Wagner SprayTech Paint Sprayer GM 5000EAC User Manual
Translation of the original  
Operating manual  
GM 5000EAC  
Edition 03/2012  
Electrostatic AirCoat  
Spray gun  
for manual operation with  
flat or round jet nozzles  
II 2 G EEx 0.24 mJ  
0102  
B_03154  
c
us  
(in submission)  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
Contents  
1
1.1  
1.2  
ABOUT THESE INSTRUCTIONS  
Languages  
Warnings, notes and symbols in these instructions  
6
6
6
2
2.1  
GENERAL SAFETY INSTRUCTIONS  
Safety instructions for the operator  
7
7
2.1.1 Electrical equipment  
2.1.2 Personnel qualifications  
2.1.3 A safe work environment  
7
7
7
2.2  
Safety instructions for staff  
7
2.2.1 Safe handling of WAGNER spray units  
2.2.2 Earth the unit  
8
8
2.2.3 Material hoses  
8
2.2.4 Cleaning  
9
2.2.5 Handling hazardous liquids, varnishes and paints  
2.2.6 Touching hot surfaces  
9
10  
10  
11  
11  
11  
11  
11  
12  
12  
2.3  
2.4  
2.5  
Correct use  
Safety-relevant information about discharges  
Use in an explosion hazard area  
2.5.1 Correct use  
2.5.2 Explosion protection identification CE  
2.5.2.1 Identification„X“  
2.5.3 Explosion protection identification FM  
2.6  
German regulations and guidelines  
3
GUARANTEE AND CONFORMITY DECLARATIONS  
Important notes on product liability  
Guarantee claim  
13  
13  
13  
14  
3.1  
3.2  
3.3  
CE-Conformity  
4
4.1  
DESCRIPTION  
15  
15  
15  
16  
17  
18  
18  
19  
20  
20  
20  
21  
Fields of application, using in accordance with the instructions  
4.1.1 Processable materials  
4.2  
4.3  
4.4  
Scope of delivery  
Technical data  
Functional description  
4.4.1 Design of spray gun (standard variant)  
4.4.2 Functions of the spray gun  
4.5  
4.5.1 AirCoat round jet spray process  
4.5.2. AirCoat atomizing flat jet spray process  
4.5.3 Electrical resistance  
Spraying process  
5
5.1  
START-UP AND OPERATION  
Installation and connection  
22  
22  
22  
23  
23  
24  
25  
5.1.1 Typical electrostatic spraying system  
5.1.2 Ventilation of the spray booth  
5.1.3 Air supplies  
5.1.4 Paint supplies  
5.1.5 Earthing  
3
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
Contents  
5.2  
5.2.1 Viscosity conversion table  
5.3 Start-up  
5.3.1 General rules for making adjustments to the spray gun  
5.3.2 Preparation for starting up  
Preparation of paints  
27  
27  
28  
28  
28  
30  
30  
31  
32  
32  
33  
34  
34  
34  
5.4  
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  
5.4.4 Exchange of round jet nozzle insert  
5.4.5 Changing from AirCoat round jet to AirCoat flat jet  
5.4.6 Replacing AirCoat flat jet nozzles  
5.4.7 Cleaning of the nozzles  
5.4.8 Eliminate nozzle clogging  
6
MAINTENANCE  
Periodically checks  
36  
36  
36  
38  
41  
42  
46  
46  
47  
47  
48  
6.1  
6.2  
6.3  
6.4  
6.5  
6.6  
Cleaning and decommissioning  
Dismantling of the spray gun  
Cleaning the parts after disassembly  
Assembling the spray gun  
Function test after assembly of the gun  
6.6.1 Checking the high-voltage  
6.6.2 Air tests  
6.6.3 Material pressure test  
6.6.4 Check spray pattern  
7
8
TROUBLE SHOOTING AND SOLUTION  
PRODUCT DISPOSAL  
49  
50  
9
9.1  
ACCESSORIES  
ACR 5000 round jet nozzle cap  
51  
51  
51  
51  
52  
54  
54  
55  
55  
56  
57  
57  
9.1.1 AirCoat round jet nozzle inserts  
9.2 ACF 5000 air caps (flat jet)  
9.2.2 ACF 5000 AirCoat flat jet nozzles  
9.3  
9.4  
9.5  
9.5.1 Standard hose sets and components  
9.5.2 Hose sets for low impedance materials  
9.5.3 Gun cable and gun cable extensions  
Filters  
Reduction fittings for high-pressure hoses  
Hoses and electrical cables  
9.6  
Miscellaneous  
4
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
Contents  
10  
SPARE PARTS  
59  
10.1  
10.2  
How to order spare parts?  
GM 5000EAC spare parts list  
59  
60  
62  
64  
66  
66  
67  
10.2.1 GM 5000EAC spare parts list- End piece  
10.2.2 GM 5000EAC spare parts list - Handle  
10.3  
10.3.1 Flat jet nozzles spare parts list  
10.3.2 ACR 5000 round jet nozzle cap spare parts list  
Accessories spare parts lists  
5
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
1 ABOUT THESE INSTRUCTIONS  
4HIS OPERATING MANUAL CONTAINS INFORMATION ABOUT THE OPERATIONꢀREPAIR AND MAINTENANCE  
OF THE UNITꢁ  
œ !LWAYS FOLLOW THESE INSTRUCTIONS WHEN OPERATING THE UNITꢁ  
4HIS EQUIPMENT CAN BE DANGEROUS IF IT IS NOT OPERATED IN ACCORDANCE WITH THIS MANUALꢁ  
%LECTROSTATIC SPRAY GUNS MAY BE OPERATED ONLY BY TRAINED PERSONNELꢁ  
#OMPLIANCE WITH THESE INSTRUCTIONS CONSTITUTES AN INTEGRAL COMPONENT OF THE GUARANTEE  
AGREEMENTꢁ  
1.1 LANGUAGES  
4HIS OPERATING MANUAL IS AVAILABLE IN THE FOLLOWING LANGUAGESꢂ  
,ANGUAGEꢀ  
'ERMAN  
&RENCH  
0ART .Oꢁ  
2310481  
2320152  
2320153  
,ANGUAGEꢀ  
%NGLISH  
$UTCH  
0ART .Oꢁ  
2319150  
-
2320154  
)TALIAN  
3PANISH  
1.2 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. Non-observance will result  
in death, serious injury and serious material damage.  
DANGER  
This line warns of the hazard!  
Possible consequences of failing to observe the warning instructions.  
The signal word points out the hazard level.  
œ
The measures for preventing the hazard and its consequences.  
SIHI_0100_GB  
Warning - possible danger. Non-observance can result  
in death, serious injury and serious material damage.  
WARNING  
This line warns of the hazard!  
Possible consequences of failing to observe the warning instructions.  
The signal word points out the hazard level.  
œ
The measures for preventing the hazard and its consequences.  
SIHI_0103_GB  
Caution - a possibly hazardous situation.  
Non-observance can result in minor injury.  
CAUTION  
This line warns of the hazard!  
Possible consequences of failing to observe the warning instructions.  
The signal word points out the hazard level.  
œ
The measures for preventing the hazard and its consequences.  
SIHI_0101_GB  
SIHI_0102_GB  
Caution - a possibly hazardous situation.  
CAUTION  
Non-observance can cause material damage.  
This line warns of the hazard!  
Possible consequences of failing to observe the warning instructions. The signal word  
points out the hazard level.  
œ
The measures for preventing the hazard and its consequences.  
Note - provide information on particular characteristics and how to proceed.  
6
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
2 GENERAL SAFETY INSTRUCTIONS  
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR  
œ Keep these operating instructions to hand near the unit at all times.  
œ Always follow local regulations concerning occupational safety and accident prevention.  
2.1.1 ELECTRICAL EQUIPMENT  
Electrical plant and unit  
œ To be provided in accordance with the local safety requirements with regard to the  
operating mode and ambient influences.  
œ May only be maintained by skilled electricians or under their supervision.  
œ Must be operated in accordance with the safety regulations and electrotechnical  
regulations.  
œ Must be repaired immediately in the event of problems.  
œ Must be put out of operation if they pose a hazard.  
œ Must be de-energized before work is commenced on active parts. Inform staff about  
planned work, observe electrical safety regulations.  
2.1.2 PERSONNEL QUALIFICATIONS  
œ %NSURE THAT THE UNIT IS OPERATED AND REPAIRED ONLY BY TRAINED PERSONSꢁ  
2.1.3 A SAFE WORK ENVIRONMENT  
Make sure that the floor in the area where you are working is anti-static in accordance  
with EN 61340-4-1 (the resistance value may not exceed 100 MOhm).  
Ensure that all persons within the working area wear antistatic shoes. Footwear must  
comply with EN 20344.The measured insulation resistance may not exceed 100 MOhm.  
Ensure that during spraying, persons wear anti-static gloves so that they are earthed  
via the handle of the spray gun.  
If protective clothing is worn, including gloves, it has to comply with EN 1149-5. The  
measured insulation resistance may not exceed 100 MOhm.  
Paint mist extraction systems must be fitted on site according to the local regulations.  
Ensure that the following components of a safe working environment are available:  
– Material/air hoses adapted to the working pressure.  
– Personal safety equipment (breathing and skin protection).  
Ensure that there are no ignition sources such as naked flame, glowing wires or hot  
surfaces in the vicinity. Do not smoke.  
2.2 SAFETY INSTRUCTIONS FOR STAFF  
œ Always follow the information in these instructions, particularly the general safety  
instructions and the warning instructions.  
œ Always follow local regulations concerning occupational safety and accident  
prevention.  
