WAGNER PEA-C4-HiCoat FM Operating Manual

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

=

3

1

0

m

m

3

0

m

m

1

.

)

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.

Working with the spray guns

01 / 2008 0390882 - PEA-C4-HiCoat FM 15

3.3 Performing a color change

0303_.doc

During a color change all parts carrying powder must be thoroughly cleaned of powder
residue. In the following only the procedure for the powder spray gun is described.

Hint

During a color change, the nozzle system does not necessarily have to disassemble.

Caution

If the outer nut is not screwed on tightly up to the stop position, the colors may smear.

• Switch off the powder coating plant after automatic purging and secure it against

inadvertent switch on.

• If you do not use automatic purging, flush the powder spray gun manually and clear any

residues of powder before you shut down the plant:

- Disconnect the powder hose from the spray gun.

- Clear the spray gun using the air gun and clear any residues of powder.

- Shut down the plant and secure it against inadvertent switch on.

• Before you commence to connect the powder hose again, all parts carrying powder must

be thoroughly cleaned.

The spray gun is ready for use again.

Maintenance and cleaning

16 0390882 - PEA-C4-HiCoat FM 01 / 2008

4. Maintenance and cleaning

WARNING

CAUTION

WHEN CLEANING THE ELECTROSTATIC SYSTEM,
THESE SAFETY PROCEDURES MUST BE FOLLOWED.
FAILURE TO FOLLOW THESE PROCEDURES MAY
RESULT IN AN EXPLOSION/FIRE.

• Turn power pack to the "OFF" position and unplug from
power source before starting to clean.

• Exhaust and fresh air introduction must be maintained
during the clean up operation.

• Keep cleaning materials in approved safety containers.

• All personnel and cleaning equipment, including

container used in cleaning operation, must be
grounded.

• DO NOT turn on the POWER PACK until the cleaning
operation has been completed, all cleaning materials
have been removed from spray area, and spray area is
free of any mixtures of powder and air produced by the
cleaning operation.

• If defects in the equipment are found, DO NOT use until
repairs are completed.

• Clean equipment immediately after use.

• NEVER IMMERSE SPRAY GUN OR PARTS OF IT IN

ANY FLUID AT ANY TIME.

• Be sure the Power Pack is turned off and unplugged
from the power source.

NOTE

• The powder passages of the spray gun should be
cleaned while cleaning the powder hose and
powder pump, following instructions, provided with
the powder pump (injector).

(See powder injector operating manual)

• Clean the spray tip by removing from spray gun,
flushing with air and replacing on spray gun.

4.1 Replacing the spray gun

0401_ .doc

Before you commence the replacement of the spray gun any powder residue must be
removed

thoroughly.

Caution

Repair or replacement of the spray gun or parts of the spray gun are only allowed to be
performed outside the hazard area and in a suitable place by specialist personnel!

The wearing parts in the spray gun, marked in the spare parts list with *, must be regularly
checked and, if necessary replaced.

Maintenance and cleaning

01 / 2008 0390882 - PEA-C4-HiCoat FM 17

0401_.doc

G

J

H

F

E

D

Peac4_0004

• Switch off the plant and/or the high voltage generator.

• Disconnect the electrical cable E from the spray gun D.

• Disconnect the hoses for powder feed G and atomizing air F from the spray gun D.

• Undo the locking nuts H and disconnect the spray gun D from the support J.

• Replace the spray gun with a new gun and fit this in the reverse order of removal.

Maintenance and cleaning

18 0390882 - PEA-C4-HiCoat FM 01 / 2008

4.2 Cleaning the spray gun and replacing the wearing parts

0402_Verschleissteile.doc

1

3

5

2

peac4_0005

• Unscrew the outer nut 1 from the spray gun housing 5.

• Pull the fan spray nozzle 2 off the electrode holder 3.

•

Carefully pull the electrode holder 3 out of the spray
gun housing

5.

Caution

When pulling out and inserting the electrode holder, ensure that the insert is not
damaged!

• Remove powder residue from the parts removed and from the spray gun.

Caution

Never place the spray gun or parts of the spray gun in cleaning agent!

• Clean the parts removed and spray gun of powder residue.

• As a rule you only need to check the protective wedge 4 for wear and replace it as

necessary.

