WAGNER GA 5000EACIC, GA 5000EACEC Operating Manual

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Translation of the Original Operating Manual

GA 5000EACIC GA 5000EACEC

Version 09/2016

Electrostatic Air Spray Gun

for automatic operation for  at or round jet nozzles

B_05738

II 2 G 0.24mJ X

VERSION 09/2016 ORDER NUMBER DOC2360922

GA 5000EAC

OPERATING MANUAL

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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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

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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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 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.

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

Note - provides information about particular characteristics and how to proceed.

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1.3 LANGUAGES

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:

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

GA 5000EAC

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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

Electrician Can assess the work assigned to him/her and detect possible

Skilled person in the context of DGUV209-052

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.

hazards based on his/her technical training, knowledge and experience in relevant provisions.

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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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!

2.3 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)

2.4 SAFETY PARAMETERS

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

Please contact your local WAGNER dealer and the lacquer manufacturer if you encounter

application problems.

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2.6 REASONABLY FORESEEABLE MISUSE

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.

GA 5000EAC

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

Lacquer in air outside the de ned working area

Handling of lacquers and cleaning agents

Lacquering outside the de ned working area

Skin irritations, Wear protective allergies maintenance,

Inhalation of substances hazardous to health

clothing Observe safety data

sheets Observe work and

operation instructions

Operation,

disassembly

Operation, maintenance

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3 IDENTIFICATION

3.1 CE 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: 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"

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

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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WARNING

Incorrect use!

Risk of injury and damage to the device.

Connect the GA 5000EAC automatic spray gun only to original

WAGNER control units.

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.

GA 5000EAC

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3.4 TYPE PLATE

GA 5000EACIC

GA 5000EAC

B_05768

Serial No.

YY-XXX

GA 5000EACEC

Serial number

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4 GENERAL 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 EQUIPMENT

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. Must be operated in accordance with the safety regulations and electrotechnical regulations. 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.

GA 5000EAC

4.1.2 PERSONNEL QUALIFICATIONS

Ensure that the device is only operated, maintained and repaired by trained persons.

4.1.3 SAFE WORK ENVIRONMENT

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).

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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.

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!

GA 5000EAC

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, the liquid ejection devices should 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.

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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.

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.

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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.

GA 5000EAC

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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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.

4.2.6 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.

GA 5000EAC

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.

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4.4 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS

The spray gun may be used in potentially explosive areas. The following safety regulations must be observed and followed.

4.4.1 SAFETY REGULATIONS

Observe safety instructions in Chapter 3.2.

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.

Surface spraying, electrostatics

Never spray device parts using electrostatic equipment (electrostatic spray gun!).

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. Use only a damp cloth to clean the device.

4.5 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 o the high voltage without a key.

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4.6 SAFETYRELEVANT INFORMATION ABOUT DISCHARGES

The plastic parts of the spray gun are charged electrostatically by the high-voltage  eld of the spray gun. 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 inches between spray gun and object to be sprayed, the corona discharge at the end of the electrode is visible in the dark.

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5 DESCRIPTION

5.1 STRUCTURE STANDARD VARIANT

5.1.1 GA 5000EACIC DESIGN

GA 5000EAC

B_05739

1 Front cover 2 Union nut with nozzle protection 3 Air cap 4 Flat jet nozzle 5 Gun adapter 6 Piston housing 7 Rear cover 8 Air di user housing

Connections on the rear side:

9 Shaping air setting 10 Gun holder 11 Product hose 12 Sealing  tting 13 Nozzle screw joint 14 Nozzle attachment 15 Round jet nozzle

1 Connection closed with dummy plug

2 Product connection NPSM 1/4"

3 Control air connection (D6/red)

4 Gun cable connection

5 Shaping air or atomizing air connection (D10/blue)

B_05740

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5.1.2 GA 5000EACEC DESIGN

B_05740

GA 5000EAC

1 Front cover 2 Union nut with nozzle protection 3 Air cap 4 Flat jet nozzle 5 Gun adapter 6 Piston housing 7 Rear cover

Connections on the rear side:

B_05742

8 Air di user housing

9 Gun holder 10 Product hose 11 Sealing  tting 12 Nozzle screw joint 13 Nozzle attachment 14 Round jet nozzle

1 Atomizing air connection (D10/blue) 2 Product connection, G1/4" 3 Control air connection (D6/red) 4 Gun cable connection 5 Shaping air connection (D8/green)

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5.2 MODE OF OPERATION

Note:

Operation of the spray gun in conjunction with the EPG 5000 control unit is described in this operating manual.

➞ The high voltage for the GA 5000EAC spray gun is activated directly on the EPG5000

control unit or by a signal from the superordinate controller.

➞ The high voltage for the spray gun can be adapted via the voltage regulator on the

EPG 5000 control unit and can be adjusted to the paint or to the spraying object.

➞ Secure gun:

1. Switch o the mains at the EPG 5000

2. Switch o the air supply at the EPG 5000

3. Relieve the pressure of the spray gun and system

5.2.1 GA 5000EACIC MODE OF OPERATION

Pneumatic diagram:

SA = Shaping air AA = Atomizing air CA = Control air M = Product

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 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.

AA / SA

B_06007

Nozzle

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5.2.2 GA 5000EACEC MODE OF OPERATION

Pneumatic diagram:

SA = Shaping air AA = Atomizing air CA = Control air M = Product

Open:

First, the external air valve, which enables the shaping and atomizing air, is opened. The diaphragm in the drive is then charged with control air and moves toward the rear, opening the product valve. In this position, the pressurized coating product is applied to the work piece.

CA SA

B_06008

Nozzle

SA AA

Close:

If the control air is deactivated, the product valve closes due to the pressure spring. The air valve is then closed externally.

Additional functions:

The shaping air pressure and the atomizing air pressure are set externally via separate pressure regulators. Both air  ows are supplied separately, which allows them to be set separately.

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5.3 PROTECTIVE AND MONITORING EQUIPMENT

The following functions are provided for safety:

- Electrical monitoring of high voltage and spray current (maximum ignition energy 0.24 mJ) No ignition danger and personnel danger

- Electrical monitoring of the spray gun

- Anti-contact guard for  at jet nozzle

WARNING

Protective and monitoring equipment!

Risk of injury and damage to the device.

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.

5.4 SCOPE OF DELIVERY

Order No. Description

2360898 GA 5000EACIC spray gun 2360899 GA 5000EACEC spray gun

The spray guns are delivered without control unit, product and air hose, electric cable, air cap and nozzle.

Each spray gun includes the following as standard equipment:

Order No. Description

2309368 Valve needle assembly tool 2325263 Clamping screw assembly tool 2360925 Declaration of Conformity for ES 5000 Automatic 2360921 Operating manual German

see Chapter 1.3 Operating manual in local language

The spray gun basic version can be adapted optimally to any application depending upon the requirements and the desired accessories with the help of spray gun con guration.

The delivery note shows the exact scope of delivery.

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5.5 TECHNICAL DATA

Control air pressure (open product valve) 0.4–0.8 MPa; 4–8 bar; 58–116 psi Maximum atomizing air pressure 8 bar; 0.8 MPa; 116 psi Maximum shaping air pressure 0.8 MPa; 8 bar; 116 psi Maximum product pressure 250 bar; 25 MPa; 3626 psi Input voltage maximum 20 Vpp Input current maximum 1.0 A AC Maximum output voltage 80 kV Maximum output current 100 µA Polarity Negative Maximum discharge energy 0.24 mJ Product connection NPSM 1/4"-18 Atomizer air connection D10 Shaping air connection (only for GA 5000EACEC) D8 Control air connection D6 Weight (without houses) 1.0 kg; 2.2 lb

Flow rate

Ambient temperature 0 °C - 40 °C; 32 °F - 104 °F Maximum product temperature 50 °C; 122 °F Maximum surface temperature 85 °C; 185 °F

Compressed air quality: free from oil and water

Sound level at 0.3 MPa; 3 bar; 43.5 psi air pressure and 0.3 MPa; 3 bar; 43.5 psi product pressure *

* A-rated sound pressure level measured at 1 m distance, LpA1m, in accordance with DIN EN 14462: 2005.

according to nozzle size (see nozzle table in "Accessories" chapter)

Quality standard 6.5.2 according to ISO 8573.1, 2010 6: Particle density ≤ 5mg/m 5: Humidity: pressure dew point ≤ +7°C 2: Oil content ≤ 0.1mg/m

76 dB(A)

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5.5.1 GA 5000EAC DIMENSIONS

GA 5000EAC with  at jet nozzle

GA 5000EAC

291

GA 5000EAC with round jet nozzle

274

135

B_05748

Connecting dimensions of the connection plate:

B_05761

4x ∅ 3.2

18 18

2x M5

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5.6 THE WAGNER ELECTROSTATIC AIRCOAT SPRAYING SYSTEM

The nozzle range (chapter 13) provided by WAGNER allows optimum coating results for any application.

General criteria for selection of nozzles

Flat jet Round jet for smaller delicate parts

Options for in uencing the jet spray / spray pattern:

Description Modi cation Product pressure

Atomizing air pressure + or -

Shaping air regulation from open to closed

for large-surface parts

+ or -

Nozzle sizes

Flow rate

Electrostatics + or - or o

The spray jet width by GA 5000EACIC spray gun is adjusted via the shaping air regulation (A) on the gun and on the GA 5000EACEC spray gun via the air control knob (B) on the EPG 5000 control unit in the case of  at jet spraying.

GA 5000EACECGA 5000EACIC

Atomizing air

Zerstäuberluft

B_05769

Fan air

Formluft

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5.6.1 SPRAYING PROCEDURE FOR AIRCOAT ROUND JET

In the AirCoat process, the spray product is atomized under a pressure of 3-15 MPa; 30-150 bar; 435-2176 psi. With the help of an air pressure of 0-0.25 MPa; 0-2.5 bar; 0-36 psi, a soft, spray jet is produced. The spray jet diameter can be adjusted by turning the nozzle nut.

AirCoat air

Advantages

- Large application volume

- Low fogging tendency

- Good  nish

- High viscosity products can easily be applied

- High endurance of the nozzles

- Jet width adjustment

Spray product

AirCoat air

"?

Multi-channel swirl nozzle

Nozzle nut

5.6.2 SPRAYING PROCEDURE FOR AIRCOAT FLAT JET

In the AirCoat process, the spray product is atomized under a pressure of 3-15 MPa; 30-150 bar; 435-2176 psi With the help of the AirCoat air, with a pressure of 0-0.25 MPa; 0-2.5 bar; 0-36 psi, a soft,  at spray jet is produced which largely eliminates the problem of overlapping in the peripheral zones. With shaping air, there is the possibility of reducing the width of the spray jet.

Shaping air

Advantages

- Large application volume

- Low fogging tendency

- Good  nish

- High viscosity products can easily be applied

- High endurance of the nozzles

- Jet width adjustment

Variable spray jet width

Spray jet

Air cap

Atomizing air

B_00020

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5.6.3 ELECTROSTATIC EFFECT

The spray gun produces an electrostatic  eld by means of the high-voltage electrode. As a result, the paint particles atomized by the spray gun are carried to the grounded work piece by kinetic and electrostatic energy, where they adhere  nely dispersed to the object to be sprayed.

Paint particle

Object to be sprayed is grounded

Advantages

- Very high application e ectiveness

- Low over spray

- Coating of entire circumferences due to the electrostatic e ect

- Savings in working time

Electrode

"?

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6 ASSEMBLY AND COMMISSIONING

6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF

WARNING

Incorrect installation/operation!

Risk of injury and damage to the device.

The assembly and commissioning sta must have the technical

skills to safely commission the device. When assembling, commissioning and carrying out all work,

read and follow the operating manuals and safety regulations

for the additionally required system components.

GA 5000EAC

A skilled person must check to ensure that the device is in a reliable state after it is installed and commissioned.

6.2 STORAGE CONDITIONS

Until the point of assembly, the device must be stored in a dry location, free from vibrations and with a minimum of dust. The device must be stored in closed rooms.

The air temperature at the storage location must be between -20 °C and +60 °C (-4 °F and +140 °F).

The relative air humidity at the storage location must be between 10 and 95% (without condensation).

6.3 INSTALLATION CONDITIONS

The air temperature at the installation site must be in a range between 0 °C and 40 °C; 32 °F and 132 °F.

The relative air humidity at the installation site must be between 10 and 95% (without condensation).

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6.4 ASSEMBLY AND INSTALLATION

6.4.1 TYPICAL ELECTROSTATIC SPRAYING SYSTEM

The GA 5000EAC spray gun must be combined with various components to make up a spraying system. The system shown in the  gure is only one example of an electrostatic AirCoat spraying system. Your WAGNER distributor would be happy to assist you in creating a spraying system solution that meets your individual needs. You must familiarize yourself with the operating manuals and the safety regulations of all additional system components before starting commissioning.

WARNING

Incorrect installation/operation!

Risk of injury and damage to the device.

When commissioning and for all work, read and follow the

operating manual and safety regulations for the additionally

required system components.

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GA 5000EAC

B_05775

A Spray booth

B Controller C Reciprocator

D Electrostatic spray gun

E Work piece

f Conveyor

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6.4.2 CONNECTING GA 5000EACIC

WARNING

Incorrect installation/operation!

Risk of injury and damage to the device.

When commissioning and for all work, read and follow the

operating manual and safety regulations for the additionally

required system components.

Procedure:

1. Place the control unit outside the explosion zone.

2. Mount spray gun to an grounded gun mounting.

3. Connect the grounding cable to the control unit and the signal ground.

4. Connect the gun connection cable to the control unit.

5. Connect the control unit to the higher-level controller (if available).

6. Connect the air hoses to the control unit and the spray gun in accordance with the  gure below.

7. Set all airs to "0" using the regulator on the front side of the control unit.

8. Connect the control unit to the compressed air supply.

9. Connect the spray gun to the product supply system.

10. Connect the control unit to the power supply.

GA 5000EAC

GA 5000

1 5

II (2) G

0102

2359451

115VAC - 230VAC 50Hz / 60Hz

max. 40W

max. 0.5A IP 40 EN 50176:2009

EN 50050-1:2013

EPG 5000

Main Switch

Hauptschalter

Prim. Fuse

Sicherung

1.0 AT

Mains power IN

Netz Eingang

Spraygun

Sprühpistole

Umax. = 20Vpp Imax. = 1.0A

Interface

Schnittstelle

IN CAN Bus OUT

Data and Interlock

Daten und Verriegelung

CAN

Address

Service

Port

Air input

Atomizing air

Lufteingang

Zerstäuberluft

SIRA 16 ATEX 5290X

Wagner International AG Industriestrasse 22 CH - 9450 Altstätten Made in Switzerland

Typ / Type: EPG 5000 Artikel Nr.: Article No.: Serie Nr.: Serial No.:

Fan air

Control air

Steuerluft

Air input 6 - 8bar 87-116 psi Clean and dry air

Saubere und trockene Luft

6.5.2 (ISO 8573-1:2010)

Restrictor for air during cleaning

Drossel für Luft während dem Spülen

Formluft

B_05743

Baujahr: Year of manufacture: Spannung: Voltage: Eingangsleistung: Input Power: Eingangsstrom: Input Current: Schutzart: IP Code: Norm: Standard:

6 7

1 for the product supply system 4 Gun cable 7 Grounding cable 2 Shaping air and atomizing air hose 5 for the compressed air supply 8 Mains cable 3 Control air hose 6 Control cable

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6.4.3 CONNECTING GA 5000EACEC

WARNING

Incorrect installation/operation!

Risk of injury and damage to the device.

When commissioning and for all work, read and follow the

operating manual and safety regulations for the additionally required system components.

Procedure:

1. Place the control unit outside the explosion zone.

2. Mount spray gun to an grounded gun mounting.

3. Connect the grounding cable to the control unit and the signal ground.

4. Connect the gun connection cable to the control unit.

5. Connect the control unit to the higher-level controller (if available).

6. Connect the air hoses to the control unit and the spray gun in accordance with the  gure below.

7. Set all airs to "0" using the regulator on the front side of the control unit.

8. Connect the control unit to the compressed air supply.

9. Connect the spray gun to the product supply system.

10. Connect the control unit to the power supply.

GA 5000EAC

GA 5000

1 6

II (2) G

0102

2359451

115VAC - 230VAC 50Hz / 60Hz

max. 40W

max. 0.5A IP 40 EN 50176:2009

EN 50050-1:2013

EPG 5000

Main Switch

Hauptschalter

Prim. Fuse

Sicherung

1.0 AT

Mains power IN

Netz Eingang

Spraygun

Sprühpistole

Umax. = 20Vpp Imax. = 1.0A

Interface

Schnittstelle

IN CAN Bus OUT

Data and Interlock

Daten und Verriegelung

CAN

Address

Service

Port

Air input

Atomizing air

Lufteingang

Zerstäuberluft

SIRA 16 ATEX 5290X

Wagner International AG Industriestrasse 22 CH - 9450 Altstätten Made in Switzerland

Typ / Type: EPG 5000 Artikel Nr.: Article No.: Serie Nr.: Serial No.:

Fan air

Control air

Steuerluft

Air input 6 - 8bar 87-116 psi Clean and dry air

Saubere und trockene Luft

6.5.2 (ISO 8573-1:2010)

Restrictor for air during cleaning

Drossel für Luft während dem Spülen

Formluft

B_05727

Baujahr: Year of manufacture: Spannung: Voltage: Eingangsleistung: Input Power: Eingangsstrom: Input Current: Schutzart: IP Code: Norm: Standard:

7 8

1 for the product supply system 4 Control air hose 7 Control cable 2 Shaping air hose 5 Gun cable 8 Grounding cable 3 Atomizing air hose 6 for the compressed air supply 9 Mains cable

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6.4.4 VENTILATION OF THE SPRAY BOOTH

The electrostatic spraying equipment may only be operated in de ned spraying areas and in accordance with the EN 12215 standard or under comparable ventilation conditions. The electrostatic spraying equipment must be locked to the technical ventilation so that the coating product supply and the high voltage are not e ective as long as the technical ventilation is not operated with the minimum exhaust air volume  ow or a larger exhaust air volume  ow. Ensure that the excess coating product (overspray) will be collected up safely.

