WAGNER GM5000 Operating Manual
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WAGNER GM5000 Operating Manual

3-in-1 electrostatic, aircoat & airless system
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Inclusive of F230 diaphragm,
VM500 Power Pack &
GM5000 EAC electrostatic gun
Operating manual
3-in-1 Electrostatic, AirCoat
& Airless System
Edition 02/2024

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Summary of Contents for WAGNER GM5000

  • Page 1 Operating manual 3-in-1 Electrostatic, AirCoat & Airless System Edition 02/2024 Inclusive of F230 diaphragm, VM500 Power Pack & GM5000 EAC electrostatic gun...
  • Page 19 Prime/Spray Valve ASSY 0555901________...
  • Page 22 Translation of the original Operating manual VM 500 Edition 03/2012 Electrostatic control unit for electrostatic hand spray guns B_03416 II 3 G (in submission)

  • Page 24: 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 staff 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 25 VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL Contents MAINTENANCE AND REPAIR Maintenance Repair PRODUCT DISPOSAL ACCESSORIES SPARE PARTS 11.1 How to order spare parts? 11.2 VM 500 spare parts list...

  • Page 26: About These Instructions

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL ABOUT THESE INSTRUCTIONS LANGUAGES 2310485 2318724 2318725 2318726 2318728 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS Warning instructions in this manual point out particular dangers to users and equipment and state measures for avoiding the hazard. These warning instructions fall into the following categories: Danger - imminent danger.

  • Page 27: General Safety Instructions

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep these operating instructions to hand near the unit at all times. Always follow local regulations concerning occupational safety and accident prevention. 2.1.1 ELECTRICAL EQUIPMENT Electrical plant and unit...

  • Page 28: Safety Instructions For Staff

    Always follow local regulations concerning occupational safety and accident prevention. 2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or cleaning agents: Never point the spray gun at people.

  • Page 29: Cleaning

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL 2.2.4 CLEANING De-energize the unit electrically. Disconnect the pneumatic supply line. Relieve the pressure from the unit. Ensure that the flash point of the cleaning agent is at least 15K above the ambient tem- perature.

  • Page 30: Correct Use

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL CORRECT USE SAFETY-RELEVANT INFORMATION ABOUT DISCHARGES The plastic parts of the spray gun are charged electrostatically by the high-voltage field of the spray pistol. Harmless discharges (brush discharges) are possible after contact with plastic parts.

  • Page 31: Explosion Protection According To Fm

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL Authorization for zone 2 (control unit) II 3 G Ex nR IIA T4 Gc Communautés Européennes Symbol for explosion protection Unit class II Category 3 (Zone 2) Ex-atmosphere gas Ex nR Ignite protection class „Restricted breathing“...

  • Page 32: Guarantee And Conformity Declarations

    fitted , operated and maintained. If other makes of accessory and spare parts are used, the manufacturer‘s liability could be fully or partially null and void. The usage of original WAGNER accessories and spare parts guarantees that all safety regulations are observed. GUARANTEE CLAIM...

  • Page 33: Ce-Conformity

    II 2 G EEx 0.24mJ 0102 SIRA 11 ATEX 5374X CE Certificate of Conformity The certificate is enclosed with this product. The certificate of conformity can be reordered from your WAGNER representative, quoting the product and serial number. Part number : 2310487...

  • Page 34: Description

    DESCRIPTION FIELDS OF APPLICATION, USING IN ACCORDANCE WITH THE INSTRUCTIONS WAGNER‘s electrostatic control unit VM 500 controls the high voltage supply to the spray guns used to apply liquid coating media GM 5000EAC and GM 5000EA. The VM 500 may only be operated together with the above-mentioned hand spray guns.

  • Page 35: Technical Data

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL TECHNICAL DATA Input voltage 115 VAC - 230 VAC, 50 Hz / 60 Hz Input power max. 40 W Input current max. 0.5 A Output voltage max. 20 Vpp Output current max.

