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OPERATING MANUAL

EDITION 05/2015

ORDER NUMBER DOC2319150

IDENTIFICATION

3.1

CE EXPLOSION PROTECTION IDENTIFICATION

As defi ned in the Directive 94/9/EC (ATEX), the device is suitable for use in potentially
explosive areas.

Temperature notes

- Maximum surface temperature: 85 °C; 185 °F
- Maximum permissible product temperature: 50 °C; 122 °F
- Permissible ambient temperature: 0 to +40 °C; +32 to +104 °F

Device type:

GM 5000EAC electrostatic manual spray gun

Manufacturer:

J. Wagner AG
CH-9450 Altstätten, Switzerland

SIRA 11 ATEX5374X

European Communities

Notifi ed body: PTB

Explosion-proof equipment

Device class II (not mining)

Category 2 device (suitable for zone 1)

Ex-atmosphere gas

Explosion protection for electrical devices

Maximum ignition energy

Number of type examination certifi cate

"X": see chapter 3.2

3.2

IDENTIFICATION "X"

Note:

The EC Type Examination Certifi cate from SIRA can be found in Chapter 15.4.
This certifi cation covers the following:

- use of the spray gun in Zone 1;
- use of the VM 5000 or VM 500 control unit as related equipment for the spray gun.

The control unit may be used in zone 2. This usage is certifi ed by the manufacturer (see
operating manual of the control unit).

Содержание GM 50000EAC

Страница 1: ...B_03154 Electrostatic AirCoat Spray Gun for manual operation for flat or round jet nozzles Version 05 2015 Translation of the Original Operating Manual...

Страница 2: ......

Страница 3: ...ipment 14 4 1 2 Personnel Qualifications 14 4 1 3 Safe Work Environment 14 4 2 Safety Instructions for Staff 15 4 2 1 Safe Handling of WAGNER Spray Devices 15 4 2 2 Grounding the Device 16 4 2 3 Produ...

Страница 4: ...ng Staff 38 7 2 Safety Instructions 38 7 2 1 Emergency Deactivation 39 7 2 2 General Rules for Making Adjustments to the Spray Gun 39 7 3 Work 40 7 3 1 Filling with Working Material 41 7 3 2 Checking...

Страница 5: ...t Jet Nozzles 80 13 2 1 ACF 5000 Air Caps Flat Jet 80 13 2 2 ACF5000 AirCoat Flat Jet Nozzles 81 13 3 Filter 83 13 4 Hoses and Electric Cables 84 13 4 1 Standard Hose Sets and Components 84 13 4 2 Hos...

Страница 6: ...tsconsequences DANGER This notice warns you of a hazard Possible consequences of not observing the warning instructions The signal word indicates the hazard level Themeasuresforpreventingthedangerandi...

Страница 7: ...rder No Language Order No German 2310481 English 2319150 French 2320152 Italian 2320153 Spanish 2320154 Dutch 2358832 Danish 2359979 Swedish 2360027 Additional languages on request or at Order No Orde...

Страница 8: ...essary 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 provisio...

Страница 9: ...e Chapter 3 Explosion Protection Identification 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 t...

Страница 10: ...do not directly measure the specific paint resistance Multiplying the result of the measurement with the device specific cell constant K we obtain the specific resistance value of the product Example...

Страница 11: ...e defined working area Lacquering outside the defined working area Inhalation of substances hazardous to health Observe work and operation instructions Operation maintenance The forms of misuse listed...

Страница 12: ...n Switzerland SIRA 11 ATEX5374X European Communities Notified body PTB Explosion proof equipment Device class II not mining Category 2 device suitable for zone 1 Ex atmosphere gas Explosion protection...

Страница 13: ...ing injured by high pressure jet 2 Device type 3 Article number 4 Maximum high voltage 5 Maximum current 6 Maximum product pressure 7 Maximum air pressure 8 Do not dispose of used electrical equipment...

