WAGNER GA 5000EACIC User manual

GA 5000EACIC
GA 5000EACEC
II 2 G 0.24mJ X
B_05738
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 5000EAC
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360922
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 5000EACIC Design 23
5.1.2 GA 5000EACEC Design 24
5.2 Mode of Operation 25
5.2.1 GA 5000EACIC Mode of Operation 25
5.2.2 GA 5000EACEC Mode of Operation 26
5.3 Protective and Monitoring Equipment 27
5.4 Scope of Delivery 27

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Table of Contents
5.5 Technical Data 28
5.5.1 GA 5000EAC Dimensions 29
5.6 The WAGNER Electrostatic AirCoat Spraying System 30
5.6.1 Spraying Procedure for AirCoat Round Jet 31
5.6.2 Spraying Procedure for AirCoat Flat Jet 31
5.6.3 Electrostatic Eect 32
6 ASSEMBLY AND COMMISSIONING 33
6.1 Training Assembly/Commissioning Sta 33
6.2 Storage Conditions 33
6.3 Installation Conditions 33
6.4 Assembly and Installation 34
6.4.1 Typical Electrostatic Spraying System 34
6.4.2 Connecting GA 5000EACIC 36
6.4.3 Connecting GA 5000EACEC 37
6.4.4 Ventilation of the Spray Booth 38
6.4.5 Air Supply 39
6.4.6 Product Supply 39
6.4.7 Grounding 40
6.5 Preparation of Lacquer 42
6.5.1 Viscosity Conversion Table 42
6.6 Commissioning 43
6.6.1 Safety Instructions 43
6.6.2 Preparation for Commissioning 43
6.6.3 Commissioning 43
6.7 Verifying a Safe Operational Condition 44
7 OPERATION 45
7.1 Training the Operating Sta 45
7.2 Safety Instructions 45
7.2.1 Emergency Deactivation 46
7.2.2 General Rules for Making Adjustments to the Spray Gun 46
7.3 Working 47
7.3.1 Setting the Spray Pattern Using the Air Pressure Regulator 47
7.3.2 Spraying 48
7.3.3 Pressure Relief/Work Interruption 49
7.3.4 Dismantling the Gun Cover 50
7.3.5 Flushing Out Clogged Round Jet Nozzles 51
7.3.6 Replacing Round Jet Nozzle's Nozzle Insert 51
7.3.7 Changing from AirCoat Round Jet to AirCoat Flat Jet 52
7.3.8 Replacing the AirCoat Flat Jet Nozzles 54
7.3.9 Cleaning of the Nozzle Parts 55
7.3.10 Eliminate Nozzle Clogging 56
7.3.11 Changing the Valve Housing 58

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Table of Contents
8 CLEANING AND MAINTENANCE 59
8.1 Cleaning 59
8.1.1 Cleaning Sta 59
8.1.2 Safety Instructions 59
8.1.3 Cleaning and Flushing the Device 61
8.2 Maintenance 63
8.2.1 Maintenance Sta 63
8.2.2 Safety Instructions 63
8.2.3 Safety Checks 64
8.2.4 Product Hoses, Tubes and Couplings 65
9 TROUBLE SHOOTING AND RECTIFICATION 66
10 REPAIR WORK 67
10.1 Repair Sta 67
10.2 Safety Instructions 67
10.3 Spray Gun 68
10.3.1 Tools 68
10.3.2 Dismantling of the Spray Gun 69
10.3.3 Cleaning the Parts After Disassembly 74
10.3.4 Assembling the Spray Gun 75
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 Round Jet Nozzles 86
13.1.1 ACR 5000 Round Jet Nozzle Attachment 86
13.1.2 AirCoat Round Jet Nozzle Inserts 86
13.2 Flat Jet Nozzles 86
13.2.1 ACF 5000 Air Caps (Flat Jet) 86
13.2.2 ACF5000 AirCoat Flat Jet Nozzles 87
13.3 Filter 89
13.4 Electric Cables and Hoses 89
13.4.1 Gun Cable 89
13.4.2 Extension Cable for Gun Cable 89
13.4.3 Product Hoses, Standard 90
13.4.4 Product Hoses, LowR 90
13.4.5 Product Hose, 1.5 mm 90
13.4.6 Air Hoses 91
13.5 Miscellaneous 92

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GA 5000EAC
Table of Contents
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360922
14 SPARE PARTS 94
14.1 How Can Spare Parts Be Ordered? 94
14.2 GA 5000EACIC Spray Gun 95
14.2.1 GA 5000EAC – Adapter 98
14.3 GA 5000EACEC Spray Gun 100
14.4 Accessories Spare Parts Lists 102
14.4.1 Flat Jet Nozzles 102
14.4.2 ACR 5000 Round Jet Nozzle Attachment 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 5000EAC
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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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GA 5000EAC
OPERATING MANUAL
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1.3 LANGUAGES
1.4 ABBREVIATIONS
Order No. Order number
Spare part
Marking in the spare parts lists
Automatic gun
C Electrostatics Air Coat
Shaping and atomizing air controlled via valve within gun
Shaping and atomizing air controlled via valve outside of gun
Low R Low-resistance
Stainless steel
Position
Number of pieces
Wrench size
The GA 5000EAC operating manual is available in the following languages:
Language Order No. Language Order No.
German 2360921 English 2360922
French 2367694 Italian 2367695
Spanish 2367696
Additional languages on request or at:

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GA 5000EAC
OPERATING MANUAL
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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 5000EAC
OPERATING MANUAL
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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 5000EAC 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 5000EAC 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.

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2.5 PROCESSIBLE WORKING MATERIALS
Lacquers which contain ingredients of explosion class IIA and IIB substances (maximum
ignition energy 0.24 mJ) can be processed with the GA 5000EAC spray gun.
The spray gun basic 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).
The application eectiveness 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 specic paint resistance.
Multiplying the result of the measurement with the device-specic cell constant (K), we
obtain the specic 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
Specic resistance (RS)
Note:
Using sprayed substances with too low an electrical resistance, the application of
electrostatics does not show any eect, 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
No wrap-around
Pleasecontact yourlocalWAGNERdealerandthelacquermanufacturerifyouencounter
application problems.

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2.6 REASONABLY FORESEEABLE MISUSE
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be ruled out even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk Source Consequences Specic measures Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Handling of
lacquers and
cleaning agents
Skin irritations, Wear protective
clothing
Operation,
allergies maintenance,
Observe safety data
sheets
disassembly
Lacquer in air
outside the dened
working area
Lacquering outside
the dened working
area
Inhalation of
substances
hazardous to health
Observe work and
operation instructions
Operation,
maintenance
The forms of misuse listed below may result in physical injury or property damage:
use with non-authorized control units;
coating work pieces which are not grounded;
working with an ungrounded lacquer supply system;
performing unauthorized conversions or modications to the device;
processing inadmissible coating products;
processing dry or similar coating products, e.g., powder;
using defective components, spare parts or accessories other than those described in
the "Accessories" chapter of this operating manual;
continuing work with a defective or kinked product hose;
working with incorrectly set values;
processing food.

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GA 5000EAC
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3 IDENTIFICATION
3.1 CE EXPLOSION PROTECTION IDENTIFICATION
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
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device type: GA 5000EAC electrostatic automatic spray gun
Manufacturer: Wagner International AG
CH-9450 Altstätten, Switzerland
II 2 G 0.24mJ X
SIRA 16 ATEX5290X
European Communities
Notied body: PTB
Explosion-proof equipment
Device class II (not mining)
Category 2 device (suitable for zone 1)
Ex-atmosphere gas
Maximum ignition energy
X Special Notes (see Chapter 3.2)
SIRA 16 ATEX 5290X Number of type examination certicate
3.2 SPECIAL NOTICE "X"
Cable connections
Only cable assigned to the device may be used (see Chapter 13).
Permissible Device Combinations
The GA 5000EAC automatic spray gun may only be connected to the control units listed
below:
- EPG 5000 control unit

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GA 5000EAC
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3.3 IDENTIFICATION "X" (TYPE EXAMINATION CERTIFICATE)
Note:
The EC Type Examination Certicate from SIRA covers the following:
- use of the spray gun in Zone 1;
- use of the EPG 5000 control unit as related equipment for the spray gun.
Incorrect use!
Risk of injury and damage to the device.
Connect the GA 5000EAC automatic spray gun only to original
WAGNER control units.
WARNING

15
GA 5000EAC
B_05768
GA 5000EACIC
GA 5000EACEC
Serial No.
YY-XXX
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360922
3.4 TYPE PLATE
Serial number

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GA 5000EAC
OPERATING MANUAL
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL EQUIPMENT
4.1.2 PERSONNEL QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident prevention.
Ensure that the device is only operated, maintained and repaired by trained persons.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 megohms).
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 megohms.
If protective clothing is worn, including gloves, it has to comply with EN 1149-5.
The measured insulation resistance must not exceed 100 megohms.
Paint mist extraction systems/ventilation systems must be tted on site according to
local regulations.
Ensure that the following components of a safe working environment are available:
- Product/air hoses adapted to the working pressure.
- Personal safety equipment (breathing and skin protection).
Electrical devices and equipment
To be provided 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, there is a danger from line voltage.
Mustbeoperatedinaccordancewiththesafetyregulationsandelectrotechnicalregulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard or are damaged.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Connect 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.

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GA 5000EAC
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4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.
Anyone tted with a pacemaker must not enter the high-voltage area!
4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before all work on the device, in the event of work interruptions and functional faults:
- Switch o the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
- In the event of functional faults, remedy the fault as described in the "Troubleshooting"
chapter.
If necessary or at least every 12 months,theliquid ejectiondevicesshould be checked for
safe working conditions by an expert (e.g., WAGNER Service Technician) in accordance
with the guidelines for liquid ejection devices (DGUV regulation 100-500).
- 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 paint or ushing agents:
Note the paint or ushing agent that you have been using.
Consult a doctor immediately.
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
strength and 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.

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GA 5000EAC
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4.2.3 PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products and the
used ushing agents.
Ensure that the product hose is 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 lifts), 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.
Make sure that the hoses are never used to pull or move the equipment.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coecient. In some cases their volume can rise with
consequent damage to pipes, ttings, etc. and cause uid leakage.
When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can
enter the tank. Thus a negative pressure is avoided. The vacuum could implode the tank
(squeeze) and can cause it to break. The tank would leak and the liquid would ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
4.2.2 GROUNDING THE DEVICE
Friction, owing liquids and air or electrostatic coating processes create charges. Flames or
sparks can form during discharge. Grounding prevents electrostatic charging.
Ensure that the device is grounded. See Chapter "Grounding".
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.

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GA 5000EAC
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4.2.4 CLEANING AND FLUSHING
Relieve the pressure from the device.
De-energize the device electrically.
Preference should be given to non-ammable cleaning and ushing agents.
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.
Take measures for workplace safety (see Chapter 4.1.3).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- depending on the ushing agent (solvent) used,
explosive mixture inside the lines and items 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:
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 nor even immersed into solvent.
Which cleaning agent is used to clean the spray gun depends on which parts of the
spray gun have to be cleaned and which product has to be removed.When cleaning the
spray gun, only use non-polar cleaning agents to prevent conductive residues on the
surface of the spray gun. Should it however, be necessary to use a polar cleaning agent,
all residues of this cleaning agent have to be removed by using a non-conductive and
non-polar cleaning agent, once the cleaning is nished.

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GA 5000EAC
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4.2.6 TOUCHING HOT SURFACES
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C; 109.4 °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.
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
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 skin 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.
4.3 PROTECTIVE AND MONITORING EQUIPMENT
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.