Translation of the Original Operating Manual. Automatic Powder Spray Gun PEA-C4XL-S. Version 03 / II 2 D EEx 2mJ 85 C P_02330

Transcription

1 Translation of the Original Operating Manual Automatic Powder Spray Gun Version 03 / 2014 P_ II 2 D EEx 2mJ 85 C

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3 Table of Contents 1 GENERAL INFORMATION Preface Warnings, Notices, and Symbols in this Operating Manual Languages Abbreviations 7 2 CORRECT USE Device Type Type of Use Use in Potentially Explosive Areas Safety Parameters Processible Working Materials Reasonably Foreseeable Misuse Residual Risks 9 3 IDENTIFICATION Explosion Protection Identification Permissible Device Combinations Safety Feature Identification 11 4 GENERAL SAFETY INSTRUCTIONS Safety Instructions for the Operator Electrical Devices and Equipment Staff Qualifications Safe Work Environment Safety Instructions for Staff Safe Handling of WAGNER Powder Spray Devices Grounding the Device Accessories and Spare Parts Cleaning and Maintenance Handling Powder Lacquers Note on Safe Discharges Protective and Monitoring Equipment Release Guns (High-voltage/Pneumatic System) 16 5 DESCRIPTION Spray Gun Design Functioning of the Spray Gun Technical Data Dimensions Permitted Accessories Scope of Delivery 20 6 ASSEMBLY AND COMMISSIONING Training Assembly/Commissioning Staff Storage Conditions Installation Conditions Preparing the Spray Gun Selection of the Suitable Nozzle System Handling of the Hose Coupling Assembling the Spray Gun 26 3

4 Table of Contents 6.7 Grounding Grounding the Powder Coating System 29 7 OPERATION Training the Operating Staff Safety Instructions Switching on the Spray Gun Switching Off the Spray Gun Switching Off the Spray Gun in the Event of Faults or Emergencies Optimizing the Powder Cloud for Your Coating Performing a Paint Change Impulse Flushing Reproducible Setting of the Nozzle Position 35 8 CLEANING AND MAINTENANCE Cleaning Cleaning Staff Safety Instructions Cleaning Procedures Maintenance Maintenance Staff Safety Instructions Maintenance Procedures Replacing the Spray Gun Cleaning the Gun and Dismantling the Flat Spray Nozzle Replacing the Protective Wedge Fitting the Round Spray Nozzle Assembling the Angle Adapter Removing the Nozzle and Electrode Holder Fitting the Angle Adapter Replacement of the Wearing Parts Assembling the Corona-Star Corona-Star for Angle Adapter Assembling the Corona-Star 51 9 INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: Overview of Inspections DISASSEMBLY AND DISPOSAL Disassembly Disposal TROUBLESHOOTING AND RECTIFICATION ACCESSORIES Flat Spray Nozzles Deflector Cone for Round Spray Nozzle Corona-Star Retrofit Set Corona-Star WA C Wedge Tool Electric Cables and Hoses Angle Adapter Powder Measuring Bag 64 4

5 Table of Contents 13 SPARE PARTS How Can Spare Parts Be Ordered? Corona Automatic Gun C4 R Electrode Holder with Nozzles WA90 C4 Angle Adapter WA60 C4 Angle Adapter WA30 C4 Angle Adapter DECLARATION OF WARRANTY AND CONFORMITY Important Notes Regarding Product Liability Warranty Claim Declaration of Conformity 72 5

6 1 GENERAL INFORMATION 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 operating and service staff. Operating and service staff 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 instructions in this operating manual. 1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS Warning instructions in this operating 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. DANGER This notice 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 - possible imminent danger. Non-observance may result in death or serious injury. WARNING This notice 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 - a possibly hazardous situation. Non-observance may result in minor injury. CAUTION This notice 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 - a possibly hazardous situation. Non-observance may result in material damage. NOTICE This notice 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. Note - provides information about particular characteristics and how to proceed. 6

7 1.3 LANGUAGES The operating manual is available in the following languages: Language: Order No. Language: Order No. German English Italian ABBREVIATIONS Order No. Number of pieces Position Marking in the spare parts lists Order number Spare part 7

8 2 CORRECT USE 2.1 DEVICE TYPE Automatic spray gun for automatic coating 2.2 TYPE OF USE The spray gun serves as stationary equipment for industrial electrostatic coating with flammable 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 areas (zone 22). (See Chapter 3.1 Explosion Protection Identification). 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 staff 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 standards 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. 8

9 2.5 PROCESSIBLE WORKING MATERIALS Types of powder which can be charged electrostatically Metallic powder 2.6 REASONABLY FORESEEABLE MISUSE The following is prohibited: coating work pieces which are not grounded, unauthorized conversions and modifications to the spray gun, processing liquid or similar coating products, and 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 material damage: use of damp powder paint, incorrectly set values for powder discharge, and incorrectly set electrostatic values. 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 Specific measures Lifecycle phase Skin contact with Handling powder Skin irritations, Wear protective Operation, powder lacquers and cleaning agents lacquers and cleaning agents Allergies clothing, Observe safety data sheets Maintenance, Disassembly Powder lacquer Lacquering outside Inhalation of Observe work and Operation, in air outside the the defined working substances operation instructions defined working area area hazardous to health Maintenance Falling down of spray guns Residual voltage on live parts Loosening of the securing nuts Injuries Regular check of fastenings Operation, Maintenance Deficient grounding Electrical shock Indication of danger, Operation, Instruction by trainer Maintenance 9

