WAGNER GA 2000EAC Operational manual

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GA 2000EAC

GA 2005EAC

II 2G EEx 0,24 mJ T6 (Atex 95)

Translation of the original

Operating manual

Electrostatic AirCoat spray gun

for automatic operating mode

with ﬂat or round jet nozzles

Edition 12/ 2008

GA 2000EAC,GA 2005EAC

OPERATING MANUAL

EDITION 12/ 2008 PART NO. 350741

Contents

1 ABOUT THESE INSTRUCTIONS 5

1.1 Languages 5

1.2 Warnings, notes and symbols in these instructions 5

2 GENERAL SAFETY INSTRUCTIONS 6

2.1 Safety instructions for the operator 6

2.1.1 Electrical equipment 6

2.1.2 Personnel qualiﬁcations 6

2.1.3 A safe work environment 6

2.2 Safety instructions for personnel 6

2.2.1 Safe handling of WAGNER spray units 7

2.2.2 Earth the unit 7

2.2.3 Material hoses 7

2.2.4 Cleaning 8

2.2.5 Handling hazardous liquids, varnishes and paints 8

2.2.6 Touching hot surfaces 8

2.3 Correct use 8

2.4 Safety-relevant information about discharges 9

2.5 Use in an explosion hazard area 9

2.5.1 Correct use 9

2.5.2 Explosion protection identiﬁcation 9

2.5.3 Maxi. surface temperature 9

2.5.4 Safety instructions 10

2.6 Establishment of stationary electrostatic systems 10

3 PRODUCT LIABILITY AND WARRANTY 11

3.1 Important notes on product liability 11

3.2 Warranty 11

3.3 CE-Conformity 12

3.4 German Regulations and guidelines 13

3.5 PTB Conformity Certiﬁcation 14

4 DESCRIPTION 15

4.1 Area of application, using in accordance with the instructions 15

4.1.1 What kind of spraying material can be applied 15

4.2 Scope of supply 16

4.3 Technical Data 17

4.4 Functional description 18

4.4.1 Design of spray gun 18

4.4.2 Functions of the gun 18

4.5 Air atomizing spray process 19

4.5.1 Round jet spray process 19

4.5.2 AirCoat atomizing ﬂat jet spray process 20

4.5.3 Electrostatic effect 20

5 PREPARATION BEFORE STARTING WORK 21

5.1 Set up and connect 21

5.1.1 Typical electrostatic spraying system 21

5.1.2 Ventilation of the spray booth 22

5.1.3 Air Supply 22

GA 2000EAC,GA 2005EAC

OPERATING MANUAL

EDITION 12/ 2008 PART NO. 350741

5.1.4 Fluid (Paint) hoses 22

5.1.5 Earthing 23

5.2 Preparation of paint 25

5.2.1 Viscosity conversion table 25

5.3 Preparation before starting work 26

5.3.1 General rules for making adjustments to the spray gun 26

5.3.2 Preparation 27

5.4 Working 28

5.4.1 Start-up for spraying 28

5.4.2 Adjust the spray angle with ﬂat jet nozzles 28

5.4.3 Cleaning of clogged round jet nozzles 29

5.4.4 Exchange of AirCoat round jet nozzle insert 29

5.4.5 Changing from aircoat round jet to aircoat ﬂat jet 30

5.4.6 Replacing AirCoat ﬂat jet nozzle 31

5.4.7 Protection of the gun against pollution 31

6 MAINTENANCE 32

6.1 Finishing work and cleaning 33

7 TROUBLE SHOOTING AND SOLUTIONS 34

8 REPAIR WORK 36

8.1 Exchange or cleaning of ﬁlters 36

8.2 Adjustment of the valve rod seal 36

8.3 Exchange of complete valve rod 37

8.4 Exchange of valve rod seals 38

8.5 Exchange of paint channel 39

8.6 Disassembly of aircoat nozzle body (round jet) 40

9 ACCESSORIES 41

9.1 Round jet nozzle inserts 41

9.1.1 Nozzle screw joint assy 41

9.2 Nozzles AC-brillant 42

9.3 Long ﬁlter housing and ﬁlter inserts 44

9.4 Electrical cables 45

9.5 Hoses and ﬁttings 45

9.6 Miscellaneous 45

10 SPARE PARTS 47

10.1 How to order spare parts? 47

10.2 Spare parts list GA 2000EAC 48

10.3 Spare parts list GA 2005EAC 50

10.4 Spare parts list valve rod EAC 52

