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B_03154
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Electrostatic AirCoat Spray Gun for
Manual Operation and for Flat or
Round Jet Nozzles
Version 07/2014
Translation of the Original
Operating Manual
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OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
Contents
1 ABOUT THIS OPERATING MANUAL 6
1.1 Preface 6
1.2 Warnings, Notices, and Symbols in this Operating Manual 6
1.3 Languages 7
1.4 Abbreviations 7
2 CORRECT USE 8
2.1 Device Type 8
2.2 Correct Use 8
2.3 Use in an Explosion Hazard Area 8
2.4 Safety Parameters 8
2.5 Processible Products 9
2.6 Reasonably Foreseeable Misuse 10
2.7 Residual Risks 10
3 IDENTIFICATION 11
3.1 Explosion Protection Identi cation FM 11
3.2 Information for safe and correct operation 11
3.3 Permissible Device Combinations 12
4 GENERAL SAFETY INSTRUCTIONS 13
4.1 Safety Instructions for the Operator 13
4.1.1 Electrical Equipment 13
4.1.2 Sta Quali cations 13
4.1.3 Safe Work Environment 13
4.2 Safety Instructions for Sta 14
4.2.1 Safe Handling of WAGNER Spray Devices 14
4.2.2 Grounding the Device 15
4.2.3 Material Hoses 15
4.2.4 Cleaning 16
4.2.5 Handling Hazardous Liquids, Varnishes, and Paints 17
4.2.6 Touching Hot Surfaces 17
4.3 Correct Use 17
4.4 Safety Information on Discharges 18
4.5 Use in an Explosion Hazard Area 18
4.6 Notes to German Regulations and Guidelines 18
5 DESCRIPTION 19
5.1 Functional Description 19
5.1.1 Design of the Spray Gun (Basic Version) 19
5.1.2 Functioning of the Spray Gun 20
5.2 Scope of Delivery 22
5.3 Technical Data 23
5.4 Spray Process 24
5.4.1 AirCoat Round Jet Spray Process 24
5.4.2 AirCoat Flat Jet Spray Process 24
5.4.3 Electrostatic E ect 25
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Table of Contents
6 COMMISSIONING AND OPERATION 26
6.1 Training Assembly/Commissioning Sta 26
6.2 Storage Conditions 26
6.3 Installation Conditions 26
6.4 Installation and Connection 27
6.4.1 Typical Electrostatic Spraying System 27
6.4.2 Ventilation of the Spray Booth 28
6.4.3 Air Supply 29
6.4.4 Material Supply 29
6.4.5 Grounding 30
6.5 Preparation of Lacquer 33
6.5.1 Viscosity Conversion Table 33
6.6 Commissioning 34
6.6.1 General Rules for Manipulation of the Spray Gun 34
6.6.2 Preparation for Starting Up 34
7 OPERATION 37
7.1 Training the Operating Sta 37
7.2 Safety Instructions 37
7.3 Work 38
7.3.1 Filling with Working Product 38
7.3.2 Start-up for Spraying AirCoat 39
7.3.3 Flushing Out Clogged Round Jet Nozzles 40
7.3.4 Replacing Round Jet Nozzle's Nozzle Insert 40
7.3.5 Changing from AirCoat Round Jet to AirCoat Flat Jet 41
7.3.6 Replacing the AirCoat Flat Jet Nozzles 42
7.3.7 Cleaning of the Nozzle Parts 42
7.3.8 Eliminate Nozzle Clogging 42
7.3.9 Changing the Valve Housing 44
8 CLEANING AND MAINTENANCE 45
8.1 Cleaning 45
8.1.1 Cleaning Sta 45
8.1.2 Safety Instructions 45
8.1.3 Cleaning and Decommissioning 46
8.2 Maintenance 48
8.2.1 Maintenance Sta 48
8.2.2 Safety Instructions 48
8.3 Disassembly of the Spray Gun 49
8.3.1 Tools 49
8.3.2 Disassembly of the Spray Gun 50
8.4 Cleaning the Parts after Disassembly 53
8.5 Assembly of the Spray Gun 54
8.6 Function Test after Assembly of the Gun 59
8.6.1 Test of the High-Voltage 59
8.6.2 Air Test 60
8.6.3 Product Pressure Test 60
8.6.4 Test of Spray Pattern 61
8.7 High-Pressure Hoses 62
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Table of Contents
9 INSPECTIONS 63
9.1 Periodical Inspections 63
10 TROUBLESHOOTING AND RECTIFICATION 64
11 PRODUCT DISPOSAL 65
12 ACCESSORIES 66
12.1 Round Jet Nozzles 66
12.1.1 ACR 5000 Round Jet Nozzle Cap 66
12.1.2 AirCoat Round Jet Nozzle Inserts 66
12.2 Flat Jet Nozzles 66
12.2.1 ACF 5000 Air Caps (Flat Jet) 66
12.2.2 ACF5000 AirCoat Flat Jet Nozzles 67
12.3 Filter 69
12.4 Reduction Fittings for High-Pressure Hoses 69
12.5 Hoses and Electric Cables 70
12.5.1 Standard Hose Sets and Components 70
12.5.2 Hose Sets for Low-resistance Products 72
12.5.3 Gun Cables and Gun Cable Extensions 74
12.6 Miscellaneous 74
13 SPARE PARTS 77
13.1 How Can Spare Parts Be Ordered? 77
13.2 GM 5000EAC Spare Parts List 78
13.2.1 GM 5000EAC - Adapter Spare Parts List 80
13.2.2 GM 5000EAC - Handle Spare Parts List 82
13.3 Accessories Spare Parts Lists 84
13.3.1 Flat Jet Nozzles Spare Parts List 84
13.3.2 ACR 5000 Round Jet Nozzle Cap Spare Parts List 85
14 WARRANTY 86
14.1 Important Notes Regarding Product Liability 86
14.2 Warranty Claim 86
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1 ABOUT THIS OPERATING MANUAL
1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
Warning instructions in this operating manual highlight particular dangers to users and to
the device and state measures for avoiding the hazard. These warning instructions fall into
the following categories:
Danger - immediate risk of danger.
Non-observance will result in death or serious injury.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Notice - a possibly hazardous situation.
Non-observance may result in material damage.
Note - provides information about particular characteristics and how to proceed.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The following are measures which can be taken to prevent
the hazard and its consequences.
DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The following are measures which can be taken to prevent
the hazard and its consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The following are measures which can be taken to prevent
the hazard and its consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The following are measures which can be taken to prevent the hazard and its
consequences.
NOTICE
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 .
Operating and service sta should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
Electrostatic spray guns may only be operated by trained personnel.
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1.3 LANGUAGES
The operating manual is available in the following languages:
German English 2344500
1.4 ABBREVIATIONS
Order No. Order number
ET Spare part
Marking in the spare parts lists
Low R Low-resistance
Position
Number of pieces
Width across ats
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2 CORRECT USE
2.1 DEVICE TYPE
Electrostatic manual spray gun for manual coating of grounded work pieces
2.2 CORRECT USE
The GM 5000EAC electrostatic hand 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.
