WAGNER GA 5000EAC User manual

B_05738

GA 5000EAC

Electrostatic Automatic Spray Gun (AirCoat)

Translation of the Original Operating Manual

0102 II2G0.24mJ

For professional use.

Always observe the information in this manual, particularly the safety

instructions and the warning instructions. Store the manual in a safe place. Edition: 09/2022

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)

Table of Contents

Order number 2360922 | Edition 09/2022 3

TABLE OF CONTENTS

1 About these Instructions 6

1.1 Preface 6

1.2 Warnings, Notices and Symbols in these Instructions 6

1.3 General Characters and Symbols 6

1.4 Languages 7

1.5 Abbreviations 7

1.6 Terminology for the Purpose of this Manual 7

2 Using in Accordance with the Instructions 9

2.1 Device Type 9

2.2 Type of Use 9

2.3 For Use in Potentially Explosive Areas 9

2.4 Processible Working Materials 9

2.5 Misuse 10

3 Identification 11

3.1 Explosion Protection Identification 11

3.2 Identification "X" 11

3.3 Use in Areas Subject to Explosion Hazards 12

3.4 Type Plate 13

4 Basic Safety Instructions 14

4.1 Safety Instructions for the Operator 14

4.1.1 Electrical Devices and Equipment 14

4.1.2 A Safe Work Environment 14

4.1.3 Personnel Qualifications 15

4.2 Safety Instructions for the Personnel 15

4.2.1 Personal Safety Equipment 15

4.2.2 Safe Handling of WAGNER Spray Devices 16

4.2.3 Grounding the Device 16

4.2.4 Product Hoses 17

4.2.5 Cleaning and Flushing 17

4.2.6 Touching Hot Surfaces 18

4.2.7 Maintenance and Repair 18

4.2.8 Protective and monitoring equipment 19

4.2.9 Safety-Relevant Information about Discharges 19

4.2.10 Setting up Stationary Electrostatic Systems 19

5 Description 20

5.1 Structure (Basic Version) 20

5.1.1 GA 5000EACIC Design 20

5.1.2 GA 5000EACEC Design 21

5.2 General Information on Mode of Operation 22

5.2.1 Functioning 22

5.3 Protective and monitoring equipment 24

5.4 Extent of Delivery 24

5.5 Technical Data 25

5.5.1 Dimensions of GA 5000EAC 26

5.6 Spraying Procedure 26

5.6.1 Spraying Procedure with Round Jet Nozzle 26

5.6.2 Spray process with Flat Jet Nozzle 27

5.6.3 The Electrostatic Effect 28

5.7 The WAGNER Electrostatic AirCoat Spraying System 28

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)

Table of Contents

4 Order number 2360922 | Edition 09/2022

6 Assembly and Commissioning 30

6.1 Training of Assembly/Commissioning Personnel 30

6.2 Storage Conditions 30

6.3 Installation Conditions 30

6.4 Assembly and Installation 30

6.4.1 Typical Electrostatic Spraying System 30

6.4.2 Connecting the GA 5000EACIC Spray Gun 32

6.4.3 Connecting the GA 5000EACEC Spray Gun 33

6.4.4 Ventilation of the Spray Booth 33

6.4.5 Air Supply Lines 34

6.4.6 Product Supply Lines 34

6.4.7 Grounding 34

6.5 Lacquer Preparations 36

6.5.1 Viscosity Conversion Table 37

6.6 Start up 37

6.6.1 Verifying a Safe Operational Condition 38

7 Operation 39

7.1 Training the Operating Personnel 39

7.2 Tasks 39

7.2.1 Emergency Deactivation 39

7.3 Setting the spray pattern using the air pressure regulator 39

7.4 Spraying 40

7.5 Pressure Relief / Work Interruption 41

7.6 Dismounting the Gun Cover 42

7.7 Flushing Out Clogged Round Jet Nozzles 43

7.8 Replacing nozzle insert of round jet nozzle 43

7.9 Changing from AirCoat Round Jet / AirCoat Flat Jet 44

7.10 Replacing the AirCoat Flat Jet Nozzles 46

7.11 Cleaning of the Nozzle Parts 47

7.12 Eliminating Nozzle Clogging 47

7.13 Changing the valve housing 48

8 Cleaning and Maintenance 49

8.1 Cleaning 49

8.1.1 Cleaning Personnel 49

8.1.2 Safety Instructions 49

8.1.3 Cleaning and flushing the device 50

8.2 Maintenance 50

8.2.1 Maintenance Personnel 50

8.2.2 Safety instructions 51

8.2.3 Safety Checks and Maintenance Intervals 51

8.2.4 Product Hoses, Pipes and Couplings 52

9 Troubleshooting and Rectification 53

10 Repairs 54

10.1 Repair Personnel 54

10.2 Repair Notes 54

10.3 Assembly aids 55

10.4 Spray Gun 55

10.4.1 Tools 55

10.4.2 Dismantling the Spray Gun 55

10.4.3 Cleaning the Parts after Disassembly 59

10.4.4 Assembling the Spray Gun 60

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)

