WAGNER GA 4000ACIC-S Operational manual

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

3
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

4
VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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

5
VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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

6
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.

7
VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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

8
VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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.

9
VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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.

10
VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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.

11
VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
3.3 TYPE PLATE
GA 4000ACIC
GA 4000ACIC
II 2 G X
MAX. TEMPERATURE FLUID 25 MPa / 3625 psi / 250 bar MAX. PRESSURE FLUID
80°C / 176°F
MAX. PRESSURE AIR 0.6 MPa / 90 psi / 6 bar MAX. TEMPERATURE AIR 50°C / 125°F
SERIAL.NO: IC-XXXXX
J. WAGNER AG
CH-9450 ALTSTÄTTEN
MADE IN SWITZERLAND
1 2
3
4 5
B_06637
Designation
1 Maximum product pressure
2 Maximum product temperature
3 Serial number
4 Maximum air temperature
5 Maximum air inlet pressure

12
VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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/air hoses that have been 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 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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.
Carry out the work steps as described in the "Pressure relief" chapter:
– if pressure relief is required,
– if the spraying work is interrupted or stopped.
– before the device is cleaned on the outside, checked, or serviced,
– before the spray nozzle is installed or cleaned.
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 all devices and tanks are grounded before each spraying process.
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 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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 M .
Suction hoses may not be subjected to pressure.

17
VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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.
Explosive gases are produced when aluminum comes into contact with
halogenated hydrocarbons. To clean aluminum, do not use liquids containing
halogenated hydrocarbons.
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 gun. Cleaning the device must not damage
it in any way.
Ensure that no electrical component is cleaned with or even immersed in solvent.

18
VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
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.
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.
Exclusively use accessories listed in Chapter 13 and that are assigned to the unit.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve the pressure from the spray gun and device.
– Secure the spray gun against actuation.
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 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
5 DESCRIPTION
5.1 COMPONENTS
B_06650
A
F
I
G
H
B
D
J
N
B_06651
C
L
E
K
M
Designation
A Gun head
B Spray gun body
C Tension sleeve drive
D Base plate
E Atomizing air connection (blue)
F Union nut
G Air cap (blue, red or bronze)
H Nozzle
I Standard holder
J Connecting tting (product)
K Connecting tting (product)
L Connection for control air (red)
M Shaping air throttle
N Product channel lock pin
The device consists of a gun head (A), gun body (B), drive (C) and base plate (D). The air cap
(G), appropriate nozzle (H) and various parts for sealing and fastening are attached to the
gun head (A). The product valve and packing are housed in the gun head (A). The clamping
mechanism for the packing is installed in the gun body (B). The gun body also serves as
a connecting piece between the drive (C) and the gun head (A). The drive (C) consists a
diaphragm and a pressure spring for the product valve. The base plate (D) contains all
connections (E, J, K) and a shaping air throttle (M). It can be used to connect the gun to the
corresponding reciprocator or gun holder.

20
VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC
5.2 FUNCTIONAL DESCRIPTION
5.2.1 MODE OF OPERATION
Diagram:
AA / SA
CA
SA
AA
M
C
B_00521
Nozzle
SA = Shaping air
AA = Atomizing air
CA = Control air
M = Product
C = Circulation
Open:
The piston in the drive is charged with control air and moves toward the rear. This ensures
that the air valve which releases the shaping and atomizing air is opened rst. The product
valve is then opened with a mechanical delay. In this position, the pressurized coating
product is applied to the work piece.
Close:
The piston is relieved, and the product valve closes due to the pressure spring which
presses against the product valve tappet. The air valve is then closed, again with a spring
force and mechanical delay.
Additional functions:
The shaping air throttle is used to regulate the shaping air volume, while the atomizing air
is adjusted via an external pressure regulator. The two air streams do not ow separately
until they are downstream of the air valve, so that the pressure of the shaping air
corresponds roughly to that of the atomizing air and so that they inuence each other
during adjustment.
The product connections and the paint channels in the base plate are arranged so that
several guns can run in circulation mode.