WAGNER GA 4000ACIC-R Operating Manual
For aircoat series automatic spray gun
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Summary of Contents for WAGNER GA 4000ACIC-R
- Page 1 Translation of the original Operating manual GA 4000ACIC-R GA 4000ACIC-S Edition 06/ 2011 AirCoat Automatic spray gun B_03045 II 2GX (Atex 95)
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Page 3: Table Of Contents
Safety instructions for the operator 2.1.1 Electrical equipment 2.1.2 Personnel qualifi cations 2.1.3 A safe work environment Safety instructions for staff 2.2.1 Safe handling of WAGNER spray units 2.2.2 Earth the unit 2.2.3 Material hoses 2.2.4 Cleaning 2.2.5 Handling hazardous liquids, varnishes and paints 2.2.6... - Page 4 GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL Contents 4.4.2 Mode “NC” and “C” 4.4.2.1 Mode “NC” without material circulation 4.4.2.2 Mode “C” with material circulation 4.4.3 Functions of the spray gun Spraying process 4.5.1 AirCoat atomizing fl at jet spray process 4.5.2 AirCoat round jet spray process STARTING WORK AND HANDLING...
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Page 5: About These Instructions
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL ABOUT THESE INSTRUCTIONS This operating manual contains information on the operation, repair and maintenance of the unit. Always observe these instructions when operating the unit. This equipment can be dangerous if it is not operated in accordance with this manual. Compliance with these instructions constitutes an integral component of the warranty agreement. -
Page 6: General Safety Instructions
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep these operating instructions to hand near the unit at all times. Always follow local regulations concerning occupational safety and accident prevention. 2.1.1 ELECTRICAL EQUIPMENT Electrical plant and unit... -
Page 7: Safe Handling Of Wagner Spray Units
EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or cleaning agents: Never point the spray gun at people. -
Page 8: Cleaning
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 2.2.4 CLEANING De-energize the unit electrically. Disconnect the pneumatic supply line. Relieve the pressure from the unit. Ensure that the flash point of the cleaning agent is at least 5 K above the ambient temperature. -
Page 9: Use In An Explosion Hazard Area
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL USE IN AN EXPLOSION HAZARD AREA 2.4.1 CORRECT USE 2.4.2 EXPLOSION PROTECTION IDENTIFICATION As defined in the Directive 94/9/CE (ATEX 95), the unit is suitable for use in areas where there is an explosion hazard. -
Page 10: Guarantee And Conformity Declarations
fitted , operated and maintained. If other makes of accessory and spare parts are used, the manufacturer‘s liability could be fully or partially null and void. The usage of original WAGNER accessories and spare parts guarantees that all safety regulations are observed. GUARANTEE CLAIM... -
Page 11: Ce-Conformity
Identifi cation: II 2G X CE Certificate of Conformity The certificate is enclosed with this product. The certificate of conformity can be reordered from your WAGNER representative, quoting the product and serial number. Part number : GA 4000AC 2315627 NATIONAL TECHNICAL SPECIFICATIONS a) BGR 500 Part 2, chapter 2.36... -
Page 12: Description
Top-coat paints, primer paints, corrosion protection solvents, textured paints, lyes, staining solvents, clear paints, separating fl uid, etc. on a solvent or water basis. Note: In the event of application problems, contact your WAGNER branch and the paint manu- facturer. DELIVERY SCOPE 4.2.1... -
Page 13: Overview
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 4.2.2 OVERVIEW The Aircoat automatic spray gun is composed of a gun and the base plate and supplemen- tary components. Circulation operating mode is possible. 4.2.3 Basic versions 4.2.4.4 Supplementary Automatic gun GA 4000ACIC components Nozzle round 4.2.4.3 Supplementary... -
Page 14: Standard Variant
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 4.2.3 STANDARD VARIANT Part No. Description 2312132 AirCoat automatic spray gun GA 4000ACIC The standard equipment includes: Part No. Description 2312132 AirCoat automatic spray gun GA 4000ACIC 2315627 CE-Conformity 2312955 Operating manual German see chapter 1 Operating manual in the local language... -
Page 15: Air Caps
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 4.2.4.2 AIR CAPS Part No. Description 2308809 Air cap HV plus (blue) for high viscosity paints B_03048 2308808 Air cap LV plus (red) for low viscosity paints B_03049 2313493 Air cap LA plus (bronze) B_03098 4.2.4.3 AIRCOAT FLAT JET NOZZLE ACF3000... -
Page 16: Material Connections
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 4.2.4.5 MATERIAL CONNECTIONS Part No. Description 350550 Connection nipple straight B_03074 2314065 Connection nipple 90° B_03097 4.2.4.6 AIR CONNECTIONS Part No. Description Screw-in screw connection, straight 9998090 ø 6 mm - 1/8“; ø 0.24 inch - 1/8“ * Standard Screw-in screw connection, straight 9998993... -
Page 17: Data
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL DATA 4.3.1 TECHNICAL DATA Description Units GA 4000ACIC Maxi. air inlet pressure MPa; bar; psi 0.6; 6; 87 Maxi. material pressure MPa; bar; psi 25; 250; 3625 Material connection (internal thread) Inch G1/4“... -
Page 18: Measurements And Connections
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 4.3.2 MEASUREMENTS AND CONNECTIONS inch 5.08 1.85 Ø 3.2 77.5 3.05 2.17 18±0.1 0.71±0.004 18±0.1 0.71±0.004 B_03486 Connection data: Ground plate to GA 4000ACIC R CA = G1/8“ -> 6 mm; 0.24 inch (control air) AA = G1/8“... -
Page 19: Materials Of Paint Wetted Parts
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL inch 5.08 1.85 Ø 3.2 2.36 37.5 1.48 18±0.1 0.71±0.004 18±0.1 0.71±0.004 B_03057 Connection data: Ground plate to GA 4000ACIC S CA = G1/8“ -> 6 mm; 0.24 inch (control air) AA = G1/8“... -
Page 20: Functional Description
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL FUNCTIONAL DESCRIPTION 4.4.1 DESIGN OF SPRAY GUN B_03051 B_03052 Description Gun head Gun body Drive Clamping sleeve Base plate Connection atomizing air (blue) Union nut Air cap (blue, red or bronze) Nozzle Holder Standard Connection nipple (Material) -
Page 21: Mode "Nc" And "C
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 4.4.2 4x 4 Nm; 2.95 lbft MODE “NC” AND “C” 4.4.2.1 MODE “NC” WITHOUT MATERIAL CIRCULATION In this mode of operation the left or the right material channel in the gun head (A) is locked by the locking pin (M) and the material entrance (ME) is always lying on the opposite side B_03069... -
Page 22: Spraying Process
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL Close: The piston is relieved, and the material valve closes due to the pressure spring which presses against the material valve tappet. The air valve is then closed, again delayed by spring force and mechanically. -
Page 23: Aircoat Round Jet Spray Process
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 4.5.2 AIRCOAT ROUND JET SPRAY PROCESS With the AirCoat round jet process the spray material is atomized at a pressure of 3-12 MPa; 30-120 bar; 435-1740 psi. The air at 0.05-0.25 MPa; 0.5-2.5 bar; 7.2-36 psi produces a soft jet (used standard). The spray jet can be adjusted by turning the nozzle nut. -
Page 24: Starting Work And Handling
Supply air system and exhaust air-system The pray gun must be used a part of an spraying system. The spraying system shown in the fi gure is only one example. Contact your Wagner distributor for assistance in designing a system to meet your needs. -
Page 25: Ventilation Of The Spray Booth
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 5.1.2 VENTILATION OF THE SPRAY BOOTH WARNING Toxic and/or flammable vapor mixtures! Risk of poisoning and burns Operate the unit in a spraying booth approved for the working materials. -or- Operate the unit on an appropriate spraying wall with the ventilation (extraction) switched on. -
Page 26: Earthing The System
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 5.1.5 EARTHING THE SYSTEM WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic sparks or flames Earth all unit components. Earth the workpieces being painted. SIHI_0027_GB WARNING Heavy paint mist if earthing is insufficient! -
Page 27: Preparation Of Paints
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL PREPARATION OF PAINTS The viscosity of the paints is of great importance. The best results are obtained for paints of 80 and 150 mPas. Processing of up to 260 mPas is generally possible without problem, if high coating thicknesses are required. -
Page 28: Starting-Up
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL STARTING-UP 5.3.1 GENERAL RULES FOR HANDLING THE SPRAY GUN ➞ Observe safety instructions in chapter 2. The following rules must be observed before all work on the unit, in the event of work interruptions and functional faults: WARNING Unintentional putting into operation! -
Page 29: Preparation For Starting Up
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 5.3.2 PREPARATION FOR STARTING UP 1. Mount the spray gun on the automatic movement system. 2. Connect material hoses to spray gun and to material supply system. 3. Place the nozzle into the nozzle seal. Fit the air cap over the nozzle. Take care that the nozzle fi... -
Page 30: Works
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL WORKS 5.4.1 START-UP FOR SPRAYING AIRCOAT 1. Set material pressure approx. 8 MPa; 80 bar; 1160 psi at material pump. 2. Spray (release trigger safety catch and pull trigger) and check the atomisation. 3. -
Page 31: Changing Aircoat Nozzle
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 5.4.3 CHANGING AIRCOAT NOZZLE CAUTION Defective AirCoat nozzle! Insufficient paint application quality Do not use sharp-edged objects to treat hard metal on the AirCoat nozzle. SIHI_0020_GB CAUTION Defective nozzle seal! Material sprays into the air cap next to the nozzle Risk of contamination Do not clean the nozzle seal with sharp-edged objects. -
Page 32: Eliminate Nozzle Clogging
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 5.4.5 ELIMINATE NOZZLE CLOGGING 1. Relieve the pressure of gun and unit. 2. Secure gun (Remove the control air hose). 3. Screw off the union nut (A). 4. Remove air cap (B). 5. -
Page 33: Exchange Of Round Jet Nozzle Insert
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 5.4.6 EXCHANGE OF ROUND JET NOZZLE INSERT 1. Relieve the pressure of gun and unit. 2. Secure gun (Remove the control air hose). 3. Remove nozzle insert (B) with nozzle spanner (A). 4. -
Page 34: Maintenance
Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply. -
Page 35: Shutting Down And Cleaning
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL SHUTTING DOWN AND CLEANING CAUTION Solvent in air conduit! Problems By cleaning the spraygun use with min. 0.05 MPa; 0.5 bar; 7.25 psi shaping air. Cleaning solvent must not get into the air ducts. SIHI_0064_GB DANGER Exploding gas/ air mixture! -
Page 36: Replacing The Paint Hose
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL REPLACING THE PAINT HOSE 1. Finishing work and cleaning. 2. Relieve the pressure of gun and unit and remove the detergent supply. 3. Secure gun (Remove the control air hose). 4. -
Page 37: Changing Round Jet Sealing Nipple
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL CHANGING ROUND JET SEALING NIPPLE CAUTION Defective nozzle body! Poor spray pattern Handle the nozzle body (A) with care. SIHI_0042_GB Unscrew by hand the nozzle B_03059 Counter hold with socket spanner size 13 mm;... -
Page 38: Replacing Parts Of The Gun Body
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL REPLACING PARTS OF THE GUN BODY 6.5.1 DISMANTLING GA 4000ACIC CAUTION Defective plunger shaft! Packing leaks Greater wear on the packing Handle the plunger shaft (K) with care. The plunger shaft has the function of a sliding surface. SIHI_0043_GB Note: Base plate assy. - Page 39 GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL Blow gun Note: M5 SW 3; 0.12 inch Stuck components can be pushed out with a drift maxi. Ø 3 mm; 0.12 inch. Note: Pull the damaged seal (F) out using a pliers.
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Page 40: Re-Assemble Ga 4000Acic
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 6.5.2 RE-ASSEMBLE GA 4000ACIC General note: SW 12; 0.47 inch Lightly greased o-rings and sliding surfaces with vaseline white PHV II 25 Nm; 8.85 lbft M5 SW 3; 0.12 inch 4 Nm;... - Page 41 GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL Dismount union nut and air cap. SW 12; 0.47 inch 10 Nm; 7.38 lbft Dismount union nut and air cap M5 SW 3 mm; 0.12 inch 4 Nm; 2.95 lbft B_03068...
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Page 42: Trouble Shooting And Solution
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL TROUBLE SHOOTING AND SOLUTION Functional faults Cause Remedy Insuffi cient material Nozzle too small Select larger nozzle output (see paragraph 8.1) Material pressure too low Increase material pressure Gun fi lter blocked or high pressure Clean or replace fi... - Page 43 GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL...
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Page 44: Accessories
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL ACCESSORIES AIRCOAT NOZZLES ACF3000 Recommended gunfilter Size Spraying Recommended edge filter Part No. Marking inch; mm angle Application Natural paint 379107 07/10 0.007-0.18 379207 07/20 0.007-0.18 Transparent paint 379209 09/20 0.009-0.23 379309 09/30... - Page 45 GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL 379219 19/20 0.019-0.48 379319 19/30 0.019-0.48 379419 19/40 0.019-0.48 379519 19/50 0.019-0.48 379619 19/60 0.019-0.48 379819 19/80 0.019-0.48 379221 21/20 0.021-0.53 379421 21/40 0.021-0.53 379521 21/50 0.021-0.53 379621 21/60 0.021-0.53 379821 21/80 0.021-0.53...
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Page 46: Round-Jet Nozzle Cap
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL ROUND-JET NOZZLE CAP Part No. Description 8.2.2 394180 Round-jet nozzle cap (without nozzle insert) B_03072 8.2.1 8.2.1 NOZZLE INSERTS RXX Part No. Description Marking Jet-ø ** 132720 Nozzle insert R11 approx. -
Page 47: Hoses
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL HOSES Part No. Description 9984405 High pressure hose M16x1.5, 1 m; 3.28 ft, DN 4 mm; ID 0.16 inch, 27 MPa; 270 bar; 3916 psi 9984507 High pressure hose M16x1.5, 15 m; 98.4 ft, DN 6 mm;... - Page 48 GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL Part No. Description 2314079 Adapter plate Cefl a B_03099 380942 Gun holder turnable (standard) 380945 Gun holder turnable 40/40/5 380943 Swivel drive assy. 380944 Cross attaching piece for swivel drive...
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Page 49: Spare Parts
Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply. -
Page 50: Spare Parts List Ga 4000Acic
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL SPARE PARTS LIST GA 4000ACIC 10 Nm; 7.38 lbft 4 Nm; 2.95 lbft 25 Nm; 18.44 lbft 25 Nm; 18.44 lbft 1 Nm; 0.74 lbft P_03070 Special version in EPDM Locite 243 3 Nm;... - Page 51 GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL Bestell-Nr. Description ◆ 2312132 Spray gun body GA 4000ACIC ◆ 2321825 Spray gun body GA 4000ACIC (longlife) ◆● 2312144 Ground plate GA 4000ACIC S assy. ◆● 2308810 Ground plate GA 4000ACIC R assy. 2309945 Screw spring 2314274...
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Page 52: Service Sets And Spare Parts Groups
GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL Bestell-Nr. Description ◆ 9971025 O-ring ◆ 2314275 Piston IC assy. ◆ 2314273 Valve rod IC assy. ● 9992698 Vaseline white PHHV 9998991 Screw spring 2314242 Ground plate GA 4000ACIC R ◆... - Page 53 GA 4000ACIC EDITION 06/ 2011 PART NO. DOC2312956 OPERATING MANUAL...
- Page 54 DK- 8600 Silkeborg Telephone: +32 (0)2 269 4675 Telephone: +45 70 200 245 Telefax: +32 (0)2 269 7845 Telefax: +45 86 856 027 E-Mail: info@wsb-wagner.be / HP www.wsb-wagner.eu E-Mail info@wagner-industri.com United Kingdom France WAGNER Spraytech (UK) Ltd. J. WAGNER France S.A.R.L.
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