WAGNER AirCoat GM 4100 AC Manuel utilisateur

B_02254

GM 4100 AC

AirCoat Manual Gun for Flat

and Round Jet Nozzles

Version 01/2018

VERSION 01/2018 ORDER NUMBER DOC 394821

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 7

2 CORRECT USE 8

2.1 Device Type 8

2.2 Type of Use 8

2.3 For Use in Potentially Explosive Areas 8

2.4 Processible Working Materials 8

2.5 Misuse 8

3 IDENTIFICATION 9

3.1 Explosion Protection Identication 9

3.2 Identication "X" 9

3.3 Type plate 10

4 BASIC SAFETY INSTRUCTIONS 11

4.1 Safety Instructions for the Operator 11

4.1.1 Electrical Devices and Equipment 11

4.1.2 A Safe Work Environment 11

4.1.3 Personnel Qualications 12

4.2 Safety Instructions for the Personnel 12

4.2.1 Personal Safety Equipment 12

4.2.2 Safe Handling of WAGNER Spray Devices 13

4.2.3 Grounding the Unit 13

4.2.4 Product hoses 14

4.2.5 Cleaning and Flushing 15

4.2.6 Touching Hot Surfaces 15

4.2.7 Maintenance and Repair 16

4.2.8 Protective and Monitoring Equipment 16

5 DESCRIPTION 17

5.1 Components 17

5.2 Mode of Operation 17

5.3 Protective and Monitoring Equipment 17

5.4 Included Items 17

5.4.1 Version for application up to 25 MPa; 250 bar; 3,625 psi 17

5.4.2 Standard equipment 17

5.5 Data 18

5.5.1 Materials of Paint-wetted Parts 18

5.5.2 Technical data 18

5.5.3 Dimensions and Connections 18

VERSION 01/2018 ORDER NUMBER DOC 394821

6 ASSEMBLY AND COMMISSIONING 19

6.1 Training of Assembly/Commissioning Personnel 19

6.2 Storage Conditions 19

6.3 Installation Conditions 19

6.4 Installation and Connection 20

6.4.1 Typical AirCoat spraying system 20

6.4.2 Ventilation of the Spray Booth 20

6.4.3 Air Supply Lines 21

6.4.4 Product supply lines 21

6.5 Grounding 21

6.6 Safety Checks 21

6.7 Lacquer Preparations 21

6.8 Commissioning 22

6.8.1 Procedure 22

6.8.2 Verifying a Safe Operational Condition 22

7 OPERATION 23

7.1 Training the Operating Personnel 23

7.2 Tasks 23

7.2.1 Starting to Spray with the AirCoat 23

7.2.2 Adjusting the Spray Pattern 24

7.3 Pressure Relief/Work Interruption 24

7.4 Changing AirCoat Nozzle 25

7.4.1 Cleaning AirCoat Nozzle 25

7.4.2 Eliminating Nozzle Clogging 26

8 CLEANING AND MAINTENANCE 27

8.1 Cleaning 27

8.1.1 Cleaning Personnel 27

8.1.2 Flushing and Cleaning the Spray Gun 27

8.2 Maintenance 28

8.2.1 Maintenance Personnel 28

8.2.2 Safety instructions 28

8.2.3 Safety Checks and Maintenance Intervals 29

8.2.4 Replacing the Product Hose or Air Hose 30

8.2.5 Changing or Cleaning the Edge Filter 31

9 TROUBLESHOOTING AND RECTIFICATION 32

10 REPAIR WORK 33

10.1 Repair Personnel 33

10.2 Repair Notes 33

10.3 Tools 33

10.4 Replacing Parts on the Valve Rod 34

10.4.1 Replacing Valve Tappet Seals 35

10.4.2 Replacing the Rod Seal (35) 35

10.4.3 Assembly 36

10.5 Replacing the Nozzle Seal 36

10.6 Replacing the "Air" Sealing Ring 37

10.7 Replacing the Spring Cap 37

VERSION 01/2018 ORDER NUMBER DOC 394821

11 FUNCTION TEST AFTER REPAIR WORK 38

12 DISPOSAL 39

13 ACCESSORIES 40

13.1 Round Jet Nozzle Attachment 40

13.1.1 Nozzle Inserts RXX 40

13.1.2 Nozzle Screw Joint, Complete 40

13.2 AirCoat Nozzles ACF3000 41

13.3 Air caps 42

13.4 Anodized Union Nut 43

13.5 Swivel Joints and Filter 43

13.6 Hoses 44

13.7 Miscellaneous 44

14 SPARE PARTS 45

14.1 How can spare parts be ordered? 45

14.2 Spare Parts List GM 4700AC 46

15 EU DECLARATION OF CONFORMITY 48

VERSION 01/2018 ORDER NUMBER DOC 394821

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 can 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 01/2018 ORDER NUMBER DOC 394821

1.3 LANGUAGES

The operating manual is available in the following languages:

Original operating manual

Language Order no.

German 394820

Translation of the original operating manual

Language Order no. Language Order no.

English 394821 Danish 2301125

French 2301121 Dutch 2301122

Italian 2301118 Swedish 2301129

Spanish 2301119 -- --

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

1.4 ABBREVIATIONS

Order

no.

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

Number of pieces AirCoat

Wrench size -- --

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 01/2018 ORDER NUMBER DOC 394821

2 CORRECT USE

2.1 DEVICE TYPE

Manual gun for manually coating work pieces.

GM 4100 AC

2.2 TYPE OF USE

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

products, using the AirCoat process.

– Non-ignitable products.

– Products in accordance with their classication in explosion class IIB.

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 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 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.

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

VERSION 01/2018 ORDER NUMBER DOC 394821

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 manual gun GM 4100 AC

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 5.5.2.

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.

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.

Use only a damp cloth to clean the device.

VERSION 01/2018 ORDER NUMBER DOC 394821

3.3 TYPE PLATE

WARNING

SKIN INJECTION HAZARD

READ INSTRUCTION MANUAL

II 2GX

Serial-No. XXXXX

Max. p air 0.8 MPa (115 psi)

Max. p fluid see tension nut

Max. T fluid 55°C (131°F)

Wagner International AG, Altstaetten

Made in Switzerland

B_04173

Designation

1 Serial number

2 Maximum air inlet pressure

3 Maximum product pressure see spring cap

4 Maximum product temperature

5 Warning

6 Danger of injury from injection/read operating manual

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