WAGNER GM 5000EAC F User manual

GM 5000EAC
II 2 G EEx 0.24 mJ
0102
B_03154
cus
Electrostatic AirCoat
Spray gun
for manual operation with
flat or round jet nozzles
Edition 03/2012
Translation of the original
Operating manual
(in submission)

3
GM 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
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 AirCoat round jet spray process 20
4.5.2. AirCoat atomizing flat jet spray process 20
4.5.3 Electrical resistance 21
5 START-UP AND OPERATION 22
5.1 Installation and connection 22
5.1.1 Typical electrostatic spraying system 22
5.1.2 Ventilation of the spray booth 23
5.1.3 Air supplies 23
5.1.4 Paint supplies 24
5.1.5 Earthing 25

4
GM 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
Contents
5.2 Preparation of paints 27
5.2.1 Viscosity conversion table 27
5.3 Start-up 28
5.3.1 General rules for making adjustments to the spray gun 28
5.3.2 Preparation for starting up 28
5.4 Working 30
5.4.1 Filling with working material 30
5.4.2 Start-up for spraying AirCoat 31
5.4.3 Cleaning of clogged round jet nozzles 32
5.4.4 Exchange of round jet nozzle insert 32
5.4.5 Changing from AirCoat round jet to AirCoat flat jet 33
5.4.6 Replacing AirCoat flat jet nozzles 34
5.4.7 Cleaning of the nozzles 34
5.4.8 Eliminate nozzle clogging 34
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 51
9.1 ACR 5000 round jet nozzle cap 51
9.1.1 AirCoat round jet nozzle inserts 51
9.2 ACF 5000 air caps (flat jet) 51
9.2.2 ACF 5000 AirCoat flat jet nozzles 52
9.3 Filters 54
9.4 Reduction fittings for high-pressure hoses 54
9.5 Hoses and electrical cables 55
9.5.1 Standard hose sets and components 55
9.5.2 Hose sets for low impedance materials 56
9.5.3 Gun cable and gun cable extensions 57
9.6 Miscellaneous 57

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GM 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
Contents
10 SPARE PARTS 59
10.1 How to order spare parts? 59
10.2 GM 5000EAC spare parts list 60
10.2.1 GM 5000EAC spare parts list- End piece 62
10.2.2 GM 5000EAC spare parts list - Handle 64
10.3 Accessories spare parts lists 66
10.3.1 Flat jet nozzles spare parts list 66
10.3.2 ACR 5000 round jet nozzle cap spare parts list 67

6
GM 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
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
2310481 2319150
2320152 -
2320153 2320154
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 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
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 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
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.

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GM 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
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 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
2.3 CORRECT USE
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
 5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2
 /PERATETHEUNITONLYASANENTIREUNIT
 $ONOTDEACTIVATESAFETYEQUIPMENT
 5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES
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

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GM 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
2.4 SAFETY-RELEVANT INFORMATION ABOUT DISCHARGES
2.5 USE IN AN EXPLOSION HAZARD AREA
2.5.1 CORRECT USE
2.5.2 EXPLOSION PROTECTION IDENTIFICATION CE
2.5.2.1 IDENTIFICATION„X“
Safety instructions
The plastic parts of the spray gun are charged electrostatically by the high-voltage field
of the spray pistol. Harmless discharges (brush discharges) are possible after contact with
plastic parts. They are completely harmless for people.
The corona discharge at the electrode end is visible during darkness at a distance of be
between 4 and 10 mm; 0.15 and 0.4 inches, between the spray gun and spray object.
3AFEHANDLINGOF7!'.%2SPRAYUNITS
-ECHANICALSPARKSCANFORMIFTHEUNITCOMESINTOCONTACTWITHMETAL
)NANEXPLOSIVEATMOSPHERE
 $ONOTKNOCKORPUSHTHEUNITAGAINSTSTEELORRUSTYIRON
 $ONOTDROPTHEGUN
 5SEONLYTOOLSTHATAREMADEOFAPERMITTEDMATERIAL
The electrostatic hand spray gun GM 5000EAC is suitable for spraying liquid materials,
particularly coating materials, using the AirCoat method. Coating materials containing
solvents of Explosion Class II A may be used. The spray gun may only be used in
combination with the control unit VM 500 and VM 5000.
As defined in the Directive 94/9/EC (ATEX), the unit is suitable for use in areas where there
is an explosion hazard.
0102 II 2 G EEx 0.24mJ
SIRA 11 ATEX 5374X
Maximum surface temperature
CE Communautés
Européennes
0102 Notified body: PTB
Ex Symbol for explosion
protection
II Unit class II
2 Category 2 (zone 1)
G Ex-atmosphere gas
E European Standard
Ex Explosion protected
0.24mJ Max. firing power
SIRA 11
ATEX 5374X
Number of the type
examination certificate
sMaximum surface temperature: 85 °C; 185 °F
sMaxi. Permissible material temperature: 50 °C; 122 °F
sPermissible ambient temperature: +0 to +40 °C; +32 to +104 °F

