WAGNER EvoMotion 5-60 Translation Of The Original Operating Manual
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WAGNER EvoMotion 5-60 Translation Of The Original Operating Manual

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B_04138
Piston Pump
EvoMotion 5-60
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: 10/2020

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  • Page 1 B_04138 Piston Pump EvoMotion 5-60 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: 10/2020...

  • Page 3: Table Of Contents

    Operating manual Piston Pump EvoMotion 5-60 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 5-60 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 5-60 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 5-60 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 5-60 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 5-60 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 5-60 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 5-60 Piston Pump Manufacturer Wagner International AG 9450 Altstätten Switzerland  ...

  • Page 11: Type Plate

    Operating manual Piston Pump EvoMotion 5-60 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 5-60 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 5-60 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 5-60 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 5-60 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 5-60 5   Description 5   DESCRIPTION 5.1   COMPONENTS B_04140 Air motor Grounding connection Air input Reversing Valve Mounting flange 10 Safety valve (air motor) Separating agent container 11 Air pressure regulator Product output 12 Ball valve...

  • Page 19: Protective And Monitoring Equipment

    Operating manual Piston Pump EvoMotion 5-60 5   Description 5.2.2   Fluid section The fluid section (6) has been designed as a piston pump with exchangeable ball valves. The pump piston runs in two fixed packings which are self-adjusting by means of a pressure spring, thus resulting in a long service life.

  • Page 20: Data

    Operating manual Piston Pump EvoMotion 5-60 5   Description Order no. Designation 9992504 Separating agent 250 ml 2322562 Operating manual, in German See Chapter EU Declaration of Con- Declaration of Conformity formity [8 63] 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 5-60 5   Description 5.5.3   Technical Data Description Units Evo Motion 20-30 Pump ratio Volume flow per double stroke (DH) cm³ / cc Maximum operating pressure Maximum possible strokes in operation DH/min Maximum recommended strokes per minute...
  • Page 22 Operating manual Piston Pump EvoMotion 5-60 5   Description Description Units Evo Motion 20-30 Ambient temperature - Storage °C -20–60 °F -4–140 Relative humidity 10–95 (without condensation) ∠° Allowable inclination for operation ± 10 * Measured A-rated emission sound pressure level at distance of 1 m, LpA1m in accordance with DIN EN 14462: 2015.
  • Page 23 Operating manual Piston Pump EvoMotion 5-60 5   Description 5.5.4   Dimensions and Connections B_04139 inch 5.91 7.20 28.0 7.56 11.2 G 3/8" Order number 2333563 | Edition 10/2020...
  • Page 24 Operating manual Piston Pump EvoMotion 5-60 5   Description inch M36×2 ø 8 ø 0.31 8.27 8.15 3.15 ø 7 ø 0.28 7.17 3.15 4.17 96.5 3.80 ø 9 ø 0.35 ø 7 ø 0.28 5.87 ø 25 ø 0.98 5.5.5   Performance Diagrams...

  • Page 25: Operating Elements

    Operating manual Piston Pump EvoMotion 5-60 5   Description EvoMotion 5-60 bar (MPa) nl/min <psi> <scfm> 40 (4) <7.1> <580> 30 (3) <5.3> <440> 20 (2) <3.5> <290> 10 (1) <1.8> <150> l/min <0.16> <0.32> <0.48> <0.63> <0.79> <0.95> <gpm> C_00174 Product pressure in bar;...
  • Page 26 Operating manual Piston Pump EvoMotion 5-60 5   Description Ball valve positions: B_04088 Open: working position Closed: the air motor can still be under pressure 5.6.2   Return valve Installing a return valve is absolutely necessary for carrying out a complete depressurization of the pump (see Chapter Pressure Relief / Work Interruption [8 34]).

  • Page 27: Assembly And Commissioning

    This pump can be used as part of a spraying or feed system. Individual supplement components for this pump can be found in the Wagner accessories catalogue, or can be put together with a spraypack configurator. The nozzles must be selected according to the spray gun operating manual.
  • Page 28 Operating manual Piston Pump EvoMotion 5-60 6   Assembly and Commissioning B_04143 Pump Pressure regulator Sliding tables Spray gun Suction system Return tube Return valve 1. Mount pump (1) on wall mount or trolley (6). 2. With an AirSpray system, fit the air hose on the spray gun and on the air line (cleaned compressed air).

