WAGNER GM 2800EA User manual
0102 "?
GM 2800EA
II 2G EEx 0.24 mJ T6 (Atex 95)
Translation of the original
Operating manual
Electrostatic Air spray gun
for manual operation
with flat or round jet nozzles
Edition 03/ 2007
3
GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
Contents
1 ABOUT THESE INSTRUCTIONS 5
1.1 Language 5
1.2 Warnings, notes and symbols in these instructions 5
2 GENERAL SAFETY INSTRUCTIONS 6
2.1 Safety instructions for the operator 6
2.1.1 Electrical equipment 6
2.1.2 Personnel qualifications 6
2.1.3 A safe work environment 6
2.2 Safety instructions for personnel 6
2.2.1 Safe handling of WAGNER spray units. 7
2.2.2 Earth the unit 7
2.2.3 Material hoses 7
2.2.4 Cleaning 8
2.2.5 Handling hazardous liquids, varnishes and paints 8
2.2.6 Touching hot surfaces 8
2.3 Correct use 8
2.4 Safety-relevant information about discharges 9
2.5 Use in an explosion hazard area 9
2.5.1 Correct use 9
2.5.2 Explosion protection identification 9
2.5.3 Maxi. surface temperature 9
2.5.4 Safety instructions 10
2.6 German Regulations and guidelines 10
3 PRODUCT LIABILITY AND WARRANTY 11
3.1 Important notes on product liability 11
3.2 Warranty 11
3.3 CE-Conformity 12
3.5 PTB Conformity Certification 13
4 DESCRIPTION 14
4.1 Area of application, using in accordance with the instructions 14
4.1.1 What kind of spraying material can be applied 14
4.2 Scope of supply 15
4.3 Technical data 16
4.4 Function 17
4.4.1 Design of spray gun 17
4.4.2 Functions of the gun 17
4.5 Air atomizing spray process 18
4.5.1 Round and flat jet 18
4.5.2 Round jet 18
4.5.3 Flat jet 18
4.5.4 Electrostatic effect 19
5 PREPARATION BEFORE STARTING WORK 20
5.1 Set up and connect 20
5.1.1 Typical electrostatic spraying system 20
5.1.2 Ventilation of the spray booth 21
5.1.3 Air Supply 21
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GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
5.1.4 Fluid (Paint) hoses 21
5.1.5 Earthing 22
5.2 Preparation of paint 24
5.2.1 Viscosity conversion table 24
5.3 Start-up 25
5.3.1 General rules for making adjustments to the spray gun 25
5.3.2 Preparation 25
5.4 Working 26
5.4.1 Start-up for spraying 26
5.4.2 Adjust the spray angle with flat jet nozzle 27
5.4.3 Fitting or changing round jet nozzle 27
5.4.4 Changing from round jet nozzle to flat jet nozzle 28
5.4.5 Fitting or changing flat jet nozzle 28
6 MAINTENANCE 29
6.1 Finishing work and cleaning 30
7 TROUBLE SHOOTING AND SOLUTIONS 31
8 REPAIR WORK 33
8.1 Replacing the value seat 33
8.2 Exchange of complete valve rod 34
8.3 Exchange of valve rod seals 35
8.4 Electrode replacement 36
8.5 Replacing the paint hose 37
9 PRODUCT DISPOSAL 38
10 ACCESSORIES 39
10.1 Nozzles EA Flat-jet 39
10.1.1 Paint output measured with synthetic enamel 39
10.2 EA Round jet nozzle (SUPRA) 40
10.2.1 Paint output measured with synthetic enamel 40
10.3 Hoses, fittings and electrical cables 41
10.4 Special tools 41
10.5 Valve seat and Valve needle head - Plastic 41
10.6 Miscellaneous 41
11 SPARE PARTS CATALOGUE 42
11.1 How to order spare parts? 42
11.2 Spare parts list 43
Contents
5
GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
1.1 LANGUAGE
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
1 ABOUT THESE INSTRUCTIONS
4HISOPERATINGMANUALCONTAINSINFORMATIONABOUTTHEOPERATIONREPAIRANDMAINTENANCE
OFTHEUNIT
!LWAYSFOLLOWTHESEINSTRUCTIONSWHENOPERATINGTHEUNIT
4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL
%LECTROSTATICSPRAYGUNSMAYBEOPERATEDONLYBYTRAINEDPERSONNEL
#OMPLIANCEWITHTHESEINSTRUCTIONSCONSTITUTESANINTEGRALCOMPONENTOFTHEGUARANTEE
AGREEMENT
Warning instructions in this manual point out particular dangers to users and equipment
and state measures for avoiding the hazard. These warning instructions fall into the follo-
wing categories:
Danger - imminent danger. Non-observance will result
in death, serious injury and serious material damage.
