WAGNER GM 5000EA Operating Manual
B_03229
C
us
Electrostatic Air Spray Gun
for manual operation
for at or round jet nozzles
Version 04/2016
Translation of the Original
Operating Manual
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Contents
1 ABOUT THESE INSTRUCTIONS 7
1.1 Preface 7
1.2 Warnings, Notices and Symbols in these Instructions 7
1.3 Languages 8
1.4 Abbreviations 8
1.5 Terminology for the Purpose of this Manual 9
2 CORRECT USE 10
2.1 Device Type 10
2.2 Type of Use 10
2.3 Use in an Explosion Hazard Area 10
2.4 Safety Parameters 10
2.5 Processible Working Materials 11
2.6 Reasonably Foreseeable Misuse 12
2.7 Residual Risks 12
3 IDENTIFICATION 13
3.1 Explosion Protection Identi cation FM 13
3.2 Type Plate 14
4 GENERAL SAFETY INSTRUCTIONS 15
4.1 Safety Instructions for the Operator 15
4.1.1 Electrical Equipment 15
4.1.2 Personnel Quali cations 15
4.1.3 Safe Work Environment 15
4.2 Safety Instructions for Sta 16
4.2.1 Safe Handling of WAGNER Spray Devices 16
4.2.2 Grounding the Device 17
4.2.3 Product Hoses 17
4.2.4 Cleaning and Flushing 18
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 19
4.2.6 Touching Hot Surfaces 19
4.3 Protective and Monitoring Equipment 19
4.4 Use in Areas Subject to Explosion Hazards 20
4.4.1 Safety Regulations 20
4.5 Safety-Relevant Information about Discharges 20
5 DESCRIPTION 21
5.1 Structure (Standard Variant) 21
5.2 Mode of Operation 22
5.3 Scope of Delivery 24
5.3.1 Design Variants 25
5.4 Technical Data 26
5.5 Spraying Procedure 28
5.5.1 Spraying Procedure for Round Jet Air Atomizing 28
5.5.2 Spraying Procedure for Flat Jet Air Atomizing 29
5.5.3 Electrostatic E ect 30
5.6 The WAGNER Electrostatic Air Spraying System 31
5.6.1 Pressure Settings for Round Jet Nozzles 31
5.6.2 Pressure Settings for Flat Jet Nozzles 32
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5.6.3 Adjusting Screw 32
5.6.4 Electrostatic and Atomization 33
5.6.5 Discharge Quantity Measurements 33
6 ASSEMBLY AND COMMISSIONING 34
6.1 Training Assembly/Commissioning Sta 34
6.2 Storage Conditions 34
6.3 Installation Conditions 34
6.4 Transportation 34
6.5 Assembly and Installation 35
6.5.1 Typical Electrostatic Air Spraying System 35
6.5.2 Ventilation of the Spray Booth 36
6.5.3 Air Supply 37
6.5.4 Product Supply 37
6.5.5 Grounding 38
6.6 Preparation of Lacquer 40
6.6.1 Viscosity Conversion Table 40
6.7 Commissioning 41
6.7.1 Safety Instructions 41
6.7.2 Preparation for Commissioning 41
6.7.3 Commissioning 41
6.7.3.1 Gun Cables and Gun Cable Extensions 42
6.7.4 Verifying a Safe Operational Condition 43
7 OPERATION 44
7.1 Training the Operating Sta 44
7.2 Safety Instructions 44
7.2.1 Emergency Deactivation 45
7.2.2 General Rules for Making Adjustments to the Spray Gun 45
7.3 Working 46
7.3.1 Filling with Working Material 46
7.3.2 Checking the Spray Pattern (Without Electrostatics) 47
7.3.3 Spraying 48
7.3.4 Pressure Relief/Work Interruption 50
7.3.5 Changing from Air Round Jet to Air Flat Jet 51
7.3.6 Cleaning of the Nozzle Parts 52
7.3.7 Changing the Valve Housing 52
8 CLEANING AND MAINTENANCE 53
8.1 Cleaning 53
8.1.1 Cleaning Sta 53
8.1.2 Safety Instructions 53
8.1.3 Cleaning and Flushing the Device 55
8.2 Maintenance 57
8.2.1 Maintenance Sta 57
8.2.2 Safety Instructions 57
8.2.3 Safety Checks 58
8.2.4 Product Hoses, Tubes and Couplings 59
9 TROUBLE SHOOTING AND RECTIFICATION 60
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10 REPAIR WORK 61
10.1 Repair Sta 61
10.2 Safety Instructions 61
10.3 Dismantling of the Gun 62
10.3.1 Tools 62
10.3.2 Dismantling of the Spray Gun 63