7
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GM 5000EAC.  
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:  
œ
œ
Never point the spray gun at people.  
Never reach into the spray jet.  
œ Before all work on the unit, in the event of work interruptions and functional faults:  
– Switch off the energy/compressed air supply.  
– Secure the spray gun against actuation.  
– Relieve the pressure from the spray gun and unit.  
– By functional faults: Identify and correct the problem, proceed as described in  
chapter „Trouble shooting“.  
In the event of skin injuries caused by paint or cleaning agents:  
œ
œ
Note down the paint or cleaning agent that you have been using.  
Consult a doctor immediately.  
Avoid danger of injury through recoil forces:  
œ
œ
Ensure that you have a firm footing when operating the spray gun.  
Only hold the spray gun briefly in any one position.  
2.2.2 EARTH THE UNIT  
Depending on the high-voltage of the spray electrode and the flow rate at spray pressures  
can produce an electrostatic charge in the equipment.These can cause sparks and flames  
upon discharge.  
Ensure that the unit is always earthed.  
Earth the work pieces to be coated.  
Ensure that all persons inside the working area are earthed, e.g. that they are wearing  
derivable shoes.  
When spraying, wear derivable gloves to earth yourself via the spray gun handle.  
2.2.3 MATERIAL HOSES  
œ
œ
œ
Ensure that the hose material is chemically resistant to the sprayed materials.  
Ensure that the material hose is suitable for the pressure generated in the unit.  
Ensure that the following information is visible on the high pressure hose:  
– Manufacturer  
– Permissible operating overpressure  
– Date of manufacture.  
œ
The electrical resistance of the complete high pressure hose must be less than 1 MOhm.  
8
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GM 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. Otherwise, the cleaning works shall be carried out at forced ventilated clea-  
ning place.  
To clean, use only solvent-soaked cloths and brushes. The cleaning process mustn´t  
damage parts of the spray gun, it mustn´t be an abrasive procedure.  
Parts of spray gun mustn´t submerged or soaked into solvent.  
Non-ignitable cleaning liquids shall be preferred.  
A suitable solvent for cleaning the spray gun depends on the part of the gun and on the  
material that needs to be removed. It´s recommended to use only non-polar solvents  
to prevent a conductive residue on critical components. If it´s necessary to use polar  
solvents to clean the spray gun components, all residue must be removed by using a  
nonconductive non-polar solvent.  
All electrical components cannot be cleaned or soaked in any solvents.  
An explosive gas/air mixture forms in closed containers.  
When cleaning units with solvents, never spray into a closed container.  
For cleaning liquids only electrically leading containers may be used.  
The containers must be earthed.  
2.2.5 HANDLING HAZARDOUS LIQUIDS,VARNISHES AND PAINTS  
œ When preparing or working with paint and when cleaning the unit, follow the working  
instructions of the manufacturer of the paints, solvents and cleaning agents being  
used.  
œ Take the specified protective measures, in particular wear safety goggles, protective  
clothing and gloves, as well as hand protection cream if necessary.  
œ Use a mask or breathing apparatus if necessary.  
œ For sufficient health and environmental safety: Operate the unit in a spray booth or on  
a spraying wall with the ventilation (extraction) switched on.  
œ Wear suitable protective clothing when working with hot materials.  
9
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GM 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“.  
Order No.  
9998910 Information label  
9998911 Safety label  
2.3 CORRECT USE  
7!'.%2 ACCEPTS NO LIABILITY FOR ANY DAMAGE ARISING FROM INCORRECT USEꢁ  
œ 5SE THE UNIT ONLY TO WORK WITH THE MATERIALS RECOMMENDED BY 7!'.%2ꢁ  
œ /PERATE THE UNIT ONLY AS AN ENTIRE UNITꢁ  
œ $O NOT DEACTIVATE SAFETY EQUIPMENTꢁ  
œ 5SE ONLY 7!'.%2 ORIGINAL SPARE PARTS AND ACCESSORIESꢁ  
10  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
2.4 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. They are completely harmless for people.  
The corona discharge at the electrode end is visible during darkness at a distance of be  
between 4 and 10 mm; 0.15 and 0.4 inches, between the spray gun and spray object.  
2.5 USE IN AN EXPLOSION HAZARD AREA  
2.5.1 CORRECT USE  
The electrostatic hand spray gun GM 5000EAC is suitable for spraying liquid materials,  
particularly coating materials, using the AirCoat method. Coating materials containing  
solvents of Explosion Class II A may be used. The spray gun may only be used in  
combination with the control unit VM 500 and VM 5000.  
2.5.2 EXPLOSION PROTECTION IDENTIFICATION CE  
As defined in the Directive 94/9/EC (ATEX), the unit is suitable for use in areas where there  
is an explosion hazard.  
II 2 G EEx 0.24mJ  
0102  
SIRA 11 ATEX 5374X  
CE  
Communautés  
Européennes  
G
E
Ex-atmosphere gas  
European Standard  
Explosion protected  
Max. firing power  
0102  
Ex  
Notified body: PTB  
Ex  
Symbol for explosion  
protection  
0.24mJ  
SIRA 11  
Number of the type  
II  
2
Unit class II  
ATEX 5374X examination certificate  
Category 2 (zone 1)  
2.5.2.1 IDENTIFICATION„X“  
Maximum surface temperature  
Maximum surface temperature:  
Maxi. Permissible material temperature: 50 °C; 122 °F  
Permissible ambient temperature:  
85 °C; 185 °F  
s
s
+0 to +40 °C; +32 to +104 °F  
s
Safety instructions  
3AFE HANDLING OF 7!'.%2 SPRAY UNITS  
-ECHANICAL SPARKS CAN FORM IF THE UNIT COMES INTO CONTACT WITH METALꢁ  
)N AN EXPLOSIVE ATMOSPHEREꢂ  
œ $O NOT KNOCK OR PUSH THE UNIT AGAINST STEEL OR RUSTY IRONꢁ  
œ $O NOT DROP THE GUNꢁ  
œ 5SE ONLY TOOLS THAT ARE MADE OF A PERMITTED MATERIALꢁ  
11  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
)GNITION TEMPERATURE OF THE COATING MATERIAL  
œ %NSURE THAT THE IGNITION TEMPERATURE OF THE COATING MATERIAL IS ABOVE THE MAXIMUM  
SURFACE TEMPERATUREꢁ  
3URFACE SPRAYINGꢂELECTROSTATIC  
œ $O NOT SPRAY UNIT PARTS WITH ELECTROSTATIC ꢃEꢁGꢁELECTROSTATIC SPRAY GUN ꢁ  
-EDIUM SUPPORTING ATOMIZING  
œ 4O ATOMIZE THE MATERIALꢀUSE ONLY WEAKLY OXIDIZING GASESꢀEꢁGꢁAIRꢁ  
Cleaning  
If there are deposits on the surfaces, the unit may form electrostatic charges. Flames or  
sparks can form if there is a discharge.  
œ Remove deposits from the surfaces to maintain conductivity.  
œ Use only a damp cloth to clean the unit.  
2.5.3 EXPLOSION PROTECTION IDENTIFICATION FM  
For Electrostatic Finishing Applications  
using Class I, Group D, Spray Material  
C
US  
In accordance with 2316160  
(the device is in submission)  
This device has been manufactured and tested according to the FM (Factory Mutual)  
standard „Class Number 7260“ (Approval Standard for Electrostatic Finishing Equipment)  
by FM.All tested combinations of devices including accessories are given in the FM Control  
Document with part number 2316160.  
2.6 GERMAN REGULATIONS AND GUIDELINES  
a) BGV A3  
b) BGR 500  
c) BGR 500  
d) BGR 104  
Electrical units and equipment  
Part 2, Chap. 2.36 Working with liquid ejection devices  
Part 2, Chap. 2.29 Using coating materials  
Explosion protection rules  
e) TRBS 2153 Avoiding ignition risks  
f) BGR 180  
Setting up for cleaning with solvents for cleaning workpieces with  
solvents  
g) ZH 1/406  
h) BGI 740  
j) BGI 764  
Guidelines for liquid ejection devices  
Painting rooms and equipment  
Electrostatic coating  
j) Betr.Sich.V. Plant Safety Ordinance  
Note: All titles can be ordered from Heymanns Publishing House in Cologne, or they are  
to be found in the Internet.  
12  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
3 GUARANTEE AND CONFORMITY DECLARATIONS  
3.1 IMPORTANT NOTES ON PRODUCT LIABILITY  
As a result of an EC regulation, effective as from January 1, 1990, the manufacturer shall  
only be liable for his product if all parts come from him or are approved by him, and if the  
devices are properly 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.  
3.2 GUARANTEE CLAIM  
Full guarantee is provided for this device:  
We will at our discretion repair or replace free of charge all parts which within 24 months  
in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by  
the Purchaser are found to be wholly or substantially unusable due to causes prior to the  
sale, in particular faulty design, defective materials or poor workmanship.  
The type of guarantee provided is such that the device or individual components of the  
device are either replaced or repaired as we think fit. The resulting costs, in particular  
shipping charges, road tolls, labour and material costs will be borne by us except where  
these costs are increased due to the subsequent shipment of the unit to a location other  
than the address of the purchaser.  
We do not provide guarantee for damage that has been caused or contributed to for the  
following reasons:  
Unsuitable or improper use, faulty installation or commissioning by the purchaser or a  
third party, normal wear, negligent handling, defective maintenance, unsuitable coating  
products, substitute materials and the action of chemical, electro chemical or electrical  
agents, except when the damage is attributable to us.  
Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc dust  
paints and similar reduce the service life of valves, packings, spray guns, tips, cylinders,  
pistons etc. Signs of wear and tear due to such causes are not covered by this guarantee.  
Components that have not been manufactured by WAGNER are subject to the original  
guarantee of the manufacturer.  
Replacement of a component does not extend the period of guarantee of the device.  
The unit should be inspected immediately upon receipt. To avoid losing the guarantee, we  
or the supplier company are to be informed in writing about obvious faults within 14 days  
upon receipt of the device.  
We reserve the right to have the guarantee compliance met by a contracting company.  
The services provided by this guarantee depend on evidence being provided in the form  
of an invoice or delivery note. If an examination discovers that no guarantee claim exists,  
the costs of repairs are charged to the purchaser.  
It is clearly stipulated that this guarantee claim does not represent any constraint to statutory  
regulations or regulations agreed contractually in our general terms and conditions.  
J. Wagner AG  
13  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
3.3 CE-CONFORMITY  
EC declaration of conformity as defined by Atex-directive 94/9/EC  
Herewith we declare that the supplied version of  
Electrostatic hand spraying system  
VM 500  
VM 5000  
GM 5000EA  
GM5000EAC  
Complies with the following guidelines:  
94/9/EG  
2004/108/EG  
2002/95/EG  
2002/96/EG  
2006/42/EG  
Applied standards, in particular:  
DIN EN 50050:2007  
DIN EN 61000-6-2:2006  
DIN EN 61000-6-4:2011  
DIN EN 60204-1: 2007  
DIN EN ISO 12100:2011  
DIN EN 60079-0: 2010  
DIN EN 1953:2010  
DIN EN 60079-15: 2011  
Applied national technical standards and specifications, in particular:  
BGI 764  
EC type examination certificate:  
SIRA 11 ATEX 5374X issued by SIRA Certification,  
CH4 9JN, Chester, England, notified body no. 0518  
Identification:  
Control unit:  
II (2) G  
SIRA 11 ATEX 5374X  
0102  
II 3 G Ex nR IIC T4 Gc  
Spray gun:  
II 2 G EEx 0.24mJ  
SIRA 11 ATEX 5374X  
0102  
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  
14  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
4 DESCRIPTION  
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.  
4.1.1 PROCESSABLE MATERIALS  
➞
With the GM 5000EAC 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 > 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 > 50 k(according to  
the WAGNER scale) process successfully.  
➞ The application effectiveness is always dependant on the composition of the paint  
being used, e.g. pigments or resin.  
Conversion of the resistance of paint  
There are paint resistance measuring devices on the market that do not measure directly  
the specific resistance of paint. Multiplying the result of measurement with the  
device-specific cell constant (K), we obtain the resistivity value of the material.  
Example:  
The Wagner paint resistance measuring device is the cell constant K =123.  
Measured value according to the WAGNER scale R = 500 k  
Specific resistance (RS)  
RS = R x K = 500 kx 123 = 61.5 M.cm  
Note  
With sprayed substances and those with too low electrical resistance the electrostatic  
effect will not have any effect, i.e., there will be no „wrap around“ noticeable at the spray  
object. The relationship between the values of the high-voltage (kV) and the current (µA),  
shown on the VM 5000 control unit and/or on the spray gun,denotes the charging capacity  
of a spray material.  
High kV value, low µA value = ok  
Low kV-value, high µA-value = Excessive conductivity of the paint -> no wrap-around  
In the event of application problems, contact your WAGNER branch and the paint  
manufacturer.  
15  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
4.2 SCOPE OF DELIVERY  
Quantity  
Part No. Description  
2309871 GM 5000EAC spray gun  
1
Without control unit, material and air hose, electrical cable,  
air cap and nozzle.  
Each gun includes as standard equipment:  
Part No.  
2309368  
2325263  
2319653  
2310487  
2310481  
see 1.1  
Description  
1
1
1
1
-
Assembly tool valve needle  
Assembly tool clamping screw  
Glove against ink mist precipitation  
CE-Conformity  
Operating manual German  
Operating manual in the local language  
1
The spray gun basic version can be set according to requirement and the desired  
accessories with the help of the spray gun configuration.  
The delivery note shows the exact scope of delivery.  
16  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
4.3 TECHNICAL DATA  
Max. air pressure  
Max. material pressure  
Material connection  
Air connection  
0.8 MPa; 8 bar; 116 psi  
25 MPa; 250 bar; 3626 psi  
NPSM 1/4“-18  
G 1/4“ A  
Input voltage  
max. 20 Vpp  
max. 1.0 A AC  
max. 80 kV DC  
max. 100 µA DC  
negative  
Input current  
Output voltage  
Output current  
Polarity  
Weight (without hose set)  
710 g  
(incl. union nut, nozzle, air cap and edge filter)  
Working temperature range  
0 °C to 40 °C; 32 °F to 104 °F  
50 °C; 122 °F  
Max. material temperature  
Sound level at 0.3 MPa; 3 bar; 43.5 psi air pressure and  
0.3 MPa; 3 bar; 43.5 psi material pressure  
73 dB(A) *  
* A rated sound pressure level measured at 1 m distance according to DIN EN 14462: 2005.  
Measurements  
B
A
GM 5000EAC F  
with flat jet nozzle  
mm  
280  
46  
inches  
11.02  
1.81  
A
B
C
264  
10.39  
B_03155  
GM 5000EAC R  
with round jet nozzle  
B
A
mm  
264  
46  
inches  
10.39  
1.81  
A
B
C
264  
10.39  
B_03193  
17  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
4.4 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“.  
9
1
8
2
3
22  
4
7
15  
16  
6
21  
10  
11  
5
20  
12  
17  
18  
13  
B_03156  
14  
19  
Item Description  
Item Description  
11  
12  
13  
Trigger lock  
Trigger  
1
2
3
4
Hook  
Display (spray current and recipe)  
Display standby  
Round jet nozzle cap  
(see Accessories chapter 9)  
Operating button  
14  
Round jet nozzle insert  
(standby and recipe change)  
(see Accessories chapter 9)  
5
6
7
Protection against contact  
with union nut  
15  
16  
17  
18  
19  
20  
21  
22  
Lock plug  
Air adjustment  
Air cap for flat jet nozzle  
(see Accessories chapter 9)  
Electrical cable connection  
Atomizing air connection  
Material connection  
Filter housing with filter  
Type plate left  
ACF 5000 flat jet nozzle  
(see Accessories chapter 9)  
8
9
End piece  
Cover  
10  
Handle  
Type plate right  
Note:  
The gun type (T) on the type plate (21) and the serial number (S) on  
the underside of the handle.  
B_03558  
S
18  
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GM 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-defined  
recipe (R1, R2 or R3) is shown on the gun display (2) as  
follows.  
Recipe 1 -> ●❍❍❍❍ R1  
2
Recipe 2 -> ●●●❍❍ R2  
3
Recipe 3 -> ●●●●● R3  
4
Recipe change R1 -> R2 -> R3 -> R1  
Press the operating button (4) and hold the button  
pressed of at least 2 seconds, then it is advanced by  
1 recipe.  
B_03182  
Display (2) -> ●●❍❍❍ = recipe values changed temporarily:  
The stored recipe values of the previously selected recipe  
number are re-loaded from memory by pressing the operating  
button (4) for 2 seconds.  
The trigger can be used to activate, one after the other, the  
various functions of the spray gun.  
Distance Description  
1
2
AirCoat air opens.  
AirCoat air opened and electrostatic (HV)  
activated.  
-> Display (2) for „spray current“ on the spray  
gun ●❍❍❍❍ to ●●●●● activated.  
3
4
AirCoat air opened and electrostatic (HV)  
activated and material valve opened.  
1
2
4
3
Max way of trigger.  
An increase in the tension needed to pull the trigger back  
will be felt at the position where the material valve opens.  
•
•
E
For spraying without high-voltage, the high-voltage can  
be switched off using the operating button (4). Press the  
operating button (4) briefly: High-voltage is switched off.  
The standby display (3) illuminates.  
16  
In the event of a malfunction the spray gun switches to  
„standby“ operating mode and the display (3) illuminates.  
•
•
The width of the spray jet can be adjusted using the air  
adjustment (16) (only for flat-jet method).  
B_03262  
19  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
4.5 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.  
Nozzle nut  
AirCoat air  
Spray material  
AirCoat air  
"?ꢄꢄꢄꢅꢆ  
Advantages  
High painting capacity  
Low fogging tendency  
Good finish  
High viscosity paints can easily be applied  
High endurance of the nozzles  
Change in width the jet  
•
•
Multi-channel  
swirl nozzle  
Spray jet  
•
•
•
•
4.5.2. AIRCOAT ATOMIZING FLAT 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 AirCoat air at 0-0.25 MPa; 0-2.5 bar; 0-36 psi produces a soft jet, which largely eliminates the problem of  
overlapping boundaries.There´s a possibility to reduce the jet by form air.  
Shaping air  
Air cap  
Variable spray  
jet width  
B_00020  
Atomizing air  
Advantages  
High painting capacity  
Low fogging tendency  
Good finish  
High viscosity paints can easily be applied  
High endurance of the AC-nozzles  
Change in width the jet  
•
•
•
•
•
•
20  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
4.5.3 ELECTRICAL RESISTANCE  
The spray gun produces an electrostatic field 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, finely distributed, to  
the object being sprayed.  
