Page 1
AquaCoat
10
0
8
0
60
40
2
0
μ
A
80
60
4
0
20
10
kV
R3
R
2
R1
Z
erstä
u
berluft
Atomizing a
ir
Mat.
Druc
kregler
M
at
. pressure reg.
Pumpe
Pump
POWER
0
1
AquaCoat
1
B_03520
AquaCoat AirCoat
- EvoMotion 20-30S
- Wildcat 18-40
- Puma 28-40
- Cobra 40-10
AquaCoat
AirCoat-Spray system for noncombustible spray media
Edition 04/2012
Translation of the original
Operating manual
Page 2
Page 3
3
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Languages 6
1.2 Warnings, notes and symbols in these instructions 6
2 GENERAL SAFETY INSTRUCTIONS 7
2.1 Safety instructions for the operator 7
2.1.1 Electrical equipment 7
2.1.2 Personnel qualifi cations 7
2.1.3 A safe work environment 7
2.2 Safety instructions for staff 7
2.2.1 Safe handling of WAGNER spray units 8
2.2.2 Earth the unit 8
2.2.3 Material hoses 8
2.2.4 Cleaning 9
2.2.5 Handling hazardous liquids, varnishes and paints 9
2.2.6 Touching hot surfaces 9
2.3 Correct use 9
2.4 Safety-relevant information about discharges 9
3 GUARANTEE AND CONFORMITY DECLARATIONS 10
3.1 Important notes on product liability 10
3.2 Guarantee claim 10
3.3 CE-Conformity 11
3.4 German regulations and guidelines 12
4 DESCRIPTION 13
4.1 Fields of application, using in accordance with the instructions 13
4.1.1 Processable materials 13
4.2 Scope of delivery 14
4.2.1 Spraypack confi guration 15
4.3 Technical data 17
4.3.1 Control unit VM 5000W 18
4.3.2 Spray gun GM 5000EACW 19
4.3.3 Pneumatic piston pump EvoMotion 20-30S PE+T 20
4.3.4 Pneumatic piston pump Type PP3000 20
4.3.5 Double diaphragm pump Cobra 40-10 20
4.4 Functional description 21
4.4.1 Design of unit and function 21
4.4.1.1 Control unit VM 5000W 24
4.4.1.2 Spray gun GM 5000EACW 28
4.4.1.2.1 AirCoat round jet spray process 30
4.4.1.2.2 AirCoat atomizing fl at jet spray process 31
4.4.1.2.3 The electrostatic effect 32
5 START-UP AND OPERATION 33
5.1 Installation and connection 33
5.1.1 Ventilation of the spray booth 33
5.1.2 Air supplies 34
5.1.3 Paint supplies 34
5.1.4 Earthing 35
Page 4
4
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Contents
5.1.5 Safety checks 36
5.1.5.1 Earthing check 36
5.1.5.2 Inspection of the safety elements 36
5.2 Preparation of water-based paints 37
5.2.1 Viscosity conversion table 37
5.3 Starting operation 39
5.3.1 General rules for making adjustments to the spray gun 39
5.3.2 Preparation for starting up 40
5.3.2.1 Spray pack with pneumatic pump EvoMotion 20-30S 40
5.3.2.2 Spraypack examples with double diaphragm pump Cobra 40-10 42
5.4 Works 44
5.4.1 Preparation for spraying with fl at-jet nozzle 44
5.4.2 Start-up for spraying 45
5.4.3 Check spray pattern 46
5.4.4 Cleaning of clogged round jet nozzles 47
5.4.5 Exchange of round jet nozzle insert 47
5.4.6 Changing from AirCoat round jet to AirCoat fl at jet 48
5.4.7 Replacing AirCoat fl at jet nozzles 49
5.4.8 Cleaning of the nozzles 49
5.4.9 Eliminate nozzle clogging 49
5.4.10 Start-up the control unit VM 5000W 51
5.4.11 Set and save recipes 52
5.4.12 Setting the high voltage 53
5.4.13 Setting the current limiting 54
5.4.14 Spray display 55
5.4.15 Standby Mode 56
5.4.16 Operating hours counter/warning display 57
5.4.17 Maintenance display setup 58
5.4.18 “Conduct service” display 59
5.5 Device confi guration 60
5.5.1 Overview of parameters 60
5.5.2 Access to the device confi guration mode 61
5.5.3 Setting example “Parameter C13” 62
6 MAINTENANCE 64
6.1 Finishing work and cleaning 65
7 TROUBLE SHOOTING AND SOLUTION 66
7.1 Faults in the system 66
7.2 Error displays at the control unit VM 5000W 68
8 REPAIR WORK 70
8.1 Dismantling of the spray gun 71
8.2 Cleaning the parts after disassembly 74
8.3 Assembling the spray gun 75
8.4 Replacing the spray gun including hose set 79
8.5 Change material hose and/or air hose 80
8.6 Disassembling control unit VM 5000W 81
8.7 Opening the control unit 82
Page 5
5
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Contents
9 FUNCTIONAL CHECK AFTER ASSEMBLY 83
9.1 AquaCoat Complete device 83
10 PRODUCT DISPOSAL 85
11 ACCESSORIES 86
11.1 Round jet nozzles 86
11.1.1 AirCoat round jet nozzle inserts 86
11.2 ACF air caps (fl at jet) 86
11.2.1 ACF5000 AirCoat fl at jet nozzles 87
11.3 Hoses and electrical cables 89
11.4 Miscellaneous 90
12 SPARE PARTS 93
12.1 How to order spare parts? 93
12.2 Spare parts list AquaCoat Basic unit 94
12.2.1 Additional list of spare parts for variants with PP pump or Cobra 97
12.3 Spare parts list VM 5000W 98
12.4 Spare parts list GM 5000EACW 102
12.4.1 Spare parts list End-piece GM 5000EACW 104
12.4.2 Spare parts list GM 5000EAC - Handle 106
12.5 Spare parts lists Accessories 108
12.5.1 Spare parts list Flat jet nozzles 108
12.5.2 Spare parts list Round jet nozzle cap ACR5000 109
Page 6
6
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
1 ABOUT THESE INSTRUCTIONS
1.1 LANGUAGES
4HISOPERATINGMANUALCONTAINSINFORMATIONABOUTTHEOPERATIONREPAIRANDMAINTENANCE
OFTHEUNIT
!LWAYSFOLLOWTHESEINSTRUCTIONSWHENOPERATINGTHEUNIT
4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL
%LECTROSTATICSPRAYGUNSMAYBEOPERATEDONLYBYTRAINEDPERSONNEL
#OMPLIANCEWITH THESE INSTRUCTIONSCONSTITUTESAN INTEGRAL COMPONENT OF THE GUARANTEE
AGREEMENT
4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES
,ANGUAGE 0ART.O ,ANGUAGE 0ART.O
'ERMAN %NGLISH
&RENCH $UTCH
)TALIAN 3PANISH
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 - imminent danger. Non-observance will result
in death, serious injury and serious material damage.
Warning - possible danger. Non-observance can result
in death, serious injury and serious material damage.
Caution - a possibly hazardous situation.
Non-observance can result in minor injury.
Note - provide information on particular characteristics and how to proceed.
Caution - a possibly hazardous situation.
Non-observance can cause material damage.
SIHI_0102_GB
CAUTION
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions . The signal word
points out the hazard level.
The measures for preventing the hazard and its consequences.
2310483 2321362
2324673 -2324674 2324675
SIHI_0101_GB
C AUTION
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions.
The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0103_GB
WARNING
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions.
The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0100_GB
DANGER
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions.
The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
Page 7
7
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
2 GENERAL SAFETY INSTRUCTIONS
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
2.1.1 ELECTRICAL EQUIPMENT
2.1.2 PERSONNEL QUALIFICATIONS
2.1.3 A SAFE WORK ENVIRONMENT
Keep these operating instructions to hand near the unit at all times.
Always follow local regulations concerning occupational safety and accident prevention.
Electrical plant and unit
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient influences.
May only be maintained by skilled electricians or under their supervision.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be put out of operation if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform staff about
planned work, observe electrical safety regulations.
Make sure that the floor in the area where you are working is anti-static in accordance
with EN 61340-4-1 (the resistance value may not exceed 100 MOhm).
Ensure that all persons within the working area wear antistatic shoes. Footwear must
comply with EN 20344. The measured insulation resistance may not exceed 100 MOhm.
Ensure that during spraying, persons wear anti-static gloves so that they are earthed
via the handle of the spray gun.
If protective clothing is worn, including gloves, it has to comply with EN 1149-5. The
measured insulation resistance may not exceed 100 MOhm.
Paint mist extraction systems must be fitted on site according to the local regulations.
Ensure that the following components of a safe working environment are available:
– Material/air hoses adapted to the working pressure.
– Personal safety equipment (breathing and skin protection).
Ensure that there are no ignition sources such as naked flame, glowing wires or hot
surfaces in the vicinity. Do not smoke.
2.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
%NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS
Page 8
8
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS
2.2.2 EARTH THE UNIT
2.2.3 MATERIAL HOSES
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.
Before all work on the unit, in the event of work interruptions and functional faults:
– Switch off the energy/compressed air supply.
– Secure the spray gun against actuation.
– Relieve the pressure from the spray gun and unit.
– By functional faults: Identify and correct the problem, proceed as described in
chapter „Trouble shooting“.
In the event of skin injuries caused by paint or cleaning agents:
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
Ensure that you have a firm footing when operating the spray gun.
Only hold the spray gun briefly in any one position.
Depending on the electrostatic charge and the flow speed of the spray, an electrostatic
charge may occur in the equipment. This could cause a spark or flame on discharging.
Ensure that the unit is earthed for every spraying operation.
Earth the work pieces being painted.
Ensure that all persons inside the working area are earthed, e.g. that they are wearing
derivable shoes.
When spraying, wear derivable gloves to earth yourself via the spray gun handle.
Ensure that the hose material is chemically resistant to the sprayed materials.
Ensure that the material hose is suitable for the pressure generated in the unit.
Ensure that the following information is visible on the high pressure hose:
– Manufacturer
– Permissible operating overpressure
– Date of manufacture.
The electrical resistance of the complete high pressure hose must be less than 1 MOhm.
Page 9
9
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
2.2.4 CLEANING
2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
2.2.6 TOUCHING HOT SURFACES
2.3 CORRECT USE
$EENERGIZETHEUNITELECTRICALLY
$ISCONNECTTHEPNEUMATICSUPPLYLINE
2ELIEVETHEPRESSUREFROMTHEUNIT
%NSURETHATONLYNONCOMBUSTIBLEDETERGENTSAREUSED
4OCLEANUSE ONLY CLOTHS AND BRUSHES .EVER USE HARD OBJECTS OR SPRAYON CLEANING
AGENTSAGUN
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.
