18: Description

    Operating manual Piston Pump EvoMotion 5-125 5   Description 5   DESCRIPTION 5.1   COMPONENTS B_06865 Air motor Fluid section Reversing Valve Air pressure regulator (option) Silencer 10 Ball valve (option) Air input 11 Safety valve (option) Product input 12 Spacer (separating fluid tank)

  • Page 19: Protective And Monitoring Equipment

    Operating manual Piston Pump EvoMotion 5-125 5   Description 5.2.2   Fluid section The fluid section is designed as a piston pump with flap valves. The pump piston runs in the upper fixed packings which are self-adjusting by means of a pressure spring. This results in the packing having a long service life.

  • Page 20: Data

    Operating manual Piston Pump EvoMotion 5-125 5   Description Order no. Designation 9992504 Separating agent 250 ml 2316595 Operating manual, in German See Chapter EU Declaration of Con- Declaration of Conformity formity [8 61] See Chapter Languages [8 6] Operating manual in the local lan- guage The delivery note shows the exact scope of delivery.
  • Page 21 Operating manual Piston Pump EvoMotion 5-125 5   Description 5.5.3   Technical data Description Units Evo Motion 5-125 Pump ratio Flow volume per double stroke (DS) cm³ / cc Maximum operating pressure Maximum possible strokes in operation DS/min Minimum/maximum air inlet pressure 0.2–0.8...
  • Page 22 Operating manual Piston Pump EvoMotion 5-125 5   Description WARNING Exhaust air containing oil! Risk of poisoning if inhaled. 4 Provide compressed air free from oil and water. 5.5.4   Dimensions and connections B_03460 Order number 2316596 | Edition 03/2021...
  • Page 23 Operating manual Piston Pump EvoMotion 5-125 5   Description inch 126.5 1338.5 52.7 944.5 37.2 ø 8 ø 0.31 G1/2“ ø 110 4.33 ø 11 0.43 * On-site: possible wall mount fixing 5.5.5   Performance Diagrams Example 8 bar 6 bar 4 bar B_00301 Product pressure in bar;...
  • Page 24 Operating manual Piston Pump EvoMotion 5-125 5   Description EvoMotion 5-125 bar (MPa) nl/min <psi> <scfm> 40 (4) <11> <580> 30 (3) <8> <440> 20 (2) <6> <290> 10 (1) <3> <150> 1.25 2.50 3.75 5.00 6.25 7.50 l/min <0.33> <0.66>...

  • Page 25: Operating Elements

    Operating manual Piston Pump EvoMotion 5-125 5   Description 5.6   OPERATING ELEMENTS 5.6.1   Pressure Regulator Unit B_06876 Open: working position Pressure regulator Closed: the air motor can still be under Pressure gauge (air inlet pressure) pressure Ball valve Compressed air input Safety valve (See chapter Protective and Monitoring Equipment [8 19])

  • Page 26: Assembly And Commissioning

    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 Operating manual Piston Pump EvoMotion 5-125 6   Assembly and Commissioning B_06877 Closed: The air motor may still be un- Open: working position der pressure. 1. Ensure that the product tank is equipped with the correct drum adaptor or the correct mounting bracket (ø...

  • Page 28: Grounding

    Operating manual Piston Pump EvoMotion 5-125 6   Assembly and Commissioning 6.5.2   Air Supply Lines WARNING Hose connections! Risk of injury and damage to the device. 4 Do not mix up hose connections of product hose and air hose. 4 Ensure that only dry, clean atomizing air is used in the spray gun! Dirt and moisture in the atomizing air worsens the spraying quality and spray pattern.
  • Page 29 Operating manual Piston Pump EvoMotion 5-125 6   Assembly and Commissioning B_00304 Earthing schema (example) Part / workstation Cable cross section Conveyor 16 mm²; AWG6 Work piece < 1 MΩ Spraying stand 16 mm²; AWG6 Alternative: Spray booth Floor, static dissipative Product tank 6 mm²; AWG10 Pump 4 mm²;...
  • Page 30 Operating manual Piston Pump EvoMotion 5-125 6   Assembly and Commissioning Info Safe operation of the pump is only guaranteed with a grounding connection. Connect all grounding cables using a short and direct route. B_06878 Grounding cable 1. Screw on grounding cable with eyelet.

