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PEA-C4-HiCoat
Automatic Powder Gun
Version 05/2019
0102
P_01610
II 2D 2mJ
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VERSION 05/2019
ORDER NUMBER DOC390829
PEA-C4-HiCoat
Table of Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 8
2 CORRECT USE 9
2.1 Device Type 9
2.2 Type of Use 9
2.3 For Use in Potentially Explosive Areas 9
2.4 Processible Working Materials 9
2.5 Misuse 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Type Plate 10
3.3 Permissible Device Combinations 10
4 BASIC SAFETY INSTRUCTIONS 11
4.1 Safety Instructions for the Operator 11
4.1.1 Electrical Devices and Equipment 11
4.1.2 A Safe Work Environment 12
4.1.3 Personnel Qualications 12
4.2 Safety Instructions for the Personnel 13
4.2.1 Personal Safety Equipment 13
4.2.2 Safe Handling of WAGNER Powder Spray Devices 13
4.2.3 Grounding the Device 14
4.2.4 Product Hoses 14
4.2.5 Electrical Connection Cables 15
4.2.6 Cleaning and Flushing 15
4.2.7 Maintenance and Repair 16
4.2.8 Protective and Monitoring Equipment 16
4.3 Information about Safe Discharges 17
5 DESCRIPTION 18
5.1 Construction of the Automatic Gun 18
5.2 Mode of Operation of the Automatic Gun 18
5.3 Scope of Delivery 19
5.4 Data 19
5.4.1 Technical Data 19
5.4.2 Dimensions 20
5.5 Accessories 21
6 ASSEMBLY AND COMMISSIONING 22
6.1 Training of Assembly/Commissioning Personnel 22
6.2 Storage Conditions 22
6.3 Installation Conditions 22
6.4 Preparing the Automatic Gun 22
6.4.1 Selection of a Suitable Nozzle System 22
6.5 Connecting the Automatic Gun 24
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6.6 Grounding 25
6.6.1 Grounding the Powder Coating System 26
6.7 Safety Checks 26
7 OPERATION 27
7.1 Training the Operating Personnel 27
7.2 Tasks 27
7.3 Switching On the Automatic Gun 27
7.4 Switching O the Automatic Gun 27
7.4.1 Switching O in Normal Operation 27
7.4.2 Switching O the Automatic Gun in the Event of Faults or Emergencies 27
7.4.3 Pressure Relief/Work Interruption 28
7.5 Optimizing the Powder Cloud for Coating 28
7.6 Reproducible Setting of the Nozzle Position 28
8 CLEANING AND MAINTENANCE 29
8.1 Cleaning 29
8.1.1 Cleaning Personnel 29
8.1.2 Cleaning Procedures 29
8.1.3 Performing a Paint Change 29
8.2 Maintenance 30
8.2.1 Maintenance Personnel 30
8.2.2 Maintenance Instructions 30
8.2.3 Safety Checks and Maintenance Intervals 30
8.2.4 Maintenance Procedures 30
8.3 Replacing the Automatic Gun 32
8.4 Removing the Flat Jet Nozzle 33
8.5 Replacing the Protective Wedge 34
8.5.1 Removing the Protective Wedge 34
8.5.2 Installing the Protective Wedge 35
8.6 Changing from Flat Jet Nozzle to Round Jet Nozzle 36
8.7 Assembling the Angle Adapter 37
8.7.1 Removing the Nozzle and Electrode Holder 37
8.7.2 Fitting the Angle Adapter 38
8.7.3 Replacing the Wearing Parts 39
8.8 Assembly of the CoronaStar 40
8.9 Assembly of the CoronaStar for Angle Adapter 41
ORDER NUMBER DOC390829
PEA-C4-HiCoat
9 TROUBLESHOOTING AND RECTIFICATION 42
10 INSPECTIONS 43
11 DISASSEMBLY AND DISPOSAL 46
11.1 Disassembly 46
11.2 Disposal 46
12 ACCESSORIES 47
12.1 Flat Jet nozzle 47
12.2 Deector Cone 47
12.3 Flat Jet Nozzle Set C4 F5 (Not FM Approved) 47
12.4 Flat Jet Nozzle C4 F5-X (Not FM Approved) 48
12.5 Flat Jet Nozzle F1-X (Not FM Approved) 48
12.6 Retrot Set CoronaStar 48
12.7 CoronaStar WA C4 49
12.8 CoronaStar PEA-C4 F5 Retrot Set 49
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12.9 Wedge Tool 49
12.10 Gun Mounting and Fixation 50
12.11 Angle Adapter 50
12.12 Hoses 50
12.13 Electrical Connection Cable 50
12.14 Powder Measuring adapter 51
12.14.1 Powder Measuring Adapter for Flat Jet Nozzle C4 51
12.14.2 Powder Measuring Adapter for Flat Jet Nozzle C4-F5/X1-F5 51
13 SPARE PARTS 52
13.1 How Can Spare Parts Be Ordered? 52
13.2 PEA-C4-HiCoat Corona Automatic Gun 53
13.3 Electrode Holder C4 R with Nozzles 54
13.4 Angle Adapter, WA90 C4 55
13.5 Angle Adapter, WA60 C4 56
13.6 Angle Adapter, WA30 C4 57
14 EU DECLARATION OF CONFORMITY 58
14.1 EU Declaration of Conformity - Automatic Gun 58
ORDER NUMBER DOC390829
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PEA-C4-HiCoat
1 ABOUT THESE INSTRUCTIONS
1.1 PREFACE
The operating manual contains information about safely operating, maintaining, cleaning and
repairing the device.
The operating manual is part of the device and must be available to the operating and service
personnel.
The device may only be operated by trained personnel and in compliance with this operating
manual.
Operating and service personnel should be instructed according to the safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this manual highlight particular dangers to users and to the device
and state measures for avoiding the hazard. These warning instructions fall into the following
categories:
DANGER
WARNING
CAUTION
NOTICE
Note:
Explanation of warning notice:
Immediate risk of danger.
Non-observance will result in death or serious injury.
Potential danger.
Non-observance may result in death or serious injury.
Potentially dangerous situation.
Non-observance may result in minor injury.
Potentially dangerous situation.
Non-observance may result in damage to property.
Provides information about particular characteristics and
how to proceed.
LEVEL OF DANGER
This notice warns you of a danger!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.
