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
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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)
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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.

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
3 Identification
Order number 2360922 | Edition 09/2022 11
3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As defined in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device Type Electrostatic automatic spray gun GA 5000EAC
Manufacturer Wagner International AG
9450 Altstätten
Switzerland
0102 II2G0.24mJ
SIRA16 ATEX5290X
CE European Communities
0102 Notified body: PTB
Ex Explosion-proof equipment
II Device groupII (not mining)
2 Category2 device (suitable for zone1)
G Ex-atmosphere gas
0.24mJ Maximum ignition energy
SIRA16 ATEX5290X Number of type examination certificate
"X": see chapter Identification "X" [811].
Temperature notes
– Maximum surface temperature: 85 °C; 185 °F
– Maximum permissible product temperature: 50 °C; 122 °F
– Permissible ambient temperature: 0 to +40 °C; +32 to +104 °F
3.2 IDENTIFICATION "X"
Notice: SIRA16ATEX5290X
The EU Type Examination Certificate covers the following:
– The use of the spray gun in Zone 1
– The use of the EPG5000 control unit as related equipment for the spray gun.
Cable connections
Only cables assigned to the device may be used (see chapter Accessories [869]).
Permissible device combinations
The GA 5000EAC automatic spray gun may only be connected to the control units listed
below:
– EPG5000

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
3 Identification
12 Order number 2360922 | Edition 09/2022
WARNING
Incorrect use!
Risk of injury and damage to the device.
4Connect the GA 5000EAC automatic spray gun only to original WAGNER control
units.
3.3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS
Electrostatic surface spraying
4Never spray device parts using electrostatic equipment (electrostatic spray gun)!
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames or
sparks can form during discharge.
1. Remove deposits from the surfaces to maintain conductivity.
2. Use only a damp cloth to clean the device.

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
3 Identification
Order number 2360922 | Edition 09/2022 13
3.4 TYPE PLATE
B_05768
GA 5000EACIC
GA 5000EACEC
Serial No.
YY-XXX
Wagner International AG
CH-9450 Altstätten
GA 5000EACIC Art. Nr. 2357746
high voltage: max. 80kV DC
current: max. 100uA DC
max. mat. pressure: 25MPa; 250bar; 3626psi
max. air pressure: 0.8Pa; 8bar; 116psi
Wagner International AG
CH-9450 Altstätten
GA 5000EACEC Art. Nr. 2360829
high voltage: max. 80kV DC
current: max. 100uA DC
max. mat. pressure: 25MPa; 250bar; 3626psi
max. air pressure: 0.8Pa; 8bar; 116psi
SIRA 16 ATEX 5290 X
EN 50176:2009
EN 50050-1:2013
Ta = 0°C - 40°C, Temp code = T6
II 2 G 0.24mJ
SIRA 16 ATEX 5290 X
EN 50176:2009
EN 50050-1:2013
Ta = 0°C - 40°C, Temp code = T6
01020518
II 2 G 0.24mJ
01020518
CSAE 21 UKEX 5232 X
BS EN 50176:2009
BS EN 50050-1:2013
CSAE 21 UKEX 5232 X
BS EN 50176:2009
BS EN 50050-1:2013
1
1 Serial number

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
4 Basic Safety Instructions
14 Order number 2360922 | Edition 09/2022
4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4Keep this operating manual at hand near the device at all times.
4Always follow existing regulations concerning occupational safety and accident
prevention regulations.
4.1.1 Electrical Devices and Equipment
Danger of electric shock!
Danger to life from electric shock:
4Place and operate device in accordance with the existing safety requirements with
regard to the operating mode and ambient influences.
4May only be maintained by skilled electricians or under their supervision. With open
housings, the mains voltage poses a danger.
4Operate device in accordance with the safety regulations and electrotechnical
regulations.
4Do not disconnect any plug connections during operation.
4Label plug connections with the warning "Do not disconnect when energized".
4Must be repaired immediately in the event of problems.
4Decommission if device poses a danger or is damaged.
4Must be de-energized before work is commenced.
4Secure the device against being switched back on without authorization.
4Inform personnel about planned work.
4Observe electrical safety regulations.
4Ground all devices to a common grounding point.
4Only operate the device with a properly installed socket with a protective ground wire
connection.
4Keep liquids away from electrical devices.
4.1.2 A Safe Work Environment
Danger due to dangerous fluids or vapors!
Severe or fatal injuries due to explosion danger or inhalation, swallowing or contact with the
skin or eyes.
4Ensure that the floor in the working area is static dissipative in accordance with
EN1081:2018+A1:2020 or EN61340-4-1:2004+A1:2015 (resistance must not exceed 100
MΩ).
4Paint mist extraction systems/ventilation systems must be fitted on site according to
local regulations.
4Make 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).
4Ensure that product hoses/air hoses adapted to the working pressure are used.
4Ensure that personal protective equipment is available and is used.

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
4 Basic Safety Instructions
Order number 2360922 | Edition 09/2022 15
4Make sure that all people within the work area wear static dissipative shoes. Footwear
must comply with EN 20344. The measured insulation resistance must not exceed 100
MΩ.
4Ensure that during spraying, persons wear static dissipative gloves. The grounding
takes place via the spray gun's handle or its trigger.
4Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 MΩ.
4Ensure that there are no ignition sources such as naked flames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
4Ensure that the pipe joints, hoses, equipment parts and connections are permanently,
technically leak-proof:
4Periodic preventative maintenance and service (replacing hoses, checking tightness
strength of connections, etc.)
4Regular monitoring of leaks and defects via visual inspection and odor testing, e.g.,
daily before commissioning, at the end of work or weekly.
4Ensure that maintenance and safety checks are performed regularly.
4In 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
Danger due to incorrect use of device!
Risk of death due to untrained personnel.
4Ensure 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 qualifications.
4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
4Always observe the information in this manual, particularly the safety instructions and
the warning instructions.
4Always follow existing regulations concerning occupational safety and accident
prevention regulations.
Danger due to high-voltage field!
Danger to life from malfunction of active implants.
4Persons 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
Danger due to dangerous fluids or vapors!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
4When 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.
4Implement the prescribed safety measures, in particular the wearing of safety glasses,
safety clothing and protective gloves as well as the use of protective hand cream.
4Use a mask or breathing apparatus if necessary.

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
4 Basic Safety Instructions
16 Order number 2360922 | Edition 09/2022
4For sufficient health and environmental safety: Operate the device in a spray booth or
on a spraying wall with the ventilation (extraction) switched on.
4Wear suitable protective clothing when working with hot products.
4.2.2 Safe Handling of WAGNER Spray Devices
Danger due to injection of lacquer or flushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of lacquer or flushing agents:
4Never point the spray gun at people.
4Never reach into the spray jet.
4Perform the following measures before any work on the device, in the event of work
interruptions and malfunctions:
4Switch off the energy/compressed air supply
4Relieve the pressure from the spray gun and device
4Secure the spray gun against actuation
4Disconnect the control unit from the mains
4In the event of functional faults, remedy the fault as described in the chapter on
troubleshooting and rectification.
4If needed, the liquid ejection devices must be checked by experts (e.g., WAGNER service
technician) at least every 12 months for their work-safe condition in accordance with
DGUV regulation 100-500 chapter 2.29 and chapter 2.36.
4For shut down devices, the examination can be suspended until the next start-up.
In the event of skin injuries caused by lacquer or flushing agents:
4Note the lacquer or flushing agent that you have been using.
4Consult a doctor immediately.
Danger due to recoil forces!
Actuating the trigger can causes strong recoil forces. Thereby, the user can lose his balance
and injure himself when falling.
Avoid risk of injury from recoil forces:
4Ensure that you have firm footing when operating the spray gun.
4.2.3 Grounding the Device
Danger due to electrostatic charge!
Risk of injury, explosion hazard and damage to the device.
Friction, flowing 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.
4Ensure that all devices and tanks are grounded before each spraying process.
4Make sure that the ground and potential equalization of all system parts are performed
reliably and continuously and can withstand the expected stress (e.g., mechanical
stress, corrosion).
4Earth the workpieces being painted.
4Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
4 Basic Safety Instructions
Order number 2360922 | Edition 09/2022 17
4Wear static dissipative gloves when spraying. The grounding takes place via the spray
gun's handle or its trigger.
4.2.4 Product Hoses
Danger due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
4Ensure that the hose material is chemically resistant to the sprayed products and the
flushing agents used.
4Ensure that the product hoses and the fittings are suitable for the pressure generated.
4Ensure that the following information can be seen on the high-pressure hose:
4Manufacturer
4Permissible operating pressure
4Date of manufacture
4Make sure that the hoses are laid only in suitable places. Hoses should not be laid in the
following places under any circumstances:
4in high traffic areas
4on sharp edges
4on moving parts
4on hot surfaces
4Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses
are never put under pressure from the outside in any other way.
4Ensure that the hoses are never kinked. Observe maximum bending radii.
4Ensure that no work is ever performed with a damaged hose.
4Make sure that the hoses are never used to pull or move the device.
4The electrical resistance of the product hose, measured at both valves, must be less
than 1 MΩ.
4Suction hoses may not be subjected to pressure.
4.2.5 Cleaning and Flushing
Danger due to cleaning and flushing!
Explosion hazard and damage to the device.
4Non-ignitable cleaning agents and flushing agents should preferably be used.
4When carrying out cleaning work with flammable cleaning agents, make sure that all
equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or
static dissipative and grounded.
4Observe the specifications of the lacquer manufacturer.
4Ensure that the flash 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.
4Never use chloride or halogenated solvents (such as trichloroethane and methylene
chloride) with devices containing aluminium or galvanized/zinc-plated parts. They may
react chemically thus producing an explosion danger.
4Take measures for workplace safety.

