GM 2000 EACR - EN GM 2000 EACF

Operating Manual
Electrostatic AirCoat Spraygun,
with flat or round jet tips
GM 2000 EACR - EN
GM 2000 EACF - EN
Edition 03/98
0179 887 GB
GM 2000 EAC - EN
CONTENTS
Paragraph
1
1.1
1.2
1.3
1.4
1.5
2
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.4
3
3.1
3.2
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
5.1
5.2
5.3
5.4
5.5
5.6
6
Chapter.Page
INTRODUCTION
Using the manual
SAFETY REGULATIONS
PTB Conformity certification
Product liability and guarantee
CE conformity
DESCRIPTION
Scope of supply
Technical data
Functional description
Function of the gun
AirCoat round jet process
AirCoat flat jet process
Electrostatic effect
What kind of spraying material can be applied?
PREPARATION BEFORE STARTING WORK
Preparation of paint
Earthing
STARTING WORK, AND HANDLING
Preparation
General rules for handling the spray gun
Starting-up for AirCoat spraying
Cleaning of clogged round jet tips
Exchange of AirCoat round jet tip insert. (EAC round)
Changing from AirCoat round jet to AirCoat flat jet
Replacing AirCoat flat jet tips
Cleaning of AirCoat flat jet tips
Clogging of AirCoat flat jet tips
MAINTENANCE
Decommissioning and cleaning
Dissassembly of AirCoat nozzle body
Exchange or cleaning of filters
Adjustment of the valve rod seal
Exchange of complete valve rod, or of valve rod seals
Exchange of paint channel
TROUBLE SHOOTING AND SOLUTIONS
0.1
1.1
1.1
1.2
1.4
1.5
1.6
2.1
2.1
2.1
2.1
2.1
2.3
2.3
2.4
2.4
3.1
3.1
3.1
4.1
4.1
4.1
4.1
4.2
4.2
4.2
4.3
4.3
4.3
5.1
5.1
5.2
5.2
5.3
5.3
5.4
6.1
GM 2000 EAC - EN
CONTENTS
Paragraph
7
7.1
7.2
7.3
7.4
7.5
7.6
8
8.1
8.2
8.3
Chapter.Page
ACCESSORIES
Round jet tip inserts
AirCoat flat tips
Filter (standard)
Long filter housing and filters
Hoses and fittings
Special tools
SPARE PARTS CATALOGUE
How to order spare parts?
Special marks in spare parts lists
Spare parts list and drawing
0.2
7.1
7.1
7.2
7.3
7.3
7.3
7.3
8.1
8.1
8.1
8.2
GM 2000 EAC - EN
1.
INTRODUCTION
This operating manual contains information and instruction for the operation, repair
and maintenance of the spray gun.
This equipment can be dangerous if it is not operated in accordance with this Operating manual!
Compliance with these instructions constitutes an integral component of the guarantee
agreement.
This operating manual is available in various languages:
1.1
Language
No. ord.
german
english
french
italian
swedish
danish
0179 886
0179 887
0179 888
0179 889
0179 150
0179 151
Using the manual
"Caution"
This heading is used wherever non-compliance with operating instructions, working instructions, specified working sequences etc. may result in injury or accident.
"Attention"
This heading is used wherever non-compliance with operating instructions, working instructions, specified working sequences etc. may result in damage to the equipment.
"Note"
This heading is used to draw attention to a particular passage in the text.
Subject to change without notice
Printed in Switzerland
1.1
GM 2000 EAC - EN
1.2
SAFETY REGULATIONS
The safety requirements for electrostatic hand spraying equipement are laid
down in the following documents: (Germany)
1) ZH 1/250
Electrostatic enamelling with hand-held spraying equipment
(Published by C. Heymanns-Verlag, Cologne)
2) ZH 1/406
Guidelines for jet stream equipment (spraying devices)
3) EX-RL/ZH 1/10
Explosion protection guidelines - spraying equipment
(Published by C. Heymanns-Verlag, Cologne)
(Published by C. Heymanns-Verlag, Cologne)
4) VBG 23
Working with coating materials
5) DIN-VDE 0165
Installation of electrical equipment in a potentially explosive
atmosphere (Published by VDE-Verlag, Berlin)
Electrostatic hand spraying equipment
(Published by C. Heymanns-Verlag, Cologne)
6) EN 50050/DINVDE 0745 Part 100 (Published by VDE-Verlag, Berlin)
7) EN 50053/DINSelection, installation and use of electrostatic spraying
VDE 0745 Part 101 equipment - electrostatic hand spraying equipment for combustible liquid spray media (Published by VDE-Verlag,Berlin)
Caution
The following points should receive special attention for the safe use of the
electrostatic spraying equipment:
1.2.1
Caution! Danger of injury by injection
The pressure should be released from the spray gun during breaks in
work or while assembling and dismantling the nozzle. It should be
secured, the control unit switched off, and the plug pulled out. Never
point the gun at yourself or any other person, the spray jet can cause
injury by injection.
Never put your finger or hand in the spray jet.
In case of injury to skin by paint or cleaning agents consult a doctor
immediately. Inform the doctor of the type of paint or cleaning agent
used.
