WAGNER GM 5000EAC F User manual

B_03154
cus
Electrostatic AirCoat Spray Gun for
Manual Operation and for Flat or
Round Jet Nozzles
Version 07/2014
Translation of the Original
Operating Manual

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OPERATING MANUAL
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Contents
1 ABOUT THIS OPERATING MANUAL 6
1.1 Preface 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 14
4.2.1 Safe Handling of WAGNER Spray Devices 14
4.2.2 Grounding the Device 15
4.2.3 Material Hoses 15
4.2.4 Cleaning 16
4.2.5 Handling Hazardous Liquids, Varnishes, and Paints 17
4.2.6 Touching Hot Surfaces 17
4.3 Correct Use 17
4.4 Safety Information on Discharges 18
4.5 Use in an Explosion Hazard Area 18
4.6 Notes to German Regulations and Guidelines 18
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 AirCoat Round Jet Spray Process 24
5.4.2 AirCoat Flat Jet Spray Process 24
5.4.3 Electrostatic Eect 25

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Table of Contents
6 COMMISSIONING AND OPERATION 26
6.1 Training Assembly/Commissioning Sta 26
6.2 Storage Conditions 26
6.3 Installation Conditions 26
6.4 Installation and Connection 27
6.4.1 Typical Electrostatic Spraying System 27
6.4.2 Ventilation of the Spray Booth 28
6.4.3 Air Supply 29
6.4.4 Material Supply 29
6.4.5 Grounding 30
6.5 Preparation of Lacquer 33
6.5.1 Viscosity Conversion Table 33
6.6 Commissioning 34
6.6.1 General Rules for Manipulation of the Spray Gun 34
6.6.2 Preparation for Starting Up 34
7 OPERATION 37
7.1 Training the Operating Sta 37
7.2 Safety Instructions 37
7.3 Work 38
7.3.1 Filling with Working Product 38
7.3.2 Start-up for Spraying AirCoat 39
7.3.3 Flushing Out Clogged Round Jet Nozzles 40
7.3.4 Replacing Round Jet Nozzle's Nozzle Insert 40
7.3.5 Changing from AirCoat Round Jet to AirCoat Flat Jet 41
7.3.6 Replacing the AirCoat Flat Jet Nozzles 42
7.3.7 Cleaning of the Nozzle Parts 42
7.3.8 Eliminate Nozzle Clogging 42
7.3.9 Changing the Valve Housing 44
8 CLEANING AND MAINTENANCE 45
8.1 Cleaning 45
8.1.1 Cleaning Sta 45
8.1.2 Safety Instructions 45
8.1.3 Cleaning and Decommissioning 46
8.2 Maintenance 48
8.2.1 Maintenance Sta 48
8.2.2 Safety Instructions 48
8.3 Disassembly of the Spray Gun 49
8.3.1 Tools 49
8.3.2 Disassembly of the Spray Gun 50
8.4 Cleaning the Parts after Disassembly 53
8.5 Assembly of the Spray Gun 54
8.6 Function Test after Assembly of the Gun 59
8.6.1 Test of the High-Voltage 59
8.6.2 Air Test 60
8.6.3 Product Pressure Test 60
8.6.4 Test of Spray Pattern 61
8.7 High-Pressure Hoses 62

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Table of Contents
9 INSPECTIONS 63
9.1 Periodical Inspections 63
10 TROUBLESHOOTING AND RECTIFICATION 64
11 PRODUCT DISPOSAL 65
12 ACCESSORIES 66
12.1 Round Jet Nozzles 66
12.1.1 ACR 5000 Round Jet Nozzle Cap 66
12.1.2 AirCoat Round Jet Nozzle Inserts 66
12.2 Flat Jet Nozzles 66
12.2.1 ACF 5000 Air Caps (Flat Jet) 66
12.2.2 ACF5000 AirCoat Flat Jet Nozzles 67
12.3 Filter 69
12.4 Reduction Fittings for High-Pressure Hoses 69
12.5 Hoses and Electric Cables 70
12.5.1 Standard Hose Sets and Components 70
12.5.2 Hose Sets for Low-resistance Products 72
12.5.3 Gun Cables and Gun Cable Extensions 74
12.6 Miscellaneous 74
13 SPARE PARTS 77
13.1 How Can Spare Parts Be Ordered? 77
13.2 GM 5000EAC Spare Parts List 78
13.2.1 GM 5000EAC - Adapter Spare Parts List 80
13.2.2 GM 5000EAC - Handle Spare Parts List 82
13.3 Accessories Spare Parts Lists 84
13.3.1 Flat Jet Nozzles Spare Parts List 84
13.3.2 ACR 5000 Round Jet Nozzle Cap Spare Parts List 85
14 WARRANTY 86
14.1 Important Notes Regarding Product Liability 86
14.2 Warranty Claim 86

