Krautzberger RA 6v User manual

T-Dok-686-GB-Rev.1
GB Control unit RA 6v
Operating instructions
Item number: 200-0408 ■ 200-0322
Translation of the original operating instructions

Thank you for selecting a Krautzberger product.
This product has been manufactured following state-of-the-art manufacturing procedures and
extensive quality assurance measures. We promise you a product of the highest quality.
If you have questions, requests or suggestions, please contact us. We are always glad to assist
you.
Information about the operating manual
This manual provides important information on how to work with the device safely and efficiently.
The manual is part of the device and must always be kept in the immediate proximity of the device
so that it is accessible to the personnel at all times.
The personnel must have read and understood this manual before starting any work. Compliance
with all specified safety information and instructions is a basic requirement for safe working condi-
tions.
In addition, the local occupational safety regulations and general safety rules apply for the area of
application of the device.
Due to optional finishing variants, it is possible that the figures shown in this operating manual
deviate from your device.
Information about explosion protection
Many of our competitors have been marking their products with the Ex symbol as a matter of prin-
ciple for some time now.
At Krautzberger we do not do that.
We engineer and manufacture our products in line with currently applicable directives.
If the labelling on the product is required, it is affixed to the product as the result of the necessary
analysis of ignition sources. If no labelling is affixed, the analysis of ignition sources and previous
experience with the assessment of the suitability of products for use in a potentially explosive area
have shown that the product described in this operating manual does not represent a potential
source of ignition, with the exception of an electrostatic charge.
Taking into account the potential equalisation (provided by proper earth connection), the use in an
area at risk for explosions is permitted in accordance with the currently valid directives.
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GB–2

Table of contents
1 Function and identification................................................................................................ 5
1.1 Function....................................................................................................................... 5
1.2 Identification................................................................................................................. 6
2 Using this operating manual............................................................................................. 7
2.1 Information about the operating manual...................................................................... 7
2.2 Symbols in this operating manual................................................................................ 7
2.3 Personnel requirements............................................................................................... 9
2.4 Personal protective equipment.................................................................................... 9
3 Safety and responsibility................................................................................................. 12
3.1 Responsibility of the owner........................................................................................ 12
3.2 Intended use.............................................................................................................. 12
3.3 Specification for the operation of a complete machine.............................................. 12
3.4 Predictable misuse.................................................................................................... 12
3.5 General safety instructions........................................................................................ 13
3.6 Residual risks............................................................................................................ 14
3.7 Course of action in an emergency............................................................................. 14
4 Transport, storage, and packaging................................................................................. 15
4.1 Transport................................................................................................................... 15
4.2 Storage...................................................................................................................... 15
4.3 Packaging.................................................................................................................. 15
5 Overview............................................................................................................................ 16
6 Installation......................................................................................................................... 17
6.1 Safety......................................................................................................................... 17
6.2 General installation information................................................................................. 17
6.3 Assemble extension and control piston with fluid needle.......................................... 18
6.4 Assemble control unit................................................................................................ 21
6.5 Changing the main elements..................................................................................... 22
6.6 Connecting the control unit........................................................................................ 23
6.7 Connection scheme................................................................................................... 25
6.8 Preliminary air control................................................................................................ 25
7 Operation........................................................................................................................... 27
7.1 Safety......................................................................................................................... 27
7.2 General information about commissioning and start-up............................................ 28
7.3 Operation................................................................................................................... 28
7.4 Adjusting the spray pattern........................................................................................ 29
7.5 Adjusting the needle stroke....................................................................................... 31
7.6 Shutting down............................................................................................................ 31
Control unit RA 6v ENGLISH
Item number: 200-0408 ■ 200-0322
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8 Maintenance...................................................................................................................... 32
8.1 Safety......................................................................................................................... 32
8.2 Maintenance schedule............................................................................................... 32
8.3 Cleaning the control unit............................................................................................ 33
8.4 Changing the needle seals........................................................................................ 35
9 Troubleshooting............................................................................................................... 37
9.1 Customer Care.......................................................................................................... 39
10 Spare parts........................................................................................................................ 40
11 Accessories...................................................................................................................... 41
12 Disassembly and disposal............................................................................................... 42
12.1 Safety....................................................................................................................... 42
12.2 Disassembly............................................................................................................ 42
12.3 Disposal................................................................................................................... 42
13 Technical data................................................................................................................... 43
13.1 Dimensions and weight............................................................................................ 43
13.2 General specifications............................................................................................. 43
13.3 Dimensions.............................................................................................................. 43
14 Declaration of incorporation........................................................................................... 44
15 Notes.................................................................................................................................. 45
16 Index.................................................................................................................................. 47
Operating instructions T-Dok-686-GB-Rev.1
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1 Function and identification
1.1 Function
In conjunction with an extension, the control unit RA 6v is used for:
nautomatic coating/marking of surfaces
ndosing of fluids
nplacement of adhesive or marking points
Typical spray fluids are paints, dyes, adhesives, glazes, enamels, release agents, etc.