Paint particles  
Electrode  
Grounded  
object  
"?ꢄꢄꢇꢆꢈ  
Advantages  
Very high application effectiveness  
Little over spray  
Coating of entire circumferences due to an electrostatic field  
Less working time  
•
•
•
•
21  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
5 START-UP AND OPERATION  
5.1 INSTALLATION AND CONNECTION  
5.1.1 TYPICAL ELECTROSTATIC SPRAYING SYSTEM  
1
16  
15  
2
5
3
21  
4
14  
12  
11  
3
6
80  
R1  
60  
40  
20  
10  
kV  
100  
R2  
R3  
8
0
60  
40  
20  
EXT  
μ
A
10  
VM 5000  
9
13  
17  
7
8
B_03158  
19  
18  
Item Designation  
20  
1
2
3
4
5
6
GM 5000EACF spray gun  
Gun cable  
Item Designation  
Item Designation  
Grounding cable  
Pneumatic pumps  
Carriage  
10 Compressed air  
connection  
16 Material hose  
17 Return valve  
11 Stop valve  
18 Container for the return  
flow  
Pressure regulator +  
air filter  
12 Air pressure regulator  
13 VM 5000 control unit  
14 Protective hose  
15 Air hose  
19 Colour container  
20 Container, cleaning agent  
21 Mains cable  
7
8
9
Material suction system  
Return hose  
High pressure filter  
22  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
The GM 5000EAC spray gun must be used a part of an electrostatic spraying system  
(Spraypack). The spraying system shown in the figure 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.  
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 system components.  
SIHI_0050_GB  
5.1.2 VENTILATION OF THE SPRAY BOOTH  
WARNING  
Toxic and/or flammable vapor mixtures!  
Risk of poisoning and burns  
œ Operate the unit in a spraying booth approved for the working  
materials.  
-or-  
œ Operate the unit on an appropriate spraying wall with the  
ventilation (extraction) switched on.  
œ Observe national and local regulations for the outgoing air  
speed.  
SIHI_0028_GB  
5.1.3 AIR SUPPLIES  
The use of an air filter with the air pressure regulator (6) 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 finished piece.  
23  
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GM 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  
œ 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  
œ Ensure that the hose material is chemically resistant.  
œ Ensure that the spray gun, threaded joints and material hose  
between the unit and the spray gun is suitable for the pressure  
generated in the unit.  
œ Ensure that the following information can be seen on the high  
pressure hose:  
- Manufacturer  
- Permissible operating pressure  
- Date of manufacture.  
SIHI_0029_GB  
24  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
5.1.5 EARTHING  
Perfect earthing of all conductive parts such as floors, 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.  
Parts of the booth must be grounded in accordance with EN 12215.  
WARNING  
Discharge of electrostatically charged components in atmospheres  
containing solvents!  
Explosion hazard from electrostatic sparks or flames  
œ Earth all unit components.  
œ Earth the workpieces being painted.  
SIHI_0027_GB  
WARNING  
Heavy paint mist if earthing is insufficient!  
Risk of poisoning  
Insufficient paint application quality  
œ Earth all unit components.  
œ Earth the workpieces being painted.  
SIHI_0003_GB  
The imperfect earthing of a work piece will result in:  
• Very poor wrap-around.  
• Uneven coating thickness.  
• Back spraying to the spray gun, i.e. contamination.  
The prerequisites for perfect earthing and coating are:  
• Clean work piece suspension.  
• Earthing of spray booth, conveyor system and suspension on the building side in  
accordance with the operating instruction or the manufacturer‘s information.  
• Earthing of all conductive parts within the working area.  
• The earthing resistance of the work piece may not exceed 1 M(Mega Ohm).  
Note:  
Resistance to earth measured at 500 V or 1000 V.  
• Connect the control unit to the mains system earth.  
25  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
Earthing schema (example)  
Conveyor  
Note for the sprayer  
The work shoes and if  
used the gloves must be  
derivable.  
Control unit  
Work piece  
Earthing  
cable  
Pump  
R max < 1 MΩ  
Paint container  
Spraying stand  
B_03234  
Floor, derivable  
Minimum cable cross-section  
Control unit  
Pump  
4 mm² (AWG 12)  
4 mm² (AWG 12)  
Paint container 4 mm² (AWG 12)  
Conveyor  
Booth  
16 mm² (AWG 6)  
16 mm² (AWG 6)  
Spraying stand 16 mm² (AWG 6)  
26  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
5.2 PREPARATION OF PAINTS  
The viscosity of the paints is of great importance. The best spraying results are obtained  
with values between 25 and 40 DIN-s (measured in immersion flow cup DIN 4 mm;  
0.16 inches). Processing of up to 60 DIN-s is generally possible without problem, if high  
coating thicknesses are required.  
The Wagner AirCoat flat jet spraying process determined optimally the different viscosity  
of the paint by two air cap types.These can be found in the Accessories.  
In the case of application problems contact the paint producer.  
5.2.1 VISCOSITY CONVERSION TABLE  
milli Pascal x Centipoise  
Sec mPas  
Poise  
DIN Cup  
4 mm ; 0.16 inch  
Ford Cup 4  
Zahn 2  
10  
15  
10  
15  
0.1  
0.15  
0.2  
0.25  
0.3  
0.4  
0.5  
0.6  
0.7  
0.8  
0.9  
1
5
16  
17  
18  
19  
20  
22  
24  
27  
30  
34  
37  
41  
49  
58  
66  
74  
82  
8
20  
20  
10  
12  
14  
18  
22  
26  
28  
31  
32  
34  
41  
45  
50  
54  
58  
62  
65  
68  
70  
74  
25  
25  
14  
15  
17  
19  
21  
23  
25  
28  
30  
33  
37  
43  
46  
49  
52  
56  
62  
65  
70  
30  
30  
40  
40  
50  
50  
60  
60  
70  
70  
80  
80  
90  
90  
100  
120  
140  
160  
180  
200  
220  
240  
260  
280  
300  
320  
340  
360  
380  
400  
100  
120  
140  
160  
180  
200  
220  
240  
260  
280  
300  
320  
340  
360  
380  
400  
1.2  
1.4  
1.6  
1.8  
2
2.2  
2.4  
2.6  
2.8  
3
3.2  
3.4  
3.6  
3.8  
4
80  
90  
27  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
5.3 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:  
œ Do not work with the electrostatic spray gun.  
œ Remain outside the area of the electrostatic spray gun/work-  
piece.  
SIHI_0049_GB  
WARNING  
Unintentional putting into operation!  
Risk of injury  
Before all work on the unit, in the event of work interruptions and  
functional faults:  
œ Switch off the energy/compressed air supply.  
œ Relieve the pressure from the spray gun and unit.  
œ Secure the spray gun against actuation.  
œ By functional faults: Identify and correct the problem, proceed  
as described in chap„Trouble shooting“.  
SIHI_0065_GB  
5.3.2 PREPARATION FOR STARTING UP  
The following points should be noted before commissioning:  
➞
For earthing see paragraph 5.1.5; make sure that all other conductive parts within the  
work area are earthed.  
➞
➞
➞
Connect the material hose to spray gun and material pump..  
Check that all material-conveying connections are correctly connected.  
Connect air hose to spray gun and to oil-free, dry air, approx. 0.25 MPa; 2.5 bar; 36 psi.  
Compressed air quality class 3.5.2 according to ISO 8573.1.  
Check that all air supply connections are connected properly.  
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.  
28  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
➞
➞
Check the level of the release agent in the Wagner pneumatic pump and if necessary  
fill the release agent up.  
Provide material container, containers for detergent and an empty container for  
return.  
➞
➞
Connect the system with a safe gun to the air and power supply.  
A basic flushing of system must be carried out for initial start up. Make sure, that no  
nozzle is inserted into the gun.  
WARNING  
Sparks form when the plug is removed!  
Explosion hazard  
When using the spray gun in explosion hazard areas:  
œ The cable connection may neither be separated nor put together  
in this area. Cover sleeve plus warning sign have to be secured  
over the screw on the connector.  
SIHI_0139_ENG  
Attention: gun cable to control unit  
Cover sleeve with warning sign have to be secured over the screw (84) on the connector.  
84  
GM 5000E gun cable  
B_03691  
Attention: guns with electrical extension cable  
Cover sleeves with warning signs have to be secured over the screws (84) on the connectors.  
Extension cable to the  
GM 5000E gun cable  
control unit  
84  
84  
B_03690  
29  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
1
16  
15  
2
3
4
5
21  
14  
12  
11  
10  
3
6
80  
R1  
60  
40  
20  
10  
kV  
100  
R2  
R3  
8
0
60  
40  
20  
EXT  
μ
A
VM 5000  
9
13  
17  
7
8
B_03158  
19  
18  
20  
5.4 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. Adjust approx. 0.05 MPa; 0.5 bar; 7.25 psi on the pressure regulator (12).  
4. Open return valve (17).  
5. Slowly open the ball valve (11).  
6. Adjust the air pressure on the pressure regulator (12) so that the pump runs regularly.  
7. Close ball valve (11) as soon as pure working material starts coming from the return  
tube (8).  
30  
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GM 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.  
12. When there is no pressure remaining in the system close gun.  
13. Secure gun.  
14. Dispose of the contents of the container (18) according to the local regulations.  
5.4.2 START-UP FOR SPRAYING AIRCOAT  
1. Secure gun and place the desired nozzle.  
2. Set pump (4) to about 8 Mpa;80 bar;1160 psi operating pressure and switch on control  
unit (13).  
3. Spray (press the trigger).  
4. Adjust the spray pressure at the paint pump according to the nozzle and object being  
sprayed.  
5. Now open AirCoat air (6), approx. 0.01-0.25 MPa; 1-2.5 bar; 14,5-36 psi, and adjust for  
the optimal atomization.  