  • Page 31: Commissioning

    Operating manual Piston Pump EvoMotion 5-125 6   Assembly and Commissioning 6.7   COMMISSIONING WARNING Gas mixtures can explode if there is an incompletely filled pump! Danger to life from flying parts. 4 Ensure that the pump and suction system are always completely filled with flushing agent or working medium.
  • Page 32 Operating manual Piston Pump EvoMotion 5-125 6   Assembly and Commissioning 2. Carry out pressure relief in accordance with Chapter Pressure Relief / Work Interruption [8 34]. 6.7.4   Verifying a Safe Operational Condition A skilled person must check to ensure that the device is in a reliable state after it is assembled and commissioned.

  • Page 33: Operation

    Operating manual Piston Pump EvoMotion 5-125 7   Operation 7   OPERATION 7.1   TRAINING THE OPERATING PERSONNEL – The operating personnel must be qualified 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 34: Pressure Relief / Work Interruption

    Operating manual Piston Pump EvoMotion 5-125 7   Operation 6. Open and close the valve (4) and/or the the lock units on the product line in order to start and/or interrupt the product flow. 7. Start work process. B_06879 closed open 7.4 ...

  • Page 35: Basic Flushing

    Operating manual Piston Pump EvoMotion 5-125 7   Operation Process for relieving pressure B_06879 Closed Open 1. Close the valve (4). 2. Completely close the ball valve (2). 3. Place grounded metal tank (5) for return product under the return tube (3).
  • Page 36 Operating manual Piston Pump EvoMotion 5-125 7   Operation WARNING Incompatibility of cleaning/flushing agent and working medium! Risk of explosion and danger of poisoning by toxic gases. 4 Examine the compatibility of the flushing and cleaning agents and working media on the basis of the safety data sheets.

  • Page 37: Filling With Working Product

    Operating manual Piston Pump EvoMotion 5-125 7   Operation 6. Repeat steps under Flushing return valve and Flushing via valve as needed. External Cleaning 1. Clean the outside of the system. 2. Fully assemble the system. 3. Relieve the pump's pressure according to Chapter Pressure Relief / Work Interruption [8 34].

  • Page 38: Cleaning And Maintenance

    Operating manual Piston Pump EvoMotion 5-125 8   Cleaning and Maintenance 8   CLEANING AND MAINTENANCE 8.1   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.
  • Page 39 DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.
  • Page 40 Yearly or as required 1. In accordance with DGUV regulation 100-500, Chapters 2.29 and 2.36: 4 Have the liquid ejection devices checked by an expert (e.g. WAGNER service technician) as required, but no later than every 12 months to ensure that they are in safe working order.
  • Page 41 Operating manual Piston Pump EvoMotion 5-125 8   Cleaning and Maintenance 4. Replace the complete hose if one of the following two periods is exceeded: 4 6 years from the date of the hose crimping (see fitting embossing). 4 10 years from the date of the hose imprinting.
  • Page 42 Operating manual Piston Pump EvoMotion 5-125 8   Cleaning and Maintenance 2. Place an empty, grounded collection tank (5) under the return tube (3). 3. Close pressure regulator (1) (0 MPa; 0 bar; 0 psi). Emptying via return line 1. Open return valve (3).
  • Page 43 Operating manual Piston Pump EvoMotion 5-125 8   Cleaning and Maintenance 8.2.7   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. 4 Empty and fill the device slowly and in a controlled manner.
  • Page 44 Operating manual Piston Pump EvoMotion 5-125 8   Cleaning and Maintenance 10. Relieve the system's pressure upstream of the valve (4) in accordance with the superordinate operating manual. Open the valve (4). 11. Slowly open the ball valve (2). Be prepared for the switch from air to working product and avoid backspray.

  • Page 45: Troubleshooting And Rectification

    Air motor is iced up. There is a lot of condensation water in Install a water separator. the air supply. If the problem is not listed above consult your WAGNER Service Center. Order number 2316596 | Edition 03/2021...

  • Page 46: Repairs

    DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.

  • Page 47: Cleaning The Parts After Disassembly

    Operating manual Piston Pump EvoMotion 5-125 10   Repairs – Torque wrench 4.5 Nm; 3.3 lbft. – Torque wrench 7 Nm; 5.1 lbft. – Torque wrench 18 Nm; 13.2 lbft. – Torque wrench 20 Nm; 14.7 lbft. – Torque wrench 30 Nm; 22.1 lbft.

  • Page 48: Function Test After Repair Work

    Operating manual Piston Pump EvoMotion 5-125 11   Function Test after Repair Work 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 49: Disposal

    Operating manual Piston Pump EvoMotion 5-125 12   Disposal 12   DISPOSAL 12.1   DEVICE When the devices must be scrapped, please differentiate the disposal of the waste materials. The following materials have been used: – Stainless steel – Aluminum – Elastomers – Plastics –...