10 3 IDENTIFICATION 3.1 EXPLOSION PROTECTION IDENTIFICATION Gun type: Manufacturer: J. Wagner AG CH Altstätten 0102 II 2 D EEx 2mJ 85 C CE: European Communities 0102: Number of notified 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: Maximum ignition energy 2 mj 85 C: Maximum surface temperature 3.2 PERMISSIBLE DEVICE COMBINATIONS WARNING Incorrect use of the spray gun! Risk of injury and damage to the device. Only connect original Wagner devices to the HiCoat spray gun. The powder spray gun may only be connected to the control devices listed below: EPG-S2 EPG-Sprint X 10

11 3.3 SAFETY FEATURE IDENTIFICATION Plates bearing information for the user have been attached to the work openings of the powder coating booth. The plate size corresponds to the standard category Ø 100 mm; 3.94 inches. The label plates, which must be attached, are shown below: Explosive atmosphere! Forbidden for unauthorized persons! Close to the spray area a warning sign (included in the delivery of the system) has to be placed with the following indications: The equipment may only be operated by trained staff. Before starting cleaning the spray gun or carrying out any other work in the spray area, the high-voltage must be shut down in such a way that it cannot be activated again by actuating the trigger of the spray gun. Use only metallic tanks for cleaning fluids. Preferably use solvents with the highest possible flash point, higher than the ambient temperature if possible. The electrostatic spraying unit must be maintained regularly according to the manufacturer's instructions. Repairs may only be performed according to the manufacturer's instructions. 11

12 4 GENERAL SAFETY INSTRUCTIONS 4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention ELECTRICAL DEVICES AND EQUIPMENT 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. Must be operated in accordance with the safety regulations and electrotechnical regulations. Must be repaired immediately in the event of problems. Must be decommissioned if they pose a hazard. Must be de-energized before work is commenced on active parts. Secure the device against being switched back on without authorization. Inform staff about planned work. Observe electrical safety regulations STAFF QUALIFICATIONS Ensure that the device is operated, maintained and repaired only by trained persons SAFE WORK ENVIRONMENT The floor in the working area must be electrostatically conductive (measurements according to EN 1081 and EN ). The footwear worn by the operators must comply with the requirements of EN ISO The measured insulation resistance must not exceed 100 megohms. The protective clothing, including gloves, must comply with the requirements of EN ISO The measured insulation resistance must not exceed 100 megohms. The powder release must be electrically interlocked with the powder spray system's exhaust air equipment. Excess coating product (overspray) must be collected up safely. Ensure that there are no ignition sources such as naked flames, sparks, glowing wires, or hot surfaces in the vicinity. Do not smoke. Maintain sufficient quantities of suitable fire extinguishers and ensure that they are serviceable. The operating company must ensure that an average concentration of powder paint in the air does not exceed 50% of the lower explosion limit (LEL = max. permitted concentration of powder to air). If no reliable LEL value is available, the average concentration may not exceed 10 g/m³. 12

13 4.2 SAFETY INSTRUCTIONS FOR STAFF Always follow the information in this manual, particularly the general safety instructions and the warning instructions. Always follow local regulations concerning occupational safety and accident prevention. Under no circumstances may people with pacemakers enter the area where the highvoltage field between the spray gun and the work piece to be coated builds up! SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES Do not point spray guns at people. Before all work on the device, in the event of work interruptions and functional faults: - Switch off the energy/compressed air supply. - Secure the spray gun against actuation. - Relieve pressure on spray guns and device. - In case of functional faults: Identify and correct the problem, proceed as described in the "Fault Rectification" chapter GROUNDING THE DEVICE The electrostatic charge may, in certain cases, give rise to electrostatic charges on the device. This may result in the formation of sparks or flames when discharging. Ensure that the device is grounded before each coating process. Ground the work pieces to be coated. Ensure that all persons inside the working area are grounded, e.g. by wearing electrostatically conductive shoes. The functionality of grounding cables must be checked regularly (see EN 60204) ACCESSORIES AND SPARE PARTS Only use an original Wagner powder hose. 13

14 4.2.4 CLEANING AND MAINTENANCE Before starting cleaning or any other manual work, the high-voltage in the spray area must be shut down and locked to prevent it from being switched back on. Lock the compressed air supply and decompress the system. Secure the device against being switched back on without authorization. Use only electrically conducting and grounded tanks for cleaning fluids. Preference should be given to non-flammable cleaning fluids. Flammable cleaning liquids may only be used if, after switching off the high-voltage, all high-voltage conducting parts are discharged to a discharge energy of less than 0.24 mj before they can be accessed. Most flammable solvents have an ignition energy of around 0.24 mj or 60 nc. The cleaning agent's flash point must be at least 15 K above the ambient temperature. Only mobile industrial vacuum cleaners of design 1 (see EN ) may be used to remove dust deposits HANDLING POWDER LACQUERS When preparing or processing the powder and cleaning the device, take note of the processing regulations, laid down by the manufacturer of the powder lacquers, being used. Take note of the manufacturer s instructions and the relevant environmental protection regulations when disposing of powder lacquers. Take the prescribed safety measures, in particular the wearing of safety glasses and safety clothing as well as the use of protective hand cream. Use a mask or breathing apparatus if necessary. To ensure sufficient protection of health and the environment, only operate the device in a powder booth or on a spray wall with activated ventilation (exhaust air). 14

15 4.3 NOTE ON SAFE DISCHARGES Nozzle Electrode Luminous discharge Work piece P_01091 With the high-voltage switched on, a luminous or corona discharge occurs at the electrode tip; this can only be seen in the dark. This physical effect can be seen when the electrode is brought near the grounded work piece. This luminous discharge does not involve any ignition energy and has no effect on system handling. When the electrode approaches the work piece, the control unit automatically reduces the high-voltage to a safe value. If you touch plastic parts of the spray gun with your finger, harmless discharges may occur due to the high-voltage field around the spray gun (so-called brush discharges). However, these do not contain any ignition energy. 15

