Page 1
0102
II 2 D EEx 2mJ 85 °C
P_02330
Automatic Powder Spray Gun
PEA-C4XL-S
Version 03 / 2014
Translation of the
Original Operating
Manual
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PEA-C4XL-S
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
Table of Contents
1 GENERAL INFORMATION 6
1.1 Preface 6
1.2 Warnings, Notices, and Symbols in this Operating Manual 6
1.3 Languages 7
1.4 Abbreviations 7
2 CORRECT USE 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 Use in Potentially Explosive Areas 8
2.4 Safety Parameters 8
2.5 Processible Working Materials 9
2.6 Reasonably Foreseeable Misuse 9
2.7 Residual Risks 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identi cation 10
3.2 Permissible Device Combinations 10
3.3 Safety Feature Identi cation 11
4 GENERAL SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Equipment 12
4.1.2 Sta Quali cations 12
4.1.3 Safe Work Environment 12
4.2 Safety Instructions for Sta 13
4.2.1 Safe Handling of WAGNER Powder Spray Devices 13
4.2.2 Grounding the Device 13
4.2.3 Accessories and Spare Parts 13
4.2.4 Cleaning and Maintenance 14
4.2.5 Handling Powder Lacquers 14
4.3 Note on Safe Discharges 15
4.4 Protective and Monitoring Equipment 16
4.4.1 Release Guns (High-voltage/Pneumatic System) 16
5 DESCRIPTION 17
5.1 Spray Gun Design 17
5.2 Functioning of the Spray Gun 17
5.3 Technical Data 18
5.3.1 Dimensions 19
5.4 Permitted Accessories 20
5.5 Scope of Delivery 20
6 ASSEMBLY AND COMMISSIONING 21
6.1 Training Assembly/Commissioning Sta 21
6.2 Storage Conditions 21
6.3 Installation Conditions 21
6.4 Preparing the Spray Gun 22
6.4.1 Selection of the Suitable Nozzle System 22
6.5 Handling of the Hose Coupling 25
6.6 Assembling the Spray Gun 26
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6.7 Grounding 28
6.7.1 Grounding the Powder Coating System 29
7 OPERATION 30
7.1 Training the Operating Sta 30
7.2 Safety Instructions 30
7.3 Switching on the Spray Gun 31
7.4 Switching O the Spray Gun 31
7.5 Switching O the Spray Gun in the Event of Faults or Emergencies 31
7.6 Optimizing the Powder Cloud for Your Coating 32
7.7 Performing a Paint Change 33
7.7.1 Impulse Flushing 34
7.8 Reproducible Setting of the Nozzle Position 35
8 CLEANING AND MAINTENANCE 36
8.1 Cleaning 36
8.1.1 Cleaning Sta 36
8.1.2 Safety Instructions 36
8.1.3 Cleaning Procedures 37
8.2 Maintenance 38
8.2.1 Maintenance Sta 38
8.2.2 Safety Instructions 38
8.2.3 Maintenance Procedures 39
8.2.4 Replacing the Spray Gun 40
8.3 Cleaning the Gun and Dismantling the Flat Spray Nozzle 42
8.4 Replacing the Protective Wedge 43
8.5 Fitting the Round Spray Nozzle 45
8.6 Assembling the Angle Adapter 47
8.6.1 Removing the Nozzle and Electrode Holder 47
8.6.2 Fitting the Angle Adapter 48
8.6.3 Replacement of the Wearing Parts 48
8.7 Assembling the Corona-Star 50
8.8 Corona-Star for Angle Adapter 51
8.8.1 Assembling the Corona-Star 51
9
INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 201004 52
9.1 Overview of Inspections 53
10 DISASSEMBLY AND DISPOSAL 56
10.1 Disassembly 56
10.2 Disposal 57
11 TROUBLESHOOTING AND RECTIFICATION 58
12 ACCESSORIES 60
12.1 Flat Spray Nozzles 60
12.2 De ector Cone for Round Spray Nozzle 60
12.3 Corona-Star Retro t Set 61
12.4 Corona-Star WA C4 61
12.5 Wedge Tool 62
12.6 Electric Cables and Hoses 62
12.7 Angle Adapter 63
12.8 Powder Measuring Bag 64
Table of Contents
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13 SPARE PARTS 65
13.1 How Can Spare Parts Be Ordered? 65
13.2 PEA-C4XL-S Corona Automatic Gun 66
13.3 C4 R Electrode Holder with Nozzles 67
13.4 WA90 C4 Angle Adapter 68
13.5 WA60 C4 Angle Adapter 69
13.6 WA30 C4 Angle Adapter 70
14 DECLARATION OF WARRANTY AND CONFORMITY 71
14.1 Important Notes Regarding Product Liability 71
14.2 Warranty Claim 71
14.3 Declaration of Conformity 72
Table of Contents
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1 GENERAL INFORMATION
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 operating and service
sta .
Operating and service sta should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.1 PREFACE
1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
Warning instructions in this operating 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 - immediate risk of danger.
Non-observance will result in death or serious injury.
Warning - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Note - provides information about particular characteristics and how to proceed.
Notice - a possibly hazardous situation.
Non-observance may result in material damage.
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
DANGER
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
WARNING
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
CAUTION
This notice warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the hazard and its consequences.
NOTICE
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1.3 LANGUAGES
The operating manual is available in the following languages:
Language: Order No. Language: Order No.
German 2345333 English 2345334
Italian 2345335
1.4 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part
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2 CORRECT USE
2.1 DEVICE TYPE
Automatic spray gun for automatic coating
2.2 TYPE OF USE
The PEA-C4XL-S spray gun serves as stationary equipment for industrial electrostatic
coating with ammable powder in automatic systems. It can be operated either with
single control units or switch cabinet modules.
2.3 USE IN POTENTIALLY EXPLOSIVE AREAS
This type A-P electrostatic powder spray gun is suitable for processing industrial powder
paints for coating electrically conductive objects and can be used in potentially explosive
areas (zone 22). (See Chapter 3.1 Explosion Protection Identi cation).
2.4 SAFETY PARAMETERS
The powder spray gun is only suited to the application of powder paint.
J. Wagner AG forbids any other use!
The powder spray gun may only be operated under the following conditions if:
the operating sta have previously been trained on the basis of this operating
manual,
the safety regulations listed in this operating manual are observed,
the operating, maintenance and repair information in this operating manual is
observed,
and the statutory requirements and accident prevention regulations standards in the
country of use are observed.
The spray gun may only be used if all parameters are set and all measurements/safety
checks are carried out correctly.
