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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VERSION 01/2021 ORDER NUMBER DOC2422004 TOPFINISH Bell 1S ECH
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