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WAGNER GM 5000EA Operating manual

Manual is about: Electrostatic Airspray gun for manual operation with fl at or round jet nozzles

Summary of GM 5000EA

  • Page 1

    Gm 5000ea ii 2 g eex 0.24 mj 0102 c us b_03229 electrostatic airspray gun for manual operation with fl at or round jet nozzles edition 03/2012 translation of the original operating manual (in submission).

  • Page 3: Contents

    3 gm 5000ea operating manual edition 03/2012 order number doc 2319149 contents 1 about these instructions 6 1.1 languages 6 1.2 warnings, notes and symbols in these instructions 6 2 general safety instructions 7 2.1 safety instructions for the operator 7 2.1.1 electrical equipment 7 2.1.2 personnel ...

  • Page 4: Contents

    4 gm 5000ea operating manual edition 03/2012 order number doc 2319149 contents 5.2 preparation of paints 27 5.2.1 viscosity conversion table 27 5.3 wagner electrostatic air spraying system 28 5.3.1 pressure settings for round jet nozzles 28 5.3.2 pressure settings for fl at jet nozzles 29 5.3.3 elec...

  • Page 5: Contents

    5 gm 5000ea operating manual edition 03/2012 order number doc 2319149 contents 10 spare parts 59 10.1 how to order spare parts? 59 10.2 gm 5000ea spare parts list 60 10.2.1 gm 5000ea spare parts list- end piece 62 10.2.2 gm 5000ea spare parts list - handle 64 10.3 accessories spare parts lists 66 10...

  • Page 6

    6 gm 5000ea operating manual edition 03/2012 order number doc 2319149 1.2 warnings, notes and symbols in these instructions 1 about these instructions 1.1 languages 4hisoperatingmanualcontainsinformationabouttheoperationrepairandmaintenance oftheunit œ !Lwaysfollowtheseinstructionswhenoperatingtheun...

  • Page 7

    7 gm 5000ea operating manual edition 03/2012 order number doc 2319149 2 general safety instructions 2.1 safety instructions for the operator 2.1.1 electrical equipment 2.1.2 personnel qualifications 2.1.3 a safe work environment 2.2 safety instructions for staff œkeep these operating instructions to...

  • Page 8

    8 gm 5000ea operating manual edition 03/2012 order number doc 2319149 2.2.1 safe handling of wagner spray units 2.2.2 earth the unit 2.2.3 material hoses the spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or cleaning agents: œ never point the spray gun at peop...

  • Page 9

    9 gm 5000ea operating manual edition 03/2012 order number doc 2319149 2.2.4 cleaning 2.2.5 handling hazardous liquids, varnishes and paints œwhen preparing or working with paint and when cleaning the unit, follow the working instructions of the manufacturer of the paints, solvents and cleaning agent...

  • Page 10

    10 gm 5000ea operating manual edition 03/2012 order number doc 2319149 2.3 correct use 7!'.%2acceptsnoliabilityforanydamagearisingfromincorrectuse œ 5setheunitonlytoworkwiththematerialsrecommendedby7!'.%2 œ /peratetheunitonlyasanentireunit œ $onotdeactivatesafetyequipment œ 5seonly7!'.%2originalspar...

  • Page 11

    11 gm 5000ea operating manual edition 03/2012 order number doc 2319149 2.4 safety-relevant information about discharges 2.5 use in an explosion hazard area 2.5.1 correct use 2.5.2 explosion protection identification ce 2.5.2.1 identification „x“ safety instructions the plastic parts of the spray gun...

  • Page 12

    12 gm 5000ea c us operating manual edition 03/2012 order number doc 2319149 )gnitiontemperatureofthecoatingmaterial œ %nsurethattheignitiontemperatureofthecoatingmaterialisabovethemaximum surfacetemperature 3urfacesprayingelectrostatic œ $onotsprayunitpartswithelectrostaticegelectrostaticspraygun -e...

  • Page 13

    13 gm 5000ea operating manual edition 03/2012 order number doc 2319149 3 guarantee and conformity declarations 3.1 important notes on product liability 3.2 guarantee claim as a result of an ec regulation, effective as from january 1, 1990, the manufacturer shall only be liable for his product if all...

