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WAGNER AquaCoat AirCoat GM 5000EACW Operating Manual

Aquacoat aircoat-spray system for noncombustible spray media aquacoat aircoat - evomotion 20-30s - wildcat 18-40 - puma 28-40 - cobra 40-10
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AquaCoat
AirCoat-Spray system for non-
combustible spray media
Translation of the original
Operating manual
AquaCoat AirCoat
- EvoMotion 20-30S
- Wildcat 18-40
- Puma 28-40
- Cobra 40-10
Edition 04/2012
80
100
R1
60
Zerstäube
rluft
80
Atomizing
air
Mat. Druckregl
Mat. pressure
er
40
reg.
Pumpe
60
Pump
R2
20
40
10
20
R3
kV
μA
POWER
0
1
1
Aqua Coat
Aqua Coat
B_03520

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Summary of Contents for WAGNER AquaCoat AirCoat GM 5000EACW

  • Page 1 Translation of the original Operating manual AquaCoat AirCoat - EvoMotion 20-30S - Wildcat 18-40 - Puma 28-40 - Cobra 40-10 Edition 04/2012 AquaCoat AirCoat-Spray system for non- combustible spray media Zerstäube rluft Atomizing Mat. Druckregl Mat. pressure reg. Pumpe Pump μA POWER Aqua Coat...

  • Page 3: Table Of Contents

    Safety instructions for the operator 2.1.1 Electrical equipment 2.1.2 Personnel qualifi cations 2.1.3 A safe work environment Safety instructions for staff 2.2.1 Safe handling of WAGNER spray units 2.2.2 Earth the unit 2.2.3 Material hoses 2.2.4 Cleaning 2.2.5 Handling hazardous liquids, varnishes and paints 2.2.6...
  • Page 4 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Contents 5.1.5 Safety checks 5.1.5.1 Earthing check 5.1.5.2 Inspection of the safety elements Preparation of water-based paints 5.2.1 Viscosity conversion table Starting operation 5.3.1 General rules for making adjustments to the spray gun 5.3.2 Preparation for starting up 5.3.2.1...
  • Page 5 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Contents FUNCTIONAL CHECK AFTER ASSEMBLY AquaCoat Complete device PRODUCT DISPOSAL ACCESSORIES 11.1 Round jet nozzles 11.1.1 AirCoat round jet nozzle inserts 11.2 ACF air caps (fl at jet) 11.2.1 ACF5000 AirCoat fl at jet nozzles 11.3 Hoses and electrical cables 11.4...

  • Page 6: About These Instructions

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL ABOUT THESE INSTRUCTIONS LANGUAGES 2310483 2321362 2324673 2324674 2324675 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS Warning instructions in this manual point out particular dangers to users and equipment and state measures for avoiding the hazard. These warning instructions fall into the following categories: DANGER Danger - imminent danger.

  • Page 7: General Safety Instructions

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep these operating instructions to hand near the unit at all times. Always follow local regulations concerning occupational safety and accident prevention. 2.1.1 ELECTRICAL EQUIPMENT Electrical plant and unit...

  • Page 8: Safe Handling Of Wagner Spray Units

    EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or cleaning agents: Never point the spray gun at people. Never reach into the spray jet.

  • Page 9: Cleaning

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 2.2.4 CLEANING 2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS When preparing or working with paint and when cleaning the unit, follow the working instructions of the manufacturer of the paints, solvents and cleaning agents being used.

  • Page 10: Guarantee And Conformity Declarations

    fitted , operated and maintained. If other makes of accessory and spare parts are used, the manufacturer‘s liability could be fully or partially null and void. The usage of original WAGNER accessories and spare parts guarantees that all safety regulations are observed. GUARANTEE CLAIM...

  • Page 11: Ce-Conformity

    BGR 500 Part 2 chap. 2.36 BGI 740 BGI 764 Identifi cation mark: CE Certificate of Conformity The certificate is enclosed with this product. The certificate of conformity can be reordered from your WAGNER representative, quoting the product and serial number. Part number : 2314228...

