REITER AGR-08-N User manual

REITER GmbH + Co. KG
Oberächentechnik Phone: [phone] / 185 - 0
Berglenstraße 23 - 25 Telefax: +49 (0) 71 95 / 185 - 30
D-71364 Winnenden Internet: www.reiter-oft.de
Operating Manual
Automatic spray gun AGR-08 for
conventional and AGR-08-N for
low-pressure atomization
Product No.: S-AGR08GB (Translation)
Issue: 05/15 - 3

S-AGR08gbDB 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)

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1 General
1.1 Introduction
This operating instruction contains information for the assembly and maintenance of the automatic
spray gun AGR-08. The technical data and procedures contained herein should be considered as
standard and may differ depending on the customized installation.
Because every system is designed differently, the automatic spray gun AGR-08 must only be
placed in operation by personnel authorised by REITER.
To better understand this device and to achieve optimum error-free operation for an extended pe-
riod, please read this operating instruction carefully. The specied fault identication should be per-
formed before calling for a service technician.
The automatic spray gun AGR-08 is subject to additional development and improvements.
1.2 Operating area – Specied normal use
The automatic spray gun AGR-08 is designed for processing coatings based on solvents or water.
It must only be used to atomise materials that are explicitly listed in the order conrmation. Use of
other coating materials can only be considered if there is no possibility of:
• hazard to people or the environment
• harmful effects on the spray gun
In case of doubt, please contact the manufacturer of the automatic spray gun AGR-08.
The automatic spray gun AGR-08 is designed for use on a xed location spraying system and on
the hollow wrist or ex arm robots, on automatic machines (hoisting devices), and on tripods.
Any usage beyond what is specied is considered improper use. The manufacturer shall not be re-
sponsible for any resulting damages.
Table of Contents
1.1 Introduction ........................................................................................................................1
1.2 Operating area – Specied normal use .............................................................................1
1.2.1 Usage contrary to intended use.........................................................................................2
1.3 Guarantee..........................................................................................................................2
1.4 Copyright............................................................................................................................2

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1 General
Danger of injury or damage!!
This device may be dangerous if it is not operated according to the
specications in this operating instruction.
Note!
During the processing of highly corrosive or very abrasive materials,
an increased demand in spare parts can be expected. The suitability
must be checked with the material manufacturer based on the sub-
stance list.
1.2.1 Usage contrary to intended use
Usage is contrary to intended use if:
• any media other that those specied in the operating instruction are directed through the gun
• operating conditions other than those specied in the operating instruction are present
• safety instructions are not observed during operation, assembly, and maintenance
• unauthorised conversions or modications are made to the gun have a negative
effect on safety and/or functionality
1.3 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 1.2
„Operating Area“.
Any other use is considered improper and REITER can not be held liable for any possible damage.
1.4 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: [phone] / 185 - 0
Berglenstraße 23 - 25 Fax: [phone] / 185 - 30
D-71364 Winnenden Email: [email protected]
!

S-AGR08gb02 05/15 - 3 Page 1 of 4
2 Safety Regulations
!
Attention!
2.1 Explanation of symbols and special directions
2.1.1 Symbol of working safety
This symbol found on all work safety notes in these instructions, if
ignored, may cause hazards. The instructions must be particularly
observed by the users of the machine. Inform other users of potential
hazards that can occur when using the machine. Besides the recom-
mendations in this BA to the general safety and accident prevention
and safety regulations.
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 Basic safety instructions
The spray system with the automatic spray gun AGR-08 must only be operated by trained person-
nel.
A warning sign must be posted in a conspicuous place close to the spraying area. This warning
sign should contain the most important functions and safety measures that users must observe.
The dangers present when cleaning spray guns must be clearly highlighted.
The start-up of the system by the user may only be performed after an initial test by an authorised
technician prior to the transfer of risk to the user.
Table of Contents
2.1 Explanation of symbols and special directions ..................................................................1
2.1.1 Symbol of working safety...................................................................................................1
2.1.2 Directions for “Attention“ ....................................................................................................1
2.2 Basic safety instructions ....................................................................................................1
2.3 Instructions.........................................................................................................................2
2.4 Work stations ..................................................................................................................... 2
2.5 Cleaning.............................................................................................................................2
2.6 Requirement for the entering of spray booth .....................................................................2
2.7 Explosive areas (DIN EN 12215).......................................................................................3

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2 Safety Regulations
2.3 Instructions
Persons who work with the spraying device must be instructed about dangers before beginning
their activities.
This instruction must be repeated and documented at least once per year.
2.4 Work stations
Danger!
Danger of re and explosion!
• Smoking and open ames are strictly prohibited in areas prone to
re and explosion.
• No accumulations of coating materials must be allowed to collect in
spray booths, on spraying stands, or anywhere in the entire work
area.
• Access doors to the spray booths must remain closed during
spraying.
• Sources of ignition must be avoided.
2.5 Cleaning
Danger!
Danger of re and explosion!
Accumulations of coating materials must be removed. The following
must be cleaned regularly:
• Workpiece xtures
• Suction devices
• Leakage mist separators and their immediate vicinity
Technical ventilation must be active during cleaning work.
Use only electrically conductive containers for the cleaning uids. Ad-
ditionally, these containers must be earthed.
Use only solvents with a ashpoint that is at least 5°C higher than the
surrounding temperature. When cleaning the guns, wear suitable pro-
tective clothing, such as gloves, safety goggles, etc.
2.6 Requirement for the entering of spray booth
Warning!
Danger of inhaling substances hazardous to your health!
During the spraying operation, no persons are permitted to remain in
the spray booth.
The concentration of solvent in the air must be under the limit that is
harmful to health. If appropriate, wear suitable protective breathing
equipment when entering the spray booth.
!
!
!

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2 Safety Regulations
2.7 Explosive areas (DIN EN 12215)
The categorization of danger zones is a signicant component of the safety concept for explosion
protection. The ignition protection type of equipment and components integrated into the spray
booth depends on the limit of concentration for ammable substances by technical ventilation.
a) If the concentration of ammable substances is limited to less than 25% of the LEL, the in-
side of the spray booth, including ambient and exhaust air lines, together with external areas
formed around permanent openings at a distance of up to 1 m should be categorised as Zone
2.
b) If the concentration of ammable substances is between 25% and 50% of the LEL, the inside
of the spray booth, including ambient and exhaust air lines, should be categorised as Zone 1.
c) If the concentration of ammable substances is between 25% and 50% of the LEL, external
areas formed around permanent openings at a distance of up to 1 m should be categorised as
Zone 2.
This categorization of areas with explosive atmospheres into zones corresponds to the category for
ignition protection type according to prEN 13463-1.

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2 Safety Regulations
Example of zone categorization in a spray booth with open access side (spraying stand)
Categorization of danger zones into Zone 1 or Zone 2
Example of zone categorization in a spray booth that is open on top

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3 Technical Data
3.1 Designs
The automatic spray gun AGR-08 is available in different designs. They differ in the use of a variety
of components and/or in the material ow.
Note!
There are two versions of gun heads possible – dead end or circulation.
The gun heads with circulation have two material lines, allowing coating material to circulate
through the head so a colour change can be performed while the gun is closed.
Only the nozzle area must be ushed on the gun itself.
Table of Contents
3.1 Designs..............................................................................................................................1
3.2 Technical data....................................................................................................................2
3.2.1 Automatic gun AGR-08 and AGR-08-N..............................................................................2

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3 Technical Data
3.2 Technical data
3.2.1 Automatic gun AGR-08 and AGR-08-N
Spray system:
AGR-08 conventional air atomization
AGR-08-N Low-pressure air atomization
Max. pressures: 0 to 14 bar material (MAT)
6 bar control air (CYL)
9 bar atomiser air (ATOM) and fan air (FAN)
Switching times: < 60 msec. at 5,8 bar control air
Weight: 610 g
Materials:
Gun head: Stainless steel 1.4305
Paint needle (standard): Stainless steel 1.4305
Nozzle (standard): Stainless steel 1.4305
incl. plastic insert (POM)
Needle pack: UHMPE
Piston: POM
Head holder: AlZnMgCu1,5 blue anodized
End plate: AlZnMgCu1,5 blue anodized
Cover: AlZnMgCu1,5 blue anodized
Air distribution ring: Brass, chemically nickel-plated
Air cap: Brass, chemically nickel-plated
Air cap retaining ring: Brass, chemically nickel-plated
Material-contacting seals: VITON for water-based coatings (on request)
VITON EX for solvent-based coatings (standard)
Perourelastomer for highest resistance (on request)
Dimensions:
AGR-08/AGR-08-N with intermediate plate

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7 Commissioning and Operation
7.1 Commissioning
Supply line (VL)
Return line (RL)
Fan air (HL)
Atomizer air (ZL)
Main needle (HN)
The automatic spray gun AGR-08, depending on the built-in version, is attached on a intermediate
plate, which serves as an adapter to be able to use the gun as diverse as possible. This plate is
mounted on an adapter to which the material and the air can be connected.
Depending on the version, the gun sits directly on an adapter without an intermediate plate is re-
quired.
The adapter is attached to the movement device (robot or hoisting device) or to a tripod.
All compressed air and material lines are connected to the adapter.
Table of Contents
7.1 Commissioning ..................................................................................................................1
7.2 Usage conditions ...............................................................................................................2
7.3 Tools and other materials required.....................................................................................2
7.4 Fastening onto intermediate plates (if available) ...............................................................2
7.4.1 Intermediate plate AGR......................................................................................................2
7.5 Adjusting the jet geometry .................................................................................................3
7.5.1 Distance to workpiece........................................................................................................3

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7 Commissioning and Operation
7.2 Usage conditions
Operating temperature: max. 80°C
Ambient temperature: max. 40°C
7.3 Tools and other materials required
The following tools are required for installing and removing the automatic spray gun AGR-08:
 • Hexagonsocketheadwrench,size4
 • Gungrease(partno.65026530)fortheo-ring-wettingwhileplacingthegun.
7.4 Fastening onto intermediate plates (if available)
7.4.1 Intermediate plate AGR
Note!
Fortheintermediateplate(partno.63316350)theautomaticgunAGR-08isttedwiththelocking
device(partno.64045940).
1. Fixing gun on the intermediate plate.
2. Fixing automatic gun AGR-08 and the „stud
with tip“ with a hexagon socket head wrench,
size 4

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7 Commissioning and Operation
7.5 Adjusting the jet geometry
Note!
Thegunhasavariablejetgeometrytoproducearoundoratspraypattern.
Youshouldonlyworkwithclean,dry,ltered,oil-freeair.
 1. Selectasuitableairap.
2. Position the air distributing ring to produce
the desired jet geometry.
3. Make the appropriate setting for the atomiser air.
4. Make the appropriate setting for the horn air.
7.5.1 Distance to workpiece
Positon the automatic gun AGR-08 about 15 to 30 cm from the workpiece.
Position
for vertical
spray pattern
Position
for horizontal
spray pattern

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8 Maintenance
Note: The air cap can be replaced on the automatic spray gun AGR-08 without removing it from
the system.
For all other maintenance jobs, the automatic spray gun AGR-08 must be removed from the inter-
mediate plate/adapter and replaced by a reserve gun.
8.1 Required tools and lubricants
The following are required for installation and removal:
 • Socketwrenchornut,size13
 • Hexagonsocketheadwrench,size4andsize6
 • TorxwrenchTO40
 • Torquewrench
 • Gungrease(partno.65026530)forwettingoftheo-ringwhenplacingthegun
Note: Needle,needlesetandpistonshouldonlybeexposedtogungrease(partno.65026530).
OthergreasecanleadtoamalfunctionoftheautomaticspraygunAGR-08(unsuitablegrease
couldcauseswellingofneedlesetandpiston).
8.2 Removing gun
Caution!
Danger of injury due to lines under pressure!
• WhenremovingtheautomaticspraygunAGR-08,sprayuidmay
emerge under high pressure.
• Makecertainnopaintmaterialgetsintotheairchannels.
Rinse and blow out the material lines, then depressurise them.
Wearprotectiveclothingand/orglasses.
1. Loosen stud on intermediate plate
 2. RemovingautomaticgunAGR-08up.
!
Table of Contents
8.1 Required tools and lubricants ............................................................................................1
8.2 Removinggun....................................................................................................................1
8.3 Dismantling of the automatic gun.......................................................................................2
8.4 Reassemblyoftheautomaticgun......................................................................................6
8.4.1 Possiblesourcesoferrorforthereassembly...................................................................10
8.5 Maintenanceofneedleset............................................................................................... 11
8.6 AssemblydeviceforsprayingsystemAGR-08(option)...................................................13
8.7 Faults ...............................................................................................................................14

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8 Maintenance
8.3 Dismantling of the automatic gun
•Rinsetheautomaticgun
•Securethegunagainstrestarting
•Wearprotectionclothes(glasesandgloves)
•Noticethegenerallyapplicableaccidentpreventionregulations
1. Loosen and remove the gun with a hexagon
socketheadwrench,size4fromtheinterme-
diate plate or the adapter.
 2. Loosenandremovethecover(19).
 3. Loosenandremovethethreescrews(18)and
removetheendplate(17).
Attention!

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8 Maintenance
 4. Slidingheadholder(11)backwardsfromthe
sprayhead(8).Removepaintneedle(13),
smallcompressionspring(16),bigcompres-
sionring(15)andspringpin(14).
  RemovetwoVitonO-rings(10)fromthespray
headholderforfanairandatomizingair.
Attention: Risk of injury!
Needle can be very sharp.

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8 Maintenance
 5. Presspiston(12)byhandorwithablunttool
fromtheheadholder(11).
 6. Loosenretainingring(1)byhandandremove
ittogetherwiththeaircap(3)andtheaircap
gasket(2).
 7. Loosennozzle(4)withsocketwrenchornut
SW13andremoveittogetherwiththeairdis-
tributingring(7)andthetwogaskets(6).

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8 Maintenance
 8. UnscrewtheneedlepackingwithaTorx
wrenchTO40.
Attention: This applies only to the standard
packing of plastic.
Clean all individual parts with a suitable detergent and dry.
Gasketsandpackingshouldbechangedfundamentallyduringdisassembly.
Checkallpartsfordamageorwear,andreplacethemwithneworiginalsparepartsfromthecom-
pany Reiter.

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8 Maintenance
8.4 Reassembly of the automatic gun
1. Lay out all components and the required tools
on a clean level surface.
  2. Mountthesprayhead(8)intothegreased
standardneedleset(9)with0.8Nmormount
thespecialpackagemadeinstainlesssteel
withKalrezo-ringsintothesprayhead(8)and
tighten with a suitable tool with 3.0 Nm.
 3. Wetgaskets(6)withlittlefatandputitinthe
airdistributionring(7).
Attention: The gaskets are different. The
smaller diameter is in the air distributing
ring.
Too much grease can be carried away by
the fan air and atomizing air and reected
in painting/coating on the workpiece.
  Thatthegasketsdonotslip,itmakessense
to hold the gun with the needle down vertically
and insert the air distribution ring with the gas-
ketsfrombelow.
Attention: Risk of injury!
Needle can be very sharp.

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8 Maintenance
 4. Turngunto180°(needleup),placeuidnoz-
zleandtightenitto30Nm.Placeaircapand
tighten it manually with retaining ring. Little
gun grease on the threads facilitates subse-
quent removal.
 5. Wetslightlytwoo-rings(10)fromnotsolvent
resistantViton,forfanairandatomizingair
with gun grease and insert into the head hold-
er(11).
Attention: Too much grease can be carried
away by the fan air and atomizing air and
reected in painting/coating on the work-
piece.
 6. Lubricatepiston(12)andpushintothehead
holder(11)manually.
 7. Fitsprayhead(8)andheadholder(11)to-
gether.