1.2.2
Cleaning
The gun must be switched off when being cleaned and should never be
sprayed in "closed" containers (formation of a gas air/mixture which can
explode). The containers must be earthed.
1.2.3
Safety
Spraying can only be carried out safely, both for people and the environment, if
it is done in a spray booth or in front of a spraying wall with sufficient ventilation
(removal by suction).
In order to avoid occupational illness the safety regulations laid down by the
manufacturer of the paint or cleaning agent used must be adhered to during
preparation and application of the paint and while cleaning the equipment. In
particular, protective clothing, gloves, skin protection cream and breathing
equipment must be used to protect the skin and respiratory tracts.
1.2
GM 2000 EAC - EN
1.2.4
Protective breathing masks
Although the E-Static AirCoat spraying procedure produces very little mist, it is
not completely mist free. There are, in fact, few paint particles to be found in
the air. Nevertheless, the operator must use a protective breathing mask, (see
respiratory equipment instruction sheet ZH 1/134 and VGB 23 from the
professional trade association) during spraying operations.
1.2.5
The spray gun and the high pressure hoses between the pump and the
spray gun must be of a sufficient quality for the pressure produced by the
pump.
A permanent marking on the high pressure hoses must indicate the maximum
permitted working pressure, the manufacturer and date of production.
Furthermore, it must be of a suitable quality so that the electric resistance
between the pump connection and the spray gun is less than 1 megaohm.
1.2.6
Earthing
Depending on the electrostatic charge and the flow speed of the spray an
electrostatic charge may, in certain cases, occur on the equipment. This could
cause a spark or flame on discharging. In order to avoid this the equipment
must always be earthed.
There must be a conductive connection (potential equalisation cable) between
the material container and the equipment.
All persons within the working area must wear shoes with electricallyconductive
soles (e.g. shoes with leather soles). Gloves must also be conductive, because
the operator is earthed through the handle of the spraygun. The floor of the
working area must be conductive, in accordance with VDE 0745, part 1,
paragraph 35: measurements according to DIN 51953.
1.2.7
Extraction systems
Paint mist extraction systems must be fitted on site according to the local
regulations.
1.2.8
Accessories and spare parts
The manufacturer's guarantee and product liability are only valid if original
Wagner accessories are used.
1.2.9
Safety information on harmless electrostatic discharges
If the plastic parts of the spray gun are touched with the hand this can result in
a harmless discharging (so-called brush discharge). The same occurs when
you electrostatically charge yourself by walking on a synthetic carpet and then
touch a metallic door handle, thus discharging the electrostatic charge. The
charge on the plastic parts is caused by the high-voltage field of the gun. The
discharging is completely safe for people and is not able to cause any ignition.
A corona glow may occur at the electrode end of the gun when it is in use (only
visible under dark conditions). A corona discharge can occur if the electrode
(spray gun) comes within a distance of 4 - 10 mm from the object being sprayed. The corona glow does not cause any ignition hazard.
1.3
GM 2000 EAC - EN
1.3
PTB Conformity certification
1.4
GM 2000 EAC - EN
1.4
Product liability and guarantee
Wichtiger Hinweis zur Produkthaftung
Aufgrund einer ab 01. 01. 1990 gültigen EG-Verordnung haftet der Hersteller nur dann für sein Produkt,
wenn alle Teile vom Hersteller stammen oder von diesem freigegeben wurden, bzw. die Geräte sachgemäss montiert, betrieben und gewartet werden.
Bei Verwendung von fremdem Zubehör und Ersatzteilen kann die Haftung ganz oder teilweise entfallen.
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.
Mit Original WAGNER-Zubehör und Ersatzteilen haben Sie die Gewähr, dass alle Sicherheitsvorschriften
erfüllt sind.
The usage of original WAGNER accessories and
spare parts guarantees that all safety regulations are
observed.
G a r a n tie e r k lä r u n g
W a r r e n ty
Für dieses Gerät leisten wir Werksgarantie in folgendem Umfang:
Alle diejenigen Teile werden unentgeltlich nach unserer Wahl
ausgebessert oder neu geliefert, die sich innerhalb von 24 Monaten bei Einschicht-, 12 Monaten bei Zweischicht- oder 6 Monaten bei Dreischichtbetrieb seit Übergabe an den Käufer infolge eines vor dieser Übergabe liegenden Umstandes – insbesondere wegen fehlerhafter Bauart, schlechter Baustoffe oder
mangelhafter Ausführung – als unbrauchbar oder in ihrer
Brauchbarkeit erheblich beeinträchtigt erweisen.
Die Garantie wird in der Form geleistet, dass nach unserer Entscheidung das Gerät oder Einzelteile hiervon ausgetauscht
oder repariert werden. Die hierfür erforderlichen Aufwendungen, insbesondere Transport-, Wege-, Arbeits-, und Materialkosten werden von uns getragen, es sei denn, dass sich die Aufwendungen erhöhen, weil das Gerät nachträglich an einen anderen Ort als den Sitz des Bestellers verbracht worden ist.