  • Page 14

    14 gm 5000ea operating manual edition 03/2012 order number doc 2319149 3.3 ce-conformity 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 : ec d...

  • Page 15

    15 gm 5000ea operating manual edition 03/2012 order number doc 2319149 4.1 fields of application, using in accordance with the instructions the electrostatic spray gun can only be used with the vm 5000 or vm 500 control units. 4 description 4.1.1 processable materials ➞ with the gm 5000ea gun, paint...

  • Page 16

    16 gm 5000ea operating manual edition 03/2012 order number doc 2319149 4.2 scope of delivery quantity part no. Description 1 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 1 ...

  • Page 17

    17 gm 5000ea b_03230 c a b c a b b_03231 operating manual edition 03/2012 order number doc 2319149 4.3 technical data max. Air pressure 0.8 mpa; 8 bar; 116 psi max. Material pressure 0.8 mpa; 8 bar; 116 psi paint connection g 1/4“ a air connection g 1/4“ a input voltage max. 20 vpp input current max...

  • Page 18

    18 gm 5000ea 6 14 20 6 5 7 16 15 2 4 3 1 9 10 11 8 19 18 17 b _03232 22 12 21 b_03558 s operating manual edition 03/2012 order number doc 2319149 4.4 functional description 4.4.1 design of spray gun (standard variant) item description 1 suspension hook 2 display (spray current and recipe) 3 display ...

  • Page 19

    19 gm 5000ea 1 2 3 4 r1 r3 r2 b_03182 2 4 3 r1 r3 r2 b_03183 16 operating manual edition 03/2012 order number doc 2319149 4.4.2 functions of the spray gun distance description 1 atomizing air open. 2 atomizing air open and electrostatically (hv) activated. -> display (2) for „spray current“ on the s...

  • Page 20

    20 gm 5000ea b_00180 b_03446 operating manual edition 03/2012 order number doc 2319149 4.5 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). The atomizing air at approx. 0.2...

  • Page 21

    21 gm 5000ea "? Operating manual edition 03/2012 order number doc 2319149 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 o...

  • Page 22

    22 gm 5000ea 1 2 4 11 10 12 13 14 10 3 5 9 6 6 7 8 8 15 b_03233 p zl l fl p mat operating manual edition 03/2012 order number doc 2319149 5 start-up and operation 5.1 installation and connection item description 1 pressure tank 2 stop valve 3 air pressure regulator tank 4 air pressure regulator with...

  • Page 23: Warning

    23 gm 5000ea operating manual edition 03/2012 order number doc 2319149 warning incorrect installation/operation! Risk of injury and damage to equipment œ when putting into operation and for all work, read and follow the operating instructions and safety regulations for the additionally required syst...

  • Page 24: Caution

    24 gm 5000ea operating manual edition 03/2012 order number doc 2319149 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 ...

  • Page 25: Warning

    25 gm 5000ea operating manual edition 03/2012 order number doc 2319149 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 o...

  • Page 26

    26 gm 5000ea b_03234 r max Ω operating manual edition 03/2012 order number doc 2319149 minimum cable cross-section control unit 4 mm² (awg 12) pump 4 mm² (awg 12) paint container 4 mm² (awg 12) conveyor 16 mm² (awg 6) booth 16 mm² (awg 6) spraying stand 16 mm² (awg 6) control unit earthing cable spr...

  • Page 27

    27 gm 5000ea milli pascal x sec mpas centipoise poise din cup 4 mm ; 0.16 inch ford cup 4 zahn 2 10 10 0.1 5 16 15 15 0.15 8 17 20 20 0.2 10 18 25 25 0.25 14 12 19 30 30 0.3 15 14 20 40 40 0.4 17 18 22 50 50 0.5 19 22 24 60 60 0.6 21 26 27 70 70 0.7 23 28 30 80 80 0.8 25 31 34 90 90 0.9 28 32 37 100...

  • Page 28

    28 gm 5000ea b_03266 operating manual edition 03/2012 order number doc 2319149 5.3 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 lar...

  • Page 29

    29 gm 5000ea b_03267 operating manual edition 03/2012 order number doc 2319149 spraying direction by turning the adjusting screw (a mv ) 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 creat...