For round-jet method:  
6. By turning the nozzle nut, the atomizing air jet can  
additionally be adjusted.  
Notes  
Do not turn the nozzle nut until it is flush with the  
nozzle body. There must be play for the atomizing air  
between the nozzle nut and the nozzle body.  
The air adjustment at the back of the gun does not  
B_03192  
affect the spray pattern in this process.  
For flat-jet method:  
7. Change the width of the spray jet by turning the air  
adjustment back to the spray gun or by appropriate  
selection of the nozzle.  
B_03159  
31  
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GM 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  
œ Never spray into a closed container.  
œ Earth the container.  
SIHI_0008_GB  
1. By means of nozzle spanner (2), loosen nozzle  
insert (1) by a half turn.  
2. Remove the nozzle spanner and briefly  
actuate trigger guard.  
3. After cleaning the nozzle, re-tighten the  
nozzle insert.  
1/2  
1
B_03160  
2
5.4.4 EXCHANGE OF ROUND JET NOZZLE INSERT  
1. Remove nozzle insert (1) using nozzle  
spanner (2).  
2. Fit the new nozzle insert.  
B_03161  
1
2
32  
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GM 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.  
1
2. Relieve the pressure of gun and unit.  
3. Save the spray gun (1) using the trigger lock.  
4. Unscrew round jet nozzle cap (2) incl. nozzle  
insert (3).  
5. Unscrew nozzle insert (3) using nozzle  
spanner (4).  
2
3
6. Unscrew nozzle nut (5) and remove nozzle  
4
screw connection (7) and sealing nipple (8)  
out off the nozzle body (6) and clean all parts  
thoroughly.  
8
7
6
7. Insert desired ACF 5000 nozzle (11) into the  
valve housing.  
5
8. Put the air cap (10) on the nozzle (11) and paying  
attention to the position of the guide surfaces.  
9. Screw union nut with attached nozzle guard (9) to the  
gun body and make sure that the air cap horns lie in the  
designated recess (Y).  
10. Before tightening the air cap horns (Y) set the desired  
jet level and then tighten the union nut to the stop by  
hand.  
1
11  
10  
9
Y
B_03162  
33  
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GM 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. Remove ACF 5000 AirCoat nozzle (11) and brush cleaning solvent until all traces of  
paint are dissolved.  
CAUTION  
Defective AirCoat nozzle!  
Insufficient paint application quality  
œ Do not use sharp-edged objects to treat hard metal on the AirCoat nozzle.  
SIHI_0020_GB  
6. Insert new ACF 5000 nozzle (11) into the valve housing.  
7. Put the air cap (10) on the nozzle (11) and pay attention to the position of the guide  
surfaces.  
8. Screw union nut with attached nozzle guard (9) to the gun body and make sure that  
the air cap horns lie in the designated recess (Y).  
9. Before tightening the air cap horns (Y) set the desired jet level and then tighten the  
union nut to the stop by hand.  
5.4.7 CLEANING OF THE NOZZLES  
The AirCoat ACF 5000 nozzles (11), the nozzle inserts (3) and the nozzle screw connection  
(7) can be placed in a cleaning solvent recommended by the paint manufacturer.  
All other nozzle parts may not be put into cleaning solvent.  
Clean these parts with cleaning solvent recommended by the manufacturer and dry with  
a cloth or a air-jet gun.  
5.4.8 ELIMINATE NOZZLE CLOGGING  
1. Switch off control unit.  
2. Relieve the pressure of gun and unit.  
2. Save the spray gun (1) using the trigger lock (14).  
3. Unscrew union nut (12) complete with air cap (10) and ACF 5000 nozzle (11).  
4. Remove air cap (10).  
5. Pull out the ACF 5000 nozzle (11) from the air cap (10) by hand, reverse it and put it  
towards the rear into the air cap (10).Pay attention to the position of the guide surfaces  
(X).  
34  
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GM 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. Screw preassembled union nut (12) to gun (1) and tighten by hand.  
8. Switch the material pressure back on.  
9. Turn the trigger lock (14) to the spraying position and briefly pull trigger.  
10. When the blockage has been flushed out secure the gun with trigger lock.  
11. Relieve the pressure of gun and unit.  
12. Unscrew union nut (12).  
13. Remove air cap (10) and put ACF 5000 nozzle (11) out off air cap by hand. Clean ACF  
5000 nozzle and insert it in spraying position into the valve housing.  
14. Put the air cap (10) on the nozzle (11) and pay attention to the position of the guide  
surfaces (X).  
15. Screw union nut with attached nozzle guard (9) to the gun body and make sure that  
the air cap horns lie in the designated recess (Y).  
16. Before tightening the air cap horns (Y) set the desired jet level and then tighten the  
union nut to the stop by hand.  
17. Switch the material pressure and the air pressure back on.  
18. Switch on the control unit.  
1
X
Y
14  
11  
B_03211  
Y
10  
12  
9
ACF 5000 nozzle in  
„spray“ position  
ACF 5000 nozzle in  
„cleaning“ position  
12  
35  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
6 MAINTENANCE  
➞ Observe safety instructions in chapter 2.  
6.1 PERIODICALLY CHECKS  
For the safe operation of electrostatic manual coating systems for flammable liquid  
spraying materials are intervals for periodically inspections defined as follows:  
Inspection point  
Inspection interval Remarks  
Gun cleaning, flushing  
Earthing measures  
Inspection for damage  
daily  
Chapter 2.2.4; chapter 6.1  
weekly  
weekly  
Chapter 2.2.2; chapter 5.1.5  
Chapter 6.2; 6.3; 6.4 and 6.5  
Chapter 5.1.2  
Locking of the technical ventilation yearly  
with the electrostatic manual  
coating system  
The above recommended intervals are maximum values and may be modified from  
operator depending on the local and operational conditions and contamination.  
Damaged devices must be taken out of service immediately and repaired.  
6.2 CLEANING AND DECOMMISSIONING  
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!  
Functional faults caused by swollen seals  
œ Never immerse the spray gun in cleaning agent.  
SIHI_0066_GB  
WARNING  
Incorrect maintenance/repair!  
Risk of injury and damage to the equipment  
œ Repairs and part replacement may only be carried out by  
specially trained staff or a WAGNER service center.  
œ Before all work on the unit and in the event of work interruptions:  
- Switch off the energy/compressed air supply.  
- Relieve the pressure from the spray gun and unit.  
- Secure the spray gun against actuation.  
œ Observe the operating instructions when carrying out all work.  
SIHI_0141_GB  
36  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
DANGER  
Exploding gas/ air mixture!  
Danger to life from flying parts and burns  
œ Never spray into a closed container.  
œ 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. Connect up the supply of cleaning solvent.  
With round jet nozzle fitted:  
4. By means of nozzle spanner, loosen nozzle insert by a half turn.  
5. Actuate the trigger guard. Flush the gun through thoroughly.  
6. Relieve the material pressure on the spray gun and the devise!  
7. Tighten nozzle insert.  
8. Clean the spray gun body with a cleaning agent recommended by the manufacturer  
and dry with a cloth or blow gun.  
With flat jet nozzle fitted:  
4. Remove AirCoat nozzle and clean separately (see paragraph 5.4.7).  
5. Actuate the trigger guard. Flush the gun through thoroughly.  
6. Relieve the material pressure on the spray gun and the devise!  
7. Clean gun body with a cleaning agent recommended by the manufacturer and dry  
with a cloth or blow gun.  
CAUTION  
Cleaning agent in the air duct!  
Functional faults caused by swollen seals  
Discharge current to ground -> no high voltage  
Always point the spray gun down when cleaning.  
Ensure that neither paint nor cleaning agent enters the air duct.  
When taking a break from work or when stored for a longer period, the spray gun  
has to be positioned correctly with the attachment pointing downwards.  
SIHI_0145_GB  
B_03453  
37  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
6.3 DISMANTLING OF THE SPRAY GUN  
1
SW3  
SW12  
SW12  
B_03194  
2
Torx 25  
3
SW3  
B_03195  
SW19  
SW21  
38  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
4
Carefully release the  
cascade without pliers.  
SW19  
B_03196  
SW22  
SW19  
Assembly tool for  
needle valve.  
Note:  
5
6
Loosen AC valve tip by hand  
using an assembly tool.  
Part no. 2309368  
Use assembly tool, socket or ring spanner  
(no wrench).  
SW9  
Assembly tool for  
valve housing.  
Part no. 2325263  
B_03197  
Do not pull out on contact wire.  
39  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
7
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.  
4. If the loosened package (3) in the  
hole jammed, emit from the front  
(see upper image).  
5
4
1
SW5  
SW6  
3
B_03198  
2
SW2  
6
7
8
9
1. Undo the oval head screw (1).  
2. Pull the air valve (2) out off the  
hole.  
SW8  
Torx 20  
SW9  
Removing air valve:  
1
Unscrew and remove sealing  
nut SW8. Hold the piston rear  
(2) and unscrew piston front  
SW5.  
2
SW14  
SW5  
B_03199  
40  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
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 cleaning  
agent.  
The end piece, plug compl. and the handle inside must be clean and dry after  
cleaning. Care should be taken that these parts remain free of solvents, grease or  
sweat from the hands (salt water).  
Only spare parts are used which have undergone an EC type examination  
and are subject to a quality assessment (production monitoring) according to  
Directive 94/9/EC.  
➞
➞
Spare parts may have safety-relevant properties.  
Defective parts, O-rings and seal sets must always be re-placed.  
WARNING  
Incompatibility of cleaning agent and working medium!  
