WAGNER GA 5000EAIC Translation Of The Original Operating Manual
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WAGNER GA 5000EAIC Translation Of The Original Operating Manual

WAGNER GA 5000EAIC Translation Of The Original Operating Manual

Electrostatic air spray gun
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Electrostatic Air Spray Gun
for automatic operation
for fl at or round jet nozzles
B_06009
II 2 G 0.24mJ X
Translation of the Original
Operating Manual
GA 5000EAIC
GA 5000EAEC
Version 09/2016

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Summary of Contents for WAGNER GA 5000EAIC

  • Page 1 Translation of the Original Operating Manual GA 5000EAIC GA 5000EAEC Version 09/2016 Electrostatic Air Spray Gun for automatic operation for fl at or round jet nozzles B_06009 II 2 G 0.24mJ X...

  • Page 3: Table Of Contents

    4.1.1 Electrical Equipment 4.1.2 Personnel Qualifi cations 4.1.3 Safe Work Environment Safety Instructions for Staff 4.2.1 Safe Handling of WAGNER Spray Devices 4.2.2 Grounding the Device 4.2.3 Product Hoses 4.2.4 Cleaning and Flushing 4.2.5 Handling Hazardous Liquids, Varnishes and Paints 4.2.6...
  • Page 4 Spraying Procedure for Round Jet Air Atomizing 5.6.2 Spraying Procedure for Flat Jet Air Atomizing 5.6.3 Electrostatic Eff ect The WAGNER Electrostatic Air Spraying System 5.7.1 Pressure Settings for Round Jet Nozzles 5.7.2 Pressure Settings for Flat Jet Nozzles 5.7.3 Adjusting Screw 5.7.4...
  • Page 5 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL Table of Contents CLEANING AND MAINTENANCE Cleaning 8.1.1 Cleaning Staff 8.1.2 Safety Instructions 8.1.3 Cleaning and Flushing the Device Maintenance 8.2.1 Maintenance Staff 8.2.2 Safety Instructions 8.2.3 Safety Checks 8.2.4 Product Hoses, Tubes and Couplings TROUBLE SHOOTING AND RECTIFICATION REPAIR WORK 10.1...
  • Page 6 ORDER NUMBER DOC2360924 OPERATING MANUAL Table of Contents SPARE PARTS 14.1 How Can Spare Parts Be Ordered? 14.2 GA 5000EAIC Spray Gun 14.2.1 GA 5000EA Adapter 14.3 GA 5000EAEC Spray Gun 14.4 Accessories Spare Parts Lists 14.4.1 AR 5000 Nozzle (D8) 14.4.2 AR 5000 Nozzle (D12)

  • Page 7: About These Instructions

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL ABOUT THESE INSTRUCTIONS PREFACE The operating manual contains information about safely operating, maintaining, cleaning and repairing the device. The operating manual is part of the device and must be available to the operating and service personnel.

  • Page 8: Languages

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL LANGUAGES The GA 5000EA operating manual is available in the following languages: Language Order No. Language Order No. German 2360923 English 2360924 French 2367556 Italian 2367557 Spanish 2367558 Additional languages on request or at: ABBREVIATIONS Order No.

  • Page 9: Terminology For The Purpose Of This Manual

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL Cleaning Manual cleaning of devices and device parts with cleaning agent Flushing Internal fl ushing of paint-wetted parts with fl ushing agent Staff qualifi cations Trained person Is instructed in the tasks assigned to him/her, the potential risks associated with improper behavior as well as the necessary...

  • Page 10: Correct Use

    Explosion Protection Identifi cation (see Chapter 3) SAFETY PARAMETERS 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 fi xtures.

  • Page 11: Processible Working Materials

    EPG 5000 control unit. High kV value, low μA value = ok Low kV value, high μA value = excessive conductivity of the paint No wrap-around Please contact your local WAGNER dealer and the lacquer manufacturer if you encounter application problems.

  • Page 12: Reasonably Foreseeable Misuse

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL REASONABLY FORESEEABLE MISUSE 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; performing unauthorized conversions or modifi cations to the device;...

