WAGNER EvoMotion 40-15 Installation instructions

II 2G IIB c T3/T4 X B_04119
Translation of the Original
Operating Manual
Piston Pump
Flow Rate 15 cm3
Version 12/2015

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OPERATING MANUAL
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Table of Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations in the Text 7
1.5 Terminology for the Purpose of this Manual 8
2 CORRECT USE 9
2.1 Device Types 9
2.2 Type of Use 9
2.3 Use in an Explosion Hazard Area 9
2.4 Safety Parameters 9
2.5 Processible Working Materials 10
2.6 Reasonably Foreseeable Misuse 11
2.7 Residual Risks 11
3 IDENTIFICATION 12
3.1 Explosion Protection Identication 12
3.2 Identication X 12
3.3 Type Plate 13
4 GENERAL SAFETY INSTRUCTIONS 14
4.1 Safety Instructions for the Operator 14
4.1.1 Electrical Equipment 14
4.1.2 Personnel Qualications 14
4.1.3 Safe Work Environment 14
4.2 Safety Instructions for Sta 15
4.2.1 Safe Handling of WAGNER Spray Devices 15
4.2.2 Grounding the Device 16
4.2.3 Product Hoses 16
4.2.4 Cleaning and Flushing 17
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 18
4.2.6 Touching Hot Surfaces 18
5 DESCRIPTION 19
5.1 Components 19
5.2 Mode of Operation 19
5.3 Protective and Monitoring Equipment 20
5.4 Scope of Delivery 20
5.5 Data 21
5.5.1 Materials of Paint-wetted Parts 21
5.5.2 Technical Data 21
5.5.2.1 Technical Data 22
5.5.2.2 Measurements and Connections 23
5.5.3 Performance Diagrams 24
5.6 Pressure Regulator Unit 25
5.6.1 Safety and Motor Pressure Relief Valve 26
5.6.2 Return Valve 26

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Table of Contents
6 ASSEMBLY AND COMMISSIONING 27
6.1 Training Assembly/Commissioning Sta 27
6.2 Storage and Installation Conditions 27
6.3 Transportation 27
6.4 Assembly and Installation 28
6.4.1 Ventilation of the Spray Booth 28
6.5 Grounding 29
6.6 Commissioning 31
7 OPERATION 33
7.1 Training the Operating Sta 33
7.2 Safety Instructions 33
7.2.1 General Rules for Making Adjustments to the Spray Gun 34
7.3 Emergency Stop 35
7.4 Spraying 36
7.5 Pressure Relief/Work Interruption 37
7.6 Basic Flushing 38
7.6.1 Filling with Working Material 39
8 CLEANING AND MAINTENANCE 40
8.1 Cleaning 40
8.1.1 Cleaning Sta 40
8.1.2 Safety Instructions 40
8.1.3 Decommissioning and Cleaning 41
8.1.4 Long-term Storage 41
8.2 Maintenance 42
8.2.1 Maintenance Sta 42
8.2.2 Safety Instructions 42
8.2.3 Regular Maintenance Work 43
8.2.4 Filling Separating Agent 43
8.2.5 Emptying the Pump 44
8.2.6 Filling the Empty Pump 46
8.2.7 Product Hoses, Tubes and Couplings 48
9 TROUBLESHOOTING AND RECTIFICATION 49
10 REPAIR 50
10.1 Repair Personnel 50
10.2 Mounting Materials 50
11 DISPOSAL 51
12 ACCESSORIES 52
12.1 EvoMotion 40-15 accessories 52
12.2 Accessories for Product Outlet 52
12.3 Accessories for Product Inlet 52
12.4 Wall Mount and Trolley 55

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Table of Contents
13 SPARE PARTS 56
13.1 How Can Spare Parts Be Ordered? 56
13.2 Overview of the Components 57
13.3 Air Motor 58
13.3.1 Reversing Valve 61
13.4 Fluid Section 15 62
13.5 Air Regulator Set for EvoMotion 40-15 65
13.6 Air Regulator Set for AirCoat Air 66
13.7 Trolley 4" 67
13.8 4-Wheel Trolley 68
14 WARRANTY AND CONFORMITY DECLARATIONS 69
14.1 Important Notes Regarding Product Liability 69
14.2 Warranty Claim 69
14.3 CE Declaration of Conformity 70
14.4 Notes on German Regulations and Guidelines 70

