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1. milli Pascal x Centipoise Poise DIN Cup Ford Cup 4 Zahn 2 Sec mPas 4 mm 0 16 inch 10 10 0 1 5 16 15 15 0 15 8 17 20 20 0 2 10 18 25 25 0 25 14 12 19 30 30 0 3 15 14 20 40 40 0 4 17 18 22 50 50 0 5 19 22 24 60 60 0 6 21 26 27 70 70 0 7 23 28 30 80 80 0 8 25 31 34 90 90 0 9 28 32 37 100 100 1 30 34 41 120 120 1 2 33 41 49 140 140 1 4 37 45 58 160 160 1 6 43 50 66 180 180 1 8 46 54 74 200 200 2 49 58 82 220 220 2 2 52 62 240 240 2 4 56 65 260 260 2 6 62 68 280 280 2 8 65 70 300 300 3 70 74 320 320 3 2 340 340 3 4 360 360 3 6 80 380 380 3 8 400 400 4 90 34 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 5 3 START UP 5 3 1 GENERAL RULES FOR HANDLING 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 NWARNING 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
2. A OPERATING MANUAL WAGNER 8 5 REPLACING THE SPRAY GUN INCLUDING HOSE SET B_01912 Dismantling spray gun assy 1 1 Loosen the connection nut 6 on the bared part of the material hose 3 with a universal spanner Unscrew union nut 2 Loosen the connection nut 4 of the air hose at the AquaCoat cabinet Loosen the locking screw on the gun cable 5 and remove connector Carefully remove the gun 1 together with the hose set GAS ur isa 56 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL WAGNER 4 preassembled guns are available with different hose set lengths Part No Description 353861 Spray gun GM 2900EAW with Hose set 7 5 m 24 6 ft 353871 Spray gun GM 2900EAW with Hose set 10 m 32 81 ft 353872 Spray gun GM 2900EAW with Hose set 15 m 492 ft 353873 Spray gun GM 2900EAW with Hose set 20 m 65 6 ft Assembly spray gun assy 1 1 Secure the spray gun Turn tension cap 9 clockwise until stop viewed from back of gun Connect gun cable 5 to AquaCoat cabinet and secure with screw Screw air hose for the spray gun 4 to the AquaCoat cabinet Push bared part of material hose approx 1 15 m 3 77 ft through the opening as far as the mounting plate Fix mounting plate 3 to earthing screw with knurled nut 2 Screw bared end of material hose 3 with connection nut 6 to relief combination 8 6 REPLACING THE PAINT HOSE AND
3. Translation of the original Operating manual A WAGNER AquaCoat Air LDG20 ZIP52 3 130S VM 2900W Edition 01 2008 AquaCoat air spray system for non combustible liquids AquaCoat WAISNER A A EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL Contents AquaCoat GM 2900EAW A WAGNER 1 1 1 1 2 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 3 3 1 32 3 3 3 4 4 4 1 4 1 1 4 2 4 2 1 4 3 4 3 1 4 3 2 4 3 4 4 3 5 4 3 6 4 4 4 4 1 4 4 1 1 4 4 1 2 4 4 1 2 1 4 4 1 2 1 1 4 4 1 2 1 2 4 4 1 2 1 3 4 4 1 3 4 4 1 4 4 4 1 5 5 5 1 ABOUT THESE INSTRUCTIONS Languages Warnings notes and symbols in these instructions 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 Paint hoses Cleaning Handling hazardous liquids varnishes and paints Touching hot surfaces Correct use Safety relevant information about discharges PRODUCT LIABILITY AND WARRANTY Important notes on product liability Warranty CE conformity German regulations and guidelines DESCRIPTION Fields of application using in accordance with the instructions Processible materials Extent of delivery Spraypack Configuration Technical data Control unit VM 2900W Spray gun
4. Air connection R 1 4 Hose set lengths 7 5m 24 6 ft 10m 32 8 ft 15m 49 2 ft 20m 65 6 ft Weight without cables 0 7 kg 1 54 Ib Working temperature range 5 40 C 41 104 F Maxi material temperature 60 C 140 F Paint output volume According to nozzle sizes See nozzle list on accessories Sound power at 0 2 MPa 2 bar 29 psi air pressure depending on nozzle used 65 79 dB A Dimensions B 02164 mm inch A 347 13 66 255 10 04 C 40 1 58 18 EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL AquaCoat GM 2900EAW A WAGNER 4 3 4 MATERIAL PRESSURE TANK LDG20 See separate operating instructions 4 3 5 DOUBLE DIAPHRAGM PUMP ZIP52 See separate operating instructions 4 3 6 PISTON PUMP 3 130S PE TG See separate operating instructions 19 EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL AquaCoat GM 2900EAW A WAGNER 4 4 FUNCTIONAL DESCRIPTION 4 4 1 DESIGN OF THE UNIT AND FUNCTION tw T S NX 01889 Pos Description 1 Cabinet AquaCoat assembly 2 Front panel with 2 handles 3 Control unit VM 2900W 4 Spray gun GM 2900EAW 5 Hose set EAW 6 Paint hose Filter relief combination for spray gun 7 Cascade AquaCoat 8 Air inlet assy with ball valve 9 Inlet for mains cable 10 Earth
5. OR AIR HOSE 1 Isolate spray gun and hose set from the AquaCoat cabinet in accordance with chapter 8 5 Loosen 2 screws 8 remove cable ties and push protective tube 7 back Loosen knurled nut 9 with universal soanner and remove material hose 3 from the material connection of the gun Unscrew connection nut 10 from the air hose 4 B_01926 57 AquaCoat GM 2900EAW A OPERATING MANUAL WAGNER EDITION 01 2008 PART NO DOC353841 5 Support the clamping sleeve 13 with the universal spanner and unscrew the double nipple 11 7 Remove the cable lug 12 8 Carefully remove the air hose 4 backwards from the protective tube 7 9 Carefully remove the completely assembled material hose 3 backwards from the protective tube 7 10 Assemble in reverse order Assembly instructions The following aids must be used Insulating oil 14 gt Paint hose Clean length inserted into the gun and wet with HV oil Loctite 243 gt Double nipple 11 Threaded joint with clamping sleeve 13 4 preassembled material hoses and 4 preassembled air hoses are available in the corre sponding hose set lengths Hose set Paint hose assy Air hose assy Length Part No Part No 7 5 m 24 6 ft 353874 353212 10 m 32 81 ft 353875 353213 15m 49 2 ft 353876 353214 20 m 65 6 ft 353877 353215 B_01927 58 EDITION 01 2008 AquaCoat GM 2900EAW PART NO DOC353841 OPERATING MAN
6. for changing the front valve rod seal 353560 Mounting tool for valve needle head 179901 Universal spanner 10 4 MISCELLANEOUS PartNo Description 353702 Insulating oil for material hose gt Assembly 9992511 Loctite 243 50 ml 50 cc for Air connection gt Assembly 9992590 Loctite 222 50 ml 50 cc for Metal Valve needle head gt Assembly 9994682 Glove against ink mist precipitation 259005 H V tester HV 200 A WAGNER B_01921 Pd N 62 EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL AquaCoat GM 2900EAW A WAGNER PartNo Description 999080 Wet film thickness gauge 50342 Viscosity cup DIN4 353050 Hose holder assy 353051 Base frame assy 353052 Feedtank _ B_01916 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 11 SPARE PARTS 11 1 HOWTO 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 subassembly 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
