Wagner SprayTech GM 2000 EACF, GM 2000 EACR User Manual

Operating Manual

Electrostatic AirCoat Spraygun,

with flat or round jet tips

GM 2000 EACR - EN

GM 2000 EACF - EN

Edition 03/98

0179 887 GB

GM 2000 EAC - EN

CONTENTS

Paragraph Chapter.Page

1	INTRODUCTION	1.1
1.1	Using the manual	1.1
1.2	SAFETY REGULATIONS	1.2
1.3	PTB Conformity certification	1.4
1.4	Product liability and guarantee	1.5
1.5	CE conformity	1.6
2	DESCRIPTION	2.1
2.1	Scope of supply	2.1
2.2	Technical data	2.1
2.3	Functional description	2.1
2.3.1	Function of the gun	2.1
2.3.2	AirCoat round jet process	2.3
2.3.3	AirCoat flat jet process	2.3
2.3.4	Electrostatic effect	2.4
2.4	What kind of spraying material can be applied?	2.4
3	PREPARATION BEFORE STARTING WORK	3.1
3.1	Preparation of paint	3.1
3.2	Earthing	3.1
4	STARTING WORK, AND HANDLING	4.1
4.1	Preparation	4.1
4.2	General rules for handling the spray gun	4.1
4.3	Starting-up for AirCoat spraying	4.1
4.4	Cleaning of clogged round jet tips	4.2
4.5	Exchange of AirCoat round jet tip insert. (EAC round)	4.2
4.6	Changing from AirCoat round jet to AirCoat flat jet	4.2
4.7	Replacing AirCoat flat jet tips	4.3
4.8	Cleaning of AirCoat flat jet tips	4.3
4.9	Clogging of AirCoat flat jet tips	4.3
5	MAINTENANCE	5.1
5.1	Decommissioning and cleaning	5.1
5.2	Dissassembly of AirCoat nozzle body	5.2
5.3	Exchange or cleaning of filters	5.2
5.4	Adjustment of the valve rod seal	5.3
5.5	Exchange of complete valve rod, or of valve rod seals	5.3
5.6	Exchange of paint channel	5.4
6	TROUBLE SHOOTING AND SOLUTIONS	6.1

0.1

GM 2000 EAC - EN

CONTENTS

Paragraph Chapter.Page

7	ACCESSORIES	7.1
7.1	Round jet tip inserts	7.1
7.2	AirCoat flat tips	7.2
7.3	Filter (standard)	7.3
7.4	Long filter housing and filters	7.3
7.5	Hoses and fittings	7.3
7.6	Special tools	7.3
8	SPARE PARTS CATALOGUE	8.1
8.1	How to order spare parts?	8.1
8.2	Special marks in spare parts lists	8.1
8.3	Spare parts list and drawing	8.2

0.2

GM 2000 EAC - EN

1. INTRODUCTION

This operating manual contains information and instruction for the operation, repair and maintenance of the spray gun.

This equipment can be dangerous if it is not operated in accordance with this Operating manual!

Compliance with these instructions constitutes an integral component of the guarantee agreement.

1.1Using the manual

"Caution"

This heading is used wherever non-compliance with operating instructions, working instructions, specified working sequences etc. may result in injury or accident.

"Attention"

This heading is used wherever non-compliance with operating instructions, working instructions, specified working sequences etc. may result in damage to the equipment.

"Note"

This heading is used to draw attention to a particular passage in the text.

Subject to change without notice

Printed in Switzerland

1.1

GM 2000 EAC - EN

1.2SAFETY REGULATIONS

The safety requirements for electrostatic hand spraying equipement are laid down in the following documents: (Germany)

1)	ZH 1/250	Electrostatic enamelling with hand-held spraying equipment
		(Published by C. Heymanns-Verlag, Cologne)
2)	ZH 1/406	Guidelines for jet stream equipment (spraying devices)
		(Published by C. Heymanns-Verlag, Cologne)
3)	EX-RL/ZH 1/10	Explosion protection guidelines - spraying equipment
		(Published by C. Heymanns-Verlag, Cologne)
4)	VBG 23	Working with coating materials
		(Published by C. Heymanns-Verlag, Cologne)
5)	DIN-VDE 0165	Installation of electrical equipment in a potentially explosive
		atmosphere (Published by VDE-Verlag, Berlin)

