WAGNER GM 5000EA Operational manual

cus

B_03229

Electrostatic Airspray Gun

for Manual Operation with

Flat or Round Jet Nozzles

Version 07/2014

Translation of the Original

Operating Manual

GM 5000EA

OPERATING MANUAL

EDITION 07/2014 ORDER NUMBER DOC 2344499

Contents

1 GENERAL 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 13

4.2.1 Safe Handling of WAGNER Spray Devices 14

4.2.2 Grounding the Device 14

4.2.3 Material Hoses 15

4.2.4 Cleaning 15

4.2.5 Handling Hazardous Liquids, Lacquers and Paints 16

4.2.6 Touching Hot Surfaces 16

4.3 Correct Use 17

4.4 Safety Information on Discharges 17

4.5 Use in an Explosion Hazard Area 17

4.6 Notes to German Regulations and Guidelines 17

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 Air Atomizing Spray Process - Round Jet 24

5.4.2 Air Atomizing Spray Process - Flat Jet 24

5.4.3 Electrostatic Eect 25

6 COMMISSIONING AND OPERATION 26

6.1 Training Assembly/Commissioning Sta 26

6.2 Storage Conditions 26

6.3 Installation Conditions 26

GM 5000EA

OPERATING MANUAL

EDITION 07/2014 ORDER NUMBER DOC 2344499

Contents

6.4 Installation and Connection 27

6.4.1 Typical Electrostatic Air Spraying System 27

6.4.2 Ventilation of the Spray Booth 28

6.4.3 Air Supply 29

6.4.4 Product Supply 29

6.4.5 Grounding 30

6.5 Preparation of Lacquer 32

6.5.1 Viscosity Conversion Table 32

6.6 Wagner Electrostatic Air Spraying System 33

6.6.1 Pressure Settings for Round Jet Nozzles 33

6.6.2 Pressure Settings for Flat Jet Nozzles 34

6.6.3 Electrostatic and Atomization 35

6.6.4 Output Measuring 35

6.7 Commissioning 36

6.7.1 General Rules for Manipulation of the Spray Gun 36

6.7.2 Preparation for Starting Up 36

7 OPERATION 39

7.1 Training the Operating Sta 39

7.2 Safety Instructions 39

7.3 Work 40

7.3.1 Filling with Working Product 40

7.3.2 Start-up Spraying 41

7.3.3 Changing from Air Round Jet to Air Flat Jet 42

7.3.4 Cleaning of the Nozzle Parts 42

7.3.5 Changing the Valve Housing 43

8 CLEANING AND MAINTENANCE 44

8.1 Cleaning 44

8.1.1 Cleaning Sta 44

8.1.2 Safety Instructions 44

8.1.3 Cleaning and Decommissioning 45

8.2 Maintenance 47

8.2.1 Maintenance Sta 47

8.2.2 Safety Instructions 47

8.3 Disassembly of the Spray Gun 48

8.3.1 Tools 48

8.3.2 Disassembly of the Spray Gun 49

8.4 Cleaning the Parts after Disassembly 52

8.5 Assembly of the Spray Gun 53

8.6 Function Test after Assembly of the Gun 57

8.6.1 Test of the High-Voltage 57

8.6.2 Air Test 58

8.6.3 Product Pressure Test 58

8.6.4 Test of Spray Pattern 59

8.7 High Pressure Hoses 60

9 INSPECTIONS 60

9.1 Periodical Inspections 60

10 TROUBLESHOOTING AND RECTIFICATION 61

GM 5000EA

OPERATING MANUAL

EDITION 07/2014 ORDER NUMBER DOC 2344499

Contents

11 PRODUCT DISPOSAL 62

12 ACCESSORIES 63

12.1 Valve Seats / Valve Tips 63

12.1.1 Valve Seats 63

12.1.2 Valve Tips 63

12.2 Round Jet Nozzles 64

12.2.1 AR 5000 Air Caps 64

12.2.2 AR 5000 Nozzles 64

12.3 Flat Jet Nozzles 64

12.3.1 AF 5000 Air Caps 64

12.3.2 AF 5000 Nozzles 65

12.4 Hoses and Electric Cables 66

12.4.1 Standard Hose Sets and Components 66

12.4.2 Hose Sets for Low-resistance Products 68

12.4.3 Gun Cables and Gun Cable Extensions 70

12.5 Reduction Fittings for High-Pressure Hoses 70

12.6 Miscellaneous 71

13 SPARE PARTS 73

13.1 How Can Spare Parts Be Ordered? 73

13.2 Spare Parts List GM 5000EA 74

13.2.1 Spare Parts List GM 5000EA - Adapter 76

13.2.2 Spare Parts List GM 5000EA - Handle 78

13.3 Accessories Spare Parts Lists 80

13.3.1 Spare Parts List AR 5000 Nozzle (D8) 81

13.3.2 Spare Parts List AR 5000 Nozzle (D12) 81

14 WARRANTY 82

14.1 Important Notes Regarding Product Liability 82

14.2 Warranty Claim 82

GM 5000EA

OPERATING MANUAL

EDITION 07/2014 ORDER NUMBER DOC 2344499

1 GENERAL

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.

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

GM 5000EA

OPERATING MANUAL

EDITION 07/2014 ORDER NUMBER DOC 2344499

1.3 LANGUAGES

The operating manual is available in the following languages:

German English 2344499

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

GM 5000EA

OPERATING MANUAL

EDITION 07/2014 ORDER NUMBER DOC 2344499

2 CORRECT USE

2.1 DEVICE TYPE

Electrostatic manual spray gun for manual coating of grounded work pieces

2.2 CORRECT USE

The GM 5000EA electrostatic manual spray gun is suitable for spraying liquid products,

particularly coating products, using the air atomizing method. Coating products containing

solvents of explosion class II A may be used.

2.4 SAFETY PARAMETERS

The GM 5000EA 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 5000EA 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")

GM 5000EA

OPERATING MANUAL

EDITION 07/2014 ORDER NUMBER DOC 2344499

2.5 PROCESSIBLE PRODUCTS

With the GM 5000EA spray gun, lacquers can be processed which contain solvents

of explosion class II A.

The spray gun basic version is suitable for processing of 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 accessory) you can also process sprayed substances with an electrical

resistance > 50 kΩ (according to the WAGNER scale) successfully.

The transfer eciency is always dependant on the composition of the product

being used, e.g. pigmentation or resin.

Conversion of Lacquer Resistance

There are lacquer resistance measuring devices available on the market that do not

directly measure the specic lacquer resistance.

Multiplying the result of measurement with the device-specic cell constant (K), we

obtain the specic resistance value of the product.

Example:

With Wagner lacquer 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

lacquer manufacturer.

GM 5000EA

OPERATING MANUAL

EDITION 07/2014 ORDER NUMBER DOC 2344499

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

lacquer in air

outside the dened

working area

Lacquering outside

the dened

working area

Inhalation of

substances

hazardous to health

Observe work

and operation

instructions

Operation,

maintenance

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