Krautzberger A 10 User manual

■ 200-0148
Translation of the original operating instructions
T-Dok-040-GB-Rev.1
GB Automatic spray gun A-10
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, must always be kept in the device's direct proximity and should
be available 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 this.
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 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 current valid directives.
[email protected], www.krautzberger.com
GB–2

Table of contents
1 Function and identification................................................................................................ 5
1.1 Function....................................................................................................................... 5
1.2 Identification................................................................................................................. 5
2 Safety and responsibility................................................................................................... 6
2.1 Labelling of the safety information............................................................................... 6
2.2 Safety information in operating instructions................................................................. 7
2.3 Personnel requirements............................................................................................... 7
2.4 Personal safety equipment and clothing...................................................................... 8
2.5 Responsibility of the system owner............................................................................. 9
2.6 Intended use.............................................................................................................. 10
2.7 General safety information......................................................................................... 11
3 Transport and storage..................................................................................................... 13
3.1 Transport................................................................................................................... 13
3.2 Storage...................................................................................................................... 13
3.3 Unpacking.................................................................................................................. 13
4 Overview............................................................................................................................ 14
5 Installation......................................................................................................................... 15
5.1 General installation information................................................................................. 15
5.2 Dimensions................................................................................................................ 15
5.3 Mounting the automatic spray guns........................................................................... 16
5.4 Connection scheme................................................................................................... 16
5.5 Connecting the automatic spray gun......................................................................... 17
5.6 Checking connections................................................................................................ 18
6 Commissioning................................................................................................................. 19
6.1 General Information about the commissioning.......................................................... 19
6.2 Operation................................................................................................................... 20
6.3 Adjusting the spray pattern........................................................................................ 21
6.4 Setting the zero point of the needle stroke setting..................................................... 22
6.5 Operation breaks....................................................................................................... 22
7 Maintenance...................................................................................................................... 23
7.1 Maintenance schedule............................................................................................... 23
7.2 Cleaning spray guns.................................................................................................. 24
7.3 Changing the air and fluid nozzles............................................................................. 25
7.4 Changing the fluid needle.......................................................................................... 26
7.5 Changing needle packing.......................................................................................... 28
8 Faults................................................................................................................................. 30
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9 Spare parts........................................................................................................................ 32
9.1 Spare parts................................................................................................................ 33
10 Accessories...................................................................................................................... 37
11 Disposal............................................................................................................................. 38
12 Technical data................................................................................................................... 39
12.1 Dimensions and weight............................................................................................ 39
12.2 General specifications............................................................................................. 39
12.3 Tightening torques................................................................................................... 39
13 Declaration of incorporation........................................................................................... 40
14 Notes.................................................................................................................................. 41
15 Index.................................................................................................................................. 43
Operating instructions T-Dok-040-GB-Rev.1
[email protected], www.krautzberger.com GB–4

1 Function and identification
1.1 Function
Automatic spray guns are used for the
nautomatic coating/marking of surfaces
ndosing of fluids
nplacement of adhesive or marking points
Typical spray fluids are paints, dyes, adhesives, glazes, enamels, debonding agents, etc.
The spray fluid is fed into the automatic spray gun under pressure. This pressure is typically gener-
ated by pumps or pressure containers. The automatic spray gun is controlled via compressed air.
Upon opening, the control piston charged with compressed air initially opens the air nozzle and
then with a short delay the fluid nozzle of the spray gun. Upon closing, initially the fluid nozzle and
then the air nozzle is closed in order to prevent a subsequent dripping of the spray fluid.
For the precise control of the automatic spray gun, electrically-activated solenoid valves can be
used, for example. Switching times of 60 ms can be achieved this way.
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
nChanging of the atomisation air pressure
nChanging of the spray fluid pressure
nAdjustment of the needle stroke on the regulator of the automatic spray gun.
The automatic spray gun also features the following additional characteristics:
nHead section only in aluminium, hard-coated
nHead section with lower fluid connection
nMain element with flat jet regulator
or with flat and round jet regulator
1.2 Identification
Type Weight aluminium Width/length/height (mm) Product number
A-10 0.75 kg 40 / max. 178 / 74 200-0148
Further information can be found in ( Ä Chapter 12 ‘Technical data’ on page 39)
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2 Safety and responsibility
2.1 Labelling of the safety information
This manual uses symbols to identify safety information. The safety information is preceded by
signal words that indicate the severity of the hazard.
DANGER!
This combination of symbol and signal word indicates an immediate dangerous situation
which causes death or severe injuries if it is not averted.
WARNING!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause death or severe injuries if it is not averted.
CAUTION!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause slight injuries if it is not averted.
NOTICE!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause property and environmental damage if it is not averted.
This symbol highlights useful tips and recommendations as well as information for efficient
and fault-free operation.
