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 spray gun
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Translation of the Original
Operating Manual
PEA-C4-HiCoat
Automatic Powder Spray Gun
Version 05 / 2012
P_01610
II 2 D EEx 2mJ 85 °C
0102

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Summary of Contents for WAGNER PEA-C4-HiCoat

  • Page 1 Translation of the Original Operating Manual PEA-C4-HiCoat Automatic Powder Spray Gun Version 05 / 2012 P_01610 II 2 D EEx 2mJ 85 °C 0102...

  • Page 3: Table Of Contents

    Electrical Devices and Operating Equipment 4.1.2 Personnel Qualifi cations 4.1.3 A safe Work Environment Safety Instructions for Staff 4.2.1 Safe Handling of WAGNER Powder Spray Devices 4.2.2 Grounding the Device 4.2.3 Accessories and Spare Parts 4.2.4 Cleaning and Maintenance 4.2.5...
  • Page 4 PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL Contents Grounding 6.6.1 Grounding the Powder Coating System 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...
  • Page 5 VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 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: General Information

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL GENERAL INFORMATION 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 .

  • Page 7: Copyright

    ORDER NUMBER DOC 390829 OPERATING MANUAL COPYRIGHT 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.

  • Page 8: Correct Use

    Automatic spray gun for automatic coating TYPE OF USE The spray gun PEA-C4-HiCoat serves as stationary equipment for industrial electrostatic coating with fl ammable powder in automatic systems. It can be operated either with single control units or switch cabinet modules.

  • Page 9: Processing Materials

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL PROCESSING MATERIALS Types of powder which can be charged electrostatically Metallic powder REASONABLY FORESEEABLE MISUSE The following is prohibited: coating work pieces which are not grounded unauthorized conversions and modifi cations to the spray gun...

  • Page 10: Identification

    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. The PEA-C4-HiCoat powder spray gun may only be connected to the control devices listed below: EPG-Sprint HVM-D 1...

  • Page 11: Safety Identifications

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL SAFETY IDENTIFICATIONS 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.

  • Page 12: General Safety Instructions

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL GENERAL SAFETY INSTRUCTIONS 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. 4.1.1...

  • Page 13: Safety Instructions For Staff

    4.2.1 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.

  • Page 14: Cleaning And Maintenance

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 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.

  • Page 15: Note On Harmless Discharges

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL NOTE ON HARMLESS 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 eff ect can be seen when the electrode is brought near the grounded work piece.

  • Page 16: Protective And Monitoring Equipment

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL PROTECTIVE AND MONITORING EQUIPMENT WARNING Incorrect use! Risk of injury and damage to the device. Protective and monitoring equipment must not be removed, modifi ed or rendered unusable. Regularly check that they are working perfectly.

  • Page 17: Description

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL DESCRIPTION DESIGN OF SPRAY GUN P_01612 Description Flat spray nozzle (defl ector cone) Electrode Cap nut Gun body Electrical connection Atomizing air connection Powder hose connection Type plate FUNCTIONING OF THE SPRAY GUN The spray gun is switched on and off via the superordinated control unit.

  • Page 18: Technical Data

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL TECHNICAL DATA Dimensions: Length/width/height see chapter 5.3.1 Weight 555 g; 1.22 lbs Electrical: Input voltage max. 22 Vpp Input current max. 0.9 A Frequency 19 - 30 kHz Output voltage max. 100 kV DC...

  • Page 19: Dimensions

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 5.3.1 DIMENSIONS P_01611 Measurement inch 133.66 1.18 12.20 2.99 3.23 Measurement for installation dimension C calculation when utilizing a defl ector cone...

  • Page 20: Permitted Accessories

    PERMITTED ACCESSORIES Only the accessories listed in this operating manual may be connected to the PEA-C4-HiCoat powder spray gun. The accessories listed in chapter 12 were included in the EC type examination and are approved for use with the gun.

  • Page 21: Assembly And Commissioning

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL ASSEMBLY AND COMMISSIONING 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 50177.

