WAGNER EvoMotion 5-125 Translation Of The Original Operating Manual

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EvoMotion 5-125

Piston pump Delivery volume 125cm³

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 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

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 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

Pump or pressure tank. generator

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

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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 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.

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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 sucient 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 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!

Wagner International AG

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!

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 inuences.

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 EN61340-4-1 (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 qualications.

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 specied 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 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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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 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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4.2.5 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 specications 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, modied 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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5 DESCRIPTION

5.1 COMPONENTS

Designation

1 Air motor 2 Reversing valve 3 Silencer 4 Air inlet 5 Product inlet 6 Grounding connection 7 Mounting ange 8 Fluid section

9 Air pressure regulator (option) 10 Ball valve (option) 11 Safety valve (option) 12 Spacer (separating uid tank) 13 Product outlet

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2 3

B_06865

5.2 MODE OF OPERATION

The piston pump is driven with compressed air (4). This compressed air moves the air piston up and down in the air motor (1) and it also moves the the associated pump piston up and down in the uid section (8). At the end of each stroke, the compressed air ow is redirected by a reversing valve (2). The working material is sucked up during the upwards stroke and is continuously conveyed towards the product outlet (13) in both stroke directions.

5.2.1 AIR MOTOR

The air motor (1) with its pneumatic reversing valve (2) does not require pneumatic oil. The compressed air can be fed to the motor via an air regulator (9, option) and a ball valve (10 option). The air pressure regulator (9) is tted with a safety valve (11, see Chapter 5.3.1).

5.2.2 FLUID SECTION

The uid section is designed as a piston pump with ap valves. The pump piston runs in the upper xed packings which are self-adjusting by means of a pressure spring. This results in the packing having a long service life. There is a spacer (12) between the air motor and the uid section. It serves to collect the separating agent.

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5.3 PROTECTIVE AND MONITORING EQUIPMENT

5.3.1 SAFETY VALVE

WARNING

Overpressure!

Danger to life from bursting device components.

Never change the safety valve setting.

The air motor is tted with a safety valve. The safety valve (11) 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. As well as handling pressure limits, the valve is also used as a pressure relief valve for the air motor.

Procedure:

1. Close ball valve (10).

2. Pull the ring on the safety valve (11) and hold it until the pressure in the air motor has been equalized.

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5.4 INCLUDED ITEMS

Pneumatic piston pump

– Fluid section – Air motor – Connection elements

The standard equipment includes:

Order no. Designation

1 9992504 Separating agent 250 ml 1 2316595 Operating manual, in German 1 see Chapter 15 Declaration of Conformity 1 see Chapter 1.3 Operating manual in the local language

The delivery note shows the exact scope of delivery. Accessories: see Chapter 13.

5.5 DATA

5.5.1 MATERIALS OF PAINTWETTED PARTS

Description EvoMotion 5-125

Pump housing Carbon steel Piston Carbon steel with silicon carbide coating Valve balls Stainless steel Valve seats Stainless steel Static seals EPDM Sealing packages PE/ T

= Ultra high molecular weight polyethylene

T = Polytetrauorethylene (PTFE)

5.5.2 RECOMMENDED PACKINGS

WAGNER packings for this device:

Product Color

Ultra high molecular weight

transparent polyethylene PTFE white

Each product has the following properties, which inuence the packings:

Designation PE T

Mechanical stability good poor Friction coecient good very good Sealing force good good Chemical resistance very good very good Temperature resistance very good poor

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5.5.3 TECHNICAL DATA

Description Unit

Pump ratio 5:1 Volume ow per double stroke (DH) 125

Maximum operating overpressure

Maximum possible strokes in operation 60

Minimum/maximum air inlet pressure

Compressed air quality: free from oil and water

Air inlet (inside thread) 8.0; 0.31 Minimum Ø of the compressed air supply line 9.0; 0.35 Air consumption at 0.6 MPa; 6 bar; 87 psi per double

stroke Sound pressure level at maximum permissible air

pressure* Sound pressure level at 0.6 MPa; 6bar; 87psi air

pressure* Sound pressure level at 0.4 MPa; 4bar; 58psi air

pressure* Air motor piston diameter 80; 3.15 Product inlet (inside thread) -Product outlet (inside thread) G 1/2“ Weight 25; 55

Maximum product pressure at pump inlet

Product temperature

Ambient temperature

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. Reference measurements have been made by Suva (Swiss National Accident Insurance Fund).

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4.0 40

581

0.2–0.8 2–8

28–116

Quality standard 7.5.4 according to ISO 8573.1, 2010

7: Particle concentration 5–10mg/m³ 5: Humidity: pressure dew point ≤ 7 °C 4: Oil content ≤ 5mg/m3

4.0; 0.14

5–80

41–176

5–60

41–140

WARNING

Exhaust air containing oil!

Risk of poisoning if inhaled.

Provide compressed air free from oil and water.

