Preview only show first 10 pages with watermark. For full document please download

Aquacoat Air Spraying System For Non

Rating
Date

September 2018
Size

6.8MB
Views

8,586
Categories

Home Do-It-Yourself tools Power tools Paint Sprayer

Transcript

Translation of the original Operating manual Edition 04/2012 AquaCoat air spraying system for non-combustible liquids 80 Zerstäuberluft Atomizing air R1 Mat. Druckregler Mat. pressure reg. 100 60 80 40 Pumpe Pump 60 R2 20 40 10 20 R3 kV μA 0 POWER 1 1 AquaCoa AquaCoat t B_03360 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Contents 1 1.1 1.2 ABOUT THESE INSTRUCTIONS Languages Warnings, notes and symbols in these instructions 6 6 6 2 2.1 2.1.1 2.1.2 2.1.3 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.3 2.4 GENERAL SAFETY INSTRUCTIONS Safety instructions for the operator Electrical equipment Personnel qualifications A safe work environment Safety instructions for staff Safe handling of WAGNER spray units Earth the unit Material hoses Cleaning Handling hazardous liquids, varnishes and paints Touching hot surfaces Correct use Safety-relevant information about discharges 7 7 7 7 7 7 8 8 8 9 9 9 9 9 3 3.1 3.2 3.3 3.4 GUARANTEE AND CONFORMITY DECLARATIONS Important notes on product liability Guarantee claim CE-Conformity German regulations and guidelines 10 10 10 11 12 4 4.1 4.1.1 4.2 4.2.1 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.4 4.4.1 4.4.1.1 4.4.1.2 4.4.1.2.1 4.4.1.2.2 4.4.1.2.3 DESCRIPTION Fields of application, using in accordance with the instructions Processable materials Scope of delivery Spraypack configuration Technical data Control unit VM 5000W Spray gun GM 5000EAW Pneumatic piston pump EvoMotion 5-60S Double diaphragm pump ZIP52 Material pressure tank LDG20 Functional description Design of unit and function Control unit VM 5000W Spray gun GM 5000EAW Air atomizing spray process-round jet Air atomizing spray process - flat jet The electrostatic effect 13 13 13 14 15 17 18 19 20 20 20 21 21 24 28 30 31 32 5 5.1 5.1.1 5.1.2 5.1.3 5.1.4 START-UP AND OPERATION Installation and connection Ventilation of the spray booth Air supply Paint supplies Earthing 33 33 33 34 34 35 3 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Contents 5.1.5 5.1.5.1 5.1.5.2 5.2 5.2.1 5.3 5.3.1 5.3.2 5.3.2.1 5.3.2.2 5.3.2.3 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8 5.4.9 5.4.10 5.4.11 5.4.12 5.4.13 5.5 5.5.1 5.5.2 5.5.3 Safety checks Earthing check Inspection of the safety elements Preparation of water-based paints Viscosity conversion table Starting operation General rules for making adjustments to the spray gun Preparation for starting up Spraypack with pressure tank Spray pack with double diaphragm pump Spray pack with pneumatic pump EvoMotion Working Preparation for spraying with flat-jet nozzle Start-up for spraying Changing from Air-round jet to Air-flat jet Cleaning of the nozzle parts Start-up the control unit VM 5000W Set and save recipes Setting the high voltage Setting the current limiting Spray display Standby Mode Operating hours counter/warning display Maintenance display setup „Conduct service“ display Device configuration Overview of parameters Access to the device configuration mode Setting example „Parameter C13“ 36 36 36 37 37 39 39 40 40 42 44 46 46 47 48 49 49 50 51 52 53 54 55 56 57 58 58 59 60 6 6.1 MAINTENANCE Finishing work and cleaning 62 63 7 7.1 7.2 TROUBLE SHOOTING AND SOLUTION Faults in the system Error displays at the control unit VM 5000W 64 64 66 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 REPAIR WORK Dismantling of the spray gun Cleaning the parts after disassembly Assembling the spray gun Replacing the spray gun including hose set Change material hose and/or air hose Disassembling control unit VM 5000W Opening the control unit 68 69 72 73 77 78 79 80 9 9.1 FUNCTIONAL CHECK AFTER ASSEMBLY AquaCoat Complete device 81 81 10 PRODUCT DISPOSAL 83 4 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Contents 11 11.1 11.1.1 11.1.2 11.1.3 11.2 11.2.1 11.2.2 11.2.3 11.3 11.4 11.5 ACCESSORIES Round jet nozzles EAR air caps EAR nozzles Output measured with paint Flat jet nozzles EAF air caps EAF flat jet nozzles Output measured with paint Special tools Hose sets and components Miscellaneous 12 12.1 12.2 12.2.1 12.2.2 12.3 12.4 12.4.1 12.4.2 SPARE PARTS How to order spare parts? Spare parts list AquaCoat Basic unit Additional list of spare parts for variants with PP pump or Cobra Additional list of spare parts for variants with ZIP or EvoMotion pumps Spare parts list VM 5000W Spare parts list GM 5000EAW Spare parts list End-piece GM 5000EAW Spare parts list GM 5000EA - Handle 84 84 84 84 85 86 86 86 87 88 88 89 91 91 92 95 96 98 101 103 105 5 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 1 ABOUT THESE INSTRUCTIONS 4HISOPERATINGMANUALCONTAINSINFORMATIONABOUTTHEOPERATION REPAIRANDMAINTENANCE OFTHEUNIT !LWAYSFOLLOWTHESEINSTRUCTIONSWHENOPERATINGTHEUNIT 4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL %LECTROSTATICSPRAYGUNSMAYBEOPERATEDONLYBYTRAINEDPERSONNEL #OMPLIANCEWITHTHESEINSTRUCTIONSCONSTITUTESANINTEGRALCOMPONENTOFTHEGUARANTEE AGREEMENT 1.1 LANGUAGES 4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES ,ANGUAGE 0ART.O ,ANGUAGE 'ERMAN 2310482 %NGLISH &RENCH 2324125 $UTCH )TALIAN 2324126 3PANISH $ANISH -3WEDISH 1.2 0ART.O 2321361 -2324127 -- WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS Warning instructions in this manual point out particular dangers to users and equipment and state measures for avoiding the hazard. These warning instructions fall into the following categories: Danger - imminent danger. Non-observance will result in death, serious injury and serious material damage. DANGER This line warns of the hazard! Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level. SIHI_0100_GB Warning - possible danger. Non-observance can result in death, serious injury and serious material damage. WARNING This line warns of the hazard! Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level. SIHI_0103_GB Caution - a possibly hazardous situation. Non-observance can result in minor injury. The measures for preventing the hazard and its consequences. CAUTION This line warns of the hazard! Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level. SIHI_0101_GB Caution - a possibly hazardous situation. Non-observance can cause material damage. The measures for preventing the hazard and its consequences. The measures for preventing the hazard and its consequences. 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. Note - provide information on particular characteristics and how to proceed. 6 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 2 GENERAL SAFETY INSTRUCTIONS 2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR Keep these operating instructions to hand near the unit at all times. Always follow local regulations concerning occupational safety and accident prevention. 2.1.1 ELECTRICAL EQUIPMENT Electrical plant and unit 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. 2.1.2 PERSONNEL QUALIFICATIONS %NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS 2.1.3 A SAFE WORK ENVIRONMENT 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. 7 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or cleaning agents: Never point the spray gun at people. Never reach into the spray jet. 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. 2.2.2 EARTH THE UNIT 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. 2.2.3 MATERIAL HOSES 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. 8 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 2.2.4 CLEANING $E ENERGIZETHEUNITELECTRICALLY $ISCONNECTTHEPNEUMATICSUPPLYLINE 2ELIEVETHEPRESSUREFROMTHEUNIT %NSURETHATONLYNON COMBUSTIBLEDETERGENTSAREUSED 4O CLEAN USE ONLY CLOTHS AND BRUSHES .EVER USE HARD OBJECTS OR SPRAY ON CLEANING AGENTSAGUN 2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS When preparing or working with paint and when cleaning the unit, follow the working instructions of the manufacturer of the paints, solvents and cleaning agents being used. 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. 2.2.6 TOUCHING HOT SURFACES ➞ 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 2.3 CORRECT USE 7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE 5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2 /PERATETHEUNITONLYASANENTIREUNIT $ONOTDEACTIVATESAFETYEQUIPMENT 5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES 2.4 SAFETY-RELEVANT INFORMATION ABOUT DISCHARGES 4HE PLASTIC PARTS OF THE CABINET ARE CHARGED ELECTROSTATICALLY BY THE HIGH VOLTAGE lELD (ARMLESSDISCHARGESBRUSHDISCHARGES AREPOSSIBLEAFTERCONTACTWITHPLASTICPARTS4HEY ARECOMPLETELYHARMLESSFORPEOPLE 9 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 3 GUARANTEE AND CONFORMITY DECLARATIONS 3.1 IMPORTANT NOTES ON PRODUCT LIABILITY 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. 