WAGNER GM 5000EA User manual

GM 5000EA
II 2 G EEx 0.24 mJ
0102
cus
B_03229
Electrostatic Airspray gun
for manual operation
with flat or round jet nozzles
Edition 03/2012
Translation of the original
Operating manual
(in submission)

3
GM 5000EA
OPERATING MANUAL
EDITION 03/2012 ORDER NUMBER DOC 2319149
Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Languages 6
1.2 Warnings, notes and symbols in these instructions 6
2 GENERAL SAFETY INSTRUCTIONS 7
2.1 Safety instructions for the operator 7
2.1.1 Electrical equipment 7
2.1.2 Personnel qualifications 7
2.1.3 A safe work environment 7
2.2 Safety instructions for staff 7
2.2.1 Safe handling of WAGNER spray units 8
2.2.2 Earth the unit 8
2.2.3 Material hoses 8
2.2.4 Cleaning 9
2.2.5 Handling hazardous liquids, varnishes and paints 9
2.2.6 Touching hot surfaces 10
2.3 Correct use 10
2.4 Safety-relevant information about discharges 11
2.5 Use in an explosion hazard area 11
2.5.1 Correct use 11
2.5.2 Explosion protection identification CE 11
2.5.2.1 Identification„X“ 11
2.5.3 Explosion protection identification FM 12
2.6 German regulations and guidelines 12
3 GUARANTEE AND CONFORMITY DECLARATIONS 13
3.1 Important notes on product liability 13
3.2 Guarantee claim 13
3.3 CE-Conformity 14
4 DESCRIPTION 15
4.1 Fields of application,using in accordance with the instructions 15
4.1.1 Processable materials 15
4.2 Scope of delivery 16
4.3 Technical data 17
4.4 Functional description 18
4.4.1 Design of spray gun (standard variant) 18
4.4.2 Functions of the spray gun 19
4.5 Spraying process 20
4.5.1 Air atomizing spray process - round jet 20
4.5.2 Air atomizing spray process - flat jet 20
4.5.3 The electrostatic effect 21
5 START-UP AND OPERATION 22
5.1 Installation and connection 22
5.1.1 Typical electrostatic air spraying system 22
5.1.2 Ventilation of the spray booth 23
5.1.3 Air supplies 24
5.1.4 Paint supplies 24
5.1.5 Earthing 25

4
GM 5000EA
OPERATING MANUAL
EDITION 03/2012 ORDER NUMBER DOC 2319149
Contents
5.2 Preparation of paints 27
5.2.1 Viscosity conversion table 27
5.3 Wagner electrostatic air spraying system 28
5.3.1 Pressure settings for round jet nozzles 28
5.3.2 Pressure settings for flat jet nozzles 29
5.3.3 Electrostatic and atomization 30
5.3.4 Output measured 30
5.4 Start-up 31
5.4.1 General rules for making adjustments to the spray gun 31
5.4.2 Preparation for starting up 31
5.5 Working 33
5.5.1 Filling with working material 33
5.5.2 Start-up for spraying 34
5.5.3 Changing from Air-round jet to Air-flat jet 35
5.5.4 Cleaning of the nozzle parts 35
6 MAINTENANCE 36
6.1 Periodically checks 36
6.2 Cleaning and decommissioning 36
6.3 Dismantling of the spray gun 38
6.4 Cleaning the parts after disassembly 41
6.5 Assembling the spray gun 42
6.6 Function test after assembly of the gun 46
6.6.1 Checking the high-voltage 46
6.6.2 Air tests 47
6.6.3 Material pressure test 47
6.6.4 Check spray pattern 48
7 TROUBLE SHOOTING AND SOLUTION 49
8 PRODUCT DISPOSAL 50
9 ACCESSORIES 50
9.1 Valve seats, Air/ Valve tips, Air 50
9.1.1 Valve seats 50
9.1.2 Valve tips 50
9.2 Round jet nozzles 51
9.2.1 AR 5000 air caps 51
9.2.2 AR 5000 nozzles 51
9.3 Flat jet nozzles 51
9.3.1 AF 5000 air caps 51
9.3.2 AF 5000 nozzles 52
9.4 Hoses and electrical cables 53
9.4.1 Standard hose sets and components 53
9.4.2 Hose sets for low impedance materials 54
9.4.3 Gun cable and gun cable extensions 55
9.5 Reduction fittings for high-pressure hoses 55
9.6 Miscellaneous 56

5
GM 5000EA
OPERATING MANUAL
EDITION 03/2012 ORDER NUMBER DOC 2319149
Contents
10 SPARE PARTS 59
10.1 How to order spare parts? 59
10.2 GM 5000EA spare parts list 60
10.2.1 GM 5000EA spare parts list- End piece 62
10.2.2 GM 5000EA spare parts list - Handle 64
10.3 Accessories spare parts lists 66
10.3.1 AR 5000 (D8) nozzle spare parts list 66
10.3.2 AR 5000 (D12) nozzle spare parts list 66