  • Page 36: Functional Description

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL FUNCTIONAL DESCRIPTION The VM 500 control unit together with the suitable GM 5000EA or GM 5000EAC spray gun and other components 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.

  • Page 37: Connections On The Rear Side

    I = The control unit is activated. Gun connection To connect a GM 5000EA or GM 5000EAC gun. Warning - Do not disconnect under voltage. Cover of the service connections For Wagner service personnel only! 10 Knurled nut earthing Earthing cable connection to the system earth.

  • Page 38: Preparation Before Starting Work

    This control unit can be used to complete an electro-static hand spraying system. If this is the objective, only a suitable spray gun and the relevant components for the selected spray technique are required (see WAGNER accessories). Spray guns that are compatible with the VM 500:...

  • Page 39: Positioning Of The Unit

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL POSITIONING OF THE UNIT DANGER Incorrect installation of the unit! Risk of explosion and equipment damage Place the unit outside the spray booth/zone. Place the unit, if possible, outside the explosion zone (Positioning in explosion zone 2 is enables).
  • Page 40 VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL WARNING Heavy paint mist if earthing is insufficient! Risk of poisoning Insufficient paint application quality Earth all unit components. Earth the workpieces being painted. SIHI_0003_GB The imperfect earthing of a work piece will result in: •...

  • Page 41: Example For Aircoat Spraying System

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL EXAMPLE FOR AIRCOAT SPRAYING SYSTEM 5 0 0 B_03422 Item Description Item Description Item Description Air hose GM 5000EACF spray gun Return hose Gun cable Material hose High pressure fi lter Earthing cable Compressed air Return valve...
  • Page 42 VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL The following points should be noted before commissioning: ➞ Lay earthing cable from the earthing screw on the device to the signal ground and ensure that all other conductive parts within the area of work are earthed. ➞...

  • Page 43: Start-Up And Operation

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL START-UP AND OPERATION ➞ Observe safety instructions in chapter 2. DANGER High voltage field! Danger to life from malfunctioning heart pacemakers Ensure that persons with heart pacemakers: Do not work with the electrostatic spray gun. Remain outside the area of the electrostatic spray gun/work - piece.

  • Page 44: Standby Mode

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL STANDBY MODE VM 500 B_03423 If you want to spray without high-voltage, select standby mode. Press push button (3) briefl y and the standby (4) LED display lights up. Note: This function can be activated and used from the gun.

  • Page 45: Trouble Shooting And Solution

    • Switch on mains power supply. does not light up • Fuses defective. • Replace fuse. No illuminated display lights • WAGNER Service. Green illuminated display (1) • Spray gun cable not connected or • Connect spray gun cable. does not light up, defective.

  • Page 46: Maintenance And Repair

    DIN EN 60079-15:2011 have to be fulfi lled. This inspection may only be carried out by an authorized person or by trained Wagner Service personnel. The mains input terminal shall serve as the test port in the leak-tightness check.

  • Page 47: Accessories

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL ACCESSORIES Part No. Description 241270 Mains cable Europe 3 m; 9.8 ft 2330628 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;...

  • Page 48: Spare Parts

    Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 49: Vm 500 Spare Parts List

    VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL 11.2 VM 500 SPARE PARTS LIST 17 18 B_03424...
  • Page 50 VM 500 EDITION 03/2012 PART NUMBER DOC 2318724 OPERATING MANUAL Item Part No. Description 2310478 VM 500 control unit 9950330 Safety catch for connector sockets 9903306 Oval head screw, phillips screwdriver, form H 9910102 Hexagon nut 9910522 High knurled nut 9920118 Washer 9922017...
  • Page 51 DK- 8600 Silkeborg Telephone: +32 (0)2 269 4675 Telephone: +45 70 200 245 Telefax: +32 (0)2 269 7845 Telefax: +45 86 856 027 E-Mail: info@wsb-wagner.be / HP www.wsb-wagner.eu E-Mail info@wagner-industri.com United Kingdom France WAGNER Spraytech (UK) Ltd. J. WAGNER France S.A.R.L.
  • Page 53 2318724...
  • Page 54 Translation of the original Operating manual GM 5000EAC Edition 03/2012 Electrostatic AirCoat Spray gun for manual operation with fl at or round jet nozzles II 2 G EEx 0.24 mJ 0102 B_03154 (in submission)
  • Page 56 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 staff 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 57 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL Contents Preparation of paints 5.2.1 Viscosity conversion table Start-up 5.3.1 General rules for making adjustments to the spray gun 5.3.2 Preparation for starting up Working 5.4.1 Filling with working material 5.4.2 Start-up for spraying AirCoat 5.4.3 Cleaning of clogged round jet nozzles...
  • Page 58 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL Contents SPARE PARTS 10.1 How to order spare parts? 10.2 GM 5000EAC spare parts list 10.2.1 GM 5000EAC spare parts list- End piece 10.2.2 GM 5000EAC spare parts list - Handle 10.3 Accessories spare parts lists 10.3.1 Flat jet nozzles spare parts list...

  • Page 59: About These Instructions

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL ABOUT THESE INSTRUCTIONS LANGUAGES 2310481 2319150 2320152 2320153 2320154 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS Warning instructions in this manual point out particular dangers to users and equipment and state measures for avoiding the hazard. These warning instructions fall into the following categories: Danger - imminent danger.

  • Page 60: General Safety Instructions

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep these operating instructions to hand near the unit at all times. Always follow local regulations concerning occupational safety and accident prevention. 2.1.1 ELECTRICAL EQUIPMENT Electrical plant and unit To be provided in accordance with the local safety requirements with regard to the...

  • Page 61: Safe Handling Of Wagner Spray Units

    EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or cleaning agents: Never point the spray gun at people.

  • Page 62: Cleaning

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 2.2.4 CLEANING De-energize the unit electrically. Disconnect the pneumatic supply line. Relieve the pressure from the unit. Ensure that the flash point of the cleaning agent is at least 15K above the ambient tem- perature.

  • Page 63: Touching Hot Surfaces

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 2.2.6 TOUCHING HOT SURFACES ➞ Touch hot surfaces only if you are wearing protective gloves. ➞ When operating the unit with a coating material with a temperature of > 43 °C; 109.4 °F: - Identify the unit with a warning label that says „Warning - hot surface“.

  • Page 64: Safety-Relevant Information About Discharges

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL SAFETY-RELEVANT INFORMATION ABOUT DISCHARGES The plastic parts of the spray gun are charged electrostatically by the high-voltage field of the spray pistol. Harmless discharges (brush discharges) are possible after contact with plastic parts.

  • Page 65: Explosion Protection Identification Fm

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL Cleaning If there are deposits on the surfaces, the unit may form electrostatic charges. Flames or sparks can form if there is a discharge. Remove deposits from the surfaces to maintain conductivity. Use only a damp cloth to clean the unit.

  • Page 66: Guarantee And Conformity Declarations

    fitted , operated and maintained. If other makes of accessory and spare parts are used, the manufacturer‘s liability could be fully or partially null and void. The usage of original WAGNER accessories and spare parts guarantees that all safety regulations are observed. GUARANTEE CLAIM...

  • Page 67: Ce-Conformity

    II 2 G EEx 0.24mJ 0102 SIRA 11 ATEX 5374X CE Certificate of Conformity The certificate is enclosed with this product. The certificate of conformity can be reordered from your WAGNER representative, quoting the product and serial number. Part number : 2310487...

  • Page 68: Description

    ➞ The spray gun basic version is suitable for processing of sprayed substances with an electrical resistance of > 150 k (according to the WAGNER scale). Equipped with a special material hose for low impedance sprayed substances (available as accessory) you can also sprayed substances with an electrical conductivity >...

