WAGNER GM 2000 EACF User manual

Operating Manual
GM 2000 EACR - EN
GM 2000 EACF - EN
0179 887 GBEdition 03/98
Electrostatic AirCoat Spraygun,
with flat or round jet tips

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
GM 2000 EAC - EN
0.1

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
GM 2000 EAC - EN
0.2

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 Opera-
ting manual!
Compliance with these instructions constitutes an integral component of the guarantee
agreement.
1.1 Using the manual
"Caution"
This heading is used wherever non-compliance with operating instructions, working in-
structions, specified working sequences etc. may result in injury or accident.
"Attention"
This heading is used wherever non-compliance with operating instructions, working in-
structions, 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
GM 2000 EAC - EN
1.1

1.2 SAFETY 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/DIN- Electrostatic hand spraying equipment
VDE 0745 Part 100 (Published by VDE-Verlag, Berlin)
7) EN 50053/DIN- Selection, 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:
1.2.1 Caution! 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.
1.2.2 Cleaning
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.
1.2.3 Safety
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.
GM 2000 EAC - EN
1.2

1.2.4 Protective 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.
1.2.5 The 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.
1.2.6 Earthing
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.
1.2.7 Extraction systems
Paint mist extraction systems must be fitted on site according to the local
regulations.
1.2.8 Accessories and spare parts
The manufacturer's guarantee and product liability are only valid if original
Wagner accessories are used.
1.2.9 Safety 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 spray-
ed. The corona glow does not cause any ignition hazard.
GM 2000 EAC - EN
1.3

1.3 PTB Conformity certification
GM 2000 EAC - EN
1.4

1.4 Product liability and guarantee
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.
GM 2000 EAC - EN
1.5
Important notes on product liability
As a result of an EC regulation being effective as from January 1, 1990, the manu-
facturer shall only be liable for his product if all parts come from him or are releas-
ed 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.

1.5 CE Conformity
1.5.1 Short 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.
1.5.2 EC Certificate of Conformity
The certificate with the Part No.:
0179 780
is enclosed with this product. This can be reordered from your WAGNER representa-
tive, quoting the product and serial number.
GM 2000 EAC - EN
1.6

2. DESCRIPTION
2.1 Scope 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.
2.2 Technical 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 µA DC
Polarity negative
Cable length 11 m
Weight approx. 600 g
(without cables)
Paint output acc. to nozzle
see tip table
2.3 Functional description
2.3.1 Functions 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....
300
255
GM 2000 EAC - EN
2.1

●The trigger can be used to
activate, one after the other, the
various functions of the spray
gun.
An increase in the tension
needed to pull the trigger back
will be felt at the position where
the material valve opens.
●In order to overcome Faraday
cages in corners, the high volta-
ge can be switched off by flip-
ping the HV switch (F) down.
●The supply of atomizing and flat
jet air is adjusted by means of
the star handles (D)
Legend
A Tip
B Tip nut
C Spray gun body
D Air control knob
E Locking nut for trigger
F HV flip switch (integrated into
trigger)
G Handle with integrated high vol-
tage generator
H Air connection
I Cable connection
K Paint connection
L Trigger
M Paint filter
GM 2000 EAC - EN
2.2
BCD
F
H
I
A
E
G
K
LM
AirCoat - air open
AirCoat - air open and
electrostatics activated
AirCoat - air open, electrostatics
activated and material valve open

