WAGNER GM 5000EA, Translation Of The Original Operating Manual

Page 1: ...c us B_03229 Electrostatic Airspray Gun for Manual Operation with Flat or Round Jet Nozzles Version 07 2014 Translation of the Original Operating Manual...

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Page 3: ...4 1 3 Safe Work Environment 13 4 2 Safety Instructions for Staff 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 Handlin...

Page 4: ...ing Staff 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 P...

Page 5: ...rd 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...

Page 6: ...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 No...

Page 7: ...C 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...

Page 8: ...manual spray gun may only be operated under the following conditions the operating staff have previously been trained on the basis of this operating manual the safety regulations listed in this opera...

Page 9: ...y measure the specific lacquer resistance Multiplying the result of measurement with the device specific cell constant K we obtain the specific resistance value of the product Example With Wagner lacq...

Page 10: ...signs at the relevant points of risk indicate residual risks Residual risk Source Consequences Specific measures Lifecycle phase Skin contact with solvent based paints and cleaning agents Handling of...

Page 11: ...losive atmosphere Do not knock or push the unit against steel or rusty iron Do not drop the spray gun Only use tools that are made of a permitted material For Electrostatic Finishing Applications usin...

Page 12: ...EA manual spray gun only to original Wagner control units WARNING Surface spraying electrostatics Never spray device parts using electrostatic equipment electrostatic spray gun Medium supporting atomi...

Page 13: ...nd repaired only by trained persons Ensure that the floor in the working area is static dissipative in accordance with EN 61340 4 1 resistance must not exceed 100 Mohm Ensure that all persons within t...

Page 14: ...ional faults Switch off the energy compressed air supply Relieve the pressure from the spray gun and device Secure the spray gun against actuation Intheeventoffunctionalfaults remedythefaultasdescribe...

Page 15: ...he spray gun only use non polar cleaning agents to prevent conductive residues on the surface of the spray gun Should it however be necessary to use a polar cleaning agent all residues of this cleanin...

Page 16: ...For sufficient health and environmental safety operate the device in a spray booth or on a spraying wall with the ventilation extraction switched on Wear suitable protective clothing when working with...

Page 17: ...o 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 fixtures Use only...

Page 18: ...18 GM 5000EA OPERATING MANUAL EDITION 07 2014 ORDER NUMBER DOC 2344499...

Page 19: ...2 8 Adapter 9 Cover 10 Handle Designation 11 Adjusting screw stop 12 Trigger lever 14 AR 5000 nozzle Accessories see Chapter 12 15 Sealing plug 16 Air adjustment 17 Electric cable connection 18 Atomiz...

Page 20: ...on the gun display 2 as follows Recipe 1 Recipe 2 Recipe 3 Recipe change R1 R2 R3 R1 Press the operating button 4 and hold the button pressed of at least 2 seconds then it is advanced by 1 recipe Duri...

Page 21: ...be used to activate one after the other the various functions of the spray gun An increase in the force needed to pull the trigger back will be perceived at the position where the product valve opens...

Page 22: ...udes as standard equipment Order No Designation 1 2309368 Assembly tool valve needle 1 2325263 Assembly tool clamping screw 1 2319653 Protection gloves against spray mist 1 2316160 FM Control Document...

Page 23: ...Input current maximum 1 0 A AC Output voltage maximum 70 kV DC Output current maximum 100 A DC Polarity negative Weight without hose set 630g incl union nut nozzle and air cap Operating temperature ra...

Page 24: ...ar 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 There are various nozzles and air caps avail...

Page 25: ...ic field by means of the high voltage electrode As a result the paint particles atomized by the spray gun are carried to the grounded work piece by kinetic and electrostatic energy where they adhere f...

Page 26: ...ionally required system components WARNING 6 2 STORAGE CONDITIONS Until the point of assembly the manual spray gun must be stored in a dry location free from vibrations and with a minimum of dust The...

Page 27: ...ure tank 2 Stop valve 3 Air pressure regulator tank 4 Air pressure regulator with air filter 5 Grounding cable 6 Air hose 7 Air adjustment 8 Gun cable Designation 9 VM 5000 controller 10 Product hose...