3.2 GUARANTEE CLAIM 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 10 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 3.3 CE-CONFORMITY Herewith we declare that the supplied version of: AquaCoat Airspray GM 5000EAW Complies with the following guidelines: 2006/42/EG 2006/95/EG 2004/108/EG 2002/95/EG 2002/96/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 specifications, in particular: BGR 500 Part 2 chap. 2.29 BGR 500 Part 2 chap. 2.36 BGI 740 BGI 764 Identification mark: CE Certificate of Conformity The certiﬁcate is enclosed with this product. The certiﬁcate of conformity can be reordered from your WAGNER representative, quoting the product and serial number. Part number: 2314228 11 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 3.4 GERMAN REGULATIONS AND GUIDELINES a) b) c) d) e) f) BGV A3 BGR 500 BGR 500 BGR 104 TRBS 2153 BGR 180 g) h) j) j) ZH 1/406 BGI 740 BGI 764 Betr.Sich.V. Electrical units and equipment Part 2, Chap. 2.36 Working with liquid ejection devices Part 2, Chap. 2.29 Using coating materials Explosion protection rules Avoiding ignition risks Setting up for cleaning with solvents for cleaning workpieces with solvents Guidelines for liquid ejection devices Painting rooms and equipment Electrostatic coating Plant Safety Ordinance Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they are to be found in the Internet. 12 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 4 DESCRIPTION 4.1 FIELDS OF APPLICATION, USING IN ACCORDANCE WITH THE INSTRUCTIONS AquaCoat Spray Packs are equipped ready-for-use with the VM 5000W control unit, a GM 5000EAW air spray gun and matching hose set, a high voltage generator, all safety devices and spray material supply, and are therefore suitable for air atomizing applications. 4.1.1 PROCESSABLE MATERIALS Water-dilutable paints such as are in principle divided into 3 groups: Green Non-flammable (non-combustible) paints Yellow Paints with low flammability Red Flammable paints Only non-flammable (non-combustible) liquid spray materials (green group) can be processed with the present spray system. The specific 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 nonflammable: Gew. % H2O > 1.70 x Gew. % LM + 0.96 x Gew. % ORG Where: Gew. % H2O LM ORG Weight percent Water Liquid organic phase (solvent mainly consisting of higher ethylene glycol esters) Solid organic phase (solids mainly consisting of binding agents and pigments) Such paints behave like water in respect of flammability in liquid form (liquid phase) and in sprayed form. Cleaners and thinners must also be non-flammable. 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. 13 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 4.2 SCOPE OF DELIVERY AquaCoat-Airspray Spray Packs can be assembled according to requirement and the desired accessories with the help of the Spray Pack configuration. All devices are assembled ready-for-use in the factory on the basis of the resulting configuration number. The scope of delivery of each system includes: Part No. Description AquaCoat Spraypack consisting of: - AquaCoat cabinet - Spray gun GM 5000EAW - Control unit VM 5000W - Pump or pressure tank and - Accessories 2310482 see chapter 1 Operating manual German Operating manual in the local language Operating manual Pump or pressure tank, german Operating manual pump or pressure tank in the local language see chapter 3.3 CE explanation AquaCoat The delivery note shows the exact scope of delivery. 14 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 4.2.1 SPRAYPACK CONFIGURATION In order to order the high-rotating atomizer please use the model identification 2327676 ABCDEFGHI in connection with the tables listed below. Tables -> A B C D E F G H I Examples -> - 1 3 1 1 4 2 1 2 2 Configuration no. - 7 2 1 1 1 1 1 1 1 Model identification Pump/ pressure tank Table “A“ Nozzle system Table “B“ Agitator Table “C“ Level monitoring Table “D“ Hose length Table “E“ Feed tank Table “F“ Barrel cover Table “G“ Under frame Table “H“ Hose holder Table “I“ 15 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL Table “A” - Pump No. Type Table “B” - Level monitoring No. Description 1 No pump 1 no 2 Doppelmembranpumpe ZIP52 2 yes 3 Pumpe EvoMotion 5-60S Table “C” - Barrel cover/ Agitator No. Type Table “D” - Feed tank No. Description 1 no 1 no 2 Barrel cover Ø 350 mm; Ø 13.8 inch 2 yes 3 Barrel cover Ø 350 mm; Ø 13.8 inch with Agitator Table “E” - Under frame No. Description Table “F” - Hose holder No. Description 1 no 1 no 2 yes 2 yes Table “G” - Hose 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 “H” - Nozzle system No. Description 1 Flat jet incl. Nozzle 0.4 2 Flat jet incl. Nozzle 0.6 3 Flat jet incl. Nozzle 0.8 4 Flat jet incl. Nozzle 1.0 5 Flat jet incl. Nozzle 1.2 6 Flat jet incl. Nozzle 1.4 7 Flat jet incl. Nozzle 1.6 8 Flat jet incl. Nozzle 1.8 9 Flat jet incl. Nozzle 2.0 10 Jet rond (D8) 11 Jet rond (D12) Table “I” - Air cap No. Type 1 Flat jet small 2 Flat jet large 3 Jet rond 16 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 4.3 TECHNICAL DATA Weight (without paint container and pump) Working temperature range Maxi. material temperature Sound pressure level 70 kg; 154 lb 5 °C - 40 °C; 41 °F - 104 °F 50 °C; 122 °F 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. Measurements: 80 R1 60 40 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R2 R3 20 100 80 60 40 10 20 kV μA POWER 1 A 0 mm inch A 1390 54.72 B 616 24.25 C 1000 39.37 B C B_03361 17 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 4.3.1 CONTROL UNIT VM 5000W Input voltage 115 V AC/ 230 V AC / 50 Hz/ 60 Hz Input power max. 40 W Output voltage max. 20 Vpp Output current max. 1.0 A AC High voltage limit 70 kV DC Spraying current limit 100 µA DC Polarity for negative high voltage generator Weight (without cables) 6.2 kg; 13.67 lb Working temperature range 5 - 40 °C; 41 - 104 °F Measurements: 80 R1 A Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R2 R3 60 100 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B inch 136 5.35 B 370 14.57 C 220 8.66 D 252 9.92 D C mm A B_03362 18 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 4.3.2 SPRAY GUN GM 5000EAW Maxi. air pressure 0.8 MPa; 8 bar; 116 psi Max. material pressure 0.8 MPa; 8 bar; 116 psi Material connection G 1/4“ A Air connection G 1/4“ A Weight (without hose set) Working temperature range 580 g; 1.28 lb 5 °C to 40 °C; 41 °F to 104 °F Maxi. material temperature 50 °C; 122 °F Material flow volume According to nozzle sizes (See nozzle list on accessories) Sound level at 0.3 MPa; 3 bar; 43.5 psi air pressure 78 dB (A) * and 0.3 MPa; 3 bar; 43.5 psi material pressure * A rated sound pressure level measured at 1 m distance according to DIN EN 14462: 2005. Measurements: A A C B mm inch 261 10.28 B 46 1.81 C 264 10.39 B_03519 19 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 4.3.3 PNEUMATIC PISTON PUMP EVOMOTION 5-60S 4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES ,ANGUAGE 0ART.O ,ANGUAGE 'ERMAN 2312675 %NGLISH &RENCH 2312677 $UTCH )TALIAN 2312679 3PANISH $ANISH -3WEDISH 0ORTUGUESE 2322146 4URKISH 0ART.O 2312676 2312678 2312680 --C_00154 4.3.4 DOUBLE DIAPHRAGM PUMP ZIP52 4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES ,ANGUAGE 0ART.O ,ANGUAGE 'ERMAN ZZ170 %NGLISH &RENCH ZZ170 $UTCH )TALIAN ZZ170 3PANISH 4.3.5 0ART.O ZZ170 --- MATERIAL PRESSURE TANK LDG20 See separate operating manuals 20 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 4.4 FUNCTIONAL DESCRIPTION 4.4.1 DESIGN OF UNIT AND FUNCTION 8 10 9 3 24 14 4 80 Zerstäuberlu Atomizing ft air R1 Mat. Druckregler Mat. pressure reg. 60 40 Pumpe Pump R2 20 10 R3 5 kV 100 80 60 40 20 μA 0 11 19 7 18 POWER 1 AquaCoat 1 21 20 25 16 6 12 26 15 22 13 23 17 B_03363 2 Item Description 1 Cabinet AquaCoat assy. 2 Front panel with 2 handles 3 Control unit VM 5000W 4 Spray gun GM 5000EAW 5 Hose set EAW 6 Material hose (Filter discharge combination for spray gun) 7 High voltage generator (High voltage cascade) 8 Air inlet complete with ball valve 9 Inlet for mains cable 21 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL Item Description 10 Earthing cable 11 Material pressure generator such as pneumatic pump or double diaphragm pump 12 Suction system, compl.. 13 Paint reservoir or material pressure tank 14 Earthing switch (Cylinder AquaCoat) 15 Earthing band 16 Filter-relief combination 17 Door switch 18 Material hose (Pump to the material pressure regulator) 19 Leakage resistance 3GOhm 20 Air hose (material pressure regulator) 21 Air hose (material pressure generator) 22 High voltage cable 23 Base frame assy. (available, however, as additional extra) 24 Hose holder assy. (available, however, as additional extra) 25 Material pressure regulator 26 Return tube The AquaCoat spray system is designed for processing non-combustible liquids in accordance with the air spraying method. The spray product is regulated via the trigger guard on the spray gun (4) and by the VM 5000W control unit (3), pressurized in the pressure tank or 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 atomizing air. The pressure tank or 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 leakage resistance (19). 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. 0OWER S "? 22 J3 P1 Earth Dat dls Dat sw Earth monitoring J2 Coil + Door switch Coil - Door switch Control unit VM 5000W L N PE Spray gun white whitw Door switch blue black Coil - Coil + yellow/green Casting compound AquaCoat resistor Casting compound Cascade AquaCoat B_03513 Pneumatic cylinder Part No. DOC2321361 Earthing 6 5 4 3 2 1 4 3 2 1 4 3 2 1 Power supply Shield 6 5 green 4 brown 3 white 2 1 6 5 yellow 4 3 2 green 1 brown 7 8 white yellow/green Earthing switch AquaCoat EDITION 04/2012 AquaCoat GM 5000EAW OPERATING MANUAL Electrical block diagram AquaCoat 23 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 4.4.1.1 CONTROL UNIT VM 5000W The assembled spray system can be operated and regulated with the VM 5000W control unit. Operating elements on the front: 12 13 14 18 15 23 16 17 21 22 24 80 R1 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R2 R3 25 27 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03364 11 10 9 20 19 8 7 6 5 43 2 1 26 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 configuration mode. 3 Push button “Standby“ to switch to stand-by mode. 4 “Standby” indicator 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” 24 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 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 or the material pressure in the pressure tank. ● 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 or the material pressure in the pressure tank. ● 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. 25 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 21 Illuminated display “High voltage” ● lights up green ● Display range: 0 - 70 kV ● Single display: Preset value of high voltage ● Bar display: Set voltage. 22 Illuminated display “Spraying current” ● lights up green ● Display range: 0 - 100 µA ● Single display: Spraying current limit. ● Bar display: Actual spraying current. 23 Illuminated display „Door control“ ● Lights up green, 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. ● Information about the parameter setting. 26 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Connections on the rear side: 28 29 30 31 32 33 Pumpe Pump Prim. 1AT Netzeingang Main power Pistole Gun HS-Erzeuge r HV-Generato r 34 35 36 Mat. Druckregler Mat. pressure reg. Zerstäuberlu ft Atomizing air Service Spannung: max. 18Vpp Voltage: Strom: max. 1,0A Current: J. WAGNER AG CH - 9450 Altstätten Made in Switzerlan d Typ / Type: Artikel Nr.: Article No.: Erdungs-Zylinder Grounding cylind er VM 5000W 2311001 Serie Nr.: Serial No.: Spannung: 85-264 VAC Voltage: / 47-440 Hz Eingangsleistung: Line Power: max. 40W Schutzklasse: Protection Class: IP 54 Norm: Standard: EN 50059 Lufteingang Air inlet B_03365 38 37 28 Mains power input Connection for mains cable with securing 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). 27 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 4.4.1.2 SPRAY GUN GM 5000EAW 9 1 8 23 2 3 4 16 15 22 7 11 5 10 17 19 14 6 18 20 12 B _03366 6 21 Item Description Item Description 1 Suspension hook 11 Adjusting screw material valve (Stop) 2 Display (spray current and recipe) 12 Trigger 3 Display standby and fault 14 EAR nozzle (Accessory chapter 11.1) 4 Operating button (standby and recipe change) 15 Lock plug 16 Air adjustment 5 Air cap EAF (Accessory chapter 11.2.1) 17 Electrical cable connection 6 Union nut 18 Connection atomizing air 7 EAF flat jet nozzle x.x (Accessory chapter 11.2) 19 Material connection 8 Gun barrel 20 EAR air cap (Accessory chapter 11.1.1) 9 Cover 21 Protective hose 10 Handle 22 Type plate left 23 Type plate right Note: The type of gun (T) and the series number (S) are visible after removing the cover plate. S B_03558 28 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Functions of the spray gun If the gun is connected to the control unit and the control unit is switched on, the preset recipe (R1, R2 or R3) is shown on the display (2) of the gun: Recipe 1 -> ●❍❍❍❍ R1 Recipe 2 -> ●●●❍❍ R2 2 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. R2 R1 R3 3 4 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. B_03182 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 1 2 3 4 ● 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) briefly: High-voltage is switched off. The standby display (3) illuminates. R1 R2 R3 16 ● 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 flat-jet method). 29 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 4.4.1.2.1 AIR ATOMIZING SPRAY PROCESS-ROUND JET In this process, the material (paint) is fed to the nozzle with low pressure approx. 0.05-0.2 MPa; 0.5-2 bar; 7.25-29 psi. The atomizing air at approx. 0.25-0.4 MPa; 2.5-4 bar; 36-58 psi produces a soft jet, which largely eliminates the problem of overlapping boundaries. There are various nozzles and air caps available as accessories for the respective spraying material and the output amounts. Union nut Spray pattern Atomizing air Spray material B_03446 Advantages: low coating thickness uniform coating thickness ● perfect finish ● ● 30 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 4.4.1.2.2 AIR ATOMIZING SPRAY PROCESS - FLAT JET In this process, the material (paint) is fed to the nozzle with low pressure 0.05-0.2 MPa; 0.5-2 bar; 7-29 psi. The atomizing air at approx. 0.25-0.4 MPa; 2.5-4 bar; 36-58 psi produces a soft jet, which largely eliminates the problem of overlapping boundaries. The spray jet can be changed using the shaping air. There are various nozzles and air caps available as accessories for the respective spraying material and the output amounts. Air cap Spray pattern Shaping air Spray material Spray angle Atomizing air B_00180 Advantages: large range of adjustment of the jet spray low coating thickness uniform coating thickness ● perfect finish ● ● ● 31 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 4.4.1.2.3 THE ELECTROSTATIC EFFECT After being electrically charged in the system and atomized by the spray gun, the paint particles are now transported by kinetic and electrostatic energy to the earthed work piece and adhere to the sprayed object, finely distributed over the entire surface. Paint particle Grounded object "? 32 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 5 START-UP AND OPERATION 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 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 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 33 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 5.1.2 AIR SUPPLY 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 finished piece. 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 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_0029_GB CAUTION Electrical discharges! Danger due to electrically charged material lines The conductive sheath of the material hose must not be removed and the connections to the earth potential must not be loosened. 1. Earth connection in the cabinet. 2. Earth connection in the gun. SIHI_0128_GB 34 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.1.4 EARTHING Perfect earthing of all system components (workpieces, conveyor, paint supply system, control unit, spray booth or spraying stand, see illustration) is a prerequisite for optimum coating efficiency 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 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. Earthing schema (example) Conveyor 80 R1 60 40 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R2 R3 20 Workpiece 100 80 60 40 10 20 kV μA 0 POWER 1 Rmax.< 1 MΩ Spraying stand Floor, derivable B_03367 System earth System earth 35 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Minimum cable cross-section AquaCoat cabinet Conveyor Spray booth Spraying stand 5.1.5 4 mm²; AWG11 16 mm²; AWG5 16 mm²; AWG5 16 mm²; AWG5 SAFETY CHECKS 5.1.5.1 EARTHING CHECK Every day: Before starting work, carry out a visual check to ensure that the earthing connection is present in the AquaCoat cabinet and in all relevant components. 