WAGNER GM 50000EAC Operational manual

B_03154
Electrostatic AirCoat Spray Gun
for manual operation
for at or round jet nozzles
Version 05/2015
Translation of the Original
Operating Manual

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OPERATING MANUAL
EDITION 05/2015 ORDER NUMBER DOC2319150
Table of Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 8
2 CORRECT USE 9
2.1 Device Type 9
2.2 Type of Use 9
2.3 Use in an Explosion Hazard Area 9
2.4 Safety Parameters 9
2.5 Processible Working Materials 10
2.6 Reasonably Foreseeable Misuse 11
2.7 Residual Risks 11
3 IDENTIFICATION 12
3.1 CE Explosion Protection Identication 12
3.2 Identication "X" 12
3.3 Type Plate 13
4 GENERAL SAFETY INSTRUCTIONS 14
4.1 Safety Instructions for the Operator 14
4.1.1 Electrical Equipment 14
4.1.2 Personnel Qualications 14
4.1.3 Safe Work Environment 14
4.2 Safety Instructions for Sta 15
4.2.1 Safe Handling of WAGNER Spray Devices 15
4.2.2 Grounding the Device 16
4.2.3 Product Hoses 16
4.2.4 Cleaning and Flushing 17
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 18
4.2.6 Touching Hot Surfaces 18
4.3 Protective and Monitoring Equipment 18
4.4 Use in Areas Subject to Explosion Hazards 19
4.4.1 Safety Regulations 19
4.5 Safety-Relevant Information about Discharges 19
5 DESCRIPTION 20
5.1 Structure (Standard Variant) 20
5.1.1 Securing the Spray Gun Against Actuation 21
5.2 Mode of Operation 21
5.3 Protective and Monitoring Equipment 23
5.4 Scope of Delivery 23
5.5 Technical Data 24
5.6 Spraying Procedure 25
5.6.1 Spraying Procedure for AirCoat Round Spray 25
5.6.2 Spraying Procedure for AirCoat Fan Spray 25
5.6.3 Electrostatic Eect 26

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OPERATING MANUAL
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Table of Contents
6 ASSEMBLY AND COMMISSIONING 27
6.1 Training Assembly/Commissioning Sta 27
6.2 Storage Conditions 27
6.3 Installation Conditions 27
6.4 Assembly and Installation 27
6.4.1 Typical Electrostatic Spraying System 28
6.4.2 Ventilation of the Spray Booth 29
6.4.3 Air Supply 31
6.4.4 Product Supply 31
6.4.5 Grounding 32
6.5 Preparation of Lacquer 34
6.5.1 Viscosity Conversion Table 34
6.6 Commissioning 35
6.6.1 Safety Instructions 35
6.6.2 Preparation for Commissioning 35
6.6.3 Commissioning 35
6.6.3.1 Gun Cables and Gun Cable Extensions 36
6.6.4 Verifying a Safe Operational Condition 37
7 OPERATION 38
7.1 Training the Operating Sta 38
7.2 Safety Instructions 38
7.2.1 Emergency Deactivation 39
7.2.2 General Rules for Making Adjustments to the Spray Gun 39
7.3 Work 40
7.3.1 Filling with Working Material 41
7.3.2 Checking the Spray Pattern (Without Electrostatics) 41
7.3.3 Spraying 43
7.3.4 Pressure Relief / Work Interruption 44
7.3.5 Flushing Out Clogged Round Jet Nozzles 45
7.3.6 Replacing Round Jet Nozzle's Nozzle Insert 45
7.3.7 Changing from AirCoat Round Jet to AirCoat Flat Jet 46
7.3.8 Replacing the AirCoat Flat Jet Nozzles 48
7.3.9 Cleaning of the Nozzle Parts 49
7.3.10 Eliminate Nozzle Clogging 50
7.3.11 Changing the Valve Housing 52
8 CLEANING AND MAINTENANCE 54
8.1 Cleaning 54
8.1.1 Cleaning Sta 54
8.1.2 Safety Instructions 54
8.1.3 Cleaning and Flushing the Device 56
8.2 Maintenance 58
8.2.1 Maintenance Sta 58
8.2.2 Safety Instructions 58
8.2.3 Safety Checks 59
8.2.4 Product Hoses, Tubes and Couplings 60