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
4 Basic Safety Instructions
18 Order number 2360922 | Edition 09/2022
4It should be noted that when the device is put into operation or emptied: depending
on the coating product used, depending on the rinsing agent (solvent) used, there may
briefly be a mixture inside the pipes and equipment which can ignite.
4Only use electrically conductive tanks for cleaning and flushing agents.
4The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
4Never spray into a closed tank when using solvents for flushing.
External cleaning
When cleaning the exterior of the device or its parts, also observe the following:
4Relieve the pressure from the device.
4De-energize the device electrically.
4Disconnect the pneumatic supply line.
4Use 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.
4Ensure that no electric component is cleaned with or immersed into solvent.
4.2.6 Touching Hot Surfaces
Danger due to hot surfaces because of hot coating products!
Risk of burn injuries
4Only touch hot surfaces if you are wearing protective gloves.
4When operating the device with a coating product with a temperature of > 43°C;
109°F, apply a warning label to the device that says "Warning - Hot Surface."
Instruction label: Order no. 9998910
Protection label: Order no. 9998911
Info
Order the two labels together.
4.2.7 Maintenance and Repair
Danger due to improper maintenance and repair!
Danger to life and equipment damage.
4Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
4Repair or replacement of devices or parts of devices are only allowed to be performed
outside the hazard area by qualified personnel.
4Use only WAGNER original spare parts and accessories.
4Do not change or modify the device; if change is necessary, contact WAGNER.
4Only repair and replace parts that are listed in the chapters Accessories [869] and
Spare Parts and that are assigned to the device.
4Do not use any defective components.
4Before all work on the device and in the event of work interruptions:
4Relieve the pressure from the spray gun, product hoses and all devices.
4Secure the spray gun against actuation.

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
4 Basic Safety Instructions
Order number 2360922 | Edition 09/2022 19
4Switch off the energy and compressed air supply.
4Disconnect the control unit from the mains.
4Observe the operating and service manual for all work.
4.2.8 Protective and monitoring equipment
Danger due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
4Protective and monitoring equipment must not be removed, modified or rendered
unusable.
4Regularly check for perfect functioning.
4If defects are detected on protective and monitoring equipment, the system must not
be operated until these defects are remedied.
4.2.9 Safety-Relevant Information about Discharges
The plastic parts of the spray gun are charged electrostatically by the high-voltage field. In
case of contact with plastic parts, harmless discharges (brush discharges) may occur. They
are completely non-hazardous for human health.
When keeping a distance of 4 to 10mm; 0.15 to 0.4inch between the spray gun and the
object to be sprayed, the corona discharge at the end of the electrode is visible in the dark.
4.2.10 Setting up Stationary Electrostatic Systems
The spray gun is a component of a stationary coating system. When setting up stationary
coating systems, comply strictly with EN 50176. One of the requirements is that activation of
the high voltage is only possible by using a key. But it must be possible to switch off the high
voltage without a key.

Operating manual GA 5000EAC Electrostatic Automatic Spray Gun (AirCoat)
5 Description
20 Order number 2360922 | Edition 09/2022
5 DESCRIPTION
5.1 STRUCTURE (BASIC VERSION)
5.1.1 GA 5000EACIC Design
B_05739
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2
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9
1 Front cover 9 Shaping air setting
2 Union nut on nozzle protection 10 Gun holder
3 Air cap 11 Product hose
4 Flat jet nozzle 12 Sealing fitting
5 Gun adapter 13 Nozzle screw joint
6 Piston housing 14 Nozzle attachment
7 Rear cover 15 Round jet nozzle
8 Air diffuser housing
Order numbers see chapter Round Jet Nozzles [869]