7. 08750 Molins de Rei Barcelona Telephone 34 0 93 680 0028 Telefax 34 0 93 668 0156 E Mail info wagnerspain com Czechoslovakia WAGNER s r o Nedasovsk Str 345 15521 Praha 5 Zlicin Telephone 42 0 2 579 50 412 Telefax 42 0 2 579 51 052 E Mail info wagner cz 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 info wagnersystemsinc com 70 Order number 353841 Germany J WAGNER GmbH Otto Lilienthal Str 18 Postfach 1120 D 88677 Markdorf Telephone 49 0 7544 5050 Telefax 49 0 7544 505200 E Mail service standard wagner group com Switzerland J WAGNER AG Industriestrasse 22 Postfach 663 CH 9450 Altst tten Telephone 41 0 71 757 2211 Telefax 41 0 71 757 2222 E Mail rep ch wagner group ch www wagner group com
8. 23 1 353874 Paint hose assy for Hose set 7 5 m 24 6 ft 23 1 353875 Paint hose assy for Hose set 10 m 32 808 ft 23 1 353876 Paint hose assy for Hose set 15 m 49 2 ft 23 1 353877 Paint hose assy for Hose set 20 m 65 6 ft 24 1 9994627 Double nipple Wearing part 9 Not part of standard equipment for spray gun Available however as additional extra v available in different sizes Note For repairs please use service instructions article number 353895 68 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 69 EDITION 01 2008 OPERATING MANUAL PART NO DOC353841 AquaCoat GM 2900EAW Germany J WAGNER GmbH Otto Lilienthal Str 18 Postfach 1120 D 88677 Markdorf Telephone 49 7544 5050 Telefax 49 7544 505200 E Mail service standard wagner group com A WAGNER Switzerland J WAGNER AG Industriestrasse 22 Postfach 663 CH 9450 Altstatten Telephone 41 0 71 757 2211 Telefax 41 0 71 757 2222 E Mail rep ch wagner group ch Belgium WAGNER Spraytech Benelux BV Veilinglaan 58 B 1861 Wolvertem Telephone 32 0 2 269 4675 Telefax 32 0 2 269 7845 E Mail info wsb wagner be Denmark WAGNER Industrial Solution Scandinavia AB Viborgvej 100 Skoergoer DK 8600 Silkeborg Telephone 45 702 00245 Telefax 45 868 5602
9. EAF 2 0 black 2303640 Flat jet nozzle EAF 0 6 black 353969 Flat jet nozzle EAF 0 8 yellow 353970 Flat jet nozzle EAF 1 0 red 353955 Flatjet nozzle EAF 1 2 green Ka 353956 Flat jet nozzle EAF 1 4 brown K 353957 Hat jet nozzle EAF 1 6 white 00113 353958 _ Flat jet nozzle EAF 1 8 blue 353959 Flat jet nozzle EAF 2 0 black Note Only install nozzle parts of the same colour air cap colour and nozzle colour must be identical 10 1 1 OUTPUT MEASURED WITH PAINT Unit GM 2900EAWF Viscosity 22 DIN 4 sec 80 8 1 0 bm 1 2 91 4 9 1 6 Output in g min e 9 1 8 22 0 2 bar Material pressure in bar 3 bar B 00170 60 EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL AquaCoat GM 2900EAW A WAGNER 10 2 NOZZLES EA ROUND JET SUPRA Part No Description 363239 Nozzle set EAW R 353966 Nozzle nut EAR 2000 353965 Nozzle body Supra 353953 Nozzle insert Supra EAW 353210 Air nozzle spanner 2800 EA 10 2 1 OUTPUT MEASURED WITH PAINT Unit GM 2900EAWR Viscosity 22 DIN 4 sec 600 8 00085 500 400 300 200 Output in g min 100 B 00171 2 Material pressure in bar w AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL 10 3 SPECIAL TOOLS Part No Description 353805 Special spanner
10. GM 2900EAW Material pressure tank LDG20 Double diaphragm pump ZIP52 Piston pump 3 130S PE TG Functional description Design of the unit and Function Control unit VM 2900W Spray gun GM 2900EAW Air atomizing round and flat jet process Air atomizing round jet process Air atomizing flat jet process The electrostatic effect Material pressure tank LDG20 Double diaphragm pump ZIP52 Pneumatic pump 3 130S PE TG STARTING UP AND OPERATING Installation and connection o M D M OO oO OO OO OD JJJ OO uM Mi 221212221202 26 OMOWOAN A HAM NNNNNNNNNN WN VD VD vw OD OD JJ Oh OC ww oo EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL Contents 5 1 1 Ventilation of the spray booth 5 1 2 Air supply 5 1 3 Fluid paint hoses 5 1 4 Earthing 5 1 5 Safety checks 5 1 5 1 Earthing check 5 1 5 2 Inspection of the safety elements 5 2 Preparation of water paint 5 2 1 Viscosity conversion table 5 3 Start up 5 3 1 General rules for handling the spray gun 5 3 2 Preparation for starting up 5 3 2 1 Spraypack with pressure tank 5 3 2 2 Spraypack with Double diaphragm pump 5 3 2 3 Spraypack with pneumatic pump 3 130S 5 4 Works 5 4 1 Start up for spraying with flat jet nozzle 5 4 2 Adjust the spray angle by flat jet nozzles 5 4 3 Exchange of round jet nozzle insert round jet nozzle 5 4 4 Changing from round jet nozzle to flat jet nozzle 5 4 5 Control unit VM 2900W formulas 5 4 6 Control uni
11. OPERATING MANUAL AquaCoat GM 2900EAW A WAGNER Table A Pump Pressure tank Table B Nozzle system Number Type Number Description 1 Flat jet incl nozzle set 0 6 1 Pressure tank LDG 5 2 Flat jet incl nozzle set 0 8 2 Pressure tank LDG 10 3 Flat jet incl nozzle set 1 0 3 Pressure tank LDG 20 4 Flat jet incl nozzle set 1 2 4 Pressure vessel MDGS 5 Flat jet incl nozzle set 1 4 6 Flat jet incl nozzle set 1 6 3 Pressure vessel MDG 60 7 Flat jet incl nozzle set 1 8 6 Double diaphragm pump ZIP52 8 Flat jet incl nozzle set 2 0 7 Pneumatic pump 3 130S 2 Round jet Table C Agitator Table D Level monitoring 3 15 m 49 2 ft Number Type Number Description 1 not Agitator 1 no 2 Agitator 2 yes Table E Hoselength Table F Feedtank Number Type Number Description 1 7 5 m 24 6 ft 1 no 2 10 m 32 8 ft 2 yes 4 20 m 65 6 ft Table G Barrel cover Table H Underframe Number Type 1 no 2 350 mm 13 8 inch Number Description 1 no 2 yes Table Hose holder Number Description 1 no 2 yes 15 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 4 3 TECHNICAL DATA Weight 70 kg 154 Ib without Paint container and
12. material hose is suitable for the pressure generated in the unit 9 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 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 2 2 4 CLEANING De energize the unit electrically Disconnect the pneumatic supply line Relieve the pressure from the unit Ensure that only non combustible detergents are used To clean use only cloths and brushes Never use hard objects or spray on cleaning agents a gun 2 2 5 HANDLING HAZARDOUS LIQUIDS VARNISHES AND PAINTS When preparing or working with paint and when cleaning the unit follow the work ing 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 Ld 2 2 6 TOUCHING HOT SURFACES Touch hot surfaces only if you are wearing protecti
13. of delivery required air freight or mail sea route or overland route etc Marks in spare parts lists Note to column kK in the following spare parts lists Wearing parts Note No liability is assumed for wearing parts Not part of standard equipment available however as additional extra NWARNING Incorrect maintenance repair Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by spe cially trained staff or a WAGNER service center Before all work on the unit and in the event of work interrup tions 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 64 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 11 2 SPARE PART LIST AQUACOAT BASIC UNIT AquaCoat B_01924 Spare parts list AquaCoat basic unit Pos K Qty Part No Description 1 1 353862 Control unit VM 2900W 2 1 353867 Front plate assy Note For repairs please use service instructions article number 353895 NWARNING Incorrect maintenance repair Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by spe cially trained staff or a WAGNER service center Before all work on the un
