Krautzberger A15 eco User manual

200-0383
Translation of the original operating instructions
T-Dok-665-GB-Rev. 0
GB Automatic spray gun A15 eco
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................................................................................................................. 5
2 Safety and responsibility................................................................................................... 7
2.1 Symbols in this manual................................................................................................ 7
2.2 Personnel requirements............................................................................................... 8
2.3 Personal safety equipment and clothing...................................................................... 9
2.4 Responsibility of the owner........................................................................................ 10
2.5 Intended use.............................................................................................................. 11
2.6 General safety instructions........................................................................................ 12
2.7 Residual risks............................................................................................................ 13
2.8 Course of action in an emergency............................................................................. 14
3 Transport and storage..................................................................................................... 15
3.1 Transport................................................................................................................... 15
3.2 Storage of packaged units......................................................................................... 15
3.3 Packaging.................................................................................................................. 15
4 Menu.................................................................................................................................. 16
5 Installation......................................................................................................................... 17
5.1 General installation information................................................................................. 17
5.2 Mounting automatic spray gun................................................................................... 17
5.3 Connection scheme................................................................................................... 18
5.4 Connecting the automatic spray gun......................................................................... 19
5.5 Checking connections................................................................................................ 20
6 Operation........................................................................................................................... 21
6.1 Safety......................................................................................................................... 21
6.2 General information about commissioning/start-up................................................... 22
6.3 Operation................................................................................................................... 23
6.4 Adjusting the spray pattern........................................................................................ 23
6.5 Setting the zero point of the needle stroke setting..................................................... 26
6.6 Shut-down.................................................................................................................. 26
7 Maintenance...................................................................................................................... 27
7.1 Maintenance schedule............................................................................................... 28
7.2 Cleaning automatic spray gun................................................................................... 29
7.3 Changing the material nozzle and the air nozzle....................................................... 30
7.4 Changing the fluid needle.......................................................................................... 31
7.5 Changing needle packing.......................................................................................... 33
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8 Troubleshooting............................................................................................................... 35
8.1 Customer Care.......................................................................................................... 35
9 Spare parts........................................................................................................................ 38
9.1 Spare parts................................................................................................................ 38
10 Accessories...................................................................................................................... 39
11 Disposal............................................................................................................................. 40
12 Technical data................................................................................................................... 41
12.1 Dimensions and weight............................................................................................ 41
12.2 General specifications............................................................................................. 41
12.3 Dimensions.............................................................................................................. 41
13 Declaration of incorporation........................................................................................... 42
14 Index.................................................................................................................................. 43
Operating instructions T-Dok-665-GB-Rev. 0
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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, 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 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
nMain element with flat jet regulator
or with flat and round jet control
1.2 Identification
Scope of delivery Model Product number
nAluminium head section; fluid connection on the
bottom
200-0383
Operating instructions T-Dok-665
Serial number
The serial number of the automatic spray gun is located on the main element. It serves as a unique
identifier.
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Additional information can be found in ( Ä Chapter 12 ‘Technical data’ on page 41).
Operating instructions T-Dok-665-GB-Rev. 0
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2 Safety and responsibility
2.1 Symbols in this manual
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 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 environmental hazards.
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 it does not disrupt the reading flow during the exe-
cution of the action. The signal words described above are used.
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Example:
1. Loosen screw.
2.
CAUTION!
Pinching hazard at the cover!
Carefully close cover.
3. Tighten screw.
Special safety instructions
The following symbols are used in safety instructions to draw the attention to special hazards:
Warning signs Type of danger
Warning – danger zone.
Tips and recommendations
This symbol highlights useful tips and recommendations as well as information for efficient
and fault-free operation.
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 operating instructions
ðResults of procedural steps
References to sections in this manual and other applicable docu-
ments
Lists without specified sequence
[Pushbutton] Operating elements (e.g. buttons, switches), display elements
(e.g. signal lights)
‘Display’ Screen elements (e.g. buttons, assignment of function keys)
2.2 Personnel requirements
Operating instructions T-Dok-665-GB-Rev. 0
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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.
2.3 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.
The selection of the personal safety equipment depends on the coating material that is used.
To ensure the proper selection of personal safety equipment, the information provided by the
spray material manufacturer indicated on the safety data sheet must be adhered to.