  • Page 30

    30 gm 5000ea 0 100 200 300 400 500 600 700 ø 0. 6mm ø 0. 8mm ø 1. 0mm ø 1. 2mm ø 1. 4mm ø 1. 6mm ø 1. 8mm ø 2. 0mm 1 2 3 b_03455 0 100 200 300 400 500 600 1 2 3 d8 d12 b_03456 operating manual edition 03/2012 order number doc 2319149 5.3.3 electrostatic and atomization the electrostatic charging of ...

  • Page 31: Danger

    31 gm 5000ea operating manual edition 03/2012 order number doc 2319149 5.4 start-up 5.4.1 general rules for making adjustments to the spray gun ➞ observe safety instructions in chapter 2. 5.4.2 preparation for starting up the following points should be noted before starting up: ➞ for earthing see pa...

  • Page 32: Warning

    32 gm 5000ea b_03690 84 84 84 b_03691 84 operating manual edition 03/2012 order number doc 2319149 ➞ 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...

  • Page 33

    33 gm 5000ea 1 2 4 11 10 12 13 14 10 3 5 9 6 6 7 8 8 15 b_03233 p zl l fl p mat operating manual edition 03/2012 order number doc 2319149 5.5 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...

  • Page 34

    34 gm 5000ea b_03261 operating manual edition 03/2012 order number doc 2319149 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 mat . 5. Spray on a test object (pull ...

  • Page 35: #!54)/.

    35 gm 5000ea b_03268 1 3 4 7 2 5 6 8 2 operating manual edition 03/2012 order number doc 2319149 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 ...

  • Page 36: Caution

    36 gm 5000ea operating manual edition 03/2012 order number doc 2319149 6 maintenance ➞ observe safety instructions in chapter 2. The spray gun and the unit must be cleaned every day. Only use the cleaning solvent recommended by the paint manufacturer. Caution cleaning agent in the air duct! Function...

  • Page 37: Danger

    37 gm 5000ea b_03447 operating manual edition 03/2012 order number doc 2319149 danger exploding gas/ air mixture! Danger to life from flying parts and burns œnever spray into a closed container. œearth the container. Sihi_0008_gb 1. Switch off control unit. 2. Ensure that the material pressure is rel...

  • Page 38

    38 gm 5000ea b_03246 sw3 sw12 sw12 b_03247 sw3 sw19 sw19 torx 25 1 2 3 operating manual edition 03/2012 order number doc 2319149 6.3 dismantling of the spray gun.

  • Page 39

    39 gm 5000ea b_03248 sw19 sw19 b_03449 sw11 4 5 6 operating manual edition 03/2012 order number doc 2319149 assembly tool for needle valve. Part no. 2309368 note: loosen valve tip air by hand using an assembly tool. Carefully release the cascade without pliers. Use socket or ring spanner (no wrench)...

  • Page 40

    40 gm 5000ea b_03250 sw14 sw9 sw8 1 torx 20 sw5 2 8 9 7 b_03198 sw6 sw5 sw2 1 4 5 2 6 7 3 ø 3.0 operating manual edition 03/2012 order number doc 2319149 1. Remove pressure spring (4). 2. Loosen clamping screw (1) completely with assembly tool (5). 3. Unscrew the complete package (3) via the complet...

  • Page 41: Attention

    41 gm 5000ea operating manual edition 03/2012 order number doc 2319149 6.4 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 ...

  • Page 42

    42 gm 5000ea 3 b_03251 sw14 3 nm sw9 sw5 sw8 1 4 2 2 2 to rx 20 1 2 b_03448 operating manual edition 03/2012 order number doc 2319149 6.5 assembling the spray gun mounting materials: item part no. Description 1 9992590 loctite 222 2 9992698 vaseline white phhv ii 3 9992831 loctite 542 4 9992511 loct...

  • Page 43

    43 gm 5000ea 3 b_03253 0.5 nm sw5 0.4-0.5 nm sw6 0.4 - 0.5 nm sw5 2 2 2 x = 122 ± 0.1 sw2 1nm x 1 4 5 b_03450 1.2 nm sw11 4 5 operating manual edition 03/2012 order number doc 2319149 insertion position compl. Package ensure the correct insertion position! Valve rod unit length adjusting measure pus...

