WAGNER GM5000, Operating Manual

Page 1: ...3 in 1 Electrostatic AirCoat Airless System Inclusive of F230 diaphragm VM500 Power Pack GM5000 EAC electrostatic gun Operating manual Edition 02 2024...

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Page 19: ...Prime Spray Valve ASSY 0555901________...

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Page 22: ...VM 500 B_03416 VM 500 II 3 G c us Electrostatic control unit for electrostatic hand spray guns Edition 03 2012 Translation of the original Operating manual in submission...

Page 23: ......

Page 24: ...losion hazard area 9 2 5 1 Correct use 9 2 5 2 Explosion protection according to CE 9 2 5 3 Explosion protection according to FM 10 2 6 German regulations and guidelines 10 3 GUARANTEE AND CONFORMITY...

Page 25: ...TION 03 2012 PART NUMBER DOC 2318724 Contents 8 MAINTENANCE AND REPAIR 25 8 1 Maintenance 25 8 2 Repair 25 9 PRODUCT DISPOSAL 25 10 ACCESSORIES 26 11 SPARE PARTS 27 11 1 How to order spare parts 27 11...

Page 26: ...result in death serious injury and serious material damage Caution a possibly hazardous situation Non observance can result in minor injury Note provide information on particular characteristics and h...

Page 27: ...cordance 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...

Page 28: ...rrect 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 Consu...

Page 29: ...e energize the unit electrically Disconnect the pneumatic supply line Relieve the pressure from the unit Ensure that the ash point of the cleaning agent is at least 15K above the ambient tem perature...

Page 30: ...e is a discharge Remove deposits from the surfaces to maintain conductivity Use only a damp cloth to clean the unit 2 5 USE IN AN EXPLOSION HAZARD AREA 2 5 1 CORRECT USE The VM 500 control unit may on...

Page 31: ...osion protection II Unit class II 3 Category 3 Zone 2 G Ex atmosphere gas Ex nR Ignite protection class Restricted breathing IIA Equipment group IIA T4 Temperature class T4 Gc Equipment protection typ...

Page 32: ...f 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...

Page 33: ...0 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 121...

Page 34: ...proof type of explosion protection the control unit is suitable for use in ex zone 2 This is guaranteed providing all sealed elements in the control unit are available and undamaged During operation...

Page 35: ...High voltage limit 80 kV DC Spraying current limit 100 A DC Polarity for negative high voltage generator Protection class IP 54 Weight without cables 2 3 kg 5 07 lb Working temperature range 0 40 C 32...

Page 36: ...form an electro static hand spray system The VM 500 supplies the control voltage for the spray gun in which high voltage is subsequently produced The high voltage supply is switched on and off with th...

Page 37: ...under voltage 0102 II 2 G SIRA 11 ATEX 5374X II 3 G Ex nR IIA T4 Gc B_03419 5 6 7 8 9 10 OPERATING MANUAL EDITION 03 2012 PART NUMBER DOC 2318724 5 Mains power input Connection for mains cable with s...

Page 38: ...not disconnect under voltage 0102 II 2 G SIRA 11 ATEX 5374X II 3 G Ex nR IIA T4 Gc B_03421 1 2 3 4 5 OPERATING MANUAL EDITION 03 2012 PART NUMBER DOC 2318724 5 PREPARATION BEFORE STARTING WORK 5 1 AD...

Page 39: ...he unit outside the spray booth zone Place the unit if possible outside the explosion zone Positioning in explosion zone 2 is enables Protect the unit from extreme temperature and moisture changes Pro...

Page 40: ...cordance 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 M Mega Ohm...

Page 41: ...able 3 Earthing cable 4 Pneumatic pump 5 Carriage 6 Pressure regulator air filter 7 Material suction system Item Description 8 Return hose 9 High pressure filter 10 Compressed air connection 11 Stop v...

Page 42: ...5 2 according to ISO 8573 1 ConnecttheGM5000EAorGM5000EACtothepaintsupplyasdescribedintherelevant operating manual Check that all material conveying connections are correctly connected Check that all...

