WAGNER PEA-C4-HiCoat Translation Of The Original Operating Manual
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WAGNER PEA-C4-HiCoat Translation Of The Original Operating Manual

Automatic powder gun
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Version 05/2019
PEA-C4-HiCoat
Automatic Powder Gun
P_01610
II 2D 2mJ
0102

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Summary of Contents for WAGNER PEA-C4-HiCoat

  • Page 1 Version 05/2019 PEA-C4-HiCoat Automatic Powder Gun P_01610 II 2D 2mJ 0102...

  • Page 3: Table Of Contents

    4.1.2 A Safe Work Environment 4.1.3 Personnel Qualifications Safety Instructions for the Personnel 4.2.1 Personal Safety Equipment 4.2.2 Safe Handling of WAGNER Powder Spray Devices 4.2.3 Grounding the Device 4.2.4 Product Hoses 4.2.5 Electrical Connection Cables 4.2.6 Cleaning and Flushing 4.2.7...
  • Page 4 PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 Grounding 6.6.1 Grounding the Powder Coating System Safety Checks OPERATION Training the Operating Personnel Tasks Switching On the Automatic Gun Switching Off the Automatic Gun 7.4.1 Switching Off in Normal Operation 7.4.2 Switching Off the Automatic Gun in the Event of Faults or Emergencies 7.4.3...
  • Page 5 12.14.1 Powder Measuring Adapter for Flat Jet Nozzle C4 12.14.2 Powder Measuring Adapter for Flat Jet Nozzle C4-F5/X1-F5 SPARE PARTS 13.1 How Can Spare Parts Be Ordered? 13.2 PEA-C4-HiCoat Corona Automatic Gun 13.3 Electrode Holder C4 R with Nozzles 13.4 Angle Adapter, WA90 C4 13.5 Angle Adapter, WA60 C4 13.6...

  • Page 6: About These Instructions

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 ABOUT THESE INSTRUCTIONS 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.

  • Page 7: Languages

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 LANGUAGES The operating manual is available in the following languages: Original operating manual Language Order no. German 390822 Translation of the original operating manual Language Order no. Language Order no. English 390829 Portuguese 2315719...

  • Page 8: Terminology For The Purpose Of This Manual

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL Cleaning Cleaning Manual cleaning of devices and device parts with cleaning agent Flushing Internal flushing of paint-wetted parts with compressed air Personnel qualifications 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.

  • Page 9: Correct Use

    PROCESSIBLE WORKING MATERIALS – types of powder that can be charged electrostatically; – metallic powder. Note: Contact your local WAGNER dealer and the lacquer manufacturer if you encounter application problems. MISUSE Misuse can lead to physical injury and/or property damage! Special attention must be paid that: liquid coating products, e.g., solvents or water-based lacquers are not processed;...

  • Page 10: Identification

    PERMISSIBLE DEVICE COMBINATIONS WARNING Incorrect use! Risk of injury and damage to the device. Only connect the automatic powder gun to original WAGNER devices. The automatic PEA-C4 HiCoat powder gun may only be used with the following control units: Guns Control units –...

  • Page 11: Basic Safety Instructions

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 BASIC SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual at hand near the device at all times. Always follow local regulations concerning accident prevention regulations. 4.1.1 ELECTRICAL DEVICES AND EQUIPMENT Danger of electric shock! Danger to life from electric shock.

  • Page 12: A Safe Work Environment

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 4.1.2 A SAFE WORK ENVIRONMENT Danger due to dust formation! Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with the skin or eyes. The floor in the working area must be electrostatically conductive (measurements according to EN 1081 and EN 61340-4-1).

  • Page 13: Safety Instructions For The Personnel

    For sufficient health and environmental safety: Operate the device in a powder coating booth or on a spraying wall with the ventilation (extraction) switched on. 4.2.2 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES Danger due to dust formation! Do not point spray guns at people.

  • Page 14: Grounding The Device

    Danger due to damaged product hoses! The product hose may cause dangerous injuries. Use only an original WAGNER powder hose. Make sure that the hoses are laid only in suitable places. Hoses should not be laid in the following places under any circumstances: –...

