WAGNER AquaCoat 5010 GA 5000EAW User manual

B_06146
AquaCoat 5010 / 5020
GA 5000EAW
Low pressure
Automatic
Air Spraying System
for Non-ignitable Liquids
Version 03/2018

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VERSION 03/2018 ORDER NUMBER DOC 2369735
Table of Contents
1 ABOUT THESE INSTRUCTIONS 7
1.1 Preface 7
1.2 Warnings, Notices and Symbols in these Instructions 7
1.3 Languages 8
1.3.1 Operating Manuals for the Individual Components 8
1.4 Abbreviations 8
1.5 Terminology for the Purpose of this Manual 9
2 CORRECT USE 10
2.1 Device Type 10
2.2 Type of Use 10
2.3 Field of Application 10
2.4 Processible Working Materials 11
2.5 Misuse 11
3 IDENTIFICATION 12
3.1 CE Identication 12
3.2 Type Plates 12
3.3 Safety Signage 13
4 BASIC SAFETY INSTRUCTIONS 14
4.1 Safety Instructions for the Operator 14
4.1.1 Electrical Devices and Equipment 14
4.1.2 A Safe Work Environment 14
4.1.3 Personnel Qualications 15
4.2 Safety Instructions for Sta 15
4.2.1 Personal Safety Equipment 15
4.2.2 Safe Handling of WAGNER Spray Devices 16
4.2.3 Ground the Unit 16
4.2.4 Product Hoses 17
4.2.5 Cleaning and Flushing 18
4.2.6 Touching Hot Surfaces 19
4.2.7 Maintenance and Repair 19
4.2.8 Protective and Monitoring Equipment 19
4.2.9 Safety-relevant Information about Discharges 19
5 DESCRIPTION 20
5.1 Components 20
5.2 Mode of Operation 24
5.3 Protective and Monitoring Equipment 24
5.4 Included Items 26
5.5 Technical Data 28
5.5.1 AquaCoat 5010/5020 Entire System 28
5.5.2 Product Pressure Generator 29
5.5.3 VM5020WA Control Unit 30
5.5.4 GA 2800EAW Automatic Gun 31
5.5.5 AquaCoat Electric Block Diagram 33

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5.6 Operating Elements 34
5.6.1 VM5020WA Control Unit 34
5.6.2 Product Pressure Generator 38
5.7 GA 5000EAW Automatic Gun 39
5.7.1 Components 39
5.7.2 Mode of Operation 40
5.7.3 Securing the Spray Gun against Actuation 41
5.7.4 Stop Screw Valve Rod 41
5.7.5 Spraying Procedure for Round and Flat Jet Air Atomizing 42
5.7.6 The Electrostatic Eect 43
5.8 Use with Two Automatic Guns 44
6 ASSEMBLY AND COMMISSIONING 46
6.1 Training of Assembly/Commissioning Sta 46
6.2 Storage and Installation Conditions 46
6.3 Transportation 46
6.4 Assembly and Installation 47
6.4.1 Assembling the AquaCoat System 47
6.4.2 Ventilation of the Spray Booth 49
6.4.3 Pneumatic Connections 49
6.4.4 Product Connections 50
6.5 Grounding 50
6.6 Safety Checks 52
6.7 Preparation of Water-based Lacquer 52
6.7.1 Viscosity Conversion Table 52
6.8 Commissioning 53
6.8.1 Preparation 53
6.8.2 Commissioning 53
6.8.3 Verifying a Safe Operational Condition 55
7 OPERATION 56
7.1 Training the Operating Sta 56
7.2 Electrical Discharge 56
7.3 Emergency Deactivation 57
7.4 Working 58
7.4.1 Starting the System 58
7.4.2 Adjusting the Spray Angle 59
7.4.3 Pressure Relief/Work Interruption 61
7.4.4 Changing the Nozzle, Changing from Round Jet/Flat Jet 62
7.4.5 Cleaning of the Nozzle Parts 63
7.4.6 Starting up the VM 5020WA Control Unit 63
7.4.7 Set and Save Recipes 64
7.4.8 Setting the High Voltage 65
7.4.9 Setting the Current Limitation 66
7.4.10 Display during Spraying Mode 67
7.4.11 Standby Mode 67
7.4.12 Operating Hours Counter/Service Display 68

