WAGNER GA 2000EAC Translation Of The Original Operating Manual Download Page 55

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Summary of Contents for GA 2000EAC

Page 1: ...2 GA 2000EAC GA 2005EAC II 2G EEx 0 24 mJ T6 Atex 95 Translation of the original Operating manual Electrostatic AirCoat spray gun for automatic operating mode with flat or round jet nozzles Edition 12 2008 ...

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Page 3: ...ection identification 9 2 5 3 Maxi surface temperature 9 2 5 4 Safety instructions 10 2 6 Establishment of stationary electrostatic systems 10 3 PRODUCT LIABILITY AND WARRANTY 11 3 1 Important notes on product liability 11 3 2 Warranty 11 3 3 CE Conformity 12 3 4 German Regulations and guidelines 13 3 5 PTB Conformity Certification 14 4 DESCRIPTION 15 4 1 Area of application using in accordance wi...

Page 4: ...ection of the gun against pollution 31 6 MAINTENANCE 32 6 1 Finishing work and cleaning 33 7 TROUBLE SHOOTING AND SOLUTIONS 34 8 REPAIR WORK 36 8 1 Exchange or cleaning of filters 36 8 2 Adjustment of the valve rod seal 36 8 3 Exchange of complete valve rod 37 8 4 Exchange of valve rod seals 38 8 5 Exchange of paint channel 39 8 6 Disassembly of aircoat nozzle body round jet 40 9 ACCESSORIES 41 9 ...

Page 5: ...material damage Caution a possibly hazardous situation Non obser vance can result in minor injury Note provide information on particular characteristics and how to proceed Caution a possibly hazardous situation Non obser vance can cause material damage 3 2 4HIS LINE WARNS OF THE HAZARD 0OSSIBLE CONSEQUENCES OF FAILING TO OBSERVE THE WARNING INSTRUC TIONS 4HE SIGNAL WORD POINTS OUT THE HAZARD LEVEL...

Page 6: ...ON ACTIVE PARTS NFORM STAFF ABOUT PLANNED WORK OBSERVE ELECTRICAL SAFETY REGULATIONS NSURE THAT THE UNIT IS OPERATED AND REPAIRED ONLY BY TRAINED PERSONS NSURE THAT THE mOOR OF THE WORKING AREA IS ANTI STATIC IN ACCORDANCE WITH 0ART e MEASUREMENT IN ACCORDANCE WITH NSURE THAT ALL PERSONS WITHIN THE WORKING AREA WEAR ANTI STATIC SHOES E G SHOES WITH LEATHER SOLES NSURE THAT DURING SPRAYING PERSONS ...

Page 7: ... doctor immediately Avoid danger of injury through recoil forces Ensure that you have a ﬁrm footing when operating the spray gun Only hold the spray gun brieﬂy in any one position Electrostatic charges can occur on the unit due to the electrostatic charge and the ﬂow speed involved in spraying These can cause sparks and ﬂames upon discharge Ensure that the unit is always earthed Earth the work pie...

Page 8: ... OF THE PAINTS SOLVENTS AND CLEANING AGENTS BEING USED 4AKE THE SPECIlED PROTECTIVE MEASURES IN PARTICULAR WEAR SAFETY GOGGLES PROTECTIVE CLOTHING AND GLOVES AS WELL AS HAND PROTECTION CREAM IF NECESSARY 5SE A MASK OR BREATHING APPARATUS IF NECESSARY OR SUFlCIENT HEALTH AND ENVIRONMENTAL SAFETY PERATE THE UNIT IN A SPRAY BOOTH OR ON A SPRAYING WALL WITH THE VENTILATION EXTRACTION SWITCHED ON 7EAR ...

Page 9: ...e spray gun are charged electrostatically by the high voltage ﬁeld of the spray pistol Harmless discharges brush discharges are possible after contact with plastic parts They are completely harmless for people The corona discharge at the electrode end is visible during darkness at a distance of be tween 4 and 10 mm 0 15 and 0 4 inches between the spray gun and spray object S DElNED IN THE IRECTIVE...

Page 10: ...ACE SPRAYING ELECTROSTATIC O NOT SPRAY SYSTEM PARTS WITH ELECTROSTATIC E G ELECTROSTATIC SPRAY GUN EDIUM SUPPORTING ATOMIZING 4O ATOMIZE THE MATERIAL USE ONLY WEAKLY OXIDIZING GASES E G AIR LEANING F THERE ARE DEPOSITS ON THE SURFACES THE UNIT MAY FORM ELECTROSTATIC CHARGES LAMES OR SPARKS CAN FORM IF THERE IS A DISCHARGE 2EMOVE DEPOSITS FROM THE SURFACES TO MAINTAIN CONDUCTIVITY 5SE ONLY A DAMP C...

Page 11: ...T OF THE UNIT TO A LOCATION OTHER THAN THE ADDRESS OF THE PURCHASER 4HIS WARRANTY DOES NOT COVER DAMAGE CAUSED BY 5NSUITABLE 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...

Page 12: ...spray gun GA 2000EACFB Automatic spray gun GA 2000EAR Automatic spray gun GA 2000EACR Automatic spray gun GA 2005EAF Automatic spray gun GA 2005EACFB Automatic spray gun GA 2005EAR Automatic spray gun GA 2005EACR Complies with the following guidelines 98 37 EG 89 336 EWG 2002 95 EG 94 9 EG 73 23 EWG 2002 96 EG Applied standards in particular EN 12100 1 EN 1953 EN 55022 EN 61000 4 4 EN 61000 6 1 EN...

Page 13: ...n ﬂammable liquids e CHV 11 Regulations on electrical equipment in Ex areas f BGR 104 Explosion protection rules g BGR 132 Avoiding ignition risks h BGR 180 Setting up for cleaning with solvents for cleaning workpieces with solvents i ZH 1 406 Guidelines for liquid ejection devices j BGI 740 Painting rooms and equipment k BGI 764 Electrostatic coating Note All titles can be ordered from Heymanns P...

Page 14: ...14 GA2000EAC GA2005EAC OPERATING MANUAL EDITION 12 2008 PART NO 350741 3 5 PTB CONFORMITY CERTIFICATION ...

Page 15: ...ing solvents of the explosion class II A Enamels primers textured paints etc which have a specific resistance of 150 kΩ according to the WAGNER or Ransburg scale The effectiveness of the spraying action is always dependant on the composition of the paint being used e g pigments or resin Note With very highly conductive materials or those with a very high electrical resistance the electrostatic eff...

Page 16: ...862 350024 350043 350071 350003 2301864 350027 350044 350045 350070 1 1 1 1 1 1 1 1 1 1 1 179901 Universal spanner 1 1 1 1 1 128901 Nozzle spanner 1 1 1 1 1 1 1 1 1 1 1 350910 Set of seals valve rod 1 1 1 384555 Connector M16x1 5 NPSM1 4 1 1 1 1 1 1 1 1 1 1 1 9100577 Instruction tag 1 1 1 1 1 1 1 1 1 1 1 380891 CE Declaration of Conformity 1 1 1 1 1 1 1 1 350740 Operating manual German 1 1 1 35074...

Page 17: ...ergy accord EN 50176 classification for type A 0 24 mJ Material hose connection M16x1 5 Atomizing air connection ø 10 mm ø 0 39 inch Fan air connection ø 8 mm ø 0 31 inch Control air connection ø 8 mm ø 0 31 inch Gun cable 11 m 36 1 ft or 0 2 m 0 7 ft Weight without cables 1 450 kg 3 20 lb Maxi temperature material 60 C 140 F Working temperature range 5 40 C 41 104 F Min electric material resistan...

Page 18: ...r is opened The spray jet width is adjusted via the air control knob on the control unit EPG 3000 or via the fan air regulation D1 on the spray gun GA 2000EA in the case of flat jet spraying The high voltage at the spray gun can be adjusted at the voltage regulator in the control unit EPG 3000 and can be adapted to the paint or to the spraying object Securing the gun 1 Switch off the mains at the ...

Page 19: ...to atom ize the material The AirCoat air at 0 0 25 MPa 0 2 5 bar 0 36 psi produces a soft jet which largely eliminates the problem of overlapping boundaries The spray jet can be adjusted by turning the nozzle nut AirCoat air Multi channel swirl nozzle Spray jet Nozzle nut Material AirCoat air Advantages of AirCoat High painting capacity Low fogging tendency Good finish High viscosity paints can ea...

Page 20: ...trostatic field Less working time Electrode Charged particles Grounded object 4 5 2 AIRCOAT ATOMIZING FLAT JET SPRAY PROCESS In the Brillant AirCoat process high pressure of 3 15 MPa 30 150 bar 435 2176 psi is used to atomize the material The AirCoat air at 0 05 0 25 MPa 0 5 2 5 bar 7 36 psi produces a soft jet which largely eliminates the problem of overlapping boundaries There is a pos sibility ...

Page 21: ...the figure is only one example of an electrostatic AirCoat spraying system It is not an ac tual system design Contact your WAGNER distributor for as sistance in designing a system to meet your needs The operating instructions and the safe ty regulations for the additional system components used must be read before starting up 5 1 SET UP AND CONNECT WARNING Incorrect installation operation Risk of ...

Page 22: ...opriate spraying wall with the venti lation extraction switched on Observe national and local regulations for the outgoing air speed SIHI_0028_GB 54 MPURITIES IN THE SPRAYING SYSTEM 3PRAY GUN BLOCKAGE MATERIALS HARDEN IN THE SPRAYING SYSTEM LUSH THE SPRAY GUN AND PAINT SUPPLY WITH A SUITABLE CLEANING AGENT 3 SIHI_0029_GB DANGER Bursting hose bursting threaded joints Danger to life from injection o...

Page 23: ...thing of spray booth conveyor system and hangers to the building earth in accordance with the operating instruction or the manufacturer s information Earthing of all conductive parts within the working area The earthing resistance of the work piece must not exceed 1 MΩ Mega Ohm Connect the control unit to the mains system earth 7 2 ISCHARGE OF ELECTROSTATICALLY CHARGED COMPONENTS IN ATMO SPHERES C...

Page 24: ...m cable cross section Control unit 4 mm AWG 12 Pump 4 mm AWG 12 Paint container 4 mm AWG 12 Movement unit 16 mm AWG 6 Conveyor 16 mm AWG 6 Spraying booth 16 mm AWG 6 Spraying stand 16 mm AWG 6 Conveyor Floor antistatic Pump Paint container Spraying stand Earthing cable Control module System earth System earth Work piece ...

Page 25: ...viscosity of the paints is of great importance The best results are obtained with paints between 25 and 40 DIN sec measured in immersion flow cup DIN 4 mm 0 16 inch In most cases the application of paints of up to 60 DIN sec for thick layers does not cause problems In the case of application problems contact the paint producer 5 2 1 VISCOSITY CONVERSION TABLE ...

Page 26: ...makers Do not work with the electrostatic spray gun Remain outside the area of the electrostatic spray gun work piece SIHI_0049_GB SIHI_0065_GB WARNING Unintentional putting into operation Risk of injury Before all work on the unit in the event of work interruptions and functional faults Switch off the energy compressed air supply Relieve the pressure from the spray gun and unit Secure the spray g...

Page 27: ...air hose ø 8 mm ø 0 31 inches marked red for the control air to the control unit EPG 3000 When using flat jet nozzles Connect the air hose ø 8 mm ø 0 31 inches marked green for the fan air to the control unit EPG 3000 Connect electric cable to the control unit Old equipment New equipment Visually check the permissible pressures for all the system components Set material pressure and use a suitable...

Page 28: ...other flat jet nozzle See accessories 5 4 WORKING 5 4 2 ADJUST THE SPRAY ANGLE WITH FLAT JET NOZZLES Spray gun GA 2000EAC The spray pattern can be adjusted to suit the object being sprayed using the fan air regula tor on the gun Other nozzle sizes can be used to obtain larger or smaller spraying patterns Spray gun GA 2005EAC The spray pattern can be adjusted to suit the object being sprayed using ...

Page 29: ...o table 9 1 with nozzle spanner 1 By means of nozzle spanner A loosen nozzle insert B by a half turn 2 Remove nozzle spanner and switch on for a short amount of time 3 After cleaning the nozzle retighten 5 4 4 EXCHANGE OF AIRCOAT ROUND JET NOZZLE INSERT DANGER Exploding gas air mixture Danger to life from ﬂying parts and burns Never spray into a closed container Earth the container SIHI_0008_GB ...

Page 30: ... C 5 Remove seal nipple E and nozzle body D with universal spanner from adapter F 6 Screw seal ring together O ring G to adapter F and tighten seal ring by hand 7 Fit Brillant flat jet nozzle K on paint channel in the adapter F 8 Fit air cap H onto Brillant flat jet nozzle K Attention Make sure that the pins in the air cap fit into the grooves in the flat nozzle 9 Fit cap ring I with air cap H ont...

Page 31: ...n nozzle K Attention Make sure that the pins in the air cap fit into the grooves in the nozzle 8 Fit cap ring I with air cap H onto spray gun body F 9 Adjust desired jet level by means of air cap horns X and tighten cap ring I by hand 5 4 7 PROTECTION OF THE GUN AGAINST POLLUTION To protect the gun against pollution it is recommended to cover it with a plastic bag from dirt ever spray etc Advantag...

Page 32: ...er immerse the spray gun in cleaning agent SIHI_0066_GB SIHI_0004_GB WARNING Incorrect maintenance repair Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by spe cially trained staff or a WAGNER service center Before all work on the unit and in the event of work interrup tions Switch off the energy compressed air supply Relieve the pressure from the s...

Page 33: ...le insert B by a half turn If the flat jet nozzle is fitted Remove and clean the AirCoat nozzle 5 Thoroughly flush spray gun 6 Relieve spray gun and unit pressure 7 Clean the body of the gun with solvent which has been recommended by the paint manufacturer and dry with a cloth or blow gun DANGER Exploding gas air mixture Danger to life from ﬂying parts and burns Never spray into a closed container...

Page 34: ...pter 9 Material viscosity too high Thin material acc to manufacturer s instruction Material pressure too high Reduce material pressure Damaged nozzle Replace nozzle Damaged electrode Replace nozzle body or air cap Leaking air valve Damaged seals on the valve rod Exchange seals see chapter 8 4 Sealing screw loose Tighten sealing screw Poor wrap round or electrostatic effect Poor earthing at object ...

Page 35: ...p round No high voltage Check function of control unit in accordance with its manual Air passages damp Cleaning air passages and drying Paint conductivity too high Check resistance of paint in accordance with paragraph 4 1 1 Leaking air valve Damaged seals on the valve rod Exchange seals see chap 8 4 ...

Page 36: ...ace it with a new one Assemble in reverse order 8 2 ADJUSTMENT OF THE VALVE ROD SEAL In case paint leaks at the valve rod near the area A 1 Pull trigger and thoroughly clean paint channel with solvent 2 Tighten the sealing screw 4 carefully with universal spanner 3 If leaking continues see chapter 8 3 Pump Gun SIHI_0048_GB WARNING Incorrect maintenance repair Danger to life and equipment damage On...

Page 37: ...m the paint seal housing 9 5 Carefully pull out complete valve rod using surface D replace if necessary 6 Reassemble in reverse order do not forget to screw in the centre packing screw 4 Put locking nut X and compression spring in place and tighten by hand CAUTION Unsuitable tool Damage to seals and sealing surfaces Do not hold the valve rod with pliers or a similar tool SIHI_0006_GB 54 EAKING SPR...

Page 38: ...ling element 1 D using a small pliers 3 Remove compression ring with O ring 2 and seal 3 4 If the tappet seal is faulty undo the nut 6 with the universal spanner and pull out the tappet seal 7 5 Replace the O ring 2 the front seal 3 and if necessary the tappet seal 7 or the piston seal 5 6 Reassemble valve rod in reverse order and secure thread with Loctite 270 See chap 8 3 Secure screw connection...

Page 39: ...zle is fitted 1 Unscrew cap ring 5 2 Remove air cap 6 and Brillant AirCoat nozzle 7 3 Unscrew seal screw 3 with paint channel assembly tool 4 Pull off the paint channel 4 with the round screw hook out of the gun attachment Assemble in reverse order use screw 3 again Note Clean attachment and paint channel separately Otherwise they can stick together Insert the paint channel as shown below note pos...

Page 40: ...round jet nozzle insert C and threaded fitting E with care do not clean with sharp metal objects Use nozzle cleaning brush parts no 9997001 Replace any worn out parts Assemble in reverse order Note round jet EAC Care must be taken when assembling that the nozzle nut is not tight to the nozzle body D There must be room for the AirCoat air between nut and nozzle body CAUTION Defective AirCoat nozzle...

Page 41: ...UAL EDITION 12 2008 PART NO 350741 Part No Marking Jet width mm inch Recommended gun filter red 200 meshes yellow 100 meshes white 50 meshes 9 ACCESSORIES 9 1 ROUND JET NOZZLE INSERTS The round jet tips are especially suited to spray pipes profiles and complex work pieces 9 1 1 NOZZLE SCREW JOINT ASSY Part No Description 132922 Nozzle screw joint assy Standard nozzle Jet width in mm inch at a dist...

Page 42: ...17 17 20 17 30 17 40 17 50 17 60 17 80 0 43 0 017 20 30 40 50 60 80 148219 148319 148419 148519 148619 148819 19 20 19 30 19 40 19 50 19 60 19 80 0 48 0 019 20 30 40 50 60 80 OPERATING MANUAL EDITION 12 2008 PART NO 350741 9 2 NOZZLES AC BRILLANT O T R A 0 G N I K R A E Z I 3 H C N I M M G N I Y A R P 3 E L G N A D E D N E M M O C E 2 R E T L l N U G PPLICATION ATURAL PAINT 4RANSPARENT LACQUER IL ...

Page 43: ...60 80 148431 148631 148831 31 40 31 60 31 80 0 79 0 031 40 60 80 148435 148635 148835 35 40 35 60 35 80 0 90 0 035 40 60 80 OPERATING MANUAL EDITION 12 2008 PART NO 350741 Nozzles AC brillant o N t r a P g n i k r a M e z i S h c n i m m e l g n a d e d n e m m o c e R r e t l fi n u g Application Mica paint Zinc dust coating Rustprooﬁng paint Distemper s e h s e M 0 5 e t i h w Spraying Jet width...

Page 44: ... piece Part No for 10 pieces Filter type Mesh For use with nozzle sizes 34383 97022 Filter insert red 200 0 007 0 015 43235 97023 Filter insert yellow 100 0 015 0 019 34377 97024 Filter insert white 50 0 017 0 021 Part No Description 139045 In line filter with filter inlet 200 mesh 42029 Lifting screw use removing filter insert ...

Page 45: ...0 28 0 39 inches blue order by the meter 381151 Air hose ø 5 5 8 mm ø 0 22 0 31 inches red order by the meter 381152 Air hose ø 5 5 8 mm ø 0 22 0 31 inches green order by the meter 9984481 High pressure hose M16x1 5 7 5 m DN 4 mm 27 MPa 270 bar M16x1 5 24 6 ft ID 0 16 inches 3916 psi 9984482 High pressure hose NPSM1 4 7 5 m DN 4 mm 27 MPa 270 bar NPSM1 4 24 6 ft ID 0 16 inches 3916 psi 123446 Doub...

Page 46: ...46 GA2000EAC GA2005EAC OPERATING MANUAL EDITION 12 2008 PART NO 350741 ...

Page 47: ...T OF ANY QUERIES 4YPE OF DELIVERY REQUIRED AIR FREIGHT OR MAIL SEA ROUTE OR OVERLAND ROUTE ETC ARKS IN SPARE PARTS LISTS OTE TO COLUMNu h IN THE FOLLOWING SPARE PARTS LISTS U 7EARING PARTS OTE O LIABILITY IS ASSUMED FOR WEARING PARTS L OT PART OF STANDARD EQUIPMENT AVAILABLE HOWEVER AS ADDITIONAL EXTRA SIHI_0004_GB WARNING Incorrect maintenance repair Risk of injury and damage to the equipment Rep...

Page 48: ...50111 Valve rod GA 2000EAC assy 5 1 9992743 Screwed connecting piece straight 6 1 9998617 Thrust collar red 7 1 9998043 Screwed connecting piece straight 8 1 9998045 Thrust collar blue 9 1 9971164 O ring 10 1 9994269 Compression spring 11 1 350501 Paint channel 12 1 179789 Sealing screw Attachment must only be removed by WAGNER Service Agency Must only be removed by WAGNER Service Agency 10 2 SPAR...

Page 49: ...nut 27 1 350344 Plate 28 1 9998041 Knurled cap 29 1 350342 Nipple 30 1 350341 Air control valve 31 1 9971319 O ring 32 1 350309 Gun bracket 33 1 350214 Air regulator assy 34 1 9998974 Threaded plug 35 2 350319 Distance bush 36 2 9900318 Cheese head screw M8 20 mm 0 79 inches long 37 1 350371 Distributor 38 1 350370 Banjo bolt 44 1 see chapter 9 5 48 2 9900810 Pan head screw 49 1 350620 Data plate ...

Page 50: ...ocking piece 4 1 350111 Valve rod GA 2000EAC assy 5 1 9992743 Screwed connecting piece 6 1 9998617 Straight 7 1 9998043 Thrust collar red 8 1 9998045 Screwed connecting piece straight 9 1 9971164 Thrust collar blue 10 1 9994269 O ring 11 1 350501 Compression spring Attachment must only be removed by WAGNER Serv ice Agency Must only be removed by WAGNER Service Agency 10 3 SPARE PARTS LIST GA 2005E...

Page 51: ... 1 350274 Air cap EAC Brillant 25 1 350377 Cap ring 32 1 350309 Gun bracket 34 1 9998974 Threaded plug 35 2 350319 Distance bush 36 2 9900318 Cheese head screw M8 20 mm 0 79 inches long 37 1 350371 Distributor 38 1 350370 Banjo bolt 39 1 9998074 Screw fitting elbow 44 1 see chapter 9 5 48 2 9900810 Pan head screw 49 1 350620 Data plate GA 2005EAC 52 1 350427 Locking bracket 53 1 9903314 Phillips h...

Page 52: ... spring 7 1 350322 Valve rod spring guide 8 1 179339 Tappet seal 9 1 350323 Nut 10 1 350508 Valve rod 11 1 179342 Sealing screw 12 1 350505 Seal 13 1 9971182 O ring 14 1 179343 Compression ring 15 1 179236 Valve ball holder Wearing part Included in set of seals valve rod 350910 Length compensation on this treated connection Hold in position with Loctite 270 10 4 SPARE PARTS LIST VALVE ROD EAC ...

Page 53: ...scription 1 1 161360 Handle 2 1 43303 Handle sealing washer 3 1 Filter insert see chapter 9 3 4 1 43590 Compression spring 5 1 139259 Adapter 6 1 42029 Lifting screw 139045 In line filter assy Not part of standard equipment for the spray gun But is available as an optional extra 10 5 SPARE PARTS LIST IN LINE FILTER ...

Page 54: ...s WAGNER SPRAYTECH Benelux BV Zonnebaan 10 NL 3542 EC Utrecht PO Box 1656 3600 BR Maarssen Telephone 31 0 30 241 4155 Telefax 31 0 30 241 1787 E Mail info wagner wsb eu Italy WAGNER COLORA S r l Via Fermi 3 I 20040 Burago di Molgora MI Telephone 39 039 625021 Telefax 39 039 6851800 E Mail info wagnercolora com Japan WAGNER Spraytech Ltd 2 35 Shinden Nishimachi J Daito Shi Osaka 574 0057 Telephone ...

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Page 56: ...ERMANY 7 2 MB TTO ILIENTHAL 3TR 0OSTFACH ARKDORF 4ELEPHONE 4ELEFAX AIL SERVICE STANDARD WAGNER GROUP COM 3WITZERLAND 7 2 NDUSTRIESTRASSE 0OSTFACH LTSTËTTEN 4ELEPHONE 4ELEFAX AIL REP CH WAGNER GROUP CH WWW WAGNER GROUP COM 350741 ...

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