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WAGNER GA 4000ACIC-R Translation Of The Original Operating Manual

Aircoat automatic spray gun
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AirCoat
Automatic Spray Gun
Translation of the Original
Operating Manual
Version 06/2013
B_03045

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Summary of Contents for WAGNER GA 4000ACIC-R

  • Page 1 Translation of the Original Operating Manual Version 06/2013 AirCoat Automatic Spray Gun B_03045...

  • Page 3: Table Of Contents

    Safety Instructions for the Operator 4.1.1 Electrical Equipment 4.1.2 Staff 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 Unit 4.2.3 Product Hoses 4.2.4 Cleaning 4.2.5 Handling Hazardous Liquids, Lacquers, and Paints 4.2.6...
  • Page 4 VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL Table of Contents Data 5.3.1 Technical Data 5.3.2 Measurements and Connections 5.3.3 Materials of Paint Wetted Parts Functional Description 5.4.1 Design of Spray Gun 5.4.2 Modes "NC" and "C" 5.4.2.1 Mode "NC" without Product Circulation 5.4.2.2 Mode "C"...
  • Page 5 VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL Table of Contents ACCESSORIES 10.1 AirCoat Nozzles ACF3000 10.2 Round Jet Nozzle Cap 10.2.1 Nozzle Inserts RXX 10.2.2 Complete Nozzle Screw Joint 10.3 Hoses 10.4 Miscellaneous SPARE PARTS 11.1 How Can Spare Parts Be Ordered? 11.2 Spare Parts List for GA 4000ACIC 11.3...

  • Page 6: About This Operating Manual

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL ABOUT THIS OPERATING MANUAL 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 operating and service staff .

  • Page 7: Languages

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL LANGUAGES The operating manual is available in the following languages: Language: Order No. Language: Order No. German 2312955 English 2312956 French 2312957 Italian 2312958 Spanish 2312959 Swedish 2316798 Russian 2327992 ABBREVIATIONS IN THE TEXT Number of pieces Position Marking in the spare parts lists...

  • Page 8: Correct Use

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL CORRECT USE DEVICE TYPES AirCoat automatic spray gun with the type designation: GA 4000ACIC TYPE OF USE The device is suitable for processing liquid products such as paints and lacquers in accordance with their classifi cation into explosion classes IIA or IIB, especially coating products using the AirCoat process.

  • Page 9: Safety Parameters

    PROCESSIBLE PRODUCTS Top-coat paints, primer paints, corrosion protection, textured paints, lyes, staining solvents, clear paints, separating agents, etc. with a solvent or water basis. Note: Please contact your local WAGNER dealer and the lacquer manufacturer if you encounter application problems.

  • Page 10: Reasonably Foreseeable Misuse

    The forms of misuse listed below may result in health issues and/or material damage: use of powder as a coating product Wagner devices are not designed for use with food. RESIDUAL RISKS Residual risks are risks which cannot be excluded even in the event of correct use.

  • Page 11: Identification

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL IDENTIFICATION EXPLOSION PROTECTION IDENTIFICATION AirCoat automatic spray gun with the type designation: GA 4000ACIC As defi ned in Directive 94/9/EC (ATEX 95), the device is suitable for use in areas where there is an explosion hazard. European Communities Symbol for explosion protection Device class II...

  • Page 12: General Safety Instructions

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual at hand near the unit 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 operating mode and ambient infl uences.

  • Page 13: Safety Instructions For Staff

    The liquid ejection devices are to be checked for safe working conditions by an expert (e.g. Wagner Service Technician) as often as necessary or at least every 12 months, in accordance with the guidelines for liquid ejection devices (ZH 1/406 and BGR 500 Part 2 Chapter 2.36).

  • Page 14: Product Hoses

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 4.2.3 PRODUCT HOSES Ensure that the hose material is chemically resistant to the sprayed products. Ensure that the product hose is suitable for the pressure generated in the device. Make sure that the hoses are laid only in suitable places. In no case, should hoses be laid in the following places: –...

  • Page 15: Touching Hot Surfaces

    4.3.1 SAFETY REGULATIONS 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 unit against steel or rusty iron.

  • Page 16: Description

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL DESCRIPTION FIELD OF APPLICATION The device is suitable for processing liquid products such as paints and lacquers in accordance with their classifi cation into explosion classes IIA or IIB, especially coating products using the AirCoat process. SCOPE OF DELIVERY 5.2.1 TYPE DESIGNATION...

  • Page 17: Overview

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 5.2.2 OVERVIEW The Aircoat automatic spray gun is composed of the gun body and supplementary components. Circulation operating mode is possible. 5.2.3 Gun Body of GA 4000ACIC 5.2.4.4 Automatic Gun Round Nozzles, Supplementary Component 5.2.4.3 5.2.4.7...

