WAGNER GA 250AL User manual

GA 250AL
GA 400AL
Airless automatic spray gun
Version 12/2018
B_00859
B_00861

3
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
Table of Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 8
2 CORRECT USE 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 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Identication "X" 10
3.3 Type Plate 11
4 BASIC SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Equipment 12
4.1.2 A Safe Work Environment 13
4.1.3 Personnel Qualications 13
4.2 Safety Instructions for the Personnel 14
4.2.1 Personal Safety Equipment 14
4.2.2 Safe Handling of WAGNER Spray Devices 15
4.2.3 Grounding the Unit 15
4.2.4 Product Hoses 16
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 18
5 DESCRIPTION 19
5.1 Components 19
5.2 Functional Description 19
5.3 Scope of Delivery 20
5.3.1 Type Description 20
5.3.2 Standard Variant 20
5.4 Data 20
5.4.1 Materials of Paint-wetted Parts 20
5.4.2 Technical Data 21
5.4.3 Dimensions 21

4
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
6 ASSEMBLY AND COMMISSIONING 22
6.1 Training of Assembly/Commissioning Personnel 22
6.2 Storage Conditions 22
6.3 Installation Conditions 22
6.4 Installation and Connection 22
6.4.1 Typical Spraying System 23
6.4.2 Ventilation of the Spray Booth 23
6.4.3 Product Supply Lines 24
6.5 Grounding 24
6.6 Safety Checks 24
6.7 Lacquer Preparations 24
6.7.1 Viscosity Conversion Table 25
6.8 Commissioning 26
6.8.1 Preparation Before Commissioning 26
6.8.2 Verifying a Safe Operational Condition 26
7 OPERATION 27
7.1 Training the Operating Personnel 27
7.2 Tasks 27
7.2.1 Starting Airless spraying 27
7.2.2 Pressure Relief/Work Interruption 28
7.2.3 Replacing the Airless Flat Jet Nozzle 29
7.2.4 Cleaning the Airless Flat Jet Nozzle 29
8 CLEANING AND MAINTENANCE 30
8.1 Cleaning 30
8.1.1 Cleaning Personnel 30
8.1.2 Flushing and Cleaning the Spray Gun 30
8.2 Maintenance 31
8.2.1 Maintenance Personnel 31
8.2.2 Maintenance Instructions 31
8.2.3 Safety Checks and Maintenance Intervals 32
9 TROUBLESHOOTING AND RECTIFICATION 33
10 REPAIR WORK 34
10.1 Repair Personnel 34
10.2 Repair Notes 34
10.3 Tools 35
10.3.1 Replacing of Parts on the Valve Rod 35
10.3.2 Assembling the Valve Rod and Spray Gun 36
11 FUNCTION TEST AFTER REPAIR WORK 37
12 DISPOSAL 38
13 ACCESSORIES 39
13.1 Airless Flat Jet Nozzles 39
13.2 Hoses 41
13.3 Miscellaneous 41

5
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
14 SPARE PARTS 42
14.1 How Can Spare Parts Be Ordered? 42
14.2 Spare Parts List GA 400AL 43
14.3 GA 250AL Spare Parts List 44
15 DECLARATION OF CONFORMITY 45
15.1 EU Declaration of Conformity 45

6
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
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 risk.
Non-observance may result in death or serious injury.
CAUTION Potentially hazardous situation.
Non-observance may result in minor injury.
NOTICE Potentially hazardous situation.
Non-observance may result in damage to property.
Note: Provides information about particular characteristics and how
to proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.

7
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 350939
Translation of the Original Operating Manual
Language Order no. Language Order no.
English 350941 Swedish 350950
French 350946 Dutch 350947
Italian 350948 Danish 350951
Spanish 350949 Portuguese 2404528
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order no. Order number
Spare part
Marking in the spare parts lists
Position
Number of pieces
Wrench size (tool)
UWMW-PE Ultra-high molecular polyethylene
POM Polyoxymethylene (Acetal)

8
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Product pressure
generator
Pump or pressure tank
Personnel 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
accordance with
TRBS 1203
(2010/Revision 2012)
A person who, based on his/her technical training, experience and
recent vocational experience, has sucient technical knowledge
in the areas of explosion protection, protection from pressure
hazards and electric hazards (if applicable) 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.

