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GM 5000EA

1. 9 3 FLAT JET NOZZLES 9 3 1 AF 5000 AIR CAPS Part No Description 2310506 AF 5000 air cap 0 4 0 8S 2310507 AF 5000 air cap 1 0 1 45 2310508 AF 5000 air cap 1 6 2 0S 2314255 AF 5000 air cap 0 4 0 8W wide 2314256 AF 5000 air cap 1 0 1 4W wide 2314258 AF 5000 air cap 1 6 2 0W wide B 03239 B 03239 03240 51 EDITION 03 2012 OPERATING MANUAL GM 5000EA ORDER NUMBER DOC 2319149 A WAGNER 9 3 2 AF 5000 NOZZLES PartNo Description 2310539 AF 5000 nozzle 0 6 mm black 2310540 AF 5000 nozzle 0 8 mm yellow 2310541 AF 5000 nozzle 1 0 mm red 2310542 AF 5000 nozzle 1 2 mm green 2310543 AF 5000 nozzle 1 4 mm brown 2310544 AF 5000 nozzle 1 6 mm white 2310545 AF 5000 nozzle 1 8 mm blue 2310546 5000 nozzle 2 0 mm black B 03241 03241 B 03241 B 03241 B 03241 2 B_03241 B_03241 B_03241 52 EDITION 03 2012 OPERATING MANUAL 9 4 HOSES AND ELECTRICAL CABLES 9 4 1 STANDARD HOSE SETS AND COMPONENTS 03245 Item Qty Part No Description 1 1 2309853 GM 5000EA hose set 7 5 m Consisting of 2 1 2312012 Low pressure hose DN6 PN15 G14 7 5 m PFA 3 1 2312060 Air hose compl 8 0 m 4 1 2307293 GM 5000E gun ca
2. The measures for preventing the hazard and its consequences SIHI 0103 GB N This line warns of the hazard ww Possible consequences of failing to observe the warning instructions The signal word points out the hazard level em 0101 ep 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 Note provide information on particular characteristics and how to proceed GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 2 GENERAL SAFETY INSTRUCTIONS 2 1 SAFETY INSTRUCTIONS FOR THE OPERATOR Keep these operating instructions to hand near the unit at all times H Always follow local regulations concerning occupational safety and accident prevention 2 1 1 ELECTRICAL EQUIPMENT 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 gt Must be put out of operation if they pose a hazard Must be de en
3. B_03251 LA Item Part No Description i 1 9992590 Loctite 222 2 9992698 Vaseline white PHHV II 3 9992831 Loctite 542 4 9992511 Loctite 243 42 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER Insertion position compl package EE FEE TER HIE Ue wellt LK Valve rod unit Length adjusting measure X 122 0 1 Push together the valve rod unit and the compl package 0 4 0 5 Nm Screw in together the valve rod unit and SW5 ER the compl package Remove the valve rod unit Tighten the compl package 2 ch Carefully insert the valve rod unit and mount the complete clamping screw 1 00 with assembly tool 5 2 0 5 Nm 4 s B_03253 1 Tighten slightly valve needle by hand using an assembly tool Part No 2309368 SO p d 03450 Note Use socket or ring spanner no wrench SW11 1 2 Nm Ensure the correct insertion position 43 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER Clean and degrease the inside of the end piece and the cascade then grease the cascade surface with Vaseline B_03254 Push the trigger upward into the air valve piston B_03256 44 GM 5000EA ORDER NUMBER DOC 2319149 EDITION 03 2012 A WAGNER OPERATING MANUAL Ensure the correct
4. Remain outside the area of the electrostatic spray gun work piece SIHI_0049_GB NWARNING Unintentional putting into operation Risk of injury Before all work on the unit in the event of work interruptions and functional faults gt Switch off the energy compressed air supply Relieve the pressure from the spray gun and unit Secure the spray gun against actuation By functional faults Identify and correct the problem proceed as described in chap Trouble shooting SIHI 0065 GB 5 4 2 PREPARATION FOR STARTING UP The following points should be noted before starting up For earthing see paragraph 5 1 5 make sure that all other conductive parts within the work area are earthed Connect the material hose to spray gun and material pump or pressure tank Check that all material conveying connections are correctly connected Connect air hose to spray gun and to oil free dry air approx 0 25 MPa 2 5 bar 36 psi Compressed air quality class 3 5 2 according to ISO 8573 1 Check that all air conveying connections are correctly connected Connect the electric cable to the spray gun and to the VM 5000 or VM 500 control unit Visually check the permissible pressures for all the system components When using a Wagner pneumatic pump Check the level of the release agent and if necessary fill the release agent up 11 14 31 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC
5. SIHI 0145 GB 37 GM 5000EA ORDER NUMBER DOC 2319149 EDITION 03 2012 A WAGNER OPERATING MANUAL 6 3 DISMANTLING OF THE SPRAY GUN B_03246 38 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER Carefully release the Aw cascade without pliers LM B 03248 Assembly tool for needle valve Part No 2309368 Note Loosen valve tip Air by hand using an assembly tool no wrench KABA Y SW11 Use socket or ring spanner 2 LS NN ANN US INN WMD Q B_03449 39 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER _ pe 2 7 TR i u AS 1 Remove pressure spring 4 2 Loosen clamping screw 1 completely with assembly tool 5 3 Unscrew the complete package 3 via the complete valve rod unit 2 6 and 7 or pull out the valve rod unit and unscrew it using an Allen key SW5 4 If the loosened package 3 in the hole jammed emit from the front see upper image B 03198 1 Undo the oval head screw 1 2 Pull the air valve out off the 2 d hole d We y E 9 Torx 20 dl Removing air valve SW9 Unscrew and remove sealing 1 nut SW8 Hold the piston rear 2 and unscrew piston front SWS B 03250 3 40 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 6 4 CLEANING T
6. F Identify the unit with a warning label that says Warning hot surface Order No 9998910 Information label 9998911 Safety label 2 3 CORRECT USE WAGNER accepts no liability for any damage arising from incorrect use A Use the unit only to work with the materials recommended by WAGNER AM Operate the unit only as an entire unit gt Do not deactivate safety equipment Use only WAGNER original spare parts and accessories 10 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 2 4 SAFETY RELEVANT INFORMATION ABOUT DISCHARGES 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 2 5 USE IN AN EXPLOSION HAZARD AREA In hazardous locations only approved explosion proof electrical equipment is used 2 5 1 CORRECT USE The GM 5000EA electrostatic hand spray gun is suitable for spraying liquid materials particularly coating materials using the air atomizing method Coating materials containing solvents of Explosion Class A may be used The spray gun may only be used in combination with the VM 500 and VM 5000 control unit 2
