Wagner GM 5000EAC User Manual

Download

Translation of the Original Operating Manual

Electrostatic AirCoat Spray Gun

for manual operation for  at or round jet nozzles

Version 05/2015

B_03154

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Table of Contents

1 ABOUT THESE INSTRUCTIONS 6

1.1 Preface 6

1.2 Warnings, Notices and Symbols in these Instructions 6

1.3 Languages 7

1.4 Abbreviations 7

1.5 Terminology for the Purpose of this Manual 8

2 CORRECT USE 9

2.1 Device Type 9

2.2 Type of Use 9

2.3 Use in an Explosion Hazard Area 9

2.4 Safety Parameters 9

2.5 Processible Working Materials 10

2.6 Reasonably Foreseeable Misuse 11

2.7 Residual Risks 11

3 IDENTIFICATION 12

3.1 CE Explosion Protection Identi cation 12

3.2 Identi cation "X" 12

3.3 Type Plate 13

4 GENERAL SAFETY INSTRUCTIONS 14

4.1 Safety Instructions for the Operator 14

4.1.1 Electrical Equipment 14

4.1.2 Personnel Quali cations 14

4.1.3 Safe Work Environment 14

4.2 Safety Instructions for Sta 15

4.2.1 Safe Handling of WAGNER Spray Devices 15

4.2.2 Grounding the Device 16

4.2.3 Product Hoses 16

4.2.4 Cleaning and Flushing 17

4.2.5 Handling Hazardous Liquids, Varnishes and Paints 18

4.2.6 Touching Hot Surfaces 18

4.3 Protective and Monitoring Equipment 18

4.4 Use in Areas Subject to Explosion Hazards 19

4.4.1 Safety Regulations 19

4.5 Safety-Relevant Information about Discharges 19

5 DESCRIPTION 20

5.1 Structure (Standard Variant) 20

5.1.1 Securing the Spray Gun Against Actuation 21

5.2 Mode of Operation 21

5.3 Protective and Monitoring Equipment 23

5.4 Scope of Delivery 23

5.5 Technical Data 24

5.6 Spraying Procedure 25

5.6.1 Spraying Procedure for AirCoat Round Spray 25

5.6.2 Spraying Procedure for AirCoat Fan Spray 25

5.6.3 Electrostatic E ect 26

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Table of Contents

6 ASSEMBLY AND COMMISSIONING 27

6.1 Training Assembly/Commissioning Sta 27

6.2 Storage Conditions 27

6.3 Installation Conditions 27

6.4 Assembly and Installation 27

6.4.1 Typical Electrostatic Spraying System 28

6.4.2 Ventilation of the Spray Booth 29

6.4.3 Air Supply 31

6.4.4 Product Supply 31

6.4.5 Grounding 32

6.5 Preparation of Lacquer 34

6.5.1 Viscosity Conversion Table 34

6.6 Commissioning 35

6.6.1 Safety Instructions 35

6.6.2 Preparation for Commissioning 35

6.6.3 Commissioning 35

6.6.3.1 Gun Cables and Gun Cable Extensions 36

6.6.4 Verifying a Safe Operational Condition 37

7 OPERATION 38

7.1 Training the Operating Sta 38

7.2 Safety Instructions 38

7.2.1 Emergency Deactivation 39

7.2.2 General Rules for Making Adjustments to the Spray Gun 39

7.3 Work 40

7.3.1 Filling with Working Material 41

7.3.2 Checking the Spray Pattern (Without Electrostatics) 41

7.3.3 Spraying 43

7.3.4 Pressure Relief / Work Interruption 44

7.3.5 Flushing Out Clogged Round Jet Nozzles 45

7.3.6 Replacing Round Jet Nozzle's Nozzle Insert 45

7.3.7 Changing from AirCoat Round Jet to AirCoat Flat Jet 46

7.3.8 Replacing the AirCoat Flat Jet Nozzles 48

7.3.9 Cleaning of the Nozzle Parts 49

7.3.10 Eliminate Nozzle Clogging 50

7.3.11 Changing the Valve Housing 52

8 CLEANING AND MAINTENANCE 54

8.1 Cleaning 54

8.1.1 Cleaning Sta 54

8.1.2 Safety Instructions 54

8.1.3 Cleaning and Flushing the Device 56

8.2 Maintenance 58

8.2.1 Maintenance Sta 58

8.2.2 Safety Instructions 58

8.2.3 Safety Checks 59

8.2.4 Product Hoses, Tubes and Couplings 60

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Table of Contents

9 TROUBLESHOOTING AND RECTIFICATION 61

10 REPAIR WORK 63

10.1 Repair Sta 63

10.2 Safety Instructions 63

10.3 Spray Gun 64

10.3.1 Tools 64

10.3.2 Disassembly of the Spray Gun 65

10.3.3 Cleaning the Parts After Disassembly 69

10.3.4 Assembling the Spray Gun 70

11 FUNCTIONAL CHECK AFTER REPAIR 76

11.1 Checking the High-voltage 76

11.2 Air Test 78

11.3 Product Pressure Test 78

11.4 Test of Spray Pattern 78

12 DISPOSAL 79

13 ACCESSORIES 80

13.1 Round Spray Nozzles 80

13.1.1 ACR 5000 Round Jet Nozzle Cap 80

13.1.2 AirCoat Round Jet Nozzle Inserts 80

13.2 Flat Jet Nozzles 80

13.2.1 ACF 5000 Air Caps (Flat Jet) 80

13.2.2 ACF5000 AirCoat Flat Jet Nozzles 81

13.3 Filter 83

13.4 Hoses and Electric Cables 84

13.4.1 Standard Hose Sets and Components 84

13.4.2 Hose Sets for Low-resistance Products 86

13.4.3 Product Hose 1.5 mm 88

13.4.4 Gun Cables and Gun Cable Extensions 88

13.5 Miscellaneous 89

14 SPARE PARTS 91

14.1 How Can Spare Parts Be Ordered? 91

14.2 GM 5000EAC Spray Gun 92

14.2.1 GM 5000EAC Adapter 94

14.2.2 GM 5000EAC Handle 96

14.3 Accessories Spare Parts Lists 98

14.3.1 Fan Spray Nozzles 98

14.3.2 ACR 5000 Round Jet Nozzle Cap 99

15 WARRANTY AND CONFORMITY DECLARATIONS 100

15.1 Important Notes Regarding Product Liability 100

15.2 Warranty Claim 100

15.3 CE Declaration of Conformity 101

15.4 EC Type Examination Certi cate 102

15.5 Notes on German Regulations and Guidelines 105

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1 ABOUT THESE INSTRUCTIONS

1.1 PREFACE

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.

1.2 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.

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 - a possibly hazardous situation. Non-observance may result in damage to property.

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

Note - provides information about particular characteristics and how to proceed.

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1.3 LANGUAGES

The GM 5000EAC operating manual is available in the following languages:

Language Order No. Language Order No. German 2310481 English 2319150

French 2320152 Italian 2320153 Spanish 2320154 Dutch 2358832 Danish 2359979 Swedish 2360027

Additional languages on request or at:

1.4 ABBREVIATIONS

Order No. Order number

Spare part Marking in the spare parts lists AirCoat Electrostatic AirCoat Manual gun (gun, manual) Low-resistance Stainless steel Position Number of pieces Wrench size

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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

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

Electrician Can assess the work assigned to him/her and detect possible

Skilled person A person who, based on his/her technical training, experience in the context of BGI 764

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.

hazards based on his/her technical training, knowledge and experience in relevant provisions.

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.

Additional requirements for skilled persons can also be referred to in TRBS1203(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 5000EAC electrostatic manual spray gun is suitable for spraying liquid products, particularly coating products, using the AirCoat method. Coating products containing solvents of explosion class II A may be used.

WAGNER forbids any other use!

2.3 USE IN AN EXPLOSION HAZARD AREA

The GM 5000EAC electrostatic manual spray gun is suitable for coating electrically conductive objects with liquid coating products and can be used in potentially explosive areas. (See Chapter 3. "Explosion Protection Identi cation".)

2.4 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.

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 containing solvents of explosion class II A can be processed with the GM 5000EAC 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)

Note:

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

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.

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

Lacquer in air outside the de ned working area

Handling of lacquers and cleaning agents

Lacquering outside the de ned working area

Skin irritations, Wear protective allergies maintenance,

Inhalation of substances hazardous to health

clothing Observe safety data

sheets Observe work and

operation instructions

Operation,

disassembly

Operation, maintenance

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3 IDENTIFICATION

3.1 CE EXPLOSION PROTECTION IDENTIFICATION

As de ned in the Directive 94/9/EC (ATEX), the device is suitable for use in potentially explosive areas.

Device type: GM 5000EAC electrostatic manual spray gun Manufacturer: J. Wagner AG

CH-9450 Altstätten, Switzerland

SIRA 11 ATEX5374X

European Communities Noti ed body: PTB Explosion-proof equipment Device class II (not mining) Category 2 device (suitable for zone 1) Ex-atmosphere gas Explosion protection for electrical devices Maximum ignition energy Number of type examination certi cate "X": see chapter 3.2

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

3.2 IDENTIFICATION "X"

Note:

The EC Type Examination Certi cate from SIRA can be found in Chapter 15.4. This certi cation covers the following:

- use of the spray gun in Zone 1;

- use of the VM 5000 or VM 500 control unit as related equipment for the spray gun.

The control unit may be used in zone 2. This usage is certi ed by the manufacturer (see operating manual of the control unit).

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Cable connections

Only cable assigned to the device may be used (see Chapter 13).

Permissible Device Combinations

The GM 5000EAC manual spray gun may only be connected to the control units listed below:

- VM 500 control unit

- VM 5000 control unit

WARNING

Incorrect use!

Risk of injury and damage to the device.

3.3 TYPE PLATE

J. Wagner AG

CH-9450 Altstätten

GM 5000EAC

Art. Nr.:

high voltage: current:

max. air pressure: 0.8MPa, 8bar; 116psi

2309823

max. 80kV DC max. 100μA DC 25MPa; 250bar; 3626psimax. mat. pressure:

Connect the GM 5000EAC manual spray gun only to original

WAGNER control units.

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

For Electro. Fin. Appl. CL. I, GP. D, Spray Matl.

B_04366

II 2 G

0102

EEx 0.24 mJ

SIRA 11 ATEX 5374X

Serial number

The serial number (S) on the underside of the handle.