Take the specified protective measures, in particular wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sufficient health and environmental safety: Operate the unit in a spray booth or on
a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot materials.
➞ Touch hot surfaces only if you are wearing protective gloves.
➞ When operating the unit with a coating material with a temperature of > 43 °C; 109.4 °F:
- Identify the unit with a warning label that says „Warning - hot surface“.
Order No.
9998910 Information label
9998911 Safety label
2.4 SAFETY-RELEVANT INFORMATION ABOUT DISCHARGES
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2
/PERATETHEUNITONLYASANENTIREUNIT
$ONOTDEACTIVATESAFETYEQUIPMENT
5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES
4HE PLASTICPARTS OF THECABINET ARE CHARGED ELECTROSTATICALLY BYTHE HIGHVOLTAGE lELD
(ARMLESSDISCHARGESBRUSHDISCHARGESAREPOSSIBLEAFTERCONTACTWITHPLASTICPARTS4HEY
ARECOMPLETELYHARMLESSFORPEOPLE
Page 10
10
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
3 GUARANTEE AND CONFORMITY DECLARATIONS
3.1 IMPORTANT NOTES ON PRODUCT LIABILITY
3.2 GUARANTEE CLAIM
As a result of an EC regulation, effective as from January 1, 1990, the manufacturer shall
only be liable for his product if all parts come from him or are approved by him, and if the
devices are properly 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.
Full guarantee is provided for this device:
We will at our discretion repair or replace free of charge all parts which within 24 months
in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by
the Purchaser are found to be wholly or substantially unusable due to causes prior to the
sale, in particular faulty design, defective materials or poor workmanship.
The type of guarantee provided is such that the device or individual components of the
device are either replaced or repaired as we think fit. The resulting costs, in particular
shipping charges, road tolls, labour and material costs will be borne by us except where
these costs are increased due to the subsequent shipment of the unit to a location other
than the address of the purchaser.
We do not provide guarantee for damage that has been caused or contributed to for the
following reasons:
Unsuitable or improper use, faulty installation or commissioning by the purchaser or a
third party, normal wear, negligent handling, defective maintenance, unsuitable coating
products, substitute materials and the action of chemical, electro chemical or electrical
agents, except when the damage is attributable to us.
Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust
paints and similar reduce the service life of valves, packings, spray guns, tips, cylinders,
pistons etc. Signs of wear and tear due to such causes are not covered by this guarantee.
Components that have not been manufactured by WAGNER are subject to the original
guarantee of the manufacturer.
Replacement of a component does not extend the period of guarantee of the device.
The unit should be inspected immediately upon receipt. To avoid losing the guarantee, we
or the supplier company are to be informed in writing about obvious faults within 14 days
upon receipt of the device.
We reserve the right to have the guarantee compliance met by a contracting company.
The services provided by this guarantee depend on evidence being provided in the form
of an invoice or delivery note. If an examination discovers that no guarantee claim exists,
the costs of repairs are charged to the purchaser.
It is clearly stipulated that this guarantee claim does not represent any constraint to statutory
regulations or regulations agreed contractually in our general terms and conditions.
J. Wagner AG
Page 11
11
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
3.3 CE-CONFORMITY
2314228
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 :
Herewith we declare that the supplied version of:
AquaCoat AirCoat GM 5000EACW
Complies with the following guidelines:
2006/42/EG 2006/95/EG 2002/96/EG
2004/108/EG 2002/95/EG
Applied standards, in particular:
DIN EN ISO 12100-1, 2004 DIN EN ISO 12100-2, 2004 DIN EN ISO 14121, 2007
DIN EN 1953, 2010 DIN EN 60204-1, 2007 DIN EN 50059, 1992
DIN EN 61000-6-2, 2006 DIN EN 61000-6-4, 2007
Applied national technical standards and specifi cations, in particular:
BGR 500 Part 2 chap. 2.29 BGR 500 Part 2 chap. 2.36 BGI 740 BGI 764
Identifi cation mark:
Page 12
12
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
3.4 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 Avoiding ignition risks
f) BGR 180 Setting up for cleaning with solvents for cleaning workpieces with
solvents
g) ZH 1/406 Guidelines for liquid ejection devices
h) BGI 740 Painting rooms and equipment
j) BGI 764 Electrostatic coating
j) Betr.Sich.V. Plant Safety Ordinance
Note: All titles can be ordered from Heymanns Publishing House in Cologne,or they are
to be found in the Internet.
Page 13
13
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
AquaCoat Spray Packs are equipped ready-for-use with the VM 5000W control unit, a
GM 5000EACW AirCoat spray gun and matching hose set, a high voltage generator,
all safety devices and spray material supply, and are therefore suitable for AirCoat
applications.
4.1.1 PROCESSABLE MATERIALS
4 DESCRIPTION
Water-dilutable paints such as are in principle divided into 3 groups:
Green Non-fl ammable (non-combustible) paints.
Yellow Paints with low fl ammability.
Red Flammable paints.
Only non-fl ammable (non-combustible) liquid spray materials (green group) can be
processed with the present spray system. The specifi c resistance of the spray material must
be between 1k.cm and 1M.cm.
The following recipe can be used to determine whether the spray material is nonfl ammable:
Gew. % H
2
O > 1.70 x Gew. % LM + 0.96 x Gew. % ORG
Where:
Gew. % Weight percent
H2O Water
LM Liquid organic phase (solvent mainly consisting of higher ethylene glycol esters).
ORG Solid organic phase (solids mainly consisting of binding agents and pigments).
Such paints behave like water in respect of fl ammability in liquid form (liquid phase) and
in sprayed form. 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.
4.1 FIELDS OF APPLICATION, USING IN ACCORDANCE WITH THE INSTRUCTIONS
Page 14
14
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
4.2 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 guration number.
The scope of delivery of each system includes:
Part No. Description
AquaCoat Spraypack consisting of:
- AquaCoat cabinet
- Spray gun GM 5000EACW
- Control unit VM 5000W
- Pump
- Accessories
2310483 Operating manual German
see Chapter 1 Operating manual in the local language
Operating manual pump German
Operating manual pump in the local language
see Chapter 3.3 CE explanation AquaCoat
The delivery note shows the exact scope of delivery.
Page 15
15
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
To order the AquaCoat Spray Pack, please use model identifi cation 2327677-ABCDEFGHIK together with the
following tables.
Model identifi cation
Pump
Table “A“
High pressure fi lter
Table “B“
Level monitoring
Table “C“
Barrel cover/ Agitator
Table “D“
Feed tank
Table “E“
Under frame
Table “F“
Hose holder
Table “G“
Hose set length
Table “H“
Nozzle
Table “I“
Air cap
Table “K“
Tables -> A B C D E F G H I K
Examples -> 2327677 221112124131
Confi guration no. 2327677
4.2.1 SPRAYPACK CONFIGURATION
Page 16
16
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Table “A” - Pump
No. Type
1no
2 EvoMotion 20-30S
3 Wildcat 18-40
4 Puma 28-40
5 Cobra 40-10
6- Cobra 40-10 mounted to frame
Table “B” - High pressure fi lter
No. Description
1 Filter-relief combination
2 High pressure fi lter
3no
Table “D” - Barrel cover/ Agitator
No. Description
1no
2 Barrel cover Ø 350 mm; Ø 13.8 inch
3
Barrel cover Ø 350 mm; Ø 13.8 inch
with Agitator
Table “E” - Feed tank
No. Description
1no
2yes
Table “F” - Under frame
No. Description
1no
2yes
Table “G” - Hose holder
No. Description
1no
2yes
Table “H” - Hose set length
No. Type
1 7.5 m; 24.6 ft
2 10 m; 32.8 ft
3 15 m; 49.2 ft
4 20 m; 65.6 ft
Table “C” - Level monitoring
No. Description
1no
2yes
(*) 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
round-jet nozzles the identifi cation digits with preceding “R” are used.
Table “I” - Nozzle system (Examples)*
No. Description
411 Flat jet incl. Nozzle 11/40
413 Flat jet incl. Nozzle 13/40
513 Flat jet incl. Nozzle 13/50
615 Flat jet incl. Nozzle 15/60
R12 Round jet incl. nozzle R 12
R13 Round jet incl. nozzle R 13
R14 Round jet incl. nozzle R 14
Table “K” - Air cap
No. Type
1 Flat jet - LV (red)
2 Flat jet - HV (blue)
3 Round jet
Page 17
17
AquaCoat GM 5000EACW
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
Zerstäuberluft
Atomizing air
Mat. Druckregler
Mat. pressure reg.
Pumpe
Pump
POWER
01
B_03361
C
BA
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Weight
(without paint container and pump)
70 kg; 154 lb
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
found in the enclosed operating instructions.
When the cabinet is closed:
The values are 10 - 12 dB(A) lower.
4.3 TECHNICAL DATA
Measurements:
Page 18
18
AquaCoat GM 5000EACW
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
Zerstäuberluft
Atomizing air
Mat. Druckregler
Mat. pressure reg.
Pumpe
Pump
POWER
01
B_03362
B
A
D
C
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
4.3.1 CONTROL UNIT VM 5000W
Measurements:
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. 1.0 A AC
High voltage limit 70 kV DC
Spraying current limit 100 µA DC
Polarity for positive and negative high voltage generator
Weight (without cables) 6.2 kg; 13.67 lb
Working temperature range 5 - 40 °C; 41 - 104 °F
Page 19
19
AquaCoat GM 5000EACW
C
A
B
B_03521
C
A
B
B_03522
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
4.3.2 SPRAY GUN GM 5000EACW
GM 5000EAC F
with fl at jet nozzle
mm inch
A 280 11.02
B 46 1.81
C 264 10.39
GM 5000EAC R
with round jet nozzle
mm inch
A 264 10.39
B 46 1.81
C 264 10.39
Measurements:
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. union nut, nozzle and air cap)
Working temperature range 5 °C to 40 °C; 41 °F to 104 °F
Maxi. material temperature 50 °C; 122 °F
Material fl ow volume According to nozzle sizes (See nozzle list on
accessories)
Sound level at 0.3 MPa; 3 bar; 43.5 psi air pressure
and 11 MPa; 110 bar; 1549 psi material pressure
73 dB (A)
* A rated sound pressure level measured at 1 m distance according to DIN EN 14462: 2005.