7. 32 0 2 269 7845 E Mail info wsb wagner be HP www wsb wagner eu Denmark WAGNER Industrial Solution Scandinavia Viborgvej 100 Skaergaer DK 8600 Silkeborg Telephone 45 70 200 245 Telefax 45 86 856 027 E Mail info wagner industri com United Kingdom WAGNER Spraytech UK Ltd Haslemere Way Tramway Industrial Estate GB Banbury OXON OX16 8TY Telephone 44 0 1295 265 353 Telefax 44 0 1295 269861 E Mail enquiries wagnerspraytech co uk France J WAGNER France S A R L Parc de Gutenberg B timent F8 8 Voie la Cardon F 91127 Palaiseau Cedex Telephone 33 1 825 011 111 Telefax 33 1691 946 55 E Mail division solutionsindustrielles wagner france fr Netherlands WSB Finishing Equipment B V De Heldinnenlaan 200 NL 3543 MB Utrecht Telephone 31 0 30 241 4155 Telefax 31 0 30 241 1787 E Mail info wsb wagner nl HP www wsb wagner eu Italy WAGNER COLORA S r l Via Fermi 3 l 20875 Burago di Molgora MB Telephone 39 039 625021 Telefax 39 039 6851800 E Mail info wagnercolora com Japan WAGNER Spraytech Ltd 2 35 Shinden Nishimachi J Daito Shi Osaka 574 0057 Telephone 81 0 720 874 3561 Telefax 81 0 720 874 3426 E Mail marketing wagner japan co jp Austria J WAGNER GmbH Otto Lilienthal Str 18 Postfach 1120 D 88677 Markdorf Telephone 49 0 7544 5050 Telefax 49 0 7544 505200 E Mail service standard wagner group com Swed
8. A WAGNER 4 3 TECHNICAL DATA Max air pressure 0 8 MPa 8 bar 116 psi Max material pressure 0 8 MPa 8 bar 116 psi Paint connection G 1 4 A Air connection G 1 4 A Input voltage max 20 Vpp Input current max 1 0A AC Output voltage max 80 kV DC Output current max 100 yA DC Polarity negative Weight without hose set 630 incl union nut nozzle and air cap Working temperature range 0 C to 40 C 32 F to 104 F Material temperature 50 C 122 F 0 3 MPa 3 bar 43 5 psi material pressure Sound level at 0 3 MPa 3 bar 43 5 psi air pressure and 78 dB A A rated sound pressure level measured at 1 m distance according to DIN EN 14462 2005 Measurements A NER B_03231 A B_03230 E 245 9 65 GM 5000EA F with flat jet nozzle mm inches A 261 10 28 B 46 1 81 GM 5000EA R with round jet nozzle mm inches 261 10 28 B 46 1 81 245 9 65 17 EDITION 03 2012 OPERATING MANUAL GM 5000EA ORDER NUMBER DOC 2319149 A WAGNER 4 4 FUNCTIONAL DESCRIPTION 4 4 1 DESIGN OF SPRAY GUN STANDARD VARIANT Note The nozzle parts item 5 7 14 and 20 do not belong to the basic equipment of the spray gun The different versions can be found in Chapter 9 Accessories Item
9. gt 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 ifthere is a discharge Remove deposits from the surfaces to maintain conductivity gt Use only a damp cloth to clean the unit 5 YY 2 5 3 EXPLOSION PROTECTION IDENTIFICATION FM For Electrostatic Finishing Applications using Class I Group D Spray Material 5 APPROVED In accordance with 2316160 the device is in submission 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 2 6 GERMAN REGULATIONS AND GUIDELINES a A3 Electrical units and equipment b BGR 500 Part 2 Chap 2 36 Working with liquid ejection devices c BGR500 Part 2 Chap 2 29 Using coating materials d BGR 104 Explosion protection rules e TRBS2153 Avoiding ignition risks f BGR 180 Setting up for cleaning with solvents for cleaning workpieces with solvents g ZH 1 406 Guidelines for liquid ejection devices h BGI 740 Painting rooms and equipment j BGI 764 Electrostatic coating j BetrSich V Plant Safety Ordinance Note Alltitles can be ordered from Heymanns Publishing House in Cologne or they ar
10. that they are wearing derivable shoes When spraying wear derivable gloves to earth yourself via the spray gun handle 2 2 3 MATERIAL HOSES 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 A WAGNER EDITION 03 2012 OPERATING MANUAL 2 2 4 CLEANING 111 D 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 D gt 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 componen
11. 10 ex 1 2311562 Rod seal 11 9 1 2312177 Valve rod unit Air 12 Ox 1 2312178 Package compl 17 1 2311624 O ring 18 1 2307051 Clamping screw package 21 1 2307059 Withdrawal nut 22 1 9901411 Thread pin with hexagon 23 1 2320256 O ring 24 1 2325263 Assembly tool clamping screw 1 2326335 GM 5000EA service set Wear part x Included in service set e Not part of standard equipment available however as additional extra 63 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 10 2 2 GM 5000EA SPARE PARTS LIST HANDLE B 03237 64 EDITION 03 2012 OPERATING MANUAL Handle spare parts list Item K Quantity Part No Description 1 1 GM 5000EA handle compl 2 1 2307288 Nipple 3 Ox 1 9971025 O ring 4 1 2315344 Hose holder 5 1 2312182 Plug compl 6 1 2314270 Handle compl 7 1 2307232 End piece seal 8 1 2325789 Adjusting screw compl 9 1 2309825 Oval head screw with hexagon 10 ex 1 2310692 Seal 12 1 2307281 Threaded bolt 13 1 2312189 Air valve 14 1 2307935 Piston front 15 x 1 2307557 Seal 16 1 2312846 Cylindrical helical spring 17 1 2310680 Sleeve 18 ex 1 9974218 O ring 19 ex 1 2310682 Seal 20 1 2316246 Piston rear 23 Ox 1 9974166 O ring 24 ex 1 2303437 O ring 25 1 2325291 Sealing nut 26 1 2325294 Air valve washer 1 2326335 GM 5000EA se
12. 16 mm AWG 6 Spraying stand 16 mm AWG 6 26 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 5 2 PREPARATION OF PAINTS The viscosity of the paints is of great importance The best spraying results are obtained with values between 15 and 30 DIN s measured in immersion flow cup DIN 4 mm 0 16 inches In the case of application problems contact the paint producer 5 2 1 VISCOSITY CONVERSION TABLE milli Pascal x Centipoise Poise DIN Cup Ford Cup 4 Zahn 2 Sec mPas 4 mm 0 16 inch 10 10 0 1 5 16 15 15 0 15 8 17 20 20 0 2 10 18 25 25 0 25 14 12 19 30 30 0 3 15 14 20 40 40 0 4 17 18 22 50 50 0 5 19 22 24 60 60 0 6 21 26 27 70 70 0 7 23 28 30 80 80 0 8 25 31 34 90 90 0 9 28 32 37 100 100 1 30 34 41 120 120 1 2 33 41 49 140 140 1 4 37 45 58 160 160 1 6 43 50 66 180 180 1 8 46 54 74 200 200 2 49 58 82 220 220 2 2 52 62 240 240 2 4 56 65 260 260 2 6 62 68 280 280 2 8 65 70 300 300 3 70 74 320 320 3 2 340 340 3 4 360 360 3 6 80 380 380 3 8 400 400 4 90 27 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 5 3 WAGNER ELECTROSTATIC AIR SPRAYING SYSTEM The nozzle range chapter 9 provided by Wagner allows optimum coating results for each application General criteria for selection of nozzles Flat jet gt for parts with large s
13. 2319149 A OPERATING MANUAL WAGNER Provide material container containers for detergent and an empty container for return Connect the system to the air and power supply A basic flushing of system must be carried out for initial start up Make sure that no nozzle is inserted into the gun L 4 NWARNING Sparks form when the plug is removed Explosion hazard When using the spray gun in explosion hazard areas The cable connection may neither be separated nor put together in this area Cover sleeve plus warning sign have to be secured over the screw on the connector Attention gun cable to control unit Cover sleeve with warning sign have to be secured over the screw 84 on the connector GM 5000E gun cable B_03691 Attention guns with electrical extension cable Cover sleeves with warning signs have to be secured over the screws 84 on the connectors Extension cable to the control unit e ui GM 5000E gun cable 32 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER Bi 5 5 WORKING 5 5 1 FILLING WITH WORKING MATERIAL 1 2 w e Provide an empty container for return 13 See image 03233 Put the container with work material into the pressure tank 1 and close the pressure tank Open the stop valve 2 Adjust approx 0 05 to 0 15 MPa 0 5 to 1 5 bar 7 to 22 psi on the pressure regulator 3 Point the gun without