14. rod 14 closes VM 2900W No green LED displays 2 and 3 visible Mains power not turned on Turn on mains power Stand by Mode Deactivate stand by mode Fuse defective Replace fuse VM 2900W Fault display 1 lights up together with LED 1 Internal error HV module defective Wagner Service VM 2900W Fault display 1 lights up together with LED 2 Calibration value lost HV module defective Wagner Service VM 2900W Fault display 1 lights up together with LED 3 Cascade not connected or defective Connect or replace cascade VM 2900W Fault display 1 lights up together with LED 5 Earth monitoring Check spray gun earth B 01907 49 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 50 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 8 REPAIRS 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 interrup tions Disconnect the co
15. 3841 OPERATING MANUAL CAUTION Defective sealing surface Equipment damage to the gun Coating error gt Do not damage the sealing surface SIHI_0034_GB 8 Replace in reverse order do not forget to screw 10 in the centre packing screw 9 Place the locking nut 8 with pressure spring 7 in position and tighten with the trigger 5 open until a considerable resistance is noticeable 9 Carefully tighten the sealing screw 3 with the valve rod spanner 15 until a slight change is perceptible in the trigger force when the trigger guard 5 is actuated 10 Mount complete valve seat 2 in accordance with chapter 5 2 1 Il Mount round jet nozzle 11 or flat jet nozzle 12 in accordance with chapter 5 4 3 or 5 4 4 8 3 REPLACING THE VALVE ROD TIP 8 3 1 STARTING FROM INSTALLED VALVE ROD 1 2 3 Remove nozzle according to chapter 5 4 3 or 5 4 4 With the trigger guard actuated prevents damage to the valve rod sealing surfaces loosen and unscrew the complete valve seat 2 with the air nozzle key 1 Insert the assembly tool D order number 353560 over the valve rod tip 13 into the end piece and loosen and unscrew the tip B_01908 A WAGNER 53 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 4 5 01930 Soni 222 Only bond mn Hie case of metal tips Note If the valve rod tip 13 cannot be loosened the complete val
16. 7 E Mail info wagner industri com 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 enquiries wagnerspraytech co uk France J WAGNER France S A R L Parc de Gutenberg Batiment F8 8 Voie la Cardon F 91127 Palaiseau Cedex Telephone 33 1 825 011 111 Telefax 33 1691 946 55 E Mail division solutionsindustrielles wagner france fr Netherlands WAGNER SPRAYTECH Benelux BV Zonnebaan 10 NL 3542 EC Utrecht Telephone 31 0 30 241 4155 Telefax 31 0 30 241 1787 E Mail info wsb wagner nl Italy WAGNER COLORA S r l Via Fermi 3 l 20040 Burago di Molgora MI Telephone 39 039 625021 Telefax 39 039 6851800 E Mail info wagnercolora com 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 marketing wagner japan co jp 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 service standard wagner group com Sweden WAGNER Industrial Solutions Scandinavia AB Skolgaten 61 SE 56831 Skillingaryd Telephone 46 0 421 500 20 Telefax 46 0 370 798 48 E Mail info wagner industri com Spain WAGNER Spraytech Iberica S A Ctra N 340 Km 1245 4 E
17. ATING MANUAL WAGNER Minimum cable diameters AquaCoat cabinet 4 mm AWG 12 Conveyor 16 mm2 AWG 6 Spraying booth 16 mm AWG 6 Spraying stand 16 mm AWG 6 5 1 5 SAFETY CHECKS 5 1 5 1 EARTHING CHECK Daily 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 Daily General visual inspection Earthing band all cables and connections for damage or loose contacts examine Monthly Door switch test Remove the front panel Turn on control unit Actuate the trigger guard on the spray gun The high voltage must remain switched off Earthing cylinder test Insert front panel Turn on control unit Acoustically ascertain switch movement Check that the front panel is locked Turn off control unit Acoustically ascertain switch movement 33 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 5 2 PREPARATION OF WATER PAINT The viscosity of the paints is of great importance The best results are obtained with paints between 25 and 40 DIN sec measured in immersion flow cup DIN 4 mm 0 16 inch Processing of up to 60 DIN s is generally possible without problem if high coating thick nesses are required In the case of application problems contact the paint producer 5 2 1 VISCOSITY CONVERSION TABLE
18. GI 740 BGI 764 BGR 500 Marking d 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 353890 10 EDITION 01 2008 AquaCoat GM 2900EAW PART NO DOC353841 A OPERATING MANUAL WAGNER 3 4 GERMAN REGULATIONS AND GUIDELINES a BGVA2 b BGR500 c BGR500 d CHV9 e CHV11 f BGR 104 g BGR 132 h BGR 180 i ZH1 406 j BGI740 k BGI 764 Electrical units and equipment Part 2 Chap 2 36 Working with liquid ejection devices Part 2 Chap 2 29 Using coating materials Regulations on flammable liquids Regulations on electrical equipment in Ex areas 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 Note All titles can be ordered from Heymanns Publishing House in Cologne or download from Internet 11 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 4 DESCRIPTION 4 1 FIELDS OF APPLICATION USING IN ACCORDANCE WITH THE INSTRUCTIONS AquaCoat Spray Packs are equipped ready for use with the VM 2900W control unit a GM 2900EAW air spray gun and matching hose set a high voltage generator all safety devices and spray material supply and are therefore
19. IHI 0130 GB 11 The system is ready for use 41 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 5 4 WORKS 5 4 1 START UP FOR SPRAYING WITH FLAT JET NOZZLE NER AquaCoat 1 Turn on the control unit VM 2900W 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 manual formula setting 7 2 Set the desired formula 3 Switch on the material supply 2 adjust from approx 0 05 0 15 MPa 0 5 1 5 bar 7 22 psi 4 Unlock spray gun with tension cap 5 Ifthe trigger guard is now actuated the high voltage is switched on and both displays 6 and 5 change from point to bar display i e the actual value of the high voltage 6 and the actual value of the spray current 5 are displayed 6 The high voltage can be switched on and off with the push button 4 7 Spray on a test object press the trigger 8 Adjust the spray pressure 2 and atomizing air 3 in accordance with the nozzle and object Note The paint output volume can be changed by Changing the material pressure or e Fitting another nozzle See accessories 42 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 5 4 2 ADJUST THE SPRAY ANGLE BY FLAT JET NOZZLES The spray pattern shape can be optimal adapted to the sprayed object with the
