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WAGNER EvoMotion 5-125, Translation Of The Original Operating Manual, Page: 1 / 56

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EvoMotion 5-125

Piston pump

Delivery volume 125 cm³

Version 01/2018

C_00116

Summary of Contents for EvoMotion 5-125

Page 1: ...EvoMotion 5 125 Piston pump Delivery volume 125 cm Version 01 2018 C_00116 ...

Page 2: ......

Page 3: ...ent 12 4 1 2 A Safe Work Environment 12 4 1 3 Personnel Qualifications 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 DESCRIPT...

Page 4: ...ncy 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...

Page 5: ... 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 ...

Page 6: ... IN THESE INSTRUCTIONS Warning instructions in this manual highlight particular dangers to users and to the device and state measures for avoiding the hazard These warning instructions fall into the following categories DANGER Immediate risk of danger Non observance will result in death or serious injury WARNING Potential risk Non observance can result in death or serious injury CAUTION Potentiall...

Page 7: ...essure tank Personnel qualifications 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 devi...

Page 8: ...ion 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 fixtures 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 EXPLOSIV...

Page 9: ...ter 5 5 Check if the fluids 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 Constructio...

Page 10: ...esponds 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 m...

Page 11: ...tion to the presence of air in the pumped fluid Filling and emptying Ignitable gas mixtures can form in the fluid section or product hoses if the pump must be emptied for maintenance and or repair purposes Empty and fill the device slowly and in a controlled manner Avoid potentially explosive atmosphere in the surroundings 3 3 TYPE PLATES Designation 1 Manufacturer and CE Identification 2 Pump typ...

Page 12: ...nd wire connection Keep liquids away from electrical devices 4 1 2 A SAFE WORK ENVIRONMENT Hazard due to dangerous fluids or vapors Severe or fatal injuries due to explosion hazard or inhalation swallowing or contact with the skin or eyes Ensure that the floor in the working area is static dissipative in accordance with EN 61340 4 1 resistance must not exceed 100 MΩ Paint mist extraction systems v...

Page 13: ...fer to the operating instructions for information about the required personnel qualifications 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 ...

Page 14: ...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 flushing agents Note the lacquer or flushing 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...

Page 15: ...ver 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 th...

Page 16: ...d depending on the flushing 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 flushing 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 flushing External Cleaning When cleaning the exterio...

Page 17: ...pter 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 off 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 MONITORI...

Page 18: ... compressed air flow 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 opti...

Page 19: ...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 B_06875 10 11 Procedure 1 Close ball valve 10 2 Pull the ring on the safety valve 11 a...

Page 20: ...ED 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 Polytetrafluorethylene PTFE 5 5 2 RECOMMENDED PACKINGS WAGNER packings for this device Product Color Ultra high molecular weight polyethylene transpa...

Page 21: ... 6 MPa 6 bar 87 psi per double stroke 4 0 0 14 Sound pressure level at maximum permissible air pressure 72 Sound pressure level at 0 6 MPa 6 bar 87 psi air pressure 69 Sound pressure level at 0 4 MPa 4 bar 58 psi air pressure 62 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 5 ...

Page 22: ...R NUMBER DOC 2316596 5 5 4 DIMENSIONS AND CONNECTIONS B_03460 A F G B H C D E I J K 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 J 110 4 33 K 11 0 43 On site possible wall mount fixing ...

Page 23: ...0 60 240 8 160 6 80 3 0 7 50 1 98 6 25 1 65 5 00 1 32 3 75 0 99 2 50 0 66 1 25 0 33 0 A B C bar MPa psi nl min scfm l min gpm A B C 40 4 580 320 11 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 C_00062 EvoMotion 5 125 stainless steel Stroke frequency Product pressure Air consumption Product flow water A 8 bar 0 8 MPa 116 psi air pressu...

Page 24: ...TING ELEMENTS 5 6 1 PRESSURE REGULATOR UNIT B_06876 geschlossen 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 ...

Page 25: ...d 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 INSTALL...

Page 26: ...oduct 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 b...

Page 27: ...T 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 fittings 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 m...

Page 28: ...e pump is only guaranteed with a grounding connection Connect all grounding cables using a short and direct route 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...

Page 29: ...ccordance with Chapter 8 2 3 1 Fill the pump with flushing agent The devices are tested during manufacturing with emulsifying oil pure oil or solvent Possible residues must be flushed out of the circuits with a solvent flushing agent before commissioning Fill the empty device with flushing agent in accordance with Chapter 8 2 5 Pressure tightness test WARNING Overpressure Risk of injury from burst...

