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

WAGNER GM 2800EA Operating Manual

Electrostatic air spray gun for manual operation with fl at or round jet nozzles
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Translation of the original
Operating manual
GM 2800EA
Edition 03/ 2007
Electrostatic Air spray gun
for manual operation
with fl at or round jet nozzles
0102
II 2G EEx 0.24 mJ T6 (Atex 95)

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  • Page 1 Translation of the original Operating manual GM 2800EA Edition 03/ 2007 Electrostatic Air spray gun for manual operation with fl at or round jet nozzles 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 03/ 2007 PART NO. DOC388891 OPERATING MANUAL Contents 5.1.4 Fluid (Paint) hoses 5.1.5 Earthing Preparation 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 03/ 2007 PART NO. DOC388891 OPERATING MANUAL ABOUT THESE INSTRUCTIONS LANGUAGE 388890 388891 388892 388893 388894 388895 388897 388896 388898 The corresponding service instructions are available under the following order number: Language: Part No. Language: Part No.

  • Page 6: General Safety Instructions

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 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

    EDITION 03/ 2007 PART NO. DOC388891 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 8: Cleaning

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 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 03/ 2007 PART NO. DOC388891 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 10: Safety Instructions

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL 2.5.4 SAFETY INSTRUCTIONS GERMAN REGULATIONS AND GUIDELINES a) BGV A2 Electrical units and equipment b) BGR 500 Part 2, Chap. 2.36 Working with liquid ejection devices c) BGR 500 Part 2, Chap. 2.29 Using coating materials d) CHV 9 Regulations on flammable liquids...

  • Page 11: Product Liability And Warranty

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL PRODUCT LIABILITY AND WARRANTY IMPORTANT NOTES ON PRODUCT LIABILITY WARRANTY...

  • Page 12: Ce-Conformity

    Marking: 0102 II 2G EEx 0.24 mJ T6 (Atex 95) 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: 179780...

  • Page 13: Ptb Conformity Certifi Cation

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL PTB CONFORMITY CERTIFICATION...

  • Page 14: Description

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

  • Page 15: Scope Of Supply

    Description 179037 Spray gun GM 2800EA 179060 Spray gun GM 2800EA USA 179047 Spray gun GM 2800EA Special lengths 179061 Spray gun GM 2800EA Special lengths USA The standard equipment includes: Quantity Part No. Description 179901 Universal spanner 353210 Nozzle spanner...

  • Page 16: Technical Data

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL TECHNICAL DATA Maxi. air pressure 0.8 MPa; 8 bar; 116 psi Maxi. material pressure 0.8 MPa; 8 bar; 116 psi Material connection ø 10 mm; 0.39 inch Material hose length 7.5 m;...

  • Page 17: Function

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL FUNCTION 4.4.1 DESIGN OF SPRAY GUN 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 18: Air Atomizing Spray Process

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL AIR ATOMIZING SPRAY PROCESS 4.5.1 ROUND AND FLAT JET In this process, the material (paint) is fed to the nozzle with low pressure at approx. 0.05- 0.2 MPa; 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 19: Electrostatic Effect

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 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 20: 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 assist- ance in designing a system to meet your needs.

  • Page 21: Ventilation Of The Spray Booth

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL 5.1.2 VENTILATION OF THE SPRAY BOOTH WARNING Toxic and/or flammable vapor mixtures! Risk of poisoning and burns Operate the unit in a spraying booth approved for the working materials. -or- Operate the unit on an appropriate spraying wall with the venti- lation (extraction) switched on.

  • Page 22: Earthing

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 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 23 GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL Earthing scheme (example) Conveyor Control module 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...

  • Page 24: Preparation Of Paint

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL PREPARATION 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 inch).

  • Page 25: Start-Up

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL START-UP 5.3.1 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN ➞ See safety regulations 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 26: Working

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 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 spray gun with tension cap.

  • Page 27: Adjust The Spray Angle With Fl At Jet Nozzle

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 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 28: Changing From Round Jet Nozzle To Fl At Jet Nozzle

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL 5.4.4 CHANGING FROM ROUND JET NOZZLE TO FLAT JET NOZZLE 1. Switch off control unit. Round jet nozzle 2. Relieve spray gun and unit pressure. 3. Unscrew the nozzle nut EAR (B).

  • Page 29: Maintenance

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

  • Page 30: Finishing Work And Cleaning

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL FINISHING WORK AND CLEANING 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.