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1.3 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
French 390836 Danish 390870
Italian 390840 Serbian 390871
Spanish 390851 Norwegian 390880
Russian 2335894 Slovenian 390863
Chinese -- Czech 390896
Dutch 390876 Polish 2320221
Swedish 2400205 Turkish 2400976
Hungarian 2338222 -- --
Additional languages on request or at: www.wagner-group.com
ORDER NUMBER DOC390829
PEA-C4-HiCoat
1.4 ABBREVIATIONS
Order no. Order number
Spare part
Marking in the spare parts lists
Position
Number of pieces
-- Item not available as spare part
/ Item does not exist
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1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning agent
Flushing Internal ushing of paint-wetted parts with compressed air
Personnel qualications
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.
Electrically trained
person
Electrician Can assess the work assigned to him/her and detect possible
Skilled person in the
context of
DGUV 209-052
Is instructed by an electrician about the tasks assigned to him/her,
the potential risks associated with improper behavior as well as
the necessary protective devices and measures.
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
A person who, based on his/her technical training, experience and
recent vocational experience, has sucient technical knowledge
in the area of electrostatic coating and is familiar with the relevant
and generally accepted rules of technology so that he/she can
inspect and assess the status of devices and coating systems
based on workplace safety.
in TRBS1203(2010/amendment 2012): Expert knowledge in the
areas of protection against excessive pressure, electrical hazards,
and explosion protection (where applicable).
ORDER NUMBER DOC390829
Additional requirements for skilled persons can also be found
PEA-C4-HiCoat
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PEA-C4-HiCoat
2 CORRECT USE
2.1 DEVICE TYPE
Automatic powder gun for the automatic coating of grounded workpieces.
2.2 TYPE OF USE
The automatic PEA-C4 HiCoat gun serves as stationary equipment for industrial electrostatic
coating with ignitable powder in automatic systems. It can be operated either with single
control units or switch cabinet modules.
WAGNER explicitly prohibits any other use!
The automatic powder gun may only be operated in a temperature range from 5–40 °C;
41–104 °F.
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
Follow the instructions in the operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
This type A-P electrostatic powder gun is suitable for processing industrial powder lacquers
for coating electrically conductive objects and can be used in potentially explosive areas
(zone 22) (see Explosion Protection Identication, Chapter 3.1).
In explosion hazard areas, only use approved explosion-proof electrical devices.
2.4 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.
2.5 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;
no food, medicine or cosmetics are processed.
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
Device type: Automatic powder gun, PEA-C4 HiCoat
Manufacturer: Wagner International AG
9450 Altstätten
Switzerland
PEA-C4-HiCoat
0102
II 2D 2mJ
CE European Communities
0102 Notied body: PTB
Ex Symbol for explosion protection
II Device class II
2 Category 2
D Ex-atmosphere dust
2 mJ Maximum ignition energy 2 mJ
3.2 TYPE PLATE
PEA-C4 Serial Number:
0102 II 2 D 2mJ
PTB 05 ATEX 5008
Made in Switzerland
P_03903
3.3 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
– PEA-C4-HiCoat – EPG-Sprint – EPG Prima – HVM-DP
– EPG-Sprint X – EPG 2008 – EPG-DP 5
– EPG-Sprint XE – EPG 2007 – EPG–SL 5
– EPG-D1 – HVM-D 1 – EPG 2025 Digiow
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4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning accident prevention regulations.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Danger of electric shock!
Danger to life from electric shock.
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision.
With open housings, the mains voltage poses a danger.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if device poses a danger or is damaged.
Must be de-energized before work is commenced. Secure the device against being
switched back on without authorization. Inform personnel about planned work.
Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground wire
connection.
Keep liquids away from electrical devices.
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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 oor in the working area must be electrostatically conductive
(measurements according to EN 1081 and EN 61340-4-1).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts are
reliable and continuous and can withstand the expected stress (e.g., mechanical stress,
corrosion).
Ensure that personal protective equipment (see Chapter 4.2.1) is available and is used.
Ensure that all persons within the working area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 M .
Protective clothing, including gloves, must comply with EN 1149-5.
The measured insulation resistance must not exceed 100 M .
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. No smoking.
Maintain sucient quantities of suitable re extinguishers and ensure that they are
serviceable.
The powder release must be electronically interlocked with the powder spray system
exhaust equipment.
Excess coating product (overspray) must be collected up safely.
The operating company must ensure that an average concentration of powder lacquer
in the air does not exceed 50% of the lower explosion limit (LEL = max. permitted
concentration of powder to air). If no reliable LEL value is available, the average
concentration must not exceed 10 g/m³.
Ensure that maintenance and safety checks are performed regularly.
In the event of defects, immediately bring the device or system to a stop and arrange
to have repairs carried out immediately.
ORDER NUMBER DOC390829
PEA-C4-HiCoat
4.1.3 PERSONNEL QUALIFICATIONS
Danger due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in accordance
with the operating manual and the operating instructions. The device must only
be operated, maintained and repaired by trained personnel. Refer to the operating
instructions for information about the required personnel qualications.
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4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning accident prevention regulations.
In electrostatics applications: Persons belonging to a risk group according to
EMF guideline 2013/35/EU (e.g., carriers of active implants), must not enter the
high-voltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Danger due to dust formation!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
Observe the processing regulations laid down by the manufacturer of the powder
lacquer being used, when preparing or processing the powder.
Take note of the manufacturer’s notication and the relevant environmental protection
regulations when disposing of powder lacquers.
Take the specied protective measures. In particular, wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient health and environmental safety: Operate the device in a powder coating
booth or on a spraying wall with the ventilation (extraction) switched on.
ORDER NUMBER DOC390829
PEA-C4-HiCoat
4.2.2 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
Danger due to dust formation!
Do not point spray guns at people.
Do not spray device parts using electrostatic equipment.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve pressure on powder spray gun and device.
– Secure the powder spray gun against actuation.
– Disconnect the control unit from the mains.
– In the event of functional faults: remedy the fault as described in the
"Troubleshooting" chapter.
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4.2.3 GROUNDING THE DEVICE
Danger due to electrostatic charge!
Explosion hazard and damage to the device.
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the device.
Flames or sparks can form during discharge.
Correct grounding of the entire coating system prevents electrostatic charges:
Ensure that all devices and tanks are grounded before each coating process.
All of the system's conductive elements, such as oors, walls, ceilings, protective
grating, transport equipment, work pieces, powder tanks, automatic moving devices
or construction parts etc. in the spray area, with the exception of parts which carry high
voltage during operation, must be connected to the grounding system.
Parts of the booth must be grounded in accordance with EN 12981.
Ensure that all persons inside the working area are grounded, e.g., that they are wearing
static dissipative shoes.
Grounding cables must be checked regularly to ensure that they are serviceable
(see EN 60204).
ORDER NUMBER DOC390829
PEA-C4-HiCoat
4.2.4 PRODUCT HOSES
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:
– in high-traffic areas,
– on sharp edges,
– on moving parts or
– on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses
are never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Ensure that no work is ever performed with a damaged hose.
