Wagner SprayTech GA 250AL User's Manual
Contents
1. Applications Diameter S Part No aridis Spray angle of bore pip inch mm B 00857 0090217 217 20 0 017 0 43 117 4 60 Spray primer 0090317 317 30 0 017 0 43 153 6 02 Rustproofing paint 0090417 417 40 0 017 0 43 190 7 48 nn j 0090517 517 50 0 017 0 43 235 9 25 0090617 617 60 0 017 0 43 283 11 14 0090717 717 70 0 017 0 43 342 13 46 0090219 219 20 0 019 0 48 147 5 79 0090319 319 30 0 019 0 48 168 6 61 0090419 419 40 0 019 0 48 192 7 56 0090519 519 50 0 019 0 48 272 10 71 0090619 619 60 0 019 0 48 315 12 40 0090719 719 70 0 019 0 48 330 12 99 0090819 819 80 0 019 0 48 402 15 83 0090221 221 20 0 021 0 53 148 5 83 Mica paint 0090421 421 40 0 021 0 53 183 7 20 Zinc dust coating 0090521 521 50 0 021 0 53 252 9 92 SES 0090621 621 60 0 021 0 53 313 12 32 0090821 821 80 0 021 0 53 380 14 96 0090223 223 20 0 023 0 58 130 5 12 Rustproofing paint 0090423 423 40 0 023 0 58 185 7 28 0090523 523 50 0 023 0 58 253 9 96 0090623 623 60 0 023 0 58 298 11 73 0090723 723 70 0 023 0 58 340 13 38 0090823 823 80 0 023 0 58 355 13 98 27 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER Airless flat jet nozzles Applications Diameter Part No Wiere Spray angle of bore en inch mm B_00857 0090225 2252. Touch hot surfaces only if you are wearing protective gloves When operating the unit with a coating material with a temperature of gt 43 C 109 4 F Identify the unit with a warning label that says Warning hot surface Order No 9998910 Information label 9998911 Safety label 2 3 CORRECT USE WAGNER accepts no liability for any damage arising from incorrect use Use the unit only to work with the materials recommended by WAGNER Operate the unit only as an entire unit gt Do not deactivate safety equipment Use only WAGNER original spare parts and accessories EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 2 4 USE IN AN EXPLOSION HAZARD AREA 2 4 1 CORRECT USE The unit is suitable for working liquid materials in accordance with the classification into explosion classes 2 4 2 EXPLOSION PROTECTION IDENTIFICATION As defined in the Directive 94 9 CE ATEX 95 the unit is suitable for use in areas where there is an explosion hazard C E 126 x CE Communaut s Europ ennes Ex Symbol for explosion protection Il Unit class II 2 Category 2 Zone 1 G Ex atmosphere gas X Special identification 2 4 2 MAX SURFACE TEMPERATURE The gun s maximum surface temperature depends on the temperature of the coating ma terial The spray gun is suitable for coating materials with a max temperature of 80 C 176 F Ambient temperature Permissible ambi
3. Part No merid Spray angle of bore an inch mm B_00857 0090407 407 40 0 007 0 18 163 6 42 Natural paint 0090507 507 50 0 007 0 18 190 7 48 Transparent lacquer 0090209 209 20 0 009 0 23 148 5 83 a 0090309 309 30 0 009 0 23 158 6 22 0090409 409 40 0 009 0 23 198 7 79 0090509 509 50 0 009 0 23 215 8 46 0090609 609 60 0 009 0 23 225 8 85 0090111 111 10 0 011 0 28 87 3 42 Synthetic resin paint 0090211 211 20 0 011 0 28 93 3 66 PVC paint 0090311 311 30 0 011 0 28 127 5 0 0090411 411 40 0 011 0 28 210 8 23 0090511 511 50 0 011 0 28 225 8 85 009061 1 611 60 0 011 0 28 270 10 63 0090113 113 10 0 013 0 33 103 4 05 Paint 0090213 213 20 0 013 0 33 107 4 21 Undercoat 0090313 313 30 0 013 0 33 142 5 59 Aue mom d y primer 0090413 413 40 0 013 0 33 207 8 15 Priming paint 0090513 513 50 0 013 0 33 255 10 04 Filler 0090613 613 60 0 013 0 33 282 11 10 0090813 813 80 0 013 0 33 375 14 76 0090115 115 10 0 015 0 38 98 3 86 Filler 0090215 215 20 0 015 0 38 100 3 94 Spray primer 0090315 315 30 0 015 0 38 162 6 38 Rustpros ng Pall 0090415 415 40 0 015 0 38 202 7 95 0090515 515 50 0 015 0 38 252 9 92 0090615 615 60 0 015 0 38 268 10 55 0090715 715 70 0 015 0 38 295 11 61 0090815 815 80 0 015 0 38 395 15 55 26 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER Airless flat jet nozzles
4. 5 1 SETUP AND CONNECT 5 1 1 TYPICAL AUTOMATIC SPRAYING SYSTEM Description Control cabinet Conveyer Object Spraying booth Movement device system Paint supply system Part identification Sprayguns Gasper air system and exhaust air system Ia nm olal N The spray gun must be used a part of an Airless spraying system The Airless system shown in the figure is only one example Contact your WAGNER distributor for assistance in de signing a system to meet your needs The operating instructions and the safety regulations for the additional system compo nents used must be read before starting up 16 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 5 1 2 VENTILATION OF THE SPRAY BOOTH NWARNING Toxic and or flammable vapor mixtures Risk of poisoning and burns Operate the unit in a spraying booth approved for the working materials or Operate the unit on an appropriate spraying wall with the venti lation extraction switched on Observe national and local regulations for the outgoing air speed SIHI 0028 GB 5 1 3 FLUID PAINT HOSES CAUTION Impurities in the spraying system Spray gun blockage materials harden in the spraying system Flush the spray gun and paint supply with a suitable cleaning agent SIHI 0001 GB N DANGER Bursting hose Danger to life from injection of ma