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5.5.4 DIMENSIONS AND CONNECTIONS

A 126.5 5.0

B 142 5.6

C 1338.5 52.7

D 944.5 37.2

E 170 6.7 F

8 0.31

G - -

H - G1/2“

I 54 2.1

110 4.33

11 0.43

* On-site: possible wall mount xing

B_03460

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5.5.5 PERFORMANCE DIAGRAMS

Example

Stroke frequency

8 bar

6 bar

4 bar

Product pressure bar (MPa) <psi>

B_00301

Product ow - water l/min <gpm>

EvoMotion 5-125 stainless steel

Stroke frequency

bar (MPa)

<psi>

40 (4)

<580>

30 (3)

<440>

20 (2)

<290>

10 20 30 40 50 60

6 bar

4 bar

Air consumption nl/min <scfm>

nl/min

<scfm>

320

<11>

240

<8>

160

<6>

Product pressure

10 (1)

<150>

C_00062

<0.33>

<0.66>

<0.99>

<1.32>

<1.65>

6.25

5.00

3.75

2.50

1.25

Product ow - water A = 8 bar; 0.8 MPa; 116 psi air pressure B = 6 bar; 0.6 MPa; 87 psi air pressure C = 4 bar; 0.4 MPa; 58 psi air pressure

7.50

<1.98>

<3>

l/min

<gpm>

Air consumption

VERSION 01/2018

5.6 OPERATING ELEMENTS

5.6.1 PRESSURE REGULATOR UNIT

ORDER NUMBER DOC 2316596









geschlossen

B_06876



Designation

1 Ball valve Open: working position

Closed: The air motor may still be under pressure.

2 Safety valve 3 Pressure regulator 4 Pressure gauge (air inlet pressure) 5 Compressed air inlet

VERSION 01/2018

ORDER NUMBER DOC 2316596

6 ASSEMBLY AND COMMISSIONING

6.1 TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL

The assembly and commissioning personnel must have the technical skills to safely commission the device.

When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.

A skilled person must check to ensure that the device is in a reliable state after it is installed and commissioned.

6.2 STORAGE CONDITIONS

Until the point of assembly, the device must be stored in a dry location, free from vibrations and with a minimum of dust. The device must be stored in closed rooms.

The air temperature at the storage location must be between -20 °C and 60 °C (-4 °F and 140 °F).

The relative air humidity at the storage location must be between 10% and 95% (without condensation).

6.3 INSTALLATION CONDITIONS

The air temperature at the installation site must be in a range between 4 °C and 40 °C; 39 °F and 104 °F.

The relative air humidity at the installation site must be between 10% and 95% (without condensation).

6.4 TRANSPORTATION

The pump can be moved manually without lifting equipment.

VERSION 01/2018

ORDER NUMBER DOC 2316596

6.5 ASSEMBLY AND INSTALLATION

National regulations

Ensure that the national explosion prevention rules and regulations are observed when setting up the device.

This pump can be used as part of a spraying system or it can be used in a TwinControl system, for example. 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.

Further valves (e.g. spray guns) downstream of the product non-return valve are not discussed in this manual. Observe superordinate operating manual!

Procedure

1. Ensure that the product tank is equipped with the correct drum adaptor or the correct mounting bracket (ø suction tube pump 54 mm, 2.1 inch).

2. Mount the pump vertically with the drum adaptor or with the mounting bracket. The pump must be vertical during operation (maximum permissible tilt of the pump ±10° -> see Chapter 5.5.3).

3. Mount a pressure regulator unit (1).

4. Mount a return valve with corresponding return hose (3).

5. Mount a suitable product non-return valve (4) on the product line.

6. Place the pump in the product tank (6).

7. Provide an empty tank (5).

closed

B_06877

open

VERSION 01/2018

6.5.1 VENTILATION OF THE SPRAY BOOTH

Operate the device in a spray booth approved for the working materials.

- or -

Operate the device on an appropriate spraying wall with the ventilation (extraction) switched on.

Observe national and local regulations for the exhaust air speed.

6.5.2 AIR SUPPLY LINES

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.

ORDER NUMBER DOC 2316596

WARNING

Hose connections!

Risk of injury and damage to the device.

Do not mix up hose connections of product hose and air hose.

6.5.3 PRODUCT SUPPLY LINES

DANGER

Bursting hose, bursting threaded joints!

Danger to life from injection of product.

Ensure that the hose material is chemically resistant to the sprayed products.

Ensure that the spray gun, ttings and product hose between the device and the spray gun are suitable for the pressure generated in the device.

Ensure that the following information can be seen on the high-pressure hose:

- manufacturer,

- permissible operating pressure,

- date of manufacture.

6.6 GROUNDING

WARNING

Discharge of electrostatically charged components in atmospheres containing solvents!

Explosion hazard from electrostatic sparks.

Clean the pump only with a damp cloth.

WARNING

Heavy paint mist if grounding is insucient!

Danger of poisoning. Insucient paint application quality.

Ground all device components. Ground the work pieces to be coated.

VERSION 01/2018

Grounding scheme (example)

ORDER NUMBER DOC 2316596

Ex zone

Conveyor

Work piece

Product tank

B_00304

Floor, static dissipative

Part / workstation Cable cross sections

Pump 4 mm2; AWG 12 Product tank 6 mm2; AWG 10 Conveyor 16 mm2; AWG 6 Spray booth 16 mm2; AWG 6 Spraying stand 16 mm2; AWG 6 Safe operation of the pump is only guaranteed with a grounding

connection. Connect all grounding cables using a short and direct route.

