WAGNER AquaCoat 5010 Operational manual

B_05900
AirCoat Spraying System
for
Non-ammable Liquids
Version 02/2016
Translation of the Original
Operating Manual
Manual
GM 5020EACW
High pressure

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OPERATING MANUAL
EDITION 02/2016 ORDER NUMBER DOC 2366600
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 9
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 Use in an Explosion Hazard Area 10
2.4 Safety Parameters 10
2.5 Processible Working Materials 11
2.6 Reasonably Foreseeable Misuse 12
2.7 Residual Risks 12
3 IDENTIFICATION 13
3.1 CE Identication 13
3.2 Type Plates 13
3.3 Safety Signage 14
4 GENERAL SAFETY INSTRUCTIONS 15
4.1 Safety Instructions for the Operator 15
4.1.1 Electrical Equipment 15
4.1.2 Personnel Qualications 15
4.1.3 Safe Work Environment 15
4.2 Safety Instructions for Sta 16
4.2.1 Safe Handling of WAGNER Spray Devices 16
4.2.2 Grounding the Device 17
4.2.3 Product Hoses 17
4.2.4 Cleaning and Flushing 18
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 19
4.2.6 Touching Hot Surfaces 19
4.3 Protective and Monitoring Equipment 19
4.4 Safety-Relevant Information about Discharges 19
5 DESCRIPTION 20
5.1 Components 20
5.2 Mode of Operation 23
5.3 Protective and Monitoring Equipment 24
5.4 Scope of Delivery 26
5.4.1 Basic Sets 27
5.5 Technical Data 28
5.5.1 VM 5020W Control Unit 29
5.5.2 Product Pressure Generator 29
5.5.3 GM 5020EACW Spray Gun 30
5.5.4 Electric Block Diagram, AquaCoat 31

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Table of Contents
5.6 Controls 32
5.6.1 VM 5020W Control Unit 32
5.6.1.1 Operating Elements, Front Side 32
5.6.1.2 Connections on the Rear Side 35
5.6.2 Product Pressure Generator 36
5.6.2.1 Puma 28-40 PE+TG Pneumatic Piston Pump 36
5.6.2.2 Cobra 40-10 Double Diaphragm Pump 37
5.6.2.3 EvoMotion 20-30 Piston Pump 38
5.6.2.4 Working in Accordance with Pump's Operating Manual 38
5.6.3 GM 5020EACW Spray Gun 39
5.6.3.1 Securing the Spray Gun Against Actuation 40
5.6.3.2 Functioning of the Spray Gun 40
5.6.3.3 Spraying Procedure for AirCoat Round Spray 42
5.6.3.4 Spraying Procedure for AirCoat Fan Spray 42
5.6.3.5 Electrostatic Eect 43
6 ASSEMBLY AND COMMISSIONING 44
6.1 Training Assembly/Commissioning Sta 44
6.2 Storage Conditions 44
6.3 Installation Conditions 44
6.4 Transportation 45
6.5 Assembly and Installation 45
6.5.1 Assembling the AquaCoat System 46
6.5.2 Ventilation of the Spray Booth 48
6.5.3 Air Supply 48
6.5.4 Product Supply 49
6.6 Grounding 50
6.7 Safety Checks 52
6.8 Preparation of Water-Based Lacquer 52
6.8.1 Viscosity Conversion Table 52
6.9 Commissioning 53
6.9.1 Safety Instructions 53
6.9.2 Preparation 53
6.9.3 Commissioning 54
6.9.3.1 AquaCoat with Puma 28-40 or EvoMotion 20-30 54
6.9.3.2 AquaCoat with Cobra 40-10 Double Diaphragm Pump 56
6.9.4 Verifying a Safe Operational Condition 57
7 OPERATION 58
7.1 Training the Operating Sta 58
7.2 Safety Instructions 58
7.2.1 Emergency Deactivation for Puma 59
7.2.2 Emergency Deactivation for Cobra 60
7.2.3 Emergency Deactivation for EvoMotion 61
7.2.4 General Rules for Making Adjustments to the Spray Gun 62
7.2.4.1 Electrical Discharge 63

