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WAGNER AquaCoat AirCoat GM 5000EACW Operating manual - Contents

Manual is about: AquaCoat AirCoat-Spray system for noncombustible spray media AquaCoat AirCoat - EvoMotion 20-30S - Wildcat 18-40 - Puma 28-40 - Cobra 40-10

Summary of AquaCoat AirCoat GM 5000EACW

  • Page 1

    Aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 zerstäuberluft atomizing a ir mat. Druckregler mat. 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 non- combustible spray med...

  • Page 3: Contents

    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 pers...

  • Page 4: Contents

    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 rule...

  • Page 5: Contents

    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....

  • 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 œ !Lwaysfollowtheseinstructionswhenoperatin...

  • 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 œkeep these operating instructions to hand near the unit at all t...

  • 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: œ never point the spray gun a...

  • 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 œ $eenergizetheunitelectrically œ $isconnectthepneumaticsupplyline œ 2elievethepressurefromtheunit œ %nsuretha...

  • 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 ...

  • 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...

  • 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 pr...

  • 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 therefor...

  • 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 th...

  • 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“ barre...

  • Page 16

    16 aquacoat gm 5000eacw operating manual edition 04/2012 part no. Doc2321362 table “a” - pump no. Type 1 no 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 l...

  • 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 0 1 b_03361 c ba operating manual edition 04/2012 part no. Doc2321362 weight (without paint container and pump) 70 kg; 154 lb working temperature ra...

  • 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 0 1 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 /...

  • 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:...

  • 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 4hisoperatingmanualisavailableinthefoll...

  • Page 21

    21 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. Pressu re reg. Pumpe pump 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 functiona...

  • 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 con...

  • Page 23

    23 aquacoat gm 5000eacw 6 j2 j3 3 2 4 1 5 4 3 2 1 3 2 4 1 3 2 1 4 3 1 6 2 5 l n pe b_03513 4 5 6 7 8 p1 operating manual edition 04/2012 part no. Doc2321362 electrical block diagram aquacoat ear thing d o or swit ch c oil - c oil + d o or swit ch c o ntr ol unit vm 5000w ear th ear th monit oring p ...

  • 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 0 1 b_03364 21 17 15 22 12 24 25 3 5 20 10 9 11 6 1 16 18 13 14 19 23 2 4 7 8 26 27 operating manual edition 04/2012 part no. Doc2321362 4....

  • 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 ...

  • 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. ● ...

  • 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. ...

  • 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...

  • 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...

  • 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 si...

  • 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 prod...

  • 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 nel...

  • Page 33: Warning

    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, r...

  • Page 34: Caution

    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 œ flush the spray gun and paint supply with a suitable cleaning agent. Sihi_0001...

  • Page 35: Warning

    35 aquacoat gm 5000eacw b_03525 r max. Ω 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 operating manual edition 04/2012 part no. Doc2321362 perfect earthing of all system components (workpieces, conveyor, paint sup...

  • 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...

  • 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 2...

  • Page 38

    38 aquacoat gm 5000eacw operating manual edition 04/2012 part no. Doc2321362.

  • Page 39: Danger

    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 mal...

  • Page 40: Caution

    40 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. Pressu re reg. Pumpe pump 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 prepara...

  • Page 41: Caution

    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. S...

  • Page 42

    42 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 80 60 40 20 10 r3 r2 r1 zerstäuberluft atomizing air mat. Druckregler mat. Pressure reg . Pumpe pump power 0 1 μa kv 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 spray...

  • Page 43: Caution

    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 zerstäuberluft atomizing air mat. Druckregler mat. Pressu re reg. Pumpe pump power 0 1 μa kv operating manual edition 04/2012 part no. Doc2321362 start-up for sprayi...

  • 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 0 1 21 15 22 1 10 9 11 3 b_03371 aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 zerstäuberluft atomizing air mat. Druckregler mat. ...

  • Page 45

    45 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. T...

  • 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 tr...

  • 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 ha...

  • 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)...

  • Page 49: Caution

    49 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. ...

  • Page 50

    50 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...

  • Page 51

    51 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03372 b_03373 aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03374 operating manual edition 04/2012 part no. Doc2321362 5.4.10 start-up the control unit vm 5000w 1. Turn switch ...

