Krautzberger RA 5 Operating Instructions Manual

GB

Operating instructions Automatic spray gun RA 5

T-Dok-449-GB-Rev.7

200-0319 ■ 200-0321 ■ 200-0323 ■ 200-0324

Translation of the original operating instructions

Thank you for selecting a Krautzberger product.

This product has been manufactured following state-of-the-art manufacturing procedures and extensive quality assurance measures. We promise you a product of the highest quality.

If you have questions, requests or suggestions, please contact us. We are always glad to assist you.

Information about the operating manual

This manual provides important information on how to work with the device safely and efficiently. The manual is part of the device and must always be kept in the immediate proximity of the device so that it is accessible to the personnel at all times.

The personnel must have read and understood this manual before starting any work. Compliance with all specified safety information and instructions is a basic requirement for safe working conditions.

In addition, the local occupational safety regulations and general safety rules apply for the area of application of the device.

Due to optional finishing variants, it is possible that the figures shown in this operating manual deviate from your device.

Information about explosion protection

Many of our competitors have been marking their products with the Ex symbol as a matter of principle for some time now.

At Krautzberger we do not do that.

We engineer and manufacture our products in line with currently applicable directives.

If the labelling on the product is required, it is affixed to the product as the result of the necessary analysis of ignition sources. If no labelling is affixed, the analysis of ignition sources and previous experience with the assessment of the suitability of products for use in a potentially explosive area have shown that the product described in this operating manual does not represent a potential source of ignition, with the exception of an electrostatic charge.

Taking into account the potential equalisation (provided by proper earth connection), the use in an area at risk for explosions is permitted in accordance with the currently valid directives.

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1 Function and identification

1.1 Function

Automatic spray guns are used for

n automatic coating/marking of surfaces n Dosing of fluids n Placement of adhesive or marking points

Typical spray media are paints, dyes, adhesives, glazes, enamels, release agents, etc.

The spray medium is fed into the automatic spray gun under pressure. The pressure is typically generated by pumps or pressure containers. The automatic spray gun is controlled via compressed air.

For precision control of the automatic spray gun, electrically-activated solenoid valves can be used.

The spray medium is atomised using compressed air. The geometry of the spray jet and the sprayed quantity of the spray medium can be adjusted using the following measures:

n Selection of air and material nozzle n Change of atomiser air pressure n Changing the spray medium pressure n Adjustment of the needle stroke on the regulator of the automatic spray gun

Optional equipment:

Automatic spray gun:

n Main element (stainless steel or aluminium, chemically nickel-plated, PTFE-coated) n Needle stroke adjustment n Circulation connection n Double controller (interruption of the material supply through spring force or pneumatically) n Nozzle fixing (

Adapter:

n Connections: From below or behind (the connections can be made using nipples, screw-type

or plug connectors of different sizes)

n Fastening: Clamp or screw-type fastening of the adapter

Ä

Chapter 6.5 ‘Nozzle fixing (optional)’ on page 20)

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Operating instructions

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Fig. 1: Adapter variants

Pos. Description

1 Connections from behind, clamp fastening of the automatic spray gun

2 Connections from below, clamp fastening of the automatic spray gun

3 Connections from behind, screw fastening of the automatic spray gun

4 Connections from below, screw fastening of the automatic spray gun

1.2 Identification

Scope of delivery Type Item number

with adapter and conventional nozzle system 200-0319

without adapter and with conventional nozzle system 200-0321

with adapter and HVLP nozzle system * 200-0323

without adapter and with HVLP nozzle system * 200-0324

Operating manual T-Dok-449

* HVLP = High Volume, Low Pressure

Serial number

The serial number of the automatic spray gun is located on the main element. It serves as a unique identifier.

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2 Using this operating manual

2.1 Information about the operating manual

n Knowledge of the fundamental safety instructions and safety regulations is a basic require-

ment for safe handling and defect-free operation of the product.

n This operating manual contains the most important information about enabling safe operation

of the product.

n This operating manual and, in particular, the safety instructions are to be observed by all per-

sons who work on or with the product.

n Furthermore, the rules and regulations for accident prevention in force at the respective oper-

ating site are to be observed.

2.2 Symbols in this operating manual

Safety instructions

This operating manual uses symbols to identify safety instructions. The safety instructions are preceded by signal words that indicate the severity of the hazard.

DANGER!

This combination of symbol and signal word indicates an immediate dangerous situation, which will cause death or severe injuries if it is not averted.

WARNING!

This combination of symbol and signal word indicates a potentially dangerous situation which can cause death or severe injuries if it is not averted.

CAUTION!

This combination of symbol and signal word indicates a potentially dangerous situation which can cause slight injuries if it is not averted.

NOTICE!

This combination of symbol and signal word indicates a potentially dangerous situation which can cause property and environmental damage if it is not averted.

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ENVIRONMENT!

This combination of symbol and signal word indicates potential dangers to the environment.

Tips and recommendations

This symbol highlights useful tips and recommendations as well as information for efficient and defect-free operation.

Example for safety instructions in operating instructions

Safety instructions can refer to specific, individual operating instructions. Such safety instructions are embedded in the operating instructions so that they do not disrupt the reading flow when performing the action. The signal words described above are used.

1. Loosen the screw.

2.

CAUTION!

Pinching hazard at the lid!

