Krautzberger DA3 User manual

T-Dok-553-GB-Rev.4
GB Steam spray gun DA3
Operating instructions
Article no. ■200-0348
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................................................................................................................. 5
2 Using this operating manual............................................................................................. 6
2.1 Symbols in this manual................................................................................................ 6
2.2 Personnel requirements............................................................................................... 7
2.3 Personal protective equipment.................................................................................... 8
3 Safety and responsibility................................................................................................. 11
3.1 General safety instructions........................................................................................ 11
3.2 Intended use.............................................................................................................. 12
3.3 Specification for the operation of a complete machine.............................................. 12
3.4 Predictable misuse.................................................................................................... 12
3.5 Responsibility of the owner........................................................................................ 13
3.6 Residual risks............................................................................................................ 13
3.7 Course of action in an emergency............................................................................. 13
4 Transport, storage, and packaging................................................................................. 14
4.1 Transport................................................................................................................... 14
4.2 Storage...................................................................................................................... 14
4.3 Packaging.................................................................................................................. 14
5 Menu.................................................................................................................................. 15
6 Installation and disassembly........................................................................................... 16
6.1 Safety......................................................................................................................... 16
6.2 General installation information................................................................................. 16
6.3 Installing the steam spray gun................................................................................... 17
6.4 Connecting connections of the steam spray gun....................................................... 18
6.5 Unfastening connections of the steam spray gun...................................................... 19
6.6 Dismantling the steam spray gun.............................................................................. 20
7 Operation........................................................................................................................... 21
7.1 Safety......................................................................................................................... 21
7.2 General information about commissioning and start-up............................................ 23
7.3 Functional check........................................................................................................ 23
7.4 Adjusting the spray pattern........................................................................................ 25
7.5 Adjusting the needle stroke (optional)....................................................................... 28
7.6 Shutting down............................................................................................................ 28
8 Maintenance...................................................................................................................... 29
8.1 Safety......................................................................................................................... 29
8.2 Maintenance schedule............................................................................................... 30
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8.3 Cleaning the steam spray gun................................................................................... 30
8.4 Changing fluid and steam nozzle............................................................................... 32
8.5 Changing the fluid needle.......................................................................................... 33
8.6 Changing seals and needle pack............................................................................... 36
8.7 Changing connections............................................................................................... 37
9 Troubleshooting............................................................................................................... 38
9.1 Troubleshooting table................................................................................................ 38
9.2 Customer Care.......................................................................................................... 40
10 Spare parts........................................................................................................................ 41
11 Accessories...................................................................................................................... 42
12 Disassembly and disposal............................................................................................... 43
12.1 Safety....................................................................................................................... 43
12.2 Disassembly............................................................................................................ 43
12.3 Disposal................................................................................................................... 43
13 Technical data................................................................................................................... 44
13.1 Dimensions and weight............................................................................................ 44
13.2 General specifications............................................................................................. 44
13.3 Dimensions.............................................................................................................. 44
14 Declaration of incorporation........................................................................................... 45
15 Notes.................................................................................................................................. 46
16 Index.................................................................................................................................. 47
Operating instructions T-Dok-553-GB-Rev.4
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1 Function and identification
1.1 Function
For steam spray guns, the compressed air that is ordinarily required for the atomisation process at
the nozzle is replaced by steam. This process uses a steam generator to generate pressure. The
control of the steam spray gun is still carried out via compressed air, which is generated by com-
pressors.
Steam spray guns are used for the following applications:
nAutomatic coating of surfaces
Especially spray fluids such as lacquers, paints, adhesives, glazing, enamel, debonding agents
and other processing aids are used with this technique.
The geometry of the spray jet and the quantity of the spray fluid to be applied can be changed by
adjusting the following factors:
nSelection of the air and fluid nozzle
nChanging the atomising steam pressure
nChanging the spray fluid pressure
nAdjustment of the needle stroke at the control of the steam spray gun (option)
nChanging the round and flat jet
The steam spray gun can be operated both as an independent device as well as in a larger system
(as a component of a fully-automatic coating system as well as a spray robot).