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2.6 REASONABLY FORESEEABLE MISUSE
The following is prohibited:
coating work pieces which are not grounded,
unauthorized conversions and modi cations to the spray gun,
processing liquid or similar coating products,
and using defective components, spare parts or accessories other than those
described in Chapter 12 of this operating manual.
The forms of misuse listed below may result in health issues and/or material damage:
use of damp powder paint,
incorrectly set values for powder discharge,
and incorrectly set electrostatic values.
2.5 PROCESSIBLE WORKING MATERIALS
Types of powder which can be charged electrostatically
Metallic powder
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be excluded even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual risk Source Consequences Speci c measures Lifecycle phase
Skin contact with
powder lacquers
and cleaning agents
Handling powder
lacquers and
cleaning agents
Skin irritations, Wear protective
clothing,
Operation,
Allergies Observe safety data
sheets
Maintenance,
Disassembly
Powder lacquer
in air outside the
de ned working
area
Lacquering outside
the de ned working
area
Inhalation of
substances
hazardous to health
Observe work and
operation instructions
Operation,
Maintenance
Falling down of
spray guns
Loosening of the
securing nuts
Injuries Regular check of
fastenings
Operation,
Maintenance
Residual voltage on
live parts
De cient grounding Electrical shock Indication of danger, Operation,
Instruction by trainer Maintenance
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OPERATING MANUAL
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
3.2 PERMISSIBLE DEVICE COMBINATIONS
The PEA-C4XL-S powder spray gun may only be connected to the control devices listed
below:
EPG-S2 EPG-Sprint X
Gun type: PEA-C4XL-S
Manufacturer: J. Wagner AG
CH - 9450 Altstätten
II 2 D EEx 2mJ 85 °C
CE: European Communities
0102: Number of noti ed body which is involved in the production
monitoring phase
E: according to European standard
Ex: Symbol for explosion protection
II: Device class II
2: Category 2
D: Ex-atmosphere dust
2mJ: Maximum ignition energy 2 mJ
85 °C: Maximum surface temperature
Incorrect use of the spray gun!
Risk of injury and damage to the device.
Only connect original Wagner devices to the PEA-C4XL-S HiCoat
spray gun.
WARNING
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3.3 SAFETY FEATURE IDENTIFICATION
Plates bearing information for the user have been attached to the work openings of the
powder coating booth.
The plate size corresponds to the standard category Ø 100 mm; 3.94 inches.
The label plates, which must be attached, are shown below:
Explosive atmosphere!
Close to the spray area a warning sign (included in the delivery of the system) has to be
placed with the following indications:
The equipment may only be operated by trained sta .
Before starting cleaning the spray gun or carrying out any other work in the spray
area, the high-voltage must be shut down in such a way that it cannot be activated
again by actuating the trigger of the spray gun.
Use only metallic tanks for cleaning uids.
Preferably use solvents with the highest possible ash point, higher than the ambient
temperature if possible.
The electrostatic spraying unit must be maintained regularly according to the
manufacturer's instructions. Repairs may only be performed according to the
manufacturer's instructions.
Forbidden for
unauthorized persons!
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
4.1.2 STAFF QUALIFICATIONS
4.1.3 SAFE WORK ENVIRONMENT
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient in uences.
May only be maintained by skilled electricians.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be decommissioned if they pose a hazard.
Must be de-energized before work is commenced on active parts.
Secure the device against being switched back on without authorization. Inform sta
about planned work.
Observe electrical safety regulations.
Ensure that the device is operated, maintained and repaired only by trained persons.
The oor in the working area must be electrostatically conductive (measurements
according to EN 1081 and EN 61340-4-1).
The footwear worn by the operators must comply with the requirements of
EN ISO 20344. The measured insulation resistance must not exceed 100 megohms.
The protective clothing, including gloves, must comply with the requirements of
EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.
The powder release must be electrically interlocked with the powder spray system's
exhaust air equipment.
Excess coating product (overspray) must be collected up safely.
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires,
or hot surfaces in the vicinity. Do not smoke.
Maintain su cient quantities of suitable re extinguishers and ensure that they are
serviceable.
The operating company must ensure that an average concentration of powder paint
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 may not exceed 10 g/m³.
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4.2.1 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
4.2.2 GROUNDING THE DEVICE
4.2.3 ACCESSORIES AND SPARE PARTS
4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in this manual, particularly the general safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
Under no circumstances may people with pacemakers enter the area where the high-
voltage eld between the spray gun and the work piece to be coated builds up!
Do not point spray guns at people.
Before all work on the device, in the event of work interruptions and functional faults:
- Switch o the energy/compressed air supply.
- Secure the spray gun against actuation.
- Relieve pressure on spray guns and device.
-
In case of functional faults: Identify and correct the problem, proceed as described
in the "Fault Recti cation" chapter.
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the
device. This may result in the formation of sparks or ames when discharging.
Ensure that the device is grounded before each coating process.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g. by wearing
electrostatically conductive shoes.
The functionality of grounding cables must be checked regularly (see EN 60204).
Only use an original Wagner powder hose.
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4.2.5 HANDLING POWDER LACQUERS
4.2.4 CLEANING AND MAINTENANCE
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 system.
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- ammable cleaning uids.
Flammable cleaning liquids may only be used if, after switching o the high-voltage,
all high-voltage conducting parts are discharged to a discharge energy of less than
0.24 mJ before they can be accessed.
Most ammable 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.
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used to
remove dust deposits.
When preparing or processing the powder and cleaning the device, take note of the
processing regulations, laid down by the manufacturer of the powder lacquers, being
used.
Take note of the manufacturer’s instructions and the relevant environmental protection
regulations when disposing of powder lacquers.
Take the prescribed safety measures, in particular the wearing of safety glasses and
safety clothing as well as the use of protective hand cream.
Use a mask or breathing apparatus if necessary.
To ensure su cient protection of health and the environment, only operate the device
in a powder booth or on a spray wall with activated ventilation (exhaust air).
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4.3 NOTE ON SAFE DISCHARGES
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 e ect 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 e ect 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.
Work piece
Luminous discharge
Nozzle
Electrode
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4.4 PROTECTIVE AND MONITORING EQUIPMENT
4.4.1 RELEASE GUNS HIGHVOLTAGE/PNEUMATIC SYSTEM
Enabling high-voltage depends on:
Exhaust air is OK
Fire extinguishing system/ re detection system is OK (external signal)
No EMERGENCY STOP
Control voltage ON
As soon as one of these conditions is not fulfilled, the high-voltage is switched off
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.
Incorrect use!
Risk of injury and damage to the device.
Protective and monitoring equipment must not be removed,
modi ed 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.