14. Cheese head screw with hexagon 9 1 2312183 Cover compl 10 1 9900386 Cheese head screw with hexagon 11 1 2311970 Sealing plug 12 1 2307104 Lock screw 13 1 2312180 Air regulation compl 14 ex 1 9971182 O ring 15 Ox 1 9971182 O ring 16 9 1 2314360 Trigger 17 1 2311849 Cylindrical helical spring 18 2 2310617 Oval head screw with hexagon 19 1 2314358 Material hose Air compl 20 1 2307039 Union nut 21 Ox 1 2311217 O ring 22 ex 1 2308699 Sealing cover 1 2326335 GM 5000EA service set Wear part x Included in service set 61 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 10 2 1 GM 5000EA SPARE PARTS LIST END PIECE Ensure the correct insertion position es A A OA POTON AID A 122 0 1 62 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER End piece spare parts list Item K Quantity Part No Description 1 1 GM 5000EA end piece compl 2 1 2309391 Air manifold ring Air 3 Ox 1 2307180 O ring sheathed 4 Ox 1 2312179 Valve seat Air compl Steel 4 99 1 2312176 Valve seat Air compl PEEK 5 Ox 1 2312184 Valve tip Air compl PEEK 5 00 1 2312185 Valve tip Air compl Steel 6 1 2314271 GM 5000EA end piece 7 1 2312181 Cascade compl 8 ex 1 9974166 O ring 9 1 2307062 Clamping screw valve rod
15. Description 1 Suspension hook 2 Display spray current and recipe 3 Display standby and fault 4 Operating button standby and recipe change 5 Air cap Air Accessories chapter 9 6 Union nut 7 Fan spray nozzle AF 5000 x x Accessories chapter 9 End piece Cover Note S 03558 20 aud Item Description 10 Handle 11 Adjusting screw stop 12 Trigger 14 Nozzle AR 5000 Accessories chapter 9 15 Lock plug 16 Airadjustment 17 Electrical cable connection 18 Atomizing air connection 19 Material connection 20 Air cap AR 5000 Accessories chapter 9 21 Type plate left 22 Type plate right The gun type T on the type plate 21 and the serial number S on the underside of the handle 18 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 4 4 2 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 gt 00000 RI Recipe 2 gt 00000 R2 Recipe 3 gt 00000 R3 Recipe change R1 gt R2 gt R3 gt 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 gt OOO recipe values changed temporarily 8 053182 The stored recipe values of the previ
16. GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL A WAGNER 8 PRODUCT DISPOSAL directly to this purpose SIHI_0127_GB 9 ACCESSORIES Do not dispose of waste electrical equipment with the house hold refuse In accordance with European Directive 2002 96 EC on the disposal of waste electrical equipment and its implementation in national law this product may not be disposed of with the household refuse but must rather be recycled in an environmentally correct manner Your waste Wagner electrical device will be taken back by us or our representatives and disposed of environmentally correctly Please contact one of our service points or one of our representatives or us 9 1 VALVE SEATS AIR VALVE TIPS AIR 9 1 1 VALVE SEATS Part No Description 2312179 Valve seat Air compl Steel 2312176 Valve seat Air compl PEEK 9 1 2 VALVETIPS Part No Description 2312184 Valve tip Air compl PEEK 2312185 Valve tip Air compl Steel 03697 B 03697 NN 03698 50 EDITION 03 2012 OPERATING MANUAL GM 5000EA ORDER NUMBER DOC 2319149 A WAGNER 9 2 ROUND JET NOZZLES 9 2 1 AR 5000 AIR CAPS Part No Description 2310557 AR 5000 air cap D8 2315049 AR 5000 air cap D12 9 2 2 AR5000 NOZZLES Part No Description 2310558 AR 5000 nozzle D8 2315050 AR 5000 nozzle D12
17. WAGNER Functional fault Cause Remedy Insufficient material output Nozzle too small Select larger nozzle see nozzle table 9 1 and 9 2 Material pressure too low Increase material pressure High pressure filter at pump clogged Nozzle is clogged Clean or replace filter Nozzle cleaning Poor spray pattern Wrongly adjusted atomizing air Readjust the atomizing air Nozzle too large Select smaller nozzle see nozzle table Material pressure too low Increase material pressure at the material supply Material viscosity too high Thin material in accordance with the manufacturer s instructions Valve rod leaks Seals at the valve rod are damaged Replace the seals see chapter 6 Poor wrap around Inadequate earthing Check earthing Inadequate electrical resistance of the paint Check resistance of paint see paragraph 4 1 1 Spraying pressure too high Readjust spraying pressure Back spray Inadequate earthing Check earthing Distance between spray gun and object too large Reduce distance between spray gun and object No wrap around High voltage switch is in the off position No electrostatics Switch on high voltage Repair malfunction as laid down in the control unit operating instructions 49
18. in the event of any queries Type of delivery required air freight or mail sea route or overland route etc Marks in spare parts lists Note to column K in the following spare parts lists Wearing parts Note No liability is assumed for wearing parts Not part of standard equipment available however as additional extra NWARNING Incorrect maintenance repair Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center Before all work on the unit and in the event of work interruptions Switch off the energy compressed air supply Relieve the pressure from the spray gun and unit Secure the spray gun against actuation gt Observe the operating instructions when carrying out all work 59 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 10 2 GM 5000EA SPARE PARTS LIST B 03235 60 EDITION 03 2012 OPERATING MANUAL GM 5000EA ORDER NUMBER DOC 2319149 A WAGNER GM 5000EA spare parts list Item K Quantity Part No Description 1 1 2309870 GM 5000EA basic version 2 1 2315709 Protection cap for valve needle 5 1 GM 5000EA end piece compl Details see chapter 10 2 1 6 9 1 2314361 Hook 1 ES 5000 Air handle compl Details see chapter 10 2 2 8 2 9900308
19. 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 uA 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 pA value ok Low kV value high uA value Excessive conductivity of the paint gt no wrap around In the event of application problems contact your WAGNER branch and the paint manufacturer 15 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 4 2 SCOPE OF DELIVERY Quantity PartNo Description 1 2309870 GM 5000EA spray gun Without control unit material and air hose electrical cable air cap and nozzle Each gun includes as standard equipment PartNo Description 1 2309368 Assembly tool valve needle 2325263 Assembly tool clamping screw 2319653 Glove against ink mist precipitation 1 2310487 CE Conformity 2310480 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 16 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL
20. 0 Telefax 49 0 7544 505200 E Mail service standard wagner group com Switzerland J WAGNER AG Industriestrasse 22 Postfach 663 CH 9450 Altst tten Telephone 41 0 71 757 2211 Telefax 41 0 71 757 2222 E Mail rep ch wagner group ch www wagner group com