This unit is covered by our warranty on the following terms:
Wir übernehmen keine Garantie für Schäden, die durch folgende Gründe verursacht oder mitverursacht worden sind:
Ungeeignete oder unsachgemäße Verwendung, fehlerhafte
Montage, bzw. Inbetriebsetzung durch den Käufer oder durch
Dritte, natürliche Abnutzung, fehlerhafte Behandlung oder Wartung, ungeeignete Beschichtungsstoffe, Austauschwerkstoffe
und chemische, elektrochemische oder elektrische Einflüsse,
sofern die Schäden nicht auf ein Verschulden von uns zurückzuführen sind. Schmirgelnde Beschichtungsstoffe wie z.B.
Menninge, Dispersionen, Glasuren, flüssige Schmirgel, Zinkstaubfarben usw. verringern die Lebensdauer von Ventilen,
Packungen, Spritzpistolen, Düsen, Zylinder, Kolben usw.. Hierauf zurückzuführende Verschleißerscheinungen sind durch diese Garantie nicht gedeckt.
Komponenten die nicht von Wagner hergestellt wurden, unterliegen der ursprünglichen Herstellergarantie.
Der Austausch eines Teiles verlängert nicht die Garantiezeit
des Gerätes.
Das Gerät ist unverzüglich nach Empfang zu untersuchen.
Offensichtliche Mängel sind bei Vermeidung des Verlustes der
Garantie innerhalb von 14 Tagen nach Empfang des Gerätes
der Lieferfirma oder uns schriftlich mitzuteilen.
Wir behalten uns vor, die Garantie durch ein Vertragsunternehmen erfüllen zu lassen.
Die Leistung dieser Garantie ist abhängig vom Nachweis durch
Rechnung oder Lieferschein. Ergibt die Prüfung, daß kein Garantiefall vorliegt, so geht die Reparatur zu Lasten des Käufers.
Klargestellt wird, daß diese Garantieerklärung keine Einschränkung der gesetzlichen, bzw. der durch unsere allgemeinen Geschäftsbedingungen vertraglich vereinbarten Ansprüche darstellt.
J. Wagner AG
1.5
We will at our discretion repair or replace free of charge all
parts which within 24 months in single-shift, 12 months in 2shift 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 terms of the warranty are met at our discretion by the repair or replacement of the unit or parts thereof. 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.
This warranty does not cover damage caused by:
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, electrochemical or electrical agents, except when the damage is attributable to us.
Abrasive coating products such as redlead, emulsions, glazes,
liquid abrasives, zinc dust paints and similar reduce the service life of valves, packings, spray guns, tips, cylinders, pistons
etc. Any wear resulting from the aforementioned causes is not
covered by this warranty.
Components not manufactured by Wagner are subject to the
warranty terms of the original maker.
The replacement of a part does not extend the warranty period
of the unit.
The unit should be inspected immediately upon receipt.
Any apparent defect should be notified to us or the dealer in
writing within 14 days from date of sale of the unit.
The right to commission warranty services to a third party is reserved.
Warranty claims are subject to proof of purchase by submitting
an invoice or delivery note. If an inspection finds damage not
covered by the present warranty, the repair will be carried out
at the expense of the purchaser.
Note that this warranty does not in any way restrict legally entitled claims or those contractually agreed to in our general
terms and conditions.
J. Wagner AG
GM 2000 EAC - EN
1.5
CE Conformity
1.5.1
Short explanation
CE = Communauté Européenne:
Products identified with the CE mark have been manufactured and checked according
to EU guidelines. This means that, in terms of materials used, manufacturing process
and operation, they are in accordance with the EU safety and health requirements and
therefore the EU regulations and standards. The regulations and standards applying to
a particular product can be found in the CE Certificate of Conformity. This is enclosed
with the product or can be requested from the manufacturer. The CE identification
has been compulsory in Europe since 1st January 1995, and only products bearing
CE identification may be released into circulation.
EMC test:
The electromagnetic compatibility test forms an integral part of the CE conformity.
EMC tested products are built such that their interference radiation does not influence
other devices within the stipulated limits (noise on the radio, etc.). The EMC standard
differentiates between use in domestic, business and commercial or industrial areas.
Moreover, if required for comfort or safety reasons, products can be EMC tested for
their interference immunity. This means they are protected from the influence of
external interference.
1.5.2
EC Certificate of Conformity
The certificate with the Part No.:
0179 780
is enclosed with this product. This can be reordered from your WAGNER representative, quoting the product and serial number.
1.6
GM 2000 EAC - EN
2.
DESCRIPTION
2.1
Scope of supply
Part No.
0179 018
Quantity
1
or
0179 019
1
Description
Electrostatic AirCoat spray gun GM 2000 EAC R, with
round jet tip R 15 .
Electrostatic Air coat spray gun GM 2000 EAC F, without
flat jet tip.
The standard equipment includes:
0179 901
Universal spanner
0128 901
Tip spanner
0034 041
Coupler fitting NPS1/4-M16x1.5
9994 682
Glove
0179 941❋ Spare parts kit EAC/AC
0179 887
Operating manual
GM 2000 EACR GM 2000 EACF
1 piece
1 piece
1 piece
1 piece
1 piece
1 piece
1 piece
1 piece
1 piece
1 piece
1 piece
❋ Spare parts kit EAC/AC comprises of:
0179 946
Set of seals
9995 611
Cylindrical filter 180 meshes
1 piece
3 pieces
For "special" models the delivery note is valid for specific details.