Page 28: ...electrostatic hand spraying equipment has to be locked to the technical ventilation so that the coating product supply and the high voltage are not effective as long as the technical ventilation is no...

Page 29: ...paint supply with a suitable cleaning agent NOTICE Bursting hose bursting threaded joints Danger to life from injection of product Ensure that the hose product is chemically resistant to the sprayed...

Page 30: ...nents Ground the work pieces to be coated WARNING Heavy paint mist if grounding is insufficient Danger of poisoning Insufficient paint application quality Ground all device components Ground the work...

Page 31: ...praying stand Floor static dissipative Work piece Pump or pressure tank Paint tank or tank for return flow Grounding schema example Note for the sprayer Safety shoes and gloves if used must be static...

Page 32: ...pplication problems contact the lacquer manufacturer 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 7...

Page 33: ...zzle sizes delivery rate Electrostatics or or off 6 6 1 PRESSURE SETTINGS FOR ROUND JET NOZZLES pressure setting Nozzle D8 small Nozzle D12 large Product pressure 0 8 bar to 1 2 bar 0 8 bar to 1 6 bar...

Page 34: ...ar to 2 5 bar 1 5 bar to 3 0 bar Note The table contains default values Depending on the product conditions and the desired result different values are possible or necessary By turning the lateral adj...

Page 35: ...499 6 6 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 5 4 3 6 6 4 OUTPUT MEAS...

Page 36: ...check the permissible pressures for all the system components When using a Wagner pneumatic pump Check the level of the separating agent and fill the separating agent up if necessary 6 7 1 GENERAL RUL...

Page 37: ...before commissioning Make sure that no nozzle is inserted into the gun Attention gun cable to control unit Secure the cover sleeve with the warning sign by means of the screw 84 on the connector GM 50...

Page 38: ...the connectors Note In order to prevent power losses keep the cable length as short as possible The maximum power is available with the standard cable length of 10 m An extension to a total length of...

Page 39: ...tact with solvent based paints or cleaning agents causes skin irritation appropriate precautionary measures must be taken e g wearing protective clothing The footwear worn by operating staff must comp...

Page 40: ...lose the pressure tank 3 Open stop valve 2 4 Adjust approx 0 05 to 0 15 MPa 0 5 to 1 5 bar 7 to 22 psi on the pressure regulator 3 5 Point the gun without nozzle into tank 13 and open it 6 Close stop...

Page 41: ...the gun to the center position and open now atomizing air 4 and adjust to an optimum according to the nozzle and the object being sprayed For round jet method 8 By turning the air adjustment or the st...

Page 42: ...p cloth Pay attention to the electrode 1 Use the protection cap for the valve needle 8 10 Screw in and slightly tighten AF 5000 flat jet nozzle 6 by hand 11 Put the AF 5000 air cap 5 in place Screw th...

Page 43: ...GING THE VALVE HOUSING Changing the valve housing Equipment damage Activate the spray gun trigger when changing the valve housing NOTICE To prevent damage to the gun valve seat rubs on the valve needl...

Page 44: ...wder air mixes Danger to life and equipment damage Before starting cleaning or other manual work the high voltage mustbeshutdownandlockedtopreventitfrombeingswitched back on The spray gun must be sepa...

Page 45: ...faults caused by swollen seals Never immerse the spray gun in cleaning agent NOTICE Incorrect maintenance repair Risk of injury and equipment damage Have repairs and part replacements be carried out...

Page 46: ...an the spray gun body with a cleaning agent recommended by the lacquer manufacturer and dry with a cloth or blow gun Exploding gas air mixture Danger to life from flying parts and burns Never spray in...

Page 47: ...2 2 SAFETY INSTRUCTIONS Incorrect maintenance repair Danger to life and equipment damage Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area...

Page 48: ...Assembly tool valve needle Order No 2309368 Assembly tool clamping screw Order No 2325263 DANGER Incorrect maintenance repair Danger to life and equipment damage Only a WAGNER service center or a sui...

Page 49: ...49 GM 5000EA B_03247 SW3 SW19 SW19 Torx 25 1 2 3 B_03246 SW3 SW12 SW12 OPERATING MANUAL EDITION 07 2014 ORDER NUMBER DOC 2344499 8 3 2 DISASSEMBLY OF THE SPRAY GUN...

