WAGNER GA 5000EAIC Operational manual

GA 5000EAIC

GA 5000EAEC

II 2 G 0.24mJ X

B_06009

Electrostatic Air Spray Gun

for automatic operation

for at or round jet nozzles

Version 09/2016

Translation of the Original

Operating Manual

GA 5000EA

Table of Contents

1 ABOUT THESE INSTRUCTIONS 7

1.1 Preface 7

1.2 Warnings, Notices and Symbols in these Instructions 7

1.3 Languages 8

1.4 Abbreviations 8

1.5 Terminology for the Purpose of this Manual 9

2 CORRECT USE 10

2.1 Device Type 10

2.2 Type of Use 10

2.3 Use in an Explosion Hazard Area 10

2.4 Safety Parameters 10

2.5 Processible Working Materials 11

2.6 Reasonably Foreseeable Misuse 12

2.7 Residual Risks 12

3 IDENTIFICATION 13

3.1 CE Explosion Protection Identication 13

3.2 Special Notice "X" 13

3.3 Identication "X" (Type Examination Certicate) 14

3.4 Type Plate 15

4 GENERAL SAFETY INSTRUCTIONS 16

4.1 Safety Instructions for the Operator 16

4.1.1 Electrical Equipment 16

4.1.2 Personnel Qualications 16

4.1.3 Safe Work Environment 16

4.2 Safety Instructions for Sta 17

4.2.1 Safe Handling of WAGNER Spray Devices 17

4.2.2 Grounding the Device 18

4.2.3 Product Hoses 18

4.2.4 Cleaning and Flushing 19

4.2.5 Handling Hazardous Liquids, Varnishes and Paints 20

4.2.6 Touching Hot Surfaces 20

4.3 Protective and Monitoring Equipment 20

4.4 Use in Areas Subject to Explosion Hazards 21

4.4.1 Safety Regulations 21

4.5 Setting up Stationary Electrostatic Systems 21

4.6 Safety-Relevant Information about Discharges 22

5 DESCRIPTION 23

5.1 Structure (Standard Variant) 23

5.1.1 GA 5000EAIC Design 23

5.1.2 GA 5000EAEC Design 24

5.2 Mode of Operation 25

5.2.1 GA 5000EAIC Mode of Operation 25

5.2.2 GA 5000EAEC Mode of Operation 26

5.3 Protective and Monitoring Equipment 27

5.4 Scope of Delivery 27

OPERATING MANUAL

VERSION 09/2016 ORDER NUMBER DOC2360924

GA 5000EA

5.5 Technical Data 28

5.5.1 GA 5000EA Dimensions 29

5.6 Spraying Procedure 30

5.6.1 Spraying Procedure for Round Jet Air Atomizing 30

5.6.2 Spraying Procedure for Flat Jet Air Atomizing 31

5.6.3 Electrostatic Eect 32

5.7 The WAGNER Electrostatic Air Spraying System 33

5.7.1 Pressure Settings for Round Jet Nozzles 34

5.7.2 Pressure Settings for Flat Jet Nozzles 34

5.7.3 Adjusting Screw 35

5.7.4 Electrostatic and Atomization 36

5.7.5 Discharge Quantity Measurements 36

6 ASSEMBLY AND COMMISSIONING 37

6.1 Training Assembly/Commissioning Sta 37

6.2 Storage Conditions 37

6.3 Installation Conditions 37

6.4 Transportation 37

6.5 Assembly and Installation 38

6.5.1 Typical Electrostatic Spraying System 38

6.5.2 Connecting GA 5000EAIC 40

6.5.3 Connecting GA 5000EAEC 41

6.5.4 Ventilation of the Spray Booth 42

6.5.5 Air Supply 43

6.5.6 Product Supply 43

6.5.7 Grounding 44

6.6 Preparation of Lacquer 46

6.6.1 Viscosity Conversion Table 46

6.7 Commissioning 47

6.7.1 Safety Instructions 47

6.7.2 Preparation for Commissioning 47

6.7.3 Commissioning 47

6.8 Verifying a Safe Operational Condition 48

7 OPERATION 49

7.1 Training the Operating Sta 49

7.2 Safety Instructions 49

7.2.1 Emergency Deactivation 50

7.2.2 General Rules for Making Adjustments to the Spray Gun 50

7.3 Working 51

7.3.1 Checking the GA 5000EA Spray Pattern (Without Electrostatics) 51

7.3.2 Spraying GA 5000EA 53

7.3.3 Pressure Relief/Work Interruption 54

7.3.4 Dismantling the Gun Cover 55

7.3.5 Changing from Air Round Jet to Air Flat Jet 56

7.3.6 Changing the Valve Housing 58

7.3.7 Cleaning of the Nozzle Parts 59

OPERATING MANUAL

VERSION 09/2016 ORDER NUMBER DOC2360924

Table of Contents

GA 5000EA

8 CLEANING AND MAINTENANCE 60

8.1 Cleaning 60

8.1.1 Cleaning Sta 60

8.1.2 Safety Instructions 60

8.1.3 Cleaning and Flushing the Device 62

8.2 Maintenance 64

8.2.1 Maintenance Sta 64

8.2.2 Safety Instructions 64

8.2.3 Safety Checks 65

8.2.4 Product Hoses, Tubes and Couplings 66

9 TROUBLE SHOOTING AND RECTIFICATION 67

10 REPAIR WORK 68

10.1 Repair Sta 68

10.2 Safety Instructions 68

10.3 Dismantling of the Gun 69

10.3.1 Tools 69

10.3.2 Dismantling of the Spray Gun 70

10.3.3 Cleaning the Parts After Disassembly 75

10.3.4 Assembling the Spray Gun 76

11 FUNCTION TEST AFTER THE REPAIR 82

11.1 Checking the High voltage 82

11.2 Air Test 84

11.3 Product Pressure Test 84

11.4 Test of Spray Pattern 84

12 DISPOSAL 85

13 ACCESSORIES 86

13.1 Valve Housing 86

13.2 Valve Tips 86

13.3 Round Spray Nozzles 86

13.3.1 AR 5000 Air Caps 86

13.3.2 AR 5000 Nozzles 86

13.3.3 EARV Nozzle set 87

13.4 Flat Jet Nozzles 87

13.4.1 AF 5000 Air Caps 87

13.4.2 AF 5000 Nozzles 88

13.5 Electric Cables and Hoses 89

13.5.1 Gun Cable 89

13.5.2 Extension Cable for Gun Cable 89

13.5.3 Product Hoses Standard 89

13.5.4 Product Hoses for Low-resistance Products 90

13.5.5 Spiral Hose 90

13.5.6 Air Hoses 90

13.6 Miscellaneous 91

OPERATING MANUAL

VERSION 09/2016 ORDER NUMBER DOC2360924

Table of Contents

GA 5000EA

14 SPARE PARTS 93

14.1 How Can Spare Parts Be Ordered? 93

14.2 GA 5000EAIC Spray Gun 94

14.2.1 GA 5000EA Adapter 96

