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

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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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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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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
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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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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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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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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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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

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OPERATING MANUAL
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION FM
3.2 INFORMATION FOR SAFE AND CORRECT OPERATION
Safety instructions
Maximum surface temperature
Maximum surface temperature: 85 °C; 185 °F
Maximum permissible product temperature: 50 °C; 122 °F
Permissible ambient temperature: 0 to +40 °C; +32 to +104 °F
Safe handling of WAGNER spray devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the unit against steel or rusty iron.
Do not drop the spray gun.
Only use tools that are made of a permitted material.
For Electrostatic Finishing Applications
using Class I, Group D, Spray Material
In accordance with 2316160
This device has been manufactured according to the FM (Factory Mutual) standard "Class
number 7260" (Approval Standard for Electrostatic Finishing Equipment) and tested by
FM. All tested combinations of devices including accessories are given in the FM Control
Document with part number 2316160.
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.

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3.3 PERMISSIBLE DEVICE COMBINATIONS
The GM 5000EA manual spray gun may only be connected to the control units listed below:
VM 500 controller
VM 5000 controller
Incorrect use!
Risk of injury and equipment damage.
Connect the GM 5000EA manual spray gun only to original
Wagner control units.
WARNING
Surface spraying, electrostatics
Never spray device parts using electrostatic equipment (electrostatic spray gun!).
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g. air.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Only use a damp cloth to clean the device.

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GM 5000EA
OPERATING MANUAL
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL EQUIPMENT
4.1.2 STAFF QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
4.2 SAFETY INSTRUCTIONS FOR STAFF
Keep this operating manual at hand near the unit at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
Electrical devices and equipment
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Ensure that the device is operated and repaired only by trained persons.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 Mohm).
Ensure that all persons within the working area wear static dissipative shoes. Footwear
must comply with EN 20344. The measured insulation resistance must not exceed
100 Mohm.
Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun handle.
If protective clothing is worn, including gloves, it has to comply with EN 1149-5. The
measured insulation resistance may not exceed 100 Mohm.
Paint mist extraction systems must be tted on site according to local regulations.
Ensure that the following components of a safe working environment are available:
– Product/air hoses adapted to the working pressure.
– Personal safety equipment (breathing and skin protection).
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.

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4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
4.2.2 GROUNDING THE DEVICE
In order to avoid electrostatic charging of the device, the device must be grounded.
Friction, owing liquids, and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Ensure that the device is grounded at all times.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g. that they are wearing
static dissipative shoes.
Wear dissipative gloves when spraying. The grounding takes place via the spray gun
handle.
Grounding of the coating product supply (coating product tank, pump, etc.) is mandatory.
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 device, in the event of work interruptions and functional faults:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
– In the event of functional faults: remedy the fault as described in the "Troubleshooting"
chapter.
The liquid ejection devices are to be checked for safe working conditions by an expert
(e.g. Wagner Service Technician) as often as necessary or at least every 12 months, in
accordance with the guidelines for liquid ejection devices (ZH1/406 and BGR500 Part2
Chapter2.36).
– For shut down devices, the examination can be suspended until the next commissioning.
Carry out the work steps as described in the "Pressure Relief/Work Interruptions"
chapter:
– if pressure relief is required.
– if the spraying work is interrupted or stopped.
– before the device is cleaned on the outside, checked, or serviced.
– before the spray nozzle is installed or cleaned.
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 firm footing when operating the spray gun.
Only hold the spray gun briey in a position.

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4.2.4 CLEANING
De-energize the device electrically.
Disconnect the pneumatic supply line.
Relieve the pressure from the device.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical ventilation.
To clean, use cloths and brushes moistened with solvent. Abrasive agents or objects
must not be used. Ensure that the spray gun is not damaged in any way while cleaning.
Parts of the spray gun must not be sprayed with or immersed into cleaning agent.
Preferably, non-combustible cleaning agents should be used.
The choice of the appropriate cleaning agent for cleaning purposes of the spray gun
depends on which parts of the spray gun have to be cleaned and which product has
to be detached. When cleaning the spray gun only use non-polar cleaning agents to
prevent conductive residues on the surface of the spray gun. Should it, however, be
necessary to use a polar cleaning agent, all residues of this cleaning agent have to be
removed by using a non-conductive and non-polar cleaning agent, once the cleaning
is nished.
Ensure that no electrical component is cleaned with nor even immersed into solvent.
Ensure that the hose material is chemically resistant to the sprayed products.
Ensure that the product hose is suitable for the pressure generated in the device.
Ensure that the following information can be seen on the high-pressure hose:
- Manufacturer
- Permissible operating overpressure
- Date of manufacture.
Make sure that the hoses are laid only in suitable places. In no case, should hoses be laid
in the following places:
– in high-traffic areas,
– on sharp edges,
– on moving parts, or
– on hot surfaces
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the complete high-pressure hose must be less than 1 Mohm.
4.2.3 MATERIAL HOSES

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GM 5000EA
OPERATING MANUAL
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4.2.6 TOUCHING HOT SURFACES
4.2.5 HANDLING HAZARDOUS LIQUIDS, LACQUERS AND PAINTS
When preparing or working with lacque and when cleaning the unit, follow the working
instructions of the manufacturer of the lacquers, solvents and cleaning agents being
used.
Take the specied protective measures. In particular wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient health and environmental safety: operate the device in a spray booth or
on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.
An explosive gas/air mixture forms in closed tanks.
When cleaning devices with solvents, never spray into a closed tank.
Only use electrically conductive tanks for cleaning liquids.
The tanks must be grounded.
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C; 109°F:
- Identify the device with a warning label "Warning - hot surface".
Order No.
9998910 Instruction label
9998911 Protection sticker
Note: Order the two stickers together.

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GM 5000EA
OPERATING MANUAL
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4.6 NOTES TO GERMAN REGULATIONS AND GUIDELINES
Electrical devices and equipment
Part 2, Chapter 2.36 Working with Liquid Ejection Devices
Part 2, Chapter 2.29 Working with Coating Products
Explosion protection rules
Avoiding ignition risks
Equipment for cleaning work pieces with solvents
Guidelines for liquid ejection devices
Painting rooms and equipment
Electrostatic coating
Plant Safety Ordinance
Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they
can be found on the Internet.
4.3 CORRECT USE
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.
4.4 SAFETY INFORMATION ON DISCHARGES
The plastic parts of the spray gun are charged electrostatically by the high-voltage eld of
the spray gun. In case of contact with plastic parts harmless discharges (brush discharges)
may occur. They are completely non-hazardous for human health.
When keeping a distance of 4 to 10 mm; 0.15 to 0.4 inch between spray gun and object
to be sprayed, the corona discharge at the end of the electrode is visible during darkness.
4.5 USE IN AN EXPLOSION HAZARD AREA
In explosion hazard areas only use approved explosion-proof electrical devices.

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19
GM 5000EA
6
14
20
6
5
7
16
15
2
4
3
1
9
10
11
8
19 18
17
B _03232
22
12
21
B_03558
S
OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344499
5 DESCRIPTION
5.1 FUNCTIONAL DESCRIPTION
Designation
1 Suspension hook
2 Display (spray current and recipe)
3 Display standby and fault
4 Operating button
(standby and recipe change)
5 Air cap (Accessories: see Chapter 12)
6 Union nut
7 AF 5000 x.x at spray nozzle
(Accessories: see Chapter 12)
8 Adapter
9Cover
10 Handle
Designation
11 Adjusting screw (stop)
12 Trigger lever
14 AR 5000 nozzle (Accessories: see Chapter 12)
15 Sealing plug
16 Air adjustment
17 Electric cable connection
18 Atomizing air connection
19 Product connection
20 AR 5000 air cap (Accessories Chapter 12)
21 Type plate left
22 Type plate right
Note:
The nozzle parts (pos 5; 7; 14 and 20) do not belong to the basic equipment of the spray
gun. The dierent versions can be found in Chapter 12 "Accessories".
Note:
The gun type (T) can be found on the type plate (21) and the serial number
(S) on the underside of the handle.
5.1.1 DESIGN OF THE SPRAY GUN BASIC VERSION

20
GM 5000EA
R1
R3
R2
B_03182
2
4
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OPERATING MANUAL
EDITION 07/2014 ORDER NUMBER DOC 2344499
5.1.2 FUNCTIONING OF THE SPRAY GUN
Display (2) -> = recipe values changed temporarily:
The stored recipe values of the previously selected recipe number
are re-loaded from memory by pressing the operating button (4)
for 2 seconds.
When the spray gun is connected to the control unit and the
control unit is switched on, the pre-dened recipe (R1, R2 or
R3) is shown on the gun display (2) as follows.
Recipe 1 ->
Recipe 2 ->
Recipe 3 ->
Recipe change R1 -> R2 -> R3 -> R1.
Press the operating button (4) and hold the button pressed
of at least 2 seconds, then it is advanced by 1 recipe.
During spraying (trigger lever pressed), the status is shown in the display (2) by LEDs.
LED display Description
LEDs 1 - 3 light up green The spray gun is working in an optimal
high-voltage spray current range
one or both right-hand LEDs light up
orange
spray current too high
Possible causes:
(Warning display: You can continue
working without any limitations.)
Spray gun too close to the work piece
Contamination of the spray gun
Lacquer conductivity too high