  • Page 69: Scope Of Delivery

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL SCOPE OF DELIVERY Quantity Part No. Description 2309871 GM 5000EAC spray gun Without control unit, material and air hose, electrical cable, air cap and nozzle. Each gun includes as standard equipment: Part No.

  • Page 70: Technical Data

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL TECHNICAL DATA Max. air pressure 0.8 MPa; 8 bar; 116 psi Max. material pressure 25 MPa; 250 bar; 3626 psi Material connection NPSM 1/4“-18 Air connection G 1/4“ A Input voltage max.

  • Page 71: Functional Description

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL FUNCTIONAL DESCRIPTION 4.4.1 DESIGN OF SPRAY GUN (STANDARD VARIANT) Note: The nozzle parts (item 6; 7; 13 and 14) do not belong to the basic equipment of the spray gun. The different versions can be found in Chapter 9 „Accessories“. B_03156 Item Description...

  • Page 72: Functions Of The Spray Gun

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 4.4.2 FUNCTIONS OF THE SPRAY GUN When the spray gun is connected to the control unit and the control unit is switched on, the pre-defi ned recipe (R1, R2 or R3) is shown on the gun display (2) as follows.

  • Page 73: Spraying Process

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL SPRAYING PROCESS 4.5.1 AIRCOAT ROUND JET SPRAY PROCESS In the AirCoat process, high pressure of 3-15 MPa; 30-150 bar; 435-2176 psi is used to atomize the material. The air at 0-0.25 MPa; 0-2.5 bar; 0-36 psi produces a soft jet. The size of the spray jet can be adjusted by turning the nozzle nut.

  • Page 74: Electrical Resistance

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 4.5.3 ELECTRICAL RESISTANCE 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 75: Start-Up And Operation

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL START-UP AND OPERATION INSTALLATION AND CONNECTION 5.1.1 TYPICAL ELECTROSTATIC SPRAYING SYSTEM B_03158 Item Designation GM 5000EACF spray gun Gun cable Item Designation Grounding cable Item Designation Compressed air Material hose Pneumatic pumps connection Carriage Return valve...

  • Page 76: Ventilation Of The Spray Booth

    (Spraypack). The spraying system shown in the fi gure B_03158 is only one example of an electrostatic spraying system. Contact your Wagner distributor for assistance in designing a system to meet your needs. The operating instructions and the safety regulations for the additional system components used must be read before starting-up.

  • Page 77: Paint Supplies

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 5.1.4 PAINT SUPPLIES CAUTION Impurities in the spraying system! Spray gun blockage, materials harden in the spraying system Flush the spray gun and paint supply with a suitable cleaning agent. SIHI_0001_GB DANGER Bursting hose, bursting threaded joints! Danger to life from injection of material...

  • Page 78: Earthing

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 5.1.5 EARTHING Perfect earthing of all conductive parts such as fl oors, walls, roofs, is important for optimum coating and safety. Barriers, work pieces, transport devices, coating material container, automatic movement system or construction parts in the spray area must be connected to the earthing system, with exception of the high-voltage parts during normal operation.
  • Page 79 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL Earthing schema (example) Conveyor Note for the sprayer The work shoes and if Control unit used the gloves must be derivable. Work piece Earthing cable Pump R max < 1 MΩ Paint container Spraying stand B_03234...

  • Page 80: Preparation Of Paints

    0.16 inches). Processing of up to 60 DIN-s is generally possible without problem, if high coating thicknesses are required. The Wagner AirCoat fl at jet spraying process determined optimally the different viscosity of the paint by two air cap types. These can be found in the Accessories.