Страница 14: ...measured insulation resistance must not exceed 100 megohms Paint mist extraction systems ventilation systems must be fitted on site according to local regulations Ensure that the following components...

Страница 15: ...n devices ZH 1 406 and BGR 500 Part 2 Chapter 2 29 and 2 36 For shut down devices the examination can be suspended until the next start up Carry out the work steps as described in the Pressure Relief...

Страница 16: ...oses may not be subjected to pressure Several liquids have a high expansion coefficient In some cases their volume can rise with consequent damage to pipes fittings etc and cause fluid leakage When th...

Страница 17: ...used for cleaning and flushing agents The tanks must be grounded An explosive gas air mixture forms in closed tanks Never spray into a closed tank when using solvents for flushing External cleaning W...

Страница 18: ...r of the lacquers solvents and cleaning agents being used Take the specified protective measures in particular wear safety goggles protective clothing and gloves as well as skin protection cream if ne...

Страница 19: ...ay form electrostatic charges Flames or sparks can form during discharge Remove deposits from the surfaces to maintain conductivity Use only a damp cloth to clean the device Safe handling of WAGNER sp...

Страница 20: ...er 13 2 2 8 Adapter 9 Cover 10 Handle 11 Trigger lock 12 Trigger lever Pos Description 13 Round jet nozzle adapter see accessories in Chapter 13 1 1 14 Round jet nozzle insert see accessories in Chapt...

Страница 21: ...ously selected recipes numbers will be reloaded from the memory During spraying mode trigger lever pressed the status is shown in the display 2 by LEDs LED display Description LEDs 1 3 light up green...

Страница 22: ...force needed to pull the trigger back will be perceived at the position where the product valve opens For spraying without high voltage the high voltage can be switched off using the operating button...

Страница 23: ...gun basic version can be adapted optimally to any application depending upon the requirements and the desired accessories with the help of spray gun configuration The delivery note shows the exact sc...

Страница 24: ...Output voltage maximum 80 kV DC Output current maximum 100 A DC Operating temperature range 0 C 40 C 32 F 104 F Maximum permissible product temperature 50 C 122 F Maximum surface temperature 85 C 185...

Страница 25: ...applied High endurance of the nozzles Jet width adjustment In the AirCoat process the spray product is atomized under a pressure of 3 15 MPa 30 150 bar 435 2 176 psi With the help of an air pressure...

Страница 26: ...ge 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 finely dispersed to the object to be...

Страница 27: ...ed in closed rooms The air temperature at the storage location must be between 20 C and 60 C 4 F and 140 F The relative air humidity at the storage location must be between 10 and 95 without condensat...

Страница 28: ...cable 4 Pneumatic pump 5 Sliding tables 6 Air pressure regulator air filter 7 Product suction system 8 Return hose 9 High pressure filter Description 10 Compressed air connection 11 Stop valve 12 Air...

Страница 29: ...fety regulations for the additionally required system components WARNING Toxic and or flammable vapor mixtures Risk of poisoning and burns Operate the device in a spray booth approved for the working...

Страница 30: ...30 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150...

Страница 31: ...the spraying quality and spraying pattern Bursting hose bursting threaded joints Danger to life from injection of product Ensure that the hose material is chemically resistant to the sprayed products...

Страница 32: ...st if grounding is insufficient Danger of poisoning Insufficient paint application quality Ground all device components Ground the work pieces to be coated WARNING A poorly grounded work piece causes...

Страница 33: ...unding scheme example Conveyor Mains cable Minimum cable cross section Control unit 4 mm2 AWG 12 Product supply Paint tank Conveyor 16 mm2 AWG 6 Booth Spraying stand Grounding of spray gun The spray g...

Страница 34: ...ocess the different viscosities of the lacquer are optimally covered by two air cap types These can be found in Accessories In the case of application problems contact the paint producer mPa s 10 10 0...