  • Page 12: German Regulations And Guidelines

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL GERMAN REGULATIONS AND GUIDELINES a) BGV A3 Electrical units and equipment b) BGR 500 Part 2, Chap. 2.36 Working with liquid ejection devices c) BGR 500 Part 2, Chap. 2.29 Using coating materials d) BGR 104 Explosion protection rules e) TRBS 2153...

  • Page 13: Description

    Cleaners and thinners must also be non-fl ammable. A possible cleaner and thinner is, e.g. water with less than 37 weight percent 1:1 butylene glycol/N-propanol. Please contact your local WAGNER dealer and the paint manufacturer if you encounter application problems.

  • Page 14: Scope Of Delivery

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL SCOPE OF DELIVERY AquaCoat-AirCoat Packs can be assembled according to requirement and the desired accessories with the help of the Spray Pack confi guration. All devices are assembled ready-for-use in the factory on the basis of the resulting confi...

  • Page 15: Spraypack Confi Guration

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 4.2.1 SPRAYPACK CONFIGURATION To order the AquaCoat Spray Pack, please use model identifi cation 2327677-ABCDEFGHIK together with the following tables. Tables -> Examples -> 2327677 Confi guration no. 2327677 Model identifi cation Pump Table “A“...
  • Page 16 Round jet incl. nozzle R 14 (*) Note for table “I“: The complete Wagner nozzle range can be found in the accessories in Chapter 11. For fl at-jet nozzles, the last 3 digits of the order number are used, and for...

  • Page 17: Technical Data

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL TECHNICAL DATA Weight 70 kg; 154 lb (without paint container and pump) Working temperature range 5 °C - 40 °C; 41 °F - 104 °F Maxi. material temperature 50 °C; 122 °F Sound pressure level When the cabinet is open: Dependent on the installed pump, data can be...

  • Page 18: Control Unit Vm 5000W

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 4.3.1 CONTROL UNIT VM 5000W Input voltage 115 V AC / 230 V AC 50 Hz / 60 Hz Input power max. 40 W Output voltage max. 20 Vpp Output current max.

  • Page 19: Spray Gun Gm 5000Eacw

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 4.3.2 SPRAY GUN GM 5000EACW Maxi. air pressure 0.8 MPa; 8 bar; 116 psi Max. material pressure 25 MPa; 250 bar; 3626 psi Material connection NPSM 1/4“-18 Air connection G 1/4“ A Weight (without hose set) 700 g (incl.

  • Page 20: Pneumatic Piston Pump Evomotion 20-30S Pe+T

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 4.3.3 PNEUMATIC PISTON PUMP EVOMOTION 20-30S PE+T 2314783 2314784 2314785 2314786 2314787 2314788 2314790 2314789 2321572 4.3.4 PNEUMATIC PISTON PUMP TYPE PP3000 Wildcat 10-70 PE+TG Puma 15-70 PE+TG Puma 28-40 PE+TG 367850 367851 367852...

  • Page 21: Functional Description

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL FUNCTIONAL DESCRIPTION 4.4.1 DESIGN OF UNIT AND FUNCTION Zerstäu berluft Atomiz ing Mat. Druckr Mat. pressu egler re reg. Pumpe Pump μA POW ER Aqu aCo at B_03523 Pos Description Cabinet AquaCoat assy.
  • Page 22 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Pos Description Earthing cable Material pressure generator such as pneumatic pump or double diaphragm pump Suction system, compl. Paint container Earthing switch (Cylinder AquaCoat) Earthing band Filter-relief combination Door switch Leakage resistance 3GOhm Air hose (material pressure generator) High voltage cable (2 pieces)
  • Page 23 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Electrical block diagram AquaCoat...