  • Page 13: Identification

    As defi ned in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially explosive areas. Device type: GA 5000EA electrostatic automatic spray gun Manufacturer: Wagner International AG CH-9450 Altstätten, Switzerland II 2 G 0.24mJ X SIRA 16 ATEX5290X European Communities...

  • Page 14: Identification "X" (Type Examination Certificate)

    Incorrect use! Risk of injury and damage to the device. Connect the GA 5000EA automatic spray gun only to original WAGNER control units. IDENTIFICATION "X" (TYPE EXAMINATION CERTIFICATE) Note: The EC Type Examination Certifi cate from SIRA covers the following: - use of the spray gun in Zone 1;...

  • Page 15: Type Plate

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL TYPE PLATE GA 5000EAIC GA 5000EAEC Serial number B_05766...

  • Page 16: General Safety Instructions

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention. 4.1.1 ELECTRICAL EQUIPMENT Electrical devices and equipment To be provided in accordance with the local safety requirements with regard to the...

  • Page 17: Safety Instructions For Staff

    If necessary or at least every 12 months, the liquid ejection devices should be checked for safe working conditions by an expert (e.g., WAGNER Service Technician) in accordance with the guidelines for liquid ejection devices (DGUV regulation 100-500 Chapter 2.29 and 2.36).

  • Page 18: Grounding The Device

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 4.2.2 GROUNDING THE DEVICE Friction, fl owing liquids and air or electrostatic coating processes create charges. Flames or sparks can form during discharge. Grounding prevents electrostatic charging. Ensure that the device is grounded. See Chapter "Grounding".

  • Page 19: Cleaning And Flushing

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 4.2.4 CLEANING AND FLUSHING Relieve the pressure from the device. De-energize the device electrically. Preference should be given to non-fl ammable cleaning and fl ushing agents. Observe the specifi cations of the lacquer manufacturer. Ensure that the fl ash point of the cleaning agent is at least 15 K above the ambient temperature or that cleaning is undertaken at a cleaning station with technical ventilation.

  • Page 20: Handling Hazardous Liquids, Varnishes And Paints

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 4.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS When preparing or working with lacquer and when cleaning the device, follow the working instructions of the manufacturer of the lacquers, solvents and cleaning agents being used.

  • Page 21: Use In Areas Subject To Explosion Hazards

    4.4.1 SAFETY REGULATIONS Observe safety instructions in Chapter 3.2. 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 device against steel or rusty iron.

  • Page 22: Safety-Relevant Information About Discharges

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL SAFETY-RELEVANT INFORMATION ABOUT DISCHARGES The plastic parts of the spray gun are charged electrostatically by the high-voltage fi eld of the spray gun. Contact with plastic parts harmless discharges (brush discharges) may occur.

  • Page 23: Description

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL DESCRIPTION STRUCTURE (STANDARD VARIANT) 5.1.1 GA 5000EAIC DESIGN B_05745 1 Front cover 10 Air diff user housing 2 Union nut 11 Gun holder 3 Air cap 12 Product hose 4 Flat jet nozzle...

  • Page 24: Ga 5000Eaec Design

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 5.1.2 GA 5000EAEC DESIGN B_05746 1 Front cover 9 Air diff user housing 2 Union nut 10 Gun holder 3 Air cap 11 Product hose 4 Flat jet nozzle 12 Nozzle, AR 5000 5 Gun adapter 13 Air cap, AR 5000 6 Piston housing...

  • Page 25: Mode Of Operation

    1. Switch off the mains at the EPG 5000 2. Switch off the air supply at the EPG 5000 3. Relieve the pressure of the spray gun and system 5.2.1 GA 5000EAIC MODE OF OPERATION Pneumatic diagram: Nozzle SA = Shaping air...

  • Page 26: Ga 5000Eaec Mode Of Operation

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 5.2.2 GA 5000EAEC MODE OF OPERATION Pneumatic diagram: Nozzle SA = Shaping air AA = Atomizing air CA = Control air Product B_06008 Open: First, the external air valve, which enables the shaping and atomizing air, is opened. The diaphragm in the drive is then charged with control air and moves toward the rear, opening the product valve.