10.3.3 Cleaning the Parts After Disassembly 66
10.3.4 Assembling the Spray Gun 67
11 FUNCTION TEST AFTER THE REPAIR 72
11.1 Checking the High voltage 72
11.2 Air Test 74
11.3 Product Pressure Test 74
11.4 Test of Spray Pattern 74
12 DISPOSAL 75
13 ACCESSORIES 76
13.1 Valve Housing 76
13.2 Valve Tips 76
13.3 Round Spray Nozzles 76
13.3.1 AR 5000 Air Caps 76
13.3.2 AR 5000 Nozzles 76
13.3.3 Nozzle set EARV 77
13.4 Flat Jet Nozzles 77
13.4.1 AF 5000 Air Caps 77
13.4.2 AF 5000 Nozzles 78
13.5 Hoses and Electric Cables 79
13.5.1 Standard Hose Sets and Components 79
13.5.2 Hose Sets for Low-resistance Products 81
13.5.3 Spiral Hose (no FM Approval) 84
13.5.4 Gun Cables and Gun Cable Extensions 84
13.5.5 Air Regulation 84
13.5.6 4 Finger Trigger 85
13.6 Miscellaneous 86
14 SPARE PARTS 87
14.1 How Can Spare Parts Be Ordered? 87
14.2 GM 5000EA Spray Gun 88
14.2.1 Basic version GM 5000EA 88
14.2.2 Spiral Hose for GM 5000EA 90
14.2.3 4 Finger Trigger for GM 5000EA 92
14.2.4 GM 5000EA Adapter 94
14.2.5 GM 5000EA Handle 96
14.3 Accessories Spare Parts Lists 98
14.3.1 AR 5000 Nozzle (D8) 99
14.3.2 AR 5000 Nozzle (D12) 99
14.3.3 Nozzle Set EARV 5000 100
15 WARRANTY 101
15.1 Important Notes Regarding Product Liability 101
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15.2 Warranty Claim 101
15.3 FM Approval 102
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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 hazard 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 hazard 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 hazard 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 hazard and its consequences.
NOTICE
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 the operating and
service personnel.
The device may only be operated by trained personnel 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.
Electrostatic spray guns may only be operated by trained personnel.
1.1 PREFACE
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1.3 LANGUAGES
1.4 ABBREVIATIONS
Order No. Order number
Spare part
Marking in the spare parts lists
Electrostatics Air
Manual gun
Low R Low-resistance
Polyether ether ketone (high temperature-resistant thermoplastic plastic)
Stainless steel
Position
Number of pieces
Wrench size
The GM 5000EA operating manual is available in the following languages:
Language Order No. Language Order No.
German 2356789 English 2344499
Additional languages on request or at:
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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Product pressure
generator
Pump or pressure tank
Sta quali cations
Trained person Is instructed in the tasks assigned to him/her, the potential
risks associated with improper behavior as well as the
necessary protective devices and measures.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as
well as the necessary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person A person who, based on his/her technical training, experience
and recent vocational experience, has su cient technical
knowledge in the area of electrostatic coating and is familiar
with the relevant and generally accepted rules of technology
so that he/she can inspect and assess the status of devices and
coating systems based on workplace safety.
in the context of BGI 764
Additional requirements for skilled persons can also be
referred to in TRBS1203(2010): Expert knowledge in the areas
of protection against excessive pressure, electrical hazards,
and explosion protection (where applicable).