Page 43: ...the electrostatic spray gun Remain outside the area of the electrostatic spray gun work piece SIHI_0049_GB Observe safety instructions in chapter 2 6 1 STARTING UP AND SPRAYING 1 Set main power switc...

Page 44: ...EDITION 03 2012 PART NUMBER DOC 2318724 If you want to spray without high voltage select standby mode Press push button 3 briefly and the standby 4 LED display lights up Note This function can be act...

Page 45: ...ective Switch on mains power supply Replace fuse WAGNER Service Green illuminated display 1 does not light up no high voltage Spray gun cable not connected or defective Spray gun not connected or defe...

Page 46: ...n all electric connections in the control unit and relevant plug connectors or shut off devices have to be tightly sealed The leak tightness of the unit has to be checked every 3 years at least The Ga...

Page 47: ...m 9 8 ft Mains cable Europe 10 m 32 8 ft 241271 Mains cable Switzerland 3 m 9 8 ft 264626 Mains cable USA 2 m 6 6 ft 264625 Mains cable Japan 3 m 9 8 ft 130215 Earthing cable 10 m 32 8 ft 264332 Eart...

Page 48: ...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 U Wearing parts Note N...

Page 49: ...ng an gs lei stu ng In pu t Po we r Sc hu tzk las se Pr ot ec tio n Cl as s No rm St an da rd EN 50 05 0 IP 54 Ei ng an gs str om In pu t Cu rre nt m ax 0 5A I 0 M ai n Sw it ch Pr im 1 0 AT Nicht un...

Page 50: ...compl VM 500 control 13 3 263400 Distance bush 14 3 9922011 Lock washer outside toothed 15 3 9910103 Hexagon nut 16 5 2312348 Hexagon lock nut 17 4 9922011 Lock washer outside toothed 18 4 9903312 Ov...

Page 51: ...les 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...

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Page 53: ...MANY 7 2 MB TTO ILIENTHAL 3TR 0OSTFACH ARKDORF 4ELEPHONE 4ELEFAX AIL SERVICE STANDARD WAGNER GROUP COM 3WITZERLAND 7 2 NDUSTRIESTRASSE 0OSTFACH LTST TTEN 4ELEPHONE 4ELEFAX AIL REP CH WAGNER GROUP CH W...

Page 54: ...5000EAC II 2 G EEx 0 24 mJ 0102 B_03154 c us Electrostatic AirCoat Spray gun for manual operation with flat or round jet nozzles Edition 03 2012 Translation of the original Operating manual in submiss...

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Page 56: ...ion 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...

Page 57: ...NCE 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...

Page 58: ...1 How to order spare parts 59 10 2 GM 5000EAC spare parts list 60 10 2 1 GM 5000EAC spare parts list End piece 62 10 2 2 GM 5000EAC spare parts list Handle 64 10 3 Accessories spare parts lists 66 10...

Page 59: ...arning 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 Note provide infor...

Page 60: ...PAIRED ONLY BY TRAINED PERSONS Make sure that the oor 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 pers...

Page 61: ...diately Avoid danger of injury through recoil forces Ensure that you have a rm footing when operating the spray gun Only hold the spray gun brie y in any one position Depending on the high voltage of...

Page 62: ...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 cle...

Page 63: ...ERATE THE UNIT ONLY AS AN ENTIRE UNIT O NOT DEACTIVATE SAFETY EQUIPMENT 5SE ONLY 7 2 ORIGINAL SPARE PARTS AND ACCESSORIES 2 2 6 TOUCHING HOT SURFACES Touch hot surfaces only if you are wearing protect...

Page 64: ...E UNIT AGAINST STEEL OR RUSTY IRON O NOT DROP THE GUN 5SE ONLY TOOLS THAT ARE MADE OF A PERMITTED MATERIAL The electrostatic hand spray gun GM 5000EAC is suitable for spraying liquid materials particu...