21. 0EA ORDER NUMBER DOC 2319149 A WAGNER 34 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL A WAGNER 5 5 3 CHANGING FROM AIR ROUND JET TO AIR FLAT JET CAUTION Defective electrode Material damage due to functional faults gt Do not damage the electrode SIHI_0033_GB Switch off the control unit Relieve spray gun and unit pressure Replace paint with cleaning solvent Set material pressure Switch off the atomizing air Flush the spray gun out thoroughly Unscrew nozzle nut 2 by hand NOY iN es Relieve the material pressure on the spray gun and the devise Remove AR 5000 air cap 3 Unscrew and remove AR 5000 nozzle 4 by hand Clean the spray gun front page with dampened cloth carefully Pay attention to the electrode 1 Use the protection cap for the valve needle 8 10 Screw in and tighten slightly AF 5000 flat jet nozzle 6 by hand 11 Put on the AF 5000 air cap 5 Screw the union nut 2 onto the spray gun body 12 Set the desired flat jet level with the air cap horns 7 and then tighten slightly the union nut by hand 5 5 4 CLEANING OF THE NOZZLE PARTS The nozzle parts 2 3 4 5 and 6 may only be immersed into a cleaning solvent recommended by the manufacturer and must be immediately removed again They may not be loaded for a long time in cleaning solvent Clean these parts with a brush and dry them with a cloth or a blow gun a
22. 5 2 EXPLOSION PROTECTION IDENTIFICATION CE As defined in the Directive 94 9 EC ATEX the unit is suitable for use in areas where there is an explosion hazard CE 11 2G EEx 0 24mJ X 0102 SIRA 11 ATEX 5374X GE Communaut s Europ ennes E European Standard 0102 Notified body PTB Ex Explosion protected Ex Symbol for explosion protection 0 24mJ Max firing power I Unit class II SIRA Number of the type 2 Category 2 Zone 1 11 examination certificate ATEX Ex atmosphere gas 5374X 2 5 2 1 IDENTIFICATION X Max surface temperature e Maximum surface temperature 85 C 185 F Maxi Permissible material temperature 50 C 122 F e Permissible ambient temperature 0 to 40 C 32 to 104 F Safety instructions Safe handling of WAGNER spray units Mechanical sparks can form if the unit comes into contact with metal In an explosive atmosphere Do not knock or push the unit against steel or rusty iron Donot drop the gun Use only tools that are made of a permitted material 11 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER Ignition temperature of the coating material gt Ensure that the ignition temperature of the coating material is above the maximum surface temperature Surface spraying electrostatic Do not spray unit parts with electrostatic e g electrostatic spray gun Medium supporting atomizing
23. 9149 A WAGNER 9 6 MISCELLANEOUS Part No Description 2319653 Gun protective cover 259010 HV200 N high voltage tester 2326041 Paint resistance measuring device 999080 Wet film thickness measurer 50342 Viscosity cup DIN 4 mm 0 16 inches 2309368 Assembly tool valve needle 2325263 Assembly tool clamping screw 03693 P_00265 B_03224 B_03451 B_03681 56 EDITION 03 2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL GM 5000EA A WAGNER Part Description 2326485 GM 5000E wall mount left right 2324766 Swivel for air 57 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 58 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 10 SPARE PARTS 10 1 HOWTO ORDER SPARE PARTS Always supply the following information to ensure delivery of the right spare part Part Number description and quantity The quantity need not be the same as the number given in the Quantity column This number merely indicates how many of the respective parts are used in each sub assembly The following information is also required to ensure smooth processing of your order Address for the invoice Address for delivery Name of the person to be contacted
24. A WAGNER Translation of the original Operating manual o o Edition 03 2012 Electrostatic Airspray gun for manual operation with flat or round jet nozzles B_03229 E y N e x Lu Lu 9 N w v a gt o a n a ubmissio in s EDITION 03 2012 GM 5000EA ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 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 Asafe work environment 7 22 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 24 Cleaning 9 2 2 5 Handling hazardous liquids varnishes and paints 9 2 2 6 Touching hot surfaces 10 2 3 Correct use 10 24 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 32 Guarantee claim 13 3 3 CE Conformity 14 4 DESCRIPTION 15 4 1 Fields of application using in accordance with the ins
25. HE PARTS AFTER DISASSEMBLY ATTENTION Please note gt Allreusable parts except for the parts that conduct the high voltage such as cascade end piece plug compl etc should be cleaned thoroughly using a suitable cleaning agent The end piece plug compl and the handle inside must be clean and dry after cleaning Care should be taken that these parts remain free of solvents grease or sweat from the hands salt water Only spare parts are used which have undergone an EC type examination and are subject to a quality assessment production monitoring according to Directive 94 9 EC Spare parts may have safety relevant properties Defective parts O rings and seal sets must always be re placed L4 NWARNING Incompatibility of cleaning agent and working medium Risk of explosion and danger of poisoning by toxic gasses Checkthe compatibility of cleaning agent and working medium in accordance with safety data sheets In chapter 10 can be found part numbers for gun spare parts as well as for wearing parts such as seals 41 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 6 5 ASSEMBLING THE SPRAY GUN 1 11 11 11 1 Mm Y 0 E DIT EET T gen ERD o 2 N i Gels eoj E oz 6 vo E o S 20 c ui E Mounting materials
26. S y DEE S AH LOZ A A 35 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 6 MAINTENANCE Observe safety instructions in Chapter 2 6 1 PERIODICALLY CHECKS For the safe operation of electrostatic manual coating systems for flammable liquid spraying materials are intervals for periodically inspections defined as follows Inspection point Inspection interval Remarks Gun cleaning flushing daily Chapter 2 2 4 chapter 6 1 Earthing measures weekly Chapter 2 2 2 chapter 5 1 5 Inspection for damage weekly Chapter 6 2 6 3 6 4 and 6 5 Locking of the technical ventilation with the yearly Chapter 5 1 2 electrostatic manual coating system The above recommended intervals are maximum values and may be modified from operator depending on the local and operational conditions and contamination Damaged devices must be taken out of service immediately and repaired 6 2 CLEANING AND DECOMMISSIONING The spray gun and the unit must be cleaned every day Only use the cleaning solvent recommended by the paint manufacturer CAUTION Cleaning agent in the air duct Functional faults caused by swollen seals Never immerse the spray gun in cleaning agent NWARNING Incorrect maintenance repair Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially train
27. 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 t
