WAGNER GM 2800EA Operating Manual
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WAGNER GM 2800EA Operating Manual

WAGNER GM 2800EA Operating Manual

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Electrostatic Airspray gun
for manual operation
with fl at or round jet tips
0102
II 2G EEx 0.24 mJ T6 (Atex 95)
Operating Manual
GM 2800EA
Edition 10/2005

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Summary of Contents for WAGNER GM 2800EA

  • Page 1 Operating Manual GM 2800EA Edition 10/2005 Electrostatic Airspray gun for manual operation with fl at or round jet tips 0102 II 2G EEx 0.24 mJ T6 (Atex 95)

  • Page 3: Table Of Contents

    Safety instructions for the operator 2.1.1 Electrical equipment 2.1.2 Personnel qualifi cations 2.1.3 A safe work environment Safety instructions for personnel 2.2.1 Safe handling of WAGNER spray units. 2.2.2 Earth the unit 2.2.3 Material hoses 2.2.4 Cleaning 2.2.5 Handling hazardous liquids, varnishes and paints 2.2.6...
  • Page 4 GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL Contents 5.1.4 Fluid (Paint) hoses 5.1.5 Earthing Pepraration of paint 5.2.1 Viscosity conversion table Start-up 5.3.1 General rules for making adjustments to the spray gun 5.3.2 Preparation Working 5.4.1 Start-up for spraying 5.4.2...

  • Page 5: About These Instructions

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL ABOUT THESE INSTRUCTIONS LANGUAGE 0388890 0388891 0388892 0388893 0388893 0388895 0388897 0388896 0353931 0353931 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS...

  • Page 6: General Safety Instructions

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR 2.1.1 ELECTRICAL EQUIPMENT 2.1.2 PERSONNEL QUALIFICATIONS 2.1.3 A SAFE WORK ENVIRONMENT SAFETY INSTRUCTIONS FOR PERSONNEL...

  • Page 7: Safe Handling Of Wagner Spray Units

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL 2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS. 2.2.2 EARTH THE UNIT 2.2.3 MATERIAL HOSES...

  • Page 8: Cleaning

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL 2.2.4 CLEANING 2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS 2.2.6 TOUCHING HOT SURFACES CORRECT USE...

  • Page 9: Safety-Relevant Information About Discharges

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL SAFETY-RELEVANT INFORMATION ABOUT DISCHARGES USE IN AN EXPLOSION HAZARD AREA 2.5.1 CORRECT USE 2.5.2 EXPLOSION PROTECTION IDENTIFICATION 2.5.3 MAX. SURFACE TEMPERATURE • Max. surface temperature: 85°C; 185°F • Permissible material temperature: 60°C; 140°F •...

  • Page 10: Safety Instructions

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL 2.5.4 SAFETY INSTRUCTIONS...

  • Page 11: Product Liability And Warranty

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL PRODUCT LIABILITY AND WARRANTY IMPORTANT NOTES ON PRODUCT LIABILITY WARRANTY...

  • Page 12: Ce-Conformity

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL CE-CONFORMITY GM 2800EA 0179780...

  • Page 13: German Regulations And Guidelines

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL GERMAN REGULATIONS AND GUIDELINES...

  • Page 14: Ptb Conformity Certification

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL PTB CONFORMITY CERTIFICATION...

  • Page 15: Description

    High kV-value, low µA-value (no wrap around) = Paint with too high el. resistance. Low kV-value, high µA-value (no wrap-around) = Paint with too low el. resistance In the event of application problems, contact your WAGNER branch and the paint manu- facturer.

  • Page 16: Scope Of Supply

    Part No. Description 0179037 Spray gun GM 2800EA 0179060 Spray gun GM 2800EA USA 0179047 Spray gun GM 2800EA special 0179061 Spray gun GM 2800EA special USA The standard equipment includes: Quantity Part No. Description 0179901 Universal spanner 0353210 Tip spanner...

  • Page 17: Technical Data

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL TECHNICAL DATA Max. air pressure 0.8 MPa; 8 bar; 116 psi Max. material pressure 0.8 MPa; 8 bar; 116 psi Material connection ø 10 mm; 0.39 in Material hose length 7.5 m; 24.6 ft Inner diam.