WARNING
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B
C
A
F
G
H
X
X
P_02331
G
K
I
L
D
E
A
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
5 DESCRIPTION
5.1 SPRAY GUN DESIGN
Designation
A Fan spray nozzle or round spray nozzle
BDe ector cone for round spray nozzle
C Round spray nozzle electrode
D Union nut
E Interlocking
F Spray gun body
G Powder hose connection
H Supporting tube
I Electrical connection
K Atomizing air connection
L Grounding screw
5.2 FUNCTIONING OF THE SPRAY 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 spray gun!
If changing from the at spray nozzle to the round spray nozzle with de ector cone, the
depth control must be adjusted!
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Dimensions:
Length/width/height see Chapter 5.3.1
Weight
Electrical:
Input voltage maximum 22 Vpp
Input current maximum 0.9 A
Frequency 19 - 30 kHz
Output voltage maximum 100 kV DC
Polarity negative
Construction type in accordance with DIN EN 50177
types A-P
Protection class IP 54
Pneumatic:
Input air pressure (atomizing air volume) maximum 3 bar; 0.3 MPa, 43.51 psi
Powder output quantity maximum 450 g/min;
maximum 0.99 lbs/min
Ambient conditions:
Operating temperature range 5 - 45 °C; 41 - 113 °F
Relative humidity < 75 %
5.3 TECHNICAL DATA
Outgoing air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water (Quality
Standard 3.5.2 according to ISO 8573.1) 3.5.2 = 5 μm / +7 °C;
44.6 °F / 0.1 mg/m³.
WARNING
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 speci ed in Nm³ (standard cubic meters). One cubic meter of a gas at 0 °C and
1.013 bar is called norm cubic meter.
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E
D
X
X
A*
P_02332
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OPERATING MANUAL
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5.3.1 DIMENSIONS
Measurement mm inch
A* 30 1.18
B 400 15.75
C 1,100 43.31
D 60 2.36
E 72 2.83
Measurement for installation dimension C calculation when utilizing a round spray
nozzle with de ector cone
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Quantity Order No. Designation
1 2344249 PEA-C4XL-S automatic gun
1 --- Nozzle set
The standard equipment includes:
1 2347535 Conformity certi cate
1 2345333 Operating manual, German
1 see Chapter 1.3 Operating manual in local language
5.5 SCOPE OF DELIVERY
5.4 PERMITTED ACCESSORIES
Only the accessories listed in this operating manual may be connected to the PEA-C4XL-S
powder spray gun.
The accessories listed in Chapter 12 were included in the EC type examination and are
approved for use with the gun.
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6 ASSEMBLY AND COMMISSIONING
6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF
6.2 STORAGE CONDITIONS
Until the point of assembly, the powder spray gun must be stored in a dry location, free
from vibrations and with a minimum of dust. The powder spray gun 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 between 0 °C and +35 °C; 32 °F and
95 °F.
Depending on the powder lacquer used, the maximum permissible ambient temperature
for reliable operation can be signi cantly below +40 °C; 104 °F.
The relative air humidity at the installation site must be between 10 and 95% (without
condensation).
Incorrect installation/operation!
Risk of injury and damage to the device.
The commissioning sta must have the technical skills to safely
undertake commissioning.
The commissioning sta must be familiar with the provisions of
European standard DIN EN 50177.
When commissioning and for all work, read and follow the
operating manual and safety regulations for the additionally
required system components.
WARNING
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6.4 PREPARING THE SPRAY GUN
6.4.1 SELECTION OF THE SUITABLE NOZZLE SYSTEM
Nozzle Application Distance to
work piece
Powder
discharge
(mm) (g/min)
F1¹ Universal application (slow
powder cloud)
120 … 300 50 … 250
deep and complex part
geometries
extensive work pieces
F2¹ Targeted application (dense
powder cloud)
120 … 400 30 … 200
high penetration
Wide coating range
F3¹ for small total air volume and
small jet width
120 … 300 ≤ 180
(fastest powder cloud)
high penetration capability
for pro le parts
high stability
F4¹ Wide at spray nozzle for high
powder application (slow
powder cloud)
> 200
(Total air >
4.5 Nm³/h)
150 … 400
good atomization
specially for extensive work
pieces
The process of changing from the fan spray nozzle to a round spray nozzle with a de ector
cone is described in Chapter 8.5 "Fitting a Round Spray Nozzle".
You will nd the article numbers of the di erent nozzles in Chapter 12 "Accessories".
Nozzle Application overview Powder cloud
Flat jet nozzle Di cult work pieces
Widely spread at powder cloud
Undercuts
Pro les
Flat work pieces (reduced
picture frame)
De ector cone
Oval powder cloud:
Size of the powder cloud is
dependent on the de ector plate
diameter
Wire goods
Grid designs
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P_00695
P_00694
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P_01107
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
Nozzle Application Distance to
work piece
Powder
discharge
(mm) (g/min)
HPO-1¹ Wide at spray nozzle for high
powder application (slow
powder cloud)
> 200
(Total air >
4.5 Nm³/h)
150
400
good atomization
specially for extensive work
pieces
1.) Nozzles are labeled on the back.
De ector cone Application Distance to
work piece
Powder
discharge
(mm) (g/min)
R20
100 … 300 30 … 250
20 mm
Smaller at parts
R28
100 … 300 50 … 250
28 mm
Medium sized at parts
Lateral application with
Z-axis
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6.5 HANDLING OF THE HOSE COUPLING
Loosening the hose coupling:
1. Lift the O-ring 1 out of the groove and slide it towards spray gun.
2. Turning the locking nut 2 in a clockwise direction up to the stop and pull the hose
coupling 3 out of the coupling piece 4.
Connecting the hose coupling:
3. Insert the hose coupling 3 into the coupling piece 4 and turning the locking nut 2
counterclockwise up to the stop.
4. Press the O-ring 1 into the groove again (securing function).
Note:
Slide the powder hose as much as possible up to the stop onto the hose coupling!
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X
1
2
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5
G
K
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6.6 ASSEMBLING THE SPRAY GUN
Unintentional putting into operation!
Risk of injury.
Before any work on the device, in the event of work interruptions
and malfunctions:
Switch o the energy/compressed air supply.
Relieve spray gun and device pressure.
Secure the spray gun against actuation.
In the event of malfunctions, remedy the fault as described in
the "Troubleshooting" chapter.
WARNING
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Procedure:
1. Switch o the high-voltage generation on the control unit.
2. Press locking button 1 and move supporting tube 2 away backwards.
3. Connect electrical cable 3 to connection I on the spray gun and to the control unit.
4. Connect the powder feed hose 4 to connection G on the spray gun and to the powder
injector.
The handling of the hose coupling is described in Chapter 6.5.