B_03558

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4 GENERAL SAFETY INSTRUCTIONS

4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR

Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention.

4.1.1 ELECTRICAL EQUIPMENT

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.

4.1.2 PERSONNEL QUALIFICATIONS

Ensure that the device is only operated, maintained and repaired by trained persons.

4.1.3 SAFE WORK ENVIRONMENT

Ensure that the  oor in the working area is static dissipative in accordance with

EN61340-4-1 (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

100megohms. Ensure that during spraying, persons wear static dissipative gloves. Grounding takes

place via the spray gun handle. 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).

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Ensure that there are no ignition sources such as naked  ames, sparks, glowing wires,

or hot surfaces in the vicinity. Do not smoke. 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.

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.

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 (ZH1/406 and BGR500 Part2 Chapter2.29 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.

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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.

4.2.3 PRODUCT HOSES

Ensure that the hose material is chemically resistant to the sprayed products and the

 ushing agents used.

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 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.

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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 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.

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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4.2.5 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.

4.2.6 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; 109.4 °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.

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.

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 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.

4.5 SAFETYRELEVANT 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

5.1 STRUCTURE STANDARD VARIANT

Note:

The nozzle parts (pos. 6; 7; 13 and 14) do not belong to the basic equipment of the spray gun. The di erent versions can be found in Chapter 13 "Accessories".

10 11

Pos Description

1 Suspension hook 2 Display (spray current and recipe) 3 Display standby 4 Operating button (standby and recipe change) 5 Protection against contact with union nut 6 Air cap for  at jet nozzle

(see accessories in Chapter 13.2.1)

7 ACF 5000  at jet nozzle

(see accessories in Chapter 13.2.2) 8 Adapter 9Cover

10 Handle 11 Trigger lock 12 Trigger lever

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.

Pos Description

13 Round jet nozzle adapter

(see accessories in Chapter 13.1.1)

14 Round jet nozzle insert

(see accessories in Chapter 13.1.2) 15 Sealing plug 16 Air regulation 17 Electric cable connection 18 Atomizing air connection 19 Product connection 20 Filter housing with  lter 21 Type plate left 22 Type plate right

B_03156

B_03558

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5.1.1 SECURING THE SPRAY GUN AGAINST ACTUATION

Secure the spray gun against actuation:

Use the trigger lock (11) to engage the trigger (12).

Note: To secure the entire spraying system, pressure must be relieved as described in Chapter 7.3.4.

5.2 MODE OF OPERATION

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.

Display (2) 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.

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

One or both right-hand LEDs illuminate in orange.

(Warning display: You can continue working without any limitations.)

= Recipe values changed temporarily:

high-voltage spray current range. Spray current too high. Possible causes:

- Spray gun too close to the work piece

- Contamination of the spray gun

- Paint conductivity too high

B_03182

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OPERATING MANUAL

The trigger can be used to activate, one after the other, the various functions of the spray gun.

Distance Description

1 AirCoat air opens. 2 AirCoat air opened and electrostatic (high-voltage)

activated.

Display (2) for "spray current" on the spray gun

to activated.

3 AirCoat air opened and electrostatic (high-voltage)

activated and product valve opened.

4 Overall way of trigger.

B_03157

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).

B_03262

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

5.3 PROTECTIVE AND MONITORING EQUIPMENT

The following functions are provided for safety:

- trigger lock (11);

- anti-contact guard for  at jet nozzle (5).

WARNING

Protective and monitoring equipment!

Risk of injury and damage to the device.

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.

5.4 SCOPE OF DELIVERY

Order No. Description

2309871 GM 5000EAC spray gun

Without control unit, product and air hose, electric cable, air cap and nozzle.

Each spray gun includes the following as standard equipment:

Order No. Description

2309368 Assembly tool valve needle 2325263 Assembly tool clamping screw 2319653 Protection gloves against spray mist 2310487 CE Declaration of Conformity 2310481 Operating manual, German

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.

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OPERATING MANUAL

5.5 TECHNICAL DATA

Maximum air pressure 0.8 MPa; 8 bar; 116 psi Maximum product pressure 25 MPa; 250 bar; 3626 psi Fluid inlet NPSM 1/4"-18 Air connection G 1/4" A Input voltage maximum 20 Vpp Input current maximum 1.0 A AC Output voltage maximum 80 kV DC Output current maximum 100 µA DC Operating temperature range 0 °C – 40 °C; 32 °F – 104 °F Maximum permissible product temperature: 50 °C; 122 °F Maximum surface temperature 85 °C; 185 °F

Quality standard 6.5.2 according to ISO 8573.1, 2010

Compressed air quality: free from oil and water

Weight (without hose set) 710 g (including union nut, nozzle, air cap and edge  lter) Sound level at 0.3 MPa; 3 bar; 43.5 psi air pressure

and 11 MPa; 110 bar; 1,549 psi product pressure

* A-rated sound pressure level measured at 1 m distance, LpA1m, in accordance with DIN EN 14462: 2005.

6: Particle density ≤ 5mg/m 5: Humidity: Pressure dew point ≤ +7°C 2: Oil content ≤ 0.1mg/m

73 dB(A) *

Dimensions

GM 5000EAC F

with  at jet nozzle

mm inch A 280 11.02 B 46 1.81 C 264 10.39

B_03193

GM 5000EAC R

with round jet nozzle

A 264 10.39 B 46 1.81 C 264 10.39

B_03155

mm inch

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

5.6 SPRAYING PROCEDURE

5.6.1 SPRAYING PROCEDURE FOR AIRCOAT ROUND SPRAY

In the AirCoat process, the spray product is atomized under a pressure of 3-15 MPa; 30-150 bar; 435-2,176 psi. With the help of an air pressure of 0-0.25 MPa; 0-2.5 bar; 0-36 psi, a soft, spray jet is produced. The spray jet diameter can be adjusted by turning the nozzle nut.

AirCoat air

Spray product

AirCoat air

Advantages

- Large application volume

- Low fogging tendency

- Good  nish

- High viscosity products can easily be applied

- High endurance of the nozzles

- Jet width adjustment

"?

Multi-channel swirl nozzle

Nozzle nut

5.6.2 SPRAYING PROCEDURE FOR AIRCOAT FAN SPRAY

In the AirCoat process, the spray product is atomized under a pressure of 3-15 MPa; 30-150bar; 435-2,176 psi. With the help of the AirCoat air, with a pressure of 0-0.25 MPa; 0-2.5 bar; 0-36 psi, a soft,  at spray jet is produced which largely eliminates the problem of overlapping in the peripheral zones. With shaping air, there is the possibility of reducing the width of the spray jet.

Spray jet

Advantages

- Large application volume

- Low fogging tendency

- Good  nish

- High viscosity products can easily be applied

- High endurance of the nozzles

- Jet width adjustment

Variable spray jet width

Shaping air

Air cap

B_00020

Atomizing air

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

5.6.3 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.

ElectrodePaint particle

Object to be sprayed grounded

Advantages

- Very high application e ectiveness

- Low over spray

- Coating of entire circumferences due to the electrostatic e ect

- Savings in working time

"?

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

6 ASSEMBLY AND COMMISSIONING

6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF

WARNING

Incorrect installation/operation!

Risk of injury and damage to the device.

The assembly and commissioning sta must have the technical

skills to safely undertake commissioning.

When assembling, commissioning and carrying out all work,

read and follow the operating manuals and safety regulations for the additionally required system components.

A skilled person must check to ensure that the device is in a reliable state after it is installed and commissioned.

6.2 STORAGE CONDITIONS

Until the point of assembly, the device must be stored in a dry location, free from vibrations and with a minimum of dust. The device must be stored in closed rooms.

The air temperature at the storage location must be between -20 °C and +60 °C (-4 °F and +140 °F).

The relative air humidity at the storage location must be between 10 and 95% (without condensation).

6.3 INSTALLATION CONDITIONS

The air temperature at the installation site must be in a range between 0 and 40 °C; 32 and 132 °F.

The relative air humidity at the installation site must be between 10 and 95% (without condensation).

6.4 ASSEMBLY AND INSTALLATION

Check the delivery package against the delivery note. Become familiar with the function of the spray gun and all the other components used. Carefully read the accompanying operating manual. Note the special requirements of the designated electrostatic AirCoat spray procedure.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

6.4.1 TYPICAL ELECTROSTATIC SPRAYING SYSTEM

B_03158

100

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μA

VM 5000

Description

1 GM 5000EACF spray gun 2 Gun cable 3 Grounding cable 4 Pneumatic pump 5 Sliding tables 6 Air pressure regulator + air

 lter 7 Product suction system 8 Return hose 9 High-pressure  lter

Description

10 Compressed air connection 11 Stop valve 12 Air pressure regulator 13 VM 5000 control unit 14 Protective hose 15 Air hose 16 Product hose

Description

17 Return valve 18 Tank for return  ow 19 Paint tank 20 Tank for  ushing agent 21 Mains cable

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

The GM 5000EAC spray gun must be combined with various components to make up a spraying system (spraypack). The system shown in the  gure is only one example of an electrostatic spraying system. Your WAGNER distributor would be happy to assist you in creating a spraying system solution that meets your individual needs. You must familiarize yourself with the operating manuals and the safety regulations of all additional system components before starting commissioning.

WARNING

Incorrect installation/operation!

Risk of injury and damage to the device.

When commissioning and for all work, read and follow the

operating manual and safety regulations for the additionally required system components.

6.4.2 VENTILATION OF THE SPRAY BOOTH

The electrostatic spraying equipment may only be operated in de ned spraying areas and in accordance with the EN 12215 standard or under comparable ventilation conditions. The electrostatic spraying equipment must be locked to the technical ventilation so that the coating product supply and the high-voltage are not e ective as long as the technical ventilation is not operated with the minimum exhaust air volume  ow or a larger exhaust air volume  ow. Ensure that the excess coating product (overspray) will be collected up safely.

WARNING

Toxic and/or  ammable vapor mixtures!

Risk of poisoning and burns.

Operate the device in a spray booth approved for the working

materials.

– or –

Operate the device on an appropriate spraying wall with the

ventilation (extraction) switched on.

Observe national and local regulations for the outgoing air

speed.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

6.4.3 AIR SUPPLY

The use of an air  lter with air regulator (6) ensures that only dry, clean atomizing air gets into the spray gun. Dirt and moisture in the atomizing air worsens the spraying quality and spraying pattern.

WARNING

Hose connections!