Make sure that the hoses are never used to pull or move the device.
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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.
Do not lay connection cables on routes used by product handling vehicles and not
through doors/gates.
Do not route connection cables near aisles or walkways in order to avoid tripping.
4.2.6 CLEANING AND FLUSHING
Danger due to cleaning and ushing!
Explosion hazard and damage to the device.
Before starting cleaning or any other manual work, the high voltage in the spray
area must be shut down and locked to prevent it from being switched back on.
Lock the compressed air supply and decompress the device.
Secure the device against being switched back on without authorization.
Use only electrically conducting and grounded tanks for cleaning uids.
Preference should be given to non-ignitable cleaning uids.
If ignitable cleaning uids are used, all parts carrying high voltage must be discharged
to a discharge energy of less than 0.24 mJ, once the high voltage has been switched
o, before they can be reached. Most ignitable solvents have an ignition energy of
around 0.24 mJ or 60 nC.
The cleaning agent's ash point must be at least 15 K above the ambient temperature.
Note the details provided by the powder lacquer manufacturer.
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used
for getting rid of dust build-up.
Take measures for workplace safety (see Chapter 4.1.2).
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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.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in Chapter 12 and Chapter 13 that are
assigned to the device.
Do not use any defective components.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve pressure on powder spray gun and device.
– Secure the powder spray gun against actuation.
Observe the operating and service manual for all work.
4.2.8 PROTECTIVE AND MONITORING EQUIPMENT
ORDER NUMBER DOC390829
PEA-C4-HiCoat
Danger due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.
4.2.8.1 RELEASING GUNS HIGH VOLTAGE/PNEUMATIC SYSTEM
Enabling high voltage depends on:
– Exhaust air is OK
– Fire extinguishing system/re detection signal OK (external signal)
– No EMERGENCY STOP
– Control voltage ON
As soon as one of these conditions is not fullled, the high voltage is switched o
immediately. After the fault has been eliminated and acknowledged, the enabling
mechanism can be selected again. An automatic switch on is prevented by the hardware
locking.
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4.3 INFORMATION ABOUT SAFE DISCHARGES
Designation
1 Nozzle
2 Electrode
3 Luminous discharge
4 Work piece
ORDER NUMBER DOC390829
1
2
3
4
PEA-C4-HiCoat
P_03925
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 eect can be seen when the electrode
is brought near the grounded work piece. This luminous discharge does not involve any
ignition energy and has no eect on system handling. When the electrode approaches the
work piece, the control unit automatically reduces the high voltage to a safe value. If you
touch plastic parts of the spray gun with your nger, harmless discharges may occur due to
the high-voltage eld around the spray gun (so-called brush discharges). However, these
do not contain any ignition energy.
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5 DESCRIPTION
5.1 CONSTRUCTION OF THE AUTOMATIC GUN
PEA-C4-HiCoat
2
1
7
Designation
1 Electrode
2 Deector cone
3 Union nut
4 Type plate
5 Powder hose connection
6 Spray gun body
7 Flat jet nozzle
8 Electrical connection
9 Atomizer air connection
3
4
X
5
X
8
6
5
P_03904
9
5.2 MODE OF OPERATION OF THE AUTOMATIC GUN
The spray gun is switched on and o via the superordinated control unit.
At the same time the air supply and high voltage are activated.
The distance of the installed spray guns to each other must be at least 300 mm; 11.81 inches
for functional reasons.
The gun control cabinet must be switched o in order to lock the automatic gun!
If changing from the at jet nozzle to the deector cone, the depth control must be adjusted.
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5.3 SCOPE OF DELIVERY
Order no. Designation
1 390004 Automatic gun, PEA-C4 HiCoat
-- Nozzle set
The standard equipment includes:
1 390893 Declaration of Conformity
1 390822 Operating manual, in German
1 see Chapter 1.3 Operating manual in local language
5.4 DATA
5.4.1 TECHNICAL DATA
Dimensions:
Length/width/height see Chapter 5.4.2
Weight 555 g; 1.22 lbs
Electrical:
Input voltage maximum 22 Vpp
Input current maximum 0.9A
Frequency 19–30 kHz
Output voltage maximum 100 kV DC
maximum Corona current 120 µA
Polarity negative
Construction type in accordance with DIN EN 50177 types A-P
Protection class IP 54
ORDER NUMBER DOC390829
PEA-C4-HiCoat
Pneumatic:
Input air pressure (atomizing air volume) maximum 3 bar; 0.3 MPa, 43.51 psi
Powder discharge quantity maximum 450 g/min;
maximum 0.99 lbs/min
WARNING
Exhaust air containing oil!
Risk of poisoning if inhaled.
Insucient paint application quality
Provide compressed air free from oil and water
(Quality Standard 6.5.2 according to ISO 8573.1, 2010)
6.5.2 = particle density ≤ 5 mg/m; pressure dew point ≤ +7 °C; oil content ≤ 0.1mg/m
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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 specied in Nm³ (standard cubic meters). One cubic meter
of a gas at 0 °C and 1.013 bar is called norm cubic meter.
Ambient conditions:
Operating temperature range 5–40 °C; 41–104 °F
Relative humidity < 75%
5.4.2 DIMENSIONS
ORDER NUMBER DOC390829
PEA-C4-HiCoat
X
A
B
C
Measurement mm inch
A 395 133.66
B* 30 1.18
C 310 12.20
D 76 2.99
E 82 3.23
X
E
D
P_01611
* Measurement for installation dimension C calculation when utilizing a deector cone
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5.5 ACCESSORIES
Only the accessories listed in Chapter 12 of this operating manual may be connected to
the automatic PEA-C4 HiCoat gun.
The accessories listed in Chapter 12 were included in the EC type examination and are
approved for use with the automatic gun.
ORDER NUMBER DOC390829
PEA-C4-HiCoat
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6 ASSEMBLY AND COMMISSIONING
6.1 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.
A skilled person must check to ensure that the device is in a reliable state after it is assembled
and commissioned.
6.2 STORAGE CONDITIONS
Until the point of assembly, the device must be stored in a dry location, free from vibrations
and with a minimum of dust. The device must be stored in closed rooms.
The air temperature at the storage location must be between -20 °C and +60 °C
(-4 °F and +140 °F).
The relative air humidity at the storage location must be between 10 and 95%
(without condensation).
6.3 INSTALLATION CONDITIONS
The air temperature at the installation site must be in a range between 0 °C and 40 °C;
32 °F and 104 °F.
The relative air humidity at the installation site must be between 10 and 95%
(without condensation).