5. BP 47 F 91122 Palaiseau Cedex Telephone 33 0 1 69 19 46 76 Telefax 33 0 1 69 81 7257 E Mail division batiment wagner france fr Netherlands WAGNER SPRAYTECH Benelux BV Zonnebaan 10 NL 3542 EC Utrecht PO Box 1656 3600 BR Maarssen Telephone 31 0 30 241 4155 Telefax 31 0 30 241 1787 E Mail info wagner group nl Italy WAGNER COLORA S r l Via Fermi 3 l 20040 Burago di Molgora MI Telephone 39 039 625021 Telefax 39 039 6851800 E Mail info wagnercolora com Japan WAGNER Spraytech Ltd 2 35 Shinden Nishimachi J Daito Shi Osaka 574 0057 Telephone 81 0 720 874 3561 Telefax 81 0 720 874 3426 E Mail marketing wagner japan co jp Sweden WAGNER SVERIGE AB Musk tgatan 19 S 25466 Helsingborg Telephone 46 0 42 150 020 Telefax 46 0 42 150 035 E Mail mailbox wagner se Austria J WAGNER GmbH Otto Lilienthal Str 18 Postfach 1120 D 88677 Markdorf Telephone 49 0 7544 5050 Telefax 49 0 7544 505200 E Mail service standard wagner group com Spain WAGNER Spraytech Iberica S A Ctra N 340 Km 1245 4 E 08750 Molins de Rei Barcelona Telephone 34 0 93 680 0028 Telefax 34 0 93 668 0156 E Mail info wagnerspain com Czechoslovakia WAGNER s r o Na Belidle 1 63 C 15000 Praha 5 Telephone 420 0 2 573 123 24 Telefax 420 0 2 545 001 E Mail wagner s r o Gtelecom cz USA Walt
6. 0350487 Thrust piece 0335 707 Disc spring set 6 pieces 11 0350488 Seal screw 12 0350418 Plug 13 0 x 0350 161 Valve seat assy 14 0 x 0350 489 Sealing 15 9913014 Hex nut M3 16 0350 882 Tension cap AL assy 17 A 0350422 Sealing 18 0350 491 Pressure ring 19 0097 404 Nozzle nut v 0350 883 Service set GA 250AL GA 400AL Wear part Included in service set e Not part of standard equipment for spray gun Available however as additional extra 33 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 9 3 AUTOMATIC SPRAYGUN GA 250AL B_00865 34 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER Item K Qty Part Nr Description al 0350481 Piston 2 1 0350498 Compression spring 250 bar 25 MPa 3626 psi red marked 3 e 1 0090xxx Standard nozzle see accessories 4 zl 0350483 Piston seal 5 A AN 0350884 Valve stem GA 250AL GA 400AL SP 6 1 0350512 Housing GA 250AL 7 1 0350485 Sealing screw 8 0 x 1 0350486 Packing 9 1 0350487 Thrust piece 10 1 0335707 Disc spring set 6 pieces 11 1 0350488 Seal screw 12 1 0350418 Plug 13 x 1 0350161 Valve seat assy 14 x 1 0350489 Sealing 15 1 9913014 Hex nut M3 16 1 0350882 Tension cap AL assy 17 x 1 0350422 Sealing 18 1 0350491 Pressure ring 19 1 0097404
7. 20 0 025 0 64 133 5 24 Dispersions 0090425 425 40 0 025 0 64 198 7 79 Dispersion paint 0090525 525 50 0 025 0 64 250 9 84 Se rau d y Filler paint 0090625 625 60 0 025 0 64 265 10 43 0090825 825 80 0 025 0 64 360 14 17 0090227 227 20 0 027 0 69 143 5 63 0090427 427 40 0 027 0 69 222 8 74 0090527 527 50 0 027 0 69 233 9 17 0090627 627 60 0 027 0 69 270 10 93 0090827 827 80 0 027 0 69 353 13 90 0090629 629 60 0 029 0 75 288 11 34 0090231 231 20 0 031 0 79 130 5 12 0090431 431 40 0 031 0 79 220 8 66 0090531 531 50 0 031 0 79 223 8 78 0090631 631 60 0 031 0 79 273 10 75 0090433 433 40 0 033 0 84 220 8 66 0090235 235 20 0 035 0 90 120 4 72 0090435 435 40 0 035 0 90 220 8 66 0090535 535 50 0 035 0 90 270 10 93 0090635 635 60 0 035 0 90 310 12 20 0090839 839 80 0 039 0 99 480 18 90 0090243 243 20 0 043 1 10 165 6 50 Large area 0090543 543 50 0 043 1 10 260 10 24 paintwork 0090552 552 50 0 052 1 30 280 11 02 28 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 8 2 HOSES Part No Description 9981939 Air hose polyamide red 6 4 mm 0 24 0 16 in Length given in meters 9987008 HP hose DN10 15m 49 21 ft 530 bar 53 MPa 7687 psi M16x1 5 9984431 HP hose DN10 10m 32 81 ft 530 bar 53 MPa 7687 psi M16x1 5 9984420 HP hose DN6 10m 32 81 ft 530 bar 53 MPa 7687 psi M16x1 5 9984421 HP hose NPS 1
8. 4 DN6 ND 530 bar 53 MPa 7687 psi 10m 32 81 ft 9987118 HD Schlauch NPS 3 8 DN10 ND 530 bar 53 MPa 7687 psi 15m 49 21 ft 8 3 MISCELLANEOUS Part No Description 0350480 Suspension bolt for spraygun mounting 0350499 Double nipple G1 4 M16x1 5 for paint connection 9998110 Coupling L 1 8 D6 for control air connection 0350883 Service Set for spraygun 0350550 Douple nipple G1 4 NPS1 4 for paint connection 0367560 Douple nipple NPS1 4 NPS1 4 0367561 Douple nipple NPS3 8 NPS1 4 29 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 9 SPARE PARTS 9 1 HOWTO ORDER SPARE PARTS Always supply the following information to ensure delivery of the right spare part Part Number description and quantity The quantity need not be the same as the number given in the Quantity column This number merely indicates how many of the respective parts are used in each subassembly The following information is also required to ensure smooth processing of your order Address for the invoice Address for delivery Name of the person to be contacted in the event of any queries Type of delivery required air freight or mail sea route or overland route etc Marks in spare parts lists Note to column K in the following spare parts lists Wearing parts Note No liability is assumed for wearing parts O Not part of stand
