WAGNER GA 5000EACIC Operating Manual
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WAGNER GA 5000EACIC Operating Manual

Electrostatic air spray gun for automatic operation, for flat or round jet nozzles
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Electrostatic Air Spray Gun
for automatic operation
for fl at or round jet nozzles
B_05738
II 2 G 0.24mJ X
Translation of the Original
Operating Manual
GA 5000EACIC
GA 5000EACEC
Version 09/2016

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Summary of Contents for WAGNER GA 5000EACIC

  • Page 1 Translation of the Original Operating Manual GA 5000EACIC GA 5000EACEC Version 09/2016 Electrostatic Air Spray Gun for automatic operation for fl at or round jet nozzles B_05738 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 VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL Table of Contents Technical Data 5.5.1 GA 5000EAC Dimensions The WAGNER Electrostatic AirCoat Spraying System 5.6.1 Spraying Procedure for AirCoat Round Jet 5.6.2 Spraying Procedure for AirCoat Flat Jet 5.6.3 Electrostatic Eff ect...
  • Page 5 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 DOC2360922 OPERATING MANUAL Table of Contents SPARE PARTS 14.1 How Can Spare Parts Be Ordered? 14.2 GA 5000EACIC Spray Gun 14.2.1 GA 5000EAC – Adapter 14.3 GA 5000EACEC Spray Gun 14.4 Accessories Spare Parts Lists 14.4.1 Flat Jet Nozzles 14.4.2 ACR 5000 Round Jet Nozzle Attachment...

  • Page 7: About These Instructions

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL LANGUAGES 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 request or at: ABBREVIATIONS Order No.

  • Page 9: Terminology For The Purpose Of This Manual

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 5000EAC 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 5000EAC 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 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL TYPE PLATE GA 5000EACIC GA 5000EACEC Serial number B_05768...

  • Page 16: General Safety Instructions

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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). - For shut down devices, the examination can be suspended until the next start-up.

  • Page 18: Grounding The Device

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL DESCRIPTION STRUCTURE (STANDARD VARIANT) 5.1.1 GA 5000EACIC DESIGN B_05739 1 Front cover 9 Shaping air setting 2 Union nut with nozzle protection 10 Gun holder 3 Air cap 11 Product hose...

  • Page 24: Ga 5000Eacec Design

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 5.1.2 GA 5000EACEC DESIGN B_05740 1 Front cover 8 Air diff user housing 2 Union nut with nozzle protection 9 Gun holder 3 Air cap 10 Product hose 4 Flat jet nozzle 11 Sealing fi tting 5 Gun adapter 12 Nozzle screw joint...

  • 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 5000EACIC MODE OF OPERATION Pneumatic diagram: Nozzle SA = Shaping air...

  • Page 26: Ga 5000Eacec Mode Of Operation

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 5.2.2 GA 5000EACEC 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 2360898 GA 5000EACIC spray gun 2360899 GA 5000EACEC spray gun The spray guns are delivered without control unit, product and air hose, electric cable, air cap and nozzle.

  • Page 28: Technical Data

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 250 bar;...

  • Page 29: Ga 5000Eac Dimensions

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 5.5.1 GA 5000EAC DIMENSIONS GA 5000EAC with fl at jet nozzle B_05748 GA 5000EAC with round jet nozzle Connecting dimensions of the connection plate: 18 18 B_05761 2x M5 4x ∅ 3.2...

  • Page 30: The Wagner Electrostatic Aircoat Spraying System

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

  • Page 31: Spraying Procedure For Aircoat Round Jet

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 5.6.1 SPRAYING PROCEDURE FOR AIRCOAT ROUND JET 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.

  • Page 32: Electrostatic Effect

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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: Assembly And Commissioning

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 34: Assembly And Installation

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

  • Page 36: Connecting Ga 5000Eacic

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 6.4.2 CONNECTING GA 5000EACIC 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 37: Connecting Ga 5000Eacec

    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 38: Ventilation Of The Spray Booth

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 6.4.4 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 39: Air Supply

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 6.4.5 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 spray pattern.

  • Page 40: Grounding

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 6.4.7 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 41 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 42: Preparation Of Lacquer

    Processing of up to 60 DIN/4 seconds is generally possible without problem if high coating thicknesses are required. With the WAGNER AirCoat fl at jet spraying process, the diff erent viscosities of the lacquer are optimally covered by two air cap types. These can be found in "Accessories".

  • Page 43: Commissioning

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL COMMISSIONING 6.6.1 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. 6.6.2 PREPARATION FOR COMMISSIONING NOTICE Impurities in the spraying system! Spray gun blockage.

  • Page 44: Verifying A Safe Operational Condition

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 45: Operation

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 46: Emergency Deactivation

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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. Tighten the union nut, especially with nozzle in the cleaning position.

  • Page 47: Working

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL WORKING 7.3.1 SETTING THE SPRAY PATTERN USING THE AIR PRESSURE REGULATOR The air pressure regulator regulates the air supply (shaping and atomizing air) to the gun. B_00071 No air Not enough air Correct amount of air Spray pattern and air regulation When IC variant the air regulation regulates the ratio of shaping/atomizing air.