6.4 PREPARING THE AUTOMATIC GUN
6.4.1 SELECTION OF A SUITABLE NOZZLE SYSTEM
The process of changing from the at jet nozzle to the deector cone is described in
Chapter 8.6.
You will nd the article numbers of the dierent nozzles in Chapter 12.
Application overview Powder cloud Nozzle
Complex part geometries Widely spread at powder cloud Flat jet nozzle
– Flat work pieces
(reduced picture frame)
– Prole
– Undercuts
Round powder cloud Deector cone
– Wire goods Size of the powder cloud is
– Grid designs
dependent on the deector plate
diameter
P_00694
P_00935
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ORDER NUMBER DOC390829
PEA-C4-HiCoat
Application Distance to
work piece
(mm)
Universal application
(slow powder cloud)
– Deep and complex part
120 … 300 50 … 250
geometries
– Parts with large surfaces
Targeted application
(dense powder cloud)
– Excellent coating coverage
120 … 400 30 … 200
For a small total air volume and
small jet width
(fastest powder cloud)
– Excellent coating coverage
120 … 400 ≤ 180
for prole parts
– High stability
Wide at jet nozzle for large
powder quantities
(slow powder cloud)
– Good atomization
150 … 400
– Especially for parts with
large surfaces
Wide at jet nozzle for large
powder quantities
(slow powder cloud)
– Good atomization
150 … 400
– Especially for parts with
large surfaces
Powder
Nozzle
discharge
(g/min)
> 200
(Total air >
4.5 Nm³/h)
> 200 HPO-1
(Total air >
4.5 Nm³/h)
F1
P_00694
F2
P_00694
F3
P_00694
F4
P_00694
P_00694
1.) The nozzles are labeled on the back.
F1
P_01107
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Application Distance to
work piece
(mm)
Ø 20 mm
– Smaller at parts
100 … 300 30 … 250
Ø 28 mm
– Medium sized at parts
100 … 300 50 … 250
– Lateral application with
Z-axes
6.5 CONNECTING THE AUTOMATIC GUN
Powder
discharge
(g/min)
1
2
Deector cone
R20
P_00935
R28
P_00695
3
4
P_03905
Designation
1 Atomizing air
2 Electrical connection of the control unit or high-voltage generator
3 Powder feed from feed system
4 Ground the spray gun via the gun support
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Procedure:
1. Switch o 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.
The distance of the installed spray guns to each other must be at least 300 mm;
11.81 inches for functional reasons!
3. Connect the automatic gun's electrical cable to the control unit.
4. Connect the powder feed hose to the automatic gun and to the feed system.
5. Connect the atomizing air hose to the automatic gun and to the control unit.
6.6 GROUNDING
For safety reasons, the automatic gun and the work piece must be properly grounded.
The grounding of the automatic gun takes place via the gun mounting.
Good grounding of the work piece is also necessary for optimum powder coating.
ORDER NUMBER DOC390829
PEA-C4-HiCoat
A poorly grounded work piece causes:
– dangerous electric charging of the work piece
– very poor wrap-around
– uneven coating
– back spraying to the spray gun, i.e., contamination
Prerequisites for perfect grounding and coating of a work piece are:
– clean suspension of the work piece to be coated,
– the grounding resistance of the work piece must not exceed 1 M
(resistance to ground measured at 500 V or 1000 V).
Sparks between conveyor, conveyor hooks (hangers) and work piece can occur if electric
contact points between conveyor, conveyor hooks (hangers) and work piece are not
suciently cleaned and therefore the work pieces are not suciently grounded!
These sparks can cause heavy radio frequency interference (EMC).
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6.6.1 GROUNDING THE POWDER COATING SYSTEM
PEA-C4-HiCoat
3
5
P_01614
4
1
2
6
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!
4 Wear electrostatically conductive gloves!
5 Wear electrostatically conductive footwear!
6 The oor must be electrostatically conductive!
6.7 SAFETY CHECKS
A skilled person must check to ensure that the device is in a reliable state after it is assembled
and commissioned.
This includes:
– Carry out safety checks in accordance with Chapter 8.2.3.
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7 OPERATION
7.1 TRAINING THE OPERATING PERSONNEL
The operating personnel must be qualied to operate the entire system.
The operating sta must be familiar with the potential risks associated with improper
behavior as well as the necessary protective devices and measures.
Before work commences, the operating personnel must receive appropriate system
training.
7.2 TASKS
Ensure that:
the regular safety checks are carried out in accordance with chapter 8.2.3;
commissioning is carried out in accordance with Chapters 6.4 and 6.5.
7.3 SWITCHING ON THE AUTOMATIC GUN
The automatic 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.
7.4 SWITCHING OFF THE AUTOMATIC GUN
7.4.1 SWITCHING OFF IN NORMAL OPERATION
The automatic gun is switched o dierently depending on the type of powder injector.
In most cases, this process is performed by the coating system controller.
Note:
For each interruption of work, the automatic gun should be blown through (ushed) and
powder residue removed. In this way, powder deposits and a surge, the next time the spray
gun is switched on, can be largely avoided.
If the automatic gun should be switched o manually and the powder injector is not
suitable for automatic ushing mode, please proceed as follows:
Procedure:
1. The atomizing air has to remain open to prevent powder from penetrating into the
atomizing air channels and the cascade compartment during the ushing process.
2. Switch o the powder feed and high voltage generation.
3. If the settings of the feed and dosing air should not be changed, in order to continue
coating with the same powder cloud, remove the powder injector from the injector
connection of the powder tank.
4. When switching on again no more powder will be delivered.
5. Switch the powder feed on again to blow out any powder remaining in the gun.
6. The powder feed can now be switched o.
7.4.2 SWITCHING OFF THE AUTOMATIC GUN IN THE EVENT OF FAULTS OR EMERGENCIES
In the event of faults or emergencies the gun, together with the system, can be switched o
by means of the emergency stop equipment. At the same time, the high voltage and the
coating material supply are switched o.
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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,
– before the spray nozzle is installed or cleaned.
7.5 OPTIMIZING THE POWDER CLOUD FOR COATING
Procedure:
1. Switch on the high-voltage generation and the powder feed.
Note:
To minimize wear on the wearing parts, the total air volume should be below 5 Nm³/h.
The atomizing air should be adjusted for the:
– at jet nozzle to 0.1 Nm³/h
– round jet nozzle to > 0.2 Nm³/h
2. Adjust the powder quantity and the powder speed on a test piece.
PEA-C4-HiCoat
7.6 REPRODUCIBLE SETTING OF THE NOZZLE POSITION
– For a horizontal powder cloud, the at jet nozzle is set so
that the protective wedge is in the 0° position.
