WAGNER GM 2800EA User manual
0102 "?
GM 2800EA
II 2G EEx 0.24 mJ T6 (Atex 95)
Operating Manual
Electrostatic Airspray gun
for manual operation
with flat or round jet tips
Edition 10/2005
3
GM 2800EA
OPERATING MANUAL
EDITION 10/2005 PART NO. DOC0388891
Contents
1 ABOUT THESE INSTRUCTIONS 5
1.1 Language 5
1.2 Warnings, notes and symbols in these instructions 5
2 GENERAL SAFETY INSTRUCTIONS 6
2.1 Safety instructions for the operator 6
2.1.1 Electrical equipment 6
2.1.2 Personnel qualifications 6
2.1.3 A safe work environment 6
2.2 Safety instructions for personnel 6
2.2.1 Safe handling of WAGNER spray units. 7
2.2.2 Earth the unit 7
2.2.3 Material hoses 7
2.2.4 Cleaning 8
2.2.5 Handling hazardous liquids, varnishes and paints 8
2.2.6 Touching hot surfaces 8
2.3 Correct use 8
2.4 Safety-relevant information about discharges 9
2.5 Use in an explosion hazard area 9
2.5.1 Correct use 9
2.5.2 Explosion protection identification 9
2.5.3 Max. surface temperature 9
2.5.4 Safety instructions 10
3 PRODUCT LIABILITY AND WARRANTY 11
3.1 Important notes on product liability 11
3.2 Warranty 11
3.3 CE-Conformity 12
3.4 German Regulations and guidelines 13
3.5 PTB Conformity Certification 14
4 DESCRIPTION 15
4.1 Area of application, using in accordance with the instructions 15
4.1.1 What kind of spraying material can be applied 15
4.2 Scope of supply 16
4.3 Technical data 17
4.4 Function 18
4.4.1 Design of spraygun 18
4.4.2 Functions of the gun 18
4.5 Air atomizing spray process 19
4.5.1 Round and flat jet 19
4.5.2 Round jet 19
4.5.3 Flat jet 19
4.5.4 Electrostatic effect 20
5 PREPARATION BEFORE STARTING WORK 21
5.1 Set up and connect 21
5.1.1 Typical electrostatic spraying system 21
5.1.2 Ventilation of the spray booth 22
5.1.3 Air Supply 22
4
GM 2800EA
OPERATING MANUAL
EDITION 10/2005 PART NO. DOC0388891
5.1.4 Fluid (Paint) hoses 22
5.1.5 Earthing 23
5.2 Pepraration of paint 25
5.2.1 Viscosity conversion table 25
5.3 Start-up 26
5.3.1 General rules for making adjustments to the spray gun 26
5.3.2 Preparation 26
5.4 Working 27
5.4.1 Start-up for spraying 27
5.4.2 Adjust the spray angle with flat jet nozzle 28
5.4.3 Fitting or changing round jet nozzle 28
5.4.4 Changing from round jet nozzle to flat jet nozzle 29
5.4.5 Fitting or changing flat jet nozzle 29
6 MAINTENANCE 30
6.1 Finishing work and cleaning 31
7 TROUBLE SHOOTING AND SOLUTIONS 32
8 REPAIR WORK 34
8.1 Replacing the value seat 34
8.2 Exchange of complete valve rod 35
8.3 Exchange of valve rod seals 36
8.4 Electrode replacement 37
8.5 Replacing the paint hose 38
9 ACCESSORIES 39
9.1 Nozzles EA Flat-jet 39
9.1.1 Paint output measured with synthetic enamel 39
9.2 EA Round jet nozzle (SUPRA) 40
9.2.1 Paint output measured with synththetic enamel 40
9.3 Hoses, fittings and electrical cables 41
9.4 Specialtools 41
9.5 Miscellaneous 41
10 SPARE PARTS CATALOGUE 42
10.1 How to order spare parts? 42
10.2 Spare parts list 43
Contents
5
GM 2800EA
0353931
0353931
OPERATING MANUAL
EDITION 10/2005 PART NO. DOC0388891
