Krautzberger MA-1 User manual

T-Dok-015-GB-Rev.0
GB Mini spray gun MA-1
Operating instructions
■ 200-0345
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 Symbols in this manual................................................................................................ 7
2.2 Personnel requirements............................................................................................... 8
2.3 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 Overview............................................................................................................................ 16
6 Installation......................................................................................................................... 17
6.1 Safety......................................................................................................................... 17
6.2 General installation information................................................................................. 18
6.3 Installing the mini spray gun...................................................................................... 19
6.4 Connecting mini spray gun........................................................................................ 19
6.5 Preliminary air control................................................................................................ 21
6.6 Connection scheme................................................................................................... 21
7 Operation........................................................................................................................... 23
7.1 Safety......................................................................................................................... 23
7.2 General information about start-up / commissioning................................................. 24
7.3 Shutting down............................................................................................................ 25
7.4 Start-up...................................................................................................................... 25
7.5 Adjusting the spray pattern........................................................................................ 25
7.6 Adjusting the needle stroke....................................................................................... 26
8 Maintenance...................................................................................................................... 27
8.1 Safety......................................................................................................................... 27
8.2 Maintenance schedule............................................................................................... 28
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8.3 Cleaning..................................................................................................................... 28
8.4 Changing the material nozzle and the air nozzle....................................................... 29
8.5 Changing the material needle.................................................................................... 30
8.6 Changing the needle seals........................................................................................ 32
9 Troubleshooting............................................................................................................... 34
9.1 Customer Care.......................................................................................................... 35
10 Spare parts........................................................................................................................ 36
11 Accessories...................................................................................................................... 37
12 Disassembly and disposal............................................................................................... 38
12.1 Safety....................................................................................................................... 38
12.2 Disassembly............................................................................................................ 38
12.3 Disposal................................................................................................................... 38
13 Technical data................................................................................................................... 39
13.1 Dimensions and weight............................................................................................ 39
13.2 General specifications............................................................................................. 39
13.3 Dimensions.............................................................................................................. 40
14 Declaration of incorporation........................................................................................... 41
15 Notes.................................................................................................................................. 42
16 Index.................................................................................................................................. 43
Operating instructions T-Dok-015-GB-Rev.0
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1 Function and identification
1.1 Function
The mini spray gun MA-1 is used for:
nautomatic coating/marking of surfaces
ndosing of fluids
nplacement of adhesive or marking points
Typical spray fluids are paints, dyes, adhesives, glazes, enamels, release agents, etc.
The spray fluid is fed into the mini spray gun under pressure. This pressure is typically generated
by pumps or pressure containers. The mini spray gun is controlled via compressed air.
For the precise control of the automatic spray gun, for example electrically-activated solenoid
valves can be used. 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 material nozzle of the mini spray gun. Upon closing the
control, first the material nozzle and then the atomizer air valve is closed in order to prevent a sub-
sequent dripping of the spray fluid.
The spray medium is atomized using compressed air. The geometry of the spray jet and the
sprayed quantity of the spray medium can be adjusted with the following measures:
nSelection of air and material nozzle
nChanging of atomizer air pressure
nChanging of spray medium pressure
nAdjustment of the needle stroke on the regulator of the mini spray gun (optional design)
All parts in contact with the coating material are made of stainless steel, the needle seals are made
of UHMW-PE or PTFE.
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1.2 Identification
Scope of delivery Type Product number
nMA-1 with cover 200-0345
nMA-1 with needle stroke adjustment 200-0345
Operating manual T-Dok-015
Serial number
The serial number of the mini spray gun is located on the main element. It serves as a unique iden-
tifier.
Operating instructions T-Dok-015-GB-Rev.0
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2 Using this operating manual
2.1 Symbols in this manual
Safety instructions
This manual uses symbols to identify safety instructions. The safety instructions are preceded by
signal words that indicate the severity of the hazard.
DANGER!
This combination of symbol and signal word indicates an immediate dangerous situation,
which will cause death or severe injuries if it is not averted.
WARNING!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause death or severe injuries if it is not averted.
CAUTION!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause slight injuries if it is not averted.
NOTICE!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause property and environmental damage if it is not averted.
ENVIRONMENT!
This combination of symbol and signal word indicates potential dangers to the environment.
Tips and recommendations
This symbol highlights useful tips and recommendations as well as information for efficient
and trouble-free operation.
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Example for safety instructions in operating instructions
Safety instructions can refer to specific, individual operating instructions. Such safety instructions
are embedded in the operating instructions so that they do not disrupt the reading flow during the
execution of the action. The signal words described above are used.
1. Unfasten screw.
2.
CAUTION!
Pinching hazard at the lid!
Carefully close lid.
3. Tighten screw.
Special safety instructions
The following symbols are used in safety instructions to draw the attention to specific hazards:
Warning signs Type of danger
Warning – 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
[Pushbutton] Operating elements (e.g. pushbuttons, switches), display ele-
ments (e.g. signal lights)
‘Display’ Screen elements (e.g. pushbuttons, assignment of function keys)
2.2 Personnel requirements
Operating instructions T-Dok-015-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.
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 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
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Protective work clothing are tight fitting work clothes with low tear resistance, with tight sleeves,
and without any protruding parts.
Ear protection
Ear protection provides protection against hearing damage.
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.
Operating instructions T-Dok-015-GB-Rev.0
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Safety shoes
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.
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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 mini spray gun is used to spray different media. The nozzle size depends on the spray vis-
cosity of the spray medium.
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 mini spray gun must be assembled to form a complete machine.
nOnly operate the mini 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 mini 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.
nAdhere to the spray media manufacturer's safety data sheets.
nOnly use the manufacturer's OEM parts.
nOnly operate the mini spray gun after proper fastening on a suitable carrier construction.
nDo not hold the mini spray gun in your hand during operation.
Operating instructions T-Dok-015-GB-Rev.0
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nOnly operate the mini spray gun in compliance with the values specified in ( Ä Chapter 13
‘Technical data’ on page 39).
nMake sure that the connected compressed air is oil-free and free from solid matter.
nOperate the mini 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.
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.
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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
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.
Operating instructions T-Dok-015-GB-Rev.0
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4 Transport, storage, and packaging
4.1 Transport
nThe mini spray gun is protected by cardboard packaging.
nThe cardboard packaging can be reused for storage.
4.2 Storage
Store the mini spray gun under the following conditions:
nStore 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 mini spray gun is packaged in accordance with the anticipated transport conditions and the
packaging needs to protect it against transport damage, corrosion, and other damage.
nRemove packaging material.
nRemove potentially present transport safety restraints.
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5 Overview
Fig. 1: Overview
1 Connection for flat jet air "F"
2 Connection for material supply "M"
3 Connection for round jet air "R"
4 Connection for control air "St"
5 Cover, or optional needle stroke adjustment
6 Main element
7 Air nozzle
8 Installation drill hole for retaining bolts
The connections are marked with letter abbreviations.
Operating instructions T-Dok-015-GB-Rev.0
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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.
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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.
6.2 General installation information
Adhere to the following general information for the 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 mini spray gun after proper fastening on a suitable carrier construction.
nMake sure that the connected compressed air is oil-free and free from solid matter.
nOperate the mini 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 mini spray gun during operation. Ensure suffi-
cient fastening.
nNever point the compressed air at living beings.
Operating instructions T-Dok-015-GB-Rev.0
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6.3 Installing the mini spray gun
Changing the installation position of the mini spray gun
The mini spray gun can be mounted on one side on the retaining bolts in order to change the
installation position.
Fig. 2: Installing the mini spray gun
1. Position the enclosed retaining bolt ( Fig. 2/3) with the flattened end along the mini spray
gun ( Fig. 2/1) and fixate through the opening ( Fig. 2/2) with suitable screws.
2. Ensure proper earth connection of the mini spray gun.
6.4 Connecting mini spray gun
WARNING!
Danger of injury due to improper connection!
When the material supply is pressurised, e.g. from pressure containers or with pumps, the
range of the material jet can increase by a multiple in case of atomizer air failure. This
presents a hazard to people and property.
– Make sure that the material supply is interrupted if the atomizer air pressure drops off
quickly.
– It is recommended to regulate the atomizer air pressure via a filter pressure reducer.
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The connections for material input, control air and flat jet air as well as round jet air are
marked with letter abbreviations.
Fig. 3: Connecting mini spray gun
1. Connect the material line to connection "M" ( Fig. 3/1).
2. Connect the control air to connection "St" ( Fig. 3/2).
3. Connect the round jet air to connection "R" ( Fig. 3/3).
4. Connect the flat jet air to connection "F" ( Fig. 3/4).
Operating instructions T-Dok-015-GB-Rev.0
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