10.5 Spare parts list in line ﬁlter 53

Contents

GA 2000EAC,GA 2005EAC

OPERATING MANUAL

EDITION 12/ 2008 PART NO. 350741

1.1 LANGUAGES

1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS

1 ABOUT THESE INSTRUCTIONS

4HISOPERATINGMANUALCONTAINSINFORMATIONABOUTTHEOPERATIONREPAIRANDMAINTENANCE

OFTHEUNIT

 !LWAYSFOLLOWTHESEINSTRUCTIONSWHENOPERATINGTHEUNIT

4HISEQUIPMENTCANBEDANGEROUSIFITISNOTOPERATEDINACCORDANCEWITHTHISMANUAL

%LECTROSTATICSPRAYGUNSMAYBEOPERATEDONLYBYTRAINEDPERSONNEL

#OMPLIANCEWITHTHESEINSTRUCTIONSCONSTITUTESANINTEGRALCOMPONENTOFTHEGUARANTEE

AGREEMENT

4HISOPERATINGMANUALISAVAILABLEINTHEFOLLOWINGLANGUAGES

,ANGUAGE 0ART.O ,ANGUAGE 0ART.O

'ERMAN  %NGLISH

&RENCH  $UTCH

)TALIAN  3PANISH

$ANISH  3WEDISH

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 follo-

wing categories:

Danger - imminent danger.Non-observance will result

in death, serious injury and serious material damage.

Warning - possible danger.Non-observance can result

in death, serious injury and serious material damage.

Caution - a possibly hazardous situation. Non-obser-

vance can result in minor injury.

Note - provide information on particular characteristics and how to proceed.

Caution - a possibly hazardous situation. Non-obser-

vance can cause material damage.

3)()??'"

$!.'%2

4HISLINEWARNSOFTHEHAZARD

0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC

TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL

 4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES

3)()??'"

 7!2.).'

4HISLINEWARNSOFTHEHAZARD

0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC

TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL

 4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES

3)()??'" #!54)/.

4HISLINEWARNSOFTHEHAZARD

0OSSIBLECONSEQUENCESOFFAILINGTOOBSERVETHEWARNINGINSTRUCTIONS4HESIGNALWORD

POINTSOUTTHEHAZARDLEVEL

 4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES

3)()??'"

#!54)/.

4HISLINEWARNSOFTHEHAZARD

0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC

TIONS4HESIGNALWORDPOINTSOUTTHEHAZARDLEVEL

 4HEMEASURESFORPREVENTINGTHEHAZARDANDITSCONSEQUENCES

350740 350741

350742 350743

350744 350745

350747 350746

350870 350871

The corresponding service instructions are available under the following order number:

Language: Part No. Language: Part No.

German English

GA 2000EAC,GA 2005EAC

OPERATING MANUAL

EDITION 12/ 2008 PART NO. 350741

2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR

2.1.1 ELECTRICAL EQUIPMENT

2.1.2 PERSONNEL QUALIFICATIONS

2.1.3 A SAFE WORK ENVIRONMENT

2.2 SAFETY INSTRUCTIONS FOR PERSONNEL

2 GENERAL SAFETY INSTRUCTIONS

 +EEPTHESEOPERATINGINSTRUCTIONSTOHANDNEARTHEUNITATALLTIMES

 !LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN

TION

%LECTRICALPLANTANDUNIT

 4O BE PROVIDED IN ACCORDANCE WITH THE LOCAL SAFETY REQUIREMENTS WITH REGARD TO THE

OPERATINGMODEANDAMBIENTINmUENCES

 -AYONLYBEMAINTAINEDBYSKILLEDELECTRICIANSORUNDERTHEIRSUPERVISION

 -USTBEOPERATEDINACCORDANCEWITHTHESAFETYREGULATIONSANDELECTROTECHNICALREGU

LATIONS

 -USTBEREPAIREDIMMEDIATELYINTHEEVENTOFPROBLEMS

 -USTBEPUTOUTOFOPERATIONIFTHEYPOSEAHAZARD

 -USTBEDEENERGIZEDBEFOREWORKISCOMMENCEDONACTIVEPARTS)NFORMSTAFFABOUT

PLANNEDWORKOBSERVEELECTRICALSAFETYREGULATIONS

 %NSURETHATTHEUNITISOPERATEDANDREPAIREDONLYBYTRAINEDPERSONS

 %NSURETHATTHEmOOROFTHEWORKINGAREAISANTISTATICINACCORDANCEWITH%.0ART

eMEASUREMENTINACCORDANCEWITH$).

