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WAGNER GA 2800EA Operating Manual

Electrostatic air spray gun for automatic operating mode - with fl at or round jet nozzles
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Electrostatic Air spray gun
for automatic operating mode -
with fl at or round jet nozzles
0102
II 2G EEx 0.24 mJ T6 (Atex 95)
Translation of the original
Operating manual
GA 2800EA
GA 2805EA
Edition
12/2008

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Summary of Contents for WAGNER GA 2800EA

  • Page 1 Translation of the original Operating manual GA 2800EA GA 2805EA Edition 12/2008 Electrostatic Air spray gun for automatic operating mode - with fl at or round jet nozzles 0102 II 2G EEx 0.24 mJ T6 (Atex 95)

  • Page 3: Table Of Contents

    Safety instructions for the operator 2.1.1 Electrical equipment 2.1.2 Personnel qualifi cations 2.1.3 A safe work environment Safety instructions for personnel 2.2.1 Safe handling of WAGNER spray units 2.2.2 Earth the unit 2.2.3 Material hoses 2.2.4 Cleaning 2.2.5 Handling hazardous liquids, varnishes and paints 2.2.6...
  • Page 4 Hoses and fi ttings Valve seat and Valve needle head - Plastic Miscellaneous SPARE PARTS 10.1 How to order spare parts? 10.2 Spare parts list GA 2800EA 10.3 Spare parts list GA 2805EA 10.4 Spare parts list valve rod EA...

  • Page 5: About These Instructions

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL ABOUT THESE INSTRUCTIONS LANGUAGES 350730 350731 350732 350733 350734 350755 350737 350736 The corresponding service instructions are available under the following order number: Language: Part No. Language: Part No.

  • Page 6: General Safety Instructions

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR 2.1.1 ELECTRICAL EQUIPMENT 2.1.2 PERSONNEL QUALIFICATIONS 2.1.3 A SAFE WORK ENVIRONMENT SAFETY INSTRUCTIONS FOR PERSONNEL...

  • Page 7: Safe Handling Of Wagner Spray Units

    EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL 2.2.1 SAFE HANDLING OF WAGNER SPRAY UNITS The spray jet is under pressure and can cause dangerous injuries. Avoid injection of paint or cleaning agents: Never point the spray gun at people. Never reach into the spray jet.

  • Page 8: Cleaning

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL 2.2.4 CLEANING 2.2.5 HANDLING HAZARDOUS LIQUIDS, VARNISHES AND PAINTS 2.2.6 TOUCHING HOT SURFACES CORRECT USE...

  • Page 9: Safety-Relevant Information About Discharges

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL SAFETY-RELEVANT INFORMATION ABOUT DISCHARGES The plastic parts of the spray gun are charged electrostatically by the high-voltage field of the spray pistol. Harmless discharges (brush discharges) are possible after contact with plastic parts.

  • Page 10: Establishment Of Stationary Electrostatic Systems

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL ESTABLISHMENT OF STATIONARY ELECTROSTATIC SYSTEMS GERMAN REGULATIONS AND GUIDELINES a) BGV A2 Electrical units and equipment b) BGV D15 Working with liquid ejection devices c) BGV D25 Using coating materials d) CHV 9 Regulations on flammable liquids...

  • Page 11: Product Liability And Warranty

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL PRODUCT LIABILITY AND WARRANTY IMPORTANT NOTES ON PRODUCT LIABILITY WARRANTY...

  • Page 12: Ce-Conformity

    II (2) G 0102 II 2G EEx 0,24 mJ T6 CE Certificate of Conformity The certificate is enclosed with this product.The certificate of conformity can be reordered from your WAGNER representative, quoting the product and serial number. Part number: 381891...

  • Page 13: Ptb Conformity Certifi Cation

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL PTB CONFORMITY CERTIFICATION...

  • Page 14: Description

    ➞ High kV value, low µA value (no wrap around) = Paint with too high el. resistance. ➞ Low kV value, high µA value (no wrap-around) = Paint with too low el. resistance In the event of application problems, contact your WAGNER branch and the paint manu- facturer.

  • Page 15: Scope Of Supply

    Automatic spray gun GA 2800EA USA 350046 Automatic spray gun GA 2805EA 350047 Automatic spray gun GA 2805EA USA 2301861 Automatic spray gun GA 2800EA with short cable 350074 Automatic spray gun GA 2805EA with short cable The standard equipment includes: Quantity Part No.

  • Page 16: Technical Data

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL TECHNICAL DATA Maxi. air pressure 0.8 MPa; 8 bar; 116 psi Maxi. atomizing air pressure 0.8 MPa; 8 bar; 116 psi Maxi. material pressure 0.8 MPa; 8 bar; 116 psi Input voltage maxi.