Risk of injury and damage to the device.

Do not exchange hose connections of product hose and air

hose.

6.4.4 PRODUCT SUPPLY

NOTICE

Impurities in the spraying system!

Spray gun blockage, products harden in the spraying system.

Flush the spray gun and paint supply with a suitable  ushing agent.

DANGER

Bursting hose, bursting threaded joints!

Danger to life from injection of product.

Ensure that the hose material is chemically resistant to the

sprayed products.

Ensure that the spray gun, threaded joints and product hose

between the device and the spray gun are suitable for the pressure generated in the device.

Ensure that the following information can be seen on the

high-pressure hose:

- Manufacturer

- Permissible operating pressure

- Date of manufacture

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

6.4.5 GROUNDING

Perfect grounding of all conductive parts such as  oors, walls, roofs is important for optimum coating and safety. Barriers, work pieces, transport devices, coating product tank, coating product supply or construction parts in the spray area with exception of the high-voltage parts during normal operation. Parts of the booth must be grounded in accordance with EN 12215.

WARNING

Discharge of electrostatically charged components in atmospheres containing solvents!

Explosion hazard from electrostatic sparks or  ames.

Ground all device components. Ground the work pieces to be coated.

WARNING

Heavy paint mist if grounding is insu cient!

Danger of poisoning. Insu cient paint application quality.

Ground all device components. Ground the work pieces to be coated.

A poorly grounded work piece causes:

- Very bad wrap around.

- Uneven coating.

- Back spraying to the spray gun (contamination) and coater.

Prerequisites for perfect grounding and coating are:

- Clean work piece suspension.

- Grounding of spray booth, conveyor system and suspension on the building side in accordance with the operating manuals or the manufacturer's information.

- Grounding of all conductive parts within the working area.

- The grounding resistance of the work piece may not exceed 1 leakage resistance measured at 500 V or 1000 V).

- Connect the control unit to the signal ground.

- Connect all ground cables using a short and direct route.

- Safety shoes and gloves, if used, must be static dissipative.

(megaohm) (ground

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Grounding scheme (example)

Conveyor

Mains cable

Grounding cable

B_03234

Control unit

Pump or pressure tank

Paint tank or tank for return  ow

Work piece

R max < 1 MΩ

Spraying stand

Floor, static dissipative

Minimum cable cross-section

Control unit

4 mm / AWG 12Product supply Paint tank Conveyor

16 mm / AWG 6Booth Spraying stand

Grounding of spray gun

The spray gun is grounded via the spray gun cable.

The GM 5000EAC spray gun must be connected by the gun cable with the VM500 or

VM5000 control unit.

Note for the sprayer

Safety shoes and gloves, if used, must be static dissipative.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

6.5 PREPARATION OF LACQUER

The viscosity of the lacquer is of great importance. The best spraying results are obtained with values between 25 and 40 DIN/4 seconds (measured in immersion  ow cup DIN 4mm; 0.16 inches).

Processing of up to 60 DIN/4 seconds is generally possible without problem if high coating thicknesses are required.

With the WAGNER AirCoat  at jet spraying process, the di erent viscosities of the lacquer are optimally covered by two air cap types. These can be found in "Accessories".

In the case of application problems contact the paint producer.

6.5.1 VISCOSITY CONVERSION TABLE

mPa s

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

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

6.6 COMMISSIONING

6.6.1 SAFETY INSTRUCTIONS

Observe the safety instructions in Chapter 4 and Chapter 8.1.2. Observe the general rules for making adjustments to the spray gun. Chapter 7.2.2

6.6.2 PREPARATION FOR COMMISSIONING

NOTICE

Impurities in the spraying system!

Spray gun blockage.

Flush the spray gun and paint supply with a suitable  ushing agent before

commissioning.

6.6.3 COMMISSIONING

The following points must be noted:

Grounding see Chapter 6.4.5. Make sure that all other conductive parts within the work area are grounded.

Connect the product hose to the spray gun and the product pump. Check that all product-conveying connections are correctly connected. Connect air hose to spray gun and to supply of oil-free dry air, approx. 0.25 MPa;

2.5bar; 36 psi. For compressed air quality see Chapter 5.5. Check that all air-conveying connections are correctly connected. Connect the electric cable to the spray gun and to the VM 5000 or VM 500 control

unit. Visually check the permissible pressures for all the system components. Check the level of the separating agent in the WAGNER pneumatic pump and  ll the

separating agent up if necessary. Provide product tank, tanks for  ushing agent and an empty tank for return  ow. Connect the system with a secured gun to the air and power supply. A basic  ushing of system must be carried out before commissioning. Make sure that no nozzle is inserted into the gun.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

6.6.3.1 GUN CABLES AND GUN CABLE EXTENSIONS

WARNING

Sparks form when the plug is removed!

Explosion hazard.

When using the spray gun in potentially explosive areas:

The cable connection on the gun and the connection to any

cable extensions may not be disconnected or connected in this area.

The following points must be noted:

The cable connection to the gun and the connection to a cable extension may not be

disconnected or connected in a potentially explosive area.

Only disconnect or connect all cable extensions from the gun cable and the cable

extension when the control unit is switched o .

In order that the GM 5000EA spray gun is grounded, it must be connected via the gun

cable with the VM500 or VM5000 control unit.

Gun cable is available in various lengths. Order No., see Chapter 13.4.3.

Attention: gun cable to control unit

Secure the cover sleeve with the warning sign by means of the screw (84) on the connector.

Warning: "Do not disconnect under voltage"

GM 5000E gun cable

B_03691

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OPERATING MANUAL

Attention: guns with electric extension cable

Secure the cover sleeves with the warning sign by means of the screws (84) on the connectors.

Power loss

In order to prevent power losses, keep the cable length as short as possible. The maximum power is available with the standard cable length of 10 m. An extension to a total length of up to 40 m will cause a power loss of up to 10%. The gun cable can be extended to a total length of 80m, however, a power loss of up to 30% will be caused.

Extension cable to the control unit

GM 5000E gun cable

B_03690

6.6.4 VERIFYING A SAFE OPERATIONAL CONDITION

A skilled person must check to ensure that the device and the spraying system are in a safe state after they are installed and commissioned.

This includes:

- Carry out a safety check in accordance with Chapter 8.2.3.

- Function test in accordance with Chapter 11.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

7 OPERATION

7.1 TRAINING THE OPERATING STAFF

WARNING

Incorrect operation!

Risk of injury and damage to the device.

The operating sta must be quali ed and  t to operate the

entire system.

The operating sta must be familiar with the potential risks

associated with improper behavior as well as the necessary protective devices and measures.

Before work commences, the operating sta must receive

appropriate system training.

7.2 SAFETY INSTRUCTIONS

Observe safety instructions in Chapter 4.

WARNING

Incorrect operation!

Risk of injury and damage to the device.

If contact with lacquers or cleaning agents causes skin irritation,

appropriate precautionary measures must be taken, e.g., wearing protective clothing.

The footwear worn by operating sta must comply with

EN ISO 20344. The measured insulation resistance must not exceed 100 megohms.

The protective clothing, including gloves, must comply with

EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.

WARNING

Unintentional putting into operation!

Risk of injury.

Before any work on the device, in the event of work interruptions and malfunctions:

Switch o the energy/compressed air supply. Relieve the pressure from the spray gun and unit. Secure the spray gun against actuation. In the event of functional faults: remedy the fault as described in

the "Troubleshooting" chapter.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

WARNING

Discharge of electrostatically charged components in atmospheres containing solvents!

Explosion hazard from electrostatic spark-over.

Use gun only with  tted nozzle, air cap and union nut. Tighten the union nut, especially with nozzle in the cleaning

position.

7.2.1 EMERGENCY DEACTIVATION

In the case of unforeseen occurrences, proceed as follows:

1. Switch o control unit.

2. Close the compressed air supply.

3. Relieve pressure according to the operating manual of the product pressure generator.

4. Point the spray gun toward the grounded collecting tray.

5. Pull the trigger of the spray gun until no further pressure is present.

7.2.2 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN

DANGER

High-voltage  eld!

Danger to life from malfunction of heart pacemakers.

Make sure that persons with pacemakers:

Do not work with the electrostatic spray gun. Do not enter the high-voltage area.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent.

Never reach into the spray jet. Never point the spray gun at people. Consult a doctor immediately in the event of skin injuries caused

by paint or solvent. Inform the doctor about the paint or solvent used.

Never seal defective high-pressure parts, instead relieve the

pressure from them and replace them.

Wear the appropriate protective clothing, gloves, eyewear and

respiratory protection.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

7.3 WORK

Ensure that:

the regular safety checks are carried out in accordance with Chapter 8.2.3, commissioning is carried out in accordance with Chapter 6.6.

100

EXT

μA

VM 5000

B_03158

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

7.3.1 FILLING WITH WORKING MATERIAL

1. Place empty tank (18) under return tube (8).

2. Place suction hose (7) in the tank with working material (19). Note: If the pump is equipped with a rigid suction system, it should only be dipped

in into the working material up to the middle of the inlet housing at the maximum!

3. Adjust the pump-pressure regulator (12) to approx. 0.05 MPa; 0.5 bar; 7.25 psi.

4. Open return valve (17).

5. Slowly open the ball valve (11).

6. Adjust the air pressure on the pump-pressure regulator (12) so that the pump runs smoothly.

7. Close ball valve (11) as soon as pure working material starts coming from the return tube (8).

8. Close return valve (17).

9. Point the gun, without nozzle, into tank (18) and open it.

10. Slowly open the ball valve (11).

11. Close ball valve (11) as soon as pure working material starts coming from the gun.

12. When there is no pressure remaining in the system, close the gun.

13. Secure the gun.

14. Dispose of the contents of the tank (18) according to the local regulations.

7.3.2 CHECKING THE SPRAY PATTERN WITHOUT ELECTROSTATICS

1. Switch o control unit. ( The grounding of the spray gun via the gun cable is maintained.)

2. Start up with product supply set to approx. 8 MPa; 80 bar; 1160 psi operating pressure. See corresponding operating manual.

Flat-jet method: AirLess spraying (without electrostatics)

3. Turn air pressure regulator (6) all the way down.

4. Spray (release locking device and pull trigger) and at the same time, check the atomization.

5. Set the product pressure on the product supply to the point where a good product atomization is achieved.

For round and  at-jet method: AirCoat spraying (without electrostatics)

6. Adjust the air pressure regulator (6) until optimal atomization is achieved.

see below, "Adjusting the spray pattern with the air pressure regulator"

7. With the air adjustment on the gun, set the ratio of shaping air/atomizing air so as to achieve an optimum spray pattern.