Страница 35: ...eck the permissible pressures for all the system components Check the level of the separating agent in the WAGNER pneumatic pump and fill the separating agent up if necessary Provide product tank tank...

Страница 36: ...tion gun cable to control unit Secure the cover sleeve with the warning sign by means of the screw 84 on the connector The following points must be noted The cable connection to the gun and the connec...

Страница 37: ...e maximum power is available with the standard cable length of 10 m An extension to a total length of up to 40 m will cause a power loss of up to 10 The gun cable can be extended to a total length of...

Страница 38: ...ms WARNING Observe safety instructions in Chapter 4 Incorrect operation Risk of injury and damage to the device The operating staff must be qualified and fit to operate the entire system The operating...

Страница 39: ...Danger to life from injecting paint or solvent Never reach into the spray jet Never point the spray gun at people Consult a doctor immediately in the event of skin injuries caused by paint or solvent...

Страница 40: ...5 9 17 1 2 16 15 14 21 12 11 10 B_03158 18 19 20 3 3 13 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150 7 3 WORK Ensure that the regular safety checks are carried out in accordance with Chapt...

Страница 41: ...e an optimum spray pattern See below Spray pattern and air regulation Repeat points 6 and 7 until the optimum spray pattern is reached iterative process 1 Place empty tank 18 under return tube 8 2 Pla...

Страница 42: ...t being sprayed The illustration shows the influence of the regulator on the spraying pattern Other nozzle sizes can be used to obtain larger or smaller spraying patterns Changing the Flow Rate Adapt...

Страница 43: ...pray gun does not affect the spray pattern in this process Flow rate 9 Product quantity may be able to be reduced by Minimizing the product pressure Use a different nozzle see Chapter 13 1 Secure gun...

Страница 44: ...aint or solvent Never reach into the spray jet Never point the spray gun at people Consult a doctor immediately in the event of skin injuries caused by paint or solvent Inform the doctor about the pai...

Страница 45: ...1 by a half turn 2 Remove the nozzle spanner and briefly actuate trigger 3 After flushing the nozzle re tighten the nozzle insert 7 3 6 REPLACING ROUND JET NOZZLE S NOZZLE INSERT Exploding gas air mix...

Страница 46: ...using 12 Put the air cap 10 on the nozzle 11 and pay attention to the position of the guide surfaces 13 Screw union nut with attached nozzle guard 9 to the gun body and make sure that the air cap horn...

Страница 47: ...47 B_03162 1 2 3 4 5 6 7 8 10 9 Y 11 1 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150...

Страница 48: ...aces of paint have been removed Defective AirCoat nozzle Insufficient paint application quality Do not use sharp edged objects to treat carbide on the AirCoat nozzle NOTICE 6 Insert new ACF5000 nozzle...

Страница 49: ...henozzlescrewconnection 7 can be placed in a cleaning solvent recommended by the lacquer manufacturer All other nozzle parts may not be put into cleaning solvent Clean these parts with a cleaning solv...

Страница 50: ...n 9 Turn the trigger lock 14 to the spraying position and briefly pull the trigger 10 When the blockage has been flushed out secure the gun with trigger lock 14 11 Relieve pressure Chapter 7 3 4 12 Un...

Страница 51: ...51 B_04388 10 11 X Y 1 14 Y 9 12 12 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150 ACF5000 nozzle in cleaning position ACF5000 nozzle in spray position...

Страница 52: ...ng Damage to the device Activate the spray gun trigger when changing the valve housing NOTICE To prevent damage to the gun valve seat rubs on the valve needle valve needle may loosen activate the spra...

Страница 53: ...53 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150...

Страница 54: ...8 1 1 CLEANING STAFF Observe safety instructions in Chapter 4 DANGER Incorrect maintenance repair Danger to life and equipment damage Only a WAGNER service center or a suitably trained person may car...

Страница 55: ...ay gun have to be cleaned and which product has to be removed When cleaning the spray gun only use non polar cleaning agents to prevent conductive residues on the surface of the spray gun Should it ho...