Page 20
20
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
4.3.5 DOUBLE DIAPHRAGM PUMP COBRA 40-10
4.3.4 PNEUMATIC PISTON PUMP TYPE PP3000
4.3.3 PNEUMATIC PISTON PUMP EVOMOTION 20-30S PE+T
Wildcat 10-70 PE+TG
Puma 15-70 PE+TG
Puma 28-40 PE+TG
4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES
,ANGUAGE 0ART.O ,ANGUAGE 0ART.O
'ERMAN %NGLISH
&RENCH $UTCH
)TALIAN 3PANISH
$ANISH 3WEDISH
0ORTUGUESE 4URKISH
2314783 2314784
2314785 2314786
2314787 2314788
2314790 2314789
2321572 --
4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES
,ANGUAGE 0ART.O ,ANGUAGE 0ART.O
'ERMAN %NGLISH
&RENCH $UTCH
)TALIAN 3PANISH
$ANISH 3WEDISH
0ORTUGUESE 4URKISH
367850 367851
367852 367853
367854 367855
367857 367856
367859 367858
4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES
,ANGUAGE 0ART.O ,ANGUAGE 0ART.O
'ERMAN %NGLISH
&RENCH $UTCH
)TALIAN 3PANISH
$ANISH 3WEDISH
0ORTUGUESE 4URKISH
322850 322851
322852 322853
322854 322855
322857 322856
322858 --
Page 21
21
AquaCoat GM 5000EACW
AquaCoat
10
0
80
60
40
20
μA
8
0
60
40
20
10
kV
R3
R2
R1
Ze
rstäube
r
l
u
f
t
Atomizin
g
air
Mat. Druckregler
Mat. pressu
re reg
.
Pumpe
P
u
mp
POWER
0
1
B_03523
1
13
23
15
7
5
12
26
22
6
20
16
19
2
4
8
9
10
3
24
14
11
17
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
4.4 FUNCTIONAL DESCRIPTION
4.4.1 DESIGN OF UNIT AND FUNCTION
Pos Description
1 Cabinet AquaCoat assy.
2 Front panel with 2 handles
3 Control unit VM 5000W
4 Spray gun GM 5000EACW
5 Hose set EACW
6 Material hose (Filter discharge combination for spray gun)
7 High voltage generator (HV-Cascade)
8 Air inlet complete with ball valve
9 Inlet for mains cable
Page 22
22
AquaCoat GM 5000EACW
"?
S
0OWER
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
The AquaCoat spray system is designed for processing non-combustible liquids in
accordance with the AirCoat method.
The spray product is regulated via the trigger guard on the spray gun (4) and by the
VM5000W control unit (3), drawn in with a material pressure generator (11) via a suction
system (12), electrostatically charged in the sealed off inner chamber of the AquaCoat
cabinet (1) and sprayed in the nozzle of the spray gun with the help of AirCoat air.
The material pressure generator and spray gun are connected by the high pressure
material hose.
The following functions are provided for system safety:
The earthing switch (14), the door switch (17), the earthing strip (15) and the integrated
AquaCoat resistor (19).
Pos Description
10 Earthing cable
11 Material pressure generator such as pneumatic pump or double diaphragm
pump
12 Suction system, compl.
13 Paint container
14 Earthing switch (Cylinder AquaCoat)
15 Earthing band
16 Filter-relief combination
17 Door switch
19 Leakage resistance 3GOhm
20 Air hose (material pressure generator)
22 High voltage cable (2 pieces)
23 Base frame assy. (available, however, as additional extra)
24 Hose holder assy. (available, however, as additional extra)
26 Return hose
Note
:
Only mount or remove the front panel
(2) when the control unit (3) is switched
off. 1 second after the control unit (3) has
been switched off, the system is earthed
and the door lock opened.
Page 23
23
AquaCoat GM 5000EACW
6
J2
J3
324
1
54321
324
1
321
43162
5
LNPE
B_03513
456
7
8
P1
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Electrical block diagram AquaCoat
Earthing
Door switch
Coil -
Coil +
Door switch
Control unit VM 5000W
Earth
Earth monitoring
Power supply
brown
green
white
Shield
brown
green
yelllow
white
blue
black
white
white
Door switch
Coil+
Coil-
Cascade AquaCoat
Casting compound
AquaCoat resistor
Casting compound
Earthing switch AquaCoat
gelb/grün
Pneumatic cylinder
yellow/green
Spray gun
Dat dis
Dat sw
Page 24
24
AquaCoat GM 5000EACW
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
Zerstäuberluft
Atomizing air
Mat. Druckregler
Mat. pressure reg.
Pumpe
Pump
POWER
01
B_03364
2117
15
22
12
24
25
352010 911 6 1
16
18
13 14
19
23
2478
26
27
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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:
1 Selector (mains supply)
0 = control unit switched off
1 = control unit switched on.
2 Universal rotary controller
● Dynamic digital rotary controller with 32 positions per revolution.
● Adjustment speed is proportional to rotational speed.
● Used to adjust high voltage and spray voltage.
● For setting parameter values in confi guration mode.
3 Push button “Standby“
To switch to stand-by mode.
4 Illuminated display “Standby”
Lights up when the unit is in standby mode.
5 Push button “Spraying current”
To activate the function, the current limiting is set with the rotary controller (2) and is
indicated in the LED display (27).
● Adjusting range: 10 - 100 µA
● Resolution: 1 µA.
6 Illuminated display “Spraying current”
Page 25
25
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
7 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
● Resolution: 1 kV.
8 Illuminated display “High voltage”
9 Regulator “Pump pressure“
Pressure regulator for the pump pressure when using an EvoMotion 20-30S pump.
● Adjusting range 0-1.0 MPa; 0-10 bar; 0-145 psi.
10 Regulator “Material pressure“
Pressure regulator for the material pressure.
● Adjusting range 0-1.0 MPa; 0-10 bar; 0-145 psi.
11 Regulator “Atomizing air“
Pressure regulator for the atomizing air.
● Adjusting range 0-1.0 MPa; 0-10 bar; 0-145 psi.
12 Pressure gauge “Atomizing air“
Atomizing air pressure display for the spray gun.
● Display range 0-1.0 MPa; 0-10 bar; 0-145 psi.
13 Pressure gauge “Material pressure“
Pressure display for the material pressure.
● Display range 0-1.0 MPa; 0-10 bar; 0-145 psi.
14 Pressure gauge “Pump pressure“
Display for the pump pressure when using an EvoMotion 20-30S pump.
● Display range 0-1.0 MPa; 0-10 bar; 0-145 psi.
15 Push button: Recipe 1
16 Illuminated display Recipe 1
Lights up if recipe 1 is used.
17 Push button: Recipe 2
18 Illuminated display Recipe 2
Lights up if recipe 2 is used.
19 Push button: Recipe 3
20 Illuminated display Recipe 3
Lights up if recipe 3 is used.
Page 26
26
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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.
● Display range: 0 - 100 µA
● Single display: Spraying current limit.
● Bar display: Actual spraying current.
23 Illuminated display “Door control“
Lights up, when the front plate is fitting.
24 Illuminated display “Fault”
Lights up, when a malfunction at the unit occurs.
25 Press push button “Service”
26 Illuminated display “Service“
27 Display LED: 7 segments, three-digit number
● Indicates the target and actual values of high voltage and spray voltage.
● Displaying error number about warnings and malfunctions.
Page 27
27
AquaCoat GM 5000EACW
Pumpe
Pump
Netzeingang
Main power
Lufteingang
Air inlet
Erdungs-Zylinder
Grounding cylinder
Prim. 1AT
Mat. Druckregler
Mat. pressure reg.
Zerstäuberluft
Atomizing air
Pistole
Gun
HS-Erzeuger
HV-Generator
Service
Typ / Type:
VM 5000W
85-264 VAC / 47-440 Hz
2311001
max. 40W
J. WAGNER AG
CH - 9450 Altstätten
Made in Switzerland
Serie Nr.:
Serial No.:
Spannung:
Voltage:
Artikel Nr.:
Article No.:
Eingangsleistung:
Line Power:
Schutzklasse:
Protection Class:
Norm:
Standard:
EN 50059
IP 54
Spannung:
Voltage:
Strom:
Current:
max. 18Vpp
max. 1,0A
28 29 30 31 32 33 34 35 36
3738
B_03365
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Connections on the rear side:
28 Mains power input
Connection for mains cable with safety clip.
29 Primary fuse
1.0 ampere slow-acting.
30 Gun connection
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 8 mm; ø 0.32 inches.
35 Connection Earthing switch air
Hose connector ø 6 mm; ø 0.24 inches.
36 Connection atomizing air
Hose connector ø 8 mm; ø 0.32 inches.
37 Compressed air inlet
Hose connector ø 10 mm; ø 0.39 inches.
38 Self-locking nut Earthing
Connection for the earthing cable (system earth).
Page 28
28
AquaCoat GM 5000EACW
14
13
6
7
15
16
2
4
3
1
9
10
11
8
19
B _03524
12
18
17
20
5
21
22
B_03558
S
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
4.4.1.2 SPRAY GUN GM 5000EACW
Pos Description
1 Suspension hook
2 Display (spray current and recipe)
3 Display standby and fault
4 Operating button
(standby and recipe change)
5 Union nut with Protection against contact
6 Air cap for fl at jet nozzle
(see chapter 11.2)
7 Flat jet nozzle AFC5000 (see chapter 11.2.2)
8 Attachment
9Cover
10 Handle
Pos Description
11 Trigger lock
12 Trigger
13 Round jet nozzle cap (see chapter 11.1)
14 Round jet nozzle insert
(see accessories in chapter 11.1.1)
15 Lock plug
16 Air adjustment
17 Electrical cable connection
18 Connection atomizing air
19 Material connection
20 Protective hose
21 Type plate left
22 Type plate right
Note:
The type of gun (T ) and the series number (S) are visible after
removing the cover plate.
Page 29
29
AquaCoat GM 5000EACW
1
2
3
4
R1
R3
R2
B_03182
2
4
3
R1
R3
R2
E
B_03262
16
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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 -> ●❍❍❍❍ R1
Recipe 2 -> ●●●❍❍ R2
Recipe 3 -> ●●●●● R3
Recipe change R1 -> R2 -> R3 -> R1.
Press operating key (4) and keep pressed down for min. 2 seconds
to go forward one recipe.
Display (2) -> ●●❍❍❍ = recipe values temporarily changed:
If the operating key (4) is pressed for 2 seconds, the saved recipe
values for the previously selected recipes numbers will be
reloaded from the memory.
Functions of the spray gun
The trigger can be used to activate, one after the other, the
various functions of the spray gun.
Distance Description
1 Atomizing air open
2 Atomizing air open and electrostatically (HV)
activated.
Display (2) for „spray current“ on the spray
gun ●❍❍❍❍ to ●●●●● activated.
3 Atomizing air open, electrostatically (HV)
activated and material valve open
4 Max way of trigger
● An increase in the tension needed to pull the trigger back will
be felt at the position where the material valve opens.
● For spraying without high-voltage, the high-voltage can
be switched off using the operating button (4). Press the
operating button (4) briefl y: High-voltage is switched off. The
„standby display“ (3) illuminates.
● In the event of a malfunction the spray gun switches to
“standby” operating mode and the display (3) illuminates.
● The width of the spray jet can be adjusted using the air
adjustment (16) (only for fl at-jet method).
