WAGNER GA 4000ACIC-R Operational manual

B_03045
AirCoat
Automatic Spray Gun
Version 06/2013
Translation of the Original
Operating Manual

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OPERATING MANUAL
VERSION 06/2013 ORDER NUMBER DOC 2312956
Table of Contents
1 ABOUT THIS OPERATING MANUAL 6
1.1 Preface 6
1.2 Warnings, Notices, and Symbols in this Operating Manual 6
1.3 Languages 7
1.4 Abbreviations in the Text 7
2 CORRECT USE 8
2.1 Device Types 8
2.2 Type of Use 8
2.3 Use in an Explosion Hazard Area 8
2.4 Safety Parameters 9
2.5 Processible Products 9
2.6 Reasonably Foreseeable Misuse 10
2.7 Residual Risks 10
3 IDENTIFICATION 11
3.1 Explosion Protection Identication 11
3.2 "X" Special Notices 11
4 GENERAL SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Equipment 12
4.1.2 Sta Qualications 12
4.1.3 Safe Work Environment 12
4.2 Safety Instructions for Sta 13
4.2.1 Safe Handling of WAGNER Spray Devices 13
4.2.2 Grounding the Unit 13
4.2.3 Product Hoses 14
4.2.4 Cleaning 14
4.2.5 Handling Hazardous Liquids, Lacquers, and Paints 14
4.2.6 Touching Hot Surfaces 15
4.3 Use in Areas Subject to Explosion Hazards 15
4.3.1 Safety Regulations 15
5 DESCRIPTION 16
5.1 Field of Application 16
5.2 Scope of Delivery 16
5.2.1 Type Designation 16
5.2.2 Overview 17
5.2.3 Standard Equipment 18
5.2.4 Supplementary Components 18
5.2.4.1 Base Plates 18
5.2.4.2 Air Caps 19
5.2.4.3 AirCoat Flat Jet Nozzles ACF3000 19
5.2.4.4 AirCoat Round Jet Nozzles ACR3000 19
5.2.4.5 Product Connections 20
5.2.4.6 Air Supply Connections 20
5.2.4.7 Lock Pin 20
5.2.4.8 Packing Insert GA 4000AC 20
5.2.4.9 Distributor Mountings 20

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Table of Contents
5.3 Data 21
5.3.1 Technical Data 21
5.3.2 Measurements and Connections 22
5.3.3 Materials of Paint Wetted Parts 23
5.4 Functional Description 24
5.4.1 Design of Spray Gun 24
5.4.2 Modes "NC" and "C" 25
5.4.2.1 Mode "NC" without Product Circulation 25
5.4.2.2 Mode "C" with Product Circulation 25
5.4.3 Functions of the Spray Gun 25
5.5 Spraying Process 26
5.5.1 Flat AirCoat Jet Spray Process 26
5.5.2 AirCoat Round Jet Spray Process 27
6 ASSEMBLY AND COMMISSIONING 28
6.1 Installation and Connection 28
6.1.1 Typical Automatic Spraying System 28
6.1.2 Ventilation of the Spray Booth 29
6.1.3 Air Supply 29
6.1.4 Product Supply 29
6.1.5 Grounding the System 30
6.2 Lacquer Preparations 31
6.2.1 Viscosity Conversion Table 31
6.3 Commissioning 32
6.3.1 General Rules for Handling the Spray Gun 32
6.3.2 Preparations for Starting Up 33
7 OPERATION 34
7.1 Start-up for AirCoat Spraying 34
7.2 Spray Pattern Shapes 34
7.3 Changing AirCoat Nozzle 35
7.4 Cleaning AirCoat Nozzle 35
7.5 Eliminating Nozzle Clogging 36
7.6 Replacing Nozzle Insert of Round Jet Nozzle 37
8 TROUBLESHOOTING AND RECTIFICATION 38
9 CLEANING AND MAINTENANCE 39
9.1 Decommissioning and Cleaning 40
9.2 Replacing Product Hose 41
9.3 Replacing the Nozzle Seal 41
9.4 Replacing Sealing Fitting of Round Jet Nozzle 42
9.5 Replacing Parts in Gun Body 44
9.5.1 Disassembly of GA 4000ACIC 44
9.5.2 Packing Insert GA 4000AC (RP) 46
9.5.3 Assembly of GA 4000ACIC 48

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OPERATING MANUAL
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Table of Contents
10 ACCESSORIES 50
10.1 AirCoat Nozzles ACF3000 50
10.2 Round Jet Nozzle Cap 52
10.2.1 Nozzle Inserts RXX 52
10.2.2 Complete Nozzle Screw Joint 52
10.3 Hoses 53
10.4 Miscellaneous 53
11 SPARE PARTS 55
11.1 How Can Spare Parts Be Ordered? 55
11.2 Spare Parts List for GA 4000ACIC 56
11.3 Service Sets and Spare Parts Groups 58
11.4 Packing Insert GA 4000AC (RP) 58
11.5 Sealing Set GA 4000 Packing RP and RP Special 59
12 WARRANTY AND CONFORMITY DECLARATIONS 60
12.1 Important Notes Regarding Product Liability 60
12.2 Warranty Claim 60
12.3 CE Declaration of Conformity 61
12.4 National Technical Specications 61

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OPERATING MANUAL
VERSION 06/2013 ORDER NUMBER DOC 2312956
1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
1 ABOUT THIS OPERATING MANUAL
WARNING
NOTICE
DANGER
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The following are measures which can be taken to prevent
the hazard and its consequences.
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 material damage.
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 following are measures which can be taken to prevent
the hazard and its consequences.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The following are measures which can be taken to prevent
the hazard and its consequences.
This notice warns you of a hazard!
Possible consequences of not observing the warning
instructions. The signal word indicates the hazard level.
The following are measures which can be taken to prevent the hazard and its
consequences.
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 operating and service
sta.
Operating and service sta should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.1 PREFACE

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OPERATING MANUAL
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1.3 LANGUAGES
The operating manual is available in the following languages:
Language: Order No. Language: Order No.
German 2312955 English 2312956
French 2312957 Italian 2312958
Spanish 2312959 Swedish 2316798
Russian 2327992
1.4 ABBREVIATIONS IN THE TEXT
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
(replaceable packing)
Polytetrafluoroethylene
Fiber optics
Polyethylene
Ultra-high molecular polyethylene
Fluoropolymer rubber (Viton)
Polyoxymethylene (Acetal)
Polyamide
Wrench size for tool
Torx size (tool)

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OPERATING MANUAL
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2 CORRECT USE
2.1 DEVICE TYPES
2.2 TYPE OF USE
2.3 USE IN AN EXPLOSION HAZARD AREA
AirCoat automatic spray gun with the type designation:
GA 4000ACIC
The device is suitable for processing liquid products such as paints and lacquers in
accordance with their classication into explosion classes IIA or IIB, especially coating
products using the AirCoat process.
The device can be employed in explosion hazard zones (Zone 1).

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2.4 SAFETY PARAMETERS
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.
2.5 PROCESSIBLE PRODUCTS
The device may only be operated under the following conditions:
The operating sta have previously been 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.
Top-coat paints, primer paints, corrosion protection, textured paints, lyes, staining solvents,
clear paints, separating agents, etc. with a solvent or water basis.
Note:
Please contact your local WAGNER dealer and the lacquer manufacturer if you encounter
application problems.

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2.6 REASONABLY FORESEEABLE MISUSE
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be excluded even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk Source Consequences Specic measures Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Handling of
lacquers and
cleaning agents
Skin irritations, Wear protective
clothing,
Operation,
allergies observe safety data
sheets
maintenance,
disassembly
Lacquer in air
outside the dened
working area
Lacquering outside
the dened working
area
Inhalation of
substances
hazardous to health
Observe working
and operating
instructions
Operation,
maintenance
The following is prohibited:
coating work pieces which are not grounded,
unauthorized conversions and modications to the device,
processing dry or similar coating products, and
using defective components, spare parts or accessories other than those described in
Chapter 10 of this operating manual.
The forms of misuse listed below may result in health issues and/or material damage:
use of powder as a coating product
Wagner devices are not designed for use with food.