WAGNER TOPFINISH Bell 1S ECH Operational manual

TOPFINISH Bell 1S ECH
High-speed rotary atomizer
with external charging
Version 01/2021
II 3G T6 X
B_07798

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VERSION 01/2021 ORDER NUMBER DOC2422004 TOPFINISH Bell 1S ECH
Table of Contents
1 ABOUT THESE INSTRUCTIONS 7
1.1 Preface 7
1.2 Warnings, Notices and Symbols in these Instructions 7
1.3 Languages 8
1.4 Abbreviations 8
1.5 Terminology for the Purpose of this Manual 8
1.6 Device-Specic Terminology in this Manual 9
2 CORRECT USE 10
2.1 Device type 10
2.2 Type of Use 10
2.3 For Use in Potentially Explosive Areas 10
2.4 Processible Working Materials 10
2.4.1 Ignitable Liquid Coating Products 11
2.4.2 Non-Ignitable Liquid Coating Products 11
2.4.3 Categorization of Products 11
2.5 Misuse 12
3 IDENTIFICATION 13
3.1 Explosion Protection Identication 13
3.2 Identication "X" 13
3.3 Type Plate 14
4 BASIC SAFETY INSTRUCTIONS 15
4.1 Safety Instructions for the Operator 15
4.1.1 Electrical Devices and Equipment 15
4.1.2 A Safe Work Environment 15
4.1.3 Personnel Qualications 16
4.2 Safety Instructions for the Personnel 16
4.2.1 Personal Safety Equipment 16
4.2.2 Safe Handling of WAGNER Spray Devices 17
4.2.3 Grounding the Device 17
4.2.4 Product Hoses 18
4.2.5 Electrical Connection Cables 18
4.2.6 Cleaning and Flushing 19
4.2.7 Touching Hot Surfaces 20
4.2.8 Maintenance and Repair 20
4.2.9 Protective and Monitoring Equipment 20
5 DESCRIPTION 21
5.1 Components 21
5.2 Functional Description 22
5.2.1 Functional Description of the Individual Components 22
5.2.2 Atomization Process 23
5.3 Scope of Delivery 24
5.3.1 Standard variant 24

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5.4 Data 24
5.4.1 Materials of Paint-wetted Parts 24
5.4.2 Technical Data 25
5.4.3 Dimensions 26
5.4.4 Air consumption 26
5.4.5 Connections on Valve Block - 1-Paint 27
5.4.6 Connections at Transition Piece 28
5.4.7 Connections on Control Cabinet RBC 1E (Single-Paint Valve Block) 28
6 COMMISSIONING 29
6.1 Training of Assembly/Commissioning Personnel 29
6.2 Storage Conditions 29
6.3 Installation Conditions 29
6.4 Transportation 29
6.5 Air Quality, Air Quantity and Air Pressure 29
6.6 Assembly and Installation 30
6.6.1 Typical Electrostatic Spraying System 30
6.7 Setting up Stationary Electrostatic Systems 31
6.7.1 Assembly of High-Speed Rotary Atomizer on Reciprocator 33
6.7.2 Ventilation of the Spray Booth 35
6.7.3 Air Supply Lines 35
6.7.4 Product Supply Lines 35
6.8 Grounding 36
6.9 Commissioning 37
6.9.1 Presettings 37
6.9.2 Safety Checks 38
6.9.3 Lacquer Preparations 38
6.9.4 Viscosity conversion table 38
6.9.5 Operating Instructions for Safe Operation 38
6.9.6 Calibration 40
6.9.7 Verifying a Safe Operational Condition 41
7 OPERATION 41
7.1 Training the Operating Personnel 41
7.2 Emergency Deactivation 41
7.3 Tasks 41
7.3.1 Adjusting the Spray Pattern 41
7.3.2 Pressure Relief/Work Interruption 42
7.4 For Internal Charging and Use of Solvent-Based Paints 42
7.5 Conversion from External to Internal Charging 42
7.6 Basic Flushing 43
7.6.1 Changing Bell Plate 44
7.6.2 Changing Complete Electrode Finger or Resistor Package 45
7.6.3 Changing Air Control Ring 46
7.6.4 Changing Carrier Ring 47
7.6.5 Changing Product Nozzle 48

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8 CLEANING AND MAINTENANCE 49
8.1 Cleaning 49
8.1.1 Cleaning Personnel 49
8.1.2 Flushing High-Speed Rotary Atomizers (Inside) 49
8.1.3 Cleaning High-Speed Rotary Atomizer (Outside) 50
8.1.4 Flushing Entire System 50
8.2 Maintenance 51
8.2.1 Maintenance Personnel 51
8.2.2 Maintenance Instructions 51
8.2.3 Safety Checks 51
8.2.4 Change Intervals for Key Components 52
8.2.5 Maintenance Procedures 52
9 TROUBLESHOOTING AND RECTIFICATION 55
9.1 Air Bearing 55
9.2 Product valves 56
9.3 Atomization 57
9.4 Spray Pattern Geometry 57
9.5 Product Application 58
9.6 Bell Plate 58
9.7 Optical Fiber 58
9.8 Electrode Fingers 59
10 REPAIR WORK 59
10.1 Repair Personnel 59
10.2 Repair Notes 59
10.3 Changing Valve 60
10.4 Replacing Optical Fiber 60
11 FUNCTION TEST AFTER REPAIR WORK 61
12 DISPOSAL 61
13 INSPECTIONS 61
13.1 Inspections in Accordance with DIN 50176 61
13.1.1 Overview of Inspections 61
13.1.2 Inspection Intervals in Accordance with Table 4 of DIN EN 50176: 2010-04 62
13.2 Inspections in Accordance with DIN EN 50348 62
13.2.1 Overview of Inspections 63
13.2.2 Inspection Intervals in Accordance with Table 4 of DIN EN 50348: 2010-05 63
14 ACCESSORIES 64
14.1 Basic device 64
14.2 Distributor disc 64
14.3 Product Nozzle 64
14.4 Air Deector Rings 64
14.5 Valve block 64
14.6 Optical Fiber, 9.9 m with Sleeve 65
14.7 Optical Fiber, 15 m with Sleeve 65
14.8 Hose Sets 65
14.8.1 Air hose set, 10 m 65
14.8.2 Air Hose Set, 15 m 65
14.8.3 Product Hose Set and 10 m Optical Fiber 66
14.8.4 Product Hose Set and 15 m Optical Fiber 66

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14.9 Miscellaneous 66
14.10 Cable Sets 66
14.11 Air lter 66
14.12 Speed / Bearing Air Monitoring 67
14.13 Control Cabinets 67
14.14 Mounting bracket 67
14.15 Miscellaneous 67
15 SPARE PARTS 68
15.1 How Can Spare Parts Be Ordered? 68
15.2 Spare Parts List for TOPFINISH Bell 1S ECH 70
15.3 O-Ring Set - Air Deector Ring 72
15.4 O-ring set - product tube 72
15.5 O-ring set air bearing 72
15.6 Bolt set 72
16 EU DECLARATION OF CONFORMITY 73
17 CONNECTION PLANS 74
17.1 High-Voltage System with Discharger 74
17.2 High-Voltage System with Ground Switch 74

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1 ABOUT THESE INSTRUCTIONS
1.1 PREFACE
The operating manual contains information about safely operating, maintaining, cleaning
and repairing the device.
The operating manual is part of the device and must be available to the operating and
service personnel.
The device may only be operated by trained personnel and in compliance with this
operating manual.
Operating and service personnel should be instructed according to the safety instructions.
This equipment can be dangerous if it is not operated according to the instructions in this
operating manual.
1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this manual highlight particular dangers to users and to the
device and state measures for avoiding the hazard. These warning instructions fall into the
following categories:
DANGER Immediate risk of danger.
Non-observance will result in death or serious injury.
WARNING Potential danger.
Non-observance may result in death or serious injury.
CAUTION Potentially dangerous situation.
Non-observance may result in minor injury.
NOTICE Potentially dangerous situation.
Non-observance may result in damage to property.
Notice Provides information about particular characteristics and
how to proceed.
Explanation of warning notice:
LEVEL OF DANGER
This notice warns you of a danger!
Possible consequences of not observing the warning notice.
The measures for preventing the hazard and its consequences.