6)EN 50050/DINElectrostatic hand spraying equipment

VDE 0745 Part 100 (Published by VDE-Verlag, Berlin)

7)EN 50053/DINSelection, installation and use of electrostatic spraying

VDE 0745 Part 101 equipment - electrostatic hand spraying equipment for combu-

stible liquid spray media (Published by VDE-Verlag,Berlin)

Caution

The following points should receive special attention for the safe use of the electrostatic spraying equipment:

1.2.1Caution! Danger of injury by injection

The pressure should be released from the spray gun during breaks in work or while assembling and dismantling the nozzle. It should be secured, the control unit switched off, and the plug pulled out. Never point the gun at yourself or any other person, the spray jet can cause injury by injection.

Never put your finger or hand in the spray jet.

In case of injury to skin by paint or cleaning agents consult a doctor immediately. Inform the doctor of the type of paint or cleaning agent used.

1.2.2Cleaning

The gun must be switched off when being cleaned and should never be sprayed in "closed" containers (formation of a gas air/mixture which can explode). The containers must be earthed.

1.2.3Safety

Spraying can only be carried out safely, both for people and the environment, if it is done in a spray booth or in front of a spraying wall with sufficient ventilation (removal by suction).

In order to avoid occupational illness the safety regulations laid down by the manufacturer of the paint or cleaning agent used must be adhered to during preparation and application of the paint and while cleaning the equipment. In particular, protective clothing, gloves, skin protection cream and breathing equipment must be used to protect the skin and respiratory tracts.

1.2

GM 2000 EAC - EN

1.2.4Protective breathing masks

Although the E-Static AirCoat spraying procedure produces very little mist, it is not completely mist free. There are, in fact, few paint particles to be found in the air. Nevertheless, the operator must use a protective breathing mask, (see respiratory equipment instruction sheet ZH 1/134 and VGB 23 from the professional trade association) during spraying operations.

1.2.5The spray gun and the high pressure hoses between the pump and the spray gun must be of a sufficient quality for the pressure produced by the pump.

A permanent marking on the high pressure hoses must indicate the maximum permitted working pressure, the manufacturer and date of production. Furthermore, it must be of a suitable quality so that the electric resistance between the pump connection and the spray gun is less than 1 megaohm.

1.2.6Earthing

Depending on the electrostatic charge and the flow speed of the spray an electrostatic charge may, in certain cases, occur on the equipment. This could cause a spark or flame on discharging. In order to avoid this the equipment must always be earthed.

There must be a conductive connection (potential equalisation cable) between the material container and the equipment.

All persons within the working area must wear shoes with electricallyconductive soles (e.g. shoes with leather soles). Gloves must also be conductive, because the operator is earthed through the handle of the spraygun. The floor of the working area must be conductive, in accordance with VDE 0745, part 1, paragraph 35: measurements according to DIN 51953.

1.2.7Extraction systems

Paint mist extraction systems must be fitted on site according to the local regulations.

1.2.8Accessories and spare parts

The manufacturer's guarantee and product liability are only valid if original Wagner accessories are used.

1.2.9Safety information on harmless electrostatic discharges

If the plastic parts of the spray gun are touched with the hand this can result in a harmless discharging (so-called brush discharge). The same occurs when you electrostatically charge yourself by walking on a synthetic carpet and then touch a metallic door handle, thus discharging the electrostatic charge. The charge on the plastic parts is caused by the high-voltage field of the gun. The discharging is completely safe for people and is not able to cause any ignition.

A corona glow may occur at the electrode end of the gun when it is in use (only visible under dark conditions). A corona discharge can occur if the electrode (spray gun) comes within a distance of 4 - 10 mm from the object being sprayed. The corona glow does not cause any ignition hazard.

1.3

GM 2000 EAC - EN

1.3PTB Conformity certification

1.4

GM 2000 EAC - EN

1.4Product liability and guarantee

Important notes on product liability

As a result of an EC regulation being effective as from January 1, 1990, the manufacturer shall only be liable for his product if all parts come from him or are released by him, and if the devices are properly mounted and operated.