Carefully close the lid.

3. Tighten the screw.

Special safety instructions

The following symbols are used in safety instructions to draw attention to specific hazards:

Warning signs Type of danger

Warning – danger zone.

Additional markings

The following markings are used in this manual to highlight operating instructions, outcomes, lists, references, and other elements:

Identification Explanation

Step-by-step instructions

ð

Results of procedural steps

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Identification Explanation

References to sections in this manual and other applicable documents

Lists without specified order

[Button] Operating elements (e.g. buttons, switches), display elements

(e.g. signal lights)

‘Display’ Screen elements (e.g. pushbuttons, assignment of function keys)

2.3 Personnel requirements

This manual identifies the qualifications of the personnel for the different scopes of work as listed below:

Qualified personnel

Due to their specialised professional training, knowledge, and experience as well as knowledge of the industry-specific standards and regulations, qualified personnel are in a position to perform assigned tasks and to identify and avert potential risks on their own.

Specialised personnel

Due to their specialised professional training, knowledge, and experience as well as knowledge of the industry-specific standards and regulations, qualified personnel are in a position to perform assigned tasks and to identify and avert potential hazards on their own.

User

The user is familiar with the basic regulations on occupational safety and accident prevention.

2.4 Personal protective equipment

Personal protective equipment is used to protect persons against adverse effects on their health and safety when working.

Personnel must wear personal protective equipment while carrying out the different tasks on and with the machine.

In the course of regular, recurring trainings, the owner should inform operating personnel that working without protective equipment can be detrimental to their health.

Protective equipment is selected according to the ambient conditions at the owner’s premises and the raw materials that are used. The information provided by the material manufacturer on the safety data sheet must be adhered to in order to ensure the proper selection of protective equipment.

The recommended personal protective equipment is described below:

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Light respiratory protection

Light respiratory protection is used as protection against hazardous dusts.

Protective gloves

Protective gloves protect hands from friction, abrasion, puncture wounds, or deeper injuries, as well as from contact with hot surfaces.

Safety goggles

Safety goggles are used to protect the eyes from airborne components and splashes of liquid.

Protective clothing

Protective clothing are tight fitting work clothes with low tear resistance, with tight sleeves, and without any protruding parts.

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Safety shoes

Safety shoes protect the feet against crushing, falling parts or slipping on slippery ground.

Safety helmet

The helmet protects the head from falling parts and oscillating loads on the one hand, and it can protect it from injuries in cramped situations on the other.

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Operating instructions

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3 Safety and responsibility

3.1 Responsibility of the owner

Owner

The owner is the person, who directly operates the machine for commercial or economical purposes or who allows a third-party to use/apply it and who is responsible for the legal product stewardship for the protection of the user, the personnel or third parties.

Owner responsibilities

The machine is used in an industrial environment. The owner of the machine is therefore subject to the obligations as stipulated by the Occupational Health and Safety Act.

In addition to the safety information in this manual, the country-specific safety, accident prevention guidelines and environmental protection regulations, applicable at the site of implementation of the machine must be adhered to.

Furthermore, the owner is responsible for making sure that the machine is always in perfect technical condition. Therefore, the following applies:

n The owner must ensure that the maintenance intervals described in this operating manual are

adhered to.

n The owner must have all safety equipment checked regularly for functionality and complete-

ness.

3.2 Intended use

The automatic spray gun is used to spray paints, colours, adhesives, glazes, enamels, release agents, as well as other fluids. The nozzle size depends on the spray viscosity of the spray fluid.

The intended use also includes the compliance with all the information in this operating manual.

3.3 Specification for the operation of a complete machine

n The operation without CE-marking is prohibited. n Prior to its use, the automatic spray gun must be assembled to form a complete machine. n Only operate the automatic spray gun after proper fastening on a suitable carrier construction.

3.4 Predictable misuse

Any use beyond the intended use or any other use constitutes misuse.

n Only carry out the installation and start-up in accordance with the steps described in this oper-

ating manual.

n Always observe the applicable country-specific safety, accident prevention, occupational

safety, and environmental protection regulations for the area of use for the automatic spray gun.

n Ensure that the utilised hose lines fulfil the requirements with respect to pressure, chemical,

and mechanical loads.

n Do not use sharply abrasive, chemically aggressive, very hot or very cold spray media without

first consulting with and receiving approval from Krautzberger GmbH.

n Adhere to the safety data sheets of the spray medium manufacturer. n Only use the manufacturer's OEM parts. n Only operate the automatic spray gun after proper fastening on a suitable carrier construction. n Do not hold the automatic spray gun in your hand during operation.

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n Only operate the automatic spray gun while adhering to the values specified in ( Ä Chapter

13 ‘Technical data’ on page 45).

n Make sure that the connected compressed air is oil-free and free from solid matter. n Operate the automatic spray gun with processed, dried compressed air (air quality pursuant to

DIN ISO 8573-1: quality class 4).

n Never point the compressed air at living beings.

WARNING!

Misuse of the automatic spray gun can cause dangerous situations.

No claims of any kind can be asserted due to damage resulting from misuse!

3.5 General safety instructions

WARNING!

Life threatening risk of injury or property damage through the application of hazardous media!

The application of hazardous media can lead to death, serious injuries or property damage.