  • Page 52

    52 aquacoat gm 5000eacw 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 availabl...

  • Page 53

    53 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03375 7 8 aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03376 7 8 27 operating manual edition 04/2012 part no. Doc2321362 5.4.12 setting the high voltage works procedure: 1. Pr...

  • Page 54

    54 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03377 5 6 aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03378 22 2 27 operating manual edition 04/2012 part no. Doc2321362 5.4.13 setting the current limiting works procedure: ...

  • Page 55

    55 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03379 aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03380 operating manual edition 04/2012 part no. Doc2321362 5.4.14 spray display spray using recipe r2: high voltage is creat...

  • Page 56

    56 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03381 3 4 aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03379 operating manual edition 04/2012 part no. Doc2321362 5.4.15 standby mode press pushbutton (3) to return from this ...

  • Page 57

    57 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03382 25 26 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 o...

  • Page 58

    58 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03383 27 25 26 2 5 19 20 aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03384 2 5 6 17 18 25 26 27 22 operating manual edition 04/2012 part no. Doc2321362 5.4.17 maintenance dis...

  • Page 59

    59 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03385 25 26 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...

  • Page 60

    60 aquacoat gm 5000eacw 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; yo...

  • Page 61

    61 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03381 3 4 aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03507 2 25 27 aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03508 27 6 8 4 operating manual e...

  • Page 62

    62 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03508 27 6 8 4 aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03509 27 5 7 25 3 operating manual edition 04/2012 part no. Doc2321362 for ease of operation the confi guration set...

  • Page 63

    63 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03510 27 2 26 25 aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03511 3 operating manual edition 04/2012 part no. Doc2321362 the fl ashing led display “ maintenance” (26) indica...

  • Page 64: Caution

    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 age...

  • Page 65: Caution

    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...

  • Page 66: Warning

    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 œ repairs and part replacement may only be carried out by specially trained staff or a wagner ser...

  • 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 pres...

  • 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 0 1 b_03506 24 27 operating manual edition 04/2012 part no. Doc2321362 7.2 error displays at the control unit vm 5000w functional fault cau...

  • Page 69

    69 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 power 0 1 power b_03505 24 27 25 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 vo...

  • Page 70: Warning

    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 œ only a wagner service center or a suitably trained person may carry out repairs and replace parts. œ only repair and rep...

  • 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 need- le 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 ...

  • Page 74: Attention

    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 ...

  • Page 75

    75 aquacoat gm 5000eacw 1 2 b_03559 sw14 3 nm sw9 1 nm sw8 sw5 to rx 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! Ensur e the c o rr ec t inser tion position! Mounting materials: pos part no. Descrip...

  • 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 ...

  • 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 ein...

  • Page 79

    79 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 80 60 40 20 10 r3 r2 r1 zerstäuberluft atomizing air mat. Druckre gler mat. Pressure reg. Pumpe pump power 0 1 μa kv 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 disassemblin...

  • 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...

  • Page 81

    81 aquacoat gm 5000eacw aquacoat 100 80 60 40 20 80 60 40 20 10 r3 r2 r1 zerstäuberluft atomizing air mat. Druckregler mat. Press ure reg. Pumpe pump power 0 1 μa kv b_03550 1 2 3 2 operating manual edition 04/2012 part no. Doc2321362 8.6 disassembling control unit vm 5000w 1. Switch off the control...

  • 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 aquacoa...

  • 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 an...

  • 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...

  • Page 85: Note

    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 house- hold refuse! In accordance with european directive 2002/96/ec on the disposal of waste electrical equipment and its implemen...

  • 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 13273...

  • 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....

  • 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...

  • 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 ass...

  • 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...

  • 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 23264...

  • Page 92

    92 aquacoat gm 5000eacw operating manual edition 04/2012 part no. Doc2321362.

  • Page 93: Warning

    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 œ repairs and part replacement may only be carried out by specially trained staff o...

  • 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 ...

  • Page 95

    95 aquacoat gm 5000eacw b e aquacoat 100 80 60 40 20 μa 80 60 40 20 10 kv r3 r2 r1 zerstäuberluft atomizing air mat. Druckregler mat. Press ure reg. Pumpe pump power 0 1 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 2...