5. Connect the atomizing air hose 5 to connection K on the spray gun and to the control
unit.
6. Connect the grounding cable 6 to grounding screw L on the spray gun and to the
signal ground.
7. Press locking button 1 and supporting tube 2 forwards on the spray gun housing up
to stop.
The locking button 1 must snap into place in the drilled hole in supporting tube 2.
8. Fasten gun on the gun carrier with a suitable device.
Note:
For connecting and fastening the spray gun use the parts listed in the "Accessories"
chapter.
The distance of the installed spray guns to each other must be at least 300 mm;
11.81 inches for functional reasons!
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6.7 GROUNDING
For safety reasons, the spray gun and the work piece must be properly grounded. For the
spray gun, this is done via the grounding connection.
Perfect grounding of the work piece is also necessary to achieve an optimum powder
coating.
A poorly grounded work piece causes:
dangerous electric charging of the work piece,
very poor wrap-around,
uneven coating,
and back spraying to the spray gun, i.e. contamination.
Prerequisites for perfect grounding and coating are:
clean suspension of the work piece to be coated,
grounding of spraying booth, conveyor system and suspension on the part of
the building site in accordance with the operating manual or the manufacturer's
information,
and grounding of all conductive parts of the system.
The resistance to ground of every work piece's locating point must not exceed 1 MΩ
(megohm) (measurement voltage must be 500 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 su ciently cleaned and therefore the work pieces are not su ciently
grounded!
These sparks can cause heavy radio frequency interference (EMC).
Heavy paint mist if grounding is insu cient!
Danger of poisoning.
Insu cient paint application quality.
Ground all device components.
Ground the work pieces to be coated.
WARNING
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2
4
3
5
6
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6.7.1 GROUNDING THE POWDER COATING SYSTEM
1 Only use mains cables with grounding strand!
2 Connect grounding cable with signal ground!
3 Remove all paint from hooks and other hanger parts!
4 Do not wear non-conducting gloves!
5 Wear electrostatically conductive shoes!
6 The oor must be electrostatically conductive!
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7 OPERATION
7.1 TRAINING THE OPERATING STAFF
7.2 SAFETY INSTRUCTIONS
Incorrect operation!
Risk of injury and damage to the device.
The operating sta must be quali ed to operate the entire
system.
Before work commences, the operating sta must receive
appropriate system training.
The operating sta must be familiar with the provisions of
European standard DIN EN 50177.
WARNING
Incorrect operation!
Risk of injury and damage to the device.
If contact with powder products or cleaning agents causes skin
irritation, appropriate precautionary measures must be taken,
e.g. wearing protective clothing.
The footwear worn by operating sta must comply with
EN ISO 20344. The measured insulation resistance must not
exceed 100 megohms.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 megohms.
WARNING
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7.3 SWITCHING ON THE SPRAY GUN
The spray gun is switched on via the superordinated control unit of the system. At the
same time, the high-voltage and the powder feed are activated.
7.4 SWITCHING OFF THE SPRAY GUN
The gun is switched o di erently depending on the type of powder injector. In most
cases, this process is performed by the coating system controller.
Note:
On each interruption of work, the spray 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 a manual switch-o is required and provided that the powder injector is not suitable for
the 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 channel and the cascade compartment during the ushing process.
Switch o the powder feed and the high-voltage generation.
2. If you do not want to modify the settings of the feed and dosage air to continue
coating with the same powder cloud, remove the powder injector from the injector
connection of the powder container. When switching on again no more powder will
be delivered.
3. Switch the powder feed on again to blow out any powder remaining in the spray
gun.
4. The powder feed can now be switched o .
7.5 SWITCHING OFF THE SPRAY 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 powder feed are switched o .
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Procedure:
1. Switch on the high-voltage generation and the powder feed.
Note:
To minimize the wear on the wearing parts, the total feed air and dosing 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 with de ector cone to 0.2 Nm³/h.
2. Adjust the powder quantity and the powder speed on a test piece.
7.6 OPTIMIZING THE POWDER CLOUD FOR YOUR COATING
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7.7 PERFORMING A PAINT CHANGE
In the case of a paint change, powder residues must be thoroughly removed from all
powder-conveying 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.
Procedure:
1. Switch o the powder coating system after an automatic ushing and secure it
against being switched back on.
2. In case no automatic ushing is used, ush the gun manually and remove any powder
residues from it before switching o the system:
- Disconnect the powder hose from the spray gun.
- Blow through the spray gun using the air gun and thus remove any powder
residues.
- Switch o the system and secure against unauthorized reactivation.
3. Before starting to connect the powder hose again, all parts carrying powder must be
thoroughly cleaned.
4. The spray gun is ready for use again.
Dust formation!
Danger of poisoning.
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 booth suction system and the
lter cleaning system must remain activated!
WARNING
NOTICE
Paint carry-over!
If the union nut is not screwed on tightly up to the stop position, the paint may smear.
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7.7.1 IMPULSE FLUSHING
If the gun is supplied with coating powder from a powder center, you can initiate an
impulse ushing from there. Further details are contained in the powder center's operating
manual.
Note:
During a paint change, the nozzle system does not necessarily have to disassembled.
Powder supply hose coupling may be hurled around!
Risk of injury and damage to the device.
Check whether the hose is correctly attached to the hose
coupling.
Completely lock the hose coupling and secure it with an O-ring.
WARNING
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15°
0°
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7.8 REPRODUCIBLE SETTING OF THE NOZZLE POSITION
For a horizontal powder cloud, the
at spray nozzle is set where the
protective wedge is in the 0° position.
When attaching a round spray nozzle,
we recommend turning the protective
wedge to the 90° position to achieve
smoother coating (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
spray nozzle.
It permits turning the at spray nozzle
without damaging the electrodes and
without removing the union nut.
The union nut only has to be slackened.
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8 CLEANING AND MAINTENANCE
Cleaning work should be undertaken regularly and carefully by quali ed and trained sta .
The sta must be familiar with the DIN EN 50177 provisions. They should be informed of
speci c hazards during their training.
The following hazards may arise during cleaning work:
Health hazard from cleaning agents
Health hazard from inhaling powder lacquer
Use of unsuitable cleaning tools and aids
8.1 CLEANING
8.1.2 SAFETY INSTRUCTIONS
8.1.1 CLEANING STAFF
Explosive powder/air mixes!
Danger to life and damage to the device.
Before starting cleaning or other manual work, the high-voltage
must be shut down and locked to prevent it from being switched
back on!
Use only electrically conductive tanks for cleaning liquids!
Ground the tank!
Preference should be given to non- ammable cleaning uids.
Flammable cleaning liquids may only be used if, after switching
o the high-voltage, all high-voltage conducting parts are
discharged to a discharge energy of less than 0.24 mJ before
they can be accessed.
