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.
4 351874 - PEA-T3 03/2008
Safety regulations
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
manufacturers 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.
03/2008 351874 - PEA-T35
Safety regulations
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.
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!
010102_ .doc
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.
1.2 EC Declaration of conformity
Wagner hereby declares that the unit described in these operating instructions has been
designed and manufactured according to the provisions of EU Directives 98/37/EG,
94/9/EG, 73/23 EWG and 89/336 EWG.
The following
The following
There is an
necessary from your WAGNER dealer by giving details of the product and serial number
involved.
European standards were applied:
EN 12100-1/-2 EN 50281-1-1/-1-2 EN 61000-6-1
EN 61000-6-2 EN 61000-6-3 EN 60204-1
EN 50053-2 EN 50050 EN 50177
German standards and/or Guidelines were applied:
BGI 764
EC Declaration of Conformity with the product. This can be ordered again if
0103_ .doc
The number of the EC Declaration of Conformity is
351962.
6 351874 - PEA-T3 03/2008
Preparing the spray gun
2. Preparing the spray gun
2.1 Select the suitable nozzle system
0201_Duesenauswahl_tribo.doc
Nozzle Overview Application Spray pattern
Oval powder cloud:
Deflector cone
Wire goods
Grid designs
Size is dependent on the deflector
cone diameter.
For powder quantities from:
50 ... 300 g/min
Fan spray nozzle
Wide fan spray
nozzle
Nozzle
Finger nozzles
1
Z
Difficult work pieces:
Undercuts
Profiles
Difficult work pieces:
Undercuts
Profiles
Overview Application Spray pattern
Flat surfaces
for uniform coating thickness
Widely spread flat powder cloud.
For powder quantities:
from 50 ... 150 g/min
Widely spread flat powder cloud.
For powder quantities:
from 100 ... 250 g/min
0201_Duesenauswahl_finger.doc
Directed spray with:
the standard nozzle
1
or
powder shower
2
2
For powder quantities from:
100 ... 200 g/min
1
03/2008 351874 - PEA-T37
Preparing the spray gun
Crossed finger nozzles
1
Z
1
Complicated profiles
for uniform coating thickness
Directed spray with:
the standard nozzle
or
powder shower
For powder quantities
100 ... 200 g/min
1
3
3
from:
Note that the installation dimensions
nozzles. The finger nozzle has a length of:
The following result applies to the
Article numbers and other information on nozzle systems are to found in chapter Fehler!
Verweisquelle konnte nicht gefunden werden. "
Z (as described on page 2) changes when using finger
Z1 = 315 mm.
PEA-T3: Z = 340 - 46 + Z1 = 294 + 315 = 609 mm
Finger nozzles".
8 351874 - PEA-T3 03/2008
Preparing the spray gun
2.2 Connecting the spray gun
Before you commence connecting the gun, switch off the powder feed. 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.
The spacing between the spray guns when fitted must be at least 300 mm.
E
A
Electrical connection
from control unit
Atomizing air
P
Powder feed
T
Grounding the spray gun
via the gun support
Mount the spray gun on the hanger and secure both, for example on the gun holder of the
reciprocator. If an oscillator is being used, the spray gun must be fixed with a clamping
element (see accessories).
Connect the spray gun to the Tribo current measuring or display module with the electrical
E.
cable
Connect the powder feed hose P to the spray gun.
Connect the hose for Tribo air T and the hose for atomizing air A to the spray gun.
from powder injector
Tribo air
Hint
By using a Wagner PI-F1 powder injector and a suitable control unit, it is
possible to blow out or flush the spray gun automatically each time before it is switched
off.
03/2008 351874 - PEA-T39
Preparing the spray gun
2.3 Grounding
For safety reasons, the spray gunmust be properly grounded. This occurs through thegun
mounting.
Good grounding of the work piece is also necessary for optimum powder coating.
A poorly grounded work piece causes:
dangerous electric charging of the work piece
back-spray onto spray gun and user
uneven coating
very bad wrap around
Warning
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 sufficiently cleaned and therefore the work pieces are not
sufficiently grounded!
These sparks can cause heavy radio frequency interference.
0203_ .doc
10 351874 - PEA-T3 03/2008
Working with the spray guns
3. Working with the spray guns
3.1 Optimize the spray pattern
0301_Pulverwolke_peat.doc
Switch on the powder feed.
Caution
To minimize the wear on the consumables, the total feed air and dosage air must give
the following values:
for powder hose with an inner diameter of 11 mm: between 3.5 and 5 Nm3/h
for powder hose with an inner diameter of 12 mm: between 4.5 and 6 Nm3/h
The total feed air; dosage air and Tribo air should not exceed
First open the atomizing air so that powder deposits are cleared from the deflector cone.
You can alter the size of the spray pattern during powdering by adjusting the atomizing air.
Adjust the powder volume and the powder speed on a test piece.
The Tribo air should only be opened far enough to attain a Tribo current indication of
approx. 3
A.
7.5 Nm3/h!
Caution
Tribo air must be reduced or shut off if the Tribo current (charging current) exceeds
3.5
A!
The charging current depends on the type of powder used and should be between 2.5 and
A under ideal circumstances.
3.5
03/2008 351874 - PEA-T311
Working with the spray guns
3.2 Switching off the spray gun
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
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
designed for automatic purging, proceed as follows: The atomizing air must be left open so that no powder can enter the atomizing air ducts
during purging. Switch off the powder feed.
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 feedback on so that the spray gun is blown clear of powder.
Finally, switch the powder feed and the high-voltage generator back off and secure against
inadvertent switching on.
0302_Ausschalten_peat.doc
powder deposits and a surge the next time the
not
12 351874 - PEA-T3 03/2008
Working with the spray guns
3.3 Carrying out a change of color
All parts carrying powder in the entire coating system
deposits on a change of color. In the following, only the procedure for the spray gun is
described.
3
4
2
A
25
B
Peat3_0005a
must be thoroughly cleaned of powder
Flush the gun manually and remove
all powder residues.
Switch off the powder feed and secure
it against inadvertent switch on.
Pull off the deflector cone A from the
charging body
Unscrew the outer nut 2 from the gun
housing
Carefully pull the nozzle body 3 and
the charging body
tube
B.
25.
4.
4 out of the powder
Caution
Ensure in particular that none of the charging body’s components are damaged when
removing and replacing the wear parts!
Clean the parts, which have been dismantled, and the spray gun from powder deposits.
Carefully re-fit the charging body 4 and the nozzle body 3 in the powder tube 25 and
tighten it up with the outer nut
Slide the deflector cone A onto the charging body 4 again.
The spray gun is again ready for operation.
2.
03/2008 351874 - PEA-T313
Maintenance and cleaning
4. Maintenance and cleaning
4.1 Replacing the spray gun
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 is 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.
0401_ .doc
0401_Peat3_Ausbauen.doc
D
C
E
B
F
G
H
Peat3_0004
Switch off the system.
Disconnect the electrical cable D from the spray gun B.
Disconnect the hoses for powder feed E, atomizing air C and Tribo air F from the spray
gun
B.
Undo the locking nut G and disconnect the spray gun B from the support H.
Exchange the spray gun for a new one and assemble it in reverse order.
14 351874 - PEA-T3 03/2008
Maintenance and cleaning
4.2 Cleaning the spray gun and replace the wear parts
Caution
Never place the spray gun or parts of it into any wet cleaning agent!
While pulling out and replacing the wearing parts make sure that the parts of the
charging body are not damaged!
4.2.1 Replacing the charging body
0402_Peat3_Verschleiss.doc
20/32
2
A
L
Pull the deflector cone A off the charging
L.
body
Unscrew the outer nut 2 from the gun
housing
Pull the nozzle body 20/32 off the powder
tube
B.
25.
Carefully extract the charging body L out
of the powder tube
25.
Check the removed parts for wear. The
25
B
Peat3_0005b
entire charging body can be replaced
with a
new one during this procedure.