1.2 Identification
Scope of delivery Model Product number
DA3 steam spray gun 200-0348
Operating manual T-Dok-553
Serial number
The serial number of the steam spray gun is located on the underside. It serves as a unique identi-
fier.
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Article no. ■200-0348
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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.
Operating instructions T-Dok-553-GB-Rev.4
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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 cover!
Carefully close cover.
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 – hot surface.
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
[Pushbuttons] 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
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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.
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.
Operating instructions T-Dok-553-GB-Rev.4
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Ear protection
Ear protection provides protection against hearing damage.
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
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Safety shoes protect the feet against crushing, falling parts or slipping on slippery ground.
Safety helmet
The helmet protects the head against injuries from falling parts and oscillating loads as well as in
tight spaces.
Operating instructions T-Dok-553-GB-Rev.4
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3 Safety and responsibility
3.1 General safety instructions
WARNING!
Risk of death, risk of injury or property damage due to hazardous media!
Potential consequences: The application of hazardous media can lead to death, severe inju-
ries or property damage.
When handling hazardous substances, ensure that the current safety data sheets of the haz-
ardous substance manufacturer are available. The necessary measures can be derived from
the content of the safety data sheet. Since the hazardous potential of a material may be reas-
sessed at any time due to new lessons learned, the safety data sheet must be checked regu-
larly and replaced if necessary.
The system owner is responsible for the presence and the up-to-date status of the safety data
sheet and the associated generation of the risk assessment of the effected workstations.
CAUTION!
Risk of injury due to the discharge of hot steam!
Exiting steam can reach high temperatures. Direct contact with expelled hot media can cause
scalding of the skin.
Note:
– Switch off steam generator and wait until the system has cooled down prior to working on
the steam spray gun.
– The steam pressure line of the steam spray gun can be under pressure and must be
closed if necessary.
– Do not direct the steam jet at people.
CAUTION!
Risk of injury from compressed air!
During the work on the steam spray gun, compressed air may exit and thereby cause injuries.
– Switch off compressor prior to any work on the steam spray gun.
– The pressure line of the steam spray gun can be under pressure and must be vented if
necessary.
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3.2 Intended use
The steam spray gun is used for the automatic coating of surfaces. Typical coating materials are
lacquers, paints, adhesives, glazes, enamels, debonding agents, etc.
The steam spray gun can be operated both as an independent device as well as in a larger
system (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 operating manual.
3.3 Specification for the operation of a complete machine
nThe operation without CE-marking is prohibited.
nPrior to its use, the steam spray gun must be assembled to form a complete machine.
nOnly operate the steam spray gun after properly fastening it on a suitable support 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 steam spray
gun.
nThe chemical resistance of the materials which we use cannot always be assessed with
authority due to the large number of fluids, concentrations, temperatures and impurities used.
For this reason, please test the suitability because we cannot extend any respective guaran-
tees.
nAdhere to the safety data sheets of the spray fluid manufacturer.
nEnsure that the utilised hose lines fulfil the requirements with respect to temperature, pres-
sure, chemical, and mechanical loads.
nOnly use the manufacturer's OEM parts.
nThe conformity of the product is voided in case of structural modifications.
nOnly operate the steam spray gun in compliance with the values specified in the (
Ä Chapter
13 ‘Technical data’ on page 44).
nOnly operate the steam spray gun after properly fastening it on a suitable support structure.
nDo not hold the steam spray gun in your hand during operation.
nOperate the steam spray gun with processed, dried compressed air (air quality pursuant to
DIN ISO 8573-1: quality class 4).
nNever point the compressed air and the steam jet towards living beings.
nDo not operate the steam spray gun in areas that are at risk for explosions.
WARNING!
Misuse of the steam spray gun can cause hazardous situations.
No claims of any kind can be asserted due to damage resulting from misuse!
Operating instructions T-Dok-553-GB-Rev.4
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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.
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
Devices, machines or systems made by Krautzberger GmbH have been manufactured based on
state-of-the-art technology and in compliance with technical safety regulations.