12
GM 5000EAC.
CUS
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
)GNITIONTEMPERATUREOFTHECOATINGMATERIAL
 %NSURETHATTHEIGNITIONTEMPERATUREOFTHECOATINGMATERIALISABOVETHEMAXIMUM
SURFACETEMPERATURE
3URFACESPRAYINGELECTROSTATIC
 $ONOTSPRAYUNITPARTSWITHELECTROSTATICEGELECTROSTATICSPRAYGUN
-EDIUMSUPPORTINGATOMIZING
 4OATOMIZETHEMATERIALUSEONLYWEAKLYOXIDIZINGGASESEGAIR
Cleaning
If there are deposits on the surfaces, the unit may form electrostatic charges. Flames or
sparks can form if there is a discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the unit.
2.6 GERMAN REGULATIONS AND GUIDELINES
a) BGV A3 Electrical units and equipment
b) BGR 500 Part 2, Chap. 2.36 Working with liquid ejection devices
c) BGR 500 Part 2, Chap. 2.29 Using coating materials
d) BGR 104 Explosion protection rules
e) TRBS 2153 Avoiding ignition risks
f) BGR 180 Setting up for cleaning with solvents for cleaning workpieces wit
h
solvents
g) ZH 1/406 Guidelines for liquid ejection devices
h) BGI 740 Painting rooms and equipment
j) BGI 764 Electrostatic coating
j) Betr.Sich.V. Plant Safety Ordinance
Note: All titles can be ordered from Heymanns Publishing House in Cologne,or they ar
e
to be found in the Internet.
2.5.3 EXPLOSION PROTECTION IDENTIFICATION FM
For Electrostatic Finishing Applications
using Class I, Group D, Spray Material
In accordance with 2316160
This device has been manufactured and tested according to the FM (Factory Mutual)
standard „Class Number 7260“ (Approval Standard for Electrostatic Finishing Equipment)
by FM.All tested combinations of devices including accessories are given in the FM Control
Document with part number 2316160.
(the device is in submission)

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GM 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
3 GUARANTEE AND CONFORMITY DECLARATIONS
3.1 IMPORTANT NOTES ON PRODUCT LIABILITY
3.2 GUARANTEE CLAIM
As a result of an EC regulation, effective as from January 1, 1990, the manufacturer shall
only be liable for his product if all parts come from him or are approved by him, and if the
devices are properly fitted , operated and maintained.
If other makes of accessory and spare parts are used, the manufacturer‘s liability could be
fully or partially null and void.
The usage of original WAGNER accessories and spare parts guarantees that all safety
regulations are observed.
Full guarantee is provided for this device:
We will at our discretion repair or replace free of charge all parts which within 24 months
in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by
the Purchaser are found to be wholly or substantially unusable due to causes prior to the
sale, in particular faulty design, defective materials or poor workmanship.
The type of guarantee provided is such that the device or individual components of the
device are either replaced or repaired as we think fit. The resulting costs, in particular
shipping charges, road tolls, labour and material costs will be borne by us except where
these costs are increased due to the subsequent shipment of the unit to a location other
than the address of the purchaser.
We do not provide guarantee for damage that has been caused or contributed to for the
following reasons:
Unsuitable or improper use, faulty installation or commissioning by the purchaser or a
third party, normal wear, negligent handling, defective maintenance, unsuitable coating
products, substitute materials and the action of chemical, electro chemical or electrical
agents, except when the damage is attributable to us.
Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust
paints and similar reduce the service life of valves, packings, spray guns, tips, cylinders,
pistons etc. Signs of wear and tear due to such causes are not covered by this guarantee.
Components that have not been manufactured by WAGNER are subject to the original
guarantee of the manufacturer.
Replacement of a component does not extend the period of guarantee of the device.
The unit should be inspected immediately upon receipt. To avoid losing the guarantee, we
or the supplier company are to be informed in writing about obvious faults within 14 days
upon receipt of the device.
We reserve the right to have the guarantee compliance met by a contracting company.
The services provided by this guarantee depend on evidence being provided in the form
of an invoice or delivery note. If an examination discovers that no guarantee claim exists,
the costs of repairs are charged to the purchaser.
It is clearly stipulated that this guarantee claim does not represent any constraint to statutory
regulations or regulations agreed contractually in our general terms and conditions.
J. Wagner AG

