01 / 2008 0390882
http://www.wagner-group.com
Operating Manual
Automatic Powder Spray Gun
DANGER
High Voltage!
Turn power off
before servicing!
CAUTION
Read rules for safe
operation and
instructions
carefully!
Peac4_0000
PEA-C4-HiCoat FM
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Introduction
2 0390882 - PEA-C4-HiCoat FM 01 / 2008
Powder spray gun PEA-C4-HiCoat FM Article No. 0390016
00_.doc
3
9
5
m
m
Z
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0
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0
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m
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G
X
A
A
C
D
B
76 mm
F
G
E
X
Peac4_0001
A Fan spray nozzle (Deflector cone)
B Electrode
C Outer nut
D Spray gun body
E Electrical connection
F Atomizing air connection
G Powder hose connection
Z Assembly dimension on the reciprocator
1.) Length for installation dimension
Z calculation when utilizing a deflector cone.
00_.doc
The Corona automatic spray gun can be used for conventional types of powder and metal
powder that can be electrostatically charged.
The spray gun is used for industrial powder coating in
automatic plants and can be oper-
ated with
individual control units or with control cabinet modules.
Caution
The operator must ensure that the spray gun is only connected to Wagner devices!
The distance of the installed spray guns to each other
must be at least 300 mm.
High room temperatures and, in particular, laying hoses in areas exposed to sunlight in
factory buildings
must be avoided!
To secure the spray guns, the "spray guns" control cabinet
must be switched off!
When changing from a fan spray nozzle to a deflector cone, the depth control
must be
readjusted!
Introduction
01 / 2008 0390882 - PEA-C4-HiCoat FM 3
Table of contents Page
1. Safety regulations......................................................................................................5
1.1 Safety hints...................................................................................................................5
1.2 Note on harmless discharges....................................................................................... 8
1.3 Declaration of conformity..............................................................................................9
2. Preparing the spray gun..........................................................................................10
2.1 Selection of the suitable nozzle system ..................................................................... 10
2.2 Connecting the spray gun .......................................................................................... 11
2.3 Grounding...................................................................................................................12
2.4 Reproducible setting of the nozzle position................................................................ 13
3. Working with the spray guns..................................................................................14
3.1 Optimizing the spray pattern for your coating.............................................................14
3.2 Switching off the spray gun........................................................................................14
3.3 Performing a color change.........................................................................................15
4. Maintenance and cleaning.......................................................................................16
4.1 Replacing the spray gun.............................................................................................16
4.2 Cleaning the spray gun and replacing the wearing parts...........................................18
4.3 Replacing the protective wedge.................................................................................19
4.4 Fitting the round spray nozzle....................................................................................22
4.5 Mounting the angle adapter........................................................................................23
4.5.1 Dismantling the nozzle and the electrode holder .......................................... 23
4.5.2 Fitting the angle adapter................................................................................24
4.5.3 Replacing the wearing parts.......................................................................... 24
4.6 Mounting the Corona-Star..........................................................................................26
4.7 Disposal......................................................................................................................27
5. Rectification of malfunctions..................................................................................28
6. Technical data .......................................................................................................... 29
7. Warranty.................................................................................................................... 30
8. Scope of delivery and spare parts lists..................................................................31
8.1 How to order spare parts............................................................................................ 31
8.2 Scope of delivery and spare parts spray gun PEA-C4-HiCoat FM.............................32
9. Accessories..............................................................................................................33
9.1 Electrode holder C4 R FM with nozzles.....................................................................33
9.2 Electrical cables and hoses........................................................................................34
9.3 Spray gun mounting and fastening.............................................................................34
9.4 Fan spray nozzle and deflector cone ......................................................................... 34
9.5 Wedge tool.................................................................................................................35
Introduction
4 0390882 - PEA-C4-HiCoat FM 01 / 2008
9.6 Angle adapter with accessories..................................................................................35
9.6.1 Assembly tool for angle adapter .................................................................... 35
9.6.2 Angle adapter................................................................................................36
9.7 Powder measuring bag ..............................................................................................39
9.8 Retrofit-Set Corona-Star.............................................................................................39
00_..doc
This manual contains information and hints for the service, repair and maintenance of the
equipment. The user must obey all the rules of operation found in this manual; failure to do
so will render the warranty invalid.
Wagner powder systems are designed to meet the most stringent safety requirements.
They can be operated in compliance with generally applicable safety codes and applicable
national safety regulations.
Please pay particular attention to the parts marked by the following symbols. Follow the
instructions exactly, in the interests of both your own safety and the correct functioning of
the
unit.