  • Page 22: Preparing The Spray Gun

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL PREPARING THE SPRAY GUN 6.4.1 SELECTION OF THE SUITABLE NOZZLE SYSTEM The process of changing from the fl at spray nozzle to the defl ector cone is described in chapter 8.5 "Fitting the Round Spray Nozzle".
  • Page 23 PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL Nozzle Application Distance to Powder Work Piece Discharge (mm) (g/min) HPO-1¹ Wide fl at spray nozzle for high powder application > 200 (slow powder cloud) good atomization (Total air > 4.5 Nm³/h)

  • Page 24: Mounting The Spray Gun

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL MOUNTING 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.

  • Page 25: Grounding

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL GROUNDING WARNING Defective grounding will result in high levels of powder mist! Danger of poisoning. Insuffi cient paint application quality. Ground all device components. Ground the work pieces to be coated.

  • Page 26: Grounding The Powder Coating System

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 6.6.1 GROUNDING THE POWDER COATING SYSTEM P_01614 Only use mains cables with grounding strand! Connect grounding cable with booth and system ground! Connect grounding cable to an uncoated metal part of the booth!

  • Page 27: Operation

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL OPERATION TRAINING THE OPERATING STAFF WARNING Incorrect operation! Risk of injury and damage to the device. The operating staff must be qualifi ed to operate the entire system. Before work commences, the operating staff must receive appropriate training.

  • Page 28: Switching On The Spray Gun

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 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 coating material supply are activated.

  • Page 29: Optimizing The Powder Cloud For Your Coating

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 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 dosage air should be under 5 Nm³/h!

  • Page 30: Performing A Color Change

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL PERFORMING A COLOR CHANGE WARNING Dust formation! Danger of poisoning. Danger due to escaping dust, contamination of 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...

  • Page 31: Reproducible Setting Of The Nozzle Position

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL REPRODUCIBLE SETTING OF THE NOZZLE POSITION 30° For a horizontal powder cloud, the fl at spray nozzle is set where the protective wedge is in the 0° position. 15° When attaching a round spray nozzle, we recommend turning the protective wedge in the 90°...

  • Page 32: Cleaning And Maintenance

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL CLEANING AND MAINTENANCE CLEANING 8.1.1 CLEANING STAFF Cleaning work should be regularly and carefully undertaken by qualifi ed and trained staff . The staff must be familiar with the DIN EN 50177 provisions. They should be informed of specifi c hazards during their training.

  • Page 33: Cleaning Procedures

    The cleaning intervals should be adapted by the operator depending on the level of use and if necessary the level of soiling. In doubt, we recommend contacting J. Wagner AG's specialist personnel. The valid health and safety specifi cations and the safety instructions provided in chapter 4...

  • Page 34: Maintenance

    Risk of injury and damage to the device. Have repairs and part replacements be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 35: Maintenance Procedures

    The maintenance intervals should be adapted by the operator depending on the level of use and if necessary the level of soiling. In doubt, we recommend contacting J. Wagner AG's specialist personnel. The valid health and safety specifi cations and safety instructions provided in chapter 3...

  • Page 36: Replacing The Spray Gun

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 8.2.4 REPLACING THE SPRAY GUN 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 " ", must be regularly checked and, if necessary replaced.

  • Page 37: Cleaning The Spray Gun And Dismantling The Flat Spray Nozzle

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL CLEANING THE SPRAY GUN AND DISMANTLING THE FLAT SPRAY NOZZLE Procedure: 1. Unscrew cap nut 1 from spray gun housing 5. 2. Pull fl at spray nozzle 2 off the electrode holder 3.

  • Page 38: Replacing The Protective Wedge

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL REPLACING THE PROTECTIVE WEDGE Note: A wedge tool is available to prevent the protective wedge from being damaged when dismantling and inserting. You will fi nd the necessary wearing parts and spare parts in chapter 13 "Spare Parts" of this operating manual.
  • Page 39 PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL Note: The same wedge tool is used to insert the protective wedge. 1 Wedge tool 2 Protective wedge (when positioned) 3 Electrode holder (cut open view) Procedure: P_00597 1. Guide protective wedge 2 into wedge tool 1.