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7.5 Device Conguration 70
7.5.1 Overview of Parameters 70
7.5.2 Access to the Device Conguration Mode 71
7.5.3 Setting Example: "Parameter C13" 73
7.6 External Interface 74
8 CLEANING AND MAINTENANCE 76
8.1 Cleaning 76
8.1.1 Cleaning Sta 76
8.1.2 Safety Instructions 76
8.1.3 Flushing and Cleaning the System 77
8.1.4 Decommissioning 78
8.1.5 Long-term Storage 78
8.2 Maintenance 79
8.2.1 Maintenance Sta 79
8.2.2 Safety Instructions 79
8.2.3 Safety Checks and Maintenance Intervals 80
8.2.4 Product Hoses, Tubes and Couplings 81
8.2.5 Dismounting Gun Cover 81
8.2.6 Replacing the Valve Seat 81
8.2.7 Replacing the Product Hose 82
9 TROUBLESHOOTING 84
9.1 Fault Displays at the VM 5020WA Control Unit 84
9.2 Faults in the System 86
10 REPAIRS 87
10.1 Repair Sta 87
10.2 Safety Instructions 87
10.3 Mounting Materials 88
10.4 Spray Gun 88
10.4.1 Tools 88
10.4.2 Dismantling of the Spray Gun 89
10.4.3 Cleaning the Parts after Disassembly 92
10.4.4 Assembling the Spray Gun 92
10.5 Disassembling VM 5020WA Control Unit 97
10.6 Opening the Control Unit 97
11 FUNCTION TEST AFTER THE REPAIR 98
11.1 Function Tests for Spray Gun 99
11.1.1 Air Tests 99
11.1.2 Product Pressure Test 100
11.1.3 Check Spray Pattern 100
12 DISPOSAL 101

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13 ACCESSORIES 102
13.1 Valve Seats/Valve Tips 102
13.2 Round Spray Nozzles 102
13.2.1 Adjustable EAWRV5000 Round Jet Nozzle 102
13.2.2 AWR 5000 Air Caps and Nozzles 102
13.2.3 Discharge Quantity Measurements with Lacquer 103
13.3 Flat Jet Nozzles 104
13.3.1 AF 5000 Air Caps 104
13.3.2 AF 5000 Flat Jet Nozzles 104
13.3.3 Discharge Quantity Measurements with Lacquer 105
13.4 Hoses and Cables 106
13.5 Product Pressure Regulator for DD10 106
13.6 Miscellaneous 106
14 SPARE PARTS 108
14.1 How can Spare Parts be Ordered? 108
14.2 AquaCoat Basic Device 109
14.2.1 VM5020WA Control Unit 114
14.3 Pump Sets 120
14.3.1 DD10 Set 120
14.3.2 DD10 Set with Product Pressure Regulator 121
14.3.3 ZIP52 Set 122
14.4 Spray Gun 124
14.4.1 GA 5000EAWIC 124
14.4.2 GA 5000EAWEC 127
14.4.3 Adapter 130
14.5 Accessories Spare Parts Lists 132
14.5.1 AWR 5000 Round Jet Nozzles 132
14.5.2 Adjustable EAWRV 5000 Round Jet Nozzles 133
14.5.3 Underframe with Rolls 134
14.5.4 Level Monitoring with Alarm Horn 135
14.5.5 D350 Drum Cover 136
15 DECLARATION OF WARRANTY AND CONFORMITY 137
15.1 Important Notes on Product Liability 137
15.2 Warranty Claim 137
15.3 EC Declaration of Conformity 138

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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 operating manual highlight particular dangers to users and to
the device and state measures for avoiding the hazard. These warning instructions fall into
the following categories:
DANGER Immediate risk of danger.
Non-observance will result in death or serious injury.
WARNING Potential risk.
Non-observance may result in death or serious injury.
CAUTION Potentially hazardous situation.
Non-observance may result in minor injury.
NOTICE Potentially hazardous situation.
Non-observance may result in damage to property.
Notice Provides information about particular characteristics and
how to proceed.
Explanation of warning:
LEVEL OF DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The measures for preventing the hazard and its consequences.