Страница 56: ...the compatibility of the cleaning and flushing agents and working media on the basis of the safety data sheets WARNING Damage to electrical devices Never immerse the spray gun in cleaning agent NOTIC...

Страница 57: ...9 Remove flushing agent supply With flat jet nozzle fitted 5 Dismount AirCoat nozzle and clean separately Chapter 7 3 8 6 Point the spray gun toward the collecting tray and actuate the trigger 7 Flush...

Страница 58: ...cked for being in a reliable state after maintenance work is completed 8 2 1 MAINTENANCE STAFF 8 2 2 SAFETY INSTRUCTIONS Observe the safety instructions in Chapter 4 and Chapter 8 1 2 Prior to mainten...

Страница 59: ...all times when carrying out work For the safe operation of electrostatic manual coating systems for flammable liquid coating products intervals for periodical inspections are defined as follows Inspe...

Страница 60: ...device is reduced due to environmental influences even when handled correctly Check hoses pipes and couplings every day and replace if necessary Before every commissioning check all connections for le...

Страница 61: ...ance too high too low Check paint resistance see Chapter 2 5 Spraying pressure too high Readjust spraying pressure No wrap around No high voltage Switch on high voltage at the control unit Repair malf...

Страница 62: ...62 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150...

Страница 63: ...and check for leaks Chapter 11 3 Function test in accordance with Chapter 11 In accordance with the guideline for liquid ejection devices ZH 1 406 and BGR 500 Part 2 Chapter 2 29 and Chapter 2 36 The...

Страница 64: ...end wrench SW14 Open end wrench SW19 Open end wrench SW21 Open end wrench SW22 Ring spanner SW9 Ring spanner SW11 Torx wrench 20 Torx wrench 25 Slide gauge Valve needle assembly tool Order No 2309368...

Страница 65: ...Torx 25 1 2 3 B_03194 SW3 SW12 SW12 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150 10 3 2 DISASSEMBLY OF THE SPRAY GUN Air hose When unscrewing the air hose a second open ended box wrench m...

Страница 66: ...ute slight rotational movements Fitting 25 If the fitting 25 does not come out with the product hose it must be removed from the gun adapter as follows Screwthewoodscrew 3mm 0 12inches length40mm 1 6i...

Страница 67: ...ssembly tool or socket or ring spanner no open end wrench O ring 8 1 Use screwdriver no 1 to press under the O ring 2 Lever up the O ring and remove it Air distribution 9 1 Locate the start of the thr...

Страница 68: ...ired Remove rod seal 10 Do not damage the housing in the process Two gold contact sleeves either remain in the handle 1 or are seated on the two gold pins 2 Do not lose 1 Loosen the oval head screw 3...

Страница 69: ...ease note All reusable parts except for the parts conducting high voltage such as cascade adapter plug compl etc should be cleaned thoroughly using a suitable cleaning agent The adapter connector insi...

Страница 70: ...ringly sparingly Ensure the correct insertion position Ensure the correct insertion position Only as required if the seal was removed press in using handle seal assembly tool Order No 2342334 not incl...

Страница 71: ...in 6 using an Allen key SW2 Coat the hollow section with a brush Note Avoid the pin and hexagon sparingly Wear gloves The outside thread of the packing 9 must be free of lacquer Valve rod unit 8 and p...

Страница 72: ...3 fingers using an assembly tool 3 Use assembly tool socket or ring spanner no open end wrench to tighten the valve housing 3 4 Slide the valve rod to the forward position at the valve seat 4 Valve ne...

Страница 73: ...the inside of the adapter and the cascade then grease the cascade surface with Vaseline Fitting 25 Before assembling the product hose check that no fitting 25 is in the gun adapter Check the fitting f...

Страница 74: ...ocess only exert counter pressure on the sleeve bracket and not on the entire cover 2 Position cover straight and level and carefully press in Use only minimal force gently rocking from side to side i...