  • Page 44

    44 gm 5000ea b_03254 sw19 2.5 nm 2 6 7 b_03255 sw3 0.8 nm sw19 sw19 8 b_03256 torx 25 operating manual edition 03/2012 order number doc 2319149 push the trigger upward into the air valve piston. Clean and degrease the inside of the end piece and the cascade, then grease the cascade surface with vase...

  • Page 45

    45 gm 5000ea 9 10 b_03258 sw3 0.8 nm sw12 sw12 2 b_03257 r1 r3 r2 operating manual edition 03/2012 order number doc 2319149 flat jet nozzle diverse nozzle sizes see chapter 9.3. Round spray nozzle diverse nozzle sizes see chapter 9.2. Ensure the correct insertion position!.

  • Page 46

    46 gm 5000ea b_03259 operating manual edition 03/2012 order number doc 2319149 6.6 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 ca...

  • Page 47: Danger

    47 gm 5000ea b_03260 operating manual edition 03/2012 order number doc 2319149 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. 0.8 mpa; 8 bar; 1...

  • Page 48

    48 gm 5000ea b_03261 operating manual edition 03/2012 order number doc 2319149 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. 2. Spray (pull trigger) and check the...

  • Page 49

    49 gm 5000ea operating manual edition 03/2012 order number doc 2319149 7 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 low. • increase material pressure. • h...

  • Page 50: Note

    50 gm 5000ea b_03697 b_03697 b_03698 b_03698 operating manual edition 03/2012 order number doc 2319149 9 accessories 9.1 valve seats, air/ valve tips, air 8 product disposal sihi_0127_gb note do not dispose of waste electrical equipment with the house- hold refuse! In accordance with european direct...

  • Page 51

    51 gm 5000ea b_03238 b_03238 b_03239 b_03239 b_03240 b_03240 b_03240 b_03240 b_03240 b_03240 operating manual edition 03/2012 order number doc 2319149 9.3.1 af 5000 air caps part no. Description 2310506 af 5000 air cap - 0.4-0.8s 2310507 af 5000 air cap - 1.0-1.4s 2310508 af 5000 air cap - 1.6-2.0s ...

  • Page 52

    52 gm 5000ea b_03241 b_03241 b_03241 b_03241 b_03241 b_03241 b_03241 b_03241 operating manual edition 03/2012 order number doc 2319149 9.3.2 af 5000 nozzles part no. Description 2310539 af 5000 nozzle - 0.6 mm (black) 2310540 af 5000 nozzle - 0.8 mm (yellow) 2310541 af 5000 nozzle - 1.0 mm (red) 231...

  • Page 53

    53 gm 5000ea 2 3 4 5 b_03245 1 operating manual edition 03/2012 order number doc 2319149 9.4 hoses and electrical cables 9.4.1 standard hose sets and components item qty part no. Description 1 1 2309853 gm 5000ea hose set (7.5 m) consisting of: 2 1 2312012 low pressure hose-dn6-pn15-g¼“-7.5 m-pfa 3 ...

  • Page 54

    54 gm 5000ea b_03244 2 3 4 5 1 operating manual edition 03/2012 order number doc 2319149 9.4.2 hose sets for low impedance materials item qty part no. Description 1 1 2309878 gm 5000ea hose set (7.5 m), low r consisting of: 2 1 2310464 ea material hose, compl. (7.5 m) lowr 3 1 2312060 air hose, comp...

  • Page 55

    55 gm 5000ea b_03218 b_03221 m f operating manual edition 03/2012 order number doc 2319149 part no. Description 2307295 gm 5000e extension cable 10 m 2307296 gm 5000e extension cable 20 m 9.4.3 gun cable and gun cable extensions 9.5 reduction fittings for high-pressure hoses the classifi cation of w...

  • Page 56

    56 gm 5000ea p_00265 b_03224 b_03451 b_03693 b_03692 b_03681 operating manual edition 03/2012 order number doc 2319149 9.6 miscellaneous part no. Description 2319653 gun protective cover 259010 hv200 n high-voltage tester 2326041 paint resistance measuring device 999080 wet fi lm thickness measurer ...