  • Page 15: Electrical Connection Cables

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 4.2.5 ELECTRICAL CONNECTION CABLES Risk caused by improperly laid cables! Risk of injury and damage to the device. Properly lay connection cables and check them regularly. Immediately replace damaged connection cables. Ensure that no work is ever performed with a damaged connection cable.

  • Page 16: Maintenance And Repair

    4.2.7 MAINTENANCE AND REPAIR Danger due to improper maintenance and repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Use only WAGNER original spare parts and accessories.

  • Page 17: Information About Safe Discharges

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 INFORMATION ABOUT SAFE DISCHARGES P_03925 Designation 1 Nozzle 2 Electrode 3 Luminous discharge 4 Work piece 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.

  • Page 18: Description

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 DESCRIPTION CONSTRUCTION OF THE AUTOMATIC GUN P_03904 Designation 1 Electrode 2 Deflector cone 3 Union nut 4 Type plate 5 Powder hose connection 6 Spray gun body 7 Flat jet nozzle 8 Electrical connection...

  • Page 19: Scope Of Delivery

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 SCOPE OF DELIVERY Order no. Designation 390004 Automatic gun, PEA-C4 HiCoat Nozzle set The standard equipment includes: 390893 Declaration of Conformity 390822 Operating manual, in German see Chapter Operating manual in local language DATA 5.4.1 TECHNICAL DATA...

  • Page 20: Dimensions

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 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 1.013 bar is called norm cubic meter.

  • Page 21: Accessories

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 ACCESSORIES Only the accessories listed in Chapter of this operating manual may be connected to the automatic PEA-C4 HiCoat gun. The accessories listed in Chapter were included in the EC type examination and are...

  • Page 22: Assembly And Commissioning

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 ASSEMBLY AND COMMISSIONING TRAINING OF ASSEMBLY/COMMISSIONING PERSONNEL The assembly and commissioning personnel must have the technical skills to safely commission the device. When assembling, commissioning and carrying out all work, read and follow the operating manuals and safety regulations for the additionally required system components.
  • Page 23 PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 Application Distance to Powder Nozzle work piece discharge (mm) (g/min) Universal application (slow powder cloud) – Deep and complex part 120 … 300 50 … 250 geometries – Parts with large surfaces P_00694 Targeted application (dense powder cloud) –...

  • Page 24: Connecting The Automatic Gun

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 Application Distance to Powder Deflector cone work piece discharge (mm) (g/min) Ø 20 mm 100 … 300 30 … 250 – Smaller flat parts P_00935 Ø 28 mm – Medium sized flat parts 100 … 300 50 …...

  • Page 25: Grounding

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 Procedure: 1. Switch off the high-voltage generation on the control unit. 2. Mount the automatic gun on the mounting bracket and mount both parts, for example, on the reciprocator's gun support. Note: For connecting and fastening the spray gun, use the parts listed in Chapter 12.

  • Page 26: Grounding The Powder Coating System

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 6.6.1 GROUNDING THE POWDER COATING SYSTEM P_01614 1 Only use mains cables with grounding strand! 2 Connect the control unit's grounding cable with the signal ground! 3 Remove all paint from hooks and other hanger parts!

  • Page 27: Operation

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 OPERATION TRAINING THE OPERATING PERSONNEL The operating personnel must be qualified to operate the entire system. The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures.

  • Page 28: Pressure Relief/Work Interruption

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 7.4.3 PRESSURE RELIEF/WORK INTERRUPTION Carry out the work steps as described in the "Pressure relief" chapter: – if pressure relief is required, – if the coating work is interrupted or stopped, – before the device is cleaned on the outside, checked, or serviced, –...

  • Page 29: Cleaning And Maintenance

    8.1.2 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 WAGNER's specialist personnel. 8.1.3 PERFORMING A PAINT CHANGE WARNING Dust formation! Risk of poisoning if inhaled.

  • Page 30: Maintenance

    Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.
  • Page 31 PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 Maintenance work Time stamp once each shift weekly Blow out gun and check for sintering Check gun settings Check gun discharge pressure Blow out powder hoses Check grounding Check compressed air quality Check gun voltage...

