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REITER AGR-08-E Operating Manual

Automatic spray gun agr-08-e for electrostatic atomization for solventborne paint
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Operating Manual
Automatic spray gun AGR-08-E
for electrostatic atomization for
solventborne paint
Product No.: S-AGR08E-GB (Translation)
Issue:
05/15 - 3
REITER GmbH + Co. KG
Oberflächentechnik
Berglenstraße 23 - 25
D-71364 Winnenden
Phone:
+49 (0) 71 95 / 185 - 0
Fax:
+49 (0) 71 95 / 185 - 30
Internet: www.reiter-oft.de

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  • Page 1 Operating Manual Automatic spray gun AGR-08-E for electrostatic atomization for solventborne paint Product No.: S-AGR08E-GB (Translation) Issue: 05/15 - 3 REITER GmbH + Co. KG Oberflächentechnik Phone: +49 (0) 71 95 / 185 - 0 Berglenstraße 23 - 25 Fax:...
  • Page 2 Contents of the Operating Manual Chapter 1 General Chapter 2 Safety Regulations Chapter 3 Technical Data Chapter 4 Transport (not assigned) Chapter 5 Function Description (not assigned) Chapter 6 Installation (not assigned) Chapter 7 Commissioning and Operation Chapter 8 Maintenance Chapter 9 Spare Parts Chapter 10...
  • Page 3 KG surface technology is essential. • This manual provides information for the operation, maintenance and care of this electrostatic device from REITER GmbH + Co. KG Oberflächentechnik in a typical system configuration. The values and procedures g iven herein are to be regarded as standard and may vary slightly from the different installations. • For a better understanding of this product and to achieve an optimal, error-free operation over a long period, the instructions must be read carefully. • The specified tests and checks should be carried out at a troubleshooting section before a service technician is required. In any case, with such a requirement, a person should be in charge, who is familiar with the device and holds the operating instructions. • For the various adapters and accessories separate manuals are available. Automatic gun AGR-08-E The automatic gun AGR-08-E is an air atomizing electrostatic automatic pistol. The gun can be a set screw in the machine adapter removed quickly from same. The machine adapter receives all material, air, and power lines. AGR-08-E is suitable for use on industrial robots, automatic machines (reciprocators) or supports. The AGR-08-E automatic spray gun creates a voltage of up to 85 kV at the atomising point for the coating material. The particles charged here are transported to the workpiece by compressed air, where they are electrostatically attracted and held. The electrostatic field between the charged par- ticles and the earthed workpiece also enables a high proportion of the overspray to reach the sides and back of the workpiece being coated. This guarantees that a high percentage of the atomised spray is deposited on the workpiece. The guns in this series are suitable for coatings, solvent-or water-based. S-AGR08-Egb01 05/15 - 3 Page 1 of 2...
  • Page 4 Components The system AGR-08-E consists of a gun AGR-08-E, the machine adapter, the high voltage cable, the high voltage generator (REMO HSE HE-30-100k-100), the control board (SMI-1230-30-320m (DC)) as well as the high-voltage distributor (HVE06/01). Guarantee Therefore, it is recommended to read this operating manual carefully before start-up, as we can- not be held liable for damage or malfunctions resulting from the non-observance of this operating manual. During the guarantee period repair work and changes only may be carried out by our assemblers or with our consent. The system is designed only for the use according to the operating area described in chapter 2 „Operating Area“. Any other use is considered improper and REITER can not be held liable for any possible damage. Copyright The copyright for this operating manual is retained by REITER GmbH + Co. KG Oberflächentech- nik. This operating manual is intended for personnel involved in installation, operation and supervi- sion. The operating manual include regulations and technical drawings which may not be copied, distributed, used for commercial purpose or given to others, either in full or in part. REITER GmbH + Co. KG Oberflächentechnik Phone: +49 (0) 71 95 / 185 - 0 Berglenstraße 23 - 25 Fax: +49 (0) 71 95 / 185 - 30 D-71364 Winnenden Email: info@reiter-oft.de S-AGR08-Egb01 05/15 - 3 Page 2 of 2...

