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GA 5000EAC

OPERATING MANUAL

VERSION 09/2016

ORDER NUMBER DOC2360922

6.4

ASSEMBLY AND INSTALLATION

6.4.1

TYPICAL ELECTROSTATIC SPRAYING SYSTEM

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

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

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Summary of Contents for GA 5000EACEC

Page 1: ...GA 5000EACIC GA 5000EACEC II 2 G 0 24mJ X B_05738 Electrostatic Air Spray Gun for automatic operation for flat or round jet nozzles Version 09 2016 Translation of the Original Operating Manual ...

Page 2: ......

Page 3: ...nstructions for the Operator 16 4 1 1 Electrical Equipment 16 4 1 2 Personnel Qualifications 16 4 1 3 Safe Work Environment 16 4 2 Safety Instructions for Staff 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 an...

Page 4: ...ding 40 6 5 Preparation of Lacquer 42 6 5 1 Viscosity Conversion Table 42 6 6 Commissioning 43 6 6 1 Safety Instructions 43 6 6 2 Preparation for Commissioning 43 6 6 3 Commissioning 43 6 7 Verifying a Safe Operational Condition 44 7 OPERATION 45 7 1 Training the Operating Staff 45 7 2 Safety Instructions 45 7 2 1 Emergency Deactivation 46 7 2 2 General Rules for Making Adjustments to the Spray Gu...

Page 5: ...Spray Gun 69 10 3 3 Cleaning the Parts After Disassembly 74 10 3 4 Assembling the Spray Gun 75 11 FUNCTION TEST AFTER THE REPAIR 82 11 1 Checking the High Voltage 82 11 2 Air Test 84 11 3 Product Pressure Test 84 11 4 Test of Spray Pattern 84 12 DISPOSAL 85 13 ACCESSORIES 86 13 1 Round Jet Nozzles 86 13 1 1 ACR 5000 Round Jet Nozzle Attachment 86 13 1 2 AirCoat Round Jet Nozzle Inserts 86 13 2 Fla...

Page 6: ...000EACIC Spray Gun 95 14 2 1 GA 5000EAC Adapter 98 14 3 GA 5000EACEC Spray Gun 100 14 4 Accessories Spare Parts Lists 102 14 4 1 Flat Jet Nozzles 102 14 4 2 ACR 5000 Round Jet Nozzle Attachment 103 15 WARRANTY AND CONFORMITY DECLARATIONS 104 15 1 Important Notes Regarding Product Liability 104 15 2 Warranty Claim 104 15 3 EU Declaration of Conformity 105 ...

Page 7: ...ce 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...

Page 8: ...ing and atomizing air controlled via valve within gun Shaping and atomizing air controlled via valve outside of gun Low R Low resistance Stainless steel Position Number of pieces Wrench size The GA 5000EAC operating manual is available in the following languages Language Order No Language Order No German 2360921 English 2360922 French 2367694 Italian 2367695 Spanish 2367696 Additional languages on...

Page 9: ...ecessary 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 DGUV 209 052 A person who based on his her technical training experience and recent vocational experience has sufficient technical knowledge in the area of electr...

Page 10: ... in potentially explosive areas Explosion Protection Identification 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 fixtures Use only WAGNER original spare parts and accessories The device may only be operated under the following condit...

Page 11: ...uring devices available on the market that do not directly measure the specific paint resistance Multiplying the result of the measurement with the device specific cell constant K we obtain the specific resistance value of the product Example With WAGNER s paint resistance measuring device the cell constant is K 123 Measured value according to theWAGNER scale Specific resistance RS Note Using spra...

Page 12: ...side the defined working area Lacquering outside the defined 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 perform...

Page 13: ...atic automatic spray gun Manufacturer Wagner International AG CH 9450 Altstätten Switzerland II 2 G 0 24mJ X SIRA 16 ATEX5290X European Communities Notified body PTB Explosion proof equipment Device class II not mining Category 2 device suitable for zone 1 Ex atmosphere gas Maximum ignition energy X Special Notes see Chapter 3 2 SIRA 16 ATEX 5290X Number of type examination certificate 3 2 SPECIAL...

Page 14: ...TE Note The EC Type Examination Certificate 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 5000EAC automatic spray gun only to original WAGNER control units WARNING ...

Page 15: ...15 GA 5000EAC B_05768 GA 5000EACIC GA 5000EACEC Serial No YY XXX OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 3 4 TYPE PLATE Serial number ...