  • Page 29: Grounding

    Operating manual Piston Pump EvoMotion 5-60 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 30 Operating manual Piston Pump EvoMotion 5-60 6   Assembly and Commissioning B_00304 Grounding scheme (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 31: Commissioning

    Operating manual Piston Pump EvoMotion 5-60 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_04144 Grounding cable 1. Screw on grounding cable with eyelet.
  • Page 32 Operating manual Piston Pump EvoMotion 5-60 6   Assembly and Commissioning 1. Secure spray gun with safety lever. 2. Check the permissible pressures. 3. Check all connections for leaks. 4. Check hoses for damage in accordance with chapter Safety Checks and Maintenance Intervals [8 39].

  • Page 33: Operation

    Operating manual Piston Pump EvoMotion 5-60 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 5-60 7   Operation B_04097 open closed 7.3.1   Feed System After basic flushing, the pump can be filled with working material. 1. Close return valve (8). 2. Slowly open the ball valve (2). 3. Set the required operating pressure on the pressure regulator (1).
  • Page 35 Operating manual Piston Pump EvoMotion 5-60 7   Operation Process for relieving pressure B_04312 Closed 1. Close the spray gun. 2. Close ball valve (2). 3. Release the system of pressure by opening the spray gun. 4. Close and secure the spray gun.

  • Page 36: Basic Flushing

    Operating manual Piston Pump EvoMotion 5-60 7   Operation NOTICE Hardened working product in the spraying system when 2K product is processed! Using 2K materials can destroy the pump and spraying system. 4 Observe the manufacturer's processing rules, particularly in regards to the pot life.

  • Page 37: Filling With Working Product

    Operating manual Piston Pump EvoMotion 5-60 7   Operation 4. Place the suction hose (7) in the grounded tank with flushing agent (10). 5. Open the ball valve (2) and set the pressure regulator (1) to approx. 0.05 MPa; 0.5 bar;...

  • Page 38: Cleaning And Maintenance

    Operating manual Piston Pump EvoMotion 5-60 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 5-60 8   Cleaning and Maintenance 1. Check hoses, pipes, and couplings every day and replace if necessary. 2. Before every commissioning, check all connections for leaks. 3. Additionally, the operator must regularly check the complete hoses for wear and tear as well as for damage at intervals that he/she has set.
  • Page 42 Operating manual Piston Pump EvoMotion 5-60 8   Cleaning and Maintenance B_04093 Open Closed 1. Visual check: personal safety equipment, grounding and all devices ready to use. 2. Place an empty, grounded collection tank (9) under the return tube (4). 3. Place the suction hose (7) in an empty, grounded tank (10).
  • Page 43 Operating manual Piston Pump EvoMotion 5-60 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: Troubleshooting And Rectification

    Operating manual Piston Pump EvoMotion 5-60 9   Troubleshooting and Rectification 9   TROUBLESHOOTING AND RECTIFICATION Malfunction Cause Remedy The pump does not The pump does not start or stops. Open and close ball valve on the pres- work. sure regulator unit or briefly disconnect compressed air supply.
  • Page 45 Operating manual Piston Pump EvoMotion 5-60 9   Troubleshooting and Rectification If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER service center. Order number 2333563 | Edition 10/2020...

  • 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: Tools

    Operating manual Piston Pump EvoMotion 5-60 10   Repairs 10.3   TOOLS The following tools are required for assembling and disassembling the device (if possible, always bring entire tool sets with you): – Torque wrench 2.5 Nm; 1.84 lbft / 5; 3.7 / 10; 7.4 / 15; 11.1 / 30; 22.1 / 40; 29.5 –...

  • Page 48: Function Test After Repair Work

    Operating manual Piston Pump EvoMotion 5-60 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 5-60 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 5-60 13   Accessories 13   ACCESSORIES DN16 DN25 B_04147 Order no. Designation 2329535 Piston pump 2330596 Piston pump for sensor 236219 Grounding cable, complete 3 m; 9.8 ft 9992504 Separating agent 250 ml; 250 cc 9992505 Separating agent 500 ml;...

  • Page 51: Wall Mount And Trolley

    Operating manual Piston Pump EvoMotion 5-60 13   Accessories Order no. Designation ♦ 2324110 Suction hose, DN16-SSt, complete 2323225 Suction elbow for hopper SSt 2332169 Hopper set, 5 l for piston pump ♦ 2323325 Suction filter, DN25-18mesh-SSt ♦ ♦ 2323396 Suction filter, DN16-18 mesh-SSt...
  • Page 52 Operating manual Piston Pump EvoMotion 5-60 13   Accessories Order no. Designation ♦ 367943 Connecting part 4“ Tube plug, ribbed Saddle feet for round tubes Plug 9900218 Hexagon screw 2332143 Wall mount 3061695 Hexagon screw without shaft, M6x55 9998747 Handle ♦...