The spray fluid is fed into the control unit under pressure. This pressure is typically generated by
pumps or pressure containers. The control unit is operated via compressed air.
For the precise control of the control unit, for example electrically-activated solenoid valves can be
used.
The spray fluid is atomised using compressed air. The geometry of the spray jet and the sprayed
quantity of the spray fluid can be adjusted with the following measures:
nSelection of the air and fluid nozzle for the extension
nChanging of the atomiser air pressure
nChanging of the spray fluid pressure
nAdjustment of the needle stroke on the regulator of the control unit
Optional equipment:
Adapter:
nConnections: From behind (the connections can be made using nipples, screw-type or plug
connectors of different sizes)
nFastening: Plug or screw-type fastening of the adapter
Fig. 1: Adapter variants
Pos. Description
1 Connections from behind, plug fastening of the control unit
2 Connections from behind, screw fastening of the control unit
Control unit RA 6v ENGLISH
Item number: 200-0408 ■ 200-0322
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1.2 Identification
Scope of delivery Model Product number
Control unit RA 6v 200-0408
Adapter 200-0322
Operating manual T-Dok-686
Serial number
The serial number of the control unit is located on the main element. It serves as a unique identi-
fier.
Operating instructions T-Dok-686-GB-Rev.1
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2 Using this operating manual
2.1 Information about the operating manual
nKnowledge of the fundamental safety instructions and safety regulations is a basic require-
ment for safe handling and defect-free operation of the product.
nThis operating manual contains the most important information about enabling safe operation
of the product.
nThis operating manual and, in particular, the safety instructions are to be observed by all per-
sons who work on or with the product.
nFurthermore, the rules and regulations for accident prevention in force at the respective oper-
ating site are to be observed.
2.2 Symbols in this operating manual
Safety instructions
This operating manual uses symbols to identify safety instructions. The safety instructions are pre-
ceded by signal words that indicate the severity of the hazard.
DANGER!
This combination of symbol and signal word indicates an immediate dangerous situation,
which will cause death or severe injuries if it is not averted.
WARNING!
This combination of symbol and signal word indicates a potentially dangerous situation which
can cause death or severe injuries if it is not averted.
CAUTION!
This combination of symbol and signal word indicates a potentially dangerous situation which
can cause slight injuries if it is not averted.
NOTICE!
This combination of symbol and signal word indicates a potentially dangerous situation which
can cause property and environmental damage if it is not averted.
Control unit RA 6v ENGLISH
Item number: 200-0408 ■ 200-0322
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ENVIRONMENT!
This combination of symbol and signal word indicates potential dangers to the environment.
Tips and recommendations
This symbol highlights useful tips and recommendations as well as information for efficient
and defect-free operation.
Example for safety instructions in operating instructions
Safety instructions can refer to specific, individual operating instructions. Such safety instructions
are embedded in the operating instructions so that they do not disrupt the reading flow when per-
forming the action. The signal words described above are used.
1. Loosen the screw.
2.
CAUTION!
Pinching hazard at the lid!
Carefully close the lid.
3. Tighten the screw.
Special safety instructions
The following symbols are used in safety instructions to draw attention to specific hazards:
Warning signs Type of danger
Warning – danger zone.