R max < 1 MΩ

Spraying stand

Grounding cable

B_06878

Procedure:

1 Screw on grounding cable with eyelet. 2 Clamp the grounding cable clip to a grounding connection on site. 3 Ground the product tank to an on-site grounding connection. 4 Ground the other parts of the system to an on-site grounding connection (16mm2;

AWG 6).

Ex zone

All devices and equipment must be suitable for use in potentially explosive areas.

All paints, ushing agents and waste tanks have to be electrically conductive.

All tanks must be grounded.

VERSION 01/2018

6.7 COMMISSIONING

ORDER NUMBER DOC 2316596

WARNING

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from ying parts.

Ensure that the pump and suction system are always completely ﬁlled with ushing agent or working medium.

Do not spray the device empty after cleaning.

NOTICE

Impurities in the spraying system!

Spray gun blockage.

Flush the spray gun and paint supply with a suitable ushing agent before commissioning.

Emergency stop, see Chapter 7.2.

Preparation

Before every start-up, the following points should be observed as laid down in the operating manual:

− Secure spray gun with safety lever.

− Check the permissible pressures.

− Check all connections for leaks.

− Check hoses for damage in accordance with Chapter 8.2.3.2.

− Fill the separating agent in accordance with Chapter 8.2.3.1.

Fill the pump with ushing agent

The devices are tested during manufacturing with emulsifying oil, pure oil or solvent. Possible residues must be ushed out of the circuits with a solvent (ushing agent) before commissioning.

− Fill the empty device with ushing agent in accordance with Chapter 8.2.5.

Pressure tightness test

WARNING

Overpressure!

Risk of injury from bursting components.

The operating pressure must not exceed the value shown on the type plate.

− Gradually increase the pressure in pump with the pressure regulator until maximum pressure is reached. Maintain the pressure for 3 minutes and check all connection points for leaks.

− Depressurization in accordance with Chapter 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 installed and commissioned. This includes:

− Carry out safety checks in accordance with Chapter 8.2.3.

Filling with Working Material

− According to Chapter 8.2.5.

VERSION 01/2018

ORDER NUMBER DOC 2316596

7 OPERATION

7.1 TRAINING THE OPERATING PERSONNEL

The operating personnel must be qualied to operate the entire system.

The operating personnel must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.

Before work commences, the operating personnel must receive appropriate system training.

7.2 EMERGENCY STOP

In the case of unforeseen occurrences:

− Close ball valve (2).

− Open the safety valve (5) until the piston pump is entirely depressurized.

Relieve the pressure of the product-transporting parts (3 and

4) with the provided valves.

closed

open

VERSION 01/2018

7.3 TASKS

ORDER NUMBER DOC 2316596

closed

open

B_06877

Ensure that:

commissioning was carried out in accordance with Chapter 6.7.

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Close the valve (3).

3. Slowly open the ball valve (2).

4. Observe superordinate operating manual. Open the valve (4).

5. Activate the pressure regulator (1) and set the required operating pressure.

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 ow.

7. Start work process.

VERSION 01/2018

ORDER NUMBER DOC 2316596

7.4 PRESSURE RELIEF/WORK INTERRUPTION

The pressure must always be relieved when:

− after the spraying tasks are nished,

− before servicing or repairing the spraying system,

− before carrying out cleaning tasks on the spraying system,

− Before moving the spraying system to another location.

− before something must be checked on the spraying system,

− before the nozzle or the lter is removed from the spray gun.

The components for pressure relief on a CE-compliant spraying system include:

− Air cock with pressure relief valve mounted between the compressed air source and the pneumatic pump. In this case, the pressure relief valve is the safety valve (10).

− Outlet equipment (return valve) mounted between pump and spray gun.

Pressure relief procedure

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).

4. Slowly open the return valve (3).

5. When no further overpressure is detected,

close the return valve (3).

6. Pressure can still be present after the valve (4). Relieve the pressure in the product line downstream of valve (4) towards the front if necessary. When doing so, observe the

superordinate operating manual.

Note:

Control air pressure is still present.

Pressure relief of the air (in case of longer work interruptions)

1. Carry out pressure relief of the product (as mentioned above).

2. Ensure that the ball valve (2) is closed.

3. Pull the ring on the safety valve (8) and hold it until the pressure in the air motor has been equalized.

closed

open

B_06877

VERSION 01/2018

B_06936

ORDER NUMBER DOC 2316596

7.5 BASIC FLUSHING

Regular ushing

Regular ushing, cleaning and maintenance ensures the pump's high pumping and extraction capacity.

The cleaning and ushing agents used must be compatible with the working material.

WARNING

Incompatibility of ushing / cleaning agent with the working medium!

Risk of explosion and danger of poisoning by toxic gases.

Examine the compatibility of the ushing and cleaning agents and working media on the basis of the safety data sheets.

Flushing procedures

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Relieve the pump's pressure according to Chapter 7.4.

3. Place empty, grounded metal tank (5) for return product under the return tube (3).

4. Place pump in grounded metal tank (6) with ushing agent.

5. Adjust the pressure regulator (1) to approx. 0.05 MPa; 0.5 bar;

7.25 psi.