– When attaching a round jet nozzle, we recommend turning
it to the 90° position to achieve a better spray pattern
(the protective wedge is now in the vertical position).
It is possible to change this position as needed for special
applications.
On the nozzle body and electrode holders, there are X markings.
The position can be changed as required in 15° increments and
later reproduced.
The union nut has to be removed for exact positioning.
An adjustment tool is provided for the at jet nozzle.
It permits turning the at jet nozzle without damaging the
electrodes and without removing the union nut.
The union nut only has to be slackened.
30°
0°
15°
X
X
P_01095
P_01096
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8 CLEANING AND MAINTENANCE
8.1 CLEANING
8.1.1 CLEANING PERSONNEL
Cleaning work should be undertaken regularly and carefully by qualied and trained personnel.
They should be informed of specic hazards during their training.
The following hazards may arise during cleaning work:
– health hazard from inhaling powder lacquer,
– use of unsuitable cleaning tools and aids.
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.
Danger due to escaping dust, contamination of the device and device components.
Before starting cleaning or other manual work, the high voltage must be shut down
and locked to prevent it from being switched back on!
During every paint change, the extraction system of the booth and the lter cleaning
system must remain switched on!
In the case of a paint change, powder residues must be thoroughly removed from all powder
feeding parts. In the following, only the procedure for the powder spray gun is described.
Note:
During a paint change, the nozzle system does not necessarily have to disassembled.
If the union nut is not screwed on tightly up to the stop position, this may cause the paint
to smear.
Procedure:
1. Automatically ush powder coating system, switch it o and secure it from being
switched back on.
2. If no automatic ushing takes place, manually ush the automatic gun and remove
any powder residue before the powder coating system is switched o.
– Disconnect the powder feed hose from the automatic gun.
– Blow through the automatic gun using an air gun and thus remove any powder residues.
– Switch o powder coating system and secure it from being switched back on.
3. After cleaning all powder feeding parts, reconnect the powder feed hose to the
automatic gun.
4. The automatic gun is ready for use again.
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8.2 MAINTENANCE
8.2.1 MAINTENANCE PERSONNEL
Maintenance work should be undertaken regularly and carefully by qualied and trained
personnel. They should be informed of specic hazards during their training.
The following hazards may arise during maintenance work:
– health hazard from inhaling powder lacquer,
– use of unsuitable tools and aids.
A skilled person must ensure that the device is checked for being in a reliable state after
maintenance work is completed.
8.2.2 MAINTENANCE INSTRUCTIONS
ORDER NUMBER DOC390829
PEA-C4-HiCoat
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.
Only repair and replace parts that are listed in the "Spare parts" chapter and that are
assigned to the unit.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve spray gun and device pressure.
– Secure the spray gun against actuation.
Observe the operating and service manual for all work.
Prior to maintenance
– Flush and clean the system. Chapter 8.1.2
After maintenance
– Carry out safety checks in accordance with Chapter 8.2.3.
– Put the system into operation and check for leaks.
– Have the system checked for safe condition by a skilled person.
8.2.3 SAFETY CHECKS AND MAINTENANCE INTERVALS
Daily: Before starting work, carry out a visual inspection to ensure that the system is grounded.
8.2.4 MAINTENANCE PROCEDURES
The maintenance intervals should be adapted by the operator depending on the level of
use and if necessary the level of soiling.
If in doubt, we recommend contacting WAGNER's specialist personnel.
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Maintenance work Time stamp
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
Check powder hoses for bends and sintering
ORDER NUMBER DOC390829
once each shift weekly
PEA-C4-HiCoat
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8.3 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.
ORDER NUMBER DOC390829
1
6
PEA-C4-HiCoat
5
P_03906
Procedure:
1. Switch o the powder coating system and/or the high voltage generation.
2. Disconnect the electrical cable 1 from the automatic gun 5.
3. Disconnect powder feed hose 2 and atomizing air hose 6 from the automatic gun 5.
4. Disconnect automatic gun 5 from the mounting bracket 4 by loosening the
locking nuts 3.
5. Insert the new automatic gun 5 into the mounting bracket 4 and fasten it with
locking nuts 3.
4. Connect powder feed hose 2 and atomizing air hose 6 to the automatic gun 5.
5. Connect electrical cable 1 to the automatic gun 5.
7. The automatic gun is ready for use again.
2
3
4
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8.4 REMOVING THE FLAT JET NOZZLE
PEA-C4-HiCoat
Procedure:
1. Unscrew union nut 1 from gun housing 4.
2. Pull at jet nozzle 2 o 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.
4. Remove powder residues from the removed parts and from the
automatic gun.
Note:
Never place the automatic gun or parts of the automatic gun in
cleaning agent.
As a rule, the protective wedge needs to be checked for wear and
replaced if necessary.
New protective wedge
3
2
1
4
P_03907
P_00592
Worn protective wedge
It is recommended to replace the protective wedge.
P_00593
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8.5 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 nd the necessary spare parts and wearing parts in Chapter 13 of this operating
manual.
1 Protective wedge (when positioned)
2 Electrode holder (shown with a cut-away
view to improve comprehension)
3 Wedge tool
2
3
1
Procedure:
1. Guide wedge tool 3 into electrode holder 2
up to stop.
2. Pull protective wedge 1 out of electrode
holder 2 using wedge tool 3.
3. Press protective wedge 1 sideways out of
wedge tool 3 manually (without tool).
P_03908
3
1
2
P_03909
3
2
1
P_03910
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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
ORDER NUMBER DOC390829
2
P_03911
PEA-C4-HiCoat
3
1
Procedure:
1. Guide protective wedge 1 into wedge tool 3.
2. Insert both parts into opening on electrode
holder 2 up to stop.
3. If it is not possible to push the wedge tool in
as far as the X mark, rotate the wedge tool a
little until it can be pushed up to the mark.
The mark X must be ush with the Y end of
the electrode holder.
4. The protective wedge is now correctly
assembled and the wedge tool can be pulled
out of the electrode holder.
The protective wedge remains inserted in
the electrode holder.
3
1
2
Y
X
P_03912
Y
X
P_00599
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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 nd the necessary spare parts and
wearing parts in Chapter 13 of this
operating manual.
6. Prior to re-tting, check whether the contact
points on electrode holder 3 and in gun
housing 4 have been thoroughly cleaned
so that the electrode tip is electrically
connected to the high-voltage generator.
7. Carefully t electrode holder 3 in gun
housing 4.
8. Slide the at jet nozzle 2 back over
electrode holder 3 and fasten in place using
union nut 1.
