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

4
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
4HISOPERATINGMANUALCONTAINSINFORMATIONABOUTTHEOPERATIONREPAIRANDMAINTENANCE
OFTHEUNIT
 !LWAYSFOLLOWTHESEINSTRUCTIONSWHENOPERATINGTHEUNIT
4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL
%LECTROSTATICSPRAYGUNSMAYBEOPERATEDONLYBYTRAINEDPERSONNEL
#OMPLIANCEWITHTHESEINSTRUCTIONSCONSTITUTESANINTEGRALCOMPONENTOFTHEGUARANTEE
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.
4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES
,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
 +EEPTHESEOPERATINGINSTRUCTIONSTOHANDNEARTHEUNITATALLTIMES
 !LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
%LECTRICALPLANTANDUNIT
 4O BE PROVIDED IN ACCORDANCE WITH THE LOCAL SAFETY REQUIREMENTS WITH REGARD TO THE
OPERATINGMODEANDAMBIENTINmUENCES
 -AYONLYBEMAINTAINEDBYSKILLEDELECTRICIANSORUNDERTHEIRSUPERVISION
 -USTBEOPERATEDINACCORDANCEWITHTHESAFETYREGULATIONSANDELECTROTECHNICALREGU
LATIONS
 -USTBEREPAIREDIMMEDIATELYINTHEEVENTOFPROBLEMS
 -USTBEPUTOUTOFOPERATIONIFTHEYPOSEAHAZARD
 -USTBEDEENERGIZEDBEFOREWORKISCOMMENCEDONACTIVEPARTS)NFORMSTAFFABOUT
PLANNEDWORKOBSERVEELECTRICALSAFETYREGULATIONS
 %NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS
 %NSURETHATTHEmOOROFTHEWORKINGAREAISANTISTATICINACCORDANCEWITH%.0ART
eMEASUREMENTINACCORDANCEWITH$).
 %NSURETHATALLPERSONSWITHINTHEWORKINGAREAWEARANTISTATICSHOESEGSHOESWITH
LEATHERSOLES
 %NSURETHATDURINGSPRAYINGPERSONSWEARANTISTATICGLOVESSOTHATTHEYAREEARTHEDVIA
THEHANDLEOFTHESPRAYGUN
 #USTOMERTOPROVIDEPAINTMISTEXTRACTIONSYSTEMSCONFORMINGTOLOCALREGULATIONS
 %NSURETHATTHEFOLLOWINGCOMPONENTSOFASAFEWORKINGENVIRONMENTAREAVAILABLE
n-ATERIALAIRHOSESADAPTEDTOTHEWORKINGPRESSURE
n0ERSONALSAFETYEQUIPMENTBREATHINGANDSKINPROTECTION
 %NSURETHATTHERE ARENO IGNITIONSOURCESSUCH ASNAKED mAMEGLOWINGWIRES ORHOT
SURFACESINTHEVICINITY$ONOTSMOKE
 !LWAYSFOLLOWTHEINFORMATIONINTHESEINSTRUCTIONSPARTICULARLYTHEGENERALSAFETYIN
STRUCTIONSANDTHEWARNINGINSTRUCTIONS
 !LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
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.
 %NSURETHATTHEHOSEMATERIALISCHEMICALLYRESISTANTTOTHESPRAYEDMATERIALS
 %NSURETHATTHEMATERIALHOSEISSUITABLEFORTHEPRESSUREGENERATEDINTHEUNIT
 %NSURETHATTHEFOLLOWINGINFORMATIONISVISIBLEONTHEHIGHPRESSUREHOSE
 n -ANUFACTURER
 n 0ERMISSIBLEOPERATINGOVERPRESSURE
 n $ATEOFMANUFACTURE
 4HEELECTRICALRESISTANCEOFTHECOMPLETEHIGHPRESSUREHOSEMUSTBELESSTHAN
 -/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
 $EENERGIZETHEUNITELECTRICALLY
 $ISCONNECTTHEPNEUMATICSUPPLYLINE
 2ELIEVETHEPRESSUREFROMTHEUNIT
 %NSURETHATTHEmASHPOINTOFTHECLEANINGAGENTISATLEAST+ABOVETHEAMBIENTTEM
PERATURE
 4OCLEANUSEONLYSOLVENTFREECLOTHSANDBRUSHES.EVERUSEHARDOBJECTSORSPRAYON
CLEANINGAGENTSWITHAGUN
!NEXPLOSIVEGASAIRMIXTUREFORMSINCLOSEDCONTAINERS
 7HENCLEANINGUNITSWITHSOLVENTSNEVERSPRAYINTOACLOSEDCONTAINER
 %ARTHTHECONTAINER
 7HENPREPARINGORWORKINGWITHPAINTANDWHENCLEANINGTHEUNITFOLLOWTHEWORK
INGINSTRUCTIONSOFTHEMANUFACTUREROFTHEPAINTSSOLVENTSANDCLEANINGAGENTSBEING
USED
 4AKE THESPECIlEDPROTECTIVEMEASURESIN PARTICULAR WEAR SAFETYGOGGLES PROTECTIVE
CLOTHINGANDGLOVESASWELLASHANDPROTECTIONCREAMIFNECESSARY
 5SEAMASKORBREATHINGAPPARATUSIFNECESSARY
 &ORSUFlCIENTHEALTHANDENVIRONMENTALSAFETY/PERATETHEUNITINASPRAYBOOTHORON
ASPRAYINGWALLWITHTHEVENTILATIONEXTRACTIONSWITCHEDON
 7EARSUITABLEPROTECTIVECLOTHINGWHENWORKINGWITHHOTMATERIALS
 4OUCHHOTSURFACESONLYIFYOUAREWEARINGPROTECTIVEGLOVES
 7HENOPERATINGTHEUNITWITHACOATINGMATERIALWITHATEMPERATUREOF²#²&
 )DENTIFYTHEUNITWITHAWARNINGLABELTHATSAYSu7ARNINGHOTSURFACEh
/RDER.O
 )NFORMATIONLABEL
 3AFETYLABEL
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
 5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2
 /PERATETHEUNITONLYASANENTIREUNIT
 $ONOTDEACTIVATESAFETYEQUIPMENT
 5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES

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.
4HEELECTROSTATICHANDSPRAYGUN'-%!ISSUITABLEFORSPRAYINGLIQUIDMATERIALSPAR
TICULARLYCOATINGMATERIALSUSINGTHEAIRATOMIZINGMETHOD
#OATINGMATERIALSCONTAININGSOLVENTSOF%XPLOSION#LASS))!MAYBEUSED4HESPRAYGUN
MAYONLYBEUSEDINCOMBINATIONWITHACONTROLUNIT6-6-AND6-WITH
(6-
!SDElNEDINTHE$IRECTIVE#%!4%8THEUNITISSUITABLEFORUSEINAREASWHERE
THEREISANEXPLOSIONHAZARD
 ))'%%XM*4
#% #OMMUNAUTÏS%UROPÏENNES
 .OMINATEDTESTINGBODY04"
%X 3YMBOLFOREXPLOSIONPROTECTION
)) 5NITCLASS))
 #ATEGORY:ONE
' %XATMOSPHEREGAS
% %UROPEANSTANDARD
%X %XPLOSIONPROTECTION
M* -AXIGNITIONENERGY
4 4EMPERATURECLASS
s-AXSURFACETEMPERATURE ²#²&
s0ERMISSIBLEMATERIALTEMPERATURE ²#²&
s0ERMISSIBLEAMBIENTTEMPERATURE ²#²&

10
GM 2800EA
OPERATING MANUAL
EDITION 03/ 2007 PART NO. DOC388891
2.5.4 SAFETY INSTRUCTIONS
3AFEHANDLINGOF7!'.%2SPRAYUNITS
-ECHANICALSPARKSCANFORMIFTHEUNITCOMESINTOCONTACTWITHMETAL
)NANEXPLOSIVEATMOSPHERE
 $ONOTKNOCKORPUSHTHEUNITAGAINSTSTEELORRUSTYIRON
 $ONOTDROPTHEUNIT
 5SEONLYTOOLSTHATAREMADEOFAPERMITTEDMATERIAL
)GNITIONTEMPERATUREOFTHECOATINGMATERIAL


%NSURETHATTHEIGNITION TEMPERATUREOF THECOATINGMATERIALIS ABOVETHEMAXIMUM
SURFACETEMPERATURE
3URFACESPRAYINGELECTROSTATIC


$ONOTSPRAYSYSTEMPARTSWITHELECTROSTATICEGELECTROSTATICSPRAYGUN
-EDIUMSUPPORTINGATOMIZING
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4OATOMIZETHEMATERIALUSEONLYWEAKLYOXIDIZINGGASESEGAIR
#LEANING
)FTHERE AREDEPOSITSON THESURFACESTHE UNITMAYFORMELECTROSTATICCHARGES&LAMESOR
SPARKSCANFORMIFTHEREISADISCHARGE
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2EMOVEDEPOSITSFROMTHESURFACESTOMAINTAINCONDUCTIVITY
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5SEONLYADAMPCLOTHTOCLEANTHEUNIT
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.