WAGNER AquaCoat 5010 GM 5020EAW Bedienungsanleitung

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

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

OPERATING MANUAL

VERSION 02/2018 ORDER NUMBER DOC 2366717

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

OPERATING MANUAL

VERSION 02/2018 ORDER NUMBER DOC 2366717

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

OPERATING MANUAL

VERSION 02/2018 ORDER NUMBER DOC 2366717

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

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.

OPERATING MANUAL

VERSION 02/2018 ORDER NUMBER DOC 2366717

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)

OPERATING MANUAL

VERSION 02/2018 ORDER NUMBER DOC 2366717

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).

OPERATING MANUAL

VERSION 02/2018 ORDER NUMBER DOC 2366717

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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