28. art number 2310487 14 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 4 DESCRIPTION 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 1 1 PROCESSABLE MATERIALS With the GM 5000EA 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 kO 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 kO 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 2123 Measured value according to the WAGNER scale R 500 kQ Specific resistance RJ R RxK 500 kQ x 123 61 5 MQ cm Note With sprayed substances and those with too
29. ble 10 0 m 5 7m 3676437 PP30 protective hose mesh 7 0 m Item Qty Part No Description 1 1 2309854 GM 5000EA hose set 10 m Consisting of 2 1 2312013 Low pressure hose DN6 PN15 G 4 10 m PFA 3 1 2312061 Air hose compl 10 5 m 4 1 2309474 GM 5000E gun cable 15 0 m 5 95m 3676437 PP30 protective hose mesh 9 5 m Item Qty Part No Description 1 1 2309855 GM 5000EA hose set 15 m Consisting of 2 1 2312014 Low pressure hose DN6 PN15 G 4 15 m PFA 3 1 2312062 Air hose compl 15 5 m 4 1 2309475 GM 5000E gun cable 20 0 m 5 14 5 m 3676437 PP30 protective hose mesh 14 5 m Item Qty PartNo Description 1 1 2309856 GM 5000EA hose set 20 m Consisting of 2 1 2312015 Low pressure hose DN6 PN15 G 4 20 m PFA 3 1 2312063 Air hose compl 20 5 m 4 1 2309476 GM 5000E gun cable 25 0 m 5 19 5m 3676437 PP30 protective hose mesh 19 5 m GM 5000EA ORDER NUMBER DOC 2319149 A WAGNER 53 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 9 4 2 HOSE SETS FOR LOW IMPEDANCE MATERIALS Note to the material hose nominal pressure 20 bar inlet diameter 6 mm inside hose material FEP Item Qty Part No Description 1 1 2309878 GM 5000EA hose set 7 5 m Low R Consisting of 2 1 2310464 EA material hose compl 7 5 m LowR 3 1 2312060 Air hose compl 8 0 m 4 1 2307293 GM 5000E gun cabl
30. ctions 9 gt Always follow local regulations concerning occupational safety and accident prevention GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL 2 2 1 SAFE HANDLING OF WAGNER SPRAY UNITS 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 2 2 2 EARTH THE UNIT 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
31. e 10 0 m 5 7m 3676437 PP30 protective hose mesh 7 0 m Item Oty Part No Description 1 1 2309879 GM 5000EA hose set 10 0 m Low R Consisting of 2 1 2310465 EA material hose compl 10 0 m LowR 3 1 2312061 Air hose compl 10 5 m 4 1 2309474 GM 5000E gun cable 15 0 m 5 9 5 m 3676437 PP30 protective hose mesh 9 5 m Item Qty Part No Description 1 1 2309880 GM 5000EA hose set 15 0 m Low R Consisting of 2 1 2310466 EA material hose compl 15 0 m LowR 3 1 2312062 Air hose compl 15 5 m 4 1 2309475 GM 5000E gun cable 20 0 m 5 14 5m 3676437 PP30 protective hose mesh 14 5 m Item Qty PartNo Description 1 1 2309881 GM 5000EA hose set 20 0 m Low R Consisting of 2 1 2310467 EA material hose compl 20 0 m LowR 3 1 2312063 Air hose compl 20 5 m 4 1 2309476 GM 5000E gun cable 25 0 m 5 19 5m 3676437 PP30 protective hose mesh 19 5 m 54 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 9 4 3 GUN CABLE AND GUN CABLE EXTENSIONS Part No Description 2307295 GM 5000E extension cable 10 m 2307296 GM 5000E extension cable 20 m 9 5 REDUCTION FITTINGS FOR HIGH PRESSURE HOSES The classification of WAGNER fittings is consistent with the following classification each separated by high pressure and low press
32. e to be found in the Internet 12 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 3 GUARANTEE AND CONFORMITY DECLARATIONS 3 1 IMPORTANT NOTES ON PRODUCT LIABILITY 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 3 2 GUARANTEE CLAIM 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
33. e read before starting up NWARNING Incorrect installation operation Risk of injury and damage to equipment When putting into operation and for all work read and follow the operating instructions and safety regulations for the additionally required system components 5 1 2 VENTILATION OF THE SPRAY BOOTH The electrostatic hand spraying equipment is for use only in spray areas which correspond with standard EN 12215 The electrostatic hand spraying equipment has to be locked to the technical ventilation so that the coating material supply and the high voltage are not effective as long as the technical ventilation is not operated with the minimum exhaust air volume flow or a larger exhaust air volume flow Ensure that the excess coating material overspray will be collected up safely NWARNING Toxic and or flammable vapor mixtures Risk of poisoning and burns Operate the unit in a spraying booth approved for the working materials Or Operate the unit on an appropriate spraying wall with the ventilation extraction switched on gt Observe national and local regulations for the outgoing air speed 23 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 5 1 3 AIR SUPPLIES The use of an air filter with the air regulator 4 ensures that only dry clean atomizing air gets into the spray gun Dirt and moisture in the atomizing air reduce the spraying qua
34. e with this manual Electrostatic spray guns may be operated only by trained personnel Compliance with these instructions constitutes an integral component of the guarantee agreement 1 1 LANGUAGES This operating manual is available in the following languages Language Part No Language German 2310480 English French 2320149 Dutch Italian 2320150 Spanish Part No 2319149 2320151 1 2 WARNINGS NOTES AND SYMBOLS IN THESE INSTRUCTIONS 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 Caution a possibly hazardous situation Non observance can cause material damage t N DANGER This line warns of the hazard Possible consequences of failing to observe the warning instructions The signal word points out the hazard level 0100 GB The measures for preventing the hazard and its consequences N WARNING This line warns of the hazard Possible consequences of failing to observe the warning instructions The signal word points out the hazard level
35. ed staff or a WAGNER service center Before all work on the unit and in the event of work interruptions Switch off the energy compressed air supply Relieve the pressure from the spray gun and unit Secure the spray gun against actuation Observe the operating instructions when carrying out all work SIHI_0141_GB 36 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER DANGER Exploding gas air mixture Danger to life from flying parts and burns Never spray into a closed container Earth the container Switch off control unit Ensure that the material pressure is relieved and shut off the atomizing air supply to the gun Connect the detergent supply Set material pressure Actuate the trigger guard Flush the gun through thoroughly Relieve the pressure of gun and unit Remove nozzle and clean separately Clean the spray gun body with a cleaning agent recommended by the manufacturer and dry with a cloth or blow gun M Qo D vu de us CAUTION Cleaning agent in the air duct Functional faults caused by swollen seals Discharge current to ground no high voltage Always point the spray gun down when cleaning Ensure that neither paint nor cleaning agent enters the air duct gt When taking a break from work or when stored for a longer period the spray gun has to be positioned correctly with the attachment pointing downwards
