WAGNER GA 5000EAC User manual

B_05738
GA 5000EAC
Electrostatic Automatic Spray Gun (AirCoat)
Translation of the Original Operating Manual
0102 II2G0.24mJ
For professional use.
Always observe the information in this manual, particularly the safety
instructions and the warning instructions. Store the manual in a safe place. Edition: 09/2022

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
Table of Contents
Order number 2360922 | Edition 09/2022 3
TABLE OF CONTENTS
1 About these Instructions 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 General Characters and Symbols 6
1.4 Languages 7
1.5 Abbreviations 7
1.6 Terminology for the Purpose of this Manual 7
2 Using in Accordance with the Instructions 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 10
3 Identification 11
3.1 Explosion Protection Identification 11
3.2 Identification "X" 11
3.3 Use in Areas Subject to Explosion Hazards 12
3.4 Type Plate 13
4 Basic Safety Instructions 14
4.1 Safety Instructions for the Operator 14
4.1.1 Electrical Devices and Equipment 14
4.1.2 A Safe Work Environment 14
4.1.3 Personnel Qualifications 15
4.2 Safety Instructions for the Personnel 15
4.2.1 Personal Safety Equipment 15
4.2.2 Safe Handling of WAGNER Spray Devices 16
4.2.3 Grounding the Device 16
4.2.4 Product Hoses 17
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 19
4.2.9 Safety-Relevant Information about Discharges 19
4.2.10 Setting up Stationary Electrostatic Systems 19
5 Description 20
5.1 Structure (Basic Version) 20
5.1.1 GA 5000EACIC Design 20
5.1.2 GA 5000EACEC Design 21
5.2 General Information on Mode of Operation 22
5.2.1 Functioning 22
5.3 Protective and monitoring equipment 24
5.4 Extent of Delivery 24
5.5 Technical Data 25
5.5.1 Dimensions of GA 5000EAC 26
5.6 Spraying Procedure 26
5.6.1 Spraying Procedure with Round Jet Nozzle 26
5.6.2 Spray process with Flat Jet Nozzle 27
5.6.3 The Electrostatic Effect 28
5.7 The WAGNER Electrostatic AirCoat Spraying System 28

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
Table of Contents
4 Order number 2360922 | Edition 09/2022
6 Assembly and Commissioning 30
6.1 Training of Assembly/Commissioning Personnel 30
6.2 Storage Conditions 30
6.3 Installation Conditions 30
6.4 Assembly and Installation 30
6.4.1 Typical Electrostatic Spraying System 30
6.4.2 Connecting the GA 5000EACIC Spray Gun 32
6.4.3 Connecting the GA 5000EACEC Spray Gun 33
6.4.4 Ventilation of the Spray Booth 33
6.4.5 Air Supply Lines 34
6.4.6 Product Supply Lines 34
6.4.7 Grounding 34
6.5 Lacquer Preparations 36
6.5.1 Viscosity Conversion Table 37
6.6 Start up 37
6.6.1 Verifying a Safe Operational Condition 38
7 Operation 39
7.1 Training the Operating Personnel 39
7.2 Tasks 39
7.2.1 Emergency Deactivation 39
7.3 Setting the spray pattern using the air pressure regulator 39
7.4 Spraying 40
7.5 Pressure Relief / Work Interruption 41
7.6 Dismounting the Gun Cover 42
7.7 Flushing Out Clogged Round Jet Nozzles 43
7.8 Replacing nozzle insert of round jet nozzle 43
7.9 Changing from AirCoat Round Jet / AirCoat Flat Jet 44
7.10 Replacing the AirCoat Flat Jet Nozzles 46
7.11 Cleaning of the Nozzle Parts 47
7.12 Eliminating Nozzle Clogging 47
7.13 Changing the valve housing 48
8 Cleaning and Maintenance 49
8.1 Cleaning 49
8.1.1 Cleaning Personnel 49
8.1.2 Safety Instructions 49
8.1.3 Cleaning and flushing the device 50
8.2 Maintenance 50
8.2.1 Maintenance Personnel 50
8.2.2 Safety instructions 51
8.2.3 Safety Checks and Maintenance Intervals 51
8.2.4 Product Hoses, Pipes and Couplings 52
9 Troubleshooting and Rectification 53
10 Repairs 54
10.1 Repair Personnel 54
10.2 Repair Notes 54
10.3 Assembly aids 55
10.4 Spray Gun 55
10.4.1 Tools 55
10.4.2 Dismantling the Spray Gun 55
10.4.3 Cleaning the Parts after Disassembly 59
10.4.4 Assembling the Spray Gun 60

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
Table of Contents
Order number 2360922 | Edition 09/2022 5
11 Function Test after Repair Work 66
11.1 Check High Voltage 66
11.2 Function Tests for Spray Gun 67
11.2.1 Air Tests 67
11.2.2 Product Pressure Test 67
11.2.3 Check Spray Pattern 67
12 Disposal 68
12.1 Device 68
12.2 Consumable Products 68
13 Accessories 69
13.1 Round Jet Nozzles 69
13.1.1 ACR 5000 Round Jet Nozzle Attachment 69
13.1.2 AirCoat Round Jet Nozzle Inserts 69
13.2 Flat jet nozzles 69
13.2.1 ACF 5000 Air Caps (Flat Jet) 69
13.2.2 ACF 5000 AirCoat Flat Jet Nozzles 70
13.3 Filter 71
13.4 Hoses and Cables 72
13.4.1 Gun Cables and Gun Cable Extensions 72
13.4.2 Product Hoses 72
13.4.3 Air hoses 72
13.4.4 Miscellaneous 73
14 Spare Parts 75
14.1 How to Order Spare Parts 75
14.2 GA 5000EAC spray gun 76
14.2.1 GA 5000EACIC - Basic Version 76
14.2.2 GA 5000EAC – Adapter 79
14.2.3 GA 5000EACEC - Basic Version 81
14.3 Accessories Spare Parts Lists 83
14.3.1 Flat jet nozzles 83
14.3.2 ACR 5000 Round Jet Nozzle Attachment 83
15 Declaration of Conformity 85
15.1 EU Declaration of Conformity 85

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
1 About these Instructions
6 Order number 2360922 | Edition 09/2022
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 danger.
Non-observance may result in death or serious injury.
CAUTION Potentially dangerous situation.
Non-observance may result in minor injury.
NOTICE Potentially dangerous situation.
Non-observance may result in damage to property.
Info Provides information about particular characteristics and how to
proceed.
Explanation of warning notice:
WARNING
This notice warns you of a danger!
Possible consequences of not observing the warning notice.
4The measures for preventing the hazard and its consequences.
1.3 GENERAL CHARACTERS AND SYMBOLS
The characters and symbols in this operating manual indicate the following:
üRequirement that must be fulfilled before an action can be performed.
1. Step 1 of an action to be performed with several action steps.
4Second level action step
2. Step 2
ðIntermediate result of an action
ðResult of a complete action
4Action to be performed with an action step
1. Numbered list, first level
– Numbered list, second level

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
1 About these Instructions
Order number 2360922 | Edition 09/2022 7
– Non-numbered list, first level
– Non-numbered list, second level
= cross-reference on page
♦ = wearing parts
⋆ = included in service set
● = not part of the standard equipment but available as a special accessory
1.4 LANGUAGES
The operating manual GA 5000EAC is available in the following languages:
Original operating manual
Language Order no.
German 2360921
Translation of the original operating manual
Language Order no. Language Order no.
English 2360922 Spanish 2367696
French 2367694 Russian 2373688
Italian 2367695 Chinese 2373690
Japanese 2382578
Additional languages upon request or at: www.wagner-group.com
1.5 ABBREVIATIONS
Order no. Order number
ET Spare part
K Marking in the spare parts lists
Pos Position
Stk Number of pieces
GA Automatic gun
EAC Electrostatic AirCoat
IC Shaping and atomizing air controlled via valve within gun
EC Shaping and atomizing air controlled via valve outside of gun
Low R Low resistance
SW Wrench size
Materials
SSt Stainless steel
1.6 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning agent.
Flushing Internal flushing of paint-wetted parts with flushing agent.

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
1 About these Instructions
8 Order number 2360922 | Edition 09/2022
Personnel qualifications
Trained person Is instructed in the tasks assigned to him/her, the potential risks associ-
ated 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 neces-
sary 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 rele-
vant provisions.
Skilled person in
the context of
DGUV209‑052
A person who, based on his/her technical training, experience and re-
cent vocational experience, has sufficient technical knowledge in the
area of electrostatic coating and is familiar with the relevant and gener-
ally accepted rules of technology so that he/she can inspect and assess
the status of devices and coating systems based on workplace safety.
Additional requirements for skilled persons can also be found in
TRBS1203(2010/amendment 2012): Expert knowledge in the areas of
protection against excessive pressure, electrical hazards and explosion
protection (where applicable).

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
2 Using in Accordance with the Instructions
Order number 2360922 | Edition 09/2022 9
2 USING IN ACCORDANCE WITH THE INSTRUCTIONS
2.1 DEVICE TYPE
Electrostatic automatic spray gun for coating of grounded work pieces in automatic coating
systems.
2.2 TYPE OF USE
The GA 5000EAC electrostatic automatic spray gun is suitable for spraying liquid products,
particularly coating products. Coating products may be processed which contain
components of substances of explosion group IIA and IIB (maximum ignition energy 0.24
mJ).
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
4Use the device only to work with the materials recommended by WAGNER.
4Do not deactivate safety fixtures.
4Use only WAGNER original spare parts and accessories.
4The operating personnel must be trained on the basis of this operating manual.
4Follow the instructions in the operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The GA 5000EAC electrostatic automatic spray gun is suitable for coating electrically
conductive objects with liquid coating products and can be used in potentially explosive
areas.
(See Explosion Protection Identification in chapter Explosion Protection Identification
[811].)
2.4 PROCESSIBLE WORKING MATERIALS
4Coating products whose ingredients contain substances of explosion class IIA and IIB
(maximum ignition energy 0.24 mJ) can be processed with the GA 5000EAC spray gun.
4The basic spray gun version is suitable for processing sprayed substances with an
electrical resistance of > 150 kΩ (according to the WAGNER scale). Equipped with a
special product hose for low-resistance sprayed substances (available as an accessory),
you can also successfully process sprayed substances with an electrical resistance > 50
kΩ (according to the WAGNER scale).
4When processing metallic lacquers, it is advisable to use the spiral hose.
4The application effectiveness is always dependant on the composition of the product
being used, e.g., pigments or resin.
Conversion of Paint Resistance
There are paint resistance measuring devices available on the market that do not directly
measure the specific paint resistance.
Multiplying the result of the measurement with the device-specific cell constant (K), we
obtain the specific resistance value of the product.
Example:
With WAGNER's paint resistance measuring device the cell constant is K123.
Measured value according to the WAGNER
scale
R=500kΩ

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
2 Using in Accordance with the Instructions
10 Order number 2360922 | Edition 09/2022
Specific resistance (RS) RS=RxK=500kΩx123=61.5MΩcm
Note:
Using sprayed substances with too low an electrical resistance, the application of
electrostatics does not show any effect, i.e. there is no "paint wrap around" on the object to
be sprayed.
The suitability of the spray product with regard to the charging ability can be read from the
actual values for high voltage (kV) and for the spray current (μA) shown in the illuminated
displays on the EPG 5000 control unit.
High kV value, low μA value = ok
Low kV value, high μA value = excessive conductivity of the paint
4no wrap-around
Info
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:
4No dry coating products, e.g., powder are processed.
4No food, medicine or cosmetics are processed. It is important to note that the device's
materials are not food-safe.