Page 50: ...ON 07 2014 ORDER NUMBER DOC 2344499 Assembly tool for needle valve Order No 2309368 Note Loosen valve tip Air by hand using an assembly tool Carefully release the cascade without pliers Use socket or...

Page 51: ...spring 4 2 Loosen clamping screw compl 1 with assembly tool 5 3 Unscrew the complete package 3 via valve rod unit complete 2 6 and 7 or pull out the valve rod unit and unscrew it using an Allen wrench...

Page 52: ...gent The adapter 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 Spare par...

Page 53: ...ITION 07 2014 ORDER NUMBER DOC 2344499 8 5 ASSEMBLY OF THE SPRAY GUN Mounting aids Order No Designation 1 9992590 Loctite 222 2 9992698 Vaseline white PHHV II 3 9992831 Loctite 542 4 9992511 Loctite 2...

Page 54: ...e valve rod unit and the complete package Screw in together the valve rod unit and the complete package As required only Remove the valve rod unit Tighten the complete package Carefully insert the val...

Page 55: ...W3 0 8 Nm SW19 SW19 B_03256 Torx 25 OPERATING MANUAL EDITION 07 2014 ORDER NUMBER DOC 2344499 Push the trigger upward into the air valve piston Clean and degrease the inside of the adapter and the cas...

Page 56: ...m SW12 SW12 2 B_03257 R1 R3 R2 OPERATING MANUAL EDITION 07 2014 ORDER NUMBER DOC 2344499 Flat jet nozzle Various nozzle sizes see Chapter 12 3 Round jet nozzle Various nozzle sizes see Chapter 12 2 En...

Page 57: ...e measured value can reduce to 40 to 50 kV High voltage measurement with high voltage tester Place the ball of the high voltage tester on the gun electrode and turn on the high voltage The measured va...

Page 58: ...8 MPa 8 bar 116 psi Air tightness With the trigger unactuated test for air tightness at the points marked in the illustration Connect low pressure hose to the spray gun Test the spray gun for tightnes...

Page 59: ...chieve optimal atomization 5 With the air adjustment on the gun set the ratio shaping air atomizing air so as to achieve an optimum spray pattern Influence of the air adjustment on the spray pattern s...

Page 60: ...ues and may be modified by the operator depending on the local and operational conditions and the contamination Damaged devices must be decommissioned and repaired immediately 8 7 HIGH PRESSURE HOSES...

Page 61: ...supply The product viscosity is too high Thin product in accordance with the lacquer manufacturer s instructions Valve rod leaks Seals at the valve rod are damaged Replace the seals see Chapter 8 Poor...

Page 62: ...al equipment and its implementation in national law this product may not be disposed of with the household refuse but must be recycled in an environmentally correct manner Wagner or one of our dealers...

Page 63: ...12ACCESSORIES 12 1 VALVE SEATS VALVE TIPS Order No Designation 2312179 Valve seat Air complete steel Standard version 2312176 Valve seat Air complete PEEK Order No Designation 2312184 Valve tip Air co...

Page 64: ...ap 1 0 1 4S 2310508 AF 5000 air cap 1 6 2 0S 2314255 AF 5000 air cap 0 4 0 8W breit 2314256 AF 5000 air cap 1 0 1 4W wide 2314258 AF 5000 air cap 1 6 2 0W wide 12 3 FLAT JET NOZZLES 12 2 2 AR 5000 NOZ...

Page 65: ...499 Order No Designation 2310539 AF 5000 nozzle 0 6 mm black 2310540 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...

Page 66: ...of 2 1 2339131 Low pressure hose DN6 PN20 G 10 m PA 3 1 2339153 Air hose complete 10 5 m 4 1 2339158 GM 5000E gun cable 15 0 m 5 10 5 m 3676437 Protection hose fabric PP30 10 5 m Order No Designation...

Page 67: ...0 20 10 1500 100 2339168 GM 5000EA hose set 10m 29 2 47 2 300 10 20 10 1500 100 2339169 GM 5000EA hose set 15 m 29 2 47 2 300 10 20 10 1500 100 2339170 GM 5000EA hose set 20m 29 2 47 2 300 10 20 10 15...