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2 CORRECT USE
2.1 DEVICE TYPE
Electrostatic manual spray gun for manual coating of grounded work pieces.
2.2 TYPE OF USE
The GM 5000EA electrostatic manual spray gun is suitable for spraying liquid products,
particularly coating products, using the air atomizing method. Coating products which
contain ingredients of explosion class IIA and IIB substances (maximum ignition energy
0.24 mJ) may be used.
WAGNER forbids any other use!
2.4 SAFETY PARAMETERS
2.3 USE IN AN EXPLOSION HAZARD AREA
The GM 5000EA electrostatic manual spray gun is suitable for coating electrically
conductive objects with liquid coating products and can be used in potentially explosive
areas (see explosion protection marking in Chapter 3).
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 personnel 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.
The electrostatic manual spray gun may only be operated if all parameters are set and all
measurements/safety checks are carried out correctly.
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2.5 PROCESSIBLE WORKING MATERIALS
Lacquers which contain ingredients of explosion class IIA and IIB substances (maximum
ignition energy 0.24 mJ) can be processed with the GM 5000EA spray gun.
The spray gun basic version is suitable for processing sprayed substances with an
electrical resistance of > 150 kΩ (according to the WAGNER scale).
Equipped with a special product hose for low-resistance sprayed substances (available
as an accessory), you can also successfully process sprayed substances with an
electrical resistance > 50 kΩ (according to the WAGNER scale).
The application e ectiveness is always dependant on the composition of the product
being used, e.g. pigments or resin.
Conversion of Paint Resistance
There are paint resistance measuring devices available on the market that do not directly
measure the speci c paint resistance.
Multiplying the result of the measurement with the device-speci c cell constant (K), we
obtain the speci c resistance value of the product.
Example:
With WAGNER's paint resistance measuring device the cell constant is K =123.
Measured value according to the WAGNER
scale
Speci c resistance (RS)
Notice
Using sprayed substances with too low an electrical resistance, the application of
electrostatics does not show any e ect, i.e. there is no "paint wrap around" on the object
to be sprayed.
The suitability of the spray product with regard to the charging ability can be read from the
actual values for high-voltage (kV) and for the spray current (μA) shown in the illuminated
displays either on the VM 5000 control unit or on the spray gun.
High kV value, low μA value = ok.
Low kV value, high μA value = Excessive conductivity of the paint.
No wrap-around
Please contact your local WAGNER dealer and the lacquer manufacturer if you encounter
application problems.
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2.6 REASONABLY FORESEEABLE MISUSE
2.7 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 maintenance,
Observe safety data
sheets
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
The forms of misuse listed below may result in physical injury or property damage:
use with non-authorized control units;
coating work pieces which are not grounded;
working with an ungrounded lacquer supply system;
performing unauthorized conversions or modi cations to the device;
processing inadmissible coating products;
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;
use in the pharmaceutical sector.
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION FM
This device has been manufactured and tested by FM, according to the FM (Factory Mutual)
standard "Class Number 7260" (Approval Standard for Electrostatic Finishing Equipment).
All tested combinations of devices including accessories are given in the FM Control
Document with part number 2316160.
Temperature notes
- Maximum surface temperature: 85 °C; 185 °F
- Maximum permissible product temperature: 50 °C; 122 °F
- Permissible ambient temperature: 0 to +40 °C; +32 to +104 °F
For electrostatic nishing applications using class I,
group D, spray product
In accordance with document 2316160
Cable connections
Only cable assigned to the device may be used (see Chapter 13).
Permissible Device Combinations
The GM 5000EA manual spray gun may only be connected to the control units listed below:
- VM 500 control unit (USA)
- VM 5000 control unit (USA)
Incorrect use!