Warning - possible danger. Non-observance can result
in death, serious injury and serious material damage.
Caution - a possibly hazardous situation. Non-obser-
vance can result in minor injury.
Note - provide information on particular characteristics and how to proceed.
Caution - a possibly hazardous situation. Non-obser-
vance can cause material damage.
SIHI_0100_GB
DANGER
This line warns of the hazard!
Possible consequences of failing to observe the warning instruc-
tions. The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0103_GB
WARNING
This line warns of the hazard!
Possible consequences of failing to observe the warning instruc-
tions. The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0101_GB
CAUTION
This line warns of the hazard!
Possible consequences of failing to observe the warning instruc-
tions. The signal word points out the hazard level.
The measures for preventing the hazard and its consequences.
SIHI_0102_GB CAUTION
This line warns of the hazard!
Possible consequences of failing to observe the warning instructions. The signal word
points out the hazard level.
The measures for preventing the hazard and its consequences.
4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES
,ANGUAGE 0ART.O ,ANGUAGE 0ART.O
'ERMAN %NGLISH
&RENCH $UTCH
)TALIAN 3PANISH
$ANISH 3WEDISH
0ORTUGUESE 4URKISH
388890 388891
388892 388893
388894 388895
388897 388896
388898 --
353934 353935
The corresponding service instructions are available under the following order number:
Language: Part No. Language: Part No.
German English
6
GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
2.1.1 ELECTRICAL EQUIPMENT
2.1.2 PERSONNEL QUALIFICATIONS
2.1.3 A SAFE WORK ENVIRONMENT
2.2 SAFETY INSTRUCTIONS FOR PERSONNEL
2 GENERAL SAFETY INSTRUCTIONS
+EEPTHESEOPERATINGINSTRUCTIONSTOHANDNEARTHEUNITATALLTIMES
!LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
%LECTRICALPLANTANDUNIT
4O BE PROVIDED IN ACCORDANCE WITH THE LOCAL SAFETY REQUIREMENTS WITH REGARD TO THE
OPERATINGMODEANDAMBIENTINmUENCES
-AYONLYBEMAINTAINEDBYSKILLEDELECTRICIANSORUNDERTHEIRSUPERVISION
-USTBEOPERATEDINACCORDANCEWITHTHESAFETYREGULATIONSANDELECTROTECHNICALREGU
LATIONS
-USTBEREPAIREDIMMEDIATELYINTHEEVENTOFPROBLEMS
-USTBEPUTOUTOFOPERATIONIFTHEYPOSEAHAZARD
-USTBEDEENERGIZEDBEFOREWORKISCOMMENCEDONACTIVEPARTS)NFORMSTAFFABOUT
PLANNEDWORKOBSERVEELECTRICALSAFETYREGULATIONS
%NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS
%NSURETHATTHEmOOROFTHEWORKINGAREAISANTISTATICINACCORDANCEWITH%.0ART
eMEASUREMENTINACCORDANCEWITH$).
%NSURETHATALLPERSONSWITHINTHEWORKINGAREAWEARANTISTATICSHOESEGSHOESWITH
LEATHERSOLES
%NSURETHATDURINGSPRAYINGPERSONSWEARANTISTATICGLOVESSOTHATTHEYAREEARTHEDVIA
THEHANDLEOFTHESPRAYGUN
#USTOMERTOPROVIDEPAINTMISTEXTRACTIONSYSTEMSCONFORMINGTOLOCALREGULATIONS
%NSURETHATTHEFOLLOWINGCOMPONENTSOFASAFEWORKINGENVIRONMENTAREAVAILABLE
n-ATERIALAIRHOSESADAPTEDTOTHEWORKINGPRESSURE
n0ERSONALSAFETYEQUIPMENTBREATHINGANDSKINPROTECTION
%NSURETHATTHERE ARENO IGNITIONSOURCESSUCH ASNAKED mAMEGLOWINGWIRES ORHOT
SURFACESINTHEVICINITY$ONOTSMOKE
!LWAYSFOLLOWTHEINFORMATIONINTHESEINSTRUCTIONSPARTICULARLYTHEGENERALSAFETYIN
STRUCTIONSANDTHEWARNINGINSTRUCTIONS
!LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
7
GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
2.2.2 EARTH THE UNIT
2.2.3 MATERIAL HOSES
2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS.