If the user applies outside accessories and spare parts, the manufacturer's liability can fully or partially be inapplicable.

Only the usage of original WAGNER accessories and spare parts guarantees that all safety regulations are observed.

Warranty

12 months / 6 months for multi-shift operation

This equipment is covered by the following manufacturing warranty:

All parts which prove unusable or the use of which is seriously impaired within 12 months or 6 months of receipt by the purchaser due to circumstances predating receipt, such as faulty design, defective materials or poor workmanship, shall be repaired or replaced at our discretion and free of charge.

No liability is assumed for damage attributable to the following factors:

Inappropriate or incorrect use, faulty installation or start-up by the purchaser or third parties, natural wear and tear, as well as wear parts (marked * in the list of spare parts), incorrect handling or maintenance.

The equipment must be checked immediately upon receipt. Obvious defects must be reported to the supplier or to us in writing within 14 days of receipt in order to avoid losing the right of complaint.

We reserve the right to assign warranty performances to a contractual partner.

Warranty performances shall only be rendered if the purchaser returns the warranty card bearing the date of sale and seller's signature together with the equipment. The repair costs will be charged to the purchaser if it is found that the warranty does not apply.

1.5

GM 2000 EAC - EN

1.5CE Conformity

1.5.1Short explanation

CE = Communauté Européenne:

Products identified with the CE mark have been manufactured and checked according to EU guidelines. This means that, in terms of materials used, manufacturing process and operation, they are in accordance with the EU safety and health requirements and therefore the EU regulations and standards. The regulations and standards applying to a particular product can be found in the CE Certificate of Conformity. This is enclosed with the product or can be requested from the manufacturer. The CE identification

has been compulsory in Europe since 1st January 1995, and only products bearing CE identification may be released into circulation.

EMC test:

The electromagnetic compatibility test forms an integral part of the CE conformity. EMC tested products are built such that their interference radiation does not influence other devices within the stipulated limits (noise on the radio, etc.). The EMC standard differentiates between use in domestic, business and commercial or industrial areas. Moreover, if required for comfort or safety reasons, products can be EMC tested for their interference immunity. This means they are protected from the influence of external interference.

1.5.2EC Certificate of Conformity

The certificate with the Part No.:

0179 780

is enclosed with this product. This can be reordered from your WAGNER representative, quoting the product and serial number.

1.6

GM 2000 EAC - EN

2.DESCRIPTION

2.1Scope of supply

Part No.	Quantity	Description
0179 018	1	Electrostatic AirCoat spray gun GM 2000 EAC R, with
		round jet tip R 15 .
or
0179 019	1	Electrostatic Air coat spray gun GM 2000 EAC F, without
		flat jet tip.

The standard equipment includes:		GM 2000 EACR	GM 2000 EACF
0179 901	Universal spanner	1 piece	1 piece
0128 901	Tip spanner	1 piece	-
0034 041	Coupler fitting NPS1/4-M16x1.5	1 piece	1 piece
9994 682	Glove	1 piece	1 piece
0179 941 Spare parts kit EAC/AC		1 piece	1 piece
0179 887	Operating manual	1 piece	1 piece
Spare parts kit EAC/AC comprises of:
0179 946	Set of seals	1 piece
9995 611	Cylindrical filter 180 meshes	3 pieces

For "special" models the delivery note is valid for specific details.

2.2Technical data

Max. air pressure	8 bar
Max. paint pressure	250 bar
Air connection	R 1/4"
Paint connection	NPS 1/4"
Filter (standard)	180 M
Input voltage	max. 22 V AC
Input current	max. 0.7 A AC
Output voltage	max. 80 kV DC
Output current	max. 150 A DC
Polarity	negative
Cable length	11 m
Weight	approx. 600 g
	(without cables)
Paint output	acc. to nozzle
	see tip table

300

255

2.3Functional description

2.3.1Functions of the gun

Attention

The electrostatic spray gun GM 2000 EAC EN can only be used with the control units VM 200 EN, VM2000 EN or EPP 200 EN.

continued....

2.1