Page 16: ...ed 100 megohms Paint mist extraction systems ventilation systems must be fitted 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 requiremen...

Page 17: ... g WAGNER Service Technician in accordance with the guidelines for liquid ejection devices DGUV regulation 100 500 For shut down devices the examination can be suspended until the next start up Carry out the work steps as described in the Pressure relief chapter If pressure relief is required If the spraying work is interrupted or stopped Before the device is cleaned on the outside checked or serv...

Page 18: ...are never used to pull or move the equipment Suction hoses may not be subjected to pressure Several liquids have a high expansion coefficient In some cases their volume can rise with consequent damage to pipes fittings etc and cause fluid 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 i...

Page 19: ... may be used for cleaning and flushing 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 flushing 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 obje...

Page 20: ...facturer of the lacquers solvents and cleaning agents being used Take the specified 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 sufficient health and environmental safety Operate the device in a spray booth or on a spraying wall with the ventilation extraction s...

Page 21: ... 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 devic...

Page 22: ...arged electrostatically by the high voltage field 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 ...

Page 23: ...lat jet nozzle 5 Gun adapter 6 Piston housing 7 Rear cover 8 Air diffuser housing 9 Shaping air setting 10 Gun holder 11 Product hose 12 Sealing fitting 13 Nozzle screw joint 14 Nozzle attachment 15 Round jet nozzle 1 Connection closed with dummy plug 2 Product connection NPSM 1 4 3 Control air connection D6 red 4 Gun cable connection 5 Shaping air or atomizing air connection D10 blue Connections ...

Page 24: ...protection 3 Air cap 4 Flat jet nozzle 5 Gun adapter 6 Piston housing 7 Rear cover 8 Air diffuser housing 9 Gun holder 10 Product hose 11 Sealing fitting 12 Nozzle screw joint 13 Nozzle attachment 14 Round jet nozzle 1 Atomizing air connection D10 blue 2 Product connection G1 4 3 Control air connection D6 red 4 Gun cable connection 5 Shaping air connection D8 green Connections on the rear side ...

Page 25: ...e 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 first 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 produ...

Page 26: ...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 flows are supplied separately whic...

Page 27: ...be adapted optimally to any application depending upon the requirements and the desired accessories with the help of spray gun configuration The delivery note shows the exact scope of delivery 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 sp...

Page 28: ... Atomizer air connection D10 Shaping air connection only for GA 5000EACEC D8 Control air connection D6 Weight without houses 1 0 kg 2 2 lb Flow rate 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 ...

Page 29: ...748 18 18 4x 3 2 2x M5 M8 18 18 B_05761 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 5 5 1 GA 5000EAC DIMENSIONS GA 5000EAC with flat jet nozzle GA 5000EAC with round jet nozzle Connecting dimensions of the connection plate ...

Page 30: ...selection of nozzles Flat jet for large surface parts Round jet for smaller delicate parts Options for influencing the jet spray spray pattern Description Modification Product pressure or Atomizing air pressure or Shaping air regulation from open to closed Nozzle sizes Flow rate Electrostatics or or off The spray jet width by GA 5000EACIC spray gun is adjusted via the shaping air regulation A on t...

Page 31: ...d High endurance of the nozzles Jet width adjustment In the AirCoat process the spray product is atomized under a pressure of 3 15 MPa 30 150 bar 435 2176 psi With the help of an air pressure of 0 0 25 MPa 0 2 5 bar 0 36 psi a soft spray jet is produced The spray jet diameter can be adjusted by turning the nozzle nut 5 6 1 SPRAYING PROCEDURE FOR AIRCOAT ROUND JET In the AirCoat process the spray p...

Page 32: ...gh 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 finely dispersed to the object to be sprayed Advantages Very high application effectiveness Low over spray Coating of entire circumferences due to the electrostatic effect Savings in working time 5 6 3 ELECTROSTATIC EFFECT ...

Page 33: ... 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 tempe...

Page 34: ...at 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 wo...

Page 35: ...35 GA 5000EAC B_05775 E B C D A F OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 A Spray booth B Controller C Reciprocator D Electrostatic spray gun E Work piece f Conveyor ...

Page 36: ...PG 5000 6 1 2 3 4 5 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 6 4 2 CONNECTING GA 5000EACIC 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...

Page 37: ... 5000 7 1 2 3 4 5 6 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 6 4 3 CONNECTING GA 5000EACEC 1 for the product supply system 4 Control air hose 7 Control cable 2 Shaping air hose 5 Gun cable 8 Grounding cable 3 Atomizing air hose 6 for the compressed air supply 9 Mains cable Incorrect installation operation Risk of injury and damage to the device When commissioning and for all work r...