Page 30
30
AquaCoat GM 5000EACW
"?
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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.
AirCoat air
Multi-channel
swirl nozzle
Spray jet
Nozzle nut
Spray material
AirCoat air
Advantages
● High painting capacity
● Low fogging tendency
● Good fi nish
● High viscosity paints can easily be applied
● High endurance of the nozzles
● Change in width the jet
Page 31
31
AquaCoat GM 5000EACW
B_00020
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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. With shaping air the possibility exists of changing the jet spray width.
Shaping air
Air cap
Variable spray
jet width
Atomizing air
Advantages
● High painting capacity
● Low fogging tendency
● Good fi nish
● High viscosity paints can easily be applied
● High endurance of the nozzles
● Change in width the jet
Page 32
32
AquaCoat GM 5000EACW
"?
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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 nely distributed over the entire surface.
Paint particle
Grounded
object
4.4.1.2.3 THE ELECTROSTATIC EFFECT
Page 33
33
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5 START-UP AND OPERATION
Check the individual components of the AquaCoat spray system against the delivery note.
Familiarize yourself with the mode of functioning of the individual components of the
AquaCoat spray system, reading the enclosed operating instructions thoroughly. Note the
special requirements of the electrostatic air spray procedure.
5.1.1 VENTILATION OF THE SPRAY BOOTH
5.1 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.
SIHI_0050_GB
WARNING
Toxic and/or flammable vapor mixtures!
Risk of poisoning and burns
Operate the unit in a spraying booth approved for the working
materials.
-or-
Operate the unit on an appropriate spraying wall with the
ventilation (extraction) switched on.
Observe national and local regulations for the outgoing air
speed.
SIHI_0028_GB
Page 34
34
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.1.2 AIR SUPPLIES
5.1.3 PAINT SUPPLIES
CAUTION
Impurities in the spraying system!
Spray gun blockage, materials harden in the spraying system
Flush the spray gun and paint supply with a suitable cleaning agent.
SIHI_0001_GB
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.
SIHI_0029_GB
DANGER
Bursting hose, bursting threaded joints!
Danger to life from injection of material
Ensure that the hose material is chemically resistant.
Ensure that the spray gun,
threaded joints
and material hose
between the unit and the spray gun is suitable for the pressure
generated in the unit.
Ensure that the following information can be seen on the high
pressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture.
SIHI_0128_GB
CAUTION
Electrical discharges!
Danger due to electrically charged material lines
The conductive sheath of the material hose must not be remo -
ved and the connections to the earth potential must not be loo sened.
1. Earth connection in the cabinet.
2. Earth connection in the gun.
Page 35
35
AquaCoat GM 5000EACW
B_03525
Rmax.< 1 MΩ
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
Zerstäuberluft
Atomizing air
Mat. Druckregler
Mat. pressure reg.
Pumpe
Pump
POWER
01
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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
Insufficient paint application quality
Earth all unit components.
Earth the workpieces being painted.
SIHI_0003_GB
Earthing schema (example)
Conveyor
Spraying stand
Floor, derivable
Object
System earth
5.1.4 EARTHING
System earth
The imperfect earthing of a work piece will result in:
● Very poor wrap-around.
● Uneven coating thickness.
● Back spraying to the spray gun, i.e. contamination.
The prerequisites for perfect earthing and coating are:
● Clean work piece suspension.
● Earthing of spray booth, conveyor system and suspension on the building side in
accordance with the operating instruction or the manufacturer’s information.
● Earthing of all conductive parts within the working area.
● The earthing resistance of the work piece may not exceed 1 M (Mega Ohm).
Resistance to earth measured at 500 V or 1000 V.
● Connect the AquaCoat cabinet to the system earth.
● The work shoes and if uses the gloves must be derivable.
Page 36
36
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Minimum cable cross-section
AquaCoat cabinet 4 mm²; AWG11
Conveyor 16 mm²; AWG5
Spray booth 16 mm²; AWG5
Spraying stand 16 mm²; AWG5
5.1.5.1 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.
5.1.5.2 INSPECTION OF THE SAFETY ELEMENTS
Every day:
- General visual inspection:
Earthing band, all cables and connections for damage or loose contacts examine.
Monthly:
- Door switch test:
Remove the front panel.
Switch on the control unit.
Actuate the trigger guard on the spray gun.
The high voltage must remain switched off.
- Earthing cylinder test:
Insert front panel.
Switch on the control unit.
Acoustically ascertain switch movement.
Check that the front panel is locked.
Switch off control unit.
Acoustically ascertain switch movement.
5.1.5 SAFETY CHECKS
Page 37
37
AquaCoat GM 5000EACW
milli Pascal x
Sec mPas
Centipoise Poise DIN Cup
4 mm ; 0.16 inch
Ford Cup 4 Zahn 2
10 10 0.1 5 16
15 15 0.15 8 17
20 20 0.2 10 18
25 25 0.25 14 12 19
30 30 0.3 15 14 20
40 40 0.4 17 18 22
50 50 0.5 19 22 24
60 60 0.6 21 26 27
70 70 0.7 23 28 30
80 80 0.8 25 31 34
90 90 0.9 28 32 37
100 100 1 30 34 41
120 120 1.2 33 41 49
140 140 1.4 37 45 58
160 160 1.6 43 50 66
180 180 1.8 46 54 74
200 200 2 49 58 82
220 220 2.2 52 62
240 240 2.4 56 65
260 260 2.6 62 68
280 280 2.8 65 70
300 300 3 70 74
320 320 3.2
340 340 3.4
360 360 3.6 80
380 380 3.8
400 400 4 90
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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.
In the case of application problems contact the paint producer.
5.2.1 VISCOSITY CONVERSION TABLE
5.2 PREPARATION OF WATER-BASED PAINTS
Page 38
38
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Page 39
39
AquaCoat GM 5000EACW
A
A
A
A
A = 100 mm
A = 4 inch
B_03526
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.3.1 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN
➞ Observe general safety instructions in chapter 2.
5.3 STARTING OPERATION
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.
Remain outside the area of the electrostatic spray gun/work -
piece.
SIHI_0049_GB
SIHI_0065_GB
WARNING
Unintentional putting into operation!
Risk of injury
Before all work on the unit, in the event of work interruptions and
functional faults:
Switch off the energy/compressed air supply.
Relieve the pressure from the spray gun and unit.
Secure the spray gun against actuation.
By functional faults: Identify and correct the problem, proceed
as described in chap „Trouble shooting“.
Note:
In order to avoid electrical discharges,
a distance of 100 mm; 4 inches must be
maintained from the work piece and
other earthed objects during the spray
process.
SIHI_0129_GB
CAUTION
Electrical discharge!
Risk of injury
➞ Maintain a safety distance of 100 mm; 4 inches from the nozzle
area of the spray gun during the spraying process and at least 20
seconds after the end of the spraying process.
Danger zone:
Page 40
40
AquaCoat GM 5000EACW
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
Ze
rstäube
r
luft
Atomizin
g
air
Mat. Druckregler
Mat. pressu
re reg
.
Pumpe
P
ump
POWER
0
1
B_03523
1
13
23
15
7
5
12
26
22
6
20
16
19
2
4
8
9
10
3
24
14
11
17
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.3.2 PREPARATION FOR STARTING UP
5.3.2.1 SPRAY PACK WITH PNEUMATIC PUMP EVOMOTION 20-30S
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
Page 41
41
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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. Set maximum pressure 0.8 MPa: 8 bar; 116 psi on the pump control unit.
6. Maintain the pressure for 5 minutes and check all connecting parts for leaks.
7. When the tightness of the system has been ascertained, release the spray gun (4).
8. Flush system through well.
9. Relieve system pressure and secure the spray gun (4).
10. Remove the detergent.
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).
4. Connect the AquaCoat system to the electric socket with the electric cable (9).
5. Insert front panel (2).
6. Switch on mains switch on the VM 5000W.
7. The system is ready for use.
SIHI_0130_GB
CAUTION
Electrical discharge when using coated material containers!
Risk of injury, material charge not optimal
Ensure that the metal part of the container is connected to
the HV cable (e.g. remove coating from around the connection
point).
Page 42
42
AquaCoat GM 5000EACW
AquaCoat
100
80
60
40
20
80
60
40
20
10
R3
R2
R1
Ze
rstäube
r
luft
Atomizin
g
air
Mat. Druckregler
Mat. pressure reg
.
Pumpe
P
ump
POWER
01
μAkV
B_03527
1
13
23
15
7
5
12
26
22
22
6
20
19
4
8
9
10
3
24
14
11
2
17
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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. Connect the earth.
4. Connect the AquaCoat system to the compressed air source (8).
5. Set a maximum pressure of 0.6 MPa; 6 bar; 87 psi on the control unit of the Cobra 40-10.
6. Maintain the pressure for 5 minutes and check all connecting parts for leaks.
7. When the tightness of the system has been ascertained, release the spray gun (4).
8. Flush system through well.
9. Relieve system pressure and secure the spray gun (4).
10. Remove the detergent.
Cobra 40-10 vertical mounted
with suction system
Page 43
43
AquaCoat GM 5000EACW
B_03528
1
13
23
15
7
5
26
22
6
20
19
2
4
8
9
10
3
24
14
11
17
AquaCoat
100
80
60
40
20
80
60
40
20
10
R3
R2
R1
Ze
rstäube
r
luft
Atomizin
g
air
Mat. Druckregler
Mat. pressu
re reg
.
Pumpe
P
ump
POWER
0
1
μAk
V
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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).
4. Connect the AquaCoat system to the electric socket with the electric cable (9).
5. Insert front panel (2).
6. Switch on mains switch on the VM 5000W.
7. The system is ready for use.
SIHI_0130_GB
CAUTION
Electrical discharge when using coated material containers!
Risk of injury, material charge not optimal
Ensure that the metal part of the container is connected to
the HV cable (e.g. remove coating from around the connection
point).
Cobra 40-10 mounted to frame
with upper container fi ttings
Page 44
44
AquaCoat GM 5000EACW
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
Zerstäuberluft
Atomizing air
Mat. Druckregler
Mat. pressure reg.
Pumpe
Pump
POWER
01
2115 22
110 911 3
B_03371
AquaCoat
1
0
0
80
60
4
0
20
μ
A
80
6
0
40
20
1
0
kV
R
3
R
2
R1
Z
e
rst
ä
u
be
rl
uft
Atomi
zi
ng
a
ir
M
at
.
D
ru
c
k
re
g
le
r
M
a
t
. p
re
s
s
ure reg.
Pu
m
pe
P
u
m
p
P
O
WE
R
0
1
AquaCoat
1
B_03520
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.4 WORKS
1. Turn on the control unitVM 5000W. Set main switch (1) to position 1. During the
start-up phase, the device automatically performs an internal function test and then
automatically switches to recipe 1 (15).