2.4 SAFETY PARAMETERS
The GM 5000EAC electrostatic manual spray gun is only suitable for spraying liquid
products, particularly coating products.
J. Wagner AG forbids any other use!
The electrostatic manual spray gun may only be operated under the following conditions:
the operating sta have previously been trained on the basis of this operating manual,
the safety regulations listed in this operating manual are observed,
the operating, maintenance and repair information in this operating manual is
observed,
and the statutory requirements and accident prevention regulations standards in the
country of use are observed.
The electrostatic manual spray gun may only be operated if all parameters are set and all
measurements/safety checks are carried out correctly.
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 "Identi cation".)
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2.5 PROCESSIBLE PRODUCTS
With the GM 5000EAC gun, paints can be applied which contain solvents of
explosion class II A.
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 transfer e ciency is always dependant on the composition of the product
being used, e.g. pigmentation or resin.
Conversion of Paint Resistance
There are paint resistance measuring devices available on the market that do not directly
measure the speci c paint resistance.
Multiplying the result of the measurement with the device-speci c cell constant (K), we
obtain the speci c resistance value of the product.
Example:
With Wagner’s paint resistance measuring device the cell constant is K =123.
Measured value according to the WAGNER scale
Speci c resistance (RS)
Notice
Using sprayed substances with too low an electrical resistance, the application of
electrostatics does not show any e ect, i.e. there is no "paint wrap around" on the object
to be sprayed.
The suitability of the sprayed product with regard to the charging ability can be read
from the indicators showing the actual values for the high-voltage (kV) and for the spray
current (μA) the actual values are shown 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
In the event of application problems, please contact your local WAGNER o ce and the
paint manufacturer.
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2.6 REASONABLY FORESEEABLE MISUSE
Processing inadmissible coating products
Use of defective spare parts
Use for foodstu s
Use in the pharmaceutical sector
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be excluded 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
solvent-based
paints and cleaning
agents
Handling of
solvent-based
paints and cleaning
agents
Skin irritations, Wear protective
clothing,
Operation,
allergies observe safety data
sheets
maintenance,
disassembly
Solvent-based
paint in air outside
the de ned
working area
Painting outside
the de ned
working area
Inhalation of
substances
hazardous to health
Observe work
and operation
instructions
Operation,
maintenance
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3 IDENTIFICATION
Safety instructions
Maximum surface temperature
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
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 unit against steel or rusty iron.
Do not drop the spray gun.
Only use tools that are made of a permitted material.
3.1 EXPLOSION PROTECTION IDENTIFICATION FM
For Electrostatic Finishing Applications
using Class I, Group D, Spray Material
In accordance with 2316160
This device has been manufactured and tested by FM, according to the FM (Factory Mutual)
standard "Class Number 7260" (Approval Standard for Electrostatic Finishing Equipment).
All tested combinations of devices including accessories are given in the FM Control
Document with part number 2316160.
3.2 INFORMATION FOR SAFE AND CORRECT OPERATION
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating material is above the maximum
surface temperature.
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3.3 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
Incorrect use!
Risk of injury and equipment damage.
Connect the GM 5000EAC manual spray gun only to original
Wagner control units.
WARNING
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.
Only use a damp cloth to clean the device.
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL EQUIPMENT
4.1.2 STAFF QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual at hand near the unit at all times.
Always follow local regulations concerning occupational safety and accident prevention.
Electrical devices and equipment
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient in uences.
May only be maintained by skilled electricians or under their supervision.
Must be operated in accordance with the safety regulations and electrotechnical regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Ensure that the device is operated and repaired only by trained persons.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 Mohm).
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 Mohm.
Ensure that during spraying, persons wear static dissipative gloves. The 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 Mohm.
Paint mist extraction systems must be tted on site according to local regulations.
Ensure that the following components of a safe working environment are available:
– Product/air hoses adapted to the working pressure.
– Personal safety equipment (breathing and skin protection).
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
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4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.
4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or cleaning agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before all work on the device, in the event of work interruptions and functional faults:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
– In the event of functional faults: remedy the fault as described in the "Troubleshooting"
chapter.
The liquid ejection devices are to be checked for safe working conditions by an expert
(e.g. Wagner Service Technician) as often as necessary or at least every 12 months,
in accordance with the guidelines for liquid ejection devices (ZH1/406 and BGR 500
Part2 Chapter2.36).
– For shut down devices, the examination can be suspended until the next commissioning.
Carry out the work steps as described in the "Pressure Relief/Work Interruptions" 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 cleaning agents:
Note down the paint or cleaning agent that you have been using.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
Ensure that you have 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
In order to avoid electrostatic charging of the device, the device must be grounded.
Friction, owing liquids, and air or electrostatic coating processes create charges. Flames or
sparks can form during discharge.
Ensure that the device is grounded at all times.
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 dissipative gloves when spraying. The grounding takes place via the spray gun handle.
Grounding of the coating product supply (coating product tank, pump, etc.) is mandatory.
Ensure that the hose material is chemically resistant to the sprayed products.
Ensure that the product hose is suitable for the pressure generated in the device.
Ensure that the following information can be seen on the high-pressure hose:
– Manufacturer
– Permissible operating overpressure
– Date of manufacture
Make sure that the hoses are laid only in suitable places. In no case, should hoses be laid
in the following places:
– in high-traffic areas,
– on sharp edges,
– on moving parts, or
– on hot surfaces
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the complete high-pressure hose must be less than 1 Mohm.
4.2.3 MATERIAL HOSES
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4.2.4 CLEANING
De-energize the device electrically.
Disconnect the pneumatic supply line.
Relieve the pressure from the device.
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.
To clean, use cloths and brushes moistened with solvent. Abrasive agents or objects
must not be used. Ensure that the spray gun is not damaged in any way while cleaning.
Parts of the spray gun must not be sprayed with or immersed into cleaning agent.
Preferably, non-combustible cleaning agents should be used.
The choice of the appropriate cleaning agent 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.
Ensure that no electrical component is cleaned with nor even immersed into solvent.
An explosive gas/air mixture forms in closed tanks.
When cleaning devices with solvents, never spray into a closed tank.
Only use electrically conductive tanks for cleaning liquids.
The tanks must be grounded.
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4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES, AND PAINTS
When preparing or working with paint and when cleaning the device, follow the
working instructions of the manufacturer of the paints, 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 a 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 sticker
Note: Order the two stickers together.
4.3 CORRECT USE
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.
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4.4 SAFETY INFORMATION ON DISCHARGES
The plastic parts of the spray gun are charged electrostatically by the high-voltage eld of
the spray gun. In case of 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 during darkness.
4.5 USE IN AN EXPLOSION HAZARD AREA
In explosion hazard areas only use approved explosion-proof electrical devices.
4.6 NOTES TO GERMAN REGULATIONS AND GUIDELINES
Electrical devices and equipment
Part 2, Chapter 2.36 Working with Liquid Ejection Devices
Part 2, Chapter 2.29 Working with Coating Products
Explosion protection rules
Avoiding ignition risks
Equipment for cleaning work pieces with solvents
Guidelines for liquid ejection devices
Painting rooms and equipment
Electrostatic coating
Plant Safety Ordinance
Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they
can be found on the Internet.