  • Page 57

    57 gm 5000ea b_03699 b_03720 operating manual edition 03/2012 order number doc 2319149 part no. Description 2326485 gm 5000e wall mount (left/right) 2324766 swivel for air.

  • Page 58

    58 gm 5000ea operating manual edition 03/2012 order number doc 2319149.

  • Page 59: Warning

    59 gm 5000ea operating manual edition 03/2012 order number doc 2319149 10 spare parts 10.1 how to order spare parts? Always supply the following information to ensure delivery of the right spare part: part number, description and quantity the quantity need not be the same as the number given in the ...

  • Page 60

    60 gm 5000ea b_03235 2 20 21 19 7 5 8 9 10 22 12 11 13 14 15 18 16 17 6 1 e operating manual edition 03/2012 order number doc 2319149 10.2 gm 5000ea spare parts list.

  • Page 61

    61 gm 5000ea operating manual edition 03/2012 order number doc 2319149 gm 5000ea spare parts list item k quantity part no. Description 1 1 2309870 gm 5000ea basic version 2 1 2315709 protection cap for valve needle 5 1 - gm 5000ea end piece, compl. Details see chapter 10.2.1 6 ◆ 1 2314361 hook 7 1 -...

  • Page 62

    62 gm 5000ea b_03236 2 1 12 10 9 8 3 4 24 5 6 7 17 18 21 122 ±0.1 22 11 23 operating manual edition 03/2012 order number doc 2319149 10.2.1 gm 5000ea spare parts list- end piece ensure the correct insertion position!.

  • Page 63

    63 gm 5000ea operating manual edition 03/2012 order number doc 2319149 end piece spare parts list item k quantity part no. Description 1 1 - gm 5000ea end piece, compl. 2 ★ 1 2309391 air manifold ring air 3 ◆ ★ 1 2307180 o-ring, sheathed 4 ◆ ★ 1 2312179 valve seat air, compl. (steel) 4 ◆ ● 1 2312176...

  • Page 64

    64 gm 5000ea b_03237 20 16 17 18 19 13 15 25 26 14 7 8 9 10 12 5 6 3 2 1 4 23 24 operating manual edition 03/2012 order number doc 2319149 10.2.2 gm 5000ea spare parts list - handle.

  • Page 65

    65 gm 5000ea operating manual edition 03/2012 order number doc 2319149 handle spare parts list item k quantity part no. Description 1 1 - gm 5000ea handle, compl. 2 1 2307288 nipple 3 ◆ ★ 1 9971025 o-ring 4 1 2315344 hose holder 5 1 2312182 plug, compl. 6 1 2314270 handle, compl. 7 ★ 1 2307232 end p...

  • Page 66

    66 gm 5000ea b_03263 4 3 2 1 b_03264 4 3 2 1 operating manual edition 03/2012 order number doc 2319149 10.3.1 ar 5000 (d8) nozzle spare parts list 10.3.2 ar 5000 (d12) nozzle spare parts list ar 5000 (d8) nozzle spare parts list item k quantity part no. Description 1 1 2310558 ar 5000 nozzle, compl....

  • Page 67

    67 gm 5000ea operating manual edition 03/2012 order number doc 2319149 germany j. Wagner gmbh otto-lilienthal-str. 18 postfach 1120 d- 88677 markdorf telephone: +49 7544 5050 telefax: +49 7544 505200 e-mail: service.Standard@wagner-group.Com switzerland j. Wagner ag industriestrasse 22 postfach 663 ...

  • Page 68

    68 gm 5000ea operating manual edition 03/2012 order number doc 2319149.

  • Page 69

    69 gm 5000ea operating manual edition 03/2012 order number doc 2319149.

  • Page 70

    70 gm 5000ea operating manual edition 03/2012 order number doc 2319149.

  • Page 72: Cert

    Cert if ie d /rdernumber 'ermany *7!'.%2'mb( /tto,ilienthal3tr 0ostfach $-arkdorf 4elephone 4elefax %-ailservicestandard wagnergroupcom 3witzerland *7!'.%2!' )ndustriestrasse 0ostfach #(!LtstËtten 4elephone 4elefax %-ailrepch wagnergroupch wwwwagnergroupcom 2319149.