WAGNER AquaCoat AirCoat GM 5000EACW Operating Manual
AquaCoat
10
0
8
0
60
40
2
0
μ
A
80
60
4
0
20
10
kV
R3
R
2
R1
Z
erstä
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Atomizing a
ir
Mat.
Druc
kregler
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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
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
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
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
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.
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
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.
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
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
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:
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.
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
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.
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
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
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:
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
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.
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 --
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
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.
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
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”
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.
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.
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).
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.
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).
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
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