Risk of injury and damage to the device.
Connect the GM 5000EA manual spray gun only to original
WAGNER control units.
WARNING
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B_04191
1
GM 5000EA
Art. Nr.:
0.8MPa; 8bar; 116psimax. mat. pressure:
max. air pressure: 0.8MPa, 8bar; 116psi
2344472
current: max. 100μA D C
high voltage: max. 70kV DC
J. Wagner AG
CH-9450 Altstätten
In accordance
with 2316160
FM
CUS
APPROVED
For Electro. Fin. Appl. CL. I, GP. D, Spray Matl.
Ta = 0°C to 40°C, Temp code = T6
1
3
4
5
6
7
2
8
9
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3.2 TYPE PLATE
Serial number
The serial number (S) on the underside
of the handle.
1 Warning: Danger of becoming injured by high-
pressure jet
2 Device type
3 Article number
4 Maximum high voltage
5 Maximum current
6 Maximum product pressure
7 Maximum air pressure
8 Do not dispose of used electrical equipment with
household refuse.
9 Identi cation and test centre
10
Type plate left Type plate right
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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.
Ensure that the device is only operated, maintained and repaired 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 spray gun handle or the trigger guard.
If protective clothing is worn, including gloves, it has to comply with EN1149-5. 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).
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. With open
housings, there is a danger from line voltage.
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 or are damaged.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Connect all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground wire
connection.
Keep liquids away from electrical devices.
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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.
Anyone tted with a pacemaker must not enter the high-voltage area!
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.
The liquid ejection devices are with need, at least however every 12 months to examine
by experts (e.g., WAGNER Service Technician) in accordance with the guidelines for
liquid ejection devices (DGUV regulation 100-500).
- 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.
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. No smoking.
Ensure that the pipe joints, hoses, equipment parts and connections are permanently,
technically leak-proof:
- Periodic preventative maintenance and service (replacing hoses, checking tightness
strength and connections etc.).
- Regular monitoring of leaks and defects via visual inspection and odor testing, e.g.,
daily before commissioning, at the end of work or weekly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
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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,
- on sharp edges,
- on moving parts or
- 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.
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 tank
(squeeze) and can cause it to break. The tank would leak and the liquid would ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
4.2.2 GROUNDING THE DEVICE
Friction, owing liquids and air or electrostatic coating processes create charges. Flames or
sparks can form during discharge. Grounding prevents electrostatic charging.
Ensure that the device is grounded. See chapter "Grounding".
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 spray
gun handle.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.
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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 lacquer 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.
Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
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 gun. Cleaning the device must not damage it in any
way.
Ensure that no electrical component is cleaned with nor even immersed into solvent.
Which cleaning agent is used to clean the spray gun depends on which parts of the
spray gun have to be cleaned and which product has to be removed. When cleaning the
spray gun, only use non-polar cleaning agents to prevent conductive residues on the
surface of the spray gun. Should it however, be necessary to use a polar cleaning agent,
all residues of this cleaning agent have to be removed by using a non-conductive and
non-polar cleaning agent, once the cleaning is nished.
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4.2.6 TOUCHING HOT SURFACES
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109°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.
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.
4.3 PROTECTIVE AND MONITORING EQUIPMENT
Protective and monitoring equipment must not be removed, modi ed or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must not
be operated until these defects are remedied.
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4.4 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS
The spray gun may be used in potentially explosive areas. The following safety regulations
must be observed and followed.
4.4.1 SAFETY REGULATIONS
Observe safety instructions in Chapter 3.2.
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.
Surface spraying, electrostatics
Never spray device parts using electrostatic equipment (electrostatic spray gun!).
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
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.
Use only a damp cloth to clean the device.
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.
4.5 SAFETYRELEVANT INFORMATION ABOUT DISCHARGES
The plastic parts of the spray gun are charged electrostatically by the high-voltage eld
of the spray gun. Contact with plastic parts harmless discharges (brush discharges) may
occur. They are completely non-hazardous for human health.