  • Page 5: Table Of Contents

    Safety Regulations Table of Contents Explanation of symbols and special directions ..............2 2.1.1 Symbol of working safety ....................2 2.1.2 Directions for “Attention“ ....................2 Operating area ........................2 Electrostatic automatic spray gun ..................3 2.3.1 Forced ventilation....................... 4 General demands for safe operation .................

  • Page 6: Explanation Of Symbols And Special Directions

    This equipment can be dangerous if it is not operated in accord- ance with the instructions of this manual! The electrostatic gun AGR-08-E, hereinafter called device, is designed and built for the use in a stationary electrostatic application equipment designed for flammable liquid coating materials.

  • Page 7: Electrostatic Automatic Spray Gun

    Safety Regulations Paragraph 0, Point 01 of EN 50176:2009 is applicable to the fields of application of the apparatus. This Standard also defines the design requirements for safe operation of the apparatus and the electrical installation, including the forced ventilation. The constructional requirements for the spray booth, defined in Standard EN 12215:2005, are also applicable.

  • Page 8: Forced Ventilation

    2.3.1 Forced ventilation Pursuant to EN 50176:2009, Section 5.4, the AGR-08-E electrostatic spray gun may only be used in spraying areas with forced or equivalent conditions of ventilation. This means that the maximum concentration of 50% of the lower explosion limit (LEL) of the coat- ing material to be applied may not be exceeded in the spraying areas.

  • Page 9: Work Stations

    Safety Regulations Work stations • Ensure all sources of ignition are avoided. Smoking and open flames are prohibited in fire and explosion hazardous areas. • Ensure that coating material deposits are kept to a minimum in spray booths, spray stands and in the entire work area.

  • Page 10: Personal Protective Gear

    Safety Regulations 2.11 Personal protective gear • Ensure that persons working with electrostatic spraying systems and any persons present on the electrically conducting floor wear antistatic shoes. • Where protective gloves are required, these must be antistatic or have similar properties. 2.12 Working with ignition risk •...

  • Page 11: Explosion Protection Document

    Safety Regulations 2.13 Explosion protection document 2.13.1 Directives DIRECTIVE 1999/92/EC OF THE EUROPEAN PARLIAMENT AND THE COUNCIL (ATEX 137), dated 16 December 1999, on minimum requirements for improvement of safety and health protec- tion of workers potentially at risk from explosive atmospheres (fifteenth individual Directive relevant to Article 16 (1) of Directive 89/391/EEC), the company, in this case the operator of electrostatic spraying equipment, is required, pursuant to Article 8, to compile an explosion protection document identifying explosion hazardous areas (zones).
  • Page 12 Safety Regulations Type of ventilation Area classification in zones Stand and booth interiors Forced ventilation Zone 1: interior Around stand openings (permanent openings, but no doors) Forced ventilation Zone 2: 1m S-AGR08-Egb02 05/15 - 3 Page 8 of 10...

  • Page 13: Checks

    Safety Regulations 2.13.3 Checks • An automatic (fixed) spray plant for electrostatic spraying of coating materials must be checked by an expert prior to first start-up. • Type, extent and frequency of the checks must in individual cases be stipulated by the operat- ing company in due consideration of operational and local conditions.

  • Page 14: Normative References

    Safety Regulations 2.14 Normative references 2.14.1 Demands of design and quality for facilities used for electrostatic coating EN 12215:2005 Spray booths for application of organic liquid coating materials - Safety requirements BGI 764:2009 Electrostatic coating (valid only in Germany) EN 50176:2009 Stationary electrostatic application equipment for ignitable liquid coating material - Safety require- ments EN 12100-1/-2:2004...

  • Page 15: Automatic Gun Agr-08-E

    3.2.1 Automatic gun AGR-08-E....................2 Designs The automatic spray gun AGR-08-E is available in different designs. They differ in the use of a vari- ety of components and/or in the material flow. Note! There are two versions of gun heads possible – dead end or circulation.