2. Set the desired recipe.
3. Set operating pressure of approx. 8 MPa; 80 bar; 1160 psi for the pump regulator (9).
Note:
In the case of material pressure generators with attached control unit, use the regulator
on the device.
4. Release the spray gun.
5. Spray on a test object (pull trigger).
Note:
If the trigger guard is now actuated, the high voltage is switched on and both displays
(21) and (22) change from point to bar display, i.e. the actual value of the high voltage
(21) and the actual value of the spray current (22) are displayed.
6. The high voltage can be switched on and off with the pushbutton (3).
7. Now open AirCoat air (11), approx. 0.01-0.25 MPa; 1-2.5 bar; 14,5-36 psi, and adjust for
the optimal atomization.
5.4.1 PREPARATION FOR SPRAYING WITH FLAT-JET NOZZLE
Page 45
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AquaCoat GM 5000EACW
B_03529
B_03530
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.4.2 START-UP FOR SPRAYING
For round-jet method:
6. By turning the nozzle nut, the atomizing air jet can
additionally be adjusted.
Note:
Do not turn the nozzle nut until it is fl ush with the nozzle
body. There must be play for the atomizing air between the
nozzle nut and the nozzle body.
The air adjustment at the back of the gun does not affect the
spray pattern in this process
For fl at-jet method:
6. Change the width of the spray jet by turning the air
adjustment back to the spray gun or by appropriate selection
of the nozzle.
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. Spray (pull trigger).
4. Adjust the spray pressure at the paint pump according to the nozzle and object being sprayed.
5. Open AirCoat air, approx. 0.01-0.25 MPa; 1-2.5 bar; 14,5-36 psi, and adjust for the optimal atomization.
Page 46
46
AquaCoat GM 5000EACW
B_00071
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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. Set the fl uid pressure on the material supply to the point where a further increase in fl uid pressure would
signifi cantly improve fl uid atomization.
4. Open air pressure regulator for the atomizer air and adjust so as to achieve optimal atomization (the
interrelation between spray pattern and atomizer air is shown in the fi gure below).
5. With the air adjustment on the gun, the ratio form adjustement to atomization until the optimum spray
pattern is achieved.
Note:
Repeat point 4 and 5 until the optimum spray pattern is reached (process iterative).
Closed air adjustment.
Completely opened air
adjustment.
Infl uence of the air adjustment on the spray pattern shape
The spray pattern can be adjusted to suit the object being sprayed using the air adjustment. The illustration
below shows the infl uence of the shaping air regulator on the spraying pattern.
Other nozzle sizes can be used to obtain larger or smaller spraying patterns.
Note
The paint output volume can be changed by:
•
Changing the material pressure or
•
Using a different fl at jet nozzle (see chap. 11).
No atomizing air Correct amount of atomizing airToo little atomizing air
Spray pattern
Page 47
47
AquaCoat GM 5000EACW
1/2
1
2
B_03531
B_03532
1
2
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.4.4 CLEANING OF CLOGGED ROUND JET NOZZLES
1. Remove nozzle insert (1) using nozzle
spanner (2).
2. Fit the new nozzle insert.
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.
3. After cleaning the nozzle, re-tighten the
nozzle insert.
5.4.5 EXCHANGE OF ROUND JET NOZZLE INSERT
Page 48
48
AquaCoat GM 5000EACW
B_03534
1
2
3
4
5
6
7
8
9
10
Y
11
1
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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. Unscrew round jet nozzle cap (2) incl. nozzle insert
(3).
5. Unscrew nozzle insert (3) using nozzle spanner (4).
6. Unscrew nozzle nut (5) and remove nozzle screw
connection (7) and sealing nipple (8) out off the
nozzle body (6) and clean all parts thoroughly.
7. Insert desired ACF5000 nozzle (11) into the valve
housing.
8. Put the air cap (10) on the nozzle (11) and pay
attention to the position of the guide surfaces.
9. Screw union nut with attached nozzle guard (9) to
the gun body and make sure that the air cap horns
lie in the designated recess (Y).
10. Before tightening the air cap horns (Y) set the
desired jet level and then tighten the union nut to
the stop by hand.
Page 49
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AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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. Unscrew union nut (12) and remove air cap (10).
5. Remove ACF5000 AirCoat nozzle (11) and brush cleaning solvent until all traces of
paint are dissolved.
6. Insert new ACF5000 nozzle (11) into the valve housing.
7. Put the air cap (10) on the nozzle (11) and pay attention to the position of the guide
surfaces.
8. Screw union nut with attached nozzle guard (9) to the gun body and make sure that
the air cap horns lie in the designated recess (Y).
9. Before tightening the air cap horns (Y) set the desired jet level and then tighten the
union nut to the stop by hand.
The AirCoat ACF5000 nozzles (11), the nozzle inserts (3) and the nozzle screw connection
(7) can be placed in a cleaning solvent recommended by the paint manufacturer.
All other nozzle parts may not be put into cleaning solvent. Clean these parts with
cleaning solvent recommended by the manufacturer and dry with a cloth or a air-jet
gun.
CAUTION
Defective AirCoat nozzle!
Insufficient paint application quality
Do not use sharp-edged objects to treat hard metal on the AirCoat nozzle.
SIHI_0020_GB
1. Switch off control unit.
2. Relieve the pressure of gun and unit.
2. Save the spray gun (1) using the trigger lock (14).
3. Unscrew union nut (12) complete with air cap (10) and ACF5000 nozzle (11).
4. Remove air cap (10).
5. Pull out the ACF5000 nozzle (11) from the air cap (10) by hand, reverse it and put it
towards the rear into the air cap (10). Pay attention to the position of the guide surfaces
(X).
6. Insert air cap (10) with integrated ACF5000 nozzle (11) into the union nut (9). Make
sure that the air cap horns (Y) lie in the recess of the nozzle guard..
5.4.8 CLEANING OF THE NOZZLES
5.4.9 ELIMINATE NOZZLE CLOGGING
Page 50
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AquaCoat GM 5000EACW
B_03535
9
10
11
X
Y
Y
1
14
12
12
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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. When the blockage has been fl ushed out secure the gun with trigger lock (14).
11. Relieve the pressure of gun and unit.
12. Unscrew union nut (12).
13. Remove air cap (10) and put ACF5000 nozzle (11) out off air cap by hand. Clean ACF5000
nozzle and insert it in spraying position into the valve housing.
14. Put the air cap (10) on the nozzle (11) and pay attention to the position of the guide
surfaces (X).
15. Screw union nut with attached nozzle guard (9) to the gun body and make sure that
the air cap horns lie in the designated recess (Y).
16. Before tightening the air cap horns (Y) set the desired jet level and then tighten the
union nut to the stop by hand.
17. Switch the material pressure and the air pressure back on.
18. Switch on the control unit.
ACF5000 nozzle in
“cleaning“ position.
ACF5000 nozzle in
“spray“ position.
Page 51
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AquaCoat GM 5000EACW
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03372
B_03373
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03374
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.4.10 START-UP THE CONTROL UNIT VM 5000W
1. Turn switch to position 1.
2. All LEDs on the control unit illuminate
for approx. 1 second.
Hardware-version Software-version
3. The hardware version and the software
version are shown on the display
alternately in succession.
4. After a few seconds the control unit is
ready for operation.
Note:
Each start process is concluded by
allocating the saved target data in the
recipe „R1“.
Page 52
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OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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. Target high voltage in kV Target spray current limiter in µA
R1 70 100
R2 60 100
R3 40 80
Recipes 1-3 can be selected and saved directly using program buttons R1, R2 and R3. Once
the recipe required has been called up, the individual coating parameters can be called
up and changed using the corresponding selection buttons (see chapter 5.4.7 and 5.4.8).
When a parameter is changed, the LED on the left of the program button fl ashes to indicate
that a parameter value has been changed.
The process for saving parameters is described below.
● To reuse the originally set values, press the program button briefly. The modifi ed values
are not taken over.
● To save the modified values, press the appropriate program button and hold for
approx. 2 seconds until the LED beside the button flashes quickly. The modified values
are then saved.
Page 53
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AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03375
78
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03376
78
27
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.4.12 SETTING THE HIGH VOLTAGE
Works procedure:
1. Press the „High voltage“ button (7) to
adjust the high voltage. The LED (8)
indicates that high voltage is selected.
2. The high voltage can now be adjusted
using the universal rotary controller (2)
between 5 to 70 kV with a resolution
of 1 kV. The value is shown in the LED
display (27).
Above the „High voltage“ button (7) is the „High voltage“ bar graph display 21). When the
control unit is in the ready position, this display shows the set point as a dot.
Page 54
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AquaCoat GM 5000EACW
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03377
56
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03378
22 2
27
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.4.13 SETTING THE CURRENT LIMITING
Works procedure:
1. Press the „Current limiting“ button (5)
to adjust the limitation of the spray
current. The LED (6) indicates that
current limiting is selected.
2. The current limiting can now be
adjusted using the universal rotary
controller (2) between 10 - 100 µA with
a resolution of 1 µA. The value is shown
in the LED display (27).
Above the „current limiting“ button (5) is the „Current limiting“ bar graph display (22). When
the control unit is in the ready position, this display shows the set point as a dot.
The current limiting is an adjustable threshold. If this threshold is exceeded, for example by
approach of the spray gun to the spraying object, the high-voltage is adjusted downwards
until the threshold is no longer exceeded.
The values set in the examples for target high voltage at 40 kV and current limiter at 83 µA
are stored in R2 through prolonged pressing of the recipe pushbutton (> 2 sec.).
Page 55
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AquaCoat GM 5000EACW
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03379
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03380
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.4.14 SPRAY DISPLAY
Spray using recipe R2:
High voltage is created by pressing the trigger on the spray gun. The LEDs light up in a bar
and display the actual values. The current actual value of the activated pushbutton for the
high voltage (kV) is digitally displayed on the LED display. If the pushbutton for the spray
current limiter is pressed, the relevant LED lights up and the corresponding actual value in
µA appears in the LED 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. If you press the current limiter pushbutton, the set nominal value for the
spray current limiter is digitally displayed in the LED display.
Page 56
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AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03381
34
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03379
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.4.15 STANDBY MODE
Press pushbutton (3) to return from this standby mode to the previously saved standby
mode (see fi gure below).
Note:
This function can be activated and used from the gun.
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.
Page 57
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AquaCoat
100
80
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40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03382
2526
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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.
Press the „Service“ button (25) to go from the standby position of the control unit to the
maintenance menu display.
Structure of the maintenance menu (LED display 26 illuminates):
Push button Description of display
R1 Display of absolute accrued operating hours of the spray gun.
Display format:
Counter status < 999 hours: 001 = 1 hour.: 291 = 291 hours.
Counter status > 1000 hour: 1.23 = 1230 hours; 45.2 = 45200 hours.
Maximum display value = 99.9 = 99900 hours.