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5 DESCRIPTION
5.1 FUNCTIONAL DESCRIPTION
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 12.2.1)
7 Flat jet nozzle ACF 5000
(see accessories in Chapter 12.2.2)
8 Adapter
9Cover
10 Handle
11 Trigger lock
Description
12 Trigger lever
13 Round jet nozzle adapter
(see accessories in Chapter 12.1.1)
14 Round jet nozzle insert
(see accessories in Chapter 12.1.2)
15 Sealing plug
16 Air adjustment
17 Electric cable connection
18 Atomizing air connection
19 Product connection
20 Filter housing with lter
21 Type plate left
22 Type plate right
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 12 "Accessories".
Note:
The gun type (T) on the type plate (21) and the serial number (S) on
the underside of the handle.
5.1.1 DESIGN OF THE SPRAY GUN BASIC VERSION
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R3
R2
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5.1.2 FUNCTIONING OF THE SPRAY GUN
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 keep the button pressed
of at least 2 seconds, then it is advanced by 1 recipe.
Display (2) ->
= recipe values changed temporarily:
The stored recipe values of the previously selected recipe number
are re-loaded from memory by pressing the operating button (4)
for 2 seconds.
During spraying (trigger lever pressed), the status is shown in the display (2) by LEDs.
LED display Description
LEDs 1 - 3 light up green The spray gun is working in an optimal
high-voltage spray current range
one or both right-hand LEDs light up
orange
spray current too high
Possible causes:
(Warning display: You can continue
working without any limitations.)
Spray gun too close to the work piece
Contamination of the spray gun
Paint conductivity too high
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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
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) blinks.
The width of the spray jet can be adjusted using the air
adjustment (16) (only for at-jet method).
The trigger can be used to activate, one after the other, the
various functions of the spray gun.
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Stk Order No. Description
1 2344473 GM 5000EAC spray gun
Without control unit, product and air hose, electric cable, air cap and nozzle.
Each gun includes as standard equipment:
Order No. Description
1 2309368 Assembly tool valve needle
1 2325263 Assembly tool clamping screw
1 2319653 Protection gloves against spray mist
1 2316160 FM Control Document GM 5000E
1 see Chapter 1.3 Operating manual in local language
The spray gun basic version can be set according to requirement and the desired accessories
by means of the spray gun con guration.
The delivery note shows the exact scope of delivery.
5.2 SCOPE OF DELIVERY
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5.3 TECHNICAL DATA
GM 5000EAC F
with at jet nozzle
mm inch
A 280 11.02
B 46 1.81
C 264 10.39
GM 5000EAC R
with round jet nozzle
mm inch
A 264 10.39
B 46 1.81
C 264 10.39
Dimensions
Maximum air pressure 0.8 MPa; 8 bar; 116 psi
Maximum product pressure 25 MPa; 250 bar; 3,626 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 70 kV DC
Output current maximum 100 μA DC
Polarity negative
Weight (without hose set) 710g
(including union nut, nozzle, air cap and edge lter
Operating temperature range 0 °C to 40 °C
32 °F to 104 °F
Maximum product temperature 50°C
122 °F
Sound level at 0.3 MPa; 3 bar; 43.5 psi air pressure and
11 MPa; 110 bar; 1,549 psi product pressure.
73 dB(A) *
* A-rated sound pressure level measured at 1 m distance, LpA1m, in accordance with DIN EN 14462: 2005.
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5.4 SPRAY PROCESS
AirCoat air
Multi-channel
swirl nozzle
Spray jet
Nozzle nut
Spray product
AirCoat air
Advantages
Large application volume
Low fogging tendency
Good nish
High viscosity paints can easily be applied
High endurance of the nozzles
Jet width adjustment
5.4.2 AIRCOAT FLAT JET SPRAY PROCESS
Shaping air
Aircap
Variable spray jet
width
Atomizing air
Advantages
Large application volume
Low fogging tendency
Good nish
High viscosity paints can easily be applied
High endurance of the AC-nozzles
Jet width adjustment
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.
5.4.1 AIRCOAT ROUND JET SPRAY PROCESS
In the AirCoat process, the spray product is atomized under a pressure of 3-15 MPa; 30-150 bar; 435-2,176psi.
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.
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ElectrodePaint particle
Object to be sprayed
grounded
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.
5.4.3 ELECTROSTATIC EFFECT
Advantages
Very high application e ectiveness
Low over spray
Coating of entire circumferences due to the electrostatic e ect
Savings in working time
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6 COMMISSIONING AND OPERATION
6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF
Incorrect installation/operation!
Risk of injury and equipment damage.
The commissioning sta must have the technical skills to safely
undertake commissioning.
When commissioning and for all work, read and follow the
operating manual and safety regulations for the additionally
required system components.
WARNING
6.2 STORAGE CONDITIONS
Until the point of assembly, the manual spray gun must be stored in a dry location, free
from vibrations and with a minimum of dust. The manual spray gun must be stored in
closed rooms.
The air temperature at the storage location must be between -20 - +60 °C; -4 - +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 between 0 - 40°C; 32 - 132°F.
The relative air humidity at the installation site must be between 10 and 95 %
(without condensation).
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100
80
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40
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μA
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60
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20
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kV
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R2
VM 5000
7
6
8
4
5
9
17
1
2
16
15
14
21
12
11
10
B_03158
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6.4 INSTALLATION AND CONNECTION
Description
1 GM 5000EACF spray gun
2 Gun cable
3 Grounding cable
4 Pneumatic pump
5 Trolley
6 Pressure regulator + air
lter
7 Product suction system
8 Return hose
9 High-pressure lter
10 Compressed air connection
Description
11 Stop valve
12 Air pressure regulator
13 VM 5000 control unit
14 Protective hose
15 Air hose
16 Product hose
17 Return valve
18 Tank for return ow
Description
19 Paint tank
20 Tank, cleaning agent
21 Power cable
6.4.1 TYPICAL ELECTROSTATIC SPRAYING SYSTEM
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6.4.2 VENTILATION OF THE SPRAY BOOTH
The GM 5000EAC spray gun must be used as part of a spraying system (Spraypack). The
system shown in gure B_03158 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
instructions and the safety regulations of all additional system components before starting
commissioning.
Incorrect installation/operation!
Risk of injury and equipment damage.
When commissioning and for all work, read and follow the
operating manual and safety regulations for the additionally
required system components.
WARNING
Toxic and/or ammable vapor mixtures!
Risk of poisoning and burns.
Operate the device in a spray booth approved for the working
products.
-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.
WARNING
The electrostatic hand spraying equipment is for use only in spray areas which correspond
with standard EN 12215.
The electrostatic hand spraying equipment has to 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.
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6.4.4 MATERIAL SUPPLY
Impurities in the spraying system!
Spray gun blockage, products harden in the spraying system.
Flush the spray gun and paint supply with a suitable cleaning agent.
NOTICE
6.4.3 AIR SUPPLY
The use of an air lter with the 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.
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
DANGER
Hose connections
Risk of injury and equipment damage.