  • Page 48: Spraying

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 7.3.2 SPRAYING 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.

  • Page 49: Pressure Relief/Work Interruption

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 50: Dismantling The Gun Cover

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 51: Flushing Out Clogged Round Jet Nozzles

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 7.3.5 FLUSHING OUT CLOGGED ROUND JET NOZZLES DANGER Exploding gas / air mixture! Danger to life from fl ying parts and burns. Never spray into a closed tank. Ground the tank. 1.

  • Page 52: Changing From Aircoat Round Jet To Aircoat Flat Jet

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 7.3.7 CHANGING FROM AIRCOAT ROUND JET TO AIRCOAT FLAT JET Flush spray gun 1. Switch off control unit. 2. Relieve pressure Chapter 7.3.3. 3. Connect the system to the fl ushing agent supply. 4.
  • Page 53 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL B_05754...

  • Page 54: Replacing The Aircoat Flat Jet Nozzles

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 7.3.8 REPLACING THE AIRCOAT FLAT JET NOZZLES 1. Switch off control unit. 2. Unscrew union nut completely (12) and remove air cap (10). 3. Remove and clean the ACF 5000 AirCoat nozzle (11). NOTICE Defective AirCoat nozzle! Insuffi cient paint application quality.

  • Page 55: Cleaning Of The Nozzle Parts

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 7.3.9 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 56: Eliminate Nozzle Clogging

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 7.3.10 ELIMINATE NOZZLE CLOGGING 1. Switch control unit to standby operation. 2. Unscrew union nut completely (12) and remove air cap (10). 3. Push ACF 5000 nozzle (11) out of air cap (10) by hand, reverse it and put it into the air cap (10) with the nozzle tip towards the rear.
  • Page 57 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL B_05774 ACF5000 nozzle in spray position ACF5000 nozzle in cleaning position...

  • Page 58: Changing The Valve Housing

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 7.3.11 CHANGING THE VALVE HOUSING Relieve pressure prior changing the valve housing. Chapter 7.3.3 Use socket or ring spanner (no wrench) to tighten the valve housing. 1.8 Nm 1.32 lb ft B_06426...

  • Page 59: 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 60 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 61: Cleaning And Flushing The Device

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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!
  • Page 62 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 63: Maintenance

    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.

  • Page 64: 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 65: 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 66: Trouble Shooting And Rectification

    Connect gun and gun cable/check for defect. Check paint 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 67: Repair Work

    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.

  • Page 68: Spray Gun

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 10.3 SPRAY 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 3 - Wrench, SW 5 - Wrench, SW 7 - Wrench, SW 8 - Wrench, SW 19...

  • Page 69: Dismantling Of The Spray Gun

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 10.3.2 DISMANTLING OF THE SPRAY GUN B_05779 B_05780...
  • Page 70 6 mm deep. - Pull out straight with suitable pliers. Possibly rotate clockwise simultaneously. - Thereafter, the fi tting must be replaced. If the fi tting is broken in the gun adapter, WAGNER Service Department must be contacted. B_05782...
  • Page 71 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL B_05783 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 B_05784...
  • Page 72 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL Valve needle assembly tool, Order No. 2309368 B_04786 Clamping screw assembly tool, Valve housing: Use an assembly tool or socket or ring spanner Order No. 2325263 (not a wrench). Valve tip (27) Loosen valve tip by hand using the valve needle assembly tool (Order No.
  • Page 73 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 B_05785 the process.

  • Page 74: Cleaning The Parts After Disassembly

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 75: Assembling The Spray Gun

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 76 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 77 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL Gold contact sleeve (10) Check whether the gold contact sleeve is located in the end piece (11). Otherwise, insert the sleeve onto the resistance (12). Ensure the correct B_04379 insertion position and installation direction.
  • Page 78 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL Clean and degrease the inside of the adapter and the outside of the cascade, then grease the cascade surface with Vaseline. 0.8 Nm; 0.6 lb ft B_05788 1.3±0.1mm Set dimension 1.3 mm: Via setting the dimension, soiling of air B_06083 cap will be decreased.
  • Page 79 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL B_05783 Assembling the collet chuck: When assembling the collet chuck, a second size 7 wrench must be used for bracing. SW26 B_05789 10 Nm; 7.37 lb ft...
  • Page 80 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL SW19 5 Nm; 2.5 Nm; 3.69 lb ft 1.84 lb ft B_05790 SW22 SW19 10 Nm; 7.37 lb ft Fitting (25) Before assembling the product hose, check that no fi tting (25) is in the gun adapter! Check the fi tting for damage and replace if necessary (Order No.
  • Page 81 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 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 B_05792...

  • Page 82: Function Test After The Repair

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 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 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 11.2 AIR TEST GA 5000EAC 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 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL ACCESSORIES 13.1 ROUND JET NOZZLES 13.1.1 ACR 5000 ROUND JET NOZZLE ATTACHMENT Order No. Designation 2309883 ACR 5000 round jet nozzle attachment (with nozzle spanner, without AC round jet nozzle insert) B_03210 13.1.2 AIRCOAT ROUND JET NOZZLE INSERTS...