Page 30: ...ciated 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 5 4 2 1 5 6 3 closed open Open the safety valve 5 until the piston pump is entirely depressurized Relieve the pressure of the product transporting par...

Page 31: ...afety 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 flow 7 Start work process ...

Page 32: ...lve 10 Outlet equipment return valve mounted between pump and spray gun Pressure relief procedure 4 2 1 B_06877 5 6 8 3 open closed 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 ...

Page 33: ...e 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 flows 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 va...

Page 34: ...rry out the basic flushing Chapter 7 5 3 Empty system in a controlled manner Chapter 8 2 4 4 Clean and check the suction system and the suction filter 5 Clean the outside of the system 6 Fully assemble the system 7 Check fill level of the separating agent in accordance with Chapter 8 2 3 1 8 Fill the system with flushing agent in accordance with Chapter 8 2 5 8 1 3 LONG TERM STORAGE If storing the...

Page 35: ...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 off the energy and compressed air supply Disconnect the control unit from ...

Page 36: ...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 ...

Page 37: ...arly 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 fitting embossing 10 years from the date of the hose imprinting Fitting embossing Meaning xxx bar Pressure yymm...

Page 38: ...wly 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 flowing from the return tube 3 close the ball valve...

Page 39: ...owly 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 flowing from the return tube 3 9 Close return valve 3 10 Relieve the system s pressure upstream ...

Page 40: ...rregular operation of product pump spray jet with irregular pressure pulsation Viscosity is too high Dilute the working material Valves are clogged Clean product pump if necessary leave it to soak in cleaning agent Foreign body in suction valve Dismantle suction valve housing clean and check valve seat Diameter of compressed air line too small Assemble a larger incoming line Technical Data Chapter...

Page 41: ...essure from the spray gun high pressure hoses and all devices Secure the spray gun against actuation Switch off 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 ...

Page 42: ... 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 specifications in accordance with Chapter 14 Assembly aids Order no Quantity Des...

Page 43: ...ak test on the device the product pressure with the flushing 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 off When the air supply is turned off a drop in pressure must be watched for Check seal of following module...

Page 44: ...n pump 1 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 ...

Page 45: ...ng 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 ...

Page 46: ...46 VERSION 01 2018 ORDER NUMBER DOC 2316596 14 2 OVERVIEW OF THE COMPONENTS 1 2 B_03468 3 4 5 6 7 8 9 10 11 20 Nm 14 7 lbft 7 Nm 5 1 lbft ...

Page 47: ... 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 ...

Page 48: ... 28 29 2 3 4 5 7 8 9 13 31 32 33 34 35 14 6 23 25 19 26 16 24 11 7 10 3 17 15 22 21 20 12 30 Nm 22 1 lbft 35 Nm 25 8 lbft 20 Nm 14 7 lbft 4 5 Nm 3 3 lbft 29 29 27 27 30 29 29 30 18 Installation instructions Mount piston rod 12 always from bottom to top by the assigned rod seal 18 ...

Page 49: ...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 fitting 27 1 9992831 Loctite 542 28 4 9907241 Hexagon socket cylinder head screw 29 1 9998808 Mobilux EP 2 ...

Page 50: ...ERSION 01 2018 ORDER NUMBER DOC 2316596 14 4 FLUID SECTION 125 B_03470 1 2 12 14 15 16 18 10 19 20 21 22 23 24 25 26 27 3 5 6 7 8 9 28 10 11 13 17 30 31 30 4 31 30 31 29 33 33 32 33 33 32 18 Nm 13 2 lbft 33 ...

Page 51: ... 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 Sup...

Page 52: ..._06880 13 14 Order no Designation 1 1 T6140 00 Set pump air regulator 2 1 M101 00 Ball valve FM 3 1 9998039 Screw fitting 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...

Page 53: ...urchaser 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 influence of chemical electrochemical or electrical agents except when the damage is ...

Page 54: ... 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 specifications in particular DGUV regulation 100 500 Chapter 2 29 and Chapter 2 36 Identification EU Declaration of Conformity The EU Declaration of Conformity is enclosed with this product If ne...

Page 55: ......

Page 56: ...56 CERTI F I E D ts liquid wagner group com www wagner group com Document No 11118908 Version B Order no 2316596 Edition 01 2018 ...

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