WARNING

Toxic and/or  ammable vapor mixtures!

Risk of poisoning and burns.

Operate the device in a spray booth approved for the working

materials.

-or Operate the device on an appropriate spraying wall with the

ventilation (extraction) switched on.

Observe national and local regulations for the exhaust air speed.

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6.4.5 AIR SUPPLY

The use of an air  lter with air regulator ensures that only dry, clean atomizing air gets into the spray gun. Dirt and moisture in the atomizing air worsens the spraying quality and spray pattern.

WARNING

Hose connections!

Risk of injury and damage to the device.

Do not exchange hose connections of product hose and air hose.

6.4.6 PRODUCT SUPPLY

NOTICE

Impurities in the spraying system!

Spray gun blockage, products harden in the spraying system.

Flush the spray gun and paint supply with a suitable  ushing agent.

DANGER

Bursting hose, bursting threaded joints!

Danger to life from injection of product.

Ensure that the hose material is chemically resistant to the

sprayed products.

Ensure that the spray gun, threaded joints and product hose

between the device and the spray gun are suitable for the pressure generated in the device.

Ensure that the following information can be seen on the high-

pressure hose:

- Manufacturer

- Permissible operating pressure

- Date of manufacture.

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6.4.7 GROUNDING

Perfect grounding of all conductive parts such as  oors, walls, roofs, barriers, work pieces, transport devices, coating product tank, coating product supply or construction parts in the spray area with exception of the high-voltage parts during normal operation is important for optimum coating and safety. Parts of the booth must be grounded in accordance with EN 12215.

WARNING

Discharge of electrostatically charged components in atmospheres containing solvents!

Explosion hazard from electrostatic sparks or  ames.

Ground all device components. Ground the work pieces to be coated.

WARNING

Heavy paint mist if grounding is insu cient!

Danger of poisoning. Insu cient paint application quality.

Ground all device components. Ground the work pieces to be coated.

A poorly grounded work piece causes:

- very bad wrap around,

- uneven coating,

- back spraying to the spray gun (contamination) and coater.

Prerequisites for perfect grounding and coating are:

- Clean work piece suspension.

- Grounding of spray booth, conveyor system and suspension on the building side in accordance with the operating manuals or the manufacturer's information.

- Grounding of all conductive parts within the working area.

- The grounding resistance of the work piece must not exceed 1 MΩ (megohm). (Resistance to ground measured at 500 V or 1000 V).

- Connect the control unit to the signal ground.

- Mount spray gun to an grounded gun mounting.

- Connect all ground cables using a short and direct route.

- Safety shoes must be static dissipative.

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Grounding scheme (example)

Control unit

Grounding cable

Pump

GA 5000EAC

Conveyor

Work piece

Paint tank

B_00137

Minimum cable cross-section

Control unit 4 mm² (AWG 12) Pump 4 mm² (AWG 12) Paint tank 4 mm² (AWG 12) Reciprocator 16 mm² (AWG 6) Conveyor 16 mm² (AWG 6) Booth 16 mm² (AWG 6) Spraying stand 16 mm² (AWG 6)

Signal ground Signal ground

Floor, static dissipative

Spraying stand

Rmax < 1MΩ

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6.5 PREPARATION OF LACQUER

The viscosity of the lacquer is of great importance. The best spraying results are obtained with values between 25 and 40 DIN/4 seconds (measured in immersion  ow cup DIN 4 mm;

0.16 inches). Processing of up to 60 DIN/4 seconds is generally possible without problem if high coating

thicknesses are required. With the WAGNER AirCoat  at jet spraying process, the di erent viscosities of the lacquer

are optimally covered by two air cap types. These can be found in "Accessories". In the case of application problems contact the lacquer manufacturer.

6.5.1 VISCOSITY CONVERSION TABLE

mPa s

10 10 0.1 5 16 15 15 0.15 8 17 20 20 0.2 10 18 25 25 0.25 14 12 19 30 30 0.3 15 14 20 40 40 0.4 17 18 22 50 50 0.5 19 22 24 60 60 0.6 21 26 27 70 70 0.7 23 28 30 80 80 0.8 25 31 34

90 90 0.9 28 32 37 100 100 1 30 34 41 120 120 1.2 33 41 49 140 140 1.4 37 45 58 160 160 1.6 43 50 66 180 180 1.8 46 54 74 200 200 2 49 58 82 220 220 2.2 52 62 240 240 2.4 56 65 260 260 2.6 62 68 280 280 2.8 65 70 300 300 3 70 74 320 320 3.2 340 340 3.4 360 360 3.6 80 380 380 3.8 400 400 4 90

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6.6 COMMISSIONING

6.6.1 SAFETY INSTRUCTIONS

Observe the safety instructions in Chapter 4 and Chapter 7.2. Observe the general rules for making adjustments to the spray gun Chapter 7.2.2.

6.6.2 PREPARATION FOR COMMISSIONING

NOTICE

Impurities in the spraying system!

Spray gun blockage.

Flush the spray gun and paint supply with a suitable  ushing agent before

commissioning.

GA 5000EAC

6.6.3 COMMISSIONING

The following points should be noted before commissioning:

Make sure that all other conductive parts within the work area are grounded. Lock the external release with the exhaust air unit. Lock the external release with an appropriate tool (e.g., key switch) (the high-voltage

supply must be secured to prevent unauthorized persons from switching it on). Check that all product-conveying connections are correctly connected. Check that all air-conveying connections are correctly connected. Visually check the permissible pressures for all the system components. Check the level of the separating agent in the pump and  ll up if necessary. Provide product tank, tanks for  ushing agent and an empty tank for return  ow. The interface on the rear of the control unit must be protected with a cover. Connect the system to the air supply. When  rst commissioning the unit Flush the system in accordance with the operating

manuals for the other components.

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6.7 VERIFYING A SAFE OPERATIONAL CONDITION

A skilled person must check to ensure that the device and the spraying system are in a safe state after they are installed and commissioned.

This includes: – Carry out a safety checks in accordance with Chapter 8.2.3. – Function test in accordance with Chapter 11.

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7 OPERATION

7.1 TRAINING THE OPERATING STAFF

WARNING

Incorrect operation!

Risk of injury and damage to the device.

The operating sta must be quali ed to operate the entire

system.

The operating sta must be familiar with the potential risks

associated with improper behavior as well as the necessary protective devices and measures.

Before work commences, the operating sta must receive

appropriate system training.

GA 5000EAC

7.2 SAFETY INSTRUCTIONS

Observe safety instructions in Chapter 4.

WARNING

Incorrect operation!

Risk of injury and damage to the device.

If contact with lacquers or cleaning agents causes skin irritation,

appropriate precautionary measures must be taken, e.g., wearing protective clothing.

The footwear worn by operating sta must comply with

EN ISO 20344. The measured insulation resistance must not exceed 100megohms.

The protective clothing, including gloves, must comply with

EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.

WARNING

Unintentional putting into operation!

Risk of injury.

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 unit. Secure the spray gun against actuation. In the event of functional faults: remedy the fault as described in

the "Troubleshooting" chapter.

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GA 5000EAC

WARNING

Discharge of electrostatically charged components in atmospheres containing solvents!

Explosion hazard from electrostatic spark-over.

Use gun only with  tted nozzle, air cap and union nut. Tighten the union nut, especially with nozzle in the cleaning

position.

7.2.1 EMERGENCY DEACTIVATION

In the case of unforeseen occurrences, proceed as follows:

1. Switch o control unit.

2. Close the compressed air supply.

3. Relieve pressure according to the operating manual of the product pressure generator.

7.2.2 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN

DANGER

High-voltage  eld!