  • Page 27: Protective And Monitoring Equipment

    SCOPE OF DELIVERY Order No. Description 2360900 Spray gun, GA 5000EAIC 2360901 Spray gun, GA 5000EAEC The spray guns are delivered without control unit, product and air hose, electric cable, air cap and nozzle.

  • Page 28: Technical Data

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL TECHNICAL DATA Control air pressure (open product valve) 0.4–0.8 MPa; 4–8 bar; 58–116 psi Maximum atomizing air pressure 8 bar; 0.8 MPa; 116 psi Maximum shaping air pressure 0.8 MPa; 8 bar; 116 psi Maximum product pressure 8 bar;...

  • Page 29: Ga 5000Ea Dimensions

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 5.5.1 GA 5000EA DIMENSIONS GA 5000EA with fl at jet nozzle B_05747 GA 5000EA with round jet nozzle Connecting dimensions of the connection plate: 18 18 B_05778 2x M5 4x ∅ 3.2...

  • Page 30: Spraying Procedure

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL SPRAYING PROCEDURE 5.6.1 SPRAYING PROCEDURE FOR ROUND JET AIR ATOMIZING In this process, the spray product is fed to the nozzle with a pressure of approx. 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 psi produces a soft round jet, which largely eliminates the problem of overlapping boundaries.

  • Page 31: Spraying Procedure For Flat Jet Air Atomizing

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 5.6.2 SPRAYING PROCEDURE FOR FLAT JET AIR ATOMIZING 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 psi produces a soft round jet, which largely eliminates the problem of overlapping boundaries.

  • Page 32: Electrostatic Effect

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 5.6.3 ELECTROSTATIC EFFECT The spray gun produces an electrostatic fi eld by means of the high-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 fi nely dispersed to the object to be sprayed.

  • Page 33: The Wagner Electrostatic Air Spraying System

    + or - or off The spray jet width by GA 5000EAIC spray gun is adjusted via the shaping air regulation (A) on the gun and on the GA 5000EAEC spray gun via the air control knob (B) on the EPG 5000 control unit in the case of fl at jet spraying.

  • Page 34: Pressure Settings For Round Jet Nozzles

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 5.7.1 PRESSURE SETTINGS FOR ROUND JET NOZZLES There are 4 nozzle sizes, D8, D12, EARV LV and EARV HV available. The air cap and nozzle are adjusted according to size to each other and may not be exchanged. Pressure setting Nozzle D8 (small) Nozzle D12 (large)

  • Page 35: Adjusting Screw

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 5.7.3 ADJUSTING SCREW By turning the rear adjusting screw of the gun, the outlet cross-section can be adjusted on the product valve. This cross-section is maximized by turning the screw leftwards, by turning the screw rightwards the cross-section is minimized.

  • Page 36: Electrostatic And Atomization

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 5.7.4 ELECTROSTATIC AND ATOMIZATION The electrostatic charging of the spray cloud produces a more homogeneous distribution of paint particles on the object. - See also Chapter 5.6.3. 5.7.5 DISCHARGE QUANTITY MEASUREMENTS Flat jet nozzles Device: GA 5000EA / fl at jet nozzle Product hose: Length 7.5 m;...

  • Page 37: Assembly And Commissioning

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL ASSEMBLY AND COMMISSIONING TRAINING ASSEMBLY/COMMISSIONING STAFF WARNING Incorrect installation/operation! Risk of injury and damage to the device. The assembly and commissioning staff must have the technical skills to safely commission the device. When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.

  • Page 38: Assembly And Installation

    The system shown in the fi gure is only one example of an electrostatic air 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.
  • Page 39 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL B_05775 A Spray booth B Controller C Reciprocator D Electrostatic spray gun E Work piece f Conveyor...

  • Page 40: Connecting Ga 5000Eaic

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 6.5.2 CONNECTING GA 5000EAIC WARNING 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.

  • Page 41: Connecting Ga 5000Eaec

    Atomizing air II (2) G Main Switch 0102 Lufteingang Zerstäuberluft Hauptschalter SIRA 16 ATEX 5290X Wagner International AG Industriestrasse 22 CH - 9450 Altstätten Made in Switzerland CAN Bus OUT Typ / Type: EPG 5000 Data and Interlock Artikel Nr.:...

