Translation of the original Operating manual. AquaCoat air spraying system for non-combustible liquids. Edition 04/2012 B_03360.

Transcription

1 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R1 R2 R3 10 kv 100 μa POWER AquaCoat AquaCoat Translation of the original Operating manual Edition 04/12 AquaCoat air spraying system for non-combustible liquids B_033

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3 Contents 1 ABOUT THESE INSTRUCTIONS Languages Warnings, notes and symbols in these instructions 6 2 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 9 3 GUARANTEE AND CONFORMITY DECLARATIONS Important notes on product liability Guarantee claim CE-Conformity German regulations and guidelines 12 4 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-S Double diaphragm pump ZIP Material pressure tank LDG 4.4 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 32 5 START-UP AND OPERATION Installation and connection Ventilation of the spray booth Air supply Paint supplies Earthing 35 3

4 Contents 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 6 MAINTENANCE Finishing work and cleaning 63 7 TROUBLE SHOOTING AND SOLUTION Faults in the system Error displays at the control unit VM 5000W 66 8 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 9 FUNCTIONAL CHECK AFTER ASSEMBLY AquaCoat Complete device PRODUCT DISPOSAL 83 4

5 Contents 11 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 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 105 5

6 1 ABOUT THESE INSTRUCTIONS 1.1 LANGUAGES 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. Warning - possible danger. Non-observance can result in death, serious injury and serious material damage. SIHI_0100_GB SIHI_0103_GB DANGER This line warns of the hazard! Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level. The measures for preventing the hazard and its consequences. WARNING This line warns of the hazard! Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level. The measures for preventing the hazard and its consequences. Caution - a possibly hazardous situation. Non-observance can result in minor injury. SIHI_0101_GB C AUTION This line warns of the hazard! Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level. The measures for preventing the hazard and its consequences. Caution - a possibly hazardous situation. Non-observance can cause material damage. SIHI_0102_GB CAUTION This line warns of the hazard! Possible consequences of failing to observe the warning instructions. The signal word points out the hazard level. The measures for preventing the hazard and its consequences. Note - provide information on particular characteristics and how to proceed. 6

7 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 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 PERSONNEL QUALIFICATIONS A SAFE WORK ENVIRONMENT Make sure that the floor in the area where you are working is anti-static in accordance with EN (the resistance value may not exceed 100 MOhm). Ensure that all persons within the working area wear antistatic shoes. Footwear must comply with EN 344. 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 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

8 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 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 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

9 2.2.4 CLEANING 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 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; F: - Identify the unit with a warning label that says Warning - hot surface. Order No Information label Safety label 2.3 CORRECT USE 2.4 SAFETY-RELEVANT INFORMATION ABOUT DISCHARGES 9

10 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

11 3.3 CE-CONFORMITY Herewith we declare that the supplied version of: AquaCoat Airspray GM 5000EAW Complies with the following guidelines: 06/42/EG 06/95/EG 02/96/EG 04/108/EG 02/95/EG Applied standards, in particular: DIN EN ISO , 04 DIN EN ISO , 04 DIN EN ISO 14121, 07 DIN EN 1953, 10 DIN EN 4-1, 07 DIN EN 50059, 1992 DIN EN , 06 DIN EN , 07 Applied national technical standards and specifications, in particular: BGR 500 Part 2 chap BGR 500 Part 2 chap BGI 7 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 :

12 3.4 GERMAN REGULATIONS AND GUIDELINES a) BGV A3 Electrical units and equipment b) BGR 500 Part 2, Chap Working with liquid ejection devices c) BGR 500 Part 2, Chap Using coating materials d) BGR 104 Explosion protection rules e) TRBS 2153 Avoiding ignition risks f ) BGR 1 Setting up for cleaning with solvents for cleaning workpieces with solvents g) ZH 1/6 Guidelines for liquid ejection devices h) BGI 7 Painting rooms and equipment j) BGI 764 Electrostatic coating j) Betr.Sich.V. Plant Safety Ordinance Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they are to be found in the Internet. 12

13 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 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. % H 2 O > 1.70 x Gew. % LM x Gew. % ORG Where: Gew. % Weight percent H 2 O Water LM Liquid organic phase (solvent mainly consisting of higher ethylene glycol esters) ORG Solid organic phase (solids mainly consisting of binding agents and pigments) Such paints behave like water in respect of 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

