WAGNER GM 5000EA User manual

B_03229

Cus

Electrostatic Air Spray Gun

for manual operation

for at or round jet nozzles

Version 04/2016

Translation of the Original

Operating Manual

GM 5000EA

OPERATING MANUAL

EDITION 04/2016 ORDER NUMBER DOC2344499

Contents

1 ABOUT THESE INSTRUCTIONS 7

1.1 Preface 7

1.2 Warnings, Notices and Symbols in these Instructions 7

1.3 Languages 8

1.4 Abbreviations 8

1.5 Terminology for the Purpose of this Manual 9

2 CORRECT USE 10

2.1 Device Type 10

2.2 Type of Use 10

2.3 Use in an Explosion Hazard Area 10

2.4 Safety Parameters 10

2.5 Processible Working Materials 11

2.6 Reasonably Foreseeable Misuse 12

2.7 Residual Risks 12

3 IDENTIFICATION 13

3.1 Explosion Protection Identication FM 13

3.2 Type Plate 14

4 GENERAL SAFETY INSTRUCTIONS 15

4.1 Safety Instructions for the Operator 15

4.1.1 Electrical Equipment 15

4.1.2 Personnel Qualications 15

4.1.3 Safe Work Environment 15

4.2 Safety Instructions for Sta 16

4.2.1 Safe Handling of WAGNER Spray Devices 16

4.2.2 Grounding the Device 17

4.2.3 Product Hoses 17

4.2.4 Cleaning and Flushing 18

4.2.5 Handling Hazardous Liquids, Varnishes and Paints 19

4.2.6 Touching Hot Surfaces 19

4.3 Protective and Monitoring Equipment 19

4.4 Use in Areas Subject to Explosion Hazards 20

4.4.1 Safety Regulations 20

4.5 Safety-Relevant Information about Discharges 20

5 DESCRIPTION 21

5.1 Structure (Standard Variant) 21

5.2 Mode of Operation 22

5.3 Scope of Delivery 24

5.3.1 Design Variants 25

5.4 Technical Data 26

5.5 Spraying Procedure 28

5.5.1 Spraying Procedure for Round Jet Air Atomizing 28

5.5.2 Spraying Procedure for Flat Jet Air Atomizing 29

5.5.3 Electrostatic Eect 30

5.6 The WAGNER Electrostatic Air Spraying System 31

5.6.1 Pressure Settings for Round Jet Nozzles 31

5.6.2 Pressure Settings for Flat Jet Nozzles 32

GM 5000EA

OPERATING MANUAL

EDITION 04/2016 ORDER NUMBER DOC2344499

Table of Contents

5.6.3 Adjusting Screw 32

5.6.4 Electrostatic and Atomization 33

5.6.5 Discharge Quantity Measurements 33

6 ASSEMBLY AND COMMISSIONING 34

6.1 Training Assembly/Commissioning Sta 34

6.2 Storage Conditions 34

6.3 Installation Conditions 34

6.4 Transportation 34

6.5 Assembly and Installation 35

6.5.1 Typical Electrostatic Air Spraying System 35

6.5.2 Ventilation of the Spray Booth 36

6.5.3 Air Supply 37

6.5.4 Product Supply 37

6.5.5 Grounding 38

6.6 Preparation of Lacquer 40

6.6.1 Viscosity Conversion Table 40

6.7 Commissioning 41

6.7.1 Safety Instructions 41

6.7.2 Preparation for Commissioning 41

6.7.3 Commissioning 41

6.7.3.1 Gun Cables and Gun Cable Extensions 42

6.7.4 Verifying a Safe Operational Condition 43

7 OPERATION 44

7.1 Training the Operating Sta 44

7.2 Safety Instructions 44

7.2.1 Emergency Deactivation 45

7.2.2 General Rules for Making Adjustments to the Spray Gun 45

7.3 Working 46

7.3.1 Filling with Working Material 46

7.3.2 Checking the Spray Pattern (Without Electrostatics) 47

7.3.3 Spraying 48

7.3.4 Pressure Relief/Work Interruption 50

7.3.5 Changing from Air Round Jet to Air Flat Jet 51

7.3.6 Cleaning of the Nozzle Parts 52

7.3.7 Changing the Valve Housing 52

8 CLEANING AND MAINTENANCE 53

8.1 Cleaning 53

8.1.1 Cleaning Sta 53

8.1.2 Safety Instructions 53

8.1.3 Cleaning and Flushing the Device 55

8.2 Maintenance 57

8.2.1 Maintenance Sta 57

8.2.2 Safety Instructions 57

8.2.3 Safety Checks 58

8.2.4 Product Hoses, Tubes and Couplings 59

9 TROUBLE SHOOTING AND RECTIFICATION 60

GM 5000EA

OPERATING MANUAL

EDITION 04/2016 ORDER NUMBER DOC2344499

Table of Contents

10 REPAIR WORK 61

10.1 Repair Sta 61

10.2 Safety Instructions 61

10.3 Dismantling of the Gun 62

10.3.1 Tools 62

10.3.2 Dismantling of the Spray Gun 63

10.3.3 Cleaning the Parts After Disassembly 66

10.3.4 Assembling the Spray Gun 67

11 FUNCTION TEST AFTER THE REPAIR 72

11.1 Checking the High voltage 72

11.2 Air Test 74

11.3 Product Pressure Test 74

11.4 Test of Spray Pattern 74

12 DISPOSAL 75

13 ACCESSORIES 76

13.1 Valve Housing 76

13.2 Valve Tips 76

13.3 Round Spray Nozzles 76

13.3.1 AR 5000 Air Caps 76

13.3.2 AR 5000 Nozzles 76

13.3.3 Nozzle set EARV 77

13.4 Flat Jet Nozzles 77

13.4.1 AF 5000 Air Caps 77

13.4.2 AF 5000 Nozzles 78

13.5 Hoses and Electric Cables 79

13.5.1 Standard Hose Sets and Components 79

13.5.2 Hose Sets for Low-resistance Products 81

13.5.3 Spiral Hose (no FM Approval) 84

13.5.4 Gun Cables and Gun Cable Extensions 84

13.5.5 Air Regulation 84

13.5.6 4 Finger Trigger 85

13.6 Miscellaneous 86

14 SPARE PARTS 87

14.1 How Can Spare Parts Be Ordered? 87

14.2 GM 5000EA Spray Gun 88

14.2.1 Basic version GM 5000EA 88

14.2.2 Spiral Hose for GM 5000EA 90

14.2.3 4 Finger Trigger for GM 5000EA 92

14.2.4 GM 5000EA Adapter 94

14.2.5 GM 5000EA Handle 96