20. N BD CAUTION Cleaning agent in the air duct Functional faults caused by swollen seals Always point the spray gun down when cleaning Ensure that neither paint nor cleaning agent enters the air duct SIHI_0005_GB B_01906 The gun barrel X may only be detached by the WAGNER Service Station 47 EDITION 01 2008 OPERATING MANUAL PART NO DOC353841 AquaCoat GM 2900EAW A WAGNER 7 TROUBLE SHOOTING AND SOLUTION Problem Cause Solution Insufficient material discharge Nozzle too small Flat jet Select larger nozzle See nozzle list Material pressure to low Increase material pressure Material viscosity to 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 Union screw is screwed in to far Turn union screw anticlockwise Poor spray pattern Air leaks Wrongly adjusted atomizing air Readjust atomizing air Nozzle too large Select smaller nozzle See nozzle list Material viscosity to high Thin material in accordance with the manufacturer s instructions Material pressure to high Reduce material pressure Damaged nozzle Air valve seal on valve tappet leaking Replace nozzle Have seal replaced by WAGNER Service Department Se
21. UAL 9 DISPOSAL OF THE PRODUCT A WAGNER SIHI_0127_GB Note Do not dispose of waste electrical equipment with the hou sehold 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 device will be taken back by us or our represen tatives and disposed of environmentally correctly Please contact one of our service points or one of our representatives or us directly to this purpose 59 AquaCoat GM 2900EAW A WAGNER EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL 10 ACCESSORIES 10 1 NOZZLES EA FLAT JET PartNo Description Colour 363228 Nozzle set EAF 0 6 black 363229 _ Nozzle set EAF 0 8 ellow 363230 Nozzle set EAF 1 0 red a 363231 Nozzle set EAF 1 2 green 363232 Nozzle set EAF 1 4 brown FR N 363233 Nozzle set EAF 1 6 white N 363234 Nozzle set EAF 1 8 blue N oz 363235 Nozzle set EAF 2 0 black 2303641 Air cap assy EAF 0 6 black 353968 Air cap assy EAF 0 8 yellow 353973 Air cap assy EAF 1 0 red 353960 Air cap assy EAF 1 2 green 353961 Air cap assy EAF 1 4 brown 353962 Air cap assy EAF 1 6 white 353963 Air cap assy EAF 1 8 blue niu 353964 Aircap assy
22. al on air regulating pin leaking Have seal replaced by WAGNER Service Department Tappet seal leaking Have tappet seal replaced by WAGNER Service Department Poor wrap around Poor earthing at object Check earthing of object or hanger with ohmmeter Paint resistance to high to low Check resistance of paint in accordance with chap 4 1 1 Spraying pressure to high Readjust pressure Backspraying Object not earthed Check earthing Distance between spray gun and object to large Reduce distance between spray gun and object High voltage set wrongly to high Adapt high voltage to material 48 EDITION 01 2008 OPERATING MANUAL PART NO DOC353841 AquaCoat GM 2900EAW A WAGNER Problem Cause Solution No wrap around No high voltage Check function of control unit in accordance with its manual Switch on HV Seal in end piece defective e Repaired by Wagner Service Air passages damp Cleaning air passages and drying Leaking material at the nozzle Valve seat 2 worn Replace part and check for leaks with air in water see chap 8 1 If still leaking change valve rod tip Valve rod tip 13 worn Seal 4 in chap 8 2 or seal 16 in chap 8 2 over tightened Replace valve rod tip see chap 8 3 Loosen sealing screw 3 or sealing screw 10 until valve
23. and correct the problem proceed as described in chap Trouble shooting 5 0065 GB NCAUTION Electrical discharge Risk of injury Maintain a safety distance of 100 mm 4 inches from the nozzle area ofthe 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 workpiece and other earthed objects during the spray process 35 EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL AquaCoat GM 2900EAW 5 3 2 PREPARATION FOR STARTING UP CAUTION Impurities in the spraying system Spray gun blockage into operation SIHI_0010_GB 5 3 2 1 SPRAYPACK WITH PRESSURE TANK 4 8 24 3 IE 5 RR 19 4 7 B H i lt a Flush the spray gun and paint supply with a suitable cleaning agent before putting A WAGNER 20 22 wae A quaCoat 25 aL E E 23 B_01901 36 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER The following points must be noted Open the outlet valve on the pressure tank 13 Clamp the HV cable 22 to the pressure tank Loosen the knurled nuts by turning to the left and remove the cover Fill the pressure tank with a suitable detergent so that the system can be checked for leaks 5 Put on th
24. by Wagner are subject to the warranty terms of the origi nal maker The replacement of a part does not extend the warranty period of the unit The unit should be inspected immediately upon receipt To avoid loss warranty aniy apparent defect should be notified to us or the dealer in wri ting within 14 days from date of sale of the unit The right to commission warranty services to a third party is reserved Warranty claims are subject to proof of purchase by submitting an invoice or delivery note If an inspection finds damage not covered by the present warranty the repair will be car ried out at the expense of the purchaser Note that this warranty does not in any way restrict legally entitled claims or those contrac tually agreed to in our general terms and conditions J Wagner AG AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 3 3 CE CONFORMITY Herewith we declare that the supplied version of 353010 Spraypack AquaCoat Air spray 353020 Spraypack AquaCoat LDG20 353021 Spraypack AquaCoat ZIP52 353022 Spraypack AquaCoat 3 130S 353040 AquaCoat with VM 2900W Complies with the following guidelines 98 37 EG 73 23 EWG 89 336 EWG 2002 95 EG 2002 96 EG Applied standards in particular EN 12100 1 EN 12100 2 EN 1050 EN 1953 EN 563 EN 60204 1 EN 50059 EN 61000 6 1 EN 61000 6 2 EN 61000 6 3 EN 61000 6 4 Applied national technical standards and specifications in particular B
25. cket Connection for mains cable with securing clip Connection pump air Hose connection 10 mm 0 39 inch Connection Material pressure regulator Hose connection 8 mm 9 0 32 inch Connection atomization air Hose connection 8 mm 9 0 32 inch Mains socket Connection for gun cable Mains socket Connection for high voltage generator Self locking nut earthing Connection for the earthing cable system earth Primary fuse 1 0 ampere slow acting Compressed air inlet Hose connection 10 mm 0 39 inch Connection Earthing switch air Hose connection 6 mm 0 24 inch Cover Service connection A WAGNER 25 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 4 4 1 2 SPRAY GUN GM 2900EAW B_01919 Nozzle set EAF Protective cap Protective hose Suspension hook A Nozzle set EAR Supra B Attachment C Gun body D Atomising air regulator E Tension nut F High Voltage switch integrated into trigger G Handle H Air hose Atomising air Material hose K Trigger L Gun cable M N P Q R Flat jet air regulation 26 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER The trigger can be used to activate one after the other the various functions of the spray gun AW Maxi way of trigger LM Air open LE Air open and electrostatics activated LO Air