1.1 LANGUAGE
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
1 ABOUT THESE INSTRUCTIONS
4HISOPERATINGMANUALCONTAINSINFORMATIONABOUTTHEOPERATIONREPAIRANDMAINTENANCE
OFTHEUNIT
!LWAYSFOLLOWTHESEINSTRUCTIONSWHENOPERATINGTHEUNIT
4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL
%LECTROSTATICSPRAYGUNSMAYBEOPERATEDONLYBYTRAINEDPERSONNEL
#OMPLIANCEWITHTHESEINSTRUCTIONSCONSTITUTESANINTEGRALCOMPONENTOFTHEGUARANTEE
AGREEMENT
7ARNINGINSTRUCTIONSINTHISMANUALPOINTOUTPARTICULARDANGERSTOUSERSANDEQUIPMENT
ANDSTATEMEASURESFORAVOIDINGTHEHAZARD4HESEWARNINGINSTRUCTIONSFALLINTOTHEFOLLO
WINGCATEGORIES
$ANGERIMMINENTDANGER.ONOBSERVANCEWILLRESULT
INDEATHSERIOUSINJURYANDSERIOUSMATERIALDAMAGE
7ARNINGPOSSIBLEDANGER.ONOBSERVANCECANRESULT
INDEATHSERIOUSINJURYANDSERIOUSMATERIALDAMAGE
#AUTION A POSSIBLY HAZARDOUS SITUATION .ONOBSER
VANCECANRESULTINMINORINJURY
.OTEPROVIDEINFORMATIONONPARTICULARCHARACTERISTICSANDHOWTOPROCEED
#AUTION A POSSIBLY HAZARDOUS SITUATION .ONOBSER
VANCECANCAUSEMATERIALDAMAGE
3)()??'"
$!.'%2
4HISLINEWARNSOFTHEHAZARD
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC
TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
3)()??'"
7!2.).'
4HISLINEWARNSOFTHEHAZARD
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC
TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
3)()??'"
#!54)/.
4HISLINEWARNSOFTHEHAZARD
0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC
TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
3)()??'" #!54)/.
4HISLINEWARNSOFTHEHAZARD
0OSSIBLECONSEQUENCESOFFAILINGTOOBSERVETHEWARNINGINSTRUCTIONS4HESIGNALWORD
POINTSOUTTHEHAZARDLEVEL
4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES
4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES
,ANGUAGE /RDER.O ,ANGUAGE /RDER.O
'ERMAN %NGLISH
&RENCH $UTCH
)TALIAN 3PANISH
$ANISH 3WEDISH
4HECORRESPONDINGSERVICEINSTRUCTIONSAREAVAILABLEUNDERTHEFOLLOWINGORDERNUMBER
,ANGUAGE /RDER.O
'ERMAN
%NGLISH
0388890 0388891
0388892 0388893
0388893 0388895
0388897 0388896
6
GM 2800EA
OPERATING MANUAL
EDITION 10/2005 PART NO. DOC0388891
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
2.1.1 ELECTRICAL EQUIPMENT
2.1.2 PERSONNEL QUALIFICATIONS
2.1.3 A SAFE WORK ENVIRONMENT
2.2 SAFETY INSTRUCTIONS FOR PERSONNEL
2 GENERAL SAFETY INSTRUCTIONS
+EEPTHESEOPERATINGINSTRUCTIONSTOHANDNEARTHEUNITATALLTIMES
!LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
%LECTRICALPLANTANDUNIT
4O BE PROVIDED IN ACCORDANCE WITH THE LOCAL SAFETY REQUIREMENTS WITH REGARD TO THE
OPERATINGMODEANDAMBIENTINmUENCES
-AYONLYBEMAINTAINEDBYSKILLEDELECTRICIANSORUNDERTHEIRSUPERVISION
-USTBEOPERATEDINACCORDANCEWITHTHESAFETYREGULATIONSANDELECTROTECHNICALREGU
LATIONS
-USTBEREPAIREDIMMEDIATELYINTHEEVENTOFPROBLEMS
-USTBEPUTOUTOFOPERATIONIFTHEYPOSEAHAZARD
-USTBEDEENERGIZEDBEFOREWORKISCOMMENCEDONACTIVEPARTS)NFORMSTAFFABOUT
PLANNEDWORKOBSERVEELECTRICALSAFETYREGULATIONS
%NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS
%NSURETHATTHEmOOROFTHEWORKINGAREAISANTISTATICINACCORDANCEWITH%.0ART
eMEASUREMENTINACCORDANCEWITH$).