When keeping a distance of 4 to 10 mm; 0.15 to 0.4 inch between spray gun and object to
be sprayed, the corona discharge at the end of the electrode is visible in the dark.
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5 DESCRIPTION
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 (accessories: see Chapter 13)
6 Union nut
7 Flat spray nozzle AF 5000 x.x
(accessories: see Chapter 13)
8 Adapter
9Cover
10 Handle
Description
11 Adjusting screw (stop)
12 Trigger lever
14 Nozzle AR 5000 (accessories: see Chapter 13)
15 Sealing plug
16 Air regulation
17 Electric cable connection
18 Atomizing air connection
19 Product connection
20 Air cap AR 5000 (accessories: see Chapter 13)
21 Type plate left
22 Type plate right
Note:
The nozzle parts (pos. 5; 7; 14 and 20) do not belong to the basic equipment of the spray
gun. The di erent versions can be found in Chapter 13 "Accessories".
5.1 STRUCTURE STANDARD VARIANT
Note:
The gun type (T) is speci ed on the type plate and the serial number (S) is
speci ed on the underside of the handle.
22
GM 5000EA
R1
R3
R2
B_03182
2
4
3
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.2 MODE OF OPERATION
Display (2)
= Recipe values changed temporarily:
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.
When the spray gun is connected to the control unit and the
control unit is switched on, the pre-de ned recipe (R1, R2 or
R3) is shown on the gun display (2) as follows.
Recipe 1
Recipe 2
Recipe 3
Recipe change R1 R2 R3 R1.
Press the operating button (4) and hold the button pressed for
at least 2 seconds to go forward 1 recipe.
During spraying mode (trigger lever pressed), the status is shown in the display (2) by LEDs.
LED display Description
LEDs 1 - 3 light up green The spray gun is working in an optimal
high-voltage spray current range.
One or both right-hand LEDs illuminate
in orange.
Spray current too high.
Possible causes:
(Warning display: You can continue
working without any limitations.)
- Spray gun too close to the work piece
- Contamination of the spray gun
- Paint conductivity too high
23
GM 5000EA
R1
R3
R2
B_03183
16
2
4
3
1
2
3
4
B_03157
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Distance Description
1 Atomizing air open.
2 Atomizing air open and electrostatically (high
voltage) activated.
Display (2) for "spray current" on the spray
gun to activated.
3 Atomizing air open, electrostatically (high
voltage) activated and product valve open.
4 Overall way of trigger.
The trigger can be used to activate, one after the other, the
various functions of the spray gun.
- An increase in the force needed to pull the trigger back will
be perceived at the position where the product valve opens.
- For spraying without high voltage, the high voltage can
be switched o using the operating button (4). Press the
operating button (4) brie y: High voltage is switched o .
The standby display (3) illuminates.
- In the event of a malfunction the spray gun switches to
"standby" operating mode and the display (3) illuminates.
- The relationship between forming air and atomizing air is
set using the air regulator (16).
24
GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.3 SCOPE OF DELIVERY
Order No. Description
2344471 GM 5000EA spray gun (USA)
2363670 GM 5000EA spray gun spiral hose (USA)*
2367744 GM 5000EA spray gun 4 nger trigger (USA)
All variants without control unit, product and air hose, electric cable,
air cap and nozzle.
* no FM approval, in submission
Each spray gun includes the following as standard equipment:
Order No. Description
2309368 Valve needle assembly tool
2325263 Clamping screw assembly tool
2319653 Protection gloves against spray mist
2316160 FM Control Document
see Chapter 1.3 Operating manual in local language
The spray gun basic version can be adapted optimally to any application depending upon
the requirements and the desired accessories with the help of spray gun con guration.
The delivery note shows the exact scope of delivery.