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Table of Contents
9 TROUBLESHOOTING AND RECTIFICATION 61
10 REPAIR WORK 63
10.1 Repair Sta 63
10.2 Safety Instructions 63
10.3 Spray Gun 64
10.3.1 Tools 64
10.3.2 Disassembly of the Spray Gun 65
10.3.3 Cleaning the Parts After Disassembly 69
10.3.4 Assembling the Spray Gun 70
11 FUNCTIONAL CHECK AFTER REPAIR 76
11.1 Checking the High-voltage 76
11.2 Air Test 78
11.3 Product Pressure Test 78
11.4 Test of Spray Pattern 78
12 DISPOSAL 79
13 ACCESSORIES 80
13.1 Round Spray Nozzles 80
13.1.1 ACR 5000 Round Jet Nozzle Cap 80
13.1.2 AirCoat Round Jet Nozzle Inserts 80
13.2 Flat Jet Nozzles 80
13.2.1 ACF 5000 Air Caps (Flat Jet) 80
13.2.2 ACF5000 AirCoat Flat Jet Nozzles 81
13.3 Filter 83
13.4 Hoses and Electric Cables 84
13.4.1 Standard Hose Sets and Components 84
13.4.2 Hose Sets for Low-resistance Products 86
13.4.3 Product Hose 1.5 mm 88
13.4.4 Gun Cables and Gun Cable Extensions 88
13.5 Miscellaneous 89
14 SPARE PARTS 91
14.1 How Can Spare Parts Be Ordered? 91
14.2 GM 5000EAC Spray Gun 92
14.2.1 GM 5000EAC Adapter 94
14.2.2 GM 5000EAC Handle 96
14.3 Accessories Spare Parts Lists 98
14.3.1 Fan Spray Nozzles 98
14.3.2 ACR 5000 Round Jet Nozzle Cap 99
15 WARRANTY AND CONFORMITY DECLARATIONS 100
15.1 Important Notes Regarding Product Liability 100
15.2 Warranty Claim 100
15.3 CE Declaration of Conformity 101
15.4 EC Type Examination Certicate 102
15.5 Notes on German Regulations and Guidelines 105

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1 ABOUT THESE INSTRUCTIONS
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
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 damage to property.
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 measures for preventing the danger 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 measures for preventing the danger 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 measures for preventing the danger 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 measures for preventing the danger 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.
The device may only be operated by trained sta and in compliance with this operating
manual. Operating and service personnel should be instructed according to the safety
instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.

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1.3 LANGUAGES
1.4 ABBREVIATIONS
The GM 5000EAC operating manual is available in the following languages:
Language Order No. Language Order No.
German 2310481 English 2319150
French 2320152 Italian 2320153
Spanish 2320154 Dutch 2358832
Danish 2359979 Swedish 2360027
Additional languages on request or at:
Order No. Order number
Spare part
Marking in the spare parts lists
AirCoat
Electrostatic AirCoat
Manual gun (gun, manual)
Low-resistance
Stainless steel
Position
Number of pieces
Wrench size

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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Sta qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as
well as the necessary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person A person who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the area of electrostatic coating and is familiar
with the relevant and generally accepted rules of technology
so that he/she can inspect and assess the status of devices and
coating systems based on workplace safety.
in the context of BGI 764
Additional requirements for skilled persons can also be
referred to in TRBS1203(2010): Expert knowledge in the areas
of protection against excessive pressure, electrical hazards, and
explosion protection (where applicable).

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2 CORRECT USE
2.1 DEVICE TYPE
Electrostatic manual spray gun for manual coating of grounded work pieces.
2.2 TYPE OF USE
The GM 5000EAC electrostatic manual 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.
WAGNER forbids any other use!
2.4 SAFETY PARAMETERS
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. "Explosion Protection Identication".)
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.
The device may only be operated under the following conditions:
The operating sta must be trained on the basis of this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must be
observed.
The statutory requirements and accident prevention regulation standards in the
country of use must be observed.
The electrostatic manual spray gun may only be operated if all parameters are set and all
measurements/safety checks are carried out correctly.

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2.5 PROCESSIBLE WORKING MATERIALS
Lacquers containing solvents of explosion class II A can be processed with the
GM 5000EAC spray gun.
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 application eectiveness is always dependant on the composition of the product
being used, e.g., pigments 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)
Note:
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 spray product with regard to the charging ability can be read from the
actual values for high-voltage (kV) and for the spray current (µA) shown in the illuminated
displays 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
Pleasecontact yourlocalWAGNER dealer and the lacquermanufacturer if youencounter
application problems.