  • 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. ...

  • 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 ◆ = wear...

  • Page 98

    98 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 c...

  • 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. 1a t 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 ma...

  • Page 101

    101 aquacoat gm 5000eacw operating manual edition 04/2012 part no. Doc2321362.

  • Page 102

    102 aquacoat gm 5000eacw 17 5 3 6 7 8 10 9 11 12 13 16 14 15 4 2 18 1 b_03548 20 operating manual edition 04/2012 part no. Doc2321362 12.4 spare parts list gm 5000eacw.

  • Page 103

    103 aquacoat gm 5000eacw operating manual edition 04/2012 part no. Doc2321362 spare parts list gm 5000eacw pos k qty part no. Description 1 1 2309873 gm 5000eacw 2 1 2313630 plug eacw 3 1 - end-piece gm 500eacw assy. See details in chapter 12.4.1 4 2314361 hook 5 - gm 5000eac handle complete, see de...

  • Page 104

    104 aquacoat gm 5000eacw 2 1 11 9 8 7 3 4 5 12 13 14 123 ±0.1 15 10 16 6 b_03549 operating manual edition 04/2012 part no. Doc2321362 12.4.1 spare parts list end-piece gm 5000eacw ensure the correct insertion position!.

  • Page 105

    105 aquacoat gm 5000eacw operating manual edition 04/2012 part no. Doc2321362 spare parts list end-piece gm 5000eacw pos k menge bestell-nr. Benennung 1 1 - gm 5000eacw end piece complete 2 1 2313314 ac air manifold ring 3 ◆ 1 2307180 o-ring, sheathed 4 ◆ 1 2312175 valve housing ac assy. 5 ◆ 1 23121...

  • Page 106

    106 aquacoat gm 5000eacw 20 16 17 18 19 15 25 26 14 24 13 7 1 b_03165 8 9 10 12 5 6 3 2 4 23 11 operating manual edition 04/2012 part no. Doc2321362 12.4.2 spare parts list gm 5000eac - handle.

  • Page 107

    107 aquacoat gm 5000eacw operating manual edition 04/2012 part no. Doc2321362 spare parts list handle gm 5000eac pos k qty part no. Description 1 1 - gm 5000eac handle compl. 2 1 2307288 nipple 3 ◆ ★ 1 9971025 o-ring 4 1 2315344 hose holder 5 1 2312182 plug complete 6 1 2314270 handle complete 7 ◆ ★...

  • Page 108

    108 aquacoat gm 5000eacw b_03554 3 1 4 5 2 operating manual edition 04/2012 part no. Doc2321362 12.5 spare parts lists accessories 12.5.1 spare parts list flat jet nozzles flat jet nozzles spare parts list pos k qty part no. Description 1 1 2315775 union nut ac assy. 2 1 2309901 air cap lv eacw (red...

  • Page 109

    109 aquacoat gm 5000eacw b_03555 2 3 1 4 5 9 10 11 12 operating manual edition 04/2012 part no. Doc2321362 12.5.2 spare parts list round jet nozzle cap acr5000 spare parts list round jet nozzle cap eacw pos k qty part no. Description 1 1 2309902 round jet nozzle cap acwr 5000 2 1 2307220 nozzle nut ...

  • Page 110

    110 aquacoat gm 5000eacw operating manual edition 04/2012 part no. Doc2321362 germany j. Wagner gmbh otto-lilienthal-str. 18 postfach 1120 d- 88677 markdorf telephone: +49 7544 5050 telefax: +49 7544 505200 e-mail: service.Standard@wagner-group.Com switzerland j. Wagner ag industriestrasse 22 postfa...

  • Page 112: Cert

    Cert if ie d /rdernumber 'ermany *7!'.%2'mb( /tto,ilienthal3tr 0ostfach $-arkdorf 4elephone 4elefax %-ailservicestandard wagnergroupcom 3witzerland *7!'.%2!' )ndustriestrasse 0ostfach #(!LtstËtten 4elephone 4elefax %-ailrepch wagnergroupch www wagner group com 2321362.