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1 ABOUT THESE INSTRUCTIONS
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this operating manual highlight particular dangers to users and
to the device and state measures for avoiding the hazard. These warning instructions fall
into the following categories:
Danger - immediate risk of danger.
Non-observance will result in death or serious injury.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
Note - provides information about particular characteristics and how to proceed.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the danger and its consequences.
NOTICE
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 operating and service
sta.
Operating and service personnel should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.1 PREFACE

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1.3 LANGUAGES
The operating manual is available in the following languages:
Language Order No. Language Order No.
German 2333557 English 2333558
French 2333559 Spanish 2333561
Italian 2333560 Hungarian 2352156
Russian 2367138
1.4 ABBREVIATIONS IN THE TEXT
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Double stroke
DN Nominal diameter
PN Nominal pressure
Two components
Materials
Stainless steel
Polyethylene
Ultra-high molecular weight
polyethylene
Polytetrauorethylene
PTFE with graphite
PTFE
Leather
Additional languages on request or at:

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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Sta qualications
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.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as
well as the necessary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person A person who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge and is familiar with the relevant and generally
accepted rules of technology so that he/she can inspect and
assess the status of devices and coating systems based on
workplace safety.
In the context of
TRBS1203 (2010 /
Revision 2012)
Additional requirements for skilled persons are given in
the TRBS1203(2010/Revision 2012): Expert knowledge in
the areas of protection against excessive pressure, electrical
hazards, and explosion protection (where applicable).

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40-15
2 CORRECT USE
2.1 DEVICE TYPES
2.2 TYPE OF USE
2.3 USE IN AN EXPLOSION HAZARD AREA
Pneumatic pump with spraypack:
The device is suitable for processing liquid materials like paints and lacquers in accordance
with the classication into explosion classes IIA or IIB.
The pneumatic pump can be employed in explosion hazard zones (Zone 1).
See Chapter 3.
2.4 SAFETY PARAMETERS
WAGNER accepts no liability for any damage arising from incorrect use.
Use the device only to work with the products recommended by WAGNER.
Only operate the device as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The pneumatic pump may only be operated under the following conditions:
The operating sta must be trained on the basis of this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must
be observed.
The statutory requirements and accident prevention regulation standards in the
country of use must be observed.

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2.5 PROCESSIBLE WORKING MATERIALS
Abrasive working materials and pigments!
Greater wear of parts carrying the product.
Do not use any grainy and abrasive working materials with large, sharp-edged
pigments.
Use the application-related model (ow rate/cycle, material packaging, valve seat,
etc.), as specied in Chapter 5.5.
Check if the uids and solvents used are compatible with the pump construction
materials as indicated in Chapter 5.5.1.
NOTICE
Wear caused by abrasive working materials is not covered by the warranty.
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
Legend
recommended limited suitability less suitable

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2.7 RESIDUAL RISKS
Residual risks are risks which cannot be ruled out even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk Source Consequences Specic measures Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Handling of
lacquers and
cleaning agents
Skin irritation,
allergies
Use personal safety
equipment.
Operation,
Observe safety data
sheets
maintenance,
disassembly
Lacquer in air
outside the dened
working area
Lacquering outside
the dened
working area
Inhalation of
substances
hazardous to
health
Observe work and
operation instructions.
Use personal safety
equipment
Operation,
maintenance
2.6 REASONABLY FORESEEABLE MISUSE
The forms of misuse listed below may result in physical injury or property damage:
coating work pieces which are not grounded;
unauthorized conversions or modications to the pneumatic pump;
processing dry or similar coating products, e.g., powder;
using defective components, spare parts or accessories other than those described in
the "Accessories" chapter of this operating manual;
continuing work with a defective or kinked product hose;
working with incorrectly set values;
processing food.

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3.1 EXPLOSION PROTECTION IDENTIFICATION
3 IDENTIFICATION
3.2 IDENTIFICATION X
Maximum surface temperature
The maximum surface temperature of the piston pump can be reached if it runs dry.
Ensure that the piston pump is lled with sucient working or ushing agent.
Ensure that the separating agent tank is lled with sucient separating agent.
Temperature class T3: No dry running protection
Temperature class T4: With dry running protection
Ignition temperature
Ensure that the ignition temperature of the surrounding gases (pumping product,
cleaning agents) is higher than the maximum permitted surface temperature of the
device.
Ambient temperature
The permissible ambient temperature is: +5 °C to +50 °C; +41 °F to +122 °F.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
As dened in Directive 94/9/EC (ATEX 95), the device is suitable for use in potentially
explosive areas.
CE CE mark (European Communities)
Explosion-proof equipment
II Device class II (not mining)
2 Category 2 device (suitable for zone 1)
G Ex-atmosphere gas
c Constructional security
IIB Device class (Gas) IIB
T3 Temperature class T3: maximum surface temperature 200 °C; 392 °F
T4 Temperature class T4: maximum surface temperature 135 °C; 275 °F
X Special instructions exist for safe operation. See the following
Chapter "Identication X".