  • Page 24: Control Unit Vm 5000W

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 4.4.1.1 CONTROL UNIT VM 5000W The assembled spray system can be operated and regulated with the VM 5000W control unit. Operating elements on the front: 24 25 Zerstäuberluft Mat. Druckregler Pumpe Atomizing air Mat.
  • Page 25 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Push button “High voltage” To activate the function; the high-voltage is set with the rotary controller (2) and is indicated in the LED display (27). Adjusting range: 5 - 70 kV ●...
  • Page 26 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 21 Illuminated display “High voltage” lights up green. ● Display range: 0 - 70 kV ● Single display: Preset value of high voltage. ● Bar display: Set voltage. ● 22 Illuminated display “Spraying current” lights up green.
  • Page 27 To connect a spray gun. 31 High voltage connection Connection for high voltage generator. 32 Cover of the service connections For Wagner service personnel only! 33 Connection Pump air Hose connector ø 10 mm; ø 0.39 inches. 34 Connection Material pressure regulator Hose connector ø...

  • Page 28: Spray Gun Gm 5000Eacw

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 4.4.1.2 SPRAY GUN GM 5000EACW B _03524 Description Description Suspension hook Trigger lock Display (spray current and recipe) Trigger Display standby and fault Round jet nozzle cap (see chapter 11.1) Operating button Round jet nozzle insert (standby and recipe change)
  • Page 29 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Functions of the spray gun When the spray gun is connected to the control unit and the control unit is switched on, the pre-defi ned recipe (R1, R2 or R3) is shown on the gun display (2) as follows: Recipe 1 ->...

  • Page 30: Aircoat Round Jet Spray Process

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 4.4.1.2.1 AIRCOAT ROUND JET SPRAY PROCESS In the AirCoat process, high pressure of 3-15 MPa; 30-150 bar; 435-2176 psi is used to atomize the material.The air at 0-0.25 MPa; 0-2.5 bar; 0-36 psi produces a soft jet. The size of the spray jet can be adjusted by turning the nozzle nut.

  • Page 31: Aircoat Atomizing Fl At Jet Spray Process

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 4.4.1.2.2 AIRCOAT ATOMIZING FLAT JET SPRAY PROCESS In the AirCoat process, high pressure of 3-15 MPa; 30-150 bar; 435-2176 psi is used to atomize the material. The AirCoat air at 0-0.25 MPa; 0-2.5 bar; 0-36 psi produces a soft jet, which largely eliminates the problem of overlapping boundaries.

  • Page 32: The Electrostatic Effect

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 4.4.1.2.3 THE ELECTROSTATIC EFFECT After being electrically charged in the system and atomized by the spray gun, the paint particles are now transported by kinetic and electrostatic energy to the earthed work piece and adhere to the sprayed object, fi...

  • Page 33: Start-Up And Operation

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL START-UP AND OPERATION INSTALLATION AND CONNECTION WARNING Incorrect installation/operation! Risk of injury and damage to equipment When putting into operation and for all work, read and follow the operating instructions and safety regulations for the additionally required system components.

  • Page 34: Air Supplies

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.1.2 AIR SUPPLIES You must ensure that only dry, clean atomizing air is used in the spray gun. Dirt and moisture in the atomizing air reduce the spraying quality and the appearance of the fi nished piece. 5.1.3 PAINT SUPPLIES CAUTION...

  • Page 35: Earthing

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.1.4 EARTHING Perfect earthing of all system components (workpieces, conveyor, paint supply system, control unit, spray booth or spraying stand, see illustration) is a prerequisite for optimum coating effi ciency and safety. WARNING Heavy paint mist if earthing is insufficient! Risk of poisoning...

  • Page 36: Safety Checks

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Minimum cable cross-section AquaCoat cabinet 4 mm²; AWG11 Conveyor 16 mm²; AWG5 Spray booth 16 mm²; AWG5 Spraying stand 16 mm²; AWG5 5.1.5 SAFETY CHECKS 5.1.5.1 EARTHING CHECK Every day: Before starting work, carry out a visual check to ensure that the earthing connection is present in the AquaCoat cabinet and in all relevant components.

  • Page 37: Preparation Of Water-Based Paints

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL PREPARATION OF WATER-BASED PAINTS The viscosity of the paints is of great importance. The best results are obtained with paints between 25 and 40 DIN sec (Measured in immersion fl ow cup DIN 4 mm; 0.16 inch). Processing of up to 60 DIN-s is generally possible without problem, if high coating thicknesses are required.
  • Page 38 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL...