Additional markings
The following markings are used in this manual to highlight operating instructions, outcomes, lists,
references, and other elements:
Identification Explanation
Step-by-step instructions
ðResults of procedural steps
Operating instructions T-Dok-686-GB-Rev.1
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Identification Explanation
References to sections in this manual and other applicable docu-
ments
Lists without specified order
[Button] Operating elements (e.g. buttons, switches), display elements
(e.g. signal lights)
‘Display’ Screen elements (e.g. pushbuttons, assignment of function keys)
2.3 Personnel requirements
This manual identifies the qualifications of the personnel for the different scopes of work as listed
below:
Qualified personnel
Due to their specialised professional training, knowledge, and experience as well as knowledge of
the industry-specific standards and regulations, qualified personnel are in a position to perform
assigned tasks and to identify and avert potential risks on their own.
Specialised personnel
Due to their specialised professional training, knowledge, and experience as well as knowledge of
the industry-specific standards and regulations, qualified personnel are in a position to perform
assigned tasks and to identify and avert potential hazards on their own.
User
The user is familiar with the basic regulations on occupational safety and accident prevention.
2.4 Personal protective equipment
Personal protective equipment is used to protect persons against adverse effects on their health
and safety when working.
Personnel must wear personal protective equipment while carrying out the different tasks on and
with the machine.
In the course of regular, recurring trainings, the owner should inform operating personnel that
working without protective equipment can be detrimental to their health.
Protective equipment is selected according to the ambient conditions at the owner’s premises
and the raw materials that are used. The information provided by the material manufacturer
on the safety data sheet must be adhered to in order to ensure the proper selection of protec-
tive equipment.
The recommended personal protective equipment is described below:
Control unit RA 6v ENGLISH
Item number: 200-0408 ■ 200-0322
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Light respiratory protection
Light respiratory protection is used as protection against hazardous dusts.
Protective gloves
Protective gloves protect hands from friction, abrasion, puncture wounds, or deeper injuries, as
well as from contact with hot surfaces.
Safety goggles
Safety goggles are used to protect the eyes from airborne components and splashes of liquid.
Protective clothing
Protective clothing are tight fitting work clothes with low tear resistance, with tight sleeves, and
without any protruding parts.
Operating instructions T-Dok-686-GB-Rev.1
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Safety shoes
Safety shoes protect the feet against crushing, falling parts or slipping on slippery ground.
Safety helmet
The helmet protects the head from falling parts and oscillating loads on the one hand, and it can
protect it from injuries in cramped situations on the other.
Control unit RA 6v ENGLISH
Item number: 200-0408 ■ 200-0322
GB–11

3 Safety and responsibility
3.1 Responsibility of the owner
Owner
The owner is the person, who directly operates the machine for commercial or economical pur-
poses or who allows a third-party to use/apply it and who is responsible for the legal product stew-
ardship for the protection of the user, the personnel or third parties.
Owner responsibilities
The machine is used in an industrial environment. The owner of the machine is therefore subject to
the obligations as stipulated by the Occupational Health and Safety Act.
In addition to the safety information in this manual, the country-specific safety, accident prevention
guidelines and environmental protection regulations, applicable at the site of implementation of the
machine must be adhered to.
Furthermore, the owner is responsible for making sure that the machine is always in perfect tech-
nical condition. Therefore, the following applies:
nThe owner must ensure that the maintenance intervals described in this operating manual are
adhered to.
nThe owner must have all safety equipment checked regularly for functionality and complete-
ness.
3.2 Intended use
The control unit RA 6v in conjunction with a screwed-on extension is used to spray paints, dyes,
adhesives, glazes, enamels, release agents, as well as other fluids. The nozzle size of the exten-
sion depends on the spray viscosity of the spray fluid.
The intended use also includes the compliance with all the information in this operating manual.
3.3 Specification for the operation of a complete machine
nThe operation without CE-marking is prohibited.
nPrior to its use, the control unit with extension must be assembled to form a complete
machine.
nOnly operate the control unit with extension after fastening it properly to a suitable supporting
structure.