New protective wedge

Worn protective wedge:

• We recommended replacing the protective

wedge

In the next section it is described how the protective wedge is to be dismantled and inserted.

Maintenance and cleaning

01 / 2008 0390882 - PEA-C4-HiCoat FM 19

4.3 Replacing the protective wedge

0403_ .doc

Hint

To ensure that the protective wedge is not damaged when dismantling and inserting
them, a

wedge tool is available for assembly.

1 Wedge tool
2 Protective wedge (install position)
3 Electrode holder (cut open view)

Proceed as described below:

• Guide the wedge tool 1 into the electrode

holder

3 to the stop.

• Pull the protective wedge 2 out of the

electrode holder

3 using the wedge tool.

• Press the protective wedge lateral out of the

wedge tool

manually without a tool.

Maintenance and cleaning

20 0390882 - PEA-C4-HiCoat FM 01 / 2008

Hint

For inserting the protective wedge the same wedge tool will be used.

1 Wedge tool
2 Protective wedge
3 Electrode holder (cut open view)

Proceed as described below:

• Guide the protective wedge 2 into the

wedge tool

1.

• Insert both parts in the opening on the

electrode holder

3 to the stop.

• If it is not possible to push the wedge tool in

as far as the mark

X, rotate the wedge tool

a little until it can be pushed into the mark.

The mark

X must be flush with the end Y of

the electrode holder.

• The protective wedge is now correctly

assembled and the wedge tool can be
pulled back out of the electrode holder.

The protective wedge remains inserted in

the electrode holder.

Maintenance and cleaning

01 / 2008 0390882 - PEA-C4-HiCoat FM 21

• After extended use or replacement of the protective wedge several times on the same

spray gun, the other parts carrying power should be checked for wear and replaced if
necessary.

You will find the necessary wearing parts and spare parts in chapter 8.2

of this manual.

030302_ .doc

• Prior to re-fitting, check whether the mating surface on the electrode holder 3 and in the

spray gun housing

5 have been thoroughly cleaned so that the electrode tip is electrically

connected to the high voltage generator.

030303_ .doc

1

3

5

2

peac4_0006

• Carefully fit the electrode holder 3 in the spray gun

housing

5.

• Slide the fan spray nozzle 2 back over the electrode

holder

3 and fasten in place using the outer nut 1.

Maintenance and cleaning

22 0390882 - PEA-C4-HiCoat FM 01 / 2008

4.4 Fitting the round spray nozzle

040401_FM.doc

The standard Corona spray gun is delivered with a fan spray nozzle. The nozzle can be
changed easily, as described in the following.

Caution

When changing from a fan spray nozzle to a deflector cone, the depth control must be
readjusted!

The electrode holder C4 R FM is necessary to perform the change.

030301_ .doc

1

3

5

2

peac4_0005

• Unscrew the outer nut 1 from the spray gun housing 5.

• Pull the fan spray nozzle 2 off the electrode holder 3.

• Carefully pull the electrode holder 3 out of the spray

gun housing

5.

Caution

When pulling out and inserting the electrode holder, ensure that the insert is not
damaged!

• Remove powder residue from the parts removed and from the spray gun.

040402_FM.doc

Caution

Be careful when mounting the electrode holder C4 R FM.

Otherwise there is a

risk of injury by the electrode tip.

6

5

7

1

8

7

Y

X

peac4_0008

• Carefully fit the new electrode holder C4 R FM 6

into the spray gun housing

5.

• Slide the deflector cone sleeve 7 onto the electrode

holder

6.

• Align the marks X and Y.

• Fasten in place using the outer nut 1.

• Slide the deflector cone 8 back over the deflector

cone sleeve

7.

The spray gun is ready for use again.

Maintenance and cleaning

01 / 2008 0390882 - PEA-C4-HiCoat FM 23

4.5 Mounting the angle adapter

4.5.1 Dismantling the nozzle and the electrode holder

0405_Umbau_zurwinkeldüse.doc

The standard Corona spray gun is delivered with a fan spray nozzle. The nozzle can be
changed easily, as described in the following.

Caution

When changing from a fan spray nozzle to an angle nozzle, the depth control must be
readjusted!

The angle adapter is necessary to perform the change:

WA90 C4, WA60 C4 or WA30 C4

as it is specified in the accessory list.

Hint

Both a fan spray and a round spray nozzle can be installed in the angle adapter.