Danger to life from malfunction of heart pacemakers.

Make sure that persons with pacemakers:

Do not work with the electrostatic spray gun. Do not enter the high-voltage area.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent.

Never reach into the spray jet. Never point the spray gun at people. Consult a doctor immediately in the event of skin injuries caused

by paint or solvent. Inform the doctor about the paint or solvent used. Never seal defective high-pressure parts; instead relieve the pressure from them and replace them immediately.

Wear the appropriate protective clothing, gloves, eyewear and

respiratory protection.

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GA 5000EAC

7.3 WORKING

7.3.1 SETTING THE SPRAY PATTERN USING THE AIR PRESSURE REGULATOR

The air pressure regulator regulates the air supply (shaping and atomizing air) to the gun.

B_00071

No air Correct amount of airNot enough air

Spray pattern and air regulation

When IC variant the air regulation regulates the ratio of shaping/atomizing air. When IC variant the shaping and atomizing air are set individually. The spray pattern can then be adjusted to suit the object being sprayed. The illustration shows the in uence of the regulator on the spray pattern. Other nozzle sizes can be used to obtain larger or smaller spray patterns.

Air regulation fully opened

= maximum shaping air

Changing the Flow Rate

Adapt product pressure Use a di erent nozzle (see Chapter 13)

Changing the Spray Jet Width

Use a di erent nozzle (see Chapter 13)

B_05762

Air regulation closed

= minimum shaping air

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7.3.2 SPRAYING

1. Secure gun (switch o controller) and insert the desired nozzle.

2. Turn on the control unit.

3. Start up with product supply set to approx. 8 MPa; 80 bar; 1160 psi operating pressure. See corresponding operating manual.

AirLess spraying

4. Turn both air pressure regulators at the control unit all the way down.

5. Spray on a test object (switch on the controller).

6. Adjust the product pressure and gun air in accordance with the nozzle and object.

AirCoat spraying

7. When IC variant open the air pressure regulator (approx. 0.05–0.25 MPa; 0.5–2.5 bar;

7–36 psi) and adjust for optimal atomization. When EC variant set shaping and atomizing air on the pressure regulators.

Flat-jet method: Changing the spray jet width

8. Change the spray jet width by selecting the appropriate nozzle. By turning the air regulation (1), the spray jet can additionally be adjusted

(IC variant). Increase or decrease shaping air (EC variant)

See corresponding operating manual.

Round-jet method

8. By gently turning the nozzle nut (2), the atomizing air jet can additionally be adjusted.

Do not fully tighten the nozzle nut:

Do not turn the nozzle nut (2) until it is  ush with the nozzle body (3). There must be play for the atomizing air between the nozzle nut and the nozzle body.

Flow rate

9. The  ow rate can be reduced by:

- Minimizing the product pressure.

- Use a di erent nozzle (see Chapter 13).

B_05776

B_05777

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7.3.3 PRESSURE RELIEF/WORK INTERRUPTION

The pressure must always be relieved when:

- The spraying tasks are  nished.

- The spraying system is maintained.

- Cleaning tasks are carried out on the spraying system.

- The spraying system is moved to another location.

- Something must be checked on the spraying system.

- The valve seat is replaced on the gun.

Observe general safety instructions in Chapter 4.

WARNING

High-pressure spray jet!

Danger to life from injecting paint or solvent.

GA 5000EAC

Never reach into the spray jet. Never point the spray gun at people. Consult a doctor immediately in the event of skin injuries caused

by paint or solvent. Inform the doctor about the paint or solvent used.

Never seal defective high-pressure parts; instead relieve the pressure

from them and replace them.

Wear the appropriate protective clothing, gloves, eyewear and

respiratory protection.

Process for relieving pressure

1. Switch o high voltage at the control unit.

2. Turn compressed air supply for shaping and atomizing air on the EPG 5000 to "0".

3. Close the compressed air supply on the material side upon the product pressure generator.

4. Relieve the pressure of gun and system, e.g., by switching on gun without high voltage.

5. Filling  ushing agent.

6. Thoroughly  ush out the spray gun.

7. Relieve the pressure on the gun and the system.

8. Clean gun and dry it with a cloth or a blow gun.

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7.3.4 DISMANTLING THE GUN COVER

Note:

For changing nozzles, the cover does not have to be removed!

1. Press the snap  t (2) together and pull o the rear cover (1) to the back.

2. Unscrew union nut (3) and pull o front cover (4) to the front.

GA 5000EAC

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OPERATING MANUAL

7.3.5 FLUSHING OUT CLOGGED ROUND JET NOZZLES

DANGER

Exploding gas / air mixture!

Danger to life from  ying parts and burns.

Never spray into a closed tank. Ground the tank.

1. Remove nozzle insert (1) completely using nozzle spanner (2).

2. Actuate spray gun brie y.

3. Blow out and clean nozzle opposite the spraying direction.

4. After  ushing, re-tighten the nozzle insert.

GA 5000EAC

1/2

7.3.6 REPLACING ROUND JET NOZZLE'S NOZZLE INSERT

1. Remove nozzle insert (1) using nozzle spanner (2).

2. Assembling new nozzle insert.

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B_05773

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OPERATING MANUAL

7.3.7 CHANGING FROM AIRCOAT ROUND JET TO AIRCOAT FLAT JET

Flush spray gun

1. Switch o control unit.

2. Relieve pressure

3. Connect the system to the  ushing agent supply.

4. Set product pressure. Close air pressure regulator.

5. Thoroughly  ush out the spray gun.

6. Relieve pressure

Changing from round jet to  at jet

7. Unscrew round jet nozzle attachment (2) incl. nozzle insert (3).

8. Unscrew nozzle insert (3) using nozzle spanner (4).

9. Unscrew nozzle nut (5). Remove nozzle screw joint (7) and sealing  tting (8) from the nozzle body (6). Thoroughly clean all parts.

10. Insert desired ACF5000 nozzle (11) into the valve housing.

11. Put the air cap (10) on the nozzle (11) and pay attention to the position of the guide surfaces.

12. Screw union nut with attached nozzle guard (9) to the gun body and make sure that the air cap horns lie in the designated recess (Y).

13. Before tightening with the air cap horns (Y), set the desired jet level and then tighten the union nut to stop by hand.

Chapter 7.3.3.

Changing from  at jet to round jet

7. Unscrew union nut (9) with air cap (10) and ACF5000 nozzle (11).

8. Remove air cap (10).

9. Press ACF5000 nozzle (11) out of air cap (10) by hand. Thoroughly clean all parts.

10. Insert nozzle screw connection (7) and sealing  tting (8) into nozzle body (6).

11. Screw nozzle nut (5) onto nozzle body (6). Do not screw on nozzle nut completely. There must be play for the atomizing air

between the nozzle nut and the nozzle body.

12. Screw on nozzle insert (3) using nozzle spanner (4).

13. Screw round jet nozzle attachment (2) with nozzle insert (3) onto spray gun and tighten by hand.

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GA 5000EAC

B_05754

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OPERATING MANUAL

7.3.8 REPLACING THE AIRCOAT FLAT JET NOZZLES

1. Switch o control unit.

2. Unscrew union nut completely (12) and remove air cap (10).

3. Remove and clean the ACF 5000 AirCoat nozzle (11).

NOTICE

Defective AirCoat nozzle!

Insu cient paint application quality.

Do not use sharp-edged objects to treat carbide on the AirCoat nozzle.

4. Insert new ACF5000 nozzle (11) into the valve housing.

5. Put the air cap (10) on the nozzle (11) and pay attention to the position of the guide surfaces.

6. Screw union nut with attached nozzle guard (9) to the gun body and make sure that the air cap horns lie in the designated recess (Y).

7. Before tightening with the air cap horns (Y), set the desired jet level and then tighten the union nut to stop by hand.

B_05755

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GA 5000EAC

7.3.9 CLEANING OF THE NOZZLE PARTS

The nozzle parts may only be immersed into a cleaning solvent recommended by the manufacturer and must be removed again immediately. They may only remain in a cleaning solvent for a short time. Clean these parts with a brush and dry them with a cloth or a blow gun.

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GA 5000EAC

OPERATING MANUAL

7.3.10 ELIMINATE NOZZLE CLOGGING

1. Switch control unit to standby operation.

2. Unscrew union nut completely (12) and remove air cap (10).

3. Push ACF 5000 nozzle (11) out of air cap (10) by hand, reverse it and put it into the air cap (10) with the nozzle tip towards the rear.

Pay attention to the position of the guide surfaces (X).

4. Insert air cap (10) with integrated ACF5000 nozzle (11) into the union nut (9). Make sure that the air cap horns (Y) lie in the recess of the nozzle guard.