14 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 Operating manual German see chapter 1 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

15 4.2.1 SPRAYPACK CONFIGURATION In order to order the high-rotating atomizer please use the model identification ABCDEFGHI in connection with the tables listed below. Tables -> A B C D E F G H I Examples -> Configuration no 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

16 Table A - Pump No. Type 1 No pump 2 Doppelmembranpumpe ZIP52 Table B - Level monitoring No. Description 1 no 2 yes 3 Pumpe EvoMotion 5-S Table C - Barrel cover/ Agitator No. Type 1 no 2 Barrel cover Ø 350 mm; Ø 13.8 inch 3 Barrel cover Ø 350 mm; Ø 13.8 inch with Agitator Table D - Feed tank No. Description 1 no 2 yes Table E - Under frame No. Description 1 no 2 yes Table F - Hose holder No. Description 1 no 2 yes Table G - Hose length No. Type m; 24.6 ft 2 10 m; 32.8 ft 3 15 m; 49.2 ft 4 m; 65.6 ft Table H - Nozzle system No. Description 1 Flat jet incl. Nozzle Flat jet incl. Nozzle Flat jet incl. Nozzle Flat jet incl. Nozzle Flat jet incl. Nozzle Flat jet incl. Nozzle Flat jet incl. Nozzle Flat jet incl. Nozzle Flat jet incl. Nozzle 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

17 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R1 R2 10 kv R3 100 μa POWER 0 1 EDITION 04/ TECHNICAL DATA Weight (without paint container 70 kg; 154 lb and pump) Working temperature range 5 C - C; 41 F F Maxi. material temperature 50 C; 122 F Sound pressure level When the cabinet is open: Dependent on the installed pump, data can be found in the enclosed operating instructions. When the cabinet is closed: The values are db(a) lower. Measurements: B A C mm inch A B C B_

18 10 kv 100 μa EDITION 04/ CONTROL UNIT VM 5000W Input voltage 115 V AC/ 230 V AC / 50 Hz/ Hz Input power max. W Output voltage max. 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; lb Working temperature range 5 - C; F Measurements: R1 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R2 A R3 POWER 0 1 AquaCoat B mm inch A B C D D C B_

19 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) 5 g; 1.28 lb Working temperature range 5 C to 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: 05. Measurements: B A C mm inch A B C B_

20 4.3.3 PNEUMATIC PISTON PUMP EVOMOTION 5-S C_ DOUBLE DIAPHRAGM PUMP ZIP52 ZZ170 ZZ170 ZZ ZZ MATERIAL PRESSURE TANK LDG See separate operating manuals

21 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R1 R2 R3 10 kv 100 μa POWER 0 1 EDITION 04/ FUNCTIONAL DESCRIPTION DESIGN OF UNIT AND FUNCTION AquaCoat AquaCoat B_03363 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

22 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 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. 22

23 J3 J N PE B_03513 L EDITION 04/12 Electrical block diagram AquaCoat Control unit VM 5000W Door switch Coil - Coil + Door switch Earth Dat dls Dat sw Earth monitoring P1 white yellow green brown green brown white Shield Power supply Earthing whitw white blue black Door switch Spray gun Coil + Coil - Cascade AquaCoat Casting compound AquaCoat resistor yellow/green Casting compound Earthing switch AquaCoat yellow/green Pneumatic cylinder 23

24 CONTROL UNIT VM 5000W The assembled spray system can be operated and regulated with the VM 5000W control unit. Operating elements on the front: R1 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R2 10 R3 kv μa POWER 0 1 AquaCoat B_ 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: µa Resolution: 1 µa. 6 Illuminated display Spraying current 24

25 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 MPa; 0-10 bar; psi. 10 Regulator Material pressure Pressure regulator for the material pressure. Adjusting range MPa; 0-10 bar; psi. 11 Regulator Atomizing air Pressure regulator for the atomizing air. Adjusting range MPa; 0-10 bar; psi. 12 Pressure gauge Atomizing air Atomizing air pressure display for the spray gun. Display range MPa; 0-10 bar; psi. 13 Pressure gauge Material pressure Pressure display for the material pressure. Display range MPa; 0-10 bar; psi. 14 Pressure gauge Pump pressure Display for the pump pressure or the material pressure in the pressure tank. Display range MPa; 0-10 bar; 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 Illuminated display Recipe 3 Lights up if recipe 3 is used. 25