9. BLESHOOTING AND SOLUTIONS WAGNER Problem Cause Solution Paint output too low Nozzle too small Select larger nozzle see chapter 8 1 Paint pressure too low Adjust material pressure required Nozzle blocked High pressure filter of pump blocked Clean nozzle see chapter 5 0 Clean or replace filter Poor quality spray pattern Nozzle damaged Replace the nozzle Nozzle too large Select smaller nozzle see chapter 8 1 Paint pressure too low Increase pressure Material viscosity too high e Thin material acc to manufacturer s instruction Nozzle partially blocked Clean the nozzle see chapter 5 4 3 Valve stem leaks Packing worn Sealing screw retighten Replace the packing on the valve stem see chapter 6 2 Valve stem demaged Replace valve stem Spaygun will not shut off correctly dripping Valve seat or valve ball is worn out Check valve stem and flat jet nozzle and replace the wornpart Packingscrew too tight Check tightness if required loosen then re tigthen ac cording to chapter 6 2 2 25 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 8 ACCESSORIES 8 1 AIRLESS FLAT JET NOZZLES Applications Diameter
10. CE identification has been compulsory in Europe since 1st January 1995 and only pro ducts bearing CE identification may be released into circulation EC 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 GA 250AL GA 400AL 0350907 3 4 GERMAN REGUALTIONS AND GUIDELINES a BGVD15 Working with liquid ejection devices b BGVD25 Using coating materials c CHV9 Regulations on flammable liquids d BGR104 Explosion protection rules e BGR 132 Avoiding ignition risks f BGR 180 Setting up for cleaning workpieces with solvents g ZH1 406 Guidelines for liquid ejection devices h BGI 740 Painting rooms and equipment Note All titles can be ordered from Heymanns Publishing House in Cologne 11 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 4 DESCRIPTION 4 1 TYPICAL APPLICATIONS USING IN ACCORDANCE WITH THE INSTRUCTIONS The gun is suitable for atomising liquid materials particularly coating materials using the Airless process 4 1 1 WHAT KIND OF SPRAY MATERIAL CAN BE APPLIED Top coat paints primer paints corrosion protection solvents textured paints lyes staining solvents clear paints parting solvents etc on a solvent or water basis As well as e High viscosity materials i e special paints undercoating sealers thick o
11. G 1 8 Weight 545g Max temperature material 60 C 140 F Working temperature range 5 40 C 41 104 F Min el material resistance 150kO Max el material resistance 1250 kQ Sound power at 4 bar 0 4 MPa 58 psi air pressure 84 dB A Dimensions 104 mm 4 094 in 55 mm 2 165 in G 1 8 23 mm 0 90 in 6 4025 in G 1 4 40 mmy 1 574 in 14 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 4 4 FUNCTION OF SPRAYGUN 4 4 1 DESIGN OF SPRAYGUN B_00860 Tension cap Control air connection Housing Paint connection Nozzle nut Flat jet nozzle Valve stem see chapter 4 4 2 Compression spring see chapter 4 4 2 ToOmTmognosz 4 4 2 FUNCTIONAL DESCRIPTION B 00866 The automatic gun GA 250AL or GA 400AL is controlled by way of the control air B The control piston on the valve stem in the housing C of the spray gun GA 250AL or GA 400AL has pressure applied to it and thereby opens the paint duct to the flat jet nozzle F Closure takes place with the compression spring H after the pressure drop of the control air B valve e The set of seals I prevents that material can flow into the housing C Secure the gun Remove the air hose from the control air connection B on the spray gun 15 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 5 STARTING UP AND OPERATION
12. Nozzle nut v 0350883 Service set GA 250AL GA 400AL Wearing part Included in service set e Not part of standard equipment for spray gun Available however as additional extra 35 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 36 EDITION 07 2005 OPERATING MANUAL PART NO DOC0350941 GA 250AL_GA 400AL WAGNER Germany J WAGNER GmbH Otto Lilienthal Str 18 Postfach 1120 D 88677 Markdorf Telephone 49 0 7544 5050 Telefax 49 0 7544 505200 E Mail service standard wagner group com Switzerland J WAGNER AG Industriestrasse 22 Postfach 663 CH 9450 Altstatten Telephone 41 0 71 757 2211 Telefax 41 0 71 757 2222 E Mail rep ch wagner group ch Belgium WAGNER Spraytech Benelux BV Veilinglaan 56 B 1861 Wolvertem Telephone 32 0 2 269 4675 Telefax 32 0 2 269 7845 E Mail info wagner group be Denmark WAGNER Spraytech Scandinavia A S Kornmarksvej 26 DK 2605 Brondby Telephone 45 43 271 818 Telefax 45 43 43 05 28 E Mail wagner wagner group dk United Kingdom WAGNER Spraytech UK Ltd Haslemere Way Tramway Industrial Estate GB Banbury OXON OX16 8TY Telephone 44 0 1295 265 353 Telefax 44 0 1295 269861 E Mail enquiry wagnerspraytech co uk France J WAGNER France S A R L 5 Ave du 1er Mai