5. Screw preassembled union nut (12) to gun (1) and tighten by hand.

6. Switch on gun without high voltage and  ush gun.

7. When the blockage has been  ushed out, switch control unit back to standby operation.

8. Unscrew union nut (12) completely.

9. Remove air cap (10) and push ACF5000 nozzle (11) out of the air cap by hand. Clean ACF5000 nozzle and insert it in the spraying position into the valve housing.

10. Put the air cap (10) on the nozzle (11) and pay attention to the position of the guide surfaces (X).

11. Screw union nut with attached nozzle guard (9) to the gun body and make sure that the air cap horns lie in the designated recess (Y).

12. Before tightening with the air cap horns (Y), set the desired jet level and then tighten the union nut to stop by hand.

13. Switch control unit to the required operating mode.

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GA 5000EAC

ACF5000 nozzle in

spray position

ACF5000 nozzle in

cleaning position

B_05774

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7.3.11 CHANGING THE VALVE HOUSING

GA 5000EAC

Relieve pressure prior changing the valve housing.

Use socket or ring spanner (no wrench) to tighten the valve housing.

SW9

1.8 Nm

1.32 lb ft

Chapter 7.3.3

B_06426

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GA 5000EAC

8 CLEANING AND MAINTENANCE

8.1 CLEANING

8.1.1 CLEANING STAFF

Cleaning work should be undertaken regularly and carefully by quali ed and trained sta . They should be informed of speci c hazards during their training.

The following hazards may arise during cleaning work:

- Health hazard from inhaling solvent vapors

- Use of unsuitable cleaning tools and aids

8.1.2 SAFETY INSTRUCTIONS

Observe safety instructions in Chapter 4.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the "Spare parts"

chapter and that are assigned to the unit.

Before all work on the device and in the event of work interruptions:

- Switch o the energy supply and the 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.

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DANGER

Explosive powder/air mixes!

Danger to life and equipment damage.

Before starting cleaning, rinsing, or other manual work, the high

voltage must be shut down and locked to prevent it from being switched back on!

The spray gun must be separated from the high-voltage supply

before any cleaning work is started!

Only electrically conductive tanks may be used for cleaning and

 ushing agents. Ground the tank.

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.

Preference should be given to non- ammable cleaning and

 ushing agents. Only cleaning and  ushing agents which contain ingredients of explosion classes IIA and IIB may be used (maximum ignition energy 0.24 mJ).

The cleaning and  ushing agent's  ash point must be at least 15 K

above the ambient temperature.

Ensure that no electric component is cleaned with or immersed

into solvent.

GA 5000EAC

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GA 5000EAC

8.1.3 CLEANING AND FLUSHING THE DEVICE

The spraying system and the spray gun must be cleaned and  ushed daily. The cleaning and  ushing agents used must be compatible with the working material.

WARNING

Incompatibility of cleaning/ ushing agent and working medium!

Risk of explosion and danger of poisoning by toxic gases.

Examine the compatibility of the cleaning and  ushing agents

and working media on the basis of the safety data sheets.

NOTICE

Damage to electrical devices!

Never immerse the spray gun in cleaning agent.

NOTICE

Liquid in air tube!

Functional faults caused by swollen seals. Discharge current to ground No high voltage.

Always point the spray gun down when cleaning. Ensure that neither lacquers nor cleaning or  ushing agent enters the air duct. When taking a break from work or when stored for a longer period, the spray gun

should be positioned with the adapter pointing downwards.

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DANGER

Exploding gas / air mixture!

Danger to life from  ying parts and burns.

Never spray into a closed tank. Ground the tank.

Clean nozzle

1. Switch o control unit.

2. Dismount nozzle and clean separately Chapter 7.3.

Flush spraying system and spray gun

3. Connect spraying system to  ushing agent supply in accordance with operating manual for the product pressure generator.

4. Point the spray gun toward the collection tray and switch it on. Switch o gun as soon as clean  ushing agent emerges.

5. Remove  ushing agent supply.

Blowing out the air passages of the spray gun

6. Close pump pressure regulator. Switch on compressed air supply on the control unit, open air pressure regulator for shaping and atomizing air.

7. Actuate the spray gun without activated high voltage and thoroughly blow out the air passages.

8. For switching off the shaping and atomizing air press the "Standby" button on the control unit.

9. Switch o the compressed air supply.

Clean the outside of the spray gun

10. Clean the spray gun body and other components of the spraying system with a cleaning agent recommended by the lacquer manufacturer and dry with a cloth or blow gun.

Cleaning the nozzle parts Eliminating nozzle clogging see Chapter 7.3.10

see Chapter 7.3.9

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8.2 MAINTENANCE

8.2.1 MAINTENANCE STAFF

Maintenance work should be undertaken regularly and carefully by quali ed and trained sta . They should be informed of speci c hazards during their training.

The following hazards may arise during maintenance work:

- Health hazard from inhaling solvent vapors

- Use of unsuitable tools and aids

An authorized person must ensure that the device is checked for being in a reliable state after maintenance work is completed.

8.2.2 SAFETY INSTRUCTIONS

Observe the safety instructions in Chapter 4 and Chapter 8.1.2.

Prior to maintenance

- Flush and clean the system

After maintenance

- Carry out a safety checks in accordance with Chapter 8.2.3.

- Put the system into operation (Chapter 6.6) and check for leaks.

- Carry out a function test, if required, in accordance with Chapter 11.

In accordance with the guideline for liquid ejection devices (DGUV regulation 100-500):

- The liquid ejection devices should be checked by an expert (e.g., WAGNER service technician) for their safe working conditions as required and at least every 12 months.

- For shut down devices, the examination can be suspended until the next start-up.

Chapter 8.1.3.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Repair or replacement of devices or parts of devices are only

allowed to be performed outside the hazard area by quali ed personnel.

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DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the "Spare parts"

chapter and that are assigned to the unit.

Before all work on the device and in the event of work interruptions:

- Switch o the energy supply and the 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.

GA 5000EAC

8.2.3 SAFETY CHECKS

For the safe operation of stationary electrostatic spraying equipment for  ammable liquid coating products, intervals for periodical inspections are de ned as follows:

Inspection point Inspection interval Remarks

Gun cleaning, gun  ushing daily Chapter 4.2.4, Chapter 8.1 Hoses, tubes, couplings daily Chapter 8.2.4 Grounding weekly Chapter 4.2.2, Chapter 6.4.7 Inspection for damage weekly Chapter 8.1.3, 8.2, 10 Locking of the technical ventilation with the

electrostatic spraying equipment

The above recommended intervals are maximum values and may be modi ed by the operator depending on the local and operational conditions and the contamination.

Damaged devices must be decommissioned and repaired immediately.

annually Chapter 6.4.4

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8.2.4 PRODUCT HOSES, TUBES AND COUPLINGS

DANGER

Bursting hose, bursting threaded joints!

Danger to life from injection of product and from  ying parts.

Ensure that the hose material is chemically resistant to the

sprayed products and the used  ushing agents.

Ensure that the spray gun, threaded joints, and product hose

between the device and the spray gun are suitable for the generated pressure.

Ensure that the following information can be seen on the hose:

- Manufacturer

- Permissible operating pressure

- Date of manufacture

GA 5000EAC

The service life of the complete hoses between product pressure generator and application device is reduced due to environmental in uences even when handled correctly.

Check hoses, pipes, and couplings every day and replace if necessary. Before every commissioning, check all connections for leaks. Additionally, the operator must regularly check the complete hoses for wear and tear

as well as for damage at intervals that he/she has set. Records of these checks must be kept.

Undamaged complete hoses are to be replaced when one of the two following intervals has been exceeded:

– 6 years from the date of the hose crimping (see  tting embossing). – 10 years from the date of the hose imprinting.

Fitting embossing

(if present) xxx bar Pressure

yymm

XX Internal code

Meaning

Crimping date (year/month)

Hose imprinting Meaning

WAGNER Name/Manufacturer

yymm

xxx bar (xx MPa) e.g., 270 bar (27 MPa)

XX Internal code DNxx (e.g., DN10) Nominal diameter

Date of manufacture (year/month)

Pressure

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9 TROUBLE SHOOTING AND RECTIFICATION

Functional fault Cause Remedy

Insu cient product output Nozzle too small Select larger nozzle

(see "Accessories" chapter). Product pressure too low Increase product pressure. Product pressure generator blocked Clean or replace  lter. Nozzle is clogged Clean or replace nozzle.

Poor spray pattern Wrongly adjusted atomizing air Readjust the atomizing air.

Unfavorable nozzle size Select a di erent nozzle (see

"Accessories" chapter). Product pressure too high/too low Adapt product pressure. Spray product viscosity too high Thin product in accordance with the

manufacturer's instructions. Damaged nozzle Attach new nozzle.

Poor wrap-around Poor grounding at object Check grounding of object or hanger

with ohmmeter. Lacquer resistance too high/too low Check paint resistance (see Chapter 2.5) Spraying pressure too high Readjust spraying pressure.

No wrap-around No high voltage Switch on high voltage at the control

unit. / Repair malfunction as explained

in the control unit operating manuals.

Connect gun and gun cable/check for

defect.

Check paint resistance (see Chapter 2.5) Seal in end piece defective Repair by WAGNER Service Department. Air-passages damp Clean and dry air passages.

Back-spray Poor grounding at object Check grounding.

Distance between spray gun and object too large

High voltage set wrongly (too high) Adapt high voltage to product. Loosen the nozzle union nut for

round jet method

Valve seat leaks Valve seat or valve tip worn Replace valve seat or valve tip.

Reduce distance between spray gun

and work piece.

Tighten union nut by hand.

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10 REPAIR WORK

10.1 REPAIR STAFF

Repair work should be undertaken carefully by quali ed and trained personnel. They should be informed of speci c hazards during their training.

The following hazards may arise during repair work:

- Health hazard from inhaling solvent vapors

- Use of unsuitable tools and aids

A skilled person must check to ensure that the device is in a reliable state after it is repaired. Carry out function test in accordance with Chapter 11.

10.2 SAFETY INSTRUCTIONS

Observe the safety instructions in Chapter 4 and Chapter 8.1.2.

Before a Repair

- Flush and clean the system Chapter 8.1.3.

After a Repair

- Carry out a safety checks in accordance with Chapter 8.2.3.

- Put the system into operation (Chapter 6.7) and check for leaks.

- Function test in accordance with Chapter 11.

In accordance with the guideline for liquid ejection devices (DGUV regulation 100-500):

- The liquid ejection devices should be checked by an expert (e.g., WAGNER service technician) for their safe working conditions as required and at least every 12 months.

- For shut down devices, the examination can be suspended until the next start-up.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the "Spare parts"

chapter and that are assigned to the unit.

Before all work on the device and in the event of work interruptions:

- Switch o the energy supply and the 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.

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10.3 SPRAY GUN

Plastic parts

Gently handle all plastic parts.

10.3.1 TOOLS

For disassembling and assembling the spray gun, the following tools are required:

- Allen wrench, SW 3

- Wrench, SW 5

- Wrench, SW 7

- Wrench, SW 8

- Wrench, SW 19

- Wrench, SW 22

- Ring spanner, SW 9

- Slide gauge

- Valve needle assembly tool, Order No. 2309368

- Clamping screw assembly tool, Order No. 2325263

GA 5000EAC

Brand notice:

The brands speci ed in this document are property of the respective owners. Loctite®, for example, is a registered brand of Henkel.

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10.3.2 DISMANTLING OF THE SPRAY GUN

B_05779

GA 5000EAC

B_05780

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GA 5000EAC

SW3

SW22

SW19

Product hose:

Do not tilt, but pull it straight out in direction indicated by arrow. At the same time, execute slight rotational movements.

Fitting (25), if  tting has any leaks:

If the  tting (25) does not come out with the product hose, it must be removed from the gun adapter as follows:

- Screw the wood screw ( max. 6 mm deep.

- Pull out straight with suitable pliers. Possibly rotate clockwise simultaneously.

- Thereafter, the  tting must be replaced.

If the  tting is broken in the gun adapter, WAGNER Service Department must be contacted.

3 mm; 0.12 inches, length 40 mm; 1.6 inches) into the  tting (25),

B_05781

SW19

B_05782

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SW7

SW8

GA 5000EAC

B_05783

Unscrew the collet chuck:

When unscrewing the collet chuck, a second size 7 wrench must be used for bracing.

Carefully release the cascade without pliers

SW3

B_05784

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GA 5000EAC

Clamping screw assembly tool, Order No. 2325263

Valve needle assembly tool, Order No. 2309368

B_04786

SW9

Valve housing: Use an assembly tool or socket or ring spanner (not a wrench).

Valve tip (27) Loosen valve tip by hand using the valve needle assembly tool (Order No. 2309368).

The gold contact sleeve (10) remains in adapter (11) or sits on resistance (12). Do not lose! (The other gold contact sleeve is in the contacting (13)).

Do not pull out on contact wire.

O-ring (8):

1. Use screwdriver no. 1 to

press under the O-ring.

2. Lever up the O-ring and

remove it.

Air manifold ring (9):

1. Locate the start of the thread for recessed internal threading.

2. Lever under the air distribution ring directly in front of the start of the thread using screwdriver no. 1.

3. As soon as the ring disengages, carefully undo it on all sides.

B_04377

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B_05785

SW5

GA 5000EAC

1. Loosen clamping screw (1) with assembly tool (5).

2. Remove valve rod unit (2, 3, 4, 6).

3. Only as required: Remove rod seal (10).

Do not damage the housing in the process.

SW7

SW8

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10.3.3 CLEANING THE PARTS AFTER DISASSEMBLY

ATTENTION

Please note:

All reusable parts (except for the parts conducting high voltage such as cascade,

adapter, plug compl. etc.) should be cleaned thoroughly using a suitable cleaning agent.

The adapter, plug and all dismantled parts must be clean and dry after cleaning.

Care should be taken that these parts remain free of solvents, grease or sweat from the hands (salt water). Clean and mount wearing gloves.

Spare parts may have safety-relevant properties.

Only repair and replace parts that are listed in the "Spare parts" chapter and that are

assigned to the unit.

Defective parts, O-rings and seal sets must always be re-placed.

GA 5000EAC

WARNING

Incompatibility of cleaning agent and working medium!

Risk of explosion and danger of poisoning by toxic gases.

Examine the compatibility of the cleaning agents and working

media on the basis of the safety data sheets.

In Chapter 14 the part numbers for gun spare parts can be found as well as for wearing parts such as seals.

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10.3.4 ASSEMBLING THE SPRAY GUN

Assembly aids:

Pos Order No. Description

2 * 9992698 Vaseline white, PHHV II

4 9992511 Loctite® 243

* Use Vaseline sparingly

Valve rod unit:

Set length adjusting measure X with collet chuck (6) and lock with a hexagon nut (2).

GA 5000EAC

2Nm; 1.48 lbft

Coat the hollow section with a brush. Note: avoid the pin and hexagon.

B_05786

(sparingly)

B_06042

X = 130 ±0.1 mm X = 5.12 ±0.004 inch

SW7

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GA 5000EAC

Wear gloves!

The outside thread of the packing (3) must be free of lacquer.

Valve rod unit (4) and packing (3):

- grease,

- slide together,

- screw together

Grease clamping screw (1) and mount using assembly tool (5).

0.8 Nm + 0.1 Nm;

0.6 + 0.07 lbft

SW5

Only as required (if the rod seal was removed): Press in rod seal (10). In the process, press only on the lowest area of the rod seal.

B_05787

SW7

0.4 - 0.5 Nm

0.3 - 0.37 lb ft

0.5 Nm

0.37 lb ft

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Gold contact sleeve (10)

Check whether the gold contact sleeve is located in the end piece (11). Otherwise, insert the sleeve onto the resistance (12).

GA 5000EAC

Ensure the correct insertion position and installation direction.

Valve needle assembly tool, Order No. 2309368

Ensure the correct insertion position.

(1)

(4)

B_04379

0.1 Nm; 0.07 lb ft

SW9

1.8 Nm; 1.33 lb ft

Clamping screw assembly tool, Order No. 2325263

B_04793

1. Move the valve rod to the rear position so that the sealing area does not become scratched (1).

2. Slightly tighten AC valve tip (2) by hand (3  ngers) using an assembly tool.

3. Use socket or ring spanner (no wrench) to tighten the valve housing (3).

4. Slide the valve rod to the forward position (at the valve seat) (4).

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GA 5000EAC

B_05788

Clean and degrease the inside of the adapter and the outside of the cascade, then grease the cascade surface with Vaseline.

SW3

0.8 Nm; 0.6 lb ft

B_06083

1.3±0.1mm

Set dimension 1.3 mm:

Via setting the dimension, soiling of air cap will be decreased.

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SW7

SW8

GA 5000EAC

B_05783

Assembling the collet chuck:

When assembling the collet chuck, a second size 7 wrench must be used for bracing.

SW26 10 Nm;

7.37 lb ft

B_05789

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GA 5000EAC

SW3

5 Nm;

3.69 lb ft

SW19

10 Nm;

7.37 lb ft

SW19

2.5 Nm;

1.84 lb ft

SW22

B_05790

Fitting (25)

Before assembling the product hose, check that no  tting (25) is in the gun adapter! Check the  tting for damage and replace if necessary (Order No. 2338853).

