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
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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
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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