DeVilbiss AGMD Series User manual

1-1-AGMD-514&515-E-002-1
High-performance automatic spray gun AGMD
For conventional atomisation: AGMD-514
For Trans-Tech or HVLP atomisation: AGMD-515
Operating instruction
AUTOMOTIVE REFINISHING
EN
ISS.02

High-performance automatic gun
AGMD
1-1-AGMD-514&515-E-002-1
Table of contents
1General.................................................................................................................. 3
1.1 Purpose of this operating instruction...................................................................... 3
1.2 Notes and symbols used ....................................................................................... 3
1.3 Abbreviations......................................................................................................... 4
2Safety.................................................................................................................... 5
2.1 Specified normal use............................................................................................. 5
2.2 Usage contrary to intended use............................................................................. 5
2.3 Basic safety instructions ........................................................................................ 6
2.4 Instructions............................................................................................................ 6
2.5 Work stations......................................................................................................... 6
2.6 Cleaning................................................................................................................ 6
2.7 Requirement for the entering of spray booths........................................................ 7
2.8 Explosive areas (DIN EN 12215)........................................................................... 7
3Designs ................................................................................................................. 9
3.1Technical data....................................................................................................... 9
3.1.1 High-performance automatic spray guns AGMD-514 and AGMD-515.................... 9
4Installation ........................................................................................................... 10
4.1 Usage conditions................................................................................................. 10
4.2 Tools and other materials required....................................................................... 10
4.3 Fastening onto intermediate plates...................................................................... 10
4.3.1 Intermediate plate AGMD-245-1........................................................................... 10
4.3.2 Intermediate plate AGMD-245-8........................................................................... 12
4.4 Adjusting the jet geometry ................................................................................... 13
4.4.1 Distance to workpiece.......................................................................................... 13
5Maintenance........................................................................................................ 14
5.1 Required tools and lubricants .............................................................................. 14
5.2 Removing the high-performance automatic spray gun AGMD ............................. 14
5.3 Removing the high-performance automatic spray gun AGMD ............................. 15
5.4 Cleaning gun parts .............................................................................................. 18
5.5 Checking components......................................................................................... 18
5.6 Assembling the high-performance automatic spray gun AGMD........................... 19
6Faults................................................................................................................... 26
7Spare parts.......................................................................................................... 28
7.1 AGMD-514 (conventional atomisation) ................................................................ 28
7.1.1 Exploded drawing ................................................................................................ 28
7.1.2 Parts list............................................................................................................... 29
7.1.3 Nozzle and needle combination, air caps............................................................. 30
7.2 AGMD-515 (Trans Tech and HVLP atomisation)................................................. 31
7.2.1 Exploded drawing ................................................................................................ 31
7.2.2 Parts list............................................................................................................... 32
7.2.3 Nozzle and needle combination, air caps............................................................. 32
7.3 Spare parts for special applications..................................................................... 33
7.3.1 AGMD-243 piston (hard anodised aluminium)...................................................... 33
7.3.2 AGMD-405-H and AGMD-405-H-C (needle set)................................................... 33
7.3.3 AGMD-421-FZ paint needle (coated)................................................................... 34
7.3.4 AGMD-422 paint needle (ceramic)....................................................................... 34
7.3.5 AGMD-202-1 end plate for needle stroke setting.................................................. 34

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7.3.6 AGMD-205 head for gravity cup........................................................................... 35
7.3.7 AGMD round spray nozzle................................................................................... 35
8EC declaration of conformity.............................................................................. 366
9Product liability and warranty............................................................................. 377

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1 General
1.1 Purpose of this operating instruction
This operating instruction contains information for the assembly, maintenance, and care of the
high-performance automatic spray gun AGMD. The technical data and procedures contained
herein should be considered as standard and may differ depending on the actual installation.
Because every system is designed differently, the high-performance automatic spray gun
AGMD must only be placed in operation by personnel authorised by DeVilbiss.
To better understand this device and to achieve optimum error-free operation for an extended
period, please read this operating instruction carefully. The specified tests and fault
identification should be performed before calling for a service technician.
The high-performance automatic spray gun AGMD is subject to additional development and
improvements.
Separate operating instructions are available for the different adaptors and attachments.
1.2 Notes and symbols used
Danger!
Warning of imminent danger.
Consequences of failure to heed warning:
Death or extremely severe injuries.
Warning!
Warning of a possible very dangerous situation.
Possible consequences of failure to heed warning:
Death or extremely severe injuries. Warning of general danger.
Caution!
Warning of a possible dangerous situation.
Possible consequences of failure to heed warning:
Slight or minor injuries.
Note!
This symbol is used to draw your attention to user tips and other
useful information.
All safety instructions in this operating instruction have the same uniform structure:
Signal word!
Instruction text
The pictogram identifies the type of danger.
The signal word identifies the severity of the danger.
The instruction text describes the danger and provides information about how
you can avoid the danger.

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1.3 Abbreviations
AGMD
Automatic Gun
HVLP atomisation
High Volume, Low pressure
LEL
Lower Explosion Protection Level

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2 Safety
2.1 Specified normal use
The high-performance automatic spray gun AGMD is designed for processing coatings
based on solvents or water. It must only be used to atomise materials that are explicitly
listed in the order confirmation. Use of other coating materials can only be considered if
there is no possibility of:
hazard to people or the environment
harmful effects on the spray gun
In case of doubt, please contact the manufacturer of the high-performance automatic
spray gun AGMD.
The high-performance automatic spray gun AGMD is designed for use on a fixed
location spraying system and on the hollow wrist or FLEXARM robots, on automatic
machines (hoisting devices), and on tripods.
Any usage beyond what is specified is considered improper use. The manufacturer
shall not be responsible for any resulting damages.
Caution!
Danger of injury and damage!
This device may be dangerous if it is not operated according to the specifications
in this operating instruction.
Note!
During the processing of highly corrosive or very abrasive materials, an increased
demand in spare parts can be expected. The suitability must be checked with the
material manufacturer based on the substance list.
2.2 Usage contrary to intended use
Usage is contrary to intended use if:
any media other that those specified in the operating instruction are directed
through the valves
operating conditions other than those specified in the operating instruction are
present
safety instructions are not observed during operation, assembly, and maintenance
unauthorised conversions or modifications are made to the double seat valve that
have a negative effect on safety and/or functionality

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2.3 Basic safety instructions
The spray system with the high-performance automatic spray gun AGMD must only be
operated by trained personnel.
A warning sign must be posted in a conspicuous place close to the spraying area. This
warning sign should contain the most important functions and safety measures that
users must observe.
The dangers present when cleaning spray guns must be clearly highlighted.
The start-up of the system by the user may only be performed after an initial test by an
authorised technician prior to the transfer of risk to the user.
2.4 Instructions
Persons who work with the spraying device must be instructed about dangers before
beginning their activities.
This instruction must be repeated and documented at least once per year.
2.5 Work stations
Danger!
Danger of fire and explosion!
Smoking and open flames are strictly prohibited in areas prone to fire and
explosion.
No accumulations of coating materials must be allowed to collect in spray
booths, on spraying stands, or anywhere in the entire work area.
Access doors to the spray booths must remain closed during spraying.
Sources of ignition must be avoided.
2.6 Cleaning
Danger!
Danger of fire and explosion!
Accumulations of coating materials must be removed.
The following must be cleaned regularly:
Work piece fixtures
Suction devices
Leakage mist separators and their immediate vicinity
Technical ventilation must be active during cleaning work.
Use only electrically conductive containers for the cleaning fluids. Additionally,
these containers must be earthed.
Use only solvents with a flashpoint that is at least 5°C higher than the surrounding
temperature.
When cleaning the guns, wear suitable protective clothing, such as gloves, safety
goggles, etc.

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2.7 Requirement for the entering of spray booths
Warning!
Danger of inhaling substances hazardous to your health!
During the spraying operation, no persons are permitted to remain in the spray
booth.
The concentration of solvent in the air must be under the limit that is harmful to
health. If appropriate, wear suitable protective breathing equipment when entering
the spray booth.
2.8 Explosive areas (DIN EN 12215)
The categorisation of danger zones is a significant component of the safety
concept for explosion protection. The ignition protection type of equipment and
components integrated into the spray booth depends on the limit of
concentration for flammable substances by technical ventilation.
a) If the concentration of flammable substances is limited to less than 25% of the
LEL, the inside of the spray booth, including ambient and exhaust air lines,
together with external areas formed around permanent openings at a distance of
up to 1 m should be categorised as Zone 2.
b) If the concentration of flammable substances is between 25% and 50% of the
LEL, the inside of the spray booth, including ambient and exhaust air lines,
should be categorised as Zone 1.
c) If the concentration of flammable substances is between 25% and 50% of the
LEL, external areas formed around permanent openings at a distance of up to
1 m should be categorised as Zone 2.
This categorisation of areas with explosive atmospheres into zones corresponds
to the category for ignition protection type according to prEN 13463-1.
Example of zone categorisation in a spray booth with open access side
(spraying stand)
Categorisation of danger zones into Zone 1 or Zone 2