2.2
Technical data
Max. air pressure
Max. paint pressure
Air connection
Paint connection
Filter (standard)
Input voltage
Input current
Output voltage
Output current
Polarity
Cable length
Weight
Paint output
8 bar
250 bar
R 1/4"
NPS 1/4"
180 M
max. 22 V AC
max. 0.7 A AC
max. 80 kV DC
max. 150 A DC
negative
11 m
approx. 600 g
(without cables)
acc. to nozzle
see tip table
2.3
Functional description
2.3.1
Functions of the gun
300
255
Attention
The electrostatic spray gun GM 2000 EAC EN can only be used with the control units
VM 200 EN, VM2000 EN or EPP 200 EN.
continued....
2.1
GM 2000 EAC - EN
O The trigger can be used to
activate, one after the other, the
various functions of the spray
gun.
An increase in the tension
needed to pull the trigger back
will be felt at the position where
the material valve opens.
O In order to overcome Faraday
cages in corners, the high voltage can be switched off by flipping the HV switch (F) down.
O The supply of atomizing and flat
jet air is adjusted by means of
the star handles (D)
AirCoat - air open
AirCoat - air open and
electrostatics activated
AirCoat - air open, electrostatics
activated and material valve open
Legend
A Tip
B Tip nut
C Spray gun body
D Air control knob
E Locking nut for trigger
F HV flip switch (integrated into
trigger)
G Handle with integrated high voltage generator
H Air connection
I Cable connection
K Paint connection
L Trigger
M Paint filter
2.2
D
C
B
E
F
G
A
H
I
M
L
K
GM 2000 EAC - EN
2.3.2
AirCoat round jet process
In the AirCoat process, high pressure of 30 to 150 bar is used to atomize the material.
The AirCoat air at 0 to 2.5 bar produces a soft jet, which largely eliminates the problem
of overlapping boundaries. The spray jet can be adjusted by turning the nozzle nut.
The multi-channel swirl nozzle produces fine paint particles, while at the same time
reducing their forwards speed and swirling them to produce a rotating motion. The
result is a soft, extremely well atomized spraying cloud.
Nozzle nut
Advantages of AirCoat
O
O
O
O
AirCoat air
High painting capacity
Low fogging tendency
Good finish
High- viscosity paints can easily
be applied
Material
AirCoat air
Multi-channel swirl nozzle
2.3.3
AirCoat flat jet process
In the AirCoat process, high pressure of 30 to 150 bar is used to atomize the material.
The AirCoat air at 0 to 2.5 bar produces a soft jet, which largely eliminates the problem
of overlapping boundaries.
Advantages of AirCoat
AirCoat air
●
●
●
●
High painting capacity
Low fogging tendency
Good finish
High- viscosity paints can easily
be applied
Material
AirCoat air
2.3
GM 2000 EAC - EN
2.3.4
Electrostatic effect
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.
Charged particles
Electrode
Advantages of
electrostatics:
● Very efficient spraying
● Little overspray
● Coating of entire circumferences due to an
electrostatic field
● Less working time
Grounded object
2.4
What kind of spraying material can be applied?
● Paints containing solvents of the explosion class II A.
● Enamels, primers, textured paints etc., which have a specific resistance of > 50 k
(according to the Wagner or Ransburg scale).
● The effectiveness of the spraying action is always dependant on the composition
of the paint being used, e.g. pigments, resins and solvents.
Note
With highly conductive materials, or those with a very high electrical resistance, the
electrostatic effect does not work so efficiently.
In the case of application problems contact the Wagner branch and the paint producer.
2.4
GM 2000 EAC - EN
3.
PREPARATION BEFORE STARTING WORK
Caution
The operating instructions and the safety regulations for the additional system
components used must be read before starting-up .
This spray gun must be used a part of an AirCoat-Electrostatic spraying system.
The control units VM 200 EN, VM 2000 EN or EPP 200 EN and other various
components are also needed (see Wagner-accesories).
The spray gun and paint supply system must be flushed out with a suitable cleaning
solvent before being used.
3.1
Preparation of paint
The viscosity of the paints is of great importance. The best results are obtained with
paints between 18 and 30 DIN sec. (measured in immersion flow cup DIN 4 mm). In
most cases, the application of paints of up to 50-60 DIN sec. for thick layers does not
cause problems.
3.2
Earthing
Perfect earthing is a prerequisite for optimum coating efficiency and safety.
The imperfect earthing of a workpiece will result in:
● Sparks between the object being sprayed and the suspension hook.
● Insufficient electrostatic effect (no wrap-around)
● Uneven coating thickness
● Back spraying to spray gun and sprayer
The prerequisites for perfect earthing and coating are:
● Clean workpiece suspension.
● Earthing of spraying cabin, conveyor system and suspension with 10mm2 copper
cable to system earth, earthing strip or ring.
● Earthing of all conductive parts within the working area.