  • Page 81: Start-Up

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL START-UP 5.3.1 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN ➞ Observe safety instructions in Chapter 2. DANGER High voltage field! Danger to life from malfunctioning heart pacemakers Ensure that persons with heart pacemakers: Do not work with the electrostatic spray gun.
  • Page 82 PART NUMBER DOC 2319150 OPERATING MANUAL ➞ Check the level of the release agent in the Wagner pneumatic pump and if necessary fi ll the release agent up. ➞ Provide material container, containers for detergent and an empty container for return.

  • Page 83: Working

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL B_03158 WORKING 5.4.1 FILLING WITH WORKING MATERIAL 1. Provide an empty container for return (18). See image B_03158. 2. Place suction 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 housing! 3.

  • Page 84: Start-Up For Spraying Aircoat

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 8. Close return valve (17). 9. Point the gun, without nozzle, into container (18) and open it. 10. Slowly open the ball valve (11). 11. Close ball valve (11) as soon as pure working material without any air inclusions starts coming from the gun.

  • Page 85: Cleaning Of Clogged Round Jet Nozzles

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 5.4.3 CLEANING OF CLOGGED ROUND JET NOZZLES DANGER Exploding gas/ air mixture! Danger to life from flying parts and burns Never spray into a closed container. Earth the container. SIHI_0008_GB 1. By means of nozzle spanner (2), loosen nozzle insert (1) by a half turn.

  • Page 86: Changing From Aircoat Round Jet To Aircoat Flat Jet

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 5.4.5 CHANGING FROM AIRCOAT ROUND JET TO AIRCOAT FLAT JET 1. Flush the spray gun (1) out thoroughly with cleaning agent. 2. Relieve the pressure of gun and unit. 3. Save the spray gun (1) using the trigger lock. 4.

  • Page 87: Replacing Aircoat Flat Jet Nozzles

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 5.4.6 REPLACING AIRCOAT FLAT JET NOZZLES 1. Switch off control unit. 2. Relieve the pressure of gun (1) and unit! 3. Save the spray gun (1) using the trigger lock. 4. Unscrew union nut (12) and remove air cap (10). 5.
  • Page 88 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 6. Insert air cap (10) with integrated ACF 5000 nozzle (11) into the union nut (9). Make sure that the air cap horns (Y) lie in the recess of the nozzle guard. 7.

  • Page 89: Maintenance

    Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.
  • Page 90 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL DANGER Exploding gas/ air mixture! Danger to life from flying parts and burns Never spray into a closed container. Earth the container. SIHI_0008_GB 1. Switch off control unit. 2. Ensure that the material pressure is relieved and shut off the air supply to the gun. 3.

  • Page 91: Dismantling Of The Spray Gun

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL DISMANTLING OF THE SPRAY GUN SW12 SW12 B_03194 Torx 25 SW19 B_03195 SW21...
  • Page 92 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL Carefully release the cascade without pliers. SW19 B_03196 SW22 SW19 Assembly tool for Note: needle valve. Loosen AC valve tip by hand Part no. 2309368 using an assembly tool. Use assembly tool, socket or ring spanner (no wrench).
  • Page 93 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 1. Remove pressure spring (4). 2. Loosen clamping screw (1) completely with 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.

  • Page 94: Cleaning The Parts After Disassembly

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL CLEANING THE PARTS AFTER DISASSEMBLY ATTENTION Please note: ➞ All reusable parts (except for the parts that conduct the high-voltage such as cascade, end piece, plug compl. etc.) should be cleaned thoroughly using a suitable cleaning agent.

  • Page 95: Assembling The Spray Gun

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL ASSEMBLING THE SPRAY GUN SW9 1 Nm B_03448 Ensure the correct insertion position! Mounting materials: Item Part No. Description 9992590 Loctite 222 B_03201 9992698 Vaseline white PHHV II 9992831 Loctite 542 SW14 3 Nm 9992511 Loctite 243...
  • Page 96 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL Insertion position compl. package Set measure X with withdrawal nut and then fasten it with the threaded pin (SW2). X = 123 ±0.1 Push together the valve rod unit and the compl.
  • Page 97 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL Clean and degrease the inside of the end piece and the cascade, then grease the cascade surface with Vaseline. SW19 0.8 Nm 2.5 Nm SW19 B_03205 SW21 B_03204 SW22 SW19 Push the trigger upward into the air valve piston.
  • Page 98 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 0.8 Nm Ensure the correct insertion position! SW12 SW12 B_03207 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 nozzle sizes see chapter 9.1. B_03208...