See below, "Spray pattern and air regulation"

Repeat points 6 and 7 until the optimum spray pattern is reached (iterative process).

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Setting the Spray Pattern Using the Air Pressure Regulator (6)

The air pressure regulator regulates the air supply (shaping and atomizing air) to the gun.

B_00071

No air Correct amount of airNot enough air

Spray pattern and air regulation

Air regulation regulates the ratio of shaping/atomizing air. The spray pattern can then be adjusted to suit the object being sprayed. The illustration shows the in uence of the regulator on the spraying pattern. Other nozzle sizes can be used to obtain larger or smaller spraying patterns.

Air regulation closed

= minimum shaping air

Changing the Flow Rate

Adapt product pressure Use a di erent nozzle (see Chapter 13)

Changing the Spray Jet Width

Use a di erent nozzle (see Chapter 13)

B_04384

Air regulation fully opened

= maximum shaping air

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

7.3.3 SPRAYING

1. Secure gun with trigger lock and insert the desired nozzle.

2. Turn on the control unit.

3. Start up with product supply set to approx. 8 MPa; 80 bar; 1,160 psi operating pressure. See corresponding operating manual.

AirLess spraying

4. Turn air pressure regulator (6) all the way down.

5. Spray on a test object (pull trigger).

Pressing the trigger on the spray gun switches the high-voltage supply on.

6. Adjust the product pressure and gun air in accordance with the nozzle and object.

AirCoat spraying

7. Open the air pressure regulator (6) (approx. 0.05 - 0.25 MPa; 0.5 - 2.5 bar; 7 - 36 psi) and

adjust for optimal atomization.

See corresponding operating manual.

Flat-jet method: Changing the spray jet width

8. Change the spray jet width by selecting the appropriate nozzle. By turning the air regulation (33), the spray jet can additionally be

adjusted.

Round-jet method

8. By gently turning the nozzle nut (31), the atomizing air jet can additionally be adjusted.

Do not fully tighten the nozzle nut:

Do not turn the nozzle nut (31) until it is  ush with the nozzle body(32). There must be play for the atomizing air between the nozzle nut and the nozzle body.

The air adjustment at the back of the spray gun does not a ect the spray pattern in this process.

B_04385

B_04386

Flow rate

9. Product quantity may be able to be reduced by:

- Minimizing the product pressure.

- Use a di erent nozzle (see Chapter 13).

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

7.3.4 PRESSURE RELIEF / WORK INTERRUPTION

The pressure must always be relieved when:

- The spraying tasks are  nished.

- The spraying system is maintained.

- Cleaning tasks are carried out on the spraying system.

- The spraying system is moved to another location.

- Something must be checked on the spraying system.

- The nozzle is removed from the gun.

Observe general safety instructions in Chapter 4.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent.

Never reach into the spray jet. Never point the spray gun at people. Consult a doctor immediately in the event of skin injuries caused

by paint or solvent. Inform the doctor about the paint or solvent used.

Never seal defective high-pressure parts; instead relieve the pressure

from them and replace them.

Wear the appropriate protective clothing, gloves, eyewear and

respiratory protection.

Process for relieving pressure

1. Secure the spray gun with the trigger lock.

2. Switch o control unit.

3. Close the compressed air supply.

4. Relieve pressure according to the operating manual of the pump.

5. Point the spray gun toward the grounded collecting tray and release.

6. Pull the trigger of the spray gun until no further pressure is present.

7. Secure the spray gun with the trigger lock.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

7.3.5 FLUSHING OUT CLOGGED ROUND JET NOZZLES

DANGER

Exploding gas / air mixture!

Danger to life from  ying parts and burns.

Never spray into a closed tank. Ground the tank.

1. Use nozzle spanner (2) to loosen nozzle insert (1) by a half turn.

2. Remove the nozzle spanner and brie y actuate trigger.

3. After  ushing the nozzle, re-tighten the nozzle insert.

1/2

7.3.6 REPLACING ROUND JET NOZZLE'S NOZZLE INSERT

1. Remove nozzle insert (1) using nozzle spanner (2).

2. Assembling new nozzle insert.

B_03160

B_03161

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

7.3.7 CHANGING FROM AIRCOAT ROUND JET TO AIRCOAT FLAT JET

Flush spray gun

1. Switch o control unit.

2. Relieve pressure

3. Connect the system to the  ushing agent supply.

4. Set product pressure. Close air pressure regulator.

5. Thoroughly  ush out the spray gun.

6. Relieve pressure

7. Secure the spray gun with the trigger lock.

Changing from round jet to  at jet

8. Unscrew round jet nozzle cap (2) incl. nozzle insert (3).

9. Unscrew nozzle insert (3) using nozzle spanner (4).

10. Unscrew nozzle nut (5). Remove nozzle screw joint (7) and sealing  tting (8) from the nozzle body (6). Thoroughly clean all parts.

11. Insert desired ACF5000 nozzle (11) into the valve housing.

12. Put the air cap (10) on the nozzle (11) and pay attention to the position of the guide surfaces.

13. Screw union nut with attached nozzle guard (9) to the gun body and make sure that the air cap horns lie in the designated recess (Y).

14. Before tightening with the air cap horns (Y), set the desired jet level and then tighten the union nut to stop by hand.

Chapter 7.3.4.

Changing from  at jet to round jet

8. Unscrew union nut (9) with air cap (10) and ACF5000 nozzle (11).

9. Remove air cap (10).

10. Press ACF5000 nozzle (11) out of air cap (10) by hand. Thoroughly clean all parts.

11. Insert nozzle screw connection (7) and sealing  tting (8) into nozzle body (6).

12. Screw nozzle nut (5) onto nozzle body (6). Do not screw on nozzle nut completely. There must be play for the atomizing air

between the nozzle nut and the nozzle body.

13. Screw on nozzle insert (3) using nozzle spanner (4).

14. Screw round jet nozzle cap (2) with nozzle insert (3) onto spray gun and tighten by hand.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

B_03162

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

7.3.8 REPLACING THE AIRCOAT FLAT JET NOZZLES

1. Switch o control unit.

2. Relieve pressure

3. Secure the spray gun with the trigger lock.

4. Unscrew union nut completely (12) and unscrew air cap (10).

5. Remove ACF5000 AirCoat nozzle (11) and treat it with cleaning agent until all traces of paint have been removed.

Chapter 7.3.4.

NOTICE

Defective AirCoat nozzle!

Insu cient paint application quality.

Do not use sharp-edged objects to treat carbide on the AirCoat nozzle.

6. Insert new ACF5000 nozzle (11) into the valve housing.

7. Put the air cap (10) on the nozzle (11) and pay attention to the position of the guide surfaces.

8. Screw union nut with attached nozzle guard (9) to the gun body and make sure that the air cap horns lie in the designated recess (Y).

9. Before tightening with the air cap horns (Y), set the desired jet level and then tighten the union nut to stop by hand.

B_04387

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

7.3.9 CLEANING OF THE NOZZLE PARTS

The ACF5000 AirCoat nozzles (11), the nozzle inserts (3) and the nozzle screw connection(7) can be placed in a cleaning solvent recommended by the lacquer manufacturer.

All other nozzle parts may not be put into cleaning solvent.

Clean these parts with a cleaning solvent recommended by the lacquer manufacturer and dry with a cloth or blow gun.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

7.3.10 ELIMINATE NOZZLE CLOGGING

1. Switch o control unit.

2. Relieve pressure Chapter 7.3.4.

3. Secure the spray gun (1) using the trigger lock (14).

4. Unscrew union nut completely (12) and remove air cap (10).

5. Push ACF 5000 nozzle (11) out of air cap (10) by hand, reverse it and put it into the air cap (10) with the nozzle tip towards the rear.

Pay attention to the position of the guide surfaces (X).

6. Insert air cap (10) with integrated ACF5000 nozzle (11) into the union nut (9). Make sure that the air cap horns (Y) lie in the recess of the nozzle guard.

7. Screw preassembled union nut (12) to gun (1) and tighten by hand.

8. Switch the product pressure back on.

9. Turn the trigger lock (14) to the spraying position and brie y pull the trigger.

10. When the blockage has been  ushed out, secure the gun with trigger lock (14).

11. Relieve pressure

12. Unscrew union nut (12) completely.

13. Remove air cap (10) and push ACF5000 nozzle (11) out of the air cap by hand. Clean ACF5000 nozzle and insert it in the spraying position into the valve housing.

14. Put the air cap (10) on the nozzle (11) and pay attention to the position of the guide surfaces (X).

15. Screw union nut with attached nozzle guard (9) to the gun body and make sure that the air cap horns lie in the designated recess (Y).

16. Before tightening with the air cap horns (Y), set the desired jet level and then tighten the union nut to stop by hand.

17. Switch the product pressure and the air pressure back on.

18. Switch on the control unit.

Chapter 7.3.4:

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

ACF5000 nozzle in

spray position

ACF5000 nozzle in

cleaning position

B_04388

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

7.3.11 CHANGING THE VALVE HOUSING

NOTICE

Changing the valve housing!

Damage to the device.

Activate the spray gun trigger when changing the valve housing.

To prevent damage to the gun (valve seat rubs on the valve needle, valve needle may loosen), activate the spray gun trigger when changing the valve housing.

Use a socket or ring spanner (not an open-end wrench) to tighten the valve housing.

B_03847

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

8 CLEANING AND MAINTENANCE

8.1 CLEANING

8.1.1 CLEANING STAFF

Cleaning work should be undertaken regularly and carefully by quali ed and trained sta . They should be informed of speci c hazards during their training.

The following hazards may arise during cleaning work:

- Health hazard from inhaling solvent vapors

- Use of unsuitable cleaning tools and aids

8.1.2 SAFETY INSTRUCTIONS

Observe safety instructions in Chapter 4.

DANGER

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" and that are assigned to the unit.

Before all work on the device and in the event of work interruptions:

- Switch o the energy and compressed air supply.

- Relieve the pressure from the spray gun and device.

- Secure the spray gun against actuation. Observe the operating manual and service manuals at all times

when carrying out work.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

DANGER

Explosive powder/air mixes!

Danger to life and equipment damage.

