GA 5000EAIC
GA 5000EAEC
II 2 G 0.24mJ X
B_06009
Electrostatic Air Spray Gun
for automatic operation
for at or round jet nozzles
Version 09/2016
Translation of the Original
Operating Manual
3
GA 5000EA
Table of Contents
1 ABOUT THESE INSTRUCTIONS 7
1.1 Preface 7
1.2 Warnings, Notices and Symbols in these Instructions 7
1.3 Languages 8
1.4 Abbreviations 8
1.5 Terminology for the Purpose of this Manual 9
2 CORRECT USE 10
2.1 Device Type 10
2.2 Type of Use 10
2.3 Use in an Explosion Hazard Area 10
2.4 Safety Parameters 10
2.5 Processible Working Materials 11
2.6 Reasonably Foreseeable Misuse 12
2.7 Residual Risks 12
3 IDENTIFICATION 13
3.1 CE Explosion Protection Identi cation 13
3.2 Special Notice "X" 13
3.3 Identi cation "X" (Type Examination Certi cate) 14
3.4 Type Plate 15
4 GENERAL SAFETY INSTRUCTIONS 16
4.1 Safety Instructions for the Operator 16
4.1.1 Electrical Equipment 16
4.1.2 Personnel Quali cations 16
4.1.3 Safe Work Environment 16
4.2 Safety Instructions for Sta 17
4.2.1 Safe Handling of WAGNER Spray Devices 17
4.2.2 Grounding the Device 18
4.2.3 Product Hoses 18
4.2.4 Cleaning and Flushing 19
4.2.5 Handling Hazardous Liquids, Varnishes and Paints 20
4.2.6 Touching Hot Surfaces 20
4.3 Protective and Monitoring Equipment 20
4.4 Use in Areas Subject to Explosion Hazards 21
4.4.1 Safety Regulations 21
4.5 Setting up Stationary Electrostatic Systems 21
4.6 Safety-Relevant Information about Discharges 22
5 DESCRIPTION 23
5.1 Structure (Standard Variant) 23
5.1.1 GA 5000EAIC Design 23
5.1.2 GA 5000EAEC Design 24
5.2 Mode of Operation 25
5.2.1 GA 5000EAIC Mode of Operation 25
5.2.2 GA 5000EAEC Mode of Operation 26
5.3 Protective and Monitoring Equipment 27
5.4 Scope of Delivery 27
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5.5 Technical Data 28
5.5.1 GA 5000EA Dimensions 29
5.6 Spraying Procedure 30
5.6.1 Spraying Procedure for Round Jet Air Atomizing 30
5.6.2 Spraying Procedure for Flat Jet Air Atomizing 31
5.6.3 Electrostatic E ect 32
5.7 The WAGNER Electrostatic Air Spraying System 33
5.7.1 Pressure Settings for Round Jet Nozzles 34
5.7.2 Pressure Settings for Flat Jet Nozzles 34
5.7.3 Adjusting Screw 35
5.7.4 Electrostatic and Atomization 36
5.7.5 Discharge Quantity Measurements 36
6 ASSEMBLY AND COMMISSIONING 37
6.1 Training Assembly/Commissioning Sta 37
6.2 Storage Conditions 37
6.3 Installation Conditions 37
6.4 Transportation 37
6.5 Assembly and Installation 38
6.5.1 Typical Electrostatic Spraying System 38
6.5.2 Connecting GA 5000EAIC 40
6.5.3 Connecting GA 5000EAEC 41
6.5.4 Ventilation of the Spray Booth 42
6.5.5 Air Supply 43
6.5.6 Product Supply 43
6.5.7 Grounding 44
6.6 Preparation of Lacquer 46
6.6.1 Viscosity Conversion Table 46
6.7 Commissioning 47
6.7.1 Safety Instructions 47
6.7.2 Preparation for Commissioning 47
6.7.3 Commissioning 47
6.8 Verifying a Safe Operational Condition 48
7 OPERATION 49
7.1 Training the Operating Sta 49
7.2 Safety Instructions 49
7.2.1 Emergency Deactivation 50
7.2.2 General Rules for Making Adjustments to the Spray Gun 50
7.3 Working 51
7.3.1 Checking the GA 5000EA Spray Pattern (Without Electrostatics) 51
7.3.2 Spraying GA 5000EA 53
7.3.3 Pressure Relief/Work Interruption 54
7.3.4 Dismantling the Gun Cover 55
7.3.5 Changing from Air Round Jet to Air Flat Jet 56
7.3.6 Changing the Valve Housing 58
7.3.7 Cleaning of the Nozzle Parts 59
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8 CLEANING AND MAINTENANCE 60
8.1 Cleaning 60
8.1.1 Cleaning Sta 60
8.1.2 Safety Instructions 60
8.1.3 Cleaning and Flushing the Device 62
8.2 Maintenance 64
8.2.1 Maintenance Sta 64
8.2.2 Safety Instructions 64
8.2.3 Safety Checks 65
8.2.4 Product Hoses, Tubes and Couplings 66
9 TROUBLE SHOOTING AND RECTIFICATION 67
10 REPAIR WORK 68
10.1 Repair Sta 68
10.2 Safety Instructions 68
10.3 Dismantling of the Gun 69
10.3.1 Tools 69
10.3.2 Dismantling of the Spray Gun 70
10.3.3 Cleaning the Parts After Disassembly 75
10.3.4 Assembling the Spray Gun 76
11 FUNCTION TEST AFTER THE REPAIR 82
11.1 Checking the High voltage 82
11.2 Air Test 84
11.3 Product Pressure Test 84
11.4 Test of Spray Pattern 84
12 DISPOSAL 85
13 ACCESSORIES 86
13.1 Valve Housing 86
13.2 Valve Tips 86
13.3 Round Spray Nozzles 86
13.3.1 AR 5000 Air Caps 86
13.3.2 AR 5000 Nozzles 86
13.3.3 EARV Nozzle set 87
13.4 Flat Jet Nozzles 87
13.4.1 AF 5000 Air Caps 87
13.4.2 AF 5000 Nozzles 88
13.5 Electric Cables and Hoses 89
13.5.1 Gun Cable 89
13.5.2 Extension Cable for Gun Cable 89
13.5.3 Product Hoses Standard 89
13.5.4 Product Hoses for Low-resistance Products 90
13.5.5 Spiral Hose 90
13.5.6 Air Hoses 90
13.6 Miscellaneous 91
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14 SPARE PARTS 93
14.1 How Can Spare Parts Be Ordered? 93
14.2 GA 5000EAIC Spray Gun 94
14.2.1 GA 5000EA Adapter 96
14.3 GA 5000EAEC Spray Gun 98
14.4 Accessories Spare Parts Lists 101
14.4.1 AR 5000 Nozzle (D8) 102
14.4.2 AR 5000 Nozzle (D12) 102
14.4.3 Adjustable EARV 5000 Round Jet Nozzle 103
15 WARRANTY AND CONFORMITY DECLARATIONS 104
15.1 Important Notes Regarding Product Liability 104
15.2 Warranty Claim 104
15.3 EU Declaration of Conformity 105
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1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this operating manual highlight particular dangers to users and to
the device and state measures for avoiding the hazard. These warning instructions fall into
the following categories:
Danger - immediate risk of danger.
Non-observance will result in death or serious injury.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
Note - provides information about particular characteristics and how to proceed.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the hazard and its consequences.
NOTICE
1 ABOUT THESE INSTRUCTIONS
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device.