Warning
This symbol draws attention to the fact that if the operating instructions, working
instructions, prescribed working sequences etc. are not followed exactly, this can
lead to injury or even fatal accidents.
Caution
This symbol indicates that failure to follow the operating instructions, working instructions, prescribed working sequences etc. exactly can lead to material damage.
Hint
This symbol draws your attention to useful additional information and tips. Failure to
observe these instructions can cause malfunctions.
Safety regulations
01 / 2008 0390882 - PEA-C4-HiCoat FM 5
1. Safety regulations
1.1 Safety hints
010101_ .doc
Warning
This equipment can be dangerous if it is not operated in accordance with this
operating manual!
There might be additional regulations to be observed, put into effect by
governmental, state or other official agencies or local security (fire)
departments
!
Warning
Under no circumstance may persons with a cardiac pacemaker come close
to the area between the tip of the spray gun and the work piece to be
coated!
The following rules must be observed in order to ensure a safe and efficient use of the
equipment:
• The user has to observe particularly the safety
guidelines of the VdS, the local professional and
security institutions.
• Trained and qualified personnel may only operate the electrostatic coating equipment.
• The spray gun may only be operated in powder
coating booths or on powder coating stands that
are equipped with a ventilation system.
• The user has to make sure, that the average
powder/air concentration does not exceed 50%
of the LEL (maximum allowed concentration of
powder in air). If a reliable LEL value is not
available, the average powder/air concentration
may not exceed 10 g/m³.
• Over sprayed powder must be reliably collected.
• Adhere to the instructions given by the manufac-
turers and to the prevalent local laws on the
environment when disposing of waste coating
powder.
• The main power connection for operation of the
Wagner powder equipment must be electrically
interlocked with the exhaust system of the
powder coating booth.
• In the event of faults or defects, repair work is to
be performed at the user's discretion.
• The user must conduct periodic checks of the
powder spray equipment (at least every year)
with regard to explosion-protection.
• Repairs may only be carried out by trained technicians and may never be carried out in an
explosion hazardous area. Protective measures
against explosions must still be installed.
• The work area must have an electrostatically
conductive floor (measured in accordance with
EN 1081).
• All conductive parts in the work area must be
electrostatically grounded (work area = 1 m
around every spray location or opening in the
booth).
• All persons inside the work area must wear
electrostatically conductive footwear.
• Spray guns should be operated with bare hands!
If gloves are used they must be made of conductive material.
• Guideline 94/9/EG: The device is suited for the
applications it was designed for, even in
explosion-hazard areas.
Safety regulations
6 0390882 - PEA-C4-HiCoat FM 01 / 2008
010102_ .doc
• Wear suitable work clothing
• Use breathing protection or a vizard for work
which produces powder and when
developing solvent steams:
Avoid health dangers by inhalation and skin
contacts of solvent steams and lacquer aerosols; Cornea injuries by splashes in the eye.
• Check the equipment for damage
Before operating the system, check if slightly
damaged parts still function correctly. Check
whether the moving parts operate properly,
whether they jam and whether parts are
damaged.
Damaged parts should be repaired or
replaced by a Wagner customer service.
Warning
For your own safety, use only accessories and equipment listed in the
operating manual. The use of individual parts other than those
recommended in the operating manual may create a hazard to personal safety.
Use only original Wagner replacement parts!
Alteration or repair of Wagner original spare parts may cause fatal
accidents or explosions in the coating system!
Safety regulations
01 / 2008 0390882 - PEA-C4-HiCoat FM 7
HAZARD PREVENTION
Electrostatic arcing may cause an explosion or fire.
Mixtures of powder and air can explode or ignite
causing property damage and/or severe injury.
• Operator must be grounded. Grounding straps must be used
when wearing rubber soled shoes.
• Operator must remove all metallic objects from his or her
person, which are not grounded.
• The object being sprayed must be grounded.
• All metallic objects within the spray area must be grounded
(including spray booth, part hangers, fire extinguishers, etc.)
• Grounded conductive floor must be provided in spray area.
• Turn off the Power Pack and unplug from outlet before flushing
out the gun, cleaning or replacing parts on the gun such as
changing tips.
Explosion or fire. Mixtures of powder and air can
explode or ignite causing property damage and/or
severe injury.
• Exhaust and fresh air introduction must be provided to keep the
air within the spray area free of accumulation of flammable
atmosphere.
• Smoking must not be allowed in spray area.
• Fire extinguishing equipment must be present and in working
order.
