Wagner GM 5000EAC User Manual

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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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

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EDITION 05/2015 ORDER NUMBER DOC2319150

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).

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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.

EDITION 05/2015 ORDER NUMBER DOC2319150

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

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100

EXT

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

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