Flushing via the return valve

6. Open return valve (3).

7. Slowly open the ball valve (2).

8. Adjust the air pressure on the pressure regulator (1) so that the pump runs smoothly.

9. Flush the system until the cleaning agent that ows into the tank (5) is clean.

10. Close ball valve (2).

11. As soon as there is no pressure remaining in the system, close the return valve (3).

Flushing via the valve

12. Relieve the system's pressure upstream of the valve (4) in accordance with the superordinate operating manual. Open the valve (4).

13. Slowly open the ball valve (2).

14. Rinse until clean ushing agent ows from the system.

15. Close ball valve (2).

16. As soon as there is no pressure remaining in the system, close the valve (4). Observe superordinate operating manual.

17. Repeat steps 6 – 16 if necessary.

External Cleaning

18. Clean the outside of the system.

19. Fully assemble the system.

20. Relieve the pump's pressure according to Chapter 7.4.

21. Dispose of the contents of the tank (5) according to the local regulations.

7.6 FILLING WITH WORKING MATERIAL

closed

open

After basic ushing, the pump can be lled with working material. Proceed according to Chapter 8.2.5, but use working material instead of ushing agent.

VERSION 01/2018

ORDER NUMBER DOC 2316596

8 CLEANING AND MAINTENANCE

8.1 CLEANING

8.1.1 CLEANING PERSONNEL

Cleaning work should be undertaken regularly and carefully by qualied and trained personnel. They should be informed of specic hazards during their training. The following hazards may arise during cleaning work:

− Health hazard from inhaling solvent vapors.

− Use of unsuitable cleaning tools and aids.

8.1.2 DECOMMISSIONING AND CLEANING

Notice

The device should be cleaned for maintenance purposes, etc. Ensure that no remaining product dries on and sticks to the device.

Procedure

1. Carry out work interruption Chapter 7.4.

2. Carry out the basic ushing Chapter 7.5.

3. Empty system in a controlled manner Chapter 8.2.4.

4. Clean and check the suction system and the suction lter.

5. Clean the outside of the system.

6. Fully assemble the system.

7. Check ll level of the separating agent in accordance with Chapter 8.2.3.1.

8. Fill the system with ushing agent in accordance with Chapter 8.2.5.

8.1.3 LONGTERM STORAGE

If storing the system for a prolonged period of time, thorough cleaning and corrosion protection are necessary. Replace the water or solvent in the product pump with a suitable preserving oil and ll the separating agent tank with separating agent.

Procedure

1. Perform points 1 to 7 in Chapter 8.1.2.

2. Fill with preservative according to Chapter 8.2.5.

3. Empty the system in a controlled manner in accordance with Chapter 8.2.4 and seal the openings.

VERSION 01/2018

8.2 MAINTENANCE

8.2.1 MAINTENANCE PERSONNEL

Maintenance work should be undertaken regularly and carefully by qualied and trained personnel. They should be informed of specic hazards during their training. The following hazards may arise during maintenance work:

− Health hazard from inhaling solvent vapors.

− Use of unsuitable tools and aids.

An authorized person must ensure that the device is checked for being in a reliable state after maintenance work is completed.

8.2.2 MAINTENANCE INSTRUCTIONS

ORDER NUMBER DOC 2316596

DANGER

Incorrect maintenance/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. Only repair and replace parts that are listed in the "Spare parts" chapter 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.

Prior to Maintenance

It should be ensured that the device is in the following state before carrying out any work on it:

− Flush and clean the system. Chapter 8.1.2

− Interrupt the air supply.

After maintenance

− Carry out safety checks in accordance with Chapter 8.2.3.

− Put the system into operation and check for leaks as described in Chapter 6.7.

− Have the system checked for safe condition by an authorized person.

− If necessary, carry out a function test in accordance with Chapter 11.

VERSION 01/2018

C_00107

ORDER NUMBER DOC 2316596

8.2.3 SAFETY CHECKS AND MAINTENANCE INTERVALS

Every day

Check grounding: see Chapter 6.6. Check hoses, tubes and couplings: see Chapter 8.2.3.2 Check the level of separating agent in the separating agent tank and top up, if

necessary, in accordance with Chapter 8.2.3.1. For each decommissioning, the process according to Chapter 8.1.2 must be followed. If the pump has to be emptied for maintenance work, proceed according to Chapter

7.5 and Chapter 8.2.4.

Weekly

Check system for damage. Check that the safety xtures function properly (see Chapter 5.3).

Yearly or as required

In accordance with DGUV regulation 100-500 Chapter 2.29 and 2.36:

– The liquid ejection devices should be checked by an expert (e.g., WAGNER

service technician) for their safe working conditions as required and at least every 12 months.

– For shut down devices, the examination can be suspended until the next start-

up.

8.2.3.1 FILLING WITH SEPARATING AGENT

NOTICE

Piston pump dry run!

High wear/damage to the packings. Paint or solvent can escape if the seals are dry.

Ensure that the separating agent tank is lled with sucient separating agent.

To prevent potential transportation issues, the separating uid chamber of the pump is not lled at the factory. Pour the supplied separating agent into the intended opening.