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 unit, in the event of work interruptions and functional
faults:
– Switch off the energy/compressed air supply.
– Secure the spray gun against actuation.
– Relieve the pressure from the spray gun and unit.
– By functional faults: Identify and correct the problem, proceed as described in
chap. „Trouble shooting“.
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 a firm footing when operating the spray gun.
Only hold the spray gun briefly in any one position.
Electrostatic charges can occur on the unit due to the electrostatic charge and the flow
speed involved in spraying.These can cause sparks and flames upon discharge.
Ensure that the unit is always earthed.
Earth the work pieces to be coated.
Ensure that all persons inside the working area are earthed, e.g. that they are wearing
antistatic shoes.
When spraying, wear antistatic gloves to earth yourself via the spray gun handle.
%NSURETHATTHEHOSEMATERIALISCHEMICALLYRESISTANTTOTHESPRAYEDMATERIALS
%NSURETHATTHEMATERIALHOSEISSUITABLEFORTHEPRESSUREGENERATEDINTHEUNIT
%NSURETHATTHEFOLLOWINGINFORMATIONISVISIBLEONTHEHIGHPRESSUREHOSE
n -ANUFACTURER
n 0ERMISSIBLEOPERATINGOVERPRESSURE
n $ATEOFMANUFACTURE
4HEELECTRICALRESISTANCEOFTHECOMPLETEHIGHPRESSUREHOSEMUSTBELESSTHAN
-/HM
8
GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
2.2.5 HANDLING HAZARDOUS LIQUIDS,VARNISHES AND PAINTS
2.2.6 TOUCHING HOT SURFACES
2.3 CORRECT USE
2.2.4 CLEANING
$EENERGIZETHEUNITELECTRICALLY
$ISCONNECTTHEPNEUMATICSUPPLYLINE
2ELIEVETHEPRESSUREFROMTHEUNIT
%NSURETHATTHEmASHPOINTOFTHECLEANINGAGENTISATLEAST+ABOVETHEAMBIENTTEM
PERATURE
4OCLEANUSEONLYSOLVENTFREECLOTHSANDBRUSHES.EVERUSEHARDOBJECTSORSPRAYON
CLEANINGAGENTSWITHAGUN
!NEXPLOSIVEGASAIRMIXTUREFORMSINCLOSEDCONTAINERS
7HENCLEANINGUNITSWITHSOLVENTSNEVERSPRAYINTOACLOSEDCONTAINER
%ARTHTHECONTAINER
7HENPREPARINGORWORKINGWITHPAINTANDWHENCLEANINGTHEUNITFOLLOWTHEWORK
INGINSTRUCTIONSOFTHEMANUFACTUREROFTHEPAINTSSOLVENTSANDCLEANINGAGENTSBEING
USED
4AKE THESPECIlEDPROTECTIVEMEASURESIN PARTICULAR WEAR SAFETYGOGGLES PROTECTIVE
CLOTHINGANDGLOVESASWELLASHANDPROTECTIONCREAMIFNECESSARY
5SEAMASKORBREATHINGAPPARATUSIFNECESSARY
&ORSUFlCIENTHEALTHANDENVIRONMENTALSAFETY/PERATETHEUNITINASPRAYBOOTHORON
ASPRAYINGWALLWITHTHEVENTILATIONEXTRACTIONSWITCHEDON
7EARSUITABLEPROTECTIVECLOTHINGWHENWORKINGWITHHOTMATERIALS
4OUCHHOTSURFACESONLYIFYOUAREWEARINGPROTECTIVEGLOVES
7HENOPERATINGTHEUNITWITHACOATINGMATERIALWITHATEMPERATUREOF²#²&
)DENTIFYTHEUNITWITHAWARNINGLABELTHATSAYSu7ARNINGHOTSURFACEh
/RDER.O
)NFORMATIONLABEL
3AFETYLABEL
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2
/PERATETHEUNITONLYASANENTIREUNIT
$ONOTDEACTIVATESAFETYEQUIPMENT
5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES
9
GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
2.5.2 EXPLOSION PROTECTION IDENTIFICATION
2.5 USE IN AN EXPLOSION HAZARD AREA
2.5.1 CORRECT USE
2.5.3 MAXI. SURFACE TEMPERATURE
2.4 SAFETY-RELEVANT INFORMATION ABOUT DISCHARGES
The plastic parts of the spray gun are charged electrostatically by the high-voltage field
of the spray pistol. Harmless discharges (brush discharges) are possible after contact with
plastic parts. They are completely harmless for people.