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. 36 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.2 PREPARATION OF WATER-BASED PAINTS The viscosity of the paints is of great importance. The best spraying results are obtained with values between 25 and 40 DIN-s (measured in immersion flow cup DIN 4 mm; 0.16 inches). 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 milli Pascal x Sec mPas Centipoise Poise DIN Cup 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 82 4 mm ; 0.16 inch 200 200 2 49 58 220 220 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 3.6 380 380 3.8 400 400 4 80 90 37 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 38 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.3 STARTING OPERATION 5.3.1 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN ➞ Observe general safety instructions in chapter 2. DANGER High voltage field! Danger to life from malfunctioning heart pacemakers Ensure that persons with heart pacemakers: Do not work with the electrostatic spray gun. Remain outside the area of the electrostatic spray gun/workpiece. SIHI_0049_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“. SIHI_0065_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. SIHI_0129_GB Danger zone: 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. A A A A A = 100 mm A = 4 inch B_03368 39 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.3.2 PREPARATION FOR STARTING UP CAUTION Impurities in the spraying system! Spray gun blockage Flush the spray gun and paint supply with a suitable cleaning agent before putting into operation. SIHI_0010_GB 5.3.2.1 SPRAYPACK WITH PRESSURE TANK 10 9 8 4 3 24 80 Zerstäuberlu Atomizing ft air R1 Mat. Druckregler Mat. pressure reg. 60 40 Pumpe Pump R2 20 10 R3 kV 100 80 60 40 20 μA 0 5 14 POWER 1 AquaCoat 19 7 1 20 22 6 25 15 13 23 17 2 B_03369 40 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL The following points must be noted: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Open the outlet valve on the pressure tank (13). Connect HV cable (22) to the pressure tank. Loosen knurled nuts on the pressure tank and remove cover. Fill the pressure tank with a suitable detergent, so that the system can be checked for leaks. Put on the pressure tank cover and tighten all knurled nuts by hand. Set the maximum value on the pressure tank pressure controller. Connect the earth. Connect the AquaCoat system to the compressed air source (8). Set maximum pressure 0.6 MPa; 6 bar; 87 psi on the material pressure control unit. Maintain the pressure for 5 minutes and check all connecting parts for leaks. When the tightness of the system has been ascertained, the spray gun can be unlocked and the system flushed through. Relieve system pressure and secure the spray gun. Open pressure tank (13) and empty detergent or water. Fill the pressure tank with paint, taking care not to exceed the maximum level. Put on the pressure tank cover and tighten all knurled nuts by hand. Connect the AquaCoat system to the electric socket with the electric cable (9). Insert front panel (2). Switch on mains switch on the VM 5000W. The system is ready for use. 41 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.3.2.2 SPRAY PACK WITH DOUBLE DIAPHRAGM PUMP 8 4 10 9 3 24 80 Zerstäuberlu Atomizing ft air R1 Mat. Druckregler Mat. pressure reg. 60 40 Pumpe Pump R2 20 10 R3 kV 14 100 80 60 40 20 μA 5 0 POWER 1 AquaCoat 19 7 18 11 1 21 20 25 16 1 6 12 22 15 26 13 17 2 B_03370 The following points must be noted: 1. Place container (13) with suitable detergent into the AquaCoat cabinet and immerse the suction system, so that the system can be checked for leaks. 2. Connect the earth. 3. Connect the AquaCoat system to the compressed air source (8). Set maximum pressure 0.6 MPa; 6 bar; 87 psi on the material pressure control unit. Maintain the pressure for 5 minutes and check all connecting parts for leaks. 4. When the tightness of the system has been ascertained, the spray gun can be unlocked and the system flushed through. 5. Relieve system pressure and secure the spray gun (4). 6. Remove the detergent. 7. Fill the material container (13) with paint, place in the cabinet and immerse the suction system (12). 8. Clamp high voltage cable (22) to the metal material container (13) or, in the case of a plastic container, to the metal part of the suction system (12). 42 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 9. Connect the AquaCoat system to the electric socket with the electric cable (9). 10. Insert front panel (2). Switch on mains switch on the VM 5000W. 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). SIHI_0130_GB 11. The system is ready for use. 43 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.3.2.3 SPRAY PACK WITH PNEUMATIC PUMP EVOMOTION 8 10 9 3 24 14 4 80 Zerstäuberlu Atomizing ft air R1 Mat. Druckregler Mat. pressure reg. 60 40 Pumpe Pump R2 20 10 R3 5 kV 100 80 60 40 20 μA 0 11 19 7 18 POWER 1 AquaCoat 1 21 20 25 16 6 12 26 15 22 13 23 17 B_03363 2 44 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL The following points must be noted: 1. Place container (13) with suitable detergent into the AquaCoat cabinet and immerse the suction system, so that the system can be checked for leaks. 2. Connect the earth. 3. Connect the AquaCoat system to the compressed air source (8). Set maximum pressure 0.6 MPa; 6 bar; 87 psi on the material pressure control unit. Maintain the pressure for 5 minutes and check all connecting parts for leaks. 4. When the tightness of the system has been ascertained, the spray gun can be unlocked and the system flushed through. 5. Relieve system pressure and secure the spray gun (4). 6. Remove the detergent. 7. Fill the material container (13) with paint, place in the cabinet and immerse the suction system (12). 8. Clamp high voltage cable (22) to the metal material container (13) or, in the case of a plastic container, to the metal part of the suction system (12). 9. Connect the AquaCoat system to the electric socket with the electric cable (9). 10. Insert front panel (2). Switch on mains switch on the VM 5000W. 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). SIHI_0130_GB 11. The system is ready for use. 45 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.4 WORKING 5.4.1 PREPARATION FOR SPRAYING WITH FLAT-JET NOZZLE 15 21 22 80 R1 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R2 R3 60 100 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03371 11 10 80 Zerstäuberluft Atomizing air R1 Mat. Druckregler Mat. pressure reg. 9 3 1 100 60 80 40 Pumpe Pump 60 R2 20 40 10 20 R3 kV μA 0 POWER 1 1 AquaCoat AquaCoat B_03360 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. Switch on the material supply (10) adjust from approx. 0.05-0.15 MPa; 0.5-1.5 bar; 7.25-22 psi. 4. Release the spray gun. 5. 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. Spray on a test object (pull trigger). 8. Regulate pressure of material supply (10) and atomizer air (11) according to nozzle and object. Note: The paint output volume can be changed by: ● Changing the material pressure or ● Fitting another nozzle (see Accessories). 46 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.4.2 START-UP FOR SPRAYING 1. 2. 3. 4. 5. 6. Insert the desired nozzle into the gun. Open the stop valve. Turn on the control unit. Set the material supply to operating pressure PMAT. Spray on a test object (pull trigger). Adjust the spray pressure at the paint pump and/or pressure tank according to the nozzle and object being sprayed. 7. Set air adjustment at the back of the gun to the center position and now open atomizing air and adjust optimally according to the nozzle and object being sprayed. For round-jet method: 8. The atomizing air jet can also be controlled by turning the air adjuster or the adjustment screw on the side of the gun. Note The size of the air cap must match with the nozzle size. For flat-jet method: 8. Change the width of the spray jet by turning the air adjustment back to the spray gun or by appropriate selection of the nozzle. Note A change in the material quantity is achieved by: - Changing the material pressure or - Use a different nozzle size (see Accessories). Completely opened air adjustment Closed air adjustment B_03584 47 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.4.3 CHECK SPRAY PATTERN Start air-spraying (without electrostatics) 1. Start up with material supply set to approx. 0.05 to 0.15 MPa; 0.5 to 1.5 bar; 7 to 22 psi operating pressure. 