Separating agent: Order no. 9992504

Inclination angle of the pump

Maximum permissible tilt of the pump for moving, transporting, etc. after lling separating agent is±30°. The pump must be vertical during operation.

C_00107

VERSION 01/2018

ORDER NUMBER DOC 2316596

8.2.3.2 PRODUCT HOSES, PIPES AND COUPLINGS

The service life of the complete hoses between product pressure generator and application device is reduced due to environmental inuences even when handled correctly.

Check hoses, pipes, and couplings every day and replace if necessary. Before every commissioning, check all connections for leaks. 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. Records of these checks must be kept.

Undamaged complete hoses are to be replaced when one of the two following intervals has been exceeded:

−6 years from the date of the hose crimping (see tting embossing).

−10 years from the date of the hose imprinting.

Fitting embossing Meaning

xxx bar Pressure yymm Crimping date (year/month)

XX Internal code

Hose imprinting Meaning

Wagner Name / Manufacturer yymm Date of manufacture (year/month) xxx bar (xx MPa) e.g., 270 bar (27 MPa)

Pressure

XX Internal code DNxx (e.g., DN10) Nominal diameter

VERSION 01/2018

B_06936

ORDER NUMBER DOC 2316596

8.2.4 EMPTYING PUMP

WARNING

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from ying parts. Ignition of potentially explosive surrounding atmosphere.

Empty pump slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

If the pumping product becomes heated, switch o all heaters and let the product cool o.

1. Place grounded collection tank (5) under the return tube (3).

2. Place an empty, grounded collection tank (6) under the pump.

3. Close pressure regulator (1) (0MPa; 0bar; 0psi).

Emptying via return line

4. Open return valve (3).

5. Slowly open the ball valve (2).

6. Slowly turn air pressure up on the pressure regulator (1) and only until the pump is running normally (approx. 0.05 MPa; 0.5 bar; 7.25 psi).

7. Be ready for the switch from working material to air. Turn down pressure regulator (1) far enough that the pump is still running normally (approx. 0–0.05MPa; 0–0.5bar; 0–7.25psi).

8. As soon as working material is no longer owing from the return tube (3), close the ball valve (2).

9. Close return valve (3).

Emptying the product line

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 ready for the switch from working material to air.

12. As soon as no more working material is owing out of the system, close the ball valve (2).

13. Close the valve (4).

14. Depressurization in accordance with Chapter 7.4.

15. Dispose of the contents of the tank (5) according to the local regulations.

closed

open

VERSION 01/2018

8.2.5 FILLING THE EMPTY PUMP

ORDER NUMBER DOC 2316596

WARNING

Gas mixtures can explode if there is an incompletely ﬁlled pump!

Danger to life from ying parts. Ignition of potentially explosive surrounding atmosphere.

Fill the device slowly and in a controlled manner. Avoid potentially explosive atmosphere in the surroundings.

1. Visual check: personal safety equipment, grounding and all devices ready to use.

2. Place grounded collection tank (5) under the return tube (3).

3. Place the pump in the tank (6) with working material.

4. Close pressure regulator (1) (0MPa; 0bar; 0psi).

5. Open return valve (3).

6. Slowly open the ball valve (2).

7. Slowly turn the air pressure up on the pressure regulator (1) and only until the pump is running normally (approx. 0–0.05MPa; 0–0.5 bar; 0–7.25 psi). Be ready to switch from air to working material and prevent back spray.

8. Close ball valve (2) as soon as pure working material starts owing from the return tube (3).

9. Close return valve (3).

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 ready to switch from air to working material and prevent back spray.

12. cAs soon as pure working material without air bubbles is owing out of the system, close the ball valve (2).

13. Close the valve (4).

14. Depressurization in accordance with Chapter 7.4.

15. Dispose of the contents of the tank (5) according to the local regulations.

closed

open

B_06877

VERSION 01/2018

ORDER NUMBER DOC 2316596

9 TROUBLESHOOTING AND RECTIFICATION

Problem Cause Remedy

The pump does not work.

Irregular operation of product pump; spray jet with irregular pressure (pulsation).

The pump runs when the discharge duct is closed.

Air motor is iced up. There is a lot of condensation water

If none of the causes of malfunction mentioned are present, the defect can be remedied by a WAGNER Service Center.

Air motor does not work or stops. Open and close ball valve on the pressure

regulator unit or briey disconnect compressed air supply.

No pressure indication on the pressure gauge (air pressure regulator defective).

Insucient compressed air supply. Check compressed air supply. Fluid section or high-pressure hose

are blocked. Sometimes, the pump stops at a

switching point.

Viscosity is too high. Dilute the working material. Valves are clogged. Clean product pump, if necessary leave it to

Foreign body in suction valve. Dismantle suction valve housing, clean and

Diameter of compressed air line too small.

Valves, packings, or pistons are worn out.

Control air lter or work air lter is clogged.

Suction lter is clogged. Clean lter. Ball in suction or piston valve is

stuck. Packings, valves, or pistons are

worn out.

in the air supply.

Disconnect compressed air supply briey or repair or change air pressure regulator.

Dismount and clean uid section, replace high-pressure hose.

Press the starter on the reversing valve and restart the pump.