  • Page 17: Function

    Operation of the spray gun in conjunction with the control unit EPG 3000 is described in this operating man- ual. ➞ The high voltage at the spray gun GA 2800EA or GA 2805EA is activated when the control unit EPG 3000 is switched on.

  • Page 18: Air Atomizing Spray Process

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL AIR ATOMIZING SPRAY PROCESS 4.5.1 ROUND AND FLAT JET In this process, the material (paint) is fed to the nozzle with low pressure 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 jet, which largely eliminates the problem of overlapping boundaries.

  • Page 19: Electrostatic Effect

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL 4.5.4 ELECTROSTATIC EFFECT The spray gun produces an electrostatic fi eld by means of the high voltage electrode. As a result, the particles of paint, which have been atomized by the spray gun, are carried to the earthed object by kinetic and electrostatic energy where they adhere, fi...

  • Page 20: Preparation Before Starting Work

    Control cabinet It is not an actual system design. Con- Movement device system tact your WAGNER distributor for assist- ance in designing a system to meet your Electrostatic automatic air spray gun needs. The operating instructions and...

  • Page 21: Ventilation Of The Spray Booth

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL 5.1.2 VENTILATION OF THE SPRAY BOOTH WARNING Toxic and/or flammable vapor mixtures! Risk of poisoning and burns Operate the unit in a spraying booth approved for the working materials.

  • Page 22: Earthing

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL 5.1.5 EARTHING Perfect earthing of all system components (work pieces, conveyor, paint supply system, control unit, spray booth or spraying stand, see illustration) is a prerequisite for optimum coating effi ciency and safety.
  • Page 23 GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL Earthing scheme (example) Conveyor Control module Earthing cable Pump Work piece R max < 1 MΩ Spraying stand Paint container Floor, antistatic B_00137 System earth System earth Minimum cable cross-section Control unit 4 mm²...

  • Page 24: Preparation Of Paint

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL PREPARATION OF PAINT The viscosity of the paints is of great importance. The best results are obtained with paints between 15 and 30 DIN sec. (measured in immersion fl ow cup DIN 4 mm ; 0.16 inches).

  • Page 25: Start-Up

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL START-UP 5.3.1 GENERAL RULES FOR HANDLING THE SPRAY GUN ➞ Observe safety instructions in chapter 2. DANGER High voltage field! Danger to life from malfunctioning heart pacemakers Ensure that persons with heart pacemakers: Do not work with the electrostatic spray gun.

  • Page 26: Preparation

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL 5.3.2 PREPARATION ➞ Earthing the spraying system and make sure that all other conductive parts within the work area are earthed. ➞ Secure the spray gun to the lifting unit with the suspension bracket or suspension bolt (accessories) ➞...

  • Page 27: Working

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL WORKING 5.4.1 START-UP FOR SPRAYING 1. Switch on the material supply, adjust from approx. 0.05-0.15 MPa; 0.5-1.5 bar; 7-22 psi, and the control unit. 2. Spray on a test object.

  • Page 28: Fitting Or Changing Round Jet Nozzle

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL 5.4.3 FITTING OR CHANGING ROUND JET NOZZLE 1. Switch off control unit. 2. Relieve spray gun and unit pressure! 3. Replace paint with cleaning solvent, and 4. Thoroughly fl ush spray gun.

  • Page 29: Changing From Round Jet Nozzle To Fl At Jet Nozzle

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL 5.4.4 CHANGING FROM ROUND JET NOZZLE TO FLAT JET NOZZLE Perform steps 1 and 7 of paragraph 5.4.3 8. Place fl at jet nozzle (E) into air cap (F).

  • Page 30: Maintenance

    Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by spe- cially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup- tions: - Switch off the energy/compressed air supply.

  • Page 31: Finishing Work And Cleaning

    5. Thoroughly fl ush spray gun ! 6. Relieve spray gun and system pressure. 7. Clean gun with solvent recommended by the manufacturer and dry with a cloth or blow gun. The gun attachment (X) may only be changed by the WAGNER Service Sta- tion.

  • Page 32: Troubleshooting And Maintenance

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL TROUBLESHOOTING AND MAINTENANCE Problem Cause Solution Insuffi cient • Nozzle too small • Select larger nozzle (see chapter material output 9.1) • Material pressure too low • Increase material pressure •...
  • Page 33 • Conductive sediments in the • Clean or replace the material hose material hose • High conductive paint • Use original Wagner material hose with at least 7.5 m; 25 ft length • Paint conductivity too high • Check resistance of paint in accordance with paragraph 4.1.1...