  • Page 16: Technical Data

    Air cap retaining ring: Brass, chemically nickel-plated Material-contacting seals: VITON for water-based coatings (on request) VITON EX for solvent-based coatings (standard) Perflourelastomer for highest resistance (on request) Dimensions: AGR-08-E with intermediate plate S-AGR08-Egb03 05/15 - 3 Page 2 of 2...
  • Page 17 Atomizer air (ZL) Main needle (HN) The automatic spray gun AGR-08-E, depending on the built-in version, is attached on a intermedi- ate plate, which serves as an adapter to be able to use the gun as diverse as possible. This plate is mounted on an adapter to which the material and the air can be connected.
  • Page 18 Usage conditions Operating temperature: max. 80°C Ambient temperature: max. 40°C Tools and other materials required The following tools are required for installing and removing the automatic spray gun AGR-08-E: • Hexagon socket head wrench, size 4 • Gun grease (part no. 65026530) for the o-ring-wetting while placing the gun. Fastening onto intermediate plates (if available) 7.4.1...
  • Page 19 Make the appropriate setting for the atomiser air. Make the appropriate setting for the horn air. Position for horizontal spray pattern 7.5.1 Distance to workpiece Positon the automatic gun AGR-08-E about 15 to 30 cm from the workpiece. S-AGR08-Egb07 05/15 - 3 Page 3 of 3...
  • Page 20 Assembly device for spraying system AGR-08 (option) ........... 13 Faults ..........................14 Note: The air cap can be replaced on the automatic spray gun AGR-08-E without removing it from the system. For all other maintenance jobs, the automatic spray gun AGR-08-E must be removed from the in- termediate plate/adapter and replaced by a reserve gun.

  • Page 21: Dismantling Of The Automatic Gun

    Maintenance Dismantling of the automatic gun • Rinse the automatic gun Attention! • Secure the gun against restarting • Wear protection clothes (glases and gloves) • Notice the generally applicable accident prevention regulations Loosen and remove the gun with a hexagon socket head wrench, size 4 from the interme- diate plate or the adapter. 2. Loosen and remove the cover (19). 3. Loosen and remove the three screws (18) and remove the end plate (17). S-AGR08-Egb08 05/15 - 3 Page 2 of 15...
  • Page 22 Maintenance 4. Sliding head holder (11) backwards from the spray head (8). Remove paint needle (13), small compression spring (16), big compres- sion ring (15) and spring pin (14). Remove two Viton O-rings (10) from the spray head holder for fan air and atomizing air. Attention: Risk of injury! Needle can be very sharp. S-AGR08-Egb08 05/15 - 3 Page 3 of 15...
  • Page 23 Maintenance 5. Press piston (12) by hand or with a blunt tool from the head holder (11). 6. Loosen retaining ring (1) by hand and remove it together with the air cap (3) and the air cap gasket (2). 7. Loosen nozzle (4) with socket wrench or nut SW 13 and remove it together with the air dis- tributing ring (7) and the two gaskets (6). S-AGR08-Egb08 05/15 - 3 Page 4 of 15...
  • Page 24 Maintenance 8. Unscrew the needle packing with a Torx wrench TO40. Attention: This applies only to the standard packing of plastic. Clean all individual parts with a suitable detergent and dry. Gaskets and packing should be changed fundamentally during disassembly. Check all parts for damage or wear, and replace them with new original spare parts from the com- pany Reiter. S-AGR08-Egb08 05/15 - 3 Page 5 of 15...

  • Page 25: Reassembly Of The Automatic Gun

    Maintenance Reassembly of the automatic gun Lay out all components and the required tools on a clean level surface. 2. Mount the spray head (8) into the greased standard needle set (9) with 0.8 Nm or mount the special package made in stainless steel with Kalrez o-rings into the spray head (8) and tighten with a suitable tool with 3.0 Nm. 3. Wet gaskets (6) with little fat and put it in the air distribution ring (7). Attention: The gaskets are different. The smaller diameter is in the air distributing ring.
  • Page 26 Maintenance 4. Turn gun to 180° (needle up), place fluid noz- zle and tighten it to 30 Nm. Place air cap and tighten it manually with retaining ring. Little gun grease on the threads facilitates subse- quent removal. 5. Wet slightly two o-rings (10) from not solvent resistant Viton, for fan air and atomizing air with gun grease and insert into the head hold- er (11). Attention: Too much grease can be carried away by the fan air and atomizing air and reflected in painting/coating on the work- piece.
  • Page 27 Maintenance 9. Grease tip of the paint needle (13) with gun grease and insert through the piston (12) into the needle set. Push manually careful for- wards towards the nozzle. 10. Place greased spring pin (14) and the two compression springs – small (16), large (15) – which are inserted into each other, on the paint needle (13). 11. Close housing with end plate (17). 12. Tighten the three screws with an Allen key with 4.5 Nm. S-AGR08-Egb08 05/15 - 3 Page 8 of 15...
  • Page 28 Maintenance 13. Grease necessarily cover (19) and end plate (17) in order to facilitate subsequent disman- tling. 14. Grease solvent resistant Kalrez o-rings (20) on the gun bottom with gun grease. Place it on the adapter – or left to see in the photo – on the intermediate plate and tighten with an Al- len key size 4. S-AGR08-Egb08 05/15 - 3 Page 9 of 15...