Clean the slide on the reversing valve carefully and if necessary lubricate it lightly with oil.

soak in cleaning agent.

check valve seat. Assemble a larger incoming line

-> Technical Data, Chapter 5.5.3) Replace the parts.

Check and clean it if necessary.

Clean with cleaning agent (if necessary vent device).

Replace the parts.

Install a water separator.

VERSION 01/2018

ORDER NUMBER DOC 2316596

10 REPAIRS

10.1 REPAIR PERSONNEL

Repair work must be carried out carefully and by qualied and trained personnel. They should be informed of specic hazards during their training. The following hazards may arise during repair work:

− Health hazard from inhaling solvent vapors.

− Use of unsuitable tools and aids.

A skilled person must check to ensure that the device is in a reliable state after it is repaired. Carry out function test in accordance with Chapter 11.

10.2 REPAIR NOTES

DANGER

Incorrect maintenance/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. Only repair and replace parts that are listed in the "Spare parts" chapter 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.

Before Repair Work

It should be ensured that the device is in the following state before carrying out any work on it:

− Flush and clean the system. Chapter 8.1.2

− Interrupt the air supply.

After Repair Work

− Carry out safety checks in accordance with Chapter 8.2.3.

− Put the system into operation and check for leaks as described in Chapter 6.7.

− Have the system checked for safe condition by an authorized person.

− Function test in accordance with Chapter 11.

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 4.5 Nm; 3.3 lbft. – Circlip pliers – Torque wrench 7 Nm; 5.1 lbft. – Slotted screw driver – Torque wrench 18 Nm; 13.2 lbft – Phillips screwdriver – Torque wrench 20 Nm; 14.7 lbft. – Allen wrench, wrench size (SW) 3, 5, 6, 8, 12. – Torque wrench 30 Nm; 22.1 lbft. – Wrench, wrench size (SW) 7, 10, 13. – Torque wrench 35 Nm; 25.8 lbft.

VERSION 01/2018

10.4 CLEANING THE PARTS AFTER DISASSEMBLY

ORDER NUMBER DOC 2316596

WARNING

Incompatibility of cleaning agent with the working medium!

Risk of explosion and danger of poisoning by toxic gases.

Examine the compatibility of the cleaning agents and working media on the basis of the safety data sheets.

Please note:

Thoroughly clean all reusable parts with a suitable cleaning agent. All dismantled parts have to be clean and dry after cleaning. Care should be taken

that these parts remain free of solvents, grease or sweat from the hands (salt water). Perform cleaning and mounting tasks wearing gloves.

10.5 ASSEMBLY OF THE DEVICE

In Chapter 14 the order numbers for device spare parts can be found, as well as for wearing parts such as seals.

Defective parts, O-rings and seal sets must always be replaced. Use greases and glues in accordance with Chapter 14. Observe torque specications in accordance with Chapter 14.

Assembly aids:

Order no. Quantity Designation Smaller tanks

9992831 1 pc ≙ 50 ml Loctite 542 9998157 1 pc ≙ 18 ml Loctite 480 3201587 1 pc ≙ 50 ml Loctite 577 9998808 1 pc ≙ 18 kg ! Mobilux EP 2 grease 400 g tube ≙ Order No. 2355418 9992609 1 pc ≙ 100 g Anti-seize paste

Brand notice:

The brands specied in this document are property of the respective owners. Loctite , for example, is a registered brand of Henkel.

VERSION 01/2018

ORDER NUMBER DOC 2316596

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.

Activity Means

1.1 Filling with separating agent

See Chapter 8.2.3.1.

1.2 EX-relevant inspections

− Check grounding connection between ground connection of the pump and the frame/transport cart and between the individual components of the frame/transport cart: < 1MΩ

− Check conductivity between piston and grounding connection: < 1MΩ

These inspections are - relevant!

1.3 Testing for leaks

− Connect the air motor to the air supply 7 bar. To perform a leak test on the device, the product pressure with the ushing agent is slowly increased in increments until the maximum pressure indicated on the type plate is reached. Close pump outlet. In each position (forward stroke and reverse stroke), let sit for 0.5-1 minutes and listen for audible blowing o. When the air supply is turned o, a drop in pressure must be watched for. Check seal of following modules:

− uid section

− mounted ttings and regulators

1.4 General inspections

− Check tightening torque of various screws.

See Chapter 14.

− Check all ttings.

− Empty device in a controlled manner (Chapter 8.2.4) and depressurize (Chapter 7.4).

− Check function of frame or transport trolley.

Ohmmeter (measurement voltage

500...1000 VDC)

Air motor: Test medium; compressed air Leak spray

Fluid section: Test medium; suitable Flushing agent

Torque wrench Visual check

12 DISPOSAL

When the equipment must be scrapped, please dierentiate the disposal of the waste materials.

The following materials have been used:

Stainless steel Aluminum Elastomers Plastics Carbide

Consumable products

Consumable products (lacquers, adhesives, ushing and cleaning agents and solvents) must be disposed of in accordance with all legal requirements and provisions.