Risk of explosion and danger of poisoning by toxic gasses  
œ Check the compatibility of cleaning agent and working medium  
in accordance with safety data sheets.  
SIHI_0060_GB  
In chapter 10 can be found part numbers for gun spare parts as well as for wearing parts  
such as seals.  
41  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
6.5 ASSEMBLING THE SPRAY GUN  
2
3
1
2
SW8  
SW5  
1
SW9 1 Nm  
2
1
B_03448  
2
Ensure the correct insertion position!  
Mounting materials:  
Item Part No. Description  
1
2
3
4
9992590 Loctite 222  
B_03201  
4
9992698 Vaseline white PHHV II  
9992831 Loctite 542  
SW14  
3 Nm  
9992511 Loctite 243  
42  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
Insertion position compl. package  
SW2  
1Nm  
3
X
Set measure X with withdrawal nut and  
then fasten it with the threaded pin  
(SW2).  
2
X = 123 0.1  
SW5  
Push together the valve rod unit and the  
compl. package.  
SW6  
0.4 -  
0.5 Nm  
Screw in together the valve rod unit and the  
compl. package.  
SW5/ 0.4 - 0.5 Nm  
Remove the valve rod unit.  
Tighten the compl. package.  
2
Carefully insert the valve rod unit and mount the  
complete clamping screw (1) with assembly tool  
(5).  
0.5 Nm  
5
4
B_03202  
2
1
Ensure the correct  
insertion position!  
5
4
Tighten slightly AC valve  
tip by hand using an  
assembly tool  
(Part No. 2309368).  
B_03203  
Note:  
SW9  
1.2 Nm  
Use assembly tool, socket or  
ring spanner (no wrench).  
Ensure the correct  
insertion position!  
Assembly tool  
(Part No. 2325263).  
43  
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GM 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  
6
7
with Vaseline.  
2
SW3  
SW19  
0.8 Nm  
2.5 Nm  
B_03205  
SW19  
SW21  
B_03204  
SW22  
SW19  
8
Push the trigger upward into  
the air valve piston.  
Torx 25  
B_03206  
44  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
9
0.8 Nm  
SW3  
Ensure the correct  
insertion position!  
SW12  
SW12  
B_03207  
2
10  
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  
45  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
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 cable to control unit.Take the spray gun in your hand and hold into open space.Switch on control  
unit and actuate trigger guard.  
The high-voltage should be 60 to 65 kV with dry ambient air.The value can be checked with the display on the  
control unit (VM 5000).  
Note  
The gun must be clean and dry and must not have any colour or cleaning agent residues.  
BIn the case of ambient air with a high air humidity, the measured value reduces to 50 to 55 kV.  
High-voltage measurement with high-voltage tester  
Place the ball of the high-voltage tester on the gun electrode and switch on the high-voltage. The measured  
value should be 70 to 80 kV.  
Note  
- When measuring the high-voltage the gun and the measuring device should be held at arms length as far  
away from the body as possible.  
- There should be no chargeable objects with in a radius of 1 m; 3.28 ft of the place where the measurements  
are taken.  
- The placing of the measuring ball of the high-voltage measuring device reduces the spraying of the  
high-voltage electrode. As a result the high-voltage value increases compared to the spraying in the free  
space.  
Disruptive discharge test  
Check the gun against earth with the earthing rod. No sparks should be formed.  
Note: In the vicinity of the electrode can occur harmless corona discharges.  
B_03212  
46  
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GM 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. 0.8 MPa; 8 bar; 116 psi.  
Air tightness  
With the trigger guard unactuated, test for air tightness at the points marked in the  
illustration:  
B_03213  
6.6.3 MATERIAL PRESSURE TEST  
Connect high pressure hose to the spray gun.  
Test the spray gun for tightness with solvent or spray oil (e.g. Macrol 52) and a max.  
pressure of 25 MPa; 250 bar; 3626 psi.  
Observe the following gun components:  
Material connection, nozzle body, material valve (no after-spraying).  
DANGER  
Exploding gas/ air mixture!  
Danger to life from flying parts and burns  
œ Never spray into a closed container.  
œ Earth the container.  
SIHI_0008_GB  
47  
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GM 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. Set the fluid pressure on the material supply to the point where a further increase in fluid pressure would  
significantly improve fluid atomization.  
4. Open air pressure regulator for the atomizer air and adjust so as to achieve optimal atomization. The  
interrelation between spray pattern and atomizer air is shown in the figure below.  
5. With the air adjustment on the gun, the ratio form adjustment to atomization until the optimum spray  
pattern is achieved.  
Note:  
Repeat point 4 and 5 until the optimum spray pattern is reached (process iterative).  
Spray pattern  
B_00071  
no atomizing air  
too little atomizing air  
correct amount of atomizing air  
Note:  
The paint output volume can be changed by:  
Changing the material pressure or  
using a different flat jet nozzle (see chapter 9).  
•
•
Influence of the air adjustment on the spray pattern shape  
The spray pattern can be adjusted to suit the object being sprayed using the air adjustment. The illustration  
below shows the influence of the shaping air regulator on the spraying pattern.  
Other nozzle sizes can be used to obtain larger or smaller spraying patterns.  
Completely opened  
Closed  
air adjustment  
air adjustment  
48  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
7 TROUBLE SHOOTING AND SOLUTION  
Functional fault  
Cause  
Remedy  
Insufficient material output  
• Nozzle too small.  
• Select larger nozzle  
(see Accessories chapter 9).  
• Material pressure too  
low.  
• Increase material pressure.  
• Clean or replace filter.  
• Filter of gun or high  
pressure filter at pump  
clogged.  
• Nozzle is clogged.  
• Nozzle cleaning  
(see paragraph 5.4.3 / 5.4.8).  
Poor spray pattern  
• Wrongly adjusted  
atomizing air.  
• Readjust the atomizing air.  
• Nozzle too large.  
• Select smaller nozzle  
(see nozzle table).  
• Material pressure too  
low.  
• Increase pressure at pump.  
• Material viscosity too  
high.  
• Thin material in accordance  
with the manufacturer‘s  
instructions.  
Valve rod leaks  
• Seals at the valve rod  
are damaged  
• Replace the seals  
(see chapter 6).  
• Loose package.  
• Tighten.  
Poor wrap-around  
• Inadequate earthing.  
• Check earthing.  
• Inadequate electrical  
• Check resistance of paint in  
resistance of the paint. accordance with paragraph  
4.1.1.  
• Spraying pressure too • Readjust spraying pressure.  
high.  
Back spraying  
• No earthing.  
• Check earthing.  
• Distance between  
spray gun and object  
too large.  
• Reduce distance between  
spray gun and object  
• Nozzle nut placed too • Screw back nozzle nut  
far forward.  
(decrease air distributor  
ring gap).  
No wrap-around  
• High-voltage switch is • Switch on high-voltage.  
in the off position.  
• No electrostatics.  
• Repair malfunction as laid  
down in the control unit  
operating instructions.  
49  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
8 PRODUCT DISPOSAL  
Note  
Do not dispose of waste electrical equipment with the house-  
hold refuse!  
In accordance with European Directive 2002/96/EC on the disposal  
of waste electrical equipment and its implementation in national  
law, this product may not be disposed of with the household refuse,  
but must rather be recycled in an environmentally correct manner.  
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.  
SIHI_0127_GB  
50  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
9 ACCESSORIES  
9.1 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, profiles and complex  
work pieces.  
Part No.  
Marking  
Jet width  
Recommended gun filter  
mm; inches  
132720  
132721  
132722  
132723  
132724 *  
132725  
132726  
132727  
132728  
132729  
132730  
132731  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
approx. 250; 10  
approx. 250; 10  
approx. 250; 10  
approx. 250; 10  
approx. 250; 10  
approx. 250; 10  
approx. 250; 10  
approx. 250; 10  
approx. 250; 10  
approx. 250; 10  
approx. 250; 10  
approx. 250; 10  
Edge filter  
(200 mesh)  
"?ꢄꢄꢄꢅꢉ  
Edge filter  
(100 mesh)  
Edge filter  
(50 mesh)  
* Standard version  
Jet width in mm; inches at a distance of 30 cm; 11.8 inches from the object and at a  
pressure of 10 MPa; 100 bar; 1450 psi.  
