WAGNER GM 5000EA User manual

B_03229
Cus
Electrostatic Air Spray Gun
for manual operation
for at or round jet nozzles
Version 04/2016
Translation of the Original
Operating Manual

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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
Contents
1 ABOUT THESE INSTRUCTIONS 7
1.1 Preface 7
1.2 Warnings, Notices and Symbols in these Instructions 7
1.3 Languages 8
1.4 Abbreviations 8
1.5 Terminology for the Purpose of this Manual 9
2 CORRECT USE 10
2.1 Device Type 10
2.2 Type of Use 10
2.3 Use in an Explosion Hazard Area 10
2.4 Safety Parameters 10
2.5 Processible Working Materials 11
2.6 Reasonably Foreseeable Misuse 12
2.7 Residual Risks 12
3 IDENTIFICATION 13
3.1 Explosion Protection Identication FM 13
3.2 Type Plate 14
4 GENERAL SAFETY INSTRUCTIONS 15
4.1 Safety Instructions for the Operator 15
4.1.1 Electrical Equipment 15
4.1.2 Personnel Qualications 15
4.1.3 Safe Work Environment 15
4.2 Safety Instructions for Sta 16
4.2.1 Safe Handling of WAGNER Spray Devices 16
4.2.2 Grounding the Device 17
4.2.3 Product Hoses 17
4.2.4 Cleaning and Flushing 18
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 19
4.2.6 Touching Hot Surfaces 19
4.3 Protective and Monitoring Equipment 19
4.4 Use in Areas Subject to Explosion Hazards 20
4.4.1 Safety Regulations 20
4.5 Safety-Relevant Information about Discharges 20
5 DESCRIPTION 21
5.1 Structure (Standard Variant) 21
5.2 Mode of Operation 22
5.3 Scope of Delivery 24
5.3.1 Design Variants 25
5.4 Technical Data 26
5.5 Spraying Procedure 28
5.5.1 Spraying Procedure for Round Jet Air Atomizing 28
5.5.2 Spraying Procedure for Flat Jet Air Atomizing 29
5.5.3 Electrostatic Eect 30
5.6 The WAGNER Electrostatic Air Spraying System 31
5.6.1 Pressure Settings for Round Jet Nozzles 31
5.6.2 Pressure Settings for Flat Jet Nozzles 32

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Table of Contents
5.6.3 Adjusting Screw 32
5.6.4 Electrostatic and Atomization 33
5.6.5 Discharge Quantity Measurements 33
6 ASSEMBLY AND COMMISSIONING 34
6.1 Training Assembly/Commissioning Sta 34
6.2 Storage Conditions 34
6.3 Installation Conditions 34
6.4 Transportation 34
6.5 Assembly and Installation 35
6.5.1 Typical Electrostatic Air Spraying System 35
6.5.2 Ventilation of the Spray Booth 36
6.5.3 Air Supply 37
6.5.4 Product Supply 37
6.5.5 Grounding 38
6.6 Preparation of Lacquer 40
6.6.1 Viscosity Conversion Table 40
6.7 Commissioning 41
6.7.1 Safety Instructions 41
6.7.2 Preparation for Commissioning 41
6.7.3 Commissioning 41
6.7.3.1 Gun Cables and Gun Cable Extensions 42
6.7.4 Verifying a Safe Operational Condition 43
7 OPERATION 44
7.1 Training the Operating Sta 44
7.2 Safety Instructions 44
7.2.1 Emergency Deactivation 45
7.2.2 General Rules for Making Adjustments to the Spray Gun 45
7.3 Working 46
7.3.1 Filling with Working Material 46
7.3.2 Checking the Spray Pattern (Without Electrostatics) 47
7.3.3 Spraying 48
7.3.4 Pressure Relief/Work Interruption 50
7.3.5 Changing from Air Round Jet to Air Flat Jet 51
7.3.6 Cleaning of the Nozzle Parts 52
7.3.7 Changing the Valve Housing 52
8 CLEANING AND MAINTENANCE 53
8.1 Cleaning 53
8.1.1 Cleaning Sta 53
8.1.2 Safety Instructions 53
8.1.3 Cleaning and Flushing the Device 55
8.2 Maintenance 57
8.2.1 Maintenance Sta 57
8.2.2 Safety Instructions 57
8.2.3 Safety Checks 58
8.2.4 Product Hoses, Tubes and Couplings 59
9 TROUBLE SHOOTING AND RECTIFICATION 60

