WAGNER GM 1-350, GM 1-530 Operating Manual
B_5040
Airless manual gun
Version 02/2015
Translation of the Original
Operating Manual
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GM 1-350/530
OPERATING MANUAL
VERSION 02/2015 ORDER NUMBER DOC2349369
Table of Contents
1 ABOUT THESE INSTRUCTIONS 3
1.1 Preface 3
1.2 Warnings, Notices and Symbols in these Instructions 4
1.3 Languages 4
2 CORRECT USE 5
2.1 Safety Parameters 5
2.2 Reasonably Foreseeable Misuse 5
2.3 Residual Risks 5
3 IDENTIFICATION 6
3.1 CE Explosion Protection Identi cation 6
3.2 Identi cation "X" 6
3.3 Type Plate 6
4 GENERAL SAFETY INSTRUCTIONS 7
4.1 Safety Instructions for the Operator 7
4.2 Safety Instructions for Sta 8
5 DESCRIPTION 11
5.1 Design 11
5.2 Device Type 11
5.3 Type of Use 11
5.4 Mode of Operation 11
5.5 Protective and Monitoring Equipment 11
5.6 Scope of Delivery 11
5.7 Data 12
6 ASSEMBLY AND COMMISSIONING 13
6.1 Training Assembly/Commissioning Sta 13
6.2 Assembly and Installation 13
6.3 Grounding 14
6.4 Safety Checks 14
6.5 Preparation of Lacquer 14
6.6 Commissioning 15
7 OPERATION 16
7.1 Training the Operating Sta 16
7.2 Safety Instructions 16
7.3 Work 16
8 CLEANING AND MAINTENANCE 20
8.1 Cleaning 20
8.2 Maintenance 22
8.3 Replacing the Product Hose 24
8.4 Replacing the Nozzle Seal 24
8.5 Changing or Cleaning Filter Insert 25
9 TROUBLESHOOTING AND RECTIFICATION 26
10 REPAIR WORK 26
10.1 Repair Sta 26
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GM 1-350/530
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VERSION 02/2015 ORDER NUMBER DOC2349369
Table of Contents
11 DISPOSAL 26
12 ACCESSORIES 27
12.1 Nozzles 27
12.2 Intermediate Piece 27
13 SPARE PARTS 27
13.1 How Can Spare Parts Be Ordered? 27
13.2 Spare Parts List GM 1-350/530 28
14 WARRANTY AND CONFORMITY DECLARATIONS 30
14.1 Important Notes Regarding Product Liability 30
14.2 Warranty Claim 30
14.3 CE Declaration of Conformity 31
14.4 Notes on National Regulations and Guidelines 31
1 ABOUT THESE INSTRUCTIONS
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device. The operating manual is part of the device and must be available
to operating and service sta . The device may only be operated by trained sta and in
compliance with this operating manual. Operating and service personnel should be
instructed according to the safety instructions. This equipment can be dangerous if it is
not operated according to the instructions in this operating manual.
1.1 PREFACE
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GM 1-350/530
OPERATING MANUAL
VERSION 02/2015 ORDER NUMBER DOC2349369
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this operating manual highlight particular dangers to users and to
the device and state measures for avoiding the hazard. These warning instructions fall into
the following categories:
Danger - immediate risk of danger.
Non-observance will result in death or serious injury.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
Note - provides information about particular characteristics and how to proceed.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the danger and its
consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the danger and its consequences.
NOTICE
1.3 LANGUAGES
The operating manual is available in the following languages:
Language: Order No. Language: Order No. Language: Order No.
German 2348756 English 2349369 French 2355489
Italian 2355491 Spanish 2355493 Russian 2356564
Chinese 2356565 Swedish 2356566 Polish 2356567
Norwegian 2356568 Dutch 2356570 Finnish 2356571
Czech 2356572
The service manual is available in the following languages:
Language: Order No. Language: Order No.
German 2355505 English 2355506
Additional languages on request or at:
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GM 1-350/530
OPERATING MANUAL
VERSION 02/2015 ORDER NUMBER DOC2349369
2 CORRECT USE
2.1 SAFETY PARAMETERS
WAGNER accepts no liability for any damage arising from incorrect use.
Use the device only to work with the products recommended by WAGNER.
Only operate the device as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The device may only be operated under the following conditions:
The operating sta must be trained on the basis of this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must be observed.
The statutory requirements and accident prevention regulation standards in the country of use must be
observed.
2.2 REASONABLY FORESEEABLE MISUSE
The forms of misuse listed below may result in physical injury or property damage:
coating work pieces which are not grounded;
unauthorized conversions or modi cations to the system;
processing dry or similar coating products, e.g., powder;
using defective components, spare parts or accessories other than those described in
the "Accessories" chapter of this operating manual;
continuing work with a defective or kinked product hose;
working with incorrectly set values;
processing food.
2.3 RESIDUAL RISKS
Residual risks are risks which cannot be ruled out even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual risks.
Residual risk Source Consequences Speci c measures Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Handling of
lacquers and
cleaning agents
Skin irritations, Wear protective
clothing,
operation,
allergies observe safety data
sheets
maintenance,
disassembly
Lacquer in air
outside the de ned
working area
Lacquering outside
the de ned
working area
Inhalation of
substances
hazardous to health
Observe work
and operation
instructions
operation,
maintenance
6
GM 1-350/530
Serial-No. XXXXX
J. Wagner AG
9450 Altstaetten
SWISS MADE
WARNING
SKIN INJECTION HAZARD
READ INSTRUCTION MANUAL
II 2G X
1
6
5
B_5041
GM 1-530
MAX WPR
530 bar
7687 psi
MAX TEMP
85 °C
185 °F
3
4
2
FIRE AND EXPLOSION HAZARD
READ INSTRUCTION MANUAL
7
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3 IDENTIFICATION
3.1 CE EXPLOSION PROTECTION IDENTIFICATION
The device is compliant with Ex II 2G X regulations and is suitable for use in potentially
explosive areas (zone 1) in accordance with Directive 94/9/EC (ATEX).
