WAGNER GA 4000ACIC-S Operational manual

Version 05/2018
GA 4000ACIC-S
GA 4000ACIC-R
AirCoat
Automatic spray gun
II 2G X
B_06647

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VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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 20
5.2.1 Mode of Operation 20
5.2.2 Mode "NC" and "C" 21
5.2.3 Spraying procedure 22
5.3 Included Items 23
5.3.1 Type description 23
5.3.2 Overview 24
5.3.3 Standard variant 25
5.3.4 Supplementary components 25
5.4 Data 28
5.4.1 Materials of Paint-wetted Parts 28
5.4.2 Technical data 28
5.4.3 Measurements and connections 29

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6 COMMISSIONING 31
6.1 Training of Assembly/Commissioning Personnel 31
6.2 Storage Conditions 31
6.3 Installation Conditions 31
6.4 Installation and Connection 31
6.4.1 Typical AirCoat spraying system 32
6.4.2 Ventilation of the Spray Booth 32
6.4.3 Air Supply Lines 32
6.4.4 Product supply lines 33
6.5 Grounding 33
6.6 Safety Checks 33
6.7 Lacquer Preparations 33
6.7.1 Viscosity conversion table 34
6.8 Commissioning 35
6.8.1 Preparation Before Commissioning 35
6.8.2 Commissioning 35
6.8.3 Verifying a Safe Operational Condition 35
7 OPERATION 36
7.1 Training the Operating Personnel 36
7.2 Tasks 36
7.2.1 Starting to Spray with the AirCoat 36
7.2.2 Adjusting the spray pattern 37
7.2.3 Pressure Relief/Work Interruption 37
7.2.4 Changing AirCoat nozzle 38
7.2.5 Cleaning AirCoat nozzle 38
7.2.6 Eliminating Nozzle Clogging 39
7.2.7 Replacing nozzle insert of round jet nozzle 40
8 CLEANING AND MAINTENANCE 41
8.1 Cleaning 41
8.1.1 Cleaning Personnel 41
8.1.2 Flushing and Cleaning the Gun 41
8.2 Maintenance 42
8.2.1 Maintenance Personnel 42
8.2.2 Maintenance Instructions 42
8.2.3 Safety Checks 43
8.2.4 Replacing the paint hose 44
8.2.5 Replacing the nozzle seal 44
8.2.6 Replacing the Sealing Fitting of the Round Jet Nozzle 45
9 TROUBLESHOOTING AND RECTIFICATION 46
10 REPAIR WORK 47
10.1 Repair Personnel 47
10.2 Repair Notes 47
10.3 Replacing parts of the gun body 48
10.3.1 Disassembly of GA 4000ACIC 48
10.3.2 Packing insert GA 4000AC (RP) 50
10.3.3 Assembly of GA 4000ACIC 52

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11 FUNCTION TEST AFTER REPAIR WORK 54
12 DISPOSAL 54
13 ACCESSORIES 55
13.1 AirCoat Nozzles ACF3000 55
13.2 AirCoat Nozzles ACF3000 S2 (4 pieces) 57
13.3 Round jet nozzle attachment 57
13.3.1 RXX Nozzle inserts 58
13.3.2 Nozzle screw joint, complete 58
13.4 Hoses 58
13.5 Miscellaneous 59
14 SPARE PARTS 60
14.1 How can spare parts be ordered? 60
14.2 Spare Parts List for GA 4000ACIC 61
14.3 Service sets and spare parts groups 63
14.4 Packing insert GA 4000AC (RP) 63
14.5 Sealing Set GA 4000 Packing RP and RP Special 64
15 DECLARATION OF CONFORMITY 65
15.1 EU Declaration of Conformity 65

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VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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.
Notice 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:
Language Order No. Language Order No.
German 2312955 Swedish 2316798
English 2312956 Russian 2327992
French 2312957 Hungarian 2364607
Italian 2312958 -- --
Spanish 2312959 -- --
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)
TX Torx size (tool)
RP (replaceable packing)
PTFE Polytetrauorethylene (PTFE)
GF Fiber optics
PE Polyethylene
UWMW-PE Ultra-high molecular polyethylene
FPM Fluoropolymer rubber (Viton)
POM Polyoxymethylene (Acetal)
PA Polyamide

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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 compressed air
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.
2.2 TYPE OF USE
The gun is suitable for atomizing liquid products, particularly coating products, using the
AirCoat process.
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.
Follow the instructions in the 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, (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 aWAGNER representative.
When operating the device with a coating product with a temperature of > 43 °C; 109.4
°F, identify the device with a warning label that says "Warning - hot surface" according to
Chapter 4.2.6.
Note:
Contact your local WAGNER 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.

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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: AirCoat automatic gun
Manufacturer: Wagner International AG
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 the "Technical Data"
chapter.
Safe Handling of WAGNER Spray Devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the device against steel or rusty iron.
Do not drop the spray gun.
Use only tools that are made of a permitted material.
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
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.