  • Page 39: Starting Operation

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL STARTING OPERATION 5.3.1 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN ➞ Observe general safety instructions in chapter 2. DANGER High voltage field! Danger to life from malfunctioning heart pacemakers Ensure that persons with heart pacemakers: Do not work with the electrostatic spray gun.

  • Page 40: Preparation For Starting Up

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.3.2 PREPARATION FOR STARTING UP CAUTION Impurities in the spraying system! Spray gun blockage Flush the spray gun and paint supply with a suitable cleaning agent before putting into operation. SIHI_0010_GB 5.3.2.1 SPRAY PACK WITH PNEUMATIC PUMP EVOMOTION 20-30S...
  • Page 41 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Check the unit for leaks: 1. Place container with suitable detergent into the AquaCoat cabinet. 2. Immerse the suction system (12). 3. Connect the earth. 4. Connect the AquaCoat system to the compressed air source (8). 5.

  • Page 42: Spraypack Examples With Double Diaphragm Pump Cobra

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.3.2.2 SPRAYPACK EXAMPLES WITH DOUBLE DIAPHRAGM PUMP COBRA 40-10 Check the unit for leaks: 1. Place container (13) with suitable detergent into the AquaCoat cabinet. 2. Immerse in container the suction system (12). 3.
  • Page 43 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Start-up for spraying: 1. Fill the material container (13) with paint and place in the cabinet. 2. Immerse in paint container the suction system (12). 3. Clamp high voltage cable (22) to the metal paint container (13) or, in the case of a plastic container, to the metal part of the suction system (12).

  • Page 44: Works

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL WORKS 5.4.1 PREPARATION FOR SPRAYING WITH FLAT-JET NOZZLE Zerstäuberluft Mat. Druckregler Pumpe Atomizing air Mat. pressure reg. Pump μA POWER AquaCoat B_03371 Zerstäuberluf Atomizing Mat. Druckregler Mat. pressure reg. Pumpe Pump μA POWER...

  • Page 45: Start-Up For Spraying

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.2 START-UP FOR SPRAYING 1. Secure gun and place the appropriate nozzle. 2. Switch on the pump adjust from approx. 8 MPa; 80 bar; 1160 psi, and the control unit. 3.

  • Page 46: Check Spray Pattern

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.3 CHECK SPRAY PATTERN Start AirCoat spraying (without electrostatics) 1. Start up with material supply set to approx. 8 MPa; 80 bar; 1160 psi operating pressure. 2. Spray (release trigger safety clip and pull trigger) and check the atomisation. 3.

  • Page 47: Cleaning Of Clogged Round Jet Nozzles

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.4 CLEANING OF CLOGGED ROUND JET NOZZLES 1. By means of nozzle spanner (2), loosen nozzle insert (1) by a half turn. 2. Remove the nozzle spanner and briefl y actuate trigger guard.

  • Page 48: Changing From Aircoat Round Jet To Aircoat Fl At Jet

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.6 CHANGING FROM AIRCOAT ROUND JET TO AIRCOAT FLAT JET 1. Flush the spray gun (1) out thoroughly with cleaning agent. 2. Relieve the pressure of gun and unit. 3. Save the spray gun (1) using the trigger lock. 4.

  • Page 49: Replacing Aircoat Fl At Jet Nozzles

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.7 REPLACING AIRCOAT FLAT JET NOZZLES 1. Switch off control unit. 2. Relieve the pressure of gun (1) and unit! 3. Save the spray gun (1) using the trigger lock (14). 4.
  • Page 50 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 7. Screw preassembled union nut (12) to gun (1) and tighten by hand. 8. Switch the material pressure back on. 9. Turn the trigger lock (14) to the spraying position and briefl y pull trigger. 10.

  • Page 51: Start-Up The Control Unit Vm 5000W

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.10 START-UP THE CONTROL UNIT VM 5000W 1. Turn switch to position 1. 2. All LEDs on the control unit illuminate μA for approx. 1 second. POWER POWER AquaCoat B_03372 3.