6
GM 5000EA
OPERATING MANUAL
EDITION 03/2012 ORDER NUMBER DOC 2319149
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
1 ABOUT THESE INSTRUCTIONS
1.1 LANGUAGES
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
4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES
,ANGUAGE 0ART.O ,ANGUAGE 0ART.O
'ERMAN  %NGLISH
&RENCH  $UTCH
)TALIAN  3PANISH
2310480 2319149
2320149 -
2320150 2320151
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 following 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-observance can result in minor injury.
Note - provide information on particular characteristics and how to proceed.
Caution - a possibly hazardous situation.
Non-observance can cause material damage.
SIHI_0100_GB
DANGER
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.
SIHI_0103_GB
WARNING
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.
SIHI_0101_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.
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.

7
GM 5000EA
OPERATING MANUAL
EDITION 03/2012 ORDER NUMBER DOC 2319149
2 GENERAL SAFETY INSTRUCTIONS
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 STAFF
Keep these operating instructions to hand near the unit at all times.
Always follow local regulations concerning occupational safety and accident prevention.
Electrical plant and unit
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient influences.
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 put out of operation if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform staff about
planned work, observe electrical safety regulations.
 %NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS
Make sure that the floor in the area where you are working is anti-static in accordance
with EN 61340-4-1 (the resistance value may not exceed 100 MOhm).
Ensure that all persons within the working area wear antistatic shoes. Footwear must
comply with EN 20344.The measured insulation resistance may not exceed 100 MOhm.
Ensure that during spraying, persons wear anti-static gloves so that they are earthed
via the handle of the spray gun.
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 fitted on site according to the local regulations.
Ensure that the following components of a safe working environment are available:
– Material/air hoses adapted to the working pressure.
– Personal safety equipment (breathing and skin protection).
Ensure that there are no ignition sources such as naked flame, glowing wires or hot
surfaces in the vicinity. Do not smoke.
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.

8
GM 5000EA
OPERATING MANUAL
EDITION 03/2012 ORDER NUMBER DOC 2319149
2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS
2.2.2 EARTH THE UNIT
2.2.3 MATERIAL HOSES
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
chapter „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.
Depending on the high-voltage of the spray electrode and the flow rate at spray pressures
can produce an electrostatic charge in the equipment.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
derivable shoes.
When spraying, wear derivable gloves to earth yourself via the spray gun handle.
 Ensure that the hose material is chemically resistant to the sprayed materials.
 Ensure that the material hose is suitable for the pressure generated in the unit.
 Ensure that the following information is visible on the high pressure hose:
– Manufacturer
– Permissible operating overpressure
– Date of manufacture.
 The electrical resistance of the complete high pressure hose must be less than 1 MOhm.

9
GM 5000EA
OPERATING MANUAL
EDITION 03/2012 ORDER NUMBER DOC 2319149
2.2.4 CLEANING
2.2.5 HANDLING HAZARDOUS LIQUIDS,VARNISHES AND PAINTS
When preparing or working with paint and when cleaning the unit, follow the working
instructions of the manufacturer of the paints, solvents and cleaning agents being
used.
Take the specified 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 sufficient health and environmental safety: Operate the unit in a spray booth or on
a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot materials.
De-energize the unit electrically.
Disconnect the pneumatic supply line.
Relieve the pressure from the unit.
Ensure that the flash point of the cleaning agent is at least 15K above the ambient tem-
perature. Otherwise, the cleaning works shall be carried out at forced ventilated clea-
ning place.
To clean, use only solvent-soaked cloths and brushes. The cleaning process mustn´t
damage parts of the spray gun, it mustn´t be an abrasive procedure.
Parts of spray gun mustn´t submerged or soaked into solvent.
Non-ignitable cleaning liquids shall be preferred.
A suitable solvent for cleaning the spray gun depends on the part of the gun and on the
material that needs to be removed. It´s recommended to use only non-polar solvents
to prevent a conductive residue on critical components. If it´s necessary to use polar
solvents to clean the spray gun components, all residue must be removed by using a
nonconductive non-polar solvent.
All electrical components cannot be cleaned or soaked in any solvents.
An explosive gas/air mixture forms in closed containers.
When cleaning units with solvents, never spray into a closed container.
For cleaning liquids only electrically leading containers may be used.
The containers must be earthed.

10
GM 5000EA
OPERATING MANUAL
EDITION 03/2012 ORDER NUMBER DOC 2319149
2.3 CORRECT USE
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
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2.2.6 TOUCHING HOT SURFACES
➞ Touch hot surfaces only if you are wearing protective gloves.
➞ When operating the unit with a coating material with a temperature of > 43 °C; 109.4 °F:
- Identify the unit with a warning label that says„Warning - hot surface“.
Order No.
9998910 Information label
9998911 Safety label