Krautzberger M-10 User manual

■ 200-0142
Translation of the original operating instructions
T-Dok-213-GB-Rev.2
GB Automatic spray gun M -10
Operating instructions

Thank you for selecting a Krautzberger product.
This product has been manufactured following state-of-the-art manufacturing procedures and
extensive quality assurance measures. We promise you a product of the highest quality.
If you have questions, requests or suggestions, please contact us. We are always glad to assist
you.
Information about the operating manual
This manual provides important information on how to work with the device safely and efficiently.
The manual is part of the device 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 Safety and responsibility................................................................................................... 7
2.1 Symbols in this manual................................................................................................ 7
2.2 Personnel requirements............................................................................................... 8
2.3 Personal protective equipment.................................................................................... 9
2.4 Responsibility of the owner........................................................................................ 10
2.5 Intended use.............................................................................................................. 10
2.6 Predictable misuse.................................................................................................... 10
2.7 General safety information......................................................................................... 11
2.8 Residual risks............................................................................................................ 12
2.9 Course of action in an emergency............................................................................. 13
3 Transport and storage..................................................................................................... 14
3.1 Transport................................................................................................................... 14
3.2 Storage of packaged units......................................................................................... 14
3.3 Packaging.................................................................................................................. 14
4 Overview............................................................................................................................ 15
5 Installation......................................................................................................................... 16
5.1 Safety......................................................................................................................... 16
5.2 General installation information................................................................................. 17
5.3 Connection scheme................................................................................................... 17
5.4 Mounting the automatic spray guns........................................................................... 19
5.5 Connecting the automatic spray gun......................................................................... 19
6 Operation........................................................................................................................... 21
6.1 Safety......................................................................................................................... 21
6.2 General information about the start-up...................................................................... 23
6.3 Shutting down............................................................................................................ 23
6.4 Start of operation....................................................................................................... 24
6.5 Adjusting the spray pattern........................................................................................ 24
6.6 Adjusting the needle stroke....................................................................................... 25
7 Maintenance...................................................................................................................... 26
7.1 Safety......................................................................................................................... 26
7.2 Maintenance schedule............................................................................................... 27
7.3 Cleaning..................................................................................................................... 27
7.4 Changing the air and fluid nozzles............................................................................. 29
7.5 Changing the fluid needle.......................................................................................... 29
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7.6 Changing needle seals.............................................................................................. 33
8 Troubleshooting............................................................................................................... 36
8.1 Customer Care.......................................................................................................... 38
9 Spare parts........................................................................................................................ 39
9.1 Spare parts................................................................................................................ 39
10 Accessories...................................................................................................................... 40
11 Disassembly and disposal............................................................................................... 41
11.1 Safety....................................................................................................................... 41
11.2 Disassembly............................................................................................................ 41
11.3 Disposal................................................................................................................... 41
12 Technical data................................................................................................................... 43
12.1 Dimensions and weight............................................................................................ 43
12.2 General specifications............................................................................................. 43
12.3 Dimensions.............................................................................................................. 44
13 Declaration of incorporation........................................................................................... 45
14 Notes.................................................................................................................................. 46
15 Index.................................................................................................................................. 47
Operating instructions T-Dok-213-GB-Rev.2
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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, glazes, enamels, debonding agents, etc.
The spray fluid is fed into the automatic spray gun under pressure. This pressure is typically gener-
ated by pumps or pressure containers. The automatic spray gun is controlled via compressed air.
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.
Upon opening the control, the control piston charged with compressed air first opens the atomizer
air valve and then with a short delay the fluid nozzle of the spray gun. Upon closing the control,
first the fluid nozzle and then the air nozzle is closed in order to prevent a subsequent dripping of
the spray fluid.
The spray fluid is atomised using compressed air. The geometry of the spray jet and the sprayed
quantity of the spray fluid can be adjusted with the following measures:
nSelection of the air and fluid nozzle
nChanging of the atomisation air pressure
nChanging of the spray fluid pressure
nAdjustment of the needle stroke on the regulator of the automatic spray gun
The automatic spray gun consists of the following materials:
Component Material
Head section Stainless steel or anodised aluminium
Control section Aluminium anodised
Main element
Needle Stainless steel
Nozzle
Seals Various plastics
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1.2 Identification
Scope of delivery Model Product number
nM -10 200-0142
Operating instructions T-Dok-213
* HVLP = High Volume, Low Pressure
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-213-GB-Rev.2
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2 Safety and responsibility
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 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
Operating instructions T-Dok-213-GB-Rev.2
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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.
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.
2.3 Personal protective equipment
Personal protective equipment is used to protect persons from impacts on their occupational 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 coating material that is used. To
ensure the proper selection of personal protective 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:
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Protective equipment:
nProtective clothing
nEar protection
nLight respiratory protection
nSafety goggles
nProtective gloves
nSafety shoes
nSafety helmet
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.
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 spray gun serves 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.
The intended use also includes the compliance with all the information in this manual.
2.6 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 these
operating instructions.
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 media without
first consulting with and receiving approval from Krautzberger GmbH.
Operating instructions T-Dok-213-GB-Rev.2
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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 design.
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
12 ‘Technical data’ on page 43).
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!
2.7 General safety information
WARNING!
Life threatening risk of injury or property damage through the application of hazardous
media!
The application of hazardous media can lead to death, serious injuries or property damage.
– Ensure the resistance of the machine against the medium that is to be applied.
– Always adhere to the safety data sheet of the medium that is to be applied.
WARNING!
Risk of injury through the use of incorrect spare parts!
The use of incorrect or defective spare parts can cause risks for the personnel as well as
damage, malfunctions or complete failure.
– Only use original spare parts from Krautzberger or spare parts that have been approved
by Krautzberger.
– In case of questions, always contact our service department.
CAUTION!
Risk of injury through compressed air!
Uncontrolled leaks of compressed air can lead to serious injuries!
– Prior to any work on the device, all compressed-air lines must be closed and bleed if nec-
essary.
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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.
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.
2.8 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.
Operating instructions T-Dok-213-GB-Rev.2
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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.
2.9 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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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 spray gun is packaged in accordance with the anticipated transport conditions and the pack-
aging needs to protect it against transport damage, corrosion, and other damage.
nRemove packaging material.
nRemove potentially present transport safety restraints.
Operating instructions T-Dok-213-GB-Rev.2
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4 Overview
Fig. 1: Overview
1 Air nozzle
2 Knurl nut
3 Flat jet control "F"
4 Round jet control "R"
5 Control section
6 Needle stroke adjustment screw
7 Connection of control air "St"
8 Connection of atomisation air "Z"
9 Installation screw
10 Installation drill hole for retaining bolts
11 Connection of fluid supply "M"
The connections are marked with letter abbreviations.
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5 Installation
5.1 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.
Operating instructions T-Dok-213-GB-Rev.2
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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.
5.2 General installation information
Adhere to the following general information for the installation:
nOnly carry out the installation and start of operation according to the steps described in this
operating manual.
nMake sure that the utilised hose lines meet the requirements for pressure, chemical and
mechanical loads.
nOnly operate the automatic spray gun after proper fastening on a suitable carrier design.
nMake sure that the connected compressed air is oil-free and free of solid matter.
nOperate the automatic spray gun with processed, dried compressed air (air quality pursuant to
DIN ISO 8573-1: grade 4).
nVibration and recoil forces may occur on the automatic spray gun during operation. Ensure
sufficient fastening.
nNever point the compressed air at living beings.
5.3 Connection scheme
The connection diagram shown here must be seen as an example. Other connection options are
possible depending on the installation situation or the configuration of the automatic spray gun.
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Fig. 2: Connection scheme
Z Atomisation air
St Control air
DV Pressure controller
O/S (E) 3/2 control valve
DE Pressure generator
M Material
RR Back pressure regulators
RW Agitator unit
F Filter
H Ball cock
Operating instructions T-Dok-213-GB-Rev.2
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5.4 Mounting the automatic spray guns
Changing the installation position of the spray gun
The automatic spray gun can be mounted on both sides on the retaining bolts in order to
change the installation position.
Fig. 3: Mounting the automatic spray guns
1. Slide the automatic spray gun ( Fig. 3/1) with the respectively designed drill hole over the
retaining bolt ( Fig. 3/3).
2. Fix retaining bolt with installation screws ( Fig. 3/2).
3. Ensure proper earth connection of the automatic spray gun.
5.5 Connecting the automatic spray gun
See also ( Ä Chapter 5.3 ‘Connection scheme’ on page 17).
WARNING!
Danger of injury due to improper connection!
When the fluid supply is pressurised, e.g. from pressure containers or with pumps, the range
of the fluid jet can increase by a multiple in case of atomisation air failure. This presents a
hazard to people and property.
– Make sure that the fluid supply and the control air are interrupted if the atomisation air
pressure drops off quickly.
– It is recommended to regulate the atomisation air pressure via a filter pressure reducer.
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The connections for control and atomisation 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 atomisation air to input "Z" ( Fig. 4/2).
3. Connect the fluid line to ( Fig. 4/3).
Operating instructions T-Dok-213-GB-Rev.2
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