WAGNER GA 5000EAIC Operational manual

GA 5000EAIC
GA 5000EAEC
II 2 G 0.24mJ X
B_06009
Electrostatic Air Spray Gun
for automatic operation
for at or round jet nozzles
Version 09/2016
Translation of the Original
Operating Manual

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GA 5000EA
Table of Contents
1 ABOUT THESE INSTRUCTIONS 7
1.1 Preface 7
1.2 Warnings, Notices and Symbols in these Instructions 7
1.3 Languages 8
1.4 Abbreviations 8
1.5 Terminology for the Purpose of this Manual 9
2 CORRECT USE 10
2.1 Device Type 10
2.2 Type of Use 10
2.3 Use in an Explosion Hazard Area 10
2.4 Safety Parameters 10
2.5 Processible Working Materials 11
2.6 Reasonably Foreseeable Misuse 12
2.7 Residual Risks 12
3 IDENTIFICATION 13
3.1 CE Explosion Protection Identication 13
3.2 Special Notice "X" 13
3.3 Identication "X" (Type Examination Certicate) 14
3.4 Type Plate 15
4 GENERAL SAFETY INSTRUCTIONS 16
4.1 Safety Instructions for the Operator 16
4.1.1 Electrical Equipment 16
4.1.2 Personnel Qualications 16
4.1.3 Safe Work Environment 16
4.2 Safety Instructions for Sta 17
4.2.1 Safe Handling of WAGNER Spray Devices 17
4.2.2 Grounding the Device 18
4.2.3 Product Hoses 18
4.2.4 Cleaning and Flushing 19
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 20
4.2.6 Touching Hot Surfaces 20
4.3 Protective and Monitoring Equipment 20
4.4 Use in Areas Subject to Explosion Hazards 21
4.4.1 Safety Regulations 21
4.5 Setting up Stationary Electrostatic Systems 21
4.6 Safety-Relevant Information about Discharges 22
5 DESCRIPTION 23
5.1 Structure (Standard Variant) 23
5.1.1 GA 5000EAIC Design 23
5.1.2 GA 5000EAEC Design 24
5.2 Mode of Operation 25
5.2.1 GA 5000EAIC Mode of Operation 25
5.2.2 GA 5000EAEC Mode of Operation 26
5.3 Protective and Monitoring Equipment 27
5.4 Scope of Delivery 27
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GA 5000EA
5.5 Technical Data 28
5.5.1 GA 5000EA Dimensions 29
5.6 Spraying Procedure 30
5.6.1 Spraying Procedure for Round Jet Air Atomizing 30
5.6.2 Spraying Procedure for Flat Jet Air Atomizing 31
5.6.3 Electrostatic Eect 32
5.7 The WAGNER Electrostatic Air Spraying System 33
5.7.1 Pressure Settings for Round Jet Nozzles 34
5.7.2 Pressure Settings for Flat Jet Nozzles 34
5.7.3 Adjusting Screw 35
5.7.4 Electrostatic and Atomization 36
5.7.5 Discharge Quantity Measurements 36
6 ASSEMBLY AND COMMISSIONING 37
6.1 Training Assembly/Commissioning Sta 37
6.2 Storage Conditions 37
6.3 Installation Conditions 37
6.4 Transportation 37
6.5 Assembly and Installation 38
6.5.1 Typical Electrostatic Spraying System 38
6.5.2 Connecting GA 5000EAIC 40
6.5.3 Connecting GA 5000EAEC 41
6.5.4 Ventilation of the Spray Booth 42
6.5.5 Air Supply 43
6.5.6 Product Supply 43
6.5.7 Grounding 44
6.6 Preparation of Lacquer 46
6.6.1 Viscosity Conversion Table 46
6.7 Commissioning 47
6.7.1 Safety Instructions 47
6.7.2 Preparation for Commissioning 47
6.7.3 Commissioning 47
6.8 Verifying a Safe Operational Condition 48
7 OPERATION 49
7.1 Training the Operating Sta 49
7.2 Safety Instructions 49
7.2.1 Emergency Deactivation 50
7.2.2 General Rules for Making Adjustments to the Spray Gun 50
7.3 Working 51
7.3.1 Checking the GA 5000EA Spray Pattern (Without Electrostatics) 51
7.3.2 Spraying GA 5000EA 53
7.3.3 Pressure Relief/Work Interruption 54
7.3.4 Dismantling the Gun Cover 55
7.3.5 Changing from Air Round Jet to Air Flat Jet 56
7.3.6 Changing the Valve Housing 58
7.3.7 Cleaning of the Nozzle Parts 59
OPERATING MANUAL
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Table of Contents

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GA 5000EA
8 CLEANING AND MAINTENANCE 60
8.1 Cleaning 60
8.1.1 Cleaning Sta 60
8.1.2 Safety Instructions 60
8.1.3 Cleaning and Flushing the Device 62
8.2 Maintenance 64
8.2.1 Maintenance Sta 64
8.2.2 Safety Instructions 64
8.2.3 Safety Checks 65
8.2.4 Product Hoses, Tubes and Couplings 66
9 TROUBLE SHOOTING AND RECTIFICATION 67
10 REPAIR WORK 68
10.1 Repair Sta 68
10.2 Safety Instructions 68
10.3 Dismantling of the Gun 69
10.3.1 Tools 69
10.3.2 Dismantling of the Spray Gun 70
10.3.3 Cleaning the Parts After Disassembly 75
10.3.4 Assembling the Spray Gun 76
11 FUNCTION TEST AFTER THE REPAIR 82
11.1 Checking the High voltage 82
11.2 Air Test 84
11.3 Product Pressure Test 84
11.4 Test of Spray Pattern 84
12 DISPOSAL 85
13 ACCESSORIES 86
13.1 Valve Housing 86
13.2 Valve Tips 86
13.3 Round Spray Nozzles 86
13.3.1 AR 5000 Air Caps 86
13.3.2 AR 5000 Nozzles 86
13.3.3 EARV Nozzle set 87
13.4 Flat Jet Nozzles 87
13.4.1 AF 5000 Air Caps 87
13.4.2 AF 5000 Nozzles 88
13.5 Electric Cables and Hoses 89
13.5.1 Gun Cable 89
13.5.2 Extension Cable for Gun Cable 89
13.5.3 Product Hoses Standard 89
13.5.4 Product Hoses for Low-resistance Products 90
13.5.5 Spiral Hose 90
13.5.6 Air Hoses 90
13.6 Miscellaneous 91
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14 SPARE PARTS 93
14.1 How Can Spare Parts Be Ordered? 93
14.2 GA 5000EAIC Spray Gun 94
14.2.1 GA 5000EA Adapter 96
14.3 GA 5000EAEC Spray Gun 98
14.4 Accessories Spare Parts Lists 101
14.4.1 AR 5000 Nozzle (D8) 102
14.4.2 AR 5000 Nozzle (D12) 102
14.4.3 Adjustable EARV 5000 Round Jet Nozzle 103
15 WARRANTY AND CONFORMITY DECLARATIONS 104
15.1 Important Notes Regarding Product Liability 104
15.2 Warranty Claim 104
15.3 EU Declaration of Conformity 105
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GA 5000EA
OPERATING MANUAL
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1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
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 damage to property.
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 measures for preventing the hazard and its consequences.
DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the hazard and its consequences.
NOTICE
1 ABOUT THESE INSTRUCTIONS
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.
1.1 PREFACE

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1.3 LANGUAGES
1.4 ABBREVIATIONS
Order No. Order number
Spare part
Marking in the spare parts lists
Automatic gun
Electrostatics Airspray
Shaping and atomizing air controlled via valve within gun
Shaping and atomizing air controlled via valve outside of gun
Low R Low-resistance
Polyether ether ketone (high temperature-resistant thermoplastic plastic)
Stainless steel
Position
Number of pieces
Wrench size
The GA 5000EA operating manual is available in the following languages:
Language Order No. Language Order No.
German 2360923 English 2360924
French 2367556 Italian 2367557
Spanish 2367558
Additional languages on request or at:

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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Sta 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 the context of
DGUV209-052
A person who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the area of electrostatic coating 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.
Additional requirements for skilled persons are given in the
TRBS1203 (2010/Revision2012): Expert knowledge in the areas
of protection against excessive pressure, electrical hazards, and
explosion protection (where applicable).

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GA 5000EA
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2 CORRECT USE
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 5000EA electrostatic automatic spray gun is suitable for spraying liquid products,
particularly coating products. Coating products which contain ingredients of explosion
class IIA and IIB substances (maximum ignition energy 0.24 mJ) may be used.
WAGNER forbids any other use!
2.4 SAFETY PARAMETERS
2.3 USE IN AN EXPLOSION HAZARD AREA
The GA 5000EA electrostatic automatic spray gun is suitable for coating electrically
conductive objects with liquid coating products and can be used in potentially explosive
areas. Explosion Protection Identication (see Chapter 3)
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.
The device may only be operated under the following conditions:
The operating personnel must be 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.
The electrostatic automatic spray gun may only be operated if all parameters are set and
all measurements/safety checks are carried out correctly.