26. cone of the collar G Screw nut H on the gun body K Adjust desired jet level by means of air cap horn L Tighten by hand the air cap F on the gun body K 44 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 5 4 5 CONTROL UNIT VM 2900W FORMULAS The VM 2900W control unit has 4 preset formulas These formulas are set in the factory as follows R1 Profiled parts 11 70 kV 120 uA R2 Re coating 10 60 kV 100 pA R3 Surface parts 9 40 kV 60 uA Manual setting 8 60 kV 80 uA 11 10 B 01918 5 4 6 CONTROL UNIT VM 2900W MODIFICATION AND STORAGE OF FORMULAS Increase or reduce the high voltage with key 3 or 4 Set the current limiter higher or lower with key 5 or 6 The device has switched to manual formula setting 8 Keep the formula key pressed down until the middle six diodes light up on both bar displays 1 and 2 5 Thenew values are now stored in this formula and are preserved even when the control unit is switched off JI wm 45 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 6 MAINTENANCE Observe safety instructions in chapter 2 The spray equipment AquaCoat must be cleaned and rinsed out every day Use only the cleaning solvent recommended by the material manufacturer CAUTION Cleaning agent in the air duct Functional faults cau
27. d before work is commenced on active parts Inform staff about planned work observe electrical safety regulations 2 1 2 PERSONNEL QUALIFICATIONS Ensure that the unit is operated and repaired only by trained persons 2 1 3 ASAFEWORK ENVIRONMENT Ensure that the floor of the working area is anti static in accordance with EN 50053 Part 1 57 2 measurement in accordance with DIN 51953 Ensure that all persons within the working area wear anti static shoes e g shoes with leather soles Ensure that during spraying persons wear anti static gloves so that they are earthed via the handle of the spray gun AS Customer to provide paint mist extraction systems conforming to local regulations i 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 14 2 2 SAFETY INSTRUCTIONS FOR STAFF Always follow the information in these instructions particularly the general safety in i structions and the warning instructions 9 Always follow local regulations concerning occupational safety and accident preven tion AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 2 2 1 SAFE HANDLING OF WAGNER SPRAY UNITS The sp
28. e cover and close it by turning the knurled nuts to the right then tighten 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 Depressurize the system 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 2900W 16 The system is ready for use dep m 37 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL 5 3 2 2 SPRAYPACK WITH DOUBLE DIAPHRAGM PUMP A WAGNER AquaCoat VASER The following points must be noted 1 2 3 Si Place container 13 with suitable detergent into the AquaCoat cabinet and immerse the suction system so that the system can be checked for leaks Connect the earth Connect the AquaCoat
29. e warns of the hazard ww Possible consequences of failing to observe the warning instruc tions The signal word points out the hazard level The measures for preventing the hazard and its consequences SIHI 0101 GB Caution a possibly hazardous situation Non obser su 0102 c8 CAUTION vance can cause material damage Thisiine warns of tlie hazardl 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 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 2 GENERAL SAFETY INSTRUCTIONS 2 1 SAFETY INSTRUCTIONS FOR THE OPERATOR Keep these operating instructions to hand near the unit at all times 1 Always follow local regulations concerning occupational safety and accident preven tion 2 1 1 ELECTRICAL EQUIPMENT Electrical plant and unit 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 regu lations Must be repaired immediately in the event of problems Must be put out of operation if they pose a hazard Must be de energize
30. ed only by trained personnel Compliance with these instructions constitutes an integral component of the guarantee agreement 1 1 LANGUAGES This operating manual is available in the following languages Language Part No Language Part No German 353840 English 353841 French 353842 Dutch m Italian 353844 Spanish 353845 Danish Swedish 1 2 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 follo wing categories aie t N DANGER Danger imminent danger Non observance will result This line warns of the hazard in death serious injury and serious material damage Possible consequences of failing to observe the warning instruc P s tions The signal word points out the hazard level SIHI 0100 GB The measures for preventing the hazard and its consequences Z WARNING This line warns of the hazard Possible consequences of failing to observe the warning instruc tions The signal word points out the hazard level Warning possible danger Non observance can result in death serious injury and serious material damage The measures for preventing the hazard and its consequences SIHI 0103 GB Caution a possibly hazardous situation Non obser gt A CAUTION vance can result in minor injury vi This lin
31. flat jet air regulating pin Other nozzle sizes can be used to obtain larger or smaller spraying pat terns Wide spray angle mein minimal shaping air adjustment Back sight Seen from the spraying direction Narrow spray angle B_00694 DRM E maximal shaping air adjustment 5 4 3 EXCHANGE OF ROUND JET NOZZLE INSERT ROUND JET NOZZLE B 01928 Switch off the control unit and remove the front panel Relieve spray gun and unit pressure Replace paint with cleaning solvent and Thoroughly flush spray gun Relieve spray gun and unit pressure Unscrew the nut B by hand and remove it Remove the nozzle body C and the nozzle insert Supra A Unscrew nozzle insert Supra A with nozzle spanner I from the nozzle body C Assemble in reverse order OY UT RJ be 43 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 5 4 4 CHANGING FROM ROUND JET NOZZLE TO FLAT JET NOZZLE Co 5v urs v9 NS so Round jet nozzle A C B 01929 Flat jet nozzle Switch off the control unit and remove the front panel Relieve spray gun and unit pressure Replace paint with cleaning solvent and Thoroughly flush spray gun Relieve spray gun and unit pressure Unscrew the nut B by hand and remove it Remove the nozzle body C and the nozzle insert Supra A Take flat jet nozzle E into air cap F Place both of them parts in the