9.2 ACF 5000 AIR CAPS (FLAT JET)  
Part No. Description  
2309882 ACF 5000 - LV air cap, suitable for low viscosity materials (marked red)  
2314203 ACF 5000 - HV air cap, suitable for high viscosity materials (marked blue)  
B_03454  
B_03209  
51  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
9.2.2 ACF 5000 AIRCOAT FLAT JET NOZZLES  
Application  
B_03163  
395107  
395207  
395407  
395109  
395209  
395309  
395409  
395509  
395609  
395111  
395211  
395311  
395411  
395511  
395611  
395811  
395113  
395213  
395313  
395413  
395513  
395613  
395813  
395115  
395215  
395315  
395415  
395515  
395615  
395815  
395217  
395317  
395417  
395517  
395617  
395817  
07/10 0.18; 0.007  
07/20  
07/40  
09/10 0.23; 0.009  
09/20  
09/30  
09/40  
09/50  
09/60  
11/10 0.28; 0.011  
11/20  
11/30  
11/40  
11/50  
11/60  
11/80  
13/10 0.33; 0.013  
13/20  
13/30  
13/40  
13/50  
13/60  
13/80  
15/10 0.38; 0.015  
15/20  
15/30  
15/40  
15/50  
15/60  
15/80  
17/20 0.43; 0.017  
17/30  
17/40  
17/50  
10°  
20°  
40°  
10°  
20°  
30°  
40°  
50°  
60°  
10°  
20°  
30°  
40°  
50°  
60°  
80°  
10°  
20°  
30°  
40°  
50°  
60°  
80°  
10°  
20°  
30°  
40°  
50°  
60°  
80°  
20°  
30°  
40°  
50°  
60°  
80°  
Natural paint  
Transparent lacquer  
Oil  
Synthetic resin paint  
PVC paint  
Paint, undercoat  
Priming paint  
Filler  
Filler  
Rust proofing paint  
Rust proofing paint  
Latex paint  
17/60  
17/80  
52  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
Application  
B_03163  
395219  
395319  
395419  
395519  
395619  
395819  
395221  
395421  
395521  
395621  
395821  
395423  
395623  
395823  
395425  
395625  
395825  
395427  
395627  
395827  
395429  
395629  
395829  
395431  
395631  
395831  
395435  
395635  
395835  
19/20 0.48; 0.019  
19/30  
19/40  
19/50  
19/60  
19/80  
21/20 0.53; 0.021  
21/40  
21/50  
21/60  
21/80  
23/40 0.58; 0.023  
23/60  
23/80  
25/40 0.64; 0.025  
25/60  
25/80  
27/40 0.69; 0.027  
27/60  
27/80  
29/40 0.75; 0.029  
29/60  
29/80  
31/40 0.79; 0.031  
31/60  
31/80  
35/40 0.90; 0.035  
35/60  
35/80  
20°  
30°  
40°  
50°  
60°  
80°  
20°  
40°  
50°  
60°  
80°  
40°  
60°  
80°  
40°  
60°  
80°  
40°  
60°  
80°  
40°  
60°  
80°  
40°  
60°  
80°  
40°  
60°  
80°  
Rust proofing paint  
Latex paint  
Mica paint  
Zinc dust coating  
Rust proofing paint  
Glue paints  
53  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
9.3 FILTERS  
Part No.  
3204604  
3204605  
9999002  
Description  
Edge filter 60 mesh (white)  
Edge filter 100 mesh (black)  
Edge filter 200 mesh (yellow)  
B_00019  
9.4 REDUCTION FITTINGS FOR HIGH-PRESSURE HOSES  
The classification of WAGNER fittings is consistent with the following classification, each  
separated by high-pressure and low pressure fittings.  
DF Double fitting - Male / Male thread  
RF Reduction fitting - Female / Male thread  
SF Adjustable screw - Female / Male thread: allows precise angle adjustment (Swivel)  
EF 90° elbow - Adjustable or Male / Male thread (Elbow-Fitting)  
BF Bulkhead fastener - Male / Male thread with pressure resistant execution  
PF Stopper - Male thread to be closed (Plug-Fitting)  
HF Hose fitting with union nut and sealing cone (Hose-Fitting)  
The short description of the fittings are as follows:  
DF-  
MM-  
G3/4“-  
1/4“NPS- PN270-  
SSt  
Materials, SSt = Stainless steel  
Nominal pressure (in bar)  
1.Thread, e.g. G1/4“, 1/4“NPS  
2.Thread, e.g. G1/4“, 1/4“NPS, M16x1.5  
M: Male (external thread) F: Female (internal thread)  
Short description see list above, e.g. RF = Reduction Fitting  
Part No.  
384555  
384559  
384556  
34041  
Description  
M
Reduction fitting-RF-FM-M16x1,5-1/4“NPS-PN530-SSt  
Reduction fitting-RF-FM-M16x1,5-G1/4“-PN530-SSt  
Reduction fitting-RF-FM-M16x1,5-3/8“NPSM-PN530-SSt  
Reduction fitting-RF-FM-1/4“NPS-M16x1,5--PN270-SSt  
Reduction fitting-RF-FM-1/4“NPS-3/8“NPS--PN270-SSt  
Reduction fitting-RF-FM-1/4“NPS-G1/4“--PN270-SSt  
179732  
179247  
B_03221  
F
In the large Wagner Accessories Catalogue for wet coating can also be found other  
material screw connections.  
54  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
9.5 HOSES AND ELECTRICAL CABLES  
9.5.1 STANDARD HOSE SETS AND COMPONENTS  
4
3
2
1
5
B_03217  
Item Qty  
Part No. Description  
1
1
2309857 GM 5000EAC hose set (7.5 m)  
Consisting of:  
2
3
4
5
1
1
9984573 High pressure hose-DN4-PN270-¼“NPS-7.5 m-PA  
2312060 Air hose compl. (8.0 m)  
1
2307293 GM 5000E gun cable (10.0 m)  
7 m  
3676437 Protective hose mesh PP30 (7.0 m)  
Item Qty  
Part No. Description  
1
1
2309858 GM 5000EAC hose set (10.0 m)  
Consisting of:  
2
3
4
5
1
1
9984573-10 High pressure hose-DN4-PN270-¼“NPS-10.0 m-PA  
2312061 Air hose compl. (10.5 m)  
1
2309474 GM 5000E gun cable (15.0 m)  
9.5 m  
3676437 Protective hose mesh PP30 (9.5 m)  
Item Qty  
Part No. Description  
1
1
2309859 GM 5000EAC hose set (15.0 m)  
Consisting of:  
2
3
4
5
1
1
1
9984573-15 High pressure hose-DN4-PN270-¼“NPS-15.0 m-PA  
2312062 Air hose compl. (15.5 m)  
2309475 GM 5000E gun cable (20.0 m)  
14.5 m 3676437 Protective hose mesh PP30 (14.5 m)  
Item Qty  
Part No. Description  
1
1
2309860 GM 5000EAC hose set (20.0 m)  
Consisting of:  
2
3
4
5
1
1
1
9984573-20 High pressure hose-DN4-PN270-¼“NPS-20.0 m-PA  
2312063 Air hose compl. (20.5 m)  
2309476 GM 5000E gun cable (25.0 m)  
19.5 m 3676437 Protective hose mesh PP30 (19.5 m)  
55  
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GM 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  
2
3
4
1
- inside hose material FEP  
5
B_03216  
Item  
Qty  
Part No. Description  
1
1
2309951 GM 5000EAC hose set (7.5 m), Low R  
Consisting of:  
2
3
4
5
1
1
2310468 EAC high pressure paint hose, compl. (7.5 m) LowR  
2312060 Air hose compl. (8.0 m)  
1
2307293 GM 5000E gun cable (10.0 m)  
7m  
3676437 PP30 protective hose mesh (7.0 m)  
Item  
Qty  
Part No. Description  
1
1
2309952 GM 5000EAC hose set 10.0 m), Low R  
Consisting of:  
2
3
4
5
1
1
2310469 EAC high pressure paint hose, compl. (10.0 m) LowR  
2312061 Air hose compl. (10.5 m)  
1
2309474 GM 5000E gun cable (15.0 m)  
9.5 m  
3676437 PP30 protective hose mesh (9.5 m)  
Item  
Qty  
Part No. Description  
1
1
2309953 GM 5000EAC hose set (15.0 m), Low R  
Consisting of:  
2
3
4
5
1
2310470 EAC high pressure paint hose, compl. (15.0 m) LowR  
2312062 Air hose compl. (15.5 m)  
1
1
2309475 GM 5000E gun cable (20.0 m)  
14.5 m  
3676437 PP30 protective hose mesh (14.5 m)  
Item  
Qty  
Part No. Description  
1
1
2309954 GM 5000EAC hose set (20.0 m), Low R  
Consisting of:  
2
3
4
5
1
2310471 EAC high pressure paint hose, compl. (20.0 m) LowR  
2312063 Air hose compl. (20.5 m)  
1
1
2309476 GM 5000E gun cable (25.0 m)  
19.5 m  
3676437 PP30 protective hose mesh (19.5 m)  
56  
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GM 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  
2307296 GM 5000E extension cable 20 m  
B_03219  
9.6 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  
50342  
Wet film thickness measurer  
B_03224  
Viscosity cup DIN 4 mm; 0.16 inches  
57  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
2309368 Assembly tool valve needle  
B_03451  
128901  
ACR nozzle spanner  
"?ꢄꢇꢊꢉꢇ  
B_03681  
2325263 Assembly tool clamping screw  
2326485 GM 5000E wall mount (left/right)  
2324766 Swivel for air  
B_03699  
B_03720  
2327060 Fitting-SJM-GM5000EAC-1/4“NPS (swivel material)  
B_03719  
2327061 GM 5000EAC swivel set  
B_03720  
B_03719  
58  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
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 „Quantity“ column.  
This number merely indicates how many of the respective parts are used in each sub  
assembly.  
The following information is also required to ensure smooth processing of your order:  
- Address for the invoice  
- Address for delivery  
- Name of the person to be contacted in the event of any queries  
- Type of delivery required (air freight or mail, sea route or overland route, etc.)  
Marks in spare parts lists  
Note to column„K“ in the following spare parts lists.  
U
L
=
=
Wearing parts  
Note: No liability is assumed for wearing parts  
Not part of standard equipment, available, however, as additional extra.  
WARNING  
Incorrect maintenance/repair!  
Risk of injury and damage to the equipment  
œ Repairs and part replacement may only be carried out by  
specially trained staff or a WAGNER service center.  
œ Before all work on the unit and in the event of work interruptions:  
- Switch off the energy/compressed air supply.  
- Relieve the pressure from the spray gun and unit.  
- Secure the spray gun against actuation.  
œ Observe the operating instructions when carrying out all work.  
SIHI_0141_GB  
59  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
10.2 GM 5000EAC SPARE PARTS LIST  
4
5
22  
24  
2
3
7
6
8
9
18  
17  
10  
11  
12  
1
16  
15  
14  
19  
13  
20  
21  
B_03153  
60  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
GM 5000EAC spare parts list  
Item  
K
Quantity  
Part No.  