Do not exchange hose connections of product hose and air hose.
WARNING
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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.
A poorly grounded work piece causes:
very bad wrap around,
uneven coating,
back spraying to the spray gun, i.e. contamination.
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 instruction 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 MΩ (Megohm).
Note:
Resistance to ground measured at 500 V or 1,000 V.
Connect the control unit to the system ground.
6.4.5 GROUNDING
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.
WARNING
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R max < 1 MΩ
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EDITION 07/2014 ORDER NUMBER DOC 2344500
Minimum cable cross-section
Control unit
Pump
Paint tank
Conveyor
Booth
Spraying stand
Control unit
Grounding cable
Spraying stand
Floor static dissipative
Work piece
Pump or pressure
tank
Paint tank or
tank for return
ow
Grounding schema (example):
Note for the sprayer:
Safety shoes and gloves,
if used, must be static
dissipative.
Conveyor
Power cable
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6.5 PREPARATION OF LACQUER
6.5.1 VISCOSITY CONVERSION TABLE
The viscosity of the lacquers is of great importance. The best spraying results are obtained
with values between 25 and 40 DIN-s (measured in immersion ow cup DIN 4 mm;
0.16 inch). Processing of up to 60 DIN-s 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.
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
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Observe safety instructions in Chapter 4.
The following points should be noted before commissioning
Grounding see Chapter 6.4.5. Make sure that all other conductive parts within the
work area are grounded.
Connect the product hose to spray gun and 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;
2.5bar; 36 psi. Compressed air quality class 3.5.2 according to ISO 8573.1.
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.
6.6 COMMISSIONING
6.6.1 GENERAL RULES FOR MANIPULATION OF THE SPRAY GUN
High-voltage eld!
Danger to life from malfunction of heart pacemakers.
Make sure that persons with pace makers:
Do not work with the electrostatic spray gun.
Stay outside the area of the electrostatic spray gun/work piece.
DANGER
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.
WARNING
6.6.2 PREPARATION FOR STARTING UP
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Attention: gun cable to control unit
Secure the cover sleeve with the warning sign by means of the screw (84) on the connector.
GM 5000E gun cable
Provide product tank, tanks for ushing agent and an empty tank for return.
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.
Sparks form when the plug is removed!
Explosion hazard.
When using the spray gun in explosion hazard areas:
The cable connection on the gun and the connection to any
cable extensions may not be disconnected or connected in this
area.
WARNING
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B_03690
84
84
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
GM 5000E gun cable
Extension cable to the
control unit
Attention: guns with electric extension cable
Secure the cover sleeves with the warning sign by means of the screws (84) on the
connectors.
Note:
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 80m, however, a power loss of up to 30% will
be caused.
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7 OPERATION
7.1 TRAINING THE OPERATING STAFF
7.2 SAFETY INSTRUCTIONS
Incorrect operation!
Risk of injury and equipment damage.
The operating sta must be quali ed to operate the entire
system.
Before work commences, the operating sta must receive
appropriate training.
WARNING
Incorrect operation!
Risk of injury and equipment damage.
If contact with solvent-based paints 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 MΩ.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 MΩ.
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.
WARNING
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R1
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VM 5000
7
6
8
4
5
9
17
1
2
16
15
14
21
12
11
10
B_03158
18
19
20
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EDITION 07/2014 ORDER NUMBER DOC 2344500
7.3 WORK
1. Place an empty tank (18) under the return tube (8) (see picture B_03158).
2. Place suction hose (7) in the tank with working product (19).
Note:
If the pump is equipped with a rigid suction system, it should only be dipped in into
the working product up to the middle of the inlet housing at the maximum!
3. Adjust the 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 pressure regulator (12) so that the pump runs smoothly.
7. Close ball valve (11) as soon as pure working product starts coming from the return
tube (8).
7.3.1 FILLING WITH WORKING PRODUCT
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B_03192
B_03159
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
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 product 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.
1. Secure gun and insert the desired nozzle into the gun.
2. Set pump (4) to about 8 Mpa; 80 bar; 1,160 psi operating pressure and start up
control unit (13).
3. Spraying (pull trigger).
4. Adjust the spray pressure at the paint pump according to the nozzle and object
being sprayed
5. Now open AirCoat air (6), approx. 0.01-0.25 MPa; 1-2.5 bar; 14,5-36 psi, and adjust for
the optimal atomization.
For round-jet method:
6. By turning the nozzle nut, the atomizing air jet can additionally
be adjusted.
Notes:
Do not turn the nozzle nut until it is ush with the nozzle body.
There must be play for the atomizing air between the nozzle nut
and the nozzle body.
The air adjustment at the back of the gun does not a ect the
spray pattern in this process.
For at-jet method:
7. Change the width of the spray jet by turning the air adjustment
on the back of the spray gun or by appropriate selection of the
nozzle.
7.3.2 STARTUP FOR SPRAYING AIRCOAT
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B_03160
B_03161
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7.3.3 FLUSHING OUT CLOGGED ROUND JET NOZZLES
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.
7.3.4 REPLACING ROUND JET NOZZLE'S NOZZLE INSERT
Exploding gas / air mixture!
Danger to life from ying parts and burns.
Never spray into a closed tank.
Ground the tank.
DANGER
1. Remove nozzle insert (1) using nozzle spanner (2).
2. Assembling new nozzle insert.
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B_03162
1
2
3
4
5
6
7
8
10
9
Y
11
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EDITION 07/2014 ORDER NUMBER DOC 2344500
7.3.5 CHANGING FROM AIRCOAT ROUND JET TO AIRCOAT FLAT JET
1. Flush the spray gun (1) out thoroughly with
cleaning agent.
2. Relieve the pressure of gun and device.
3. Secure the spray gun (1) using the trigger lock.
4. Unscrew round jet nozzle cap (2) incl. nozzle insert (3).
5. Unscrew nozzle insert (3) using nozzle spanner (4).
6. Unscrew nozzle nut (5) and remove nozzle screw
connection (7) and sealing tting (8) out o the
nozzle body (6) and clean all parts thoroughly.
7. Insert desired ACF 5000 nozzle (11) into the valve
housing.
8. Put the air cap (10) on the nozzle (11) and pay
attention to the position of the guide surfaces.
9. 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).
10. Before tightening with the air cap horns (Y), set the
desired jet level and then tighten the union nut to
stop by hand.
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7.3.6 REPLACING THE AIRCOAT FLAT JET NOZZLES
1. Switch o control unit.
2. Relieve pressure from the gun (1) and from the device!
3. Secure the spray gun (1) using the trigger lock.
4. Unscrew union nut (12) and remove air cap (10).
5. Remove ACF5000 AirCoat nozzle (11) and treat it with cleaning agent until all traces
of paint have been removed.
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.
1. Switch o control unit.
2. Relieve the pressure of gun and device.
3. Secure the spray gun (1) using the trigger lock (14).
4. Unscrew complete union nut (12) with air cap (10) and ACF5000 nozzle (11).
5. Remove air cap (10).
6. 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).
7. 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.
Defective AirCoat nozzle!
Insu cient paint application quality.