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Pumpentyp / Pump type
Max. Materialdruck / Fluid pressure
Übersetzungsverhältnis / Ratio
Fördermenge DH / Delivery DS
Max. Luftdruck / Air pressure
Max. Temp. Material / Fluid
Baujahr - Serie Nr. / Year of manufacture - Serial No.
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
J. WAGNER AG
MADE IN SWITZERLAND
CH-9450 ALTSTÄTTEN II 2 G c IIB T3/T4 X
1
2
4
5
6
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Safe handling of WAGNER spray devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the device against steel or rusty iron.
Do not drop the device.
Use only tools that are made of a permitted material.
Surface spraying, electrostatics
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.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the device.
National regulations
Ensure that the national explosion prevention rules and regulations are observed when
setting up the device.
Air in the pump uid
Flammable gas mixtures can form if air reaches the pump uid.
Prevent the pump from taking in air and running dry.
If air has been taken in, x the leak. Then, ll slowly and in a controlled manner until the
air has escaped.
Air in the pumped uid can be caused by damaged packings.
Avoid operating the pump with damaged packing.
Ensure that the separating uid tank is lled with sucient separating uid.
Periodically check that the pump is working smoothly, paying special attention to the
presence of air in the pumped uid.
Filling and emptying
Flammable gas mixtures can form in the uid section or product hoses if the pump must
be emptied for maintenance.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
3.3 TYPE PLATE
1 Manufacturer and CE
Identication
2 Pump type
3 Maximum product pressure
4 Pump ratio
5 Flow rate per double stroke
6 Maximum air inlet pressure
7 Maximum product temperature
8 Model year - serial number
9 Read operating manual before use!

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4 GENERAL SAFETY INSTRUCTIONS
4.1 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 EQUIPMENT
Electrical devices and equipment
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, there is a danger from line voltage.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard or are damaged.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground wire
connection.
Keep liquids away from electrical devices.
4.1.2 PERSONNEL QUALIFICATIONS
Ensure that the device is only operated, maintained and repaired by trained persons.
4.1.3 SAFE WORK ENVIRONMENT
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 megohms).
Paint mist extraction systems/ventilation systems must be tted on site according to
local regulations.
Ensure that product / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment is available and is used.
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megohms.

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Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
In electrostatics application: Anyone tted with a pacemaker must not enter the high-
voltage area!
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before all work on the device, in the event of work interruptions and functional faults:
- Relieve pressure from spray guns and devices.
- Secure spray guns against actuation.
- Switch o the energy/compressed air supply.
- Disconnect the control unit from the mains.
- In the event of functional faults, remedy the fault as described in the "Troubleshooting"
chapter.
Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun handle.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 megohms.
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
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 and connections etc.).
- Regular monitoring of leaks and defects via visual inspection and odor testing, e.g.,
daily before commissioning, at the end of work or weekly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
Grounding
Make sure that the ground and potential equalization of all system parts are performed
reliably and continuously and can withstand the expected stress (e.g., mechanical
stress, corrosion).
4.2 SAFETY INSTRUCTIONS FOR STAFF
4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES

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4.2.3 PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products and the
ushing agents used.
Ensure that the product hose is suitable for the pressure generated.
Ensure that the following information can be seen on the high-pressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture
4.2.2 GROUNDING THE DEVICE
Friction, owing liquids and air or electrostatic coating processes create charges. Flames or
sparks can form during discharge. Grounding prevents electrostatic charging.
Ensure that the device is grounded. See chapter "Grounding".
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are wearing
static dissipative shoes.
Wear static dissipative gloves when spraying. The grounding takes place via the spray
gun handle.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.
If necessary or atleastevery 12 months,theliquidejectiondevices shouldbe checked for
safe working conditions by an expert (e.g., WAGNER Service Technician) in accordance
with the guidelines for liquid ejection devices (DGUV regulation 100-500).
- For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure Relief" chapter:
- If pressure relief is required.
- If the spraying work is interrupted or stopped.
- Before the device is cleaned on the outside, checked or serviced.
- Before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by paint or ushing agents:
Note the paint or ushing agent that you have been using.
Consult a doctor immediately.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun briey in a position.