The operating manual is part of the device and must be available to the operating and
service personnel.
The device may only be operated by trained personnel and in compliance with this
operating manual. Operating and service personnel should be instructed according to the
safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.1 PREFACE
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1.3 LANGUAGES
1.4 ABBREVIATIONS
Order No. Order number
Spare part
Marking in the spare parts lists
Automatic gun
Electrostatics Airspray
Shaping and atomizing air controlled via valve within gun
Shaping and atomizing air controlled via valve outside of gun
Low R Low-resistance
Polyether ether ketone (high temperature-resistant thermoplastic plastic)
Stainless steel
Position
Number of pieces
Wrench size
The GA 5000EA operating manual is available in the following languages:
Language Order No. Language Order No.
German 2360923 English 2360924
French 2367556 Italian 2367557
Spanish 2367558
Additional languages on request or at:
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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning Manual cleaning of devices and device parts with cleaning agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Sta quali cations
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as
well as the necessary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person
in the context of
DGUV209-052
A person who, based on his/her technical training, experience
and recent vocational experience, has su cient technical
knowledge in the area of electrostatic coating and is familiar
with the relevant and generally accepted rules of technology
so that he/she can inspect and assess the status of devices and
coating systems based on workplace safety.
Additional requirements for skilled persons are given in the
TRBS1203 (2010/Revision2012): 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 5000EA electrostatic automatic spray gun is suitable for spraying liquid products,
particularly coating products. Coating products which contain ingredients of explosion
class IIA and IIB substances (maximum ignition energy 0.24 mJ) may be used.
WAGNER forbids any other use!
2.4 SAFETY PARAMETERS
2.3 USE IN AN EXPLOSION HAZARD AREA
The GA 5000EA electrostatic automatic spray gun is suitable for coating electrically
conductive objects with liquid coating products and can be used in potentially explosive
areas. Explosion Protection Identi cation (see Chapter 3)
WAGNER accepts no liability for any damage arising from incorrect use.
Use the device only to work with the products recommended by WAGNER.
Only operate the device as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The device may only be operated under the following conditions:
The operating personnel must be trained on the basis of this operating manual.
The safety regulations listed in this operating manual must be observed.
The operating, maintenance and repair information in this operating manual must be
observed.
The statutory requirements and accident prevention regulation standards in the country
of use must be observed.
The electrostatic automatic spray gun may only be operated if all parameters are set and
all measurements/safety checks are carried out correctly.
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2.5 PROCESSIBLE WORKING MATERIALS
Coating products which contain ingredients of explosion class IIA and IIB substances
(maximum ignition energy 0.24 mJ) can be processed with the GA 5000EA 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).
When processing metallic lacquers, it is advisable to use the spiral hose.
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
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be ruled out even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk Source Consequences Speci c measures Lifecycle phase
Skin contact with
lacquers and
cleaning agents
Handling of
lacquers and
cleaning agents
Skin irritations, Wear protective
clothing
Operation,
allergies maintenance,
Observe safety data
sheets
disassembly
Lacquer in air
outside the de ned
working area
Lacquering outside
the de ned working
area
Inhalation of
substances
hazardous to health
Observe work and
operation instructions
Operation,
maintenance
The forms of misuse listed below may result in physical injury or property damage:
use with non-authorized control units;
coating work pieces which are not grounded;
working with an ungrounded lacquer supply system;
performing unauthorized conversions or modi cations to the device;
processing inadmissible coating products;
processing dry or similar coating products, e.g., powder;
using defective components, spare parts or accessories other than those described in
the "Accessories" chapter of this operating manual;
continuing work with a defective or kinked product hose;
working with incorrectly set values;
processing food.
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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 5000EA 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 ATEX5290X Number of type examination certi cate
Temperature notes
- Maximum surface temperature: 85 °C; 185 °F
- Maximum permissible product temperature: 50 °C; 122 °F
- Permissible ambient temperature: 0 to +40 °C; +32 to +104 °F
3.2 SPECIAL NOTICE "X"
Cable connections
Only cable assigned to the device may be used (see Chapter 13).
Permissible Device Combinations
The GA 5000EA automatic spray gun may only be connected to the control units listed below:
- EPG 5000 control unit
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3.3 IDENTIFICATION "X" (TYPE EXAMINATION CERTIFICATE)
Note:
The EC Type Examination Certi cate from SIRA covers the following:
- use of the spray gun in Zone 1;
- use of the EPG 5000 control unit as related equipment for the spray gun.
Incorrect use!
Risk of injury and damage to the device.
Connect the GA 5000EA automatic spray gun only to original
WAGNER control units.
WARNING
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Serial No.
YY-XXX
B_05766
GA 5000EAIC
GA 5000EAEC
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Serial number
3.4 TYPE PLATE
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL EQUIPMENT
4.1.2 PERSONNEL QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident prevention.
Ensure that the device is only operated, maintained and repaired by trained persons.
Ensure that the oor in the working area is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 megohms).
Ensure that all persons within the working area wear static dissipative shoes. Footwear
must comply with EN 20344. The measured insulation resistance must not exceed
100 megohms.
If protective clothing is worn, including gloves, it has to comply with EN 1149-5.
The measured insulation resistance must not exceed 100 megohms.
Paint mist extraction systems/ventilation systems must be tted on site according to
local regulations.
Ensure that the following components of a safe working environment are available:
- Product/air hoses adapted to the working pressure.
- Personal safety equipment (breathing and skin protection).
Electrical devices and equipment
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient in uences.
May only be maintained by skilled electricians or under their supervision. With open
housings, there is a danger from line voltage.
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.
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4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident prevention.
Anyone tted with a pacemaker must not enter the high-voltage area!
4.2.1 SAFE HANDLING OF WAGNER SPRAY DEVICES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or ushing agents:
Never point the spray gun at people.
Never reach into the spray jet.
Before all work on the device, in the event of work interruptions and functional faults:
- Switch o the energy/compressed air supply.
- Relieve the pressure from the spray gun and device.
- Secure the spray gun against actuation.
- In the event of functional faults, remedy the fault as described in the "Troubleshooting"
chapter.
If necessary or at least every 12 months, 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 Chapter 2.29
and 2.36).
- For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure Relief" chapter:
- If pressure relief is required.
- If the spraying work is interrupted or stopped.
- Before the device is cleaned on the outside, checked or serviced.
- Before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by paint or ushing agents:
Note the paint or ushing agent that you have been using.
Consult a doctor immediately.
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. No smoking.
Ensure that the pipe joints, hoses, equipment parts and connections are permanently,
technically leak-proof:
- Periodic preventative maintenance and service (replacing hoses, checking tightness
strength and connections etc.).
- Regular monitoring of leaks and defects via visual inspection and odor testing, e.g.,
daily before commissioning, at the end of work or weekly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
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4.2.3 PRODUCT HOSES
Ensure that the hose material is chemically resistant to the sprayed products and the
used ushing agents.
Ensure that the product hose is suitable for the pressure generated.
Ensure that the following information can be seen on the high-pressure hose:
- Manufacturer
- Permissible operating pressure
- Date of manufacture
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in the
following places under any circumstances:
- in high-traffic areas,
- on sharp edges,
- on moving parts or
- on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses are
never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Make sure that the hoses are never used to pull or move the equipment.
Suction hoses may not be subjected to pressure.
Several liquids have a high expansion coe cient. In some cases their volume can rise with
consequent damage to pipes, ttings, etc. and cause uid leakage.
When the pump sucks liquid from a closed tank, ensure that air or a suitable gas can
enter the tank. Thus a negative pressure is avoided. The vacuum could implode the tank
(squeeze) and can cause it to break. The tank would leak and the liquid would ow out.
The pressure created by the pump is a multiplication of the inlet air pressure.
4.2.2 GROUNDING THE DEVICE
Friction, owing liquids and air or electrostatic coating processes create charges. Flames or
sparks can form during discharge. Grounding prevents electrostatic charging.
Ensure that the device is grounded. See Chapter "Grounding".
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are wearing
static dissipative shoes.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.
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4.2.4 CLEANING AND FLUSHING
Relieve the pressure from the device.
De-energize the device electrically.
Preference should be given to non- ammable cleaning and ushing agents.
Observe the speci cations of the lacquer manufacturer.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical
ventilation.
Take measures for workplace safety (see Chapter 4.1.3).
When commissioning or emptying the device, please note that an explosive mixture
may temporarily exist inside the lines and components of equipment:
- depending on the coating product used,
- depending on the ushing agent (solvent) used,
explosive mixture inside the lines and items of equipment.
Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
Never spray into a closed tank when using solvents for ushing.
External cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects and
never spray cleaning agents with a gun. Cleaning the device must not damage it in any
way.
Ensure that no electrical component is cleaned with nor even immersed into solvent.
Which cleaning agent is used to clean the spray gun depends on which parts of the
spray gun have to be cleaned and which product has to be removed. When cleaning the
spray gun, only use non-polar cleaning agents to prevent conductive residues on the
surface of the spray gun. Should it however, be necessary to use a polar cleaning agent,
all residues of this cleaning agent have to be removed by using a non-conductive and
non-polar cleaning agent, once the cleaning is nished.
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4.2.6 TOUCHING HOT SURFACES
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C; 109.4 °F:
- Identify the device with a warning label "Warning - hot surface".
Order No.
9998910 Instruction label
9998911 Protection label
Note: Order the two stickers together.
4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
When preparing or working with lacquer and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents and cleaning agents
being used.
Take the speci ed protective measures, in particular wear safety goggles, protective
clothing and gloves, as well as skin protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For su cient health and environmental safety: Operate the device in a spray booth or
on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.
4.3 PROTECTIVE AND MONITORING EQUIPMENT
Protective and monitoring equipment must not be removed, modi ed or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must not
be operated until these defects are remedied.
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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.
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.
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.
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 SAFETYRELEVANT 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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1
3
4
2
5
B_05749
1
2
3
4
5
7
9
11
12
13
14
2
8
10
B_05745
15
16
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5 DESCRIPTION
5.1 STRUCTURE STANDARD VARIANT
1 Front cover
2 Union nut
3 Air cap
4 Flat jet nozzle
5 Gun adapter
6 Shaping air setting
7 Piston housing
8 Valve rod regulating screw
9 Rear cover
10 Air di user housing
11 Gun holder
12 Product hose
13 Nozzle, AR 5000
14 Air cap, AR 5000
15 Nozzle insert, EARV Accessories
16 Nozzle, EARV Chapter 13.3.2
17 Union nut, EARV
1 Connection closed with dummy plug
2 Fluid inlet
3 Control air connection (D6/red)
4 Gun cable connection
5 Shaping air or atomizing air connection (D10/blue)
Connections on the rear side:
5.1.1 GA 5000EAIC DESIGN
24
GA 5000EA
1
3
4
2
5
B_05750
1
2
3
4
5
6
8
10
11
12
13
2
7
9
B_05746
14
15
16
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
5.1.2 GA 5000EAEC DESIGN
1 Shaping air connection (D8/green)
2 Fluid inlet
3 Control air connection (D6/red)
4 Gun cable connection
5 Atomizing air connection (D10/blue)
Connections on the rear side:
1 Front cover
2 Union nut
3 Air cap
4 Flat jet nozzle
5 Gun adapter
6 Piston housing
7 Valve rod regulating screw
8 Rear cover
9 Air di user housing
10 Gun holder
11 Product hose
12 Nozzle, AR 5000
13 Air cap, AR 5000
14 Nozzle insert, EARV Accessories
15 Nozzle, EARV Chapter 13.3.2
16 Union nut, EARV
25
GA 5000EA
M
B_06007
AA / SA
CA
SA
AA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
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 5000EA spray gun is activated directly on the EPG5000ontrol
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 5000EAIC MODE OF OPERATION
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.
Pneumatic diagram:
SA = Shaping air
AA = Atomizing air
CA = Control air
M = Product
Nozzle
26
GA 5000EA
CA
SA
AA
SA
AA
M
B_06008
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
5.2.2 GA 5000EAEC MODE OF OPERATION
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.
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.
Nozzle
Pneumatic diagram:
SA = Shaping air
AA = Atomizing air
CA = Control air
M = Product
27
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
5.4 SCOPE OF DELIVERY
Order No. Description
2360900 Spray gun, GA 5000EAIC
2360901 Spray gun, GA 5000EAEC
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
2360923 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.
5.3 PROTECTIVE AND MONITORING EQUIPMENT
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.
WARNING
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
28
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
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 8 bar; 0.8 MPa; 116 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
Fluid inlet G1/4"
Atomizer air connection D10
Shaping air connection (only for GA 5000EAEC) D8
Control air connection D6
Weight (without houses) 1.0 kg; 2.2 lb
Flow rate
according to nozzle size
(see nozzle table in "Accessories" chapter)
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
Quality standard 6.5.2 according to ISO 8573.1, 2010
6: Particle density ≤ 5mg/m
5: Humidity: pressure dew point ≤ +7°C
2: Oil content ≤ 0.1mg/m
Sound level at 0.3 MPa; 3 bar; 43.5 psi air pressure
and 0.3 MPa; 3 bar; 43.5 psi product pressure *
73 dB(A)
* A-rated sound pressure level measured at 1 m distance, LpA1m, in accordance with DIN EN 14462: 2005.
5.5 TECHNICAL DATA
29
GA 5000EA
74
135
B_05747
268
268
18 18
4x ∅ 3.2
2x M5
M8
18 18
B_05778
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
5.5.1 GA 5000EA DIMENSIONS
GA 5000EA with at jet nozzle
GA 5000EA with round jet nozzle
Connecting dimensions of the connection plate:
30
GA 5000EA
B_03446
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
5.6 SPRAYING PROCEDURE
Spray pattern
Union nut
Spray product
Atomizing air
Advantages
- Thin layers
- Uniform coating thickness
- Perfect nish
In this process, the spray product is fed to the nozzle with a pressure of approx. 0.05–0.2 MPa;
0.5–2 bar; 7–29 psi. The atomizing air at approx. 0.25 - 0.4 MPa; 2.5 - 4 bar; 36 - 58 psi produces
a soft round jet, which largely eliminates the problem of overlapping boundaries. There are
various nozzles and air caps available as accessories for the respective spray product and
the discharge quantities.
5.6.1 SPRAYING PROCEDURE FOR ROUND JET AIR ATOMIZING
31
GA 5000EA
B_00180
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
5.6.2 SPRAYING PROCEDURE FOR FLAT JET AIR ATOMIZING
Shaping air
Air cap
Spray pattern
Atomizing air
Advantages
- Large range of adjustment of the spray jet
- Thin layers
- Uniform coating thickness
- Perfect nish
Spray product
Spray angle
In this process, the spray product is fed to the nozzle at a pressure of 0.05–0.2 MPa; 0.5–2 bar;
7–29 psi. The atomizing air at approx. 0.25 - 0.4 MPa; 2.5 - 4 bar; 36 - 58 psi produces a soft
round jet, which largely eliminates the problem of overlapping boundaries. The shaping
air allows modi cation of the spray jet. There are various nozzles and air caps available as
accessories for the respective spray product and the discharge quantities.
32
GA 5000EA
"?
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Electrode
Paint particle
Object to be sprayed is
grounded
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.
Advantages
- Very high application e ectiveness
- Low over spray
- Coating of entire circumferences due to the electrostatic e ect
- Savings in working time
5.6.3 ELECTROSTATIC EFFECT
33
GA 5000EA
Atomizing air
Zerstäuberluft
Fan air
Formluft
B
GA 5000EAECGA 5000EAIC
A
B_05767
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
5.7 THE WAGNER ELECTROSTATIC AIR 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
for large-surface parts
Round jet for smaller delicate parts
Options for in uencing the jet spray / spray pattern:
Description Modi cation
Product pressure + or -
Atomizing air pressure + or -
Shaping air regulation from open to closed
Stop screw product valve
from open to closed
Nozzle sizes Flow rate
Electrostatics + or - or o
The spray jet width by GA 5000EAIC spray gun is adjusted via the shaping air regulation (A)
on the gun and on the GA 5000EAEC spray gun via the air control knob (B) on the EPG 5000
control unit in the case of at jet spraying.
34
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
5.7.1 PRESSURE SETTINGS FOR ROUND JET NOZZLES
There are 4 nozzle sizes, D8, D12, EARV LV and EARV HV available. The air cap and nozzle are
adjusted according to size to each other and may not be exchanged.
Pressure setting Nozzle D8 (small) Nozzle D12 (large)
Product pressure
0.8 bar to 1.2 bar 0.8 bar to 1.6 bar
Atomizing air pressure 2.0 bar to 3.0 bar 2.3 bar to 4.0 bar
Pressure setting EARV LV EARV HV
Product pressure 0.8 bar to 1.6 bar 0.8 bar to 1.6 bar
Atomizing air pressure 2.3 bar to 4.0 bar 2.3 bar to 4.0 bar
The table contains default values. Depending on the product, conditions and the desired
result di erent values are possible or necessary.
5.7.2 PRESSURE SETTINGS FOR FLAT JET NOZZLES
There are 8 at jet nozzle sizes from 0.6 up to 2.0 available. There are 2 air cap types
(s = small, w = wide) with 3 di erent nozzle sizes each. Each air cap can be used in
combination with 2 to 3 nozzles sizes. Only matching nozzle components may be used.
Pressure settings Air cap 0.6-0.8 Air cap 1.0-1.4 Air cap 1.6-2.0
Product pressure 0.5 bar to 1.0 bar 1.0 bar to 2.0 bar 1.0 bar to 3.0 bar
Atomizing air pressure 1.0 bar to 3.0 bar 1.5 bar to 4.0 bar 1.5 bar to 5.0 bar
The table contains default values. Depending on the product, conditions and the desired
result di erent values are possible or necessary.
Air cap type Suitable nozzle sizes
0.4 - 0.8S / 0.4 - 0.8W 0.6 / 0.8
1.0 - 1.4S / 1.0 - 1.4W 1.0 / 1.2 / 1.4
1.6 - 2.0S / 1.6 - 2.0W 1.6 / 1.8 / 2.0
35
GA 5000EA
+-
A
B_05756
AB
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
5.7.3 ADJUSTING SCREW
By turning the rear adjusting screw of the gun, the outlet cross-section can be adjusted
on the product valve. This cross-section is maximized by turning the screw leftwards,
by turning the screw rightwards the cross-section is minimized. With the same pressure
settings, turning to the right results in a reduction of the ow rate and ner atomization.
Note: The spray pattern is changed with this setting.
After adjusting x the screw (A) by tightening the nut (B) again.
Turn to the left:
Stop to back
Larger cross-section
Turn to the right:
Stop to front
Smaller cross-section
36
GA 5000EA
0
100
200
300
400
500
600
700
0.6mm
0.8mm
1.0mm
1.2mm
1.4mm
1.6mm
1.8mm
2.0mm
123
B_03455
0
100
200
300
400
500
600
123
D8
D12
B_03456
/EARV
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
5.7.4 ELECTROSTATIC AND ATOMIZATION
The electrostatic charging of the spray cloud produces a more homogeneous distribution
of paint particles on the object. - See also Chapter 5.6.3.
5.7.5 DISCHARGE QUANTITY MEASUREMENTS
Product pressure in bar
Discharge quantities in g/min
Flat jet nozzles
Device: GA 5000EA / at jet nozzle Product hose: Length 7.5 m; 24.6 ft
Viscosity: 22 DIN/4 seconds Inside diameter 6 mm; 0.24 inches
Product pressure in bar
Discharge quantities in g/min
Round spray nozzles
Device: GA 5000EA / round jet nozzle Product hose: Length 7.5 m; 24.6 ft
Viscosity: 22 DIN/4 seconds Inside diameter 6 mm; 0.24 inches
37
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
6 ASSEMBLY AND COMMISSIONING
6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF
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.
WARNING
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).
A skilled person must check to ensure that the device is in a reliable state after it is installed
and commissioned.
6.4 TRANSPORTATION
Protect valve needle with protection cap (Order No. 2315709).
38
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
6.5 ASSEMBLY AND INSTALLATION
6.5.1 TYPICAL ELECTROSTATIC SPRAYING SYSTEM
The GA 5000EA 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
air 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.
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.
WARNING
39
GA 5000EA
B_05775
E
B
C
D
A
F
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
A Spray booth
B Controller
C Reciprocator
D Electrostatic spray gun
E Work piece
f Conveyor
40
GA 5000EA
1.0 AT
I
0
Main Switch
Hauptschalter
Prim. Fuse
Sicherung
Mains power IN
Netz Eingang
Air input
6 - 8bar
87-116 psi
Clean and dry air
Saubere und trockene Luft
6.5.2 (ISO 8573-1:2010)
Air input
Lufteingang
Control air
Steuerluft
Fan air
Formluft
Atomizing air
Zerstäuberluft
Spraygun
Sprühpistole
Interface
Schnittstelle
IN CAN Bus OUT
Data and Interlock
Daten und Verriegelung
CAN
Address
Service
Port
Restrictor for air during cleaning
Drossel für Luft während dem Spülen
Imax. = 1.0A
Umax. = 20Vpp
0102
II (2) G
SIRA 16 ATEX 5290X
Typ / Type: EPG 5000
115VAC - 230VAC
50Hz / 60Hz
2359451
max. 40W
Serie Nr.:
Serial No.:
Spannung:
Voltage:
Artikel Nr.:
Article No.:
Eingangsleistung:
Input Power:
Schutzart:
IP Code:
Norm:
Standard:
IP 40
Eingangsstrom:
Input Current:
max. 0.5A
Baujahr:
Year of manufacture:
Wagner International AG
Industriestrasse 22
CH - 9450 Altstätten
Made in Switzerland
EN 50176:2009
EN 50050-1:2013
0
1
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
B_05770
7
8
GA 5000
EPG 5000
6
1
2
3
4
5
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
6.5.2 CONNECTING GA 5000EAIC
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
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.
WARNING
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.
41
GA 5000EA
1.0 AT
I
0
Main Switch
Hauptschalter
Prim. Fuse
Sicherung
Mains power IN
Netz Eingang
Air input
6 - 8bar
87-116 psi
Clean and dry air
Saubere und trockene Luft
6.5.2 (ISO 8573-1:2010)
Air input
Lufteingang
Control air
Steuerluft
Fan air
Formluft
Atomizing air
Zerstäuberluft
Spraygun
Sprühpistole
Interface
Schnittstelle
IN CAN Bus OUT
Data and Interlock
Daten und Verriegelung
CAN
Address
Service
Port
Restrictor for air during cleaning
Drossel für Luft während dem Spülen
Imax. = 1.0A
Umax. = 20Vpp
0102
II (2) G
SIRA 16 ATEX 5290X
Typ / Type: EPG 5000
115VAC - 230VAC
50Hz / 60Hz
2359451
max. 40W
Serie Nr.:
Serial No.:
Spannung:
Voltage:
Artikel Nr.:
Article No.:
Eingangsleistung:
Input Power:
Norm:
Standard:
IP 40
Eingangsstrom:
Input Current:
max. 0.5A
Baujahr:
Year of manufacture:
EN 50176:2009
EN 50050-1:2013
Wagner International AG
Industriestrasse 22
CH - 9450 Altstätten
Made in Switzerland
Schutzart:
IP Code:
0
1
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
B_05771
8
9
GA 5000
EPG 5000
7
1
2
3
4
5
6
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
6.5.3 CONNECTING GA 5000EAEC
1 for the product supply system 4 Control air hose 7 Control cable
2 Atomizing air hose 5 Gun cable 8 Grounding cable
3 Shaping air hose 6 for the compressed air supply 9 Mains cable
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.
WARNING
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.
42
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
6.5.4 VENTILATION OF THE SPRAY BOOTH
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.
WARNING
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.
43
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
6.5.5 AIR SUPPLY
6.5.6 PRODUCT 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
spraying pattern.
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.
NOTICE
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.
DANGER
Hose connections!
Risk of injury and damage to the device.
Do not exchange hose connections of product hose and air hose.
WARNING
44
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
6.5.7 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.
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.
WARNING
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.
45
GA 5000EA
B_00137
Rmax < 1MΩ
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
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)
Grounding scheme (example)
Conveyor
Control unit
Grounding cable
Spraying stand
Floor, static dissipative
Work piece
Pump
Paint tank
Signal ground Signal ground
46
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
6.6 PREPARATION OF LACQUER
6.6.1 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
The viscosity of the lacquer is of great importance. The best spraying results are obtained
with values between 15 and 30 DIN/4 seconds (measured in immersion ow cup DIN 4 mm;
0.16 inches).
In the case of application problems contact the lacquer manufacturer.
47
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
6.7 COMMISSIONING
6.7.1 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.
6.7.2 PREPARATION FOR COMMISSIONING
Impurities in the spraying system!
Spray gun blockage.
Flush the spray gun and paint supply with a suitable ushing agent before
commissioning.
NOTICE
6.7.3 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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6.8 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
7.2 SAFETY INSTRUCTIONS
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 100megohms.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 megohms.
WARNING
Observe safety instructions in Chapter 4.
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.
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.
WARNING
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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.
WARNING
7.2.2 GENERAL RULES FOR MAKING ADJUSTMENTS TO THE SPRAY GUN
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.
DANGER
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.
WARNING
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.
7.2.1 EMERGENCY DEACTIVATION
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7.3.1 CHECKING THE GA 5000EA SPRAY PATTERN WITHOUT ELECTROSTATICS
Start air-spraying (without electrostatics)
1. Switch o high voltage at the control unit. (The grounding of the spray gun via the
gun cable is maintained.)
2. Start up with product supply generator set to approx. 0.05 to 0.15 MPa; 0.5 to 1.5 bar;
7 to 22 psi operating pressure.
See corresponding operating manual.
3. Set atomizing air regulator to approx. 2 - 4 bar.
4. Open air regulation on the gun.
5. Set the union nut as far as the stop.
6. Spray (switch on controller) and check the atomization.
7. Adjust the uid pressure on the product pressure generator until correct discharge
quantity is achieved.
8. Adjust the atomizing air regulator until optimal atomization is achieved.
9. Flat jet process: with the air adjustment on the gun, set the ratio of shaping air/
atomizing air so as to achieve an optimum spray pattern.
Changing the Flow Rate
Adapt product pressure.
Use a di erent nozzle (see Chapter 13).
Limit the valve needle stroke with the adjustment screw on the rear of the gun.
Spray pattern and air regulation
The spray pattern can be optimally adjusted to suit the object being sprayed using the air
regulator. The illustration shows the in uence of the regulator on the spraying pattern.
Other nozzle sizes can be used to obtain larger or smaller spraying patterns.
Round-jet method
Close air regulation.
The size of the air cap should
match with the nozzle size.
Flat jet method
Air regulation fully
opened.
Air regulation closed.
7.3 WORKING
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Adjustable EARV5000 round jet nozzle
By turning the union nut the spray pattern can be adjusted to suit the object being
sprayed. The illustration shows the in uence of the turning on the spraying pattern.
1. Set the union nut as far as the stop.
2. Open maximum 1/4 turn. The atomizing is good in this area.
The union nut should not protrude beyond the nozzle body.
Always fully open the air regulation.
Spray pattern
Marking on union nut
Low viscosity, large diameter
Low viscosity, small diameter
High viscosity, large diameter
High viscosity, small diameter
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7.3.2 SPRAYING GA 5000EA
1. Insert the desired nozzle into the spray gun.
2. Turn on the control unit.
See corresponding operating manual.
3. Start up with product supply generator set to approx. 0.05 to 0.15 MPa; 0.5 to 1.5 bar;
7 to 22 psi operating pressure. See corresponding operating manual.
4. Set atomizing air regulator to approx. 2 - 4 bar.
5. Open air regulation of the gun.
6. Spray on a test object (switch gun on).
Activation of the spray gun takes place via the controller.
7. Adjust the product pressure and atomizing air in accordance with the nozzle and object.
Rule of thumb: Set atomizing air pressure approx. three times higher than the product
pressure.
Round-jet method
8. Open air regulation.
9. Changing the EARV 5000 spray jet width: Switch o high voltage. Turning the union
nut in accordance with Chapter 7.3.1.
Flat-jet method: Changing the spray jet width
8. Change the width of the spray jet by turning the air regulator (on the side of the spray
gun, see photo) or by appropriate selection of the air caps and nozzles combination.
Flow rate
9. The product quantity can be reduced by:
- Minimizing the product pressure.
- Use a di erent nozzle size.
See Chapter 13.
- Limit the valve needle stroke with the adjustment screw on the rear of the gun.
Round-jet method
Open air regulation.
The size of the air cap should
match with the nozzle size.
Flat-jet method
Air regulation fully opened. Air regulation closed.
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7.3.3 PRESSURE RELIEF/WORK INTERRUPTION
Process for relieving pressure
1. Switch o high voltage at the control unit.
2. Turn compressed air regulator 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. Fill ushing agent and adjust pressure.
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.
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.
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.
Wear the appropriate protective clothing, gloves, eyewear and
respiratory protection.
WARNING
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4
3
B_05757
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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.
56
GA 5000EA
B_05752
1
4
5
12
6
1
8
AR 5000
3
2
10
7
9
EARV 5000
11
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7.3.5 CHANGING FROM AIR ROUND JET TO AIR FLAT JET
Defective electrode!
Material damage due to functional faults.
Do not damage the electrode.
NOTICE
Dismount the nozzle
Flat jet
1. Unscrew the union nut (1) by hand.
2. Remove AF 5000 air cap (4).
3. Unscrew and remove AF 5000 at jet nozzle (5) by hand.
4. Clean the spray gun front carefully with damp cloth. Pay attention to the electrode (11).
Use protective cap (12).
AR 5000 – round jet
1. Unscrew the union nut (1) by hand.
2. Remove AR 5000 air cap (2). Unscrew AR 5000 nozzle (3) by hand and remove it.
3. Clean the spray gun front carefully with damp cloth. Pay attention to the electrode (11).
Use protective cap (12).
EARV 5000 – round jet
1. Unscrew the EARV union nut (7) by hand.
2. Unscrew and remove EARV nozzle (8) by hand.
3. Unscrew nozzle insert (9) from nozzle (8) using air nozzle spanner (10).
4. Clean the spray gun front carefully with damp cloth. Pay attention to the electrode (11).
Use protective cap (12).
Flush spray gun:
1. Switch o high voltage at the control unit.
2. Turn compressed air regulator 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. Fill ushing agent and adjust pressure.
6. Thoroughly ush out the spray gun.
7. Relieve the pressure on the gun and the system.
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Mount nozzle
Flat jet
1. Screw in and tighten AF 5000 at jet nozzle (5) by hand.
2. Put the AF 5000 air cap (4) in place. Screw the union nut (1) onto the spray gun body.
3. Set the desired at jet level with the air cap horns (6) and then tighten the union nut
by hand.
AR 5000 – round jet
1. Screw on and tighten AR 5000 nozzle (3) by hand.
2. Position AR 5000 air cap (2). Screw the union nut (1) onto the spray gun body and
tighten by hand.
EARV 5000 – round jet
1. Screw on EARV nozzle insert (9) into nozzle (8) using air nozzle spanner (10). Nozzle
insert and nozzle body must be ush, subsequently do not continue turning and
slightly tighten.
2. Screw on and tighten EARV nozzle (8) by hand.
3. Select EARV union nut (7) depending on the viscosity: HV or LV. Screw the union nut
onto the spray gun body and turn fully backwards by hand in order to reach a large
spray jet diameter. Unscrew the nozzle nut no more than 90° in order to reach a small
spray jet diameter.
58
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1.32 lb ft
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7.3.6 CHANGING THE VALVE HOUSING
Use a socket or ring spanner
(not an open-end wrench) to
tighten the valve housing.
Valve housing and valve tip are available in various materials:
Valve housing Valve tip
Material of the valve seat Product
Standard version Steel PEEK
Special accessories PEEK Steel
When wear-related problems occur, the valve housing and/or valve tip can be exchanged
Order No., see Chapter 13.
Relieve pressure prior changing the valve housing.
Chapter 7.3.3
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7.3.7 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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8 CLEANING AND MAINTENANCE
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 CLEANING
8.1.2 SAFETY INSTRUCTIONS
8.1.1 CLEANING STAFF
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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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.
DANGER
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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.
8.1.3 CLEANING AND FLUSHING THE DEVICE
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.
WARNING
Damage to electrical devices!
Never immerse the spray gun in cleaning agent.
NOTICE
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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Exploding gas / air mixture!
Danger to life from ying parts and burns.
Never spray into a closed tank.
Ground the tank.
DANGER
Clean nozzle
1. Switch o control unit.
2. Dismount nozzle and clean separately
Chapter 7.3.7.
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. Close 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
see Chapter 7.3.9
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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.
DANGER
8.2 MAINTENANCE
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.
8.2.1 MAINTENANCE STAFF
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 Chapter 8.1.3.
After maintenance
- Carry out a safety checks in accordance with Chapter 8.2.3.
- Put the system into operation (Chapter 6.7) 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
Chapter 2.29 and 2.36):
- 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.
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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.
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 6.5.7
Inspection for damage weekly Chapter 8.1.3, 8.2, 10
Locking of the technical ventilation with the
electrostatic spraying equipment
annually Chapter 6.5.4
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.
8.2.3 SAFETY CHECKS
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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
DANGER
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
Meaning
(if present)
xxx bar Pressure
yymm
Crimping date
(year/month)
XX Internal code
Hose imprinting Meaning
WAGNER Name/Manufacturer
yymm
Date of manufacture
(year/month)
xxx bar (xx MPa)
Pressure
e.g., 270 bar (27 MPa)
XX Internal code
DNxx (e.g., DN10) Nominal diameter
8.2.4 PRODUCT HOSES, TUBES AND COUPLINGS
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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.
Product valve travel set too small Increase product valve travel by turning
the adjusting screw.
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.
Air pressure too high Reduce air pressure
Lacquer resistance too high/too low Check lacquer 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 lacquer 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
Reduce distance between spray gun
and work piece.
High voltage set wrongly (too high) Adapt high voltage to product.
Loosen the nozzle union nut for
round jet method
Tighten union nut by hand.
Valve seat leaks Valve seat or valve tip worn Replace valve seat or valve tip.
9 TROUBLE SHOOTING AND RECTIFICATION
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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
Chapter 2.29 and 2.36):
- 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 DISMANTLING OF THE GUN
10.3.1 TOOLS
For disassembling and assembling the spray gun, the following tools are required:
- Allen wrench, SW 2.5
- Allen wrench, SW 3
- Allen wrench, SW 5
- Open-end wrench, SW 5
- Open-end wrench, SW 7
- Open-end wrench, SW 8
- Open-end wrench, SW 11
- Open-end wrench, SW 19
- Ring spanner, SW11
- Slide gauge
- Valve needle assembly tool, Order No. 2309368
- Clamping screw assembly tool, Order No. 2325263
Plastic parts
Gently handle all plastic parts.
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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2
B_05793
1.
2.
B_05794
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10.3.2 DISMANTLING OF THE SPRAY GUN
71
GA 5000EA
SW19
SW19
SW3
B_05795
B_05796
4
3
OPERATING MANUAL
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Product hose:
Do not tilt, but pull it straight out in direction indicated by arrow. At the same time, execute
slight rotational movements.
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6
SW8
SW7
B_05797
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B_05798
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Unscrew the collet chuck:
When unscrewing the collet chuck, a
second size 7 open-ended wrench must
be used for bracing.
Carefully release the cascade
without pliers
73
GA 5000EA
7
8
B_04370
SW11
B_04369
n
o
n
o
p
9
8
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
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.
Valve needle assembly tool
Order No. 2309368
Valve needle Air
Loosen valve tip by hand using the valve needle assembly tool (Order No. 2309368).
Valve housing: Use socket or ring spanner
(not an open-end wrench).
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1
4
5
2
6
7
3
10
SW5
SW7
SW7
SW8
B_05799
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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.
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10.3.3 CLEANING THE PARTS AFTER DISASSEMBLY
In Chapter 14 the part numbers for gun spare parts can be found as well as for wearing
parts such as seals.
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.
WARNING
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.
ATTENTION
76
GA 5000EA
2
2
2
2
3
4
B_05786
1
B_06042
X = 130 ±0.1 mm
X = 5.12 ±0.004 inch
2
6
2Nm; 1.48 lbft
SW7
SW7
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
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
Coat the hollow section with
a brush. Note: avoid the pin
and hexagon.
(sparingly)
Valve rod unit:
Set length adjusting measure X with collet chuck (6)
and lock with a hexagon nut (2).
77
GA 5000EA
2
2
3
4
2
SW5
10
5
0.5 Nm
0.37 lb ft
SW7
0.4 - 0.5 Nm
0.3 - 0.37 lb ft
B_05800
1
0.8 Nm + 0.1 Nm;
0.6 + 0.07 lbft
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
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).
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.
78
GA 5000EA
4
SW11
B_04373
1.8 Nm;
1.33 lb ft
0.1 Nm
0.07 lb ft
2
3
(1)
(4)
B_06001
SW3
2
0.8 Nm; 0.6 lb ft
4
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
1. Move the valve rod to the rear position so that the sealing area
does not become scratched (1).
2. Very slightly tighten valve tip (2) using an assembly tool with three
ngers.
3. Use socket or ring spanner (no open-end wrench) to tighten the
valve housing (3).
4. Slide the valve rod to the forward position (at the valve seat) (4).
Clean and degrease the inside of the adapter
and the outside of the cascade, then grease
the cascade surface with Vaseline.
3
Ensure the correct
insertion position!
Valve needle assembly tool,
Order No. 2309368
79
GA 5000EA
5
SW8
SW7
B_05797
6
A
1.3±0.1mm
B_06082
B_06002
SW26
10 Nm;
7.37 lb ft
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Assembling the collet chuck:
When assembling the collet chuck, a
second open-ended wrench SW7 must
be used for bracing.
Set dimension 1.3 mm:
Via setting the dimension, soiling of air
cap will be decreased.
80
GA 5000EA
7
8
2.
1.
B_06004
SW19
B_06003
2.5 Nm;
1.84 lb ft
2
SW19
SW3
5 Nm;
3.69 lb ft
10 Nm;
7.37 lb ft
4
4
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
81
GA 5000EA
B_06005
9
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Round jet nozzle
Assembly, see Chapter 14.4
Diverse nozzle sizes, see Chapter 13.3
Flat jet nozzle
Assembly, see Chapter 14.4
Diverse nozzle sizes, see Chapter 13.4
82
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
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.
83
GA 5000EA
B_05759
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
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
84
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Connect the product 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 0.8 MPa; 8 bar; 116 psi. Increase the pressure gradually while doing
so.
Observe the following gun components:
Product connection, nozzle body, product valve (no post-spraying).
11.2 AIR TEST
11.3 PRODUCT PRESSURE TEST
Exploding gas / air mixture!
Danger to life from ying parts and burns.
Never spray into a closed tank.
Ground the tank.
DANGER
11.4 TEST OF SPRAY PATTERN
Check spray pattern in accordance with Chapter 7.3.1
GA 5000EA
Switch o the atomizing and shaping air, switch on control air.
1. 0.4MPa; 4bar; 58psi: The air valve must switch on correctly.
2. 0.8MPa; 8bar; 116psi: Test for air seal.
3. Switch o control air: The air valve must switch o correctly.
85
GA 5000EA
OPERATING MANUAL
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12 DISPOSAL
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.
NOTICE
Consumable products
Consumable products (lacquers, adhesives, ushing and cleaning agents) must be disposed
of in accordance with all applicable legal requirements.
86
GA 5000EA
B_03697
B_03697
B_03698
B_03698
B_03238
B_03238
B_03239
B_03239
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
13 ACCESSORIES
Order No. Designation
2312179
Valve housing Air, complete (steel)
(Standard version)
2312176 Valve housing Air, complete (PEEK)
Order No. Designation
2312184
Valve tip Air, complete (PEEK)
(Standard version)
2312185 Valve tip Air, complete (steel)
13.1 VALVE HOUSING
13.2 VALVE TIPS
13.3.2 AR 5000 NOZZLES
Order No. Designation
2310557 Air cap, AR 5000 (D8)
2315049 Air cap, AR 5000 (D12)
13.3 ROUND SPRAY NOZZLES
13.3.1 AR 5000 AIR CAPS
Order No. Designation
2310558 Nozzle, AR 5000 (D8)
2315050 Nozzle, AR 5000 (D12)
87
GA 5000EA
B_03240
B_03240
B_03240
B_03240
B_03240
B_03240
B_06044
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Order No. Designation
2310506 Air cap, AF 5000 - 0.4-0.8S
2310507 Air cap, AF 5000 – 1.0–1.4S
2310508 Air cap, AF 5000 - 1.6-2.0S
2314255 Air cap, AF 5000 – 0.4–0.8W (wide)
2314256 Air cap, AF 5000 – 1.0–1.4W (wide)
2314258 Air cap, AF 5000 - 1.6-2.0W (wide)
13.4 FLAT JET NOZZLES
13.4.1 AF 5000 AIR CAPS
13.3.3 EARV NOZZLE SET
Order No. Designation
Markings on union
nut
2361290
Nozzle set, EARV 5000 LV
B_05984
suitable for low viscosity products
2365979
Nozzle set, EARV 5000 HV
B_05985
suitable for high viscosity products
Mounting tool
353210 Air nozzle spanner
"?
Spare parts, see Chapter 14.4.3.
88
GA 5000EA
B_03241
B_03241
B_03241
B_03241
B_03241
B_03241
B_03241
B_03241
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Order No. Designation
2310539 AF 5000 nozzle – 0.6 mm (black)
2310540 AF 5000 nozzle – 0.8 mm (yellow)
2310541 AF 5000 nozzle – 1.0 mm (red)
2310542 AF 5000 nozzle – 1.2 mm (green)
2310543 AF 5000 nozzle – 1.4 mm (brown)
2310544 AF 5000 nozzle – 1.6 mm (white)
2310545 AF 5000 nozzle – 1.8 mm (blue)
2310546 AF 5000 nozzle – 2.0 mm (black)
13.4.2 AF 5000 NOZZLES
89
GA 5000EA
B_03218
B_03218
B_06421
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
13.5.1 GUN CABLE
Order No. Designation
2339161 Extension cable, 10 m; 32.8 ft
2339162 Extension cable, 20 m; 65.6 ft
13.5.2 EXTENSION CABLE FOR GUN CABLE
Order No. Designation
2339157 Gun cable, 10 m; 32.8 ft
2339158 Gun cable, 15 m; 49.2 ft
2339159 Gun cable, 20 m; 65.6 ft
2339160 Gun cable, 25 m; 82.0 ft
Order No. Designation
2339130 Low pressure hose, DN6-PN20-G¼"-7.5 m-PA
2339131 Low pressure hose, DN6-PN20-G¼"-10 m-PA
2339132 Low pressure hose, DN8-PN17-G¼"-15 m-PA
2339133 Low pressure hose, DN8-PN17-G¼"-20 m-PA
13.5.3 PRODUCT HOSES STANDARD
13.5 ELECTRIC CABLES AND HOSES
90
GA 5000EA
B_06031
B_06035
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Order No. Designation
2367203 Product hose, GA EA LowR 7.5 m
2367204 Product hose, GA EA LowR 10 m
2367205 Product hose, GA EA LowR 15 m
2367206 Product hose, GA EA LowR 20 m
13.5.4 PRODUCT HOSES FOR LOWRESISTANCE PRODUCTS
13.5.6 AIR HOSES
13.5.5 SPIRAL HOSE
Order No. Designation
2367216 Spiral hose, complete
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
91
GA 5000EA
P_00265
B_03224
B_03451
B_03692
B_03681
B_03099
"?
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Order No. Designation
259010 High-voltage tester, HV 200 N
2326041 Paint resistance meter
999080 Wet lm thickness gauge
50342 Viscosity cup, DIN 4 mm; 0.16 inches
2309368 Valve needle assembly tool
2325263 Clamping screw assembly tool
380941
Standard gun holder, 180 mm; Ø 16 mm,
7.1 inches; Ø 0.63 inches
2314079 Ce a adapter plate
13.6 MISCELLANEOUS
92
GA 5000EA
"?
"?
"?
B_06075
B_06076
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Order No. Designation
380942 Rotary gun holder (standard)
380945 Rotary holder, 40/40/5
380943 Complete swivel drive
380944 Cross clamp for swivel drive
2370869 Robot connection, GA 5000
93
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
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.
94
GA 5000EA
46
21
3
4
1
5
2
6
9
10
11
12
13
14
17
18
19
20
23 24
31
32
33
34
35
38
39
40
41
42
43
44
45
B_06037
26
29
27
28
7
36
37
30
8
22
25
SW4
7 Nm;
5.16 lb ft
50
SW14
12 Nm;
8.85 lb ft
50
SW14
12 Nm;
8.85 lb ft
50
50
SW3
5 Nm;
3.68 lb ft
21
SW2.5
0.6 Nm;
0.44 lb ft
50
15
16
21
SW2.5
0.6 Nm;
0.44 lb ft
50
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
14.2 GA 5000EAIC SPRAY GUN
95
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Spare parts list for GA 5000EAIC
Pos K Stk Order No. Designation
1 1 2360900 GA 5000EAIC
2 1 2315709 Protection cap valve needle
3 1 2307039 Union nut
4
1 2311217 O-ring
51-
Adapter, complete GA 5000EA
(for details, see Chapter 14.2.1)
6 1 2307232 Adapter seal
7 2 2360690 Plug
8 2 9930128 Parallel pin
9
5 9974265 O-ring
10 1 2360689 Seal
11 1 2360813 Cable, complete
(only for WAGNER Service Department)
12 1 2357712 Locknut
13
1 9974089 O-ring
14 1 2358895 Sealing plug
15
1 2357738 Seal
16 1 2357739 Cover
17 1 2360888 Product hose, complete GA 5000EA
18 2 9900353 Hexagon socket cylinder head screw
19 2 9900329 Hexagon socket cylinder head screw
20
1 2357737 Mounting bracket
21 9 9906029 Hexagon socket cylinder head screw
22 1 9998995 Coding ring red, d6
23 1 9998987 Straight threaded tting
24 1 9998770 Coding ring blue, d10
25 1 9998274 Threaded plug, G1/4"
26 1 9998090 Straight screw-in tting
27
1 9971388 O-ring
28 1 2307739 Mounting nut
29 1 2307868 Round spray jet reduction
30 1 2313501 Piston, IC
31 7 9900308 Hexagon socket cylinder head screw
32 4 9920104 Washer
33 1 2357167 Lock plate
34 1 2357166 Seal
35 1 2357164 Contact holder
36
1 248314 O-ring
37 1 9971025 O-ring
38 1 2371130 Pull rod
39
1 2309945 Cylindrical helical spring
40 1 9998991 Cylindrical helical spring
41 1 2307741 End cap short
42 1 9913058 Hexagon nut
= Wearing part
96
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Spare parts list for GA 5000EAIC
Pos K Stk Order No. Designation
43
1 2367333 Hexagon screw without shaft
44 1 2365237 Cover, labeled
45 1 2365248 Lid, labeled EAIC
46 1 2338526 Contact spacer
50 1 9992511 Loctite
243
1 2369320 Service set Air/Controller, GA 5000EA
= Wearing part
Spare parts list for adapter
Pos K Stk Order No. Designation
1 1 - Adapter, complete GM 5000EA
2
1 2309391 Air manifold ring, Air
3 1 2307180 O-ring, sheathed
4
1 2312179 Valve housing, complete Air (steel) (standard)
1 2312176 Valve housing, complete Air (PEEK) (standard)
5
1 2312184 Valve tip, complete Air (PEEK)
1 2312185 Valve tip, complete Air (steel)
6 1 2314271 Adapter, GM 5000EA
7 1 2312181 Cascade, complete
8 1 2357665 Clamping screw valve rod, complete
9 1 2307062 Clamping screw valve rod
10
1 2311562 Rod seal
11
1 9974166 O-ring
12 1 2369017 Valve rod unit, Air
13 1 9910108 Hexagon nut
14 1 2357740 Collet chuck
15 1 2357741 Tension nut
16
1 2357106 Packing, complete
17 1 2325263 Clamping screw assembly tool
1 2369016 Service set, GA 5000EA adapter
= Wearing part
= Included in service set
= Not part of the standard equipment but available as a special accessory.
14.2.1 GA 5000EA ADAPTER
97
GA 5000EA
B_06041
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
130±0.1 mm
5.12±0.004 inch
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
98
GA 5000EA
3
4
1
5
2
6
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23 24
29
30
31
32
33
42
43
B_06038
8
36
37
38
39
40
41
34
35
28
7
25
27
26
SW4
7 Nm;
5.16 lb ft
SW2.5
0.6 Nm;
0.44 lb ft
SW14
12 Nm;
8.85 lb ft
50
50
SW3
5 Nm;
3.68 lb ft
50
21
50
SW2.5
0.6 Nm;
0.44 lb ft
50
44
21
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
14.3 GA 5000EAEC SPRAY GUN
99
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Spare parts list for GA 5000EAEC
Pos K Stk Order No. Designation
1 1 2360901 GA 5000EAEC
2 1 2315709 Protection cap valve needle
3 1 2307039 Union nut
4
1 2311217 O-ring
51-
Adapter, complete GA 5000EA
(For details, see Chapter 14.2.1)
6 1 2307232 Adapter seal
7 2 2360690 Plug
8 2 9930128 Parallel pin
9
5 9974265 O-ring
10 1 2360689 Seal
11 1 2360813 Cable, complete
(only for WAGNER Service Department)
12 1 2357712 Locknut
13
2 9974089 O-ring
14 2 2358895 Sealing plug
15
1 2357738 Seal
16 1 2357739 Cover
17 1 2360888 Product hose, complete GA 5000EA
18 2 9900353 Hexagon socket cylinder head screw
19 2 9900329 Hexagon socket cylinder head screw
20
1 2357737 Mounting bracket
21 9 9906029 Hexagon socket cylinder head screw
22 1 9998090 Straight screw-in tting
23 1 9998987 Straight threaded tting
24 1 9998770 Coding ring blue, d10
25 1 9998616 Coding ring green, d8
26 1 9998254 Straight screw-in tting
27 1 9998995 Coding ring red, d6
28 1 2313501 Piston IC
29 7 9900308 Hexagon socket cylinder head screw
30 4 9920104 Washer
31 1 2357167 Lock plate
32 1 2357166 Seal
33 1 2357164 Contact holder
34
1 248314 O-ring
35 1 9971025 O-ring
36 1 2371130 Pull rod
37
1 2309945 Cylindrical helical spring
38 1 9998991 Cylindrical helical spring
39 1 2307741 End cap short
40 1 9913058 Hexagon nut
41
1 2367333 Hexagon screw without shaft
42 1 2365237 Cover, labeled
= Wearing part
100
GA 5000EA
OPERATING MANUAL
VERSION 09/2016 ORDER NUMBER DOC2360924
Spare parts list for GA 5000EAEC
Pos K Stk Order No. Designation
43 1 2365249 Lid labeled, EAEC
44 1 2338526 Contact spacer
50 1 9992511 Loctite
243
1 2369320 Service set Air/Controller, GA 5000EA
= Wearing part
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