Do not use sharp-edged objects to treat carbide on the AirCoat nozzle.
NOTICE
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.
7.3.7 CLEANING OF THE NOZZLE PARTS
7.3.8 ELIMINATE NOZZLE CLOGGING
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10
11
X
Y
1
14
12
12
Y
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OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
8. Screw preassembled union nut (12) to gun (1) and tighten by hand.
9. Switch the product pressure back on.
10. Turn the trigger lock (14) to the spraying position and brie y pull the trigger.
11. When the blockage has been ushed out, secure the gun with the trigger lock.
12. Relieve the pressure of gun and device.
13. Unscrew union nut (12).
14. 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.
15. Put the air cap (10) on the nozzle (11) and pay attention to the position of the guide
surfaces (X).
16. 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).
17. Before tightening with the air cap horns (Y), set the desired jet level and then tighten
the union nut to stop by hand.
18. Switch the product pressure and the air pressure back on.
19. Switch on the control unit.
ACF5000 nozzle in
cleaning position
ACF5000 nozzle in
spray position
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EDITION 07/2014 ORDER NUMBER DOC 2344500
7.3.9 CHANGING THE VALVE HOUSING
Changing the valve housing!
Equipment damage.
Activate the spray gun trigger when changing the valve housing.
NOTICE
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.
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8 CLEANING AND MAINTENANCE
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 CLEANING
8.1.2 SAFETY INSTRUCTIONS
8.1.1 CLEANING STAFF
Explosive powder/air mixes!
Danger to life and equipment damage.
Before starting cleaning 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!
Use only electrically conductive tanks for cleaning liquids!
Ground the tank!
Preference should be given to non- ammable cleaning uids.
Only cleaning agents of explosion class IIA should be used
(maximum ignition energy 0.24 mJ).
The cleaning 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.
DANGER
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The spray gun and the unit must be cleaned daily. The cleaning agents used for cleaning
must correspond with the working product.
Cleaning of the nozzle parts -> Chapter 7.3.7
Eliminating Nozzle Clogging -> Chapter 7.3.8
8.1.3 CLEANING AND DECOMMISSIONING
Flushing agent in the air duct!
Functional faults caused by swollen seals.
Never immerse the spray gun in cleaning agent.
NOTICE
Incorrect maintenance/repair!
Risk of injury and equipment damage.
Have repairs and part replacements be carried out only by
specially trained sta or a WAGNER service center.
Before all work on the device and in the event of work
interruptions:
- Switch o the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating instructions for any work.
WARNING
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EDITION 07/2014 ORDER NUMBER DOC 2344500
Gun ushing
1. Switch o control unit.
2. Ensure that the product pressure is relieved and shut o the air supply to the gun.
3. Connect the cleaning agent supply.
With round jet nozzle tted:
4. By means of nozzle spanner, loosen nozzle insert by 1/2 turn.
5. Actuate the trigger. Flush the gun thoroughly.
6. Relieve the pressure from gun and unit!
7. Re-tighten the nozzle insert.
8. Clean the spray gun body with a cleaning agent recommended by the manufacturer
and dry with a cloth or blow gun.
With at jet nozzle tted:
4. Dismount AirCoat nozzle and clean separately (see Chapter 7.3.7).
5. Actuate the trigger. Flush the gun through thoroughly.
6. Relieve the pressure from gun and unit!
7. Clean the spray gun body with a cleaning agent recommended by the lacquer
manufacturer and dry with a cloth or blow gun.
Exploding gas / air mixture!
Danger to life from ying parts and burns.
Never spray into a closed tank.
Ground the tank.
DANGER
NOTICE
Flushing agent in the air duct!
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 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.
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8.2 MAINTENANCE
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
Once the maintenance work is complete, the device must be checked by a quali ed person
to ensure a reliable condition.
8.2.1 MAINTENANCE STAFF
8.2.2 SAFETY INSTRUCTIONS
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.
DANGER
Check hoses, pipes, and couplings every day and replace if necessary.
In accordance with the guideline for liquid ejection devices (ZH1/406 and BGR500
Part2 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.
- If devices have been decommissioned, the examination can be suspended until the
next start-up.
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DANGER
8.3.1 TOOLS
For disassembling and assembling the gun the following tools are required:
Allen wrench SW 2
Allen wrench SW 3
Allen wrench SW 5
Open-end wrench SW 5
Open-end wrench SW 6
Open-end wrench SW 8
Open-end wrench SW 11
Open-end wrench SW 12
Open-end wrench SW 14
Open-end wrench SW 19
Open-end wrench SW 21
Open-end wrench SW 22
Ring spanner SW 9
Torx wrench 20
Torx wrench 25
Assembly tool valve needle Order No. 2309368
Assembly tool clamping screw Order No. 2325263
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 "Spare Parts"
chapter and that are assigned to the device.
Before all work on the device and in the event of work
interruptions:
- Disconnect the control unit from the mains.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating manual and service instructions at all
times when carrying out work.
8.3 DISASSEMBLY OF THE SPRAY GUN
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SW3
SW12
SW12
B_03195
SW3
SW19
SW21
Torx 25
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8.3.2 DISASSEMBLY OF THE SPRAY GUN
Page 51
51
4
5
6
B_03197
SW9
B_03196
SW22
SW19
SW19
25
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
Assembly tool for
needle valve.
Order No. 2309368
Assembly tool for the
valve housing
Order No. 2325263
Note:
Loosen AC valve tip by hand
using an assembly tool.
Do not pull out on contact wire.
Carefully release the
cascade without pliers.
Use assembly tool, socket or ring spanner (no wrench).
Use screw driver to lever out the
ring carefully.
Note:
If the tting (25) is not on the dismounted product hose
when it is replaced, the tting must be removed from the
gun adapter.
Page 52
52
8
9
7
B_03198
SW6
SW5
SW2
1
4
5
2
6
7
3
ø 3.0
B_03199
SW14
SW9
SW5
SW8
Torx 20
2
1
2
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
1. Remove pressure spring (4).
2. Loosen clamping screw compl. (1) with
assembly tool (5).
3. Unscrew the complete packing (3) via
valve rod unit complete (2, 6 and 7) or
pull out the valve rod unit and unscrew it
using an Allen wrench SW5.
4. If the loosened packing (3) is jammed
in the hole, push from the front (see
illustration above).
1. Loosen the oval head screw (1).
2. Pull the air valve (2) out o the
hole.
Page 53
53
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
8.4 CLEANING THE PARTS AFTER DISASSEMBLY
In Chapter 13 the part numbers for gun spare parts can be found as well as for wearing
parts such as seals.
Incompatibility of cleaning agent and working medium!
Risk of explosion and danger of poisoning by toxic gasses.
Examine the compatibility of the cleaning agents and working
media on the basis of the safety data sheets.
WARNING
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, plug compl. and the handle inside 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).
Spare parts may have safety-relevant properties.
Use only WAGNER original spare parts and accessories.
Defective parts, O-rings and seal sets must always be re-placed.