  • Page 50: Accessories

    Operating manual Piston Pump EvoMotion 5-125 13   Accessories 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, complete 3 m; 9.8 ft...
  • Page 51 Operating manual Piston Pump EvoMotion 5-125 13   Accessories Order no. Designation 2328382 Check valve assy. 20 bar 377342 Fitting-RF-FM-M16x1,5-G3/8“-PN530-SSt 3201587 Loctite® 577 Order number 2316596 | Edition 03/2021...

  • Page 52: Spare Parts

    DANGER Incorrect maintenance/repair! Danger to life and equipment damage. 4 Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. 4 Use only WAGNER original spare parts and accessories. 4 Only repair and replace parts that are listed in the spare parts chapter and that are assigned to the device.

  • Page 53: Overview Of The Components

    Operating manual Piston Pump EvoMotion 5-125 14   Spare Parts 14.3   OVERVIEW OF THE COMPONENTS 10 11 7 Nm; 5.1 lbft 20 Nm; 14.7 lbft B_03468 Order no. Designation U1B05125D EvoMotion 5-125 PE/T U3B08018060A Air motor M80 EM C60 U2B125FC Fluid section 125 St PE/T A112.62...
  • Page 54 Operating manual Piston Pump EvoMotion 5-125 14   Spare Parts Order no. Designation 9920106 Washer 9900342 Hexagon socket head cap screw 9900308 Hexagon socket head cap screw 9920104 Washer E051.62B Protection - connecting piece A532.62 Spacer Order number 2316596 | Edition 03/2021...

  • Page 55: Air Motor M80 Em C60

    Operating manual Piston Pump EvoMotion 5-125 14   Spare Parts 14.4   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 B_03469 Installation instructions Always mount piston rod (12) from the bottom to the top, through the rod seal which is present (18).
  • Page 56 Operating manual Piston Pump EvoMotion 5-125 14   Spare Parts Order no. Designation 2369375 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 Sliding ring L110.06 O-ring ♦⋆...

  • Page 57: Fluid Section 125

    Operating manual Piston Pump EvoMotion 5-125 14   Spare Parts 14.5   FLUID SECTION 125 18 Nm; 13.2 lbft B_03470 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...
  • Page 58 Operating manual Piston Pump EvoMotion 5-125 14   Spare Parts Order no. Designation A645.01 Washer A644.12 Cylinder flange 9907079 Hexagon socket head cap screw D114.42A Pump rod D36 ♦ ♦⋆ G609.08 Gasket A646.03 Piston valve B0344.03 Special screw M6x35 K311.03A Self-locking hexagon nut K108.03...

  • Page 59: Reversing Valve

    Operating manual Piston Pump EvoMotion 5-125 14   Spare Parts 14.6   REVERSING VALVE B_03139 Order no. Designation P498.00 Reversing Valve 9971123 O-ring P521.00 Reversing valve seal P520.00 Damper 14.7   PUMP AIR REGULATOR B_06880 Order no. Designation T6140.00 Set - pump air regulator M101.00...
  • Page 60 Operating manual Piston Pump EvoMotion 5-125 14   Spare Parts Order no. Designation 2384362 Pressure regulator 9900353 Socket cap screw 9920308 Washer 2384363 Supporting bracket 9999138 Male stud elbow M297.00 T-connection P484.00C0 Safety valve 1/4", blue ring 9998677 Pressure gauge 0-10 bar (d40) 9982078 Hose, black AD8 x 1.25...

  • Page 61: Declaration Of Conformity

       II 2 G Ex h IIB T3/T4 Gb X 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 Order number 2316596 | Edition 03/2021...
  • Page 62 Operating manual Piston Pump EvoMotion 5-125 15   Declaration of Conformity Order number 2316596 | Edition 03/2021...
  • Page 64 Order number 2316596 Edition 03/2021 Germany J. Wagner GmbH Otto-Lilienthal-Strasse 18 Postfach 1120 D-88677 Markdorf Telephone: +49 (0)7544 5050 Fax: +49 (0)7544 505200 E-mail: ts-liquid@wagner-group.com Switzerland Wagner International AG Industriestrasse 22 CH-9450 Altstätten Telephone: +41 (0)71 757 2211 Fax: +41 (0)71 757 2222 More contact addresses on the internet at: www.wagner-group.com Subject to changes without notice...

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