Related Manuals for WAGNER AirCoat GM 4100 AC
Summary of Contents for WAGNER AirCoat GM 4100 AC
- Page 1 Version 01/2018 GM 4100 AC AirCoat Manual Gun for Flat and Round Jet Nozzles B_02254...
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Page 3: Table Of Contents
Electrical Devices and Equipment 4.1.2 A Safe Work Environment 4.1.3 Personnel Qualifications Safety Instructions for the Personnel 4.2.1 Personal Safety Equipment 4.2.2 Safe Handling of WAGNER Spray Devices 4.2.3 Grounding the Unit 4.2.4 Product hoses 4.2.5 Cleaning and Flushing 4.2.6 Touching Hot Surfaces 4.2.7... - Page 4 VERSION 01/2018 ORDER NUMBER DOC 394821 ASSEMBLY AND COMMISSIONING Training of Assembly/Commissioning Personnel Storage Conditions Installation Conditions Installation and Connection 6.4.1 Typical AirCoat spraying system 6.4.2 Ventilation of the Spray Booth 6.4.3 Air Supply Lines 6.4.4 Product supply lines Grounding Safety Checks Lacquer Preparations Commissioning...
- Page 5 VERSION 01/2018 ORDER NUMBER DOC 394821 FUNCTION TEST AFTER REPAIR WORK DISPOSAL ACCESSORIES 13.1 Round Jet Nozzle Attachment 13.1.1 Nozzle Inserts RXX 13.1.2 Nozzle Screw Joint, Complete 13.2 AirCoat Nozzles ACF3000 13.3 Air caps 13.4 Anodized Union Nut 13.5 Swivel Joints and Filter 13.6 Hoses 13.7...
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Page 6: About These Instructions
VERSION 01/2018 ORDER NUMBER DOC 394821 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 7: Languages
2301121 Dutch 2301122 Italian 2301118 Swedish 2301129 Spanish 2301119 Additional languages on request or at: www.wagner-group.com ABBREVIATIONS Order Order number for low-viscosity (LV) products Spare part for high-viscosity (HV) products Marking in the spare parts lists Low air Position Manual gun... -
Page 8: Correct Use
WAGNER explicitly prohibits any other use! The device may only be operated under the following conditions: Use the device only to work with the products recommended by WAGNER. Do not deactivate safety fixtures. Use only WAGNER original spare parts and accessories. -
Page 9: Identification
The maximum surface temperature corresponds to the permissible product temperature. This and the permissible ambient temperature can be found in Chapter 5.5.2. Safe Handling of WAGNER Spray Devices Mechanical sparks can form if the device comes into contact with metal. -
Page 10: Type Plate
WARNING Max. p air 0.8 MPa (115 psi) SKIN INJECTION HAZARD Max. p fluid see tension nut READ INSTRUCTION MANUAL Max. T fluid 55°C (131°F) Wagner International AG, Altstaetten II 2GX Made in Switzerland B_04173 Designation 1 Serial number 2 Maximum air inlet pressure... -
Page 11: Basic Safety Instructions
VERSION 01/2018 ORDER NUMBER DOC 394821 BASIC 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 DEVICES AND EQUIPMENT Electric shock hazard! Danger to life from electric shock Prepare device in accordance with the local safety requirements with regard to the... -
Page 12: Personnel Qualifications
VERSION 01/2018 ORDER NUMBER DOC 394821 Ensure that there are no ignition sources such as naked flames, sparks, glowing wires, or hot surfaces in the vicinity. No smoking. Ensure that the pipe joints, hoses, equipment parts and connections are permanently, technically leak-proof: - Periodic preventative maintenance and service (replacing hoses, checking tightness strength of the connections etc.). -
Page 13: Safe Handling Of Wagner Spray Devices
"Troubleshooting" chapter. If necessary or at least every 12 months, the liquid ejection devices must be checked for safe working conditions by an expert (e.g. WAGNER Service Technician) in accordance with the guidelines for liquid ejection devices (ZH 1/406 and DGUV 100-500 Chapters 2.29 and 2.36). -