  • Page 31: Trouble Shooting And Solutions

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 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 32 • Check function of control unit in accordance with its manual • Switch on high voltage switch • Defective sealing (71)* • Repair by WAGNER Service in gun barrel • Air-passages damp • Clean air passages and drying Leaking material the nozzle •...

  • Page 33: Repair Work

    WARNING Incorrect maintenance/repair! Danger to life and equipment damage Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the chapter "Spare parts catalog".

  • Page 34: Exchange Of Complete Valve Rod

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL EXCHANGE OF COMPLETE VALVE ROD CAUTION Defective sealing surface! Equipment damage to the gun Coating error Do not damage the sealing surface. SIHI_0034_GB Attention: Do not damage sealing surfaces 1. Remove nozzle according t paragraph 5.4.3 and 5.4.5 2.

  • Page 35: Exchange Of Valve Rod Seals

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL EXCHANGE OF VALVE ROD SEALS CAUTION Defective sealing surface! Equipment damage to the gun Coating error Do not damage the sealing surface. SIHI_0034_GB 1. Remove valve rod as described in paragraph 8.2.

  • Page 36: Electrode Replacement

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL ELECTRODE REPLACEMENT Electrode If the electrode is damaged (bent or broken) by incorrect handling, the valve needle head (12) must be replaced. CAUTION Defective sealing surface! Equipment damage to the gun Coating error Do not damage the sealing surface.

  • Page 37: Replacing The Paint Hose

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 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 38: Product Disposal

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

  • Page 39: Accessories

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL ACCESSORIES 10.1 NOZZLES EA FLAT-JET Part No. Description Colour 363228 Nozzle set EAF 0.6 black 363229 Nozzle set EAF 0.8 yellow 363230 Nozzle set EAF 1.0 363231 Nozzle set EAF 1.2...

  • Page 40: Ea Round Jet Nozzle (Supra)

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL 10.2 EA ROUND JET NOZZLE (SUPRA) Part No. Description 363238 Nozzle set EAR Supra 353966 Nozzle nut EAR 2000 353965 Nozzle body Supra 353952 Nozzle insert Supra EA 353210 Nozzle key 2800 EA 10.2.1...

  • Page 41: Hoses, Fi Ttings And Electrical Cables

    Protective sleeve (per metre) without fi xing strap 179228 Extension cable 7.5 m; 24.6 ft gun to control unit Material hose ø 6,12 mm; ø 0.24, 0.47 inch, contact your WAGNER branch for special precut lengths 353701 Material hose set EA The set includes 7.5 m; 24.6 ft material hose ø 6, 12 mm;...

  • Page 42: Spare Parts Catalogue

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

  • Page 43: Spare Parts List

    GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL 11.2 SPARE PARTS LIST B_00083 Item K Part No. Description 350903 Nozzle needle assy. metal 179325 Air control knob ◆★ 9971003 O-ring green 179354 Positioning bushing 9900962 Countersunk screw M3, 12 mm; 0.47 inch ◆...
  • Page 44 ◆ 179219 Trigger GM 2000 ◆ 179396 Trigger pin ◆ 9900808 Pan-head screw M3, 12 mm; 0.47 inch 353381 Data plate GM 2800EA 9900810 Pan-head screw M2, 4 mm; 0.16 inch 9913015 Union nut ◆ 9998290 Clamping ring ◆ 179787 Stripped hose, length 7.5 m;...
  • Page 45 GM 2800EA EDITION 03/ 2007 PART NO. DOC388891 OPERATING MANUAL Spare parts list Item K Part No. Description 350393 Sealing screw ◆ 350392 Sealing 350382 Hose fi tting ø 10 mm; ø 0.39 inch; 1/4“ 350346 Hose fi tting ø 10 mm; ø 0.39 inch; 3/8“...
  • Page 46 Telephone: +41 (0)71 757 2211 Telefax: +49 7544 505200 Telefax: +41 (0)71 757 2222 E-Mail: service.standard@wagner-group.com E-Mail: rep-ch@wagner-group.ch Belgium Denmark WAGNER Spraytech Benelux BV WAGNER Industrial Solution Scandinavia Veilinglaan 58 Viborgvej 100, Skærgær B- 1861 Wolvertem DK- 8600 Silkeborg Telephone: +32 (0)2 269 4675...
  • Page 48 388891...

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