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Example of zone categorisation in a spray booth that is open on top

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3 Designs
The high-performance automatic spray gun AGMD is available in different designs. They
differ in the use of a variety of components and/or in the material flow.
Note!
Gun heads marked with a “U” have two material lines, allowing coating material to
circulate through the head so a colour change can be performed while the gun is
closed.
Ordering example: AGMD-514 U FF-797c
Type of gun
With circulation*
Nozzle size (see table)
Air cap (see table)
AGMD-514
U
FF
797c
* Without circulation= ″U″ does not apply
3.1 Technical data
3.1.1 High-performance automatic spray guns AGMD-514 and AGMD-515
Spray system: AGMD-514 conventional air-atomisation
AGMD-515 TransTech or HVLP air-atomisation
Maximum pressures: 0 to 14 bar material (MAT)
6 bar control air system (CYL)
9 bar atomiser air (ATOM) and horn air (FAN)
Switching times: < 60 msec. At 5.8 bar control air system
Weight: Approx. 665 g
Dimensions: Refer to dimensioned sketch
Materials: Gun head: Stainless steel 1.4305
Nozzle (standard): Stainless steel 1.4305
Paint needle (standard): Stainless steel 1.4305
Air distribution ring: Brass, chemically nickel-plated
Air cap: Brass, chemically nickel-plated
Air cap retaining ring: Brass, chemically nickel-plated
Material-contacting seals:
VITON for water-based coatings (on request)
VITON EX for solvent-based coatings (standard)
Perfluorelastomer for highest resistance (on request)
AGMD-514/515
with intermediate
plate AGMD-245-1

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4 Installation
The high-performance automatic spray gun AGMD is attached to a intermediate plate.
The intermediate plate in turn is fastened to an adapter.
The adapter is attached to the movement device (robot or hoisting device) or to a tripod.
All compressed air and material lines are connected to the adapter.
4.1 Usage conditions
Operating temperature, max.
80 °C
Ambient temperature, max.
40 °C
4.2 Tools and other materials required
The following tools are required for installing and removing the high-performance
automatic spray gun AGMD:
Workstation with vice and soft braces
Hexagon socket head wrench, size 2.5
Hexagon socket head wrench, size 3
4.3 Fastening onto intermediate plates
4.3.1 Intermediate plate AGMD-245-1
Note!
For the intermediate plate AGMD-245-1, the high-performance automatic spray
gun is fitted with the locking device AGMD-244.
As an alternative to locking device AGMD-244, the centring screw AGMD-044-3
can be used. In that case, the high-performance automatic spray gun is bolted to
the intermediate plate.
1. Lightly grease the O-rings.
2. Position the high-performance automatic
spray gun AGMD at an angle of 45°
towards the intermediate plate.

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3. Insert the locking device into its position.
4. Turn the high-performance automatic
spray gun AGMD 45° clockwise until it
clicks into the rear locking device.
5. If necessary, bolt the high-performance
automatic spray gun AGMD and
intermediate plate together with a size 2.5
hexagon socket head wrench.

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4.3.2 Intermediate plate AGMD-245-8
Note!
For the intermediate plate AGMD-245-8, the high-performance automatic spray
gun AGMD is fitted with the conical locking device AGMD-244-8.
1. Lightly grease the O-rings.
2. Position the high-performance automatic
spray gun AGMD at an angle of 45°
towards the intermediate plate.
3. Insert the conical locking device into its
position.
4. Turn the high-performance automatic
spray gun AGMD 45° clockwise until it
clicks into the rear locking device.

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5. Fasten the high-performance automatic
spray gun AGMD and the “pointed tapping
screw” on the intermediate plate with a
size 3 hexagon socket head wrench.
4.4 Adjusting the jet geometry
Note!
The gun has a variable jet geometry to produce a round or flat spray pattern.
You should only work with clean, dry, filtered, oil-free air.
1. Select a suitable air flap.
2. Position the air distributing ring to
produce the desired jet geometry.
3. Make the appropriate setting for the atomiser air.
4. Make the appropriate setting for the horn air.
4.4.1 Distance to work piece
Position the high-performance automatic spray gun AGMD about 15 to 30 cm from the
work piece.