● The earthing resistance of the workpiece may not exceed 1 MΩ.
conveyor
Control unit
Object to be
sprayed
Pump
R max < 1 M
Spraying stand
Paint container
Floor, conductive
3.1
GM 2000 EAC - EN
Empty page
3.2
GM 2000 EAC - EN
4.
STARTING WORK, AND HANDLING
Caution
See SAFETY REGULATIONS in chapter 1.
4.1
Preparation
● Locking of spray gun! Turn locking nut clockwise until stop (viewed from back of
gun)
● Check that spraying pressures are suitable.
● Check that all connections are tight and do not leak.
4.2
General rules for handling the spray gun
The following rules must be observed before any work is carried out on the
equipment or during breaks in work:
● Switch off control unit.
● Relieve spray gun and system pressure.
● Lock the spray gun with the locking nut.
4.3
Start-up for AirCoat spraying
1. Connect earth cable to the earth terminal of the control unit. Fix the other end using
the clamp to the nearest earthed piece of the equipment (cabin, transport device,
or similar). Make sure that all other conductive parts within the work area are
earthed.
2. Connect material hose to spray gun and to pump.
3. Connect air hose to spray gun and to oil-free, dry air supply with regulator.
4. Connect cable to control unit VM 200 EN or EPP 200 EN.
5. Set material pressure (approx. 80 bar) at material pump and switch on control unit.
6. Spray (actuate trigger).
7. Adjust spraying pressure at the paint pump regulator, according to jet and object.
8. Now open AirCoat air (approx. 1 to 2.5 bar) and adjust for the optimum atomization.
Adjusting round jet fan:
9. By turning the tip nut , the atomizing air jet can additionally be adjusted.
By exchanging tips, various paint outputs can be achieved.
Note
Do not close the gap for atomizing air between tip nut and body.
for flat jet process :
9. To change the jet width; fit another AirCoat flat jet nozzle, with the required fan angle.
By exchanging tips, various paint outputs can be achieved.
4.1
GM 2000 EAC - EN
4.4
Cleaning of clogged round jet tips
1. By means of tip spanner (A),
loosen tip insert (B) by a half turn.
2. Remove tip spanner and briefly pull
trigger. Caution, never spray into
an enclosed vessel.
3. After cleaning the tip retighten.
4.5
A
B
Exchange of Aircoat round jet tip insert (EAC round)
B
1. Remove tip insert (B) with tip spanner (A).
2. Fit desired tip insert (acc. to table
7.1) with tip spanner.
A
4.6
Changing from AirCoat round jet to AirCoat flat jet.
1. Replace paint with cleaning solvent, actuate trigger, and thoroughly rinse paint channel.
2. Relieve spray gun and system
pressure.
3. Lock spray gun. Turn locking screw
clockwise until stop. (Look in spraying direction)
4. Unscrew tip nut (C).
5. Remove tip body (D) by means of
pin wrench.
6. Fit tip insert (F) on paint channel
(G).
7. Fit air cap (H) onto fan nozzle (F);
make sure that the pins in the air
cap fit into the grooves in the flat
nozzle.
8. Fit cap ring (I) with air cap (H) onto
spray gun body (E).
9. Adjust desired jet level by means of
air cap horns (X) and tighten cap
ring (I) by hand.
4.2
Universal spanner
C
E
D
I
H
X
F
G
E
GM 2000 EAC - EN
4.7
Replacing AirCoat flat jet tips
1. Switch off control unit.
2. Relieve spray gun and system
H
I
pressure!
3. Lock spray gun. Turn locking screw
clockwise until stop. (look in spraying direction)
4. Unsrew cap ring (I) and remove air
cap (H).
X
5. Remove AirCoat tip insert (F) and
F G
E
brush cleaning solvent until all traces of paint are dissolved.
Handle the hard metal tip insert (C) with care. Do not clean it with sharp metal objects.
6. Assembly: Fit tip insert (F) on paint channel (G).
7. Fit air cap (H) onto fan nozzle (F); make sure that the pins in the air cap fit into the
grooves in the tip.
8. Fit cap ring (I) with air cap (H) onto spray gun body (E).
9. Adjust desired jet level by means of air cap horns (X) and tighten cap ring (I) by
hand.
4.8
Cleaning of AirCoat flat jet tips
For disassembly and assembly see of AirCoat nozzles chapter 4.7.
The AirCoat nozzle (F) can be placed into a cleaning solvent which has been
recommended by the paint manufacturer. Do not treat the hard metal on the AirCoat
nozzle using sharp edged objects.
4.9
Clogging of AirCoat flat jet tips
For blockages in the AirCoat flat jet tip the accessory - tip cleaning device - is available
with the partnumber 0139 014.
This tip cleaning device can be used together with the GM 2000 EAC to flush out
blocked AirCoat flat jet tips in the opposite direction to the usual spray direction.
4.3
GM 2000 EAC - EN
Empty page
4.4
GM 2000 EAC - EN
5.
MAINTENANCE
Caution
See SAFETY REGULATIONS in chapter 1.
Attention
The spray gun and the system must be cleaned every day. Use only the cleaning solvent recommended by the material manufacture.