26 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: 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

27 Voltage: max. 1,0A J. WAGNER AG CH Altstätten Spannung: Voltage: Eingangsleistung: max. W Line Power: Schutzklasse: IP 54 Norm: EDITION 04/12 Connections on the rear side: Pumpe Pump Mat. Druckregler Netzeingang Main power Prim. 1AT Pistole Gun Spannung: Strom: Current: max. 18Vpp HS-Erzeuger HV-Generator Service Mat. pressure reg. Zerstäuberluft Atomizing air Made in Switzerland Erdungs-Zylinder Typ / Type: VM 5000W Grounding cylinder Artikel Nr.: Article No.: Serie Nr.: Serial No.: VAC / 47-4 Hz Protection Class: EN Standard: Lufteingang Air inlet B_ 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

28 SPRAY GUN GM 5000EAW B _ Item Description 1 Suspension hook 2 Display (spray current and recipe) 3 Display standby and fault 4 Operating button (standby and recipe change) 5 Air cap EAF (Accessory chapter ) 6 Union nut 7 EAF flat jet nozzle x.x (Accessory chapter 11.2) 8 Gun barrel 9 Cover 10 Handle Item Description 11 Adjusting screw material valve (Stop) 12 Trigger 14 EAR nozzle (Accessory chapter 11.1) 15 Lock plug 16 Air adjustment 17 Electrical cable connection 18 Connection atomizing air 19 Material connection EAR air cap (Accessory chapter ) 21 Protective hose 22 Type plate left 23 Type plate right S B_03558 Note: The type of gun (T) and the series number (S) are visible after removing the cover plate. 28

29 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 Recipe 3 -> R3 2 3 R1 R2 R3 Recipe change R1 -> R2 -> R3 -> R1 Press operating key (4) and keep pressed down for min. 2 seconds to go forward one recipe. 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 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. In the event of a malfunction the spray gun switches to standby operating mode and the display (3) illuminates. R1 R2 R3 16 The width of the spray jet can be adjusted using the air adjustment (16) (only for flat-jet method). 29

30 AIR ATOMIZING SPRAY PROCESS-ROUND JET In this process, the material (paint) is fed to the nozzle with low pressure approx MPa; bar; psi. The atomizing air at approx MPa; bar; 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 Atomizing air Spray pattern Spray material B_03446 Advantages: low coating thickness uniform coating thickness perfect finish 30

31 AIR ATOMIZING SPRAY PROCESS - FLAT JET In this process, the material (paint) is fed to the nozzle with low pressure MPa; bar; 7-29 psi. The atomizing air at approx MPa; bar; 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 Atomizing air Spray angle B_001 Advantages: large range of adjustment of the jet spray low coating thickness uniform coating thickness perfect finish 31

32 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

33 5 START-UP AND OPERATION 5.1 INSTALLATION AND CONNECTION SIHI_0050_GB 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. 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 VENTILATION OF THE SPRAY BOOTH SIHI_0028_GB WARNING Toxic and/or flammable vapor mixtures! Risk of poisoning and burns Operate the unit in a spraying booth approved for the working materials. -or- Operate the unit on an appropriate spraying wall with the ventilation (extraction) switched on. Observe national and local regulations for the outgoing air speed. 33

34 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 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 SIHI_0029_GB DANGER Bursting hose, bursting threaded joints! Danger to life from injection of material Ensure that the hose material is chemically resistant. Ensure that the spray gun, threaded joints and material hose between the unit and the spray gun is suitable for the pressure generated in the unit. Ensure that the following information can be seen on the high pressure hose: - Manufacturer - Permissible operating pressure - Date of manufacture. SIHI_0128_GB CAUTION Electrical discharges! Danger due to electrically charged material lines The conductive sheath of the material hose must not be remo - ved and the connections to the earth potential must not be loo - sened. 1. Earth connection in the cabinet. 2. Earth connection in the gun. 34

35 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R1 R2 10 kv R3 100 μa POWER 0 1 EDITION 04/ 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. SIHI_0003_GB WARNING Heavy paint mist if earthing is insufficient! Risk of poisoning Insufficient paint application quality Earth all unit components. Earth the workpieces being painted. 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 Workpiece Rmax.< 1 MΩ Spraying stand B_03367 System earth Floor, derivable System earth 35

36 Minimum cable cross-section AquaCoat cabinet Conveyor Spray booth Spraying stand 4 mm²; AWG11 16 mm²; AWG5 16 mm²; AWG5 16 mm²; AWG SAFETY CHECKS 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 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

37 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 DIN-s (measured in immersion flow cup DIN 4 mm; 0.16 inches). Processing of up to DIN-s is generally possible without problem, if high coating thicknesses are required. In the case of application problems contact the paint producer VISCOSITY CONVERSION TABLE milli Pascal x Sec mpas Centipoise Poise DIN Cup 4 mm ; 0.16 inch Ford Cup 4 Zahn

38 38

39 5.3 STARTING OPERATION 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/work - piece. 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 Electrical discharge! Risk of injury CAUTION Maintain a safety distance of 100 mm; 4 inches from the nozzle area of the spray gun during the spraying process and at least seconds after the end of the spraying process. SIHI_0129_GB Danger zone: A A A A 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 = 100 mm A = 4 inch B_

40 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R1 R2 R3 10 kv 100 μa POWER 0 1 EDITION 04/ PREPARATION FOR STARTING UP Impurities in the spraying system! Spray gun blockage CAUTION Flush the spray gun and paint supply with a suitable cleaning agent before putting into operation. SIHI_0010_GB SPRAYPACK WITH PRESSURE TANK AquaCoat B_03369

41 The following points must be noted: 1. Open the outlet valve on the pressure tank (13). 2. Connect HV cable (22) to the pressure tank. 3. Loosen knurled nuts on the pressure tank and remove cover. 4. Fill the pressure tank with a suitable detergent, so that the system can be checked for leaks. 5. Put on the pressure tank cover and tighten all knurled nuts by hand. 6. Set the maximum value on the pressure tank pressure controller. 7. Connect the earth. 8. 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. 9. When the tightness of the system has been ascertained, the spray gun can be unlocked and the system flushed through. 10. Relieve system pressure and secure the spray gun. 11. Open pressure tank (13) and empty detergent or water. 12. Fill the pressure tank with paint, taking care not to exceed the maximum level. 13. Put on the pressure tank cover and tighten all knurled nuts by hand. 14. Connect the AquaCoat system to the electric socket with the electric cable (9). 15. Insert front panel (2). Switch on mains switch on the VM 5000W. 16. The system is ready for use. 41

42 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R1 R2 R3 10 kv 100 μa POWER 0 1 EDITION 04/ SPRAY PACK WITH DOUBLE DIAPHRAGM PUMP AquaCoat 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

43 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. SIHI_0130_GB CAUTION Electrical discharge when using coated material containers! Risk of injury, material charge not optimal Ensure that the metal part of the container is connected to the HV cable (e.g. remove coating from around the connection point). 11. The system is ready for use. 43

44 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R1 R2 R3 10 kv 100 μa POWER 0 1 EDITION 04/ SPRAY PACK WITH PNEUMATIC PUMP EVOMOTION AquaCoat AquaCoat B_

45 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. SIHI_0130_GB CAUTION Electrical discharge when using coated material containers! Risk of injury, material charge not optimal Ensure that the metal part of the container is connected to the HV cable (e.g. remove coating from around the connection point). 11. The system is ready for use. 45

46 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R1 R2 R3 10 kv 100 μa POWER AquaCoat AquaCoat EDITION 04/ WORKING PREPARATION FOR SPRAYING WITH FLAT-JET NOZZLE R1 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R2 10 R3 kv μa POWER 0 1 B_ AquaCoat 1 B_ 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 MPa; bar; 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

47 5.4.2 START-UP FOR SPRAYING 1. Insert the desired nozzle into the gun. 2. Open the stop valve. 3. Turn on the control unit. 4. Set the material supply to operating pressure P MAT. 5. Spray on a test object (pull trigger). 6. 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_

48 5.4.3 CHECK SPRAY PATTERN Start air-spraying (without electrostatics) 1. Start up with material supply set to approx 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 B_03584 Closed air adjustment 48

49 5.4.4 CHANGING FROM AIR-ROUND JET TO AIR-FLAT JET 1. Switch off control unit. 2. Relieve spray gun and unit pressure! 3. Replace paint with cleaning solvent. 4. Set material pressure control. Switch off the atomizing air. 5. Flush the gun through thoroughly. 6. Relieve the material pressure on the spray gun and the devise! 7. Unscrew by hand the union nut (1). 8. Remove EAR air cap (2). Unscrew and remove EAR nozzle (3) by hand. 9. Clean the spray gun front page with dampened cloth carefully. 10. Screw in and tighten slightly EAF flat jet nozzle (5) by hand. 11. Put on the EAF air cap (4). Screw the union nut (1) onto the spray gun body. 12. Set the desired flat jet level with the air cap horns (6) and then tighten slightly the union nut by hand B_

50 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 START-UP THE CONTROL UNIT VM 5000W 100 R1 1. Turn switch to position All LEDs on the control unit illuminate for approx. 1 second. R2 R3 10 kv μa POWER 0 1 AquaCoat B_ The hardware version and the software version are shown on the display alternately in succession. B_03373 Hardware version Software 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. R1 R2 R3 10 kv 100 μa POWER 0 1 AquaCoat B_

51 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 R R2 100 R3 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 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

52 5.4.8 SETTING THE HIGH VOLTAGE 100 R1 Works procedure: R2 R3 10 kv μa POWER Press the High voltage button (7) to adjust the high voltage. The LED (8) indicates that high voltage is selected. AquaCoat 8 7 B_ R1 R2 R3 10 kv μa POWER 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 8 7 B_03376 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

53 5.4.9 SETTING THE CURRENT LIMITING 100 Works procedure: R1 R2 R3 10 kv μa POWER Press the Current limiting button (5) to adjust the limitation of the spray current. The LED (6) indicates that current limiting is selected. AquaCoat 6 5 B_ R1 R2 R3 10 kv μa POWER The current limiting can now be adjusted using the universal rotary controller (2) between µa with a resolution of 1 µa. The value is shown in the LED display (27). AquaCoat 22 2 B_03378 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 kv and current limiter at 83 µa are stored in R2 through prolonged pressing of the recipes pushbutton (> 2 sec.). 53

54 SPRAY DISPLAY Ready to spray using R2 recipe (see picture below). Control unit in standby position. The nominal value LEDs illuminate as dots and the high voltage value is digitally displayed in the LED display. If you press the current limiter pushbutton, the set nominal value for the spray current limiter is digitally displayed in the LED display. 100 R1 R2 10 R3 kv μa POWER 0 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. 100 R1 R2 10 R3 kv μa POWER 0 1 AquaCoat B_033 54

55 STANDBY 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. 100 R1 R2 10 R3 kv μa POWER 0 1 AquaCoat 4 3 B_03381 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. 100 R1 R2 10 R3 kv μa POWER 0 1 AquaCoat B_

56 OPERATING HOURS COUNTER/WARNING DISPLAY Two hour counters are integrated into the control unit. The absolute counter measures the ongoing hours of operation of the spray gun and with the 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 R2 R3 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 = 450 hours. Maximum display value = 99.9 = hours. Flashing lines are then displayed. Display of temporary service counter and how to reset this counter. Set service interval in hours activate or lock this function R1 R2 10 R3 kv μa POWER 0 1 AquaCoat B_

57 MAINTENANCE 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: Works procedure: R1 R2 R kv μa 5 2 POWER 0 1 AquaCoat B_ Briefly press pushbutton R3 (19), LED () 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: Works procedure: R1 R2 R kv μa POWER 0 1 AquaCoat B_ 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

58 CONDUCT SERVICE DISPLAY R1 R2 10 R3 kv μa POWER 0 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

59 5.5 DEVICE CONFIGURATION OVERVIEW OF PARAMETERS C13 C19 C Parameter Value Beschreibung User lock Reset recipes Reset configuration off (factory settings) on pro no (factory settings) res no (factory settings) res User lock is switched off User lock is switched on: no target values (kv and µa) can be adjusted; you can only select the recipe and the control functions. 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. 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

60 5.5.2 ACCESS TO THE DEVICE CONFIGURATION MODE 100 Works procedure: R1 R2 R3 10 kv μa 1. Switch device to Standby by pressing the Standby key (3). The Standby LED (4) lights up yellow. POWER 0 1 AquaCoat 4 3 B_ R1 R2 R3 10 kv 100 μa POWER 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 2 B_ R1 R2 R3 10 kv 100 μa POWER 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 AquaCoat B_03508 Note: The parameters C11 and C12 can be changed, but this will not have any effect.

61 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. Group 1: Parameters C11 to C (End users) Group 2: Parameters C21 to C30 (Wagner Service) Group 3: Parametesr C31 to C (for production plant, service center) R1 R2 R3 10 kv 100 μa 27 POWER 0 1 AquaCoat B_ 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) R1 R2 10 R3 kv μa POWER 0 1 AquaCoat B_

62 R1 R2 10 R3 kv μa POWER 0 1 AquaCoat 2 B_03510 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 C R1 R2 10 R3 kv μa POWER 0 1 AquaCoat 3 B_03511 Press the Standby key (3) to exit configuration mode. 62

63 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. SIHI_0004_GB WARNING Incorrect maintenance/repair! Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply. - Relieve the pressure from the spray gun and unit. - Secure the spray gun against actuation. Observe the operating and service instructions when carrying out all work. Cleaning agent in the air duct! Functional faults caused by swollen seals CAUTION Never immerse the spray gun in cleaning agent or water. SIHI_0002_GB 63

64 6.1 FINISHING WORK AND CLEANING 1. Switch off the control unit and remove the front panel. 2. Ensure that the material pressure is relieved and shut off the air supply to the gun. 3. Remove round-jet or flat-jet nozzle and clean separately. 4. Connect the system to the detergent supply. 5. Actuate the trigger guard and flush the gun through thoroughly. 6. Relieve the pressure of gun and unit and remove the detergent supply. 7. Switch on the air supply to the gun and blow through the air channels. 8. Switch off the air supply to the gun. 9. Relieve system pressure and secure the spray gun. 10. 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_

65 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 Clean or replace filter clogged Nozzle is clogged Clean or replace nozzle Schlechtes Spritzbild Material valve travel setting too small Wrongly adjusted atomizing air Nozzle too large Material viscosity too high Material pressure too high Damaged nozzle Increase material valve travel by turning the adjusting screw Readjust atomizing air Select smaller nozzle (see nozzle table) Thin material in accordance with the manufacturer s instructions Reduce the material pressure Replace nozzle 65

66 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 Spraying pressure too high Check resistance of paint see chapter Readjust spraying pressure Back spraying Object not earthed Check earthing Distance between spray gun and object too large High voltage set wrongly (too high) Reduce distance between spray gun and object Adapt high voltage to material No wrap-around No high voltage Repair malfunction as laid down in the control unit operating instructions Switch on high voltage Seal in end piece defective Repair by Wagner Service Center Air-passages damp Cleaning air-passages and drying Valve rod leaks Valve rod seals damaged Replace the seals (see chapter 8) 66

67 7.2 ERROR DISPLAYS AT THE CONTROL UNIT VM 5000W Functional fault Cause Remedy No illuminated display lights up No high voltage Fault LED (24) lights up Fault message in display (27) Mains not switched on Fuses defective Spray gun cable not connected or defective Spray gun not connected or defective see the following table Switch on mains power supply Replace fuse contact Wagner Service Team Connect spray gun cable contact Wagner Service Team see the following table R1 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R2 10 R3 kv μa POWER 0 1 AquaCoat B_

68 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) R1 R2 10 R3 kv μa POWER 0 1 AquaCoat B_03505 Code Fault Cause Remedy Display E11 Earth monitoring the grounding cable is interrupted Check/replace gun cable Check or replace spray gun the gun is not connected Connect the spray gun E12 No coil current/ the cascade is not connected Connect the cascade Cascade interrupt Cascade is interrupted -> defective Check or replace cascade E13 Coil current too big The cascade is defective Check or replace cascade E21-E25 Exception error Hardware defect has occurred If problem persists, contact Wagner Service Team 68

69 8 REPAIR WORK WARNING Incorrect maintenance/repair! Danger to life and equipment damage SIHI_0048_GB 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. 69

70 8.1 DISMANTLING OF THE SPRAY GUN 1 SW3 SW12 SW12 B_ Torx 25 3 SW3 SW19 B_

71 4 SW19 SW19 B_ Assembly tool for needle valve Part No Note: Loosen valve tip Air by hand using an assembly tool. SW11 Steck or box-end wrench Use (no openended). 6 B_

72 7 ø SW 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. 3 SW6 8 B_ SW2 1. Undo the oval head screw (1). 2. Pull the air valve out off the hole. Removing air valve: Hold the piston rear (2) and unscrew piston front SW6. SW8 Torx Removing air valve: Unscrew and remove the sealing nut SW8. Hold the piston rear (2) and unscrew piston front SW5. 1 SW9 2 B_03250 SW14 SW5 72

73 8.2 CLEANING THE PARTS AFTER DISASSEMBLY Please note: ATTENTION 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_00_GB In chapter 12 can be found part numbers for gun spare parts as well as for wearing parts such as seals. 73

74 8.3 ASSEMBLING THE SPRAY GUN Mounting materials: Item Part No. Description Loctite Vaseline white PHHV II Loctite Loctite SW5 SW Ensure the correct insertion position 2Torx SW9 B_ Ensure the correct insertion position B_ SW14 3 Nm 74

75 3 Insertion position compl. package SW2 1Nm X 2 Valve rod unit Length adjusting measure X = 122 ± 0.1 SW5 Push together the valve rod unit and SW6 the compl. package Nm SW Nm Screw in together the valve rod unit and 2the compl. package. Remove the valve rod unit. Tighten the compl. package. 4 B_ Nm Carefully insert the valve rod unit and mount the clamping screw. Assembly tool for needle valve Part No B_03399 Ensure the correct insertion position Note: Tighten slightly valve tip Air by SW11 hand using an assembly tool. 1.2 Nm 75

76 6 7 SW Nm SW3 0.8 Nm B_03500 SW19 B_ Push the trigger upward into the air valve piston Torx 25 B_

77 9 R1 R2 R3 0.8 Nm SW3 SW12 SW12 B_ Flat jet nozzle Diverse nozzle sizes see chapter 11.2 Round jet nozzle Diverse nozzle sizes see chapter 11.1 B_

78 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R1 R2 R3 10 kv 100 μa POWER 0 1 AquaCoat AquaCoat EDITION 04/ REPLACING THE SPRAY GUN INCLUDING HOSE SET B_03388 Disassembling gun assy. (1) 1. Loosen the knurled nut on the gun cable (5) and remove connector. 2. Loosen the union nut (4) of the air hose at the AquaCoat cabinet. 3. Unscrew knurled nut (2). 4. Loosen the union nut (6) on the bared part of the material hose (3). 5. Carefully remove the gun (1) together with the hose set. 78

79 Spray gun GM 5000EAW (order no ) 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 m; 3.77 ft through the opening as far as the mounting plate. 3. Fix mounting plate (3) to earthing screw with knurled nut (2). 4. Screw air hose for the spray gun (4) to the AquaCoat cabinet. 5. Connect gun cable (5) to AquaCoat cabinet and secure with screw. 6. Screw bared end of material hose (3) with union nut (6) to relief combination. 8.5 CHANGE MATERIAL HOSE AND/OR AIR HOSE 1. Loosen and unscrew clamping screw (1). 2. Loosen nut (2) and remove material hose from the attachment point. 3. Push protective hose (4) back. 4. Carefully remove material hose (3) from the protective hose (4). 5. Loosen union nut (5) at gun connection and carefully remove air hose (6) from the protective hose (4) B_

80 Zerstäuberluft Atomizing air Mat. Druckregler Mat. pressure reg. Pumpe Pump R1 R2 R3 10 kv 100 μa POWER AquaCoat AquaCoat EDITION 04/ DISASSEMBLING CONTROL UNIT VM 5000W 1. Switch off the control unit and remove the front panel (1). 2. Close the compressedair connection and relieve the system pressure. 3. Loosen and unscrew screw (2). 4. Carefully remove control unit (3) forwards. Pay attention to connecting lines and connecting cables at the back of the control unit! B_03390

81 Zerstäuberluft Atomizing air 10 kv μa POWER EDITION 04/ OPENING THE CONTROL UNIT 1. Dismount control unit from the AquaCoat system (see Chap.8.6). 2. Place control unit on a suitable surface. 3. Loosen and unscrew screw (1). 4. Remove cover (2) from housing. 5. When the repair is complete, replace the cover (2) on the housing and fix with the screws (1). 1 2 AquaCoat 0 1 R3 R2 100 Pumpe Pump R1 Mat. Druckregler Mat. pressure reg. B_

82 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 1. Check connections Check all material screw connections Check all air connections All electrical cables must be firmly secured Safety-relevant check 2. Check earth connection Measure resistance between earth terminal and handle of the gun (metal fittings): -> Set value max.10 Check resistance between earth terminal and earthing band: -> Set value max 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 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 -100 µa Aid tools Visually check Multi meter Hexagonal wrench SW 3 mm; 0.12 inches 82