13. WAG ERG E R Operating manual GA 250AL GA 400AL Edition 07 2005 Automatic Airless Spraygun B_00859 A Ex B_00861 Il 2GX Atex 95 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL wicHEN Contents 1 ABOUT THESE INSTRUCTIONS 5 1 1 Languages 5 1 2 Warnings notes and symbols in these instructions 5 2 GENERAL SAFETY INSTRUCTIONS 6 2 1 Safety instructions for the operator 6 2 1 1 Electrical equipment 6 2 1 2 Personnel qualifications 6 2 1 3 Asafe work environment 6 22 Safety instructions for staff 6 2 2 1 Safe handling of WAGNER spray units 7 2 2 Earth the unit 7 2 2 3 Material hoses 7 2 24 Cleaning 8 2 2 5 Handling hazardous liquids varnishes and paints 8 2 2 6 Touching hot surfaces 8 2 3 Correct use 8 2 4 Use in an explosion hazard area 9 2 4 1 Correct use 9 2 4 2 Explosion protection identification 9 2 4 2 Max surface temperature 9 2 44 Safety instructions 9 3 PRODUCT LIABILITY AND WARRANTY 10 3 1 Important notes on product liability 10 3 2 Warranty 10 3 3 CE Conformity 11 3 4 German regualtions and guidelines 11 4 DESCRIPTION 12 4 1 Typical applications Using in Accordance with the instructions 12 4 1 1 What kind of spray material can be applied 12 4 2 Scope of supply 12 4 2 1 Type designation 12 4 3 Data 14 4 4 Function of spraygun 15 4 4 1 Design of spraygun 15 4 4 2 Functional description 15 5 STARTING UP AND OPERATION 16 541 Set up and connect 16 5 1 1 Typical auto
14. ard equipment available however as additional extra WARNING Incorrect maintenance repair 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 Relieve the pressure from the spray gun and unit Secure the spray gun against actuation Observe the operating and service instructions when carrying out all work SIHI_0004_GB 30 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 31 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 9 2 AUTOMATIC SPRAYGUN GA 400AL B_00865 32 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER Item K Qty PartNr Description 0350481 Piston 0350 482 Compression spring 400 bar 40 MPa 5800 psi 0090 xxx Standard nozzle see accessories 0350 483 Piston seal 0350 884 Valve stem GA 250AL GA 400AL SP 0350 484 Housing GA 400AL 0350485 Sealing screw 0350 486 Packing COIN OD UI BI Ws N gt IEA RESIES IE sch ESES Ee EEE Ee EENT sch 1 sch 1 sch 9
15. are observed 3 2 WARRANTY This unit is covered by our warranty on the following terms We will at our discretion repair or replace free of charge all parts which within 24 months in single shift 12 months in 2 shift or 6 months in 3 shift operation from date of receipt by the Purchaser are found to be wholly or substantially unusable due to causes prior to the sale in particular faulty design defective materials or poor workmanship The terms of the warranty are met at our discretion by the repair or replacement of the unit or parts thereof The resulting costs in particular shipping charges road tolls labour and material costs will be borne by us except where these costs are increased due to the subsequent shipment of the unit to a location other than the address of the purchaser This warranty does not cover damage caused by Unsuitable or improper use faulty installation or commissioning by the purchaser or a third party normal wear negligent handling defective maintenance unsuitable coating products substitute materials and the action of chemical electrochemical or electrical agents except when the damage is attributable to us Abrasive coating products such as redlead emulsions glazes liquid abrasives zinc dust paints and similar reduce the service life of valves packings spray guns nozzles cylinders pistons etc Any wear resulting from the aforementioned causes is not covered by this warranty Components not manu
16. d wear on the valve seat and needle Use only compression spring for 250 bar 25 MPa 3626 psi order no 0350498 The compression spring is marked red gt Never use a compression spring for 400 bar 40 MPa 5800 psi order no 0350482 SIHI 0040 GB e Mount the spraygun on the automatic movement system Connect material hose to the spraygun and the paint pump Select and mount the required nozzle e Connect the air hose 86 mm 0 24 in 94 mm 0 16 in for the control air to the air connection of the spraygun e Visually check the permissible pressures for all the system components Make sure that the spraying unit and all other conductive parts within the work area are earthed e Set material pressure approx 250 bar 25 MPa 3626 psi or 400 bar 40 MPa 5800 psi and use a suitable medium solvent or water to check that connections do not leak Relieve spray gun and unit pressure T Accessorie Suspension bolt Part No 0350480 B 00856 20 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 5 4 WORK 5 4 1 START UP FOR AIRLESS SPRAYING 1 Switch on the material supply adjust from approx 150 bar 15 MPa 2175 psi and the control unit 2 Spray on a test object 3 Adjustthe spray pressure and atomizing air in accordance with the nozzle and object Note The paint output volume can be changed by e Changing the material pressure or e Fitting another flat jet
17. e following languages Language Order No Language Order No German 0350939 English 0350941 French 0350946 Dutch 0350947 Italian 0350948 Spanish 0350949 Danish 0350951 Swedish 0350950 1 2 WARNINGS NOTES AND SYMBOLS IN THESE INSTRUCTIONS Warning instructions in this manual point out particular dangers to users and equipment and state measures for avoiding the hazard These warning instructions fall into the follo wing categories Danger imminent danger Non observance will result in death serious injury and serious material damage Warning possible danger Non observance can result in death serious injury and serious material damage Caution a possibly hazardous situation Non obser vance can result in minor injury Caution a possibly hazardous situation Non obser vance can cause material damage Kan Z DANGER gt This line warns of the hazard Possible consequences of failing to observe the warning instruc tions The signal word points out the hazard level SIHI_0100_GB The measures for preventing the hazard and its consequences Z WARNING This line warns of the hazard Possible consequences of failing to observe the warning instruc tions The signal word points out the hazard level The measures for preventing the hazard and its consequences SIHI_0103_GB s This line warns of the hazard w Possible consequences of failing to observe the warning instruc tions Th
18. e signal word points out the hazard level The measures for preventing the hazard and its consequences SIHI 0101 GB SIHI 0102 GB CAUTION This line warns of the hazard Possible consequences of failing to observe the warning instructions The signal word points out the hazard level gt The measures for preventing the hazard and its consequences Note provide information on particular characteristics and how to proceed EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 2 GENERAL SAFETY INSTRUCTIONS 2 1 SAFETY INSTRUCTIONS FOR THE OPERATOR 4 Keep these operating instructions to hand near the unit at all times Always follow local regulations concerning occupational safety and accident preven tion 2 1 1 ELECTRICAL EQUIPMENT Electrical plant and unit To be provided in accordance with the local safety requirements with regard to the operating mode and ambient influences May only be maintained by skilled electricians or under their supervision Must be operated in accordance with the safety regulations and electrotechnical regu lations gt Must be repaired immediately in the event of problems gt Must be put out of operation if they pose a hazard Must be de energized before work is commenced on active parts Inform staff about planned work observe electrical safety regulations 2 1 2 PERSONNEL QUALIFICATIONS Ensure that the u
19. ent temperature 5 C to 40 C 41 F to 104 F 2 4 4 SAFETY INSTRUCTIONS Safe handling of WAGNER spray units Mechanical sparks can form if the unit comes into contact with metal In an explosive atmosphere Do not knock or push the unit against steel or rusty iron gt Do not drop the spray gun Use only tools that are made of a permitted material Ignition temperature of the coating material Ensure that the ignition temperature of the coating material is above the maximum surface temperature Medium supporting atomizing gt To atomize the material use only weakly oxidizing gases e g air Cleaning If there are deposits on the surfaces the unit may form electrostatic charges Flames or sparks can form if there is a discharge Remove deposits from the surfaces to maintain conductivity EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 3 PRODUCT LIABILITY AND WARRANTY 3 1 IMPORTANT NOTES ON PRODUCT LIABILITY As a result of an EC regulation effective as from January 1 1990 the manufacturer shall only be liable for his product if all parts come from him or are approved by him and if the devices are properly fitted operated and maintained If other makes of accessory and spare parts are used the manufacturer s liability could be fully or partially null and void The usage of original WAGNER accessories and spare parts guarantees that all safety re gulations