8.6 CHANGING FROM FLAT JET NOZZLE TO ROUND JET NOZZLE
The standard Corona automatic gun is delivered with a at jet nozzle. The nozzle can be
changed easily, as described below.
Note:
If changing from the at jet nozzle to the deector cone, the depth control must be adjusted.
1
2
3
4
P_03913
The C4 R electrode holder is necessary to perform the change.
CAUTION
Electrode tip!
Risk of injury and damage to the device.
Take care when tting the C4 R electrode holder.
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Procedure:
1. Unscrew union nut 1 from gun housing 4.
2. Pull at jet nozzle 2 o 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.
4. Remove powder residues from the removed parts and
from the automatic gun.
5. Carefully t the new C4 R electrode holder 5 into gun
housing 4.
6. Slide deector cone sleeve 6 onto electrode holder 5.
7. Align the X and Y marks.
8. Fasten union nut 1.
9. Slide deector cone 7 over deector cone sleeve 6.
10. The spray gun is ready for use again.
1
P_03907
6
7
3
2
4
5
6
1
4
X
Y
P_03914
8.7 ASSEMBLING THE ANGLE ADAPTER
8.7.1 REMOVING THE NOZZLE AND ELECTRODE HOLDER
The standard automatic gun is delivered with a at jet nozzle. The nozzle can be changed easily,
as described below.
Note:
If changing from the at jet nozzle to the deector cone, the depth control must be adjusted.
A WA90 C4, WA 60 C4 or WA30 C4 angle adapter is necessary to perform the change, as
listed in Chapter 12.
Note:
A at jet nozzle as well as a round jet nozzle can be tted to the angle adapter.
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Procedure:
1. Unscrew union nut 1 from gun housing 4.
2. Pull at jet nozzle 2 o 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.
4. Remove powder residues from the removed parts and
from the automatic gun.
8.7.2 FITTING THE ANGLE ADAPTER
Procedure:
1. Install electrode holder 3 together with nozzle 2
in nozzle insert 4 and tighten union nut 1.
2. Push angle adapter 5 onto the gun body and
gently screw threaded sleeve 6.
3. Swivel angle adapter 5 into the desired position
and then tighten threaded sleeve 6 well.
1
P_03907
3
2
4
6
1
2
3
5
4
56
P_03915
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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.
Note:
Do not damage the electrode holder, when
pulling it out and inserting it.
ORDER NUMBER DOC390829
PEA-C4-HiCoat
1
2
3
4
7
6
4. Unscrew threaded sleeve 8 and locking sleeve 9
with mounting tool 10.
5. Pull connecting element 11 out of elbow
tting 12.
6. Insert screwdriver into recess X and turn it until
the nozzle insert 13 loosens.
7. Pull out nozzle insert 13.
8. Replace the wearing parts with new components.
9. Clean all components thoroughly and remove
any powder residues.
10. Install nozzle insert 13, as shown in the magnied
gures Y1 and Y2, in such a way that the pin B1 is
guided into the hole A1.
11. Install connecting element 11 within the
elbow tting 12, as shown in the magnied
gure Z, in such a way that the pin B2 is guided
into the hole A2.
12. Screw threaded sleeve 8 and locking sleeve 9
with mounting tool 10 and tighten them well.
Ensure that it is still possible to turn threaded
sleeve 8 easily.
13. Install electrode holder 3 together with nozzle 2
in the nozzle insert 13.
14. Put on union nut 1 and tighten it well.
15. Mount the angle adapter to the gun again.
P_03916
B2
A1
12
5
Y1
13
Y2
A2
B1
11
X
8, 9
Z
10
P_03917
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8.8 ASSEMBLY OF THE CORONASTAR
The CoronaStar is a retrot set for automatic guns for achieving even better surface quality
(reduces the orange peel eect).
ORDER NUMBER DOC390829
PEA-C4-HiCoat
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 o and secured against being inadvertently switched on.
Procedure:
1.
Switch o the high voltage and the powder feed
and secure them against being inadvertently
switched on.
2.
Unscrew the standard nut 1 from the gun
housing 2.
3.
Screw the new nut 3 for the CoronaStar 4 onto
the gun housing and tighten well.
4.
Fasten the cable guide 5 onto the cover plate 7
using screw 6.
5.
Slide the CoronaStar 4 onto the gun housing 2.
Note:
Check whether the grounding is assured.
6. The spray gun is ready for use again.
21
3
4 6 75
P_03918
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8.9 ASSEMBLY OF THE CORONASTAR FOR ANGLE ADAPTER
ORDER NUMBER DOC390829
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 o and secured against being inadvertently switched on.
PEA-C4-HiCoat
Procedure:
1.
Switch o the high voltage and the powder feed
and secure them against being inadvertently
switched on.
2.
Remove plug 1 from the gun housing.
3.
Fit CoronaStar, for angle adapter 2, on the angle
adapter (direction of tting shown is merely an
example).
4.
Fasten the connection cable 3 on the gun housing.
Note:
Check whether the grounding is assured.
5. The spray gun is ready for use again.
Note:
Put stopper 1 back into hole in gun housing
when converting the gun in the normal version
without angle adapter.
1
2
3
P_01169
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9 TROUBLESHOOTING AND RECTIFICATION
DANGER
Incorrect maintenance/repair!
Danger to life and equipment damage.
WAGNER devices, protective systems and safety, monitoring and control equipment
may only be serviced/repaired as dened in Directive 2014/34/EC (ATEX) by trained
WAGNER service personnel or skilled persons in accordance with TRBS 1203!
Note national regulations!
Service, repair or replacement of devices or parts of devices may only be performed
outside the hazard area!
Malfunction Cause Remedy
No electrostatic (e.g., no wrap
around or no powder adhesion)
Poor powder wrap-around,
back-spray
Powder outlet uneven or
inadequate
Spray pattern is uneven – Parts of nozzle system worn – Replace worn parts
– Fault in the high-voltage generator – Contact a WAGNER service center
– Electrical cable from gun to
control unit faulty
– Cascade in gun faulty – Contact a WAGNER service center
– Insucient or no grounding – See Chapter 6.6
– Contamination – Blow through powder feeding
– Powder sintering – Clean powder feeding parts
– Feed unit contaminated – See operating manuals for the
– Feed air/dosing air ratio incorrect – Adjust at control module resp.
– Wear on powder injector nozzle – Replace worn parts on powder
– Replace the electric cable
parts
related devices connected
control unit
injector ¹)
1.) You will nd the wear parts and spare parts in the powder injector operating manual.
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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.
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interval
weekly
Type of inspection Inspection
potential)
Measure resistance to ground
(work piece receiver - ground
ORDER NUMBER DOC390829
manufacturer's
instructions
annually
max. 1 M @ 1000 V.