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7.3 Working 64
7.3.1 Checking the Spray Pattern (Without Electrostatics) 64
7.3.2 Starting the System 66
7.3.3 Spraying 67
7.3.4 Pressure Relief/Work Interruption 68
7.3.5 Flushing Out Clogged Round Jet Nozzles 69
7.3.6 Replacing Round Jet Nozzle's Nozzle Insert 69
7.3.7 Changing from AirCoat Round Jet to AirCoat Flat Jet 70
7.3.8 Replacing the AirCoat Flat Jet Nozzles 73
7.3.9 Cleaning of the Nozzle Parts 73
7.3.10 Eliminate Nozzle Clogging 74
7.3.11 VM 5020W Control Unit Start Up 76
7.3.12 Setting and Saving Recipes 77
7.3.13 Setting the High Voltage 78
7.3.14 Setting the Current Limitation 79
7.3.15 Display During Spraying 80
7.3.16 Standby Mode 81
7.3.17 Operating Hours Counter/Service Display 82
7.3.18 Service Display Setup 83
7.3.19 "Carry Out Service" Display 84
7.4 Device Conguration 85
7.4.1 Overview of Parameters 85
7.4.2 Access to the Device Conguration Mode 86
7.4.3 Setting Example "Parameter C13" 87
7.5 External Interface 89
8 CLEANING AND MAINTENANCE 91
8.1 Cleaning 91
8.1.1 Cleaning Sta 91
8.1.2 Safety Instructions 91
8.1.3 Flushing and Cleaning the System 92
8.2 Maintenance 94
8.2.1 Maintenance Sta 94
8.2.2 Safety Instructions 94
8.2.3 Safety Checks 95
8.2.3.1 Grounding Check 95
8.2.3.2 Inspecting the Safety Elements 95
8.2.3.3 Product Hoses, Tubes and Couplings 96
8.2.4 Changing the Spray Gun With Hose Set 97
8.2.5 Changing the Product Hose and/or Air Hose 98
8.2.6 Cleaning and Replacing the Filter 98
9 TROUBLESHOOTING AND RECTIFICATION 99
9.1 Error Displays at the VM 5020W Control Unit 99
9.2 Faults in the System 101
10 REPAIR WORK 102
10.1 Repair Personnel 102
10.2 Safety Instructions 102
10.3 Mounting Materials 103
Table of Contents

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10.4 Spray Gun 103
10.4.1 Tools 103
10.4.2 Disassembly of the Spray Gun 104
10.4.3 Cleaning the Parts After Disassembly 107
10.4.4 Assembling the Spray Gun 108
10.5 Disassembling VM 5020W Control Unit 114
10.6 Opening the Control Unit 114
11 FUNCTION TEST AFTER THE REPAIR 115
11.1 Function Tests for Spray Gun 117
11.1.1 Air Test 117
11.1.2 Product Pressure Test 117
11.1.3 Test of Spray Pattern 117
12 DISPOSAL 118
13 ACCESSORIES 119
13.1 Round Spray Nozzles 119
13.1.1 AirCoat Round Jet Nozzle Inserts 119
13.2 ACF Air Caps (Flat Jet) 119
13.2.1 ACF5000 AirCoat Flat Jet Nozzles 120
13.3 Hoses and Gun Cables 122
13.4 Miscellaneous 124
14 SPARE PARTS 126
14.1 How Can Spare Parts Be Ordered? 126
14.2 AquaCoat Basic device 127
14.2.1 VM 5020W Control Unit 132
14.3 Pump Sets 138
14.3.1 Puma 28-40 Set for AquaCoat 138
14.3.2 Cobra 40-10 Set for AquaCoat 140
14.3.3 EvoMotion 20-30 Set for AquaCoat 142
14.3.3.1 Distributor for EvoMotion 143
14.3.4 Relief Combination, 270 bar 144
14.3.5 Angled Inline Filter, 530 bar 145
14.4 GM 5020EACW Spray Gun 146
14.4.1 GM 5020EACW Adapter 148
14.4.2 GM 5000EAC Handle 150
14.5 Accessories Spare Parts Lists 152
14.5.1 Fan Spray Nozzles 152
14.5.2 ACR5000 Round Jet Nozzle Adapter 152
14.5.3 Underframe with Rolls 153
14.5.4 Hose Holder 154
14.5.5 Gun Holder 154
14.5.6 Level Monitor With Alarm Horn 155
14.5.7 D350 Drum Cover 156
15 WARRANTY AND CONFORMITY DECLARATIONS 157
15.1 Important Notes Regarding Product Liability 157
15.2 Warranty Claim 157
15.3 CE Declaration of Conformity 158
15.4 Notes on National Regulations and Guidelines 158
Table of Contents