20. er Pilot North America 46890 Continental Drive Chesterfield MI 48047 USA Telephone 1 877 925 8437 Telefax 1 586 598 1457 http www waltherpilotna com 37 WAGNER Ordernumber 0350941 Germany J WAGNER GmbH Otto Lilienthal Str 18 Postfach 1120 D 88677 Markdorf Telephone 49 0 7544 5050 Telefax 49 0 7544 505200 E Mail service standard wagner group com Switzerland J WAGNER AG Industriestrasse 22 Postfach 663 CH 9450 Altst tten Telephone 41 0 71 757 2211 Telefax 41 0 71 757 2222 E Mail rep ch wagner group ch www wagner group com
21. factured by Wagner are subject to the warranty terms of the origi nal maker The replacement of a part does not extend the warranty period of the unit The unit should be inspected immediately upon receipt To avoid loss warranty aniy apparent defect should be notified to us or the dealer in wri ting within 14 days from date of sale of the unit The right to commission warranty services to a third party is reserved Warranty claims are subject to proof of purchase by submitting an invoice or delivery note If an inspection finds damage not covered by the present warranty the repair will be car ried out at the expense of the purchaser Note that this warranty does not in any way restrict legally entitled claims or those contrac tually agreed to in our general terms and conditions J Wagner AG 10 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 3 3 CE CONFORMITY Short explanation CE Communaut Europ enne Products identified with the CE mark have been manufactured and checked according to EU guidelines This means that in terms of materials used manufacturing process and ope ration they are in accordance with the EU safety and health requirements and therefore the EU regulations and standards The regulations and standards applying to a particular product can be found in the CE Certificate of Conformity This is enclosed with the product or can be requested from the manufacturer The
22. fore all work on the unit in the event of work interruptions and functional faults Switch off the energy compressed air supply Secure the spray gun against actuation Relieve the pressure from the spray gun and unit By functional faults Identify and correct the problem proceed as described in chap Trouble shooting In the event of skin injuries caused by paint or cleaning agents Note down the paint or cleaning agent that you have been using Consult a doctor immediately Avoid danger of injury through recoil forces Ensure that you have a firm footing when operating the spray gun Only hold the spray gun briefly in any one position 2 2 2 EARTH THE UNIT Electrostatic charges can occur on the unit due to the electrostatic charge and the flow speed involved in spraying These can cause sparks and flames upon discharge Ensure that the unit is earthed for every spraying operation Earth the workpieces to be coated Ensure that all persons inside the working area are earthed e g that they are wearing antistatic shoes When spraying wear antistatic gloves to earth yourself via the spray gun handle 2 2 3 MATERIAL HOSES Ensure that the hose material is chemically resistant to the sprayed materials Ensure that the material hose is suitable for the pressure generated in the unit Ensure that the following information is visible on the high pressure hose Manufacturer Permi
23. il adhesives etc Note In the event of application problems contact your WAGNER branch and the paint manu facturer 4 2 SCOPE OF SUPPLY 4 2 1 TYPEDESIGNATION GA XXX AL Oo D GA Automatic gun 250 Gun type 250 bar 25 MPa 3626 psi 400 Gun type 400 bar 40 MPa 5802 psi AL Airless spraying system 12 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER Part No Description 0350032 Automatic gun GA 400AL 0350080 Automatic gun GA 400AL USA 0350033 Automatic gun GA 250AL 0350081 Automatic gun GA 250AL USA The standard equipment includes Quantity Part No Description SIE Sa SiS Automatic gun GA 400AL ea ay ies m Automatic gun GA 250AL ojojojo E EN Sch 0350907 CE Declaration of Conformity T 1 0350939 Operating manual German 11 1 0350941 Operating manual English UW see 1 0 An operating manual in the local language For special versions the delivery note applies 13 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL WAGNER depending on nozzle used OPERATING MANUAL 4 3 DATA GA 250AL GA 400AL 25 MPa 40 MPa Max material pressure 3626 psi 5802 psi 250 bar 400 bar 0 45 0 8 MPa Control air pressure 65 116 psi 4 5 8 bar Paint connection internal thread G 1 4 2x Control air connection int thread
24. matic spraying system 16 5 1 2 Ventilation of the spray booth 17 5 1 3 Fluid paint hoses 17 5 1 4 Earthing the system 18 5 2 Preparation of paint 19 5 2 1 Viscosity conversion table 19 5 3 Start up 20 5 3 1 General rules for handling the spray gun 20 5 3 2 Preparation 20 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER Contents 5 4 Work 21 5 4 1 Start up for airless spraying 21 5 4 2 Replacing the airless flat jet nozzle 21 5 4 3 Cleaning the airless flat jet nozzle 21 6 MAINTENANCE 22 6 1 Finishing work and Cleaning 23 6 2 Replacing the valvestem 23 6 2 1 Replacing the valve stem 23 6 2 2 Reassembling the valve stem and the spray gun 24 7 TROUBLESHOOTING AND SOLUTIONS 25 8 ACCESSORIES 26 8 1 Airless flat jet nozzles 26 8 2 Hoses 29 8 3 Miscellaneous 29 9 SPARE PARTS 30 9 1 How to order spare parts 30 9 2 Automatic spraygun GA 400AL 32 9 3 Automatic spraygun GA 250AL 34 EDITION 07 2005 OPERATING MANUAL PART NO DOC0350941 GA 250AL_GA 400AL WAGNER 1 ABOUT THESE INSTRUCTIONS This operating manual contains information on the operation repair and maintenance of the unit Always observe these instructions when operating the unit This equipment can be dangerous if it is not operated in accordance with this manual Compliance with these instructions constitutes an integral component of the warranty agreement 1 1 LANGUAGES This operating manual is available in th
25. nit is operated and repaired only by trained persons 2 1 3 ASAFEWORK ENVIRONMENT Ensure that the floor of the working area is anti static in accordance with EN 50053 Part 1 87 2 measurement in accordance with DIN 51953 Ensure that all persons within the working area wear anti static shoes e g shoes with leather soles Ensure that during spraying persons wear anti static gloves so that they are earthed via m the handle of the spray gun ug Customer to provide paint mist extraction systems conforming to local regulations Ensure that the following components of a safe working environment are available Material air hoses adapted to the working pressure Personal safety equipment breathing and skin protection Ensure that there are no ignition sources such as naked flame glowing wires or hot surfaces in the vicinity Do not smoke bd 2 2 SAFETY INSTRUCTIONS FOR STAFF Always follow the information in these instructions particularly the general safety in structions and the warning instructions Always follow local regulations concerning occupational safety and accident preven e tion EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 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 Be
26. nozzle See accessories 5 4 2 REPLACING THE AIRLESS FLAT JET NOZZLE Replace material with cleaning agent and flush the spraygun Relieve spraygun and unit pressure Secure the gun Remove the control air hose Unscrew the nozzle nut E and remove the flat jet nozzle D Note Ensure that the seal C is not lost Mounting 5 Insert a cleaned or new nozzle into the nozzle nut E 6 Insert the seal C into the nozzle nut 7 Put the nozzle nut together with the nozzle and seal onto the gun and tighten it gently 8 Turn the nozzle D so that it corresponds to the required spray pattern 9 Tighten the nozzle nut E 10 Reconnect the control air hose A B wm Sr B_00864 5 4 3 CLEANING THE AIRLESS FLAT JET NOZZLE The Airless flat jet nozzle D can be put into a cleaning solvent recommended by the paint manufacturer Attention Do not handle the flat jet noozle with sharp edged objects 21 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 6 MAINTENANCE See SAFETY REGULATIONS in Chapter 2 CAUTION Impurities in the spraying system Spray gun blockage materials harden in the spraying system Flush the spray gun and paint supply with a suitable cleaning agent SIHI_0001_GB The cleaning solvent used for this must be suitable for the spray material CAUTION Cleaning agent in the air duct Functional faults caused by swollen seal
27. paint producer 5 2 1 VISCOSITY CONVERSION TABLE milli Pascal x Centipoise Poise DIN Cup Ford Cup 4 Zahn 2 Sec mPas 4 mm 0 16 in 10 10 0 1 5 16 15 15 0 15 8 17 20 20 0 2 10 18 25 25 0 25 14 12 19 30 30 0 3 15 14 20 40 40 0 4 17 18 22 50 50 0 5 19 22 24 60 60 0 6 21 26 27 70 70 0 7 23 28 30 80 80 0 8 25 31 34 90 90 0 9 28 32 37 100 100 1 30 34 41 120 120 1 2 33 41 49 140 140 1 4 37 45 58 160 160 1 6 43 50 66 180 180 1 8 46 54 74 200 200 2 49 58 82 220 220 2 2 52 62 240 240 2 4 56 65 260 260 2 6 62 68 280 280 2 8 65 70 300 300 3 70 74 320 320 3 2 340 340 3 4 360 360 3 6 80 380 380 3 8 400 400 4 90 19 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 5 3 START UP 5 3 1 GENERAL RULES FOR HANDLING THE SPRAY GUN WARNING Unintentional putting into operation Risk of injury Before all work on the unit in the event of work interruptions and functional faults Switch off the energy compressed air supply Relieve the pressure from the spray gun and unit Secure the spray gun against actuation By functional faults Identify and correct the problem proceed as described in chap Trouble shooting SIHI_0065_GB See SAFETY REGULATIONS in Chapter 2 5 3 2 PREPARATION CAUTION Valve does not open or opens only with only limited access Increase