36. en WAGNER Industrial Solutions Scandinavia Skolgatan 61 SE 568 31 Skillingaryd Telephone 46 0 370 798 30 Telefax 46 0 370 798 48 E Mail info wagner industri com Spain WAGNER Spraytech Iberica S A Ctra N 340 Km 1245 4 E 08750 Molins de Rei Barcelona Telephone 34 0 93 680 0028 Telefax 34 0 93 668 0156 E Mail info wagnerspain com Czechoslovakia WAGNER s r o Nedasovsk Str 345 15521 Praha 5 Zlicin Telephone 42 0 2 579 50 412 Telefax 42 0 2 579 51 052 E Mail info wagner cz USA WAGNER Systems Inc 300 Airport Road unit 1 Elgin IL 60123 USA Telephone 1 630 503 2400 Telefax 630 503 2377 E Mail info wagnersystemsinc com 67 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 68 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 69 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 70 Order number 2319149 Germany J WAGNER GmbH Otto Lilienthal Str 18 Postfach 1120 D 88677 Markdorf Telephone 49 0 7544 505
37. ergized before work is commenced on active parts Inform staff about planned work observe electrical safety regulations 2 1 2 PERSONNEL QUALIFICATIONS Ensure that the unit is operated and repaired only by trained persons 2 1 3 ASAFEWORK ENVIRONMENT 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 A measured insulation resistance may not exceed 100 MOhm gt 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 2 2 SAFETY INSTRUCTIONS FOR STAFF gt Always follow the information in these instructions particularly the general safety instructions and the warning instru
38. et which largely eliminates the problem of overlapping boundaries There are various nozzles and air caps available as accessories for the respective spraying material and the output amounts Union nut Spray pattern Atomizing air Spray material B_03446 Advantages Low coating thickness Perfect finish Uniform coating thickness 4 5 2 AIR ATOMIZING SPRAY PROCESS FLAT JET In this process the material paint is fed to the nozzle with low pressure 0 05 0 2 MPa 0 5 2 bar 7 29 psi The atomizing air at approx 0 25 0 4 MPa 2 5 4 bar 36 58 psi produces a soft jet which largely eliminates the problem of overlapping boundaries The spray jet can be changed using the shaping air There are various nozzles and air caps available as accessories for the respective spraying material and the output amounts Air cap Spray pattern Shaping air Spray material Atomizing air gt B_00180 Advantages Large range of adjustment of the jet spray Uniform coating thickness Low coating thickness Perfect finish 20 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 4 5 3 ELECTROSTATIC EFFECT The spray gun produces an electrostatic field by means of the high voltage electrode As a result the particles of paint which have been atomized by the spray gun are carried to the earthed object by kinetic and electrostatic energy where they adhere finel
39. ever spray into a closed container Earth the container 47 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 6 6 4 CHECK SPRAY PATTERN Start air spraying without electrostatics 1 Start up with material supply set to approx 0 05 to 0 15 MPa 0 5 to 1 5 bar 7 to 22 psi operating pressure 2 Spray pull trigger and check the atomisation 3 Set the fluid pressure on the material supply to the point where a further increase in fluid pressure would significantly improve fluid atomization 4 Open air pressure regulator for the atomizer air and adjust so as to achieve optimal atomization 5 The width of the spray jet can be adjusted using the air adjustment 16 only for flat jet method Note The paint output volume can be changed by Changing the material pressure or using a different flat jet nozzle see Chapter 9 Reduction of the material valve stroke Influence of the air adjustment on the spray pattern shape The spray pattern can be adjusted to suit the object being sprayed using the air adjustment The illustration below shows the influence of the shaping air regulator on the spraying pattern Other nozzle sizes can be used to obtain larger or smaller spraying patterns Closed air adjustment Completely opened air adjustment B 03261 48 EDITION 03 2012 OPERATING MANUAL GM 5000EA ORDER NUMBER DOC 2319149 7 TROUBLE SHOOTING AND SOLUTION A
40. he workpieces being painted NWARNING Heavy paint mist if earthing is insufficient Risk of poisoning Insufficient paint application quality Earth all unit components Earth the workpieces being painted SIHI_0003_GB The imperfect earthing of a work piece will result in Very poor wrap around Uneven coating thickness Back spraying to the spray gun i e contamination The prerequisites for perfect earthing and coating are Clean work piece suspension Earthing of spray booth conveyor system and suspension on the building side in accordance with the operating instruction or the manufacturer s information Earthing of all conductive parts within the working area The earthing resistance of the work piece may not exceed 1 MQ Mega Ohm Note Resistance to earth measured at 500 V or 1000 V Connect the control unit to the mains system earth 25 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER Earthing scheme example Conveyor a a le S Note for the sprayer En The work shoes and if used Control unit the gloves must be D derivable Work piece Earthing cable Pump or tank R max lt 1 MQ Ut Spraying stand Floor derivable Minimum cable cross section Control unit 4 mm AWG 12 Pump 4 mm AWG 12 2 Paint container 4 mm AWG 12 Conveyor 16 mm AWG 6 Booth
41. his guarantee claim does not represent any constraint to statutory regulations or regulations agreed contractually in our general terms and conditions J Wagner AG 13 EDITION 03 2012 OPERATING MANUAL GM 5000EA ORDER NUMBER DOC 2319149 3 3 CE CONFORMITY EC declaration of conformity as defined by Atex directive 94 9 EC Herewith we declare that the supplied version of Electrostatic hand spraying system A WAGNER 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 Control unit CE o E 11 2 G SIRA 11 ATEX 5374X C amp 113 G Ex nRIICT4 Gc Spray gun CE 112 G EEx 0 24mJ SIRA 11 ATEX 5374X 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 P
42. ight create a further refinement of the atomisation i e turning the adjustment screw up 44 Spraying direction Rotate up A WINE LE AirSpray Technology Stop A y to front Stop Aw to back Smaller cross section Greater cross section LWA Rotate down 5 3 2 PRESSURE SETTINGS FOR FLAT JET NOZZLES There are 8 flat jet nozzle sizes from 0 6 to 2 0 available There are 3 air cap types Each air cap can be used in combination with 2 or 3 nozzles sizes Only matching nozzle components may be used During the calibration of the material pressure a and the atomizing air pressure the air control lever shown in the figure B_03266 must be in central position These presettings are based on a paint viscosity of 22 DIN 4 sec Pressure settings Air cap 0 4 0 8 Air cap 1 0 1 4 Air cap 1 6 2 0 T 0 5 bar to 1 0 bar 1 0 barto 2 0 bar 1 0 bar to 3 0 bar Atomizing air pressure P 1 0 bar to 2 5 bar 1 5 barto 2 5 bar 1 5 bar to 3 0 bar Material pressure P Note In the table default values are included Depending on the material conditions and the desired result different values are possible or necessary By turning the adjusting screw A side of the gun the outlet cross section can be adjusted on the material valve By reducing of this cross section under the same p
