WAGNER GA 5000EAEC Translation Of The Original Operating Manual Download Page 48

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GA 5000EA

OPERATING MANUAL

VERSION 09/2016

ORDER NUMBER DOC2360924

6.8

VERIFYING A SAFE OPERATIONAL CONDITION

A skilled person must check to ensure that the device and the spraying system are in a safe
state after they are installed and commissioned.

This includes:
– Carry out a safety checks in accordance with Chapter 8.2.3.
– Function test in accordance with Chapter 11.

Summary of Contents for GA 5000EAEC

Page 1: ...GA 5000EAIC GA 5000EAEC II 2 G 0 24mJ X B_06009 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: ...ipment 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 Produ...

Page 4: ...GA 5000EAIC 40 6 5 3 Connecting GA 5000EAEC 41 6 5 4 Ventilation of the Spray Booth 42 6 5 5 Air Supply 43 6 5 6 Product Supply 43 6 5 7 Grounding 44 6 6 Preparation of Lacquer 46 6 6 1 Viscosity Conv...

Page 5: ...ling the Spray Gun 76 11 FUNCTION TEST AFTER THE REPAIR 82 11 1 Checking the High voltage 82 11 2 Air Test 84 11 3 Product Pressure Test 84 11 4 Test of Spray Pattern 84 12 DISPOSAL 85 13 ACCESSORIES...

Page 6: ...ries Spare Parts Lists 101 14 4 1 AR 5000 Nozzle D8 102 14 4 2 AR 5000 Nozzle D12 102 14 4 3 Adjustable EARV 5000 Round Jet Nozzle 103 15 WARRANTY AND CONFORMITY DECLARATIONS 104 15 1 Important Notes...

Page 7: ...e 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 T...

Page 8: ...alve within gun Shaping and atomizing air controlled via valve outside of gun Low R Low resistance Polyether ether ketone high temperature resistant thermoplastic plastic Stainless steel Position Numb...

Page 9: ...cessary 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 provisi...

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 re...

Page 11: ...Resistance There are paint resistance measuring devices available on the market that do not directly measure the specific paint resistance Multiplying the result of the measurement with the device sp...

Page 12: ...de 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 l...

Page 13: ...body PTB Explosion proof equipment Device class II not mining Category 2 device suitable for zone 1 Ex atmosphere gas Maximum ignition energy X Special Notes see Chapter 3 2 SIRA 16 ATEX5290X Number...

Page 14: ...E 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 i...

Page 15: ...15 GA 5000EA Serial No YY XXX B_05766 GA 5000EAIC GA 5000EAEC OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924 Serial number 3 4 TYPE PLATE...

Page 16: ...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...

Page 17: ...rvice Technician in accordance with the guidelines for liquid ejection devices DGUV regulation 100 500 Chapter 2 29 and 2 36 For shut down devices the examination can be suspended until the next start...

Page 18: ...re 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...

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 clea...

Page 20: ...cturer 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...

Page 21: ...leaning 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...

Page 22: ...ged 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 keepi...

Page 23: ...ping air setting 7 Piston housing 8 Valve rod regulating screw 9 Rear cover 10 Air diffuser housing 11 Gun holder 12 Product hose 13 Nozzle AR 5000 14 Air cap AR 5000 15 Nozzle insert EARV Accessories...

Page 24: ...ntrol air connection D6 red 4 Gun cable connection 5 Atomizing air connection D10 blue Connections on the rear side 1 Front cover 2 Union nut 3 Air cap 4 Flat jet nozzle 5 Gun adapter 6 Piston housing...

Page 25: ...d 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 th...

Page 26: ...e 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...

Page 27: ...asic version can 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...

Page 28: ...Shaping air connection only for GA 5000EAEC D8 Control air connection D6 Weight without houses 1 0 kg 2 2 lb Flow rate according to nozzle size see nozzle table in Accessories chapter Ambient tempera...

Page 29: ...268 18 18 4x 3 2 2x M5 M8 18 18 B_05778 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924 5 5 1 GA 5000EA DIMENSIONS GA 5000EA with flat jet nozzle GA 5000EA with round jet nozzle Connecting di...

Page 30: ...process the spray product is fed to the nozzle with a pressure of approx 0 05 0 2 MPa 0 5 2bar 7 29psi Theatomizingairatapprox 0 25 0 4MPa 2 5 4bar 36 58psiproduces a soft round jet which largely eli...

Page 31: ...rfect finish Spray product Spray angle In this process the spray product is fed to the nozzle at a pressure of 0 05 0 2 MPa 0 5 2 bar 7 29 psi The atomizing air at approx 0 25 0 4 MPa 2 5 4 bar 36 58...

Page 32: ...h 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 objec...

Page 33: ...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...

Page 34: ...onditions and the desired result different values are possible or necessary 5 7 2 PRESSURE SETTINGS FOR FLAT JET NOZZLES There are 8 flat jet nozzle sizes from 0 6 up to 2 0 available There are 2 air...

Page 35: ...maximized by turning the screw leftwards by turning the screw rightwards the cross section is minimized With the same pressure settings turning to the right results in a reduction of the flow rate and...

Page 36: ...ogeneous distribution of paint particles on the object See also Chapter 5 6 3 5 7 5 DISCHARGE QUANTITY MEASUREMENTS Product pressure in bar Discharge quantities in g min Flat jet nozzles Device GA 500...

Page 37: ...embly 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 Theairtemperatureatthestoragelocationmustbebetween 20 Cand 6...

Page 38: ...praying 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...

Page 39: ...39 GA 5000EA B_05775 E B C D A F OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924 A Spray booth B Controller C Reciprocator D Electrostatic spray gun E Work piece f Conveyor...

Page 40: ...G 5000 6 1 2 3 4 5 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924 6 5 2 CONNECTING GA 5000EAIC 1 for the product supply system 4 Gun cable 7 Grounding cable 2 Shaping air and atomizing air h...

Page 41: ...5000 7 1 2 3 4 5 6 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924 6 5 3 CONNECTING GA 5000EAEC 1 for the product supply system 4 Control air hose 7 Control cable 2 Atomizing air hose 5 Gun c...

Page 42: ...ations 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 ventilatio...

Page 43: ...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 produ...

Page 44: ...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 b...

Page 45: ...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 un...

Page 46: ...37 100 100 1 30 34 41 120 120 1 2 33 41 49 140 140 1 4 37 45 58 160 160 1 6 43 50 66 180 180 1 8 46 54 74 200 200 2 49 58 82 220 220 2 2 52 62 240 240 2 4 56 65 260 260 2 6 62 68 280 280 2 8 65 70 300...

Page 47: ...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...

Page 48: ...SAFE OPERATIONAL CONDITION A skilled person must check to ensure that the device and the spraying system are in a safe state after they are installed and commissioned This includes Carry out a safety...

Page 49: ...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 s...

Page 50: ...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 injur...

Page 51: ...until correct discharge quantity is achieved 8 Adjust the atomizing air regulator until optimal atomization is achieved 9 Flat jet process with the air adjustment on the gun set the ratio of shaping a...

Page 52: ...llustration shows the influence of the turning on the spraying pattern 1 Set the union nut as far as the stop 2 Open maximum 1 4 turn The atomizing is good in this area The union nut should not protru...

Page 53: ...ule of thumb Set atomizing air pressure approx three times higher than the product pressure Round jet method 8 Open air regulation 9 Changing the EARV 5000 spray jet width Switch off high voltage Turn...

Page 54: ...w gun The 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...

Page 55: ...16 ORDER NUMBER DOC2360924 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 U...

Page 56: ...ve it 3 Clean the spray gun front carefully with damp cloth Pay attention to the electrode 11 Use protective cap 12 EARV 5000 round jet 1 Unscrew the EARV union nut 7 by hand 2 Unscrew and remove EARV...

Page 57: ...sition AR 5000 air cap 2 Screw the union nut 1 onto the spray gun body and tighten by hand EARV 5000 round jet 1 Screw on EARV nozzle insert 9 into nozzle 8 using air nozzle spanner 10 Nozzle insert a...

Page 58: ...tighten the valve housing Valve housing and valve tip are available in various materials Valve housing Valve tip Material of the valve seat Product Standard version Steel PEEK Special accessories PEE...

Page 59: ...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...

Page 60: ...TY 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...

Page 61: ...o 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 nece...

Page 62: ...mine 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 N...

Page 63: ...soon as clean flushing agent 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 op...

Page 64: ...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...

Page 65: ...ervice 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 Inspe...

Page 66: ...tal 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...

Page 67: ...nd Poor grounding at object Check grounding of object or hanger with ohmmeter Air pressure too high Reduce air pressure Lacquer resistance too high too low Check lacquer resistance see Chapter 2 5 Spr...

Page 68: ...ation Chapter 6 7 and check for leaks Function test in accordance with Chapter 11 In accordance with the guideline for liquid ejection devices DGUV regulation 100 500 Chapter 2 29 and 2 36 The liquid...

Page 69: ...llen wrench SW 5 Open end wrench SW 5 Open end wrench SW 7 Open end wrench SW 8 Open end wrench SW 11 Open end wrench SW 19 Ring spanner SW11 Slide gauge Valve needle assembly tool Order No 2309368 Cl...

Page 70: ...70 GA 5000EA 1 2 B_05793 1 2 B_05794 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924 10 3 2 DISMANTLING OF THE SPRAY GUN...

Page 71: ...W19 SW3 B_05795 B_05796 4 3 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924 Product hose Do not tilt but pull it straight out in direction indicated by arrow At the same time execute slight r...

Page 72: ...SW3 B_05798 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924 Unscrew the collet chuck When unscrewing the collet chuck a second size 7 open ended wrench must be used for bracing Carefully rel...

Page 73: ...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 car...

Page 74: ...SW7 SW7 SW8 B_05799 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924 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 no...

Page 75: ...heets 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 adapte...

Page 76: ...UMBER DOC2360924 10 3 4 ASSEMBLING THE SPRAY GUN Assembly aids Pos Order No Description 2 9992698 Vaseline white PHHV II 4 9992511 Loctite 243 Use Vaseline sparingly Coat the hollow section with a bru...

Page 77: ...6 ORDER NUMBER DOC2360924 Wear gloves The outside thread of the packing 3 must be free of lacquer Valve rod unit 4 and packing 3 grease slide together screw together Grease clamping screw 1 and mount...

Page 78: ...e scratched 1 2 Very slightly tighten valve tip 2 using an assembly tool with three fingers 3 Use socket or ring spanner no open end wrench to tighten the valve housing 3 4 Slide the valve rod to the...

Page 79: ...m 7 37 lb ft OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924 Assembling the collet chuck When assembling the collet chuck a second open ended wrench SW7 must be used for bracing Set dimension...

Page 80: ...80 GA 5000EA 7 8 2 1 B_06004 SW19 B_06003 2 5 Nm 1 84 lb ft 2 SW19 SW3 5 Nm 3 69 lb ft 10 Nm 7 37 lb ft 4 4 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924...

Page 81: ...9 OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924 Round jet nozzle Assembly see Chapter 14 4 Diverse nozzle sizes see Chapter 13 3 Flat jet nozzle Assembly see Chapter 14 4 Diverse nozzle si...

Page 82: ...e 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...

Page 83: ...N 09 2016 ORDER NUMBER DOC2360924 Disruptive discharge test Check the gun against ground with the grounding rod No sparks should be formed Note in the vicinity of the electrode harmless corona dischar...

Page 84: ...nnection 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...

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...

Page 86: ...d version 2312176 Valve housing Air complete PEEK Order No Designation 2312184 Valve tip Air complete PEEK Standard version 2312185 Valve tip Air complete steel 13 1 VALVE HOUSING 13 2 VALVE TIPS 13 3...

Page 87: ...14255 Air cap AF 5000 0 4 0 8W wide 2314256 Air cap AF 5000 1 0 1 4W wide 2314258 Air cap AF 5000 1 6 2 0W wide 13 4 FLAT JET NOZZLES 13 4 1 AF 5000 AIR CAPS 13 3 3 EARV NOZZLE SET Order No Designatio...

Page 88: ...4 Order No Designation 2310539 AF 5000 nozzle 0 6 mm black 2310540 AF 5000 nozzle 0 8 mm yellow 2310541 AF 5000 nozzle 1 0 mm red 2310542 AF 5000 nozzle 1 2 mm green 2310543 AF 5000 nozzle 1 4 mm brow...

Page 89: ...BLE FOR GUN CABLE Order No Designation 2339157 Gun cable 10 m 32 8 ft 2339158 Gun cable 15 m 49 2 ft 2339159 Gun cable 20 m 65 6 ft 2339160 Gun cable 25 m 82 0 ft Order No Designation 2339130 Low pres...

Page 90: ...ose GA EA LowR 10 m 2367205 Product hose GA EA LowR 15 m 2367206 Product hose GA EA LowR 20 m 13 5 4 PRODUCT HOSES FOR LOW RESISTANCE PRODUCTS 13 5 6 AIR HOSES 13 5 5 SPIRAL HOSE Order No Designation...

Page 91: ...ignation 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 2325263 Clamping...

Page 92: ...TING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924 Order No Designation 380942 Rotary gun holder standard 380945 Rotary holder 40 40 5 380943 Complete swivel drive 380944 Cross clamp for swivel drive...

Page 93: ...ry 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 c...

Page 94: ...43 44 45 B_06037 26 29 27 28 7 36 37 30 8 22 25 SW4 7 Nm 5 16 lb ft 50 SW14 12 Nm 8 85 lb ft 50 SW14 12 Nm 8 85 lb ft 50 50 SW3 5 Nm 3 68 lb ft 21 SW2 5 0 6 Nm 0 44 lb ft 50 15 16 21 SW2 5 0 6 Nm 0 4...

Page 95: ...5000EA 18 2 9900353 Hexagon socket cylinder head screw 19 2 9900329 Hexagon socket cylinder head screw 20 1 2357737 Mounting bracket 21 9 9906029 Hexagon socket cylinder head screw 22 1 9998995 Codin...

Page 96: ...Valve housing complete Air steel standard 1 2312176 Valve housing complete Air PEEK standard 5 1 2312184 Valve tip complete Air PEEK 1 2312185 Valve tip complete Air steel 6 1 2314271 Adapter GM 5000E...

Page 97: ...97 GA 5000EA B_06041 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 130 0 1 mm 5 12 0 004 inch OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924...

Page 98: ...1 32 33 42 43 B_06038 8 36 37 38 39 40 41 34 35 28 7 25 27 26 SW4 7 Nm 5 16 lb ft SW2 5 0 6 Nm 0 44 lb ft SW14 12 Nm 8 85 lb ft 50 50 SW3 5 Nm 3 68 lb ft 50 21 50 SW2 5 0 6 Nm 0 44 lb ft 50 44 21 OPER...

Page 99: ...9900353 Hexagon socket cylinder head screw 19 2 9900329 Hexagon socket cylinder head screw 20 1 2357737 Mounting bracket 21 9 9906029 Hexagon socket cylinder head screw 22 1 9998090 Straight screw in...

Page 100: ...09 2016 ORDER NUMBER DOC2360924 Spare parts list for GA 5000EAEC Pos K Stk Order No Designation 43 1 2365249 Lid labeled EAEC 44 1 2338526 Contact spacer 50 1 9992511 Loctite 243 1 2369320 Service set...

Page 101: ...SPARE PARTS LISTS Notes concerning AR5000 D8 nd D12 nozzles Parts 3 and 4 can be pushed out of the nozzle with a suitable pin 2 0 2 3 mm 0 08 0 09 inches NOTICE Incorrect assembly Damage to the parts...

Page 102: ...nation 1 1 2315050 Nozzle complete AR 5000 D12 2 1 2327661 Nozzle AR D12 3 1 2327662 Nozzle attachment AR D12 4 1 2327663 Air diffuser AR D12 Wearing part 14 4 1 AR 5000 NOZZLE D8 Spare parts list for...

Page 103: ...tk Designation Order No Order No 1 1 Nozzle set EARV 5000 2361290 2365979 2 1 Nozzle EARV 2361273 3 1 Nozzle insert EARV 2361274 4 1 Union nut EARV 2361272 2365978 5 1 O ring sheathed 2311217 Wearing...

Page 104: ...n 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...

Page 105: ...he supplied version of Electrostatic automatic spraying system EPG 5000 GA 5000EA GA 5000EAC complies with the following guidelines 2006 42 EC 2014 34 EU 2014 30 EU 2011 65 EU 2012 19 EU Applied stand...

Page 106: ...106 GA 5000EA OPERATING MANUAL VERSION 09 2016 ORDER NUMBER DOC2360924...

Page 107: ......

Page 108: ...2360924 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...

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