030301_ .doc

1

3

5

2

peac4_0005

• Unscrew the outer nut 1 from the spray gun housing 5.

• Pull the fan spray nozzle 2 off the electrode holder 3.

• Carefully pull the electrode holder 3 out of the spray

gun housing

5.

Caution

When pulling out and inserting the electrode holder, ensure that the insert is not
damaged!

• Remove powder residue from the parts removed and from the spray gun.

Maintenance and cleaning

24 0390882 - PEA-C4-HiCoat FM 01 / 2008

4.5.2 Fitting the angle adapter

0405_Anbau_winkeladapter.doc

D

E

C

1

2

0390931_montage04

C Fit the electrode holder with nozzle into the

nozzle insert and fasten in place using the
outer nut.

D Slide the angle adapter onto the spray gun

body and tighten easily using the threaded
sleeve.

E Swivel the angle adapter 2 into the desired

position and afterwards fasten in place
using the threaded sleeve

1.

4.5.3 Replacing the wearing parts

0405_Verschleiss_winkeladapter.doc

Sample assembly: Angle adapter WA90 C4

4
6
5

7

3

2

1

0390931_montage03

1. Disconnect from the spray gun body

•

Undo the threaded sleeve 1 and disconnect
the angle adapter

2 from the spray gun body

3.

•

Loosen the outer nut 4.

•

Pull the electrode holder 5 with nozzle 6 out of
the nozzle insert

7.

Caution

When pulling out and inserting the electrode
holder, ensure that the insert is not damaged!

Maintenance and cleaning

01 / 2008 0390882 - PEA-C4-HiCoat FM 25

7

12

11

10

8, 9

A2

X

A1

B1

Y1

Y2

Z

B2

0390931_montage01

2. Dismantle

•

Unscrew the threaded sleeve 8 and the
locking sleeve

9 using the assembly tool 10.

•

Pull the connecting body 11 out of the bend

12.

•

Insert a screwdriver into recess X and turn
the screwdriver so that the nozzle insert

7 is

loosened.

• Pull out the nozzle insert 7.

•

Replace worn parts with new ones.

Clean all the parts thoroughly and
remove any powder residues!

3. Assemble

• Install nozzle insert 7 as shown in insets Y1

and

Y2 so that pin B1 engages in bore A1.

• Install connecting element 11 as shown in

inset

Z inside angle 12 so that pin B1 en-

gages in bore

A2.

• Screw in threaded sleeve 8 and locking

sleeve

9 with assembly tool 10 and tighten

securely.

• Ensure that the threaded sleeve can still turn

freely.

4. Insert the nozzle system

•

Install electrode holder 5 with nozzle 6 in
nozzle insert

7.

•

Secure with outer nut 4.

Maintenance and cleaning

26 0390882 - PEA-C4-HiCoat FM 01 / 2008

4.6 Mounting the Corona-Star

0405_ .doc

The Corona-Star is a Retrofit-Set for the spray gun, which helps to achieve a better surface
quality (reduction of "orange peel").

Caution

Trained personnel may only carry out the assembling of the Corona-Star!
Prior to mounting the Corona-Star, the high voltage and the powder feed

must be

switched off and secure against inadvertent switch on!

Proceed as described below:

A

C

E F

B

D

G

1

2

3

Peac4_0012

• Switch off the high voltage and the powder

feed and secure against inadvertent switch
on.

• Unscrew the standard nut A from the spray

gun housing

B.

• Screw the new Corona-Star nut D onto the

spray gun housing and fasten in place.

• Fasten the cable guide onto the cover plate

F

by using the screw E.

• Slide the Corona-Star G onto the spray

gun housing

B.

Caution

Check whether the grounding is assured!

The spray gun is ready for use again.

Maintenance and cleaning

01 / 2008 0390882 - PEA-C4-HiCoat FM 27

4.7 Disposal

04_Entsorgung.doc

Only for EU countries

Do not dispose of electric tools together with household waste
material!

In observance of the European Directive 2002/96/EC on waste electrical
and electronic equipment and implementation in accordance with
national law, this product is not to be disposed of together with household
waste material but must be recycled in an environmentally friendly way!

Wagner or one of our dealers will take back your used Wagner waste electrical or electronic
equipment and will dispose of it for you in an environmentally friendly way. Please ask your
local Wagner service center or dealer for details or contact us direct.