Table of Contents

Order number 2360922 | Edition 09/2022 5

11 Function Test after Repair Work 66

11.1 Check High Voltage 66

11.2 Function Tests for Spray Gun 67

11.2.1 Air Tests 67

11.2.2 Product Pressure Test 67

11.2.3 Check Spray Pattern 67

12 Disposal 68

12.1 Device 68

12.2 Consumable Products 68

13 Accessories 69

13.1 Round Jet Nozzles 69

13.1.1 ACR 5000 Round Jet Nozzle Attachment 69

13.1.2 AirCoat Round Jet Nozzle Inserts 69

13.2 Flat jet nozzles 69

13.2.1 ACF 5000 Air Caps (Flat Jet) 69

13.2.2 ACF 5000 AirCoat Flat Jet Nozzles 70

13.3 Filter 71

13.4 Hoses and Cables 72

13.4.1 Gun Cables and Gun Cable Extensions 72

13.4.2 Product Hoses 72

13.4.3 Air hoses 72

13.4.4 Miscellaneous 73

14 Spare Parts 75

14.1 How to Order Spare Parts 75

14.2 GA 5000EAC spray gun 76

14.2.1 GA 5000EACIC - Basic Version 76

14.2.2 GA 5000EAC – Adapter 79

14.2.3 GA 5000EACEC - Basic Version 81

14.3 Accessories Spare Parts Lists 83

14.3.1 Flat jet nozzles 83

14.3.2 ACR 5000 Round Jet Nozzle Attachment 83

15 Declaration of Conformity 85

15.1 EU Declaration of Conformity 85

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)

1 About these Instructions

6 Order number 2360922 | Edition 09/2022

1 ABOUT THESE INSTRUCTIONS

1.1 PREFACE

The operating manual contains information about safely operating, maintaining, cleaning

and repairing the device. The operating manual is part of the device and must be available

to the operating and service personnel.

The device may only be operated by trained personnel and in compliance with this

operating manual. Operating and service personnel should be instructed according to the

safety instructions.

This equipment can be dangerous if it is not operated according to the instructions in this

operating manual.

1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS

Warning instructions in this manual highlight particular dangers to users and to the device

and state measures for avoiding the hazard.

These warning instructions fall into the following categories:

DANGER Immediate risk of danger.

Non-observance will result in death or serious injury.

WARNING Potential danger.

Non-observance may result in death or serious injury.

CAUTION Potentially dangerous situation.

Non-observance may result in minor injury.

NOTICE Potentially dangerous situation.

Non-observance may result in damage to property.

Info Provides information about particular characteristics and how to

proceed.

Explanation of warning notice:

WARNING

This notice warns you of a danger!

Possible consequences of not observing the warning notice.

4The measures for preventing the hazard and its consequences.

1.3 GENERAL CHARACTERS AND SYMBOLS

The characters and symbols in this operating manual indicate the following:

üRequirement that must be fulfilled before an action can be performed.

1. Step 1 of an action to be performed with several action steps.

4Second level action step

2. Step 2

ðIntermediate result of an action

ðResult of a complete action

4Action to be performed with an action step

1. Numbered list, first level

– Numbered list, second level

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)

1 About these Instructions

Order number 2360922 | Edition 09/2022 7

– Non-numbered list, first level

– Non-numbered list, second level

= cross-reference on page

♦ = wearing parts

⋆ = included in service set

● = not part of the standard equipment but available as a special accessory

1.4 LANGUAGES

The operating manual GA 5000EAC is available in the following languages:

Original operating manual

Language Order no.

German 2360921

Translation of the original operating manual

Language Order no. Language Order no.

English 2360922 Spanish 2367696

French 2367694 Russian 2373688

Italian 2367695 Chinese 2373690

Japanese 2382578

Additional languages upon request or at: www.wagner-group.com

1.5 ABBREVIATIONS

Order no. Order number

ET Spare part

K Marking in the spare parts lists

Pos Position

Stk Number of pieces

GA Automatic gun

EAC Electrostatic AirCoat

IC Shaping and atomizing air controlled via valve within gun

EC Shaping and atomizing air controlled via valve outside of gun

Low R Low resistance

SW Wrench size

Materials

SSt Stainless steel

1.6 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning

Cleaning Manual cleaning of devices and device parts with cleaning agent.