Page 68: ...product hose complete 10 0 m Low R 3 1 2339153 Air hose complete 10 5 m 4 1 2339158 GM 5000E gun cable 15 0 m 5 10 5 m 3676437 Protection hose fabric PP30 10 5 m Order No Designation 1 1 2339177 GM 5...

Page 69: ...0 1500 100 182 1 2339177 GM 5000EA hose set 15 m Low R 200 2 171 2 300 10 20 10 1500 100 182 1 2339178 GM 5000EA hose set 20 m Low R 200 2 171 2 300 10 20 10 1500 100 182 1 Notes Melt the hose ends at...

Page 70: ...with pressure resistant feed through Stopper male thread for closing plug fitting Hose fitting with union nut and sealing cone hose fitting The short description of the fittings are as follows Materi...

Page 71: ...No Designation 2319653 Protective gun coating 259010 HV200 N high voltage tester 2326041 Lacquer resistance meter 999080 Wet film thickness gauge 50342 Viscosity cup DIN 4 mm 0 16 inch 2309368 Assemb...

Page 72: ...72 GM 5000EA OPERATING MANUAL EDITION 07 2014 ORDER NUMBER DOC 2344499...

Page 73: ...ted in the event of any queries Type of delivery normal mail express delivery air freight courier etc Identification in spare parts lists Explanation of column K labeling in the following spare parts...

Page 74: ...74 GM 5000EA B_03235 2 20 21 19 7 5 8 9 10 22 12 11 13 14 15 18 16 17 6 1 OPERATING MANUAL EDITION 07 2014 ORDER NUMBER DOC 2344499 13 2 SPARE PARTS LIST GM 5000EA...

Page 75: ...13 2 2 8 2 9900308 Hexagon socket head cap screw 9 1 2312183 Lid complete 10 1 9900386 Hexagon socket head cap screw 11 1 2311970 Sealing plug 12 1 2307104 Screw plug 13 1 2312180 Air regulation compl...

Page 76: ...76 GM 5000EA B_04367 2 1 12 10 9 8 3 4 24 5 6 7 21 22 11 OPERATING MANUAL EDITION 07 2014 ORDER NUMBER DOC 2344499 13 2 1 SPARE PARTS LIST GM 5000EA ADAPTER...

Page 77: ...Air complete PEEK 1 2312185 Valve tip Air complete steel 6 1 2314271 GM 5000EA adapter 7 1 2312181 Cascade complete 8 1 9974166 O ring 9 1 2307062 Clamping screw valve rod 10 1 2311562 Rod seal 11 1 2...

Page 78: ...78 GM 5000EA B_04774 18 13 7 8 9 10 12 5 6 3 2 1 4 23 OPERATING MANUAL EDITION 07 2014 ORDER NUMBER DOC 2344499 13 2 2 SPARE PARTS LIST GM 5000EA HANDLE...

Page 79: ...71025 O ring 4 1 2307290 Hose holder 5 1 2312182 Plug complete 6 1 2314270 Handle complete 7 1 2307232 Adapter seal 8 1 2325789 Adjusting screw complete 9 1 2309825 Oval head screw with hexagon 10 1 2...

Page 80: ...PARE PARTS LISTS Notes concerning AR5000 D8 nd D12 nozzles Parts 3 and 4 can be pushed out of the nozzle by means of a suitable pin 2 0 2 3 mm 0 08 0 09 inch NOTICE Incorrect assembly Equipment or par...

Page 81: ...ion 1 1 2315050 AR 5000 nozzle complete D12 2 1 2327661 AR 5000 nozzle D12 3 1 2327662 AR nozzle attachment D12 4 1 2327663 AR air diffuser D12 Wearing part 13 3 1 SPARE PARTS LIST AR 5000 NOZZLE D8 S...

Page 82: ...he address of the purchaser We do not provide warranty for damage that has been caused or contributed to for the following reasons Unsuitable or improper use faulty assembly or commissioning by the pu...

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Page 84: ...der No 2344499 Edition 07 2014 Germany Phone Fax E mail Switzerland Phone Fax More contact adresses on the Internet at Enterprises Sites WAGNER worldwide Subject to changes without notice Document No...