  • Page 52: Set And Save Recipes

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.11 SET AND SAVE RECIPES Nominal values for the high voltage (kV) and for the spray current limiter (µA) are stored in a recipe. As standard, the following values are saved in the factory in the 3 storage places available for recipes: Recipe No.

  • Page 53: Setting The High Voltage

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.12 SETTING THE HIGH VOLTAGE Works procedure: 1. Press the „High voltage“ button (7) to μA adjust the high voltage. The LED (8) POWER POWER indicates that high voltage is selected. AquaCoat B_03375 2.

  • Page 54: Setting The Current Limiting

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.13 SETTING THE CURRENT LIMITING Works procedure: 1. Press the „Current limiting“ button (5) to adjust the limitation of the spray μA current. The LED (6) indicates that POWER POWER current limiting is selected.

  • Page 55: Spray Display

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.14 SPRAY DISPLAY Ready to spray using R2 recipe (see picture below). Control unit in standby position. The nominal value LEDs illuminate as dots and the high voltage value is digitally displayed in the LED display.

  • Page 56: Standby Mode

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.15 STANDBY MODE If you want to spray without high voltage, select standby mode. Briefl y press the „Standby“ pushbutton (3), LED (4) will illuminate. All other LEDs are extinguished. μA POWER POWER...

  • Page 57: Operating Hours Counter/Warning Display

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.16 OPERATING HOURS COUNTER/WARNING DISPLAY Two hour counters are integrated into the control unit. The absolute counter measures the ongoing hours of operation of the spray gun and with the maintenance hours counter, maintenance intervals can be determined and monitored for the spray gun.

  • Page 58: Maintenance Display Setup

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.17 MAINTENANCE DISPLAY SETUP When the device is fi rst used, the function for the maintenance interval is deactivated. This function can be activated via the the R3 push button (19). The service interval limit can be set within a range of 0 to 999 hours.

  • Page 59: Conduct Service" Display

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.4.18 “CONDUCT SERVICE” DISPLAY μA POWER POWER AquaCoat B_03385 Prerequisite: The function “maintenance interval limit” is activated. “Conduct service on spray gun” Once the time for the defi ned maintenance interval has expired, the LED display (26) starts to fl...

  • Page 60: Device Confi Guration

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL DEVICE CONFIGURATION 5.5.1 OVERVIEW OF PARAMETERS Parameters Value Description User lock is switched off. (Factory setting) User lock is switched on: no target values (kV and µA) can be adjusted; you can only select the recipe and the control C13 User lock functions.

  • Page 61: Access To The Device Confi Guration Mode

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 5.5.2 ACCESS TO THE DEVICE CONFIGURATION MODE Works procedure: 1. Switch device to “Standby” by pressing the “Standby” key (3). The “Standby” LED (4) lights up yellow. μA POWER POWER AquaCoat B_03381 2.

  • Page 62: Setting Example "Parameter C13

    For ease of operation the confi guration settings are divided into three groups. The fi rst group is for the end user, the other both groups, protected by a password, are reserved for Wagner Service and the Wagner production sites or the Wagner Service Center, which have the necessary infrastructure.
  • Page 63 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 26 25 μA POWER POWER AquaCoat B_03510 The fl ashing LED display “ maintenance” (26) indicates that the parameter value, “OFF” in the display (27) can be changed by the universal control dial (2). Possible values for parameter C13 are “on”...

  • Page 64: Maintenance

    Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 65: Finishing Work And Cleaning

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL FINISHING WORK AND CLEANING 1. Switch off control unit. 2. Ensure that the material pressure is relieved and shut off the air supply to the gun. 3. Connect up the supply of cleaning solvent. With round jet nozzle fi...

  • Page 66: Trouble Shooting And Solution

    Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.
  • Page 67 • No high voltage • Repair malfunction as laid down in the control unit operating instructions • Seal in end piece defective • Repair by Wagner Service Center • Air-passages damp • Cleaning air-passages and drying Ventilstange undicht • Dichtungen der Ventilstange •...

  • Page 68: Error Displays At The Control Unit Vm 5000W

    No illuminated display lights • Mains not switched on • Switch on mains power supply • Fuses defective • Replace fuses • Contact Wagner Service Team No high voltage • Spray gun cable not connected or • Connect spray gun cable defective •...
  • Page 69 Cascade is interrupted --> Check or replace cascade ● ● defective Coil current too big The cascade is defective Check or replace cascade ● ● E21-E25 Exception error Hardware defect has occurred If problem persists, ● ● contact Wagner Service Team...

  • Page 70: Repair Work

    WARNING Incorrect maintenance/repair! Danger to life and equipment damage Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the chapter "Spare parts catalog".

  • Page 71: Dismantling Of The Spray Gun

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL DISMANTLING OF THE SPRAY GUN SW12 SW12 B_03537 Torx 25 SW19 B_03538...
  • Page 72 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL SW19 B_03539 SW19 Assembly tool for need- Note: le valve, Loosen AC valve tip by hand Part No. 2309368 using an assembly tool B_03556...
  • Page 73 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 1. Remove pressure spring (4). 2. Loosen clamping screw assy. (1) using an assembly tool (5). 3. Unscrew the complete package (3) via valve rod unit (2, 6, 7) or pull out the valve rod unit and unscrew it using an Allen key SW5.

  • Page 74: Cleaning The Parts After Disassembly

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL CLEANING THE PARTS AFTER DISASSEMBLY ATTENTION Please note: ➞ All reusable parts (except for the electrical components) should be cleaned thoroughly using a suitable cleaning agent. ➞ The end piece, plug compl. and the handle inside must be clean and dry after cleaning.

  • Page 75: Assembling The Spray Gun

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL ASSEMBLING THE SPRAY GUN SW9 1 Nm B_03448 Ensure the correct insertion position! B_03559 SW14 3 Nm Mounting materials: Part No. Description 9992590 Loctite 222 9992698 Vaseline weiss PHHV II 9992831 Loctite 542 9992511...
  • Page 76 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Insertion position compl. Package Set measure X with withdrawal nut and then fasten it with the threaded pin (SW2). X = 123 ±0.1 Push together the valve rod unit and the compl. package. Screw in together the valve rod unit and 0.4 - the compl.
  • Page 77 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL SW19 2.5 Nm SW19 B_03541 B_03540 Push the trigger upward into the air valve piston. Torx 25 B_03542...
  • Page 78 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 0.8 Nm Einbaulage beachten! SW12 SW12 B_03543 Flat jet nozzle Assembly see chapter 12.5.1. Diverse nozzle sizes see chapter 11.2 Round jet nozzle Assembly see chapter 12.5.2. Diverse nozzle sizes see chapter 11.1 B_03544...

  • Page 79: Replacing The Spray Gun Including Hose Set

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL REPLACING THE SPRAY GUN INCLUDING HOSE SET Zerstäub erluft Atomizin g air Mat. Druckreg Mat. pressure reg. Pumpe Pump μA POWER Aqu aCoa B_03545 Disassembling gun assy. (1) 1. Loosen the union nut (6) on the bared part of the material hose (3) with a universal spanner.

  • Page 80: Change Material Hose And/Or Air Hose

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Spray gun GM 5000EACW (order no. 2309873) can be combined with different hose sets. The available hose sets are listed in the accessories (Chap. 11.4). Disassembling gun assy. (1) 1. Secure the spray gun. 2.

  • Page 81: Disassembling Control Unit Vm 5000W

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL DISASSEMBLING CONTROL UNIT VM 5000W 1. Switch off the control unit and remove the front panel (1). 2. Close the compressedair connection and relieve the system pressure. 3. Loosen and unscrew screw (2). 4.

  • Page 82: Opening The Control Unit

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL OPENING THE CONTROL UNIT 1. Dismount control unit from the AquaCoat system (see Chap.8.6). 2. Place control unit on a suitable surface. 3. Loosen and unscrew screw (1). 4. Remove cover (2) from housing. 5.