  • Page 99: Function Test After Assembly Of The Gun

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL FUNCTION TEST AFTER ASSEMBLY OF THE GUN 6.6.1 CHECKING THE HIGH-VOLTAGE Necessary test equipment: VM 500 or VM 5000 control unit and HV200 high-voltage tester. High-voltage measurements on spraying gun. Connect gun cable to control unit. Take the spray gun in your hand and hold into open space. Switch on control unit and actuate trigger guard.

  • Page 100: Air Tests

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 6.6.2 AIR TESTS Connect test or air hose to the spray gun and switch on mains pressure 0.8 MPa; 8 bar; 116 psi max. Checking the air valve The air valve must switch on and off cleanly. Test up to approx.

  • Page 101: Check Spray Pattern

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 6.6.4 CHECK SPRAY PATTERN Start AirCoat spraying (without electrostatics) 1. Start up with material supply set to approx. 8 MPa; 80 bar; 1160 psi operating pressure. 2. Spray (release trigger safety catch and pull trigger) and check the atomisation. 3.

  • Page 102: Trouble Shooting And Solution

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL TROUBLE SHOOTING AND SOLUTION Functional fault Cause Remedy Insuffi cient material output • Nozzle too small. • Select larger nozzle (see Accessories chapter 9). • Material pressure too • Increase material pressure. low.

  • Page 103: Product Disposal

    Your waste Wagner electrical device will be taken back by us or our representatives and disposed of environmentally correctly. Please contact one of our service points or one of our representatives or us directly to this purpose.

  • Page 104: Accessories

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL ACCESSORIES ACR 5000 ROUND JET NOZZLE CAP Part No. Description 2309883 ACR 5000 round jet nozzle cap (with nozzle spanner, without AC round jet nozzle insert) B_03210 9.1.1 AIRCOAT ROUND JET NOZZLE INSERTS The round jet nozzles are especially suited to spray pipes, profi...

  • Page 105: Acf 5000 Aircoat Flat Jet Nozzles

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 9.2.2 ACF 5000 AIRCOAT FLAT JET NOZZLES Application B_03163 395107 07/10 0.18; 0.007 10° Natural paint 395207 07/20 20° 395407 07/40 40° 395109 09/10 0.23; 0.009 10° Transparent lacquer 395209 09/20 20°...
  • Page 106 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL Application B_03163 395219 19/20 0.48; 0.019 20° Rust proofing paint 395319 19/30 30° Latex paint 395419 19/40 40° 395519 19/50 50° 395619 19/60 60° 395819 19/80 80° 395221 21/20 0.53; 0.021 20°...

  • Page 107: Filters

    Edge fi lter 200 mesh (yellow) REDUCTION FITTINGS FOR HIGH-PRESSURE HOSES The classifi cation of WAGNER fi ttings is consistent with the following classifi cation, each separated by high-pressure and low pressure fi ttings. Double fi tting - Male / Male thread Reduction fi...

  • Page 108: Hoses And Electrical Cables

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL HOSES AND ELECTRICAL CABLES 9.5.1 STANDARD HOSE SETS AND COMPONENTS B_03217 Item Part No. Description 2309857 GM 5000EAC hose set (7.5 m) Consisting of: 9984573 High pressure hose-DN4-PN270-¼“NPS-7.5 m-PA 2312060 Air hose compl. (8.0 m) 2307293 GM 5000E gun cable (10.0 m) 3676437...