43. insertion position B_03257 FL NG KS Diverse nozzle sizes see Chapter 9 3 Flat jet nozzle Diverse nozzle sizes see Chapter 9 2 Round spray nozzle 27 AT Y 45 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 6 6 FUNCTION TEST AFTER ASSEMBLY OF THE GUN 6 6 1 CHECKING THE HIGH VOLTAGE Necessary test equipment VM 500 or VM 5000 control unit and HV200 high voltage tester High voltage measurements on spraying gun Connect gun cable to control unit Take the spray gun in your hand and hold into open space Switch on control unit and actuate trigger guard The high voltage should be 60 to 65 kV with dry ambient air The value can be checked with the display on the control unit VM 5000 Note The gun must be clean and dry and must not have any colour or cleaning agent residues In the case of ambient air with a high air humidity the measured value reduces to 50 to 55 kV High voltage measurement with high voltage tester Place the ball of the high voltage tester on the gun electrode and switch on the high voltage The measured value should be 70 to 80 kV Note When measuring the high voltage the gun and the measuring device should be held at arms length as far away from the body as possible There should be no chargeable objects with in a radius of 1 m 3 28 ft of the place where the measurements are taken The placi
44. lity and the appearance of the finished piece 5 1 4 PAINT SUPPLIES CAUTION Impurities in the spraying system Spray gun blockage materials harden in the spraying system Flush the spray gun and paint supply with a suitable cleaning agent DANGER Bursting hose bursting threaded joints Danger to life from injection of material Ensure that the hose material is chemically resistant Ensure that the spray gun threaded joints and material hose between the unit and the spray gun is suitable for the pressure generated in the unit Ensure that the following information can be seen on the high pressure hose Manufacturer Permissible operating pressure Date of manufacture 24 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 5 1 5 EARTHING Perfect earthing of all conductive parts such as floors walls roofs is important for optimum coating and safety Barriers work pieces transport devices coating material container automatic movement system or construction parts in the spray area must be connected to the earthing system with exception of the high voltage parts during normal operation Part of the booth must be grounded in accordance with EN 12215 NWARNING Discharge of electrostatically charged components in atmospheres containing solvents Explosion hazard from electrostatic sparks or flames Earth all unit components gt Earth t
45. ng of the measuring ball of the high voltage measuring device reduces the spraying of the high voltage electrode As a result the high voltage value increases compared to the spraying in the free space Disruptive discharge test Check the gun against earth with the earthing rod No sparks should be formed Note In the vicinity of the electrode can occur harmless corona discharges 03259 wee T EE 46 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 6 6 2 AIRTESTS Connect test or air hose to the spray gun and switch on mains pressure 0 8 MPa 8 bar 116 psi max Checking the air valve The air valve must switch on and off cleanly Test up to approx 0 8 MPa 8 bar 116 psi Air tightness With the trigger guard unactuated test for air tightness at the points marked in the illustration El B 03260 6 6 3 MATERIAL PRESSURE TEST Connect low pressure hose to the spray gun Test the spray gun for tightness with solvent or spray oil e g Macrol 52 and a max pressure of 0 8 MPa 8 bar 116 psi Observe the following gun components Material connection nozzle body material valve no after spraying DANGER Exploding gas air mixture Danger to life from flying parts and burns N
46. nozzle into container 13 and open it Close stop valve 2 as soon as pure working material without any air inclusions starts coming from the gun Close the spray gun if the pressure tank is depressurised Dispose of the contents of the container 13 according to the local regulations 33 EDITION 03 2012 OPERATING MANUAL 5 5 2 START UP FOR SPRAYING Qv Ur ds uy mc Insert the desired nozzle into the gun Open the stop valve 2 Turn on the control unit 9 Set the material supply to operating pressure P par Spray on a test object pull trigger Adjust the spray pressure at the paint pump and or pressure tank 1 according to the nozzle and object being sprayed Setairadjustmentatthe backofthe gun tothe center position and now open atomizing air 4 and adjust optimally according to the nozzle and object being sprayed For round jet method By turning at the air adjustment or at the stop screw on the side of the gun the jet of the atomizing air is also influenced Note The size of the air cap must match with the nozzle size For flat jet method Change the width of the spray jet by turning the air adjustment back to the spray gun or by appropriate selection of the nozzle Notes A change in the material quantity is achieved by changing the material pressure or use a different nozzle size see accessories Closed air adjustment Completely opened B_03261 air adjustment GM 500
47. ously selected recipe number are re loaded from memory by pressing the operating button 4 for 2 seconds The trigger can be used to activate one after the other the various functions of the spray gun Distance Description 1 Atomizing air open 2 Atomizing air open and electrostatically HV activated Display 2 for spray current on the spray gun to 000909 activated 3 Atomizing air open electrostatically HV activated and material valve open 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 B 03183 19 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 4 5 SPRAYING PROCESS 4 5 1 AIR ATOMIZING SPRAY PROCESS ROUND JET In this process the material paint is fed to the nozzle with low pressure 0 05 0 2 MPa 0 5 2 bar 7 29 psi The atomizing air at approx 0 25 0 4 MPa 2 5 4 bar 36 58 psi produces a soft j
48. r 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 91 2 Valve tips 50 9 2 Round jet nozzles 51 9 2 1 AR5000 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 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL WAGNER 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 A 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 EDITION 03 2012 OPERATING MANUAL GM 5000EA ORDER NUMBER DOC 2319149 A WAGNER 1 ABOUT THESE INSTRUCTIONS This operating manual contains information about the operation repair and maintenance of the unit Always follow these instructions when operating the unit This equipment can be dangerous if it is not operated in accordanc