  • Page 34: Repair Work

    WARNING 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 chapter "Spare parts catalog".

  • Page 35: Exchange Of Complete Valve Rod

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL EXCHANGE OF COMPLETE VALVE ROD Attention: Do not damage sealing surfaces B_00160 1. Remove nozzle according to paragraph 5.4.3 and 5.4.5 2. Remove valve seat according to paragraph 8.1.

  • Page 36: Exchange Of Valve Rod Seals

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL EXCHANGE OF VALVE ROD SEALS 1. Remove valve rod as described in paragraph 8.2 2. Hold with universal spanner at surface (D) and unscrew valve sealing element (1/E) using a small pliers.

  • Page 37: Electrode Replacement

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL ELECTRODE REPLACEMENT Electrode If the electrode is damaged (bent or broken) by incorrect handling, the valve needle head (12) must be replaced. (15) 1. Remove valve rod as described in paragraph 8.2.

  • Page 38: Adjusting The Valve Movement

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL ADJUSTING THE VALVE MOVEMENT After changing a nozzle or needle nozzle, the valve movement can be adjusted by turning the union screw (19) of the tension nut (1). The adjustment can be locked with union nut (67).

  • Page 39: Replacing The Paint Hose

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL REPLACING THE PAINT HOSE 1. Unscrew nut (A) using the universal spanner. 2. Pull material hose (B) out of the connection (C). 3. Remove insert (D), clamping ring (E) and nut (A) from material hose.

  • Page 40: Accessories

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL ACCESSORIES NOZZLES EA FLAT-JET Part No. Description Colour 363228 Nozzle set EAF 0.6 black 363229 Nozzle set EAF 0.8 yellow 363230 Nozzle set EAF 1.0 363231 Nozzle set EAF 1.2...

  • Page 41: Ea Round Jet Nozzles (Supra)

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL EA ROUND JET NOZZLES (SUPRA) Part No. Description 363238 Nozzle set EAR Supra 353966 Outer nut Supra 353965 Nozzle body Supra 353952 Nozzle insert Supra EA 353210 Nozzle spanner 2800 EA 9.2.1...

  • Page 42: Electrical Cables

    Air hose ø 5.5/8 mm; ø 0.22/0.31 inches red (order by the meter) 381152 Air hose ø 5.5/8 mm; ø 0.22/0.31 inches green (order by the meter) Material hose ø 6/12 mm; ø 0.24/0.47 inches Contact your WAGNER branch for special precut lengths 353701 Material hose set EA.

  • Page 43: Spare Parts

    Risk of injury and damage to the equipment Repairs and part replacement may only be carried out by spe- cially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interrup- tions: - Switch off the energy/compressed air supply.

  • Page 44: Spare Parts List Ga 2800Ea

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL 10.2 SPARE PARTS LIST GA 2800EA 22 58 Must only be removed by WAGNER Service Agency Attachment must only be removed by WAGNER Service Agency B_00157 Item K Part No.
  • Page 45 GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL Spare parts list GA 2800EA Item K Part No. Description 9900318 Hexagon socket head cap screw ◆ 9971142 O-ring 9998987 Screw-in fi tting, straight 353350 Sealing sleeve 9900810 Pan-head screw M2, 4 mm; 0.16 inches long...

  • Page 46: Spare Parts List Ga 2805Ea

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL 10.3 SPARE PARTS LIST GA 2805EA 96 97 22 58 Attachment must only be removed by WAGNER Service 98 95 Agency Must only be removed by WAGNER Service Agency...
  • Page 47 GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL Spare parts list GA 2805EA Item K Part No. Description 353362 Material connection 9900318 Hexagon socket head cap screw ◆ 9971142 O-ring 9998987 Screw-in fi tting, straight 353350 Sealing sleeve 9900810 Pan-head screw M2, 4 mm;...

  • Page 48: Spare Parts List Valve Rod Ea

    GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL 10.4 SPARE PARTS LIST VALVE ROD EA Item Part No. Description 350324 Valve rod holder ◆ 350388 Piston seal 350321 Piston 9998040 Compression spring 350354 Valve rod, spring guide ◆★...
  • Page 49 GA 2800EA, GA 2805EA EDITION 12/2008 PART NO. DOC350731 OPERATING MANUAL Germany Switzerland J. WAGNER GmbH J. WAGNER AG Otto-Lilienthal-Str. 18 Industriestrasse 22 Postfach 1120 Postfach 663 D- 88677 Markdorf CH- 9450 Altstätten Telephone: ++49/ (0)7544 / 5050 Telephone: ++41/ (0)71 / 757 2211...
  • Page 52 350731...

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