3.4 Predictable misuse
Any use beyond the intended use or any other use constitutes misuse.
nOnly carry out the installation and start-up in accordance with the steps described in this oper-
ating manual.
nAlways observe the applicable country-specific safety, accident prevention, occupational
safety, and environmental protection regulations etc. for the area of use for the control unit.
nEnsure that the utilised hose lines fulfil the requirements with respect to pressure, chemical,
and mechanical loads.
nDo not use sharply abrasive, chemically aggressive, very hot or very cold spray fluids without
first consulting with and receiving approval from Krautzberger GmbH.
nAdhere to the safety data sheets of the spray fluid manufacturer.
nOnly use the manufacturer's OEM parts.
nPrior to its use, the control unit must be screwed to an extension.
Operating instructions T-Dok-686-GB-Rev.1
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nOnly operate the control unit with extension after fastening it properly to a suitable supporting
structure.
nDo not hold the control unit with extension in your hand during operation.
nOnly operate the control unit in compliance with the values specified in (
Ä Chapter 13 ‘Tech-
nical data’ on page 43).
nMake sure that the connected compressed air is oil-free and free from solid matter.
nOperate the control unit with processed, dried compressed air (air quality pursuant to DIN ISO
8573-1: quality class 4).
nNever point the compressed air at living beings.
WARNING!
Improper use of the control unit can lead to hazardous situations.
No claims of any kind can be asserted due to damage resulting from misuse!
3.5 General safety instructions
WARNING!
Life threatening risk of injury or property damage through the application of hazardous
media!
The application of hazardous media can lead to death, serious injuries or property damage.
– Ensure the resistance of the machine against the medium that is to be applied.
– Always adhere to the safety data sheet of the medium that is to be applied.
CAUTION!
Risk of injury through compressed air!
Uncontrolled leaks of compressed air can lead to serious injuries!
– Prior to any work on the device, all compressed-air lines must be closed and bleed if nec-
essary.
Control unit RA 6v ENGLISH
Item number: 200-0408 ■ 200-0322
GB–13

WARNING!
Sound pressure level
Depending on the operating conditions, the sound pressure of the device may cause hearing
damage.
Take suitable action to reduce the impact of the existing sound pressure level. The owner is
responsible for the type and implementation of suitable measures, which may depend on the
local conditions.
Outdoor operation and operation in exterior areas!
Use suitable measures to protect the device during the operation from environmental impacts
in an exterior area through:
–Moisture
–UV radiation
–Frost, etc.
3.6 Residual risks
The control unit made by Krautzberger GmbH has been manufactured based on state-of-the-art
technology and generally accepted technical safety regulations.
Nonetheless, its use can pose a threat to the life or health of users or third parties, damage the
control unit itself or cause other property damage.
nThe control unit must only be used as intended.
nThe control unit may only be operated in a defect-free condition.
nAny faults impacting the safety must be remedied immediately.
3.7 Course of action in an emergency
In principle, the applicable national, regional and internal company regulations concerning the
course of action in case of an emergency must be adhered to and if necessary respective
safety measures must be taken on the system owner's side.
Operating instructions T-Dok-686-GB-Rev.1
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4 Transport, storage, and packaging
4.1 Transport
nThe control unit is protected by cardboard packaging.
nThe cardboard packaging can be reused for storage.
4.2 Storage
Store the control unit under the following conditions:
nStore the control unit in the original packaging.
nDo not store outside.
nStore in a dry and dust-free environment.
nKeep away from any aggressive media.
nProtect from UV radiation.
nAvoid mechanical shocks.
nStorage temperature: 15 to 40 °C.
nRelative atmospheric humidity: max. 60%.
4.3 Packaging
The control unit is packaged in accordance with the anticipated transport conditions and the pack-
aging needs to protect it against transport damage, corrosion, and other damage.
nRemove packaging material.
nRemove potentially present transport safety restraints.
Control unit RA 6v ENGLISH
Item number: 200-0408 ■ 200-0322
GB–15

5 Overview
Fig. 2: Overview
1 Needle stroke setting *
2 Main element
3 Retaining bolt *
4 Lever for adapter plug connector *
5 Adapter
F Connection for flat jet air
M↑Connection for material supply (input
"M")
M↓Connection for fluid circulation line
(output "M") *
R Connection for round jet air
ST A Connection for control air "OPEN"
ST Z Connection for control air "CLOSED"
(optional)
The connections are marked with letter abbreviations.