– Ensure the resistance of the machine against the medium that is to be applied. – Always adhere to the safety data sheet of the medium that is to be applied.

CAUTION!

Risk of injury through compressed air!

Uncontrolled leaks of compressed air can lead to serious injuries!

– Prior to any work on the device, all compressed-air lines must be closed and bleed if nec-

essary.

WARNING!

Sound pressure level

Depending on the operating conditions, the sound pressure of the device may cause hearing damage.

Take suitable action to reduce the impact of the existing sound pressure level. The owner is responsible for the type and implementation of suitable measures, which may depend on the local conditions.

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Outdoor operation and operation in exterior areas!

Use suitable measures to protect the device during the operation from environmental impacts in an exterior area through:

– Moisture – UV radiation – Frost, etc.

3.6 Residual risks

The automatic spray gun made by Krautzberger GmbH has been manufactured based on state-ofthe-art technology and generally accepted technical safety regulations.

Nonetheless, its use can pose a threat to the life or health of users or third parties, damage the automatic spray gun itself or cause other property damage.

n The automatic spray gun must only be used as intended. n The automatic spray gun must only be operated in a defect-free condition. n Any faults impacting the safety must be remedied immediately.

3.7 Course of action in an emergency

In principle, the applicable national, regional and internal company regulations concerning the course of action in case of an emergency must be adhered to and if necessary respective safety measures must be taken on the system owner's side.

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4 Transport, storage, and packaging

4.1 Transport

n The automatic spray gun is protected by cardboard packaging. n The cardboard packaging can be reused for storage.

4.2 Storage

Store the automatic spray gun under the following conditions:

n Store the automatic spray gun in the original packaging. n Do not store outside. n Store in a dry and dust-free environment. n Keep away from any aggressive media. n Protect from UV radiation. n Avoid mechanical shocks. n Storage temperature: 15 to 40 °C. n Relative atmospheric humidity: max. 60%.

4.3 Packaging

The automatic spray gun is packaged in accordance with the anticipated transport conditions and the packaging needs to protect it against transport damage, corrosion, and other damage.

n Remove packaging material. n Remove potentially present transport safety restraints.

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5 Overview

Fig. 2: Overview

1 Needle stroke setting * 2 Main element 3 Cap nut 4 Air nozzle 5 Lever for adapter plug connector * 6 Adapter 7 Retaining bolt * F Connection for flat jet

Operating instructions

M↑ Connection for material supply (input

M↓ Connection of fluid circulation line

R Connection for round jet ST A Connection for control air "OPEN" ST Z Connection of control air "CLOSED"

T-Dok-449-GB-Rev.7

"M")

(output "M") *

(optional)

The connections are marked with letter abbreviations.

* optional / dependent on configuration

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6 Installation

6.1 Safety

Personnel:

Specialised personnel

n

Protective equipment:

The selection of the protective equipment depends on the installation conditions on site. Always observe the applicable country-specific safety, accident prevention, occupational safety, and environmental protection regulations for the proper selection of the protective equipment.

WARNING!

Danger of injury due to improper assembly!

Recoil forces and vibrations occur during the operation. In case of insufficient fastening, the automatic spray gun may come loose and cause serious injuries or property damage.

Note:

– Ensure sufficient fastening of the automatic spray gun.

CAUTION!

Risk of injury due to sharp edges!

Sharp edges and pointed corners can cause abrasions and cuts on the skin.

Note:

– Proceed cautiously when working on or near sharp edges and pointed corners. – Wear protective gloves, if in doubt.

6.2 General installation information

Adhere to the following general information for the installation:

n Only carry out the installation and start-up in accordance with the steps described in this oper-

ating manual.

n Ensure that the utilised hose lines meet the requirements for pressure, chemical and mechan-

ical loads.

n Only operate the automatic spray gun after proper fastening on a suitable carrier construction. n Make sure that the connected compressed air is oil-free and free from solid matter. n Operate the automatic spray gun with processed, dried compressed air (air quality pursuant to

DIN ISO 8573-1: quality class 4).

n Vibration and recoil forces may occur on the automatic spray gun during the operation.

Ensure sufficient fastening.

n Never point the compressed air at living beings.

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6.3 Installing the automatic spray gun

Changing the installation position of the automatic spray gun

To change the installation position of the automatic spray gun, the retaining bolt ( Fig. 3/2) can be screwed into the adapter ( Fig. 3/1) from the other side.

Fig. 3: Installing the automatic spray gun

1. Fasten the adapter ( Fig. 3/1) with the retaining bolts ( Fig. 3/2) to a suitable construction.

2.

The main element is either plugged in ( Ä Chapter 6.4.1 ‘Plugged-in design’ on page 19) or screwed on ( Ä Chapter 6.4.2 ‘Screw-type design’ on page 20) depending on the design.

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6.4 Changing the main elements

6.4.1 Plugged-in design

Removing the main elements

Fig. 4: Removing the main elements

1. Turn the lever ( Fig. 4/3) to the unlocking position.

The unlocking and locking positions are indicated by the symbols and .

2. Press the lever ( Fig. 4/3) in and pull the main element ( Fig. 4/1) off the adapter ( Fig. 4/4).

Mounting the main elements

1. Turn the lever ( Fig. 4/3) to the unlocking position.

2. Insert the main element ( Fig. 4/1) with the clamp bolts ( Fig. 4/2) into the adapter ( Fig. 4/4)

and let them snap in.