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1 ABOUT THESE INSTRUCTIONS
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.
1.1 PREFACE
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 - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
Note - provides information about particular characteristics and how to proceed.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its consequences.
DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the danger and its consequences.
NOTICE

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1.3 LANGUAGES
The AquaCoat GM 5020EACW operating manual is available in the following languages:
Language Order No. Language Order No.
German 2363958 English 2366600
French 2366598 Italian 2366601
Spanish 2366599
1.3.1 OPERATING MANUALS FOR THE INDIVIDUAL COMPONENTS
Puma 28-40 PE+TG piston pump operating manual
Language Order No. Language Order No.
German 2333537 English 2333538
French 2333539 Italian 2333540
Spanish 2333541
AquaCoat compressed air connection for Puma: Refer to Chapter 5.6.2.1.
Double diaphragm pump Cobra 40-10 operating manual
Language Order No. Language Order No.
German 2340850 English 2340851
French 2340852 Italian 2340853
Spanish 2340854
AquaCoat compressed air connection for Cobra: Refer to Chapter 5.6.2.2.
Additional languages on request or at:
EvoMotion 20-30 piston pump operating manual
Language Order No. Language Order No.
German 2333552 English 2333553
French 2333554 Italian 2333555
Spanish 2333556
AquaCoat compressed air connection for EvoMotion: Refer to Chapter 5.6.2.3.

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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 A person who, based on his/her technical training, experience and
recent vocational experience, has sucient technical knowledge
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.
In the context of
TRBS1203
(2010 / Revision 2012)
Additional requirements for skilled persons are given in the
TRBS1203(2010/Revision 2012): Expert knowledge in the areas
of protection against excessive pressure, electrical hazards, and
explosion protection (where applicable).
1.4 ABBREVIATIONS
Order No. Order number
Spare part
Marking in the spare parts lists
AirCoat
AirCoat electrostatic, water-based
Manual gun
High voltage
HP High pressure
Stainless steel
Ultra high molecular weight polyethylene
PTFE with graphite
Position
Number of pieces
Wrench size
LV Low viscosity
HV High viscosity

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2 CORRECT USE
2.1 DEVICE TYPE
Electrostatic spraying unit for manual coating of grounded work pieces using the AirCoat
process.
AquaCoat 5010/5020 systems are equipped with the AquaCoat 5010/5020 cabinet, the
VM 5020W control unit, a GM 5020EACW AirCoat spray gun and matching hose set, a
high-voltage generator, all safety devices and one of the following spray product supplies:
- Piston pump, Puma 28-40 PE/TG (in accordance with the spare parts catalog)
- Double diaphragm pump, Cobra 40-10 (in accordance with the spare parts catalog)
- Piston pump, EvoMotion 20-30 (in accordance with the spare parts catalog)
2.2 TYPE OF USE
2.3 USE IN AN EXPLOSION HAZARD AREA
The device is not suitable for use in potentially explosive areas.
(See Chapter 3.1 "CE Identication".)
WAGNER accepts no liability for any damage arising from incorrect use.
Use the device only to work with the products recommended by WAGNER.
Only operate the device as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
AquaCoat 5010/5020 GM 5020EACW can be used to spray liquid, non-ammable products,
in particular non-ammable coating products in accordance with Chapter 2.5.
WAGNER forbids any other use!
The system may only be used as described in this operating manual. In particular, no
conversions are permitted on the system otherwise the warranty ceases to apply and
WAGNER is not liable for any claims.
2.4 SAFETY PARAMETERS