2.3.2 AirCoat round jet process
In the AirCoat process, high pressure of 30 to 150 bar is used to atomize the material.
The AirCoat air at 0 to 2.5 bar produces a soft jet, which largely eliminates the problem
of overlapping boundaries. The spray jet can be adjusted by turning the nozzle nut.
The multi-channel swirl nozzle produces fine paint particles, while at the same time
reducing their forwards speed and swirling them to produce a rotating motion. The
result is a soft, extremely well atomized spraying cloud.
Advantages of AirCoat
●High painting capacity
●Low fogging tendency
●Good finish
●High- viscosity paints can easily
be applied
2.3.3 AirCoat flat jet process
In the AirCoat process, high pressure of 30 to 150 bar is used to atomize the material.
The AirCoat air at 0 to 2.5 bar produces a soft jet, which largely eliminates the problem
of overlapping boundaries.
Advantages of AirCoat
●High painting capacity
●Low fogging tendency
●Good finish
●High- viscosity paints can easily
be applied
GM 2000 EAC - EN
2.3
AirCoat air
AirCoat air
Material
Multi-channel swirl nozzle
Nozzle nut
AirCoat air
AirCoat air
Material

2.3.4 Electrostatic effect
The spray gun produces an electrostatic field by means of the high voltage electrode.
As a result, the particles of paint, which have been atomized by the spray gun, are
carried to the earthed object by kinetic and electrostatic energy where they adhere,
finely distributed, to the object being sprayed.
Advantages of
electrostatics:
●Very efficient spraying
●Little overspray
●Coating of entire cir-
cumferences due to an
electrostatic field
●Less working time
2.4 What kind of spraying material can be applied?
● Paints containing solvents of the explosion class II A.
●Enamels, primers, textured paints etc., which have a specific resistance of > 50 kΩ
(according to the Wagner or Ransburg scale).
●The effectiveness of the spraying action is always dependant on the composition
of the paint being used, e.g. pigments, resins and solvents.
Note
With highly conductive materials, or those with a very high electrical resistance, the
electrostatic effect does not work so efficiently.
In the case of application problems contact the Wagner branch and the paint producer.
GM 2000 EAC - EN
2.4
Charged particles
Grounded object
Electrode

3. PREPARATION BEFORE STARTING WORK
Caution
The operating instructions and the safety regulations for the additional system
components used must be read before starting-up .
This spray gun must be used a part of an AirCoat-Electrostatic spraying system.
The control units VM 200 EN, VM 2000 EN or EPP 200 EN and other various
components are also needed (see Wagner-accesories).
The spray gun and paint supply system must be flushed out with a suitable cleaning
solvent before being used.
3.1 Preparation of paint
The viscosity of the paints is of great importance. The best results are obtained with
paints between 18 and 30 DIN sec. (measured in immersion flow cup DIN 4 mm). In
most cases, the application of paints of up to 50-60 DIN sec. for thick layers does not
cause problems.
3.2 Earthing
Perfect earthing is a prerequisite for optimum coating efficiency and safety.
The imperfect earthing of a workpiece will result in:
●Sparks between the object being sprayed and the suspension hook.
●Insufficient electrostatic effect (no wrap-around)
●Uneven coating thickness
●Back spraying to spray gun and sprayer
The prerequisites for perfect earthing and coating are:
●Clean workpiece suspension.
●Earthing of spraying cabin, conveyor system and suspension with 10mm2copper
cable to system earth, earthing strip or ring.
●Earthing of all conductive parts within the working area.
●The earthing resistance of the workpiece may not exceed 1 MΩ.
GM 2000 EAC - EN
3.1
Pump
Spraying stand
Object to be
sprayed
conveyor
Control unit
R max < 1 M
Paint container
Floor, conductive

