WAGNER GM 5000EA Operating Manual
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WAGNER GM 5000EA Operating Manual

Electrostatic airspray gun for manual operation with fl at or round jet nozzles
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See also: Operating Manual
Electrostatic Airspray gun
for manual operation
with fl at or round jet nozzles
II 2 G EEx 0.24 mJ
0102
(in submission)
c
us
Translation of the original
Operating manual
GM 5000EA
Edition
03/2012
B_03229

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Summary of Contents for WAGNER GM 5000EA

  • Page 1 Translation of the original Operating manual GM 5000EA Edition 03/2012 Electrostatic Airspray gun for manual operation with fl at or round jet nozzles B_03229 II 2 G EEx 0.24 mJ 0102 (in submission)

  • 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 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 4 EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL Contents Preparation of paints 5.2.1 Viscosity conversion table Wagner electrostatic air spraying system 5.3.1 Pressure settings for round jet nozzles 5.3.2 Pressure settings for fl at jet nozzles 5.3.3 Electrostatic and atomization 5.3.4...
  • Page 5 10.1 How to order spare parts? 10.2 GM 5000EA spare parts list 10.2.1 GM 5000EA spare parts list- End piece 10.2.2 GM 5000EA spare parts list - Handle 10.3 Accessories spare parts lists 10.3.1 AR 5000 (D8) nozzle spare parts list...

  • Page 6: About These Instructions

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL ABOUT THESE INSTRUCTIONS LANGUAGES 2310480 2319149 2320149 2320150 2320151 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.

  • Page 7: General Safety Instructions

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 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.

  • Page 8: Safe Handling Of Wagner Spray Units

    EDITION 03/2012 ORDER NUMBER DOC 2319149 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 9: Cleaning

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 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 10: Touching Hot Surfaces

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 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 11: Safety-Relevant Information About Discharges

    2.5.1 CORRECT USE The GM 5000EA electrostatic hand spray gun is suitable for spraying liquid materials, particularly coating materials, using the air atomizing method. Coating materials containing solvents of Explosion Class II A may be used. The spray gun may only be used in combination with the VM 500 and VM 5000 control unit.

  • Page 12: Explosion Protection Identifi Cation Fm

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 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.

  • Page 13: 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 14: 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 15: Description

    The electrostatic spray gun can only be used with the VM 5000 or VM 500 control units. 4.1.1 PROCESSABLE MATERIALS ➞ With the GM 5000EA gun, paints can be applied which contain solvent of explosion class II A. ➞ The spray gun basic version is suitable for processing of sprayed substances with an electrical resistance of >...

  • Page 16: Scope Of Delivery

    ORDER NUMBER DOC 2319149 OPERATING MANUAL SCOPE OF DELIVERY Quantity Part No. Description 2309870 GM 5000EA spray gun Without control unit, material and air hose, electrical cable, air cap and nozzle. Each gun includes as standard equipment: Part No. Description 2309368...

  • Page 17: Technical Data

    78 dB(A) * 0.3 MPa; 3 bar; 43.5 psi material pressure * A rated sound pressure level measured at 1 m distance according to DIN EN 14462: 2005. Measurements GM 5000EA F with fl at jet nozzle inches 10.28 1.81 9.65...

  • Page 18: Functional Description

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL FUNCTIONAL DESCRIPTION 4.4.1 DESIGN OF SPRAY GUN (STANDARD VARIANT) Note: The nozzle parts (item 5; 7; 14 and 20) do not belong to the basic equipment of the spray gun. The different versions can be found in Chapter 9 „Accessories“.

  • Page 19: Functions Of The Spray Gun

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 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 20: Spraying Process

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL SPRAYING PROCESS 4.5.1 AIR ATOMIZING SPRAY PROCESS - ROUND JET In this process, the material (paint) is fed to the nozzle with low pressure (0.05-0.2 MPa; 0.5-2 bar; 7-29 psi).

  • Page 21: The Electrostatic Effect

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL 4.5.3 THE 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 22: Start-Up And Operation

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL START-UP AND OPERATION INSTALLATION AND CONNECTION 5.1.1 TYPICAL ELECTROSTATIC AIR SPRAYING SYSTEM Electrostatic air spraying system B_03233 Item Description Item Description Pressure tank VM 5000 control unit Stop valve Material hose...

  • Page 23: Ventilation Of The Spray Booth

    ORDER NUMBER DOC 2319149 OPERATING MANUAL The GM 5000EA spray gun must be used a part of an electrostatic spraying system (spray-pack). The spraying system shown in the fi gure B_03233 is only one example of an electrostatic air spraying system. Contact your Wagner distributor for assistance in designing a system to meet your needs.