The corona discharge at the electrode end is visible during darkness at a distance of be-
tween 4 and 10 mm; 0.15 and 0.4 inches, between the spray gun and spray object.
4HEELECTROSTATICHANDSPRAYGUN'-%!ISSUITABLEFORSPRAYINGLIQUIDMATERIALSPAR
TICULARLYCOATINGMATERIALSUSINGTHEAIRATOMIZINGMETHOD
#OATINGMATERIALSCONTAININGSOLVENTSOF%XPLOSION#LASS))!MAYBEUSED4HESPRAYGUN
MAYONLYBEUSEDINCOMBINATIONWITHACONTROLUNIT6-6-AND6-WITH
(6-
!SDElNEDINTHE$IRECTIVE#%!4%8THEUNITISSUITABLEFORUSEINAREASWHERE
THEREISANEXPLOSIONHAZARD
))'%%XM*4
#% #OMMUNAUTÏS%UROPÏENNES
.OMINATEDTESTINGBODY04"
%X 3YMBOLFOREXPLOSIONPROTECTION
)) 5NITCLASS))
#ATEGORY:ONE
' %XATMOSPHEREGAS
% %UROPEANSTANDARD
%X %XPLOSIONPROTECTION
M* -AXIGNITIONENERGY
4 4EMPERATURECLASS
s-AXSURFACETEMPERATURE ²#²&
s0ERMISSIBLEMATERIALTEMPERATURE ²#²&
s0ERMISSIBLEAMBIENTTEMPERATURE ²#²&
10
GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
2.5.4 SAFETY INSTRUCTIONS
3AFEHANDLINGOF7!'.%2SPRAYUNITS
-ECHANICALSPARKSCANFORMIFTHEUNITCOMESINTOCONTACTWITHMETAL
)NANEXPLOSIVEATMOSPHERE
$ONOTKNOCKORPUSHTHEUNITAGAINSTSTEELORRUSTYIRON
$ONOTDROPTHEUNIT
5SEONLYTOOLSTHATAREMADEOFAPERMITTEDMATERIAL
)GNITIONTEMPERATUREOFTHECOATINGMATERIAL
%NSURETHATTHEIGNITION TEMPERATUREOF THECOATINGMATERIALIS ABOVETHEMAXIMUM
SURFACETEMPERATURE
3URFACESPRAYINGELECTROSTATIC
$ONOTSPRAYSYSTEMPARTSWITHELECTROSTATICEGELECTROSTATICSPRAYGUN
-EDIUMSUPPORTINGATOMIZING
4OATOMIZETHEMATERIALUSEONLYWEAKLYOXIDIZINGGASESEGAIR
#LEANING
)FTHERE AREDEPOSITSON THESURFACESTHE UNITMAYFORMELECTROSTATICCHARGES&LAMESOR
SPARKSCANFORMIFTHEREISADISCHARGE
2EMOVEDEPOSITSFROMTHESURFACESTOMAINTAINCONDUCTIVITY
5SEONLYADAMPCLOTHTOCLEANTHEUNIT
2.6 GERMAN REGULATIONS AND GUIDELINES
a) BGV A2 Electrical units and equipment
b) BGR 500 Part 2, Chap. 2.36 Working with liquid ejection devices
c) BGR 500 Part 2, Chap. 2.29 Using coating materials
d) CHV 9 Regulations on flammable liquids
e) CHV 11 Regulations on electrical equipment in Ex areas
f) BGR 104 Explosion protection rules
g) BGR 132 Avoiding ignition risks
h) BGR 180 Setting up for cleaning with solvents for cleaning workpieces with
solvents
i) ZH 1/406 Guidelines for liquid ejection devices
j) BGI 740 Painting rooms and equipment
k) BGI 764 Electrostatic coating
Note: All titles can be ordered from Heymanns Publishing House in Cologne or download
from Internet.