Flashing lines are then displayed.
R2 Display of temporary maintenance counter and how to reset this
counter
R3 Set maintenance interval in hours activate or lock this function
Page 58
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100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03383
272526
251920
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03384
2561718
2526 2722
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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.
Set and save the service interval limit in hours:
Works procedure:
1. Actuate the push button R3 (19) for a
short time, the LED (20) display lights
up.
2. Use the dial (2) to set the maintenance
interval limit you want (e.g. 90 hours).
3. Check setting in the LED display (27).
4. The value is saved by pressing down
the „Spray current“ pushbutton (5)
until the LED display (27) starts to fl ash.
Works procedure:
1. Actuate the push button R2 (17) for a
short time, the LED (18) display lights
up.
2. Read off display in the LED display (27).
In the example 46 hours have passed
since the last spray gun service. The bar
display on the left (22) indicates that
50% of the set interval time has passed.
3. By keeping pushbutton (5) pressed
down, the display in the LED display
(27) can be set to „0“ (reset after expiry
of the set interval limit).
Review counter status since last service carried out on gun:
Page 59
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100
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40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03385
2526
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.4.18 “CONDUCT SERVICE” DISPLAY
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 ash.
The fl ashing service display merely acts as a warning. You can continue working without
any limitations.
Page 60
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OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
5.5 DEVICE CONFIGURATION
5.5.1 OVERVIEW OF PARAMETERS
Parameters Value Description
C13 User lock
off
(Factory setting)
User lock is switched off.
on
User lock is switched on: no target values (kV and µA) can
be adjusted; you can only select the recipe and the control
functions.
pro
User lock pro (program)
You can select recipes and control functions.
The target values (kV and µA) can be adjusted but cannot
be saved in the recipes.
C19 Reset recipes
no
(Factory setting)
No reaction
res
All programs are set to delivery status when “res” is saved
by the maintenance key.
C20
Reset
confi guration
no
(Factory setting))
No reaction
res
All confi guration parameters are set to delivery status
(factory setting) when “res” is saved by the maintenance
key.
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100
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μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03381
34
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03507
2
25 27
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03508
27
68 4
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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.
2. Press push button “Service” (25) and
hold it down.
3. Turn the universal control dial (2)
with the other hand until the LED
display (27) shows the number “10”.
Then release button “Service” (25).
The running text “confi guration” is
displayed in the LED display (27). The
device is now in confi guration mode.
4. The fi rst confi guration parameter
C11 is now displayed in the LED
display (27). The two LED displays
“Spray current” (6) and “High
voltage” (8) fl ash at the same time.
The “Standby” (4) LED display fl ashes
quickly.
Note:
The parameters C11 and C12 can be
changed, but this will not have any
effect.
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100
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40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03508
27
68 4
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03509
27
57
25
3
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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.
Group 1:
Parameters C11 to C20
(end user)
Group 2:
Parameters C21 to C30
(Wagner service)
Group 3:
Parameters C31 to C40
(production plant, service center)
5.5.3 SETTING EXAMPLE “PARAMETER C13”
After getting started in confi guration mode, the display (27) shows the parameter “C11” by
default. You can change to parameter “C13” by pressing the “Spray current” (5) or the “High
voltage” (7) button.
To change a selected parameter value (e.g. C13), press Push key “standby” (25). The content
of the parameter is displayed in the LED display (27).
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80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03510
27
2
26 25
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03511
3
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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”, “off ” or “pro”.
Keep the Push button “maintenance” (25) held down to have the set value saved to
parameter C13.
Press the “Standby” key (3) to exit confi guration mode.
Page 64
64
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
6 MAINTENANCE
➞ Observe general safety instructions in chapter 2.
The AquaCoat spray system must be cleaned and rinsed out every day. Only use the
cleaning solvent recommended by the paint manufacturer.
CAUTION
Cleaning agent in the air duct!
Functional faults caused by swollen seals
➞ Never immerse the spray gun in cleaning agent or water.
SIHI_0002_GB
SIHI_0004_GB
WARNING
Incorrect maintenance/repair!
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.
- Relieve the pressure from the spray gun and unit.
- Secure the spray gun against actuation.
Observe the operating and service instructions when carrying
out all work.
Page 65
65
AquaCoat GM 5000EACW
B_03536
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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 tted:
4. By means of nozzle spanner, loosen nozzle insert by a half turn.
5. Actuate the trigger guard. Flush the gun through thoroughly.
6. Relieve the pressure of gun and unit!
7. Re-tighten the nozzle insert.
8. Clean the spray gun body with a cleaning agent recommended by the manufacturer
and dry with a cloth or blow gun.
With fl at jet nozzle fi tted:
5. Remove AirCoat nozzle and clean separately (see chapter 5.4.7).
6. Actuate the trigger guard. Flush the gun through thoroughly.
7. Relieve the pressure of gun and unit!
8. Clean the spray gun body with a cleaning agent recommended by the manufacturer
and dry with a cloth or blow gun.
6.1 FINISHING WORK AND CLEANING
SIHI_0145_GB
CAUTION
Cleaning agent in the air duct!
Functional faults caused by swollen seals
Discharge current to ground -> no high voltage
Always point the spray gun down when cleaning.
Ensure that neither paint nor cleaning agent enters the air duct.
When taking a break from work or when stored for a longer period, the spray gun
has to be positioned correctly with the attachment pointing downwards.
Page 66
66
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
7 TROUBLE SHOOTING AND SOLUTION
SIHI_0004_GB
WARNING
Incorrect maintenance/repair!
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.
- Relieve the pressure from the spray gun and unit.
- Secure the spray gun against actuation.
Observe the operating and service instructions when carrying
out all work.
Functional fault Cause Remedy
Insuffi cient material output • Nozzle too small • Flat jet: Select larger nozzle
(see nozzle table)
• Material pressure too low • Increase material pressure
• Material viscosity too high • Thin material in accordance with the
manufacturer’s instructions
• Filter in material supply
clogged
• Clean or replace fi lter
• Nozzle is clogged • Clean or replace nozzle
Poor spray pattern • Wrongly adjusted atomizing
air
• Readjust atomizing air
• Nozzle too large • Select smaller nozzle (see nozzle table)
• Material viscosity too high • Thin material in accordance with the
manufacturer’s instructions
• Material pressure too high • Reduce the material pressure
• Damaged nozzle • Replace nozzle
7.1 FAULTS IN THE SYSTEM
Page 67
67
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Functional fault Cause Remedy
Poor wrap-around • Poor earthing at object • Check earthing of object or hanger with
ohmmeter
• Paint resistance too high / too
low
• Check resistance of paint
see chapter 4.1.1
• Spraying pressure too high • Readjust spraying pressure
Back spraying • Object not earthed • Check earthing
• Distance between spray gun
and object too large
• Reduce distance between spray gun and
object
• High voltage set wrongly (too
high)
• Adapt high voltage to material
No wrap-around • 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
beschädigt
• Replace the seals (see chapter 8)
Page 68
68
AquaCoat GM 5000EACW
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
Zerstäuberluft
Atomizing air
Mat. Druckregler
Mat. pressure reg.
Pumpe
Pump
POWER
01
B_03506
24 27
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
7.2 ERROR DISPLAYS AT THE CONTROL UNIT VM 5000W
Functional fault Cause Remedy
No illuminated display lights up• Mains not switched on
• Fuses defective
• Switch on mains power supply
• Replace fuses
• Contact Wagner Service Team
No high voltage • Spray gun cable not connected or
defective
• Spray gun not connected or
defective
• Connect spray gun cable
• Contact Wagner Service Team
Fault LED (24) lights up
Fault message in display (27)
• see the following table • see the following table
Page 69
69
AquaCoat GM 5000EACW
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
POWER
01
POWER
B_03505
24 2725
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Faults are indicated by the “Fault” LED (24). In addition the error number is shown in the
display (27). If a fault occurs, the high voltage is switched off immediately. The user can only
continue to work once the fault has been remedied and acknowledged with push button
“service” 25).
Code
Display
Malfunction Cause Remedy
E11
Earth monitoring
● The grounding cable is
interrupted
● The gun is not connected
● Check/replace gun cable
● Check or replace spray gun
● Connect the spray gun
E12
No coil current/
Cascade interrupt
● The cascade is not connected
● Cascade is interrupted -->
defective
● Connect the cascade
● Check or replace cascade
E13
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
70
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
8 REPAIR WORK
SIHI_0048_GB
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".
Before all work on the unit and in the event of work interruptions:
- Disconnect the control unit from the mains.
- Relieve the pressure from the spray gun and unit.
- Secure the spray gun against actuation.
Observe the operating and service instructions when carrying
out all work.
Page 71
71
AquaCoat GM 5000EACW
1
2
3
B_03537
SW3
SW12
SW12
SW3
SW19
Torx 25
B_03538
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
8.1 DISMANTLING OF THE SPRAY GUN
Page 72
72
AquaCoat GM 5000EACW
B_03539
SW19
SW19
4
5
6
B_03556
SW9
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Assembly tool for needle valve,
Part No. 2309368
Note:
Loosen AC valve tip by hand
using an assembly tool
Page 73
73
AquaCoat GM 5000EACW
B_03198
SW6
SW5
SW2
1
4
5
2
6
7
3
ø 3.0
B_03250
SW14
SW9
SW8
1
Torx 20
SW5
2
7
8
9
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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.
4. If the loosened package (3) in the
hole jammed, emit from the front.
1. Undo the oval head screw (1).
2. Pull the air valve out off the
hole.
Removing air valve:
Hold the piston rear (2) and unscrew
piston front SW6.
Removing air valve:
Unscrew and remove the sealing
nut SW8.
Hold the piston rear (2) and
unscrew piston front SW5.
Page 74
74
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
8.2 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. Care should be taken that these parts remain free of solvents, grease or
sweat from the hands (salt water).
➞ Spare parts may have safety-relevant properties.
➞ Defective parts, O-rings and seal sets must always be re-placed.
In chapter 12 can be found part numbers for gun spare parts as well as for wearing parts
such as seals.
WARNING
Incompatibility of cleaning agent and working medium!
Risk of explosion and danger of poisoning by toxic gasses
Check the compatibility of cleaning agent and working medium
in accordance with safety data sheets.
SIHI_0060_GB
Page 75
75
AquaCoat GM 5000EACW
1
2
B_03559
SW14
3 Nm
SW9 1 Nm
SW8
SW5
Torx 20
1
3
1
4
2
2
2
B_03448
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
8.3 ASSEMBLING THE SPRAY GUN
Ensure the correct insertion
position!
Ensure the correct insertion
position!
