EvoMotion 5-125
Piston pump
Delivery volume 125cm³
Version 01/2018
C_00116
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 Identication 10
3.2 Identication "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 Qualications 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
WARNING
CAUTION
NOTICE
Notice
Explanation of warning notice:
Immediate risk of danger.
Non-observance will result in death or serious injury.
Potential risk.
Non-observance can result in death or serious injury.
Potentially hazardous situation.
Non-observance may result in minor injury.
Potentially hazardous situation.
Non-observance may result in damage to property.
Provides information about particular characteristics and how
to proceed.
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
Polytetrauorethylene
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
Pump or pressure tank.
generator
Personnel qualications
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 sucient 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 classication 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
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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 dened 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 "Identication 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 sucient working or ushing agent.
Ensure that the separating agent tank is lled with sucient 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.
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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.
Air in the pump uid
Ignitable gas mixtures can form if air enters 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 agent tank is lled with sucient separating agent.
Periodically check that the pump is working smoothly, paying special attention to
the presence of air in the pumped uid.
Filling and emptying
Ignitable gas mixtures can form in the uid section or product hoses if the pump must
be emptied for maintenance and/or repair purposes.
Empty and ll the device slowly and in a controlled manner.
Avoid potentially explosive atmosphere in the surroundings.
3.3 TYPE PLATES
Designation
1 Manufacturer and CE Identication
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!
Wagner International AG
1
Pumpentyp / Pump type
2
Max. Materialdruck / Fluid pressure
3
Übersetzungsverhältnis / Ratio
4
Fördermenge DH / Delivery DS
5
Max. Luftdruck / Air pressure
6
Max. Temp. Material / Fluid
7
Baujahr - Serie Nr. / Year of manufacture - Serial No.
8
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
9
CH-9450 ALTSTÄTTEN
MADE IN SWITZERLAND
II 2 G Ex h IIB T3/T4 Gb X
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4 BASIC 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 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
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, the mains voltage poses a danger.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if it poses a hazard or is damaged.
Must be de-energized before work is commenced. Inform personnel 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 A SAFE WORK ENVIRONMENT
Hazard due to dangerous uids or vapors!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 MΩ).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g. mechanical
stress, corrosion).
Ensure that product hoses / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment (see Chapter 4.2.1) 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 MΩ.
Ensure that during spraying, persons wear electrically conductive gloves. The
grounding takes place via the spray gun handle or the trigger.
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 MΩ.
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Ensure that there are no ignition sources such as naked ames, 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.).
- Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g., daily before commissioning, at the end of work or weekly.
Ensure that maintenance and safety checks are performed regularly.
In the event of defects, immediately bring the device or system to a stop and
arrange to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Hazard due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.
4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
In electrostatics applications: anyone who belongs to a risk group according to EMF
Directive 2013/35/EU (e.g. those with active implants), must not enter the highvoltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or vapors!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
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 the specied protective measures. In particular wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient 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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4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Hazard due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of
lacquer or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
− Disconnect the control unit from the mains.
– In the event of functional faults, remedy the fault as described in the
"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).
− For shut-down devices, the check can be postponed until the next start-up.
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
Danger due to recoil forces!
Actuating the trigger can causes strong recoil forces. Thereby, the user can lose his
balance and injure himself when falling.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
4.2.3 GROUNDING THE UNIT
Hazard due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that all devices and tanks are grounded before each spraying process.
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 or the trigger.
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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 ushing agents used.
Ensure that the product hose and the ttings are 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
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
− in high-traffic areas
− on sharp edges
− on moving parts
− on hot surfaces
Ensure that the hoses are never run over by vehicles (e.g., fork lift trucks), 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.
Ensure that no work is ever performed with a damaged hose.
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 MΩ.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coecient. 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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4.2.5 CLEANING AND FLUSHING
Hazard due to cleaning and ushing!
Explosion hazard and damage to the device.
Preference should be given to non-ignitable 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 specications of the lacquer 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.
Never use chloride or halogenated solvents (such as trichloroethane and methylene
chloride) with units containing aluminium or galvanized and zinc-plated parts. They
may react chemically thus producing an explosion danger.
Take measures for workplace safety (see Chapter 4.1.2).
When commissioning or emptying the device, please note that:
−depending upon the coating product used,
−depending on the ushing agent (solvent) used.
an explosive mixture may temporarily exist inside the lines and components of
equipment.
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:
Relieve the pressure from the device.
De-energize the device electrically.
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.
4.2.6 TOUCHING HOT SURFACES
Hazard due to hot surfaces because of hot coating products!
Risk of burn injuries
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 device with a warning label "Warning – hot surface".
Order no.
9998910 instruction label
9998911 protection label
Note: Order the two stickers together.
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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.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in Chapter 13 and Chapter 14 that are
assigned to the unit.
Do not use any defective components.
Exclusively use accessories listed in Chapter 13 and that are assigned to the unit.
Before all work on the device and in the event of work interruptions:
- Relieve the pressure from the spray gun, high-pressure hoses and all devices.
- Secure the spray gun against actuation.
- Switch o the energy and compressed air supply.
- Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
Hazard due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.
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