Before starting cleaning, rinsing, or other manual work, the

high-voltage must be shut down and locked to prevent it from being switched back on!

The spray gun must be separated from the high-voltage supply

before any cleaning work is started!

Only electrically conductive tanks may be used for cleaning and

 ushing agents. Ground the tank.

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.

Preference should be given to non- ammable cleaning and

 ushing agents.

Only cleaning and  ushing agents of explosion class IIA may be

used (maximum ignition energy 0.24 mJ).

The cleaning and  ushing agent's  ash point must be at least

15K above the ambient temperature.

Ensure that no electric component is cleaned with or immersed

into solvent.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

8.1.3 CLEANING AND FLUSHING THE DEVICE

The spray gun and the device must be cleaned and  ushed daily. The cleaning and  ushing agents used must be compatible with the working material.

WARNING

Incompatibility of cleaning/ ushing agent and working medium!

Risk of explosion and danger of poisoning by toxic gases.

Examine the compatibility of the cleaning and  ushing agents

and working media on the basis of the safety data sheets.

NOTICE

Damage to electrical devices!

Never immerse the spray gun in cleaning agent.

NOTICE

Liquid in air tube!

Functional faults caused by swollen seals. Discharge current to ground No high-voltage.

Always point the spray gun down when cleaning. Ensure that neither paint nor cleaning or  ushing agent enters the air duct. When taking a break from work or when stored for a longer period, the spray gun

should be positioned with the adapter pointing downwards.

B_03453

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OPERATING MANUAL

DANGER

Exploding gas / air mixture!

Danger to life from  ying parts and burns.

Never spray into a closed tank. Ground the tank.

Flush spray gun

1. Switch o control unit.

2. Relieve pressure

3. Close air pressure regulator.

4. Connect spraying system to  ushing agent supply in accordance with operating manual for the pump.

With round jet nozzle  tted:

5. Use nozzle spanner to loosen nozzle insert by a half turn.

6. Point the spray gun toward the collecting tray and actuate the trigger. Flush the gun thoroughly as soon as clean  ushing agent emerges.

7. Relieve pressure

8. Re-tighten the nozzle insert.

9. Remove  ushing agent supply.

With  at jet nozzle  tted:

5. Dismount AirCoat nozzle and clean separately

6. Point the spray gun toward the collecting tray and actuate the trigger.

7. Flush the gun thoroughly as soon as clean  ushing agent emerges.

8. Relieve pressure

9. Remove  ushing agent supply.

Chapter 7.3.4.

Chapter 7.3.8.

Chapter 7.3.4.

Blowing out the air passages of the spray gun

10. Close pump pressure regulator. Switch on compressed air supply and open air pressure regulator.

11. Actuate the trigger of the spray gun and thoroughly blow out the air passages.

12. Switch o the compressed air supply.

Clean the outside of the spray gun

13. Clean the spray gun body and other components of the spraying system with a cleaning agent recommended by the lacquer manufacturer and dry with a cloth or blow gun.

Cleaning the nozzle parts Eliminating nozzle clogging see Chapter 7.3.10

see Chapter 7.3.9

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

8.2 MAINTENANCE

8.2.1 MAINTENANCE STAFF

Maintenance work should be undertaken regularly and carefully by quali ed and trained sta . They should be informed of speci c hazards during their training.

The following hazards may arise during maintenance work:

- Health hazard from inhaling solvent vapors

- Use of unsuitable tools and aids

An authorized person must ensure that the device is checked for being in a reliable state after maintenance work is completed.

8.2.2 SAFETY INSTRUCTIONS

Observe the safety instructions in Chapter 4 and Chapter 8.1.2.

Prior to maintenance

- Flush and clean the device Chapter 8.1.3.

After maintenance

- Carry out a safety check in accordance with Chapter 8.2.3.

- Put the device into operation (Chapter 6.6) and check for leaks (Chapter 11.3).

- Carry out a function test, if required, in accordance with Chapter 11.

In accordance with the guideline for liquid ejection devices (ZH1/406 and BGR500

Part2 Chapter 2.29 and Chapter 2.36):

- The liquid ejection devices should be checked by an expert (e.g., WAGNER service technician) for their safe working conditions as required and at least every 12months.

- For shut down devices, the examination can be suspended until the next start-up.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Repair or replacement of devices or parts of devices are only

allowed to be performed outside the hazard area by quali ed personnel.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

DANGER

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" and that are assigned to the unit.

Before all work on the device and in the event of work interruptions:

- Switch o the energy and compressed air supply.

- Relieve the pressure from the spray gun and device.

- Secure the spray gun against actuation. Observe the operating manual and service manuals at all times

when carrying out work.

8.2.3 SAFETY CHECKS

For the safe operation of electrostatic manual coating systems for  ammable liquid coating products, intervals for periodical inspections are de ned as follows:

Inspection point Inspection interval Remarks

Gun cleaning, gun  ushing daily Chapter 4.2.4, Chapter 8.1.3 Hoses, tubes, couplings daily Chapter 8.2.4 Grounding weekly Chapter 4.2.2, Chapter 6.4.5 Inspection for damage weekly Chapter 8.1.3, 8.2, 10 Locking of the technical ventilation with the

electrostatic manual spraying unit

The above recommended intervals are maximum values and may be modi ed by the operator depending on the local and operational conditions and the contamination.

Damaged devices must be decommissioned and repaired immediately.

annually Chapter 6.4.2

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

8.2.4 PRODUCT HOSES, TUBES AND COUPLINGS

DANGER

Bursting hose, bursting threaded joints!

Danger to life from injection of product and from  ying parts.

Ensure that the hose material is chemically resistant to the

sprayed products and the used  ushing agents.

Ensure that the spray gun, threaded joints, and product hose

between the device and the spray gun are suitable for the generated pressure.

Ensure that the following information can be seen on the hose:

- Manufacturer

- Permissible operating pressure

- Date of manufacture

The service life of the complete hoses between product pressure generator and application device is reduced due to environmental in uences even when handled correctly.

Check hoses, pipes, and couplings every day and replace if necessary. Before every commissioning, check all connections for leaks. Additionally, the operator must regularly check the complete hoses for wear and tear

as well as for damage at intervals that he/she has set. Records of these checks must be kept.

Undamaged complete hoses are to be replaced when one of the two following intervals has been exceeded:

– 6 years from the date of the hose crimping (see  tting embossing). – 10 years from the date of the hose imprinting.

Fitting embossing

(if present) xxx bar Pressure

yymm

XX Internal code

Meaning

Crimping date (year/month)

Hose imprinting Meaning

WAGNER Name / Manufacturer

yymm

xxx bar (xx MPa) e.g., 270 bar (27 MPa)

XX Internal code DNxx (e.g., DN10) Nominal diameter

Date of manufacture (year/month)

Pressure

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

9 TROUBLESHOOTING AND RECTIFICATION

Functional fault Cause Remedy

Insu cient product output Nozzle too small Select larger nozzle (see Accessories)

Product pressure too low Increase product pressure Filter of gun or pump blocked Clean or replace  lter Nozzle is clogged Clean or replace nozzle

Poor spray pattern Wrongly adjusted atomizing air Readjust air pressure regulator

Unfavorable nozzle size Select a di erent nozzle (see

Accessories) Product pressure too high/too low Adapt product pressure Spray product viscosity too high Dilute spray product in accordance

with the manufacturer's instructions Damaged nozzle Insert new nozzle

Poor wrap-around Poor grounding at object Check grounding of object or hanger

with ohmmeter Lacquer resistance too high/too low Check paint resistance (see Chapter2.5) Spraying pressure too high Readjust spraying pressure

No wrap-around No high-voltage Switch on high-voltage at the control

unit. Repair malfunction as laid

down in the control unit operating

manuals.

Connect gun and gun cable/check

for defects

Check paint resistance

(see Chapter 2.5) Seal in end piece defective Repair by WAGNER service Air-passages damp Clean and dry air-passages

Back-spray Poor grounding at object Check grounding

Distance between spray gun and object too large

High-voltage set wrongly (too high) Adapt high-voltage to product Loosen the nozzle union nut for round

jet method Distance between spray gun and object

too large

Valve rod leaks Seals at the valve rod are damaged Replace the seals (see Chapter 10)

Loose packing Tighten

Reduce distance between spray gun

and object

Slightly tighten union nut by hand

Reduce distance between spray gun

and object

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

10 REPAIR WORK

10.1 REPAIR STAFF

Repair work must be carried out carefully by quali ed and trained sta . They should be informed of speci c hazards during their training.

The following hazards may arise during repair work:

- Health hazard from inhaling solvent vapors

- Use of unsuitable tools and aids

A skilled person must ensure that the device is checked for being in a reliable state after repair work is completed. Carry out function test in accordance with Chapter 11.

10.2 SAFETY INSTRUCTIONS

Observe the safety instructions in Chapter 4 and Chapter 8.1.2.

Before repair work

- Flush and clean the system

After repair work

- Carry out a safety check in accordance with Chapter 8.2.3.

- Put the device into operation (Chapter 6.6) and check for leaks (Chapter 11.3).

- Function test in accordance with Chapter 11.

In accordance with the guideline for liquid ejection devices (ZH1/406 and BGR500

Part2 Chapter 2.29 and Chapter 2.36):

- The liquid ejection devices should be checked by an expert (e.g., WAGNER service technician) for their safe working conditions as required and at least every 12months.

- For shut down devices, the examination can be suspended until the next start-up.

Chapter 8.1.3.

DANGER

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" and that are assigned to the unit.

Before all work on the device and in the event of work interruptions:

- Switch o the energy and compressed air supply.

- Relieve the pressure from the spray gun and device.

- Secure the spray gun against actuation. Observe the operating manual and service manuals at all times

when carrying out work.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

10.3 SPRAY GUN

Plastic parts

Gently handle all plastic parts.

10.3.1 TOOLS

For disassembling and assembling the spray gun, the following tools are required:

- Allen wrench SW2

- Allen wrench SW3

- Allen wrench SW5

- Open-end wrench SW5

- Open-end wrench SW6

- Open-end wrench SW8

- Open-end wrench SW11

- Open-end wrench SW12

- Open-end wrench SW14

- Open-end wrench SW19

- Open-end wrench SW21

- Open-end wrench SW22

- Ring spanner SW9

- Ring spanner SW11

- Torx

-wrench 20

- Torx -wrench 25

- Slide gauge

- Valve needle assembly tool, Order No. 2309368

- Clamping screw assembly tool, Order No. 2325263

Only as required:

- Handle seal assembly tool (Order No. 2342334, not included in scope of delivery)

Brand notice:

The brands speci ed in this document are property of the respective owners. Loctite example, is a registered brand of Henkel.

