WAGNER GM 4700AC-H, GM 4700AC Translation Of The Original Operating Manual
GM 4700AC
GM 4700AC-H
II 2G X (Atex 95)
B_02376
AirCoat spray gun
for at - and round jet nozzles
Version 09/2011
Translation of the original
Operating manual
3
GM 4700AC
OPERATING MANUAL
VERSION 09/2011
ORDER NUMBER DOC2311730
Contents
1 ABOUT THESE INSTRUCTIONS 5
1.1 Languages 5
1.2 Warnings, notes and symbols in these instructions 5
2 GENERAL SAFETY INSTRUCTIONS 6
2.1 Safety instructions for the operator 6
2.1.1 Electrical equipment 6
2.1.2 Personnel quali cations 6
2.1.3 Safe work environment 6
2.2 Safety instructions for sta 6
2.2.1 Safe handling of WAGNER spray units 7
2.2.2 Grounding the unit 7
2.2.3 Material hoses 7
2.2.4 Cleaning 8
2.2.5 Handling hazardous liquids, varnishes and paints 8
2.2.6 Touching hot surfaces 8
2.3 Correct use 8
2.4 Use in an explosion hazard area 9
2.4.1 Correct use 9
2.4.2 Explosion protection identi cation 9
2.4.3 Maximum surface temperature 9
2.4.4 Safety instructions 9
2.5 Reference to German regulations and guidelines 9
3 GUARANTEE AND CONFORMITY DECLARATIONS 10
3.1 Important notes on product liability 10
3.2 Guarantee claim 10
3.3 CE Declaration of Conformity 11
4 DESCRIPTION 12
4.1 Fields of application, use in accordance with the instructions 12
4.1.1 Processable materials 12
4.2 Scope of delivery 12
4.2.1 Variants for application range up to 25 MPa; 250 bar; 3625 psi 12
4.2.2 Standard equipment 12
4.3 Data 13
4.3.1 Materials of wetted parts 13
4.3.2 Technical data 13
4.4 Functional description 14
4.4.1 Design of the spray gun 14
4.4.2 Functions of the spray gun 14
5 COMMISSIONING AND OPERATION 15
5.1 Installation and connection 15
5.1.1 Typical AirCoat spraying system 15
5.1.2 Ventilation of the spray booth 16
5.1.3 Air line 16
5.1.4 Material supply 16
5.1.5 Grounding 17
5.1.6 Pressure relief 18
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GM 4700AC
OPERATING MANUAL
VERSION 09/2011
ORDER NUMBER DOC2311730
Contents
5.2 Preparation of paints 19
5.3 Commissioning 19
5.3.1 General rules for making adjustments to the spray gun 19
5.3.2 Preparation for commissioning 20
5.4 Works 21
5.4.1 Start-up for spraying AirCoat 21
5.4.2 Adjusting the spray pattern 21
5.4.3 Changing the AirCoat nozzle 22
5.4.4 Cleaning AirCoat nozzle 23
5.4.5 Eliminate nozzle clogging 23
6.0 MAINTENANCE 24
6.1 Decommissioning and cleaning. 25
6.2 Replacing the material hose or air hose 26
6.3 Changing or cleaning lter insert 27
6.4 Replacing parts on the valve rod 28
6.4.1 Disassembly 28
6.4.2 Replacement of valve tappet seals 29
6.4.3 Replacing rod seal (35) 29
6.4.4 Assembly 30
6.5 Replacing the nozzle seal 31
6.6 Replacing the "air" sealing ring 32
6.7 Changing round jet sealing nipple 33
7 TROUBLE SHOOTING AND RECTIFICATION 34
8 ACCESSORIES 35
8.1 Round jet nozzle cap 35
8.1.1 Nozzle inserts RXX 35
8.1.2 Complete nozzle screw joint 35
8.2 Air caps 36
8.3 Anodized union nut 36
8.4 AirCoat Nozzles ACF3000 36
8.5 Filter insert 37
8.6 Swivel joints 37
8.7 Hoses 38
8.8 Miscellaneous 38
9 SPARE PARTS 39
9.1 How can Spare Parts be ordered? 39
9.2 Spare parts list GM 4700AC 40
9.3 Spare parts list GM 4700AC-H 43
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GM 4700AC
OPERATING MANUAL
VERSION 09/2011
ORDER NUMBER DOC2311730
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
1 ABOUT THESE INSTRUCTIONS
1.1 LANGUAGES
This operating manual contains information on the operation, repair and maintenance of
the device.
Always observe these instructions when operating the device.
This equipment can be dangerous if it is not operated according to the information in this
operating manual.
Compliance with these instructions constitutes an integral component of the guarantee
agreement.
The operating manual is available in the following languages:
Language: Order No. Language: Order No.
German 2311729 English 2311730
French 2311731 Dutch 2326027
Italian 2311732 Spanish 2311733
Russian 2328825 Chinese 2328826
Warning instructions in this operating manual highlight particular dangers to users and
device and state measures for avoiding the hazard. These warning instructions fall into the
following categories:
Danger - immediate threatening risk
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.
Note - gives information about particular characteristics and how to proceed.
Notice - a possibly hazardous situation
Non-observance can cause material damage.
This information 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 information 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 information 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 information 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
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GM 4700AC
OPERATING MANUAL
VERSION 09/2011
ORDER NUMBER DOC2311730
2 GENERAL SAFETY INSTRUCTIONS
2.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
2.1.1 ELECTRICAL EQUIPMENT
2.1.2 PERSONNEL QUALIFICATIONS
2.1.3 SAFE WORK ENVIRONMENT
2.2 SAFETY INSTRUCTIONS FOR STAFF
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
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.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be put out of operation if they pose a hazard.
Must be de-energized before work is commenced on active parts. Inform sta about
planned work. Observe electrical safety regulations.
Ensure that the device is operated and repaired only by trained persons.
Make sure that the oor in the area where you are working is electrostatically conductive
in accordance with EN 61340-4-1.
Ensure that all persons within the working area wear electrostatically conductive shoes.
Ensure that during spraying, persons wear electrostatically conductive gloves so that
they are grounded via the handle of the spray gun.
Paint mist extraction systems must be tted on site according to local regulations.
Ensure that the following components of a safe working environment are available:
– Material/air hoses adapted to the working pressure
– Personal safety equipment (breathing and skin protection).
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires or
hot surfaces in the vicinity. Do not smoke.
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
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GM 4700AC
OPERATING MANUAL
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ORDER NUMBER DOC2311730
2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS
2.2.2 GROUNDING THE UNIT
2.2.3 MATERIAL HOSES
The spray jet is under pressure and can cause dangerous injuries.
Avoid injection of paint or cleaning 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.
- Secure the spray gun against actuation.
- Relieve the pressure from the spray gun and unit.
In the event of functional faults: remedy the fault as described in the "Trouble Shooting"
chapter.
In the event of skin injuries caused by paint or cleaning agents:
Note the paint or cleaning agent that you used.
Consult a doctor immediately.
Avoid danger of injury through recoil forces:
Ensure that you have secure footing when operating the spray gun.
Only hold the spray gun brie y in any one position.
Depending on the electrostatic charge and the ow speed of the spray, an electrostatic
charge may occur in the equipment. In the event of discharge, this may result in the
formation of sparks or ames.
Ensure that the unit is grounded for every spraying operation.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g. that they are wearing
electrostatically conductive shoes.
Wear electrostatically conductive gloves for grounding via the spray gun handle when
spraying.
Ensure that the hose material is chemically resistant to the sprayed materials.
Ensure that the material hose is suitable for the pressure generated in the unit.
Ensure that the following information can be seen on the high pressure hose:
- Manufacturer
– Permissible operating overpressure
– Date of manufacture
The electrical resistance of the complete high pressure hose must be less than
1 MOhm.
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GM 4700AC
OPERATING MANUAL
VERSION 09/2011
ORDER NUMBER DOC2311730
2.2.4 CLEANING
2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS
2.2.6 TOUCHING HOT SURFACES
2.3 CORRECT USE
De-energize the unit electrically.
Disconnect the pneumatic supply line.
Relieve the pressure from the unit.
Ensure that the flash point of the cleaning agent is at least 5 K above the ambient
temperature.
To clean, use only solvent-damped cloths and brushes. Never use hard objects or spray
cleaning agents on with a gun.
An explosive gas/air mixture forms in closed containers.
When cleaning units with solvents, never spray into a closed container.
Ground the container.
When preparing or working with paint and when cleaning the unit, follow the working
instructions of the manufacturer of the paints, solvents and cleaning agents being
used.
Take the speci ed protective measures, in particular wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For su cient health and environmental safety: Operate the unit in a spray booth or on
a spraying wall with the ventilation (suction) switched on.
Wear suitable protective clothing when working with hot materials.
Touch hot surfaces only if you are wearing protective gloves.
When operating the unit with a coating material with a temperature of > 43 °C;109.4 °F:
- Identify the unit with a warning sticker "Warning - Hot Surface".
Order No.
9998910 Instruction sticker
9998911 Protection sticker
WAGNER accepts no liability for any damage arising from incorrect use.
Only use the unit to work with the materials recommended by WAGNER.
Only operate the unit as a whole.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
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GM 4700AC
OPERATING MANUAL
VERSION 09/2011
ORDER NUMBER DOC2311730
2.4.1 CORRECT USE
2.4.2 EXPLOSION PROTECTION IDENTIFICATION
2.4.3 MAXIMUM SURFACE TEMPERATURE
2.4.4 SAFETY INSTRUCTIONS
2.4 USE IN AN EXPLOSION HAZARD AREA
2.5 REFERENCE TO GERMAN REGULATIONS AND GUIDELINES
See chapter 3.3.
The unit is suitable for working liquid materials in accordance with the classi cation into
explosion classes.
X: The maximum surface temperature corresponds to the permissible material
temperature.
This and the permissible ambient temperature can be found in the "Technical Data"
chapter.
Safe handling of WAGNER spray units
Mechanical sparks can form if the unit comes into contact with metal.
In an explosive atmosphere:
Do not knock or push the unit against steel or rusty iron.
Do not drop the spray gun.
Use only tools that are made of a permitted material.
Ignition temperature of the coating material
Ensure that the ignition temperature of the coating material is above the maximum
surface temperature.
Medium supporting atomizing
To atomize the material, use only weakly oxidizing gases, e.g. air.
Cleaning
If there are deposits on the surfaces, the unit may form electrostatic charges. Flames or
sparks can form if there is a discharge.
Remove deposits from the surfaces to maintain conductivity.
As de ned in the Directive 94/9/EC (ATEX 95), the unit is suitable for use in areas where
there is an explosion hazard.
II 2G X
CE: Communautés Européennes
Ex: Symbol for explosion protection
II: Unit class II
2: Category 2 (Zone 1)
G Ex-atmosphere gas
X: Special Note
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GM 4700AC
OPERATING MANUAL
VERSION 09/2011
ORDER NUMBER DOC2311730
3.1 IMPORTANT NOTES ON PRODUCT LIABILITY
3.2 GUARANTEE CLAIM
3 GUARANTEE AND CONFORMITY DECLARATIONS
As a result of an EC regulation e ective from January 1, 1990, the manufacturer shall only
be liable for his product if all parts originate from him or are approved by him, and if the
devices are properly mounted, operated and maintained.
The manufacturer will not be held liable or will only be held partially liable if third-party
accessories or spare parts have been used.
With genuine WAGNER accessories and spare parts, you have the guarantee that all safety
regulations are complied with.
Full warranty is provided for this device to the following extent:
We will at our discretion repair or replace free of charge all parts which within 24 months
in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by
the purchaser are found to be wholly or substantially unusable due to causes prior to the
sale, in particular faulty design, defective materials or poor workmanship.
The type of warranty provided is such that the device or individual components of the
device are either replaced or repaired as we see t. The resulting costs, in particular
shipping charges, road tolls, labour and material costs will be borne by us except where
these costs are increased due to the subsequent shipment of the unit to a location other
than the address of the purchaser.
We do not provide guarantee for damage that has been caused or contributed to for the
following reasons:
Unsuitable or improper use, faulty installation or commissioning by the purchaser or a
third party, normal wear, negligent handling, defective maintenance, unsuitable coating
products, substitute materials and the action of chemical, electrochemical or electrical
agents, except when the damage is attributable to us.
Abrasive coating products such as red lead, emulsions, glazes, liquid abrasives, zinc
dust paints and so forth reduce the service life of valves, packaging, spray guns, nozzles,
cylinders, pistons etc. Wear and tear due to such causes are not covered by this guarantee.
Components that have not been manufactured by WAGNER are subject to the original
warranty of the manufacturer.
Replacement of a component does not extend the period of warranty of the device.
The unit should be inspected immediately upon receipt. To avoid losing the warranty, we
or the supplier company are to be informed in writing about obvious faults within 14 days
upon receipt of the device.
We reserve the right to have the warranty compliance met by a contracting company.
The services provided by this warranty is dependent on evidence being provided in the
form of an invoice or delivery note. If the examination discovers that no warranty claim
exists, the costs of repairs are charged to the purchaser.
It is clearly stipulated that this warranty claim does not represent any constraint on statutory
regulations or regulations agreed to contractually in our general terms and conditions.
J. Wagner AG
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GM 4700AC
OPERATING MANUAL
VERSION 09/2011
ORDER NUMBER DOC2311730
3.3 CE DECLARATION OF CONFORMITY
Herewith we declare that the supplied version of
GM 4700AC 25 MPa
GM 4700AC-H 25 MPa
complies with the following guidelines:
2006/42/EG
94/9/EG
Applied standards, in particular:
DIN EN ISO 12100-1, 2004 DIN EN ISO 14121,2007
DIN EN ISO 12100-2, 2004 DIN EN ISO 3746, 2009
DIN EN 1127-1, 2008 DIN EN 13463-1, 2002
DIN EN 1953, 2010 DIN EN 13463-5: 2004
DIN EN ISO 13732-1, 2006
Applied national technical standards and speci cations, in particular:
a) BGR 500 Part 2, chapter 2.36 "Working with liquid ejection devices"
b) BGR 500 Part 2, chapter 2.29 "Working with coating materials"
c) BGR 104 Explosion protection rules
d) TRBS 2153 Avoiding ignition risks
e) BGI 740 Painting rooms and equipment
f) ZH 1/406 Guidelines for liquid ejection devices
Note: All titles can be ordered from Heymanns Publishing House in Cologne, or
they can be found on the Internet.
CE Certi cate of Conformity
The CE certi cate of conformity is enclosed with this product. If needed, further copies
can be ordered through your WAGNER dealer by specifying the product name and serial
number.
Order number: 2316429
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GM 4700AC
OPERATING MANUAL
VERSION 09/2011
ORDER NUMBER DOC2311730
The gun is suitable for atomizing liquid materials, particularly coating materials, using the
AirCoat process.
Note:
Please contact your local WAGNER dealer and the paint manufacturer if you encounter
application problems.
4 DESCRIPTION
Qty Order No. Description
1 2313585 GM 4700AC 25 MPa, NPSM1/4“ material connection
1 2315700 GM 4700AC-H 25 MPa, NPSM1/4“ material connection
These AirCoat gun is available in two di erent variants. The choice of air cap and nozzle are
dependent on application, therefore these components are not included in the scope of
delivery. A selection guide of gun accessories can be found in chapter 8.
Qty Order No. Description
1 2316429 CE Declaration of Conformity
1 2311729 Operating manual German
1 See Chapter 1. Operating manual in local language
1 394335 Spring cap 16 MPa; 160 bar; 2320 psi
For special versions the delivery note applies.
4.2.2 STANDARD EQUIPMENT
4.1 FIELDS OF APPLICATION, USE IN ACCORDANCE WITH THE INSTRUCTIONS
4.1.1 PROCESSABLE MATERIALS
Top-coat paints, primer paints, corrosion protection solvents, textured paints, lyes, staining
solvents, clear paints, separating uid, etc. on a solvent or water basis. If you want to spray
working materials other than the aforementioned, please contact a Wagner representative.
4.2 SCOPE OF DELIVERY
4.2.1 VARIANTS FOR APPLICATION RANGE UP TO 25 MPA; 250 BAR; 3625 PSI
WARNING
Hot coating substances!
Burns
Wear antistatic protective gloves.
When operating the unit with a coating material with a
temperature of > 43 °C;109.4 °F: Identify the unit with a warning
label that says „Warning - Hot Surface“.
The standard equipment for guns includes:
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GM 4700AC
E
C
B
G
A
D
F
B_02378
OPERATING MANUAL
VERSION 09/2011
ORDER NUMBER DOC2311730
Metals Plastics
Tungsten carbide Stainless steel 1.4305 POM FPM
Stainless steel 1.4301 Stainless steel 1.4104 PTFE PA
4.3.1 MATERIALS OF WETTED PARTS
AirCoat Spray gun
Description Units GM 4700AC GM 4700AC-H
Maximum air inlet pressure MPa/ psi/ bar 0.8/ 120/ 8
Maximum material pressure * MPa/ psi/ bar 25/ 3625/ 250 (16/ 2320/ 160*)
Fluid inlet Inch NPSM1/4
Air connection Inch G1/4“
Filter ** Mesh 50/ 100/ 150/ 200
Weight g/ oz 595 g/ 20.9 oz
pH range of the material pH 3.5 - 9.0
Maximum material temperature °C/ °F 55/ 131 80/ 176
Maximum air temperature °C/ °F 43/ 109
Sound level at 0.3 MPa; 3 bar; 43.5
psi air pressure and 11 MPa; 110
bar; 1549 psi material pressure ***
dB(A) < 82
* Spring cap type 16 MPa; 160 bar; 2320 psi is included
** Filter types see paragraph 8.4.
*** A rated sound pressure level measured at 0.5 m distance according to DIN EN 14462:2005
Dimensions
Measurement mm inch
A 173 6.81
B 216 8.50
C 48 1.89
D 152 5.98
E 39 1.54
F - NPSM1/4“
G - G1/4“
4.3.2 TECHNICAL DATA
4.3 DATA
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GM 4700AC
A
J
I
H
K
B
C
E
F
G
D
P_02379
OPERATING MANUAL
VERSION 09/2011
ORDER NUMBER DOC2311730
Description
A Suspension hook
B Regulator for shaping air
C Spring cap 16 MPa; 160 bar; 2320 psi
D Trigger
E Trigger locking device
F Air connection
G Fluid inlet
H Union nut with nozzle protection
I Nozzle / Air cap
J Gun housing
K Turning handle with lter housing
If trigger (D) is operated with released locking device (E), the air valve opens rst. Atomizing
air ows through air connection (F) to air cap (I). The material valve opens rst if approx.
1/2 of the trigger guard's path is covered. The quantity of air for the atomization of the jet
spray is preset via the external air automatic controller. The spray pattern can be adjusted
using shaping air regulator (B).
The spray gun is secured with locking device (E) (the locking device turned in the spraying
direction and fastened in the groove).
4.4 FUNCTIONAL DESCRIPTION
4.4.1 DESIGN OF THE SPRAY GUN
4.4.2 FUNCTIONS OF THE SPRAY GUN
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GM 4700AC
A
M
K
B
C
E D F G
H
J
L
I
B_02380
OPERATING MANUAL
VERSION 09/2011
ORDER NUMBER DOC2311730
5 COMMISSIONING AND OPERATION
5.1.1 TYPICAL AIRCOAT SPRAYING SYSTEM
A Material pump
B Pressure air shut-o valve
C Pressure regulator
D Air pressure regulator with air lter
E Grounding cable
F Air hose
The spray gun GM 4700 AC must be combined with various components to make up
a spraying system. The spraying system shown in the gure is only one example of an
AirCoat spraying system. Your Wagner distributor would be happy to assist you in creating
a spraying system solution that meets your individual needs.
You must familiarize yourself with the operating instructions and the safety regulations for
all additional system components before starting with commissioning.
5.1 INSTALLATION AND CONNECTION
G AirCoat gun
H High pressure paint hose,
electrically conductive
I High pressure lter/ uid pressure
release
J Return line
K Pump mounting trolley
L Suction system
M Compressed air main
WARNING
Incorrect installation/operation!
Risk of injury and damage to the device
When putting into operation and during all work, read and
follow the operating instructions and safety regulations for the
additional system components required.
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