%NSURETHATALLPERSONSWITHINTHEWORKINGAREAWEARANTISTATICSHOESEGSHOESWITH
LEATHERSOLES
%NSURETHATDURINGSPRAYINGPERSONSWEARANTISTATICGLOVESSOTHATTHEYAREEARTHEDVIA
THEHANDLEOFTHESPRAYGUN
#USTOMERTOPROVIDEPAINTMISTEXTRACTIONSYSTEMSCONFORMINGTOLOCALREGULATIONS
%NSURETHATTHEFOLLOWINGCOMPONENTSOFASAFEWORKINGENVIRONMENTAREAVAILABLE
n-ATERIALAIRHOSESADAPTEDTOTHEWORKINGPRESSURE
n0ERSONALSAFETYEQUIPMENTBREATHINGANDSKINPROTECTION
%NSURETHATTHERE ARENO IGNITIONSOURCESSUCH ASNAKED mAMEGLOWINGWIRES ORHOT
SURFACESINTHEVICINITY$ONOTSMOKE
!LWAYSFOLLOWTHEINFORMATIONINTHESEINSTRUCTIONSPARTICULARLYTHEGENERALSAFETYIN
STRUCTIONSANDTHEWARNINGINSTRUCTIONS
!LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN
TION
7
GM 2800EA
OPERATING MANUAL
EDITION 10/2005 PART NO. DOC0388891
2.2.2 EARTH THE UNIT
2.2.3 MATERIAL HOSES
2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS.
4HESPRAYJETISUNDERPRESSUREANDCANCAUSEDANGEROUSINJURIES
!VOIDINJECTIONOFPAINTORCLEANINGAGENTS
.EVERPOINTTHESPRAYGUNATPEOPLE
.EVERREACHINTOTHESPRAYJET
"EFORE ALL WORK ON THE UNIT IN THE EVENT OF WORK INTERRUPTIONS AND FUNCTIONAL
FAULTS
n3WITCHOFFTHEENERGYCOMPRESSEDAIRSUPPLY
n3ECURETHESPRAYGUNAGAINSTACTUATION
n2ELIEVETHEPRESSUREFROMTHESPRAYGUNANDUNIT
n"YFUNCTIONALFAULTS)DENTIFYANDCORRECTTHEPROBLEMPROCEEDASDESCRIBEDIN
CHAPu4ROUBLESHOOTINGh
)NTHEEVENTOFSKININJURIESCAUSEDBYPAINTORCLEANINGAGENTS
.OTEDOWNTHEPAINTORCLEANINGAGENTTHATYOUHAVEBEENUSING
#ONSULTADOCTORIMMEDIATELY
!VOIDDANGEROFINJURYTHROUGHRECOILFORCES
%NSURETHATYOUHAVEAlRMFOOTINGWHENOPERATINGTHESPRAYGUN
/NLYHOLDTHESPRAYGUNBRIEmYINANYONEPOSITION
%LECTROSTATICCHARGESCANOCCURONTHEUNITDUETOTHEELECTROSTATICCHARGEANDTHEmOW
SPEEDINVOLVEDINSPRAYING4HESECANCAUSESPARKSANDmAMESUPONDISCHARGE
%NSURETHATTHEUNITISEARTHEDFOREVERYSPRAYINGOPERATION
%ARTHTHEWORKPIECESTOBECOATED
%NSURETHATALLPERSONSINSIDETHEWORKINGAREAAREEARTHEDEGTHATTHEYAREWEARING
ANTISTATICSHOES
7HENSPRAYINGWEARANTISTATICGLOVESTOEARTHYOURSELFVIATHESPRAYGUNHANDLE
%NSURETHATTHEHOSEMATERIALISCHEMICALLYRESISTANTTOTHESPRAYEDMATERIALS