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OPERATING MANUAL
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Table of Contents
10 REPAIR WORK 61
10.1 Repair Sta 61
10.2 Safety Instructions 61
10.3 Dismantling of the Gun 62
10.3.1 Tools 62
10.3.2 Dismantling of the Spray Gun 63
10.3.3 Cleaning the Parts After Disassembly 66
10.3.4 Assembling the Spray Gun 67
11 FUNCTION TEST AFTER THE REPAIR 72
11.1 Checking the High voltage 72
11.2 Air Test 74
11.3 Product Pressure Test 74
11.4 Test of Spray Pattern 74
12 DISPOSAL 75
13 ACCESSORIES 76
13.1 Valve Housing 76
13.2 Valve Tips 76
13.3 Round Spray Nozzles 76
13.3.1 AR 5000 Air Caps 76
13.3.2 AR 5000 Nozzles 76
13.3.3 Nozzle set EARV 77
13.4 Flat Jet Nozzles 77
13.4.1 AF 5000 Air Caps 77
13.4.2 AF 5000 Nozzles 78
13.5 Hoses and Electric Cables 79
13.5.1 Standard Hose Sets and Components 79
13.5.2 Hose Sets for Low-resistance Products 81
13.5.3 Spiral Hose (no FM Approval) 84
13.5.4 Gun Cables and Gun Cable Extensions 84
13.5.5 Air Regulation 84
13.5.6 4 Finger Trigger 85
13.6 Miscellaneous 86
14 SPARE PARTS 87
14.1 How Can Spare Parts Be Ordered? 87
14.2 GM 5000EA Spray Gun 88
14.2.1 Basic version GM 5000EA 88
14.2.2 Spiral Hose for GM 5000EA 90
14.2.3 4 Finger Trigger for GM 5000EA 92
14.2.4 GM 5000EA Adapter 94
14.2.5 GM 5000EA Handle 96
14.3 Accessories Spare Parts Lists 98
14.3.1 AR 5000 Nozzle (D8) 99
14.3.2 AR 5000 Nozzle (D12) 99
14.3.3 Nozzle Set EARV 5000 100
15 WARRANTY 101
15.1 Important Notes Regarding Product Liability 101

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GM 5000EA
OPERATING MANUAL
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15.2 Warranty Claim 101
15.3 FM Approval 102

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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
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 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 measures for preventing 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 measures for preventing 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 measures for preventing the hazard and its consequences.
NOTICE
1 ABOUT THESE INSTRUCTIONS
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 the operating and
service personnel.
The device may only be operated by trained personnel 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.
Electrostatic spray guns may only be operated by trained personnel.
1.1 PREFACE

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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
1.3 LANGUAGES
1.4 ABBREVIATIONS
Order No. Order number
Spare part
Marking in the spare parts lists
Electrostatics Air
Manual gun
Low R Low-resistance
Polyether ether ketone (high temperature-resistant thermoplastic plastic)
Stainless steel
Position
Number of pieces
Wrench size
The GM 5000EA operating manual is available in the following languages:
Language Order No. Language Order No.
German 2356789 English 2344499
Additional languages on request or at:

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GM 5000EA
OPERATING MANUAL
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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
Product pressure
generator
Pump or pressure tank
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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GM 5000EA
OPERATING MANUAL
EDITION 04/2016 ORDER NUMBER DOC2344499
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 5000EA electrostatic manual spray gun is suitable for spraying liquid products,
particularly coating products, using the air atomizing method. Coating products which
contain ingredients of explosion class IIA and IIB substances (maximum ignition energy
0.24 mJ) may be used.
WAGNER forbids any other use!
2.4 SAFETY PARAMETERS
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 explosion protection marking in Chapter 3).
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 personnel 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.