ENVIRONMENT!
This combination of symbol and signal word points out potential hazards for the environment.
Operating instructions T-Dok-040-GB-Rev.1
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2.2 Safety information in operating instructions
Safety information can refer to specific individual operating instructions. Such safety information is
embedded in the operating instructions so that they don't disrupt the reading flow during the execu-
tion of the action. The signal words described above are used.
Example:
1. Loosen screw.
2.
CAUTION!
Pinching hazard at the cover!
Carefully close cover.
3. Tighten screw.
2.3 Personnel requirements
WARNING!
Risk of injury in case of insufficient qualification of the personnel!
The system owner of the system/device is responsible for adhering to the qualifica-
tions.
If unqualified personnel carries out work on the device or steps into the danger zone of the
device, hazards arise which may cause severe injuries and significant material damage.
– All work must only be carried out by respectively qualified personnel.
– Unqualified personnel must be kept away from the hazard areas.
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.
Only persons who can be expected to perform their tasks reliably are permitted as personnel. Per-
sons whose reaction capability is impaired, e.g. through drugs, alcohol or medication are not per-
mitted.
When selecting the personnel, the stipulations regarding age and occupation that apply at the loca-
tion must be observed.
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Unauthorized persons
WARNING!
Risk of fatal injury for unauthorized person through hazards in the hazard zone and
work area!
Unauthorized persons, who do not fulfil the requirements described herein do not know the
dangers in the work area. Unauthorized persons are therefore subject to a risk of serious
injury including death.
– Keep unauthorized persons away from hazard zone and work area.
– If in doubt, address persons and tell them to leave the hazard zone and work area.
– Discontinue the work as long as unauthorized persons are present in the hazard zone
and the work area.
2.4 Personal safety equipment and clothing
Personal safety equipment is used to protect persons from impacts on safety and health at work.
The personnel must wear personal safety equipment while carrying out the various tasks and while
working with the device. The individual sections of this manual will indicate the personal safety
equipment separately.
Description of the personal safety equipment and clothing
The personal safety equipment and clothing is described below:
Hearing protection
Hearing protection is a protective measure against hearing damage due to noise impact.
Light respiratory protection
The light respiratory protection is used as a protection against hazardous dusts.
Protective gloves
Protective gloves are used to protect the hands against friction, abrasions, punctures, and deeper
injuries as well as against contact with hot surfaces.
Operating instructions T-Dok-040-GB-Rev.1
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Safety goggles
Safety goggles are used to protect the eyes against flying parts and splashes.
2.5 Responsibility of the system owner
System owner
The system owner is the person, who directly operates the device for commercial or economical
purposes or who allows a third party to use/apply it and who is responsible for the legal product
responsibility for the protection of the user, the personnel or third parties.
System owner responsibilities
The device is used in a commercial environment. The system owner of the device is therefore sub-
ject 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 must
be adhered to.
The following shall apply in particular:
nThe system owner must familiarize himself with the applicable occupational safety regulations
and also conduct a risk assessment to determine risks that may arise due to the specific
working conditions at the place of use of the device. The risk assessment must be imple-
mented in the form of operating instructions for operating the device.
nThe system owner must check throughout the entire implementation period of the device,
whether the work instructions that the owner has created satisfy current legislation and must
adapt the instructions if necessary.
nThe system owner must clearly regulate and specify responsibilities for installation, operation,
repair of malfunctions, maintenance, and cleaning.
nThe system owner must ensure that all employees, who handle the device, have read and
understood this manual. In addition, the system owner must train personnel at regular inter-
vals and inform the personnel of the hazards.
nThe system owner must provide the personnel with the necessary protective gear and make
the wearing of the necessary protective gear mandatory.
Furthermore, the system owner is responsible for making sure that the device is always in perfect
technical condition. Therefore, the following applies:
nThe system owner must ensure that the maintenance intervals described in this operating
manual are adhered to.
nThe system owner must have all safety equipment checked regularly for functionality and
completeness.
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2.6 Intended use
The automatic spray gun serves the purpose of automatic coating of metal, plastic, ceramic,
wood, as well as other suitable surfaces, dosing of fluids, placement of adhesive and marking
points. Typical coating materials include paints, dyes, water-soluble paints, adhesives, glazes,
enamels, debonding agents etc.
The automatic spray gun can be operated both as an independent device as well as in a larger
system (e.g. as a component of a fully-automatic coating system as well as a spray robot).
Intended use also includes adherence to all the specifications in this manual.
Any use beyond the intended use or any other use constitutes improper use.
WARNING!
Danger due to improper use!
Improper use of the automatic spray gun can cause dangerous situations.
– Only carry out the installation and commissioning according to the steps described in this
operating manual.
– Make sure that the utilised hose lines fulfil the requirements with respect to pressure,
chemical and mechanical loads.
– Always observe the applicable country-specific safety, accident prevention, occupational
safety, and environmental protection regulations for the area of use for the automatic
spray gun.
– Do not use sharply abrasive, chemically aggressive, very hot or very cold spray media
without first consulting with and receiving approval from Krautzberger GmbH.
– Adhere to the spray media manufacturer's safety data sheets.
– Only use the manufacturer's original spare parts.
– Only operate the automatic spray gun after proper fastening on a suitable carrier con-
struction.
– Do not hold the automatic spray gun in your hand during operation.
– Only operate the automatic spray gun while adhering to the values specified in the
( Ä Chapter 12 ‘Technical data’ on page 39).
– Make sure that the connected compressed air is oil-free and free of solid matter.
– Operate the automatic spray gun with processed, dried compressed air (air quality pur-
suant to DIN ISO 8573-1: grade 4).
– Never point the compressed air at living beings.
– Do not operate the automatic spray gun in areas that are at risk for explosions.
No claims of any type can be asserted due to damage resulting from improper use.
Operating instructions T-Dok-040-GB-Rev.1
[email protected], www.krautzberger.com GB–10

2.7 General safety information
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.
WARNING!
Risk of injury through the use of incorrect spare parts!
The use of incorrect or defective spare parts can cause risks for the personnel as well as
damage, malfunctions or complete failure.
– Only use original spare parts from Krautzberger or spare parts that have been approved
by Krautzberger.
– In case of questions, always contact our service department.
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.
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 system
owner is responsible for the type and implementation of suitable measures, which may
depend on the local conditions.
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NOTICE!
Property damage due to incorrect installation
Incorrect installation can lead to property damage.
– Check all lines and machines for a tight seat prior to commissioning.
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.
ENVIRONMENT!
Environmental hazard due to incorrect disposal!
Incorrect disposal may cause environmental hazards.
– After the useful life of the device has been exhausted, dispose of it via the commercial
waste.
– Properly dispose of potential spray fluid residue separately from the device.
– If in doubt, obtain information about environmentally-appropriate disposal with the local
municipalities or specialized disposal companies.
Operating instructions T-Dok-040-GB-Rev.1
[email protected], www.krautzberger.com GB–12

3 Transport and storage
3.1 Transport
nThe automatic spray gun is protected by cardboard packaging.
nThe cardboard packaging can be reused for storage.
3.2 Storage
Store packages subject to these conditions:
nDo not store outside.
nDry and dust-free storage.
nKeep away from any aggressive media.
nProtect from UV radiation.
nAvoid mechanical shocks.
nStorage temperature: 5 to 35 °C.
nRelative atmospheric humidity: max. 60%.
nFor storage for longer than 3 months, check the general condition of all parts of the packaging
on a regular basis. If necessary, refresh or renew the conservation.
It is possible that there are notes on the packing pieces concerning the storage that extend
beyond the requirements listed here. Follow those accordingly.
3.3 Unpacking
Immediately upon receipt check the delivery for completeness and damage from transport.
In the event of visible exterior transport damage, proceed as follows:
nDo not accept delivery or only do so with reservations.
nRecord scope of damage on the transport documents or on the bill of delivery of the shipping
company.
nInitiate complaint.
Report any damage as soon as it has been detected. Damage claims can only be asserted
within the applicable complaint period.
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4 Overview
Fig. 1: Overview
1 Air nozzle (flat, round, rotary jet or full-
cone rotary jet)
2 Clamping nut
3 Head section
4 Main element
5 Closing piece
6 Adjustment nut for needle stroke
7 Round jet regulator (R) (option)
8 Flat jet regulator (F)
9 Fastening screws
10 Fluid nozzle (flat, round, rotary jet or full-
cone rotary jet)
11 Connection control (St)/atomisation air
(Z)
12 Fastening hole
11 Connection (lower fluid connection)
Operating instructions T-Dok-040-GB-Rev.1
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5 Installation
Personnel:
nQualified personnel
Protective equipment:
nProtective gloves
5.1 General installation information
Adhere to the following general information for the installation:
nOnly carry out the installation and commissioning according to the steps described in this
operating manual.
nMake sure that the utilised hose lines meet the requirements for pressure, chemical and
mechanical loads.
nOnly operate the automatic spray gun after proper fastening on a suitable carrier design.
nMake sure that the connected compressed air is oil-free and free of solid matter.
nOperate the automatic spray gun with processed, dried compressed air (air quality pursuant to
DIN ISO 8573-1: grade 4).
nVibration and recoil forces may occur on the automatic spray gun during operation. Ensure
sufficient fastening.
nNever point the compressed air at living beings.