Device type: Airless manual gun
Manufacturer: J. Wagner AG, CH - 9450 Altstätten
II 2G X
3.2 IDENTIFICATION "X"
X: The maximum surface temperature corresponds to the permissible product temperature.
This and the permissible ambient temperature can be found in the "Technical Data" chapter.
Safe handling of WAGNER spray devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the device against steel or rusty iron.
Do not drop the spray gun.
Use only tools that are made of a permitted material.
Ignition temperature of the coating material
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
3.3 TYPE PLATE
3.3.1 GM 1530 EXAMPLE TYPE PLATE
1 Serial number
2 Spray gun designation
3 Maximum product pressure
4 Maximum product temperature
5 Warning
6 Danger of injury from injection/read operating manual
7 Fire and explosion hazard/read operating manual
8 "Warning – Hot surface!"
CE European Communities 2 Category 2 (Zone 1)
Ex Symbol for explosion protection G Ex-atmosphere gas
II Device class II X Special Notice
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GM 1-350/530
OPERATING MANUAL
VERSION 02/2015 ORDER NUMBER DOC2349369
4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL EQUIPMENT
4.1.2 PERSONNEL QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
Electrical devices and equipment
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient in uences.
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 decommissioned if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Ensure that the device is operated and repaired only by trained persons.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 megohms).
Ensure that all persons within the working area wear static dissipative shoes. Footwear
must comply with EN 20344. The measured insulation resistance must not exceed
100megohms.
Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the gun's bow guard.
If protective clothing is worn, including gloves, it has to comply with EN 1149-5. The
measured insulation resistance must not exceed 100 megohms.
Paint mist extraction systems/ventilation systems must be tted on site according to
local regulations.
Ensure that the following components of a safe working environment are available:
- Product/air hoses adapted to the working pressure.
- Personal safety equipment (breathing and skin protection).
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
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GM 1-350/530
OPERATING MANUAL
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4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before all work on the device, in the event of work interruptions and functional faults:
- Switch o the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
- In the event of functional faults, remedy the fault as described in the "Troubleshooting"
chapter.
If necessary or at least every 12 months, the liquid ejection devices should be checked
for safe working conditions by an expert (e.g., Wagner Service Technician) in accordance
with the guidelines for liquid ejection devices (ZH1/406 and BGR500 Part2 Chapter2.29
and 2.36).
- For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure Relief" chapter:
- If pressure relief is required.
- If the spraying work is interrupted or stopped.
- Before the device is cleaned on the outside, checked or serviced.
- Before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by paint or ushing agents:
Note the paint or ushing agent that you have been using.
Consult a doctor immediately.
Avoid risk of injury from recoil forces:
Ensure that you have firm footing when operating the spray gun.
Only hold the spray gun brie y in a position.
4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
4.2.2 GROUNDING THE DEVICE
In order to avoid electrostatic charging of the device, the device must be grounded.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Ensure that the device is grounded for every spraying operation.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
Wear static dissipative gloves when spraying. The grounding takes place via the gun's
bow guard.
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OPERATING MANUAL
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4.2.3 PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products and the
used ushing agents.
Ensure that the product hose is suitable for the pressure generated.
Ensure that the following information can be seen on the high pressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in the
following places under any circumstances:
- In high-traffic areas
- At sharp edges
- On moving parts
- On hot surfaces
Ensure that the hoses are never run over by vehicles (e.g. fork lifts), or that the hoses are
never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 megohm.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coe cient. In some cases their volume can rise with
consequent damage to pipes, ttings, etc. and cause uid leakage.
When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can enter
the tank. Thus a negative pressure is avoided. The vacuum could implode the container
(squeeze) and can cause it to break. The container would leak and the liquid would ow
out. The pressure created by the pump is a multiplication of the inlet air pressure.
4.2.4 CLEANING AND FLUSHING
Relieve the pressure from the device.
De-energize the device electrically.
Preference should be given to non- ammable cleaning and ushing agents.
Observe the speci cations of the paint manufacturer.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical
ventilation.
Take measures for workplace safety (see Chapter 4.1.3).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- depending on the ushing agent (solvent) used,
explosive mixture inside the lines and items of equipment.
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OPERATING MANUAL
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4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
When preparing or working with lacquer and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents and cleaning agents
being used.
Take the speci ed protective measures, in particular wear safety goggles, protective
clothing and gloves, as well as skin protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For su cient health and environmental safety: Operate the device in a spray booth or
on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.
Only electrically conductive tanks may be used for cleaning and ushing agents.
The containers must be grounded.
An explosive gas/air mixture forms in closed containers.
Never spray into a closed tank when using solvents for ushing.
External cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects, and
never spray cleaning agents with a spray gun. Cleaning the device must not damage it
in any way.
Ensure that no electrical component is cleaned with nor even immersed into solvent.
4.2.6 TOUCHING HOT SURFACES
Only touch hot surfaces (temperature > 43 °C; 109 °F) if you are wearing protective
gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109.4°F:
- Identify the device with a warning label, "Warning – Hot surface".
Order No.
9998910 Instruction label
9998911 Protection label
Note: Order the two stickers together.
WARNING
Hot coating products!
Burns
Wear antistatic protective gloves.
When operating the device with a coating product with a
temperature of > 43 °C;109.4 °F, identify the device with a
warning label that says "Warning - hot surface".