Page 65: ...quid ejection devices c BGR 500 Part 2 Chap 2 29 Using coating materials d BGR 104 Explosion protection rules e TRBS 2153 Avoiding ignition risks f BGR 180 Setting up for cleaning with solvents for cl...

Page 66: ...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 purchas...

Page 67: ...0 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 121...

Page 68: ...nversion 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...

Page 69: ...tandard equipment Part No Description 1 2309368 Assembly tool valve needle 1 2325263 Assembly tool clamping screw 1 2319653 Glove against ink mist precipitation 1 2310487 CE Conformity 2310481 Operati...

Page 70: ...max 100 A DC Polarity negative Weight without hose set 710 g incl union nut nozzle air cap and edge filter Working temperature range 0 C to 40 C 32 F to 104 F Max material temperature 50 C 122 F Sound...

Page 71: ...er 9 Accessories Item Description 1 Hook 2 Display spray current and recipe 3 Display standby 4 Operating button standby and recipe change 5 Protection against contact with union nut 6 Air cap for fla...

Page 72: ...e 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 adjus...

Page 73: ...Low fogging tendency Good finish High viscosity paints can easily be applied High endurance of the nozzles Change in width the jet 4 5 2 AIRCOAT ATOMIZING FLAT JET SPRAY PROCESS In the AirCoat process...

Page 74: ...ult 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 finely distributed to the object being spra...

Page 75: ...YSTEM Item Designation 1 GM 5000EACF spray gun 2 Gun cable 3 Grounding cable 4 Pneumatic pumps 5 Carriage 6 Pressure regulator air filter 7 Material suction system 8 Return hose 9 High pressure filter...

Page 76: ...lation extraction switched on Observe national and local regulations for the outgoing air speed SIHI_0028_GB The GM 5000EAC spray gun must be used a part of an electrostatic spraying system Spraypack...

Page 77: ...ent SIHI_0001_GB SIHI_0029_GB 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 th...

Page 78: ...onents Earth the workpieces being painted SIHI_0027_GB WARNING Heavy paint mist if earthing is insufficient Risk of poisoning Insuf cient paint application quality Earth all unit components Earth the...

Page 79: ...ol unit Earthing cable Spraying stand Floor derivable Work piece Pump Paint container Minimum cable cross section Control unit 4 mm AWG 12 Pump 4 mm AWG 12 Paint container 4 mm AWG 12 Conveyor 16 mm A...

Page 80: ...3 70 74 320 320 3 2 340 340 3 4 360 360 3 6 80 380 380 3 8 400 400 4 90 OPERATING MANUAL EDITION 03 2012 PART NUMBER DOC 2319150 5 2 PREPARATION OF PAINTS The viscosity of the paints is of great impor...

Page 81: ...1 Check that all air supply connections are connected properly 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 th...

Page 82: ...zzle is inserted into the gun SIHI_0139_ENG WARNING Sparks form when the plug is removed Explosion hazard When using the spray gun in explosion hazard areas The cable connection may neither be separat...

Page 83: ...ion hose 7 in the container with working material 19 Note If the pump is equipped with a rigid suction system it should only be diped in into the working material in maximum to the middle of the inlet...

Page 84: ...r 1160 psi operating pressure and switch on control unit 13 3 Spray press the trigger 4 Adjust the spray pressure at the paint pump according to the nozzle and object being sprayed 5 Now open AirCoat...

Page 85: ...the new nozzle insert 1 By means of nozzle spanner 2 loosen nozzle insert 1 by a half turn 2 Remove the nozzle spanner and briefly actuate trigger guard 3 After cleaning the nozzle re tighten the noz...

Page 86: ...le insert 3 using nozzle spanner 4 6 Unscrew nozzle nut 5 and remove nozzle screw connection 7 and sealing nipple 8 out off the nozzle body 6 and clean all parts thoroughly 7 Insert desired ACF 5000 n...