Description  
1
2
3
4
5
1
1
1
1
1
2309871  
2314283  
9952777  
9960808  
-
GM 5000EAC standard variant  
AC contacting  
◆
★
★
◆
High resistance, bare  
Socket contact component  
GM 5000EAC end piece compl.  
Details see chapter 10.2.1  
◆
6
7
1
1
2314361  
-
Hook  
GM 5000EAC handle compl.  
Details see chapter 10.2.2  
8
2
1
1
1
1
1
1
1
1
1
2
1
1
9900308  
2312183  
9900386  
2311970  
2307104  
2312180  
9971182  
9971182  
2314360  
2307283  
2310617  
2314359  
3204605  
Cheese head screw with hexagon  
Cover compl.  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
Cheese head screw with hexagon  
Sealing plug  
Seal screw  
Air regulation compl.  
O-ring  
◆
◆
◆
★
★
O-ring  
Trigger  
Cylindrical helical spring  
Oval head screw with hexagon  
AC material hose compl.  
◆
◆
Edge filter 100 mesh (black)  
(for different edge filter sizes see chapter 9.3)  
21  
22  
24  
1
1
1
1
2308764  
2315775  
2308699  
2326336  
AC hose nipple  
AC union nut compl.  
Sealing Cover  
◆
◆
★
GM 5000EAC service set  
◆ = Wear part  
★ = Included in service set’  
61  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
10.2.1 GM 5000EAC SPARE PARTS LIST- END PIECE  
2
3
4
1
5
6
B_03164  
7
12  
9
23  
10  
8
17  
18  
Ensure the correct insertion position!  
24  
11  
21  
22  
X = 123 0.1  
62  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
GM 5000EAC end piece spare parts list  
Item  
K
Quantity  
Part No.  
Description  
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
-
GM 5000EAC end piece compl.  
AC air manifold ring  
O-ring, sheathed  
AC valve housing compl.  
AC valve tip compl.  
GM 5000EAC end piece  
Cascade compl.  
★
2313314  
2307180  
2312175  
2312186  
2314272  
2312181  
9974166  
2307062  
2311562  
2313639  
2312178  
2311624  
◆
◆
◆
3
★
★
★
4
5
6
7
◆
8
★
★
★
O-ring  
9
Clamping screw valve rod  
Rod seal  
◆
◆
◆
◆
10  
11  
12  
17  
AC valve rod unit  
Package compl.  
O-ring  
18  
21  
22  
23  
24  
1
1
1
1
1
1
2307051  
2307059  
9901411  
2320256  
2325263  
2326336  
Clamping screw package  
Withdrawal nut  
Threaded pin with hexagon  
O-ring  
◆
Assembly tool clamping screw  
Service set GM 5000EAC  
◆ = Wear part  
★ = Included in service set  
63  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
10.2.2 GM 5000EAC SPARE PARTS LIST - HANDLE  
14  
25  
15  
26  
16  
17  
18  
19  
24  
20  
13  
7
10  
9
8
6
12  
11  
1
5
4
23  
3
2
B_03165  
64  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
GM 5000EAC handle spare parts list  
Item  
K
Quantity  
Part No.  
Description  
1
2
3
4
5
6
1
1
1
1
1
1
-
GM 5000EAC handle compl.  
Nipple  
2307288  
9971025  
2315344  
2312182  
2314270  
◆
★
O-ring  
Hose holder  
Plug compl.  
Handle compl.  
7
★
★
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2307232  
2311952  
2309825  
2310692  
2311182  
2309400  
2312189  
2307935  
2307557  
2312846  
2310680  
9974218  
2310682  
2316246  
9974166  
2303437  
2325291  
2325294  
2326336  
End piece seal  
Stop screw  
Oval head screw with hexagon  
Seal  
8
9
◆
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
23  
24  
25  
26  
Straight pin  
Safety catch  
Air valve  
Piston front  
Seal  
◆
★
Cylindrical helical spring  
Sleeve  
◆
◆
★
★
O-ring  
Seal  
Piston compl.  
O-ring  
◆
◆
★
★
O-ring  
Sealing nut  
Air valve washer  
Service set GM 5000EAC  
◆ = Wear part  
★ = Included in service set  
65  
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GM 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  
2
6
5
1
4
3
B_03168  
Flat jet nozzles spare parts list  
Item  
K
Quantity  
Part No.  
Description  
1
2
2
3
4
5
6
1
1
1
1
1
1
1
2315775  
2309882  
2314203  
2311777  
2311776  
2311217  
2319525  
AC union nut compl.  
LV air cap compl.  
HV air cap compl.  
AC nozzle guard  
AC union nut  
◆
◆
◆
◆
O-ring, sheathed  
Flat electrode set  
◆ = Wear part  
66  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
10.3.2 ACR 5000 ROUND JET NOZZLE CAP SPARE PARTS LIST  
11  
10  
1
9
6
5
4
3
2
12  
B_03169  
ACR 5000 round jet nozzle cap spare parts list  
Item  
K
Quantity  
Part No.  
Description  
1
2
1
1
1
1
1
1
1
1
1
1
2309883  
2307220  
2315310  
132351  
ACR 5000 round jet nozzle cap  
Nozzle nut  
◆
◆
3
O-ring  
4
Nozzle screw connection holder  
Nozzle body  
5
2307219  
2319526  
132516  
◆
◆
◆
◆
6
Round electrode set  
Nozzle screwed connection compl.  
Sealing nipple  
9
10  
11  
12  
2307216  
2311217  
128901  
O-ring  
Nozzle spanner compl.  
◆ = Wear part  
67  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
68  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
69  
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GM 5000EAC.  
EDITION 03/2012  
PART NUMBER DOC 2319150  
OPERATING MANUAL  
Germany  
Switzerland  
J.WAGNER GmbH  
J.WAGNER AG  
Otto-Lilienthal-Str. 18  
Postfach 1120  
Industriestrasse 22  
Postfach 663  
D- 88677 Markdorf  
CH- 9450 Altstätten  
Telephone: +49 7544 5050  
Telefax: +49 7544 505200  
E-Mail: [email protected]  
Telephone: +41 (0)71 757 2211  
Telefax: +41 (0)71 757 2222  
E-Mail: [email protected]  
Belgium  
Denmark  
WSB Finishing Equipment  
Veilinglaan 56/58  
WAGNER Industrial Solution Scandinavia  
Viborgvej 100, Skærgær  
B- 1861 Wolvertem  
DK- 8600 Silkeborg  
Telephone: +32 (0)2 269 4675  
Telefax: +32 (0)2 269 7845  
Telephone: +45 70 200 245  
Telefax: +45 86 856 027  
E-Mail: [email protected] / HP www.wsb-wagner.eu E-Mail [email protected]  
United Kingdom  
France  
WAGNER Spraytech (UK) Ltd.  
Haslemere Way  
J.WAGNER France S.A.R.L.  
Parc de Gutenberg - Bâtiment F8  
8, Voie la Cardon  
F- 91127 Palaiseau-Cedex  
Telephone: +33 1 825 011 111  
Telefax: +33 1691 946 55  
Tramway Industrial Estate  
GB- Banbury, OXON OX16 8TY  
Telephone: +44 (0)1295 265 353  
Telefax: +44 (0)1295 269861  
E-Mail: [email protected]  
E-Mail: [email protected]  
Netherlands  
Italy  
WSB Finishing Equipment B.V.  
De Heldinnenlaan 200  
NL- 3543 MB Utrecht  
WAGNER COLORA S.r.l  
Via Fermi, 3  
I- 20875 Burago di Molgora (MB)  
Telephone: +31 (0) 30 241 4155  
Telefax: +31 (0) 30 241 1787  
Telephone: +39 039 625021  
Telefax: +39 039 6851800  
E-Mail: [email protected] / HP www.wsb-wagner.eu  
E-Mail: [email protected]  
Japan  
Austria  
WAGNER Spraytech Ltd.  
2-35, Shinden Nishimachi  
J- Daito Shi, Osaka, 574-0057  
J.WAGNER GmbH  
Otto-Lilienthal-Str. 18  
Postfach 1120  
D- 88677 Markdorf  
Telephone: +81 (0) 720 874 3561  
Telefax: +81/ (0) 720 874 3426  
E-Mail: [email protected]  
Telephone: +49 (0) 7544 5050  
Telefax: +49 (0) 7544 505200  
E-Mail: [email protected]  
Sweden  
Spain  
WAGNER Industrial Solutions Scandinavia  
Skolgatan 61  
WAGNER Spraytech Iberica S.A.  
Ctra. N- 340, Km. 1245,4  
SE- 568 31 Skillingaryd  
E- 08750 Molins de Rei (Barcelona)  
Telephone: +34 (0) 93 680 0028  
Telefax: +34 (0) 93 668 0156  
E-Mail: [email protected]  
Telephone: +46 (0) 370 798 30  
Telefax: +46 (0) 370 798 48  
E-Mail: [email protected]  
Czechoslovakia  
USA  
WAGNER s.r.o.  
Nedasovská Str. 345  
15521 Praha 5 - Zlicin  
Telephone: +42 (0) 2 579 50 412  
Telefax: +42 (0)2 579 51 052  
E-Mail: [email protected]  
WAGNER Systems Inc.  
300 Airport Road, unit 1  
Elgin, IL 60123 USA  
Telephone: +1 630 503 2400  
Telefax: +1 630 503 2377  
E-Mail: [email protected]  
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