16 4.4 PROTECTIVE AND MONITORING EQUIPMENT WARNING Incorrect use! Risk of injury and damage to the device. Protective and monitoring equipment must not be removed, modified or rendered unusable. Regularly check for perfect functioning. If defects are detected on protective and monitoring equipment, the system must not be operated until these defects are remedied RELEASE GUNS (HIGH-VOLTAGE/PNEUMATIC SYSTEM) Enabling high-voltage depends on: Exhaust air is OK Fire extinguishing system/fire detection system is OK (external signal) No EMERGENCY STOP Control voltage ON As soon as one of these conditions is not fulfilled, the high-voltage is switched off immediately. After the fault has been eliminated and acknowledged, the enabling mechanism can be selected again. An automatic switch on is prevented by the hardware locking. 16

17 5 DESCRIPTION 5.1 SPRAY GUN DESIGN H X B A G X C F I K E L G A D P_02331 A B C D E F G H I K L Designation Fan spray nozzle or round spray nozzle Deflector cone for round spray nozzle Round spray nozzle electrode Union nut Interlocking Spray gun body Powder hose connection Supporting tube Electrical connection Atomizing air connection Grounding screw 5.2 FUNCTIONING OF THE SPRAY GUN The spray gun is switched on and off via the superordinated control unit. At the same time the air supply and high-voltage are activated. The distance of the installed spray guns to each other must be at least 300 mm; inches for functional reasons. The gun control cabinet must be switched off in order to lock the spray gun! If changing from the flat spray nozzle to the round spray nozzle with deflector cone, the depth control must be adjusted! 17

18 5.3 TECHNICAL DATA Dimensions: Length/width/height see Chapter Weight Electrical: Input voltage maximum 22 Vpp Input current maximum 0.9 A Frequency khz Output voltage maximum 100 kv DC Polarity negative Construction type in accordance with DIN EN types A-P Protection class IP 54 Pneumatic: Input air pressure (atomizing air volume) Powder output quantity maximum 3 bar; 0.3 MPa, psi maximum 450 g/min; maximum 0.99 lbs/min Ambient conditions: Operating temperature range 5-45 C; F Relative humidity < 75 % WARNING Outgoing air containing oil! Risk of poisoning if inhaled. Provide compressed air free from oil and water (Quality Standard according to ISO ) = 5 μm / +7 C; 44.6 F / 0.1 mg/m³. Ambient conditions: If low-melting powders are used, the ambient temperature may have to be lower than 30 C; 86 F. Volume measures: for volumes specified in Nm³ (standard cubic meters). One cubic meter of a gas at 0 C and bar is called norm cubic meter. 18

19 5.3.1 DIMENSIONS X A* X B C E P_02332 D Measurement mm inch A* B C 1, D E Measurement for installation dimension C calculation when utilizing a round spray nozzle with deflector cone 19

20 5.4 PERMITTED ACCESSORIES Only the accessories listed in this operating manual may be connected to the powder spray gun. The accessories listed in Chapter 12 were included in the EC type examination and are approved for use with the gun. 5.5 SCOPE OF DELIVERY Quantity Order No. Designation automatic gun Nozzle set The standard equipment includes: Conformity certificate Operating manual, German 1 see Chapter 1.3 Operating manual in local language 20

21 6 ASSEMBLY AND COMMISSIONING 6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF WARNING Incorrect installation/operation! Risk of injury and damage to the device. The commissioning staff must have the technical skills to safely undertake commissioning. The commissioning staff must be familiar with the provisions of European standard DIN EN When commissioning and for all work, read and follow the operating manual and safety regulations for the additionally required system components. 6.2 STORAGE CONDITIONS Until the point of assembly, the powder spray gun must be stored in a dry location, free from vibrations and with a minimum of dust. The powder spray gun must be stored in closed rooms. The air temperature at the storage location must be between -20 C and +60 C; -4 F and +140 F. The relative air humidity at the storage location must be between 10 and 95% (without condensation). 6.3 INSTALLATION CONDITIONS The air temperature at the installation site must be between 0 C and +35 C; 32 F and 95 F. Depending on the powder lacquer used, the maximum permissible ambient temperature for reliable operation can be significantly below +40 C; 104 F. The relative air humidity at the installation site must be between 10 and 95% (without condensation). 21

22 6.4 PREPARING THE SPRAY GUN SELECTION OF THE SUITABLE NOZZLE SYSTEM The process of changing from the fan spray nozzle to a round spray nozzle with a deflector cone is described in Chapter 8.5 "Fitting a Round Spray Nozzle". You will find the article numbers of the different nozzles in Chapter 12 "Accessories". Nozzle Application overview Powder cloud Flat jet nozzle Difficult work pieces Undercuts Profiles Flat work pieces (reduced Widely spread flat powder cloud P_00694 picture frame) Deflector cone P_00935 Wire goods Grid designs Oval powder cloud: Size of the powder cloud is dependent on the deflector plate diameter Nozzle Application Distance to Powder work piece discharge (mm) (g/min) F1¹ Universal application (slow powder cloud) deep and complex part geometries P_00694 extensive work pieces F2¹ Targeted application (dense powder cloud) high penetration Wide coating range P_00694 F3¹ for small total air volume and small jet width (fastest powder cloud) high penetration capability for profile parts P_00694 high stability F4¹ Wide flat spray nozzle for high powder application (slow powder cloud) good atomization specially for extensive work P_00694 pieces > 200 (Total air > 4.5 Nm³/h)

23 Nozzle Application Distance to work piece (mm) HPO-1¹ Wide flat spray nozzle for high powder application (slow powder cloud) > 200 P_00694 good atomization specially for extensive work pieces (Total air > 4.5 Nm³/h) Powder discharge (g/min) ) Nozzles are labeled on the back. F1 P_01107 Deflector cone Application Distance to work piece Powder discharge (mm) (g/min) R20 20 mm Smaller flat parts P_00935 R28 P_ mm Medium sized flat parts Lateral application with Z-axis