25
GM 5000EA
B_06068
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.3.1 DESIGN VARIANTS
Basic version GM 5000EA (USA)
Order No. 2344471
GM 5000EA 4 nger trigger (USA)
Order No. 2367744
Spiral hose GM 5000EA (USA)
(no FM approval, in submission)
Order No. 2363670
for processing of metallic lacquers
26
GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.4 TECHNICAL DATA
Maximum air pressure 0.8 MPa; 8 bar; 116 psi
Maximum product pressure 0.8 MPa; 8 bar; 116 psi
Fluid inlet NPSM 3/8"–18
Air connection NPSM 1/4"–18
Input voltage maximum 20 Vpp
Input current maximum 1.0 A AC
Output voltage maximum 70 kV DC
Output current maximum 100 µA DC
Ambient temperature 0 °C - 40 °C; 32 °F - 104 °F
Maximum permissible product temperature: 50 °C; 122 °F
Maximum surface temperature 85 °C; 185 °F
Compressed air quality: free from oil and water
Quality standard 6.5.2 according to ISO 8573.1, 2010
6: Particle density ≤ 5mg/m
5: Humidity: pressure dew point ≤ +7°C
2: Oil content ≤ 0.1mg/m
Weight (without hose set) 630 g (incl. union nut, nozzle and air cap)
Sound level at 0.3 MPa; 3 bar; 43.5 psi air pressure
and 0.3 MPa; 3 bar; 43.5 psi product pressure *
73 dB(A)
* A-rated sound pressure level measured at 1 m distance, LpA1m, in accordance with DIN EN 14462: 2005.
27
GM 5000EA
B_03230
C
A
B
C
A
B
B_03231
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
with at jet nozzle
mm inch
A 261 10.28
B 46 1.81
C 245 9.65
Dimensions
with round jet nozzle
mm inch
A 261 10.28
B 46 1.81
C 245 9.65
28
GM 5000EA
B_03446
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.5 SPRAYING PROCEDURE
Spray pattern
Union nut
Spray product
Atomizing air
Advantages
- Thin layers
- Uniform coating thickness
- Perfect nish
In this process, the spray product is fed to the nozzle with a pressure of approx. 0.05–0.2 MPa; 0.5–2 bar;
7–29 psi. The atomizing air at approx. 0.25 - 0.4 MPa; 0.25 - 4 bar; 36 - 58 psi produces a soft round jet, which
largely eliminates the problem of overlapping boundaries. There are various nozzles and air caps available as
accessories for the respective spray product and the discharge quantities.
5.5.1 SPRAYING PROCEDURE FOR ROUND JET AIR ATOMIZING
29
GM 5000EA
B_00180
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
5.5.2 SPRAYING PROCEDURE FOR FLAT JET AIR ATOMIZING
Shaping air
Air cap
Spray pattern
Atomizing air
Advantages
- Large range of adjustment of the spray jet
- Thin layers
- Uniform coating thickness
- Perfect nish
Spray product Spray angle
In this process, the spray product is fed to the nozzle at a pressure of 0.05–0.2 MPa; 0.5–2 bar; 7–29 psi. The
atomizing air at approx. 0.25 - 0.4 MPa; 2.5 - 4 bar; 36 - 58 psi produces a soft round jet, which largely eliminates
the problem of overlapping boundaries. The shaping air allows modi cation of the spray jet. There are various
nozzles and air caps available as accessories for the respective spray product and the discharge quantities.
30
GM 5000EA
"?
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Electrode
Paint particle
Object to be
sprayed is grounded
5.5.3 ELECTROSTATIC EFFECT
The spray gun produces an electrostatic eld by means of the high-voltage electrode. As
a result, the paint particles atomized by the spray gun are carried to the grounded work
piece by kinetic and electrostatic energy, where they adhere nely dispersed to the object
to be sprayed.
Advantages
- Very high application e ectiveness
- Low over spray
- Coating of entire circumferences due to the electrostatic e ect
- Savings in working time
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