WAGNER GA 250AL User manual

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

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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

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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

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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

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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.

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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)

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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.

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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.

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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.