Most ammable 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.
Only mobile industrial vacuum cleaners of design 1 (see
EN 60335-2) may be used to remove dust deposits.
DANGER
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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 J. Wagner AG's specialist personnel.
The valid health and safety speci cations and the safety instructions provided in Chapter 4
must be adhered to for all cleaning work.
8.1.3 CLEANING PROCEDURES
Incorrect maintenance!
Risk of injury and damage to the device.
If contact with powder products or cleaning agents causes skin
irritation, appropriate precautionary measures must be taken,
e.g. wearing protective clothing.
The footwear worn by operating sta must comply with
EN ISO 20344. The measured insulation resistance must not
exceed 100 megohms.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 megohms.
WARNING
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8.2 MAINTENANCE
Maintenance work should be undertaken regularly and carefully by quali ed and trained
sta . They should be informed of speci c hazards during their training.
The following hazards may arise during maintenance work:
Health hazard from inhaling powder lacquer
Use of unsuitable tools and aids
Once the maintenance work is complete, the device must be checked by a quali ed person
to ensure a reliable condition.
8.2.1 MAINTENANCE STAFF
8.2.2 SAFETY INSTRUCTIONS
Incorrect maintenance/repair!
Risk of injury and damage to the device.
Have repairs and part replacements carried out only by specially
trained sta or a WAGNER service center.
Before all work on the device and in the event of work
interruptions:
- Switch o the energy/compressed air supply.
- Relieve spray gun and device pressure.
- Secure the spray gun against actuation.
Observe the operating and service manuals at all times when
carrying out work.
DANGER
Incorrect maintenance/repair!
Danger to life and damage to the device.
Repair or replacement of devices or parts of devices are only
allowed to be performed outside the hazard area by quali ed
personnel.
DANGER
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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 J. Wagner AG's specialist personnel.
The valid health and safety speci cations and safety instructions provided in Chapter 4
must be adhered to for all maintenance work.
8.2.3 MAINTENANCE PROCEDURES
Incorrect maintenance!
Risk of injury and damage to the device.
If contact with powder products or cleaning agents causes skin
irritation, appropriate precautionary measures must be taken,
e.g. wearing protective clothing.
The footwear worn by operating sta must comply with
EN ISO 20344. The measured insulation resistance must not
exceed 100MΩ.
The protective clothing, including gloves, must comply with
EN ISO 1149-5. The measured insulation resistance must not
exceed 100 MΩ.
WARNING
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X
1
2
4
5
G
K
I
L
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8.2.4 REPLACING THE SPRAY GUN
Unintentional putting into operation!
Risk of injury.
Before any work on the device, in the event of work interruptions
and malfunctions:
Switch o the energy/compressed air supply.
Relieve spray gun and device pressure.
Secure the spray gun against actuation.
In the event of malfunctions, remedy the fault as described in
the "Troubleshooting" chapter.
WARNING
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Before replacing the spray gun, any powder residue must be thoroughly removed.
The wearing parts in the spray gun, marked in the spare parts list with " ", must be regularly
checked and, if necessary replaced.
Procedure:
1. Switch o the high-voltage generation on the control unit, close the compressed air
supply and relieve the system of pressure.
2. Press locking button 1 and carefully remove the gun from supporting tube 2.
3. Disconnect electrical cable 3 from connection I on the spray gun.
4. Disconnect the powder feed hose 4 from connection G on the spray gun.
The handling of the hose coupling is described in Chapter 6.5.
5. Disconnect the atomizing air hose 5 from connection K on the spray gun.
6. Detach the grounding cable 6 from grounding screw L on the spray gun.
7. Connect electrical cable 3 to connection I on the new spray gun.
8. Connect the powder feed hose 4 to connection G on the spray gun.
9. Connect the atomizing air hose 5 to connection K on the spray gun.
10. Connect the grounding cable 6 from grounding screw L to the spray gun.
11. Carefully insert the spray gun into supporting tube 2 until the locking button 1 locks
into place in the drilled hole in supporting tube 2.
12. Switch on the high-voltage and open the compressed air supply.
13. The spray gun is ready for use again.
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8.3 CLEANING THE GUN AND DISMANTLING THE FLAT SPRAY NOZZLE
Procedure:
1. Unscrew union nut 1 from gun housing 5.
2. Pull at spray nozzle 2 o electrode holder 3.
3. Carefully remove electrode holder 3 from gun housing 5.
Note:
Do not damage the electrode holder, when pulling it out and
inserting it.
4. Remove powder residues from the parts removed and from
the spray gun.
Note:
Never place the spray gun or parts of the spray gun in cleaning
agent.
As a rule the protective wedge needs to be checked for wear and
replaced if necessary.
New protective wedge
Worn protective wedge
It is recommended to replace the protective wedge.
In the next section it is described how the protective wedge is to be dismantled and
inserted.
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1
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8.4 REPLACING THE PROTECTIVE WEDGE
1 Wedge tool
2 Protective wedge (when positioned)
3 Electrode holder (shown with a cut-
away view to improve comprehension)
Procedure:
1. Guide wedge tool 1 into electrode
holder 3 up to stop.
2. Pull the protective wedge 2 out of the
electrode holder 3 using the wedge
tool 1.
3. Press the protective wedge 2 sideways
out of wedge tool 1 manually (without
tool).
Note:
A wedge tool is available to prevent the protective wedge from being damaged when
dismantling and inserting.
You will nd the necessary wearing parts and spare parts in Chapter 13 "Spare Parts" of this
operating manual.
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Procedure:
1. Guide protective wedge 2 into wedge
tool 1.
2. Insert both parts into opening on
electrode holder 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.
Note:
The same wedge tool is used to insert the protective wedge.
1 Wedge tool
2 Protective wedge (when positioned)
3 Electrode holder (shown with a cut-
away view to improve comprehension)
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8.5 FITTING THE ROUND SPRAY NOZZLE
The standard Corona spray gun is delivered with a at spray nozzle. The nozzle can be
changed easily, as described below.
Note:
If changing from the at spray nozzle to the round spray nozzle with de ector cone, the
depth control must be adjusted.
The C4 R electrode holder is necessary to perform the change.
Procedure:
1. Unscrew union nut 1 from gun housing 5.
2. Pull at spray nozzle 2 o electrode holder 3.
3. Carefully remove electrode holder 3 from gun
housing 5.
Note:
Do not damage the electrode holder, when pulling it
out and inserting it.
4. Remove powder residues from the parts
removed and from the spray gun.
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 wearing parts and
spare parts in Chapter 13 "Spare Parts" of this
operating manual.