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GM 2000 EAC - EN
3.2

4. STARTING WORK, AND HANDLING
Caution
See SAFETY REGULATIONS in chapter 1.
4.1 Preparation
● Locking of spray gun! Turn locking nut clockwise until stop (viewed from back of
gun)
● Check that spraying pressures are suitable.
● Check that all connections are tight and do not leak.
4.2 General rules for handling the spray gun
The following rules must be observed before any work is carried out on the
equipment or during breaks in work:
● Switch off control unit.
●Relieve spray gun and system pressure.
● Lock the spray gun with the locking nut.
4.3 Start-up for AirCoat spraying
1. Connect earth cable to the earth terminal of the control unit. Fix the other end using
the clamp to the nearest earthed piece of the equipment (cabin, transport device,
or similar). Make sure that all other conductive parts within the work area are
earthed.
2. Connect material hose to spray gun and to pump.
3. Connect air hose to spray gun and to oil-free, dry air supply with regulator.
4. Connect cable to control unit VM 200 EN or EPP 200 EN.
5. Set material pressure (approx. 80 bar) at material pump and switch on control unit.
6. Spray (actuate trigger).
7. Adjust spraying pressure at the paint pump regulator, according to jet and object.
8. Now open AirCoat air (approx. 1 to 2.5 bar) and adjust for the optimum atomiza-
tion.
Adjusting round jet fan:
9. By turning the tip nut , the atomizing air jet can additionally be adjusted.
By exchanging tips, various paint outputs can be achieved.
Note
Do not close the gap for atomizing air between tip nut and body.
for flat jet process :
9. To change the jet width; fit another AirCoat flat jet nozzle, with the required fan an-
gle.
By exchanging tips, various paint outputs can be achieved.
GM 2000 EAC - EN
4.1

4.4 Cleaning of clogged round jet tips
1. By means of tip spanner (A),
loosen tip insert (B) by a half turn.
2. Remove tip spanner and briefly pull
trigger. Caution, never spray into
an enclosed vessel.
3. After cleaning the tip retighten.
4.5 Exchange of Aircoat round jet tip insert (EAC round)
1. Remove tip insert (B) with tip span-
ner (A).
2. Fit desired tip insert (acc. to table
7.1) with tip spanner.
4.6 Changing from AirCoat round jet to AirCoat flat jet.
1. Replace paint with cleaning sol-
vent, actuate trigger, and thorough-
ly rinse paint channel.
2. Relieve spray gun and system
pressure.
3. Lock spray gun. Turn locking screw
clockwise until stop. (Look in spray-
ing direction)
4. Unscrew tip nut (C).
5. Remove tip body (D) by means of
pin wrench.
6. Fit tip insert (F) on paint channel
(G).
7. Fit air cap (H) onto fan nozzle (F);
make sure that the pins in the air
cap fit into the grooves in the flat
nozzle.
8. Fit cap ring (I) with air cap (H) onto
spray gun body (E).
9. Adjust desired jet level by means of
air cap horns (X) and tighten cap
ring (I) by hand.
GM 2000 EAC - EN
4.2
C
DE
F G
H
I
E
X
Universal spanner
A
B
A
B

4.7 Replacing AirCoat flat jet tips
1. Switch off control unit.
2. Relieve spray gun and system
pressure!
3. Lock spray gun. Turn locking screw
clockwise until stop. (look in spray-
ing direction)
4. Unsrew cap ring (I) and remove air
cap (H).
5. Remove AirCoat tip insert (F) and
brush cleaning solvent until all tra-
ces of paint are dissolved.
Handle the hard metal tip insert (C) with care. Do not clean it with sharp metal ob-
jects.
6. Assembly: Fit tip insert (F) on paint channel (G).
7. Fit air cap (H) onto fan nozzle (F); make sure that the pins in the air cap fit into the
grooves in the tip.
8. Fit cap ring (I) with air cap (H) onto spray gun body (E).
9. Adjust desired jet level by means of air cap horns (X) and tighten cap ring (I) by
hand.
4.8 Cleaning of AirCoat flat jet tips
For disassembly and assembly see of AirCoat nozzles chapter 4.7.
The AirCoat nozzle (F) can be placed into a cleaning solvent which has been
recommended by the paint manufacturer. Do not treat the hard metal on the AirCoat
nozzle using sharp edged objects.
4.9 Clogging of AirCoat flat jet tips
For blockages in the AirCoat flat jet tip the accessory - tip cleaning device - is available
with the partnumber 0139 014.
This tip cleaning device can be used together with the GM 2000 EAC to flush out
blocked AirCoat flat jet tips in the opposite direction to the usual spray direction.
GM 2000 EAC - EN
4.3
F G
H
I
E
X

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GM 2000 EAC - EN
4.4