32. gs between 0 1 MPa 0 10 bar 0 145 psi Pressure gauge Material pressure regulator Pressure indication Readings between 0 1 MPa 0 10 bar 0 145 psi Pressure gauge Pump pressure display or material pressure display in the pressure tank Readings between 0 1 MPa 0 10 bar 0 145 psi Push button high voltage higher Push button high voltage lower Push button Spraying current limit more Push button Spraying current limit less Push button display Manual setting of parameters Display Manual formula setting LED display Lights up green when manual formula setting is selected Push button Stand By To switch to stand by mode High voltage cannot be activated in this mode Press the button again for normal operation Display LED Stand By Lights up when stand by mode is activated Regulator Pressure for the atomization air Adjustment between 0 1 0 MPa 0 10 bar 0 145 psi Regulator Pressure for the material pressure on the material pressure controller Adjustment between 0 1 0 MPa 0 10 bar 0 145 psi Regulator Pressure for the pump pressure or the material pressure in the pressure tank Adjustment between 0 1 0 MPa 0 10 bar 0 145 psi Selector mains supply 0 Control unit switched off 1 Control unit switched on 24 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL 26 27 28 29 30 31 32 33 34 35 36 Rear B_01890 36 Mains so
33. ing cable 11 Material pressure generator such as pneumatic pump or double membrane pump 20 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER Pos Description 12 Suction system assy 13 Paint reservoir or material pressure tank 14 Earthing switch cylinder AquaCoat 15 Earthing band 16 Filter relief combination 17 Door switch 18 Paint hose pump for material pressure regulator 19 Resistor AquaCoat 20 Air hose material pressure regulator 21 Air hose Material pressure generator 22 HV 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 accord ance with the air spraying method The spray product is regulated via the trigger guard on the spray gun 4 and by the VM 2900W 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 shielded material hose The fo
34. it and in the event of work interrup tions 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 65 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 11 3 SPARE PARTS LIST VM 2900W WARNING Incorrect maintenance repair Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by spe cially trained staff or a WAGNER service center Before all work on the unit and in the event of work interrup tions 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 B_01917 Spare parts list VM 2900W Pos K Qty Part No Description 1 1 9910204 Hexagonal nut self locking 2 2 9920118 Washer 3 1 9922109 Spring washer 4 4 1 9951117 Fuse slow acting 1 0 A Wear part Note For repairs please use service instructions article number 353895 66 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER a P 11 4 SPARE PARTS LIST GM 2900EAW 1 14 bg B_01923 Spare parts list GM 2900EAW Pos K Qty Pa
35. llowing functions are provided for system safety The earthing switch 14 the door switch 17 the earthing strip 15 and the integrated AquaCoat resistor 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 B 01925 21 x Lu oy N U E o x PART NO DOC353841 EDITION 01 2008 A WAGNER OPERATING MANUAL Electrical block diagram AquaCoat 0610 8 Tapu o neunaug yozenby upiws punodwo Bunse 5215091 l yeoyenby puejsiapim Duuue T K ddns amod 4 UMOIq L un6 feidg 391b Ze Am Dok eapuaet aum Ly au 7 DW Sij 3105 peg gt 556 10 ang 5 94 85 ZL00 0 poay funoyuow puni paay MO06Z WA XUN Ku 22 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 4 4 1 1 CONTROL UNIT VM 2900W The assembled spray system can be operated and regulated with the VM 2900W control unit Front P W i i 000000000 SRSsSSSRESE rs o9 15 17 18 19 2021 22 23 24 25 B 01880 High voltage indicator Luminous display green Reading
36. nit in a spraying booth approved for the working materials or Operate the unit on an appropriate spraying wall with the venti lation extraction switched on Observe national and local regulations for the outgoing air speed SIHI 0028 GB 30 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 5 1 2 AIR SUPPLY You must ensure that only dry clean atomizing air is used in the spray gun Dirt and mois ture in the atomising air reduce the spraying quality and the appearance of the finished piece 5 1 3 FLUID PAINT HOSES 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 remo ved and the connections
37. ntrol 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 8 1 REPLACING THE VALVE SEAT ASSY 1 Remove nozzle according to paragraph 5 4 3 or 5 4 4 2 With the trigger guard actuated prevents damage to the valve rod sealing surfaces loosen and unscrew the complete valve seat 2 with the air nozzle key 1 3 Replace in reverse order 01908 51 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 8 2 REPLACING THE VALVE ROD Do not damage the sealing surface B B_01909 1 Remove nozzle 11 or 12 according to paragraph 5 4 3 or 5 4 4 2 Remove the complete valve seat in accordance with chapter 8 1 Loosen sealing screw 3 1 2 to 1 turn with the valve rod spanner 15 available as accessory Pull trigger 5 and unscrew locking nut 8 remove compression spring 7 Loosen screw 6 and remove trigger guard 5 with shaft sleeve Unscrew sealing screw 10 from sealing sleeve 9 Holding the valve rod 14 at A pull the complete assembly out carefully and replace with a new one Gei cl wr CAUTION Leaking spray gun Risk of injury from coating material coming out Do not remove the paint sealing sleeve SIHI 0035 GB 52 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC35
38. ole of the mounting plate as shown in the illustration 40 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 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 Depressurize the system and secure the spray gun 4 6 Remove the detergent 7 Fillthe material container 13 with paint place in the cabinet and immerse the suction system 12 8 Clamp HV 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 2900W NCAUTION 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 S
39. open and electrostatics activated and material valve open B_00120 An increase in the tension needed to pull the trigger back will be felt at the position where the material valve opens In order to overcome Faraday cages in corners the high voltage can be switched off by flipping the HV switch F down Du The supply of atomizing and flat jet air is adjusted by S means of the star handles D or R 4 4 1 2 1 AIR ATOMIZING ROUND AND FLAT JET PROCESS 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 29 psi The atomizing air at approx 0 25 0 4 MPa 2 5 4 bar 36 58 psi pro duces a soft jet which largely eliminates the problem of overlapping boundaries 4 4 1 2 1 1 AIR ATOMIZING ROUND JET PROCESS The jet is cone shaped B_01892 1 Atomization air 2 Spraying material 3 Nozzle nut 27 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 4 4 1 2 1 2 AIR ATOMIZING FLAT JET PROCESS The spraying angle can be adjusted using the horn air flat jet width regulation There are various nozzles and air caps available as accessories for the respective spraying material and the output amounts see accessories 1 Atomizationair 2 Spraying material 3 Aircap 4 Shaping air 4 4 1 2 1 3 THE ELECTROSTATIC EFFECT After being electrically charged in the system and atomized by the spray gun the paint pa