  • Page 109: Hose Sets For Low Impedance Materials

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 9.5.2 HOSE SETS FOR LOW IMPEDANCE MATERIALS Note to the material hose: - nominal pressure 250 bar - inlet diameter 4 mm - inside hose material FEP B_03216 Item Part No. Description 2309951 GM 5000EAC hose set (7.5 m), Low R...

  • Page 110: Gun Cable And Gun Cable Extensions

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 9.5.3 GUN CABLE AND GUN CABLE EXTENSIONS Part No. Description 2307295 GM 5000E extension cable 10 m B_03219 2307296 GM 5000E extension cable 20 m MISCELLANEOUS Part No. Description 2319653 Gun protective cover B_03693 259010 HV200 N high-voltage tester...
  • Page 111 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 2309368 Assembly tool valve needle B_03451 128901 ACR nozzle spanner 2325263 Assembly tool clamping screw B_03681 Part Part # 2357106 2326485 GM 5000E wall mount (left/right) B_03699 2324766 Swivel for air B_03720 2327060 Fitting-SJM-GM5000EAC-1/4“NPS (swivel material)

  • Page 112: Spare Parts

    Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 113: Gm 5000Eac Spare Parts List

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 10.2 GM 5000EAC SPARE PARTS LIST B_03153...
  • Page 114 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL GM 5000EAC spare parts list Item K Quantity Part No. Description 2309871 GM 5000EAC standard variant ★ ◆ 2314283 AC contacting ◆ ★ 9952777 High resistance, bare 9960808 Socket contact component GM 5000EAC end piece compl.

  • Page 115: Gm 5000Eac Spare Parts List- End Piece

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 10.2.1 GM 5000EAC SPARE PARTS LIST- END PIECE B_03164 Ensure the correct insertion position! X = 123 ±0.1...
  • Page 116 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL GM 5000EAC end piece spare parts list Item Quantity Part No. Description GM 5000EAC end piece compl. ★ 2313314 AC air manifold ring ◆ ★ 2307180 O-ring, sheathed ◆ ★ 2312175 AC valve housing compl.

  • Page 117: Gm 5000Eac Spare Parts List - Handle

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 10.2.2 GM 5000EAC SPARE PARTS LIST - HANDLE 18 19 B_03165...
  • Page 118 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL GM 5000EAC handle spare parts list Item K Quantity Part No. Description GM 5000EAC handle compl. 2307288 Nipple ◆ ★ 9971025 O-ring 2315344 Hose holder 2312182 Plug compl. 2314270 Handle compl. ★...

  • Page 119: Accessories Spare Parts Lists

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 10.3 ACCESSORIES SPARE PARTS LISTS 10.3.1 FLAT JET NOZZLES SPARE PARTS LIST B_03168 Flat jet nozzles spare parts list Item Quantity Part No. Description 2315775 AC union nut compl. 2309882 LV air cap compl. 2314203 HV air cap compl.

  • Page 120: Acr 5000 Round Jet Nozzle Cap Spare Parts List

    5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL 10.3.2 ACR 5000 ROUND JET NOZZLE CAP SPARE PARTS LIST B_03169 ACR 5000 round jet nozzle cap spare parts list Item Quantity Part No. Description 2309883 ACR 5000 round jet nozzle cap 2307220 Nozzle nut ◆...
  • Page 121 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL...
  • Page 122 5000EAC. EDITION 03/2012 PART NUMBER DOC 2319150 OPERATING MANUAL...
  • Page 123 DK- 8600 Silkeborg Telephone: +32 (0)2 269 4675 Telephone: +45 70 200 245 Telefax: +32 (0)2 269 7845 Telefax: +45 86 856 027 E-Mail: info@wsb-wagner.be / HP www.wsb-wagner.eu E-Mail info@wagner-industri.com United Kingdom France WAGNER Spraytech (UK) Ltd. J. WAGNER France S.A.R.L.
  • Page 125 2319150...

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Vm500F230

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