  • Page 24: Air Supplies

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL 5.1.3 AIR SUPPLIES The use of an air fi lter with the air regulator (4) ensures that only dry, clean atomizing air gets into the spray gun. Dirt and moisture in the atomizing air reduce the spraying quality and the appearance of the fi...

  • Page 25: Earthing

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 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 26 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL Earthing scheme (example) Conveyor Note for the sprayer The work shoes and if used Control unit the gloves must be derivable. Work piece Earthing cable Pump or pressure tank Paint container or container for R max <...

  • Page 27: Preparation Of Paints

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL PREPARATION OF PAINTS The viscosity of the paints is of great importance. The best spraying results are obtained with values between 15 and 30 DIN-s (measured in immersion fl ow cup DIN 4 mm;...

  • Page 28: Wagner Electrostatic Air Spraying System

    ORDER NUMBER DOC 2319149 OPERATING MANUAL WAGNER ELECTROSTATIC AIR SPRAYING SYSTEM The nozzle range (chapter 9), provided by Wagner, allows optimum coating results for each application. General criteria for selection of nozzles: Flat jet -> for parts with large surfaces Round jet ->...

  • Page 29: Pressure Settings For Fl At Jet Nozzles

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL By turning the adjusting screw (A ) side of the gun, the outlet cross-section can be adjusted on the material valve. By reducing of this cross-section under the same pressure settings you might create a further refi...

  • Page 30: Electrostatic And Atomization

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL 5.3.3 ELECTROSTATIC AND ATOMIZATION The electrostatic charging of the spray cloud produces a more homogeneous distribution of paint particles on the object. See also Chapter 4.5.3. 5.3.4 OUTPUT MEASURED Flat jet nozzles Device: GM 5000EAF Viscosity: 22 DIN 4 sec.

  • Page 31: Start-Up

    ➞ 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 the system components. ➞ When using a Wagner pneumatic pump: Check the level of the release agent and if necessary fi ll the release agent up.
  • Page 32 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL ➞ Provide material container, containers for detergent and an empty container for return. ➞ Connect the system to the air and power supply. ➞ A basic fl ushing of system must be carried out for initial start up. Make sure, that no nozzle is inserted into the gun.

  • Page 33: Working

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL B_03233 WORKING 5.5.1 FILLING WITH WORKING MATERIAL 1. Provide an empty container for return (13). See image B_03233. 2. Put the container with work material into the pressure tank (1) and close the pressure tank.

  • Page 34: Start-Up For Spraying

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL 5.5.2 START-UP FOR SPRAYING 1. Insert the desired nozzle into the gun. 2. Open the stop valve (2). 3. Turn on the control unit (9). 4. Set the material supply to operating pressure P 5.

  • Page 35: Changing From Air-Round Jet To Air-Fl At Jet

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL 5.5.3 CHANGING FROM AIR-ROUND JET TO AIR-FLAT JET 1. Switch off the control unit. 2. Relieve spray gun and unit pressure. 3. Replace paint with cleaning solvent. 4. Set material pressure. Switch off the atomizing air.

  • Page 36: 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 37 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 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 atomizing air supply to the gun.

  • Page 38: Dismantling Of The Spray Gun

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL DISMANTLING OF THE SPRAY GUN SW12 SW12 B_03246 Torx 25 SW19 B_03247 SW19...
  • Page 39 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL Carefully release the cascade without pliers. SW19 B_03248 SW19 Assembly tool for Note: needle valve. Loosen valve tip Air by hand Part No. 2309368 using an assembly tool. Use socket or ring spanner SW11 (no wrench).
  • Page 40 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 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 41: Cleaning The Parts After Disassembly

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 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 42: Assembling The Spray Gun

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL ASSEMBLING THE SPRAY GUN B_03448 Ensure the correct insertion position! Mounting materials: Item Part No. Description B_03251 9992590 Loctite 222 9992698 Vaseline white PHHV II SW14 9992831 Loctite 542 3 Nm...
  • Page 43 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL Insertion position compl. package Valve rod unit Length adjusting measure X = 122 ± 0.1 Push together the valve rod unit and the compl. package. 0.4 - 0.5 Nm Screw in together the valve rod unit and the compl.
  • Page 44 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 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_03255 SW19 B_03254 Push the trigger upward into the air valve piston.
  • Page 45 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL Ensure the correct 0.8 Nm insertion position! SW12 SW12 B_03257 Flat jet nozzle Diverse nozzle sizes see Chapter 9.3. Round spray nozzle Diverse nozzle sizes see Chapter 9.2. B_03258...

  • Page 46: Function Test After Assembly Of The Gun

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 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.

  • Page 47: Air Tests

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 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.

