Krautzberger KAA 1300 User manual

T-Dok-029-GB-Rev.3
GB Automatic spray gun KAA 1300
Operating instructions
Item number: 200-0201
Translation of the original operating instructions

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

Table of contents
1 Function and identification................................................................................................ 5
1.1 Function....................................................................................................................... 5
1.2 Identification................................................................................................................. 6
2 Using this operating manual............................................................................................. 7
2.1 Information about the operating manual...................................................................... 7
2.2 Symbols in this operating manual................................................................................ 7
2.3 Personnel requirements............................................................................................... 9
2.4 Personal protective equipment.................................................................................... 9
3 Safety and responsibility................................................................................................. 12
3.1 Responsibility of the owner........................................................................................ 12
3.2 Intended use.............................................................................................................. 12
3.3 Specification for the operation of a complete machine.............................................. 12
3.4 Predictable misuse.................................................................................................... 12
3.5 General safety instructions........................................................................................ 13
3.6 Residual risks............................................................................................................ 14
3.7 Course of action in an emergency............................................................................. 14
4 Transport, storage, and packaging................................................................................. 15
4.1 Transport................................................................................................................... 15
4.2 Storage...................................................................................................................... 15
4.3 Packaging.................................................................................................................. 15
5 Menu.................................................................................................................................. 16
6 Installation......................................................................................................................... 17
6.1 Safety......................................................................................................................... 17
6.2 General installation information................................................................................. 18
6.3 Installing the automatic spray gun............................................................................. 19
6.4 Connection scheme................................................................................................... 20
6.5 Connecting the automatic spray gun......................................................................... 21
6.6 Setting of nozzle........................................................................................................ 22
7 Operation........................................................................................................................... 23
7.1 Safety......................................................................................................................... 23
7.2 General information about initial start-up / commissioning........................................ 24
7.3 Commissioning.......................................................................................................... 25
7.4 Shutting down............................................................................................................ 25
8 Maintenance...................................................................................................................... 26
8.1 Safety......................................................................................................................... 26
8.2 General information about the maintenance.............................................................. 26
8.3 Maintenance schedule............................................................................................... 27
Automatic spray gun KAA 1300 ENGLISH
Item number: 200-0201 GB–3

8.4 Cleaning..................................................................................................................... 28
8.5 Checking the channel for material leak...................................................................... 29
8.6 Changing the valve needle........................................................................................ 30
8.7 Change valve seat screw and material nozzle.......................................................... 32
8.8 Changing the valve needle pack................................................................................ 33
8.9 Changing the axial ring seals..................................................................................... 37
8.10 Changing the valve spring....................................................................................... 39
9 Troubleshooting............................................................................................................... 40
9.1 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.............................................................................................................. 45
14 Declaration of incorporation........................................................................................... 46
15 Notes.................................................................................................................................. 47
16 Index.................................................................................................................................. 50
Operating instructions T-Dok-029-GB-Rev.3
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1 Function and identification
1.1 Function
The KAA 1300 automatic spray gun serves the purpose of automatic (non-manual) coating of sur-
faces like metal, plastic, ceramic, wood, as well as other suitable surfaces.
Typical coating materials include paints, dyes, water-soluble paints, adhesives, anti-adhesives etc.
Abrasive materials can also be processed with a working pressure below 5 MPa (50 bar). The
automatic spray gun operates based on the airless principle, which means the spray jet is exclu-
sively generated by the material pressure, which presses the material through a nozzle. A pump
supplies the material with a maximum pressure of 2.5 MPa (250 bar) through a hose, which is
designed for a respective pressure charge, leading to the material connection of the automatic
spray gun. Compressed air is added to the control air connection to control the spray process. The
air flowing into the air chamber completely moves the piston and thereby the valve needle back-
wards against the pressure of the spring. This provides access to the front opening of the valves
seat screw and under high pressure the material flows into the material nozzle. Here, it exits as a
flat, broad material jet and meets the workpiece that needs to be coated.
After exiting the nozzle, the spray jet takes the shape specified by the nozzle. It is directed towards
the workpiece. The effective spray jet is not quite as wide as theoretically possible.
The particles of the spray jet reach far higher speeds than with spray guns driven by compressed
air. The material flow rate is respectively higher and the jet is sharper, which means the turbulence
zone is smaller. The volume and shape of the jet can only be modified by changing the nozzle. The
diameter of the nozzle bore determines the material flow volume, while the size and geometry of
the elliptically shaped nozzle opening determine the height and width of the jet (shape of an ellip-
tical cone). A large number of airless nozzles are available. They can only be purchased from
Krautzberger GmbH.
The nozzle can be seamlessly turned in the axis of the spray jet by 360° and locked into place in
any position. This allows an optimal adjustment of the angle with which the jet hits the workpiece to
the respective conditions.
Coating materials approved for spray applications by the coating material manufacturer may be
used and Krautzberger GmbH offers special designs for materials dissolved in chlorinated hydro-
carbon containing solvents as well as abrasive or corrosive materials.
The automatic spray gun can be operated both as an individual device as well as in a larger
system together with other spray guns (e.g. as a component of a fully-automatic coating system as
well as a spray robot).
The use is particularly suitable where comparatively large volumes of material need to be pro-
cessed per unit of time. Compared to spray guns driven by compressed air, an additional
advantage is that there is less spray mist, ensuring that a far greater percentage of the coating
material reaches the workpiece.
Automatic spray gun KAA 1300 ENGLISH
Item number: 200-0201 GB–5

1.2 Identification
Scope of delivery Type Product number
nKAA 1300 200-0201
Operating manual T-Dok-029
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-029-GB-Rev.3
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2 Using this operating manual
2.1 Information about the operating manual
nKnowledge of the fundamental safety instructions and safety regulations is a basic require-
ment for safe handling and defect-free operation of the product.
nThis operating manual contains the most important information about enabling safe operation
of the product.
nThis operating manual and, in particular, the safety instructions are to be observed by all per-
sons who work on or with the product.
nFurthermore, the rules and regulations for accident prevention in force at the respective oper-
ating site are to be observed.
2.2 Symbols in this operating manual
Safety instructions
This operating manual uses symbols to identify safety instructions. The safety instructions are pre-
ceded by signal words that indicate the severity of the hazard.
DANGER!
This combination of symbol and signal word indicates an immediate dangerous situation,
which will cause death or severe injuries if it is not averted.
WARNING!
This combination of symbol and signal word indicates a potentially dangerous situation which
can cause death or severe injuries if it is not averted.
CAUTION!
This combination of symbol and signal word indicates a potentially dangerous situation which
can cause slight injuries if it is not averted.
NOTICE!
This combination of symbol and signal word indicates a potentially dangerous situation which
can cause property and environmental damage if it is not averted.
Automatic spray gun KAA 1300 ENGLISH
Item number: 200-0201 GB–7

ENVIRONMENT!
This combination of symbol and signal word indicates potential dangers to the environment.
Tips and recommendations
This symbol highlights useful tips and recommendations as well as information for efficient
and defect-free operation.
Example for safety instructions in operating instructions
Safety instructions can refer to specific, individual operating instructions. Such safety instructions
are embedded in the operating instructions so that they do not disrupt the reading flow when per-
forming the action. The signal words described above are used.
1. Loosen the screw.
2.
CAUTION!
Pinching hazard at the lid!
Carefully close the lid.
3. Tighten the screw.
Special safety instructions
The following symbols are used in safety instructions to draw attention to specific hazards:
Warning signs Type of danger
Warning – hot surface.
Warning – danger zone.
Additional markings
The following markings are used in this manual to highlight operating instructions, outcomes, lists,
references, and other elements:
Operating instructions T-Dok-029-GB-Rev.3
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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
[Button] Operating elements (e.g. buttons, switches), display elements
(e.g. signal lights)
‘Display’ Screen elements (e.g. pushbuttons, assignment of function keys)
2.3 Personnel requirements
This manual identifies the qualifications of the personnel for the different scopes of work as listed
below:
Qualified personnel
Due to their specialised professional training, knowledge, and experience as well as knowledge of
the industry-specific standards and regulations, qualified personnel are in a position to perform
assigned tasks and to identify and avert potential risks on their own.
Specialised personnel
Due to their specialised professional training, knowledge, and experience as well as knowledge of
the industry-specific standards and regulations, qualified personnel are in a position to perform
assigned tasks and to identify and avert potential hazards on their own.
Trained electrician
Due to specialised professional training, knowledge and experience as well as knowledge of the
industry specific standards and regulations, a trained electrician is able to carry out work on the
electrical systems and to identified and avert potential risks on his/her own.
The trained electrician has completed specialised training for the specific work environment where
he/she works and knows the relevant standards and regulations.
User
The user is familiar with the basic regulations on occupational safety and accident prevention.
2.4 Personal protective equipment
Personal protective equipment is used to protect persons against adverse effects on their health
and safety when working.
Personnel must wear personal protective equipment while carrying out the different tasks on and
with the machine.
In the course of regular, recurring trainings, the owner should inform operating personnel that
working without protective equipment can be detrimental to their health.
Automatic spray gun KAA 1300 ENGLISH
Item number: 200-0201 GB–9

Protective equipment is selected according to the ambient conditions at the owner’s premises
and the raw materials that are used. The information provided by the material manufacturer
on the safety data sheet must be adhered to in order to ensure the proper selection of protec-
tive equipment.
The recommended personal protective equipment is described below:
Light respiratory protection
Light respiratory protection is used as protection against hazardous dusts.
Protective gloves
Protective gloves protect hands from friction, abrasion, puncture wounds, or deeper injuries, as
well as from contact with hot surfaces.
Safety goggles
Safety goggles are used to protect the eyes from airborne components and splashes of liquid.
Operating instructions T-Dok-029-GB-Rev.3
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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.
Safety shoes
Safety shoes protect the feet against crushing, falling parts or slipping on slippery ground.
Safety helmet
The helmet protects the head from falling parts and oscillating loads on the one hand, and it can
protect it from injuries in cramped situations on the other.
Automatic spray gun KAA 1300 ENGLISH
Item number: 200-0201 GB–11

3 Safety and responsibility
3.1 Responsibility of the owner
Owner
The owner is the person, who directly operates the machine for commercial or economical pur-
poses or who allows a third-party to use/apply it and who is responsible for the legal product stew-
ardship for the protection of the user, the personnel or third parties.
Owner responsibilities
The machine is used in an industrial environment. The owner of the machine is therefore subject to
the obligations as stipulated by the Occupational Health and Safety Act.
In addition to the safety information in this manual, the country-specific safety, accident prevention
guidelines and environmental protection regulations, applicable at the site of implementation of the
machine must be adhered to.
Furthermore, the owner is responsible for making sure that the machine is always in perfect tech-
nical condition. Therefore, the following applies:
nThe owner must ensure that the maintenance intervals described in this operating manual are
adhered to.
nThe owner must have all safety equipment checked regularly for functionality and complete-
ness.
3.2 Intended use
The KAA 1300 automatic spray gun serves the purpose of automatic (non-manual) coating of sur-
faces like metal, plastic, ceramic, wood, as well as other suitable surfaces.
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
nOperation 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 installation and commissioning in accordance with the steps described in this
operating manual.
nAlways observe the applicable country-specific safety, accident prevention, occupational
safety, and environmental protection regulations etc. 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 media without
first consulting and receiving approval from Krautzberger GmbH.
nAdhere to the spray media manufacturer's safety data sheets.
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.
Operating instructions T-Dok-029-GB-Rev.3
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nOnly operate the automatic spray gun while adhering to the values specified in ( Ä Chapter
13 ‘Technical data’ on page 44).
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.
No claims of any kind can be asserted due to damage resulting from misuse!
3.5 General safety instructions
WARNING!
Life threatening risk of injury or property damage through the application of hazardous
media!
The application of hazardous media can lead to death, serious injuries or property damage.
– Ensure the resistance of the machine against the medium that is to be applied.
– Always adhere to the safety data sheet of the medium that is to be applied.
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.
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.
Automatic spray gun KAA 1300 ENGLISH
Item number: 200-0201 GB–13

Outdoor operation and operation in exterior areas!
Use suitable measures to protect the device during the operation from environmental impacts
in an exterior area through:
–Moisture
–UV radiation
–Frost, etc.
3.6 Residual risks
The 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 may only be operated in a defect-free condition.
nAny faults impacting the safety must be remedied immediately.
3.7 Course of action in an emergency
In principle, the applicable national, regional and internal company regulations concerning the
course of action in case of an emergency must be adhered to and if necessary respective
safety measures must be taken on the system owner's side.
Operating instructions T-Dok-029-GB-Rev.3
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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.
Automatic spray gun KAA 1300 ENGLISH
Item number: 200-0201 GB–15

5 Menu
Fig. 1: Menu
1 Sealing cap
2 Connection of fluid supply
3 Nozzle nut
4 Fluid nozzle
5 Main element
6 Lock screw (connection for circulation
mode)
7 Threaded connection for retaining bolt
8 Connection for control air
9 Retaining bolts
Operating instructions T-Dok-029-GB-Rev.3
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6 Installation
6.1 Safety
Personnel:
nSpecialised personnel
nTrained electrician
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!
Risk of injury due to improper installation!
Improper installation may cause serious personal injury or material damage.
Note:
– Ensure ample of space for the installation prior to starting any work.
– Carefully handle open, sharp-edged components.
– Maintain order and cleanliness at the installation site. Components that are loosely
stacked or are scattered around can cause accidents.
– Assemble components properly. Adhere to specified screw tightening torque.
– Secure components against tipping or falling.
– Ensure that the utilised hose lines meet the requirements for pressure, chemical and
mechanical loads. At the same time, adhere to the spray media manufacturer's specifica-
tions in the safety data sheet.
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.
Automatic spray gun KAA 1300 ENGLISH
Item number: 200-0201 GB–17

CAUTION!
Risk of injury due to sharp edges!
Sharp edges and pointed corners can cause abrasions and cuts on the skin.
Note:
– Proceed cautiously when working on or near sharp edges and pointed corners.
– Wear protective gloves, if in doubt.
6.2 General installation information
Adhere to the following general information for installation:
nOnly carry out installation and commissioning in accordance with the steps described in this
operating manual.
nEnsure that the utilised hose lines fulfil the requirements with respect to pressure, chemical,
and mechanical loads.
nOnly operate the automatic spray gun after proper fastening on a suitable carrier construction.
nAlways guide the hose lines so they cannot be damaged, pinched or rolled over. Avoid exces-
sive tension or bending loads.
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.
nThe pump is designed for the material supply compliance with the values stated in (
Ä Chapter 13 ‘Technical data’ on page 44).
nA shut-off valve should be connected to the pump in order to be able to quickly disrupt the
spray jet in case of a hazardous situation or accident.
nHose fittings and connections must always be secured so that a sudden forceful movement of
the hose ends is prevented in case of an unintended release. If necessary, secure hose ends
with clamps.
Operating instructions T-Dok-029-GB-Rev.3
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6.3 Installing the automatic spray gun
Fig. 2: Installing the automatic spray gun
1. Install and tighten retaining bolts ( Fig. 2/2) to the automatic spray gun using two screws (
Fig. 2/1).
2. Fastener retaining bolts ( Fig. 2/2) to the automatic spray gun using a suitable customer
provided clamping piece, e.g. a cross, flange or joint clamping piece.
3. Ensure proper grounding of the automatic spray gun.
4. Check the tight fit of all threaded connections.
NOTICE!
If the automatic spray gun is not sufficiently fastened, it can come loose during the
operation, e.g. due to vibration impact. Risk of shifting, e.g. due to repulsion. It is pos-
sible without coating material may exit uncontrollably.
Automatic spray gun KAA 1300 ENGLISH
Item number: 200-0201 GB–19

6.4 Connection scheme
Air and material supply
Fig. 3: Air and material supply
St Control 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-029-GB-Rev.3
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