VERSION 01/2018

13 ACCESSORIES

ORDER NUMBER DOC 2316596

B_06864

Order no. Designation

A U1B05125D Piston pump

9992504 Separating agent 250 ml; 250 cc

9992505 Separating agent 500 ml; 500 cc 2 T6140.00 Air regulator 3 236219 Grounding cable 3m; 9.8 ft 4 2368149 Connection set DN20 3m 5 3201040 Fitting-DF-MM-R1/2-R1/2-PN50-SSt 6 2328382 Check valve assy. 20 bar 7 377342 Fitting-RF-FM-M16x1,5-G3/8“-PN530-SSt 8 3201587 Loctite 577

VERSION 01/2018

ORDER NUMBER DOC 2316596

14 SPARE PARTS

14.1 HOW CAN SPARE PARTS BE ORDERED?

Always supply the following information to ensure delivery of the right spare part:

Order number, designation and quantity

The quantity need not be the same as the number given in the quantity column " " on the list. This number merely indicates how many of the respective parts are used in each component.

The following information is also required to ensure smooth processing of your order:

− billing address

− delivery address

− name of the person to be contacted in the event of any queries

− type of delivery (normal mail, express delivery, air freight, courier etc.)

Identication in spare parts lists

Explanation of column " " (labeling) in the following spare parts lists:

Wearing parts/ Wearing parts are not included in the warranty terms. Included in service set

Notice

These parts are not covered by warranty terms.

Not part of standard equipment, available, however, as additional extra.

Explanation of order no. column

-- Item not available as spare part. / Position does not exist.

DANGER

Incorrect maintenance/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. Only repair and replace parts that are listed in the "Spare parts" chapter 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.

VERSION 01/2018

ORDER NUMBER DOC 2316596

14.2 OVERVIEW OF THE COMPONENTS

7 Nm; 5.1 lbft

20 Nm; 14.7 lbft

B_03468

VERSION 01/2018

ORDER NUMBER DOC 2316596

Order no. Designation

1 1 U1B05125D EvoMotion 5-125 PE/T 2 1 U3B08018060A Air motor M80 EM C60 3 1 U2B125FC Fluid section 125 St PE/T 4 1 A112.62 Protection - connecting piece 5 1 A111.02 Connecting piece M/P 6 4 9920106 Washer 7 4 9900342 Hexagon socket cylinder head screw 8 4 9900308 Hexagon socket cylinder head screw

9 4 9920104 Washer 10 2 E051.62B Protection - connecting piece 11 4 A532.62 D 25 X 160 Spacer

VERSION 01/2018

14.3 AIR MOTOR M80 EM C60

30 Nm; 22.1 lbft

ORDER NUMBER DOC 2316596

35 Nm; 25.8 lbft

4.5 Nm; 3.3 lbft

20 Nm; 14.7 lbft

B_03469

Installation instructions:

Mount piston rod (12) always from bottom to top by the assigned rod seal (18).

VERSION 01/2018

ORDER NUMBER DOC 2316596

Order no. Designation

1 1 U3B08018060A Air motor M80 EM C60 2 1 F132.91C Motor ange, upper, M80 EM 3 2 L108.06 O-ring 4 1 D608.81 Cylinder motor 5 1 3055157 Hexagon nut with clamp 6 1 9992757 Threaded elbow tting 7 2 G903.06 Damper 8 1 L413.06 Seal DE 80

9 1 A164.01 Motor piston 10 1 L802.08 Sliding ring 11 1 L110.06 O-ring 12 1 D404.12 Piston rod, M80 EM 13 2 L109.06 O-ring 14 1 A408.12 Air tube, M80 EM 15 1 T616.00C Motor ange, complete M80 EM, at bottom 16 1 P498.00KNE Reversing valve ISO N/1 17 1 367258 Grounding, complete 18 1 L403.06 Rod seal 19 1 T703.00 Sensor below, M80 20 1 K606.02 Lock washer for waves 21 1 A160.01A Washer 22 1 369290 Pilot valve 23 2 H505.07 Silencer 24 1 9920106 Washer 25 1 M432.00 Reducing nipple 26 2 9992265 Angled threaded tting 27 1 9992831 Loctite 542 28 4 9907241 Hexagon socket cylinder head screw 29 1 9998808 Mobilux EP 2 grease 30 1 9998157 Loctite 480 31 1 G735.06AB Valve sealing 32 1 A818.71B Valve plate 33 4 9920104 Washer 34 4 9900386 Hexagon socket cylinder head screw 35 1 P498.00 Reversing valve P/1 SP/NUM (spare parts, see Chapter 8.3.1)

1 T910.00 Service set, air motor EM 30-30/ 40-15/ 5-125

= Wearing parts = Included in service set

VERSION 01/2018

14.4 FLUID SECTION 125

ORDER NUMBER DOC 2316596

B_03470

18 Nm; 13.2 lbft

VERSION 01/2018

ORDER NUMBER DOC 2316596

Order no. Designation

1 U2B125FC Fluid section 125 St PE/T 2 1 F142.21 Spacer MP 3 1 L136.06 O-ring 4 1 T971.00E Packing PE/T 36/50 5 1 H212.03 Spring, upper 6 1 A645.01 Washer 7 1 A644.12 Cylinder ange 8 4 9907079 Hexagon socket cylinder head screw