9
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
2 CORRECT USE
2.1 DEVICE TYPE
Automatic gun for automatic coating of work pieces.
GA 250AL
GA 400AL
2.2 TYPE OF USE
The spray gun is suitable for atomizing liquid products, particularly coating products, using
the Airless process:
Non-ignitable products.
Ignitable products.
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
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 operating personnel must be trained on the basis of this operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device is suitable for use in potentially explosive areas as dened in Directive 2014/34/EU
(ATEX), (see Explosion protection marking Chapter 3.1).
2.4 PROCESSIBLE WORKING MATERIALS
Top-coat lacquers, primer paints, corrosion protection, textured lacquers, lyes, staining solvents,
clear lacquers, separating agents, etc. with a solvent or water base. If you want to spray working
materials other than the aforementioned, contact a WAGNER representative.
Note:
Contact your localWAGNER 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:
no dry coating products, e.g. powder are processed;
no food, medicine or cosmetics are processed.
It is important to note that the device's materials are not food-safe.

10
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device type: GA 250AL / GA 400AL Airless automatic gun
Manufacturer: Wagner International AG
CH-9450 Altstätten, Switzerland
II 2G X
CE European Communities
Ex Symbol for explosion protection
II Device class II
2 Category 2 (zone 1)
G Ex-atmosphere gas
X Special notice
3.2 IDENTIFICATION "X"
The maximum surface temperature corresponds to the permissible product temperature.
This and the permissible ambient temperature can be found in Chapter 5.4.2.
Safe Handling of WAGNER Spray Devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
knocking or pushing metal against metal is to be avoided;
do not drop the device.
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges.
Flames or sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.

11
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
3.3 TYPE PLATE
2
1
4
3
B_07085
Designation
1 CE and explosion protection identication
2 Year of construction / serial number
3 Model designation (GA 250AL-DN2.6; GA 400AL-DN2.6)
4 Maximum product pressure

12
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident prevention.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Electric shock hazard!
Danger to life from electric shock.
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, the mains voltage poses a danger.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if it poses a hazard or is damaged.
Must be de-energized before work is commenced. Inform personnel about planned
work. Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground
wire connection.
Keep liquids away from electrical devices.

13
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
4.1.2 A SAFE WORK ENVIRONMENT
Hazard due to dangerous uids or vapors!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working are is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 M ).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g., mechanical
stress, corrosion).
Ensure that product hoses/air hoses adapted to the working pressure are used.
Ensure that personal protective equipment (see Chapter 4.2.1) is available and is used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 M .
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 M .
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. No smoking.
Ensure that the pipe joints, hoses, equipment parts and connections are permanently,
technically leak-proof:
– Periodic preventative maintenance and service
(replacing hoses, checking tightness of connections, etc.).
– Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g., daily before commissioning, at the end of work or weekly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Hazard due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in accordance
with the operating manual and the operating instructions. The device must only be
operated, maintained and repaired by trained personnel. Refer to the operating
instructions for information about the required personnel qualications.

14
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.
In electrostatics applications: Persons belonging to a risk group according to
EMF guideline 2013/35/EU (e.g., carriers of active implants), must not enter the
high-voltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Hazard due to dangerous uids or vapors!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
When preparing or working with lacquer and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents, and cleaning
agents being used.
Take the specied protective measures. In particular, wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient health and environmental safety: Operate the device in a spray booth
or on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.

15
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Hazard due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of lacquer
or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
– Disconnect the control unit from the mains.
– In the event of functional faults: remedy the fault as described in the "Troubleshooting"
chapter.
If necessary or at least every 12 months, the liquid ejection devices must be checked for
safe working conditions by an expert (e.g. WAGNER Service Technician) in accordance
with the guidelines for liquid ejection devices (DGUV [German Statutory Accident
Insurance] regulation 100-500 section 2.29 and 2.36).
– For shut down devices, the examination can be suspended until the next start-up.
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
4.2.3 GROUNDING THE UNIT
Hazard due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges.
Flames or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that the unit is grounded for every spraying operation.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.

