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

3
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

4
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

5
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

6
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

7
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

8
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

9
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&

10
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

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%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

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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
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2EMOVEDEPOSITSFROMTHESURFACESTOMAINTAINCONDUCTIVITY
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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