WAGNER GA 250AL Bedienungsanleitung

GA 250AL

GA 400AL

Airless automatic spray gun

Version 12/2018

B_00859

B_00861

VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL

Table of Contents

1 ABOUT THESE INSTRUCTIONS 6

1.1 Preface 6

1.2 Warnings, Notices and Symbols in these Instructions 6

1.3 Languages 7

1.4 Abbreviations 7

1.5 Terminology for the Purpose of this Manual 8

2 CORRECT USE 9

2.1 Device Type 9

2.2 Type of Use 9

2.3 For Use in Potentially Explosive Areas 9

2.4 Processible Working Materials 9

2.5 Misuse 9

3 IDENTIFICATION 10

3.1 Explosion Protection Identication 10

3.2 Identication "X" 10

3.3 Type Plate 11

4 BASIC SAFETY INSTRUCTIONS 12

4.1 Safety Instructions for the Operator 12

4.1.1 Electrical Devices and Equipment 12

4.1.2 A Safe Work Environment 13

4.1.3 Personnel Qualications 13

4.2 Safety Instructions for the Personnel 14

4.2.1 Personal Safety Equipment 14

4.2.2 Safe Handling of WAGNER Spray Devices 15

4.2.3 Grounding the Unit 15

4.2.4 Product Hoses 16

4.2.5 Cleaning and Flushing 17

4.2.6 Touching Hot Surfaces 18

4.2.7 Maintenance and Repair 18

4.2.8 Protective and Monitoring Equipment 18

5 DESCRIPTION 19

5.1 Components 19

5.2 Functional Description 19

5.3 Scope of Delivery 20

5.3.1 Type Description 20

5.3.2 Standard Variant 20

5.4 Data 20

5.4.1 Materials of Paint-wetted Parts 20

5.4.2 Technical Data 21

5.4.3 Dimensions 21

VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL

6 ASSEMBLY AND COMMISSIONING 22

6.1 Training of Assembly/Commissioning Personnel 22

6.2 Storage Conditions 22

6.3 Installation Conditions 22

6.4 Installation and Connection 22

6.4.1 Typical Spraying System 23

6.4.2 Ventilation of the Spray Booth 23

6.4.3 Product Supply Lines 24

6.5 Grounding 24

6.6 Safety Checks 24

6.7 Lacquer Preparations 24

6.7.1 Viscosity Conversion Table 25

6.8 Commissioning 26

6.8.1 Preparation Before Commissioning 26

6.8.2 Verifying a Safe Operational Condition 26

7 OPERATION 27

7.1 Training the Operating Personnel 27

7.2 Tasks 27

7.2.1 Starting Airless spraying 27

7.2.2 Pressure Relief/Work Interruption 28

7.2.3 Replacing the Airless Flat Jet Nozzle 29

7.2.4 Cleaning the Airless Flat Jet Nozzle 29

8 CLEANING AND MAINTENANCE 30

8.1 Cleaning 30

8.1.1 Cleaning Personnel 30

8.1.2 Flushing and Cleaning the Spray Gun 30

8.2 Maintenance 31

8.2.1 Maintenance Personnel 31

8.2.2 Maintenance Instructions 31

8.2.3 Safety Checks and Maintenance Intervals 32

9 TROUBLESHOOTING AND RECTIFICATION 33

10 REPAIR WORK 34

10.1 Repair Personnel 34

10.2 Repair Notes 34

10.3 Tools 35

10.3.1 Replacing of Parts on the Valve Rod 35

10.3.2 Assembling the Valve Rod and Spray Gun 36

11 FUNCTION TEST AFTER REPAIR WORK 37

12 DISPOSAL 38

13 ACCESSORIES 39

13.1 Airless Flat Jet Nozzles 39

13.2 Hoses 41

13.3 Miscellaneous 41

VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL

14 SPARE PARTS 42

14.1 How Can Spare Parts Be Ordered? 42

14.2 Spare Parts List GA 400AL 43

14.3 GA 250AL Spare Parts List 44

15 DECLARATION OF CONFORMITY 45

15.1 EU Declaration of Conformity 45

VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL

1 ABOUT THESE INSTRUCTIONS

1.1 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.

The device may only be operated by trained personnel and in compliance with this operating

manual.

Operating and service personnel should be instructed according to the safety instructions.

This equipment can be dangerous if it is not operated according to the instructions in this

operating manual.

1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS

Warning instructions in this manual highlight particular dangers to users and to the device

and state measures for avoiding the hazard. These warning instructions fall into the following

categories:

DANGER Immediate risk of danger.