  • Page 42: Ventilation Of The Spray Booth

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 6.5.4 VENTILATION OF THE SPRAY BOOTH The electrostatic spraying equipment may only be operated in defi ned 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 eff ective as long as the technical ventilation is not operated with the minimum exhaust air volume fl ow or a larger exhaust...

  • Page 43: Air Supply

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 6.5.5 AIR SUPPLY The use of an air fi lter with air regulator ensures that only dry, clean atomizing air gets into the spray gun. Dirt and moisture in the atomizing air worsens the spraying quality and spraying pattern.

  • Page 44: Grounding

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 6.5.7 GROUNDING Perfect grounding of all conductive parts such as fl oors, walls, roofs, barriers, work pieces, transport devices, coating product tank, coating product supply or construction parts in the spray area with exception of the high-voltage parts during normal operation is important for optimum coating and safety.
  • Page 45 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL Grounding scheme (example) Conveyor Control unit Grounding cable Pump Work piece Rmax < 1MΩ Spraying stand Paint tank B_00137 Signal ground Floor, static dissipative Signal ground Minimum cable cross-section Control unit 4 mm²...

  • Page 46: Preparation Of Lacquer

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL PREPARATION OF LACQUER The viscosity of the lacquer is of great importance. The best spraying results are obtained with values between 15 and 30 DIN/4 seconds (measured in immersion fl ow cup DIN 4 mm; 0.16 inches).

  • Page 47: Commissioning

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL COMMISSIONING 6.7.1 SAFETY INSTRUCTIONS Observe the safety instructions in Chapter 4 and Chapter 7.2. Observe the general rules for making adjustments to the spray gun Chapter 7.2.2. 6.7.2 PREPARATION FOR COMMISSIONING NOTICE Impurities in the spraying system! Spray gun blockage.

  • Page 48: Verifying A Safe Operational Condition

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 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: –...

  • Page 49: Operation

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL OPERATION TRAINING THE OPERATING STAFF WARNING Incorrect operation! Risk of injury and damage to the device. The operating staff must be qualifi ed 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.

  • Page 50: Emergency Deactivation

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Explosion hazard from electrostatic spark-over. Use gun only with fi tted nozzle, air cap and union nut. 7.2.1 EMERGENCY DEACTIVATION In the case of unforeseen occurrences, proceed as follows: 1.

  • Page 51: Working

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL WORKING 7.3.1 CHECKING THE GA 5000EA SPRAY PATTERN (WITHOUT ELECTROSTATICS) Start air-spraying (without electrostatics) 1. Switch off high voltage at the control unit. (The grounding of the spray gun via the gun cable is maintained.) 2.
  • Page 52 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL Adjustable EARV 5000 round jet nozzle By turning the union nut the spray pattern can be adjusted to suit the object being sprayed. The illustration shows the infl uence of the turning on the spraying pattern. 1.

  • Page 53: Spraying Ga 5000Ea

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 7.3.2 SPRAYING GA 5000EA 1. Insert the desired nozzle into the spray gun. 2. Turn on the control unit. See corresponding operating manual. 3. Start up with product supply generator set to approx. 0.05 to 0.15 MPa; 0.5 to 1.5 bar; 7 to 22 psi operating pressure.

  • Page 54: Pressure Relief/Work Interruption

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 7.3.3 PRESSURE RELIEF/WORK INTERRUPTION The pressure must always be relieved when: - The spraying tasks are fi nished. - The spraying system is maintained. - Cleaning tasks are carried out on the spraying system. - The spraying system is moved to another location.

  • Page 55: Dismantling The Gun Cover

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 7.3.4 DISMANTLING THE GUN COVER Note: For changing nozzles, the cover does not have to be removed! 1. Press the snap fi t (2) together and pull off the rear cover (1) to the back. 2.