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1.3 LANGUAGES
The AquaCoat 5020 GA 5000EAW operating manual is available in the following languages:
Language Order No. Language Order No. Language Order No.
German 2369727 English 2369735 Chinese 2374090
French 2369734 Italian 2369737 Romanian 2382504
Spanish 2369736 Russian 2374089 -- --
Additional languages on request or at: www.wagner-group.com
1.3.1 OPERATING MANUALS FOR THE INDIVIDUAL COMPONENTS
Double diaphragm pump TOPFINISH DD10 operating manual
Language Order No. Language Order No. Language Order No.
German 2366669 English 2366672 Spanish 2369232
French 2369230 Italian 2369231 -- --
Double diaphragm pump ZIP52 GHSS7 operating manual
Language Order No. Language Order No. Language Order No.
German 2330425 English 2330426 Spanish 2335555
French 2335553 Italian 2332230 -- --
Product pressure regulator T0170.00BI operating manual
Language Order No. Language Order No. Language Order No.
German ZZB019GER English ZZB019ENG Spanish ZZB019SPA
French ZZB019FRE Italian ZZB019ITA -- --
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order No. Order number
Spare part
Position
Marking in the spare parts lists
Number of pieces
Air electrostatic, water-based
EAWIC Internal shaping air setting on the
gun (Internal Control)
EAWEC External shaping air setting
(External Control)
Automatic gun
High voltage
High pressure
Wrench size
Low viscosity
High viscosity
Materials
Stainless steel
Polyether ether ketone
(high temperature-resistant
thermoplastic plastic)

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VERSION 03/2018 ORDER NUMBER DOC 2369735
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
GA5000EAW GA5000EAWIC or GA5000EAWEC
Cleaning Manual cleaning of devices and device parts with cleaning agent.
Flushing Internal ushing of paint-wetted parts with ushing agent.
Sta qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/her,
the potential risks associated with improper behavior as well as
the necessary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person in the
context of DGUV 209-052
A person who, based on his/her technical training, experience and
recent vocational experience, has sucient technical knowledge
in the area of electrostatic coating 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.
Additional requirements for skilled persons can also be found
in TRBS 1203 (2010/amendment 2012): Expert knowledge in
the areas of protection against excessive pressure, electrical
hazards, and explosion protection (where applicable).

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VERSION 03/2018 ORDER NUMBER DOC 2369735
2 CORRECT USE
2.1 DEVICE TYPE
Electrostatic spraying unit for automatic coating of grounded work pieces. The system is
suitable for air-atomizing applications.
The system is equipped with the AquaCoat 5010/5020 cabinet, the VM5020WA control unit,
a GA5000EAW automatic spray gun and matching product hose, a high-voltage generator,
all safety devices and one of the following spray product supplies:
- Double diaphragm pump,TOPFINISH DD10 (in accordance with the spare parts catalog)
- Double diaphragm pump, ZIP52 GHSS7 (in accordance with the spare parts catalog)
2.2 TYPE OF USE
AquaCoat 5010/5020 GA5020EAW can be used to spray liquid, non-ignitable products, in
particular non-ignitable coating products in accordance with Chapter 2.4.
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.
Follow the instructions in the operating manual.
2.3 FIELD OF APPLICATION
The device is not suitable for use in potentially explosive areas.
(See Chapter 3.1"CE Identication".)