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2.5 PROCESSIBLE WORKING MATERIALS
Water-dilutable lacquers are in principle divided into 3 groups:
Green Non-ammable lacquers.
Yellow Lacquers with low ammability.
Red Flammable lacquers.
Only non-ammable (non-combustible) liquid spray products (green group) 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.
The following recipe can be used to determine whether the product is non-ammable:
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.
Thinners must also be non-ammable.
If the cleaning and ushing agents also align with this category, the system may be used.
Example of non-combustible liquid:
No more than 35 weight percent, 1:1 butylglycol/n-propanol, rest water.
Please contact your localWAGNER dealer and the lacquer manufacturer if you encounter
application problems.
The device may only be operated under the following conditions:
The operating personnel must be trained on the basis of this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must be
observed.
The statutory requirements and accident prevention regulation standards in the country
of use must be observed.
The electrostatic spray unit may only be operated if all parameters are set and all
measurements/safety checks are carried out correctly.

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2.6 REASONABLY FORESEEABLE MISUSE
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be ruled out even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
The forms of misuse listed below may result in physical injury or property damage:
coating work pieces which are not grounded;
unauthorized conversions or modications to the system;
working with combustible coating products;
processing dry or similar coating products, e.g., powder;
using defective components, spare parts or accessories other than those described in
the "Accessories" chapter of this operating manual;
continuing work with a defective or kinked product hose;
working with incorrectly set values;
processing food.
Residual risk Source Consequences Specic measures Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Handling of
lacquers and
cleaning agents
Skin irritations, Use personal safety
equipment.
Operation,
allergies Observe safety data
sheets
maintenance,
disassembly
Lacquer in air
outside the dened
working area
Lacquering outside
the dened working
area
Inhalation of
substances
hazardous to health
Observe work
and operation
instructions.
Operation,
Use personal safety
equipment
maintenance

13
B_04983
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
Serie Nr. / Serial No.
Vor Gebrauch Betriebsanleitung beachten / Check manual before use!
J. WAGNER AG
Industriestrasse 22
CH-9450 ALTSTÄTTEN
MADE IN SWITZERLAND
115 - 230VAC, 50Hz / 60Hz
max. 40 W
max. 70 kV DC
PD[ȝ$'&
EN 50059
0.8 MPa, 116 psi
+50°C, +122°F
+5 / +40°C, +41 / +104°F
AquaCoat
B_05882
Typ / Type: VM 5020W
115 - 230VAC
50Hz / 60Hz
2360060
max. 40W
J.WAGNER 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:
OPERATING MANUAL
EDITION 02/2016 ORDER NUMBER DOC 2366600
3 IDENTIFICATION
3.1 CE IDENTIFICATION
The device may not be used in potentially explosive areas.
3.2 TYPE PLATES
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 Serial number
11 Read operating manual before use!
1
2
3
4
5
6
7
8
9
10
11
AquaCoat cabinet
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
VM 5020W control unit
1
2
3
4
5
6
7
8
9
10

14
B_03558
S
B_05875
geprüft nach EN 50059
For Waterborne Electrostatic
Finishing Applications
B_05877
GM 5020EACW
Art. Nr.:
25MPa; 250bar; 3626psimax. mat. pressure:
max. air pressure: 0.8MPa, 8bar; 116psi
2362837
max. high voltage: 70kV / 350mJ
J. Wagner AG
B_05871
01
1 s
Power
OPERATING MANUAL
EDITION 02/2016 ORDER NUMBER DOC 2366600
3.3 SAFETY SIGNAGE
Door lock
One second after the control unit has been switched
o, the system is grounded and the door lock opened.
AquaCoat cabinet
GM 5020EACW spray gun
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
1
2
3
4
5
6
7
AquaCoat cabinet GM 5020EACW spray gun GM 5020EACW 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
Serial number
The serial number (S) on the underside of the handle.