, for

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

10.3.2 DISASSEMBLY OF THE SPRAY GUN

SW3

SW12

B_03194

Air hose

When unscrewing the air hose, a second open-ended/box wrench must be used for bracing.

Torx® 25

SW3

SW19

SW21

B_03195

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Carefully release the cascade without pliers.

SW19

B_03196

SW22

SW19

Do not tilt the product hose, but pull it straight out in the direction of arrow. At the same time, execute slight rotational movements.

Fitting (25)

If the  tting (25) does not come out with the product hose, it must be removed from the gun adapter as follows:

- Screw the wood screw ( max. 6 mm deep.

- Pull out straight with suitable pliers. Possibly rotate clockwise simultaneously.

- Thereafter, the  tting must be replaced.

If the  tting is broken in the gun adapter, WAGNER Service must be contacted.

3 mm; 0.12 inches, length 40 mm; 1.6 inches) into the  tting(25),

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Clamping screw assembly tool, Order No. 2325263

Golden contact sleeve (10) remains in end piece (11) or sits on resistance (12). Do not lose! (The other gold contact sleeve is in the contacting (13).)

Valve needle assembly tool, Order No. 2309368

Valve tip (27)

Loosen valve tip by hand using the valve needle assembly tool (Order No. 2309368).

SW9

Valve housing: Use an assembly tool or socket or ring spanner (no open-end wrench).

B_04786

O-ring (8):

1. Use screwdriver no. 1 to

press under the O-ring.

2. Lever up the O-ring and

remove it.

Air distribution (9): 1. Locate the start of the thread for recessed internal threading.

2. Lever under the air distribution ring directly in front of the start of the thread using screwdriver no. 1.

3. As soon as the ring disengages, carefully undo it on all sides.

Do not pull out on contact wire.

B_04377

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

B_04787

SW5

SW6

1. Remove pressure spring (4).

2. Loosen clamping screw (1) with assembly tool (5).

3. Unscrew valve rod unit (2, 6, 7). The packing (3) is also unscrewed and removed.

4. Only as required: Remove rod seal (10).

Do not damage the housing in the process.

B_04777

SW14

Two gold contact sleeves either remain in the handle (1) or are seated on the two gold pins (2). Do not lose!

SW2

SW5

Torx® 20

1. Loosen the oval head screw (3).

2. Pull the air valve (4) out o the drilled hole. Do not turn! Do not damage the cylindrical surfaces. Ideally press on the tappet from behind using a transversely held screwdriver, for example.

3. Only as required: Press out seal (5) using a handle seal assembly tool (Order No. 2342334, not included in scope of delivery)

B_04788

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OPERATING MANUAL

10.3.3 CLEANING THE PARTS AFTER DISASSEMBLY

ATTENTION

Please note:

All reusable parts (except for the parts conducting high-voltage such as cascade,

adapter, plug compl. etc.) should be cleaned thoroughly using a suitable cleaning agent.

The adapter, connector, inside handle and all dismantled parts must be clean and

dry after cleaning. Care should be taken that these parts remain free of solvents, grease or sweat from the hands (salt water). Clean and mount wearing gloves.

Spare parts may have safety-relevant properties.

Only repair and replace parts that are listed in the "Spare Parts" chapter and that are

assigned to the device.

Defective parts, O-rings and seal sets must always be re-placed.

WARNING

Incompatibility of cleaning agent and working medium!

Risk of explosion and danger of poisoning by toxic gases.

Examine the compatibility of the cleaning agents and working

media on the basis of the safety data sheets.

In Chapter 14 the part numbers for gun spare parts can be found as well as for wearing parts such as seals.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

10.3.4 ASSEMBLING THE SPRAY GUN

Assembly aids:

Pos Order No. Description

2 * 9992698 Vaseline white PHHV II

4 9992511 Loctite 243 5 9992609 Anti-seize paste

* Use Vaseline sparingly

Ensure the correct insertion position!

Only as required

(if the seal was removed): press in using handle seal assembly tool (Order No. 2342334, not included in scope of delivery)

Torx® 20

Ensure the correct insertion position!

B_03448

Recess for pin

Hold the air valve so that the pin points to the left.

B_04378

SW14 3 Nm

(sparingly)

Gold contact sleeves

Check whether the two gold contact sleeves are in the handle (5). Otherwise, insert the sleeves onto the two gold pins of the connector (6). Slide connector into handle.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Valve rod unit

Set length adjusting measure X

with withdrawal nut (7) and then fasten the threaded pin (6) using an Allen key SW2.

SW2

1Nm

B_04791

Coat the hollow section with a brush. Note: Avoid the pin and hexagon.

B_04770

(sparingly)

SW5

Wear gloves!

The outside thread of the packing (9) must be free of lacquer.

Valve rod unit (8) and packing (9):

- grease,

- slide together,

- screw together (10).

Grease clamping screw (1) and mount using assembly tool (5).

Insert spring (4).

Only as required (if the rod seal was

removed): press in rod seal (11). In the process, press only on the lowest area of the rod seal.

SW6

0.4 - 0.5 Nm

0.5 Nm

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Gold contact sleeve (10)

Check whether the gold contact sleeve is located in the end piece (11). Otherwise, insert the sleeve onto the resistance (12).

Ensure the correct insertion position and installation direction.

Valve needle assembly tool, Order no. 2309368

Ensure the correct insertion position.

(1)

(4)

B_04379

0.1 Nm

SW9

1.8 Nm

Clamping screw assembly tool, Order No. 2325263

B_04793

1. Move the valve rod to the rear position so that the sealing area does not become scratched (1).

2. Slightly tighten AC valve tip (2) by hand 3  ngers) using an assembly tool.

3. Use assembly tool, socket or ring spanner (no open-end wrench) to tighten the valve housing (3).

4. Slide the valve rod to the forward position (at the valve seat) (4).

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

SW19

2.5 Nm

Clean and degrease the inside of the adapter and the cascade, then grease the cascade surface with Vaseline.

Fitting (25)

Before assembling the product hose, check that no  tting (25) is in the gun adapter! Check the  tting for damage and replace if necessary (Order No. 2338853).

SW22

SW19

B_04380

Ensure that the spring is inserted in the adapter.

Ensure that the  at gasket is inserted in the handle.

SW19

SW21

SW3

0.8 Nm

B_03205

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Push the trigger upward into the air valve piston. The recess in the trigger must engage correctly in the indentation of the piston.

Torx® 25

B_03206

Cover (5)

The cover must be handled carefully and not be twisted or distorted in any way.

(sparingly)

B_04381

1. Press metal sleeve (6) back in cover (5) (e.g., press on table). In the process, only exert counter pressure on the sleeve bracket and not on the entire cover.

2. Position cover straight and level, and carefully press in. Use only minimal force, gently rocking from side to side if necessary.

3. Ensure that the cover is  ush mounted on all sides.

4. Press back on metal sleeve for a  ush  t (e.g., press on table).

5. Position bracket (7).

6. Mount screw, plug, and air regulation.

0.8 Nm SW3

SW12

Ensure the correct insertion position!

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Flat jet nozzle

Assembly see Chapter 14.3.1 Diverse nozzle sizes, see Chapter 13.2

Round jet nozzle

Assembly see Chapter 14.3.2 Diverse nozzle sizes, see Chapter 13.1

B_03208

Air hose

When screwing on the air hose, a second open-ended/ring spanner must be used for bracing.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

11 FUNCTIONAL CHECK AFTER REPAIR

After all repairs, the device must be checked for safe condition before recommissioning. The necessary scope of inspection and testing depends on the repair carried out and must be documented by the repair sta .

11.1 CHECKING THE HIGHVOLTAGE

Necessary test equipment: VM 500 or VM 5000 control unit and HV200 high-voltage tester.

High-voltage measurement on spraying gun.

Connect gun cable to control unit. Take the spray gun in your hand and hold it in open space. Switch on control unit and actuate trigger guard. The high-voltage should be 60 to 65 kV in dry ambient air. The value can be checked with the display on the control unit (VM 5000).

Note:

The gun must be clean and dry and must not have any paint or cleaning agent residues. In the case of ambient air with a high air humidity, the measured value can reduce to 50 to 55 kV.

High-voltage measurement with high-voltage tester

Place the ball of the high-voltage tester on the gun electrode and turn on the high-voltage. The measured value should be 70 to 80 kV.

Notes:

- When measuring the high-voltage the gun and the measuring device should be held at arms length as far from the body as possible.

- There should be no chargeable objects within a radius of 1 m; 3.28 ft of the place where the measurements are taken.

- The placing of the measuring ball of the high-voltage measuring device reduces the spraying of the high-voltage electrode. As a result the high-voltage value increases compared to the spraying in the free space.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Disruptive discharge test

Check the gun against ground with the grounding rod. No sparks should be formed. Note: in the vicinity of the electrode harmless corona discharges can occur.

Grounding rod,

Order No. 175519

B_03212

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

11.2 AIR TEST

Connect test or air hose to spray gun. The following air tests are to be carried out twice each:

- at 0.1MPa; 1bar; 14.5psi

- at 0.8MPa; 8bar; 116psi

Checking the air valve

The air valve must switch on and o correctly.

Air seal

Without activating the trigger, test for air seal at the points marked in the illustration.

B_03213

11.3 PRODUCT PRESSURE TEST

Connect high-pressure hose to the spray gun. Test the seal of the spray gun with suitable medium (e.g.,  ushing agent or Marcol 52) and a maximum pressure of 25 MPa; 250 bar; 3,626 psi. Increase the pressure gradually while doing so. Observe the following gun components: Product connection, nozzle body, product valve (no post-spraying).

DANGER

Exploding gas / air mixture!

Danger to life from  ying parts and burns.

Never spray into a closed tank. Ground the tank.

11.4 TEST OF SPRAY PATTERN

Check spray pattern in accordance with Chapter 7.3.2.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

12 DISPOSAL

NOTICE

Do not dispose of used electrical equipment with household refuse!

In accordance with European Directive 2002/96/EC on the disposal of used electrical equipment and its implementation in national law, this product may not be disposed of with the household refuse, but must be recycled in an environmentally correct manner. WAGNER or one of our dealers will take back your used WAGNER electric or electronic equipment and will dispose of it for you in an environmentally-friendly way. Please contact one of our service points, one of our representatives or us directly to arrange this.