Flushing Internal flushing of paint-wetted parts with flushing agent.

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)

1 About these Instructions

8 Order number 2360922 | Edition 09/2022

Personnel qualifications

Trained person Is instructed in the tasks assigned to him/her, the potential risks associ-

ated with improper behavior as well as the necessary protective devices

and measures.

Electrically

trained person

Is instructed by an electrician about the tasks assigned to him/her, the

potential risks associated with improper behavior as well as the neces-

sary protective devices and measures.

Electrician Can assess the work assigned to him/her and detect possible hazards

based on his/her technical training, knowledge and experience in rele-

vant provisions.

Skilled person in

the context of

DGUV209‑052

A person who, based on his/her technical training, experience and re-

cent vocational experience, has sufficient technical knowledge in the

area of electrostatic coating and is familiar with the relevant and gener-

ally accepted rules of technology so that he/she can inspect and assess

the status of devices and coating systems based on workplace safety.

Additional requirements for skilled persons can also be found in

TRBS1203(2010/amendment 2012): Expert knowledge in the areas of

protection against excessive pressure, electrical hazards and explosion

protection (where applicable).

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)

2 Using in Accordance with the Instructions

Order number 2360922 | Edition 09/2022 9

2 USING IN ACCORDANCE WITH THE INSTRUCTIONS

2.1 DEVICE TYPE

Electrostatic automatic spray gun for coating of grounded work pieces in automatic coating

systems.

2.2 TYPE OF USE

The GA 5000EAC electrostatic automatic spray gun is suitable for spraying liquid products,

particularly coating products. Coating products may be processed which contain

components of substances of explosion group IIA and IIB (maximum ignition energy 0.24

mJ).

WAGNER explicitly prohibits any other use!

The device may only be operated under the following conditions:

4Use the device only to work with the materials recommended by WAGNER.

4Do not deactivate safety fixtures.

4Use only WAGNER original spare parts and accessories.

4The operating personnel must be trained on the basis of this operating manual.

4Follow the instructions in the operating manual.

2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS

The GA 5000EAC electrostatic automatic spray gun is suitable for coating electrically

conductive objects with liquid coating products and can be used in potentially explosive

areas.

(See Explosion Protection Identification in chapter Explosion Protection Identification

[811].)

2.4 PROCESSIBLE WORKING MATERIALS

4Coating products whose ingredients contain substances of explosion class IIA and IIB

(maximum ignition energy 0.24 mJ) can be processed with the GA 5000EAC spray gun.

4The basic spray gun version is suitable for processing sprayed substances with an

electrical resistance of > 150 kΩ (according to the WAGNER scale). Equipped with a

special product hose for low-resistance sprayed substances (available as an accessory),

you can also successfully process sprayed substances with an electrical resistance > 50

kΩ (according to the WAGNER scale).

4When processing metallic lacquers, it is advisable to use the spiral hose.

4The application effectiveness is always dependant on the composition of the product

being used, e.g., pigments or resin.

Conversion of Paint Resistance

There are paint resistance measuring devices available on the market that do not directly

measure the specific paint resistance.

Multiplying the result of the measurement with the device-specific cell constant (K), we

obtain the specific resistance value of the product.

Example:

With WAGNER's paint resistance measuring device the cell constant is K123.

Measured value according to the WAGNER

scale

R=500kΩ

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)

2 Using in Accordance with the Instructions

10 Order number 2360922 | Edition 09/2022

Specific resistance (RS) RS=RxK=500kΩx123=61.5MΩcm

Note:

Using sprayed substances with too low an electrical resistance, the application of

electrostatics does not show any effect, i.e. there is no "paint wrap around" on the object to

be sprayed.

The suitability of the spray product with regard to the charging ability can be read from the

actual values for high voltage (kV) and for the spray current (μA) shown in the illuminated

displays on the EPG 5000 control unit.

High kV value, low μA value = ok

Low kV value, high μA value = excessive conductivity of the paint

4no wrap-around

Info

Contact your local WAGNER dealer and the lacquer manufacturer if you encounter

application problems.

2.5 MISUSE

Misuse can lead to physical injury and/or property damage! Special attention must be paid

that:

4No dry coating products, e.g., powder are processed.

4No food, medicine or cosmetics are processed. It is important to note that the device's

materials are not food-safe.

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