Rectification of malfunctions

28 0390882 - PEA-C4-HiCoat FM 01 / 2008

5. Rectification of malfunctions

05_Stoerung_C4.doc

Malfunction Cause Rectification

No electrostatic
(e.g. no wrap around or
no powder
adhesion)

- Fault in the high voltage
generator

- Electrical cable from spray
gun to control unit faulty

- Cascade in spray gun faulty

- Contact Wagner Service

- Replace electrical cable

- Contact Wagner Service

Poor wrap around
Back spray

- Inadequate or no ground - See chapter

"

Grounding"

Powder outlet uneven
or inadequate

- Soiling

- Powder sintering

- Feed device soiled

- Feed air / dosage air ratio
incorrect

- Wear on powder injector
nozzle

- Blow through parts carrying
powder

- Clean parts carrying powder

- See operating instructions for
the related devices connected

- Adjust at control module
respective control unit

- Replace worn parts in the
powder injector 1.)

Spray pattern is
uneven

- Parts of nozzle system worn - Replace worn parts

1.) You will find the wearing parts and spare parts in the operating instructions for the powder
injector.

Technical data

01 / 2008 0390882 - PEA-C4-HiCoat FM 29

6. Technical data

Weight: 555 g

06_ .doc

Electrical:

Input voltage: max. 22 Vpp
Input current: max. 0.9 A
Frequency: 19 ... 30 kHz
Output voltage: max. 100 kV DC
Polarity: negative
Design: as per EN 50177
Protection class: IP 54

Pneumatic:

Input air pressure (atomizing air): max. 43.5 psi (3 bar)
Powder output quantity: max. 450 g/min

06_ .doc

Required compressed air quality:

Quality class

Compressed air quality according to ISO 8573.1

5

Max. residual water:

(pressure dew point in °F at 100 psi

/ °C at 700 kPa)

+44.6 °F / +7 °C

2

Max. oil contents: 0.1 mg oil/m3 / 0.1 oz/ft3

3

Max. concentration: 5 mg/m3 / 5 oz/ft3

3

Max. particle size:

5

μm / 5 microns

Ambient conditions:

If low temperature powders are used, the ambient temperature may have to be lower than
86 °F (30 °C).

Volume measures:

For volumes, specified in Nm3 (standard cubic meters). One cubic meter of a gas at

32 °F (0 °C) and 1.013 bar is called norm cubic meter.

1 Nm

3

/h = 35.3 ft3/h; 1 bar = 14.504 psi

Warranty

30 0390882 - PEA-C4-HiCoat FM 01 / 2008

7. Warranty

08_ .doc

What is covered by this warranty?

Faulty or defective parts are replaced according to our general delivery conditions.
Within the applicable warrant period, Wagner will repair or replace, at our option, defective

parts without charge if such parts are returned with transportation charges prepaid to the
nearest authorized service center. If Wagner is unable to repair this product so as to conform
to this Limited Warranty after a reasonable number of attempts, Wagner will provide, at our
option, either a replacement for this product or a full refund of the purchase price of this
product.

These remedies are the sole and exclusive remedies available for breach of express and
implied warranties.

What is not covered by this warranty?

This warranty does not cover any of the following damages or defects:

1. Damages or defects caused by use or installation of repair or replacement parts or

accessories not manufactured by Wagner,

2. Damages or defects caused by repair performed by anyone other than a Wagner

authorized service center, or

3. Damages or defects caused by or related to abrasion, corrosion, abuse, misuse,

negligence, accident, normal wear, faulty installation or tampering in a manner which
impairs normal operation.

Limitation of remedies:

IN NO CASE SHALL WAGNER BE LIABLE FOR ANY INCIDENTAL, SPECIAL OR
CONSEQUENTIAL DAMAGES OR LOSS, INCLUDING TRANSPORTATION COSTS,
WHETHER SUCH DAMAGES ARE BASED UPON A BREACH OF EXPRESS OR IMPLI ED
WARRANTIES, BREACH OF CONTRACT, NEGLIGENCE, STRICT TORT, OR ANY OTHER
LEGAL THEORY.

Disclaimer of implied warranties:

THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WA RRANTIES, EXPRESS
OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

No ability to transfer:

This warranty is extended to the original purchaser only and is not transferable.