  • Page 56: Changing From Air Round Jet To Air Flat Jet

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 7.3.5 CHANGING FROM AIR ROUND JET TO AIR FLAT JET NOTICE Defective electrode! Material damage due to functional faults. Do not damage the electrode. Flush spray gun: 1. Switch off high voltage at the control unit. AR 5000 EARV 5000 2.
  • Page 57 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL Mount nozzle Flat jet 1. Screw in and tighten AF 5000 fl at jet nozzle (5) by hand. 2. Put the AF 5000 air cap (4) in place. Screw the union nut (1) onto the spray gun body. 3.

  • Page 58: Changing The Valve Housing

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 7.3.6 CHANGING THE VALVE HOUSING Relieve pressure prior changing the valve housing. Chapter 7.3.3 Use a socket or ring spanner (not an open-end wrench) to tighten the valve housing. SW11 1.32 lb ft B_05753 Valve housing and valve tip are available in various materials: Valve housing...

  • Page 59: Cleaning Of The Nozzle Parts

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 7.3.7 CLEANING 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.

  • Page 60: Cleaning And Maintenance

    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.
  • Page 61 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL DANGER Explosive powder/air mixes! Danger to life and equipment damage. Before starting cleaning, rinsing, or other manual work, the high voltage must be shut down and locked to prevent it from being switched back on! The spray gun must be separated from the high-voltage supply before any cleaning work is started!

  • Page 62: Cleaning And Flushing The Device

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 8.1.3 CLEANING AND FLUSHING THE DEVICE The spraying system and the spray gun must be cleaned and fl ushed daily. The cleaning and fl ushing agents used must be compatible with the working material. WARNING Incompatibility of cleaning/fl ushing agent and working medium! Risk of explosion and danger of poisoning by toxic gases.
  • Page 63 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL DANGER Exploding gas / air mixture! Danger to life from fl ying parts and burns. Never spray into a closed tank. Ground the tank. Clean nozzle 1. Switch off control unit. 2.

  • Page 64: Maintenance

    In accordance with the guideline for liquid ejection devices (DGUV regulation 100-500 Chapter 2.29 and 2.36): - 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.

  • Page 65: Safety Checks

    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.

  • Page 66: Product Hoses, Tubes And Couplings

    – 6 years from the date of the hose crimping (see fi tting embossing). – 10 years from the date of the hose imprinting. Fitting Hose imprinting Meaning embossing Meaning WAGNER Name/Manufacturer (if present) Date of manufacture yymm xxx bar Pressure...

  • Page 67: Trouble Shooting And Rectification

    Connect gun and gun cable/check for defect. Check lacquer resistance (see Chapter 2.5). Seal in end piece defective Repair by WAGNER Service Department. Air-passages damp Clean and dry air passages. Back-spray Poor grounding at object Check grounding.

  • Page 68: Repair Work

    In accordance with the guideline for liquid ejection devices (DGUV regulation 100-500 Chapter 2.29 and 2.36): - 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.

  • Page 69: Dismantling Of The Gun

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 10.3 DISMANTLING OF THE GUN Plastic parts Gently handle all plastic parts. 10.3.1 TOOLS For disassembling and assembling the spray gun, the following tools are required: - Allen wrench, SW 2.5 - Allen wrench, SW 3 - Allen wrench, SW 5 - Open-end wrench, SW 5...

  • Page 70: Dismantling Of The Spray Gun

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 10.3.2 DISMANTLING OF THE SPRAY GUN B_05793 B_05794...
  • Page 71 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL SW19 B_05795 SW19 Product hose: Do not tilt, but pull it straight out in direction indicated by arrow. At the same time, execute slight rotational movements. B_05796...
  • Page 72 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL B_05797 Unscrew the collet chuck: When unscrewing the collet chuck, a second size 7 open-ended wrench must be used for bracing. Carefully release the cascade without pliers B_05798...
  • Page 73 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL Valve needle assembly tool Order No. 2309368 B_04370 SW11 Valve housing: Use socket or ring spanner (not an open-end wrench). Valve needle Air Loosen valve tip by hand using the valve needle assembly tool (Order No. 2309368). B_04369 O-ring (8): Air manifold ring (9):...
  • Page 74 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 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 B_05799 process.

  • Page 75: Cleaning The Parts After Disassembly

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 10.3.3 CLEANING THE PARTS AFTER DISASSEMBLY ATTENTION 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.