 %NSURETHATALLPERSONSWITHINTHEWORKINGAREAWEARANTISTATICSHOESEGSHOESWITH

LEATHERSOLES

 %NSURETHATDURINGSPRAYINGPERSONSWEARANTISTATICGLOVESSOTHATTHEYAREEARTHEDVIA

THEHANDLEOFTHESPRAYGUN

 #USTOMERTOPROVIDEPAINTMISTEXTRACTIONSYSTEMSCONFORMINGTOLOCALREGULATIONS

 %NSURETHATTHEFOLLOWINGCOMPONENTSOFASAFEWORKINGENVIRONMENTAREAVAILABLE

n-ATERIALAIRHOSESADAPTEDTOTHEWORKINGPRESSURE

n0ERSONALSAFETYEQUIPMENTBREATHINGANDSKINPROTECTION

 %NSURETHATTHERE ARENO IGNITIONSOURCES SUCHAS NAKEDmAMEGLOWINGWIRES ORHOT

SURFACESINTHEVICINITY$ONOTSMOKE

 !LWAYSFOLLOWTHEINFORMATIONINTHESEINSTRUCTIONSPARTICULARLYTHEGENERALSAFETYIN

STRUCTIONSANDTHEWARNINGINSTRUCTIONS

 !LWAYSFOLLOWLOCALREGULATIONSCONCERNINGOCCUPATIONALSAFETYANDACCIDENTPREVEN

TION

GA 2000EAC,GA 2005EAC

OPERATING MANUAL

EDITION 12/ 2008 PART NO. 350741

2.2.2 EARTH THE UNIT

2.2.3 MATERIAL HOSES

2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS

The spray jet is under pressure and can cause dangerous injuries.

Avoid injection of paint or cleaning agents:

 Never point the spray gun at people.

 Never reach into the spray jet.

 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

chap. „Trouble shooting“.

In the event of skin injuries caused by paint or cleaning agents:

 Note down the paint or cleaning agent that you have been using.

 Consult a doctor immediately.

Avoid danger of injury through recoil forces:

 Ensure that you have a ﬁrm footing when operating the spray gun.

 Only hold the spray gun brieﬂy in any one position.

Electrostatic charges can occur on the unit due to the electrostatic charge and the ﬂow

speed involved in spraying.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

antistatic shoes.

When spraying, wear antistatic gloves to earth yourself via the spray gun handle.

 %NSURETHATTHEHOSEMATERIALISCHEMICALLYRESISTANTTOTHESPRAYEDMATERIALS

 %NSURETHATTHEMATERIALHOSEISSUITABLEFORTHEPRESSUREGENERATEDINTHEUNIT

 %NSURETHATTHEFOLLOWINGINFORMATIONISVISIBLEONTHEHIGHPRESSUREHOSE

 n -ANUFACTURER

 n 0ERMISSIBLEOPERATINGOVERPRESSURE

 n $ATEOFMANUFACTURE

 4HEELECTRICALRESISTANCEOFTHECOMPLETEHIGHPRESSUREHOSEMUSTBELESSTHAN

 -/HM

GA 2000EAC,GA 2005EAC

OPERATING MANUAL

EDITION 12/ 2008 PART NO. 350741

2.2.4 CLEANING

2.2.5 HANDLING HAZARDOUS LIQUIDS,VARNISHES AND PAINTS

2.2.6 TOUCHING HOT SURFACES

2.3 CORRECT USE

 $EENERGIZETHEUNITELECTRICALLY

 $ISCONNECTTHEPNEUMATICSUPPLYLINE

 2ELIEVETHEPRESSUREFROMTHEUNIT

 %NSURETHATTHEmASHPOINTOFTHECLEANINGAGENTISATLEAST+ABOVETHEAMBIENTTEM

PERATURE

 4OCLEANUSEONLYSOLVENTFREECLOTHSANDBRUSHES.EVERUSEHARDOBJECTSORSPRAYON

CLEANINGAGENTSWITHAGUN

!NEXPLOSIVEGASAIRMIXTUREFORMSINCLOSEDCONTAINERS

 7HENCLEANINGUNITSWITHSOLVENTSNEVERSPRAYINTOACLOSEDCONTAINER

 %ARTHTHECONTAINER

 7HENPREPARINGORWORKINGWITHPAINTANDWHENCLEANINGTHEUNITFOLLOWTHEWORK

INGINSTRUCTIONSOFTHEMANUFACTUREROFTHEPAINTSSOLVENTSANDCLEANINGAGENTSBEING

USED

 4AKETHE SPECIlED PROTECTIVE MEASURES IN PARTICULAR WEAR SAFETY GOGGLES PROTECTIVE

CLOTHINGANDGLOVESASWELLASHANDPROTECTIONCREAMIFNECESSARY

 5SEAMASKORBREATHINGAPPARATUSIFNECESSARY

 &ORSUFlCIENTHEALTHANDENVIRONMENTALSAFETY/PERATETHEUNITINASPRAYBOOTHORON

ASPRAYINGWALLWITHTHEVENTILATIONEXTRACTIONSWITCHEDON

 7EARSUITABLEPROTECTIVECLOTHINGWHENWORKINGWITHHOTMATERIALS

 4OUCHHOTSURFACESONLYIFYOUAREWEARINGPROTECTIVEGLOVES

 7HENOPERATINGTHEUNITWITHACOATINGMATERIALWITHATEMPERATUREOF²#²&

 )DENTIFYTHEUNITWITHAWARNINGLABELTHATSAYSu7ARNINGHOTSURFACEh

/RDER.O

 )NFORMATIONLABEL

 3AFETYLABEL

7!'.%2ACCEPTSNOLIABILITYFORANYDAMAGEARISINGFROMINCORRECTUSE

 5SETHEUNITONLYTOWORKWITHTHEMATERIALSRECOMMENDEDBY7!'.%2

 /PERATETHEUNITONLYASANENTIREUNIT

 $ONOTDEACTIVATESAFETYEQUIPMENT

 5SEONLY7!'.%2ORIGINALSPAREPARTSANDACCESSORIES

GA 2000EAC,GA 2005EAC

OPERATING MANUAL

EDITION 12/ 2008 PART NO. 350741

2.4 SAFETY-RELEVANT INFORMATION ABOUT DISCHARGES

2.5.2 EXPLOSION PROTECTION IDENTIFICATION

2.5.3 MAXI. SURFACE TEMPERATURE

2.5 USE IN AN EXPLOSION HAZARD AREA

2.5.1 CORRECT USE

The electrostatic spray guns GA 2000EAC and GA 2005EAC are suitable for spraying liquid

materials, particularly coating materials, using the air atomizing method.

Coating materials containing solvents of Explosion Class IIA may be used. The spray gun

may only be used in combination with a control unit EPG 3000.

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-

tween 4 and 10 mm; 0.15 and 0.4 inches, between the spray gun and spray object.

!SDElNEDINTHE$IRECTIVE#%!4%8THEUNITISSUITABLEFORUSEINAREASWHERE

THEREISANEXPLOSIONHAZARD

 ))'%%XM*4

#% #OMMUNAUTÏS%UROPÏENNES

 .OMINATEDTESTINGBODY04"

%X 3YMBOLFOREXPLOSIONPROTECTION

)) 5NITCLASS))

 #ATEGORY:ONE

' %XATMOSPHEREGAS

% %UROPEANSTANDARD

%X %XPLOSIONPROTECTION

M* -AXIGNITIONENERGY

4 4EMPERATURECLASS

s-AXSURFACETEMPERATURE ²#²&

s0ERMISSIBLEMATERIALTEMPERATURE ²#²&

s0ERMISSIBLEAMBIENTTEMPERATURE ²#²&

GA 2000EAC,GA 2005EAC

OPERATING MANUAL

EDITION 12/ 2008 PART NO. 350741

2.5.4 SAFETY INSTRUCTIONS

2.6 ESTABLISHMENT OF STATIONARY ELECTROSTATIC SYSTEMS

3AFEHANDLINGOF7!'.%2SPRAYUNITS

-ECHANICALSPARKSCANFORMIFTHEUNITCOMESINTOCONTACTWITHMETAL

)NANEXPLOSIVEATMOSPHERE

 $ONOTKNOCKORPUSHTHEUNITAGAINSTSTEELORRUSTYIRON

 $ONOTDROPTHEUNIT

 5SEONLYTOOLSTHATAREMADEOFAPERMITTEDMATERIAL

)GNITIONTEMPERATUREOFTHECOATINGMATERIAL





%NSURETHATTHEIGNITIONTEMPERATUREOFTHECOATINGMATERIALISABOVETHEMAXIMUM

SURFACETEMPERATURE

3URFACESPRAYINGELECTROSTATIC





$ONOTSPRAYSYSTEMPARTSWITHELECTROSTATICEGELECTROSTATICSPRAYGUN

-EDIUMSUPPORTINGATOMIZING





4OATOMIZETHEMATERIALUSEONLYWEAKLYOXIDIZINGGASESEGAIR

#LEANING

)FTHERE AREDEPOSITSON THESURFACESTHEUNIT MAYFORMELECTROSTATICCHARGES&LAMESOR

SPARKSCANFORMIFTHEREISADISCHARGE





2EMOVEDEPOSITSFROMTHESURFACESTOMAINTAINCONDUCTIVITY





5SEONLYADAMPCLOTHTOCLEANTHEUNIT

4HESPRAYGUNISACOMPONENTOFASTATIONARYSPRAYINGSYSTEM7HENESTABLISHSTATIONARY

SPRAYINGSYSTEMSSTRICTLYCOMPLYWITHREGULATION%.!MONGOTHERTHINGSITISRE

QUIREDTHATSWITCHONOFHIGHVOLTAGEISONLYPOSSIBLEWITHAKEY"UTITMUSTBEPOSSIBLETO

SWITCHOFFHIGHVOLTAGEWITHOUTANYKEYFORINSTANCEWITHAEMERGENCYSTOPBUTTON

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