9 1 D114.42A Pump rod D36 10 2 G609.08 Seal 11 1 A646.03 Piston valve 12 1 B0344.03 Special screw M6x35 13 1 K311.03A Self-locking hexagon nut 14 1 K108.03 Hexagon socket cylinder head screw 15 1 A827.03 Rod coupling 16 1 D710.22 Pump cylinder 17 1 A647.03 Pump rod 18 1 A648.03 Rod bush 19 1 A649.03 Piston valve 20 1 9913031 Self-locking hexagon nut 21 2 K317.03 Hexagon nut 22 1 A179.03 Valve foot 23 1 L137.06 O-ring 24 1 A650.03 Inlet housing 25 1 K604.22 Securing ring 26 1 A651.03 Valve stop 27 1 K158.03 Hexagon socket cylinder head screw 28 1 A253.01 Support ring 29 1 A250.01 Support ring 30 3 G121.05 Sealing collar T 36/50 31 3 G121.08E Sealing collar PE 36/50 32 1 9992831 Loctite 542 33 1 9998808 Mobilux EP 2 grease

1 T958.00AE Service set - EvoMotion uid section 125 cm³ = Wearing part = Included in service set.

VERSION 01/2018

14.4.1 REVERSING VALVE

ORDER NUMBER DOC 2316596

B_03139

Order no. Designation

1 1 P498.00 Reversing valve, complete 2 6 9971123 O-ring 3 1 P521.00 Valve seal 4 2 P520.00 Damper

= Wearing parts

14.4.2 PUMP AIR REGULATOR

4 5 6

B_06880

Order no. Designation

1 1 T6140.00 Set - pump air regulator 2 1 M101.00 Ball valve, FM 3 1 9998039 Screw tting ellbow 4 1 9985682 Reducer 5 1 2384362 Pressure regulator 6 2 9900353 Socket cap screw 7 2 9920308 Washer 8 1 2384363 Supporting bracket 9 1 9999138 Male stud elbow

10 1 M297.00 T-connection 11 1 P484.00C0 Safety valve 1/4", blue ring 12 1 9998677 Pressure gauge 0-10 bar (d40) 13 1 9982078 Hose, black AD8 x 1.25 14 1 9992831 Loctite 542

= Wearing parts

VERSION 01/2018

ORDER NUMBER DOC 2316596

15 GUARANTEE AND CONFORMITY DECLARATIONS

15.1 IMPORTANT NOTES ON PRODUCT LIABILITY

As a result of an EC regulation eective from January 1, 1990, the manufacturer shall only be liable for his product if all parts originate from him or are approved by him, and if the devices are properly mounted, operated and maintained. The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with.

15.2 WARRANTY CLAIM

Full warranty is provided for this device: We will, at our discretion, repair or replace free of charge all parts which within 24 months in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by the purchaser are found to be wholly or substantially unusable due to causes prior to the sale, in particular faulty design, defective materials or poor workmanship. The type of warranty provided is such that the device or individual components of the device are either replaced or repaired as we see t. The resulting costs, in particular shipping charges, road tolls, labor and material costs will be borne by us except where these costs are increased due to the subsequent shipment of the device to a location other than the address of the purchaser. We do not provide warranty for damage that has been caused or contributed to for the following reasons: Unsuitable or improper use, faulty assembly or commissioning by the purchaser or a third party, normal wear, negligent handling, defective maintenance, unsuitable coating products, substitute products and the inuence of chemical, electrochemical or electrical agents, except when the damage is attributable to us. Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust paints and so forth reduce the service life of valves, packings, spray guns, nozzles, cylinders, pistons etc. Signs of wear traced back to these products are not covered by this warranty. Components that have not been manufactured by WAGNER are subject to the original warranty of the manufacturer. Replacement of a component does not extend the period of warranty of the device. The device should be inspected immediately upon receipt. To avoid losing the warranty, we or the supplier company are to be informed in writing about obvious faults within 14days upon receipt of the device. We reserve the right to have the warranty compliance met by a contracting company. The services provided by this warranty are dependent on evidence being provided in the form of an invoice or delivery note. If the examination discovers that no warranty claim exists, the costs of repairs are charged to the purchaser. It is clearly stipulated that this warranty claim does not represent any constraint on statutory regulations or regulations agreed to contractually in our general terms and conditions.

Wagner International AG

VERSION 01/2018

ORDER NUMBER DOC 2316596

15.3 EU DECLARATION OF CONFORMITY

We hereby declare that the supplied version of diaphragm pumps and spray packs:

5-125

complies with the following guidelines:

2006/42/EC 2014/34/EU (ATEX Directive)

Applied standards, in particular:

DIN EN ISO 12100:2010 EN 12621: 2006+A1: 2010 EN809: 1998+A1:2009+AC:2010 EN 1127-1:2011 EN ISO 4413:2010 EN ISO 80079-36:2016 EN ISO 4414:2010 EN ISO 80079-37:2016 EN ISO 13732-1:2008 EN ISO/IEC 80079-34:2011 EN14462:2015

Applied national technical standards and specications, in particular:

DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36

Identication:

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 no. 2316596 Edition 01/2018

ts-liquid@wagner-group.com

Document No. 11118908

Version B

www.wagner-group.com

WAGNER EvoMotion 5-125 Translation Of The Original Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual