WAGNER PEA-C4-HiCoat FM Betriebshandbuch

0102 II 2 D EEx 2mJ 85 °C

P_01610

Automatic Powder Spray Gun

PEA-C4-HiCoat

Version 05 / 2012

Translation of the Original

Operating Manual

PEA-C4-HiCoat

OPERATING MANUAL

VERSION 05/2012 ORDER NUMBER DOC 390829

Contents

1 GENERAL INFORMATION 6

1.1 Preface 6

1.2 Warnings, Notes and Symbols in these Instructions 6

1.3 Copyright 7

1.4 Contact Details 7

1.5 Languages 7

2 CORRECT USE 8

2.1 Device Type 8

2.2 Type of Use 8

2.3 Use in Potentially Explosive Areas 8

2.4 Safety Parameters 8

2.6 Processing Materials 9

2.6 Reasonably Foreseeable Misuse 9

2.7 Residual Risks 9

3 IDENTIFICATION 10

3.1 Explosion Protection Identication 10

3.2 Permissible Device Combinations 10

3.3 Safety Identications 11

4 GENERAL SAFETY INSTRUCTIONS 12

4.1 Safety Instructions for the Operator 12

4.1.1 Electrical Devices and Operating Equipment 12

4.1.2 Personnel Qualications 12

4.1.3 A safe Work Environment 12

4.2 Safety Instructions for Sta 13

4.2.1 Safe Handling of WAGNER Powder Spray Devices 13

4.2.2 Grounding the Device 13

4.2.3 Accessories and Spare Parts 13

4.2.4 Cleaning and Maintenance 14

4.2.5 Handling Powder Paints 14

4.3 Note on Harmless Discharges 15

4.4 Protective and Monitoring Equipment 16

4.4.1 Release Guns (High-Voltage/Pneumatic System) 16

5 DESCRIPTION 17

5.1 Design of Spray Gun 17

5.2 Functioning of the Spray Gun 17

5.3 Technical Data 18

5.3.1 Dimensions 19

5.4 Permitted Accessories 20

5.5 Scope of Delivery 20

6 ASSEMBLY AND COMMISSIONING 21

6.1 Training Assembly/Commissioning Sta 21

6.2 Storage Conditions 21

6.3 Installation Conditions 21

6.4 Preparing the Spray Gun 22

6.4.1 Selection of the Suitable Nozzle System 22

6.5 Mounting the Spray Gun 24

PEA-C4-HiCoat

OPERATING MANUAL

VERSION 05/2012 ORDER NUMBER DOC 390829

Contents

6.6 Grounding 25

6.6.1 Grounding the Powder Coating System 26

7 OPERATION 27

7.1 Training the Operating Sta 27

7.2 Safety Instructions 27

7.3 Switching on the Spray Gun 28

7.4 Switching o the Spray Gun 28

7.5 Switching o the Spray Gun in the Event of Faults or Emergencies 28

7.6 Optimizing the Powder Cloud for your Coating 29

7.7 Performing a Color Change 30

7.8 Reproducible Setting of the Nozzle Position 31

8 CLEANING AND MAINTENANCE 32

8.1 Cleaning 32

8.1.1 Cleaning Sta 32

8.1.2 Safety Instructions 32

8.1.3 Cleaning Procedures 33

8.2 Maintenance 34

8.2.1 Maintenance Sta 34

8.2.2 Safety Instructions 34

8.2.3 Maintenance Procedures 35

8.2.4 Replacing the Spray Gun 36

8.3 Cleaning the Spray Gun and Dismantling the Flat Spray Nozzle 37

8.4 Replacing the Protective Wedge 38

8.5 Fitting the Round Spray Nozzle 40

8.6 Fitting the Angle Adapter 42

8.6.1 Removing the Nozzle and Electrode Holder 42

8.6.2 Fitting the Angle Adapter 43

8.6.3 Replacement of the Wearing Parts 43

8.7 Mounting the Corona-Star 45

8.8 Corona-Star for Angle Adapter 46

8.8.1 Mounting the Corona-Star 46

9 INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 201004 47

9.1 Overview of Inspections 48

10 DISASSEMBLY AND DISPOSAL 50

10.1 Disassembly 50

10.2 Disposal 50

11 TROUBLESHOOTING AND RECTIFICATION 51

12 ACCESSORIES 53

12.1 Flat Spray Nozzles 53

12.2 Deector Cone 53

12.3 Retrot Set Corona-Star 54

12.4 Corona-Star WA C4 54

12.5 Wedge Tool 55

12.6 Gun Support and Fixation 55

12.7 Electric Cables and Hoses 55

12.8 Angle Adapter 56

12.9 Powder Measuring Bag 57

PEA-C4-HiCoat

OPERATING MANUAL

VERSION 05/2012 ORDER NUMBER DOC 390829

13 SPARE PARTS 58

13.1 How can Spare Parts be ordered? 58

13.2 PEA-C4-HiCoat Corona Automatic Gun 59

13.3 Electrode Holder C4 R with Nozzles 60

13.4 Angle Adapter WA90 C4 61

13.5 Angle Adapter WA60 C4 62

13.6 Angle Adapter WA30 C4 63

14 DECLARATION OF WARRANTY AND CONFORMITY 64

14.1 Important Notes on Product Liability 64

14.2 Warranty Claim 64

14.3 Declaration of Conformity 65

14.4 EC Type Examination Certicate 66

PEA-C4-HiCoat

OPERATING MANUAL

VERSION 05/2012 ORDER NUMBER DOC 390829

1 GENERAL INFORMATION

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 operating and service

sta.

The operating and service sta should be instructed according to the safety instructions.

The device may only be operated in compliance with this operating manual.

This equipment can be dangerous if it is not operated according to the denitions in this

operating manual.

1.1 PREFACE

1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS

Warning instructions in this operating manual highlight particular dangers to users and

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 - possible imminent danger.

Non-observance may result in death or serious injury.

Caution - a possibly hazardous situation.

Non-observance may result in minor injury.

Note - provides information about particular characteristics and how to proceed.

Notice - a possibly hazardous situation.

Non-observance may result in damage to property.

This information warns you of a hazard!

Possible consequences of not observing the warning instructions.

The signal word indicates the hazard level.

The measures for preventing the hazard and its consequences.

DANGER

This information warns you of a hazard!

Possible consequences of not observing the warning instructions.

The signal word indicates the hazard level.

The measures for preventing the hazard and its consequences.

WARNING

This information warns you of a hazard!

Possible consequences of not observing the warning instructions.

The signal word indicates the hazard level.

The measures for preventing the hazard and its consequences.

CAUTION

This information warns you of a hazard!

Possible consequences of not observing the warning instructions. The signal word

indicates the hazard level.

The measures for preventing the hazard and its consequences.

NOTICE

PEA-C4-HiCoat

OPERATING MANUAL

VERSION 05/2012 ORDER NUMBER DOC 390829

1.5 LANGUAGES

The copyright for this operating manual belongs to J. Wagner AG.

The information contained in this operating manual may only be used by the operator for

his own use, e.g. to produce operating instructions.

1.3 COPYRIGHT

J. Wagner AG Tel +41 (0)71 757 2211

Industriestrasse 22 Fax +41 (0)71 757 2222

Postfach 663 www.wagner-group.com

CH-9450 Altstätten rep-ch@wagner-group.ch

1.4 CONTACT DETAILS

The operating manual is available in the following languages:

Language: Order No. Language: Order No.

German 390822 English 390829

French 390836 Dutch 390876

Italian 390840 Spanish 390851

Danish 390870 Portuguese 2315719

Norwegian 390880 Polish 2320221

Czech 390896 Slovenian 390863

Serbian 390871

PEA-C4-HiCoat

OPERATING MANUAL

VERSION 05/2012 ORDER NUMBER DOC 390829

2 CORRECT USE

2.1 DEVICE TYPE

Automatic spray gun for automatic coating

2.2 TYPE OF USE

The spray gun PEA-C4-HiCoat serves as stationary equipment for industrial electrostatic

coating with ammable powder in automatic systems. It can be operated either with

single control units or switch cabinet modules.

2.3 USE IN POTENTIALLY EXPLOSIVE AREAS

This type A-P electrostatic powder spray gun is suitable for processing industrial powder

paints for coating electrically conductive objects and can be used in potentially explosive

atmospheres (zone 22). (See explosion protection identication Chap 3.1).

2.4 SAFETY PARAMETERS

The powder spray gun is only suited to the application of powder paint.

J. Wagner AG forbids any other use!

The powder spray gun may only be operated under the following conditions if:

the operating sta have previously been trained on the basis of this operating manual,

the safety regulations listed in this operating manual are observed,

the operating, maintenance and repair information in this operating manual is

observed,

and the statutory requirements and accident prevention regulations standard in the

country of use are observed.

The spray gun may only be used if all parameters are set and all measurements/safety

checks are carried out correctly.

PEA-C4-HiCoat

OPERATING MANUAL

VERSION 05/2012 ORDER NUMBER DOC 390829

2.6 REASONABLY FORESEEABLE MISUSE

The following is prohibited:

coating work pieces which are not grounded

unauthorized conversions and modications to the spray gun

processing liquid or similar coating materials

using defective components, spare parts or accessories other than those described in

chapter 12 of this operating manual

The forms of misuse listed below may result in health issues and/or damage to property:

use of damp powder paint

incorrectly set values for powder discharge

incorrectly set electrostatic values

2.6 PROCESSING MATERIALS

Types of powder which can be charged electrostatically

Metallic powder

2.7 RESIDUAL RISKS

Residual risks are risks which cannot be excluded even in the event of correct use.

If necessary, warning and prohibition signs at the relevant points of risk indicate residual

risks.

Residual Risk Source Consequences Specic Measures Lifecycle Phase

Skin contact with

powder paints and

cleaning agents

Handling powder

paints and cleaning

agents

Skin irritation, Wear protective

clothing

Operation,

allergies Note safety data

sheets

maintenance,

disassembly

Powder paint in air

outside the dened

working area

Painting outside the

dened working

area

Inhalation of

substances

hazardous to health

Observe working

instructions and

operating

procedures

Operation,

maintenance

Falling down of

spray guns

Loosening of the

securing nuts

Injuries Regular check of

xations

Operation,

maintenance

Residual voltage on

live parts

Decient grounding Electrical shock Danger instruction, Operation,

instruction by

trainer

maintenance

PEA-C4-HiCoat

0102

OPERATING MANUAL

VERSION 05/2012 ORDER NUMBER DOC 390829

3 IDENTIFICATION

3.1 EXPLOSION PROTECTION IDENTIFICATION

The EC type examination certicate PTB 05 ATEX 5008 can be found in chapter 14.4.

3.2 PERMISSIBLE DEVICE COMBINATIONS

The PEA-C4-HiCoat powder spray gun may only be connected to the control devices listed

below:

EPG-Sprint HVM-D 1

Bravo HVM-DP

EPG-D1 EPG-DP 5

EPG Prima EPG-SL 5

EPG 2008 EPG 2025 Digi.

EPG 2007

Gun type: PEA-C4-HiCoat

Manufacturer: J. Wagner AG

CH - 9450 Altstätten

II 2 D EEx 2mJ 85 °C

CE: Communautés Européennes

0102: Number of appointed body which is involved in the production

monitoring phase

E: according to European standard

Ex: Symbol for explosion protection

II: Device class II

2: Category 2

D: Ex-atmosphere dust

2mJ: Max. ring power 2 mJ

85 °C: Max. surface temperature

Incorrect use of the spray gun!

Risk of injury and damage to the device.

Only connect original Wagner devices to the PEA-C4-HiCoat

spray gun.

WARNING

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