  • Page 18: Function

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL FUNCTION 4.4.1 DESIGN OF SPRAYGUN Suspension hook Fan air regulation HV switch (integrated into trigger) Tension cap Trigger Handle with integrated high voltage generator Air connector Paint hose Gun cable to the control unit...

  • Page 19: Air Atomizing Spray Process

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL AIR ATOMIZING SPRAY PROCESS 4.5.1 ROUND AND FLAT JET In this process, the material (paint) is fed to the tip with low pressure at approx. 0.05-0.2MPa; 0.5-2 bar; 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.

  • Page 20: Electrostatic Effect

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL 4.5.4 ELECTROSTATIC EFFECT The spray gun produces an electrostatic fi eld by means of the high voltage electrode. As a result, 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, fi...

  • Page 21: Preparation Before Starting Work

    Fan air regulation Mains air inlet The spray gun GM 2800EA must be used a part of an electrostatic spraying system. The spraying system shown in the fi gure is only one example of an electrostatic Aircoat spray- ing system. It is not an actual system design. Contact your WAGNER distributor for assis- tance in designing a system to meet your needs.

  • Page 22: Ventilation Of The Spray Booth

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL 5.1.2 VENTILATION OF THE SPRAY BOOTH 5.1.3 AIR SUPPLY The use of an air fi lter with the air regulator (D) ensures that only dry, clean atomising air gets into the spray gun. Dirt and moisture in the atomising air reduce the spraying quality and the appearance of the fi...

  • Page 23: Earthing

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL 5.1.5 EARTHING Perfect earthing of all system components (workpieces, conveyor, paint supply system, control unit, spray booth or spraying stand, see illustration) is a prerequisite for optimum coating effi ciency and safety.
  • Page 24 GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL Earthing scheme (example) Conveyor Control modul Workpiece Earthing cable Pump Spraying stand Paint container System earth Floor, antistatic System earth Minimum cable cross-section Control unit 4 mm² (AWG 12) Pump 4 mm² (AWG 12) Paint container 4 mm²...

  • Page 25: Pepraration Of Paint

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL PEPRARATION OF PAINT The viscosity of the paints is of great importance. The best results are obtained with paints between 15 and 30 DIN sec. (measured in immersion fl ow cup DIN 4 mm ; 0.16 in).

  • Page 26: Start-Up

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL START-UP 5.3.1 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN ➞ See safety regulations in chapter 2. 5.3.2 PREPARATION • Secure the spraygun. Turn tension cap clockwise until stop. (viewed from back of gun) •...

  • Page 27: Working

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL WORKING 5.4.1 START-UP FOR SPRAYING 1. Switch on the material supply adjust from approx. 0.05-0.15 MPa; 0.5-1.5 bar; 7-22 psi and the control unit. 2. Unlock spraygun with tension cap. 3. Spray on a test object (press the trigger).

  • Page 28: Adjust The Spray Angle With Flat Jet Nozzle

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL 5.4.2 ADJUST THE SPRAY ANGLE WITH FLAT JET NOZZLE The spray pattern can be adjusted to suit the object being sprayed using the fan air regula- tor. Other nozzle sizes can be used to obtain larger or smaller spraying patterns.

  • Page 29: Changing From Round Jet Nozzle To Flat Jet Nozzle

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL 5.4.4 CHANGING FROM ROUND JET NOZZLE TO FLAT JET NOZZLE 1. Switch off control unit. Round jet tip 2. Relieve spray gun and unit pressure. 3. Unscrew the nozzle nut EAR (B).

  • Page 30: Maintenance

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL MAINTENANCE ➞ See safety regulations in chapter 2.

  • Page 31: Finishing Work And Cleaning

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL FINISHING WORK AND CLEANING 1. Switch off control unit. 2. Relieve spray gun and system pressure and cut off the atomizing air supply to the spray gun. 3. Replace material by cleansing agent.

  • Page 32: Trouble Shooting And Solutions

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL TROUBLE SHOOTING AND SOLUTIONS Problem Cause Solution Insuffi cient material output • Nozzle too small • Flat jet: Select larger nozzle. (See nozzle list) • Material pressure too • Increase material pressure •...
  • Page 33 • No high voltage • Check function of control unit in accordance with its manual • Switch on HV-switch • Defective sealing (71)* • Repair by WAGNER Service in gun barrel • Air-passages damp • Clean airpassages and drying Leaking material the nozzle •...