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1 ABOUT THIS OPERATING MANUAL
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
1.1 PREFACE
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.

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1.3 LANGUAGES
The operating manual is available in the following languages:
German English 2344500
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 5000EAC electrostatic hand spray gun is suitable for spraying liquid products,
particularly coating products, using the AirCoat method. Coating products containing
solvents of explosion class II A may be used.
2.4 SAFETY PARAMETERS
The GM 5000EAC 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 5000EAC 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 5000EAC gun, paints can be applied which contain solvents of
explosion class II A.
The spray gun basic version is suitable for processing 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 an accessory) you can also successfully process sprayed substances
with an electrical resistance > 50 kΩ (according to the WAGNER scale).
The transfer eciency is always dependant on the composition of the product
being used, e.g. pigmentation or resin.
Conversion of Paint Resistance
There are paint resistance measuring devices available on the market that do not directly
measure the specic paint resistance.
Multiplying the result of the measurement with the device-specic cell constant (K), we
obtain the specic resistance value of the product.
Example:
With Wagner’s paint 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
paint 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
paint in air outside
the dened
working area
Painting outside
the dened
working area
Inhalation of
substances
hazardous to health
Observe work
and operation
instructions
Operation,
maintenance

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3 IDENTIFICATION
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.
3.1 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 by FM, according to the FM (Factory Mutual)
standard "Class Number 7260" (Approval Standard for Electrostatic Finishing Equipment).
All tested combinations of devices including accessories are given in the FM Control
Document with part number 2316160.
3.2 INFORMATION FOR SAFE AND CORRECT OPERATION
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating material is above the maximum
surface temperature.

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3.3 PERMISSIBLE DEVICE COMBINATIONS
The GM 5000EAC manual spray gun may only be connected to the control units listed
below:
VM 500 control unit
VM 5000 control unit
Incorrect use!
Risk of injury and equipment damage.
Connect the GM 5000EAC 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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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
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.
Mustbeoperatedinaccordancewiththesafetyregulationsandelectrotechnicalregulations.
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 must 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.

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4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Alwaysfollowlocal regulations concerning occupational safety and accidentprevention.
4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
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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4.2.2 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.
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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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 depends on which parts of the spray
gun have to be cleaned and which product has to be removed. 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.
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.

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4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES, AND PAINTS
When preparing or working with paint and when cleaning the device, follow the
working instructions of the manufacturer of the paints, solvents, and cleaning agents
being used.
Take the specied protective measures. In particular, wear safety goggles, protective
clothing and gloves, as well as skin protection cream if necessary.
Use a mask or a 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.
4.2.6 TOUCHING HOT SURFACES
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109.4°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.
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.

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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.
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.

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5 DESCRIPTION
5.1 FUNCTIONAL DESCRIPTION
Description
1 Suspension 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 at jet nozzle
(see accessories in Chapter 12.2.1)
7 Flat jet nozzle ACF 5000
(see accessories in Chapter 12.2.2)
8 Adapter
9Cover
10 Handle
11 Trigger lock
Description
12 Trigger lever
13 Round jet nozzle adapter
(see accessories in Chapter 12.1.1)
14 Round jet nozzle insert
(see accessories in Chapter 12.1.2)
15 Sealing plug
16 Air adjustment
17 Electric cable connection
18 Atomizing air connection
19 Product connection
20 Filter housing with lter
21 Type plate left
22 Type plate right
Note:
The nozzle parts (pos 6; 7; 13 and 14) 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) 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

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5.1.2 FUNCTIONING OF THE SPRAY GUN
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 keep 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.
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
Paint conductivity too high