2. Spray (pull trigger) and check the atomisation. 3. Set the fluid pressure on the material supply to the point where a further increase in fluid pressure would significantly improve fluid atomization. 4. Open air pressure regulator for the atomizer air and adjust so as to achieve optimal atomization. 5. With the air adjustment on the gun, the ratio form adjustement to atomization until the optimum spray pattern is achieved. Note The paint output volume can be changed by: Changing the material pressure or Using a different flat jet nozzle (see chap. 11). Reduction of the material valve stroke. • • • Influence 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 influence of the shaping air regulator on the spraying pattern. Other nozzle sizes can be used to obtain larger or smaller spraying patterns. Completely opened air adjustment Closed air adjustment B_03584 48 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 5.4.4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. CHANGING FROM AIR-ROUND JET TO AIR-FLAT JET Switch off control unit. Relieve spray gun and unit pressure! Replace paint with cleaning solvent. Set material pressure control. Switch off the atomizing air. Flush the gun through thoroughly. Relieve the material pressure on the spray gun and the devise! Unscrew by hand the union nut (1). Remove EAR air cap (2). Unscrew and remove EAR nozzle (3) by hand. Clean the spray gun front page with dampened cloth carefully. Screw in and tighten slightly EAF flat jet nozzle (5) by hand. Put on the EAF air cap (4). Screw the union nut (1) onto the spray gun body. Set the desired flat jet level with the air cap horns (6) and then tighten slightly the union nut by hand. 2 3 1 6 1 4 5 B_03387 49 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.4.5 CLEANING OF THE NOZZLE PARTS The nozzle parts (2, 3, 4, 5 und 6) may only be immersed into a cleaning solvent, recommended by the manufacturer and must be immediately removed again. They may not be put for a long time in cleaning solvent. Clean these parts with a brush and dry them with a cloth or a blow gun. 5.4.6 START-UP THE CONTROL UNIT VM 5000W 80 R1 1. Turn switch to position 1. 2. All LEDs on the control unit illuminate for approx. 1 second. R2 R3 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03372 B_03373 3. The hardware version and the software version are shown on the display alternately in succession. Hardware version 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 recipes “R1”. 80 R1 R2 R3 Software version 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03374 50 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 5.4.7 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 recipess: 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 flashes 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 modified 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. 51 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 5.4.8 SETTING THE HIGH VOLTAGE 100 80 R1 R2 R3 60 80 40 60 20 40 10 20 kV μA Works procedure: 0 POWER 1 1. Press the “High voltage” button (7) to adjust the high voltage. The LED (8) indicates that high voltage is selected. AquaCoat B_03375 87 27 100 80 R1 R2 R3 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 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). AquaCoat B_03376 8 7 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. 52 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 5.4.9 R1 R2 R3 SETTING THE CURRENT LIMITING 80 100 60 80 40 60 20 40 10 20 kV μA Works procedure: 0 POWER 1 1. Press the “Current limiting” button (5) to adjust the limitation of the spray current. The LED (6) indicates that current limiting is selected. AquaCoat B_03377 65 27 100 80 R1 R2 R3 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 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). AquaCoat B_03378 22 2 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 recipes pushbutton (> 2 sec.). 53 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.4.10SPRAY 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. 80 R1 R2 R3 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03379 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. 80 R1 R2 R3 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03380 54 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.4.11STANDBY MODE If you want to spray without high voltage, select standby mode. Briefly press the “Standby” pushbutton (3), LED (4) will illuminate. All other LEDs are extinguished. 80 R1 R2 R3 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03381 43 Press pushbutton (3) to return from this standby mode to the previously saved standby mode (see figure below). Note: This function can be activated and used from the gun. 80 R1 R2 R3 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03379 55 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.4.12OPERATING 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 service hours counter, service 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 R1 Description of display 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 service counter and how to reset this counter. R3 Set service interval in hours activate or lock this function. 26 25 80 R1 R2 R3 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03382 56 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 5.4.13MAINTENANCE DISPLAY SETUP When the device is first 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: 26 25 R1 R2 R3 80 100 60 80 40 60 20 40 10 20 kV μA 27 Works procedure: 0 POWER 1 AquaCoat B_03383 20 19 5 2 1. Briefly press pushbutton R3 (19), LED (20) illuminates. 2. Use the dial (2) to set the service 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) and pushbutton R3 (19) until the LED display (27) starts to flash. Review counter status since last service carried out on gun: 22 26 25 R1 R2 R3 80 100 60 80 40 60 20 40 10 20 kV μA 27 Works procedure: 0 POWER 1 AquaCoat B_03384 18 17 65 2 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). 57 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 5.4.14„CONDUCT SERVICE“ DISPLAY 26 25 80 R1 R2 R3 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03385 Prerequisite: The function “Service interval limit” is activated. “Conduct service on spray gun” Once the time for the defined service interval has expired, the LED display (26) starts to flash. The flashing service display merely acts as a warning. You can continue working without any limitations. 58 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 5.5 DEVICE CONFIGURATION 5.5.1 OVERVIEW OF PARAMETERS Parameter Value off (factory settings) C13 C19 C20 Reset configuration 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. User lock Reset recipes Beschreibung no (factory settings) res no (factory settings) res No reaction All programs are set to delivery status when “res” is saved by the Service key. No reaction All configuration parameters are set to delivery status when “res” is saved by the Service key. 59 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 5.5.2 ACCESS TO THE DEVICE CONFIGURATION MODE R1 R2 R3 Works procedure: 100 80 60 80 40 60 20 40 10 20 kV μA 1. Switch device to “Standby” by pressing the “Standby” key (3). The “Standby” LED (4) lights up yellow. 0 POWER 1 AquaCoat B_03381 43 25 R1 R2 R3 80 100 60 80 40 60 20 40 10 20 kV μA 27 0 POWER 1 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 “configuration” is displayed in the LED display (27). The device is now in configuration mode. AquaCoat B_03507 2 27 R1 R2 R3 80 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03508 8 6 4 4. The first configuration parameter C11 is now displayed in the LED display (27). The two LED displays “Spray current” (6) and “High voltage” (8) flash at the same time. The “Standby” (4) LED display flashes quickly. Note: The parameters C11 and C12 can be changed, but this will not have any effect. 60 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL For ease of operation the configuration settings are divided into three groups. The first 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. 27 Group 1: Parameters C11 to C20 (End users) Group 2: Parameters C21 to C30 (Wagner Service) Group 3: Parametesr C31 to C40 (for production plant, service center) 100 80 R1 R2 R3 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03508 8 5.5.3 6 4 SETTING EXAMPLE „PARAMETER C13“ After getting started in configuration 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). 