FT
powder feed, supply air, and
high voltage are switched o
is safely stopped and the
Test whether the system
as per the
when the ventilation is shut
down.
Function test of the
ME/FT
residual energy monitoring
manufacturer's instructions.
equipment according to the
PEA-C4-HiCoat
SP ME/CM
by
The resistance to ground of
Ground leaking resistance
point must not exceed 1 M
every work piece's attachment
(measurement voltage must
from the work piece
attachment point
be 1000 V). The form of
construction of the work piece
mount must guarantee that the
work pieces remain grounded
SP
be interlocked such that the
during coating.
The technical ventilation should
Link between technical
ventilation equipment and
powder feed and high voltage
the technical ventilation is not
working eectively.
cannot be switched on, while
high voltage, compressed
air and powder feed
SP
If ignitable cleaning uids are
used, all parts carrying high
a discharge energy of less than
0.24 mJ, once the high voltage
voltage must be discharged to
Protection against ignition
of ignitable cleaning
agents
has been switched o, before
they can be reached.
Section Type of inspection Requirements Inspection
1
2
3
Legend:
ER = Employer ME = Measurement
FPO = Fire prevention ocer VI = Visual inspection
MF = Manufacturer FT = Function test
ELT = Electrician CM = Constant monitoring
SP = Skilled person OC = Organization check
TP = Trained person TT = Technical testing
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interval
weekly
VI/ME/CM
Visual check of ground
connections, perform
function test on grounding
switch, measurement of
ORDER NUMBER DOC390829
weekly
grounding resistors.
ME/CM
Measure resistance to ground
(work piece receiver - ground
potential) max. 1 megohm @
1000 V.
as per the
booth
as per the booth
manufacturer's instructions
PEA-C4-HiCoat
manufacturer's
instructions
SP
All the system's conductive
elements, such as oors, walls,
ceilings, protective grating,
Eectiveness of
grounding
transport equipment, work
pieces, powder tanks, machines
or construction parts etc. in the
spray area, with the exception of
parts which carry high voltage
during operation, must be
connected to the grounding
SP
ohms.
8
system.
The resistance of the oor must
not exceed 10
The ground leaking resistance
from the attachment point
on each work piece must not
Ground leaking
resistance from the work
piece attachment point
exceed
1 megaohm (measuring voltage
must be between 500 and
1000 V). The form of
construction of the work piece
mount must guarantee that the
work pieces remain grounded
as per the
booth
manufacturer's
instructions
during coating.
required depending on the
model and functions of the booth
(see EN 12981).
Further inspections Further inspections may be
Section Type of inspection Requirements Inspection by Type of inspection Inspection
4
5
6
Legend:
MF = Manufacturer FT = Function test
ER = Employer ME = Measurement
SP = Skilled person OC = Organization check
FPO = Fire prevention ocer VI = Visual inspection
ELT = Electrician CM = Constant monitoring
TP = Trained person TT = Technical testing
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11 DISASSEMBLY AND DISPOSAL
11.1 DISASSEMBLY
WARNING
Incorrect disassembly!
Risk of injury and damage to the device.
Before starting disassembly:
– Switch o the energy and compressed air supply.
– Ensure that all system components are grounded.
– Secure system against being switched back on without authorization.
Observe the operating manuals when carrying out all work.
Procedure:
1.
Switch o the system.
2.
Lock the compressed air supply and decompress system.
3.
Release electrical cable on control unit.
4.
Release electrical cable on spray gun.
5.
Disconnect the powder feed hose at the spray gun and on the feed system.
6.
Disconnect atomizing air hose from the spray gun and control unit.
7.
Loosen the securing nuts on the gun mounting and remove the spray gun from the gun
mounting.
PEA-C4-HiCoat
11.2 DISPOSAL
NOTICE
Do not dispose of used electrical equipment with household
refuse!
In accordance with European Directive 2012/19/EU on the disposal
of used electrical equipment and its implementation in national
law, this product may not be disposed of with the household
refuse, but must be recycled in an environmentally correct manner.
WAGNER or one of our dealers will take back your used WAGNER
electric or electronic equipment and will dispose of it for you in an
environmentally-friendly way. To arrange this, please contact one
of our service centers, one of our representatives or us directly.
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VERSION 05/2019
P_00694
12 ACCESSORIES
12.1 FLAT JET NOZZLE
Order no. Designation
390324 Flat jet nozzle F1
390325 Flat jet nozzle F2
390326 Flat jet nozzle F3
ORDER NUMBER DOC390829
PEA-C4-HiCoat
P_00694
P_00694
2311889 Flat jet nozzle F4
390331 Wide at jet nozzle HPO-1
12.2 DEFLECTOR CONE
Order no. Designation
390207 Deector cone Ø 20 mm
390208 Deector cone Ø 28 mm
12.3 FLAT JET NOZZLE SET C4 F5 NOT FM APPROVED
The C4 F5 nozzles are intended for processing metallic powders.
Order no. Designation
P_00694
P_00694
P_00935
P_00695
2387084 Set of at jet nozzles C4 F5
P_03920
For further details, see assembly manual, order no. 2389361.
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ORDER NUMBER DOC390829
12.4 FLAT JET NOZZLE C4 F5X NOT FM APPROVED
Order no. Designation
2390031 Flat jet nozzles C4 F5-X
12.5 FLAT JET NOZZLE F1X NOT FM APPROVED
Order no. Designation
PEA-C4-HiCoat
P_03595
2390016 Flat jet nozzles F1-X
12.6 RETROFIT SET CORONASTAR
1
2
3
P_01104
Pos K Stk Order no. Designation
1 1 390918 CoronaStar, complete
2 1 260296 CoronaStar electrode
3 1 390319 Union nut
P_03596
Wearing parts
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VERSION 05/2019
ORDER NUMBER DOC390829
12.7 CORONASTAR WA C4
P_01168
Pos Stk Order no. Designation
1 1 2306335 CoronaStar WA C4
12.8 CORONASTAR PEAC4 F5 RETROFIT SET
PEA-C4-HiCoat
Pos Stk Order no. Designation
1 2389178 Set CoronaStar PEA-C4 F5
12.9 WEDGE TOOL
P_00714
K Stk Order no. Designation
1 390900 Wedge tool including 20 protective wedges
Only available as a set
P_03921
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ORDER NUMBER DOC390829
12.10 GUN MOUNTING AND FIXATION
Order no. Designation
351347 Bracket for xing the spray gun
PEA-C4-HiCoat
P_01619
260215
Gun support for fastening on the
reciprocator
12.11 ANGLE ADAPTER
Order no. Designation
390927 Angle adapter, WA30 C4
390930 Angle adapter, WA60 C4
390931 Angle adapter, WA90 C4
Order no. Designation
390939 Mounting tool WA C4
12.12 HOSES
P_01620
P_01626
P_01621
Order no. Designation Application
9982079 Powder hose Ø 6x1 mm Atomizing air connection
2307502 Powder hose inside Ø 11 mm
2310700 Powder hose inside Ø 12 mm
For powder feeding
12.13 ELECTRICAL CONNECTION CABLE
Order no. Designation Application
351216 Electrical cable 5 m
351217 Electrical cable 10 m
351215 Electrical cable 20 m
For connecting the spray gun to the
high-voltage generator
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12.14 POWDER MEASURING ADAPTER
ORDER NUMBER DOC390829
WARNING
Risk of explosion due to electrostatic charging!