Never immerse the spray gun into the solvent.
The following points must be observed before every maintenance works:
● Switch off control unit.
● Relieve spray gun and system pressure.
● Secure the spray gun.
5.1
Decommissioning and cleaning
1. Switch off control unit.
2. Relieve system pressure and cut off the air supply to the spray gun.
3. Replace material by cleansing agent.
if the round jet nozzle is fitted
4. By means of tip spanner (A), loosen tip insert (B) by a half turn.
5. Remove tip spanner and briefly actuate trigger. Caution, never spray into an enclosed vessel.
6. Relieve spray gun and system pressure !
7. Tighten tip insert.
8. Clean the body of the gun with solvent which has been recommended by the paint
manufacturer and dry with a cloth or blow gun.
if the flat jet nozzle is fitted
5. Remove and clean the AirCoat tip. (see chapter 4.5)
6. Actuate trigger and thoroughly rinse paint channel.
Never spray into an enclosed vessel.
7. Relieve spray gun and system pressure!
8. Clean the body of the gun with solvent which has been recommended by the paint
manufacturer and dry with a cloth or blow gun.
Note
Keep the gun pointing downwards or horizontally, cleaning agent must not get into the air ducts.
The gun attachment (X) may only be changed
by the WAGNER Service Station.
X
5.1
GM 2000 EAC - EN
5.2
Dissassembly of AirCoat nozzle body (round jet)
1. Unscrew tip nut.
2. Remove nozzle body (3) with
spanner (B)
3. Unscrew tip insert (1) with tip
spanner (A)
4. Push threaded nozzle fitting (2)
backwards out of the nozzle
body (3).
5. Handle the round-jet tip insert (1)
and threaded fitting (2) with care,
do not clean with sharp metal
objects. Use nozzle cleaning
brush
(parts no. 9997 001).
A
1
2
B
3
Replace any worn-out parts.
Assemble in reverse order.
Note (round jet EAC)
Care must be taken when assembling that the tip nut is not tight to the nozzle body (3).
There must be room for the AirCoat air between nut and nozzle body.
5.3
Exchange or cleaning of filters
1. Place spanner, size 11, on surface (2) of material connection (3)
and counterhold.
2. Turn union nut (1) to the right
(clockwise) with open-end
wrench, size 17, and unscrew
material connection.
3. Do not unscrew counter nut (A),
as the connection will leak.
4. Remove filter screw (5) and
withdraw cylindrical filter (4).
5. Clean filter (4) with solvent, or
exchange it.
A
2
4
5
Assemble in reverse order.
3
5.2
1
3
GM 2000 EAC - EN
5.4
Adjustment of the valve rod seal
In case paint leaks at the valve rod
near the trigger:
1. Pull trigger and throughly
clean paint channel with solvent.
2. Tighten the sealing screw (A) carefully with universal spanner
3. If leaking continues, see chapter
5.5.
5.5
A
Exchange of complete valve rod, or of valve rod seals
1. Pull trigger (Y) and unscrew
locking nut (X); remove compression spring.
2. Remove flat-head screw (Z) and
take off trigger (Y).
3. Unscrew sealing screw (4/B)
from sealing sleeve (5).
4. Carefully remove complete valve
rod at surface (F) and replace.
To replace seals:
5. Hold with universal spanner at
surface (E) and unscrew valve
sealing element (1/A) using universal pliers.
2
1
3
5
4
6
7
X
Z
Y
9
8
Loctite 243
Loctite 243
A
B
D
C
E
F
6. Remove compression ring (2) and packing (3).
7. Hold with spanner at surface (D) and unscrew at surface (C), removing push-rod
cap (7).
8. Exchange compression ring (with O-ring) (2), front seal (3), rear seal (4), push-rod
seal (8) and replace air valve seal (9) of the air valve.
9. Reassemble in reverse order and secure thread with Loctite 243.
10. Place locking nut (X) with compression spring in position. Actuate trigger (Y) and
tighten the locking nut (X) until a noticeable resistance is felt.
5.3
GM 2000 EAC - EN
5.6
Exchange of paint channel
●
1.
2.
3.
4.
if the round jet nozzle is fitted
Unscrew tip nut (1).
Unscrew tip body (2) with universal spanner.
Unscrew seal screw (3) with paint channel assembly tool.
Remove paint channel.
Assemble in reverse order, use screw (3) again.
●
1.
2.
3.
4.
if the flat jet nozzle is fitted
Unscrew cap ring (5).
Remove air cap (6) and AirCoat tip (7).
Unscrew seal screw (3) with paint channel assembly tool.
Remove paint channel.
Re-Assemble in reverse order, use screw (3) again.
Note
Insert the paint channel as shown below (note position of the shoulder for the seal
screw)
1
Universal spanner
2
Round jet
4
3
Flat jet
Paint channel assembly tool
5
6
5.4
7
GM 2000 EAC - EN
6.