3. Turn the lever ( Fig. 4/3) to the locking position.

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6.4.2 Screw-type design

Removing the main elements

Fig. 5: Removing the main elements

1. Loosen the screw ( Fig. 53).

2. Remove the main element ( Fig. 5/1) from the adapter ( Fig. 5/2).

Mounting the main elements

1. Push the main element ( Fig. 5/1) onto the adapter ( Fig. 5/2).

2. Screw on the main element ( Fig. 5/1) and adapter ( Fig. 5/2) with the screw ( Fig. 5/3).

6.5 Nozzle fixing (optional)

Flat jet nozzles can be adjusted to adapt to the workpiece geometry either seamlessly or in 45° increments.

Fig. 6: Nozzle fixing

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Automatic spray gun RA 5

1. Loosen cap nut.

2. Turn flat jet nozzle anti-clockwise to the desired position.

NOTICE!

Property damage due to incorrect operation!

– The flat jet nozzle may only be turned anti-clockwise.

3. Tighten cap nut.

6.6 Connecting the automatic spray gun

6.7 Connection scheme

Fig. 8: Connection scheme

1 Compressed-air port 2 Ball cock 3 Oil- /water separator 4 Compressed air regulator round jet

4.1 Solenoid valve round jet ON 5 Pressure jet regulator flat jet

5.1 Solenoid valve flat jet air ON 6 Solenoid valve ON 7 Solenoid valve OFF

9 Back pressure regulators 10 Container F Flat jet air R Round jet air ST A Open control air ST Z Close control air (double controller,

optional) M Fluid connection M Circulation connection (optional)

8 Pump

6.8 Preliminary air control

Absolutely adhere to the preliminary air control "F" and "R" according to the scheme. Otherwise, fluid can escape non-atomised from the fluid nozzle at the beginning of the spraying procedure and when ending the spray procedure, the nozzles can be soiled or clogged.

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Fig. 9: Preliminary air control

F Flat jet air R Round jet air ST A Control air ON ST Z Control air OFF (double controller) p Air ON 0 Air OFF t Time t

Time until the atomiser air is stable

1

t

Automatic spray gun in operation

2

t

Time until the nozzle is blown clean

3

Operating instructions

T-Dok-449-GB-Rev.7

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7 Operation

7.1 Safety

Personnel:

User

n

Specialised personnel

n

Protective equipment:

The selection of the personal protective equipment depends on the utilised medium of the system owner. The information provided by the medium manufacturer indicated on the safety data sheet must be adhered to in order to ensure the proper selection of personal protective equipment.

WARNING!

Risk of injury due to improper operation!

Improper operation can lead to serious personal injuries or property damage.

Note:

– Never point compressed air at people. – Check the material and compressed air hose lines before each use for damage and tight

fit. – Adhere to the spray media manufacturer's specifications in the safety data sheet. – Make sure that the connected compressed air is oil-free and free of solid matter.

WARNING!

Life threatening risk of injury or property damage through the application of hazardous media!

The application of hazardous media can lead to death, severe injuries or property damage.

Note:

– Ensure the resistance of the device/machine against the medium that is to be applied. – Always adhere to the safety data sheet of the medium that is to be applied.

The owner is responsible for the presence and the up-to-date status of the safety data

sheet and the associated generation of the risk assessment of the effected workstations.

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Operating instructions

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WARNING!

Risk of fatal injury, risk of injury or property damage due to damaged or disconnected lines!

Damaged or disconnected lines can cause death, serious injuries or property damage due to whip-like movements and the spraying of fluids.

Note:

– Check the fluid pressure lines for damage and a tight fit prior to every work process.

7.2 General information about commissioning and start-up

Adhere to the following general information for the start-up:

n Only carry out the commissioning of the automatic spray gun pursuant to the steps described

in this operating manual.

n Check the material and compressed air hose lines for damage and tight fit before each use. n Always observe the applicable country-specific safety, accident prevention, occupational

safety, and environmental protection regulations applicable for the area of use for the automatic spray gun.

n Do not use sharply abrasive, chemically aggressive, very hot or very cold spray media without

first consulting with and receiving approval from Krautzberger GmbH.

n Adhere to the safety data sheets of the spray medium manufacturer. n Only operate the automatic spray gun while adhering to the values specified in (

Ä

Chapter

13 ‘Technical data’ on page 45).

n Only operate the automatic spray gun after proper fastening on a suitable carrier construction. n Do not hold the automatic spray gun in your hand during operation. n Never point the compressed air at living beings. n Adhere to the operating manuals for the respective components.

7.3 Operation

To achieve optimal results, adhere to the following:

– Rinse the automatic spray gun with cleaning products before commissioning. – Too-high air pressure causes unnecessarily high air consumption and too-strong atomi-

sation of the spray fluid.

– Too-low air pressure produces an unsatisfactory spray pattern. – Select the lowest possible fluid pressure.

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WARNING!

Sound pressure level

Depending on the operating conditions, the sound pressure of the device may cause hearing damage.

Take suitable action to reduce the impact of the existing sound pressure level. The owner is responsible for the type and implementation of suitable measures, which may depend on the local conditions.

CAUTION!

Risk of injury caused by compressed air!

