WAGNER AquaCoat 5010 GM 5020EAW User manual

Translation of the Original
Operating Manual
For professional use.
Always follow the information in this manual,
particularly the safety instructions and the warning
instructions. Store the manual in a safe place.
AquaCoat 5010 / 5020
GM 5020EAW
Low Pressure
Manual
Air Spraying System
for Non-ignitable Liquids
Version 02/2018
B_05905

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OPERATING MANUAL
VERSION 02/2018 ORDER NUMBER DOC 2366717
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
5.4.1 Basic Sets 27
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 5020W Control Unit 30
5.5.4 GM 5020EAW Spray Gun 31
5.5.5 AquaCoat Electric Block Diagram 32

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5.6 Operating Elements 33
5.6.1 VM 5020W Control Unit 33
5.6.2 Product Pressure Generator 37
5.7 GM 5020EAW Spray Gun 38
5.7.1 Components 38
5.7.2 Mode of Operation 39
5.7.3 Spraying Procedure for Round Jet Air Atomizing 41
5.7.4 Spraying Procedure for Flat Jet Air Atomizing 42
5.7.5 The Electrostatic Eect 42
6 ASSEMBLY AND COMMISSIONING 43
6.1 Training of Assembly/Commissioning Sta 43
6.2 Storage and Installation Conditions 43
6.3 Transportation 43
6.4 Assembly and Installation 44
6.4.1 Assembling the AquaCoat System 44
6.4.2 Ventilation of the Spray Booth 46
6.4.3 Pneumatic Connections 46
6.4.4 Product Connections 46
6.5 Grounding 47
6.6 Safety Checks 48
6.7 Preparation of Water-based Lacquer 49
6.7.1 Viscosity Conversion Table 49
6.8 Commissioning 50
6.8.1 Preparation 50
6.8.2 Commissioning 50
6.8.3 Verifying a Safe Operational Condition 51
7 OPERATION 52
7.1 Training the Operating Sta 52
7.2 Electrical Discharge 52
7.3 Emergency Deactivation 53
7.4 Working 54
7.4.1 Checking the Spray Pattern (Without Electrostatics) 54
7.4.2 Starting the System 56
7.4.3 Spraying 57
7.4.4 Pressure Relief/Work Interruption 58
7.4.5 Changing the Nozzle, Changing from Round Jet/Flat Jet 58
7.4.6 Cleaning of the Nozzle Parts 59
7.4.7 Starting up the VM 5020W Control Unit 60
7.4.8 Set and Save Recipes 60
7.4.9 Setting the High Voltage 61
7.4.10 Setting the Current Limitation 62
7.4.11 Display during Spraying Mode 63
7.4.12 Standby Mode 63
7.4.13 Operating Hours Counter/Service Display 64
7.5 Device Conguration 66
7.5.1 Overview of Parameters 66
7.5.2 Access to the Device Conguration Mode 67
7.5.3 Setting Example: "Parameter C13" 69
7.6 External Interface 70

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8 CLEANING AND MAINTENANCE 72
8.1 Cleaning 72
8.1.1 Cleaning Sta 72
8.1.2 Safety Instructions 72
8.1.3 Flushing and Cleaning the System 73
8.1.4 Decommissioning 74
8.1.5 Long-term Storage 74
8.2 Maintenance 75
8.2.1 Maintenance Sta 75
8.2.2 Safety Instructions 75
8.2.3 Safety Checks and Maintenance Intervals 76
8.2.4 Changing the Spray Gun With Hose Set 77
8.2.5 Replacing the Product Hose and/or Air Hose 78
8.2.6 Product Hoses, Tubes and Couplings 78
9 TROUBLESHOOTING 79
9.1 Fault Displays at the VM 5020W Control Unit 79
9.2 Faults in the System 81
10 REPAIRS 82
10.1 Repair Sta 82
10.2 Safety Instructions 82
10.3 Mounting Materials 83
10.4 Spray Gun 83
10.4.1 Tools 83
10.4.2 Dismantling of the Spray Gun 84
10.4.3 Cleaning the Parts after Disassembly 87
10.4.4 Assembling the Spray Gun 88
10.5 Disassembling VM 5020W Control Unit 93
10.6 Opening the Control Unit 93
11 FUNCTION TEST AFTER THE REPAIR 94
11.1 Function Tests for Spray Gun 95
11.1.1 Air Tests 95
11.1.2 Product Pressure Test 96
11.1.3 Check Spray Pattern 96
12 DISPOSAL 97
13 ACCESSORIES 98
13.1 Valve Seats/Valve Tips 98
13.2 Round Spray Nozzles 98
13.2.1 Adjustable EAWRV5000 Round Jet Nozzle 98
13.2.2 AWR 5000 Air Caps and Nozzles 98
13.2.3 Discharge Quantity Measurements with Lacquer 99
13.3 Flat Jet Nozzles 100
13.3.1 AF 5000 Air Caps 100
13.3.2 AF 5000 Flat Jet Nozzles 100
13.3.3 Discharge Quantity Measurements with Lacquer 101
13.4 Hoses and Cables 102
13.5 Product Pressure Regulator for DD10 103
13.6 Miscellaneous 104