11
GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
3 PRODUCT LIABILITY AND WARRANTY
3.1 IMPORTANT NOTES ON PRODUCT LIABILITY
3.2 WARRANTY
!SARESULTOFAN%#REGULATIONEFFECTIVEASFROM*ANUARYTHEMANUFACTURERSHALL
ONLYBELIABLEFORHISPRODUCTIFALLPARTSCOMEFROMHIMORAREAPPROVEDBYHIMANDIFTHE
DEVICESAREPROPERLYlTTEDOPERATEDANDMAINTAINED
)FOTHERMAKESOFACCESSORYANDSPAREPARTSAREUSEDTHEMANUFACTURER@SLIABILITYCOULDBE
FULLYORPARTIALLYNULLANDVOID
4HEUSAGEOFORIGINAL7!'.%2ACCESSORIESANDSPAREPARTSGUARANTEESTHATALLSAFETYRE
GULATIONSAREOBSERVED
4HISUNITISCOVEREDBYOURWARRANTYONTHEFOLLOWINGTERMS
7EWILLATOURDISCRETIONREPAIRORREPLACEFREEOFCHARGEALLPARTSWHICHWITHINMONTHS
INSINGLESHIFTMONTHSINSHIFTORMONTHSINSHIFTOPERATIONFROMDATEOFRECEIPTBY
THE0URCHASERAREFOUNDTOBEWHOLLYORSUBSTANTIALLYUNUSABLEDUETOCAUSESPRIORTOTHE
SALEINPARTICULARFAULTYDESIGNDEFECTIVEMATERIALSORPOORWORKMANSHIP
4HETERMSOFTHEWARRANTYAREMETATOURDISCRETIONBYTHEREPAIRORREPLACEMENTOFTHE
UNITORPARTSTHEREOF4HERESULTINGCOSTSINPARTICULARSHIPPINGCHARGESROADTOLLSLABOUR
ANDMATERIALCOSTSWILLBEBORNEBYUSEXCEPTWHERETHESECOSTSAREINCREASEDDUETOTHE
SUBSEQUENTSHIPMENTOFTHEUNITTOALOCATIONOTHERTHANTHEADDRESSOFTHEPURCHASER
4HISWARRANTYDOESNOTCOVERDAMAGECAUSEDBY
5NSUITABLE OR IMPROPER USE FAULTY INSTALLATION OR COMMISSIONING BY THE PURCHASER OR A
THIRDPARTY NORMALWEAR NEGLIGENT HANDLINGDEFECTIVEMAINTENANCE UNSUITABLECOATING
PRODUCTS SUBSTITUTE MATERIALS AND THE ACTION OF CHEMICAL ELECTROCHEMICAL OR ELECTRICAL
AGENTSEXCEPTWHENTHEDAMAGEISATTRIBUTABLETOUS
!BRASIVECOATING PRODUCTS SUCH AS REDLEAD EMULSIONS GLAZESLIQUID ABRASIVES ZINC DUST
PAINTSANDSIMILARREDUCETHESERVICELIFEOFVALVESPACKINGSSPRAYGUNSNOZZLESCYLINDERS
PISTONSETC!NYWEARRESULTINGFROMTHEAFOREMENTIONEDCAUSESISNOTCOVEREDBYTHIS
WARRANTY
#OMPONENTSNOTMANUFACTUREDBY7AGNERARESUBJECTTOTHEWARRANTYTERMSOFTHEORIGI
NALMAKER
4HEREPLACEMENTOFAPARTDOESNOTEXTENDTHEWARRANTYPERIODOFTHEUNIT
4HEUNITSHOULDBEINSPECTEDIMMEDIATELYUPONRECEIPT
4OAVOIDLOSSWARRANTYANIYAPPARENTDEFECTSHOULDBENOTIlEDTOUSORTHEDEALERINWRI
TINGWITHINDAYSFROMDATEOFSALEOFTHEUNIT
4HERIGHTTOCOMMISSIONWARRANTYSERVICESTOATHIRDPARTYISRESERVED
7ARRANTYCLAIMSARESUBJECTTOPROOFOFPURCHASEBYSUBMITTINGANINVOICEORDELIVERYNOTE
)FANINSPECTIONlNDSDAMAGENOTCOVEREDBYTHEPRESENTWARRANTYTHEREPAIRWILLBECAR
RIEDOUTATTHEEXPENSEOFTHEPURCHASER
.OTETHATTHISWARRANTYDOESNOTINANYWAYRESTRICTLEGALLYENTITLEDCLAIMSORTHOSECONTRAC
TUALLYAGREEDTOINOURGENERALTERMSANDCONDITIONS
*7AGNER!'