Nonetheless, their use may pose a threat to the life or health of users or third parties, or harm the
device, the machine, the system or other material assets.
nMechanical hazards (crushing, shearing, cutting, jamming, burning, etc.) are possible at any
time during the installation, during operation as well as during maintenance work and serv-
icing.
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.
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4 Transport, storage, and packaging
4.1 Transport
nThe steam spray gun is protected by cardboard packaging.
nThe cardboard packaging can be reused for storage.
4.2 Storage
Store the steam spray gun under the following conditions:
nStore the steam 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 steam 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.
Operating instructions T-Dok-553-GB-Rev.4
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5 Menu
Fig. 1: Menu
1 Needle stroke setting *
2 Type plate
3 Cap nut
4 Steam nozzle
5 Steam connection
6 Round jet control "R"
7 Sound absorber
8 Fluid connection outlet "M" (fluid circulation*)
9 Control air connection "ST"
9 Fluid connection input "M"
10 Retaining bolt *
12 Flat jet control "F"
* Optional
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6 Installation and disassembly
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.
nAlways observe the applicable country-specific safety, accident prevention, occupational
safety, and environmental protection regulations etc. for the area of use for the steam spray
gun.
nReduce the supply air through the installation of a pressure regulator to a maximum of 6 bar.
nEnsure that the utilised hose lines meet the requirements for pressure, chemical and mechan-
ical loads.
nOnly operate the steam spray gun after properly fastening it on a suitable support structure.
nOperate the steam spray gun with processed, dried compressed air (air quality pursuant to
DIN ISO 8573-1: quality class 4).
nNever point the steam jet and compressed air towards living beings.
Operating instructions T-Dok-553-GB-Rev.4
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6.3 Installing the steam spray gun
Changing the installation position of the steam spray gun
To change the installation position of the steam spray gun, the optional retaining bolt can be
screwed into the control part of the steam spray gun from the other side.
Fig. 2: Installing the steam spray gun
Insert the steam spray gun with the retaining bolt ( Fig. 2/1) into a holder that is provided
on-site by the customer and fasten it properly.
Alternatively, you can use and install an individual adapter, e.g. for a robot.
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6.4 Connecting connections of the steam spray gun
Fig. 3: Connecting the steam spray gun
1. Connect the control air to "ST" ( Fig. 3/1).
2. Connect material supply to fluid connection input "M" ( Fig. 3/3).
3. Connect fluid circulation line to fluid connection output "M" ( Fig. 3/2) (optional).
4. Connect the steam hose to steam connection ( Fig. 3/4).
5. Ensure that all connections are properly connected.
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6.5 Unfastening connections of the steam spray gun
CAUTION!
Risk of injury due to the discharge of hot steam!
Exiting steam can reach high temperatures. Direct contact with expelled hot media can cause
scalding of the skin.
Note:
– Switch off steam generator and wait until the system has cooled down prior to working on
the steam spray gun.
– The steam pressure line of the steam spray gun can be under pressure and must be
closed if necessary.
– Do not direct the steam jet at people.
1. Switch off the steam generator and secure it against restart.
2. Let the steam spray gun cool down.
3. Close the steam pressure line.
Fig. 4: Connecting the steam spray gun
4. Unfasten the control air at "ST" ( Fig. 4/1).
5. Unfasten material supply at fluid connection input "M" ( Fig. 4/3).
6. Unfasten fluid circulation line at fluid connection output "M" ( Fig. 4/2) (optional).
7. Unfasten the steam hose at steam connection ( Fig. 4/4).
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6.6 Dismantling the steam spray gun
1. Unfasten connections of the steam spray gun (
Ä Chapter 6.5 ‘Unfastening connections of
the steam spray gun’ on page 19).
Fig. 5: Dismantling the steam spray gun
2. Unfasten onsite fastening and pull the steam spray gun with the retaining bolt ( Fig. 5/1) out
of the mounting.
Operating instructions T-Dok-553-GB-Rev.4
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