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25 6.5 HANDLING OF THE HOSE COUPLING Loosening the hose coupling: 1. Lift the O-ring 1 out of the groove and slide it towards spray gun. 2. Turning the locking nut 2 in a clockwise direction up to the stop and pull the hose coupling 3 out of the coupling piece 4. Connecting the hose coupling: 3. Insert the hose coupling 3 into the coupling piece 4 and turning the locking nut 2 counterclockwise up to the stop. 4. Press the O-ring 1 into the groove again (securing function). Note: Slide the powder hose as much as possible up to the stop onto the hose coupling! P_

26 6.6 ASSEMBLING THE SPRAY GUN WARNING Unintentional putting into operation! Risk of injury. Before any work on the device, in the event of work interruptions and malfunctions: Switch off the energy/compressed air supply. Relieve spray gun and device pressure. Secure the spray gun against actuation. In the event of malfunctions, remedy the fault as described in the "Troubleshooting" chapter X I K X 6 4 L P_02333 G 26

27 Procedure: 1. Switch off the high-voltage generation on the control unit. 2. Press locking button 1 and move supporting tube 2 away backwards. 3. Connect electrical cable 3 to connection I on the spray gun and to the control unit. 4. Connect the powder feed hose 4 to connection G on the spray gun and to the powder injector. The handling of the hose coupling is described in Chapter Connect the atomizing air hose 5 to connection K on the spray gun and to the control unit. 6. Connect the grounding cable 6 to grounding screw L on the spray gun and to the signal ground. 7. Press locking button 1 and supporting tube 2 forwards on the spray gun housing up to stop. The locking button 1 must snap into place in the drilled hole in supporting tube Fasten gun on the gun carrier with a suitable device. Note: For connecting and fastening the spray gun use the parts listed in the "Accessories" chapter. The distance of the installed spray guns to each other must be at least 300 mm; inches for functional reasons! 27

28 6.7 GROUNDING WARNING Heavy paint mist if grounding is insufficient! Danger of poisoning. Insufficient paint application quality. Ground all device components. Ground the work pieces to be coated. For safety reasons, the spray gun and the work piece must be properly grounded. For the spray gun, this is done via the grounding connection. Perfect grounding of the work piece is also necessary to achieve an optimum powder coating. A poorly grounded work piece causes: dangerous electric charging of the work piece, very poor wrap-around, uneven coating, and back spraying to the spray gun, i.e. contamination. Prerequisites for perfect grounding and coating are: clean suspension of the work piece to be coated, grounding of spraying booth, conveyor system and suspension on the part of the building site in accordance with the operating manual or the manufacturer's information, and grounding of all conductive parts of the system. The resistance to ground of every work piece's locating point must not exceed 1 MΩ (megohm) (measurement voltage must be 500 or 1000 V). Sparks between conveyor, conveyor hooks (hangers) and work piece can occur if electric contact points between conveyor, conveyor hooks (hangers) and work piece are not sufficiently cleaned and therefore the work pieces are not sufficiently grounded! These sparks can cause heavy radio frequency interference (EMC). 28

29 6.7.1 GROUNDING THE POWDER COATING SYSTEM P_ Only use mains cables with grounding strand! 2 Connect grounding cable with signal ground! 3 Remove all paint from hooks and other hanger parts! 4 Do not wear non-conducting gloves! 5 Wear electrostatically conductive shoes! 6 The floor must be electrostatically conductive! 29

30 7 OPERATION 7.1 TRAINING THE OPERATING STAFF WARNING Incorrect operation! Risk of injury and damage to the device. The operating staff must be qualified to operate the entire system. Before work commences, the operating staff must receive appropriate system training. The operating staff must be familiar with the provisions of European standard DIN EN SAFETY INSTRUCTIONS WARNING Incorrect operation! Risk of injury and damage to the device. If contact with powder products or cleaning agents causes skin irritation, appropriate precautionary measures must be taken, e.g. wearing protective clothing. The footwear worn by operating staff must comply with EN ISO The measured insulation resistance must not exceed 100 megohms. The protective clothing, including gloves, must comply with EN ISO The measured insulation resistance must not exceed 100 megohms. 30

31 7.3 SWITCHING ON THE SPRAY GUN The spray gun is switched on via the superordinated control unit of the system. At the same time, the high-voltage and the powder feed are activated. 7.4 SWITCHING OFF THE SPRAY GUN The gun is switched off differently depending on the type of powder injector. In most cases, this process is performed by the coating system controller. Note: On each interruption of work, the spray gun should be blown through (flushed) and powder residue removed. In this way powder deposits and a surge, the next time the spray gun is switched on, can be largely avoided. If a manual switch-off is required and provided that the powder injector is not suitable for the automatic flushing mode, please proceed as follows: Procedure: 1. The atomizing air has to remain open to prevent powder from penetrating into the atomizing air channel and the cascade compartment during the flushing process. Switch off the powder feed and the high-voltage generation. 2. If you do not want to modify the settings of the feed and dosage air to continue coating with the same powder cloud, remove the powder injector from the injector connection of the powder container. When switching on again no more powder will be delivered. 3. Switch the powder feed on again to blow out any powder remaining in the spray gun. 4. The powder feed can now be switched off. 7.5 SWITCHING OFF THE SPRAY GUN IN THE EVENT OF FAULTS OR EMERGENCIES In the event of faults or emergencies the gun, together with the system, can be switched off by means of the emergency stop equipment. At the same time the high-voltage and the powder feed are switched off. 31