0402_Peat_Verschleiss.doc
It is also possible to dismantle the charging body and merely replace the parts affected by
wear.
Unscrew the tip 28 from the threaded
16
22
bar
22.
Carefully pull the parts 24 to 26 off the
22.
18
threaded rod
As a rule you only need to check the
24 to 26 for wear and replace
parts
them as necessary.
Clean all parts that have not been
24
23
26
28
Peat3_0005c
subject to wear.
Unscrew the air nozzle 16 from the
deflector cone rod
replace it with a
18 if worn and
new one.
Reassemble the charging body L and
carefully push it into powder tube
Carefully push the nozzle body 20/32 over the powder tube 25 and tighten on the gun
housing
B using the outer nut 2.
Slide the deflector cone A back over the charging body L.
25.
03/2008 351874 - PEA-T315
Maintenance and cleaning
4.2.2 Replacing the air manifold
34
35
Loosen the hose socket 35 and turn
the air manifold
34 and O-ring 38
carefully out of the connection cover
4.
Pull the air manifold 34 and O-ring
38 off the hose socket 35 and
replace both with new parts if
necessary.
4.3 Disposal
38
4
Peat3_0006
Push the new air manifold 34 and
O-ring
again
38 onto the hose socket
35.
Turn the new parts 35, 34 and 38
into the connection cover
4.
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/EG 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.
16 351874 - PEA-T3 03/2008
Behebung von Funktionsstörungen
5. Rectification of malfunctions
05_Stoerung_T3.doc
Malfunction Cause
No Tribo current
(e.g. no wraparound or no powder
adhesion)
- Inadequate or no powder
charging.
- Electrical cable from spray gun
to control unit faulty.
Rectification
- Contact Wagner Service.
- Replace electrical cable.
- Tribo current measuring or
display module defective.
- Powder-conveying parts in
- Contact Wagner Service.
- Replace worn parts.
spray gun worn.
Poor wrap around
Back spray
Powder outlet
uneven or
inadequate
Spray pattern is
- Inadequate or no ground. - See chapter
"
Grounding".
- Soiling.
- Powder sintering or powderconveying parts in spray gun
worn.
- Feed device soiled.
- Feed air / dosage air ratio
incorrect.
- Wear on powder injector
nozzle.
- Blow through parts carrying
powder.
- Clean parts carrying powder
and replace if necessary..
- See operating instructions for
the related devices connected.
- Adjust at control module or
control unit.
- Replace worn parts in the
powder injector 1.)
- Parts of nozzle system worn. - Replace worn parts.
uneven
1.) You will find the wearing parts and spare parts in the operating instructions for the powder
injector.
03/2008 351874 - PEA-T317
Technische Daten
6. Technical data
Weight:
900 g
Electrical:
Design: as per EN 50177 and EN 50050
Protection class: IP 54
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.
3
1 Nm
/h = 35.3 ft3/h; 1 bar = 14.504 psi
18 351874 - PEA-T3 03/2008
Warranty
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 IMPLIED
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 WARRANTIES, 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.