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1.3 LANGUAGES
The operating manual is available in the following languages:
Original operating manual
Language Order no.
German 2422003
Translation of the original operating manual
Language Order no.
English 2422004
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order no. Order number cpl complete
Spare part HV High voltage
Marking in the spare parts lists OF Optical Fiber
Position PE Polyethylene
Number of pieces GFK Fiberglass-reinforced plastic
Wrench size (tool) -- --
1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL
Cleaning
Cleaning Manual cleaning of devices and device parts with cleaning
agent
Flushing Internal ushing of paint-wetted parts with ushing agent
Product pressure
generator
Pump or pressure tank
Personnel qualications
Trained person Is instructed in the tasks assigned to him/her, the potential risks
associated with improper behavior as well as the necessary
protective devices and measures.
Electrically trained
person
Is instructed by an electrician about the tasks assigned to him/
her, the potential risks associated with improper behavior as well
as the necessary protective devices and measures.
Electrician Can assess the work assigned to him/her and detect possible
hazards based on his/her technical training, knowledge and
experience in relevant provisions.
Skilled person in the
context of DGUV
209-052
A person who, based on his/her technical training, experience
and recent vocational experience, has sucient technical
knowledge in the area of electrostatic coating and is familiar
with the relevant and generally accepted rules of technology
so that he/she can inspect and assess the status of devices and
coating systems based on workplace safety.
Additional requirements for skilled persons can also be found
in TRBS1203(2010/amendment 2012): Expert knowledge in the
areas of protection against excessive pressure, electrical hazards,
and explosion protection (where applicable).

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1.6 DEVICESPECIFIC TERMINOLOGY IN THIS MANUAL
Designation Mode of Operation
Stop air (STA) Air inlet on rear of high-speed rotary atomizer.
The drive speed is reduced by the stop air.
Dump (DM) Outlet opening on rear of high-speed rotary atomizer to
dispose of the waste liquid produced when ushing the device.
Bell ushing (FB) The bell ushing (FB) is an air inlet on the rear of the high-
speed rotary atomizer.
Bell Plate Bell-shaped plate, which rotates when in operating status and
atomizes the product.
Main needle valve (CA) Selector valve in front part of the high-speed rotary atomizer
for releasing ow rate.
High-voltage cable Cable used to connect the high-speed rotary atomizer to the
cascade.
Cascade High-voltage generator.
Bearing air (BA) Air inlet on rear of air bearing for mounting the motor.
Steering air (SA) Steering airs SA1/SA2 are air inlets on the rear of the high-
speed rotary atomizer.
The steering airs control the spray pattern of the high-speed
rotary atomizer.
Air outlet Air outlet openings on the rear of the high-speed rotary
atomizer for removing exhaust air from the high-speed rotary
atomizer using air hoses.
Product valve (M) The product valve is always open during operation and is only
closed to disconnect the high-speed rotary atomizer from the
valve block of the product supply for maintenance purposes
or to t a gun.
Closing the product valve (M) allows the high-speed rotary
atomizer to be removed without disconnecting the hosing.
Valve block Valve blocks in various designs, together with the integrated
valves, allow the various media (air/product) to be opened
and closed.
Electrode ring with
electrode ngers
The electrode ring is comprised of 8 electrode ngers. High
voltage is transferred to the ambient air via the electrode
ngers. The air is ionized and thus the product owing
through is charged.

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2 CORRECT USE
2.1 DEVICE TYPE
TOPFINISH Bell 1S ECH: Air-bearing high-speed rotary atomizer.
2.2 TYPE OF USE
The TOPFINISH Bell 1S ECH is suitable for use on a reciprocator or other rigid arrangement.
The device is suitable for atomizing liquid products, in particular water-based or solvent-
based coating products, under the inuence of electrostatic forces.When processing water-
based lacquers, the paint supply must be carried out isolated. The processed products are
applied in a low-pressure process.
WAGNER explicitly prohibits any other use!
The device may only be operated under the following conditions:
Use the device only to work with the products recommended by WAGNER.
Do not deactivate safety xtures.
Use only WAGNER original spare parts and accessories.
The operating personnel must be trained on the basis of this operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
The device is suitable for use in potentially explosive areas as dened in Directive
2014/34/EU, (see Explosion protection marking Chapter 3.1).
2.4 PROCESSIBLE WORKING MATERIALS
This high-speed rotary atomizer can be used to process both ignitable liquid coating
products (solvent-based lacquers) and non-ignitable liquid coating products (water-based
lacquers).
Product
Bell Plate
smooth with teeth with double
teeth
Primer √ √ √ x
BaseCoat √ √ √ x
Clear lacquers x √ √ √
Metallic lacquers √ √ x
UV lacquers √ √ √ x
Epoxy lacquers √ √ x
PU lacquers √ √ √
Acrylic lacquers √ √ x
1K product √ √ √
2K products x √ √
Abrasive products √ √ √ x
Frequent paint changes √ √ √ xx
High mixing capacity x √ √
√ = suitable √√ = very suitable x = less suitable xx = unsuitable

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2.4.1 IGNITABLE LIQUID COATING PRODUCTS
When using ignitable coating products, the coating system must be equipped with an
on-site extinguishing system. In case of a re alarm, the high voltage, the air supply and
the product supply must immediately be switched o. If possible, the complete lacquer
supply system must have a grounded setup. In order to keep the discharge energy at the
high-speed rotary atomizer as low as possible, the high-speed rotary atomizer must be
connected to the high-voltage power supply using an attenuated high-voltage line (R =
approx. 50 k /m) with a length of at minimum 5 m.
The discharge energy of this system can be more than 350 mJ; in this case, it is classied
as a type C-L (W < 2 J) or type D-L (W > 2 J) in accordance with EN 50176. There is a risk of
energy capable of acting as an ignition source and a risk of electric shock. The complete
system must be safely grounded before being accessed by people.
With a grounded paint supply system, coating paints, primers, corrosion protection,
structure paints and other coatings with a resistance of > 50 k (in accordance with the
WAGNER/Ransburg scale) are suitable for processing. For highly conductive products
(R < 50 k ) and for products with very high electrical resistance (approx. > 5 M ), the
electrostatic eect has little or no eect, meaning that there is little to no "paint wrap-
around" present on the sprayed object. The suitability of the spray product can be read
from the actual values for the high voltage (kV) and for the spray current (µA).
High kV value, low µA value (no wrap-around) = Paint with excessive electrical
resistance
Low kV-value, high µA-value (no wrap-around) = Excessive conductivity of the paint
With a non-grounded lacquer supply system, coating products with a resistance of < 50 k
can also be used.
2.4.2 NONIGNITABLE LIQUID COATING PRODUCTS
If water-based lacquers are used, the entire system (high-speed rotary atomizer with
lacquer supply) is brought to high-voltage potential. The system corresponds to type A-NL
(W < 350 mJ) or type B-NL (W > 350 mJ), depending on the structure in accordance with
EN 50348. If the system is classied to Type B-NL, a danger exists through electric shock.
The complete system must be safely grounded before being accessed by people.
In the event of application problems, consult your WAGNER branch and/ or the paint
manufacturer.
2.4.3 CATEGORIZATION OF PRODUCTS
A large portion of stationary electrostatic lacquer spraying systems are currently being
converted to water-based lacquers. At the same time, re and explosion protection for
these systems can be simplied considerably if the water-based lacquers in use can
demonstrably be considered non-ignitable. Water-dilutable lacquers are in principle
divided into 3 groups:
Green: Non-ignitable (non-combustible) lacquers
Yellow: Hard to ignite lacquers
Red: Ignitable lacquers
As a rule, the lacquer manufacturer determines in which of these three groups a coating
product is classied. In case no information can be obtained in this regard from the lacquer
manufacturer or lacquer supplier, a classication can be performed using the following
formula. Before performing the classication using these formulas, it is mandatory to
request classication from the lacquer manufacturer or lacquer supplier.

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2.4.3.1 GREEN: NONIGNITABLE
Lacquers in this group have the following composition:
wt. % H2O > 1.70 x wt. % LM + 0.96 x wt. % ORG
Where:
wt. % Weight percent
H2OWater
LM Liquid organic phase (solvent mainly consisting of higher ethylene glycol
esters)
ORG Solid organic phase (solids mainly consisting of binding agents and
pigments)
Such lacquers behave like water with respect to ammability in liquid form (liquid phase)
and in sprayed form. Cleaners and thinners must also be non-ignitable. A possible cleaner
and thinner is, for example, water with less than 35 weight percent 1:1 butylene glycol/N-
propanol.
Lacquers in this group are categorized as non-ignitable liquid coating products.
When using non-ignitable spray products, the requirements of EN 50348 (mainly protection
against contact) must be complied with.
2.4.3.2 YELLOW: HARD TO IGNITE
Lacquers in this group have the following composition:
wt. % H2O > 1.50 x wt. % LM + 0.49 x wt. % ORG
Spray patterns of these lacquers cannot be ignited by sparks with an energy < 4 J. Explosion
protection in the spray area is not usually necessary if ignition sources with an energy of
more than 2 J do not occur.
Lacquers in this group are categorized as hard to ignite.
The requirements of EN 50176 must be complied with when using spray products that are
hard to ignite.
2.4.3.3 RED: IGNITABLE
Lacquers that do not meet the criteria for non-ignitable or hard to ignite.
Lacquers in this group are categorized as ignitable liquid coating products.
The requirements of EN 50176 must be complied with when using ignitable spray products.
Please contact your local WAGNER dealer and the lacquer manufacturer if you encounter
application problems.
2.5 MISUSE
Misuse can lead to physical injury and/or property damage!
Special attention must be paid that:
No dry coating products, e.g. powder are processed;
No food, medicine or cosmetics are processed.
It is important to note that the device's materials are not food-safe.

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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
As dened in the Directive 2014/34/EU (ATEX), the device is suitable for use in potentially
explosive areas.
Device type: High-speed rotary atomizer
Manufacturer: J. Wagner GmbH
88677 Markdorf
Germany
II 3G T6 X
CE European Communities
Ex Symbol for explosion protection
II Device class II
3 Category 3 (zone 2)
G Ex-atmosphere gas
T6 Temperature class
X Special notice
W Maximum discharge energy
3.2 IDENTIFICATION "X"
The maximum surface temperature corresponds to the permissible product temperature.
This and the permissible ambient temperature have been listed in the 5.4.2"Technical
Data" chapter.
Safe Handling of WAGNER Spray Devices
Mechanical sparks can form if the device comes into contact with metal.
In an explosive atmosphere:
Knocking or pushing metal against metal is to be avoided.
Do not drop the device.
Ignition temperature of the coating product
Ensure that the ignition temperature of the coating product is above the maximum
surface temperature.
Medium supporting atomizing
To atomize the product, use only weakly oxidizing gases, e.g., air.
Electrostatic surface spraying
Do not spray device parts using electrostatic equipment.
Cleaning
If there are deposits on the surfaces, the device may form electrostatic charges. Flames
or sparks can form during discharge.
Remove deposits from the surfaces to maintain conductivity.
Use only a damp cloth to clean the device.

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3.3 TYPE PLATE
Fluid pressure max.
Air pressure max.
Bearing air pressure max.
Speed max.
Fluid temperature max.
Ambient temperature:
Serial No.
J. Wagner GmbH
Made in Germany
D-88677 Markdorf
Type: TOPFINISH Bell 1S ECH
II 3G T6 X
Check manual before use!
Admissible combinations of devices, see information for use.
0.8MPa, 116psi
0.8MPa, 116psi
0.55MPa, 80psi
80‘000rpm
50°C, 122°F
0° < Ta < 40°C, 32°F < Ta < 104°F
W>350mJ
B_07799
1
2
3
4
5
6
7
8
10
9
Designation
1 Manufacturer and CE identication
2 Type
3 Maximum product pressure
4 Maximum air pressure
5 Maximum air bearing pressure
6 Maximum speed
7 Maximum product temperature
8 Ambient temperature
9 Serial number
10 Read operating manual before use!
The type plate with serial number is available on the body of the atomizer below the cover.

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4 BASIC SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention regulations.
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
Danger of electric shock!
Danger to life from electric shock.
Prepare device in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians or under their supervision. With open
housings, the mains voltage poses a danger.
Operate device in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Decommission if device poses a danger or is damaged.
Must be de-energized before work is commenced. Inform personnel about planned
work. Observe electrical safety regulations.
Ground all devices to a common grounding point.
Only operate the device with a properly installed socket with a protective ground
wire connection.
Keep liquids away from electrical devices.
4.1.2 A SAFE WORK ENVIRONMENT
Danger due to dangerous uids or vapors!
Severe or fatal injuries due to explosion danger or inhalation, swallowing or contact with
the skin or eyes.
Ensure that the oor in the working are is static dissipative in accordance with
EN61340-4-1 (resistance must not exceed 100 M ).
Paint mist extraction systems/ventilation systems must be tted on site according
to local regulations.
Make sure that the ground connection and potential equalization of all system parts
are reliable and continuous and can withstand the expected stress (e.g., mechanical
stress, corrosion).
Ensure that product hoses/air hoses adapted to the working pressure are used.
Ensure that personal protective equipment (see Chapter 4.2.1) is available and is
used.
Make sure that all people within the work area wear static dissipative shoes.
Footwear must comply with EN 20344. The measured insulation resistance must not
exceed 100 M .
Protective clothing, including gloves, must comply with EN 1149-5. The measured
insulation resistance must not exceed 100 M .
Ensure that there are no ignition sources such as naked ames, sparks, glowing
wires, or hot surfaces in the vicinity. Do not smoke.

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Ensure that the pipe joints, hoses, equipment parts and connections are
permanently, technically leak-proof:
– Periodic preventative maintenance and service (replacing hoses, checking
tightness of connections, etc.).
– Regular monitoring of leaks and defects via visual inspection and odor testing,
e.g., daily before commissioning, at the end of work or weekly.
Ensure that maintenance and safety checks are performed regularly.
In the event of defects, immediately bring the device or system to a stop and
arrange to have repairs carried out immediately.
4.1.3 PERSONNEL QUALIFICATIONS
Danger due to incorrect use of device!
Risk of death due to untrained personnel.
Ensure that the operating personnel has been instructed by the operator in
accordance with the operating manual and the operating instructions. The device
must only be operated, maintained and repaired by trained personnel. Refer to the
operating instructions for information about the required personnel qualications.
4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always observe the information in this manual, particularly the safety instructions
and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention regulations.
In electrostatics applications: anyone who belongs to a risk group according to EMF
Directive 2013/35/EU (e.g., those with active implants), must not enter the high-
voltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Danger due to dangerous uids or vapors!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
When preparing or working with lacquer and when cleaning the device, follow the
working instructions of the manufacturer of the lacquers, solvents, and cleaning
agents being used.
Take the specied protective measures. In particular, wear safety goggles, protective
clothing and gloves, as well as hand protection cream if necessary.
Use a mask or breathing apparatus if necessary.
For sucient health and environmental safety: Operate the device in a spray booth
or on a spraying wall with the ventilation (extraction) switched on.
Wear suitable protective clothing when working with hot products.
Danger due to noise pollution!
Hearing damage due to noise pollution.
Wear ear protection.

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4.2.2 SAFE HANDLING OF WAGNER SPRAY DEVICES
Danger due to injection of lacquer or ushing agent into the skin!
The spray jet is under pressure and can cause dangerous injuries. Avoid injection of
lacquer or ushing agents:
Never point the high-speed rotary atomizer at persons.
Never reach into the spray jet.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve the pressure from the high-speed rotary atomizer and device.
– Secure the high-speed rotary atomizer against actuation.
– Disconnect the control unit from the mains.
– In the event of functional faults: remedy the fault as described in the
"Troubleshooting" chapter.
If necessary or at least every 12 months, the liquid ejection devices must be checked
for safe working conditions by an expert (e.g., WAGNER Service Technician) in
accordance with the guidelines for liquid ejection devices (DGUV [German Statutory
Accident Insurance] regulation 100-500 chapters 2.29 and 2.36).
– For shut down devices, the examination can be suspended until the next start-up.
Carry out the work steps as described in the "Pressure relief" chapter:
– if pressure relief is required,
– if the spraying work is interrupted or stopped.
– before the device is cleaned on the outside, checked, or serviced,
– before the spray nozzle is installed or cleaned.
In the event of skin injuries caused by lacquer or ushing agents:
Note the lacquer or ushing agent that you have been using.
Consult a doctor immediately.
4.2.3 GROUNDING THE DEVICE
Danger due to electrostatic charge!
Explosion hazard and damage to the device.
Friction, owing liquids and air or electrostatic coating processes create charges. Flames
or sparks can form during discharge.
Correct grounding of the entire spraying system prevents electrostatic charges.
Ensure that the unit is grounded for every spraying operation.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g., that they are
wearing static dissipative shoes.
The spray substance supply (spray substance tank, pump, etc.) must be grounded.

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4.2.4 PRODUCT HOSES
Danger due to bursting of product hose!
The product hose is under pressure and may cause dangerous injuries.
Ensure that the hose material is chemically resistant to the sprayed products and
the ushing agents used.
Ensure that the product hose and the ttings are suitable for the pressure
generated.
Ensure that the following information can be seen on the high-pressure hose:
– manufacturer
– permissible operating pressure
– date of manufacture
Make sure that the hoses are laid only in suitable places. Hoses should not be laid in
the following places under any circumstances:
– in high-traffic areas,
– on sharp edges,
– on moving parts or
– on hot surfaces.
Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the
hoses are never put under pressure from the outside in any other way.
Ensure that the hoses are never kinked. Observe maximum bending radii.
Ensure that no work is ever performed with a damaged hose.
Make sure that the hoses are never used to pull or move the device.
The electrical resistance of the product hose, measured at both valves, must be less
than 1 M .
Suction hoses may not be subjected to pressure.
4.2.5 ELECTRICAL CONNECTION CABLES
Properly lay connection cables and check them regularly.
Immediately replace damaged connection cables.
Ensure that no work is ever performed with a damaged connection cable.
Do not lay connection cables on routes used by product handling vehicles and not
through doors/gates.
Do not route connection cables near aisles or walkways in order to avoid tripping.

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VERSION 01/2021 ORDER NUMBER DOC2422004 TOPFINISH Bell 1S ECH
4.2.6 CLEANING AND FLUSHING
Danger due to cleaning and ushing!
Explosion hazard and damage to the device.
De-energize the device electrically.
Pneumatically deactivate paint and ushing agent valves (CA, DM, M and FB).
Deactivating the paint and ushing agent valves relieves the pressure on the device.
Preference should be given to non-ignitable cleaning and ushing agents.
When carrying out cleaning work with ammable cleaning agents, make sure
that all equipment and resources (e.g., collection tank, funnel, transport cart) are
conductive or static dissipative and grounded.
Observe the specications of the lacquer manufacturer.
Ensure that the ash point of the cleaning agent is at least 15 K above the ambient
temperature or that cleaning is undertaken at a cleaning station with technical
ventilation.
Explosive gases are produced when aluminum comes into contact with
halogenated hydrocarbons. To clean aluminum, do not use liquids containing
halogenated hydrocarbons.
Take measures for workplace safety (see Chapter 4.1.2).
When commissioning or emptying the device, please note that:
– depending upon the coating product used,
– depending on the flushing agent (solvent) used.
an explosive mixture may temporarily exist inside the lines and components of
equipment.
Only electrically conductive tanks may be used for cleaning and ushing agents.
The tanks must be grounded.
An explosive gas/air mixture forms in closed tanks.
Never spray into a closed tank when using solvents for ushing.
External Cleaning
When cleaning the exterior of the device or its parts, also observe the following:
Relieve the pressure from the device.
De-energize the device electrically.
Disconnect the pneumatic supply line.
Use only moistened cloths and brushes. Never use abrasive agents or hard objects
and never spray cleaning agents with a gun. Cleaning the device must not damage
it in any way.
Ensure that no electric component is cleaned with or immersed into solvent.

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VERSION 01/2021 ORDER NUMBER DOC2422004 TOPFINISH Bell 1S ECH
4.2.7 TOUCHING HOT SURFACES
Danger due to hot surfaces because of hot coating products!
Risk of burn injuries.
Only touch hot surfaces if you are wearing protective gloves.
When operating the device with a coating product with a temperature of > 43 °C;
109.4 °F:
– Identify the device with a warning label "Warning – hot surface".
Order no.
9998910 instruction label
9998911 protection label
Note: Order the two stickers together.
4.2.8 MAINTENANCE AND REPAIR
Danger due to improper maintenance and repair!
Danger to life and equipment damage.
Only a WAGNER service center or a suitably trained person may carry out repairs and
replace parts.
Use only WAGNER original spare parts and accessories.
Do not change or modify the device; if change is necessary, contact WAGNER.
Only repair and replace parts that are listed in Chapter 14 and Chapter 15 that are
assigned to the device.
Do not use any defective components.
Exclusively use accessories listed in Chapter 14 and that are assigned to the unit.
Before all work on the device and in the event of work interruptions:
– Relieve the pressure from the high-speed rotary atomizer and all devices.
– Secure the high-speed rotary atomizer against actuation.
– Switch o the energy and compressed air supply.
– Disconnect the control unit from the mains.
Observe the operating and service manual for all work.
4.2.9 PROTECTIVE AND MONITORING EQUIPMENT
Danger due to removal of protective and monitoring equipment!
Danger to life and equipment damage.
Protective and monitoring equipment must not be removed, modied or rendered
unusable.
Regularly check for perfect functioning.
If defects are detected on protective and monitoring equipment, the system must
not be operated until these defects are remedied.