Page 38: ...lations for the exhaust air speed WARNING The electrostatic spraying equipment may only be operated in defined 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 effective as long as the technical ventil...

Page 39: ... supply with a suitable flushing 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 s...

Page 40: ... grounding is insufficient Danger of poisoning Insufficient 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...

Page 41: ...n Control unit 4 mm AWG 12 Pump 4 mm AWG 12 Paint tank 4 mm AWG 12 Reciprocator 16 mm AWG 6 Conveyor 16 mm AWG 6 Booth 16 mm AWG 6 Spraying stand 16 mm AWG 6 Grounding scheme example Conveyor Control unit Grounding cable Spraying stand Floor static dissipative Work piece Pump Paint tank Signal ground Signal ground ...

Page 42: ...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 25 and 40 DIN 4 seconds measured in immersion flow cup DIN 4 mm 0 16 inches Processing of up to 60 DIN 4 seconds is generally possible without problem i...

Page 43: ...k 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 syste...

Page 44: ...son 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 6 7 VERIFYING A SAFE OPERATIONAL CONDITION ...

Page 45: ... 100 megohms WARNING Observe safety instructions in Chapter 4 Incorrect operation Risk of injury and damage to the device The operating staff must be qualified to operate the entire system The operating staff 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 staff must receive app...

Page 46: ...n 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 an...

Page 47: ... The spray pattern can then be adjusted to suit the object being sprayed The illustration shows the influence of the regulator on the spray pattern Other nozzle sizes can be used to obtain larger or smaller spray patterns Changing the Flow Rate Adapt product pressure Use a different nozzle see Chapter 13 Changing the Spray Jet Width Use a different nozzle see Chapter 13 No air Correct amount of ai...

Page 48: ...nozzle body Flow rate 9 The flow rate can be reduced by Minimizing the product pressure Use a different nozzle see Chapter 13 1 Secure gun switch off controller and insert the desired nozzle 2 Turn on the control unit See corresponding operating manual 3 Start up with product supply set to approx 8 MPa 80 bar 1160 psi operating pressure See corresponding operating manual AirLess spraying 4 Turn bo...

Page 49: ... pressure must always be relieved when The spraying tasks are finished 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 pa...

Page 50: ...2016 ORDER NUMBER DOC2360922 7 3 4 DISMANTLING THE GUN COVER Note For changing nozzles the cover does not have to be removed 1 Press the snap fit 2 together and pull off the rear cover 1 to the back 2 Unscrew union nut 3 and pull off front cover 4 to the front ...

Page 51: ...spanner 2 2 Actuate spray gun briefly 3 Blow out and clean nozzle opposite the spraying direction 4 After flushing re tighten the nozzle insert 7 3 6 REPLACING ROUND JET NOZZLE S NOZZLE INSERT Exploding gas air mixture Danger to life from flying parts and burns Never spray into a closed tank Ground the tank DANGER 1 Remove nozzle insert 1 using nozzle spanner 2 2 Assembling new nozzle insert ...

Page 52: ... air cap 10 on the nozzle 11 and pay attention to the position of the guide surfaces 12 Screw union nut with attached nozzle guard 9 to the gun body and make sure that the air cap horns lie in the designated recess Y 13 Before tightening with the air cap horns Y set the desired jet level and then tighten the union nut to stop by hand Changing from flat jet to round jet 7 Unscrew union nut 9 with a...

Page 53: ...53 GA 5000EAC B_05754 1 2 3 4 5 6 7 8 10 9 Y 11 1 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 ...

Page 54: ...cient paint application quality Do not use sharp edged objects to treat carbide on the AirCoat nozzle NOTICE 4 Insert new ACF5000 nozzle 11 into the valve housing 5 Put the air cap 10 on the nozzle 11 and pay attention to the position of the guide surfaces 6 Screw union nut with attached nozzle guard 9 to the gun body and make sure that the air cap horns lie in the designated recess Y 7 Before tig...

Page 55: ...NG 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 ...

Page 56: ...by hand 6 Switch on gun without high voltage and flush gun 7 Whentheblockagehasbeenflushedout switchcontrolunitbacktostandbyoperation 8 Unscrew union nut 12 completely 9 Remove air cap 10 and push ACF5000 nozzle 11 out of the air cap by hand Clean ACF5000 nozzle and insert it in the spraying position into the valve housing 10 Put the air cap 10 on the nozzle 11 and pay attention to the position of...

