WAGNER EvoMotion 5-125 Operational manual

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

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VERSION 01/2018 ORDER NUMBER DOC 2316596
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 7
1.5 Terminology for the Purpose of this Manual 7
2 CORRECT USE 8
2.1 Device Types 8
2.2 Type of Use 8
2.3 For Use in Potentially Explosive Areas 8
2.4 Processible Working Materials 9
2.5 Misuse 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Identication "X" 10
3.3 Type plates 11
4 BASIC SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Equipment 12
4.1.2 A Safe Work Environment 12
4.1.3 Personnel Qualications 13
4.2 Safety Instructions for the Personnel 13
4.2.1 Personal Safety Equipment 13
4.2.2 Safe Handling of WAGNER Spray Devices 14
4.2.3 Grounding the Unit 14
4.2.4 Product hose 15
4.2.5 Cleaning and Flushing 16
4.2.6 Touching Hot Surfaces 16
4.2.7 Maintenance and Repair 17
4.2.8 Protective and Monitoring Equipment 17
5 DESCRIPTION 18
5.1 Components 18
5.2 Mode of Operation 18
5.2.1 Air motor 18
5.2.2 Fluid section 18
5.3 Protective and Monitoring Equipment 19
5.3.1 Safety valve 19
5.4 Included Items 20
5.5 Data 20
5.5.1 Materials of Paint-wetted Parts 20
5.5.2 Recommended Packings 20
5.5.3 Technical data 21
5.5.4 Dimensions and Connections 22
5.5.5 Performance diagrams 23
5.6 Operating elements 24
5.6.1 Pressure Regulator Unit 24

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6 ASSEMBLY AND COMMISSIONING 25
6.1 Training of Assembly/Commissioning Personnel 25
6.2 Storage Conditions 25
6.3 Installation Conditions 25
6.4 Transportation 25
6.5 Assembly and Installation 26
6.5.1 Ventilation of the Spray Booth 27
6.5.2 Air Supply Lines 27
6.5.3 Product supply lines 27
6.6 Grounding 27
6.7 Commissioning 29
7 OPERATION 30
7.1 Training the Operating Personnel 30
7.2 Emergency Stop 30
7.3 Tasks 31
7.4 Pressure Relief/Work Interruption 32
7.5 Basic Flushing 33
7.6 Filling with Working Material 33
8 CLEANING AND MAINTENANCE 34
8.1 Cleaning 34
8.1.1 Cleaning Personnel 34
8.1.2 Decommissioning and Cleaning 34
8.1.3 Long-term Storage 34
8.2 Maintenance 35
8.2.1 Maintenance Personnel 35
8.2.2 Maintenance Instructions 35
8.2.3 Safety Checks and Maintenance Intervals 36
8.2.4 Emptying Pump 38
8.2.5 Filling the Empty Pump 39
9 TROUBLESHOOTING AND RECTIFICATION 40
10 REPAIRS 41
10.1 Repair Personnel 41
10.2 Repair Notes 41
10.3 Tools 41
10.4 Cleaning the Parts After Disassembly 42
10.5 Assembly of the Device 42

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11 FUNCTION TEST AFTER REPAIR WORK 43
12 DISPOSAL 43
13 ACCESSORIES 44
14 SPARE PARTS 45
14.1 How can spare parts be ordered? 45
14.2 Overview of the Components 46
14.3 Air motor M80 EM C60 48
14.4 Fluid section 125 50
14.4.1 Reversing valve 52
14.4.2 Pump air regulator 52
15 GUARANTEE AND CONFORMITY DECLARATIONS 53
15.1 Important notes on product liability 53
15.2 Warranty claim 53
15.3 EU Declaration of Conformity 54

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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.
The device may only be operated by trained personnel and in compliance with this
operating manual.
Operating and service personnel should be instructed according to the safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this 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 Potential risk.
Non-observance can result in death or serious injury.
CAUTION Potentially hazardous situation.
Non-observance may result in minor injury.
NOTICE Potentially hazardous situation.
Non-observance may result in damage to property.
Notice Provides information about particular characteristics and how
to proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.

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1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2316595
Translation of the original operating manual
Language Order no. Language Order no.
French 2316597 Dutch 2316598
Italian 2316599 Spanish 2316600
Danish 2316602 Swedish 2316601
English 2316596 -- --
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order no. Order number
Double stroke
Two components
Ultra high molecular weight polyethylene
PTFE
Polytetrauorethylene
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning
agent.
Flushing Internal ushing of paint-wetted parts with ushing agent.
Product pressure
generator
Pump or pressure tank.
Personnel 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 in
accordance with TRBS
1203
(2010/Revision 2012)
A person, who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the areas of explosion protection, protection
from pressure hazards and electric hazards (if applicable) 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.

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2 CORRECT USE
2.1 DEVICE TYPES
Pneumatic piston pump and its spray packs:
5-125
2.2 TYPE OF USE
The device is suitable for processing liquid products like paints and lacquers:
– Non-ignitable products.
– Products in accordance with their classication in explosion class IIB.
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 xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device can be employed in potentially explosive areas (Zone 1) (see Chapter 3).

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2.4 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
recommended limited suitability not suitable
NOTICE
Abrasive working materials and pigments!
Greater wear of product-wetted parts.
Use the application-oriented model (ow rate/cycle, product, valves, etc.) as
indicated 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.
Use suitable device combinations (packings, valves etc.)
Wear caused by abrasive working materials is not covered by the warranty.
Typical applications
Fields of application
Furniture industry
Kitchen manufacturers
Joinery
Window factories
Steel-processing industry
Construction of vehicles
Shipbuilding
recommended limited suitability not suitable
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
No dry coating products, e.g., powder are processed.
no food, medicine or cosmetics are processed.
It is important to note that the device's materials are not food-safe.
Do not process any 2K products.

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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened 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
Device class II
Category 2 (zone 1)
Ex-atmosphere gas
Explosion protection
Ignition protection for non-electrical devices
Explosion group
Maximum surface temperature < 200 °C; 392 °F (without drying
protection active)
Maximum surface temperature < 135 °C; 275 °F (with drying protection
active)
High safety level
There are special instructions to ensure safe operation.
See the following Chapter "Identication X".
3.2 IDENTIFICATION "X"
The maximum surface temperature corresponds to the permissible product temperature.
This and the permissible ambient temperature can be found in Chapter 5.5.3 (Technical
Data).
Safe Handling of WAGNER Spray Devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
knocking or pushing metal against metal is to be avoided;
Do not drop the device or components.
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.
Ignition temperature of the coating product
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 range is: 5 °C to 60 °C; 41 °F to 140 °F.
Surface spraying, electrostatics
Do not spray device parts using electrostatic equipment.