Krautzberger RA 5 User manual

200-0319 ■ 200-0321 ■ 200-0323 ■ 200-0324
Translation of the original operating instructions
T-Dok-449-GB-Rev.4
GB Automatic spray gun RA 5
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, must always be kept in the device's direct proximity and should
be available 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 this.
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 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 current valid directives.
[email protected], www.krautzberger.com
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 Labelling of the safety information............................................................................... 7
2.2 Safety information in operating instructions................................................................. 8
2.3 Personnel requirements............................................................................................... 8
2.4 Personal safety equipment and clothing...................................................................... 9
2.5 Responsibility of the system owner........................................................................... 10
2.6 Intended use.............................................................................................................. 11
2.7 General safety information......................................................................................... 12
2.8 Course of action in a hazardous situation.................................................................. 13
3 Transport and storage..................................................................................................... 15
3.1 Transport................................................................................................................... 15
3.2 Storage of packaged units......................................................................................... 15
3.3 Unpacking.................................................................................................................. 15
4 Overview............................................................................................................................ 16
5 Installation......................................................................................................................... 17
5.1 General installation information................................................................................. 17
5.2 Dimensions................................................................................................................ 17
5.3 Mounting the automatic spray guns........................................................................... 18
5.4 Changing the main elements..................................................................................... 19
5.5 Nozzle fixing (optional).............................................................................................. 20
5.6 Connecting the automatic spray gun......................................................................... 21
5.7 Connection scheme................................................................................................... 23
5.8 Preliminary air control................................................................................................ 23
6 Start-up.............................................................................................................................. 25
6.1 General Information about the commissioning.......................................................... 25
6.2 Start-up...................................................................................................................... 26
6.3 Adjusting the spray pattern........................................................................................ 26
6.4 Adjusting the needle stroke....................................................................................... 27
6.5 Operation breaks....................................................................................................... 27
7 Maintenance...................................................................................................................... 28
7.1 Maintenance schedule............................................................................................... 28
7.2 Cleaning..................................................................................................................... 29
7.3 Changing the air and fluid nozzles............................................................................. 30
7.4 Changing the fluid needle.......................................................................................... 31
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7.5 Changing needle seals.............................................................................................. 33
8 Faults................................................................................................................................. 34
9 Spare parts........................................................................................................................ 36
9.1 Spare parts................................................................................................................ 37
10 Accessories...................................................................................................................... 42
11 Disposal............................................................................................................................. 43
12 Technical data................................................................................................................... 44
12.1 Dimensions and weight............................................................................................ 44
12.2 General specifications............................................................................................. 44
12.3 Tightening torques................................................................................................... 44
13 Declaration of incorporation........................................................................................... 45
14 Index.................................................................................................................................. 46
Operating instructions T-Dok-449-GB-Rev.4
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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.
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
Optional equipment:
Automatic spray gun:
nMain element (stainless steel or aluminium, chemically nickel-plated, PTFE-coated)
nNeedle stroke setting
nCirculation connection
nDouble controller (interruption of the fluid feed through spring force or pneumatically)
nNozzle fixing (
Ä Chapter 5.5 ‘Nozzle fixing (optional)’ on page 20)
Adapter:
nConnections: From below or behind (the connections can be made using nipples, screw-type
or plug connectors of different sizes)
nFastening: Clamp or screw-type fastening of the adapter
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Fig. 1: Adapter variants
Pos. Description
1 Connections from behind, clamp fastening of the automatic spray gun
2 Connections from below, clamp fastening of the automatic spray gun
3 Connections from behind, screw-type fastening of the automatic spray gun
4 Connections from below, screw-type fastening of the automatic spray gun
1.2 Identification
Type Design Weight alumi-
nium / stainless
steel
Product number
RA 5 With adapter and conventional nozzle
system
0.55 kg / 0.97 kg 200-0319
RA 5 Without adapter and with conven-
tional nozzle system
0.55 kg / 0.97 kg 200-0321
RA 5 with adapter and HVLP nozzle system
*
0.55 kg / 0.97 kg 200-0323
RA 5 without adapter and with HVLP nozzle
system *
0.55 kg / 0.97 kg 200-0324
* HVLP = High Volume, Low Pressure
Additional information can be found in (
Ä Chapter 12 ‘Technical data’ on page 44)
Operating instructions T-Dok-449-GB-Rev.4
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2 Safety and responsibility
2.1 Labelling of the safety information
This manual uses symbols to identify safety information. The safety information is preceded by
signal words that indicate the severity of the hazard.
DANGER!
This combination of symbol and signal word indicates an immediate dangerous situation,
which will cause death or severe injuries if it is not averted.
WARNING!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause death or severe injuries if it is not averted.
CAUTION!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause slight injuries if it is not averted.
NOTICE!
This combination of symbol and signal word indicates a possibly dangerous situation which
can cause property and environmental damage if it is not averted.
This symbol highlights useful tips and recommendations as well as information for efficient
and fault-free operation.
ENVIRONMENT!
This combination of symbol and signal word indicates potential hazards for the environment.
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2.2 Safety information in operating instructions
Safety information can refer to specific individual operating instructions. Such safety information is
embedded in the operating instructions so that they don't disrupt the reading flow during the execu-
tion of the action. The signal words described above are used.
Example:
1. Loosen screw.
2.
CAUTION!
Pinching hazard at the cover!
Carefully close cover.
3. Tighten screw.
2.3 Personnel requirements
WARNING!
Risk of injury in case of insufficient qualification of the personnel!
The owner of the system/device is responsible for adhering to the qualifications.
If unqualified personnel carries out work on the device or steps into the danger zone of the
device, hazards arise which may cause severe injuries and significant material damage.
– All work must only be carried out by respectively qualified personnel.
– Unqualified personnel must be kept away from the hazard areas.
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.
Only persons who can be expected to perform their tasks reliably are permitted as personnel. Per-
sons whose reaction capability is impaired, e.g. through drugs, alcohol or medication are not per-
mitted.
When selecting the personnel, the stipulations regarding age and occupation that apply at the site
of implementation must be observed.
Operating instructions T-Dok-449-GB-Rev.4
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Unauthorized persons
WARNING!
Risk of fatal injury for unauthorized person through hazards in the hazard zone and
work area!
Unauthorized persons, who do not fulfil the requirements described herein do not know the
dangers in the work area. Unauthorized persons are therefore subject to a risk of serious
injury including death.
– Keep unauthorized persons away from hazard zone and work area.
– If in doubt, address persons and tell them to leave the hazard zone and work area.
– Discontinue the work as long as unauthorized persons are present in the hazard zone
and the work area.
2.4 Personal safety equipment and clothing
Personal safety equipment is used to protect persons from impacts on safety and health at work.
The personnel must wear personal safety equipment while carrying out the various tasks and while
working with the device. The individual sections of this manual will indicate the personal safety
equipment separately.
Description of the personal safety equipment and clothing
The personal safety equipment and clothing is described below:
Ear protection
Ear protection provides protection against hearing damage.
Light respiratory protection
The light respiratory protection is used as a protection against hazardous dusts.
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Protective gloves
Protective gloves protect hands from friction, abrasion, puncture wounds, or deeper injuries, as
well as from contact with hot surfaces.
Safety goggles
Safety goggles are used to protect the eyes from flying components and splashes of liquid.
2.5 Responsibility of the system owner
System owner
The operator 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.
System owner responsibilities
The machine is used in an industrial environment. The operator 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.
The following shall apply in particular:
nThe operator must familiarise himself with the applicable occupational safety regulations and
also conduct a risk assessment to determine additional risks that may arise due to the specific
working conditions at the place of use of the machine. These must be implemented in the
form of operating instructions for the operation of the machine.
nDuring the entire operating time of the machine, the operator must check whether the oper-
ating instructions that were established by the operator correspond with the respective current
applicable rules and standards and must adjust them if necessary.
nThe system owner must clearly regulate and specify the responsibilities for installation, opera-
tion, repair of malfunctions, maintenance, and cleaning.
nThe operator must ensure that all persons who work with the machine have read and under-
stood these instructions. In addition, the system owner must train personnel at regular inter-
vals and inform the personnel of the hazards.
nThe system owner must provide the personnel with the necessary protective gear and make
the wearing of the necessary protective gear mandatory.
Operating instructions T-Dok-449-GB-Rev.4
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Furthermore, the system owner is responsible for making sure that the machine is always in per-
fect technical condition. Therefore, the following applies:
nThe system owner must ensure that the maintenance intervals described in this operating
manual are adhered to.
nThe system owner must have all safety equipment checked regularly for functionality and
completeness.
2.6 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.
Intended use also includes adherence to all the specifications in this manual.
Any use beyond the intended use or any other use constitutes improper use.
WARNING!
Danger due to improper use!
Improper use of the automatic spray gun can cause dangerous situations.
– Only carry out the installation and start of operations according to the steps described in
this operating manual.
– Always observe the applicable country-specific safety, accident prevention, occupational
safety, and environmental protection regulations for the area of use for the automatic
spray gun.
– Make sure that the utilised hose lines fulfil the requirements with respect to pressure,
chemical and mechanical loads.
– Do not use sharply abrasive, chemically aggressive, very hot or very cold spray media
without first consulting with and receiving approval from Krautzberger GmbH.
– Adhere to the spray media manufacturer's safety data sheets.
– Only use the manufacturer's original spare parts.
– Only operate the automatic spray gun after proper fastening on a suitable carrier con-
struction.
– Do not hold the automatic spray gun in your hand during operation.
– Only operate the automatic spray gun while adhering to the values specified in the (
Ä Chapter 12 ‘Technical data’ on page 44).
– Make sure that the connected compressed air is oil-free and free of solid matter.
– Operate the automatic spray gun with processed, dried compressed air (air quality pur-
suant to DIN ISO 8573-1: grade 4).
– Never point the compressed air at living beings.
No claims of any type can be asserted due to damage resulting from improper use.
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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.
WARNING!
Sound pressure level
Depending on the operating conditions, the sound pressure of the device may cause hearing
damage.
Take suitable action to reduce the impact of the existing sound pressure level. The owner is
responsible for the type and implementation of suitable measures, which may depend on the
local conditions.
Operating instructions T-Dok-449-GB-Rev.4
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NOTICE!
Property damage due to incorrect installation
Incorrect installation can lead to property damage.
– Check all lines and machines for a tight seat prior to commissioning.
Outdoor operation and operation in exterior areas!
Use suitable measures to protect the device during the operation from environmental impacts
in an exterior area through:
–Moisture
–UV radiation
–Frost, etc.
ENVIRONMENT!
Environmental hazard due to incorrect disposal!
Incorrect disposal may cause environmental hazards.
– After the useful life of the device has been exhausted, dispose of it via the commercial
waste.
– Properly dispose of potential spray fluid residue separately from the device.
– If in doubt, obtain information about environmentally-appropriate disposal with the local
municipalities or specialized disposal companies.
2.8 Course of action in a hazardous situation
In principle, the country-specific and regional 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 side.
The following scenarios constitute an emergency:
nHuman life is at risk.
nThe machine or the work piece are being damaged.
In these cases, the emergency stop system of the machine must be activated immediately and
countermeasures must be initiated if necessary.
The following safety equipment must be available in the immediate proximity:
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nEmergency escape route plan
nFirst aid box
nFire extinguishing blanket or a fire extinguisher suitable for the local conditions
nSafety equipment and clothing
nEye rinsing water
nRunning water
The persons working on the machine must be informed about the escape routes, the protective
equipment and the fire fighting equipment.
Course of action in case of an accident
The following measures must be initiated in case of an accident:
nImmediate measures must be taken at the accident site
– Stay calm - do not panic
nReport the accident
The following information must be provided when reporting an accident:
– Who is the caller
– Type of accident
– Location of the accident
– Circumstances leading to the accident
– Type of injury
– Number of injured
– Waiting for clarifying questions
nAdminister first aid
Course of action in case of fire
The following measures must be initiated in case of a fire:
nTake immediate measures
– Stay calm - do not panic
nReport fire
The following information must be provided when reporting a fire:
– Who is the caller
– What is burning
– Where is the fire
– Type of injury
– Number of injured
– Waiting for clarifying questions
nAdminister first aid
nFight fire
WARNING!
Only fight the fire if this is possible without being subject to danger.
Operating instructions T-Dok-449-GB-Rev.4
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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.
nDry and dust-free storage.
nKeep away from any aggressive media.
nProtect from UV radiation.
nAvoid mechanical shocks.
nStorage temperature: 15 to 35 °C.
nRelative atmospheric humidity: max. 60%.
nFor storage for longer than 3 months, check the general condition of all parts and the pack-
aging on a regular basis. If necessary, refresh or renew the conservation.
It is possible that there are notes on the packaged units concerning the storage that extend
beyond the requirements listed here. Follow those accordingly.
3.3 Unpacking
Transport inspection
Immediately upon receipt check the delivery for completeness and damage from transport.
In the event of visible exterior transport damage, proceed as follows:
nDo not accept delivery or only do so with reservations.
nRecord scope of damage on the transport documents or on the bill of delivery of the shipping
company.
nInitiate complaint.
Report any damage as soon as it has been detected. Damage claims can only be asserted
within the applicable complaint period.
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4 Overview
Fig. 2: Overview
1 Needle stroke setting *
2 Main element
3 Clamping nut
4 Air nozzle
5 Lever for adapter plug connector *
6 Adapter
7 Retaining bolt *
F Connection of flat jet
M↑Connection of fluid supply (input "M")
M↓Connection of fluid circulation line
(output "M") *
R Connection of round jet
ST A Connection of control air "OPEN"
ST Z Connection of control air "CLOSED"
(optional)
The connections are marked with letter abbreviations.
* Optional / dependent on configuration
** not illustrated
Operating instructions T-Dok-449-GB-Rev.4
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5 Installation
Personnel:
nQualified personnel
Protective equipment:
nProtective gloves
5.1 General installation information
Adhere to the following general information for the installation:
nOnly carry out the installation and start of operations 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.
5.2 Dimensions
Fig. 3: Dimensions
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5.3 Mounting the automatic spray guns
Changing the installation position of the spray gun
To change the installation position of the spray gun, the retaining bolt ( Fig. 4/2) can be
screwed into the adapter ( Fig. 4/1) from the other side (tightening torque: see Ä Chapter 12
‘Technical data’ on page 44).
Fig. 4: Mounting the automatic spray guns
1. Fasten the adapter ( Fig. 4/1) with the retaining bolts ( Fig. 4/2) to a suitable construction.
2. The main element is either plugged in (
Ä Chapter 5.4.1 ‘Plugged-in design’ on page 19) or
screwed on (
Ä Chapter 5.4.2 ‘Screw-type design’ on page 20) depending on the design.
Operating instructions T-Dok-449-GB-Rev.4
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5.4 Changing the main elements
5.4.1 Plugged-in design
Removing the main elements
Fig. 5: Removing the main elements
1. Turn the lever ( Fig. 5/3) to the unlocking position.
The unlocking and locking positions are indicated by the symbols and .
2. Press the lever ( Fig. 5/3) in and pull the main element ( Fig. 5/1) off the adapter ( Fig. 5/4).
Mounting the main elements
1. Turn the lever ( Fig. 5/3) to the unlocking position.
2. Insert the main element ( Fig. 5/1) with the clamp bolts ( Fig. 5/2) into the adapter ( Fig. 5/4)
and let them snap in.
3. Turn the lever ( Fig. 5/3) to the locking position.
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5.4.2 Screw-type design
Removing the main elements
Fig. 6: Removing the main elements
1. Loosen the screw ( Fig. 63).
2. Remove the main element ( Fig. 6/1) from the adapter ( Fig. 6/2).
Mounting the main elements
1. Push the main element ( Fig. 6/1) onto the adapter ( Fig. 6/2).
2. Screw on the main element ( Fig. 6/1) and adapter ( Fig. 6/2) with the screw ( Fig. 6/3)
(tightening torque: see
Ä Chapter 12 ‘Technical data’ on page 44).
5.5 Nozzle fixing (optional)
Flat jet nozzles can be adjusted to adapt to the workpiece geometry either steplessly or in 45°
increments.
Fig. 7: Nozzle fixing
Operating instructions T-Dok-449-GB-Rev.4
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