Page 14: Product Hoses
VERSION 01/2018 ORDER NUMBER DOC 394821 4.2.4 PRODUCT HOSES Hazard due to bursting of product hose! The product hose is under pressure and may cause dangerous injuries. Ensure that the hose material is chemically resistant to the sprayed products and the flushing agents used. -
Page 15: Cleaning And Flushing
VERSION 01/2018 ORDER NUMBER DOC 394821 4.2.5 CLEANING AND FLUSHING Hazard due to cleaning and flushing! Explosion hazard and damage to the device. Preference should be given to non-ignitable cleaning and flushing agents. When carrying out cleaning work with flammable cleaning agents, make sure that all equipment and resources (e.g., collection tank, funnel, transport cart) are conductive or static dissipative and grounded. -
Page 16: Maintenance And Repair
4.2.7 MAINTENANCE AND REPAIR Hazard due to improper maintenance and repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Use only WAGNER original spare parts and accessories. -
Page 17: Description
VERSION 01/2018 ORDER NUMBER DOC 394821 DESCRIPTION COMPONENTS Designation A Suspension hook B Shaping air regulator C Clamping nut D Trigger E Trigger locking device F Air connection G Fluid inlet H Union nut with nozzle protection Nozzle / Air cap J Spray gun housing K Filter housing B_02255... -
Page 18: Data
VERSION 01/2018 ORDER NUMBER DOC 394821 DATA 5.5.1 MATERIALS OF PAINT-WETTED PARTS Metals Plastics Carbide Stainless steel 1.4305 Stainless steel 1.4301 Stainless steel 1.4104 PTFE 5.5.2 TECHNICAL DATA Description Units Value Maximum air inlet pressure MPa; psi; bar 0.8; 120; 8 Maximum product pressure MPa;... -
Page 19: Assembly And Commissioning
VERSION 01/2018 ORDER NUMBER DOC 394821 ASSEMBLY AND COMMISSIONING TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL The assembly and commissioning personnel 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 20: Installation And Connection
The AirCoat manual gun GM 4100AC must be combined with various components to make up a spraying system. The system shown in the figure is only one example of an AirCoat spraying system. Your WAGNER distributor would be happy to assist you in creating a spraying system solution that meets your individual needs. -
Page 21: Air Supply Lines
VERSION 01/2018 ORDER NUMBER DOC 394821 6.4.3 AIR SUPPLY LINES Ensure that only dry, clean atomizing air is used in the spray gun! Dirt and moisture in the atomizing air worsens the spraying quality and spray pattern. WARNING Hose connections! Risk of injury and damage to the device. -
Page 22: Commissioning
VERSION 01/2018 ORDER NUMBER DOC 394821 COMMISSIONING NOTICE Impurities in the spraying system! Spray gun blockage. Flush the spray gun and paint supply with a suitable flushing agent before commissioning. 6.8.1 PROCEDURE 1. Secure the spray gun. 2. Connect the product hose to the spray gun and product supply system. 3. -
Page 23: Operation
VERSION 01/2018 ORDER NUMBER DOC 394821 OPERATION TRAINING THE OPERATING PERSONNEL The operating personnel must be qualified to operate the entire system. The operating personnel must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures. Before work commences, the operating personnel must receive appropriate system training. -
Page 24: Adjusting The Spray Pattern
VERSION 01/2018 ORDER NUMBER DOC 394821 7.2.2 ADJUSTING THE SPRAY PATTERN The spray pattern can be adjusted to suit the object being sprayed using the shaping air regulator. The illustration shows the influence of the shaping air regulator on the spray pattern. -