  • Page 18: Standard Equipment

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 5.2.3 STANDARD EQUIPMENT Order No. Designation 2312132 AirCoat automatic gun GA 4000ACIC 2338603 AirCoat automatic gun GA 4000ACIC (RP) The standard equipment includes: Order No. Designation 2315627 CE Declaration of Conformity 2312955 Operating manual German Chapter 1 Operating manual in local language...

  • Page 19: Air Caps

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 5.2.4.2 AIR CAPS Order No. Designation 2308809 Air cap HV plus (blue) for high viscosity products B_03048 2308808 Air cap LV plus (red) for low viscosity products B_03049 2313493 Air cap LA plus (bronze) B_03098 2340299 Air cap LV plus (blank)

  • Page 20: Product Connections

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 5.2.4.5 PRODUCT CONNECTIONS Order No. Designation 350550 Straight connecting fi tting B_03074 2314065 90° connecting fi tting B_03097 5.2.4.6 AIR SUPPLY CONNECTIONS Order No. Designation Straight threaded fi tting 6 mm - 1/8"; 0.24 inch - 1/8" * 9998090 Standard 9998993...

  • Page 21: Data

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL DATA 5.3.1 TECHNICAL DATA Description Devices Maximum air inlet pressure Maximum product pressure 3625 Product connection (internal thread) inch G1/4" Air connection (internal thread) inch G1/8" Weight (standard equipment) Maximum product temperature °C °F Maximum air temperature...

  • Page 22: Measurements And Connections

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 5.3.2 MEASUREMENTS AND CONNECTIONS inch 5.08 1.85 77.5 3.05 Ø 3.2 2.17 18±0.1 0.71±0.004 18±0.1 0.71±0.004 B_03486 Connection data: Base plate to GA 4000ACIC R G1/8" -> 6 mm; 0.24 inch control air G1/8"...

  • Page 23: Materials Of Paint Wetted Parts

    VERSION 06/2013 ORDER NUMBER DOC 2312956 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: Base plate to GA 4000ACIC S G1/8" -> 6 mm; 0.24 inch control air G1/8" -> 8 mm; 0.31 inch atomizing air G1/4"...

  • Page 24: Functional Description

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL FUNCTIONAL DESCRIPTION 5.4.1 DESIGN OF SPRAY GUN B_03051 B_03052 Designation Gun head Spray gun body Tension sleeve drive Base plate Atomizing air connection (blue) Union nut Air cap (blue, red or bronze) Nozzle Standard holder Connecting fi tting (product)

  • Page 25: Modes "Nc" And "C

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 5.4.2 4x 4 Nm; 2.95 lbft MODES "NC" AND "C" 5.4.2.1 MODE "NC" WITHOUT PRODUCT CIRCULATION In this mode of operation, the left or the right product channel in the gun head (A) is locked by the lock pin (M) and the product entrance (ME) is always on the opposite side.

  • Page 26: Spraying Process

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL Close: The piston is relieved, and the product valve closes due to the pressure spring which presses against the product valve tappet. The air valve is then closed, again with a spring force and mechanical delay.

  • Page 27: Aircoat Round Jet Spray Process

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 5.5.2 AIRCOAT ROUND JET SPRAY PROCESS With the AirCoat round jet process, the spray product is normally 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 normally produces a soft jet. The spray jet diameter can be adjusted by turning the nozzle nut.

  • Page 28: Assembly And Commissioning

    The spray gun must be used a part of an spraying system. The spraying system shown in the fi gure is only one example of an AirCoat spraying system. Contact your Wagner distributor for assistance in putting together a system to meet your needs.

  • Page 29: Ventilation Of The Spray Booth

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 6.1.2 VENTILATION OF THE SPRAY BOOTH WARNING Toxic and/or fl ammable vapor mixtures! Risk of poisoning and burns. Operate the device in a spray booth approved for the products. -or- Operate the device on an appropriate spraying wall with the ventilation (extraction) switched on.

  • Page 30: Grounding The System

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 6.1.5 GROUNDING THE SYSTEM WARNING Discharge of electrostatically charged components in atmospheres containing solvents! Risk of explosion from electrostatic sparks or fl ames. Ground all device components. Ground the workpieces to be coated. WARNING Heavy paint mist if grounding is insuffi cient! Risk of poisoning.

  • Page 31: Lacquer Preparations

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL LACQUER PREPARATIONS The viscosity of the lacquer is of great importance. The best results are obtained with lacquers of between 80 and 150 mPas. Processing of up to 260 mPas is generally possible without problems if high coating thicknesses are required.

  • Page 32: Commissioning

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL COMMISSIONING 6.3.1 GENERAL RULES FOR HANDLING THE SPRAY GUN Observe safety instructions in Chapter 4. The following rules must be observed before all work on the device, in the event of work interruptions and functional faults: WARNING Unintentional putting into operation!

  • Page 33: Preparations For Starting Up

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 6.3.2 PREPARATIONS FOR STARTING UP 1. Mount the spray gun on the reciprocator. 2. Connect product hoses (supply and return) to spray gun and product supply system. 3. Fit nozzle on nozzle seal. Fit air cap over nozzle. Note the fl attened parts (X) on the nozzle and in the air cap.

  • Page 34: Operation

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL OPERATION START-UP FOR AIRCOAT SPRAYING 1. Set operating pressure for product supply to approx. 8 MPa; 80 bar; 1160 psi and start up. 2. Spray (release control air) and check the atomization. 3.

  • Page 35: Changing Aircoat Nozzle

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL CHANGING AIRCOAT NOZZLE NOTICE Defective AirCoat nozzle! Insuffi cient paint application quality. Do not use sharp-edged objects to treat carbide on the AirCoat nozzle. NOTICE Defective nozzle seal! Product sprays into the air cap next to the nozzle. Risk of contamination.

  • Page 36: Eliminating Nozzle Clogging

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL ELIMINATING NOZZLE CLOGGING 1. Relieve the pressure of gun and device. 2. Secure gun (remove the control air hose). 3. Unscrew union nut (A). 4. Remove air cap (B). 5. Push AirCoat nozzle (C) out of air cap (B) by hand and place on nozzle seal (D) the other way round with the nozzle tip towards the rear.

  • Page 37: Replacing Nozzle Insert Of Round Jet Nozzle

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL REPLACING NOZZLE INSERT OF ROUND JET NOZZLE 1. Relieve the pressure of gun and device. 2. Secure gun (remove the control air hose). 3. Remove nozzle insert (B) with nozzle spanner (A). 4.

  • Page 38: Troubleshooting And Rectification

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL TROUBLESHOOTING AND RECTIFICATION Functional fault Cause Remedy Insuffi cient product Nozzle too small. Select larger nozzle (see chapter 10.1). output. Product pressure too low. Increase product pressure. Filter upstream of gun or high pressure Clean or replace fi lter.

  • Page 39: Cleaning And Maintenance

    In accordance with the guideline for liquid ejection devices (ZH  1/406 and BGR  500 Part 2 Chapter 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 40: Decommissioning And Cleaning

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL DECOMMISSIONING AND CLEANING NOTICE Cleaning agent in air duct! Functional faults. When cleaning, always operate the spray gun at at least 0.05 MPa; 0.5 bar; 7.25 psi shaping air. No cleaning agent should be allowed to enter the air ducts. DANGER Exploding gas / air mixture! Danger to life from fl ying parts and burns.

  • Page 41: Replacing Product Hose

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL REPLACING PRODUCT HOSE The service life of the fl uid hoses is reduced due to environmental infl uences even when handled correctly. Check hoses, pipes, and couplings every day and replace if necessary. As a precaution, fl uid hoses should be replaced after a period specifi ed by the operator.

  • Page 42: Replacing Sealing Fitting Of Round Jet Nozzle

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL REPLACING SEALING FITTING OF ROUND JET NOZZLE NOTICE Defective nozzle body! Poor spray pattern. Handle the nozzle body (A) with care. Unscrew the nozzle by hand. B_03059 Counter hold with a size 13 mm; 0.51 inch socket wrench.
  • Page 43 VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL...

  • Page 44: Replacing Parts In Gun Body

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL REPLACING PARTS IN GUN BODY 9.5.1 DISASSEMBLY OF GA 4000ACIC NOTICE Defective plunger shaft! Packing leaking. Greater wear on the packing. Handle the plunger shaft (K) with care. The plunger shaft has the function of a sliding surface. Note: The complete base plate (B) does not have to be removed.
  • Page 45 VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL Blow gun M5 wrench size 3; 0.12 inch Note: Stuck components can be pushed out with a drift 3 mm; 0.12 inch in diameter. Note: Pull out distributor seal (F) using pliers. M5 wrench size 12;...

  • Page 46: Packing Insert Ga 4000Ac (Rp)

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 9.5.2 PACKING INSERT GA 4000AC (RP) 180° 5 Nm (Torx TX40) SW15 B_04227 Order of seals: 1) Sealing set GA4000 packing RP: order number 2339140 Material Order No. Order No. (set of 12 packings) PTFE + GF 2339141 2339142...
  • Page 47 VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 2) Sealing set GA4000 packing RP special: order number 2339810 Material Order No. Order No. (set of 12 packings) PTFE 2339143 2339142 PTFE 2339143 2339142 PTFE + GF 2339141 PTFE + GF 2339141 Mobilux EP 2 grease 9998808...