6. Prior to re- tting, check whether the contact
points on electrode holder 3 and in gun housing
5 have been thoroughly cleaned so that the
electrode tip is electrically connected to the
high-voltage generator.
7. Carefully t electrode holder 3 in spray gun
housing 5.
8. Slide the fan spray nozzle 2 back over electrode
holder 3 and fasten in place using union nut 1.
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6
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8
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5. Carefully t the new C4 R electrode holder 6
into spray gun housing 5.
6. Slide de ector cone sleeve 7 onto electrode
holder 6.
7. Align the X and Y marks.
8. Fasten union nut 1.
9. Slide de ector cone 8 over de ector cone
sleeve 7.
10. The spray gun is ready for use again.
Electrode tip!
Risk of injury.
Take care when tting the C4 R electrode holder.
CAUTION
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8.6 ASSEMBLING THE ANGLE ADAPTER
The standard Corona spray gun is delivered with a at spray nozzle. The nozzle can be
changed easily, as described below.
Note:
If changing from the at spray nozzle to the round spray nozzle with de ector 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 "Accessories".
Note:
A at spray nozzle as well as a round spray nozzle can be tted to the angle adapter.
8.6.1 REMOVING THE NOZZLE AND ELECTRODE HOLDER
Procedure:
1. Unscrew union nut 1 from gun housing 5.
2. Pull at spray nozzle 2 o electrode holder 3.
3. Carefully remove electrode holder 3 from gun
housing 5.
Note:
Do not damage the electrode holder, when pulling it
out and inserting it.
4. Remove powder residues from the parts
removed and from the spray gun.
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8.6.2 FITTING THE ANGLE ADAPTER
Procedure:
1. Install electrode holder 1 together with nozzle 2
in nozzle insert 3 and tighten union nut 4.
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.
8.6.3 REPLACEMENT OF THE WEARING PARTS
Procedure:
1. Loosen threaded sleeve 1 and separate angle
adapter 2 from gun body 3.
2. Loosen union nut 4.
3. Pull out electrode holder 5, together with
nozzle 6, from nozzle insert 7.
Note:
Do not damage the electrode holder, when pulling it
out and inserting it.
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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 7 loosens.
7. Pull out nozzle insert 7.
8. Replace the wearing parts with new
components.
9. Clean all components thoroughly and remove
any powder residues.
10. Install nozzle insert 7, as shown in magni ed
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 angle
piece 12, as shown in the magni ed 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 5 together with
nozzle 6 in the nozzle insert 7.
14. Put on union nut 4 and tighten it well.
15. Mount the angle adapter to the gun again.
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8.7 ASSEMBLING THE CORONASTAR
The Corona-Star is a retro t set for the spray gun, which helps to achieve a better surface
quality (reduction of "orange peel").
Procedure:
1. Switch o the high-voltage and the powder
feed and secure them against being
inadvertently switched on.
2. Unscrew the standard nut A from the spray
gun housing B.
3. Screw the new nut C for the Corona-Star D
onto the spray gun housing and tighten well.
4. Dismount the Corona-Star H from spray gun
housing B.
5. Fasten the cable guide onto the cover plate F
using screw E.
6. Slide the Corona-Star G onto the spray gun
housing B.
Note:
Check whether the grounding is assured.
7. The spray gun is ready for use again.
Danger from electric current!
Risk of injury and damage to the device.
Only trained personnel may modify the Corona-Star.
Prior to assembling the Corona-Star, the high-voltage and the
powder feed must be switched o and secured against being
inadvertently switched on.
WARNING
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8.8 CORONASTAR FOR ANGLE ADAPTER
8.8.1 ASSEMBLING THE CORONASTAR
Procedure:
1. Switch o the high-voltage and the powder
feed and secure them against being
inadvertently switched on.
2. Detach the Corona-Star 1 from spray gun
housing.
3. Fit Corona Star for angle adapter 2 on angle
adapter (direction of tting shown is only an
example).
4. Fasten the connection cable 3 on the spray
gun housing.
Note:
Check whether the grounding is assured.
5. The spray gun is ready for use again.
Note:
When converting the gun in the normal version, t
again without a Mini Corona-Star 1 angle adapter.
Danger from electric current!
Risk of injury and damage to the device.
Only trained personnel may modify the Corona-Star.
Prior to assembling the Corona-Star, the high-voltage and the
powder feed must be switched o and secured against being
inadvertently switched on.
WARNING
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9
INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 201004
If the system is used for electrostatic coating with ammable 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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Section Type of inspection Requirements Inspection
by
Type of inspection Inspection
interval
1E ectiveness of technical
ventilation check
E ectiveness of technical
ventilation check
TP/SP ME
e.g. measurements of air ow
speed / air quantities,
checking of the di erential
pressure indicator according
to the cabin manufacturer's
instructions
continuously
according to
the booth
manufacturer's
instructions
2 Interlock between technical
ventilation and high-voltage,
compressed air and coating
product supply
The technical ventilation should
be interlocked such that the high-
voltage cannot be switched on
while the technical ventilation is
not working e ectively.
SP FI
Test whether the system is safely
stopped and the product supply,
supply air and high-voltage
are switched o when the
ventilation is shut down.
annually
3 Protection against ignition of
ammable cleaning agents
If ammable 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.
SP ME/FI
Function test of the residual
energy monitoring equipment
according to the manufacturer's
instructions.
according to the
manufacturer's
instructions
Legend:
MA = Manufacturer
EM = Employer
SP = Skilled person
FSE = Fire safety engineer
ELC = Electrician
TP = Trained person
FI = Function inspection
ME = Measurement
SI = Standard inspection
VI = Visual inspection
CI = Continuous inspection
TI = Technical inspection
9.1 OVERVIEW OF INSPECTIONS
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Section Type of inspection Requirements Inspection by Type of inspection Inspection
interval
4E ectiveness of grounding
measures
All the system's conductive
elements, such as oors, walls,
ceilings, protective grating,
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 system. The
resistance of the oor may not
exceed 108 Ohm.
SP VI/ME/CI
Visual check of ground
connections, perform
function test on grounding
switch, measurement of
grounding resistors.
weekly
5 Resistance to ground of work
piece's locating point
The resistance to ground of
every work piece's locating point
must not exceed 1 megohm
(measurement voltage must be
500 or 1000 V). The design of the
work piece receiver must ensure
that the adapters remain grounded
during coating.