Page 25: Changing Aircoat Nozzle
VERSION 01/2018 ORDER NUMBER DOC 394821 CHANGING AIRCOAT NOZZLE NOTICE Defective AirCoat nozzle! Insufficient paint application quality. Do not use sharp-edged objects to treat carbide on the AirCoat nozzle. 1. Relieve the pressure on the spray gun and product pressure generator. 2. -
Page 26: Eliminating Nozzle Clogging
VERSION 01/2018 ORDER NUMBER DOC 394821 7.4.2 ELIMINATING NOZZLE CLOGGING 1. Relieve the pressure of the spray gun and device. 2. Secure the spray gun with the trigger locking device. 3. Unscrew the union nut with nozzle guard (A). 4. Remove air cap (B). B_02261 5. -
Page 27: Cleaning And Maintenance
VERSION 01/2018 ORDER NUMBER DOC 394821 CLEANING AND MAINTENANCE CLEANING 8.1.1 CLEANING PERSONNEL Cleaning work should be undertaken regularly and carefully by qualified and trained personnel. They should be informed of specific hazards during their training. The following hazards may arise during cleaning work: –... -
Page 28: 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. Use only WAGNER original spare parts and accessories. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit. -
Page 29: Safety Checks And Maintenance Intervals
Yearly or as required In accordance with 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 30: Replacing The Product Hose Or Air Hose
6. Screw on the product hose or air hose by hand and tighten with the two open-end wrenches. Counterhold Counterhold Note: B_02265 Do not unscrew the product connection. The upper securing nut may only be unscrewed by WAGNER- Service Station personnel. B_02266 Description Wrench A Wrench B Wrench C Wrench D 17 mm 19 mm... -
Page 31: Changing Or Cleaning The Edge Filter
VERSION 01/2018 ORDER NUMBER DOC 394821 8.2.5 CHANGING OR CLEANING THE EDGE FILTER 1. Flush and clean the spray gun in accordance with Chapter 8.1.2. 2. Relieve the pressure of the spray gun and device. 3. Secure the spray gun with the trigger locking device. 4. -
Page 32: Troubleshooting And Rectification
VERSION 01/2018 ORDER NUMBER DOC 394821 TROUBLESHOOTING AND RECTIFICATION Functional fault Cause Remedy See Chapter Insufficient product output Nozzle too small Select larger nozzle. Product pressure too Increase product pressure. low. Spray gun filter or high- Clean or replace filter. 8.2.5 pressure filter clogged at pump. -
Page 33: Repair Work
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. Use only WAGNER original spare parts and accessories. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit. -
Page 34: Replacing Parts On The Valve Rod
VERSION 01/2018 ORDER NUMBER DOC 394821 Assembly aids: Order no. Quantity Designation Smaller tanks 1 pc ≙ 50 ml 9992831 Loctite ® 542 1 pc ≙ 250 ml 9992833 Loctite ® 638 green 1 pc ≙ 50 ml 9992590 Loctite ® 222 1 pc ≙... -
Page 35: Replacing Valve Tappet Seals
VERSION 01/2018 ORDER NUMBER DOC 394821 10.4.1 REPLACING VALVE TAPPET SEALS 1. Using a size 13 mm; 0.51 inch open-end wrench, counterhold valve tappet (50) and, using a size 7 mm; 0.28 inch open-end wrench, unscrew cap (53). 2. Remove the air valve seal (51) and seal (52) and replace with new seals. 3. -
Page 36: Assembly
VERSION 01/2018 ORDER NUMBER DOC 394821 10.4.3 ASSEMBLY 1. Attach the sealing collar (11) to the valve rod (34) together with the inserted O-ring (12) and sealing screw (10). 2. Push the completely assembled valve tappet (19) onto the valve rod (34). 3. -
Page 37: Replacing The "Air" Sealing Ring