TROUBLE SHOOTING AND SOLUTIONS
Problem
Insufficient material
output
Cause
• Tip too small
• Material pressure too low
Poor spray pattern
Solution
• Select larger tip (see chapter
7.1 and 7.2)
• Increase material pressure
• Gun filter or high-pressure
filter in pump blocked
• Clean or exchange filter
• AirCoat tip (round) clogged
• Clean tip (see chapter 4.4,
4.8 and 4.9)
• Wrongly adjusted atomizing
air
• Tip too large
• Readjust the atomizing air
• Material pressure too low
• Material viscosity too high
• Select smaller tip (see chapter 7.1 and 7.2)
• Increase material pressure
• Thin material acc. to manufacturer's instruction.
Leaking air valve
• Damaged seals on the valve • Exchange seals (see chapter
5.4 and 5.5)
rod
Poor wrap round or
electrostatic effect
• Poor earth
• Check earth of object
• Paint conductivity too high /
resistance paint too high
• Check resistance of paint
(see chapter 2.4)
• Spraying pressure too high
• Adjust spraying pressure
• No earth
• Check earth. (see chapter
3.2)
Back spraying
• Distance between spray gun • Reduce distance between
spray gun and workpiece.
and workpiece too large.
No electrostatic effect
(no wrap around)
• High voltage switched off ?
• Switch on high voltage.
• High voltage failure
• Repair failure acc. to operating instructions of control
unit.
6.1
GM 2000 EAC - EN
Empty page
6.2
GM 2000 EAC - EN
7.
ACCESSORIES
7.1
Round jet tip inserts
The round jet tips are especially suited to spray pipes, profiles and
complex workpieces.
Part-No.
0132 720
0132 721
0132 722
0132 723
0132 724 ✕
0132 725
0132 726
0132 727
0132 728
0132 729
0132 730
0132 731
✕
1)
2)
Marking
Volume flow
1)
R 11
R 12
R 13
R 14
R 15
R 16
R 17
R 18
R 19
R 20
R 21
R 22
0.160
0.220
0.270
0.340
0.380
0.430
0.480
0.530
0.590
0.650
0.710
0.770
Jet width
2)
Recommended filter
appr. 250 mm
appr. 250 mm
appr. 250 mm 180 mesh
appr. 250 mm
appr. 250 mm
appr. 250 mm
appr. 250 mm 100 mesh
appr. 250 mm
appr. 250 mm
appr. 250 mm
appr. 250 mm 50 mesh
appr. 250 mm
Standard tip
Volume flow in l/min water at 100 bar
Jet width in mm at a distance of 30 cm from the object and at a pressure of
100 bar
7.1
GM 2000 EAC - EN
7.2
AirCoat flat tips
AirCoat flat jet tips are used for fast, economic application of material to
flat workpieces.
Part
number
0128 564
0128 550
0128 216
0128 567
0128 211
0128 551
0128 552
0128 217
0128 568
0128 201
0128 573
0128 553
0128 554
0128 218
0128 569
0128 212
0128 574
0128 555
0128 556
0128 219
0128 570
0128 213
0128 575
0128 557
0128 220
0128 571
0128 215
0128 558
0128 565
0128 572
0128 559
0128 560
0128 561
0128 562
0128 563
Marking
07.40
09.10
09.20
09.40
09.50
09.60
11.10
11.20
11.40
11.50
11.60
11.80
13.10
13.20
13.40
13.50
13.60
13.80
15.10
15.20
15.40
15.50
15.60
15.80
18.20
18.40
18.50
18.80
21.20
21.40
21.50
21.80
26.50
31.50
36.50
size
mm / inch
Spraying Volume
angle
flow 1)
0.18-0.007
0.23-0.009
0.23-0.009
0.23-0.009
0.23-0.009
0.23-0.009
0.28-0.011
0.28-0.011
0.28-0.011
0.28-0.011
0.28-0.011
0.28-0.011
0.33-0.013
0.33-0.013
0.33-0.013
0.33-0.013
0.33-0.013
0.33-0.013
0.38-0.015
0.38-0.015
0.38-0.015
0.38-0.015
0.38-0.015
0.38-0.015
0.46-0.018
0.46-0.018
0.46-0.018
0.46-0.018
0.53-0.021
0.53-0.021
0.53-0.021
0.53-0.021
0.66-0.026
0.79-0.031
0.91-0.036
40
10
20
40
50
60
10
20
40
50
60
80
10
20
40
50
60
80
10
20
40
50
60
80
20
40
50
80
20
40
50
80
50
50
50
0.19
0.26
0.26
0.26
0.26
0.26
0.38
0.38
0.38
0.38
0.38
0.38
0.57
0.57
0.57
0.57
0.57
0.57
0.72
0.72
0.72
0.72
0.72
0.72
1.14
1.14
1.14
1.14
1.56
1.56
1.56
1.56
2.32
3.50
4.56
Jet
width 2)
160
90
120
170
200
220
100
125
190
210
235
290
100
120
200
220
250
310
115
145
210
250
270
330
140
250
270
380
190
270
290
430
300
300
300
Recommended
filter
180 mesh
100 mesh
50 mesh
1) Volume flow in l/min water at 100 bar
2) Jet width in mm at a distance of 30 cm from the object and at a pressure of 100
bar, synthetic resin paint, 20 DIN seconds
7.2
GM 2000 EAC - EN
7.3
Filter (standard)
Part No. For use with nozzle sizes
Mesh Part No. Part No.
for 6 pcs. for 12 pcs. for 24 pcs.
round
flat
Cylindrical filter 180 0179 931 0179 932 0179 933 R 11 - R 15
.007" - .011"
Cylindrical filter 100 0179 934 0179 935 0179 936 R 16 - R 19
.012" - .015"
Cylindrical filter 50 0179 937 0179 938 0179 939 R 20 - R 22
.018" - .036"
Description
7.4
Long filter housing and and filters
Part No.