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14 SPARE PARTS 106
14.1 How can Spare Parts be Ordered? 106
14.2 AquaCoat Basic Device 107
14.2.1 VM 5020W Control unit 112
14.3 Pump Sets 118
14.3.1 DD10 Set 118
14.3.2 DD10 Set with Product Pressure Regulator 119
14.3.3 ZIP52 Set 120
14.4 GM 5020EAW Spray Gun 122
14.4.1 GM 5000EA Adapter 124
14.4.2 ES 5000 Air Handle 126
14.5 Accessories Spare Parts Lists 127
14.5.1 AWR 5000 Round Jet Nozzles 127
14.5.2 Adjustable EAWRV 5000 Round Jet Nozzles 128
14.5.3 Underframe with Rolls 129
14.5.4 Hose Holder 130
14.5.5 Gun Holder 130
14.5.6 Level Monitoring with Alarm Horn 131
14.5.7 D350 Drum Cover 132
15 DECLARATION OF WARRANTY AND CONFORMITY 133
15.1 Important Notes on Product Liability 133
15.2 Warranty Claim 133
15.3 EC Declaration of Conformity 134

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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 GM 5020EAW operating manual is available in the following languages:
Language Order No. Language Order No. Language Order No.
German 2363957 English 2366717 Spanish 2366716
French 2366718 Italian 2366719 -- --
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
Manual 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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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
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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2 CORRECT USE
2.1 DEVICE TYPE
Electrostatic spraying unit for manual 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 5020W control unit, a
GM 5020EAW spray gun and matching hose set, 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 GM5020EAW 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".)

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2.4 PROCESSIBLE WORKING MATERIALS
Water-dilutable lacquers are in principle divided into 3 groups:
Non-ignitable lacquers
Hard to ignite lacquers
Ignitable lacquers
Only non-ignitable liquid spray products can be processed with the present spray system.
The specic resistance of the spray product must be between 0.5 k cm and 1 M cm.
Assign group
Basically, the lacquermanufacturerdeterminesinwhichgroupasprayproductistobeclassied.
1. Request the group classication from the lacquer manufacturer or lacquer supplier.
2. Only if no information can be obtained from the lacquer manufacturer and the lacquer
supplier, the following recipe can be used to determine whether the spray product is
non-ignitable:
63 49
37 51
Where:
Weight percent
Water
Liquid organic phase; main components: Higher glycol esters in a mixture
with max. 1:1 of propanol.
Solid organic phase; main components: Binding agents and pigments.
Such lacquers behave like water in liquid form (liquid phase) and in sprayed form.
Cleaning and ushing agents
Cleaning and ushing agents must also align with this category.
Example of non-ignitable liquid:
No more than 35 weight percent, 1:1 butylglycol/n-propanol, rest water.
Please contact your local WAGNER dealer and the paint manufacturer if you encounter
application problems.
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.

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3 IDENTIFICATION
3.1 CE IDENTIFICATION
The device may not be used in potentially explosive areas.
3.2 TYPE PLATES
AquaCoat cabinet
B_06766
Gerätetyp / Type:
Eingangsspannung / Voltage input
Eingangsleistung / Power input
Ausgangshochspannung / High voltage output
Ausgangsstrom / Current output
Norm / Standard
Luftdruck max. / Air pressure max.
Temperatur Material max. / Fluid temp. max.
Temperatur Umgebung / Temperatur area
Baujahr - Serie Nr. /
Year of manufacture - Serial No.
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
Wagner International AG
Industriestrasse 22
CH-9450 ALTSTÄTTEN
MADE IN SWITZERLAND
115 - 230VAC, 50Hz / 60Hz
max. 40 W
max. 70 kV DC
max. 100 μA DC
EN 50059
0.8 MPa, 116 psi
+50°C, +122°F
+5 / +40°C, +41 / +104°F
AquaCoat 5010/5020 Manual
1
2
3
4
5
6
7
8
9
10
11
Designation
1 Device type
2 Input voltage
3 Input power
4 Output high voltage
5 Output current
6 Standard
7 Maximum air pressure
8 Maximum product
temperature
9 Ambient temperature
10 Year of manufacture – serial
number
11 Read operating manual
before use!
VM 5000W control unit
B_06755
Typ / Type: VM 5020W
115 - 230VAC
50Hz / 60Hz
2360060
max. 40W
Wagner International AG
Industriestrasse 22
CH - 9450 Altstätten
Made in Switzerland
Serie Nr.:
Serial No.:
Spannung:
Voltage:
Artikel Nr.:
Article No.:
Eingangsleistung:
Line Power:
Schutzart:
IP Code:
Norm:
Standard: EN 50059
IP 40
Spannung:
Voltage:
Strom:
Current:
max. 20Vpp
max. 1,0A
Baujahr:
Year of manufacture:
1
2
3
4
5
6
7
8
9
10
Designation
1 Type
2 Article number
3 Year of manufacture
4 Serial number
5 Input voltage
6 Maximum input power
7 Protection class
8 Standard
9 Maximum output voltage
10 Maximum output current

