WAGNER GA 4000ACIC-S Betriebshandbuch

Version 05/2018

GA 4000ACIC-S

GA 4000ACIC-R

AirCoat

Automatic spray gun

II 2G X

B_06647

VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC

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 20

5.2.1 Mode of Operation 20

5.2.2 Mode "NC" and "C" 21

5.2.3 Spraying procedure 22

5.3 Included Items 23

5.3.1 Type description 23

5.3.2 Overview 24

5.3.3 Standard variant 25

5.3.4 Supplementary components 25

5.4 Data 28

5.4.1 Materials of Paint-wetted Parts 28

5.4.2 Technical data 28

5.4.3 Measurements and connections 29

VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC

6 COMMISSIONING 31

6.1 Training of Assembly/Commissioning Personnel 31

6.2 Storage Conditions 31

6.3 Installation Conditions 31

6.4 Installation and Connection 31

6.4.1 Typical AirCoat spraying system 32

6.4.2 Ventilation of the Spray Booth 32

6.4.3 Air Supply Lines 32

6.4.4 Product supply lines 33

6.5 Grounding 33

6.6 Safety Checks 33

6.7 Lacquer Preparations 33

6.7.1 Viscosity conversion table 34

6.8 Commissioning 35

6.8.1 Preparation Before Commissioning 35

6.8.2 Commissioning 35

6.8.3 Verifying a Safe Operational Condition 35

7 OPERATION 36

7.1 Training the Operating Personnel 36

7.2 Tasks 36

7.2.1 Starting to Spray with the AirCoat 36

7.2.2 Adjusting the spray pattern 37

7.2.3 Pressure Relief/Work Interruption 37

7.2.4 Changing AirCoat nozzle 38

7.2.5 Cleaning AirCoat nozzle 38

7.2.6 Eliminating Nozzle Clogging 39

7.2.7 Replacing nozzle insert of round jet nozzle 40

8 CLEANING AND MAINTENANCE 41

8.1 Cleaning 41

8.1.1 Cleaning Personnel 41

8.1.2 Flushing and Cleaning the Gun 41

8.2 Maintenance 42

8.2.1 Maintenance Personnel 42

8.2.2 Maintenance Instructions 42

8.2.3 Safety Checks 43

8.2.4 Replacing the paint hose 44

8.2.5 Replacing the nozzle seal 44

8.2.6 Replacing the Sealing Fitting of the Round Jet Nozzle 45

9 TROUBLESHOOTING AND RECTIFICATION 46

10 REPAIR WORK 47

10.1 Repair Personnel 47

10.2 Repair Notes 47

10.3 Replacing parts of the gun body 48

10.3.1 Disassembly of GA 4000ACIC 48

10.3.2 Packing insert GA 4000AC (RP) 50

10.3.3 Assembly of GA 4000ACIC 52

VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC

11 FUNCTION TEST AFTER REPAIR WORK 54

12 DISPOSAL 54

13 ACCESSORIES 55

13.1 AirCoat Nozzles ACF3000 55

13.2 AirCoat Nozzles ACF3000 S2 (4 pieces) 57

13.3 Round jet nozzle attachment 57

13.3.1 RXX Nozzle inserts 58

13.3.2 Nozzle screw joint, complete 58

13.4 Hoses 58

13.5 Miscellaneous 59

14 SPARE PARTS 60

14.1 How can spare parts be ordered? 60

14.2 Spare Parts List for GA 4000ACIC 61

14.3 Service sets and spare parts groups 63

14.4 Packing insert GA 4000AC (RP) 63

14.5 Sealing Set GA 4000 Packing RP and RP Special 64

15 DECLARATION OF CONFORMITY 65

15.1 EU Declaration of Conformity 65

VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC

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.

Notice 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 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC

1.3 LANGUAGES

The operating manual is available in the following languages:

Language Order No. Language Order No.

German 2312955 Swedish 2316798

English 2312956 Russian 2327992

French 2312957 Hungarian 2364607

Italian 2312958 -- --

Spanish 2312959 -- --

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)

TX Torx size (tool)

RP (replaceable packing)

PTFE Polytetrauorethylene (PTFE)

GF Fiber optics

PE Polyethylene

UWMW-PE Ultra-high molecular polyethylene

FPM Fluoropolymer rubber (Viton)

POM Polyoxymethylene (Acetal)

PA Polyamide

VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC

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 compressed air

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 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC

2 CORRECT USE

2.1 DEVICE TYPE

Automatic gun for automatic coating of work pieces.

2.2 TYPE OF USE

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

AirCoat process.

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.

Follow the instructions in the 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, (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 aWAGNER representative.

When operating the device with a coating product with a temperature of > 43 °C; 109.4

°F, identify the device with a warning label that says "Warning - hot surface" according to

Chapter 4.2.6.

Note:

Contact your local WAGNER 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.

VERSION 05/2018 ORDER NUMBER DOC 2312956 GA 4000ACIC

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: AirCoat automatic gun

Manufacturer: Wagner International AG

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 the "Technical Data"

chapter.

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.

Do not drop the spray gun.

Use only tools that are made of a permitted material.

Ignition temperature of the coating product

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

surface temperature.

Medium supporting atomizing

To atomize the product, use only weakly oxidizing gases, e.g., air.

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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