Page 87: ...to the stop by hand 5 4 7 CLEANING OF THE NOZZLES The AirCoat ACF 5000 nozzles 11 the nozzle inserts 3 and the nozzle screw connection 7 can be placed in a cleaning solvent recommended by the paint ma...

Page 88: ...e the pressure of gun and unit 12 Unscrew union nut 12 13 Remove air cap 10 and put ACF 5000 nozzle 11 out off air cap by hand Clean ACF 5000 nozzle and insert it in spraying position into the valve h...

Page 89: ...en carrying out all work 6 1 PERIODICALLY CHECKS For the safe operation of electrostatic manual coating systems for flammable liquid spraying materials are intervals for periodically inspections defin...

Page 90: ...e AirCoat nozzle and clean separately see paragraph 5 4 7 5 Actuate the trigger guard Flush the gun through thoroughly 6 Relieve the material pressure on the spray gun and the devise 7 Clean gun body...

Page 91: ...38 GM 5000EAC B_03194 SW3 SW12 SW12 B_03195 SW3 SW19 SW21 Torx 25 1 2 3 OPERATING MANUAL EDITION 03 2012 PART NUMBER DOC 2319150 6 3 DISMANTLING OF THE SPRAY GUN...

Page 92: ...MBER DOC 2319150 Assembly tool for needle valve Part no 2309368 Assembly tool for valve housing Part no 2325263 Note Loosen AC valve tip by hand using an assembly tool Carefully release the cascade wi...

Page 93: ...h 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 hol...

Page 94: ...e 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...

Page 95: ...ANUAL EDITION 03 2012 PART NUMBER DOC 2319150 6 5 ASSEMBLING THE SPRAY GUN Mounting materials Item Part No Description 1 9992590 Loctite 222 2 9992698 Vaseline white PHHV II 3 9992831 Loctite 542 4 99...

Page 96: ...se assembly tool socket or ring spanner no wrench Ensure the correct insertion position Ensure the correct insertion position Push together the valve rod unit and the compl package Screw in together t...

Page 97: ...5 SW3 0 8 Nm SW21 SW19 8 B_03206 Torx 25 OPERATING MANUAL EDITION 03 2012 PART NUMBER DOC 2319150 Push the trigger upward into the air valve piston Clean and degrease the inside of the end piece and t...

Page 98: ...3 R2 OPERATING MANUAL EDITION 03 2012 PART NUMBER DOC 2319150 Flat jet nozzle Assembly see chapter 10 3 1 Diverse nozzle sizes see chapter 9 2 Round jet nozzle Assembly see chapter 10 3 2 Diverse nozz...

Page 99: ...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...

Page 100: ...rigger guard unactuated test for air tightness at the points marked in the illustration 6 6 3 MATERIAL PRESSURE TEST Connect high pressure hose to the spray gun Test the spray gun for tightness with s...

Page 101: ...own in the figure below 5 With the air adjustment on the gun the ratio form adjustment to atomization until the optimum spray pattern is achieved Note Repeat point 4 and 5 until the optimum spray patt...

Page 102: ...erial 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 Loose package Tighten Poor...

Page 103: ...e 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...

Page 104: ...with nozzle spanner without AC round jet nozzle insert Part No Description 2309882 ACF 5000 LV air cap suitable for low viscosity materials marked red 2314203 ACF 5000 HV air cap suitable for high vis...

Page 105: ...13 80 0 33 0 013 10 20 30 40 50 60 80 395115 395215 395315 395415 395515 395615 395815 15 10 15 20 15 30 15 40 15 50 15 60 15 80 0 38 0 015 10 20 30 40 50 60 80 395217 395317 395417 395517 395617 3958...

Page 106: ...95825 25 40 25 60 25 80 0 64 0 025 40 60 80 395427 395627 395827 27 40 27 60 27 80 0 69 0 027 40 60 80 395429 395629 395829 29 40 29 60 29 80 0 75 0 029 40 60 80 395431 395631 395831 31 40 31 60 31 80...

Page 107: ...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 SS...