Страница 75: ...9150 Flat jet nozzle Assembly see Chapter 14 3 1 Diverse nozzle sizes see Chapter 13 2 Round jet nozzle Assembly see Chapter 14 3 2 Diverse nozzle sizes see Chapter 13 1 Air hose When screwing on the...

Страница 76: ...cked with the display on the control unit VM 5000 Note The gun must be clean and dry and must not have any paint or cleaning agent residues In the case of ambient air with a high air humidity the meas...

Страница 77: ...2015 ORDER NUMBER DOC2319150 Disruptive discharge test Check the gun against ground with the grounding rod No sparks should be formed Note in the vicinity of the electrode harmless corona discharges c...

Страница 78: ...ration Connect high pressure hose to the spray gun Test the seal of the spray gun with suitable medium e g flushing agent or Marcol 52 and a maximum pressure of 25 MPa 250 bar 3 626 psi Increase the p...

Страница 79: ...th the household refuse but must be recycled in an environmentally correct manner WAGNER or one of our dealers will take back your used WAGNER electric or electronic equipment and will dispose of it f...

Страница 80: ...Recommended gun filter mm inch 132720 11 approx 250 10 red 132721 12 approx 250 10 200 meshes 132722 13 approx 250 10 132723 14 approx 250 10 132724 15 approx 250 10 132725 16 approx 250 10 yellow 132...

Страница 81: ...0 011 10 Synthetic resin lacquer 395211 11 20 20 PVC lacquer 395311 11 30 30 395411 11 40 40 395511 11 50 50 395611 11 60 60 395811 11 80 80 395113 13 10 0 33 0 013 10 Lacquers 395213 13 20 20 Base co...

Страница 82: ...0 021 20 Mica paints 395421 21 40 40 Zinc rich paints 395521 21 50 50 Rust proofing paints 395621 21 60 60 Glue paints 395821 21 80 80 395423 23 40 0 58 0 023 40 395623 23 60 60 395823 23 80 80 395425...

Страница 83: ...B_00019 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150 13 3 FILTER Order No Designation 3204604 Edge filter 60 mesh white 3204605 Edge filter 100 mesh black 9999002 Edge filter 200 mesh yell...

Страница 84: ...0 5 m 3676437 Protection hose fabric PP30 10 5 m Pos Stk Order No Designation 1 1 2339173 Hose set GM 5000EAC 15 0 m Consists of 2 1 9984573 15 High pressure hose DN4 PN270 NPS 15 0 m PA 3 1 2339154 A...

Страница 85: ...0 2339174 Hose set GM 5000EAC 20 m 29 2 65 2 300 10 20 10 1 500 100 Notes Melt the hose ends at both sides gun pump and turn approx 5 cm of each hose end to the inside Fix the protective hose with cab...

Страница 86: ...bric PP30 10 5 m Pos Stk Order No Designation 1 1 2339181 Hose set GM 5000EAC 15 0 m Low R Consists of 2 1 2310470 High pressure product hose EAC complete 15 0 m Low R inclusive pos 6 3 1 2339154 Air...

Страница 87: ...set GM 5000EAC 15 m Low R 206 2 177 2 300 10 20 10 1 500 100 188 1 2339182 Hose set GM 5000EAC 20 m Low R 206 2 177 2 300 10 20 10 1 500 100 188 1 Notes Melt the hose ends at both sides gun pump and...

Страница 88: ...49 2 ft 20 m 65 6 ft 25 m 82 0 ft 32 m 105 ft 62 m 203 ft Order No 2339157 2339158 2339159 2339160 2344995 2344996 GM 5000E extension cable Max total length of 80 m 262 ft see Chapter 6 6 3 1 Length...

Страница 89: ...015 ORDER NUMBER DOC2319150 Order No Designation 2319653 Protective gun coating 259010 High voltage tester HV 200 N 2326041 Paint resistance meter 999080 Wet film thickness gauge 50342 Viscosity cup D...