  • Page 34: Repair Work

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL REPAIR WORK REPLACING THE VALUE SEAT 1. Remove nozzle according to para- graph 5.4.3 and 5.4.5 Flat jet nozzle 2. With the trigger pressed, (protects the sealing surfaces) unscrew collar Round jet nozzle (G) with the nozzle spanner 2800 (I).

  • Page 35: Exchange Of Complete Valve Rod

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL EXCHANGE OF COMPLETE VALVE ROD Attention: Do not damage sealing surfaces 1. Remove nozzle according t paragraph 5.4.3 and 5.4.5 2. Remove valve seat according to paragraph 8.1 3. Loosen front packing screw (V) 1/2 to 1 turn, using the packing key (W) (available as accessory), in order to relieve the packing from the valvestem.

  • Page 36: Exchange Of Valve Rod Seals

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL EXCHANGE OF VALVE ROD SEALS 1. Remove valve rod as described in paragraph 8.2. 2. Hold with universal spanner at surface (D) and unscrew valve sealing element (1/E) using a small pliers .

  • Page 37: Electrode Replacement

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL ELECTRODE REPLACEMENT Electrode If the electrode is damaged (bent or broken) by incorrect handling, the valve needle head (12) must be replaced. 1. Remove valve rod as described in paragraph 8.2.

  • Page 38: Replacing The Paint Hose

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL REPLACING THE PAINT HOSE 1. Unscrew nut (A) using the universal spanner. 2. Pull material hose (B) out of the connection (C). 3. Remove insert (D), clamping ring (E) and nut (A) from material hose.

  • Page 39: Accessories

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL ACCESSORIES NOZZLES EA FLAT-JET Part No. Description Colour 0363229 Nozzle set EAF 0.8 yellow 0363230 Nozzle set EAF 1.0 0363231 Nozzle set EAF 1.2 green 0363232 Nozzle set EAF 1.4 brown 0363233 Nozzle set EAF 1.6...

  • Page 40: Ea Round Jet Nozzle (Supra)

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL EA ROUND JET NOZZLE (SUPRA) Part No. Description 0363238 Nozzle set EAR Supra 0353966 Nozzle nut EAR 2000 0353965 Nozzle body Supra 0353952 Nozzle insert Supra EA 0353210 Nozzle key 2800 EA 9.2.1...

  • Page 41: Hoses, Fittings And Electrical Cables

    Protective sleeve (per metre) without fi xing strap 0179228 Extention cable 7.5 m; 24.6 ft gun to control unit Material hose ø6; 12 mm; ø0.24; 0.47 in, contact your WAGNER branch for special pre-cut lengths 0353701 Material hose set EA The set includes 7.5 m; 24.6 ft material hose ø6;...

  • Page 42: Spare Parts Catalogue

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL SPARE PARTS CATALOGUE 10.1 HOW TO ORDER SPARE PARTS?

  • Page 43: Spare Parts List

    GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL 10.2 SPARE PARTS LIST View A Item K Part No. Description 0350903 Nozzle needle assy. 0179325 Air control knob ◆★ 9971003 O-ring green 0179354 Positioning bushing 9900962 Countersunk screw M3; 12 mm; 0.47 in long ◆...
  • Page 44 0179219 Trigger GM2000 ◆ 0179396 Trigger pin ◆ 9900808 Pan-head screw M3; 12 mm; 0.47 in long 0353381 Data plate GM 2800EA 9900810 Pan-head screw M2; 4 mm; 0.16 in long 9913015 Union nut ◆ 9998290 Clamping ring ◆ 0179787 Stripped hose, length 7.5 m;...
  • Page 45 GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL Spare parts list Item K Part No. Description 0350393 Sealing screw ◆ 0350392 Sealing 0350382 Hose fi tting ø10 mm; ø0.39 in; 1/4“ 0350346 Hose fi tting ø10 mm; ø0.39 in; 3/8“...
  • Page 46 GM 2800EA EDITION 10/2005 PART NO. DOC0388891 OPERATING MANUAL...
  • Page 48 0388891...

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