Your rights under state law:

Some states do not allow limitations on how long an implied warranty lasts or the exclusion of
incidental or consequential damages, so the above limitation and exclusion may not apply to
you. This warranty gives you specific legal rights; you may also be entitled to other rights,
which vary from state to state.

Scope of delivery and spare parts lists

01 / 2008 0390882 - PEA-C4-HiCoat FM 31

8. Scope of delivery and spare parts lists

8.1 How to order spare parts

0901_ .doc

Faulty and unserviceable parts are replaced in accordance with our General Terms and Condi­tions of Delivery.

In order to be able to guarantee safe and smooth spare parts delivery, the following informa­tion is necessary:

- Invoicing address

- Delivery address

- Name of contact persons for check back

- Type of delivery

- Quantity ordered, article number and designation

Scope of delivery and spare parts lists

32 0390882 - PEA-C4-HiCoat FM 01 / 2008

8.2 Scope of delivery and spare parts spray gun PEA-C4-HiCoat FM

03909110390311

0390342

0390969

0390310

0390324

0390006

0390006

Article No. Description

0390016 Spray gun PEA-C4-HiCoat FM

0390311 Outer nut

0390324 * Fan spray nozzle F1

0390969 * Electrode holder F FM ET **

0390310 * Protective wedge

0390911 * Powder tube C4 ET (PEA-C4)

0390342

Adjustment tool
(for fan spray nozzles)

* Wearing part ** only available as a set

Accessories

01 / 2008 0390882 - PEA-C4-HiCoat FM 33

9. Accessories

9.1 Electrode holder C4 R FM with nozzles

0390313

0390970

0390310

0390207

0390972

0390972

Article No. Designation

0390972 Electrode holder C4 R FM with nozzles

0390207 * Deflector cone

R20 = Ø20

0390208 * Deflector cone

R28 = Ø28

0390209 * Deflector cone

R38 = Ø38

0390970 * Electrode holder C4 R FM ET **

0390313 * Deflector cone sleeve

0390310 * Protective wedge

* Wearing part ** only available as a set

Accessories

34 0390882 - PEA-C4-HiCoat FM 01 / 2008

9.2 Electrical cables and hoses

10_00001

Article No. Designation Comments

0351216
0351217
0351215

Electrical cable 5 m
Electrical cable 10 m
Electrical cable 20 m

For connecting the spray gun
to the high voltage generator

9987081
9987082

Special hose (inside

∅11 mm)

Special hose (inside

∅ 12 mm)

For the powder feed

9982079 Hose 6x1 Connection of the atomizing air

9.3 Spray gun mounting and fastening

10_00002

Article No. Designation

0351347 Hanger: For fastening the spray gun

0260215

Spray gun mount:

For fastening the hanger to
the reciprocator

9.4 Fan spray nozzle and deflector cone

10_00003

Article No. Designation

0390324 *
0390325 *
0390326 *

Fan spray nozzle

F1

Fan spray nozzle F2
Fan spray nozzle F3

0390331 * Wide fan spray nozzle

HPO-1

0390207 *
0390208 *
0390209 *

Deflector cone (complete) Ø20
Deflector cone (complete) Ø28
Deflector cone (complete) Ø38

