WAGNER GM 5000EA Operational manual

cus
B_03229
Electrostatic Airspray Gun
for Manual Operation with
Flat or Round Jet Nozzles
Version 07/2014
Translation of the Original
Operating Manual

3
GM 5000EA
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344499
Contents
1 GENERAL 6
1.2 Warnings, Notices, and Symbols in this Operating Manual 6
1.3 Languages 7
1.4 Abbreviations 7
2 CORRECT USE 8
2.1 Device Type 8
2.2 Correct Use 8
2.3 Use in an Explosion Hazard Area 8
2.4 Safety Parameters 8
2.5 Processible Products 9
2.6 Reasonably Foreseeable Misuse 10
2.7 Residual Risks 10
3 IDENTIFICATION 11
3.1 Explosion Protection Identication FM 11
3.2 Information for safe and correct operation 11
3.3 Permissible Device Combinations 12
4 GENERAL SAFETY INSTRUCTIONS 13
4.1 Safety Instructions for the Operator 13
4.1.1 Electrical Equipment 13
4.1.2 Sta Qualications 13
4.1.3 Safe Work Environment 13
4.2 Safety Instructions for Sta 13
4.2.1 Safe Handling of WAGNER Spray Devices 14
4.2.2 Grounding the Device 14
4.2.3 Material Hoses 15
4.2.4 Cleaning 15
4.2.5 Handling Hazardous Liquids, Lacquers and Paints 16
4.2.6 Touching Hot Surfaces 16
4.3 Correct Use 17
4.4 Safety Information on Discharges 17
4.5 Use in an Explosion Hazard Area 17
4.6 Notes to German Regulations and Guidelines 17
5 DESCRIPTION 19
5.1 Functional Description 19
5.1.1 Design of the Spray Gun (Basic Version) 19
5.1.2 Functioning of the Spray Gun 20
5.2 Scope of Delivery 22
5.3 Technical Data 23
5.4 Spray Process 24
5.4.1 Air Atomizing Spray Process - Round Jet 24
5.4.2 Air Atomizing Spray Process - Flat Jet 24
5.4.3 Electrostatic Eect 25
6 COMMISSIONING AND OPERATION 26
6.1 Training Assembly/Commissioning Sta 26
6.2 Storage Conditions 26
6.3 Installation Conditions 26

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GM 5000EA
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344499
Contents
6.4 Installation and Connection 27
6.4.1 Typical Electrostatic Air Spraying System 27
6.4.2 Ventilation of the Spray Booth 28
6.4.3 Air Supply 29
6.4.4 Product Supply 29
6.4.5 Grounding 30
6.5 Preparation of Lacquer 32
6.5.1 Viscosity Conversion Table 32
6.6 Wagner Electrostatic Air Spraying System 33
6.6.1 Pressure Settings for Round Jet Nozzles 33
6.6.2 Pressure Settings for Flat Jet Nozzles 34
6.6.3 Electrostatic and Atomization 35
6.6.4 Output Measuring 35
6.7 Commissioning 36
6.7.1 General Rules for Manipulation of the Spray Gun 36
6.7.2 Preparation for Starting Up 36
7 OPERATION 39
7.1 Training the Operating Sta 39
7.2 Safety Instructions 39
7.3 Work 40
7.3.1 Filling with Working Product 40
7.3.2 Start-up Spraying 41
7.3.3 Changing from Air Round Jet to Air Flat Jet 42
7.3.4 Cleaning of the Nozzle Parts 42
7.3.5 Changing the Valve Housing 43
8 CLEANING AND MAINTENANCE 44
8.1 Cleaning 44
8.1.1 Cleaning Sta 44
8.1.2 Safety Instructions 44
8.1.3 Cleaning and Decommissioning 45
8.2 Maintenance 47
8.2.1 Maintenance Sta 47
8.2.2 Safety Instructions 47
8.3 Disassembly of the Spray Gun 48
8.3.1 Tools 48
8.3.2 Disassembly of the Spray Gun 49
8.4 Cleaning the Parts after Disassembly 52
8.5 Assembly of the Spray Gun 53
8.6 Function Test after Assembly of the Gun 57
8.6.1 Test of the High-Voltage 57
8.6.2 Air Test 58
8.6.3 Product Pressure Test 58
8.6.4 Test of Spray Pattern 59
8.7 High Pressure Hoses 60
9 INSPECTIONS 60
9.1 Periodical Inspections 60
10 TROUBLESHOOTING AND RECTIFICATION 61

