Krautzberger A 10 User manual

T-Dok-040-GB-Rev.5
GB Automatic spray gun A 10
Operating instructions
■ 200-0148
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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Table of contents
1 Function and identification................................................................................................ 5
1.1 Function....................................................................................................................... 5
1.2 Identification................................................................................................................. 6
2 Using this operating manual............................................................................................. 7
2.1 Symbols in this manual................................................................................................ 7
2.2 Personnel requirements............................................................................................... 8
2.3 Personal protective equipment.................................................................................... 9
3 Safety and responsibility................................................................................................. 12
3.1 General safety instructions........................................................................................ 12
3.2 Intended use.............................................................................................................. 12
3.3 Specification for the operation of a complete machine.............................................. 13
3.4 Predictable misuse.................................................................................................... 13
3.5 Responsibility of the owner........................................................................................ 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 Installing the automatic spray gun............................................................................. 18
6.4 Connection scheme................................................................................................... 18
6.5 Connecting the automatic spray gun......................................................................... 19
6.6 Checking connections................................................................................................ 20
7 Operation........................................................................................................................... 21
7.1 Safety......................................................................................................................... 21
7.2 General information about commissioning and start-up............................................ 22
7.3 Operation................................................................................................................... 22
7.4 Adjusting the spray pattern........................................................................................ 23
7.5 Setting the zero point of the needle stroke setting..................................................... 26
7.6 Shutting down............................................................................................................ 26
8 Maintenance...................................................................................................................... 27
8.1 Safety......................................................................................................................... 27
8.2 Maintenance schedule............................................................................................... 27
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8.3 Cleaning the automatic spray gun............................................................................. 29
8.4 Changing the fluid nozzle and the air nozzle............................................................. 30
8.5 Changing the fluid needle.......................................................................................... 31
8.6 Changing the seals.................................................................................................... 34
9 Troubleshooting............................................................................................................... 36
9.1 Customer Care.......................................................................................................... 38
10 Spare parts........................................................................................................................ 39
11 Accessories...................................................................................................................... 40
12 Disassembly and disposal............................................................................................... 41
12.1 Safety....................................................................................................................... 41
12.2 Disassembly............................................................................................................ 41
12.3 Disposal................................................................................................................... 41
13 Technical data................................................................................................................... 42
13.1 Dimensions and weight............................................................................................ 42
13.2 General specifications............................................................................................. 42
13.3 Dimensions.............................................................................................................. 42
14 Declaration of incorporation........................................................................................... 43
15 Notes.................................................................................................................................. 44
16 Index.................................................................................................................................. 47
Operating instructions T-Dok-040-GB-Rev.5
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1 Function and identification
1.1 Function
Automatic spray guns are 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 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 automatic 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. 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 atomiser 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 controller
or with flat and round jet controller
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1.2 Identification
Scope of delivery Model Product number
Automatic spray gun A10 200-0148
Operating manual T-Dok-040
Serial number
The serial number of the automatic spray gun is located on the main element. It serves as a unique
identifier.
Operating instructions T-Dok-040-GB-Rev.5
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2 Using this operating manual
2.1 Symbols in this manual
Safety instructions
This manual uses symbols to identify safety instructions. The safety instructions are 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 will cause 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.
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 trouble-free operation.
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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 during the
execution of the action. The signal words described above are used.
1. Unfasten screw.
2.
CAUTION!
Pinching hazard at the lid!
Carefully close lid.
3. Tighten screw.
Special safety instructions
The following symbols are used in safety instructions to draw the attention to specific hazards:
Warning signs Type of danger
Warning – danger zone.
Additional identifications
The following symbols are used in this manual to highlight operating instructions, results, lists, ref-
erences, and other elements:
Identification Explanation
Step-by-step instructions
ðResults of procedural steps
References to sections in this manual and other applicable docu-
ments
Lists without specified order
[Pushbutton] Operating elements (e.g. pushbuttons, switches), display ele-
ments (e.g. signal lights)
‘Display’ Screen elements (e.g. pushbuttons, assignment of function keys)
2.2 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.
Operating instructions T-Dok-040-GB-Rev.5
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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.
2.3 Personal protective equipment
Personal protective equipment is used to protect persons against adverse impacts on their occupa-
tional health and safety.
The personnel must wear personal protective equipment while carrying out the different tasks and
while working with the device.
The selection of the protective equipment depends on the environmental conditions at the site
of the system owner and the utilised coating material. To ensure the proper selection of per-
sonal protective equipment, the information provided by the spray material manufacturer indi-
cated on the safety data sheet must be adhered to.
Description of the personal protective equipment recommended by Krautzberger
The personal protective equipment is described below:
Protective work clothing
Protective work clothing are tight fitting work clothes with low tear resistance, with tight sleeves,
and without any protruding parts.
Ear protection
Ear protection provides protection against hearing damage.