%NSURETHATTHEMATERIALHOSEISSUITABLEFORTHEPRESSUREGENERATEDINTHEUNIT
%NSURETHATTHEFOLLOWINGINFORMATIONISVISIBLEONTHEHIGHPRESSUREHOSE
n -ANUFACTURER
n 0ERMISSIBLEOPERATINGOVERPRESSURE
n $ATEOFMANUFACTURE
4HEELECTRICALRESISTANCEOFTHECOMPLETEHIGHPRESSUREHOSEMUSTBELESSTHAN
-/HM
8
GM 2800EA
OPERATING MANUAL
EDITION 10/2005 PART NO. DOC0388891
2.2.5 HANDLING HAZARDOUS LIQUIDS,VARNISHES AND PAINTS
2.2.6 TOUCHING HOT SURFACES
2.3 CORRECT USE
2.2.4 CLEANING
$EENERGIZETHEUNITELECTRICALLY
$ISCONNECTTHEPNEUMATICSUPPLYLINE
2ELIEVETHEPRESSUREFROMTHEUNIT
%NSURETHATTHEmASHPOINTOFTHECLEANINGAGENTISATLEAST+ABOVETHEAMBIENTTEM
PERATURE
4OCLEANUSEONLYSOLVENTFREECLOTHSANDBRUSHES.EVERUSEHARDOBJECTSORSPRAYON
CLEANINGAGENTSWITHAGUN
!NEXPLOSIVEGASAIRMIXTUREFORMSINCLOSEDCONTAINERS
7HENCLEANINGUNITSWITHSOLVENTSNEVERSPRAYINTOACLOSEDCONTAINER
%ARTHTHECONTAINER
7HENPREPARINGORWORKINGWITHPAINTANDWHENCLEANINGTHEUNITFOLLOWTHEWORK
INGINSTRUCTIONSOFTHEMANUFACTUREROFTHEPAINTSSOLVENTSANDCLEANINGAGENTSBEING
USED
4AKE THESPECIlED PROTECTIVEMEASURES IN PARTICULAR WEARSAFETY GOGGLES PROTECTIVE
CLOTHINGANDGLOVESASWELLASHANDPROTECTIONCREAMIFNECESSARY
5SEAMASKORBREATHINGAPPARATUSIFNECESSARY
&ORSUFlCIENTHEALTHANDENVIRONMENTALSAFETY/PERATETHEUNITINASPRAYBOOTHORON
ASPRAYINGWALLWITHTHEVENTILATIONEXTRACTIONSWITCHEDON
7EARSUITABLEPROTECTIVECLOTHINGWHENWORKINGWITHHOTMATERIALS
4OUCHHOTSURFACESONLYIFYOUAREWEARINGPROTECTIVEGLOVES
7HENOPERATINGTHEUNITWITHACOATINGMATERIALWITHATEMPERATUREOF²#²&
)DENTIFYTHEUNITWITHAWARNINGLABELTHATSAYSu7ARNINGHOTSURFACEh
/RDER.O
)NFORMATIONLABEL
3AFETYLABEL
7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE
5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2
/PERATETHEUNITONLYASANENTIREUNIT
$ONOTDEACTIVATESAFETYEQUIPMENT
5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES
9
GM 2800EA
OPERATING MANUAL
EDITION 10/2005 PART NO. DOC0388891
2.5.2 EXPLOSION PROTECTION IDENTIFICATION
2.5 USE IN AN EXPLOSION HAZARD AREA
2.5.1 CORRECT USE