49. ressure settings you might create a further refinement of the atomisation i e turning the adjustment screw up Note In this setting the spray pattern is reduced 29 EDITION 03 2012 OPERATING MANUAL GM 5000EA ORDER NUMBER DOC 2319149 A WAGNER 5 3 3 ELECTROSTATIC AND ATOMIZATION The electrostatic charging of the spray cloud produces a more homogeneous distribution of paint particles on the object See also Chapter 4 5 3 5 3 4 OUTPUT MEASURED Flat jet nozzles 700 600 500 400 300 200 100 gt Output amounts in g min 0 gt Material pressure in bar Round jet nozzles 600 500 400 300 200 100 gt Output amounts in g min 0 1 2 gt Material pressure in bar Device GM 5000EAF Viscosity 22 DIN 4 sec 9 0 6mm 0 8mm 9 1 0mm 9 1 2mm 1 4mm s 9 1 6mm g 8 1 8mm 2 0mm 03455 Device GM 5000EAR Viscosity 22 DIN 4 sec D8 a D12 B 03456 30 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 5 4 START UP 5 4 1 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN Observe safety instructions in Chapter 2 DANGER High voltage field Danger to life from malfunctioning heart pacemakers Ensure that persons with heart pacemakers Do not work with the electrostatic spray gun
50. rvice set Wear part x Included in service set GM 5000EA ORDER NUMBER DOC 2319149 A WAGNER 65 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 10 3 ACCESSORIES SPARE PARTS LISTS 10 3 1 AR 5000 D8 NOZZLE SPARE PARTS LIST 03263 AR 5000 D8 nozzle spare parts list Item K Quantity Part No Description 1 1 2310558 AR 5000 nozzle compl D8 2 1 2327658 AR nozzle D8 3 9 1 2327659 AR nozzle cap D8 4 94 1 2327660 AR air manifold D8 Wear part 10 3 2 AR 5000 D12 NOZZLE SPARE PARTS LIST B 03264 AR 5000 D12 nozzle spare parts list Item K Quantity Part No Description 1 1 2315050 AR 5000 nozzle compl D12 2 1 2327661 AR nozzle D12 3 1 2327662 AR nozzle cap D12 4 2327663 AR air manifold D12 Wear part 66 EDITION 03 2012 OPERATING MANUAL GM 5000EA ORDER NUMBER DOC 2319149 Germany J WAGNER GmbH Otto Lilienthal Str 18 Postfach 1120 D 88677 Markdorf Telephone 49 7544 5050 Telefax 49 7544 505200 E Mail service standard wagner group com A WAGNER Switzerland J WAGNER AG Industriestrasse 22 Postfach 663 CH 9450 Altst tten Telephone 41 0 71 757 2211 Telefax 41 0 71 757 2222 E Mail rep ch wagner group ch Belgium WSB Finishing Equipment Veilinglaan 56 58 B 1861 Wolvertem Telephone 32 0 2 269 4675 Telefax
51. tructions 15 4 1 1 Processable materials 15 4 2 Scope of delivery 16 4 3 Technical data 17 44 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 Theelectrostatic 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 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 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 afte
52. ts 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 2 2 5 HANDLING HAZARDOUS LIQUIDS VARNISHES AND PAINTS gt 14 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 GM 5000EA ORDER NUMBER DOC 2319149 A WAGNER GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER 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 gt 43 C 109 4
53. ure fittings DF Double fitting Male Male thread RF Reduction fitting Female Male thread SF Adjustable screw Female Male thread allows precise angle adjustment Swivel EF 90 elbow Adjustable or Male Male thread Elbow Fitting BF Bulkhead fastener Male Male thread with pressure resistant execution PF Stopper Male thread to be closed Plug Fitting HF Hose fitting with union nut and sealing cone Hose Fitting The short description of the fittings are as follows DF MM G3 4 1 4 NPS PN270 SSt Materials SSt Stainless steel Nominal pressure in bar 1 Thread e g G1 4 1 4 NPS 2 Thread e g G1 4 1 4 NPS M16x1 5 M Male external thread F Female internal thread Short description see list above e g RF Reduction Fitting PartNo Description M 384555 Reduction fitting RF FM M16x1 5 1 4 NPS PN530 SSt 384559 Reduction fitting RF FM M16x1 5 G1 4 PN530 SSt 384556 Reduction fitting RF FM M16x1 5 3 8 NPSM PN530 SSt 34041 Reduction fitting RF FM 1 4 NPS M16x1 5 PN270 SSt 179732 Reduction fitting RF FM 1 4 NPS 3 8 NPS PN270 SSt 179247 Reduction fitting RF FM 1 4 NPS G1 4 PN270 SSt B 03221 In the large Wagner Accessories Catalogue for wet coating can also be found other material screw connections 55 EDITION 03 2012 OPERATING MANUAL GM 5000EA ORDER NUMBER DOC 231
54. urfaces Round jet gt for small delicate parts Influences on the jet spray the spray pattern Description Modification Material pressure Hu or Atomizing air pressure Pa or Air adjustment E from open to closing Stop screw material valve Aw from open to closing Nozzle sizes DS Material flow volume Electrostatic ES or or off 5 3 1 PRESSURE SETTINGS FOR ROUND JET NOZZLES There are 2 nozzle sizes D8 and D12 available The air cap and nozzle are adjusted according to size each other and may not be used reversed During the calibration of the material pressure PMAT and the atomizing air pressure PZL the air control lever shown in the figure B_03266 must be in central position Pressure setting D8 nozzle small D12 nozzle large Material pressure Piar 0 8 bar to 1 2 bar 0 8 bar to 1 6 bar Atomizing air pressure P 2 0 bar to 2 3 bar 2 3 bar to 3 0 bar Note In the table default values are included Depending on the material conditions and the desired result different values are possible or necessary Air adjustment closed Air adjustment L opened 28 B_03266 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER By turning the adjusting screw side of the gun the outlet cross section can be adjusted on the material valve By reducing of this cross section under the same pressure settings you m
55. y distributed to the object being sprayed Paint particle Electrode Grounded object B_00138 Advantages Very efficient spraying Little over spray Coating of entire circumferences due to an electrostatic field Less working time 21 EDITION 03 2012 OPERATING MANUAL ORDER NUMBER DOC 2319149 5 START UP AND OPERATION GM 5000EA A WAGNER 5 1 INSTALLATION AND CONNECTION 5 1 1 TYPICAL ELECTROSTATIC AIR SPRAYING SYSTEM B Item Description Electrostatic air spraying system Pressure tank Stop valve Air pressure regulator tank Air pressure regulator with air filter Earthing cable Air hose Air adjustment CONIA MHL WInNn gt Gun cable Item Description 9 VM 5000 control unit 10 Material hose 11 Compressed air main 12 GM 5000EAR spray gun 13 Container for return flow 14 Protective hose 15 Mains cable 22 GM 5000EA EDITION 03 2012 ORDER NUMBER DOC 2319149 A OPERATING MANUAL WAGNER The GM 5000EA spray gun must be used a part of an electrostatic spraying system spray pack The spraying system shown in the figure B_03233 is only one example of an electrostatic air spraying system Contact your Wagner distributor for assistance in designing a system to meet your needs The operating instructions and the safety regulations for the additional system compo nents used must b

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