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GM 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
3.3 CE-CONFORMITY
CE Certificate of Conformity
The certificate is enclosed with this product. The certificate of conformity can be reordered
from your WAGNER representative, quoting the product and serial number.
Part number:
EC declaration of conformity as defined by Atex-directive 94/9/EC
Herewith we declare that the supplied version of
Electrostatic hand spraying system
VM 500 VM 5000 GM 5000EA GM5000EAC
Complies with the following guidelines:
94/9/EG 2004/108/EG 2002/96/EG
2006/42/EG 2002/95/EG
Applied standards, in particular:
DIN EN 50050:2007 DIN EN 61000-6-2:2006 DIN EN ISO 12100:2011
DIN EN 1953:2010 DIN EN 61000-6-4:2011 DIN EN 60079-0: 2010
DIN EN 60079-15: 2011 DIN EN 60204-1: 2007
Applied national technical standards and specifications, in particular:
BGI 764
EC type examination certificate:
SIRA 11 ATEX 5374X issued by SIRA Certification,
CH4 9JN, Chester, England, notified body no. 0518
Identification:
Spray gun: 0102 II 2 G EEx 0.24mJ
SIRA 11 ATEX 5374X
2310487
Control unit: 0102 II (2) G
SIRA 11 ATEX 5374X
II 3 G Ex nR IIC T4 Gc

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GM 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
4.1 FIELDS OF APPLICATION, USING IN ACCORDANCE WITH THE INSTRUCTIONS
The electrostatic spray gun can only be used with the VM 5000 or VM 500 control units.
4 DESCRIPTION
4.1.1 PROCESSABLE MATERIALS
➞With the GM 5000EAC gun, paints can be applied which contain solvent of explosion
class II A.
➞The spray gun basic version is suitable for processing of sprayed substances with an
electrical resistance of > 150 k(according to the WAGNER scale). Equipped with a
special material hose for low impedance sprayed substances (available as accessory)
you can also sprayed substances with an electrical conductivity > 50 k(according to
the WAGNER scale) process successfully.
➞ The application effectiveness is always dependant on the composition of the paint
being used, e.g. pigments or resin.
Conversion of the resistance of paint
There are paint resistance measuring devices on the market that do not measure directly
the specific resistance of paint. Multiplying the result of measurement with the
device-specific cell constant (K), we obtain the resistivity value of the material.
Example:
The Wagner paint resistance measuring device is the cell constant K =123.
Measured value according to the WAGNER scale R = 500 k
Specific resistance (RS) RS= R x K = 500 kx 123 = 61.5 M.cm
Note
With sprayed substances and those with too low electrical resistance the electrostatic
effect will not have any effect, i.e., there will be no „wrap around“ noticeable at the spray
object. The relationship between the values of the high-voltage (kV) and the current (µA),
shown on the VM 5000 control unit and/or on the spray gun,denotes the charging capacity
of a spray material.
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, contact your WAGNER branch and the paint
manufacturer.

16
GM 5000EAC.
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
4.2 SCOPE OF DELIVERY
Quantity Part No. Description
12309871 GM 5000EAC spray gun
Without control unit, material and air hose, electrical cable,
air cap and nozzle.
Each gun includes as standard equipment:
Part No. Description
1 2309368 Assembly tool valve needle
1 2325263 Assembly tool clamping screw
1 2319653 Glove against ink mist precipitation
1 2310487 CE-Conformity
- 2310481 Operating manual German
1 see 1.1 Operating manual in the local language
The spray gun basic version can be set according to requirement and the desired
accessories with the help of the spray gun configuration.
The delivery note shows the exact scope of delivery.

17
GM 5000EAC.
C
A
B_03155
B
C
A
B_03193
B
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
4.3 TECHNICAL DATA
Max. air pressure 0.8 MPa; 8 bar; 116 psi
Max. material pressure 25 MPa; 250 bar; 3626 psi
Material connection NPSM 1/4“-18
Air connection G 1/4“ A
Input voltage max. 20 Vpp
Input current max. 1.0 A AC
Output voltage max. 80 kV DC
Output current max. 100 µA DC
Polarity negative
Weight (without hose set) 710 g
(incl. union nut, nozzle, air cap and edge filter)
Working temperature range 0 °C to 40 °C; 32 °F to 104 °F
Max. material temperature 50 °C; 122 °F
Sound level at 0.3 MPa; 3 bar; 43.5 psi air pressure and
0.3 MPa; 3 bar; 43.5 psi material pressure
73 dB(A) *
* A rated sound pressure level measured at 1 m distance according to DIN EN 14462: 2005.
GM 5000EAC F
with flat jet nozzle
mm inches
A 280 11.02
B 46 1.81
C 264 10.39
GM 5000EAC R
with round jet nozzle
mm inches
A 264 10.39
B 46 1.81
C 264 10.39
Measurements

