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
EDITION 07/2014 ORDER NUMBER DOC 2344500
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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OPERATING MANUAL
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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