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GM 5000EA
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344499
Contents
11 PRODUCT DISPOSAL 62
12 ACCESSORIES 63
12.1 Valve Seats / Valve Tips 63
12.1.1 Valve Seats 63
12.1.2 Valve Tips 63
12.2 Round Jet Nozzles 64
12.2.1 AR 5000 Air Caps 64
12.2.2 AR 5000 Nozzles 64
12.3 Flat Jet Nozzles 64
12.3.1 AF 5000 Air Caps 64
12.3.2 AF 5000 Nozzles 65
12.4 Hoses and Electric Cables 66
12.4.1 Standard Hose Sets and Components 66
12.4.2 Hose Sets for Low-resistance Products 68
12.4.3 Gun Cables and Gun Cable Extensions 70
12.5 Reduction Fittings for High-Pressure Hoses 70
12.6 Miscellaneous 71
13 SPARE PARTS 73
13.1 How Can Spare Parts Be Ordered? 73
13.2 Spare Parts List GM 5000EA 74
13.2.1 Spare Parts List GM 5000EA - Adapter 76
13.2.2 Spare Parts List GM 5000EA - Handle 78
13.3 Accessories Spare Parts Lists 80
13.3.1 Spare Parts List AR 5000 Nozzle (D8) 81
13.3.2 Spare Parts List AR 5000 Nozzle (D12) 81
14 WARRANTY 82
14.1 Important Notes Regarding Product Liability 82
14.2 Warranty Claim 82

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GM 5000EA
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344499
1 GENERAL
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.
Operating and service sta should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
Electrostatic spray guns may only be operated by trained personnel.
1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
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 material damage.
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 following are measures which can be taken to prevent
the hazard 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 following are measures which can be taken to prevent
the hazard 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 following are measures which can be taken to prevent
the hazard 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 following are measures which can be taken to prevent the hazard and its
consequences.
NOTICE

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GM 5000EA
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344499
1.3 LANGUAGES
The operating manual is available in the following languages:
German English 2344499
1.4 ABBREVIATIONS
Order No. Order number
ET Spare part
Marking in the spare parts lists
Low R Low-resistance
Position
Number of pieces
Width across ats

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GM 5000EA
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344499
2 CORRECT USE
2.1 DEVICE TYPE
Electrostatic manual spray gun for manual coating of grounded work pieces
2.2 CORRECT USE
The GM 5000EA electrostatic manual spray gun is suitable for spraying liquid products,
particularly coating products, using the air atomizing method. Coating products containing
solvents of explosion class II A may be used.
2.4 SAFETY PARAMETERS
The GM 5000EA electrostatic manual spray gun is only suitable for spraying liquid products,
particularly coating products.
J. Wagner AG forbids any other use!
The electrostatic manual spray gun may only be operated under the following conditions:
the operating sta have previously been trained on the basis of this operating manual,
the safety regulations listed in this operating manual are observed,
the operating, maintenance and repair information in this operating manual is
observed,
and the statutory requirements and accident prevention regulations standards in the
country of use are observed.
The electrostatic manual spray gun may only be operated if all parameters are set and all
measurements/safety checks are carried out correctly.
2.3 USE IN AN EXPLOSION HAZARD AREA
The GM 5000EA 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 "Identication")

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GM 5000EA
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344499
2.5 PROCESSIBLE PRODUCTS
With the GM 5000EA spray gun, lacquers can be processed which contain solvents
of explosion class II A.
The spray gun basic version is suitable for processing of 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 accessory) you can also process sprayed substances with an electrical
resistance > 50 kΩ (according to the WAGNER scale) successfully.
The transfer eciency is always dependant on the composition of the product
being used, e.g. pigmentation or resin.
Conversion of Lacquer Resistance
There are lacquer resistance measuring devices available on the market that do not
directly measure the specic lacquer resistance.
Multiplying the result of measurement with the device-specic cell constant (K), we
obtain the specic resistance value of the product.
Example:
With Wagner lacquer resistance measuring device the cell constant is K =123.
Measured value according to the WAGNER scale
Specic resistance (RS)
Notice
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 sprayed product with regard to the charging ability can be read
from the indicators showing the actual values for the high-voltage (kV) and for the spray
current (μA) the actual values are shown 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
In the event of application problems, please contact your local WAGNER oce and the
lacquer manufacturer.

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GM 5000EA
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344499
2.6 REASONABLY FORESEEABLE MISUSE
Processing inadmissible coating products
Use of defective spare parts
Use for foodstus
Use in the pharmaceutical sector
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be excluded even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk Source Consequences Specic measures Lifecycle phase
Skin contact with
solvent-based
paints and cleaning
agents
Handling of
solvent-based
paints and cleaning
agents
Skin irritations, Wear protective
clothing,
Operation,
allergies observe safety data
sheets
maintenance,
disassembly
Solvent-based
lacquer in air
outside the dened
working area
Lacquering outside
the dened
working area
Inhalation of
substances
hazardous to health
Observe work
and operation
instructions
Operation,
maintenance