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4 GENERAL 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 EQUIPMENT
Electrical devices and equipment
To be provided 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.
Mustbeoperatedinaccordancewiththesafetyregulationsandelectrotechnicalregulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard or are damaged.
Must be de-energized before work is commenced on active parts. 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 PERSONNEL QUALIFICATIONS
Ensure that the device is only operated, maintained and repaired by trained persons.
4.1.3 SAFE WORK ENVIRONMENT
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 megohms).
Paint mist extraction systems/ventilation systems must be tted on site according to
local regulations.
Ensure that product / air hoses adapted to the working pressure are used.
Ensure that personal protective equipment is available and is used (breathing and skin
protection).
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megohms.
Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun handle or the trigger guard.

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Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.
In electrostatics application: Anyone tted with a pacemaker must not enter the
high-voltage area!
4.2 SAFETY INSTRUCTIONS FOR STAFF
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 megohms.
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
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.
Grounding
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).
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 all work on the device, in the event of work interruptions and functional faults:
- Switch o the energy/compressed air supply.
- Relieve pressure from spray guns and devices.
- Secure spray guns against actuation.
- In the event of functional faults, remedy the fault as described in the "Troubleshooting"
chapter.
If needed, the liquid ejection devices must be checked by experts (e.g.,WAGNER service
technician) at least every 12 months to ensure they are safe for work in accordance with
the DGUV regulation 100-500.
- For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure Relief" chapter:
- If pressure relief is required.
- If the spraying work is interrupted or stopped.
- Before the device is cleaned on the outside, checked or serviced.
- Before the spray nozzle is installed or cleaned.
4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES

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4.2.3 PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products and the
ushing agents used.
Ensure that the product hose is 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.
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the product hose outer sheath, measured over the entire
length of the outer sheath, must be less than 1 megohm.
Suction hoses may not be subjected to pressure.
4.2.2 GROUNDING THE DEVICE
Friction, owing liquids and air or electrostatic coating processes create charges. Flames or
sparks can form during discharge. Grounding prevents electrostatic charging.
Ensure that the device is grounded. See chapter "Grounding".
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 guard.
In the event of skin injuries caused by paint or ushing agents:
Note the paint or ushing agent that you have been using.
Consult a doctor immediately.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun briey in a position.

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4.2.4 CLEANING AND FLUSHING
Relieve the pressure from the device.
De-energize the device electrically.
Preference should be given to non-ammable 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.
Take measures for workplace safety (see Chapter 4.1.3).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- depending on the ushing agent (solvent) used,
explosive mixture 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:
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.
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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OPERATING MANUAL
EDITION 02/2016 ORDER NUMBER DOC 2366600
4.2.6 TOUCHING HOT SURFACES
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 unit with a warning label that says "Warning - Hot Surface".
- Instruction label Order no. 9998910
- Protection label Order no. 9998911
Note: Order the two stickers together.
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
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edprotectivemeasures.In particular,usepersonalprotectiveequipment:
safety goggles, protective clothing and gloves, as well as respiratory protection and
skin 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.
4.4 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.
4.3 PROTECTIVE AND MONITORING EQUIPMENT
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.

20
B_05850
14
7
6
12
4
8
1
13
11
2
3
5
26
24
22
20 21 910
25
23
17
18
22
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OPERATING MANUAL
EDITION 02/2016 ORDER NUMBER DOC 2366600
5 DESCRIPTION
5.1 COMPONENTS
Pos Designation
1 AquaCoat cabinet
2 Cabinet door
3 VM 5020W control unit
4 GM 5020EACW spray gun
5 Hose set EACW
6 Product hose (Puma: from high-pressure lter to spray gun;
Cobra: from high-pressure lter to potential equalization connection (33))
7 High-voltage generator (high-voltage cascade)
8 Air inlet with ball valve
9 Inlet for mains cable
10 Grounding terminal (input: grounding cable)
AquaCoat with Puma28-40 piston pump