40. pump Working temperature range 5 40 C 41 104 F Maxi material temperature 60 C 140 F Sound pressure level When the cabinet is open Dependent on the installed pump data can be found in the enclosed operating instructions When the cabinet is closed The values are 10 12 dB A lower Dimensions mm inch A 1390 54 72 B 616 24 25 C 1000 39 37 AquaCoat B_02140 16 EDITION 01 2008 OPERATING MANUAL AquaCoat GM 2900EAW PART NO DOC353841 A WAGNER 4 3 1 CONTROL UNIT VM 2900W Description Date Input voltage 85 264 VAC 47 440 Hz Input power maxi 25 W Output voltage maxi 22 Vpp Output current maxi 1 2 A High voltage limiter 70 kV DC Spraying current limit 120 uA DC Polarity for positive and negative high voltage generator Weight without cable 6 2 kg 13 67 lb Working temperature range 5 40 C 41 104 F Dimensions B_01885 mm inch A 136 5 35 B 370 14 57 C 220 8 66 D 252 9 92 17 EDITION 01 2008 OPERATING MANUAL PART NO DOC353841 AquaCoat GM 2900EAW A WAGNER 4 3 2 SPRAY GUN GM 2900EAW Description Date Maxi air pressure 0 8 MPa 8 bar 116 psi Maxi material pressure 0 8 MPa 8 bar 116 psi Paint connection mm inch Ao 12 l 6 O 0 47 l 0 24
41. ray 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 chap 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 Electrostatic charges can occur on the unit due to the electrostatic charge and the flow speed involved in spraying These can cause sparks and flames upon discharge Ensure that the unit is always earthed Earth the work pieces to be coated Ensure that all persons inside the working area are earthed e g that they are wearing antistatic shoes When spraying wear antistatic gloves to earth yourself via the spray gun handle 2 2 3 PAINT HOSES Ensure that the hose material is chemically resistant to the sprayed materials z Ensure that the
42. rt No Description 1 353551 Valve needle head PEEK 1 353552 Valve needle head 1 4305 9 9971147 O ring 1 350231 Valve seat assy gt w n 353353 Sealing screw Wearing part 9 Not part of standard equipment for spray gun Available however as additional extra v available in different sizes Note For repairs please use service instructions article number 353895 67 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER Spare parts list GM 2900EAW Pos K Oty Part No Description 5 1 9994248 Compression spring 6 1 179784 Tension nut assy 7 9 1 179219 Trigger GM 2000 8 1 179396 Shaft collar 9 1 9900808 Pan head screw 10 19 1 353355 Seal 11 1 353390 Protection cap 13 1 353878 Valve rod assy mounting 14 190 1 363239 Nozzle set EAW R Supra 15 1 353966 Union nut Supra 16 e 1 353953 Nozzle insert Supra EAW 17 99 1 353965 Nozzle body Supra 18 e 1 v Nozzle set EA F 19 190 1 353967 Union nut EAW F 20 9 9 1 v Nozzle EAF 211190 v Air cap EAF 22 1 353212 Air hose assy for Hose set 7 5 m 24 6 ft 22 1 353213 Air hose assy for Hose set 10 m 32 808 ft 22 1 353214 Air hose assy for Hose set 15 m 49 2 ft 22 1 353215 Air hose assy for Hose set 20 m 65 6 ft
43. rticles are now transported by kinetic and electrostatic energy to the earthed workpiece and adhere to the sprayed object finely distributed over the entire surface Paint particles Grounded object B_01893 28 EDITION 01 2008 PART NO DOC353841 OPERATING MANUAL AquaCoat GM 2900EAW A WAGNER 4 4 1 3 MATERIAL PRESSURE TANK LDG20 See separate operating instructions 4 4 1 4 DOUBLE DIAPHRAGM PUMP ZIP52 See separate operating instructions 4 4 1 5 PNEUMATIC PUMP 3 130S PE TG See separate operating instructions 29 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 5 STARTING UP AND OPERATING 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 addi tionally 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 NWARNING Toxic and or flammable vapor mixtures Risk of poisoning and burns Operate the u
44. s are assembled ready for use in the factory on the basis of the resulting configu ration number The scope of supply of each system includes Part No Description AquaCoat Spraypack consisting of AquaCoat cabinet Spray gun GM 2900EAW Control unit VM 2900W Pump or pressure tank and Accessories 353840 Operating manual German see chapter 1 Operating manual for the other language Operating manual pump or pressure tank German Operating manual pump or pressure tank for the other language see chapter 3 3 CE Declaration AquaCoat The delivery note shows the exact scope of delivery 13 EDITION 01 2008 OPERATING MANUAL PART NO DOC353841 AquaCoat GM 2900EAW A WAGNER 4 2 1 SPRAYPACK CONFIGURATION To order the AquaCoat Spray Pack please use model identification 2304604 ABCDEFGHI together with the following tables Table gt A B c Example gt 2304604 1 3 1 Configurations Number Pump Pressure tank Table A Nozzle system Table B Agitator Table C Level monitoring Table D Hose length Table E Feed tank Table Ei Barrel cover Table G Underframe Table Hi Hose holder Table 14 EDITION 01 2008 PART NO DOC353841
45. s between 0 80 kV Resolution of 0 20 kV gt 5 kV and 20 80 kV gt 10 kV Single LED display Indicates the required high voltage value in kV with the spray gun switched off Bar graph LED display Indicates the actual high voltage value in kV with the spray gun switched on Spraying current display Luminous display green Readings between 0 120 uA Resolution of 0 80 uA 10 pA to 80 120 pA 20 uA Single LED display Current limiter activation point with the spray gun switched off Bar display Indicates the actual corona current value with the spray gun switched on Push button display R1 Push button display R2 Push button display R3 Formula LED display R1 Formula LED display lights up green when formula R1 is selected Formula LED display R2 Formula LED display lights up green when formula R2 is selected Formula LED display R3 Formula LED display lights up green when formula R3 is selected Fault LED display Illuminated display red Lights up in the event of a fault in the AquaCoat gt see also description in Chap 7 23 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 High voltage LED display Illuminated display green Lights up when the high voltage on the gun is switched on Pressure gauge Atomization air pressure display for the spray gun Readin
46. sed by swollen seals Never immerse the spray gun in cleaning agent or water SIHI_0002_GB NWARNING Incorrect maintenance repair Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by spe cially trained staff or a WAGNER service center Before all work on the unit and in the event of work interrup tions 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 5 0004 GB 46 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 6 1 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 device 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 unit pressure and secure the spray gun 0 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 an air jet gun 08