18
GM 5000EAC.
B_03558
S
B_03156
7
13
14
6
511
16
15
2
4
20
3
1
9
10
8
19
18
17
12
21
22
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
Note:
The gun type (T) on the type plate (21) and the serial number (S) on
the underside of the handle.
4.4 FUNCTIONAL DESCRIPTION
4.4.1 DESIGN OF SPRAY GUN (STANDARD VARIANT)
Note:
The nozzle parts (item 6; 7; 13 and 14) do not belong to the basic equipment of the spray
gun.The different versions can be found in Chapter 9„Accessories“.
Item Description
1 Hook
2 Display (spray current and recipe)
3 Display standby
4 Operating button
(standby and recipe change)
5 Protection against contact
with union nut
6 Air cap for flat jet nozzle
(see Accessories chapter 9)
7 ACF 5000 flat jet nozzle
(see Accessories chapter 9)
8 End piece
9Cover
10 Handle
Item Description
11 Trigger lock
12 Trigger
13 Round jet nozzle cap
(see Accessories chapter 9)
14 Round jet nozzle insert
(see Accessories chapter 9)
15 Lock plug
16 Air adjustment
17 Electrical cable connection
18 Atomizing air connection
19 Material connection
20 Filter housing with filter
21 Type plate left
22 Type plate right

19
GM 5000EAC.
1
23
4
R1
R3
R2
B_03182
2
4
3
R1
R3
R2
E
B_03262
16
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
4.4.2 FUNCTIONS OF THE SPRAY GUN
Distance Description
1 AirCoat air opens.
2 AirCoat air opened and electrostatic (HV)
activated.
-> Display (2) for„spray current“ on the spray
gun ●❍❍❍❍ to ●●●●● activated.
3 AirCoat air opened and electrostatic (HV)
activated and material valve opened.
4 Max way of trigger.
• An increase in the tension needed to pull the trigger back
will be felt at the position where the material valve opens.
•
For spraying without high-voltage, the high-voltage can
be switched off using the operating button (4). Press the
operating button (4) briefly: High-voltage is switched off.
The standby display (3) illuminates.
•
In the event of a malfunction the spray gun switches to
„standby“ operating mode and the display (3) illuminates.
•
The width of the spray jet can be adjusted using the air
adjustment (16) (only for flat-jet method).
The trigger can be used to activate, one after the other, the
various functions of the spray gun.
When the spray gun is connected to the control unit
and the control unit is switched on, the pre-defined
recipe (R1, R2 or R3) is shown on the gun display (2) as
follows.
Recipe 1 -> ●❍❍❍❍ R1
Recipe 2 -> ●●●❍❍ R2
Recipe 3 -> ●●●●● R3
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.
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.

20
GM 5000EAC.
"?
B_00020
OPERATING MANUAL
EDITION 03/2012 PART NUMBER DOC 2319150
4.5 SPRAYING PROCESS
4.5.1 AIRCOAT ROUND JET SPRAY PROCESS
In the AirCoat process, high pressure of 3-15 MPa; 30-150 bar; 435-2176 psi is used to atomize the material.
The air at 0-0.25 MPa; 0-2.5 bar; 0-36 psi produces a soft jet.The size of the spray jet can be adjusted by turning
the nozzle nut.
AirCoat air
Multi-channel
swirl nozzle
Spray jet
Nozzle nut
Spray material
AirCoat air
Advantages
• High painting capacity
• Low fogging tendency
• Good finish
• High viscosity paints can easily be applied
• High endurance of the nozzles
• Change in width the jet
4.5.2. AIRCOAT ATOMIZING FLAT JET SPRAY PROCESS
In the AirCoat process, high pressure of 3-15 MPa; 30-150 bar; 435-2176 psi is used to atomize the material.
The AirCoat air at 0-0.25 MPa; 0-2.5 bar; 0-36 psi produces a soft jet, which largely eliminates the problem of
overlapping boundaries.There´s a possibility to reduce the jet by form air.
Shaping air
Air cap
Variable spray
jet width Atomizing air
Advantages
•
High painting capacity
•
Low fogging tendency
•
Good finish
•
High viscosity paints can easily be applied
•
High endurance of the AC-nozzles
•
Change in width the jet