32 7.6 OPTIMIZING THE POWDER CLOUD FOR YOUR COATING Procedure: 1. Switch on the high-voltage generation and the powder feed. Note: To minimize the wear on the wearing parts, the total feed air and dosing air should be under 5 Nm³/h! The atomizing air should be adjusted for the: fan spray nozzle to 0.1 Nm³/h, round spray nozzle with deflector cone to 0.2 Nm³/h. 2. Adjust the powder quantity and the powder speed on a test piece. 32

33 7.7 PERFORMING A PAINT CHANGE WARNING Dust formation! Danger of poisoning. Danger due to escaping dust, contamination of the device and device components. Before starting cleaning or other manual work, the high-voltage must be shut down and locked to prevent it from being switched back on! During every paint change, the booth suction system and the filter cleaning system must remain activated! In the case of a paint change, powder residues must be thoroughly removed from all powder-conveying parts. In the following, only the procedure for the powder spray gun is described. Note: During a paint change, the nozzle system does not necessarily have to disassembled. Paint carry-over! NOTICE If the union nut is not screwed on tightly up to the stop position, the paint may smear. Procedure: 1. Switch off the powder coating system after an automatic flushing and secure it against being switched back on. 2. In case no automatic flushing is used, flush the gun manually and remove any powder residues from it before switching off the system: - Disconnect the powder hose from the spray gun. - Blow through the spray gun using the air gun and thus remove any powder residues. - Switch off the system and secure against unauthorized reactivation. 3. Before starting to connect the powder hose again, all parts carrying powder must be thoroughly cleaned. 4. The spray gun is ready for use again. 33

34 7.7.1 IMPULSE FLUSHING WARNING Powder supply hose coupling may be hurled around! Risk of injury and damage to the device. Check whether the hose is correctly attached to the hose coupling. Completely lock the hose coupling and secure it with an O-ring. If the gun is supplied with coating powder from a powder center, you can initiate an impulse flushing from there. Further details are contained in the powder center's operating manual. Note: During a paint change, the nozzle system does not necessarily have to disassembled. 34

35 7.8 REPRODUCIBLE SETTING OF THE NOZZLE POSITION X X P_01095 For a horizontal powder cloud, the flat spray nozzle is set where the protective wedge is in the 0 position. When attaching a round spray nozzle, we recommend turning the protective wedge to the 90 position to achieve smoother coating (the protective wedge is now in the vertical position). It is possible to change this position as needed for special applications. On the nozzle body and electrode holders there are X markings. The position can be changed as required in 15 increments and later reproduced. The union nut has to be removed for exact positioning. An adjustment tool is provided for the flat spray nozzle. It permits turning the flat spray nozzle without damaging the electrodes and without removing the union nut. The union nut only has to be slackened. P_

36 8 CLEANING AND MAINTENANCE 8.1 CLEANING CLEANING STAFF Cleaning work should be undertaken regularly and carefully by qualified and trained staff. The staff must be familiar with the DIN EN provisions. They should be informed of specific hazards during their training. The following hazards may arise during cleaning work: Health hazard from cleaning agents Health hazard from inhaling powder lacquer Use of unsuitable cleaning tools and aids SAFETY INSTRUCTIONS DANGER Explosive powder/air mixes! Danger to life and damage to the device. Before starting cleaning or other manual work, the high-voltage must be shut down and locked to prevent it from being switched back on! Use only electrically conductive tanks for cleaning liquids! Ground the tank! Preference should be given to non-flammable cleaning fluids. Flammable cleaning liquids may only be used if, after switching off the high-voltage, all high-voltage conducting parts are discharged to a discharge energy of less than 0.24 mj before they can be accessed. Most flammable solvents have an ignition energy of around 0.24 mj or 60 nc. The cleaning agent's flash point must be at least 15 K above the ambient temperature. Only mobile industrial vacuum cleaners of design 1 (see EN ) may be used to remove dust deposits. 36

37 WARNING Incorrect maintenance! Risk of injury and damage to the device. If contact with powder products or cleaning agents causes skin irritation, appropriate precautionary measures must be taken, e.g. wearing protective clothing. The footwear worn by operating staff must comply with EN ISO The measured insulation resistance must not exceed 100 megohms. The protective clothing, including gloves, must comply with EN ISO The measured insulation resistance must not exceed 100 megohms CLEANING PROCEDURES The cleaning intervals should be adapted by the operator depending on the level of use and if necessary the level of soiling. If in doubt, we recommend contacting J. Wagner AG's specialist personnel. The valid health and safety specifications and the safety instructions provided in Chapter 4 must be adhered to for all cleaning work. 37

38 8.2 MAINTENANCE MAINTENANCE STAFF Maintenance work should be undertaken regularly and carefully by qualified and trained staff. They should be informed of specific hazards during their training. The following hazards may arise during maintenance work: Health hazard from inhaling powder lacquer Use of unsuitable tools and aids Once the maintenance work is complete, the device must be checked by a qualified person to ensure a reliable condition SAFETY INSTRUCTIONS DANGER Incorrect maintenance/repair! Danger to life and damage to the device. Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel. DANGER Incorrect maintenance/repair! Risk of injury and damage to the device. Have repairs and part replacements carried out only by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply. - Relieve spray gun and device pressure. - Secure the spray gun against actuation. Observe the operating and service manuals at all times when carrying out work. 38

39 WARNING Incorrect maintenance! Risk of injury and damage to the device. If contact with powder products or cleaning agents causes skin irritation, appropriate precautionary measures must be taken, e.g. wearing protective clothing. The footwear worn by operating staff must comply with EN ISO The measured insulation resistance must not exceed 100 MΩ. The protective clothing, including gloves, must comply with EN ISO The measured insulation resistance must not exceed 100 MΩ MAINTENANCE PROCEDURES The maintenance intervals should be adapted by the operator depending on the level of use and if necessary the level of soiling. If in doubt, we recommend contacting J. Wagner AG's specialist personnel. The valid health and safety specifications and safety instructions provided in Chapter 4 must be adhered to for all maintenance work. 39