47. suitable for air atomizing applications 4 1 1 PROCESSIBLE MATERIALS Water dilutable paints 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 1kQ cm and 1MQ cm The following formula can be used to determine whether the spray material is non flammable Weight H O gt 1 70xWeight LM 0 96 x Weight ORG Where Weight weight percent H 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 12 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 4 2 EXTENT OF DELIVERY AquaCoat Air spray Spray Packs can be assembled according to requirement and the de sired accessories with the help of the Spray Pack configuration All device
48. 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 ofthe system has been ascertained the spray gun can be unlocked and the system flushed through Depressurize the system and secure the spray gun 4 Remove the detergent Fillthe material container 13 with paint place in the cabinet and immerse the suction system 12 Clamp HV 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 B_01904 38 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 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 2900W NCAUTION 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 39 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 5 3 2 3 SPRAYPACK WITH PNEUMATIC PUMP 3 130S wen A quaCoat Note The 3 130S pump must be mounted in the rear h
49. t VM 2900W Modification and storage of formulas 6 MAINTENANCE 6 1 Finishing work and cleaning 7 TROUBLE SHOOTING AND SOLUTION 8 REPAIRS 8 1 Replacing the valve seat assy 8 2 Replacing the valve rod 8 3 Replacing the valve rod tip 8 3 1 Starting from installed valve rod 8 3 2 Starting from disassembled valve rod 8 4 Replacing the end piece seal 8 5 Replacing the spray gun including hose set 8 6 Replacing the paint hose and or air hose 9 DISPOSAL OF THE PRODUCT 10 ACCESSORIES 10 1 Nozzles EA Flat jet 10 1 1 Output measured with paint 10 2 Nozzles EA round jet Supra 10 2 1 Output measured with paint 10 3 Special tools 10 4 Miscellaneous 11 SPARE PARTS 11 1 How to order spare parts 11 2 Spare part list AquaCoat basic unit 11 3 Spare parts list VM 2900W 11 4 Spare parts list GM 2900EAW 30 31 31 32 33 33 33 34 34 35 35 36 36 38 40 42 42 43 43 44 45 45 46 47 48 51 51 52 53 53 54 55 56 57 59 60 60 60 61 61 62 62 64 64 65 66 67 AquaCoat GM 2900EAW A WAGNER AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 1 ABOUT THESE INSTRUCTIONS This operating manual contains information about the operation repair and maintenance of the unit Always follow these instructions when operating the unit This equipment can be dangerous if it is not operated in accordance with this manual Electrostatic spray guns may be operat
50. to the earth potential must not be loo sened 1 Earth connection in the cabinet 2 Earth connection in the gun SIHI 0128 GB 31 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 5 1 4 EARTHING Perfect earthing of all system components workpieces conveyor paint supply system control unit spraying cabin or spraying stand se illustration is a prerequisite for optimum coating efficiency and safety NWARNING 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 workpiece will result in e Very poor wrap around e Uneven coating thickness e Backspraying to the spray gun i e contamination The prerequisites for perfect earthing and coating are e Clean workpiece suspension e Earthing of spraying cabin conveyor system and suspension on the building side in accordance with the operating instruction or the manufacturer s information e Earthing of all conductive parts within the working area The earthing resistance of the workpiece must not exceed 1 MO Mega Ohm e Connect the AquaCoat cabinet to the system earth Earthing scheme example Conveyor Anti static floor System earth System earth 32 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPER
51. ve gloves When operating the unit with a coating material with a temperature of gt 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 WAGNER accepts no liability for any damage arising from incorrect use Use the unit only to work with the materials recommended by WAGNER Operate the unit only as an entire unit Do not deactivate safety equipment Use only WAGNER original spare parts and accessories 2 4 SAFETY RELEVANT INFORMATION ABOUT DISCHARGES The plastic parts of the cabinet are charged electrostatically by the high voltage field Harmless discharges brush discharges are possible after contact with plastic parts They are completely harmless for people HM AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 3 PRODUCT LIABILITY AND WARRANTY 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 re gulations are obser
52. ve rod 14 must be dismounted See chap 8 3 2 Assembly Insert new valve rod tip 13 into the assembly tool screw onto the valve rod and carefully tighten Note If using a metal valve rod tip the threaded joint must be secured with Loctite 222 Complete assembly of the gun 8 3 2 STARTING FROM DISASSEMBLED VALVE ROD Loctite 222 Only bond in the case of metal tips 14 B_01920 Dismount the complete valve rod 14 in accordance with chapter 8 2 Carefully clamp the valve rod 14 in position C with padding taking care not to damage the sealing surfaces Loosen and unscrew the valve rod tip 13 with the assembly tool D order number 353560 Screw in the new valve rod tip and tighten carefully with the assembly tool D Note If using a metal valve rod tip the threaded joint must be secured with Loctite 222 Mount the complete valve rod 14 in accordance with chapter 8 2 54 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841 A OPERATING MANUAL WAGNER 8 4 REPLACING THE END PIECE SEAL D Ne Remove nozzle according to chapter 5 4 3 or 5 4 4 Remove valve rod assy 14 according to chapter 8 2 Unscrew the sealing screw 3 with the valve rod spanner 15 order number 353805 Remove the sealing ring 4 from the end piece together with the O ring with a size 5 eye bolt Assemble in reverse order Installation position 55 AquaCoat GM 2900EAW EDITION 01 2008 PART NO DOC353841
53. ved 3 2 WARRANTY This unit is covered by our warranty on the following terms 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 terms of the warranty are met at our discretion by the repair or replacement of the unit or parts thereof 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 This warranty does not cover damage caused by 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 electrochemical or electrical agents except when the damage is attributable to us Abrasive coating products such as redlead emulsions glazes liquid abrasives zinc dust paints and similar reduce the service life of valves packings spray guns nozzles cylinders pistons etc Any wear resulting from the aforementioned causes is not covered by this warranty Components not manufactured

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