16
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
4.2.4 PRODUCT HOSES
Hazard due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
Ensure that the hose material is chemically resistant to the sprayed products and
the ushing agents used.
Ensure that the product hose and the ttings are suitable for the pressure generated.
Ensure that the following information can be seen on the high-pressure hose:
– manufacturer,
– permissible operating pressure,
– date of manufacture.
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
– in high-traffic areas,
– on sharp edges,
– on moving parts or
– on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lift trucks), or that the
hoses are never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Ensure that no work is ever performed with a damaged hose.
Make sure that the hoses are never used to pull or move the equipment.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 MΩ.
Suction hoses may not be subjected to pressure.

17
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
4.2.5 CLEANING AND FLUSHING
Hazard due to cleaning and ushing!
Explosion hazard and damage to the device.
Preference should be given to non-ignitable cleaning and ushing agents.
When carrying out cleaning work with ammable cleaning agents, make sure that all
equipment and resources (e.g., collection tank, funnel, transport cart) are conductive
or static dissipative and grounded.
Observe the specications of the lacquer manufacturer.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical ventilation.
Never use chloride or halogenated solvents (such as trichloroethane and methylene
chloride) with devices containing aluminium or galvanized/zinc-plated parts.They may
react chemically thus producing an explosion danger.
Take measures for workplace safety (see Chapter 4.1.2).
When commissioning or emptying the device, please note that:
– depending upon the coating product used,
– depending on the flushing agent (solvent) used.
an explosive mixture may temporarily exist inside the lines and components of equipment.
Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
Never spray into a closed tank when using solvents for ushing.
External Cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Relieve the pressure from the device.
De-energize the device electrically.
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects,
and never spray cleaning agents with a spray gun. Cleaning the device must not
damage it in any way.
Ensure that no electric component is cleaned with or immersed into solvent.

18
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
4.2.6 TOUCHING HOT SURFACES
Hazard due to hot surfaces because of hot coating products!
Risk of burn injuries.
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C; 109 °F:
– Identify the device with a warning label "Warning – hot surface".
Order no.
9998910 instruction label
9998911 protection label
Note: Order the two stickers together.
4.2.7 MAINTENANCE AND REPAIR
Hazard due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Use only WAGNER original spare parts and accessories.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in Chapter 13 and Chapter 14 that are
assigned to the unit.
Do not use any defective components.
Before all work on the device and in the event of work interruptions:
– Relieve the pressure from the spray gun, high-pressure hoses and all devices.
– Secure the spray gun against actuation.
– Switch o the energy and compressed air supply.
– Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
Hazard due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.

19
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
5 DESCRIPTION
5.1 COMPONENTS
B
A
C
D
E
F
D
B_00860
Designation
A Clamping nut
B Control air connection
C Spray gun housing
D Fluid inlet
E Union nut
F Flat jet nozzle
GValve rod (see Chapter 10.3.1)
HPressure spring (see Сhapter 10.3.1)
5.2 FUNCTIONAL DESCRIPTION
H
B
D
G
C
I
F
B_00866
– The GA 250AL and/or GA 400AL automatic gun is switched on using control air (B).
–The control piston positioned on the valve rod (G) in the housing (C) of the spray gun
GA 250AL and/or GA 400AL is pressurized and thus opens the passageway to the at
jet nozzle (F).
–Closing is eected by means of a pressure spring (H) after the control air pressure (B)
has dropped.
– The set of seals (I) prevents product from owing into the housing (C).
–Securing the spray gun: Remove the control air line from the control air connection (B)
on the spray gun.

20
VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL
5.3 SCOPE OF DELIVERY
5.3.1 TYPE DESCRIPTION
GA XXX AL
① ② ③
①GA = Automatic gun
②250 = Gun type 25MPa; 250bar; 3626psi
400 = Gun type 40MPa; 400bar; 5802psi
③AL = Airless spraying process
5.3.2 STANDARD VARIANT
Order no. Designation
1 350033 GA 250AL Airless automatic gun
1 350032 GA 400AL Airless automatic gun
The standard equipment includes:
Order no. Designation
1 350907 CE Declaration of Conformity
1 350939 Operating manual, German
1see Chap. 1.3 Operating manual in local language
The supplementary components can be used to harmonize and supplement the standard
equipment of the automatic gun perfectly to any application depending upon requirements
and accessory requests.
The delivery note shows the exact scope of delivery.
5.4 DATA
5.4.1 MATERIALS OF PAINT-WETTED PARTS
Metals Plastics
Carbide Stainless steel 1.4305 POM
Stainless steel 1.4310 Stainless steel 1.4104 UHMW-PE