  • Page 48: Assembly Of Ga 4000Acic

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 9.5.3 ASSEMBLY OF GA 4000ACIC General note: SW 15; 0.59 inch Lightly grease o-rings and sliding surfaces with Vaseline 25 Nm; 8.85 lbft white PHV II. SW 12; 0.47 inch 25 Nm; 8.85 lbft M5 SW 3;...
  • Page 49 VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL Dismount union nut and air cap again. Wrench size 12; 0.47 inch 10 Nm; 7.38 lbft M5 wrench size 3 mm; 0.12 inch 4 Nm; 2.95 lbft B_03068...

  • Page 50: Accessories

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL ACCESSORIES 10.1 AIRCOAT NOZZLES ACF3000 Recommended gun fi lter Recommended edge fi lter Application 379107 07/10 0.007-0.18 10° Natural lacquer 379207 07/20 0.007-0.18 20° 379209 09/20 0.009-0.23 20° Clear lacquer 379309 09/30 0.009-0.23 30°...
  • Page 51 VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL Recommended gun fi lter Recommended edge fi lter Application 379219 19/20 0.019-0.48 20° Rust proofi ng paints 379319 19/30 0.019-0.48 30° Latex paints 379419 19/40 0.019-0.48 40° 379519 19/50 0.019-0.48 50° 379619 19/60 0.019-0.48 60°...

  • Page 52: Round Jet Nozzle Cap

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 10.2 ROUND JET NOZZLE CAP Order No. Designation 8.2.2 394180 Round jet nozzle cap (without nozzle insert) B_03072 8.2.1 10.2.1 NOZZLE INSERTS RXX Order No. Designation Marking Jet diameter ** 132720 Nozzle insert R11 Approx.

  • Page 53: Hoses

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 10.3 HOSES Order No. Designation 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; ID 0.24 inch, 27 MPa; 270 bar;...
  • Page 54 VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL Order No. Designation 2314079 Cefl a adapter plate B_03099 380942 Rotary gun holder (standard) 380945 Rotary holder 40/40/5 380943 Complete swivel drive 380944 Cross clamp for swivel drive...

  • Page 55: Spare Parts

    Risk of injury and equipment damage. Have repairs and part replacements be carried out only by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 56: Spare Parts List For Ga 4000Acic

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL 11.2 SPARE PARTS LIST FOR GA 4000ACIC 10 Nm; 7.38 lbft 4 Nm; 2.95 lbft 16 / 16a 25 Nm; 18.44 lbft 25 Nm; 18.44 lbft 1 Nm; 0.74 lbft B_03070 Special version in EPDM Locite 243 3 Nm;...
  • Page 57 Order No. Designation 2312132 Spray gun body GA 4000ACIC 2338603 Spray gun body GA 4000ACIC (RP) 2312144 Base plate GA 4000ACIC-S complete 2308810 Base plate GA 4000ACIC-R complete 2309945 Helical spring 2314274 End cap short 2308808 Air cap LV plus (red) 2308809...

  • Page 58: Service Sets And Spare Parts Groups

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL Order No. Designation 2314242 Base plate GA 4000ACIC R 2322531 Piston seal EPDM 2322530 O-ring 9974179 O-ring 2322532 Sealing set GA 4000ACIC(EPDM) = Wearing part -> For service sets, see chapter 11.3. = Not part of the standard equipment but available as a special accessory.

  • Page 59: Sealing Set Ga 4000 Packing Rp And Rp Special

    VERSION 06/2013 ORDER NUMBER DOC 2312956 OPERATING MANUAL Packing insert GA 4000AC (RP) 5 Nm (Torx TX40) B_04229 SW15 12 12 11.5 SEALING SET GA 4000 PACKING RP AND RP SPECIAL Order No. Designation Consisting of spare parts items 2339140 Sealing set GA 4000 packing RP 3, 6, 7, 8, 9, 12, 14 2339810...

  • Page 60: 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 61: Ce Declaration Of Conformity

    Identifi cation: EC Certifi cate of Conformity The CE certifi cate 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: 2315627 12.4...
  • Page 62 Telephone: +41 (0)71 757 2211 Telefax: +49 7544 505200 Telefax: +41 (0)71 757 2222 E-Mail: service.standard@wagner-group.com E-Mail: rep-ch@wagner-group.ch Belgium Denmark WAGNER Spraytech Benelux BV WAGNER Industrial Solution Scandinavia Veilinglaan 58 Viborgvej 100, Skærgær B- 1861 Wolvertem DK- 8600 Silkeborg Telephone: +32 (0)2 269 4675...
  • Page 64 Order No. 2312956 Germany Phone E-mail Switzerland Phone...

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