ATTENTION
Page 54
54
1
2
B_03448
B_03201a
SW14
3 Nm
SW9 1 Nm
Torx 20
1
4
2
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
8.5 ASSEMBLY OF THE SPRAY GUN
Assembly aids:
Order No. Description
1 9992590 Loctite 222
2 9992698 Vaseline white PHHV II
3 9992831 Loctite 542
4 9992511 Loctite 243
5 9992609 Anti-seize paste
Ensure the correct insertion position!
Ensure the correct insertion position!
Page 55
55
3
B_03202
0.5 Nm
SW6
0.4 -
0.5 Nm
SW5
2
2
2
SW5/ 0.4 - 0.5 Nm
X = 123 ±0.1
SW2
1Nm
X
1
4
5
4
5
B_03203
SW9
1.8 Nm
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
Set measure X with withdrawal nut and then
fasten it with the threaded pin (SW2).
Push the valve rod unit and the complete packing
together.
Screw the valve rod unit and the complete packing
together.
Only as required:
Remove the valve rod unit.
Tighten the complete packing.
Carefully insert the valve rod unit and mount the
complete clamping screw (1) with assembly tool (5).
Slightly tighten AC valve
tip by hand using an
assembly tool
(Order No. 2309368).
Assembly tool (Order No. 2325263)
Note:
Use assembly tool, socket or
ring spanner (no wrench).
Ensure the correct
insertion position.
Ensure the correct
insertion position.
Page 56
56
6
7
B_03205
SW3
0.8 Nm
SW21
SW19
B_03204
SW22
SW19
SW19
2.5 Nm
2
5
5
25
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
Clean and degrease the inside of the
adapter and the cascade, then grease
the cascade surface with Vaseline.
Note:
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).
Page 57
57
8
B_03206
Torx 25
9
B_03207
SW3
0.8 Nm
SW12
SW12
2
R1
R3
R2
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
Push the trigger upward into
the air valve piston.
Ensure the correct
insertion position!
Page 58
58
10
B_03208
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
Flat jet nozzle
Assembly see Chapter 13.3.1.
Various nozzle sizes see Chapter 12.2
Round jet nozzle
Assembly see Chapter 13.3.2.
Various nozzle sizes see Chapter 12.1.
Page 59
59
B_03212
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
8.6 FUNCTION TEST AFTER ASSEMBLY OF THE GUN
8.6.1 TEST OF THE HIGHVOLTAGE
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 into open space. Switch on control
unit and actuate trigger guard.
The high-voltage should be 50 to 60 kV in dry ambient air. The value can be checked with the display on the
control unit (VM 5000).
Notice
The gun must be clean and dry and must not have any color or cleaning agent residues.
In the case of ambient air with a high air humidity, the measured value can reduce to 40 to 50 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 60 to 70 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.
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
Page 60
60
B_03213
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
Connect test or air hose to the spray gun and switch on mains pressure to a maximum of
0.8 MPa; 8 bar; 116 psi.
Checking the air valve
The air valve must switch on and o correctly.
Test up to approx. 0.8 MPa; 8 bar; 116 psi.
Air tightness
With the trigger unactuated, test for air tightness at the points marked in the illustration:
Connect high-pressure hose to the spray gun.
Test the spray gun for tightness with solvent or spray oil (e.g. Macrol 52) and a maximum
pressure of 25 MPa; 250 bar; 3,626 psi.
Observe the following gun components:
Product connection, nozzle body, product valve (no after-spraying).
8.6.2 AIR TEST
8.6.3 PRODUCT PRESSURE TEST
Exploding gas / air mixture!
Danger to life from ying parts and burns.
Never spray into a closed tank.
Ground the tank.
DANGER
Page 61
61
B_00071
B_03214
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
8.6.4 TEST OF SPRAY PATTERN
Start AirCoat spraying (without electrostatics)
1. Start up with product supply set to approx. 8 MPa; 80 bar; 1,160 psi operating pressure.
2. Spray (release locking device and pull trigger) and at the same time, check the
atomization.
3. Set the product pressure on the product supply to the point where a good product
atomization is achieved.
4. Open the air pressure regulator for the atomizing air and adjust it so that an optimal
atomization is achieved. (The interrelation between spray pattern and atomizing air
is shown in the gure below).
5. With the air adjustment on the gun, set the ratio shaping air / atomizing air so as to
achieve an optimum spray pattern.
Note:
Repeat points 4 and 5 until the optimum spray pattern is reached (iterative process).
Spray pattern shapes
No atomization air
Too little atomization air
Correct amount of atomization air
In uence of the air adjustment on the spray pattern shape
The spray pattern can be adjusted to suit the object to be sprayed using the air adjustment.
The illustration shows the in uence of the shaping air regulator on the spraying pattern.
Other nozzle sizes can be used to obtain larger or smaller spraying patterns.
Closed air
adjustment
Completely opened air
adjustment
Notice
The paint output can be changed by:
changing the product pressure or
using a di erent at jet nozzle (see Chapter 12.2).
Page 62
62
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
8.7 HIGHPRESSURE HOSES
The service life of the uid hoses is reduced due to environmental in uences even when
handled correctly.
Check hoses, pipes, and couplings every day and replace if necessary.
As a precaution, uid hoses should be replaced after a period speci ed by the operator.
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
DANGER
Page 63
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OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
9 INSPECTIONS
Observe safety instructions in Chapter 4.
9.1 PERIODICAL INSPECTIONS
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 8.7
Grounding weekly Chapter 4.2.2, Chapter 6.4.5
Inspection for damage weekly Chapters 8.1.3, 8.2, 8.3, 8.4 and 8.5
Locking of the technical ventilation with the
electrostatic manual coating system
annually Chapter 6.4.2
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.
Page 64
64
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
Functional fault Cause Remedy
Insu cient product output Nozzle too small. Select larger nozzle
(see nozzle table 12.2 und 12.3).
Product pressure too low. Increase product pressure.
Gun lter or high pressure lter clogged
at pump.
Clean or replace lter.
Nozzle is clogged. Nozzle cleaning
(see Chapters 7.3.3 to 7.3.8).
Poor spray pattern Atomizing air incorrectly adjusted. Readjust the atomizing air.
Nozzle is too large. Select a smaller nozzle
(see nozzle table).
Product pressure too low. Increase the product pressure at
pump.
The product viscosity is too high. Thin product in accordance with the
manufacturer's instructions.
Valve rod leaks Seals at the valve rod are damaged. Replace the seals (see Chapter 8).
Loose packing Tighten
Poor wrap-around Insu cient grounding. Check grounding.
Inadequate electric resistance of the
lacquer.
Check lacquer resistance
(see Chapter 2.5).
Spraying pressure too high. Readjust spraying pressure.
Back-spray No grounding Check grounding.
Distance between spray gun and work
piece too large.
Reduce distance between spray gun
and work piece.
Nozzle nut placed too far forward Move nozzle nut back
(Decrease air distributor ring gap).
No wrap-around High-voltage switched o . Switch on the high-voltage switch.
No electrostatics. Repair malfunction as laid down
in the control unit operating
instructions.
10 TROUBLESHOOTING AND RECTIFICATION
Page 65
65
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
11 PRODUCT DISPOSAL
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.
NOTICE
Page 66
66
"?