  • Page 53: 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 54: Overview Of The Components

    Operating manual Piston Pump EvoMotion 5-60 14   Spare Parts 14.3   OVERVIEW OF THE COMPONENTS 5 Nm; 3.7 lbft 15 Nm; 11.1 lbft B_04148 Without sen- With sensor Designation Order no. Order no. 2329535 2330596 EvoMotion 5-60 PE/T U3B05012075 U3B05012075S Air motor M50 EM...

  • Page 55: M50 Air Motor With Em Fixing Sensor

    Operating manual Piston Pump EvoMotion 5-60 14   Spare Parts 14.4   M50 AIR MOTOR WITH EM FIXING SENSOR 5 Nm; 3.7 lbft 10 Nm; 7.4 lbft 2.5 Nm; 1.84 lbft 2.5 Nm; 1.84 lbft 5 Nm; 3.7 lbft 5 Nm; 3.7 lbft...
  • Page 56 Operating manual Piston Pump EvoMotion 5-60 14   Spare Parts Order no. Designation U3B05012075S M50 Air Motor, EM sensor M205.04 Double nipple 2384362 Air pressure regulator (new, starting from serial no. 1422) 9998677 Pressure gauge 9998039 Elbow fitting M106.00 Ball valve...
  • Page 57 Operating manual Piston Pump EvoMotion 5-60 14   Spare Parts Order no. Designation T6190.00 Piston rod, complete - motor K606.02 Lock washer for waves A160.01A Washer 9982078 Hose, black 9992831 Loctite® 542 9998157 Loctite® 480 9998808 Mobilux® EP 2 grease 9970154 Sealing ring ♦⋆...

  • Page 58: M50 Air Motor Without Em Fixing Sensor

    Operating manual Piston Pump EvoMotion 5-60 14   Spare Parts 14.5   M50 AIR MOTOR WITHOUT EM FIXING SENSOR 5 Nm; 3.7 lbft 10 Nm; 7.4 lbft 2.5 Nm; 1.84 lbft 2.5 Nm; 1.84 lbft 5 Nm; 3.7 lbft 5 Nm; 3.7 lbft...
  • Page 59 Operating manual Piston Pump EvoMotion 5-60 14   Spare Parts Order no. Designation 9998677 Pressure gauge 9998039 Elbow fitting M106.00 Ball valve 9998253 Male stud elbow 9906005 Hexagon socket head cap screw (old) 2334205 Hexagon socket head cap screw (new, starting from serial no. 1422) T162.71...

  • Page 60: Reversing Valve

    Operating manual Piston Pump EvoMotion 5-60 14   Spare Parts Order no. Designation 9982078 Hose, black 9992831 Loctite® 542 9998157 Loctite® 480 9998808 Mobilux® EP 2 grease ♦⋆ 9970154 Sealing ring 9992528 Loctite® 270 ● T9096.00 EvoMotion 5-60 air motor service set ♦...
  • Page 61 Operating manual Piston Pump EvoMotion 5-60 14   Spare Parts 14.7   FLUID SECTION 60 30 Nm; 22.1 lbft PTFE PTFE PTFE 30 Nm; 22.1 lbft 15 Nm; 11.06 lbft 40 Nm; 29.5 lbft B_04149 Order no. Designation 2329681 Fluid section 60 PE/T EM T6158.00...
  • Page 62 Operating manual Piston Pump EvoMotion 5-60 14   Spare Parts Order no. Designation A151.03A Pressure ring H210.03 Spring, upper B0449.03 Pump housing, upper L228.05 O-ring ♦⋆ ♦⋆ L484.05 Piston seal K643.02 Round wire snap ring for shafts B0450.03 Cylinder tube, lower D223.53...

  • Page 63: 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 2333563 | Edition 10/2020...
  • Page 64 Operating manual Piston Pump EvoMotion 5-60 15   Declaration of Conformity Order number 2333563 | Edition 10/2020...
  • Page 65 Operating manual Piston Pump EvoMotion 5-60 15   Declaration of Conformity Order number 2333563 | Edition 10/2020...
  • Page 66 Operating manual Piston Pump EvoMotion 5-60 15   Declaration of Conformity Order number 2333563 | Edition 10/2020...
  • Page 68 Order number 2333563 Edition 10/2020 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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