03/2008 351874 - PEA-T319
Scope of delivery and spare parts lists
8. Scope of delivery and spare parts lists
8.1 How to order
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
0901_ .doc
20 351874 - PEA-T3 03/2008
Scope of delivery and spare parts lists
8.2 Scope of delivery and spare parts list of the PEA-T3 automatic gun
- 1 260632 * Air nozzle (complete)
2 260473 Threaded bar
3 260469 * Deflector cone rod
4 260463 * Central air supply
5 260470 * Rod
6 260476 * Support ring
7 260471 * Charging tube
8 260474 * Ring
9 260472 * Tip
* Wearing part
4
3
2
260629 * Charging body (complete)
9
8
6
0260629b_et
22 351874 - PEA-T3 03/2008
Accessories
9. Accessories
9.1 Electrical cables and hoses
10_00008
Article No. Designation Application
351297
351296
351295
9987081
9987082
9982079
9982061
PEA-T2 electrical cable 5 m
PEA-T2 electrical cable 10 m
PEA-T2 electrical cable 20 m
Special hose (inside
Special hose (inside
Hose 6x1, black
Hose 6x1, blue
9.2 Spray gun mounting and fastening
10_00002
Article No. Designation
11 mm)
12 mm)
For connecting the spray
gun to the Tribo current
measuring or display
module
For the powder feed
Connection of the
atomizing air
Connection of the Tribo air
351347 Hanger: for fastening the spray gun
Spray gun mount:
260215
Article No. Designation
Clamp:
365201
for fastening the hanger to the
reciprocator
For fasten the powder spray
gun 260215
03/2008 351874 - PEA-T323
Accessories
9.3 Nozzle systems
9.3.1 Fan nozzle and deflector cone
10_00009
Article No. Designation
260928 * Fan nozzle
260267 *
Tribo deflector cone Ø18
* Wearing part
9.3.2 Wide fan spray nozzle
260926
1
4
3
2
0260926_et
260266 *
260268 *
Tribo deflector cone Ø25
Tribo deflector cone Ø32
ItemArticle No. Designation
1 260926 * Wide fan spray nozzle **
260280 * Wide fan spray nozzle
2
9971037 * O-ring 22x1.5
3
260627 *
4
* Wearing part
** only available as a set
Deflector cone
13
9.3.3 90° Angle nozzle
260106
ItemArticle No. Designation
- - 260106 * 90° Angle nozzle **
1
1 259474 *
Deflector cone (
22)
* Wearing part
0260106_et
** only available as a set
24 351874 - PEA-T3 03/2008
Accessories
9.3.4 WA 30 T3 Angle adapter
Item Art. No. Designation
-- 260933 ** WA 30 T3 Tribo Angle adapter
1
P_00722
1 259474 *
Deflector cone (
* Wearing part
** Only available as a set
22)
03/2008 351874 - PEA-T325
Accessories
9.3.5 Finger nozzles
10_00010
Article No. Designation
Finger nozzle x 10:
260638
For uniform coat thickness when
coating flat surfaces
260641
260518 *
260637
Crossed finger nozzles x 10:
For uniform coat thickness when
coating complicated profiles
Nozzle 10:
Standard nozzle in the
finger nozzle x 10 and
crossed finger nozzle x 10
Finger nozzles x 16:
For uniform coat thickness when
coating flat surfaces and a reduced
stripe formation
(relative to the finger nozzle x 10)
* Wearing part
26 351874 - PEA-T3 03/2008
Accessories
Article No. Designation
Crossed finger nozzles x 16:
260642
For uniform coat thickness when
coating complicated profiles and a
reduced stripe formation
(relative to the finger nozzle x 10)
* Wearing part
260519 *
260505 *
260504 *
Nozzle
8:
Standard nozzle in the 16 x finger
nozzle and 16 x crossed finger nozzle
Round nozzle
2.3:
The round nozzle generates a
concentrated spray and is suitable for
spraying in corners, holes, recesses,
etc.
Powder shower:
The powder shower generates an
extremely fine spray and is suitable for
flat surfaces.
03/2008 351874 - PEA-T327
Accessories
1003_Fingerduesenadapter.doc
Connect the finger nozzles to the associated adapters to stabilize them if you have equipped
several spray guns with a finger nozzle and mounted the guns above each other on the
reciprocator.
These adapters are described below:
10_00011
Article No. Designation
Adapter:
260639
For connecting and stabilizing several
finger nozzles
10 x
Adapter:
260648
For connecting and stabilizing several
finger nozzles
16 x
28 351874 - PEA-T3 03/2008
Notes
03/2008 351874 - PEA-T329
Notes
30 351874 - PEA-T3 03/2008
ADDRESSES
Germany Switzerland
J. WAGNER GmbH J. WAGNER AG
Otto-Lilienthal-Str. 18 Postfach 109
D-88677 Markdorf Industriestrasse 22
CH-9450 Altstätten