5.2 Dimensions
Fig. 2: Dimensions
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5.3 Mounting the automatic spray guns
Fig. 3: Mounting the automatic spray gun
1. Slide the spray gun with the fastening hole (Fig. 3/1) over an on-site retaining bolt (Æ = 12
mm).
2. Fasten the automatic spray gun with the screws (Fig. 3/2) (tightening torque: see
Ä Chapter 12 ‘Technical data’ on page 39).
3. Ensure proper earth connection of the automatic spray gun.
5.4 Connection scheme
Air and fluid supply
Fig. 4: Air and fluid supply
St Control air
Z Atomisation air
DV Pressure regulator valve
O/S (E) Opener/closer with bleed
H Tap
M Material
F Filter
DE Pressure generator
–––– Fluid supply
- - - - Air supply
Operating instructions T-Dok-040-GB-Rev.1
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5.5 Connecting the automatic spray gun
See also ( Ä Chapter 5.4 ‘Connection scheme’ on page 16).
WARNING!
Danger of injury due to improper connection!
When the fluid supply is pressurised, e.g. from pressure containers or with pumps, the range
of the fluid jet can increase by a multiple in case of atomisation air failure. This presents a
hazard to people and property.
– Make sure that the fluid supply and the control air are interrupted if the atomisation air
pressure drops off quickly.
– It is recommended to regulate the atomisation air pressure via a filter pressure reducer.
The connections for control and atomisation air are marked with letter abbreviations.
Fig. 5: Connecting the automatic spray gun
1. Connect the control air to input "St" (Fig. 5/1).
2. Connect the atomisation air to input "Z" (Fig. 5/2).
3. Connect the fluid line to (Fig. 5/3).
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5.6 Checking connections
1. Disconnect spray medium supply.
Fig. 6: Checking closures
2. Completely open the round jet regulator (Fig. 6/2, if present) and the flat jet regulator
(Fig. 6/1) . To do this, turn the regulator counter-clockwise up to the stop.
3. Open the adjusting nut (Fig. 6/3) of the needle stroke adjustment maximum 5.5 mm (Fig. 6).
To do so, turn the adjusting nut (Fig. 6/3) counter-clockwise.
One turn of the needle stroke adjustment moves the needle by 1 mm and corresponds
to 18 positions.
ðNo air may escape from the automatic spray gun.
4. Open the control air.
ðThe needle of the fluid nozzle must push itself back and air must escape from the air
nozzle.
5. Close the control air again.
6. Establish fluid supply.
ðNo spray fluid may escape from the spray gun.
Operating instructions T-Dok-040-GB-Rev.1
[email protected], www.krautzberger.com GB–18

6 Commissioning
Personnel:
nQualified personnel
Protective equipment:
nHearing protection
nLight respiratory protection
nSafety goggles
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.
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 system
owner is responsible for the type and implementation of suitable measures, which may
depend on the local conditions.
6.1 General Information about the commissioning
Adhere to the following general information for the commissioning:
nOnly carry out the commissioning of the automatic spray gun pursuant to the steps described
in this operating manual.
nCheck the material and compressed air hose lines before each use for damage and tight fit.
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nAlways observe the applicable country-specific safety, accident prevention, occupational
safety, and environmental protection regulations for the area of use for the automatic spray
gun.
nDo not use sharply abrasive, chemically aggressive, very hot or very cold spray media without
first consulting with and receiving approval from Krautzberger GmbH.
nAdhere to the spray media manufacturer's safety data sheets.
nOnly operate the automatic spray gun while adhering to the values specified in the
(
Ä Chapter 12 ‘Technical data’ on page 39).
nOnly operate the automatic spray gun after proper fastening on a suitable carrier design.
nDo not hold the automatic spray gun in your hand during operation.
nNever point the compressed air at living beings.
nAdhere to the operating manuals for the respective components
6.2 Operation
To achieve optimal results, adhere to the following:
–Rinse the automatic spray gun with cleaning products before commissioning.
–Too-high air pressure causes unnecessarily high air consumption and too-strong atomi-
sation of the spray fluid.
–Too-low air pressure produces an unsatisfactory spray pattern.
–Select the lowest possible fluid pressure.
1. Make sure that the control air and atomisation air connections are not reversed.
2. Close the control air (connection "St").
3. "Open" fluid feed.
Depending on the type of fluid feed, the "opening" of the fluid feed is carried out
–By opening the connection tap
–By applying pressure to the storage container
–By filling the fluid into a storage container (hydrostatic inherent pressure).
4. Open the control air.
ðThe fluid is sprayed. Generally, the adjustment of the spray pattern is now required
( Ä Chapter 6.3 ‘Adjusting the spray pattern’ on page 21).
Operating instructions T-Dok-040-GB-Rev.1
[email protected], www.krautzberger.com GB–20