* Wearing part

Accessories

01 / 2008 0390882 - PEA-C4-HiCoat FM 35

9.5 Wedge tool

0390900

Article No. Designation

0390900

Wedge tool **

including 20 protective wedges

* Wearing part ** only available as a set

9.6 Angle adapter with accessories

9.6.1 Assembly tool for angle adapter

0390939

Article No. Designation

0390939

Assembly tool WA C4 ET
Removal and installation aid for connector in

angle adapter WA C4

Accessories

36 0390882 - PEA-C4-HiCoat FM 01 / 2008

9.6.2 Angle adapter

0390947

0390933

0390942

0390932

0390945

0390946

0390931_et

0390931

Article No. Designation

0390931 Angle adapter WA90 C4

0390933 * Nozzle insert WA90 C4 ET

0390932 * Connecting body WA C4 ET

0390947 Outer nut WA C4 ET

0390946 Locking sleeve WA C4 ET

0390945 Threaded sleeve WA C4 ET

0390942 Bend WA90 C4 ET

* Wearing part

Accessories

01 / 2008 0390882 - PEA-C4-HiCoat FM 37

0390947

0390934

0390943

0390932

0390945

0390946

0390930_et

0390930

Article No. Designation

0390930 Angle adapter WA60 C4

0390934 * Nozzle insert WA60 C4 ET

0390932 * Connecting body WA C4 ET

0390947 Outer nut WA C4 ET

0390946 Locking sleeve WA C4 ET

0390945 Threaded sleeve WA C4 ET

0390943 Bend WA60 C4 ET

* Wearing part

Accessories

38 0390882 - PEA-C4-HiCoat FM 01 / 2008

0390947

0390935

0390944

0390932

0390945

0390946

0390927_et

0390927

Article No. Designation

0390927 Angle adapter WA30 C4

0390935 * Nozzle insert WA30 C4 ET

0390932 * Connecting body WA C4 ET

0390947 Outer nut WA C4 ET

0390946 Locking sleeve WA C4 ET

0390945 Threaded sleeve WA C4 ET

0390944 Bend WA30 C4 ET

* Wearing part

Accessories

01 / 2008 0390882 - PEA-C4-HiCoat FM 39

9.7 Powder measuring bag

0390940

Article No. Designation

0390940

Powder measuring bag (complete) C4 ET

For measuring powder quantities for the
C4-HiCoat gun generation

9.8 Retrofit-Set Corona-Star

0260296

0390319

0390918

0390918

Article No. Designation

0390918 Corona-Star (complete) **

0260296 *

Electrode Corona-Star
(included in item 1)

0390319 Outer nut

* Wearing part ** only available as a set

Notes

40 0390882 - PEA-C4-HiCoat FM 01 / 2008

Notes

01 / 2008 0390882 - PEA-C4-HiCoat FM 41

Notes

42 0390882 - PEA-C4-HiCoat FM 01 / 2008

ADDRESSES

Germany Switzerland

J. WAGNER GmbH J. WAGNER AG
Otto-Lilienthal-Str. 18 Postfach 109
D-88677 Markdorf Industriestrasse 22
CH-9450 Altstätten

Phone [phone] Phone [phone]
Fax [phone] Fax [phone]

Austria Netherlands

J. WAGNER GmbH Wagner Systemen Nederland B.V.
Otto-Lilienthal-Str. 18 Proostwetering 105 C
Postfach 1120 NL-3543 AC UTRECHT
D- 88677 Markdorf

Phone: ++49/ (0)7544 / 5050 Phone [phone]
Fax: ++49/ (0)7544 / 505200 Fax [phone]

Belgium Denmark

Estee Industries WAGNER Powder Systems Scvandinavia
Leenbeekstraat 9 Juupajokivej 8
B-9770 Kruishoutem DK-8850 Bjerringbro

Phone [phone] Phone [phone]
Fax [phone] Fax [phone]

Sweden

WAGNER Powder Systems Scandinavia AB
Hedenstorpsvägen 4
Sverige - 55593 Jönköping

Phone [phone]
Fax [phone]

Great Britain USA

WAGNER Spraytech (UK) Ltd. WAGNER Systems Inc.
Unit 3 Haslemere Way 300 Airport Road, Unit 1
Tramway Industrial Estate Elgin, IL 60123
UK-Banbury, Oxon OX 16 8TY

Phone [phone] Phone [phone]
Fax [phone] Fax [phone]

ADDRESSES

Japan

WAGNER- HOSOKAWA Micron Ltd.
No. 9, 1-Chome
Shodal Tajka, Hirakata-Shi
Osaka 673-1132

Phone [phone]
Fax [phone]

China

WAGNER SPRAYTECH SHANGHAI CO LDT.
4

th

Flr, No. 395 Jiangchangxi Road
Shibei Industrial Zone
Shanghai, 200436

Phone [phone]
Fax [phone]

France

J. Wagner France SARL
B.P. 75, 5, Avenue du 1er Mai
F-91122 Palaiseau-Cédex

Phone [phone]
Fax [phone]

Italy Spain

WAGNER Itep S.p.A. WAGNER Spraytech Iberia S.A.
Via Santa Vecchia, 109 P.O.Boc, 132, Crtra. N-340, Km. 1245,4
I-22049 Valmadrera - LC E-08750 Molins de Rei (Ba rcelona)

Phone [phone] Phone [phone]
Fax [phone] Fax [phone]