40 8.2.4 REPLACING THE SPRAY GUN WARNING Unintentional putting into operation! Risk of injury. Before any work on the device, in the event of work interruptions and malfunctions: Switch off the energy/compressed air supply. Relieve spray gun and device pressure. Secure the spray gun against actuation. In the event of malfunctions, remedy the fault as described in the "Troubleshooting" chapter X I K X 6 4 L P_02333 G 40

41 Before replacing the spray gun, any powder residue must be thoroughly removed. The wearing parts in the spray gun, marked in the spare parts list with " checked and, if necessary replaced. ", must be regularly Procedure: 1. Switch off the high-voltage generation on the control unit, close the compressed air supply and relieve the system of pressure. 2. Press locking button 1 and carefully remove the gun from supporting tube Disconnect electrical cable 3 from connection I on the spray gun. 4. Disconnect the powder feed hose 4 from connection G on the spray gun. The handling of the hose coupling is described in Chapter Disconnect the atomizing air hose 5 from connection K on the spray gun. 6. Detach the grounding cable 6 from grounding screw L on the spray gun. 7. Connect electrical cable 3 to connection I on the new spray gun. 8. Connect the powder feed hose 4 to connection G on the spray gun. 9. Connect the atomizing air hose 5 to connection K on the spray gun. 10. Connect the grounding cable 6 from grounding screw L to the spray gun. 11. Carefully insert the spray gun into supporting tube 2 until the locking button 1 locks into place in the drilled hole in supporting tube Switch on the high-voltage and open the compressed air supply. 13. The spray gun is ready for use again. 41

42 8.3 CLEANING THE GUN AND DISMANTLING THE FLAT SPRAY NOZZLE Procedure: Unscrew union nut 1 from gun housing Pull flat spray nozzle 2 off electrode holder Carefully remove electrode holder 3 from gun housing 5. 1 P_ Note: Do not damage the electrode holder, when pulling it out and inserting it. 4. Remove powder residues from the parts removed and from the spray gun. Note: Never place the spray gun or parts of the spray gun in cleaning agent. As a rule the protective wedge needs to be checked for wear and replaced if necessary. New protective wedge P_00592 Worn protective wedge It is recommended to replace the protective wedge. P_00593 In the next section it is described how the protective wedge is to be dismantled and inserted. 42

43 8.4 REPLACING THE PROTECTIVE WEDGE Note: A wedge tool is available to prevent the protective wedge from being damaged when dismantling and inserting. You will find the necessary wearing parts and spare parts in Chapter 13 "Spare Parts" of this operating manual Wedge tool 2 Protective wedge (when positioned) 3 Electrode holder (shown with a cutaway view to improve comprehension) P_ Procedure: 1. Guide wedge tool 1 into electrode holder 3 up to stop. P_ Pull the protective wedge 2 out of the electrode holder 3 using the wedge tool Press the protective wedge 2 sideways out of wedge tool 1 manually (without tool). 2 P_

44 Note: The same wedge tool is used to insert the protective wedge Wedge tool 2 Protective wedge (when positioned) 3 Electrode holder (shown with a cutaway view to improve comprehension) P_00597 Procedure: Y 1. Guide protective wedge 2 into wedge tool Insert both parts into opening on electrode holder up to stop. X Y X P_ If it is not possible to push the wedge tool in as far as the X mark, rotate the wedge tool a little until it can be pushed up to the mark. The mark X must be flush with the Y end of the electrode holder. 4. The protective wedge is now correctly assembled and the wedge tool can be pulled out of the electrode holder. The protective wedge remains inserted in the electrode holder. P_

45 1 2 3 P_ After long periods of operation or having replaced the protective wedge repeatedly, it is also recommended to check the powder tube for wear and replace if necessary. You will find the necessary wearing parts and spare parts in Chapter 13 "Spare Parts" of this operating manual. 6. Prior to re-fitting, check whether the contact points on electrode holder 3 and in gun housing 5 have been thoroughly cleaned so that the electrode tip is electrically connected to the high-voltage generator. 7. Carefully fit electrode holder 3 in spray gun housing Slide the fan spray nozzle 2 back over electrode holder 3 and fasten in place using union nut FITTING THE ROUND SPRAY NOZZLE The standard Corona spray gun is delivered with a flat spray nozzle. The nozzle can be changed easily, as described below. Note: If changing from the flat spray nozzle to the round spray nozzle with deflector cone, the depth control must be adjusted. The C4 R electrode holder is necessary to perform the change. Procedure: Unscrew union nut 1 from gun housing Pull flat spray nozzle 2 off electrode holder Carefully remove electrode holder 3 from gun housing 5. P_ Note: Do not damage the electrode holder, when pulling it out and inserting it. 4. Remove powder residues from the parts removed and from the spray gun. 45

46 CAUTION Electrode tip! Risk of injury. Take care when fitting the C4 R electrode holder X 5. Carefully fit the new C4 R electrode holder 6 into spray gun housing Slide deflector cone sleeve 7 onto electrode holder Align the X and Y marks. 8. Fasten union nut Slide deflector cone 8 over deflector cone sleeve The spray gun is ready for use again. Y P_

47 8.6 ASSEMBLING THE ANGLE ADAPTER REMOVING THE NOZZLE AND ELECTRODE HOLDER The standard Corona spray gun is delivered with a flat spray nozzle. The nozzle can be changed easily, as described below. Note: If changing from the flat spray nozzle to the round spray nozzle with deflector cone, the depth control must be adjusted. A WA90 C4, WA 60 C4 or WA30 C4 angle adapter is necessary to perform the change, as listed in Chapter 12 "Accessories". Note: A flat spray nozzle as well as a round spray nozzle can be fitted to the angle adapter. Procedure: Unscrew union nut 1 from gun housing Pull flat spray nozzle 2 off electrode holder Carefully remove electrode holder 3 from gun housing 5. P_ Note: Do not damage the electrode holder, when pulling it out and inserting it. 4. Remove powder residues from the parts removed and from the spray gun. 47

48 8.6.2 FITTING THE ANGLE ADAPTER Procedure: Install electrode holder 1 together with nozzle 2 in nozzle insert 3 and tighten union nut Push angle adapter 5 onto the gun body and gently screw threaded sleeve Swivel angle adapter 5 into the desired position and then tighten threaded sleeve 6 well. 6 5 P_ REPLACEMENT OF THE WEARING PARTS Procedure: 1. Loosen threaded sleeve 1 and separate angle adapter 2 from gun body Loosen union nut Pull out electrode holder 5, together with nozzle 6, from nozzle insert 7. 3 P_ Note: Do not damage the electrode holder, when pulling it out and inserting it. 48

49 B2 A A2 B1 11 Z 10 Y1 Y2 P_01618 X 8, 9 4. Unscrew threaded sleeve 8 and locking sleeve 9 with mounting tool Pull connecting element 11 out of elbow fitting Insert screwdriver into recess X and turn it until the nozzle insert 7 loosens. 7. Pull out nozzle insert Replace the wearing parts with new components. 9. Clean all components thoroughly and remove any powder residues. 10. Install nozzle insert 7, as shown in magnified figures Y1 and Y2, in such a way that the pin B1 is guided into the hole A Install connecting element 11 within the angle piece 12, as shown in the magnified figure Z, in such a way that the pin B2 is guided into the hole A Screw threaded sleeve 8 and locking sleeve 9 with mounting tool 10 and tighten them well. Ensure that it is still possible to turn threaded sleeve 8 easily. 13. Install electrode holder 5 together with nozzle 6 in the nozzle insert Put on union nut 4 and tighten it well. 15. Mount the angle adapter to the gun again. 49

50 8.7 ASSEMBLING THE CORONA-STAR The Corona-Star is a retrofit set for the spray gun, which helps to achieve a better surface quality (reduction of "orange peel"). WARNING Danger from electric current! Risk of injury and damage to the device. Only trained personnel may modify the Corona-Star. Prior to assembling the Corona-Star, the high-voltage and the powder feed must be switched off and secured against being inadvertently switched on P_02337 A C B G D E F H Procedure: 1. Switch off the high-voltage and the powder feed and secure them against being inadvertently switched on. 2. Unscrew the standard nut A from the spray gun housing B. 3. Screw the new nut C for the Corona-Star D onto the spray gun housing and tighten well. 4. Dismount the Corona-Star H from spray gun housing B. 5. Fasten the cable guide onto the cover plate F using screw E. 6. Slide the Corona-Star G onto the spray gun housing B. Note: Check whether the grounding is assured. 7. The spray gun is ready for use again. 50

51 8.8 CORONA-STAR FOR ANGLE ADAPTER ASSEMBLING THE CORONA-STAR WARNING Danger from electric current! Risk of injury and damage to the device. Only trained personnel may modify the Corona-Star. Prior to assembling the Corona-Star, the high-voltage and the powder feed must be switched off and secured against being inadvertently switched on. 1 Procedure: 1. Switch off the high-voltage and the powder feed and secure them against being inadvertently switched on. 2. Detach the Corona-Star 1 from spray gun housing. 3. Fit Corona Star for angle adapter 2 on angle adapter (direction of fitting shown is only an example) Fasten the connection cable 3 on the spray gun housing. Note: Check whether the grounding is assured. 5. The spray gun is ready for use again. Note: When converting the gun in the normal version, fit again without a Mini Corona-Star 1 angle adapter. P_

52 9 INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: If the system is used for electrostatic coating with flammable coating powders, testing should be undertaken in accordance with DIN EN 50177: as per Table 3 and Table 4. The inspection types and intervals are described in the following chapters. 52

53 9.1 OVERVIEW OF INSPECTIONS Section Type of inspection Requirements Inspection by 1 Effectiveness of technical ventilation check 2 Interlock between technical ventilation and high-voltage, compressed air and coating product supply Effectiveness of technical ventilation check The technical ventilation should be interlocked such that the highvoltage cannot be switched on while the technical ventilation is not working effectively. Type of inspection Inspection interval TP/SP ME e.g. measurements of air flow speed / air quantities, checking of the differential pressure indicator according to the cabin manufacturer's instructions SP FI Test whether the system is safely stopped and the product supply, supply air and high-voltage are switched off when the ventilation is shut down. continuously according to the booth manufacturer's instructions annually 3 Protection against ignition of flammable cleaning agents If flammable cleaning fluids are used, all parts carrying highvoltage must be discharged to a discharge energy of less than 0.24 mj, once the high-voltage has been switched off, before they can be reached. SP ME/FI Function test of the residual energy monitoring equipment according to the manufacturer's instructions. according to the manufacturer's instructions Legend: MA = Manufacturer EM = Employer SP = Skilled person FSE = Fire safety engineer ELC = Electrician TP = Trained person FI = Function inspection ME = Measurement SI = Standard inspection VI = Visual inspection CI = Continuous inspection TI = Technical inspection 53