25 100 80 R1 R2 R3 27 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03509 7 5 3 61 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 26 80 R1 R2 R3 25 27 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03510 2 The flashing 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. 80 R1 R2 R3 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03511 3 Press the “Standby” key (3) to exit configuration mode. 62 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 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. 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. SIHI_0004_GB 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 63 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 6.1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. FINISHING WORK AND CLEANING Switch off the control unit and remove the front panel. Ensure that the material pressure is relieved and shut off the air supply to the gun. Remove round-jet or flat-jet nozzle and clean separately. Connect the system to the detergent supply. Actuate the trigger guard and flush the gun through thoroughly. Relieve the pressure of gun and unit and remove the detergent supply. Switch on the air supply to the gun and blow through the air channels. Switch off the air supply to the gun. Relieve system pressure and secure the spray gun. Clean the body of the gun and other AquaCoat components with a washing solution recommended by the paint manufacturer and dry with a cloth or a blow gun. 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. SIHI_0145_GB B_03368 64 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 7 TROUBLE SHOOTING AND SOLUTION 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. SIHI_0004_GB 7.1 FAULTS IN THE SYSTEM Functional fault Cause Remedy Insufficient 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 filter • Nozzle is clogged • Clean or replace nozzle • Material valve travel setting too small • Increase material valve travel by turning the adjusting screw • 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 Schlechtes Spritzbild 65 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 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 • 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 high voltage • Repair malfunction as laid down in the control unit operating instructions Back spraying No wrap-around • Switch on high voltage Valve rod leaks • Seal in end piece defective • Repair by Wagner Service Center • Air-passages damp • Cleaning air-passages and drying • Valve rod seals damaged • Replace the seals (see chapter 8) 66 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 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 fuse • contact Wagner Service Team No high voltage • Spray gun cable not connected or defective • Spray gun not connected or defective • Connect spray gun cable • see the following table • see the following table Fault LED (24) lights up Fault message in display (27) 24 80 R1 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R2 R3 • contact Wagner Service Team 27 100 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03506 67 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 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). 24 R2 R3 27 100 80 R1 25 60 80 40 60 20 40 10 20 kV μA 0 POWER 1 AquaCoat B_03505 Code Fault Display E11 E12 E13 Earth monitoring No coil current/ Cascade interrupt Coil current too big E21-E25 Exception error Cause ● the grounding cable is interrupted ● the gun is not connected ● Remedy ● Check/replace gun cable ● ● Check or replace spray gun Connect the spray gun the cascade is not connected Cascade is interrupted -> defective ● Connect the cascade ● Check or replace cascade ● The cascade is defective ● Check or replace cascade ● Hardware defect has occurred ● If problem persists, contact Wagner Service Team ● 68 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 8 REPAIR WORK WARNING Incorrect maintenance/repair! Danger to life and equipment damage Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the chapter "Spare parts catalog". 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. SIHI_0048_GB 69 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 8.1 DISMANTLING OF THE SPRAY GUN 1 SW3 SW12 SW12 B_03395 2 Torx 25 3 SW3 SW19 B_03396 70 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 4 SW19 B_03397 SW19 5 Assembly tool for needle valve Part No. 2309368 Note: Loosen valve tip Air by hand using an assembly tool. SW11 Steck or box-end wrench Use (no openended). 6 B_03398 71 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL ø 3.0 7 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. 5 4 1 SW5 SW6 3 B_03198 8 Removing air valve: Hold the piston rear (2) and unscrew SW2 piston front SW6. 2 9 6 7 1. Undo the oval head screw (1). 2. Pull the air valve out off the hole. SW8 Torx 20 Removing air valve: Unscrew and remove the sealing 1 nut SW8. Hold the piston rear (2) and unscrew piston front SW5. SW9 2 SW5 SW14 B_03250 72 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 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. 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 In chapter 12 can be found part numbers for gun spare parts as well as for wearing parts such as seals. 73 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 8.3 ASSEMBLING THE SPRAY GUN Mounting materials: Item Part No. Description 1 9992590 Loctite 222 2 9992698 Vaseline white PHHV II 3 9992831 Loctite 542 4 9992511 Loctite 243 1 2 3 SW8 SW5 2 1 Torx 20 Ensure the correct insertion position 2 SW9 B_03448 2 Ensure the correct insertion position B_03569 4 SW14 3 Nm 74 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL Insertion position compl. package 3 SW2 1Nm X Valve rod unit Length adjusting measure 2 X = 122 ± 0.1 SW5 SW6 0.4 - 0.5 Nm SW5 0.4-0.5 Nm Push together the valve rod unit and the compl. package. Screw in together the valve rod unit and 2the compl. package. Remove the valve rod unit. Tighten the compl. package. 5 2 B_03253 4 4 1 0.5 Nm Carefully insert the valve rod unit and mount the clamping screw. 5 Assembly tool for needle valve Part No. 2309368 B_03399 Ensure the correct insertion position Note: Tighten slightly valve tip Air by SW11 hand using an assembly tool. 1.2 Nm 75 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 6 7 SW19 2.5 Nm SW3 0.8 Nm SW19 B_03501 B_03500 8 Push the trigger upward into the air valve piston Torx 25 B_03502 76 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 9 R1 R2 R3 0.8 Nm SW3 SW12 B_03503 SW12 2 10 Flat jet nozzle Diverse nozzle sizes see chapter 11.2 Round jet nozzle Diverse nozzle sizes see chapter 11.1 B_03504 77 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 8.4 REPLACING THE SPRAY GUN INCLUDING HOSE SET 1 80 Zerstäuberluft Atomizing air R1 Mat. Druckregler Mat. pressure reg. 100 60 80 40 Pumpe Pump 60 R2 20 R3 kV 40 10 20 μA 0 POWER 1 AquaCo AquaCoat at 6 3 B_03388 2 3 4 5 Disassembling gun assy. (1) 1. 2. 3. 4. 5. Loosen the knurled nut on the gun cable (5) and remove connector. Loosen the union nut (4) of the air hose at the AquaCoat cabinet. Unscrew knurled nut (2). Loosen the union nut (6) on the bared part of the material hose (3). Carefully remove the gun (1) together with the hose set. 78 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Spray gun GM 5000EAW (order no. 2309872) can be combined with different hose sets. The available hose sets are listed in the accessories (Chap. 11.4). Assembling 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 1. 2. 3. 4. 5. CHANGE MATERIAL HOSE AND/OR AIR HOSE Loosen and unscrew clamping screw (1). Loosen nut (2) and remove material hose from the attachment point. Push protective hose (4) back. Carefully remove material hose (3) from the protective hose (4). Loosen union nut (5) at gun connection and carefully remove air hose (6) from the protective hose (4). 1 5 6 2 3 4 B_03389 79 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 8.6 1. 2. 3. 4. DISASSEMBLING CONTROL UNIT VM 5000W Switch off the control unit and remove the front panel (1). Close the compressedair connection and relieve the system pressure. Loosen and unscrew screw (2). Carefully remove control unit (3) forwards. Pay attention to connecting lines and connecting cables at the back of the control unit! 2 3 80 Zerstäuberlu Atomizing ft air R1 Mat. Druckregler Mat. pressure reg. 2 100 60 80 40 Pumpe Pump 60 R2 20 R3 kV 40 10 20 μA 0 POWER 1 1 AquaC AquaCoat oat B_03390 1 80 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 8.7 Dismount control unit from the AquaCoat system (see Chap.8.6). Place control unit on a suitable surface. Loosen and unscrew screw (1). Remove cover (2) from housing. When the repair is complete, replace the cover (2) on the housing and fix with the screws (1). 