SP ME/CI
Measure resistance to ground
(work piece receiver - ground
potential) max. 1 MOhm @
1000 V.
weekly
6 Further inspections Depending on the design and
functions of the booth, further
inspections may be necessary (see
EN 12981).
according to
the booth
manufacturer's
instructions
according to the cabin
manufacturer's instructions
according
to the cabin
manufacturer's
instructions
Legend:
MA = Manufacturer
EM = Employer
SP = Skilled person
FSE = Fire safety engineer
ELC = Electrician
TP = Trained person
FI = Function inspection
ME = Measurement
SI = Standard inspection
VI = Visual inspection
CI = Continuous inspection
TI = Technical inspection
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X
X
1
2
4
5
G
K
I
L
P_02333
6
3
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10 DISASSEMBLY AND DISPOSAL
10.1 DISASSEMBLY
WARNING
Incorrect disassembly!
Risk of injury and damage to the device.
Before starting disassembly:
- Switch o the energy/compressed air supply.
- Ensure that all system components are grounded.
- Secure system against being switched back on without
authorization.
Observe the operating manuals for any work.
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10.2 DISPOSAL
Do not dispose of used electrical equipment with household
refuse!
In accordance with European Directive 2002/96/EC 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 waste
electrical or electronic equipment and will dispose of it for you in
an environmentally friendly way. Please contact one of our service
points, one of our representatives or us directly to arrange this.
NOTICE
Procedure:
1. Switch o the high-voltage generation on the control unit, close the compressed air
supply and relieve the system of pressure.
2. Press locking button 1 and carefully remove the gun from supporting tube 2.
3. Disconnect electrical cable 3 from connection I on the spray gun.
4. Disconnect the powder feed hose 4 from connection G on the spray gun.
(For handling of the hose coupling, see Chapter 6.5.)
5. Disconnect the atomizing air hose 5 from connection K on the spray gun.
6. Detach the grounding cable 6 from grounding screw L on the spray gun.
7. Dismount supporting tube 2 on the gun attachment.
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11 TROUBLESHOOTING AND RECTIFICATION
Incorrect maintenance/repair!
Risk of injury and damage to the device.
Have repairs and part replacements carried out only by specially
trained sta or a WAGNER service center.
Before all work on the device and in the event of work
interruptions:
- Switch o the energy/compressed air supply.
- Ensure that all system components are grounded.
- Secure the device against being switched back on without
authorization.
Observe the operating and service manuals at all times when
carrying out work.
DANGER
Incorrect maintenance/repair!
Danger to life and damage to the device.
Wagner devices, protective systems and safety, monitoring and
control equipment may only be maintained/repaired as de ned
in Directive 94/9/EC (ATEX) by trained Wagner service personnel
or capable persons in accordance with TRBS 1203! Note national
regulations!
Repair or replacement of devices or parts of devices may only be
performed outside the hazard area!
DANGER
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Fault Cause Remedy
No electrostatics (e.g. no wrap
around or powder adhesion)
Fault in the high-voltage
generator
Contact a Wagner service center
Electrical cable from spray gun
to control unit faulty
Replace the electric cable
Cascade in spray gun faulty Contact a Wagner service center
Poor wrap-around
Back-spray
Insu cient or no grounding See Chapter 6.7 "Grounding"
Powder outlet uneven or
inadequate
Contamination Blow through parts carrying
powder
Powder sintering Clean parts carrying powder
Feed device contaminated See operating manuals for the
related devices connected
Feed air / dosing air ratio
incorrect
Adjust at control module resp.
control unit
Wear on powder injector nozzle Replace worn parts on powder
injector ¹)
Spray pattern is uneven Parts of nozzle system worn Replace worn parts
1.) You will nd the wearing and spare parts in the powder injector operating manual.
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P_00935
P_00695
P_00694
P_00694
P_00694
P_00694
P_00694
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
12 ACCESSORIES
12.1 FLAT SPRAY NOZZLES
Order No. Designation
390324 Flat spray nozzle F1
390325 Flat spray nozzle F2
390326 Fan spray nozzle F3
2311889 Flat spray nozzle F4
390331 Wide at spray nozzle HPO-1
12.2 DEFLECTOR CONE FOR ROUND SPRAY NOZZLE
Order No. Designation
390207 De ector cone
20 mm
390208 De ector cone 28 mm
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1
2
3
P_01104
P_01168
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
Order No. Designation
1 1 390918 Corona-Star, complete
2
1 260296 Corona-Star electrode
3 1 390319 Union nut
Wearing parts
12.3 CORONASTAR RETROFIT SET
12.4 CORONASTAR WA C4
Pos K Order No. Designation
1 1 2306335 Corona-Star WA C4
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P_00714
OPERATING MANUAL
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12.5 WEDGE TOOL
Order No. Designation
1 390900 Wedge tool including 20 protective wedges
Only available as a set
12.6 ELECTRIC CABLES AND HOSES
Order No. Designation Application
351216 Electrical cable 5 m
for connecting the spray gun to the
high-voltage generator
351217 Electrical cable 10 m
351215 Electrical cable 20 m
2307502 Powder hose
11 mm
for powder feed
2310700 Powder hose 12 mm
9982079 Hose 6x1 Atomizing air connection
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P_01621
P_01626
OPERATING MANUAL
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12.7 ANGLE ADAPTER
Order No. Designation
390927 Angle adapter WA30 C4
390930 Angle adapter WA60 C4
390931 Angle adapter WA 90 C4
Order No. Designation
390939 Mounting tool WA C4
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P_01105
P_01106
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
12.8 POWDER MEASURING BAG
Order No. Designation
390940 Powder measuring bag, complete
For measuring powder quantities for the C4 gun generation
The powder measuring bag is slid onto the nozzle.
Risk of explosion due to electrostatic charging!
Danger to life and damage to the device.
Only use powder measuring bag when high-voltage is
switched o !
DANGER
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13 SPARE PARTS
13.1 HOW CAN SPARE PARTS BE ORDERED?
To ensure proper spare parts delivery, the following information is necessary:
Order number, designation, and quantity
The quantity need not be the same as the number given in the "Quantity" column in the
lists. 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:
Identi cation in spare parts lists
Explanation of column "K" in the following spare parts lists.
- 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.)
= Wearing parts
Note: These parts are not covered by warranty terms
= Not part of the standard equipment but available as a special accessory.
Incorrect maintenance/repair!
Risk of injury and damage to the device.
Have repairs and part replacements carried out only by specially
trained sta or a WAGNER service center.
Before all work on the device and in the event of work
interruptions:
- Switch o the energy/compressed air supply.
- Ensure that all system components are grounded.
- Secure the device against being switched back on without
authorization.
Observe the operating and service manuals at all times when
carrying out work.
