REITER AGR-08-E User manual

REITER GmbH + Co. KG
Oberächentechnik Phone: [phone] / 185 - 0
Berglenstraße 23 - 25 Fax: [phone] / 185 - 30
D-71364 Winnenden Internet: www.reiter-oft.de
Operating Manual
Automatic spray gun AGR-08-E
for electrostatic atomization for
solventborne paint
Product No.: S-AGR08E-GB (Translation)
Issue: 05/15 - 3

S-AGR08-EgbDB 05/15 - 3
Contents of the Operating Manual
Chapter 1 General
Chapter 2 Safety Regulations
Chapter 3 Technical Data
Chapter 4 Transport (not assigned)
Chapter 5 Function Description (not assigned)
Chapter 6 Installation (not assigned)
Chapter 7 Commissioning and Operation
Chapter 8 Maintenance
Chapter 9 Spare Parts
Chapter 10 Appendix (not assigned)

S-AGR08-Egb01 05/15 - 3 Page 1 of 2
1 General
1.1 About this instruction manual
 • ThisinstructionmanualonlyappliestheelectrostaticautomaticgunAGR-08-Eintheprocess-
ingofsolvent-basedpaints.
 • Theinformationcontainedinthismanualareonlyintendedtolearnaboutthecomponentsand
theiruseintypicaloperatingconditions.Thisisnotaguidetocommissioning,aseachsystem
isdesigneddifferently.TostartthetrainingbyauthorizedpersonnelfromREITERGmbH+Co.
KGsurfacetechnologyisessential.
 • Thismanualprovidesinformationfortheoperation,maintenanceandcareofthiselectrostatic
devicefromREITERGmbH+Co.KGOberächentechnikinatypicalsystemconguration.
Thevaluesandproceduresgivenhereinaretoberegardedasstandardandmayvaryslightly
fromthedifferentinstallations.
 • Forabetterunderstandingofthisproductandtoachieveanoptimal,error-freeoperationover
alongperiod,theinstructionsmustbereadcarefully.
 • Thespeciedtestsandchecksshouldbecarriedoutatatroubleshootingsectionbeforea
servicetechnicianisrequired.Inanycase,withsucharequirement,apersonshouldbein
charge,whoisfamiliarwiththedeviceandholdstheoperatinginstructions.
 • Forthevariousadaptersandaccessoriesseparatemanualsareavailable.
1.2 Automatic gun AGR-08-E
TheautomaticgunAGR-08-Eisanairatomizingelectrostaticautomaticpistol.Theguncanbea
setscrewinthemachineadapterremovedquicklyfromsame.
Themachineadapterreceivesallmaterial,air,andpowerlines.
AGR-08-Eissuitableforuseonindustrialrobots,automaticmachines(reciprocators)orsupports.
TheAGR-08-Eautomaticsprayguncreatesavoltageofupto85kVattheatomisingpointforthe
coatingmaterial.Theparticleschargedherearetransportedtotheworkpiecebycompressedair,
wheretheyareelectrostaticallyattractedandheld.Theelectrostaticeldbetweenthechargedpar-
ticlesandtheearthedworkpiecealsoenablesahighproportionoftheoverspraytoreachthesides
andbackoftheworkpiecebeingcoated.Thisguaranteesthatahighpercentageoftheatomised
sprayisdepositedontheworkpiece.
Thegunsinthisseriesaresuitableforcoatings,solvent-orwater-based.
Table of Contents
1.1 Aboutthisinstructionmanual.............................................................................................1
1.2 AutomaticgunAGR-08-E...................................................................................................1
1.3 Components.......................................................................................................................2
1.4 Guarantee..........................................................................................................................2
1.5 Copyright............................................................................................................................2

S-AGR08-Egb01 05/15 - 3 Page 2 of 2
1 General
Thismanualonlydealswiththedangersoftheuseofsolvent-based
paints.Whenprocessingwater dilutablecoatingsusethecorre-
spondingoperatinginstructions.
TheautomaticspraygunAGR-08-Eassuchandalsothelatterto-
getherwithitshighvoltagegeneratorandcablemustbeseenonlyas
componentsofasystem–theydonotassuchconstituteafunctional
systemoverall.Nodeclarationofconformityisthereforeapplicable,
onlyadeclarationofincorporation.Afunctionalsystemiscreatedonly
incombinationwithfurtherequipment(airsupply/exhaustairsystem,
materialshandlingetc.).
1.3 Components
ThesystemAGR-08-EconsistsofagunAGR-08-E,themachineadapter,thehighvoltagecable,
thehighvoltagegenerator(REMOHSEHE-30-100k-100),thecontrolboard(SMI-1230-30-320m
(DC))aswellasthehigh-voltagedistributor(HVE06/01).
1.4 Guarantee
Therefore,itisrecommendedtoreadthisoperatingmanualcarefullybeforestart-up,aswecan-
notbeheldliablefordamageormalfunctionsresultingfromthenon-observanceofthisoperating
manual.
Duringtheguaranteeperiodrepairworkandchangesonlymaybecarriedoutbyourassemblers
orwithourconsent.
Thesystemisdesignedonlyfortheuseaccordingtotheoperatingareadescribedinchapter2
„OperatingArea“.
AnyotheruseisconsideredimproperandREITERcannotbeheldliableforanypossibledamage.
1.5 Copyright
ThecopyrightforthisoperatingmanualisretainedbyREITERGmbH+Co.KGOberächentech-
nik.Thisoperatingmanualisintendedforpersonnelinvolvedininstallation,operationandsupervi-
sion.Theoperatingmanualincluderegulationsandtechnicaldrawingswhichmaynotbecopied,
distributed,usedforcommercialpurposeorgiventoothers,eitherinfullorinpart.
REITER GmbH + Co. KG
Oberächentechnik Phone: +49(0)7195/185-0
Berglenstraße23-25 Fax: +49(0)7195/185-30
D-71364Winnenden Email: [email protected]
Attention!

S-AGR08-Egb02 05/15 - 3 Page 1 of 10
2 Safety Regulations
Table of Contents
2.1 Explanation of symbols and special directions ..................................................................2
2.1.1 Symbol of working safety...................................................................................................2
2.1.2 Directions for “Attention“ ....................................................................................................2
2.2 Operating area...................................................................................................................2
2.3 Electrostatic automatic spray gun......................................................................................3
2.3.1 Forced ventilation...............................................................................................................4
2.4 General demands for safe operation .................................................................................4
2.5 Instruction ..........................................................................................................................4
2.6 Use of electrostatic spraying systems in potentially explosive areas ................................4
2.7 Work stations .....................................................................................................................5
2.8 Interior coating of hollowware ............................................................................................5
2.9 Cleaning.............................................................................................................................5
2.10 Prerequisites to accessing spray booths ...........................................................................5
2.11 Personal protective gear....................................................................................................6
2.12 Working with ignition risk ...................................................................................................6
2.13 Explosion protection document..........................................................................................7
2.13.1 Directives ...........................................................................................................................7
2.13.2 Explosion hazardous areas................................................................................................7
2.13.3 Checks...............................................................................................................................9
2.14 Normative references.......................................................................................................10
2.14.1 Demands of design and quality for facilities used for electrostatic coating......................10

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2 Safety Regulations
2.1 Explanation of symbols and special directions
2.1.1 Symbol of working safety
This symbol accompanies all special directions for working safety
given in this operating manual. Non-observance of this passages
marked with this symbol may endanger life and limbs. Observe these
directions and take special care in the cases described. Ensure all
other operators are informed of these special directions. In addition
to the special directions given in this operating manual, the generally
valid regulations for safety and prevention of accidents have also to be
observed.
2.1.2 Directions for “Attention“
This warning is shown at points where special attention needs to be
given in order that guidelines, regulations, special directions, and
proper work procedures are observed and to prevent damage or de-
struction of the machine and/or other parts of the plant.
2.2 Operating area
This equipment can be dangerous if it is not operated in accord-
ance with the instructions of this manual!
The electrostatic gun AGR-08-E, hereinafter called device, is designed and built for the use in a
stationary electrostatic application equipment designed for ammable liquid coating materials.
The apparatus may only be used in an explosive atmosphere if this is created by the spray cloud of
the applied coating material itself.
Applied standards:
• EN 12215:2005
Coating plants – Spray booths for application of organic liquid coating materials - Safety re-
quirements
• EN 50176:2009
Stationary electrostatic application equipment for ignitable liquid coating material – Safety re-
quirements
• EN ISO 12100-1:2004
Safety of machinery - Basic concepts, general principles for design - Part 1: Basic terminology,
methodology
• EN ISO 12100-2:2004
Safety of machinery - Basic concepts, general principles for design - Part 2: Technical princi-
ples
• BGI 764:2009
Electrostatic coating (valid only in Germany)
!
!
Attention!

S-AGR08-Egb02 05/15 - 3 Page 3 of 10
2 Safety Regulations
Paragraph 0, Point 01 of EN 50176:2009 is applicable to the elds of application of the apparatus.
This Standard also denes the design requirements for safe operation of the apparatus and the
electrical installation, including the forced ventilation.
The constructional requirements for the spray booth, dened in Standard EN 12215:2005, are also
applicable. This applies particularly to the identication of explosion hazardous areas.
This stipulates that the apparatus may only be used in areas where forced ventilation ensures that
during
• the application of ammable liquid coating materials, the average concentration of solvents
in the form of ammable vapour remains below 50% of the lower explosion limit (LEL) (EN
50176:2009, Para. 5.2).
Pursuant to EN 50176:2009, Para. 5.1.2/5.1.3, the apparatus is classied as a spraying system
type C-L or D-L when operated with electrostatic application equipment. This depends on the type
of installation and the local conditions.
In accordance with Para. 5.2.8 of EN 50176:2009, type C-L or D-L spraying systems must be tted
with a locally applied extinguishing system which may also be operated manually.
Section 5.2 of EN 50176:2009 must be observed. The requirements under 5.3 of EN 50176:2009
must be observed, in addition, if the apparatus is used as a 2G apparatus.
2.3 Electrostatic automatic spray gun
This electrostatic automatic spray gun meets the requirements of EN 50176:2009 – Stationary
electrostatic application equipment for ignitable liquid coating material – Safety requirements.
This Operating Manual deals only with the dangers typically associated with the automatic coat-
ing process when electrostatic spray guns in the described form are used under the conditions as
specied by the manufacturer.
These electrostatic spray guns are classied as Group II, Category 2 equipment pursuant to Di-
rective 94/9/EC, intended for use in explosive atmospheres generated by their own spray cloud.
Equipment in this category is intended for use in areas where an explosive atmosphere comprising
of gases, vapours, mist or dust/air mixtures may on occasion be expected.

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2 Safety Regulations
2.3.1 Forced ventilation
Pursuant to EN 50176:2009, Section 5.4, the AGR-08-E electrostatic spray gun may only be used
in spraying areas with forced or equivalent conditions of ventilation.
This means that the maximum concentration of 50% of the lower explosion limit (LEL) of the coat-
ing material to be applied may not be exceeded in the spraying areas.
The effectiveness of forced ventilation must be assured using special measures.
2.4 General demands for safe operation
• To guarantee safe operation of the spraying equipment and its accessories, the operating com-
pany must compile operating instructions, taking into account this Operating Manual. These
operating instructions must be available in the appropriate language and at the appropriate
location at the workplace.
• Such operating instructions must point out that the electrostatic spraying equipment may only
be operated by trained persons.
• A warning sign must be afxed in an obvious location near the spraying area, in a language
the user understands. This warning sign must explain the most important types of operation
and protective measures which the operators should comply with. The dangers involved in the
cleaning of spray guns must furthermore be clearly highlighted.
• The rst start-up of the equipment by the operator is allowed only after the initial test run by an
authorised specialist before the risk passes to the operator (BetrSichV [Ordinance on Industrial
Safety and Health] §14).
2.5 Instruction
It must be ensured that persons working with the electrostatic spraying system are instructed on
the inherent dangers and the measures necessary for prevention of these, before starting to oper-
ate the electrostatic coating equipment and accessories. These instructions should be repeated at
least once a year.
2.6 Use of electrostatic spraying systems in potentially explosive areas
• The type AGR-08-E electrostatic spraying systems (spray guns) may only be operated in areas
in which the explosive conditions are caused exclusively by own electrostatic spraying of am-
mable liquid coating materials.
• Electrostatic spraying systems may only be operated provided protective measures are taken
to protect from typical hazards of the tasks. Protective measures against electrical shock must
furthermore be taken by:
– avoiding unnecessary work on live parts of the plant
– disconnecting from mains
– suitable working clothing
– securing against accidental switch-on
– ensuring that power is off
– earthing and shorting
– access control (vehicle permission)

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2 Safety Regulations
2.7 Work stations
• Ensure all sources of ignition are avoided. Smoking and open ames are prohibited in re and
explosion hazardous areas.
• Ensure that coating material deposits are kept to a minimum in spray booths, spray stands and
in the entire work area.
• Instruct and check that access doors to spray booths are kept closed during spraying.
2.8 Interior coating of hollowware
• Interior coating of hollowware inside of which hazardous conditions may arise due to gases,
mist or dust produced by coating materials is prohibited unless special safety measures are
taken.
2.9 Cleaning
• Coating material deposits must be removed at appropriate intervals. Special attention must to
this end be given to the cleaning of spray booths and their ventilation equipment, spray-paint
mist separators (if used), and their surroundings.
• The workpiece supports must be cleaned regularly to ensure good earthing of the workpieces.
• Ensure that the forced ventilation is operational during cleaning.
• Use only electrically conducting vessels for cleaning uids. These vessels must also be
earthed.
• Use only solvents with ash points at least 5K higher than ambient.
• Ensure that the discharge energy is < 0.24 mJ before starting with cleaning work using am-
mable solvents on live components. In practice this means that the system must be securely
earthed (see also 2.9).
2.10 Prerequisites to accessing spray booths
• Ensure that solvent concentrations in the air which these persons may inhale are below health
hazardous limits.
• Ensure that the oor of the spray booth is electrically conducting.
• Ensure that no persons are present in the spray booth during painting.
• Ensure that the discharge energy is < 350 mJ if contact with high voltage circuit components
is possible. The safe time between switching off the high voltage and possible contact with live
components must be stipulated in due consideration of the operational and local conditions.
• Ensure that the discharge energy of the high voltage circuit is < 0.24 mJ if ammable liquids
are used (see also 2.8.5) for cleaning.

S-AGR08-Egb02 05/15 - 3 Page 6 of 10
2 Safety Regulations
2.11 Personal protective gear
• Ensure that persons working with electrostatic spraying systems and any persons present on
the electrically conducting oor wear antistatic shoes.
• Where protective gloves are required, these must be antistatic or have similar properties.
2.12 Working with ignition risk
• The operating company shall ensure that no work involving risk of ignition is carried out in re
and explosion hazardous areas. Exceptions are possible, provided special protective meas-
ures (e.g. removing coating material, solvents and other ammable goods, cleaning equipment
and building sections beforehand, ensuring adequate ventilation etc.) are taken.
• Ensure that work involving risk of ignition which is carried out near openings to explosion haz-
ardous rooms and areas is only performed if it can be assured that sources of ignition cannot
enter such rooms and areas.