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5 Maintenance
Note!
The air cap can be replaced on the high-performance automatic spray gun AGMD
without removing it from the system.
For all other maintenance jobs, the high-performance automatic spray gun AGMD
must be removed from the intermediate plate and replaced by a new one.
5.1 Required tools and lubricants
The following are required for installation and removal:
Workstation with vice and soft braces
Hexagon socket head wrench, size 6
Torque handle with socket wrench, size ½″
Turnscrew
AGMD-010 gun grease
Note!
Needle, needle set and piston should only be exposed to AGMD-010 grease.
Other grease can lead to a malfunction of the high-performance automatic spray
gun AGMD (unsuitable grease could cause swelling of needle set and piston).
5.2 Removing the high-performance automatic spray gun AGMD
Caution!
Danger of injury due to lines under pressure!
When removing the high-performance automatic spray gun AGMD, spray
fluid may emerge under high pressure.
Make certain no paint material gets into the air channels.
Rinse and blow out the material lines, then depressurise them.
Wear protective clothing and/or glasses.
Note!
Prior to the installation of the new high-performance automatic spray gun AGMD,
make sure that the O-rings are in place and that they are lubricated.
1. Loosen the fixing screw if there is one.
2. Push the unlocking pin on the intermediate plate.
3. Turn the high-performance automatic spray gun AGMD 45° anti-clockwise and
remove.

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5.3 Removing the high-performance automatic spray gun AGMD
Note!
Only trained personnel are permitted to install and remove parts of the high-
performance automatic spray gun AGMD.
The work should be performed on a clean horizontal work surface.
For the assembly and disassembly of the high-performance automatic spray gun
AGMD, follow the respective parts list and the exploded drawing.
After the removal and replacement of the high-performance automatic spray gun
AGMD on the adaptor, the spraying process can continue, and the defective high-
performance automatic spray gun AGMD can be serviced at a suitable location.
The item indicated in parentheses corresponds to the individual parts from Chapter 7.1
AGMD-514 (conventional atomisation) and/or Chapter 7.2 AGMD-515 (Trans
Tech and HVLP atomisation).
1. Screw on retaining ring (item 1) and
remove air cap (item 2).
2. Loosen and remove the nozzle (item 3)
with socket wrench, size ½“.
3. Remove the air distributing ring (item 5)
and both gaskets (item 4).

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4. Loosen the four hexagon screws
(item 21).
5. Remove the end plate (item 20).
6. Pull off the head holder (item 13) towards
the back away from the head.
7. Remove the two springs (items
16 and 17), spring pin (item 15) and paint
needle (item 10).

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8. Press the piston (item 14) out of the
head holder.
9. Unscrew the needle set (item 9) with a
hexagon socket head wrench, size 6.
If the hexagon socket head wrench does not
grip, pry the needle set (item 9) out with a
turnscrew.
10. Unscrew screw (item 8) with a size 6
hexagon socket head wrench and
remove the locking device (item 7).

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5.4 Cleaning gun parts
After the gun parts have been disassembled, first clean them and then inspect their
condition.
Note!
The way in which parts of the gun get dirty can provide information about the
cause of failures of the high-performance automatic spray gun AGMD.
Caution!
Danger of damage!
Individual components may be destroyed or solvent could get into the air channels.
Do not immerse the high-performance automatic spray gun AGMD in solvent.
The following are required to clean the high-performance automatic spray gun AGMD:
suitable solvent
an earthed solvent supply
cleaning brushes
1. Clean the gun parts with a brush and a suitable solvent and blow dry.
2. Clean the air and material feedthroughs with a small round cleaning brush, a pipe cleaner
saturated with solvent, or some similar item.
5.5 Checking components
Caution!
Danger of damage!
Never install defective components in the high-performance automatic spray gun
AGMD.
Use only original parts.
1. Before installing the high-performance automatic spray gun AGMD, check all components
for damage.
2. Replace damaged components with new ones.

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5.6 Assembling the high-performance automatic spray gun AGMD
The item indicated in parentheses corresponds to the individual parts from Chapter 7.1
AGMD-514 (conventional atomisation) and/or Chapter 7.2 AGMD-515 (Trans
Tech and HVLP atomisation).
1. Lay out all components and the required
tools on a clean level surface.
2. Screw the needle set (set 9) into the
head (item 6) with a size 6 hexagon
socket head wrench, to a torque of
0.8 Nm.
3. For use with the intermediate plate
AGMD-245-1, screw the locking device
(item 7) together with the fillister head
screw (item 8).
4. Position the locking device so that the
latches tilt slightly.
Note:
Torque of each locking device 4.5 Nm.