28. s Never immerse the spray gun in cleaning agent SIHI_0066_GB NWARNING Incorrect maintenance repair 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 Relieve the pressure from the spray gun and unit Secure the spray gun against actuation Observe the operating and service instructions when carrying out all work SIHI 0004 GB 22 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 6 1 FINISHING WORK AND CLEANING N DANGER Exploding gas air mixture Danger to life from flying parts and burns Never spray into a closed container Earth the container SIHL 0008 GB 1 Ensure that the material pressure has been relieved and interrupt the air supply to the gun Connect the cleaning solvent supply Detach the Airless nozzle and clean separately see Paragraph 5 4 3 Connect the air supply and thoroughly rinse the gun Relieve spray gun and unit pressure Clean body of the gun with solvent recommended by the manufacturer and dry with a cloth or blow gun OY uv uds ud NI 6 2 REPLACING THE VALVESTEM 6 2 1 REPLACING THE VALVE STEM 1 Putout of operation and clean 2 Unscrew the tension cap A and remove the compres
29. sion spring B 3 Carefully pull out the valve stem E with the piston D until the flats of the valve stem are visible 4 Hold the valve stem E with a spanner AF2 and unscrew nut C 5 Remove piston D from the valve stem E 6 With a spanner AF5 unscrew sealing screw F completely 7 Pull out valve stem E including the sealing screw F the packing G the thrust piece H the disc spring set I 6 pieces and the pressure ring K Note If parts are caught in the hole the nozzle M and the valve seat assy L have the be unscrewed The parts can be pushed out with a rod of max 4 5 mm 1 78 in 8 Exchange worn parts a 23 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 6 2 2 REASSEMBLING THE VALVE STEM AND THE SPRAY GUN 1 Place the sealing screw F the packing G the thrust piece H the disc spring set 6 pieces I and the pressure ring K on the valve stem E Note The disc springs I have to be arranged correctly 2 Insert the premounted valve stem into the housing 3 Sealing screw F screw in and only so far carefully pull tight until when shifting the valve rod E a lighter resistance is noticeable 4 Fitthe piston D the compression spring B and the tension cap A in revers order acc paragraph 6 2 1 step 5 to 2 B 00870 24 EDITION 07 2005 OPERATING MANUAL PART NO DOC0350941 GA 250AL_GA 400AL 7 TROU
30. ssible operating overpressure Date of manufacture The electrical resistance of the complete high pressure hose must be less than 1 MOhm EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 2 2 4 CLEANING gt De energize the unit electrically gt Disconnect the pneumatic supply line Relieve the pressure from the unit Ensure that the flash point of the cleaning agent is at least 5 K above the ambient tem perature To clean use only solvent free cloths and brushes Never use hard objects or spray on cleaning agents with a gun An explosive gas air mixture forms in closed containers When cleaning units with solvents never spray into a closed container Earth the container 2 2 5 HANDLING HAZARDOUS LIQUIDS VARNISHES AND PAINTS When preparing or working with paint and when cleaning the unit follow the work ing instructions of the manufacturer of the paints solvents and cleaning agents being A used Ra Take the specified protective measures in particular wear safety goggles protective clothing and gloves as well as hand protection cream if necessary Use a mask or breathing apparatus if necessary For sufficient health and environmental safety Operate the unit in a spray booth or on a spraying wall with the ventilation extraction switched on Wear suitable protective clothing when working with hot materials Ld 2 2 6 TOUCHING HOT SURFACES
31. terial Ensure that the hose material is chemically resistant Ensure that the spray gun and material hose between the unit and the spray gun is suitable for the pressure generated in the unit Ensure that the following information can be seen on the high pressure hose Manufacturer Permissible operating pressure Date of manufacture SIHI 0029 GB 17 EDITION 07 2005 PART NO DOC0350941 GA 250AL_GA 400AL OPERATING MANUAL WAGNER 5 1 4 EARTHING THE SYSTEM NWARNING Discharge of electrostatically charged components in atmo spheres containing solvents Explosion hazard from electrostatic sparks or flames Earth all unit components gt Earth the workpieces being painted SIHI 0027 GB NWARNING Heavy paint mist if earthing is insufficient Risk of poisoning Insufficient paint application quality Earth all unit components gt Earth the workpieces being painted SIHI 0003 GB Any material containers and the unit must be connected by a potential equalisation earth cable 18 EDITION 07 2005 PART NO DOC0350941 GA 250AL GA 400AL OPERATING MANUAL WAGNER 5 2 PREPARATION OF PAINT The viscosity of the paints is of great importance The best results are obtained with paints between 80 and 150 mPas In most cases the application of paints of up to 260 mPas for thick layers does not cause problems In the case of application problems contact the
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