Страница 90: ...ANUAL EDITION 05 2015 ORDER NUMBER DOC2319150 128901 Nozzle spanner ACR 2325263 Clamping screw assembly tool 2326485 Wall mount GM 5000E left right 2324766 Swivel joint air 2327060 Fitting SJM GM5000E...

Страница 91: ...express delivery air freight courier etc Identification in spare parts lists Explanation of column K labeling in the following spare parts lists Wearing parts Note These parts are not covered by warra...

Страница 92: ...92 B_03153 19 20 21 7 5 8 9 10 12 11 13 14 15 18 16 17 6 22 1 25 24 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150 14 2 GM 5000EAC SPRAY GUN Dismantling and assembly See Chapter 10...

Страница 93: ...exagon socket cylinder head screw 11 1 2311970 Sealing plug 12 1 2307104 Screw plug 13 1 2312180 Air regulation complete including item 14 14 1 9971182 O ring 15 1 9971182 O ring 16 1 2314360 Trigger...

Страница 94: ...04368 5 1 15 13 12 11 6 4 10 21 22 14 24 123 0 1 mm 4 8425 0 004 inch 2 3 25 9 8 7 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150 14 2 1 GM 5000EAC ADAPTER Dismantling and assembly See Chapt...

Страница 95: ...1 2314283 Contacting AC 8 1 9952777 High resistance bare 9 1 9960808 Socket contact component gold contact sleeve 10 1 2312181 Cascade complete 11 1 9974166 O ring 12 1 2307062 Clamping screw valve ro...

Страница 96: ...96 7 1 B_04775 8 9 10 12 5 6 3 2 4 23 11 18 13 24 25 26 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150 14 2 2 GM 5000EAC HANDLE Dismantling and assembly See Chapter 10...

Страница 97: ...2307232 Adapter seal 8 1 2311952 Stop screw 9 1 2309825 Oval head screw with hexagon 10 1 2310692 Gasket 11 1 2311182 Parallel pin 12 1 2309400 Safety clip 13 1 2312189 Air valve 18 1 9974218 O ring...

Страница 98: ...3 1 FAN SPRAY NOZZLES Flat jet nozzles spare parts list Pos K Stk Order No Designation 1 1 2315775 Union nut AC complete 2 1 2309882 Air cap ACF 5000 LV red 2 1 2314203 Air cap ACF 5000 HV blue 3 1 23...

Страница 99: ...parts list Pos K Stk Order No Designation 1 1 2309883 Round jet nozzle cap ACR 5000 2 1 2307220 Nozzle nut 3 1 2315310 O ring 4 1 132351 Nozzle screwed connection holder 5 1 2307219 Nozzle body 6 1 2...

Страница 100: ...an the 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 th...

Страница 101: ...61000 6 2 2006 DIN EN ISO 12100 2011 DIN EN 1953 2010 DIN EN 61000 6 4 2011 DIN EN 60079 0 2010 DIN EN 60079 15 2011 DIN EN 60204 1 2007 Applied national technical standards and specifications in part...

Страница 102: ...102 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150 15 4 EC TYPE EXAMINATION CERTIFICATE...

Страница 103: ...103 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150...

Страница 104: ...104 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150...

Страница 105: ...ith Liquid Ejection Devices Part 2 Chapter 2 29 Working with Coating Products Avoiding ignition risks Equipment for cleaning work pieces with solvents Guidelines for liquid ejection devices Painting r...

Страница 106: ...106 OPERATING MANUAL EDITION 05 2015 ORDER NUMBER DOC2319150...

Страница 107: ......

Страница 108: ...2319150 Edition 05 2015 Germany Phone Telefax E mail Switzerland Phone Telefax More contact addresses on the internet at Company Locations WAGNER worldwide Subject to changes without notice Document...

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