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GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
3.3 CE-CONFORMITY
179780
CE Certificate of Conformity
The certificate is enclosed with this product.The certificate of conformity can be reordered
from your WAGNER representative, quoting the product and serial number.
Part number:
Herewith we declare that the supplied version of
179037 Spray gun GM 2800EA
179047 Spray gun GM 2800EA Special lengths
Complies with the following guidelines:
73/23/EWG
89/336/EWG
92/31/EWG
93/68/EWG
98/37/EG
94/9/EG
Applied standards, in particular:
EN 292-1 EN 60204-1
EN 292-2 EN 61000-4-2
EN 1050 EN 61000-4-4
EN 1127-1 EN 61000-4-6
EN 1953 EN 61000-4-11
EN 50014 EN 61000-6-1
EN 50050 EN 61000-6-2
EN 55011 EN 61000-6-3
EN 55022 EN 61000-6-4
Applied national technical standards and specifications, in particular:
See chapter 2.6
Marking:
0102 II 2G EEx 0.24 mJ T6 (Atex 95)
13
GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
3.5 PTB CONFORMITY CERTIFICATION
14
GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
4 DESCRIPTION
4.1 AREA OF APPLICATION, USING IN ACCORDANCE WITH THE INSTRUCTIONS
The electrostatic spray gun can only be used with the control units VM 2000 or VM 200.
4.1.1 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 (accord-
ing 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 or resin.
Note
With very highly conductive materials or those with a very high electrical resistance, the
electrostatic effect does not work as efficiently.The relationship between the values of the
high-voltage (kV) and the current (µA), shown on the HVM 2082, denotes the charging
capacity of a spray material.
• High kV-value, low µA-value (no wrap around) = Paint with too high electric resistance.
• Low kV-value, high µA-value (no wrap-around) = Paint with too low electric resistance
In the event of application problems, contact your WAGNER branch and the paint manu-
facturer.
15
GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
4.2 SCOPE OF SUPPLY
Quantity Part No. Description
1 179037 Spray gun GM 2800EA
1 179060 Spray gun GM 2800EA USA
1 179047 Spray gun GM 2800EA Special lengths
1 179061 Spray gun GM 2800EA Special lengths USA
The standard equipment includes:
179037
179060
179047
179061
Quantity Part No. Description
1 1 1 1 179901 Universal spanner
1 1 1 1 353210 Nozzle spanner
1 1 1 1 179946 Set of seals
1 1 1 1 350382 Hose fitting ø 10 mm; ø 0.39 inch, 1/4“
1 1 1 1 350346 Hose fitting ø 10 mm; ø 0.39 inch, 3/8“
1 1 1 1 353390 Protection cap for electrode
1 1 1 1 9100579 Instruction tag
1 1 1 1 179780 CE-Declaration of Conformity
1 - 1 - 388890 Operating manual German
- 1 - 1 388891 Operating manual English
1 1 1 1 see chap.1 An operating manual in the local language
The spray gun is delivered without nozzle set.
The spray guns 179047 and 179061 can be ordered with cable lengths by 15 m; 49.2 ft,
20 m; 65.6 ft, 25 m; 82.0 ft, 30 m; 98.4 ft, 35 m; 114.82 ft, 40 m; 131.23 ft, 45 m; 147.64 ft or
50 m; 164.04 ft.
The standard cable length is 11 m; 36.1 ft.
Air and material hose are extended in each case thereby by the same length.
For special versions the delivery note applies.