Description
0179 160
Filter housing cpl.
Description
Gun filter, red
Gun filter, yellow
Gun filter, white
7.5
7.6
Mesh
Part No.
for 1 pc.
180
100
50
0034 383
0043 235
0034 377
Part No. For use with nozzle sizes
for 10 pcs.
round
flat
0097 022
R 11 - R 15
.007" - .011"
0097 023
R 16 - R 19
.012" - .015"
0097 024
R 20 - R 22
.018" - .036"
Hoses and fittings
Part No.
Description
0229 200
0128 510
9984 481
9982 016
0179 228
Air and HP hose DN4 - ND 270 - M16 x 1.5 - length 7.5 m
Air hose cpl. length 8.1 m
HP- Hose DN 4 - ND 270 - M16 x 1.5 - length 7.5 m
Prtective hose cover (lengths order in m )
Extension cable EN, length 7.5 m
0123 446
9994 627
Double nipple M16x1.5 (for paint hoses)
Double nipple R1/4 " (for air hoses)
Special tools
Part No.
Description
0179 926
0128 901
0179 901
0179 799
Paint channel tool
Tip spanner
Universal spanner
Service Instruction GM 2000 EA EN + EAC EN
7.3
GM 2000 EAC - EN
Empty page
7.4
GM 2000 EAC - EN
8.
SPARE PARTS CATALOGUE
8.1
How to order spare parts?
Always supply the following information to ensure delivery of the right spare part:
Part No., description and quantity.
The quantity need not be the same as the number given in the "Quantity" column. This
number merely indicates the how many of the respective parts are used in each subassembly.
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
8.2
Special marks in spare parts lists
Note to column "K" in the following spare parts list:
❋
=
Wearing part
●
=
Not a part of the standard equipment. Available, however, as additional extra
8.1
GM 2000 EAC - EN
8.3
Spare parts list
Item
Part No.
2
3
4
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
0179 354
9900 962
0179 564
0179 569
9900 810
9971 003
0179 416
0179 396
0179 254
0179 236
9971 182
0179 343
0179 341
0179 342
0179 481
0179 395
0179 339
0179 338
0179 337
0179 335
0179 394
9994 247
0179 253
9994 248
0179 784
9994 627
0128 510
0179 248
9900 808
0179 219
9995 611
0179 383
0179 241
9984 481
0179 643
0179 465
0179 644
0128 ...
0179 485
0179 486
0179 452
0132 724
0132 351
K
❋
❋
❋
❋
❋
❋
❋
●
●
❋
❋
❋
●
●
❋
Quantity Description
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Positioning bush
Countersunk screw M3x12
Data plate GM 2000 EAC R EN
Data plate GM 2000 EAC F EN
Flat head screw
O-ring green 6x1
Air control knob
Trigger pin
Valve stem assy.
Valve ball
O-ring 4x1
Thrust collar
Needle packing
Sealing screw
Tappet cap
Seal
Tappet seal
Air valve seal
Valve tappet
Valve stem
Spring guide - valve stem
Compression spring
Adjuster for valve rod
Compression spring
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Tension nut assy.
Double nipple R1/4"
Air hose
Hose cover
Pan-head screw M3x8
Trigger
Cylinder filter 180 M
Filter screw
Paint connector
HP-hose DN4 - ND270 - M16x1.5 - 7.5 m
Flat jet kit, 2000 EAC
Cap ring 2000 EAC
Air cap, 2000 EAC
AirCoat - flat tip (see chapter 7.2)
Paint channel
Seal screw
Tip nut 2000 EAC
Round jet tip R15 (see chapter 7.1)
R-Tip holder
8.2
8.3
38
42
37
39
48
40
41
51
52
54
53
50
49
55
A
57
56
View A
15
GM 2000 EAC - EN
GM 2000 EAC - EN
Item
Part No.
K
46
47
48
49
50
51
52
53
54
0132 516
0179 642
0179 641
9994 269
0179 521
0043 590
0128 389
0128 347
0179 160
.... ...
0179 482
0179 969
❋
55
56
57
0179 926
0179 946
●
●
●
●
●
●
●
Quantity Description
1
1
1
1
1
1
1
1
1
1
1
Distributor
Nozzle body 2000 EACR
Nozzle set 2000 EACR
Contact spring
Long filter housing
Compression spring
Seal
Hose connector M16x1.5
Long filter housing assembly
Gun filter (see chapter 7.4.)
Sliding cap
Tappet cap assy.
1
1
Paint channel assembly tool
Set of seals EA/EAC/AC
8.4
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