Uncontrolled leaks of compressed air can lead to serious injuries.

Note:

– Check the compressed-air hoses for damage and tight fit before start-up. – Check compressed air hoses for proper connection prior to start-up. – Never point compressed air at living beings.

1. Make sure that the control air and atomiser air connections are not reversed.

2. Close the control air (connection "St A").

3. "Open" material supply.

Depending on the type of material supply, the "opening" of the material supply is carried out

– By opening the connection tap – By applying pressure to the storage container – By filling the material into a storage container (hydrostatic inherent pressure).

4. Open the control air.

The fluid is sprayed. Generally, the adjustment of the spray pattern is now required (

ð

Ä

Chapter 7.4 ‘Adjusting the spray pattern’ on page 27).

7.4 Adjusting the spray pattern

There are air and fluid nozzles in available various sizes. There are 4 different families:

n Round jet – cone-shaped jet in front of the nozzle. n Flat jet – width-adjustable jet for flat-shaped application. Depending on the design, flat jet

nozzles can be adjusted to adapt steplessly to the workpiece geometry or in 45° increments.

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Operating instructions

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n Rotary stream – a rotary pulse produces a highly “swirled” spray jet; for difficult workpiece

geometries (angular sections etc.).

n Full-cone rotary stream – a rotary pulse produces a highly “swirled” spray jet; for difficult

workpiece geometries (back cuts, etc.).

Adjust the spray pattern with the following measures:

n Change the atomiser air pressure. n Change the pressure of the spray fluid. n Select another nozzle size. n Adjust the needle stroke (optional) (

Ä

Chapter 7.5 ‘Adjusting the needle stroke’ on page 28).

Too-high air pressure causes unnecessarily high air consumption and too-strong atomisation of the spray fluid. It is recommended that you first adjust the spray pattern by varying the air and spray fluid pressure. If you cannot achieve satisfactory results this way, you should experiment with other nozzle sizes.

To reduce overspray and the concentration of harmful substances when coating, observe the following points:

n Guide the spray jet vertically to the surface n Adjust the spray jet to suit the geometry of the workpiece n The spray gun should be as close to the workpiece as possible n Always spray in the extraction direction

7.5 Adjusting the needle stroke

Fig. 10: Adjusting the needle stroke

1. Pull out the needle stroke adjustment screw ( Fig. 10/1) until it loosens.

2. Adjust the needle stroke by turning the needle stroke adjustment screw ( Fig. 10/1).

3. Push in the needle stroke adjustment screw ( Fig. 10/1) until it tightens again.

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7.6 Shutting down

7.6.1 Temporary shut-down

Fig. 11: Shutting down

End the spray procedure by switching off the control air (connection "St A", Fig. 11/1).

7.6.2 Long-term shut-down

1. End the spray procedure by switching off the control air (connection "St A", Fig. 11/1).

2. Close the material supply and switch off the fluid pressure pump or the pressure container if

necessary.

3.

If necessary, clean the automatic spray gun ( Ä Chapter 8.3 ‘Cleaning the automatic spray gun’ on page 31).

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8 Maintenance

8.1 Safety

Personnel:

Specialised personnel

n

Protective equipment:

The selection of the protective equipment depends on the maintenance conditions on site and the medium utilized by the system owner. The applicable country-specific safety, accident prevention, occupational safety, and environmental protection regulations must adhered to for the proper selection of the protective equipment and the information given by the spray media manufacturer on the safety data sheet must be taken into consideration.

WARNING!

Risk of injury through the use of incorrect spare parts!

The use of incorrect or defective spare parts can cause hazards for the personnel as well as damage, malfunctions or complete failure.

– Only use OEM parts from Krautzberger or Krautzberger-approved spare parts. – In case of questions, always contact our Customer Care department.

CAUTION!

Risk of injury through compressed air!

Uncontrolled leaks of compressed air can lead to serious injuries!

– Prior to any work on the device, all compressed-air lines must be closed and bleed if nec-

essary.

Hose and pipelines

Even with intended use by environmental influences, the service life of hose lines and pipelines is limited. For the sake of prevention, all hose and pipelines should be replaced regularly according to their load.

8.2 Maintenance schedule

The following sections describe the maintenance work that is required for optimal and fault-free operation of the automatic spray gun. Check wearing parts such as seals, nozzles and needles at regular intervals. The level of wear depends on the abrasiveness of the spray fluid used. Escaping air and spray fluid as well as the deterioration of the spray pattern are signs that parts are worn. Contact Krautzberger Customer Care with any questions on maintenance work and maintenance intervals.

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Interval Maintenance work Personnel

before performing any maintenance work

Clean the automatic spray gun ( Ä Chapter 8.3 ‘Cleaning the automatic spray gun’ on page 31)

if needed Change material nozzle and air nozzle (

Ä

Chapter 8.4 ‘Changing the material nozzle

Specialised personnel

and the air nozzle’ on page 33)

Change fluid needle ( Ä Chapter 8.5 ‘Changing

Specialised personnel

the fluid needle’ on page 34)

Change needle seals ( Ä Chapter 8.6

Specialised personnel

‘Changing the needle seals’ on page 37)

Always replace material nozzle and material needle at the same time ( Ä Chapter 8.4 ‘Changing the material nozzle and the air nozzle’ on page 33) and ( Ä Chapter 8.5 ‘Changing the fluid needle’ on page 34).

8.3 Cleaning the automatic spray gun

WARNING!

Risk of injury due to improper cleaning!

– Adhere to the safety data sheets of the cleaning product manufacturer. – Do not fully immerse the automatic spray gun in a cleaning product.

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Operating instructions

1.

Interrupt the operation ( Ä Chapter 7.6 ‘Shutting down’ on page 29).

T-Dok-449-GB-Rev.7

2. Switch off the system and secure it against being switched on again.

3. Connect cleaning product to input "M".

For design with circulation connection (optional), connect the fluid circulation line to output "M".

The fluid connections are marked with arrows and must not be interchanged.

4. Switch on the compressed air supply.

5. Where applicable, switch on fluid pressure pump or pressure container for cleaning

product.

6. Begin the spraying procedure by switching on the control air (connection "ST A").

7. Spray until the cleaning product runs clear.

8. Interrupt the supply of cleaning product by switching off the fluid pressure pump or the pres-

sure container.

9. Blow out cleaning product residue by briefly switching on the control air.

10. Switch off the compressed air supply and secure it against a restart.

11. Clean the outside of the device with a cloth dipped in cleaning product.

12.

Remove fluid and air nozzle ( Ä Chapter 8.4 ‘Changing the material nozzle and the air nozzle’ on page 33) and clean with a soft brush. Do not use hard or sharp-edged objects.

We recommend our brush set. See the last page for contact information.

13. Slightly grease sliding parts with special Krautzberger grease.

The special grease can be purchased from Krautzberger GmbH (contact data see last page).

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Automatic spray gun RA 5

8.4 Changing the material nozzle and the air nozzle

Removing the nozzles

Fig. 12: Removing the nozzles

1. Loosen cap nut ( Fig. 12/4).

2. Remove the air nozzle ( Fig. 12/3).

3. Unscrew the fluid nozzle ( Fig. 12/2) with a flat spanner.

Always change the fluid nozzle and needle together ( Ä Chapter 8.5 ‘Changing the fluid needle’ on page 34).

ENGLISH

Attaching the nozzles

1.

The air distributor ring ( Fig. 12/1) is only required for flat jet nozzles. When fitting the automatic spray gun with round or flat jet nozzles, the air distributor ring ( Fig. 12/1) is not mounted but it is included in the scope of delivery.

If necessary, make sure that the air distributor ring ( Fig. 12/1) is positioned correctly.

2. Screw on the fluid nozzle ( Fig. 12/2) with a flat spanner.

3. Attach the air nozzle ( Fig. 12/3) and tighten it with the cap nut ( Fig. 12/4).

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Operating instructions

T-Dok-449-GB-Rev.7

8.5 Changing the fluid needle

Removing the fluid needle

Fig. 13: Removing fluid needle

1. Loosen the screws ( Fig. 13/1) slightly.

2.

Locking piece ( Fig. 13/6) (optional) is under spring force.

Turn the locking piece ( Fig. 13/6) (or depending on the design of the cover) slightly anticlockwise and remove it.

3. Remove the pressure spring ( Fig. 13/4) and if necessary the seal ( Fig. 13/5) (only for double controller).

4. Screw a screw ( Fig. 13/1) into the control piston ( Fig. 13/7).

5. Pull out the control piston ( Fig. 13/7) from the main element ( Fig. 13/8) using the screw (

Fig. 13/1).

Fig. 14: Removing fluid needle

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Automatic spray gun RA 5

6.

CAUTION!

Risk of injury due to fluid needles!

Remove the fluid needle ( Fig. 14/4) from the control piston ( Fig. 14/3).

7.

WARNING!

Risk of injury through the use of incorrect spare parts!

Check the condition of the seals ( Fig. 14/1 and 2), replace the seals if necessary.

ENGLISH

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Operating instructions

T-Dok-449-GB-Rev.7

Attaching the fluid needle

Fig. 15: Attaching the fluid needle

1.

CAUTION!

Risk of injury due to fluid needles!

Hook a new fluid needle ( Fig. 15/2) into the control piston ( Fig. 15/3).

2. Ensure that the needle stroke adjustment ( Fig. 15/4) (optionally) is relaxed. If necessary, release the pressure by turning anti-clockwise.

3. Push the fluid needle ( Fig. 15/2) with the control piston ( Fig. 15/3) into the main element ( Fig. 15/1).

Fig. 16: Attaching the fluid needle

4. Unscrew the screw ( Fig. 16/2) from the control piston ( Fig. 16/6) and screw it into the main element again ( Fig. 16/7).

5. Make sure that the seal ( Fig. 16/4) is seated properly.

6. Press in the pressure spring ( Fig. 16/3) with the locking part ( Fig. 16/5).

7. Hook the locking part ( Fig. 16/5) into the screws ( Fig. 16/1).

8. Tighten the screws ( Fig. 161) evenly.

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Automatic spray gun RA 5

ENGLISH

9. After assembly, check the tight fit of all parts.

10. Check moving parts to make sure they run easily.

8.6 Changing the needle seals

Removing the needle seals

1.

Remove the material needle ( Ä Chapter 8.5 ‘Changing the fluid needle’ on page 34).