  • Page 87: Acf5000 Aircoat Flat Jet Nozzles

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 13.2.2 ACF5000 AIRCOAT FLAT JET NOZZLES Application B_03163 395107 07/10 0.18; 0.007 10° Natural lacquer 395207 07/20 20° 395407 07/40 40° 395109 09/10 0.23; 0.009 10° Clear lacquer 395209 09/20 20° Oils 395309 09/30...
  • Page 88 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL Application B_03163 395219 19/20 0.48; 0.019 20° Rust proofi ng paints 395319 19/30 30° Latex paints 395419 19/40 40° 395519 19/50 50° 395619 19/60 60° 395819 19/80 80° 395221 21/20 0.53; 0.021 20°...

  • Page 89: Filter

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 13.3 FILTER Order No. Designation 3204604 Edge fi lter, 60 mesh (white) 3204605 Edge fi lter, 100 mesh (black) B_00019 9999002 Edge fi lter, 200 mesh (yellow) 13.4 ELECTRIC CABLES AND HOSES 13.4.1 GUN CABLE Order No.

  • Page 90: Product Hoses, Standard

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 13.4.3 PRODUCT HOSES, STANDARD Order No. Designation 9984573 High-pressure hose-DN4-PN270-¼"NPS-7.5 m-PA 2302374 High-pressure hose DN4-PN270-¼"NPS-10.0m-PA 9984573-15 High-pressure hose-DN4-PN270-¼"NPS-15.0 m-PA B_06421 9984573-20 High-pressure hose-DN4-PN270-¼"NPS-20.0 m-PA 13.4.4 PRODUCT HOSES, LOWR Order No. Designation 2367212 Product hose, GA EAC LowR 7.5 m 2367213...

  • Page 91: Air Hoses

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 13.4.6 AIR HOSES Order No. Designation Air hose, red  6 mm, per meter 9982035 Air hose, green  8 mm, per meter 9982077 Air hose, blue  10 mm, per meter 9987095...

  • Page 92: Miscellaneous

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 13.5 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 93 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL Order No. Designation 380941 Standard gun holder, 180 mm; Ø 16 mm, 7.1 inches; Ø 0.63 inches 2314079 Cefl a adapter plate B_03099 380942 Rotary gun holder (standard) 380945 Rotary holder, 40/40/5 380943 Complete swivel drive 380944...

  • Page 94: 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 95: Ga 5000Eacic Spray Gun

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 14.2 GA 5000EACIC SPRAY GUN Spare parts list for GA 5000EACIC Order No. Designation 2360898 GA 5000EACIC 2315775 Union nut AC, complete Adapter, complete GA 5000EAC (For details, see Chapter 14.2.1)
  • Page 96 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 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 24 25 SW2.5 0.6 Nm; 0.44 lb ft 17 18 B_06039 7 Nm;...
  • Page 97 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL Spare parts list for GA 5000EACIC Order No. Designation 9930128 Parallel pin 9974265 O-ring 2360689 Seal 2360813 Cable, complete (only for WAGNER Service Department) 2357712 Locknut 2307739 Mounting nut 9971388 O-ring...

  • Page 98: Ga 5000Eac - Adapter

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 14.2.1 GA 5000EAC – ADAPTER For setting, see Chapter 10. 130±0.1 mm 5.12±0.004 inch B_06046...
  • Page 99 GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL Spare parts list for adapter Order No. Designation Adapter, complete GA 5000EAC 2312175 Valve housing AC, complete 2312186 Valve needle AC, complete 2357170 Adapter, GA 5000EAC 2313314 Air manifold ring, AC 2307180 O-ring, sheathed 2314283...

  • Page 100: Ga 5000Eacec Spray Gun

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 14.3 GA 5000EACEC 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 16 17 B_06040 7 Nm;...
  • Page 101 Union nut AC, complete Adapter, complete GA 5000EAC (For details, see Chapter 14.2.1) 2307232 Adapter seal 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...

  • Page 102: Accessories Spare Parts Lists

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 14.4 ACCESSORIES SPARE PARTS LISTS 14.4.1 FLAT JET NOZZLES B_03168 Spare parts list for fl at jet nozzles Order No. Designation 2315775 Union nut AC, complete 2309882 Air cap, ACF 5000 - LV (red) 2314203 Air cap, ACF 5000 - HV (blue) 2311777...

  • Page 103: Acr 5000 Round Jet Nozzle Attachment

    GA 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL 14.4.2 ACR 5000 ROUND JET NOZZLE ATTACHMENT B_03169 Spare parts list for ACR 5000 round jet nozzle attachment Order No. Designation 2309883 Round jet nozzle attachment, ACR 5000 2307220 Nozzle nut 2315310 O-ring 132351...

  • 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 5000EAC VERSION 09/2016 ORDER NUMBER DOC2360922 OPERATING MANUAL...
  • Page 108 Order No. 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...

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