  • Page 76: Assembling The Spray Gun

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 10.3.4 ASSEMBLING THE SPRAY GUN Assembly aids: Order No. Description 9992698 Vaseline white, PHHV II 9992511 Loctite 243 * Use Vaseline sparingly Valve rod unit: 2Nm; 1.48 lbft Set length adjusting measure X with collet chuck (6) and lock with a hexagon nut (2).
  • Page 77 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 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).
  • Page 78 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL Valve needle assembly tool, Order No. 2309368 B_04373 0.1 Nm 0.07 lb ft SW11 1.8 Nm; Ensure the correct 1.33 lb ft insertion position! 1. Move the valve rod to the rear position so that the sealing area does not become scratched (1).
  • Page 79 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 1.3±0.1mm Set dimension 1.3 mm: Via setting the dimension, soiling of air B_06082 cap will be decreased. B_05797 Assembling the collet chuck: When assembling the collet chuck, a second open-ended wrench SW7 must be used for bracing.
  • Page 80 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL SW19 5 Nm; 2.5 Nm; 3.69 lb ft 1.84 lb ft B_06003 SW19 10 Nm; 7.37 lb ft B_06004...
  • Page 81 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL Flat jet nozzle Assembly, see Chapter 14.4 Diverse nozzle sizes, see Chapter 13.4 Round jet nozzle Assembly, see Chapter 14.4 Diverse nozzle sizes, see Chapter 13.3 B_06005...

  • Page 82: Function Test After The Repair

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL FUNCTION TEST AFTER THE REPAIR After all repairs, the device must be checked for safe condition before recommissioning. The necessary scope of inspection and testing depends on the repair carried out and must be documented by the repair staff .
  • Page 83 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 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.

  • Page 84: Air Test

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 11.2 AIR TEST GA 5000EA Switch off the atomizing and shaping air, switch on control air. 1. 0.4 MPa; 4 bar; 58 psi: The air valve must switch on correctly. 2. 0.8 MPa; 8 bar; 116 psi: Test for air seal. 3.

  • Page 85: Disposal

    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.

  • Page 86: Accessories

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL ACCESSORIES 13.1 VALVE HOUSING Order No. Designation Valve housing Air, complete (steel) 2312179 (Standard version) B_03697 2312176 Valve housing Air, complete (PEEK) B_03697 13.2 VALVE TIPS Order No. Designation Valve tip Air, complete (PEEK) 2312184 B_03698 (Standard version)

  • Page 87: Earv Nozzle Set

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 13.3.3 EARV NOZZLE SET Markings on union Order No. Designation Nozzle set, EARV 5000 LV 2361290 suitable for low viscosity products B_05984 Nozzle set, EARV 5000 HV 2365979 suitable for high viscosity products B_05985 B_06044 Mounting tool...

  • Page 88: Af 5000 Nozzles

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 13.4.2 AF 5000 NOZZLES Order No. Designation 2310539 AF 5000 nozzle – 0.6 mm (black) B_03241 2310540 AF 5000 nozzle – 0.8 mm (yellow) B_03241 2310541 AF 5000 nozzle – 1.0 mm (red) B_03241 2310542 AF 5000 nozzle –...

  • Page 89: Electric Cables And Hoses

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 13.5 ELECTRIC CABLES AND HOSES 13.5.1 GUN CABLE Order No. Designation 2339157 Gun cable, 10 m; 32.8 ft 2339158 Gun cable, 15 m; 49.2 ft B_03218 2339159 Gun cable, 20 m; 65.6 ft 2339160 Gun cable, 25 m;...

  • Page 90: Product Hoses For Low-Resistance Products

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 13.5.4 PRODUCT HOSES FOR LOW-RESISTANCE PRODUCTS Order No. Designation 2367203 Product hose, GA EA LowR 7.5 m 2367204 Product hose, GA EA LowR 10 m 2367205 Product hose, GA EA LowR 15 m B_06031 2367206 Product hose, GA EA LowR 20 m...