• Electrostatic arcing must be prevented.
(See Electrostatic arcing)
• When cleaning the system, use only materials recommended
by the coatings manufacturer. Be sure Power Pack is turned off
and unplugged.
• Avoid all ignition sources such as static electricity sparks, open
flames such as pilot lights, hot objects such as cigarettes and
sparks from connecting and disconnecting power cords and
working light switches.
• To prevent hazardous concentrations of flammable
atmospheres, spray only in a properly ventilated spray booth.
• Never operate spray gun unless ventilation fans are operating
properly.
• Check and follow all National, State and Local codes regarding
air exhaust velocity requirements.
• Ventilation must be maintained during the cleaning operation.
Toxic Substances: Some materials may be harmful if
swallowed or come in contact with the skin.
• Follow the requirements of the Material Safety Data Sheet
supplied by the coatings manufacturer.
• Exhaust and fresh air introduction must be provided within the
spray area to keep the air free of high powder accumulations.
• Wear a mask or respirator. Read all instructions for the mask to
insure that it will provide the necessary protection against the
inhalation of powder.
General
• Read all instructions and safety precautions before operating.
• Comply with all appropriate local, state and national codes
governing ventilation, fire prevention, and operation of
Electrostatic equipment usage.
• The United States Government Safety Standards have been
adopted under the Occupational Safety and Health Act. These
standards, particularly the General Standards, Part 1910 and
the Construction Standard, Part 1926, should be consulted.
• NFPA Standard No. 33 is to be followed when setting up your
spray area. Contact the National Fire Protection Association,
Batterymarch Park, Quincy, Massachusetts, 02269 for more
information.
• Check with insurance company for additional requirements.
• Use only identical replacement parts.
• Personnel must be given training in accordance with the
requirements of NFPA Standard No. 33 chapter 18.
• It is the duty of all personnel responsible for the spray
equipment operation and maintenance to read and understand
all safety information furnished with this equipment.
Safety regulations
8 0390882 - PEA-C4-HiCoat FM 01 / 2008
1.2 Note on harmless discharges
0102_ .doc
With the high voltage switched on, a luminous
or corona discharge occurs at the electrode tip;
this can only be seen in the dark. This physical
effect can be seen when the electrode is near
the grounded workpiece.
This luminous discharge does not involve any
ignition energy and has no effect on the usage
of the plant. When the electrode approaches
the workpiece, the control unit automatically
reduces the high voltage to a safe value or
switches the high voltage off, depending on the
setting.
Nozzle
Electrode
Luminous discharge
Workpiece
Peac4_0002
If you touch plastic parts of the spray gun with the finger, harmless discharges may occur due
to the high voltage field around the spray gun (so-called brush discharges). However, these do
not contain any ignition energy.
Safety regulations
01 / 2008 0390882 - PEA-C4-HiCoat FM 9
1.3 Declaration of conformity
Wagner hereby declares that the electrostatic powder spray guns
PEA-C4 HiCoat FM
conform to the approval standard for Electrostatic Finishing Equipment FM 7260.
This equipment to be used for electrostatic finishing applications using Class II spray material
in hazardous (Classified) location.
FM approved for US and Canada
P_00082
FM
CUS
APPROVED
For Electro.Fin.Appl. CL. II Spray Matl
Output 100 kV max.
Approved with EPG-2008/EPG-Prima
Ambient Temperature Range 45C / IP54
Preparing the spray gun
10 0390882 - PEA-C4-HiCoat FM 01 / 2008
2. Preparing the spray gun
2.1 Selection of the suitable nozzle system
0201_ .doc
Nozzle Overview Application Spray Pattern
Fan spray nozzle
Difficult workpieces:
• Undercuts
• Profiles
• Flat workpieces
(reduced picture frame)
Widely spread flat powder cloud
Deflector cone
• Wire goods
• Grid designs
Oval powder cloud:
Size is dependent on the deflector
cone diameter
Nozzle Application
Distance to
workpiece
[mm]
Powder output
[g/min]
F1 1)
Universal application
(slow powder cloud):
•
Deep and complex shapes
• Extensive workpieces
120 ... 300 50 ... 250
F2 1)
Targeted application
(dense powder cloud):
•
High penetration
• Wide coating range
120... 400 30 ... 200
F3 1)
Low powder application
(faster powder cloud):
•
Very good dispersion with low air
and powder quantities
•
For all workpieces
120... 300 30 ... 150
HPO-1 1)
Wide fan spray nozzle
for high powder application
(slow powder cloud):
•
Good dispersion
• Special for extensive workpieces
> 200
(+ total air
< 4,5 Nm
3
/h
150 ... 400
R20
∅ 20 mm:
• Small
even workpieces
100... 300 30 ... 250
1) Nozzles are labeled on the back.