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GM 5020EAW spray Gun
B_05876
GM 5020EAW
Art. Nr.:
0.8MPa; 8bar; 116psimax. mat. pressure:
max. air pressure: 0.8MPa, 8bar; 116psi
2362847
max. high voltage: 70kV / 350mJ
Wagner International AG
1
2
3
4
5
Designation B_05875
geprüft nach EN 50059
For Waterborne Electrostatic
Finishing Applications
6
7
1 Gun type
2 Article number
3 Maximum high voltage / Energy
4 Maximum product pressure
5 Maximum air pressure
6 In compliance with EN 50059
7 For electrostatic application of
water-based lacquers
Serial number
The serial number (S) on the underside of the
handle.
B_03558
S
3.3 SAFETY SIGNAGE
AquaCoat cabinet GM 5020EAW spray gun GM 5020EAW spray gun
VM 5020W control unit
Warning: Hazardous voltage Warning: Danger of becoming
injured by high-pressure jet
Do not dispose of used electrical
equipment with household refuse.
see Chapter 12
AquaCoat cabinet
B_05871
01
1 s
Power Door lock
One second after the control unit
has been switched o, the system
is grounded and the door lock
opened.

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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.
Alwaysfollowlocalregulationsconcerningoccupational safety and accidentprevention.
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, there is a danger from line voltage.
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 sta 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 steam!
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 are is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 M).
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 / 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 M.
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 M.

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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 and 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.
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.
Ensurethattheoperatingpersonnelhasbeen 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 STAFF
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.
Hazard due to high-voltage eld!
Danger to life from malfunction of active implants.
Persons belonging to a risk group according to EMF guideline 2013/35/EU
(e.g., carriers of active implants), must not enter the high-voltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or steam!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
When preparing or working with paint 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 paint
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 unit.
– Secure the spray gun against actuation.
– Disconnect the control unit from the mains.
–In theeventoffunctionalfaults:remedythefault as describedinthe "Troubleshooting"
chapter.
If needed,theliquidejection devicesmustbecheckedbyexperts (e.g.,WAGNERservice
technician) at least every 12 months for their work-safe condition in accordance with
DGUV regulation 100-500 Chapter 2.29 and Chapter 2.36.
– For shut down devices, the examination can be suspended 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 during falling.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
4.2.3 GROUND THE UNIT
Hazard due to electrostatic charge!
Risk of injury, 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.
Make sure that the ground and potential equalization of all system parts are performed
reliably and continuously and can withstand the expected stress (e.g., mechanical stress,
corrosion).
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 HOSES
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 hoses 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 or
– on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lifts), 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 M.
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 an explosive mixture
may temporarily exist inside the lines and components of equipment:
– Depending upon used coating product,
– depending on the flushing agent (solvent) used,
an explosive mixture may temporarily exist inside the lines and items 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.
Which cleaning agent is used to clean the spray gun depends on which parts of the
spray gun have to be cleaned and which product has to be removed. When cleaning
the spray gun, only use non-polar cleaning agents to prevent conductive residues
on the surface of the spray gun. Should it however, be necessary to use a polar
cleaning agent, all residues of this cleaning agent have to be removed by using a non-
conductive and non-polar cleaning agent, once the cleaning is nished.

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OPERATING MANUAL
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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".
Instruction label: Order no. 9998910
Protection label: Order no. 9998911
Note: Order the two stickers together
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.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in the Chapters 13 and 14 and that are
assigned to the device.
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:
– Switch o the energy and compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
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.
4.2.9 SAFETYRELEVANT INFORMATION ABOUT DISCHARGES
The plastic parts of the cabinet are charged electrostatically by the high-voltage eld.
Contact with plastic parts harmless discharges (brush discharges) may occur. They are
completely non-hazardous for human health.

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OPERATING MANUAL
VERSION 02/2018 ORDER NUMBER DOC 2366717
5 DESCRIPTION
5.1 COMPONENTS
AquaCoat with TOPFINISH DD10 double diaphragm pump
B_06771
14
7
6
22
4
8
1
13
3
5
12
24
22
(20) 910
25
23
21
26
17
18
16
15
11
2
19
Designation
1 AquaCoat cabinet
2 Cabinet door
3 VM 5020W control unit
4 GM 5020EAW spray gun
5 EAW hose set
6 Product hose to spray gun
7 High-voltage generator (HV cascade)
8 Air inlet with ball valve
9 Inlet for mains cable
10 Grounding terminal (input: grounding cable)
11 Product pressure generator (pump)
12 Relief combination
13 Suction system
Designation
14 Metallic product tank
15 Grounding bolt on the cabinet door
16 Grounding band in the cabinet door
17 Electrical door switch
18 Pneumatic door switch
19 Door locking device engaging
20 Air hose, 8 mm (not used)
21 Air hose, 10 mm (product pressure generator)
22 Potential equalization lines, orange (4 pieces)
23 Underframe with rolls (special accessory)
24 Hose holder (special accessory)
25 Gun holder (special accessory)
26 Return line