VERSION 01/2018 ORDER NUMBER DOC 394821 10.6 REPLACING THE "AIR" SEALING RING NOTICE Shaping air and atomizer air not separate! Poor spray pattern. Spray jet cannot be adjusted. Handle the sealing ring (14) with care. 1. Relieve the pressure of the spray gun and device in accordance with Chapter 7.3. -
Page 38: Function Test After Repair Work
VERSION 01/2018 ORDER NUMBER DOC 394821 11 FUNCTION TEST AFTER REPAIR WORK After all repair work, the spray gun 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 personnel. Assembly inspection Activity Means... -
Page 39: Disposal
VERSION 01/2018 ORDER NUMBER DOC 394821 Activity Means 4. Checking the switching sequence – Attach the AC nozzle and air cap. Visual inspection – Set the injection pressure to 100 bar; 10 MPa; 1450.40 psi, pull the trigger slowly, note the switching sequence "switch on" and "switch off". Switch on: atomizing air / shaping air on, product on Switch off: product off, atomizing air / shaping air off 5. -
Page 40: Accessories
VERSION 01/2018 ORDER NUMBER DOC 394821 13 ACCESSORIES 13.1 ROUND JET NOZZLE ATTACHMENT Order no. Designation 394180 Round jet nozzle attachment (without 13.1 nozzle insert) 13.1.2 B_02276 13.1.1 13.1.1 NOZZLE INSERTS RXX Order no. Designation Marking Volumetric flow Jet ** rate* 132720 Nozzle insert R11... -
Page 41: Aircoat Nozzles Acf3000
VERSION 01/2018 ORDER NUMBER DOC 394821 13.2 AIRCOAT NOZZLES ACF3000 Drilled hole Recommended edge filter Order no. Marking Spray angle inch; mm Application B_02280 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° Oils 379409 09/40 0.009-0.23 40°... -
Page 42: Air Caps
VERSION 01/2018 ORDER NUMBER DOC 394821 Drilled hole Recommended edge filter Order no. Marking Spray angle inch; mm Application B_02280 379219 19/20 0.019-0.48 20° Rust proofing 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°... -
Page 43: Anodized Union Nut
VERSION 01/2018 ORDER NUMBER DOC 394821 13.4 ANODIZED UNION NUT Order no. Designation Completely anodized union nut (without air cap) suitable for 2330340 the processing of water-based coatings B_03764 13.5 SWIVEL JOINTS AND FILTER Order no. Designation Swivel joint set for product connection (NPSM 1/4") and for air connection 394931 (G1/4") B_02273... -
Page 44: Hoses
VERSION 01/2018 ORDER NUMBER DOC 394821 13.6 HOSES Order no. Designation AC hose set DN3 PN270 1/4"NPS 7.5 m PA T 2309705 Product: 1/4"NPS, 7.5 m; 24.6 ft, DN 3; ID 0.12 inch, 27 MPa; 270 bar; 3916 psi Air: G1/4", 7.5 m; 24.6 ft, DN 6 mm; ID 0.24 inch, 1 MPa, 10 bar; 145 psi AC hose set DN4 PN270 1/4"NPS 7.5 m PA T 2309706 Product: 1/4"NPS, 7.5 m;... -
Page 45: 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. Use only WAGNER original spare parts and accessories. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit. -
Page 46: Spare Parts List Gm 4700Ac
VERSION 01/2018 ORDER NUMBER DOC 394821 14.2 SPARE PARTS LIST GM 4700AC 57 58 B_02747 Order no. Designation 394012 GM 4100AC; XX MPa; NPSM1/4" 9999501 Helical spring, material 9999500 Helical spring, air 2312140 Clamping sleeve 394335 Spring cap 16 MPa; 160 bar; 2320 psi 394333 Spring cap 25 MPa;... - Page 47 VERSION 01/2018 ORDER NUMBER DOC 394821 Order no. Designation 394328 Sealing collar 2324747 Sealing collar UHMW-PE, complete (including pos. 12) 9971445 O-ring 379xxx AC nozzle (see Chapter 13.2) 394339 Sealing ring 9974245 O-ring 394922 Valve housing, complete 394338 Nozzle seal 2312149 Collet chuck 394257...
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Page 48: Eu Declaration Of Conformity
DGUV regulation 100-500 Chapter 2.36 TRGS 727 Identification: 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: 394891... - Page 52 Order no. 394821 Edition 01/2018 ts-liquid@wagner-group.com www.wagner-group.com...