B_03210
B_03209
B_03454
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
12 ACCESSORIES
12.1.1 ACR 5000 ROUND JET NOZZLE CAP
Order No. Designation
2344483 ACR 5000 round jet nozzle cap
(with nozzle spanner, without AC round jet nozzle insert)
Order No. Designation
2309882 ACF 5000 air cap - LV suitable for low viscosity products (marked red)
2314203 ACF 5000 air cap - HV suitable for high viscosity products (marked blue)
12.2.1 ACF 5000 AIR CAPS FLAT JET
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
* 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.
12.1.2 AIRCOAT ROUND JET NOZZLE INSERTS
The round jet nozzles are especially suited to spray pipes, pro les and complex work pieces.
12.1 ROUND JET NOZZLES
12.2 FLAT JET NOZZLES
Page 67
67
B_03163
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
12.2.2 ACF5000 AIRCOAT FLAT JET NOZZLES
Order No.
Marking
Bore
mm;
inch
Spray angle
Application
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° Lacquer
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°
Page 68
68
B_03163
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
Order No.
Marking
Bore
mm;
inch
Spray angle
Application
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°
Page 69
69
B_00019
B_03221
M
F
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
12.3 FILTER
Order No. Designation
3204604 Edge lter 60 mesh (white)
3204605 Edge lter 100 mesh (black)
9999002 Edge lter 200 mesh (yellow)
12.4 REDUCTION FITTINGS FOR HIGHPRESSURE HOSES
The classi cation of WAGNER ttings is consistent with the following classi cation, each
separated by high-pressure and low pressure ttings:
Double tting - male / male thread
Reduction tting - female / male thread
Adjustable screw - female / male thread: allows precise angle adjustment (swivel)
90° elbow - adjustable or male / male thread (elbow tting)
Bulkhead fastener - male / male thread with pressure-resistant feed-through
Stopper - male thread for closing (plug tting)
Hose tting with union nut and sealing cone (hose tting)
The short description of the ttings are as follows:
Materials, SSt = Stainless steel
Nominal pressure (in bar)
1st thread, e.g. G1/4", 1/4"NPS
2nd thread, e.g. G1/4", 1/4"NPS, M16x1.5
M: male (outer thread) F: female (interior thread)
Short description see table above, e.g. RF = Reduction Fitting
Order No. Designation
384555 Reduction tting-RF-FM-M16x1,5-1/4"NPS-PN530-SSt
384559 Reduction tting RF-FM-M16x1,5-G1/4"-PN530-SSt
384556 Reduction tting RF-FM-M16x1,5-3/8"NPSM-PN530-SSt
34041 Reduction tting RF-FM-1/4"NPS-M16x1,5--PN270-SSt
179732 Reduction tting RF-FM-1/4"NPS-3/8"NPS--PN270-SSt
179247 Reduction tting RF-FM-1/4"NPS-G1/4"--PN270-SSt
In the large Wagner Accessories Catalogue for wet coating you will also nd other material
ttings.
Page 70
70
2
3
4
5
B_03217
1
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
12.5 HOSES AND ELECTRIC CABLES
12.5.1 STANDARD HOSE SETS AND COMPONENTS
Order No. Designation
1 1 2339171 GM 5000EAC hose set (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 (8.0 m)
4 1 2339157 GM 5000E gun cable (10.0 m)
5 7 m 3676437 Protection hose fabric PP30 (8.0 m)
Order No. Designation
1 1 2339172 GM 5000EAC hose set (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 (10.5 m)
4 1 2339158 GM 5000E gun cable (15.0 m)
5 10.5 m 3676437 Protection hose fabric PP30 (10.5 m)
Order No. Designation
1 1 2339173 GM 5000EAC hose set (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 (15.5 m)
4 1 2339159 GM 5000E gun cable (20.0 m)
5 15.5 m 3676437 Protection hose fabric PP30 (15.5 m)
Order No. Designation
1 1 2339174 GM 5000EAC hose set (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 (20.5 m)
4 1 2339160 GM 5000E gun cable (25.0 m)
5 20.5 m 3676437 Protection hose fabric PP30 (20.5 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 PA
Page 71
71
A****
B****
B_03849
1
2
3
A
BC
D
E
(**)
B_03845
(*)(***)
1
2
3
(****)
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
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
Order No. Description A [mm] B [mm] C [mm] D [mm] E [mm]
2339171 GM 5000EAC hose set (7.5 m) 29±2 65±2 300±10 20±10 1500
+100
2339172 GM 5000EAC hose set (10 m) 29±2 65±2 300±10 20±10 1500
+100
2339173 GM 5000EAC hose set (15 m) 29±2 65±2 300±10 20±10 1500
+100
2339174 GM 5000EAC hose set (20 m) 29±2 65±2 300±10 20±10 1500
+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!
1 Product hose
2 Air hose
3 Electric cable
Page 72
72
B_03216
2
3
4
5
1
6
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
12.5.2 HOSE SETS FOR LOWRESISTANCE PRODUCTS
Order No. Designation
1 1 2339179 GM 5000EAC hose set (7.5 m), Low R
Consists of:
2 1 2310468 EAC high-pressure product hose, complete (7.5 m) Low R
3 1 2339152 Air hose complete (8.0 m)
4 1 2339157 GM 5000E gun cable (10.0 m)
5 8 m 3676437 Protection hose fabric PP30 (8.0 m)
Order No. Designation
1 1 2339180 GM 5000EAC hose set (10.0 m), Low R
Consists of:
2 1 2310469 EAC high-pressure product hose, complete (10.0 m) Low R
3 1 2339153 Air hose complete (10.5 m)
4 1 2339158 GM 5000E gun cable (15.0 m)
5 10.5 m 3676437 Protection hose fabric PP30 (10.5 m)
Order No. Designation
1 1 2339181 GM 5000EAC hose set (15.0 m), Low R
Consists of:
2 1 2310470 EAC high-pressure product hose, complete (15.0 m) Low R
3 1 2339154 Air hose complete (15.5 m)
4 1 2339159 GM 5000E gun cable (20.0 m)
5 15.5 m 3676437 Protection hose fabric PP30 (15.5 m)
Order No. Designation
1 1 2339182 GM 5000EAC hose set (20.0 m), Low R
Consists of:
2 1 2310471 EAC high-pressure product hose, complete (20.0 m) Low R
3 1 2339155 Air hose complete (20.5 m)
4 1 2339160 GM 5000E gun cable (25.0 m)
5 20.5 m 3676437 Protection hose fabric PP30 (20.5 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 connecting tting AC Order No. 2338853
Page 73
73
B
FC
D
E
(**)
B_03846
(*)(***)
1
2
3
A****
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
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
Order No. Description A [mm] B [mm] C [mm] D [mm] E [mm] F [mm]
2339179 GM 5000EAC hose set (7.5 m), Low R 206±2 177±2 300±10 20±10 1500
+100
188±1
2339180 GM 5000EAC hose set (10 m), Low R 206±2 177±2 300±10 20±10 1500
+100
188±1
2339181 GM 5000EAC hose set (15 m), Low R 206±2 177±2 300±10 20±10 1500
+100
188±1
2339182 GM 5000EAC hose set (20 m), Low R 206±2 177±2 300±10 20±10 1500
+100
188±1
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) is used, the hose set has to be adapted accordingly.