  • Page 91: Miscellaneous

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 13.6 MISCELLANEOUS Order No. Designation 259010 High-voltage tester, HV 200 N P_00265 2326041 Paint resistance meter B_03692 999080 Wet fi lm thickness gauge B_03224 50342 Viscosity cup, DIN 4 mm; 0.16 inches 2309368 Valve needle assembly tool B_03451...
  • Page 92 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL Order No. Designation 380942 Rotary gun holder (standard) 380945 Rotary holder, 40/40/5 380943 Complete swivel drive 380944 Cross clamp for swivel drive B_06075 2370869 Robot connection, GA 5000 B_06076...

  • Page 93: Spare Parts

    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.

  • Page 94: Ga 5000Eaic Spray Gun

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 14.2 GA 5000EAIC SPRAY GUN 5 Nm; 3.68 lb ft SW2.5 0.6 Nm; 0.44 lb ft SW14 12 Nm; 8.85 lb ft SW14 12 Nm; 8.85 lb ft 23 24 SW2.5 0.6 Nm;...
  • Page 95 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL Spare parts list for GA 5000EAIC Order No. Designation 2360900 GA 5000EAIC 2315709 Protection cap valve needle 2307039 Union nut 2311217 O-ring Adapter, complete GA 5000EA (for details, see Chapter 14.2.1)

  • Page 96: Ga 5000Ea Adapter

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL Spare parts list for GA 5000EAIC Order No. Designation 2367333 Hexagon screw without shaft 2365237 Cover, labeled 2365248 Lid, labeled EAIC 2338526 Contact spacer 9992511 Loctite 243 2369320 Service set Air/Controller, GA 5000EA = Wearing part 14.2.1...
  • Page 97 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 130±0.1 mm 5.12±0.004 inch B_06041...

  • Page 98: Ga 5000Eaec Spray Gun

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 14.3 GA 5000EAEC SPRAY GUN 5 Nm; 3.68 lb ft SW2.5 0.6 Nm; 0.44 lb ft SW14 12 Nm; 8.85 lb ft 23 24 SW2.5 0.6 Nm; 0.44 lb ft B_06038 7 Nm;...
  • Page 99 (For details, see Chapter 14.2.1) 2307232 Adapter seal 2360690 Plug 9930128 Parallel pin 9974265 O-ring 2360689 Seal 2360813 Cable, complete (only for WAGNER Service Department) 2357712 Locknut 9974089 O-ring 2358895 Sealing plug 2357738 Seal 2357739 Cover 2360888 Product hose, complete GA 5000EA...
  • Page 100 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL Spare parts list for GA 5000EAEC Order No. Designation 2365249 Lid labeled, EAEC 2338526 Contact spacer 9992511 Loctite 243 2369320 Service set Air/Controller, GA 5000EA = Wearing part...

  • Page 101: Accessories Spare Parts Lists

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 14.4 ACCESSORIES 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). B_04094 B_03843 NOTICE...

  • Page 102: Ar 5000 Nozzle (D8)

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 14.4.1 AR 5000 NOZZLE (D8) B_03263 Spare parts list for AR 5000 nozzle (D8) Order No. Designation 2310558 Nozzle, complete AR 5000 (D8) 2327658 Nozzle, AR (D8) 2327659 Nozzle attachment, AR (D8) 2327660 Air diff user, AR (D8) = Wearing part...

  • Page 103: Adjustable Earv 5000 Round Jet Nozzle

    GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL 14.4.3 ADJUSTABLE EARV 5000 ROUND JET NOZZLE Low-viscosity (LV) High-viscosity (HV) Spare parts list for EARV 5000 products products Designation Order No. Order No. Nozzle set, EARV 5000 2361290 2365979 Nozzle, EARV 2361273 Nozzle insert, EARV 2361274...

  • Page 104: Warranty And Conformity Declarations

    The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with.

  • Page 105: Eu Declaration Of Conformity

    II 2 G 0.24mJ X SIRA 16 ATEX5290X EU Declaration of Conformity The EU Declaration of Conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order number: 2360925...
  • Page 106 GA 5000EA VERSION 09/2016 ORDER NUMBER DOC2360924 OPERATING MANUAL...
  • Page 108 Order No. 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...

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