Mounting materials:
Pos Part No. Description
1 9992590 Loctite 222
2 9992698 Vaseline weiss PHHV II
3 9992831 Loctite 542
4 9992511 Loctite 243
Page 76
76
AquaCoat GM 5000EACW
3
B_03202
0.5 Nm
SW6
0.4 -
0.5 Nm
SW5
2
2
2
SW5/ 0.4 - 0.5 Nm
X = 123 ±0.1
SW2
1Nm
X
1
4
5
4 5
B_03557
SW9
1.2 Nm
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Insertion position compl. Package
Set measure X with withdrawal nut and
then fasten it with the threaded pin
(SW2).
Push together the valve rod
unit and the compl. package.
Screw in together the valve rod unit and
the compl. package.
Remove the valve rod unit.
Tighten the compl. package.
Carefully insert the valve rod unit and mount
with an assembly tool (5) the clamping screw
assy. (1).
Tighten slightly AC
valve tip by hand using
an assembly tool.
Part No. 2309368
Ensure the correct
insertion position!
Note:
Assembly tool, Steck or boxend wrench Use (no openended).
Assembly tool
Part No. 2325263
Page 77
77
AquaCoat GM 5000EACW
6 7
8
B_03540
SW19
2.5 Nm
SW3
SW19
B_03541
Torx 25
B_03542
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Push the trigger upward into the
air valve piston.
Page 78
78
AquaCoat GM 5000EACW
9
10
B_03544
R1
R3
R2
B_03543
SW3
0.8 Nm
SW12
SW12
2
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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
Einbaulage beachten!
Page 79
79
AquaCoat GM 5000EACW
AquaCoat
1
0
0
80
60
40
2
0
80
6
0
40
20
10
R3
R
2
R1
Z
er
s
t
äub
e
rluft
A
to
mi
zin
g
ai
r
Ma
t
.
Druckre
gl
er
M
a
t
.
pr
e
ssur
e r
eg.
P
umpe
Pump
PO
WER
0
1
μ
A
k
V
1
5
2
3
4
3
6
B_03545
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
8.4 REPLACING THE SPRAY GUN INCLUDING HOSE SET
Disassembling gun assy. (1)
1. Loosen the union nut (6) on the bared part of the material hose (3) with a universal
spanner.
2. Loosen the knurled nut on the gun cable (5) and remove connector.
3. Loosen the union nut (4) of the air hose at the AquaCoat cabinet.
4. Unscrew knurled nut (2).
5. Carefully remove the gun (1) together with the hose set.
Page 80
80
AquaCoat GM 5000EACW
B_03546
1
2
3
4
5
6
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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. Push bared part of material hose approx. 1.15 m; 3.77 ft through the opening as far as
the mounting plate.
3. Fix mounting plate (3) to earthing screw with knurled nut (2).
4. Screw air hose for the spray gun (4) to the AquaCoat cabinet.
5. Connect gun cable (5) to AquaCoat cabinet and secure with screw.
6. Screw bared end of material hose (3) with union nut (6) to relief combination.
8.5 CHANGE MATERIAL HOSE AND/OR AIR HOSE
1. Loosen and unscrew clamping screw (1).
2. Loosen nut (2) and remove material hose from the attachment point.
3. Push protective hose (4) back.
4. Carefully remove material hose (3) from the protective hose (4).
5. Loosen union nut (5) at gun connection and carefully remove air hose (6) from the
protective hose (4).
Page 81
81
AquaCoat GM 5000EACW
AquaCoat
100
80
60
40
20
80
60
40
20
10
R3
R2
R1
Ze
rstäube
r
luft
Atomizin
g
air
Mat. Druckregler
Mat. pressu
re reg
.
Pumpe
Pump
POWER
0
1
μAk
V
B_03550
1
232
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
8.6 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. Carefully remove control unit (3) forwards. Pay attention to connecting lines and
connecting cables at the back of the control unit!
Page 82
82
AquaCoat GM 5000EACW
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R3
R2
R1
Zerstäuberluft
Atomizing air
Mat. Druckregler
Mat. pressure reg.
Pumpe
Pump
POWER
0
1
1
2
B_03533
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
8.7 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. When the repair is complete, replace the cover (2) on the housing and fi x with the
screws (1).
Page 83
83
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
9 FUNCTIONAL CHECK AFTER ASSEMBLY
9.1 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.
In this function check the system must not be fi lled with a liquid.
Activities Aid tools
1. Check connections
● Check all material screw connections.
● Check all air connections.
● All electrical cables must be firmly secured.
Visually check
“Safety-relevant check”
2. Check earth connection
● Measure resistance between earth terminal and handle of the gun
(metal fittings):
-> Set value max.10 .
● Check resistance between earth terminal and earthing band:
-> Set value max.10 .
Multi meter
3. Connect the device
● Connect earthing cable.
● Main tap closed.
● Connect air supply (mains pressure 0.8 MPa; 8 bar; 116 psi).
● Connect the mains.
4. Adjust horn
(only for level indication with horn).
● Loosen control unit and remove from mounting (see chapter 8.6).
● Air switch on.
● Set horn regulator to normal volume.
● Switch air off and replace control unit in cabinet.
Hexagonal wrench
SW 3 mm; 0.12 inches
5. Check door switch
● Do not fit the door.
● Air tap closed, remove gun -> No high voltage is present.
● The control unit does not indicate either high voltage or power.
6. Test earthing switch
● Fit door.
● Air tap closed.
● Remove gun -> the “High voltage” LED illuminates.
● Voltage indicator 0 kV.
● Current 80-100 µA.
Page 84
84
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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.
● Main switch on.
● Set high voltage to 5 kV.
● Remove gun.
● With the gun removed, gradually increase the high voltage up to
maximum voltage (70 kV).
No more than one LED must illuminate on the current indicator (10µA).
● Main switch off.
Page 85
85
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
10 PRODUCT DISPOSAL
SIHI_0127_GB
Note
Do not dispose of waste electrical equipment with the household refuse!
In accordance with European Directive 2002/96/EC on the disposal
of waste electrical equipment and its implementation in national
law, this product may not be disposed of with the household refuse,
but must rather be recycled in an environmentally correct manner.
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
86
AquaCoat GM 5000EACW
"?
B_03210
B_03551
B_03552
132720 11 ca. 250; 10
132721 12 ca. 250; 10
132722 13 ca. 250; 10
132723 14 ca. 250; 10
132724 * 15 ca. 250; 10
132725 16 ca. 250; 10
132726 17 ca. 250; 10
132727 18 ca. 250; 10
132728 19 ca. 250; 10
132729 20 ca. 250; 10
132730 21 ca. 250; 10
132731 22 ca. 250; 10
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
11 ACCESSORIES
11.1 ROUND JET NOZZLES
11.1.1 AIRCOAT ROUND JET NOZZLE INSERTS
The round jet nozzles are especially suited to spray pipes, profi les and complex workpieces.
* Standard
Jet width in mm; inches at a distance of 30 cm; 11.8 inches from the object and at a pressure
of 10 MPa; 100 bar; 1450 psi.
Part No. Description
2309901 LV air cap compl. suitable for low viscosity materials (marked red)
2314204 HV air cap compl. suitable for high viscosity materials (marked blue)
11.2 ACF AIR CAPS (FLAT JET)
Part No. Description
2309902 Round jet nozzle cap ACWR 5000 (with nozzle spanner, without AC
round jet nozzle insert)
Part No . Marking Jet width
mm; inch
Recommended
gun filter
red
(200 meshes)
yellow
(100 meshes)
white
(50 meshes)
Page 87
87
AquaCoat GM 5000EACW
395107
395207
395407
07/10
07/20
07/40
0.18; 0.007 10°
20°
40°
395109
395209
395309
395409
395509
395609
09/10
09/20
09/30
09/40
09/50
09/60
0.23; 0.009 10°
20°
30°
40°
50°
60°
395111
395211
395311
395411
395511
395611
395811
11/10
11/20
11/30
11/40
11/50
11/60
11/80
0.28; 0.011 10°
20°
30°
40°
50°
60°
80°
395113
395213
395313
395413
395513
395613
395813
13/10
13/20
13/30
13/40
13/50
13/60
13/80
0.33; 0.013 10°
20°
30°
40°
50°
60°
80°
395115
395215
395315
395415
395515
395615
395815
15/10
15/20
15/30
15/40
15/50
15/60
15/80
0.38; 0.015 10°
20°
30°
40°
50°
60°
80°
395217
395317
395417
395517
395617
395817
17/20
17/30
17/40
17/50
17/60
17/80
0.43; 0.017 20°
30°
40°
50°
60°
80°
B_03163
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
11.2.1 ACF5000 AIRCOAT FLAT JET NOZZLES
Part No.
Marking
Diameter
of bore
Spray angle
Application
Natural paint
Transparent lacquer
Oil
Synthetic resin paint
PVC paint
Paint, undercoat
Priming paint
Filler
Filler
Rust proofing paint
Rust proofing paint
Latex paint
mm; inch
Page 88
88
AquaCoat GM 5000EACW
B_03163
395219
395319
395419
395519
395619
395819
19/20
19/30
19/40
19/50
19/60
19/80
0.48; 0.019 20°
30°
40°
50°
60°
80°
395221
395421
395521
395621
395821
21/20
21/40
21/50
21/60
21/80
0.53; 0.021 20°
40°
50°
60°
80°
395423
395623
395823
23/40
23/60
23/80
0.58; 0.023 40°
60°
80°
395425
395625
395825
25/40
25/60
25/80
0.64; 0.025 40°
60°
80°
395427
395627
395827
27/40
27/60
27/80
0.69; 0.027 40°
60°
80°
395429
395629
395829
29/40
29/60
29/80
0.75; 0.029 40°
60°
80°
395431
395631
395831
31/40
31/60
31/80
0.79; 0.031 40°
60°
80°
395435
395635
395835
35/40
35/60
35/80
0.90; 0.035 40°
60°
80°
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
mm; inch
Rust proofing paint
Latex paint
Mica paint
Zinc dust coating
Rust proofing paint
Glue paints
Part No.
Marking
Diameter
of bore
Spray angle
Application
Page 89
89
AquaCoat GM 5000EACW
2
3
4
5
B_03547
1
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
11.3 HOSES AND ELECTRICAL CABLES
Pos Qty Part No. Description
1 1 2309865 Hose set GM 5000EACW (7.5 m; 24.6 ft)
Consisting of:
2 1 2309468 Material hose EACW assy. (7.5 m; 24.6 ft)
3 1 2310499 Air hose assy. (7.5 m; 24.6 ft)
4 1 2311813 Gun cable GM 5000E (7.5 m; 24.6 ft)
5 7m 3676437 PP30 protective hose mesh (7 m; 22.97 ft)
Pos Qty Part No. Description
1 1 2309866 Hose set GM 5000EACW (10 m; 32.81 ft)
Consisting of:
2 1 2309887 Material hose EACW assy. (10 m; 32.81 ft)
3 1 2310500 Air hose assy. (10 m; 32.81 ft)
4 1 2307293 Gun cable GM 5000E (10 m; 32.81 ft)
5 9.5m 3676437 PP30 protective hose mesh (9.5 m; 31.17 ft)
Pos Qty Part No. Description
1 1 2309867 Hose set GM 5000EACW (15 m; 49.2 ft)
Consisting of:
2 1 2309888 Material hose EACW assy. (15 m; 49.2 ft)
3 1 2310501 Air hose assy. (15 m; 49.2 ft)
4 1 2309474 Gun cable GM 5000E (15 m; 49.2 ft)
5 14.5m 3676437 PP30 protective hose mesh (14.5 m; 47.57 ft)
Pos Qty Part No. Description
1 1 2309868 Hose set GM 5000EACW (20 m; 65.62 ft)
Consisting of:
2 1 2309889 Material hose EACW assy. (20 m; 65.62 ft)
3 1 2310502 Air hose assy. (20 m; 65.62 ft)
4 1 2309475 Gun cable GM 5000E (20 m; 65.62 ft)
5 19.5m 3676437 PP30 protective hose mesh (19.5 m; 63.98 ft)
Note:
Material hose
- Inside diameter 4 mm; 0.16 inches
- Material FEP
- Nominal pressure 25 MPa; 250 bar; 3626 psi
Page 90
90
AquaCoat GM 5000EACW
B_03451
"?
B_03693
B_03681
B_03720
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
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
128901 Nozzle spanner ACR
2325263 Assembly tool clamping screw
2324766 Swivel Air
2319653 Protective gun coating
Page 91
91
AquaCoat GM 5000EACW
"?
"?
"?
B_03224
P_00265
B_03699
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Part No. Description
259010 High voltage tester HV 200 N
999080 Wet fi lm thickness measurer
50342 Viscosity cup DIN 4
353050 Hose holder assy.
353051 Base frame assy.
353052 Feed tank
2326485 Wall mount GM 5000E (left/right)
Page 92
92
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Page 93
93
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
12 SPARE PARTS
12.1 HOW TO ORDER SPARE PARTS?
SIHI_0004_GB
WARNING
Incorrect maintenance/repair!
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.
- Relieve the pressure from the spray gun and unit.
- Secure the spray gun against actuation.
Observe the operating and service instructions when carrying
out all work.
Always supply the following information to ensure delivery of the right spare part:
Part Number, description and quantity
The quantity need not be the same as the number given in the „Quantity“ column.
This number merely indicates how many of the respective parts are used in each sub
assembly.
The following information is also required to ensure smooth processing of your order:
- Address for the invoice
- Address for delivery
- Name of the person to be contacted in the event of any queries
- Type of delivery required (air freight or mail, sea route or overland route, etc.)
Marks in spare parts lists
Note to column „K“ in the following spare parts lists.
U = Wearing parts
Note: No liability is assumed for wearing parts
L = Not part of standard equipment, available, however, as additional extra.
Page 94
94
AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
12.2 SPARE PARTS LIST AQUACOAT BASIC UNIT
Spare parts list AquaCoat
Pos K Qty Part No. Description
1 1 130215 Earthing cable 10 m; 32.81 ft
2 1 241270 Mains cable with Stak200
3 1 2314234 Control unit VM 5000W (Spare parts list see chapter 11.3)
4 1 2324044 Door switch assy.
5 1 2314238 Cascade AquaCoat
6 1 353864 AquaCoat resistor 3 G
7 1 9991523 Ball valve
8 1 353868 Air connection assy.
9 1 9999440 Fitting I = G1/2“, A = G1/2“
10 1 9999109 Fitting T G1/2“
11
◆
1 353865 Cylinder AquaCoat
12
◆
1 353526 Contact for earthing
13
◆
1 353527 Earthing bush
14 1 353528 Instruction sticker AquaCoat
15 1 9999208 Angle screwing in connection G1/4“
16 2 9900308 Cheese head screw with hexagon
17 1 9900315 Cheese head screw with hexagon
18 1 9900346 Cheese head screw with hexagon
19 2 9910102 Hexagon nut M6
21 2 9910204 Hexagon nut with clamp
22 1 9911008 Hexagon nut fl at
23 3 9920103 Serrated lock washer A6.4
24 8 9920118 Washer
25 4 9922109 Serrated washer
27 1 9952558 Warning sign High voltage
28 1 9992511 Loctite 243
29 1 9992831 Loctite 542
30 1 9998090 Screw-in screw connection straight
31 1 9999437 Strain relief grommet DM7
32 1 9999438 Strain relief grommet DM4
33 1 9985685 Reducer A = G1/2“, I = G1/4“
40 1 9910522 Knurled nut
41 1 9992741 Straight bulkhead fastener
42 1 9994627 Double nipple with 2x90°
43 1 9907050 Cheese head screw with hexagon
44 1 9992528 Loctite 270
45 1 353523 Retainer
46 1 353520 Locking fl ap
◆ = Wearing part
Page 95
95
AquaCoat GM 5000EACW
B
E
AquaCoat
100
80
60
40
20
μA
80
60
40
20
10
kV
R
3
R2
R1
Zerstäuberluft
Atomizing air
Mat
.
Dr
uckr
e
g
ler
Mat. pressure reg.
Pumpe
Pump
POWER
01
AquaCoat
52
D
50
51
54
6
14
27
15
33
3
7
29
8
10
9
16
5
31
32
2
1
46
57
B_03391
18
24
28
24
25
A
17
23
24
25
24
21
B
13
23
19 25
2424
21
C
40
24
24
23
19
25
41
42
43
D
44
4
55
56
45
12
53
22
11
30
A
C
58
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
View E from out
Page 96
96
AquaCoat GM 5000EACW
Pumpe
Pump
Netzeingang
Main power
Lufteingang
Air inlet
Erdungs-Zylinder
Grounding cylinder
Prim. 1AT
Mat. Druckregler
Mat. pressure reg.
Zerstäuberluft
Atomizing air
Pistole
Gun
HS-Erzeuger
HV-Generator
Service
Typ / Type: VM 5000W
85-264 VAC / 47-440 Hz
2311001
max. 40W
J. WAGNER AG
CH - 9450 Altstätten
Made in Switzerland
Serie Nr.:
Serial No.:
Spannung:
Voltage:
Artikel Nr.:
Article No.:
Eingangsleistung:
Line Power:
Schutzklasse:
Protection Class:
Norm:
Standard:
EN 50059
IP 54
Spannung:
Voltage:
Strom:
Current:
max. 18Vpp
max. 1,0A
B_03514
48
49
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Spare parts list AquaCoat
Pos K Qty Part No. Description
47 1 353523 Retainer
48 1 2314160 Connection gun cable VM 5000W
49 1 2314159 Control cable VM 5000W
50 1 353867 Front plate assy.
51 1 353504 Sticker AquaCoat
52 1 353866 Cabinet AquaCoat pre-assembled
53 1 353869 Interlocking
54 2 9907222 Hexagon screw
55 1 9907259 Cheese head screw with slit
56 1 9907260 Countersunk screw with slit
57 1 353870 Air hose AC
58 1 9992590 Loctite 222
- 1 353285 AquaCoat cablekit
◆ = Wearing part
Page 97
97
AquaCoat GM 5000EACW
B_02227
1
2
3
4
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Pos K Qty Part No. Description
1 353870 Air hose AC assy.
1 1 9985619 Hose nozzle with sealing ring
2 2 9990404 Hose clips
3 1 9981951 Hose 1.2 m; 3.94 ft
4 1 9998812 Quick coupling with hose nozzle
◆ = Wearing part
12.2.1 ADDITIONAL LIST OF SPARE PARTS FOR VARIANTS WITH PP PUMP OR COBRA
Page 98
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AquaCoat GM 5000EACW
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
12.3 SPARE PARTS LIST VM 5000W
Pos K Qty Part No. Description
1 3 123459 Pressure gauge socket
2 1 241323 Cover
4 3 263400 Distance bush
6 1 353501 Cover
7 1 2304459 Incremental encoder
8 1 2304461 Rotary knob
9 1 2304462 Cover
11 1 2317539 Print assy. VM 5000 display (incl. item 7)
12 5 2309112 Spacer
16 1 9952587 Equipment plug
17 5 2312348 Hexagon lock nut
18 1 2314235 Print assy. VM 5000W
19 2 3114203 Straight screw in connection
20 1 3661856 Enlarging connector
from 8 mm; 0.31 inches to 10 mm; 0.39 inches
21 1 9900338 Cheese head screw with hexagon
22 2 9903306 Oval head screw
23 2 9903311 Oval head screw
24 4 9903312 Oval head screw
25 6 9907010 Countersunk screw
26 1 9910102 Hexagon nut
27 3 9910103 Hexagon nut
28 1 9910204 Hexagon nut
29 4 9920118 Washer
30 7 9922011 Lock washer outside toothed
31 2 9922109 Serrated washer inside toothed
32 1 9950330 Safety clip
33 2 9950612 Female tab lug
35 2 9951117 Delay-action fuses 1.0 AT
36 1 9955601 Fuse fast-action 2.5A
37 1 9955021 Fuse holder
38 1 9955176 Power pack
40 1 9956021 Valve Matrix assy.
41 1 9956178 Switch
42 3 9971336 O-ring
A = 2 cables shortened to to 150 mm; 5.91 inches
B = Remove absorber!
Page 99
99
AquaCoat GM 5000EACW
B_03515
(6x)
42
48
1
43
20
8
9
52
51
45
50
54
33
6
25
27 4
18
38
30
24
17
11
7
19
12
40
53
44
41
21
31
29
A
B
36
35
18
18
41
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Page 100
100
AquaCoat GM 5000EACW
Pumpe
Pump
Netzeingang
Main power
Lufteingang
Air inlet
Erdungs-Zylinder
Grounding cylinder
Prim. 1AT
Mat. Druckregler
Mat. pressure reg.
Zerstäuberluft
Atomizing air
Pistole
Gun
HS-Erzeuger
HV-Generator
Service
B_03316
28 29
31
26
35
32
22
16
37
23 2 49 46 47
OPERATING MANUAL
EDITION 04/2012 PART NO. DOC2321362
Pos K Qty Part No. Description
43 3 9992743 Screw-in screw connection, straight
44 1 9998157 Loctite 480
45 2 9998253 Screw in angle
46 1 9998614 Straight bulkhead plug-in connection
47 2 9998615 Straight bulkhead plug-in connection
48 3 9998677 Pressure gauge 0-1 MPa; 0-10 bar; 0-145 psi (d40)
49 2 9998769 Straight bulkhead plug-in connection
50 1 9999208 Angle screwing in connection
51 1 9999224 Pressure regulator
52 2 9999433 Pressure regulator
53 1 9999434 Multi-plug connection T
54 1 9999439 Angular plug connection
A = 2 cables shortened to to 150 mm; 5.91 inches
B = Remove absorber!
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