Page 108: ...9984573 10 High pressure hose DN4 PN270 NPS 10 0 m PA 3 1 2312061 Air hose compl 10 5 m 4 1 2309474 GM 5000E gun cable 15 0 m 5 9 5 m 3676437 Protective hose mesh PP30 9 5 m Item Qty Part No Descript...

Page 109: ...12061 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 2309953 GM 5000EAC hose set 15 0 m Low R Consisting o...

Page 110: ...9150 Part No Description 2307295 GM 5000E extension cable 10 m 2307296 GM 5000E extension cable 20 m 9 5 3 GUN CABLE AND GUN CABLE EXTENSIONS 9 6 MISCELLANEOUS Part No Description 2319653 Gun protecti...

Page 111: ...03 2012 PART NUMBER DOC 2319150 2309368 Assembly tool valve needle 128901 ACR nozzle spanner 2325263 Assembly tool clamping screw 2326485 GM 5000E wall mount left right 2324766 Swivel for air 2327060...

Page 112: ...e 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 U Wearing parts Note...

Page 113: ...60 GM 5000EAC B_03153 2 3 19 20 21 7 5 8 9 10 12 11 13 14 15 18 16 17 6 4 22 1 24 OPERATING MANUAL EDITION 03 2012 PART NUMBER DOC 2319150 10 2 GM 5000EAC SPARE PARTS LIST...

Page 114: ...0308 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 Seal screw 13 1 2312180 Air regulation compl 14 1 9971182...

Page 115: ...00EAC B_03164 2 1 12 10 9 8 3 4 5 6 7 17 18 21 22 11 23 24 X 123 0 1 OPERATING MANUAL EDITION 03 2012 PART NUMBER DOC 2319150 10 2 1 GM 5000EAC SPARE PARTS LIST END PIECE Ensure the correct insertion...

Page 116: ...l 6 1 2314272 GM 5000EAC end piece 7 1 2312181 Cascade compl 8 1 9974166 O ring 9 1 2307062 Clamping screw valve rod 10 1 2311562 Rod seal 11 1 2313639 AC valve rod unit 12 1 2312178 Package compl 17...

Page 117: ...64 GM 5000EAC 20 16 17 18 19 15 25 26 14 24 13 7 1 B_03165 8 9 10 12 5 6 3 2 4 23 11 OPERATING MANUAL EDITION 03 2012 PART NUMBER DOC 2319150 10 2 2 GM 5000EAC SPARE PARTS LIST HANDLE...

Page 118: ...iece seal 8 1 2311952 Stop screw 9 1 2309825 Oval head screw with hexagon 10 1 2310692 Seal 11 1 2311182 Straight pin 12 1 2309400 Safety catch 13 1 2312189 Air valve 14 1 2307935 Piston front 15 1 23...

Page 119: ...S 10 3 1 FLAT JET NOZZLES SPARE PARTS LIST Flat jet nozzles spare parts list Item K Quantity Part No Description 1 1 2315775 AC union nut compl 2 1 2309882 LV air cap compl 2 1 2314203 HV air cap comp...

Page 120: ...zzle cap spare parts list Item K Quantity Part No Description 1 1 2309883 ACR 5000 round jet nozzle cap 2 1 2307220 Nozzle nut 3 1 2315310 O ring 4 1 132351 Nozzle screw connection holder 5 1 2307219...

Page 121: ...68 GM 5000EAC OPERATING MANUAL EDITION 03 2012 PART NUMBER DOC 2319150...

Page 122: ...69 GM 5000EAC OPERATING MANUAL EDITION 03 2012 PART NUMBER DOC 2319150...

Page 123: ...elles 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 e...

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Page 125: ...MANY 7 2 MB TTO ILIENTHAL 3TR 0OSTFACH ARKDORF 4ELEPHONE 4ELEFAX AIL SERVICE STANDARD WAGNER GROUP COM 3WITZERLAND 7 2 NDUSTRIESTRASSE 0OSTFACH LTST TTEN 4ELEPHONE 4ELEFAX AIL REP CH WAGNER GROUP CH W...