Page 57: ...57 GA 5000EAC B_05774 10 11 X Y 1 Y 9 12 12 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 ACF5000 nozzle in cleaning position ACF5000 nozzle in spray position ...

Page 58: ... B_06426 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 7 3 11 CHANGING THE VALVE HOUSING Use socket or ring spanner no wrench to tighten the valve housing SW9 Relieve pressure prior changing the valve housing Chapter 7 3 3 ...

Page 59: ...ETY 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 Beforeallworkonthedeviceandintheeventofworki...

Page 60: ... 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 finished Preference should be g...

Page 61: ...s Examine the compatibility of the cleaning and flushing 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 no...

Page 62: ...ent emerges 5 Remove flushing 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 butto...

Page 63: ... 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 6 and c...

Page 64: ... service manual for all work For the safe operation of stationary electrostatic spraying equipment for flammable liquid coating products intervals for periodical inspections are defined as follows Inspection point Inspection interval Remarks Gun cleaning gun flushing daily Chapter 4 2 4 Chapter 8 1 Hoses tubes couplings daily Chapter 8 2 4 Grounding weekly Chapter 4 2 2 Chapter 6 4 7 Inspection fo...

Page 65: ...ental influences 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 ...

Page 66: ...ect Check grounding of object or hanger with ohmmeter Lacquer resistance too high too low Check paint resistance see Chapter 2 5 Spraying pressure too high Readjust spraying pressure No wrap around No high voltage Switch on high voltage at the control unit Repair malfunction as explained in the control unit operating manuals Connect gun and gun cable check for defect Check paint resistance see Cha...

Page 67: ...em into operation Chapter 6 7 and check for leaks Function test in accordance with Chapter 11 In accordance with the guideline for liquid ejection devices DGUV regulation 100 500 The liquid ejection devices should be checked by an expert e g WAGNER service technician for their safe working conditions as required and at least every 12 months For shut down devices the examination can be suspended un...

Page 68: ...en wrench SW 3 Wrench SW 5 Wrench SW 7 Wrench SW 8 Wrench SW 19 Wrench SW 22 Ring spanner SW 9 Slide gauge Valve needle assembly tool Order No 2309368 Clamping screw assembly tool Order No 2325263 Plastic parts Gently handle all plastic parts Brand notice The brands specified in this document are property of the respective owners Loctite for example is a registered brand of Henkel ...

Page 69: ...69 GA 5000EAC 1 2 B_05779 1 2 B_05780 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 10 3 2 DISMANTLING OF THE SPRAY GUN ...

Page 70: ... 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 Screw the wood screw 3 mm 0 12 inches length 40 mm 1 6 inches into the fitting 25 max 6 mm deep Pull out straight with suitable pliers Possibly rotate clockwise simultaneously Thereafter the fitting must be replaced If the fitting is broken in the gun ad...

Page 71: ...05783 6 SW3 B_05784 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 Unscrew the collet chuck When unscrewing the collet chuck a second size 7 wrench must be used for bracing Carefully release the cascade without pliers ...

Page 72: ...g Use an assembly tool or socket or ring spanner not a wrench 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 ...

Page 73: ...5 SW7 SW7 SW8 B_05785 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 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 ...

Page 74: ...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 gl...

Page 75: ...UMBER DOC2360922 1 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 ...

Page 76: ...016 ORDER NUMBER DOC2360922 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 ...

Page 77: ...ghten AC valve tip 2 by hand 3 fingers using an assembly tool 3 Use socket or ring spanner no wrench to tighten the valve housing 3 4 Slide the valve rod to the forward position at the valve seat 4 Valve needle assembly tool Order No 2309368 Ensure the correct insertion position and installation direction Clamping screw assembly tool Order No 2325263 Gold contact sleeve 10 Check whether the gold c...

Page 78: ...083 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 Set dimension 1 3 mm Via setting the dimension soiling of air cap will be decreased Clean and degrease the inside of the adapter and the outside of the cascade then grease the cascade surface with Vaseline ...

Page 79: ...7 SW8 SW7 B_05783 6 B_05789 SW26 10 Nm 7 37 lb ft OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 Assembling the collet chuck When assembling the collet chuck a second size 7 wrench must be used for bracing ...