54 Section Type of inspection Requirements Inspection by Type of inspection Inspection interval 4 Effectiveness of grounding measures 5 Resistance to ground of work piece's locating point All the system's conductive elements, such as floors, walls, ceilings, protective grating, transport equipment, work pieces, powder tanks, machines or construction parts etc. in the spray area, with the exception of parts which carry high-voltage during operation, must be connected to the grounding system. The resistance of the floor may not exceed 108 Ohm. The resistance to ground of every work piece's locating point must not exceed 1 megohm (measurement voltage must be 500 or 1000 V). The design of the work piece receiver must ensure that the adapters remain grounded during coating. 6 Further inspections Depending on the design and functions of the booth, further inspections may be necessary (see EN 12981). Legend: MA = Manufacturer EM = Employer SP = Skilled person FSE = Fire safety engineer ELC = Electrician TP = Trained person FI = Function inspection ME = Measurement SI = Standard inspection VI = Visual inspection CI = Continuous inspection TI = Technical inspection SP VI/ME/CI Visual check of ground connections, perform function test on grounding switch, measurement of grounding resistors. SP ME/CI Measure resistance to ground (work piece receiver - ground potential) max V. according to the booth manufacturer's instructions according to the cabin manufacturer's instructions weekly weekly according to the cabin manufacturer's instructions 54

55 55

56 10 DISASSEMBLY AND DISPOSAL 10.1 DISASSEMBLY WARNING Incorrect disassembly! Risk of injury and damage to the device. Before starting disassembly: - Switch off the energy/compressed air supply. - Ensure that all system components are grounded. - Secure system against being switched back on without authorization. Observe the operating manuals for any work X I K X 6 4 L P_02333 G 56

57 Procedure: 1. Switch off the high-voltage generation on the control unit, close the compressed air supply and relieve the system of pressure. 2. Press locking button 1 and carefully remove the gun from supporting tube Disconnect electrical cable 3 from connection I on the spray gun. 4. Disconnect the powder feed hose 4 from connection G on the spray gun. (For handling of the hose coupling, see Chapter 6.5.) 5. Disconnect the atomizing air hose 5 from connection K on the spray gun. 6. Detach the grounding cable 6 from grounding screw L on the spray gun. 7. Dismount supporting tube 2 on the gun attachment DISPOSAL NOTICE Do not dispose of used electrical equipment with household refuse! In accordance with European Directive 2002/96/EC on the disposal of used electrical equipment and its implementation in national law, this product may not be disposed of with the household refuse, but must be recycled in an environmentally correct manner. Wagner or one of our dealers will take back your used Wagner waste electrical or electronic equipment and will dispose of it for you in an environmentally friendly way. Please contact one of our service points, one of our representatives or us directly to arrange this. 57

58 11 TROUBLESHOOTING AND RECTIFICATION DANGER Incorrect maintenance/repair! Risk of injury and damage to the device. Have repairs and part replacements carried out only by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Switch off the energy/compressed air supply. - Ensure that all system components are grounded. - Secure the device against being switched back on without authorization. Observe the operating and service manuals at all times when carrying out work. DANGER Incorrect maintenance/repair! Danger to life and damage to the device. Wagner devices, protective systems and safety, monitoring and control equipment may only be maintained/repaired as defined in Directive 94/9/EC (ATEX) by trained Wagner service personnel or capable persons in accordance with TRBS 1203! Note national regulations! Repair or replacement of devices or parts of devices may only be performed outside the hazard area! 58

59 Fault Cause Remedy No electrostatics (e.g. no wrap Fault in the high-voltage Contact a Wagner service center around or powder adhesion) generator Electrical cable from spray gun Replace the electric cable to control unit faulty Cascade in spray gun faulty Contact a Wagner service center Poor wrap-around Insufficient or no grounding See Chapter 6.7 "Grounding" Back-spray Powder outlet uneven or inadequate Contamination Blow through parts carrying powder Powder sintering Clean parts carrying powder Feed device contaminated See operating manuals for the related devices connected Feed air / dosing air ratio incorrect Adjust at control module resp. control unit Wear on powder injector nozzle Replace worn parts on powder injector ¹) Spray pattern is uneven Parts of nozzle system worn Replace worn parts 1.) You will find the wearing and spare parts in the powder injector operating manual. 59

60 12 ACCESSORIES 12.1 FLAT SPRAY NOZZLES Order No. Designation Flat spray nozzle F1 P_ Flat spray nozzle F2 P_ Fan spray nozzle F3 P_ Flat spray nozzle F4 P_ Wide flat spray nozzle HPO-1 P_ DEFLECTOR CONE FOR ROUND SPRAY NOZZLE Order No. Designation Deflector cone 20 mm P_ Deflector cone 28 mm P_

61 12.3 CORONA-STAR RETROFIT SET P_01104 Order No. Designation Corona-Star, complete Corona-Star electrode Union nut Wearing parts 12.4 CORONA-STAR WA C4 P_01168 Pos K Order No. Designation Corona-Star WA C4 61

62 12.5 WEDGE TOOL P_00714 Order No. Designation Wedge tool including 20 protective wedges Only available as a set 12.6 ELECTRIC CABLES AND HOSES Order No. Designation Application Electrical cable 5 m for connecting the spray gun to the Electrical cable 10 m high-voltage generator Electrical cable 20 m Powder hose 11 mm for powder feed Powder hose 12 mm Hose 6x1 Atomizing air connection 62

63 12.7 ANGLE ADAPTER P_01626 Order No. Designation Angle adapter WA30 C Angle adapter WA60 C Angle adapter WA 90 C4 P_01621 Order No. Designation Mounting tool WA C4 63

64 12.8 POWDER MEASURING BAG DANGER Risk of explosion due to electrostatic charging! Danger to life and damage to the device. Only use powder measuring bag when high-voltage is switched off! For measuring powder quantities for the C4 gun generation Order No. Designation Powder measuring bag, complete P_01105 P_01106 The powder measuring bag is slid onto the nozzle. 64