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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OPERATING MANUAL
VERSION 02/2018 ORDER NUMBER DOC 2366717
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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OPERATING MANUAL
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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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OPERATING MANUAL
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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".)