Page 80: ... 1 84 lb ft 5 2 5 Nm 3 69 lb ft 10 Nm 7 37 lb ft 4 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 Fitting 25 Beforeassemblingtheproducthose check that no fitting 25 is in the gun adapter Check the fitting for damage and replace if necessary Order No 2338853 ...

Page 81: ...92 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 Flat jet nozzle Assembly see Chapter 14 4 1 Diverse nozzle sizes see Chapter 13 2 Round jet nozzle Assembly see Chapter 14 4 2 Diverse nozzle sizes see Chapter 13 1 ...

Page 82: ...he 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...

Page 83: ...ION 09 2016 ORDER NUMBER DOC2360922 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 ...

Page 84: ... 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 flying 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 5000EAC Switch off the atomizing and shaping air switch on control air 1 0 4 MPa 4 bar 58 psi The ...

Page 85: ... 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 lacque...

Page 86: ...width Recommended edge filter mm inch 132720 11 approx 250 10 yellow 132721 12 approx 250 10 200 mesh 132722 13 approx 250 10 132723 14 approx 250 10 132724 15 approx 250 10 132725 16 approx 250 10 black 132726 17 approx 250 10 100 mesh 132727 18 approx 250 10 132728 19 approx 250 10 132729 20 approx 250 10 white 132730 21 approx 250 10 60 mesh 132731 22 approx 250 10 Standard version Jet width in...

Page 87: ...0 0 28 0 011 10 Synthetic resin lacquer 395211 11 20 20 PVC lacquer 395311 11 30 30 395411 11 40 40 395511 11 50 50 395611 11 60 60 395811 11 80 80 395113 13 10 0 33 0 013 10 Lacquers 395213 13 20 20 Base coat 395313 13 30 30 Primer 395413 13 40 40 Filler 395513 13 50 50 395613 13 60 60 395813 13 80 80 395115 15 10 0 38 0 015 10 Filler 395215 15 20 20 Rust proofing paints 395315 15 30 30 395415 15...

Page 88: ...0 0 53 0 021 20 Mica paints 395421 21 40 40 Zinc rich paints 395521 21 50 50 Rust proofing paints 395621 21 60 60 Glue paints 395821 21 80 80 395423 23 40 0 58 0 023 40 395623 23 60 60 395823 23 80 80 395425 25 40 0 64 0 025 40 395625 25 60 60 395825 25 80 80 395427 27 40 0 69 0 027 40 395627 27 60 60 395827 27 80 80 395429 29 40 0 75 0 029 40 395629 29 60 60 395829 29 80 80 395431 31 40 0 79 0 03...

Page 89: ...lter 100 mesh black 9999002 Edge filter 200 mesh yellow 13 4 1 GUN CABLE Order No Designation 2339161 Extension cable 10 m 32 8 ft 2339162 Extension cable 20 m 65 6 ft 13 4 2 EXTENSION CABLE FOR GUN CABLE Order No Designation 2339157 Gun cable 10 m 32 8 ft 239158 Gun cable 15 m 49 2 ft 2339159 Gun cable 20 m 65 6 ft 2339160 Gun cable 25 m 82 0 ft 13 4 ELECTRIC CABLES AND HOSES ...

Page 90: ...A EAC LowR 15 m 2367215 Product hose GA EAC LowR 20 m 13 4 4 PRODUCT HOSES LOWR 13 4 5 PRODUCT HOSE 1 5 MM Order No Designation 2367217 Product hose ID 1 5 mm Order No Designation 9984573 High pressure hose DN4 PN270 NPS 7 5 m PA 2302374 High pressure hose DN4 PN270 NPS 10 0m PA 9984573 15 High pressure hose DN4 PN270 NPS 15 0 m PA 9984573 20 High pressure hose DN4 PN270 NPS 20 0 m PA 13 4 3 PRODU...

Page 91: ...0EAC OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 13 4 6 AIR HOSES Order No Designation 9982035 Air hose red 6 mm per meter 9982077 Air hose green 8 mm per meter 9987095 Air hose blue 10 mm per meter ...

Page 92: ...NUMBER DOC2360922 Order No Designation 259010 High voltage tester HV 200 N 2326041 Paint resistance meter 999080 Wet film thickness gauge 50342 Viscosity cup DIN 4 mm 0 16 inches 2309368 Valve needle assembly tool 128901 Nozzle spanner ACR 2325263 Clamping screw assembly tool 13 5 MISCELLANEOUS ...

Page 93: ...OC2360922 Order No Designation 380941 Standard gun holder 180 mm Ø 16 mm 7 1 inches Ø 0 63 inches 2314079 Cefla adapter plate 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 ...

Page 94: ...ery normal mail express delivery air freight courier etc Identification 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...

Page 95: ...OC2360922 Spare parts list for GA 5000EACIC Pos K Stk Order No Designation 1 1 2360898 GA 5000EACIC 2 1 2315775 Union nut AC complete 3 1 Adapter complete GA 5000EAC For details see Chapter 14 2 1 4 1 2307232 Adapter seal Wearing part 14 2 GA 5000EACIC SPRAY GUN ...

Page 96: ...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 50 22 SW14 12 Nm 8 85 lb ft 50 SW14 12 Nm 8 85 lb ft 50 50 SW3 5 Nm 3 68 lb ft SW2 5 0 6 Nm 0 44 lb ft 50 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 ...

Page 97: ... screw 21 1 2357737 Mounting bracket 22 9 9906029 Hexagon socket cylinder head screw 23 1 9998090 Straight screw in fitting 24 1 9998987 Straight threaded fitting 25 1 9998770 Coding ring blue d10 26 1 9998274 Threaded plug G1 4 27 1 9998995 Coding ring red d6 28 1 9974089 O ring 29 1 2358895 Sealing plug 30 2 2360690 Plug 31 1 2313501 Complete piston IC 32 7 9900308 Hexagon socket cylinder head s...

Page 98: ...A 5000EAC 4 B_06046 1 8 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 130 0 1 mm 5 12 0 004 inch 2 3 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 14 2 1 GA 5000EAC ADAPTER For setting see Chapter 10 ...

Page 99: ...77 High resistance bare 9 1 9960808 Socket contact component gold contact sleeve 10 1 2312181 Cascade complete 11 1 2357665 Clamping screw valve rod complete 12 1 2307062 Clamping screw valve rod 13 1 2311562 Rod seal 14 1 9974166 O ring 15 1 2369017 Valve rod unit AC 16 1 9910108 Hexagon nut 17 1 2357740 Collet chuck 18 1 2357741 Tension nut 19 1 2357106 Packing complete 20 1 2325263 Clamping scr...

Page 100: ...040 15 18 14 10 11 22 36 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 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 14 3 GA 5000EACEC SPRAY GUN ...

Page 101: ...64 Filter socket AC 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 fitting 23 1 9998254 Straight screw in fitting 24 1 9998616 Coding ring green d8 25 1 9998770 Coding ring blue d10 26 1 9998987 Straight threaded fitting 27 1 9998995 Coding ring red d6 28 2 2360690 Plug 29 1 2313501 Comple...

Page 102: ...S 14 4 1 FLAT JET NOZZLES Spare parts list for flat jet nozzles Pos K Stk Order No Designation 1 1 2315775 Union nut AC complete 2 1 2309882 Air cap ACF 5000 LV red 2 1 2314203 Air cap ACF 5000 HV blue 3 1 2311777 Nozzle guard AC 4 1 2311776 Union nut AC 5 1 2311217 O ring sheathed 6 1 2319525 Flat electrode set Wearing part ...

Page 103: ...nd jet nozzle attachment Pos K Stk Order No 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 set 9 1 132516 Nozzle screw joint complete 10 1 2307216 Sealing fitting 11 1 2311217 O ring 12 1 128901 Nozzle wrench complete Wearing part ...

Page 104: ...han the address of the purchaser We do not provide warranty for damage that has been caused or contributed to for the following reasons Unsuitable or improper use faulty assembly or commissioning by the purchaser or a third party normal wear negligent handling defective maintenance unsuitable coating products substitute products and the influence of chemical electrochemical or electrical agents ex...

Page 105: ...1 2013 EN 50176 2009 EN 61000 6 2 2005 B 2011 EN 61000 6 4 2007 A1 2011 EN ISO IEC 80079 34 2011 Applied national technical standards and specifications in particular DGUV Information 209 052 DGUV regulation 100 500 Chapter 2 29 DGUV regulation 100 500 Chapter 2 36 EC Type Examination Certificate SIRA 16 ATEX5290X by SIRA Certification Unit 6 Hawarden Industrial Park Hawarden CH5 3US United Kingdo...

Page 106: ...106 GA 5000EAC OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360922 ...

Page 107: ......

Page 108: ...o 2360922 Version 09 2016 Germany Phone Telefax E mail Switzerland Phone Telefax More contact addresses on the internet at Company Locations WAGNER worldwide Subject to changes without notice Document No 11186333 Version A ...

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