  • Page 40: Fitting The Round Spray Nozzle

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 5. After long periods of operation or having replaced the protective wedge repeatedly, it is recommended to check also the powder tube for wear and replace if necessary. You will fi nd the necessary wearing parts and spare parts in chapter 13 "Spare Parts"...
  • Page 41 PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL CAUTION Electrode tip! Risk of injury. Take care when fi tting the C4 R electrode holder. Carefully fi t the new C4 R electrode holder 6 into the spray gun housing 5.

  • Page 42: Fitting The Angle Adapter

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL FITTING THE ANGLE ADAPTER 8.6.1 REMOVING THE NOZZLE AND ELECTRODE HOLDER The standard Corona spray gun is delivered with a fl at spray nozzle. The nozzle can be changed easily, as described below.

  • Page 43: Fitting The Angle Adapter

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 8.6.2 FITTING THE ANGLE ADAPTER Procedure: 1. Install electrode holder 1 together with nozzle 2 in the nozzle insert 3 and tighten cap nut 4. 2. Push angle adapter 5 onto the gun body and screw slightly threaded sleeve 6.
  • Page 44 PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL Unscrew threaded sleeve 8 and locking sleeve 9 with mounting tool 10. Pull out connecting element 11 of angle adapter 12. Insert screwdriver into open area X and turn it until the nozzle insert 7 becomes loose.

  • Page 45: Mounting The Corona-Star

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL MOUNTING THE CORONA-STAR The Corona-Star is a Retrofi t-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.

  • Page 46: Corona-Star For Angle Adapter

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL CORONA-STAR FOR ANGLE ADAPTER 8.8.1 MOUNTING 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 mounting the Corona-Star, the high-voltage and the powder feed must be switched off and secure against inadvertent switch on.

  • Page 47: Inspections In Accordance With Din En 50177: 2010-04

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 2010-04 If the system is used for electrostatic coating with fl ammable coating powders, testing should be undertaken in accordance with DIN EN 50177: 2010-04 as per Table 3 and Table 4.

  • Page 48: Overview Of Inspections

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL OVERVIEW OF INSPECTIONS...
  • Page 49 PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL...

  • Page 50: Disassembly And Disposal

    Wagner, or one of our dealers, will take back your used Wagner equipment and will dispose of it for you in an environmentally friendly way.

  • Page 51: Troubleshooting And Rectification

    Danger to life and equipment damage. Wagner devices, protective systems and safety, monitoring and control equipment may only be repaired as defi ned in Directive 94/9/EC (ATEX) by trained Wagner service personnel or capable persons in accordance with TRBS 1203! Note national regulations!
  • Page 52 OPERATING MANUAL Malfunction Cause Remedy No electrostatics (e.g. no wrap Fault in the high-voltage Contact 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...

  • Page 53: Accessories

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL ACCESSORIES 12.1 FLAT SPRAY NOZZLES Order No. Description 390324 F1 fl at spray nozzle P_00694 390325 F2 fl at spray nozzle P_00694 390326 F3 fl at spray nozzle P_00694 2311889 F4 fl at spray nozzle...

  • Page 54: Retrofit Set Corona-Star

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 12.3 RETROFIT SET CORONA-STAR P_01104 Order No. Description 390918 Corona-Star compl. 260296 Corona-Star electrode 390319 Cap nut Wearing part 12.4 CORONA-STAR WA C4 P_01168 Order No. Description 2306335 WA C4 Corona-Star...

  • Page 55: Wedge Tool

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 12.5 WEDGE TOOL P_00714 Order No. Description 390900 Wedge tool including 20 protective wedges only available as a set 12.6 GUN SUPPORT AND FIXATION Order No. Description 351347 Bracket for fi xing the spray gun P_01619 Order No.

  • Page 56: Angle Adapter

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 12.8 ANGLE ADAPTER Order No. Description 390927 WA30 C4 angle adapter 390930 WA60 C4 angle adapter 390931 WA90 C4 angle adapter P_01626 Order No. Description 390939 WA C4 mounting tool P_01621...