F1
Preparing the spray gun
01 / 2008 0390882 - PEA-C4-HiCoat FM 11
Nozzle Application
Distance to
workpiece
[mm]
Powder output
[g/min]
R28
∅ 28 mm:
• Medium sized,
even workpieces
• Lateral application with Z-axis
100... 300 50 ... 250
R38
∅ 38 mm:
• Large,
even workpieces
• Lateral application with Z-axis
100... 300 50 ... 250
You will find the article numbers in chapter 9
"Accessories".
2.2 Connecting the spray gun
Before you commence connecting the gun, switch off the high voltage generator. For information on this activity refer to the related operating instructions for the control units and control
modules.
Hint
Use the parts listed in chapter 9 "Accessories" for connecting and fastening the spray
gun.
A
P
E
Electrical connection
Powder feed
Ground spray gun
via the gun mounting
Atomizing air
from powder injector
from control unit or
high voltage generator
Peac4_0003
Preparing the spray gun
12 0390882 - PEA-C4-HiCoat FM 01 / 2008
Caution
The distance of the installed spray guns to each other must be at least 300 mm.
• Fit the spray gun to the hanger and fasten both, for example, to the gun mounting on the
reciprocator.
• Connect the spray gun to the high voltage generator using the electrical cable E.
• Connect the hose for the powder feed P to the spray gun.
• Connect the hose for the atomizing air A to the spray gun.
Hint
Using a Wagner powder injector PI-F1 and a suitable control unit, it is possible to
automatically blow out or purge the angled spray gun each time prior to switch off.
2.3 Grounding
For safety reasons, the spray gun must be properly grounded. This occurs through the gun
mounting.
0203_ .doc
Good grounding of the workpiece is also necessary for optimum powder coating.
A poorly grounded workpiece causes:
• dangerous electric charging of the workpiece
• back-spray onto spray gun and user
• uneven coating
• very bad wrap around
Warning
Sparks between workpiece and conveyor hooks (hangers) can occur if hooks or
other hanger parts are not completely cleaned!
These sparks can cause heavy radio frequency interference.
Preparing the spray gun
01 / 2008 0390882 - PEA-C4-HiCoat FM 13
2.4 Reproducible setting of the nozzle position
0204_ .doc
• For a horizontal powder cloud, the fan spray nozzle
is set where the protective wedge is in the 0°
position.
• When attaching a round spray nozzle, we recom-
mend turning the protective wedge in the 90° position to achieve a smoother coating (the protective
wedge is now in the vertical position).
It is possible to set it other positions for special applications.
On the nozzle body and electrode holders there are
X
markings. In 15° steps, the position can be changed if
necessary and reproducibly.
The outer nut has to be removed for exact positioning.
Peac4_0014
An
adjustment tool is provided for the fan spray
nozzle.
It permits turning the fan spray nozzle without
damaging the electrodes
and without removing the
outer nut.
The outer nut only has to be slackened.
Working with the spray guns
14 0390882 - PEA-C4-HiCoat FM 01 / 2008
3. Working with the spray guns
3.1 Optimizing the spray pattern for your coating
0301_ .doc
• Switch on the high voltage generator and the powder feed.
Caution
To minimize the wear on the wearing parts, the total feed air and dosage air should be
under
5 Nm3/h!
The atomizing air should be adjusted for the
• Fan spray nozzle to 0.1 Nm3/h
• Round spray nozzle to 0.2 Nm3/h
• Adjust the powder quantity and the powder speed on a test piece.
3.2 Switching off the spray gun
0302_ .doc
The spray gun is switched off differently depending on the type of powder injector. In the
majority of cases this process is be performed by a control unit of the coating system.
Hint
On each interruption to work, the spray gun should be blown through (purged) 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 you want to manually switch off the spray gun and are using a powder injector that is
not
designed for automatic purging, proceed as follows:
• The atomizing air must be left open so that no powder can enter the atomizing air ducts
and the cascade space during purging. Switch off the powder feed and the high voltage
generator.
• If you do not want to change the settings for the feed air and dosage air so that you can
continue to coat using the same powder pattern, pull the powder injector out of the injector
connection on the powder container. No more powder will be fed when the powder feed is
switched back on.
• Switch the powder feed back on so that the spray gun is blown clear of powder.
• You can now switch off the powder feed.
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