Non-observance will result in death or serious injury.

WARNING Potential risk.

Non-observance may result in death or serious injury.

CAUTION Potentially hazardous situation.

Non-observance may result in minor injury.

NOTICE Potentially hazardous situation.

Non-observance may result in damage to property.

Note: Provides information about particular characteristics and how

to proceed.

Explanation of warning notice:

LEVEL OF DANGER

This notice warns you of a hazard!

Possible consequences of not observing the warning notice.

The measures for preventing the hazard and its consequences.

VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL

1.3 LANGUAGES

The operating manual is available in the following languages:

Original operating manual

Language Order no.

German 350939

Translation of the Original Operating Manual

Language Order no. Language Order no.

English 350941 Swedish 350950

French 350946 Dutch 350947

Italian 350948 Danish 350951

Spanish 350949 Portuguese 2404528

Additional languages on request or at: www.wagner-group.com

1.4 ABBREVIATIONS

Order no. Order number

Spare part

Marking in the spare parts lists

Position

Number of pieces

Wrench size (tool)

UWMW-PE Ultra-high molecular polyethylene

POM Polyoxymethylene (Acetal)

VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL

1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL

Cleaning

Cleaning Manual cleaning of devices and device parts with cleaning agent

Flushing Internal ushing of paint-wetted parts with ushing agent

Product pressure

generator

Pump or pressure tank

Personnel qualications

Trained person Is instructed in the tasks assigned to him/her, the potential risks

associated with improper behavior as well as the necessary

protective devices and measures.

Electrically trained

person

Is instructed by an electrician about the tasks assigned to him/her,

the potential risks associated with improper behavior as well as

the necessary protective devices and measures.

Electrician Can assess the work assigned to him/her and detect possible

hazards based on his/her technical training, knowledge and

experience in relevant provisions.

Skilled person in

accordance with

TRBS 1203

(2010/Revision 2012)

A person who, based on his/her technical training, experience and

recent vocational experience, has sucient technical knowledge

in the areas of explosion protection, protection from pressure

hazards and electric hazards (if applicable) and is familiar with

the relevant and generally accepted rules of technology so that

he/she can inspect and assess the status of devices and coating

systems based on workplace safety.

VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL

2 CORRECT USE

2.1 DEVICE TYPE

Automatic gun for automatic coating of work pieces.

GA 250AL

GA 400AL

2.2 TYPE OF USE

The spray gun is suitable for atomizing liquid products, particularly coating products, using

the Airless process:

Non-ignitable products.

Ignitable products.

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.

Only operate the device as a whole.

Do not deactivate safety xtures.

Use only WAGNER original spare parts and accessories.

The operating personnel must be trained on the basis of this operating manual.

2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS

The device is suitable for use in potentially explosive areas as dened in Directive 2014/34/EU

(ATEX), (see Explosion protection marking Chapter 3.1).

2.4 PROCESSIBLE WORKING MATERIALS

Top-coat lacquers, primer paints, corrosion protection, textured lacquers, lyes, staining solvents,

clear lacquers, separating agents, etc. with a solvent or water base. If you want to spray working

materials other than the aforementioned, contact a WAGNER representative.

Note:

Contact your localWAGNER dealer and the lacquer manufacturer if you encounter application

problems.

2.5 MISUSE

Misuse can lead to physical injury and/or property damage!

Special attention must be paid that:

no dry coating products, e.g. powder are processed;

no food, medicine or cosmetics are processed.

It is important to note that the device's materials are not food-safe.

VERSION 12/2018 ORDER NUMBER DOC 350941 GA 250AL_GA 400AL

3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially

explosive areas.

Device type: GA 250AL / GA 400AL Airless automatic gun

Manufacturer: Wagner International AG

CH-9450 Altstätten, Switzerland

II 2G X

CE European Communities

Ex Symbol for explosion protection

II Device class II

2 Category 2 (zone 1)

G Ex-atmosphere gas

X Special notice

3.2 IDENTIFICATION "X"

The maximum surface temperature corresponds to the permissible product temperature.

This and the permissible ambient temperature can be found in Chapter 5.4.2.

Safe Handling of WAGNER Spray Devices

Mechanical sparks can form if the device comes into contact with metal.

In an explosive atmosphere:

knocking or pushing metal against metal is to be avoided;

do not drop the device.

Ignition temperature of the coating product

Ensure that the ignition temperature of the coating product is above the maximum

surface temperature.

Cleaning

If there are deposits on the surfaces, the device may form electrostatic charges.

Flames or sparks can form during discharge.

Remove deposits from the surfaces to maintain conductivity.

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