  • Page 32: Replacing The Automatic Gun

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 REPLACING THE AUTOMATIC GUN Before replacing the automatic gun, any powder residue must be thoroughly removed. The wearing parts in the automatic gun, marked in the spare parts list with " ", must be regularly checked and replaced as necessary.

  • Page 33: Removing The Flat Jet Nozzle

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 REMOVING THE FLAT JET NOZZLE Procedure: 1. Unscrew union nut 1 from gun housing 4. 2. Pull flat jet nozzle 2 off electrode holder 3. 3. Carefully pull electrode holder 3 out of the gun housing 4.

  • Page 34: Replacing The Protective Wedge

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 REPLACING THE PROTECTIVE WEDGE 8.5.1 REMOVING 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 spare parts and wearing parts in Chapter of this operating manual.

  • Page 35: Installing The Protective Wedge

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 8.5.2 INSTALLING THE PROTECTIVE WEDGE Note: The same wedge tool is used to insert the protective wedge. 1 Protective wedge (when positioned) 2 Electrode holder (shown with a cut-away view to improve comprehension) 3 Wedge tool...

  • Page 36: Changing From Flat Jet Nozzle To Round Jet Nozzle

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 5. 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 spare parts and...

  • Page 37: Assembling The Angle Adapter

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 Procedure: 1. Unscrew union nut 1 from gun housing 4. 2. Pull flat jet nozzle 2 off electrode holder 3. 3. Carefully pull electrode holder 3 out of the gun housing 4. Note: Do not damage the electrode holder 3, when pulling it out and inserting it.

  • Page 38: Fitting The Angle Adapter

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 Procedure: 1. Unscrew union nut 1 from gun housing 4. 2. Pull flat jet nozzle 2 off electrode holder 3. 3. Carefully pull electrode holder 3 out of the gun housing 4. Note: Do not damage the electrode holder 3, when pulling it out and inserting it.

  • Page 39: Replacing The Wearing Parts

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 8.7.3 REPLACING THE WEARING PARTS Procedure: 1. Loosen threaded sleeve 6 and separate angle adapter 5 from gun body 7. 2. Loosen union nut 1. 3. Pull out electrode holder 3, together with nozzle 2, from nozzle insert 4.

  • Page 40: Assembly Of The Coronastar

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 ASSEMBLY OF THE CORONASTAR The CoronaStar is a retrofit set for automatic guns for achieving even better surface quality (reduces the orange peel effect). WARNING Danger from electric current! Risk of injury and damage to the device.

  • Page 41: Assembly Of The Coronastar For Angle Adapter

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 ASSEMBLY OF THE CORONASTAR FOR ANGLE ADAPTER WARNING Danger from electric current! Risk of injury and damage to the device. The conversion on the CoronaStar may only be carried out by trained personnel. Prior to assembling the CoronaStar, the high voltage and powder feed must be switched off and secured against being inadvertently switched on.

  • Page 42: Troubleshooting And Rectification

    Malfunction Cause Remedy No electrostatic (e.g., no wrap – Fault in the high-voltage generator – Contact a WAGNER service center around or no powder adhesion) – Electrical cable from gun to – Replace the electric cable control unit faulty –...

  • Page 43: Inspections

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 10 INSPECTIONS If the system is used for electrostatic coating with ignitable coating powders, testing should be undertaken in accordance with DIN EN 50177: 2010-04 as per Table 3 and Table 4. The inspection types and intervals are described in the following chapters.
  • Page 44 PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829...
  • Page 45 PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829...

  • Page 46: Disassembly And Disposal

    WAGNER or one of our dealers will take back your used WAGNER electric or electronic equipment and will dispose of it for you in an environmentally-friendly way.

  • Page 47: Accessories

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 12 ACCESSORIES 12.1 FLAT JET NOZZLE Order no. Designation 390324 Flat jet nozzle F1 P_00694 390325 Flat jet nozzle F2 P_00694 390326 Flat jet nozzle F3 P_00694 2311889 Flat jet nozzle F4 P_00694 390331...

  • Page 48: Flat Jet Nozzle C4 F5-X (Not Fm Approved)

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 12.4 FLAT JET NOZZLE C4 F5-X (NOT FM APPROVED) Order no. Designation 2390031 Flat jet nozzles C4 F5-X P_03595 12.5 FLAT JET NOZZLE F1-X (NOT FM APPROVED) Order no. Designation 2390016 Flat jet nozzles F1-X P_03596 12.6 RETROFIT SET CORONASTAR...

  • Page 49: Coronastar Wa C4

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 12.7 CORONASTAR WA C4 P_01168 Order no. Designation 2306335 CoronaStar WA C4 12.8 CORONASTAR PEA-C4 F5 RETROFIT SET P_03921 Order no. Designation 2389178 Set CoronaStar PEA-C4 F5 12.9 WEDGE TOOL P_00714 Order no. Designation...

  • Page 50: Gun Mounting And Fixation

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 12.10 GUN MOUNTING AND FIXATION Order no. Designation 351347 Bracket for fixing the spray gun P_01619 Gun support for fastening on the 260215 reciprocator P_01620 12.11 ANGLE ADAPTER Order no. Designation 390927 Angle adapter, WA30 C4...

  • Page 51: Powder Measuring Adapter

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 12.14 POWDER MEASURING ADAPTER WARNING Risk of explosion due to electrostatic charging! Danger to life and equipment damage. Only use powder measurement adapter when high voltage is switched off! The powder measuring adapter serves to measure powder quantities for the PEA-C4 HiCoat gun.

  • Page 52: Spare Parts

    DANGER Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Use only WAGNER original spare parts and accessories. Only repair and replace parts that are listed in the "Spare parts" chapter and that are assigned to the unit.

  • Page 53: Pea-C4-Hicoat Corona Automatic Gun

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 13.2 PEA-C4-HICOAT CORONA AUTOMATIC GUN P_03919 Order no. Designation 390004 Corona Automatic Gun, PEA-C4-HiCoat 390911 Powder tube, C4 ET 390342 Adjustment tool for flat jet nozzles 390311 Union nut 390324 Flat jet nozzle F1...

  • Page 54: Electrode Holder C4 R With Nozzles

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 13.3 ELECTRODE HOLDER C4 R WITH NOZZLES P_01103 Order no. Designation 390917 Electrode holder, C4 R, complete 390916 Electrode holder, C4 R 390310 Wedge 390313 Deflector cone sleeve 390207 R20 deflector cone ( 20 mm; 0.79 inch) 390208 R28 deflector cone ( 28 mm;...

  • Page 55: Angle Adapter, Wa90 C4

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 13.4 ANGLE ADAPTER, WA90 C4 P_01623 Order no. Designation 390931 Angle adapter, WA90 C4 390947 Union nut, WA C4 ET 390933 Nozzle insert, WA90 C4 ET 390942 Elbow fitting, WA90 C4 ET 390932 Connecting element, WA C4 ET...

  • Page 56: Angle Adapter, Wa60 C4

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 13.5 ANGLE ADAPTER, WA60 C4 P_01624 Order no. Designation 390930 Angle adapter, WA60 C4 390947 Union nut, WA C4 ET 390934 Nozzle insert, WA60 C4 ET 390943 Elbow fitting, WA60 C4 ET 390932 Connecting element, WA C4 ET...

  • Page 57: Angle Adapter, Wa30 C4

    PEA-C4-HiCoat VERSION 05/2019 ORDER NUMBER DOC390829 13.6 ANGLE ADAPTER, WA30 C4 P_01625 Order no. Designation 390927 Angle adapter, WA30 C4 390947 Union nut, WA C4 ET 390935 Nozzle insert, WA30 C4 ET 390944 Elbow fitting, WA30 C4 ET 390932 Connecting element, WA C4 ET...

  • Page 58: Eu Declaration Of Conformity

    PTB 05 ATEX 5008 EU Declaration of Conformity The EU Declaration of Conformity is enclosed with this product. If needed, further copies can be ordered through your WAGNER dealer by specifying the product name and serial number. Order number: 390893...
  • Page 60 Order no. 390829 Edition 05/2019 ts-powder@wagner-group.com www.wagner-group.com...

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