  • Page 29: Possible Sources Of Error For The Reassembly

    Maintenance 8.4.1 Possible sources of error for the reassembly Mount two gaskets (6) with air distributing ring (7). Essential to maintain correct position and seat! Insert the respective smaller diameter of the gaskets into the air distribution ring. Here the lower gasket is slipped! A visual check is necessary! Grease nozzle (4) and tighten with 30 Nm.

  • Page 30: Maintenance Of Needle Set

    Maintenance Maintenance of needle set 1. Unscrew the cover on the back. Loosen and remove the three Allen screws with an Allen key 4 mm. At reassembly please lubricate with grease (part no. 65026530). 2. Remove back gun cover. Remove the two springs and the spring pin and separate the spay head from the head holder by axial, manually carefully pulling. Attention: Risk of injury! Needle can be very sharp.
  • Page 31 Maintenance 4. Unscrew the worn standard needle set with a Torx 40 with light, axial pressure. Clean the spray head carefully before the new set is used. Lubricate the standard set (part no. 65077600, see image) with grease (part no. 65026530) and screw with a Torx 40 with 0,8 Nm. Push out the special needle set Kalrez cpl. (part no. 63319030) from the nozzle side with a plastic pin (part no. 64004080) after the re- taining screw M12x1 and the paint nozzle was turned by using a Allen key 6 mm (the paint needle in the photo used here only for clarity. This is not to be used for installation). Clean the spray head carefully before the new set is used.

  • Page 32: Assembly Device For Spraying System Agr-08 (Option)

    Maintenance Assembly device for spraying system AGR-08 (option) Part no. 64076420 • Simple handling of the spay gun and those items • Fast nozzle change • No damage/deformation by vice jaws on the housing of the spray gun • Shortened maintenance times because atomizer need not be re-clamped for each operation Open and close the casing with a torque wrench Disassemble and reassemble paint nozzle Change the needle packing Insert piston S-AGR08-Egb08 05/15 - 3 Page 13 of 15...

  • Page 33: Faults

    Maintenance Faults Note! In case of faults, determine the cause before disassembling to eliminate the error with as little maintenance work as possible. Faults Possible causes Corrective action No uniform atomization or Nozzle stuck or damaged or Clean nozzle/air cap with spray pattern is not symmetri- deformed on the paint trailing suitable cleaning material or edge replace it Air cap holes are clogged in...
  • Page 34 Maintenance Faults Possible causes Corrective action Paint outlet at the air cap or Nozzle not properly tightened Maintain gun material outlet hole of the noz- or dirt on the sloping sealing surface Grease nozzle and tighten with 30 Nm Paint outlet between gun and Material seals (o-rings) dam- Replace o-rings or locking intermediate plate or gun aged on gun bottom or miss- adapter ing/damaged or overstretched locking...

  • Page 35: Guarantee

    In case of damage resulting from the use of non-original spare parts and accessories, any liability or guarantee provided by REITER GmbH + Co. KG Oberflächentechnik is excluded. The stock keeping of spare parts is provision for any the validity of agreements involving system availability, service times and guarantee or systems performance.

  • Page 36: Spare Parts

    Storage The automatic gun AGR-08-E has to be stored in a dry and dust free area in its original packaging. Make sure to prevent extreme temperature fluctuations because otherwise condensation can oc- cur, which can cause damages to the device.

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