14.3 GA 5000EAEC Spray Gun 98

14.4 Accessories Spare Parts Lists 101

14.4.1 AR 5000 Nozzle (D8) 102

14.4.2 AR 5000 Nozzle (D12) 102

14.4.3 Adjustable EARV 5000 Round Jet Nozzle 103

15 WARRANTY AND CONFORMITY DECLARATIONS 104

15.1 Important Notes Regarding Product Liability 104

15.2 Warranty Claim 104

15.3 EU Declaration of Conformity 105

OPERATING MANUAL

VERSION 09/2016 ORDER NUMBER DOC2360924

Table of Contents

GA 5000EA

OPERATING MANUAL

VERSION 09/2016 ORDER NUMBER DOC2360924

1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS

Warning instructions in this operating 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 - possible imminent danger.

Non-observance may result in death or serious injury.

Caution - a possibly hazardous situation.

Non-observance may result in minor injury.

Notice - a possibly hazardous situation.

Non-observance may result in damage to property.

Note - provides information about particular characteristics and how to proceed.

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions.

The signal word indicates the hazard level.

The measures for preventing the hazard and its consequences.

DANGER

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions.

The signal word indicates the hazard level.

The measures for preventing the hazard and its consequences.

WARNING

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions.

The signal word indicates the hazard level.

The measures for preventing the hazard and its consequences.

CAUTION

This notice warns you of a hazard!

Possible consequences of not observing the warning instructions. The signal word

indicates the hazard level.

The measures for preventing the hazard and its consequences.

NOTICE

1 ABOUT THESE INSTRUCTIONS

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.

1.1 PREFACE

GA 5000EA

OPERATING MANUAL

VERSION 09/2016 ORDER NUMBER DOC2360924

1.3 LANGUAGES

1.4 ABBREVIATIONS

Order No. Order number

Spare part

Marking in the spare parts lists

Automatic gun

Electrostatics Airspray

Shaping and atomizing air controlled via valve within gun

Shaping and atomizing air controlled via valve outside of gun

Low R Low-resistance

Polyether ether ketone (high temperature-resistant thermoplastic plastic)

Stainless steel

Position

Number of pieces

Wrench size

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

Language Order No. Language Order No.

German 2360923 English 2360924

French 2367556 Italian 2367557

Spanish 2367558

Additional languages on request or at:

GA 5000EA

OPERATING MANUAL

VERSION 09/2016 ORDER NUMBER DOC2360924

1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning Manual cleaning of devices and device parts with cleaning agent

Flushing Internal ushing of paint-wetted parts with ushing agent

Sta qualications

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

associated 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 necessary 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 relevant provisions.

Skilled person

in the context of

DGUV209-052

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

and recent vocational experience, has sucient technical

knowledge in the area of electrostatic coating and is familiar

with the relevant and generally 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 are given in the

TRBS1203 (2010/Revision2012): Expert knowledge in the areas

of protection against excessive pressure, electrical hazards, and

explosion protection (where applicable).

GA 5000EA

OPERATING MANUAL

VERSION 09/2016 ORDER NUMBER DOC2360924

2 CORRECT USE

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 5000EA electrostatic automatic spray gun is suitable for spraying liquid products,

particularly coating products. Coating products which contain ingredients of explosion

class IIA and IIB substances (maximum ignition energy 0.24 mJ) may be used.

WAGNER forbids any other use!

2.4 SAFETY PARAMETERS

2.3 USE IN AN EXPLOSION HAZARD AREA

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

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

areas. Explosion Protection Identication (see Chapter 3)

WAGNER accepts no liability for any damage arising from incorrect use.

Use the device only to work with the products recommended by WAGNER.

Only operate the device as a whole.

Do not deactivate safety xtures.

Use only WAGNER original spare parts and accessories.

The device may only be operated under the following conditions:

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

The safety regulations listed in this operating manual must be observed.

The operating, maintenance and repair information in this operating manual must be

observed.

The statutory requirements and accident prevention regulation standards in the country

of use must be observed.

The electrostatic automatic spray gun may only be operated if all parameters are set and

all measurements/safety checks are carried out correctly.

This manual suits for next models

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