If the air swivel joint is used, dimension A becomes 237 mm!
1 Product hose
2 Electric cable
3 Air hose
Page 74
74
Nicht unter Spannung
trennen
"Do not part under
voltage"
B_03219
P_00265
B_03224
B_03693
B_03692
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344500
Order No. Designation
2339161 GM 5000E extension cable 10m; 32.81 ft
2339162 GM 5000E extension cable 20 m; 65.6 ft
12.5.3 GUN CABLES AND GUN CABLE EXTENSIONS
Order No. Designation
2319653 Protective gun coating
259010 HV200 N high-voltage tester
2326041 Paint resistance meter
999080 Wet lm thickness gauge
50342 Viscosity cup DIN 4 mm; 0.16 inch
12.6 MISCELLANEOUS
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B_03681
B_03699
B_03720
B_03720
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EDITION 07/2014 ORDER NUMBER DOC 2344500
2309368 Assembly tool valve needle
128901 Nozzle spanner ACR
2325263 Assembly tool clamping screw
2326485 GM 5000E wall mount (left/right)
232476 Swivel joint air
2327060 Fitting-SJM-GM5000EAC-1/4"NPS (swivel product)
2327061 GM 5000EAC swivel joint kit
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13 SPARE PARTS
13.1 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 "
" on
the lists. 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:
Billing address
Delivery address
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 "
" (labeling) in the following spare parts lists:
Wearing part
Note: No liability is assumed for wearing parts.
Not part of the standard equipment but available as a special accessory.
Incorrect maintenance/repair!
Risk of injury and equipment damage.
Have repairs and part replacements be carried out only by
specially trained sta or a WAGNER service center.
Before all work on the device and in the event of work
interruptions:
- Switch o the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
Observe the operating instructions for any work.
WARNING
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2
3
19
20
21
7
5
8
9
10
12
11
13
14
15
18
16
17
6
4
22
1
25
27
24
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13.2 GM 5000EAC SPARE PARTS LIST
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GM 5000EAC spare parts list
Order No. Designation
1 1 2344473 GM 5000EAC basic version
2
1 2314283 Contacting AC
3 1 9952777 High resistance, bare
4 1 9960808 Socket contact component
5 1 - GM 5000EAC adapter, complete
Details see Chapter 13.2.1
6
1 2314361 Hook
7 1 - GM 5000EAC handle, complete
Details see Chapter 13.2.2
8 2 9900308 Hexagon socket head cap screw
9 1 2312183 Lid complete
10 1 9900386 Hexagon socket head cap screw
11 1 2311970 Sealing plug
12 1 2307104 Screw plug
13 1 2312180 Air regulation complete
14
1 9971182 O-ring
15 1 9971182 O-ring
16 1 2314360 Trigger
17 1 2307283 Cylindrical helical spring
18 2 2310617 Oval head screw with hexagon
19
1 2314359 Product hose AC, complete
20 1 3204605 Edge lter 100 mesh (black)
(for di erent edge lter sizes see Chapter 12.3)
21 1 2308764 Hose tting AC
22 1 2350454 Union nut AC, complete
24
1 2308699 Cover seal
25 1 2338853 Connecting tting AC
27 1 2349376 Spacer
1 2326336 GM 5000EAC service set
= Wearing part
= Included in service set
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1
12
10
9
8
3
4
5
6
7
21
22
11
24
123 ±0.1 mm
4.8425 ±0.004 inch
OPERATING MANUAL
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13.2.1 GM 5000EAC ADAPTER SPARE PARTS LIST
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5000EAC adapter spare parts list
Order No. Designation
1 1 - GM 5000EAC adapter, complete
2
1 2313314 AC air manifold ring
3 1 2307180 O-ring, sheathed
4 1 2312175 Valve housing AC, complete
5 1 2312186 Valve needle AC, complete
6 1 2314272 GM 5000EAC adapter
7 1 2312181 Cascade, complete
8
1 9974166 O-ring
9 1 2307062 Clamping screw valve rod
10
1 2311562 Rod seal
11 1 2313639 Valve rod unit AC
12 1 2340024 Packing, complete
21 1 2307059 Withdrawal nut
22 1 9901411 Threaded pin with hexagon socket
24 1 2325263 Assembly tool clamping screw
1 2326336 GM 5000EAC service set
= Wearing part
= Included in service set
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7
1
B_04775
8
9
10
12
5
6
3
2
4
23
11
18
13
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13.2.2 GM 5000EAC HANDLE SPARE PARTS LIST
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GM 5000EAC handle spare parts list
Order No. Designation
1 1 - GM 5000EAC handle, complete
2 1 2307288 Fitting
3
1 9971025 O-ring
4 1 2307290 Hose holder
5 1 2312182 Plug, complete
6 1 2314270 Handle, complete
7
1 2307232 Adapter seal
8 1 2311952 Stop screw
9 1 2309825 Oval head screw with hexagon
10
1 2310692 Seal
11 1 2311182 Straight pin
12 1 2309400 Safety clip
13 1 2312189 Air valve
18
1 9974218 O-ring
23 1 9974166 O-ring
1 2326336 GM 5000EAC service set
= Wearing part
= Included in service set
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3
1
4
5
6
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EDITION 07/2014 ORDER NUMBER DOC 2344500
13.3 ACCESSORIES SPARE PARTS LISTS
13.3.1 FLAT JET NOZZLES SPARE PARTS LIST
Flat jet nozzles spare parts list
Order No. Designation
1 1 2350454 Union nut AC, complete
2
1 2309882 ACF 5000 air cap - LV (red)
1 2314203 ACF 5000 air cap - HV (blue)
3
1 2311777 Nozzle guard AC
4 1 2344488 Union nut AC
5 1 2311217 O-ring, sheathed
6
1 2319525 Flat electrode set
= Wearing part
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3
1
4
5
6
9
10
11
12
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13.3.2 ACR 5000 ROUND JET NOZZLE CAP SPARE PARTS LIST
ACR 5000 round jet nozzle cap spare parts list
Order No. Designation
1 1 2344483 ACR 5000 round jet nozzle cap
2 1 2307220 Nozzle nut
3
1 2315310 O-ring
4
1 132351 Nozzle screwed connection holder
5 1 2344487 Nozzle body
6 1 2319526 Round electrode set
9 1 132516 Nozzle screw joint, complete
10
1 2307216 Sealing tting
11 1 2311217 O-ring
12 1 128901 Nozzle wrench, complete
= Wearing part
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14 WARRANTY
14.1 IMPORTANT NOTES REGARDING PRODUCT LIABILITY
14.2 WARRANTY CLAIM
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.
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. Wear and tear due to such causes 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
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Order No. 2344500
Edition 07/2014
Germany
Phone
Fax
E-mail
Switzerland
Phone
Fax
More contact adresses on the Internet at:
Enterprises/Sites/WAGNER worldwide
Subject to changes without notice
Document No. 11163740
Version -
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