Consumable products

Consumable products (lacquers, adhesives,  ushing and cleaning agents) must be disposed of in accordance with all applicable legal requirements.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

13 ACCESSORIES

13.1 ROUND SPRAY NOZZLES

13.1.1 ACR 5000 ROUND JET NOZZLE CAP

Order No. Designation

2309883 ACR 5000 round jet nozzle cap

(with nozzle spanner, without AC round jet nozzle insert)

13.1.2 AIRCOAT ROUND JET NOZZLE INSERTS

The round jet nozzles are especially suited to spray pipes, pro les and complex work pieces.

Order No. Marking Jet width Recommended gun  lter

mm; inch

132720 11 approx. 250; 10 red 132721 12 approx. 250; 10 200 meshes 132722 13 approx. 250; 10 132723 14 approx. 250; 10

132724 * 15 approx. 250; 10

132725 16 approx. 250; 10 yellow 132726 17 approx. 250; 10 100 meshes 132727 18 approx. 250; 10 132728 19 approx. 250; 10 132729 20 approx. 250; 10 white 132730 21 approx. 250; 10 50 meshes 132731 22 approx. 250; 10

B_03210

"?

* Standard version Jet width in mm; inches at a distance of 30 cm; 11.8 inches from the object and at a pressure of 10 MPa; 100 bar; 1,450 psi.

13.2 FLAT JET NOZZLES

13.2.1 ACF 5000 AIR CAPS FLAT JET

Order No. Designation

2309882 Air cap ACF 5000 - LV suitable for low viscosity products (marked red).

2314203 Air cap ACF 5000 - HV suitable for high viscosity products (marked blue).

B_03454

B_03209

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

13.2.2 ACF5000 AIRCOAT FLAT JET NOZZLES

Order No.

395107 07/10 0.18; 0.007 10° Natural lacquer 395207 07/20 20° 395407 07/40 40° 395109 09/10 0.23; 0.009 10° Clear lacquer 395209 09/20 20° Oils 395309 09/30 30° 395409 09/40 40° 395509 09/50 50° 395609 09/60 60° 395111 11/10 0.28; 0.011 10° Synthetic resin lacquer 395211 11/20 20° PVC lacquer 395311 11/30 30° 395411 11/40 40° 395511 11/50 50° 395611 11/60 60° 395811 11/80 80° 395113 13/10 0.33; 0.013 10° Lacquers 395213 13/20 20° Base coat 395313 13/30 30° Primer 395413 13/40 40° Filler 395513 13/50 50° 395613 13/60 60° 395813 13/80 80° 395115 15/10 0.38; 0.015 10° Filler 395215 15/20 20° Rust proo ng paints 395315 15/30 30° 395415 15/40 40° 395515 15/50 50° 395615 15/60 60° 395815 15/80 80° 395217 17/20 0.43; 0.017 20° Rust proo ng paints 395317 17/30 30° Latex paints 395417 17/40 40° 395517 17/50 50° 395617 17/60 60° 395817 17/80 80°

Marking

mm; inch

Drilled hole

Application

Spray angle

B_03163

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Order No.

395219 19/20 0.48; 0.019 20° Rust proo ng paints 395319 19/30 30° Latex paints 395419 19/40 40° 395519 19/50 50° 395619 19/60 60° 395819 19/80 80° 395221 21/20 0.53; 0.021 20° Mica paints 395421 21/40 40° Zinc rich paints 395521 21/50 50° Rust proo ng paints 395621 21/60 60° Glue paints 395821 21/80 80° 395423 23/40 0.58; 0.023 40° 395623 23/60 60° 395823 23/80 80° 395425 25/40 0.64; 0.025 40° 395625 25/60 60° 395825 25/80 80° 395427 27/40 0.69; 0.027 40° 395627 27/60 60° 395827 27/80 80° 395429 29/40 0.75; 0.029 40° 395629 29/60 60° 395829 29/80 80° 395431 31/40 0.79; 0.031 40° 395631 31/60 60° 395831 31/80 80° 395435 35/40 0.90; 0.035 40° 395635 35/60 60° 395835 35/80 80°

Marking

Drilled hole

mm; inch

Application

Spray angle

B_03163

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

13.3 FILTER

Order No. Designation

3204604 Edge  lter 60 mesh (white) 3204605 Edge  lter 100 mesh (black) 9999002 Edge  lter 200 mesh (yellow)

B_00019

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

13.4 HOSES AND ELECTRIC CABLES

13.4.1 STANDARD HOSE SETS AND COMPONENTS

Note regarding the product hose:

3 2

B_03217

Pos Stk Order No. Designation

1 1 2339171 Hose set GM 5000EAC (7.5 m)

Consists of:

2 1 9984573 High-pressure hose-DN4-PN270-¼"NPS-7.5 m-PA 3 1 2339152 Air hose, complete DN6.5 (8.0 m) 4 1 2339157 Gun cable GM 5000E (10.0 m) 5 7 m 3676437 Protection hose fabric PP30 (8.0 m)

- Nominal pressure 25 MPa; 250 bar; 3,626 psi

- Internal diameter 4 mm; 0.16 inch

- Inner hose material PA

Pos Stk Order No. Designation

1 1 2339172 Hose set GM 5000EAC (10.0 m)

Consists of:

2 1 2302374 High-pressure hose-DN4-PN270-¼"NPS-10.0 m-PA 3 1 2339153 Air hose, complete DN6.5 (10.5 m) 4 1 2339158 Gun cable GM 5000E (15.0 m) 5 10.5 m 3676437 Protection hose fabric PP30 (10.5 m)

Pos Stk Order No. Designation

1 1 2339173 Hose set GM 5000EAC (15.0 m)

Consists of:

2 1 9984573-15 High-pressure hose-DN4-PN270-¼"NPS-15.0 m-PA 3 1 2339154 Air hose, complete DN6.5 (15.5 m) 4 1 2339159 Gun cable GM 5000E (20.0 m) 5 15.5 m 3676437 Protection hose fabric PP30 (15.5 m)

Pos Stk Order No. Designation

1 1 2339174 Hose set GM 5000EAC (20.0 m)

Consists of:

2 1 9984573-20 High-pressure hose-DN4-PN270-¼"NPS-20.0 m-PA 3 1 2339155 Air hose, complete DN6.5 (20.5 m) 4 1 2339160 Gun cable GM 5000E (25.0 m) 5 20.5 m 3676437 Protection hose fabric PP30 (20.5 m)

In the large WAGNER Accessories Catalogue for wet coating you will also  nd reduction and material  ttings.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Hose colors:

Product hose yellow Air hose blue

Dimensions:

Air hose: inside diameter 6.5 mm; 0.26 inch Product hose: inside diameter 4 mm; 0.16 inch, nominal pressure 25 MPa; 250 bar; 3,626 psi

Material of product hose: PA

(**)

(****)

2 3

(*)(***)

B_03845

1 Product hose 2 Air hose 3 Electrical cable

Order No. Description A [mm] B [mm] C [mm] D [mm] E [mm]

2339171 Hose set GM 5000EAC (7.5 m) 29±2 65±2 300±10 20±10 1,500 2339172 Hose set GM 5000EAC (10 m) 29±2 65±2 300±10 20±10 1,500 2339173 Hose set GM 5000EAC (15 m) 29±2 65±2 300±10 20±10 1,500 2339174 Hose set GM 5000EAC (20 m) 29±2 65±2 300±10 20±10 1,500

+100

Notes:

(*) Melt the hose ends at both sides (gun/pump) and turn approx. 5 cm of each hose end to the inside. (**) Fix the protective hose with cable ties on both sides only once at the product hose (internally). (***) Fix the hose set within the protective hose approx. once per meter by means of adhesive tape, starting

at distance E. Cable ties are only permitted at the ends of the protective hose (see **)!

(****) If the air swivel joint (Order No. 2324766) and/or the material swivel joint (Order No. 2327060) is/are

used, the hose set has to be adapted accordingly.

If the air swivel joint is used, dimension A becomes 60 mm! If the material swivel joint is used, dimension B becomes 94 mm!

B****

A****

B_03849

2 3

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

13.4.2 HOSE SETS FOR LOWRESISTANCE PRODUCTS

6 2

B_03216

Pos Stk Order No. Designation

1 1 2339179 Hose set GM 5000EAC (7.5 m), Low R

Consists of:

2 1 2310468 High-pressure product hose EAC, complete (7.5 m) Low R (inclusive pos. 6) 3 1 2339152 Air hose, complete DN6.5 (8.0 m) 4 1 2339157 Gun cable GM 5000E (10.0 m) 5 8 m 3676437 Protection hose fabric PP30 (8.0 m)

Pos Stk Order No. Designation

1 1 2339180 Hose set GM 5000EAC (10.0 m), Low R

Consists of:

2 1 2310469 High-pressure product hose EAC, complete (10.0 m) Low R (inclusive pos. 6) 3 1 2339153 Air hose, complete DN6.5 (10.5 m) 4 1 2339158 Gun cable GM 5000E (15.0 m) 5 10.5 m 3676437 Protection hose fabric PP30 (10.5 m)

Note regarding the product hose:

- Nominal pressure 25 MPa; 250 bar; 3,626 psi

- Internal diameter 4 mm; 0.16 inch

- Inner hose material FEP

- Pos. 6 connection  tting AC, Order No. 2338853

Pos Stk Order No. Designation

1 1 2339181 Hose set GM 5000EAC (15.0 m), Low R

Consists of:

2 1 2310470 High-pressure product hose EAC, complete (15.0 m) Low R (inclusive pos. 6) 3 1 2339154 Air hose, complete DN6.5 (15.5 m) 4 1 2339159 Gun cable GM 5000E (20.0 m) 5 15.5 m 3676437 Protection hose fabric PP30 (15.5 m)

Pos Stk Order No. Designation

1 1 2339182 Hose set GM 5000EAC (20.0 m), Low R

Consists of:

2 1 2310471 High-pressure product hose EAC, complete (20.0 m) Low R (inclusive pos. 6) 3 1 2339155 Air hose, complete DN6.5 (20.5 m) 4 1 2339160 Gun cable GM 5000E (25.0 m) 5 20.5 m 3676437 Protection hose fabric PP30 (20.5 m)

In the large WAGNER Accessories Catalogue for wet coating you will also  nd reduction and material  ttings.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Hose colors:

Product hose grey Air hose blue

Dimensions:

Air hose: inside diameter 6.5 mm; 0.26 inch Product hose: inside diameter 4 mm; 0.16 inch, nominal pressure 25 MPa; 250 bar; 3,626 psi

Material of product hose: FEP

(**)

1 2 3

(*)(***)

B_03846

A****

1 Product hose 2 Electrical cable 3 Air hose

Order No. Description A [mm] B [mm] C [mm] D [mm] E [mm] F [mm]

+100

2339179 Hose set GM 5000EAC (7.5 m), Low R 206±2 177±2 300±10 20±10 1,500 2339180 Hose set GM 5000EAC (10 m), Low R 206±2 177±2 300±10 20±10 1,500 2339181 Hose set GM 5000EAC (15 m), Low R 206±2 177±2 300±10 20±10 1,500 2339182 Hose set GM 5000EAC (20 m), Low R 206±2 177±2 300±10 20±10 1,500

+100

188±1 188±1 188±1 188±1

Notes:

at distance E. Cable ties are only permitted at the ends of the protective hose (see **)!