  • Page 83: Functional Check After Assembly

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL FUNCTIONAL CHECK AFTER ASSEMBLY AQUACOAT COMPLETE DEVICE After all repairs the AquaCoat system must be checked before recommissioning. The necessary scope of inspection and testing depends on the repair carried out and must be documented by the repair personnel.
  • Page 84 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Activities Aid tools 7. Test door lock Main switch off. ● Air on. ● Main switch on => door locked. ● Main switch off => door unlocks. ● 8. Test spraying Fit door.

  • Page 85: Product Disposal

    Your waste Wagner electrical device will be taken back by us or our representatives and disposed of environmentally correctly. Please contact one of our service points or one of our representatives or us directly to this purpose.

  • Page 86: Accessories

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL ACCESSORIES 11.1 ROUND JET NOZZLES Part No. Description 2309902 Round jet nozzle cap ACWR 5000 (with nozzle spanner, without AC round jet nozzle insert) B_03210 11.1.1 AIRCOAT ROUND JET NOZZLE INSERTS The round jet nozzles are especially suited to spray pipes, profi...

  • Page 87: Acf5000 Aircoat Fl At Jet Nozzles

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 11.2.1 ACF5000 AIRCOAT FLAT JET NOZZLES Application B_03163 395107 07/10 0.18; 0.007 10° Natural paint 395207 07/20 20° 395407 07/40 40° 395109 09/10 0.23; 0.009 10° Transparent lacquer 395209 09/20 20°...
  • Page 88 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Application B_03163 395219 19/20 0.48; 0.019 20° Rust proofing paint 395319 19/30 30° Latex paint 395419 19/40 40° 395519 19/50 50° 395619 19/60 60° 395819 19/80 80° 395221 21/20 0.53; 0.021 20°...

  • Page 89: Hoses And Electrical Cables

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 11.3 HOSES AND ELECTRICAL CABLES Note: Material hose - Inside diameter 4 mm; 0.16 inches - Material FEP - Nominal pressure 25 MPa; 250 bar; 3626 psi B_03547 Part No. Description 2309865 Hose set GM 5000EACW (7.5 m;...

  • Page 90: Miscellaneous

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 11.4 MISCELLANEOUS Part No. Description 353702 Insulating oil (10 ml; 10 cc) 9992511 Loctite 243 (50 ml; 50 cc) 9992590 Loctite 222 (50 ml; 50 cc) 2309368 Assembly tool valve needle B_03451 128901 Nozzle spanner ACR...
  • Page 91 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Part No. Description 259010 High voltage tester HV 200 N P_00265 999080 Wet fi lm thickness measurer B_03224 50342 Viscosity cup DIN 4 353050 Hose holder assy. 353051 Base frame assy. 353052 Feed tank 2326485...
  • Page 92 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL...

  • Page 93: Spare Parts

    Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 94: Spare Parts List Aquacoat Basic Unit

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 12.2 SPARE PARTS LIST AQUACOAT BASIC UNIT Spare parts list AquaCoat Part No. Description 130215 Earthing cable 10 m; 32.81 ft 241270 Mains cable with Stak200 2314234 Control unit VM 5000W (Spare parts list see chapter 11.3) 2324044 Door switch assy.
  • Page 95 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 18 24 Zerst äube rluft Atom izing Mat. Druck regle r Mat. press ure reg. Pump e Pump μA POW ER Aq ua Co at Aq ua Co at View E from out B_03391...
  • Page 96 HS-Erzeuger HV-Generator Prim. 1AT Erdungs-Zylinder Spannung: max. 18Vpp Voltage: Grounding cylinder Strom: Netzeingang max. 1,0A J. WAGNER AG Current: Main power CH - 9450 Altstätten Made in Switzerland Typ / Type: VM 5000W Artikel Nr.: Article No.: 2311001 Serie Nr.: Serial No.:...