  • Page 48: Check Spray Pattern

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL 6.6.4 CHECK SPRAY PATTERN Start air-spraying (without electrostatics) 1. Start up with material supply set to approx. 0.05 to 0.15 MPa; 0.5 to 1.5 bar; 7 to 22 psi operating pressure.

  • Page 49: Trouble Shooting And Solution

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL TROUBLE SHOOTING AND SOLUTION Functional fault Cause Remedy Insuffi cient material output • Nozzle too small. • Select larger nozzle (see nozzle table 9.1 and 9.2). • Material pressure too •...

  • Page 50: 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 51: Round Jet Nozzles

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL ROUND JET NOZZLES 9.2.1 AR 5000 AIR CAPS Part No. Description 2310557 AR 5000 air cap (D8) B_03239 2315049 AR 5000 air cap (D12) B_03239 9.2.2 AR 5000 NOZZLES Part No.

  • Page 52: Af 5000 Nozzles

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL 9.3.2 AF 5000 NOZZLES Part No. Description 2310539 AF 5000 nozzle - 0.6 mm (black) B_03241 2310540 AF 5000 nozzle - 0.8 mm (yellow) B_03241 2310541 AF 5000 nozzle - 1.0 mm (red)

  • Page 53: Hoses And Electrical Cables

    HOSES AND ELECTRICAL CABLES 9.4.1 STANDARD HOSE SETS AND COMPONENTS B_03245 Item Part No. Description 2309853 GM 5000EA hose set (7.5 m) Consisting of: 2312012 Low pressure hose-DN6-PN15-G¼“-7.5 m-PFA 2312060 Air hose, compl. (8.0 m) 2307293 GM 5000E gun cable (10.0 m) 3676437 PP30 protective hose mesh (7.0 m)

  • Page 54: Hose Sets For Low Impedance Materials

    - inlet diameter 6 mm - inside hose material FEP B_03244 Item Part No. Description 2309878 GM 5000EA hose set (7.5 m), Low R Consisting of: 2310464 EA material hose, compl. (7.5 m) LowR 2312060 Air hose, compl. (8.0 m) 2307293 GM 5000E gun cable (10.0 m)

  • Page 55: Gun Cable And Gun Cable Extensions

    GM 5000E extension cable 20 m 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. DF Double fi tting - Male / Male thread Reduction fi...

  • Page 56: Miscellaneous

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL MISCELLANEOUS Part No. Description 2319653 Gun protective cover B_03693 259010 HV200 N high-voltage tester P_00265 2326041 Paint resistance measuring device B_03692 999080 Wet fi lm thickness measurer B_03224 50342 Viscosity cup DIN 4 mm; 0.16 inches...
  • Page 57 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL Part No. Description 2326485 GM 5000E wall mount (left/right) B_03699 2324766 Swivel for air B_03720...
  • Page 58 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL...

  • Page 59: 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 60: Gm 5000Ea Spare Parts List

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL 10.2 GM 5000EA SPARE PARTS LIST B_03235...
  • Page 61 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL GM 5000EA spare parts list Item K Quantity Part No. Description 2309870 GM 5000EA basic version 2315709 Protection cap for valve needle GM 5000EA end piece, compl. Details see chapter 10.2.1 ◆...

  • Page 62: Gm 5000Ea Spare Parts List- End Piece

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL 10.2.1 GM 5000EA SPARE PARTS LIST- END PIECE B_03236 Ensure the correct insertion position! 122 ±0.1...
  • Page 63 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL End piece spare parts list Item K Quantity Part No. Description GM 5000EA end piece, compl. ★ 2309391 Air manifold ring Air ◆ ★ 2307180 O-ring, sheathed ★ ◆ 2312179 Valve seat Air, compl.

  • Page 64: Gm 5000Ea Spare Parts List - Handle

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL 10.2.2 GM 5000EA SPARE PARTS LIST - HANDLE B_03237...
  • Page 65 GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL Handle spare parts list Item K Quantity Part No. Description GM 5000EA handle, compl. 2307288 Nipple ◆ ★ 9971025 O-ring 2315344 Hose holder 2312182 Plug, compl. 2314270 Handle, compl. ★...

  • Page 66: Accessories Spare Parts Lists

    GM 5000EA EDITION 03/2012 ORDER NUMBER DOC 2319149 OPERATING MANUAL 10.3 ACCESSORIES SPARE PARTS LISTS 10.3.1 AR 5000 (D8) NOZZLE SPARE PARTS LIST B_03263 AR 5000 (D8) nozzle spare parts list Item Quantity Part No. Description 2310558 AR 5000 nozzle, compl. (D8)
  • Page 67 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.
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