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4.2.4 CLEANING AND FLUSHING
Relieve the pressure from the device.
De-energize the device electrically.
Preference should be given to non-ammable cleaning and ushing agents.
When carrying out cleaning work with ammable cleaning agents, make sure that all
equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or
static dissipative and grounded.
Observe the specications of the paint manufacturer.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical
ventilation.
Take measures for workplace safety (see Chapter 4.1.3).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- depending on the ushing agent (solvent) used,
explosive mixture inside the lines and items of equipment.
Make sure that the hoses are laid only in suitable places. Do not lay hoses:
- in high-traffic areas,
- on sharp edges,
- on moving parts or
- on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses are
never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 megohm.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coecient. In some cases their volume can rise with
consequent damage to pipes, ttings, etc. and cause uid leakage.
When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can
enter the tank. Thus a negative pressure is avoided. The vacuum could implode the tank
(squeeze) and can cause it to break. The tank would leak and the liquid would ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.

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4.2.6 TOUCHING HOT SURFACES
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109 °F: identify the unit with a warning label that says "Warning - Hot Surface".
- Instruction label Order no. 9998910
- Protection label Order no. 9998911
Note: Order the two stickers together.
Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
Never spray into a closed tank when using solvents for ushing.
External cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects and
never spray cleaning agents with a gun. Cleaning the device must not damage it in any
way.
Ensure that no electric component is cleaned with or immersed into solvent.
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
When preparing or working with lacquer and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents and cleaning agents
being used.
Take thespeciedprotectivemeasures.Inparticular,usepersonal protectiveequipment:
safety goggles, protective clothing and gloves, as well as respiratory protection and
skin protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient health and environmental safety: Operate the device in a spray booth or
on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.

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5 DESCRIPTION
The piston pump is driven with compressed air (11). The compressed air moves the air
piston in the air motor (1) and the associated pump pistons in the uid section(6) up and
down. At the end of each stroke, the compressed air is redirected by a reversing valve (9).
The working material is sucked up during the upwards stroke and is continuously conveyed
towards the product outlet (5) in both stroke directions.
Air motor (1)
The air motor with its pneumatic reverse (9) does not require pneumatic oil.
The compressed air is fed to the motor via an air regulator (11) and the ball valve (12).
The air motor must be equipped with a safety valve (10) in accordance with
Chapter 5.4.3. The safety valve (10) has been set and sealed at the factory. In case of
pressures over and above the permissible operating pressure, the valve, which is held with
a spring, automatically opens and releases the excess pressure.
Fluid section (9)
The uid section has been designed as a piston pump with exchangeable ball valves. The
hard chrome-plated pump piston runs in two xed packings which are self-adjusting by
means of a pressure spring, thus resulting in a long service life.
Between the air motor and the uid section there is a separating agent cup (4) for separating
the separating agent.
1 Air motor
2 Air inlet
3 Mounting ange
4 Separating uid tank
5 Product outlet
6 Fluid section
7 Product inlet
8 Grounding connection
9 Reversing valve
10 Safety valve (air motor
vent)
11 Air pressure regulator
12 Ball valve
13 Air outlet to the
reversing valve
14 Air inlet into the
reversing valve
5.1 COMPONENTS
5.2 MODE OF OPERATION

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5.3 PROTECTIVE AND MONITORING EQUIPMENT
Safety valve
The air motor is tted with a safety valve. The safety valve has been set and sealed at the
factory. In case of pressures over and above the permissible operating pressure, the valve,
which is held with a spring, automatically opens and releases the excess pressure.
Overpressure!
Risk of injury from bursting components.
Never change the safety valve setting.
WARNING
5.4 SCOPE OF DELIVERY
Pneumatic piston pump
Consists of:
-Fluid section
-Air motor
-Connection set for air motor - uid section
-Air pressure regulator for air motor
The scope of delivery also includes:
Separating agent 250 ml; 250 cc order no.: 9992504
Declaration of conformity see Chapter 14.3
Operating manual, German order no.: 2333537
Operating manual in the local language see Chapter 1.3
The delivery note shows the exact scope of delivery. Accessories: see Chapter 12.