Danger to life and equipment damage.
Only use powder measurement adapter when high voltage is switched o!
The powder measuring adapter serves to measure powder quantities for the
PEA-C4 HiCoat gun.
The powder measuring adapter is slid onto the nozzle.
12.14.1 POWDER MEASURING ADAPTER FOR FLAT JET NOZZLE C4
PEA-C4-HiCoat
P_04198
Order no. Designation
390940 Powder measuring bag, complete
12.14.2 POWDER MEASURING ADAPTER FOR FLAT JET NOZZLE C4F5/X1F5
P_04199
Order no. Designation
2403425 Measuring adapter C4-F5/X1-F5, complete
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ORDER NUMBER DOC390829
PEA-C4-HiCoat
13 SPARE PARTS
13.1 HOW CAN SPARE PARTS BE ORDERED?
Always supply the following information to ensure delivery of the right spare part:
Order number, designation and quantity
The quantity need not be the same as the number given in the quantity column " " on the list.
This number merely indicates how many of the respective parts are used in each component.
The following information is also required to ensure smooth processing of your order:
− billing address
− delivery address
− name of the person to be contacted in the event of any queries
− type of delivery (normal mail, express delivery, air freight, courier etc.)
Identication in spare parts lists
Explanation of column " " (labeling) in the following spare parts lists:
Wearing parts. Wearing parts are not included in the warranty terms.
Included in service set
Note:
These parts are not covered by warranty terms.
Not part of standard equipment, however, available as special accessory.
Explanation of order no. column
-- Item not available as spare part.
/ Position does not exist.
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.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve spray gun and device pressure.
– Secure the spray gun against actuation.
Observe the operating and service manual for all work.
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13.2 PEAC4HICOAT CORONA AUTOMATIC GUN
4
3
ORDER NUMBER DOC390829
6
5
7
PEA-C4-HiCoat
1
2
P_03919
Order no. Designation
1 1 390004 Corona Automatic Gun, PEA-C4-HiCoat
2 1 390911 Powder tube, C4 ET
3 390342 Adjustment tool for at jet nozzles
4 1 390311 Union nut
5 1 390324 Flat jet nozzle F1
6 1 390915 Electrode Holder
7 1 390310 Wedge
Only available as a set
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13.3 ELECTRODE HOLDER C4 R WITH NOZZLES
ORDER NUMBER DOC390829
PEA-C4-HiCoat
1
6
Order no. Designation
1 1 390917 Electrode holder, C4 R, complete
2 1 390916 Electrode holder, C4 R
3 1 390310 Wedge
4 1 390313 Deector cone sleeve
5 1 390207 R20 deector cone ( 20 mm; 0.79 inch)
6 1 390208 R28 deector cone ( 28 mm; 1.10 inches)
Only available as a set
2
4
5
3
P_01103
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VERSION 05/2019
13.4 ANGLE ADAPTER, WA90 C4
7
6
ORDER NUMBER DOC390829
PEA-C4-HiCoat
2
3
4
1
5
P_01623
Order no. Designation
1 1 390931 Angle adapter, WA90 C4
2 1 390947 Union nut, WA C4 ET
3 1 390933 Nozzle insert, WA90 C4 ET
4 1 390942 Elbow tting, WA90 C4 ET
5 1 390932 Connecting element, WA C4 ET
6 1 390946 Locking sleeve, WA C4 ET
7 1 390945 Threaded sleeve, WA C4 ET
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VERSION 05/2019
13.5 ANGLE ADAPTER, WA60 C4
7
6
ORDER NUMBER DOC390829
PEA-C4-HiCoat
2
3
4
1
5
P_01624
Order no. Designation
1 1 390930 Angle adapter, WA60 C4
2 1 390947 Union nut, WA C4 ET
3 1 390934 Nozzle insert, WA60 C4 ET
4 1 390943 Elbow tting, WA60 C4 ET
5 1 390932 Connecting element, WA C4 ET
6 1 390946 Locking sleeve, WA C4 ET
7 1 390945 Threaded sleeve, WA C4 ET
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VERSION 05/2019
13.6 ANGLE ADAPTER, WA30 C4
7
6
ORDER NUMBER DOC390829
PEA-C4-HiCoat
2
3
4
1
5
P_01625
Order no. Designation
1 1 390927 Angle adapter, WA30 C4
2 1 390947 Union nut, WA C4 ET
3 1 390935 Nozzle insert, WA30 C4 ET
4 1 390944 Elbow tting, WA30 C4 ET
5 1 390932 Connecting element, WA C4 ET
6 1 390946 Locking sleeve, WA C4 ET
7 1 390945 Threaded sleeve, WA C4 ET
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ORDER NUMBER DOC390829
14 EU DECLARATION OF CONFORMITY
14.1 EU DECLARATION OF CONFORMITY AUTOMATIC GUN
Herewith we declare that the supplied version of:
PEA-C4-HiCoat
complies with the following guidelines:
2014/34/EU
2006/42/EC
2014/30/EU
2011/65/EU
2012/19/EU
Applied standards, in particular:
EN ISO 12100: 2010 EN 60079-0: 2012+A11: 2013
EN 1953:2013 EN 1127-1:2011
EN ISO 13732-1: 2008 EN 61000-6-2: 2005+B: 2011
EN 14462:2015 EN 61000-6-4: 2007+A1: 2011
EN 60529: 1991+A1: 2000+A2: 2013 EN ISO/IEC 80079-34: 2011
EN 50177: 2009+A1: 2012
Applied national technical standards and specications, in particular:
DGUV-I 209-052 TRGS 727
PEA-C4-HiCoat
Identication:
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
0102
PTB 05 ATEX 5008
II 2D 2mJ
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C
E
R
T
I
F
I
E
D
Order no. 390829
Edition 05/2019
ts-powder@wagner-group.com
Document No. 11056684
Version C
www.wagner-group.com
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