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Light respiratory protection
The light respiratory protection is used as a protection against hazardous dusts.
Safety goggles
Safety goggles are used to protect the eyes from flying parts and splashes of liquid.
Protective gloves
Protective gloves protect hands from friction, abrasion, puncture wounds, or deeper injuries, as
well as from contact with hot surfaces.
Safety shoes
Safety shoes protect the feet against crushing, falling parts or slipping on slippery ground.
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Safety helmet
The helmet protects the head against injuries from falling parts and oscillating loads as well as in
tight spaces.
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3 Safety and responsibility
3.1 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.
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.
3.2 Intended use
The automatic spray gun is used to spray paints, colours, adhesives, glazes, enamels, release
agents, as well as other fluids. The nozzle size depends on the spray viscosity of the spray fluid.
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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 automatic spray gun must be assembled to form a complete machine.
nOnly operate the automatic spray gun after proper fastening on a suitable carrier construction.
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 for the area of use for the automatic spray
gun.
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.
nOnly operate the automatic spray gun after proper fastening on a suitable carrier construction.
nDo not hold the automatic spray gun in your hand during operation.
nOnly operate the automatic spray gun while adhering to the values specified in (
Ä Chapter
13 ‘Technical data’ on page 42).
nMake sure that the connected compressed air is oil-free and free from solid matter.
nOperate the automatic spray gun 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!
Misuse of the automatic spray gun can cause dangerous situations.
No claims of any kind can be asserted due to damage resulting from misuse!
3.5 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.
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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.
3.6 Residual risks
The automatic spray gun 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
automatic spray gun itself or cause other property damage.
nThe automatic spray gun must only be used as intended.
nThe automatic spray gun must 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-040-GB-Rev.5
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4 Transport, storage, and packaging
4.1 Transport
nThe automatic spray gun is protected by cardboard packaging.
nThe cardboard packaging can be reused for storage.
4.2 Storage
Store the automatic spray gun under the following conditions:
nStore the automatic spray gun 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 automatic spray gun is packaged in accordance with the anticipated transport conditions and
the packaging needs to protect it against transport damage, corrosion, and other damage.
nRemove packaging material.
nRemove potentially present transport safety restraints.
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5 Overview
Fig. 1: Overview
1 Air nozzle (flat, round, rotary jet or full-
cone rotary jet)
2 Cap nut
3 Head piece
4 Main element
5 Locking piece
6 Adjustment nut for needle stroke
7 Round jet controller (R) (option)
8 Flat jet controller (F)
9 Fastening screws
10 Fluid nozzle (flat, round, rotary jet or full-
cone rotary jet)
11 Connection for control (St)/atomiser air (Z)
12 Fastening hole
11 Connection (lower fluid connection)
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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 the 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.
nOnly operate the automatic spray gun after proper fastening on a suitable carrier construction.
nMake sure that the connected compressed air is oil-free and free from solid matter.
nOperate the automatic spray gun with processed, dried compressed air (air quality pursuant to
DIN ISO 8573-1: quality class 4).
nVibration and recoil forces may occur on the automatic spray gun during the operation.
Ensure sufficient fastening.
nNever point the compressed air at living beings.
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6.3 Installing the automatic spray gun
Fig. 2: Installing the automatic spray gun
1. Slide the automatic spray gun with the fastening hole ( Fig. 2/1) over an on-site retaining
bolt (Æ = 12 mm).
2. Fasten the automatic spray gun with the screws ( Fig. 2/2).
3. Ensure proper earth connection of the automatic spray gun.
6.4 Connection scheme
Air and fluid supply
Fig. 3: 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
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6.5 Connecting the automatic spray gun
See also ( Ä Chapter 6.4 ‘Connection scheme’ on page 18).
WARNING!
Danger of injury due to improper connection!
When the material 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 atomiser air failure. This presents a
hazard to people and property.
– Make sure that the material supply and the control air are interrupted if the atomiser air
pressure drops off quickly.
– It is recommended to regulate the atomiser air pressure via a filter pressure reducer.
The connections for control air and atomiser air are marked with letter abbreviations.
Fig. 4: Connecting the automatic spray gun
1. Connect the control air to input "St" ( Fig. 4/1).
2. Connect the atomiser air to input "Z" ( Fig. 4/2).
3. Connect the fluid line to ( Fig. 4/3).
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6.6 Checking connections
1. Disconnect spray fluid supply.
Fig. 5: Checking closures
2. Completely open the round jet controller ( Fig. 5/2, if present) and the flat jet controller (
Fig. 5/1) . To do this, turn the regulator anti-clockwise up to the stop.
3. Open the adjusting nut ( Fig. 5/3) of the needle stroke adjustment maximum 5.5 mm (
Fig. 5). To do so, turn the adjusting nut ( Fig. 5/3) 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 automatic spray gun.
Operating instructions T-Dok-040-GB-Rev.5
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