Description of the personal safety equipment recommended by Krautzberger
The personal safety equipment and clothing is described below:
Ear protection
Ear protection provides protection against hearing damage.
Light respiratory protection
The light respiratory protection is used as a protection against hazardous dusts.
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Protective clothing
Protective clothing are tight fitting work clothes with low tear resistance, with tight sleeves, and
without any protruding parts.
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 flying components and splashes of liquid.
Safety shoes
Safety shoes protect the feet against crushing, falling parts or slipping on slippery ground.
2.4 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.
Operating instructions T-Dok-665-GB-Rev. 0
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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.
2.5 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, anti-adhe-
sives etc.
The 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).
The intended use also includes the compliance with all the information in this manual.
Any use beyond the intended use or any other use constitutes misuse.
WARNING!
Danger due to misuse!
Misuse of the automatic spray gun can cause dangerous situations.
– Only carry out the installation and start-up in accordance with the steps described in
these operating instructions.
– 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.
– Ensure that the utilised hose lines fulfil the requirements with respect to pressure, chem-
ical, and mechanical loads.
– 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 OEM 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 (
Ä Chapter 12 ‘Technical data’ on page 41).
– 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: quality class 4).
– Never point the compressed air at living beings.
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No claims of any kind can be asserted due to damage resulting from misuse.
2.6 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.
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 owner is
responsible for the type and implementation of suitable measures, which may depend on the
local conditions.
Operating instructions T-Dok-665-GB-Rev. 0
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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.
2.7 Residual risks
The automatic spray gun made by Krautzberger GmbH has been manufactured based on state-of-
the-art technology and recognised 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.
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2.8 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-665-GB-Rev. 0
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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 of packaged units
Storage of packaged units
Store packaged units subject to following conditions:
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%.
3.3 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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4 Menu
Fig. 1: Menu
1 Air nozzle (flat-/round jet)
2 Clamping nut
3 Head section
4 Main element
5 Closing piece
6 Adjustment nut for needle stroke
7 Round jet control (R) (option)
8 Flat jet regulator (F)
9 Fastening screws
10 Fluid nozzle (flat-/round jet)
11 Connection control air (St) and atomiser
air (Z)
12 Fastening hole
13 Fluid connection
Operating instructions T-Dok-665-GB-Rev. 0
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5 Installation
Personnel:
nQualified personnel
Protective equipment:
nProtective clothing
nSafety goggles
nSafety shoes
nProtective gloves
5.1 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 these
operating instructions.
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 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: quality class 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 Mounting automatic spray gun
Fig. 2: Mounting automatic spray gun
1. Slide the spray gun with the fastening hole ( Fig. 2/2) over an on-site retaining bolt (Æ = 12
mm).
2. Fasten the spray gun with the screws ( Fig. 2/1).
3. Ensure proper earth connection of the automatic spray gun.
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5.3 Connection scheme
Air and material supply
Fig. 3: Air and material supply
St Control air
Z Atomiser air
DV Pressure regulator valve
O/S (E) Opener/closer with bleed
H Tap
M Material
F Filter
DE Pressure generator
–––– Material supply
- - - - Air supply
Operating instructions T-Dok-665-GB-Rev. 0
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5.4 Connecting the automatic spray gun
See also ( Ä Chapter 5.3 ‘Connection scheme’ on page 18).
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 atomiser air failure. This presents a hazard
to people and property.
– Make sure that the fluid supply and the control air are interrupted if the atomiser air pres-
sure drops off quickly.
– It is recommended to regulate the atomiser air pressure via a filter pressure reducer.
The connections for control and atomiser air are marked with letter abbreviations.
Fig. 4: Connecting the automatic spray gun
1. Connect the control air to input "St" ( Fig. 4/3).
2. Connect the atomiser air to input "Z" ( Fig. 4/2).
3. Connect the material line to the connection ( Fig. 4/1) on the underside of the head section.
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5.5 Checking connections
1. Disconnect spray medium supply.
Fig. 5: Checking connections
2. Completely open the round jet control ( Fig. 5/2, if present) and the flat jet regulator (
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. To do
so, turn the adjusting nut anti-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-665-GB-Rev. 0
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