14.3 Accessories Spare Parts Lists 98

14.3.1 AR 5000 Nozzle (D8) 99

14.3.2 AR 5000 Nozzle (D12) 99

14.3.3 Nozzle Set EARV 5000 100

15 WARRANTY 101

15.1 Important Notes Regarding Product Liability 101

GM 5000EA

OPERATING MANUAL

EDITION 04/2016 ORDER NUMBER DOC2344499

Table of Contents

15.2 Warranty Claim 101

15.3 FM Approval 102

GM 5000EA

OPERATING MANUAL

EDITION 04/2016 ORDER NUMBER DOC2344499

1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS

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 damage to property.

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 measures for preventing 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 measures for preventing 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 measures for preventing 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 measures for preventing the hazard and its consequences.

NOTICE

1 ABOUT THESE INSTRUCTIONS

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 the operating and

service personnel.

The device may only be operated by trained personnel and in compliance with this

operating manual. Operating and service personnel should be instructed according to the

safety instructions.

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.

1.1 PREFACE

GM 5000EA

OPERATING MANUAL

EDITION 04/2016 ORDER NUMBER DOC2344499

1.3 LANGUAGES

1.4 ABBREVIATIONS

Order No. Order number

Spare part

Marking in the spare parts lists

Electrostatics Air

Manual gun

Low R Low-resistance

Polyether ether ketone (high temperature-resistant thermoplastic plastic)

Stainless steel

Position

Number of pieces

Wrench size

The GM 5000EA operating manual is available in the following languages:

Language Order No. Language Order No.

German 2356789 English 2344499

Additional languages on request or at:

GM 5000EA

OPERATING MANUAL

EDITION 04/2016 ORDER NUMBER DOC2344499

1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning Manual cleaning of devices and device parts with cleaning

agent

Flushing Internal ushing of paint-wetted parts with ushing agent

Product pressure

generator

Pump or pressure tank

Sta qualications

Trained person Is instructed in the tasks assigned to him/her, the potential

risks associated with improper behavior as well as the

necessary protective devices and measures.

Electrically trained

person

Is instructed by an electrician about the tasks assigned to him/

her, the potential risks associated with improper behavior as

well as the necessary protective devices and measures.

Electrician Can assess the work assigned to him/her and detect possible

hazards based on his/her technical training, knowledge and

experience in relevant provisions.

Skilled person A person who, based on his/her technical training, experience

and recent vocational experience, has sucient technical

knowledge in the area of electrostatic coating and is familiar

with the relevant and generally accepted rules of technology

so that he/she can inspect and assess the status of devices and

coating systems based on workplace safety.

in the context of BGI 764

Additional requirements for skilled persons can also be

referred to in TRBS1203(2010): Expert knowledge in the areas

of protection against excessive pressure, electrical hazards,

and explosion protection (where applicable).

GM 5000EA

OPERATING MANUAL

EDITION 04/2016 ORDER NUMBER DOC2344499

2 CORRECT USE

2.1 DEVICE TYPE

Electrostatic manual spray gun for manual coating of grounded work pieces.

2.2 TYPE OF USE

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

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

contain ingredients of explosion class IIA and IIB substances (maximum ignition energy

0.24 mJ) may be used.

WAGNER forbids any other use!

2.4 SAFETY PARAMETERS

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 explosion protection marking in Chapter 3).

WAGNER accepts no liability for any damage arising from incorrect use.

Use the device only to work with the products recommended by WAGNER.

Only operate the device as a whole.

Do not deactivate safety xtures.

Use only WAGNER original spare parts and accessories.

The device may only be operated under the following conditions:

The operating personnel must be trained on the basis of this operating manual.

The safety regulations listed in this operating manual must be observed.

The operating, maintenance and repair information in this operating manual must be

observed.

The statutory requirements and accident prevention regulation standards in the

country of use must be observed.

The electrostatic manual spray gun may only be operated if all parameters are set and all

measurements/safety checks are carried out correctly.

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