B_05791

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Flat jet nozzle

Round jet nozzle

Assembly, see Chapter 14.4.2 Diverse nozzle sizes, see Chapter 13.1

Assembly, see Chapter 14.4.1 Diverse nozzle sizes, see Chapter 13.2

GA 5000EAC

B_05792

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OPERATING MANUAL

11 FUNCTION TEST AFTER THE REPAIR

After all repairs, the device must be checked for safe condition before recommissioning. The necessary scope of inspection and testing depends on the repair carried out and must be documented by the repair sta .

11.1 CHECKING THE HIGH VOLTAGE

Necessary test equipment: EPG 5000 control unit and HV 200 high-voltage tester.

High-voltage measurement on spraying gun.

Connect gun cable to control unit. Mount spray gun to grounded gun mounting. Switch on the control unit. The high voltage should be 60 to 65 kV in dry ambient air. The value can be checked with the display on the control unit (EPG 5000).

Note:

The gun must be clean and dry and must not have any paint or cleaning agent residues. In the case of ambient air with a high air humidity, the measured value can reduce to 50 to 55 kV.

High-voltage measurement with high-voltage tester

Place the ball of the high-voltage tester on the gun electrode and turn on the high voltage. The measured value should be 70 to 80 kV.

Notes:

- When measuring the high voltage the measuring device should be held at arms length as far from the body as possible.

- There should be no chargeable objects within a radius of 1 m; 3.28 ft of the place where the measurements are taken.

- The placing of the measuring ball of the high-voltage measuring device reduces the spraying of the high-voltage electrode. As a result the high-voltage value increases compared to the spraying in the free space.

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Disruptive discharge test

Check the gun against ground with the grounding rod. No sparks should be formed. Note: in the vicinity of the electrode harmless corona discharges can occur.

Grounding rod

Order No. 175519

GA 5000EAC

B_06049

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OPERATING MANUAL

GA 5000EAC

11.2 AIR TEST

GA 5000EAC

Switch o the atomizing and shaping air, switch on control air.

1. 0.4MPa; 4bar; 58psi: The air valve must switch on correctly.

2. 0.8MPa; 8bar; 116psi: Test for air seal.

3. Switch o control air: The air valve must switch o correctly.

11.3 PRODUCT PRESSURE TEST

Connect high-pressure hose to the spray gun. Test the seal of the spray gun with suitable medium (e.g.,  ushing agent or Marcol 52) and a maximum pressure of 25 MPa; 250 bar; 3626 psi. Increase the pressure gradually while doing so. Observe the following gun components: Product connection, nozzle body, product valve (no post-spraying).

DANGER

Exploding gas / air mixture!

Danger to life from  ying parts and burns.

Never spray into a closed tank. Ground the tank.

11.4 TEST OF SPRAY PATTERN

Check spray pattern in accordance with Chapter 7.3.1

VERSION 09/2016 ORDER NUMBER DOC2360922

OPERATING MANUAL

GA 5000EAC

12 DISPOSAL

NOTICE

Do not dispose of used electrical equipment with household refuse!

In accordance with European Directive 2002/96/EC on the disposal of used electrical equipment and its implementation in national law, this product may not be disposed of with the household refuse, but must be recycled in an environmentally correct manner. WAGNER or one of our dealers will take back your used WAGNER electric or electronic equipment and will dispose of it for you in an environmentally-friendly way. Please contact one of our service points, one of our representatives or us directly to arrange this.

Consumable products

Consumable products (lacquers, adhesives,  ushing and cleaning agents) must be disposed of in accordance with all applicable legal requirements.

VERSION 09/2016 ORDER NUMBER DOC2360922

GA 5000EAC

OPERATING MANUAL

13 ACCESSORIES

13.1 ROUND JET NOZZLES

13.1.1 ACR 5000 ROUND JET NOZZLE ATTACHMENT

Order No. Designation

2309883 ACR 5000 round jet nozzle attachment

(with nozzle spanner, without AC round jet nozzle insert)

13.1.2 AIRCOAT ROUND JET NOZZLE INSERTS

The round jet nozzles are especially suitable for spraying delicate parts, tubes, pro les and complex work pieces.

Order No. Marking Jet width Recommended edge  lter

mm; inch

132720 11 approx. 250; 10 yellow 132721 12 approx. 250; 10 200 mesh 132722 13 approx. 250; 10 132723 14 approx. 250; 10

132724 * 15 approx. 250; 10

132725 16 approx. 250; 10 black 132726 17 approx. 250; 10 100 mesh 132727 18 approx. 250; 10 132728 19 approx. 250; 10 132729 20 approx. 250; 10 white 132730 21 approx. 250; 10 60 mesh 132731 22 approx. 250; 10

* Standard version Jet width in mm; inches at a distance of 30 cm; 11.8 inches from the object and at a pressure of 10 MPa; 100 bar; 1450 psi.

B_03210

"?

13.2 FLAT JET NOZZLES

13.2.1 ACF 5000 AIR CAPS FLAT JET

Order No. Designation

2309882 Air cap ACF 5000 - LV suitable for low viscosity products (marked red).

2314203 ACF 5000 air cap - HV suitable for high viscosity products (marked blue).

B_03454

B_03209

VERSION 09/2016 ORDER NUMBER DOC2360922

OPERATING MANUAL

13.2.2 ACF5000 AIRCOAT FLAT JET NOZZLES

GA 5000EAC

Order No.

395107 07/10 0.18; 0.007 10° Natural lacquer 395207 07/20 20° 395407 07/40 40° 395109 09/10 0.23; 0.009 10° Clear lacquer 395209 09/20 20° Oils 395309 09/30 30° 395409 09/40 40° 395509 09/50 50° 395609 09/60 60° 395111 11/10 0.28; 0.011 10° Synthetic resin lacquer 395211 11/20 20° PVC lacquer 395311 11/30 30° 395411 11/40 40° 395511 11/50 50° 395611 11/60 60° 395811 11/80 80° 395113 13/10 0.33; 0.013 10° Lacquers 395213 13/20 20° Base coat 395313 13/30 30° Primer 395413 13/40 40° Filler 395513 13/50 50° 395613 13/60 60° 395813 13/80 80° 395115 15/10 0.38; 0.015 10° Filler 395215 15/20 20° Rust proo ng paints 395315 15/30 30° 395415 15/40 40° 395515 15/50 50° 395615 15/60 60° 395815 15/80 80° 395217 17/20 0.43; 0.017 20° Rust proo ng paints 395317 17/30 30° Latex paints 395417 17/40 40° 395517 17/50 50° 395617 17/60 60° 395817 17/80 80°

Marking

Drilled hole

mm; inch

Application

Spray angle

B_03163

VERSION 09/2016 ORDER NUMBER DOC2360922

OPERATING MANUAL

GA 5000EAC

Order No.

395219 19/20 0.48; 0.019 20° Rust proo ng paints 395319 19/30 30° Latex paints 395419 19/40 40° 395519 19/50 50° 395619 19/60 60° 395819 19/80 80° 395221 21/20 0.53; 0.021 20° Mica paints 395421 21/40 40° Zinc rich paints 395521 21/50 50° Rust proo ng paints 395621 21/60 60° Glue paints 395821 21/80 80° 395423 23/40 0.58; 0.023 40° 395623 23/60 60° 395823 23/80 80° 395425 25/40 0.64; 0.025 40° 395625 25/60 60° 395825 25/80 80° 395427 27/40 0.69; 0.027 40° 395627 27/60 60° 395827 27/80 80° 395429 29/40 0.75; 0.029 40° 395629 29/60 60° 395829 29/80 80° 395431 31/40 0.79; 0.031 40° 395631 31/60 60° 395831 31/80 80° 395435 35/40 0.90; 0.035 40° 395635 35/60 60° 395835 35/80 80°

Marking

mm; inch

Drilled hole

Application

Spray angle

B_03163

VERSION 09/2016 ORDER NUMBER DOC2360922

OPERATING MANUAL

13.3 FILTER

Order No. Designation

3204604 Edge  lter, 60 mesh (white) 3204605 Edge  lter, 100 mesh (black) 9999002 Edge  lter, 200 mesh (yellow)

13.4 ELECTRIC CABLES AND HOSES

13.4.1 GUN CABLE

Order No. Designation

2339157 Gun cable, 10 m; 32.8 ft

GA 5000EAC

B_00019

239158 Gun cable, 15 m; 49.2 ft

2339159 Gun cable, 20 m; 65.6 ft

2339160 Gun cable, 25 m; 82.0 ft

13.4.2 EXTENSION CABLE FOR GUN CABLE

Order No. Designation

2339161 Extension cable, 10 m; 32.8 ft

2339162 Extension cable, 20 m; 65.6 ft

B_03218

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OPERATING MANUAL

13.4.3 PRODUCT HOSES, STANDARD

Order No. Designation

9984573 High-pressure hose-DN4-PN270-¼"NPS-7.5 m-PA

2302374 High-pressure hose DN4-PN270-¼"NPS-10.0m-PA

GA 5000EAC

9984573-15 High-pressure hose-DN4-PN270-¼"NPS-15.0 m-PA

9984573-20 High-pressure hose-DN4-PN270-¼"NPS-20.0 m-PA

13.4.4 PRODUCT HOSES, LOWR

Order No. Designation

2367212 Product hose, GA EAC LowR 7.5 m

2367213 Product hose, GA EAC LowR 10 m

2367214 Product hose, GA EAC LowR 15 m

2367215 Product hose, GA EAC LowR 20 m

B_06421

B_06031

13.4.5 PRODUCT HOSE, 1.5 MM

Order No. Designation

2367217 Product hose (ID = 1.5 mm)

B_06036

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OPERATING MANUAL

13.4.6 AIR HOSES

Order No. Designation

9982035 Air hose, red  6 mm, per meter

9982077 Air hose, green  8 mm, per meter

9987095 Air hose, blue  10 mm, per meter

GA 5000EAC

VERSION 09/2016 ORDER NUMBER DOC2360922

OPERATING MANUAL

13.5 MISCELLANEOUS

Order No. Designation

259010 High-voltage tester, HV 200 N

2326041 Paint resistance meter

GA 5000EAC

P_00265

B_03692

999080 Wet  lm thickness gauge

50342 Viscosity cup, DIN 4 mm; 0.16 inches

2309368 Valve needle assembly tool

128901 Nozzle spanner, ACR

B_03224

B_03451

"?

2325263 Clamping screw assembly tool

B_03681

VERSION 09/2016 ORDER NUMBER DOC2360922

OPERATING MANUAL

Order No. Designation

380941 Standard gun holder, 180 mm; Ø 16 mm, 7.1 inches; Ø 0.63 inches

2314079 Ce a adapter plate

380942 Rotary gun holder (standard)

GA 5000EAC

"?

B_03099

380945 Rotary holder, 40/40/5

380943 Complete swivel drive

380944 Cross clamp for swivel drive

2370869 Robot connection, GA 5000

"?

"?

"?

B_06075

B_06076

VERSION 09/2016 ORDER NUMBER DOC2360922

GA 5000EAC

OPERATING MANUAL

14 SPARE PARTS

14.1 HOW CAN SPARE PARTS BE ORDERED?

Always supply the following information to ensure delivery of the right spare part:

Order number, designation and quantity

The quantity need not be the same as the number given in the quantity column "Stk" on the list. This number merely indicates how many of the respective parts are used in each component.

The following information is also required to ensure smooth processing of your order:

Address for the invoice Address for delivery Name of the person to be contacted in the event of any queries Type of delivery (normal mail, express delivery, air freight, courier, etc.)

Identi cation in spare parts lists.

Explanation of column "K" (labeling) in the following spare parts lists:

Wearing parts

Note: These parts are not covered by warranty terms.

Not part of standard equipment, available, however, as additional extra.

DANGER

Incorrect maintenance/repair!

Danger to life and equipment damage.

Only a WAGNER service center or a suitably trained person may

carry out repairs and replace parts.

Only repair and replace parts that are listed in the "Spare parts"

chapter and that are assigned to the unit.

Before all work on the device and in the event of work interruptions:

- Switch o the energy supply and the 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.

VERSION 09/2016 ORDER NUMBER DOC2360922

OPERATING MANUAL

14.2 GA 5000EACIC SPRAY GUN

Spare parts list for GA 5000EACIC

Pos K Stk Order No. Designation

1 1 2360898 GA 5000EACIC 2 1 2315775 Union nut AC, complete

31-

4 1 2307232 Adapter seal

= Wearing part

Adapter, complete GA 5000EAC (For details, see Chapter 14.2.1)

GA 5000EAC

VERSION 09/2016 ORDER NUMBER DOC2360922

OPERATING MANUAL

GA 5000EAC

SW3

5 Nm;

3.68 lb ft

32 33

SW14 12 Nm;

8.85 lb ft

17 18

45 22

13 14

6 7

22 34 35

24 25

SW2.5

0.6 Nm;

0.44 lb ft

29 28

SW2.5

0.6 Nm;

0.44 lb ft

SW14 12 Nm;

8.85 lb ft

B_06039

SW4

7 Nm;

5.16 lb ft

VERSION 09/2016 ORDER NUMBER DOC2360922

OPERATING MANUAL

Spare parts list for GA 5000EACIC

Pos K Stk Order No. Designation

5 2 9930128 Parallel pin 6 7 1 2360689 Seal 8 1 2360813 Cable, complete

9 1 2357712 Locknut 10 1 2307739 Mounting nut 11 12 1 2307868 Round spray jet reduction 13 14 1 2357739 Cover 15 1 2386373 Product hose, complete GA AC 16 17 2 9900353 Hexagon socket cylinder head screw 18 1 3204605 Edge  lter, 100 mesh 19 1 2308764 Filter socket AC 20 2 9900329 Hexagon socket cylinder head screw 21 22 9 9906029 Hexagon socket cylinder head screw 23 1 9998090 Straight screw-in  tting 24 1 9998987 Straight threaded  tting 25 1 9998770 Coding ring blue, d10 26 1 9998274 Threaded plug, G1/4" 27 1 9998995 Coding ring red, d6 28 29 1 2358895 Sealing plug 30 2 2360690 Plug 31 1 2313501 Complete piston IC 32 7 9900308 Hexagon socket cylinder head screw 33 4 9920104 Washer 34 1 2357167 Lock plate 35 1 2357166 Seal 36 1 2357164 Contact holder 37 38 1 9971025 O-ring 39 1 2371130 Pull rod 40 41 1 9998991 Cylindrical helical spring 42 1 2307741 End cap short 43 1 2365237 Cover, labeled 44 1 2365238 Lid labeled, EACIC 45 1 2338526 Contact spacer 50 1 9992511 Loctite® 243

5 9974265 O-ring

(only for WAGNER Service Department)

1 9971388 O-ring

1 2357738 Seal

1 2338853 Connecting  tting AC

1 2357737 Mounting bracket

1 9974089 O-ring

1 248314 O-ring

1 2309945 Cylindrical helical spring

GA 5000EAC

1 2369320 Service set Air/Controller, GA 5000E

= Wearing part

VERSION 09/2016 ORDER NUMBER DOC2360922

OPERATING MANUAL

14.2.1 GA 5000EAC  ADAPTER

GA 5000EAC

For setting, see Chapter 10.

130±0.1 mm

5.12±0.004 inch

B_06046

VERSION 09/2016 ORDER NUMBER DOC2360922

OPERATING MANUAL

Spare parts list for adapter

Pos K Stk Order No. Designation

1 1 - Adapter, complete GA 5000EAC

2 1 2312175 Valve housing AC, complete

3 1 2312186 Valve needle AC, complete

4 1 2357170 Adapter, GA 5000EAC

5 1 2313314 Air manifold ring, AC

7 1 2314283 Contacting, AC

8 1 9952777 High resistance, bare

9 1 9960808 Socket contact component (gold contact sleeve)

10 1 2312181 Cascade, complete 11 1 2357665 Clamping screw valve rod, complete 12 1 2307062 Clamping screw valve rod 13 14 1 9974166 O-ring 15 1 2369017 Valve rod unit, AC 16 1 9910108 Hexagon nut 17 1 2357740 Collet chuck 18 1 2357741 Tension nut 19 1 2357106 Packing, complete 20 1 2325263 Clamping screw assembly tool

1 2307180 O-ring, sheathed

1 2311562 Rod seal

GA 5000EAC

1 2369015 Service set, GA 5000EAC adapter

= Wearing part

= Included in service set

= Not part of the standard equipment but available as a special accessory.

VERSION 09/2016 ORDER NUMBER DOC2360922

OPERATING MANUAL

14.3 GA 5000EACEC SPRAY GUN

GA 5000EAC

SW3

5 Nm;

3.68 lb ft

30 31

SW14 12 Nm;

8.85 lb ft

9 10 11

16 17

6 7

44 21

12 13

21 32 33

23 24

SW2.5

0.6 Nm;

0.44 lb ft

2627

SW2.5

0.6 Nm;

0.44 lb ft

B_06040

SW4

7 Nm;

5.16 lb ft

100

WAGNER GA 5000EACIC, GA 5000EACEC Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual