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WAGNER GA 5000EAC, Operating Manual

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WAGNER GA 5000EAC Operating Manual Download Page 1

B_05738

GA 5000EAC

Electrostatic Automatic Spray Gun (AirCoat)

Translation of the Original Operating Manual

 0102 

 II 2 G 0.24 mJ

For professional use. 
Always observe the information in this manual, particularly the safety
instructions and the warning instructions. Store the manual in a safe place.

Edition: 09/2022

Summary of Contents for GA 5000EAC

Page 1: ...irCoat Translation of the Original Operating Manual 0102 II 2 G 0 24 mJ For professional use Always observe the information in this manual particularly the safety instructions and the warning instruct...

Page 2: ......

Page 3: ...nt 14 4 1 2 A Safe Work Environment 14 4 1 3 Personnel Qualifications 15 4 2 Safety Instructions for the Personnel 15 4 2 1 Personal Safety Equipment 15 4 2 2 Safe Handling of WAGNER Spray Devices 16...

Page 4: ...g the air pressure regulator 39 7 4 Spraying 40 7 5 Pressure Relief Work Interruption 41 7 6 Dismounting the Gun Cover 42 7 7 Flushing Out Clogged Round Jet Nozzles 43 7 8 Replacing nozzle insert of r...

Page 5: ...1 2 AirCoat Round Jet Nozzle Inserts 69 13 2 Flat jet nozzles 69 13 2 1 ACF 5000 Air Caps Flat Jet 69 13 2 2 ACF 5000 AirCoat Flat Jet Nozzles 70 13 3 Filter 71 13 4 Hoses and Cables 72 13 4 1 Gun Cab...

Page 6: ...instructions fall into the following categories DANGER Immediate risk of danger Non observance will result in death or serious injury WARNING Potential danger Non observance may result in death or ser...

Page 7: ...uage Order no English 2360922 Spanish 2367696 French 2367694 Russian 2373688 Italian 2367695 Chinese 2373690 Japanese 2382578 Additional languages upon request or at www wagner group com 1 5 ABBREVIAT...

Page 8: ...the work assigned to him her and detect possible hazards based on his her technical training knowledge and experience in rele vant provisions Skilled person in the context of DGUV 209 052 A person wh...

Page 9: ...ting products and can be used in potentially explosive areas See Explosion Protection Identification in chapter Explosion Protection Identification 8 11 2 4 PROCESSIBLE WORKING MATERIALS 4 Coating pro...

Page 10: ...he charging ability can be read from the actual values for high voltage kV and for the spray current A shown in the illuminated displays on the EPG 5000 control unit High kV value low A value ok Low k...

Page 11: ...ice suitable for zone 1 G Ex atmosphere gas 0 24 mJ Maximum ignition energy SIRA 16 ATEX 5290 X Number of type examination certificate X see chapter Identification X 8 11 Temperature notes Maximum sur...

Page 12: ...only to original WAGNER control units 3 3 USE IN AREAS SUBJECT TO EXPLOSION HAZARDS Electrostatic surface spraying 4 Never spray device parts using electrostatic equipment electrostatic spray gun Cle...

Page 13: ...x air pressure 0 8Pa 8bar 116psi Wagner International AG CH 9450 Altst tten GA 5000EACEC Art Nr 2360829 high voltage max 80kV DC current max 100uA DC max mat pressure 25MPa 250bar 3626psi max air pres...

Page 14: ...commission if device poses a danger or is damaged 4 Must be de energized before work is commenced 4 Secure the device against being switched back on without authorization 4 Inform personnel about plan...

Page 15: ...sonnel Qualifications Danger due to incorrect use of device Risk of death due to untrained personnel 4 Ensure that the operating personnel has been instructed by the operator in accordance with the op...

Page 16: ...at least every 12 months for their work safe condition in accordance with DGUV regulation 100 500 chapter 2 29 and chapter 2 36 4 For shut down devices the examination can be suspended until the next...

Page 17: ...from the outside in any other way 4 Ensure that the hoses are never kinked Observe maximum bending radii 4 Ensure that no work is ever performed with a damaged hose 4 Make sure that the hoses are neve...

Page 18: ...t 4 2 6 Touching Hot Surfaces Danger due to hot surfaces because of hot coating products Risk of burn injuries 4 Only touch hot surfaces if you are wearing protective gloves 4 When operating the devic...

Page 19: ...operated until these defects are remedied 4 2 9 Safety Relevant Information about Discharges The plastic parts of the spray gun are charged electrostatically by the high voltage field In case of conta...

Page 20: ...ACIC Design B_05739 1 2 3 4 5 6 7 8 10 11 12 13 14 15 9 1 Front cover 9 Shaping air setting 2 Union nut on nozzle protection 10 Gun holder 3 Air cap 11 Product hose 4 Flat jet nozzle 12 Sealing fittin...

Page 21: ...1 4 5 Shaping air or atomizing air connec tion D10 blue 3 Control air connection D6 red 5 1 2 GA 5000EACEC Design 1 2 3 4 5 6 7 9 10 11 12 13 14 8 B_05740 1 Front cover 8 Air diffuser housing 2 Union...

Page 22: ...ol unit is described in this operating manual The high voltage for the GA 5000EAC spray gun is activated directly on the EPG 5000 control unit or by a signal from the superordinate controller The high...

Page 23: ...sure regulator The two air streams do not flow separately until they are downstream of the air valve so that the pressure of the shaping air corresponds roughly to that of the atomizing air and so tha...

Page 24: ...danger to persons Electrical ground monitoring of the spray gun Anti contact guard for flat jet nozzle 5 4 EXTENT OF DELIVERY Stk Order no Designation 1 2360898 Spray gun GA 5000EACIC 1 2360899 Spray...

Page 25: ...g lb 1 0 kg 2 2 lb Flow rate according to nozzle size see nozzle table in Accessories 8 69 chapter Input voltage maximum Vpp 20 Input current maximum A AC 1 0 Output voltage maximum kV DC 80 Output cu...

Page 26: ...B_05047 Measurements in mm Connecting dimensions of the connection plate 18 18 4x 3 2 2x M5 M8 18 18 B_05761 Measurements in mm 5 6 SPRAYING PROCEDURE 5 6 1 Spraying Procedure with Round Jet Nozzle I...

Page 27: ...zzles Spray jet width adjustment 5 6 2 Spray process with Flat Jet Nozzle In the AirCoat process the spray product is atomized under a pressure of 3 15 MPa 30 150 bar 435 2176 psi With the help of the...

Page 28: ...to the grounded work piece by kinetic and electrostatic energy where they adhere finely dispersed to the object to be sprayed B_00138 3 2 1 1 Paint particle 3 Electrode 2 Object to be sprayed is cond...

Page 29: ...sing air pressure PZL or Air regulation LFL From open to closed Nozzle sizes DS Flow rate Electrostatics ES or or off The spray jet width of the GA 5000EACIC spray gun is adjusted via the shaping air...

Page 30: ...ust 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 withou...

Page 31: ...AC Electrostatic Automatic Spray Gun AirCoat 6 Assembly and Commissioning Order number 2360922 Edition 09 2022 31 B_05775 E B C D A F A Spray booth D Electrostatic spray gun B Controller E Work piece...

Page 32: ...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 Altst tten Made in Switzerland Schutzart IP Code 0...

Page 33: ...t supply 6 For the compressed air supply 2 Shaping air hose 7 Control cable 3 Atomizing air hose 8 Grounding cable 4 Control air hose 9 Mains cable 5 Gun cable 1 Place the control unit outside the exp...

Page 34: ...ing system Spray gun blockage products harden in the spraying system 4 Flush the spray gun and paint supply with a suitable flushing agent before commissioning DANGER Bursting hose bursting threaded j...

Page 35: ...rounded work piece causes Very bad wrap around Uneven coating Back spraying to the spray gun contamination and coater Prerequisites for perfect grounding and coating of a work piece are Clean suspensi...

Page 36: ...ly 4 mm2 AWG 12 8 Control unit 4 mm2 AWG 12 6 5 LACQUER PREPARATIONS The viscosity of the lacquer is of great importance The best spraying results are obtained with values between 25 and 40 DIN 4 seco...

Page 37: ...9 28 70 31 32 37 100 100 1 30 78 34 34 41 120 120 1 2 33 90 40 41 49 140 140 1 4 37 105 46 45 58 160 160 1 6 43 52 50 66 180 180 1 8 46 58 28 54 74 200 200 2 49 63 31 58 82 220 220 2 2 52 69 34 62 24...

Page 38: ...vel of the separating agent in the pump and fill up if necessary 8 Provide product tank tanks for flushing agent and an empty tank for return flow 9 The interface on the rear of the control unit must...

Page 39: ...n 4 don t stay inside the area of the electrostatic spray gun work piece WARNING Discharge of electrostatically charged components in atmospheres containing solvents Explosion hazard from electrostati...

Page 40: ...roduct pressure 2 Use a different nozzle see chapter Accessories 8 69 Changing the Spray Jet Width 4 Use a different nozzle see chapter Accessories 8 69 7 4 SPRAYING 1 Secure spray gun switch off cont...

Page 41: ...urn the nozzle nut 2 until it is flush with the nozzle body 3 There must be play for the atomizing air between the nozzle nut and the nozzle body Flow rate The flow rate can be reduced by 1 Minimizing...

Page 42: ...ctive clothing gloves eyewear and respirator Depressurizing the spray gun 1 Switch off high voltage at the control unit 2 Turn compressed air regulator for shaping and atomizing air on the EPG 5000 to...

Page 43: ...ir mixture Danger to life from flying parts and burns 4 Never spray into a closed tank 4 Ground the tank 1 2 1 2 B_05772 1 Remove nozzle insert 1 completely using nozzle wrench 2 2 Actuate spray gun b...

Page 44: ...UND JET AIRCOAT FLAT JET Flushing spray gun 1 Switch off control unit 2 Relieve pressure see chapter Pressure Relief Work Interruption 8 41 3 Connect the system to the flushing agent supply 4 Set prod...

Page 45: ...11 1 1 Unscrew round jet nozzle attachment 2 incl nozzle insert 3 2 Unscrew nozzle insert 3 using nozzle wrench 4 3 Unscrew nozzle nut 5 Remove nozzle screw joint 7 and sealing fitting 8 from the nozz...

Page 46: ...6 Do not screw on nozzle nut completely There must be play for the atomizing air between the nozzle nut and the nozzle body 6 Screw on nozzle insert 3 using nozzle wrench 4 7 Screw round jet nozzle a...

Page 47: ...a short time Clean these parts with a brush and dry them with a cloth or a blow gun 7 12 ELIMINATING NOZZLE CLOGGING B_05774 10 11 X Y 1 Y 9 12 12 A B A ACF5000 nozzle in spray position B ACF5000 noz...

Page 48: ...praying position insert it back into the valve housing 10 Put the air cap 10 on the nozzle 11 and pay attention to the position of the guide surfaces X 11 Screw union nut with attached nozzle guard 9...

Page 49: ...starting cleaning flushing or other manual work the high voltage must be shut down and locked to prevent it from being switched back on 4 The spray gun must be separated from the high voltage supply...

Page 50: ...data sheets Flushing procedures 1 Switch off control unit 2 Remove nozzle and clean separately in accordance with chapter Cleaning of the Nozzle Parts 8 47 3 Connect spraying system to flushing agent...

Page 51: ...sed air supply 4 Disconnect the control unit from the mains 4 Observe the operating and service manual for all work Prior to maintenance 4 Flush and clean the system according to chapter Cleaning and...

Page 52: ...es must be decommissioned and repaired immediately 8 2 4 Product Hoses Pipes and Couplings The service life of the complete hoses between product pressure generator and application device is reduced d...

Page 53: ...ozzle Attach new nozzle Poor wrap around Poor grounding at object Check grounding of object or hanger with ohmmeter Lacquer resistance too high too low Check lacquer resistance see chap ter Processibl...

Page 54: ...and in the event of work interruptions 4 Relieve the pressure from the spray gun product hoses and all devices 4 Secure the spray gun against actuation 4 Switch off the energy and compressed air supp...

Page 55: ...re property of the respective owners Loctite for example is a registered brand of Henkel 10 4 SPRAY GUN Plastic parts Gently handle all plastic parts 10 4 1 Tools For disassembling and assembling the...

Page 56: ...ight rotational movements Fitting 25 if fitting has any leaks If the fitting 25 does not come out with the product hose it must be removed from the gun adapter as follows 1 Screw in the wood screw 3 m...

Page 57: ...0 Repairs Order number 2360922 Edition 09 2022 57 4 B_05782 5 SW8 SW7 B_05783 Unscrewing the collet chuck 4 When unscrewing the collet chuck a second size 7 combination wrench must be used for counter...

Page 58: ...bly tool order no 2309368 8 B_04377 9 8 11 12 10 13 A A Do not pull out by contact wire The gold contact sleeve 10 remains either in the adapter 11 or rests on the resistor 12 Do not lose them The oth...

Page 59: ...rts 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 Perform cleaning and mounting tasks wearing gloves 3 Sp...

Page 60: ...aringly 1 B_06042 X 130 0 1 mm X 5 12 0 004 inch 2 6 2Nm 1 48 lbft SW7 SW7 2 2 2 2 3 4 B_05786 A B A Coat the hollow section with a brush Note Do not coat the pin and hexagon B Sparingly Valve rod uni...

Page 61: ...mount using assembly tool 5 3 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 3 B_04379 11 12 10 A B A Ensure the correct...

Page 62: ...ove the valve rod to the rear position so that the sealing area does not become scratched 1 2 Slightly tighten AC valve tip 2 by hand with three fingers using an assembly tool 3 Use a socket or ring w...

Page 63: ...Edition 09 2022 63 6 A 1 3 0 1mm B_06083 A Set dimension of 1 3 mm By setting the dimension soiling of air cap will be decreased 7 SW8 SW7 B_05783 Assembling the collet chuck 4 When assembling the col...

Page 64: ...r 2360922 Edition 09 2022 9 25 SW19 SW19 SW22 SW3 B_05790 2 5 Nm 1 84 lb ft 5 2 5 Nm 3 69 lb ft 10 Nm 7 37 lb ft 4 Fitting 25 Before assembling the product hose check that no fitting 25 is in the gun...

Page 65: ...2360922 Edition 09 2022 65 11 B_05792 Round jet nozzle Assembly see chapter Accessories Spare Parts Lists 8 83 Diverse nozzle sizes see chapter Round Jet Nozzles 8 69 Flat jet nozzle Assembly see chap...

Page 66: ...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 hig...

Page 67: ...e must switch off correctly 11 2 2 Product Pressure Test Connect high pressure hose to the spray gun Test the seal of the spray gun with suitable medium e g flushing agent or Marcol 52 and a maximum p...

Page 68: ...ective 2012 19 EU 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 environme...

Page 69: ...gun filter 132720 11 approx 250 10 yellow 200 mesh B_00027 132721 12 approx 250 10 132722 13 approx 250 10 132723 14 approx 250 10 132724 15 approx 250 10 132725 16 approx 250 10 black 100 mesh 13272...

Page 70: ...95609 09 60 60 395111 11 10 0 28 0 011 10 Synthetic resin lacquer PVC lacquer 395211 11 20 20 395311 11 30 30 395411 11 40 40 395511 11 50 50 395611 11 60 60 395811 11 80 80 395113 13 10 0 33 0 013 10...

Page 71: ...roofing paints Glue paints 395421 21 40 40 395521 21 50 50 395621 21 60 60 395821 21 80 80 395423 23 40 0 58 0 023 40 395623 23 60 60 395823 23 80 80 395425 25 40 0 64 0 025 40 395625 25 60 60 395825...

Page 72: ...pressure hose DN4 PN270 NPS 7 5 m PA B_06421 2302374 High pressure hose DN4 PN270 NPS 10 0 m PA 9984573 15 High pressure hose DN4 PN270 NPS 15 0 m PA 9984573 20 High pressure hose DN4 PN270 NPS 20 0...

Page 73: ...V 200 N P_00265 2326041 Paint resistance meter B_03692 999080 Wet film thickness gauge 50342 Viscosity cup DIN 4 4 mm 0 16 inch B_03224 2309368 Valve needle assembly tool B_03451 2325263 Clamping scre...