16
GM 2800EA
355 mm; 13.98 inch
255 mm; 10.04 inch
B_00087
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
4.3 TECHNICAL DATA
Maxi. air pressure 0.8 MPa; 8 bar; 116 psi
Maxi. material pressure 0.8 MPa; 8 bar; 116 psi
Material connection ø 10 mm; 0.39 inch
Material hose length 7.5 m; 24.6 ft
Inner diameter material hose ø 6 mm; 0.24 inch
Air connection R 1/4“
Air hose length 8.1 m; 26.6 ft
Inner diameter air hose ø 7.5 mm; 0.30 inch
Input voltage * maxi. 17 Vpp
Input current * maxi. 0.9 A
Output voltage * maxi. 80 kV DC
Output current * maxi. 100 µA DC
Polarity negative
Gun cable (standard) 11 m; 36.1 ft
Weight (without cables) 600 g; 1.32 lb
Dimension length (L) 355 mm; 13.98 inch
Dimension height (H) 255 mm; 10.04 inch
Working temperature range 5-40 °C; 41-104 °F
Maxi. temperature material 60 °C; 140 °F
Min. el. material resistance 50 kΩ**
Maxi. el. material resistance 1250 kΩ **
Sound power at 0.2 MPa; 2 bar; 29 psi air
pressure (depending on nozzle used)
65 - 79 dB(A)
*After WAGNER/Ransburg scale
Note
The specifications marked with “ * “ are maximum values. The effective values depend on
the control unit
Dimensions
17
GM 2800EA
E
G
H
I
F
AB
J
L
M
K
N
D
C
B_00163
!7
,-
,%
,/
"?
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
4.4 FUNCTION
4.4.1 DESIGN OF SPRAY GUN
A Suspension hook
B Fan air regulation
C HV switch (integrated into trigger)
D Tension cap
E Trigger
F Handle with integrated
high voltage generator
G Air connector
H Paint hose
I Gun cable to the control unit
J Nozzle set EA R Supra
K Nozzle set EA F
L Spray gun body
M Hose nipple
N Protection cap
4.4.2 FUNCTIONS OF THE GUN
The trigger can be used to activate, one after the other, the various functions of the spray
gun.
AW = Maxi. way of trigger
LM = Air open
LE = Air open and electrostatics activated
LO = Air open and electrostatics activated and
material valve open
•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
voltage can be switched off by flipping the High voltage
switch (C) down
•The supply of the flat jet air is adjusted by means of the
regulator (B).
18
GM 2800EA
"?
"?
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
4.5 AIR ATOMIZING SPRAY PROCESS
4.5.1 ROUND AND FLAT JET
In this process, the material (paint) is fed to the nozzle with low pressure at approx. 0.05-
0.2 MPa; 0.5-2 bar; 7-29 psi. The atomizing air at approx. 0.25-0.4 MPa; 2.5-4 bar; 36-58 psi
produces a soft jet, which largely eliminates the problem of overlapping boundaries.
4.5.2 ROUND JET
The jet is cone-shaped.
4.5.3 FLAT JET
The spraying angle can be changed by adjusting the„fan air“. Depend on the material and
the output, a large range of nozzles and air caps are available to suit your needs (see chap-
ter. 9.1).
1 Atomizing air 2 Material 3 Nozzle nut
Spray pattern
1 Atomizing air 4 Fan air
Spraying angle
2 Material 3 Air cap
Spray pattern
19
GM 2800EA
"?
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
4.5.4 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.
ElectrodeCharged particles
Grounded
object
Advantages of electrostatics
•Very efficient spraying
•Little over spray
•Coating of entire circumferences due to an electrostatic field
•Less working time
20
GM 2800EA
(6-
/&&
+6 !
/.
6-
1
!
/
0
)
(
,
+
'
&
%
$
#
"
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OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
5 PREPARATION BEFORE STARTING WORK
5.1 SET UP AND CONNECT
A Paint-pump H Gun cable to control unit
B Air shut off valve I Control unit
C Air regulator K Paint connection
D Air regulator with filter L Fluid hose
E Earthing cable O Stand
F Air hose P Paint container
G Fan air regulation Q Mains air inlet
The spray gun GM 2800EA must be used a part of an electrostatic spraying system. The
spraying system shown in the figure is only one example of an electrostatic AirCoat spray-
ing system. It is not an actual system design. Contact your WAGNER distributor for assist-
ance in designing a system to meet your needs.The operating instructions and the safety
regulations for the additional system components used must be read before starting-up.
5.1.1 TYPICAL ELECTROSTATIC SPRAYING SYSTEM
WARNING
Incorrect installation/operation!
Risk of injury and damage to equipment
When putting into operation and for all work, read and follow
the operating instructions and safety regulations for the addi-
tionally required system components.
SIHI_0050_GB
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