Fig. 17: Removing the needle seals

2. Unscrew the clamping screw ( Fig. 17/4) with a box spanner.

3. Remove the slotted ring ( Fig. 17/5) from the clamping screw ( Fig. 17/4).

4. Remove the bracket ( Fig. 17/2) and slotted ring ( Fig. 17/1) from the bracket ( Fig. 17/2).

5. Check the condition of the O-ring ( Fig. 17/3), replace if necessary.

6. Replace the slotted rings ( Fig. 17/1 and 5).

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Operating instructions

T-Dok-449-GB-Rev.7

Inserting the needle seals

1.

WARNING!

Risk of injury through the use of incorrect spare parts!

Insert the slotted ring ( Fig. 17/1) into the bracket ( Fig. 17/2). Here, make sure that the slotted ring ( Fig. 18/1) is in the correct position.

2. Make sure that the O-ring ( Fig. 17/3) fits correctly on the clamping screw ( Fig. 17/4). Ensure that the slotted ring ( Fig. 17/5) is correctly positioned in the clamping screw ( Fig. 17/4).

Fig. 18: Installation state

3. Place the bracket ( Fig. 17/2) with the slotted ring ( Fig. 17/1) onto the material needle and then slide it into the main element.

4. Screw in the bracket with the socket wrench until you feel gentle resistance.

5. Press the material needle with the material nozzle firmly into the main element ( Fig. 17/6).

6. Tighten the complete package with the socket wrench.

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Automatic spray gun RA 5

ENGLISH

9 Troubleshooting

Personnel:

Qualified personnel

n

If the fault is not included in the following tables or if it cannot be eliminated with the measures described, contact Krautzberger Customer Care.

Spray pattern Error Cause Remedy

Normal flat jet spray pattern

Spray pattern too heavy towards the top and towards the bottom

Spray pattern concentrated on the left or right side

Heavy application in the centre of the spray pattern

Split spray pattern

Spray pattern too thin

n Dirty air nozzle n Dirty fluid nozzle

Clean nozzles (

Ä

Chapter 8.3 ‘Cleaning the automatic spray gun’ on page 31)

n Dirty air nozzle n Dirty fluid nozzle

Clean nozzles (

Ä

Chapter 8.3 ‘Cleaning the automatic spray gun’ on page 31)

n Too much mate-

rial

n Reduce material

supply

n Material too thick n Thin material

n Insufficient mate-

rial

n Flat jet air pres-

sure too high

n Cap nut loose

n Increase material

supply

n Reduce flat jet air

pressure

Tighten cap nut

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Operating instructions

Spray pattern Error Cause Remedy

Fluid jet comes out in spurts or rapid bursts

n Insufficient mate-

rial supply

n Increase material

supply

n Blocked fluid path n Clean

n Loose or dam-

aged fluid nozzle

n Tighten or replace

( Ä Chapter 8.4 ‘Changing the material nozzle and the air nozzle’ on page 33)

n Worn needle seal n Replace needle

seal ( Ä Chapter

8.6 ‘Changing the needle seals’ on page 37)

Leakage on the clamping screw

n Needle seal

defective

n Replace needle

seal ( Ä Chapter

8.6 ‘Changing the needle seals’ on page 37)

Fluid nozzle drips

n Worn or damaged

fluid needle

n Change fluid

needle (

Ä

‘Changing the fluid needle’ on page 34)

n Dirty or damaged

fluid nozzle

n Clean (

Ä

‘Cleaning the automatic spray gun’ on page 31)

or replace fluid nozzle (

Ä

‘Changing the material nozzle and the air nozzle’ on page 33)

- Spray pattern change after reassembly. Atomisers for round

n Air distributor ring

installed wrong way

n Remove air dis-

tributor ring and

install correctly and flat jets can no longer be regulated separately

T-Dok-449-GB-Rev.7

Chapter 8.5

Chapter 8.3

Chapter 8.4

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Automatic spray gun RA 5

9.1 Customer Care

Krautzberger GmbH

Customer service

Stockbornstr. 13

65343 Eltville am Rhein

+49 6123 - 698151

customercare@krautzberger.com

ENGLISH

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GB–41

Operating instructions

10 Spare parts

– Only use OEM parts from Krautzberger or Krautzberger-approved spare parts. – In case of questions, always contact our Customer Care department.

Spare parts order – General

To make spare part ordering easier, please provide the following information:

– Serial number – Model / product name – Designation – Item number according to spare parts list – Quantity – Desired shipping method (post, freight, sea, air, express) – Delivery address

T-Dok-449-GB-Rev.7

A complete spare part overview is available on the website of Krautzberger GmbH:

www.krautzberger.de

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Automatic spray gun RA 5

ENGLISH

11 Accessories

A wide range of accessories is available for the automatic spray gun. For further information, visit us on the Internet (www.krautzberger.com) or contact your Krautzberger specialist dealer, consultant or our office staff. Here are a few examples:

n Air nozzles n Fluid needles n Fluid nozzles n Arm extension for robot n etc.

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Operating instructions

T-Dok-449-GB-Rev.7

12 Disassembly and disposal

12.1 Safety

Personnel:

Qualified personnel

n

Protective equipment:

The selection of the protective equipment depends on the environmental conditions at the site of the owner and the coating material that is used. To ensure the proper selection of personal protective equipment, the information provided by the spray material manufacturer indicated on the safety data sheet must be adhered to.

12.2 Disassembly

WARNING!

Risk of injury due to improper disassembly!

Prior to starting the disassembly:

n Switch off the device and secure it against a restart. n Physically disconnect the entire power supply from the device, and discharge any energy

stored in the machine.

n Remove and dispose of operating and auxiliary material as well as remaining processing

materials in an environmentally friendly manner.

Afterwards, properly clean components and modules and take them apart in compliance with applicable local occupational health & safety regulations as well as environmental protection regulations.

12.3 Disposal

ENVIRONMENT!

Danger to the environment due to incorrect disposal!

Incorrect disposal may cause dangers to the environment.

If no return or disposal agreement has been made, recycle the dismantled parts:

n Scrap metals. n Recycle plastic components. n Sort remaining components based on the respective material and dispose of them accord-

ingly.

n Properly dispose of potential spray media residue separately from the device.

If in doubt, obtain information about environmentally-appropriate disposal from the local authorities or specialised disposal companies.

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Automatic spray gun RA 5

ENGLISH

13 Technical data

13.1 Dimensions and weight

Specification Value Unit

Width 94.5 mm

Height max. 86.5 mm

Length 113 mm

Connection for spray fluid (M) female * G1/8 "

Connection for atomiser air (R, F) female * G1/8 "

Connection for control air (St) female * M5 -

Weight aluminium design 0.55 kg

Weight stainless steel housing 0.97 kg

* female = internal thread

13.2 General specifications

Specification Value Unit

Working pressure control air (St) max. 8 bar

Working pressure spray fluid (M) max. 12 bar

Working pressure atomiser air (R, F) max. 8 bar

Sound pressure level depends on the nozzle approx. 73 - 96 dB(A)

Spray medium temperature max. 50 °C

13.3 Dimensions

Fig. 19: Dimensions

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Operating instructions

14 Declaration of incorporation

T-Dok-449-GB-Rev.7

Fig. 20: Declaration of incorporation

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Automatic spray gun RA 5

ENGLISH

15 Notes

______________________________________________________________________________

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Operating instructions

T-Dok-449-GB-Rev.7

______________________________________________________________________________

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Automatic spray gun RA 5

ENGLISH

______________________________________________________________________________

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Operating instructions

T-Dok-449-GB-Rev.7

16 Index

C

Cleaning ......................................................31

Complete machine ................................................12

Connection values ................................................45

D

Delivery ......................................................15

Dimensions ....................................................45

Disassembly ...................................................44

E

Emissions .....................................................45

F

Function description ...............................................5

H

Health .......................................................13

I

Item number ....................................................6

M

Measurements ..................................................45

Model plate .....................................................6

N

Noise emission ..................................................45

O

Operating pressures ...............................................45

Owner .......................................................12

P

Personnel ......................................................9

Pictograms .....................................................7

R

Recycling .....................................................44

S

Serial number ...................................................6

Sound pressure level ..............................................45

Storage ......................................................15

Symbols .......................................................7

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Automatic spray gun RA 5

ENGLISH

T

Temperature specifications ..........................................45

Troubleshooting table ..............................................39

U

User qualification .................................................9

W

Weight .......................................................45

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GB–51

Krautzberger GmbH Stockbornstrasse 13 D-65343 Eltville am Rhein, Germany

Hotline: +49 (0) 6123 698-222 Head Office: +49 (0) 6123 698-0 Fax: +49 (0) 6123 698-200 Email: mail@krautzberger.com Internet: www.krautzberger.com

Krautzberger RA 5 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

1 Function and identification

1.1 Function

1.2 Identification

2 Using this operating manual

2.1 Information about the operating manual

2.2 Symbols in this operating manual

2.3 Personnel requirements

2.4 Personal protective equipment

3 Safety and responsibility

3.1 Responsibility of the owner

3.2 Intended use

3.3 Specification for the operation of a complete machine

3.4 Predictable misuse

3.5 General safety instructions

3.6 Residual risks

3.7 Course of action in an emergency

4 Transport, storage, and packaging

4.1 Transport

4.2 Storage

4.3 Packaging

5 Overview

6 Installation

6.1 Safety

6.2 General installation information

6.3 Installing the automatic spray gun

6.4 Changing the main elements

6.4.1 Plugged-in design

6.4.2 Screw-type design

6.5 Nozzle fixing (optional)

6.6 Connecting the automatic spray gun

6.7 Connection scheme

6.8 Preliminary air control

7 Operation

7.1 Safety

7.2 General information about commissioning and start-up

7.3 Operation

7.4 Adjusting the spray pattern

7.5 Adjusting the needle stroke

7.6 Shutting down

7.6.1 Temporary shut-down

7.6.2 Long-term shut-down

8 Maintenance

8.1 Safety

8.2 Maintenance schedule

8.3 Cleaning the automatic spray gun

8.4 Changing the material nozzle and the air nozzle

8.5 Changing the fluid needle

8.6 Changing the needle seals

9 Troubleshooting

9.1 Customer Care

10 Spare parts

11 Accessories

12 Disassembly and disposal

12.1 Safety

12.2 Disassembly

12.3 Disposal

13 Technical data

13.1 Dimensions and weight

13.2 General specifications

13.3 Dimensions

14 Declaration of incorporation

15 Notes

16 Index