WARNING
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PEA-C4XL-S
2
13
3
P_02336
4
5
1
9
6
7
10
11
12
8
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
13.2 PEAC4XLS CORONA AUTOMATIC GUN
PEA-C4XL-S automatic gun
Order No. Designation
1 1 2344249 PEA-C4XL-S Corona automatic gun
2 1 390311 Union nut
3
1 390324 Flat spray nozzle F1
4
1 390915 Electrode holder
5 1 390310 Wedge
6 1 390911 Powder tube, C4 ET
7 1 390957 Mini Corona-Star
8 1 2345327 XL-S ET supporting tube
9
1 2344114 Rear powder tube
10 1 9971131 O-ring, 22x3
11
1 390954 Coupling piece
12
1 390955 Hose take-up, D10-D12
13 1 390342 Adjustment tool for at spray nozzles
Wearing parts
Not part of the standard equipment but available as a special accessory
Only available as a set
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3
4
5
6
P_01103
2
1
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
C4 R electrode holder with nozzles
Order No. Designation
1
1 390917 C4 R electrode holder, complete
2
1 390916 C4 R electrode holder
3 1 390310 Wedge
4 1 390313 De ector cone sleeve
5
1 390207 R20 de ector cone ( 20 mm; 0.79 inch)
6 1 390208 R28 de ector cone ( 28 mm; 1.10 inches)
Wearing parts
Not part of the standard equipment but available as a special accessory
Only available as a set
13.3 C4 R ELECTRODE HOLDER WITH NOZZLES
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5
6
7
P_01623
1
2
3
4
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
WA90 C4 angle adapter
Order No. Designation
1 1 390931 WA90 C4 angle adapter
2 1 390947 WA C4 ET union nut
3
1 390933 WA90 C4 ET nozzle insert
4 1 390942 WA90 C4 ET elbow tting
5 1 390932 WA C4 ET connecting element
6 1 390946 WA C4 ET locking sleeve
7 1 390945 WA C4 ET threaded sleeve
Wearing parts
Not part of the standard equipment but available as a special accessory
Only available as a set
13.4 WA90 C4 ANGLE ADAPTER
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P_01624
1
2
3
4
5
6
7
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
WA60 C4 angle adapter
Order No. Designation
1 1 390930 WA60 C4 angle adapter
2 1 390947 WA C4 ET union nut
3
1 390934 WA60 C4 ET nozzle insert
4 1 390943 WA60 C4 ET elbow tting
5 1 390932 WA C4 ET connecting element
6 1 390946 WA C4 ET locking sleeve
7 1 390945 WA C4 ET threaded sleeve
Wearing parts
Not part of the standard equipment but available as a special accessory
Only available as a set
13.5 WA60 C4 ANGLE ADAPTER
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P_01625
1
2
3
4
5
6
7
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
WA60 C4 angle adapter
Order No. Designation
1 1 390927 WA30 C4 angle adapter
2 1 390947 WA C4 ET union nut
3
1 390935 WA30 C4 ET nozzle insert
4 1 390944 WA30 C4 ET elbow tting
5 1 390932 WA C4 ET connecting element
6 1 390946 WA C4 ET locking sleeve
7 1 390945 WA C4 ET threaded sleeve
Wearing parts
Not part of the standard equipment but available as a special accessory
Only available as a set
13.6 WA30 C4 ANGLE ADAPTER
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14 DECLARATION OF WARRANTY AND CONFORMITY
14.1 IMPORTANT NOTES REGARDING PRODUCT LIABILITY
14.2 WARRANTY CLAIM
As a result of an EC regulation e ective from January 1, 1990, the manufacturer shall only
be liable for his product if all parts originate from him or are approved by him, and if the
devices are properly mounted, operated and maintained.
The manufacturer will not be held liable or will only be held partially liable if third-party
accessories or spare parts have been used.
With genuine WAGNER accessories and spare parts, you have the guarantee that all safety
regulations are complied with.
Full warranty is provided for this device:
We will at our discretion repair or replace free of charge all parts which within 24 months
in single-shift, 12 months in 2-shift or 6 months in 3-shift operation from date of receipt by
the purchaser are found to be wholly or substantially unusable due to causes prior to the
sale, in particular faulty design, defective materials or poor workmanship.
The type of warranty provided is such that the device or individual components of the
device are either replaced or repaired as we see t. The resulting costs, in particular
shipping charges, road tolls, labor and material costs will be borne by us except where
these costs are increased due to the subsequent shipment of the device to a location other
than the address of the purchaser.
We do not provide warranty for damage that has been caused or contributed to for the
following reasons:
Unsuitable or improper use, faulty assembly or commissioning by the purchaser or a
third party, normal wear, negligent handling, defective maintenance, unsuitable coating
products, substitute products and the in uence of chemical, electrochemical or electrical
agents, except when the damage is attributable to us.
Components that have not been manufactured by WAGNER are subject to the original
warranty of the manufacturer.
Replacement of a component does not extend the period of warranty of the device.
The device should be inspected immediately upon receipt. To avoid losing the warranty,
we or the supplier company are to be informed in writing about obvious faults within
14 days upon receipt of the device.
We reserve the right to have the warranty compliance met by a contracting company.
The services provided by this warranty are dependent on evidence being provided in the
form of an invoice or delivery note. If the examination discovers that no warranty claim
exists, the costs of repairs are charged to the purchaser.
It is clearly stipulated that this warranty claim does not represent any constraint on statutory
regulations or regulations agreed to contractually in our general terms and conditions.
J. Wagner AG
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14.3 DECLARATION OF CONFORMITY
PEA-C4XL-S automatic gun 2347535
Herewith we declare that the supplied version of
- PEA-C4XL-S automatic gun, Order No. 2344249
complies with the following provisions:
- 94/9/EC (ATEX Directive)
- 2006/42/EC (Machine Directive)
- 2004/108/EC (EMC Directive)
- 2002/95/EC (RoHs Directive)
- 2002/96/EC (WEEE Directive)
Applied standards, in particular:
- DIN EN 50177: 2009
- DIN EN 50050: 2006
- DIN EN 60079-0: 2010
- DIN EN 1127-1: 2011
- DIN EN 1953: 2010
- DIN EN ISO 12100: 2011
- DIN EN 60529: 2000
- DIN EN 61000-6-2: 2011
- DIN EN 61000-6-4: 2011
- DIN EN 14462: 2010
- DIN EN 60204-1: 2007
Identi cation:
0102
II 2 D EEx 2mJ 85 °C
CE Certi cate of Conformity
The CE certi cate 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:
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C
E
R
T
I
F
I
E
D
Dokument-Nr. 11160384
Version -
Order No. 2345334
Edition 03/2014
Germany
Phone
Fax
E-mail
Switzerland
Phone
Fax
More contact addresses on the Internet at:
Company/Locations/WAGNER worldwide
Subject to changes without notice
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