2.5.3 MAX. SURFACE TEMPERATURE
• Max. surface temperature: 85°C; 185°F
• Permissible material temperature: 60°C; 140°F
• Permissible ambient temperature: 5-40°C; 41-104°F
2.4 SAFETY-RELEVANT INFORMATION ABOUT DISCHARGES
4HEPLASTICPARTSOFTHESPRAYGUNARECHARGEDELECTROSTATICALLYBYTHEHIGHVOLTAGElELD
OFTHESPRAYPISTOL(ARMLESSDISCHARGESBRUSHDISCHARGESAREPOSSIBLEAFTERCONTACTWITH
PLASTICPARTS4HEYARECOMPLETELYHARMLESSFORPEOPLE
4HECORONADISCHARGEATTHEELECTRODEENDISVISIBLEDURINGDARKNESSATADISTANCEOFBE
TWEENANDMMANDINBETWEENTHESPRAYGUNANDSPRAYOBJECT
4HEELECTROSTATICHANDSPRAYGUN'-%!ISSUITABLEFORSPRAYINGLIQUIDMATERIALSPAR
TICULARLYCOATINGMATERIALSUSINGTHEAIRATOMIZINGMETHOD
#OATINGMATERIALSCONTAININGSOLVENTSOF%XPLOSION#LASS))!MAYBEUSED4HESPRAYGUN
MAYONLYBEUSEDINCOMBINATIONWITHACONTROLUNIT6-6-AND6-WITH
(6-
!SDElNEDINTHE$IRECTIVE#%!4%8THEUNITISSUITABLEFORUSEINAREASWHERE
THEREISANEXPLOSIONHAZARD
))'%%XM*4
#% #OMMUNAUTÏS%UROPÏENNES
.OMINATEDTESTINGBODY04"
%X 3YMBOLFOREXPLOSIONPROTECTION
)) 5NITCLASS))
#ATEGORY:ONE
' %XATMOSPHEREGAS
% %UROPEANSTANDARD
%X %XPLOSIONPROTECTION
M* -AXIGNITIONENERGY
4 4EMPERATURECLASS
10
GM 2800EA
OPERATING MANUAL
EDITION 10/2005 PART NO. DOC0388891
2.5.4 SAFETY INSTRUCTIONS
3AFEHANDLINGOF7!'.%2SPRAYUNITS
-ECHANICALSPARKSCANFORMIFTHEUNITCOMESINTOCONTACTWITHMETAL
)NANEXPLOSIVEATMOSPHERE
$ONOTKNOCKORPUSHTHEUNITAGAINSTSTEELORRUSTYIRON
$ONOTDROPTHEUNIT
5SEONLYTOOLSTHATAREMADEOFAPERMITTEDMATERIAL
)GNITIONTEMPERATUREOFTHECOATINGMATERIAL
%NSURETHATTHEIGNITIONTEMPERATUREOFTHECOATINGMATERIAL ISABOVETHE MAXIMUM
SURFACETEMPERATURE
3URFACESPRAYINGELECTROSTATIC
$ONOTSPRAYSYSTEMPARTSWITHELECTROSTATICEGELECTROSTATICSPRAYGUN
-EDIUMSUPPORTINGATOMIZING
4OATOMIZETHEMATERIALUSEONLYWEAKLYOXIDIZINGGASESEGAIR
#LEANING
)FTHERE AREDEPOSITSON THESURFACESTHEUNITMAYFORMELECTROSTATICCHARGES&LAMESOR
SPARKSCANFORMIFTHEREISADISCHARGE
2EMOVEDEPOSITSFROMTHESURFACESTOMAINTAINCONDUCTIVITY
5SEONLYADAMPCLOTHTOCLEANTHEUNIT
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