1 2 oat uaC Aq 1 0 μA R3 R2 Pum Pumpe p Mat Mat . Druck . pr regl essu er re re g. Zers tä Atom uber izin luft g ai r R1 kV 10 20 40 60 80 20 40 60 80 100 R WE PO 1. 2. 3. 4. 5. OPENING THE CONTROL UNIT B_03533 81 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 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 filled 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“ Multi meter 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  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. 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 82 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Activities Aid tools 7. Test door lock ● Main switch off ● Air on ● Main switch on => door locked ● Main switch off => door unlocks 8. Test spraying ● Fit door ● 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 83 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 10 PRODUCT DISPOSAL 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. SIHI_0127_GB 84 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 11 ACCESSORIES 11.1 VALVE SEATS/ VALVE TIPS 11.1.1VALVE SEATS Part No. Description 2312179 Valve set Air assy. (steel) B_03697 2312176 Valve set Air assy. (PEEK) B_03697 11.1.2VALVE TIPS Part No. Description 2312187 Valve tip EAW assy. (PEEK) 2312188 Valve tip EAW assy. (steel) B_03517 B_03517 1.2 ROUND JET NOZZLES 11.2.1AR 5000 AIR CAPS Part No. Description 2310557 AR 5000 air cap (D8) B_03239 2315049 AR 5000 air cap (D12) B_03239 85 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 11.2.2NOZZLES AR 5000 Part No. Description 2310559 Nozzle AWR 5000 (D8) B_03238 2315051 Nozzle AWR 5000 (D12) B_03238 11.2.3OUTPUT MEASURED WITH PAINT Unit: GM 5000EAWR Viscosity: 22 DIN 4 sec Material pressure in bar 600 Output amounts in g/min 500 400 D8 D12 300 200 100 0 1 2 3 B_03456 86 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 11.3 FLAT JET NOZZLES 11.3.1EAF AIR CAPS Part No. Description 2310506 EAF air cap 0.4 - 0.8 B_03240 2310507 EAF air cap 1.0 - 1.4 B_03240 2310508 EAF air cap 1.6 - 2.0 B_03240 2314255 EAF air cap 0.4 - 0.8 (large) B_03240 2314256 EAF air cap 1.0 - 1.4 (large) B_03240 2314258 EAF air cap 1.6 - 2.0 (large) B_03240 11.3.2EAF FLAT JET NOZZLES Part No. Description 2310538 EAF flat jet nozzle 0.4 (blue) B_03241 2310539 EAF flat jet nozzle 0.6 (black) B_03241 2310540 EAF flat jet nozzle 0.8 (yellow) B_03241 87 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL Part No. Description 2310541 EAF flat jet nozzle 1.0 (red) B_03241 2310542 EAF flat jet nozzle1.2 (green) B_03241 2310543 EAF flat jet nozzle 1.4 (brown) B_03241 2310544 EAF flat jet nozzle 1.6 (white) B_03241 2310545 EAF flat jet nozzle 1.8 (blue) B_03241 2310546 EAF flat jet nozzle 2.0 (black) B_03241 11.3.3OUTPUT MEASURED WITH PAINT Unit: GM 5000EAWF Viscosity: 22 DIN 4 sec 700 Output amounts in g/min 600 ø 0.6mm ø 0.8mm ø 1.0mm ø 1.2mm ø 1.4mm ø 1.6mm ø 1.8mm ø 2.0mm 500 400 300 200 100 0 1 2 3 B_03455 Material pressure in bar 88 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 11.4 HOSE SETS AND COMPONENTS 1 4 3 2 Note: Material hose - Inside diameter 6 mm; 0.24 inch; - Material FEP - Nominal pressure 2 MPa; 20 bar; 290 psi 5 B_03512 Item Qty Part No. Description 1 1 2309861 Hose set GM 5000EAW (7.5 m; 24.6 ft) Consisting of: 2 1 2309907 Material hose EAW 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) Item Qty Part No. Description 1 1 2309862 Hose set GM 5000EAW (10 m; 32.81 ft) Consisting of: 2 1 2309909 Material hose EAW 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 9.5 m 3676437 PP30 protective hose mesh (9.5 m; 31.17 ft) Item Qty Part No. Description 1 1 2309863 Hose set GM 5000EAW (15 m; 49.2 ft) Consisting of: 2 1 2309910 Material hose EAW 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) 89 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Item Qty Part No. Description 1 1 2309864 Hose set GM 5000EAW (20 m; 65.62 ft) Consisting of: 2 1 2309911 Material hose EAW 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) 11.5 MISCELLANEOUS Part No. Description 353702 Insulating oil (10 ml; 10 cc) (for material hose -> assembly). 9992511 Loctite 243 (50 ml; 50 cc) (for air connection -> assembly). 9992590 Loctite 222 (50 ml; 50 cc) (for metal valve rod tip -> assembly) 2319653 Protective gun coating B_03693 2309368 Assembly tool valve needle B_03451 2325263 Assembly tool clamping screw B_03681 90 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Part No. Description 2324766 Swivel Air B_03720 259010 High voltage tester HV 200 N P_00265 999080 Wet film thickness measurer B_03224 50342 Viscosity cup DIN 4 353050 Hose holder assy. "? 353051 Base frame assy. "? 353052 Feed tank "? 2326485 Wall mount GM 5000E (left/right) B_03699 91 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 92 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 12 SPARE PARTS 12.1 HOW TO ORDER SPARE PARTS? 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. 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. SIHI_0004_GB 93 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 12.2 SPARE PARTS LIST AQUACOAT BASIC UNIT Spare parts list for AquaCoat Item K Qty Bestell-Nr. 1 1 130215 2 1 241270 3 1 2314234 4 1 2324044 5 1 2314238 6 1 353864 7 1 9991523 8 1 353868 9 1 9999440 10 1 9999109 11 ◆ 1 353865 ◆ 1 353526 12 13 ◆ 1 353527 14 1 353528 15 1 9999208 16 2 9900308 17 1 9900315 18 1 9900346 19 2 9910102 21 2 9910204 22 1 9911008 23 3 9920103 24 8 9920118 25 4 9922109 27 1 9952558 28 1 9992511 29 1 9992831 30 1 9998090 31 1 9999437 32 1 9999438 33 1 9985685 40 1 9910522 41 1 9992741 42 1 9994627 43 1 9907050 44 1 9992528 45 1 353523 46 1 353520 ◆ = Wearing part Description Earthing cable 10 m; 32.81 ft Mains cable with Stak200 Control unit VM 5000W (Spare parts list see chapter 12.3) Door switch assy. Cascade AquaCoat AquaCoat resistor 3 G Ball valve Air connection assy. Fitting I = G1/2“, A = G1/2“ Fitting T G1/2“ Cylinder AquaCoat Contact for earthing Earthing bush Instruction sticker AquaCoat Angle screwing in connection G1/4“ Cheese head screw with hexagon Cheese head screw with hexagon Cheese head screw with hexagon Hexagon nut M6 Hexagon nut with clamp Hexagon nut flat Washer A6.4 Washer Serrated washer Warning sign High voltage Loctite 243 Loctite 542 Screw-in screw connection straight Strain relief grommet DM7 Strain relief grommet DM4 Reducer A = G1/2“, I = G1/4“ Knurled nut Straight bulkhead fastener Double nipple with 2x90° Cheese head screw with hexagon Loctite 270 Retainer Locking flap 94 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 28 B C A 17 18 24 24 25 23 13 24 23 19 24 25 25 21 21 7 29 3 80 Zerstäube rluft Atomizin g air R1 Mat. Druckreg Mat. pressure ler reg. 9 15 33 100 8 10 60 80 40 Pumpe Pump 60 R2 20 40 10 20 R3 kV B μA 0 POWER 2 1 32 31 24 24 57 1 Aqua AquaCoat Coat 16 27 14 6 54 46 5 51 53 11 22 12 A C 30 58 50 E View E from out D 4 55 44 42 41 24 D 23 24 19 45 56 52 25 43 40 B_03391 95 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL Spare parts list for AquaCoat Item K Qty Bestell-Nr. 47 1 353523 48 1 2314160 49 1 2314159 50 1 353867 51 1 353504 52 1 353866 53 1 353869 54 2 9907222 55 1 9907259 56 1 9907260 57 1 353870 58 1 9992590 1 353285 ◆ = Wearing part Description Retainer Connection gun cable VM 5000W Control cable VM 5000W Front plate assy. Sticker AquaCoat Cabinet AquaCoat pre-assembled Interlocking Hexagon screw Cheese head screw with slit Countersunk screw with slit Air hose AC Loctite 222 AquaCoat cablekit Pumpe Pump Pistole Gun 49 Netzeingang Main power Spannung: max. 18Vpp Voltage: Strom: max. 1,0A Current: Mat. Druckregler Mat. pressure reg. Zerstäuberluft Atomizing air Service HS-Erzeuger HV-Generator Prim. 1AT Erdungs-Zylinder Grounding cylinder J. WAGNER AG CH - 9450 Altstätten Made in Switzerland Typ / Type: VM 5000W Artikel Nr.: Article No.: 2311001 48 Serie Nr.: Serial No.: Spannung: 85-264 VAC / 47-440 Hz Voltage: Eingangsleistung: max. 40W Line Power: Schutzklasse: IP 54 Protection Class: Norm: Standard: EN 50059 Lufteingang Air inlet B_03514 96 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 12.2.1ADDITIONAL LIST OF SPARE PARTS FOR VARIANTS WITH PP PUMP OR COBRA 1 Item ◆ 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 2 3 = Wearing part 4 B_02227 97 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 12.2.2ADDITIONAL LIST OF SPARE PARTS FOR VARIANTS WITH ZIP OR EVOMOTION PUMPS Item Qty Part No. Description 1 K 1 353530 Mounting plate 2 1 357436 Double connection 3 1 935050 Suction tube 4 4 3061695 Hexagon screw without shaft M6x55 5 4 9900108 Hexagon screw without shaft M6x20 6 4 9910102 Hexagon nut M6 7 4 9910204 Self-locking hexagon nut M6 8 12 9920103 Washer A6.4 9 4 9921502 Spring ring A6.0 10 ◆ 1 97073 Suction hose complete, stainless steel finish 11 ◆ 1 250244 Filter M15x1 12 ◆ 1 9987083 Hose lines 1 115378 Connector assy. 13 ◆ 14 ◆ 1 15 ◆ T0170.00BI Pressure reducer pneumatically controlled, Stainless steel 1 367025 Filter-relief combination 16 1 115858 Return tube 17 1 9981985 Hose (per meter) 18 1 118482 Reducing double nipple with 1x60° 19 1 9907019 Lock screw 20 1 9992528 Loctite 270 21 1 9992831 Loctite 542 = Wearing part 98 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 21 2 12 21 5 13 3 4 8 1 9 6 15 16 19 14 7 20 20 18 10 17 11 B_02226 99 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 12.3 Pos SPARE PARTS LIST VM 5000W 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 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 Primary fuse 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 inch B = Remove absorber! 100 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 27 35 4 18 18 18 42 8 9 36 41 38 20 30 43 24 1 17 48 11 B 44 A 52 7 12 19 40 51 41 33 (6x) 45 53 50 54 6 21 31 29 25 B_03515 101 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 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 inch B = Remove absorber! 16 22 32 Net ze Mai inga n po ng wer 35 26 Prim . 1A T Pis tole Gun HS -E HV- rzeu Gen ger erat or Pum Pumpe p 31 Ser vice Mat Mat . Dru . pr ckre essu gler re re g. Erd Gro ungs undi -Zyl ng inde cylin r der Zers Ato täuber miz luft ing air Lufte in Air gang inle t 28 29 B_03316 37 23 2 49 46 47 102 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 103 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 12.4 SPARE PARTS LIST GM 5000EAW 3 2 19 4 5 6 17 11 16 7 15 10 14 1 13 12 8 9 18 B_03393 104 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Spare parts list GM 5000EAW Item K Qty Part No. Description 1 1 2309872 Spray gun GM 5000EAW 2 1 - 3 1 2314361 4 1 - 5 2 9900308 Cheese head screw with hexagon 6 1 2312183 Cover, assy. 7 1 9900386 Cheese head screw with hexagon 8 1 2311970 Sealing plug 9 1 2307104 Lock screw 10 End-piece GM 500EAW assy. see detail in chapter 12.4.1 Hook ES 5000 Air handle complete, see detail in chapter 12.4.2 1 2312180 Air regulation compl. 11 ◆ 1 9971182 O-ring 12 ◆ 1 9971182 O-ring 13 ◆ 1 2314360 Trigger 14 1 2311849 Cylindrical helical spring 15 2 2310617 Oval head screw with hexagon 1 2311217 O-ring 16 ◆ 17 1 2307039 Union nut 18 ◆ 1 2309907 Material hose EAW assy. (7.5 m; 24.6 ft) 18 ◆ 1 2309909 Material hose EAW assy. (10 m; 32.81 ft) 18 ◆ 1 2309910 Material hose EAW assy. (15 m; 49.2 ft) 18 ◆ 1 2309911 Material hose EAW assy. (20 m; 65.6 ft) 19 ◆ 1 2308699 Cover seal 1 2326391 Service set GM 5000EAW ◆ = Wearing part 105 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 12.4.1SPARE PARTS LIST END-PIECE GM 5000EAW 2 3 4 5 1 6 B_03394 11 16 12 13 9 Ensure the correct insertion position! 8 17 7 10 14 15 122 ±0.1 106 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Spare parts list barrel GM 5000EAW Item K 1 Qty Part No. Description 1 - Barrel GM 5000EAW 2 ★ 1 2309391 Air manifold ring Air 3 ◆★ 1 2307180 O-ring, sheathed 4 ◆● 1 2312176 Valve set Air assy. (PEEK) 4 ◆ 1 2312179 Valve set Air assy. (steel) 5 ◆ 1 2312187 Valve tip EAW assy. (PEEK) 5 ◆● 1 2312188 Valve tip EAW assy. (steel) 1 2314271 Barrel GM 5000EA 1 9974166 O-ring 1 2307062 Clamping screw valve rod 1 2311562 Rod seal 1 2312177 Valve rod unit Air 6 7 ◆★ 8 9 ◆★ 10 11 ◆★ 1 2312178 Packing assy. 12 ◆ 1 2311624 O-ring 1 2307051 Clamping screw package 13 14 1 2307059 Withdrawal nut 15 1 9901411 Threaded pin with hexagon 1 2320256 O-ring 1 2325263 Assembly tool clamping screw 1 2326391 Service set GM 5000EAW 16 17 ◆ ◆ = Wearing part ★ = Included in service set ● = Not part of the standard equipment but available as a special accessory. 107 EDITION 04/2012 AquaCoat GM 5000EAW Part No. DOC2321361 OPERATING MANUAL 12.4.2SPARE PARTS LIST GM 5000EA - HANDLE 14 25 15 26 16 17 18 19 24 20 13 7 10 9 8 12 6 1 5 23 4 2 3 B_03237 108 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Spare parts list Handle GM 5000EAW Item Qty Part No. 1 1 - 2 1 2307288 Nipple 1 9971025 O-ring 4 1 2315344 Hose holder 5 1 2312182 Plug complete 6 1 2314270 Handle complete 1 2307232 End piece seal 8 1 2325789 Adjusting screw complete 9 1 2309825 Oval head screw with hexagon 3 7 K ◆★ ◆★ Description ES 5000 Air handle complete 10 ◆★ 1 2310692 Seal 11 ◆★ 1 9971363 O-ring 1 2307281 Threaded bolt 1 2312189 Air valve 1 2307557 Seal 15 1 2307935 Piston front 16 1 2312846 Cylindrical helical spring 17 1 2310680 Sleeve 12 13 14 ◆★ 18 ◆★ 1 9974218 O-ring 19 ◆★ 1 2310682 Seal 1 2316246 Piston rear 20 23 ◆★ 1 9974166 O-ring 24 ◆★ 1 2303437 O-ring 25 1 2325291 Sealing nut 26 1 2325294 Washer Air valve 1 2326391 Service set GM 5000EAW ◆ = Wearing part ★ = Included in service set ● = Not part of the standard equipment but available as a special accessory. 109 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 12.5 SPARE PARTS LISTS ACCESSORIES 12.5.1NOZZLE AR 5000 (D8) 4 3 2 1 B_03263 Spare parts list Nozzle AR 5000 (D8) Pos K 1 Qty Part No. Description 1 2310559 Nozzle AWR 5000 - assy. (D8) 2 ◆ 1 2327658 Nozzle AR (D8) 3 ◆ 1 2327666 Nozzle cap AWR (D8) 4 ◆ 1 2327660 Air manifold AR (D8) ◆ = Wearing part 12.5.2NOZZLE AR 5000 (D12) 4 3 2 1 B_03264 Spare parts list Nozzle AR 5000 (D12) Pos K 1 Qty Part No. Description 1 2315051 Nozzle AWR 5000 assy. (D12) 2 ◆ 1 2327661 Nozzle AR (D12) 3 ◆ 1 2327667 Nozzle cap AWR (D12) 4 ◆ 1 2327663 Air manifold AR (D12) ◆ = Wearing part 110 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 111 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 112 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL 113 EDITION 04/2012 Part No. DOC2321361 AquaCoat GM 5000EAW OPERATING MANUAL Germany J. WAGNER GmbH Otto-Lilienthal-Str. 18 Postfach 1120 D- 88677 Markdorf Telephone: +49 7544 5050 Telefax: +49 7544 505200 E-Mail: [email protected] Switzerland J. WAGNER AG Industriestrasse 22 Postfach 663 CH- 9450 Altstätten Telephone: +41 (0)71 757 2211 Telefax: +41 (0)71 757 2222 E-Mail: [email protected] Belgium WSB Finishing Equipment Veilinglaan 56/58 B- 1861 Wolvertem Telephone: +32 (0)2 269 4675 Telefax: +32 (0)2 269 7845 E-Mail: [email protected] / HP www.wsb-wagner.eu Denmark WAGNER Industrial Solution Scandinavia Viborgvej 100, Skærgær DK- 8600 Silkeborg Telephone: +45 70 200 245 Telefax: +45 86 856 027 E-Mail [email protected] United Kingdom WAGNER Spraytech (UK) Ltd. Haslemere Way Tramway Industrial Estate GB- Banbury, OXON OX16 8TY Telephone: +44 (0)1295 265 353 Telefax: +44 (0)1295 269861 E-Mail: [email protected] France J. WAGNER France S.A.R.L. Parc de Gutenberg - Bâtiment F8 8, Voie la Cardon F- 91127 Palaiseau-Cedex Telephone: +33 1 825 011 111 Telefax: +33 1691 946 55 E-Mail: [email protected] Netherlands WSB Finishing Equipment B.V. De Heldinnenlaan 200 NL- 3543 MB Utrecht Italy WAGNER COLORA S.r.l Via Fermi, 3 I- 20875 Burago di Molgora (MB) Telephone: +31 (0) 30 241 4155 Telefax: +31 (0) 30 241 1787 E-Mail: [email protected] / HP www.wsb-wagner.eu Telephone: +39 039 625021 Telefax: +39 039 6851800 E-Mail: [email protected] Japan WAGNER Spraytech Ltd. 2-35, Shinden Nishimachi J- Daito Shi, Osaka, 574-0057 Telephone: +81 (0) 720 874 3561 Telefax: +81/ (0) 720 874 3426 E-Mail: [email protected] Austria J. WAGNER GmbH Otto-Lilienthal-Str. 18 Postfach 1120 D- 88677 Markdorf Telephone: +49 (0) 7544 5050 Telefax: +49 (0) 7544 505200 E-Mail: [email protected] Sweden WAGNER Industrial Solutions Scandinavia Skolgatan 61 SE- 568 31 Skillingaryd Telephone: +46 (0) 370 798 30 Telefax: +46 (0) 370 798 48 E-Mail: [email protected] Spain WAGNER Spraytech Iberica S.A. Ctra. N- 340, Km. 1245,4 E- 08750 Molins de Rei (Barcelona) Telephone: +34 (0) 93 680 0028 Telefax: +34 (0) 93 668 0156 E-Mail: [email protected] Czechoslovakia WAGNER s.r.o. Nedasovská Str. 345 15521 Praha 5 - Zlicin Telephone: +42 (0) 2 579 50 412 Telefax: +42 (0)2 579 51 052 E-Mail: [email protected] USA WAGNER Systems Inc. 300 Airport Road, unit 1 Elgin, IL 60123 USA Telephone: +1 630 503 2400 Telefax: +1 630 503 2377 E-Mail: [email protected] 114 ED FI CERT I /RDERNUMBER 2321361 'ERMANY *7!'.%2'MB( /TTO ,ILIENTHAL 3TR 0OSTFACH $ -ARKDORF 4ELEPHONE 4ELEFAX % -AILSERVICESTANDARD WAGNER GROUPCOM 3WITZERLAND *7!'.%2!' )NDUSTRIESTRASSE 0OSTFACH #( !LTSTËTTEN 4ELEPHONE 4ELEFAX % -AILREP CH WAGNER GROUPCH WWWWAGNER GROUPCOM

Aquacoat Air Spraying System For Non

Rating

Date

Size

Views

Categories

Share

Transcript

Forgot your password?.