  • Page 57: Powder Measuring Bag

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 12.9 POWDER MEASURING BAG DANGER Risk of explosion due to electrostatic charging! Danger to life and equipment damage. Only use powder measurement bag when high-voltage is switched off ! For measuring powder quantities for the C4 gun generation.

  • Page 58: Spare Parts

    Risk of injury and damage to the device. Have repairs and part replacements be carried out by specially trained staff or a WAGNER service center. Before all work on the unit and in the event of work interruptions: - Switch off the energy/compressed air supply.

  • Page 59: Pea-C4-Hicoat Corona Automatic Gun

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 13.2 PEA-C4-HICOAT CORONA AUTOMATIC GUN P_01622 Automatic gun PEA-C4-HiCoat Quantity Order No. Description 390004 PEA-C4-HiCoat Corona automatic gun 390311 Cap nut 390324 Flat spray nozzle F1 390915 Electrode holder 390310 Wedge...

  • Page 60: Electrode Holder C4 R With Nozzles

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 13.3 ELECTRODE HOLDER C4 R WITH NOZZLES P_01103 Electrode holder C4 R with nozzles Quantity Order No. Description 390917 Electrode holder C4 R compl. 390916 Electrode holder C4 R 390310 Wedge...

  • Page 61: Angle Adapter Wa90 C4

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 13.4 ANGLE ADAPTER WA90 C4 P_01623 Angle adapter WA90 C4 Quantity Order No. Description 390931 Angle adapter WA90 C4 390947 Cap nut WA C4 ET 390933 Nozzle insert WA90 C4 ET...

  • Page 62: Angle Adapter Wa60 C4

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 13.5 ANGLE ADAPTER WA60 C4 P_01624 Angle adapter WA60 C4 Quantity Order No. Description 390930 Angle adapter WA60 C4 390947 Cap nut WA C4 ET 390934 Nozzle insert WA60 C4 ET...

  • Page 63: Angle Adapter Wa30 C4

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 13.6 ANGLE ADAPTER WA30 C4 P_01625 Angle adapter WA60 C4 Quantity Order No. Description 390927 Angle adapter WA30 C4 390947 Cap nut WA C4 ET 390935 Nozzle insert WA30 C4 ET...

  • Page 64: Declaration Of Warranty And Conformity

    The manufacturer will not be held liable or will only be held partially liable if third-party accessories or spare parts have been used. With genuine WAGNER accessories and spare parts, you have the guarantee that all safety regulations are complied with.

  • Page 65: Declaration Of Conformity

    0102 EC Certifi cate of Conformity The CE certifi cate 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: PEA-C4-HiCoat automatic gun 390893...

  • Page 66: Ec Type Examination Certificate

    PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL 14.4 EC TYPE EXAMINATION CERTIFICATE...
  • Page 67 PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL...
  • Page 68 PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL...
  • Page 69 PEA-C4-HiCoat VERSION 05/2012 ORDER NUMBER DOC 390829 OPERATING MANUAL...
  • Page 70 Fax: +45/ 86 856 027 E-mail: info@estee-industries.com E-mail: info@wagner-industri.com Great Britain France WAGNER Spraytech (UK) Ltd. Wagner - Division Solutions Industrielles The Couch House Parc Gutenberg - Bâtiment F 2, Main Road 8 voie la Cardon GB- Middleton Cheney OX17 2ND...
  • Page 72 Order No. 390829 Germany J. Wagner GmbH Otto-Lilienthal-Str. 18 Postfach 1120 D- 88677 Markdorf Tel. +49/ (0)7544 / 5050 Fax +49/ (0)7544 / 505200 E-mail: service.standard@wagner-group.com Switzerland J. Wagner AG Industriestrasse 22 Postfach 663 CH- 9450 Altstätten Tel. +41/ (0)71 / 757 2211 Fax +41/ (0)71 / 757 2222 E-mail: rep-ch@wagner-group.ch...

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