* optional / dependent on configuration
Operating instructions T-Dok-686-GB-Rev.1
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6 Installation
6.1 Safety
Personnel:
nSpecialised personnel
Protective equipment:
The selection of the protective equipment depends on the installation conditions on site. Always
observe the applicable country-specific safety, accident prevention, occupational safety, and envi-
ronmental protection regulations for the proper selection of the protective equipment.
WARNING!
Danger of injury due to improper assembly!
Recoil forces and vibrations occur during the operation. In case of insufficient fastening, the
automatic spray gun may come loose and cause serious injuries or property damage.
Note:
– Ensure sufficient fastening of the automatic spray gun.
CAUTION!
Risk of injury due to sharp edges!
Sharp edges and pointed corners can cause abrasions and cuts on the skin.
Note:
– Proceed cautiously when working on or near sharp edges and pointed corners.
– Wear protective gloves, if in doubt.
6.2 General installation information
Adhere to the following general information for installation:
nOnly carry out the installation and start-up in accordance with the steps described in this oper-
ating manual.
nEnsure that the utilised hose lines meet the requirements for pressure, chemical and mechan-
ical loads.
nPrior to its use, screw the control unit to an extension.
nOnly operate the control unit after fastening it properly to a suitable supporting structure.
nMake sure that the connected compressed air is oil-free and free from solid matter.
nOperate the control unit with processed, dried compressed air (air quality pursuant to DIN ISO
8573-1: quality class 4).
nVibration and recoil forces may occur on the control unit during the operation. Ensure suffi-
cient fastening.
nNever point the compressed air at living beings.
Control unit RA 6v ENGLISH
Item number: 200-0408 ■ 200-0322
GB–17

6.3 Assemble extension and control piston with fluid needle
Mounting the fluid needle onto the control piston
Fig. 3: Disassemble locking piece
1. Loosen the screws ( Fig. 3/1) slightly.
2.
Locking piece ( Fig. 3/6) (optional) is under spring force.
Turn the locking piece ( Fig. 3/6) (or, depending on the design, the cover) slightly clockwise
and remove it.
3. Remove the pressure spring ( Fig. 3/4) and if necessary the seal ( Fig. 3/5) (only for double
controller).
4. Screw a screw ( Fig. 3/3) into the control piston ( Fig. 3/7).
5. Pull out the control piston ( Fig. 3/7) from the main element ( Fig. 3/8) using the screw (
Fig. 3/3).
Fig. 4: Attaching the fluid needle
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6.
CAUTION!
Risk of injury due to fluid needles!
Screw fluid needle ( Fig. 4/1) into the control piston ( Fig. 4/2).
Fig. 5: Assemble extension and control piston with fluid needle
7. Screw extension ( Fig. 5/1) with cap nut on the front onto the main element ( Fig. 5/2) of the
control unit.
8. Push the fluid needle ( Fig. 5/3) with the control piston into the main element ( Fig. 5/2) to
the end position.
Fig. 6: Setting dimension
9. The setting dimension ( Fig. 6/1) of 10.4 +/- 0.2mm (space between housing and upper
edge of the control piston) must be checked!
Control unit RA 6v ENGLISH
Item number: 200-0408 ■ 200-0322
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Setting dimension
–If the setting dimension is exceeded or not met, the control piston with fluid needle
must be removed from the main element again.
–Reinsert and screw in the fluid needle into the control piston and select the screw-
in depth so that the setting dimension of 10.4 +/- 0.2 mm is adhered to after
inserting the fluid needle with the control piston into the main element .
Fig. 7: Attaching the fluid needle
10. Unscrew the screw ( Fig. 7/2) from the control piston ( Fig. 7/6) and screw it slightly into the
main element again ( Fig. 7/7).
11. Make sure that the seal ( Fig. 7/4) is seated properly.
12. Press in the pressure spring ( Fig. 7/3) with the locking piece ( Fig. 7/5).
13. Hook the locking piece ( Fig. 7/5) into the screws ( Fig. 7/1).
14. Tighten the screws ( Fig. 71) evenly.
15. After assembly, check the tight fit of all parts.
16. Check moving parts to make sure they run easily.
Operating instructions T-Dok-686-GB-Rev.1
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