  • Page 97: Additional List Of Spare Parts For Variants With Pp Pump Or Cobra

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 12.2.1 ADDITIONAL LIST OF SPARE PARTS FOR VARIANTS WITH PP PUMP OR COBRA Part No. Description 353870 Air hose AC assy. 9985619 Hose nozzle with sealing ring 9990404 Hose clips 9981951 Hose 1.2 m;...

  • Page 98: Spare Parts List Vm 5000W

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 12.3 SPARE PARTS LIST VM 5000W Part No. Description 123459 Pressure gauge socket 241323 Cover 263400 Distance bush 353501 Cover 2304459 Incremental encoder 2304461 Rotary knob 2304462 Cover 2317539 Print assy. VM 5000 display (incl. item 7) 2309112 Spacer 9952587...
  • Page 99 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL (6x) B_03515...
  • Page 100 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Part No. Description 9992743 Screw-in screw connection, straight 9998157 Loctite 480 9998253 Screw in angle 9998614 Straight bulkhead plug-in connection 9998615 Straight bulkhead plug-in connection 9998677 Pressure gauge 0-1 MPa; 0-10 bar; 0-145 psi (d40) 9998769 Straight bulkhead plug-in connection 9999208...
  • Page 101 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL...

  • Page 102: Spare Parts List Gm 5000Eacw

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 12.4 SPARE PARTS LIST GM 5000EACW B_03548...
  • Page 103 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Spare parts list GM 5000EACW Part No. Description 2309873 GM 5000EACW 2313630 Plug EACW End-piece GM 500EACW assy. see details in chapter 12.4.1 2314361 Hook GM 5000EAC handle complete, see detail in chapter 12.4.2 9900308 Cheese head screw with hexagon 2312183...

  • Page 104: Spare Parts List End-Piece Gm 5000Eacw

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 12.4.1 SPARE PARTS LIST END-PIECE GM 5000EACW B_03549 Ensure the correct insertion position! 123 ±0.1...
  • Page 105 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Spare parts list End-piece GM 5000EACW Menge Bestell-Nr. Benennung GM 5000EACW end piece complete 2313314 AC air manifold ring ◆ 2307180 O-ring, sheathed ◆ 2312175 Valve housing AC assy. ◆ 2312186 Valve tip AC assy.

  • Page 106: Spare Parts List Gm 5000Eac - Handle

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 12.4.2 SPARE PARTS LIST GM 5000EAC - HANDLE 18 19 B_03165...
  • Page 107 AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL Spare parts list Handle GM 5000EAC Part No. Description GM 5000EAC handle compl. 2307288 Nipple ◆ ★ 9971025 O-ring 2315344 Hose holder 2312182 Plug complete 2314270 Handle complete ◆ ★ 2307232 End piece seal 2311952 Stop screw 2309825 Oval head screw with hexagon...

  • Page 108: Spare Parts Lists Accessories

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 12.5 SPARE PARTS LISTS ACCESSORIES 12.5.1 SPARE PARTS LIST FLAT JET NOZZLES B_03554 Flat jet nozzles spare parts list Part No. Description 2315775 Union nut AC assy. 2309901 Air cap LV EACW (red) 2314204 Air cap HV EACW (bue) ◆...

  • Page 109: Spare Parts List Round Jet Nozzle Cap Acr5000

    AquaCoat GM 5000EACW EDITION 04/2012 PART NO. DOC2321362 OPERATING MANUAL 12.5.2 SPARE PARTS LIST ROUND JET NOZZLE CAP ACR5000 B_03555 Spare parts list Round jet nozzle cap EACW Part No. Description 2309902 Round jet nozzle cap ACWR 5000 2307220 Nozzle nut ◆...
  • Page 110 DK- 8600 Silkeborg Telephone: +32 (0)2 269 4675 Telephone: +45 70 200 245 Telefax: +32 (0)2 269 7845 Telefax: +45 86 856 027 E-Mail: info@wsb-wagner.be / HP www.wsb-wagner.eu E-Mail info@wagner-industri.com United Kingdom France WAGNER Spraytech (UK) Ltd. J. WAGNER France S.A.R.L.
  • Page 112 2321362...

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