Page 74: ...ray Gun AirCoat 13 Accessories 74 Order number 2360922 Edition 09 2022 Order no Designation 380943 Complete swivel drive B_00585 380944 Cross clamp for swivel drive B_00584 2370869 Robot connection GA...

Page 75: ...perating and service manual for all work 14 1 HOW TO ORDER SPARE PARTS Always supply the following information to ensure delivery of the right spare part Order number designation and quantity The quan...

Page 76: ...asic Version 13 14 20 22 SW2 5 0 6 Nm 0 44 lb ft 50 45 22 2 1 3 4 6 7 8 9 10 17 18 20 21 24 25 32 33 34 35 36 38 39 40 41 42 43 44 B_06039 26 11 12 16 19 15 29 28 30 5 31 37 23 27 SW4 7 Nm 5 16 lb ft...

Page 77: ...14 1 2357739 Cover 15 1 2386373 GA AC product hose complete 16 1 2338853 Connecting fitting AC 17 2 9900353 Hexagon socket head cap screw 18 1 3204605 Edge filter 100 mesh 19 1 2308764 Filter socket A...

Page 78: ...Stk Order no Designation 40 1 2309945 Cylindrical helical spring 41 1 9998991 Cylindrical helical spring 42 1 2307741 End cap short 43 1 2365237 Cover labeled 44 1 2365238 Lid labeled EACIC 45 1 2338...

Page 79: ...7 18 19 20 130 0 1 mm 5 12 0 004 inch 2 3 Dismantling and assembling in accordance with chapter Repairs 8 54 Pos K Stk Order no Designation 1 1 Adapter GM 5000EAC complete 2 1 2312175 Valve housing AC...

Page 80: ...9974166 O ring 15 1 2369017 Valve rod unit GA 5000E 16 1 9910108 Hexagon nut 17 1 2357740 Collet chuck 18 1 2357741 Clamping nut 19 1 2357106 Packing complete 20 1 2325263 Clamping screw assembly tool...

Page 81: ...37 38 39 40 35 5 29 28 26 27 25 SW4 7 Nm 5 16 lb ft SW14 12 Nm 8 85 lb ft 50 50 SW3 5 Nm 3 68 lb ft 21 50 SW2 5 0 6 Nm 0 44 lb ft 50 12 13 21 SW2 5 0 6 Nm 0 44 lb ft 50 21 Dismantling and assembling...

Page 82: ...rew 20 1 2357737 Mounting bracket 21 9 9906029 Hexagon socket head cap screw 22 1 9998090 Straight screw in fitting 23 1 9998254 Straight screw in fitting 24 1 9998616 Coding ring green d8 25 1 999877...

Page 83: ...TS LISTS 14 3 1 Flat jet nozzles B_03168 2 3 1 4 5 6 Pos K Stk Order no Designation 1 1 2315775 AC union nut complete 2 1 2309882 Air cap ACF 5000 LV red 1 2314203 Air cap ACF 5000 HV blue 3 1 2311777...

Page 84: ...o Designation 1 1 2309883 Round jet nozzle attachment ACR 5000 2 1 2307220 Nozzle nut 3 1 2315310 O ring 4 1 132351 Nozzle screwed connection holder 5 1 2307219 Nozzle body 6 1 2319526 Round electrode...

Page 85: ...0 EN 50176 2009 EN 1953 2013 EN 61000 6 2 2019 EN 60204 1 2018 EN 61000 6 4 2019 EN 60529 1991 A1 2000 A2 2013 EN IEC 63000 2018 EN 50050 1 2013 Applied national technical standards and specifications...

Page 86: ...Operating manual GA 5000EAC Electrostatic Automatic Spray Gun AirCoat 15 Declaration of Conformity 86 Order number 2360922 Edition 09 2022...

Page 87: ......

Page 88: ...lephone 49 0 7544 5050 Fax 49 0 7544 505200 E mail ts liquid wagner group com Switzerland Wagner International AG Industriestrasse 22 CH 9450 Altst tten Telephone 41 0 71 757 2211 Fax 41 0 71 757 2222...

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