83 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

84 10 PRODUCT DISPOSAL SIHI_0127_GB Note Do not dispose of waste electrical equipment with the household refuse! In accordance with European Directive 02/96/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. 84

85 11 ACCESSORIES 11.1 VALVE SEATS/ VALVE TIPS VALVE SEATS Part No. Description Valve set Air assy. (steel) B_ Valve set Air assy. (PEEK) B_ VALVE TIPS Part No. Description Valve tip EAW assy. (PEEK) B_ Valve tip EAW assy. (steel) B_ ROUND JET NOZZLES AR 5000 AIR CAPS Part No. Description AR 5000 air cap (D8) B_ AR 5000 air cap (D12) B_

86 NOZZLES AR 5000 Part No. Description Nozzle AWR 5000 (D8) B_ Nozzle AWR 5000 (D12) B_ OUTPUT MEASURED WITH PAINT Unit: GM 5000EAWR Viscosity: 22 DIN 4 sec Material pressure in bar Output amounts in g/min D8 D B_

87 11.3 FLAT JET NOZZLES EAF AIR CAPS Part No. Description EAF air cap B_ EAF air cap B_ EAF air cap B_ EAF air cap (large) B_ EAF air cap (large) B_ EAF air cap (large) B_ EAF FLAT JET NOZZLES Part No. Description EAF flat jet nozzle 0.4 (blue) B_ EAF flat jet nozzle 0.6 (black) B_ EAF flat jet nozzle 0.8 (yellow) B_

88 Part No. Description EAF flat jet nozzle 1.0 (red) B_ EAF flat jet nozzle1.2 (green) B_ EAF flat jet nozzle 1.4 (brown) B_ EAF flat jet nozzle 1.6 (white) B_ EAF flat jet nozzle 1.8 (blue) B_ EAF flat jet nozzle 2.0 (black) B_ OUTPUT MEASURED WITH PAINT Unit: GM 5000EAWF Viscosity: 22 DIN 4 sec Output amounts in g/min B_03455 ø 0.6mm ø 0.8mm ø 1.0mm ø 1.2mm ø 1.4mm ø 1.6mm ø 1.8mm ø 2.0mm Material pressure in bar 88

89 11.4 HOSE SETS AND COMPONENTS Note: Material hose - Inside diameter 6 mm; 0.24 inch; - Material FEP - Nominal pressure 2 MPa; bar; 290 psi B_03512 Item Qty Part No. Description Hose set GM 5000EAW (7.5 m; 24.6 ft) Consisting of: Material hose EAW assy. (7.5 m; 24.6 ft) Air hose assy. (7.5 m; 24.6 ft) Gun cable GM 5000E (7.5 m; 24.6 ft) 5 7 m PP30 protective hose mesh (7 m; ft) Item Qty Part No. Description Hose set GM 5000EAW (10 m; ft) Consisting of: Material hose EAW assy. (10 m; ft) Air hose assy. (10 m; ft) Gun cable GM 5000E (10 m; ft) m PP30 protective hose mesh (9.5 m; ft) Item Qty Part No. Description Hose set GM 5000EAW (15 m; 49.2 ft) Consisting of: Material hose EAW assy. (15 m; 49.2 ft) Air hose assy. (15 m; 49.2 ft) Gun cable GM 5000E (15 m; 49.2 ft) m PP30 protective hose mesh (14.5 m; ft) 89

90 Item Qty Part No. Description Hose set GM 5000EAW ( m; ft) Consisting of: Material hose EAW assy. ( m; ft) Air hose assy. ( m; ft) Gun cable GM 5000E ( m; ft) m PP30 protective hose mesh (19.5 m; ft) 11.5 MISCELLANEOUS Part No. Description Insulating oil (10 ml; 10 cc) (for material hose -> assembly) Loctite 243 (50 ml; 50 cc) (for air connection -> assembly) Loctite 222 (50 ml; 50 cc) (for metal valve rod tip -> assembly) Protective gun coating B_ Assembly tool valve needle B_ Assembly tool clamping screw B_

91 Part No. Description Swivel Air B_ High voltage tester HV 0 N P_ Wet film thickness measurer B_ Viscosity cup DIN Hose holder assy Base frame assy Feed tank Wall mount GM 5000E (left/right) B_