(****) If the air swivel joint (Order No. 2324766) is used, the hose set has to be adapted accordingly.

If the air swivel joint is used, dimension A becomes 237 mm!

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

13.4.3 PRODUCT HOSE 1.5 MM

B_04197

Pos Stk Order No. Designation

1 1 2352607 Product hose set AC 1.5 mm, complete

13.4.4 GUN CABLES AND GUN CABLE EXTENSIONS

GM 5000E gun cable

Length 10 m; 32.8ft 15 m; 49.2ft 20 m; 65.6ft 25 m; 82.0ft 32 m; 105ft 62 m; 203ft

Order No. 2339157 2339158 2339159 2339160 2344995 2344996

GM 5000E extension cable

Length 10 m; 32.8ft 20 m; 65.6ft

Order No. 2339161 2339162

Max. total length of 80m; 262ft (see Chapter 6.6.3.1)

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

13.5 MISCELLANEOUS

Order No. Designation

2319653 Protective gun coating

259010 High-voltage tester HV 200 N

B_03693

P_00265

2326041 Paint resistance meter

999080 Wet  lm thickness gauge

50342 Viscosity cup DIN 4 mm; 0.16 inch

2309368 Valve needle assembly tool

B_03692

B_03224

B_03451

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

128901 Nozzle spanner ACR

"?

2325263 Clamping screw assembly tool

2326485 Wall mount GM 5000E (left/right)

2324766 Swivel joint air

2327060 Fitting-SJM-GM5000EAC-1/4"NPS (swivel product)

B_03681

B_03699

B_03720

B_03719

2327061 Swivel joint set GM 5000EAC

B_03720

B_03719

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

14 SPARE PARTS

14.1 HOW CAN SPARE PARTS BE ORDERED?

Always supply the following information to ensure delivery of the right spare part:

Order number, designation and quantity

The quantity need not be the same as the number given in the quantity column "Stk" on the list. This number merely indicates how many of the respective parts are used in each component.

The following information is also required to ensure smooth processing of your order:

Address for the invoice Address for delivery Name of the person to be contacted in the event of any queries Type of delivery (normal mail, express delivery, air freight, courier, etc.)

Identi cation in spare parts lists.

Explanation of column "K" (labeling) in the following spare parts lists:

Wearing parts

Note: These parts are not covered by warranty terms.

Not part of standard equipment, available, however, as additional extra.

DANGER

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" and that are assigned to the unit.

Before all work on the device and in the event of work interruptions:

- Switch o the energy and compressed air supply.

- Relieve the pressure from the spray gun and device.

- Secure the spray gun against actuation. Observe the operating manual and service manuals at all times

when carrying out work.

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

14.2 GM 5000EAC SPRAY GUN

Dismantling and assembly

See Chapter 10

B_03153

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

GM 5000EAC spare parts list

Pos K Stk Order No. Designation

1 1 2309871 Basic version GM 5000EAC

51 -

71 -

8 2 9900308 Hexagon socket cylinder head screw

9 1 2312183 Lid complete (including item 24) 10 1 9900386 Hexagon socket cylinder head screw 11 1 2311970 Sealing plug 12 1 2307104 Screw plug 13 1 2312180 Air regulation, complete (including item 14) 14 15 1 9971182 O-ring 16 1 2314360 Trigger 17 1 2307283 Cylindrical helical spring 18 2 2310617 Oval head screw with hexagon 19

21 1 2308764 Filter socket AC 22 1 2315775 Union nut AC, complete 24 25

1 2314361 Hook

1 9971182 O-ring

1 2314359 Product hose AC, complete

1 3204605

1 2308699 Cover seal 1 2338853 Connecting  tting AC

Adapter GM 5000EAC, complete For details, see Chapter 14.2.1

Handle GM 5000EAC, complete For details, see Chapter 14.2.2

Edge  lter 100 mesh (black) (for di erent edge  lter sizes see Chapter 13.3)

1 2326336 Service set GM 5000EAC

= Wearing part

= Included in service set

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

14.2.1 GM 5000EAC ADAPTER

B_04368

Dismantling and assembly

See Chapter 10

123 ±0.1 mm

4.8425 ±0.004 inch

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Spare parts list adapter

Pos K Stk Order No. Designation

1 1 - Adapter GM 5000EAC, complete

3 1 2312186 Valve needle AC, complete

4 1 2353476 Adapter GM 5000EAC

5 1 2313314 Air manifold ring AC

7 1 2314283 Contacting AC

8 1 9952777 High resistance, bare

9 1 9960808 Socket contact component (gold contact sleeve) 10 1 2312181 Cascade, complete 11 12 1 2307062 Clamping screw valve rod 13 14 1 2313639 Valve rod unit AC 15 1 2340024 Packing, complete 21 1 2307059 Withdrawal nut 22 1 9901411 Threaded pin with hexagon socket 24 1 2325263 Assembly tool clamping screw 25 1 2357665 Clamping screw valve rod, complete

1 2312175 Valve housing AC, complete

1 2307180 O-ring, sheathed

1 9974166 O-ring

1 2311562 Rod seal

1 2326336 Service set GM 5000EAC

= Wearing part

= Included in service set

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

14.2.2 GM 5000EAC HANDLE

Dismantling and assembly

See Chapter 10

B_04775

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

Handle spare parts list

Pos K Stk Order No. Designation

1 1 - Handle GM 5000EAC, complete

2 1 2307288 Nipple

4 1 2307290 Hose holder

5 1 2312182 Plug, complete

6 1 2314270 Handle, complete

8 1 2311952 Stop screw

9 1 2309825 Oval head screw with hexagon 10 11 1 2311182 Parallel pin 12 1 2309400 Safety clip 13 1 2312189 Air valve 18 23 1 9974166 O-ring 24 1 2309817 Type plate, left GM 5000EAC* 25 1 2309810 Type plate, right GM 5000E* 26 1 9971364 O-ring

1 9971025 O-ring

1 2307232 Adapter seal

1 2310692 Gasket

1 9974218 O-ring

1 2326336 Service set GM 5000EAC

= Wearing part

= Included in service set

Note:

* Type plates may only from WAGNER sta or a skilled person be replaced!

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

14.3 ACCESSORIES SPARE PARTS LISTS

14.3.1 FAN SPRAY NOZZLES

B_03168

Flat jet nozzles spare parts list

Pos K Stk Order No. Designation

1 1 2315775 Union nut AC, complete

2 1 2309882 Air cap ACF 5000 - LV (red)

2 1 2314203 Air cap ACF 5000 - HV (blue)

4 1 2311776 Union nut AC

5 1 2311217 O-ring, sheathed

= Wearing part

1 2311777 Nozzle guard AC

1 2319525 Flat electrode set

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

14.3.2 ACR 5000 ROUND JET NOZZLE CAP

B_03169

ACR 5000 round jet nozzle cap spare parts list

Pos K Stk

1 1 2309883 Round jet nozzle cap ACR 5000 2 1 2307220 Nozzle nut 3 4 5 1 2307219 Nozzle body 6 1 2319526 Round electrode set

9 1 132516 Nozzle screw joint, complete 10 11 1 2311217 O-ring 12 1 128901 Nozzle wrench, complete

= Wearing part

1 2315310 O-ring 1 132351 Nozzle screwed connection holder

1 2307216 Sealing  tting

Order No. Designation

EDITION 05/2015 ORDER NUMBER DOC2319150

OPERATING MANUAL

15 WARRANTY AND CONFORMITY DECLARATIONS

15.1 IMPORTANT NOTES REGARDING PRODUCT LIABILITY

As a result of an EC regulation e ective from January 1, 1990, the manufacturer shall only be liable for his product if all parts originate from him or are approved by him, and if the devices are properly mounted, operated and maintained. The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with.

15.2 WARRANTY CLAIM

Full warranty is provided for this device: We will at our discretion repair or replace free of charge all parts which within 24 months in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by the purchaser are found to be wholly or substantially unusable due to causes prior to the sale, in particular faulty design, defective materials or poor workmanship. The type of warranty provided is such that the device or individual components of the device are either replaced or repaired as we see  t. 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 device to a location other than the address of the purchaser. We do not provide warranty for damage that has been caused or contributed to for the following reasons: Unsuitable or improper use, faulty assembly or commissioning by the purchaser or a third party, normal wear, negligent handling, defective maintenance, unsuitable coating products, substitute products and the in uence of chemical, electrochemical or electrical agents, except when the damage is attributable to us. Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust paints and so forth reduce the service life of valves, packings, spray guns, nozzles, cylinders, pistons etc. Signs of wear traced back to these products are not covered by this warranty. Components that have not been manufactured by WAGNER are subject to the original warranty of the manufacturer. Replacement of a component does not extend the period of warranty of the device. The device should be inspected immediately upon receipt. To avoid losing the warranty, we or the supplier company are to be informed in writing about obvious faults within 14days upon receipt of the device. We reserve the right to have the warranty compliance met by a contracting company. The services provided by this warranty are dependent on evidence being provided in the form of an invoice or delivery note. If the examination discovers that no warranty claim exists, the costs of repairs are charged to the purchaser. It is clearly stipulated that this warranty claim does not represent any constraint on statutory regulations or regulations agreed to contractually in our general terms and conditions.

J. Wagner AG

100

Wagner GM 5000EAC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual