WAGNER PEA-C4-HiCoat FM Operational manual

P_01610
PEA-C4-HiCoat
Automatic Powder Gun
Version 05/2019
II 2D 2mJ
0102

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VERSION 05/2019 ORDER NUMBER DOC390829 PEA-C4-HiCoat
Table of Contents
1 ABOUT THESE INSTRUCTIONS 6
1.1 Preface 6
1.2 Warnings, Notices and Symbols in these Instructions 6
1.3 Languages 7
1.4 Abbreviations 7
1.5 Terminology for the Purpose of this Manual 8
2 CORRECT USE 9
2.1 Device Type 9
2.2 Type of Use 9
2.3 For Use in Potentially Explosive Areas 9
2.4 Processible Working Materials 9
2.5 Misuse 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Type Plate 10
3.3 Permissible Device Combinations 10
4 BASIC SAFETY INSTRUCTIONS 11
4.1 Safety Instructions for the Operator 11
4.1.1 Electrical Devices and Equipment 11
4.1.2 A Safe Work Environment 12
4.1.3 Personnel Qualications 12
4.2 Safety Instructions for the Personnel 13
4.2.1 Personal Safety Equipment 13
4.2.2 Safe Handling of WAGNER Powder Spray Devices 13
4.2.3 Grounding the Device 14
4.2.4 Product Hoses 14
4.2.5 Electrical Connection Cables 15
4.2.6 Cleaning and Flushing 15
4.2.7 Maintenance and Repair 16
4.2.8 Protective and Monitoring Equipment 16
4.3 Information about Safe Discharges 17
5 DESCRIPTION 18
5.1 Construction of the Automatic Gun 18
5.2 Mode of Operation of the Automatic Gun 18
5.3 Scope of Delivery 19
5.4 Data 19
5.4.1 Technical Data 19
5.4.2 Dimensions 20
5.5 Accessories 21
6 ASSEMBLY AND COMMISSIONING 22
6.1 Training of Assembly/Commissioning Personnel 22
6.2 Storage Conditions 22
6.3 Installation Conditions 22
6.4 Preparing the Automatic Gun 22
6.4.1 Selection of a Suitable Nozzle System 22
6.5 Connecting the Automatic Gun 24

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6.6 Grounding 25
6.6.1 Grounding the Powder Coating System 26
6.7 Safety Checks 26
7 OPERATION 27
7.1 Training the Operating Personnel 27
7.2 Tasks 27
7.3 Switching On the Automatic Gun 27
7.4 Switching O the Automatic Gun 27
7.4.1 Switching O in Normal Operation 27
7.4.2 Switching O the Automatic Gun in the Event of Faults or Emergencies 27
7.4.3 Pressure Relief/Work Interruption 28
7.5 Optimizing the Powder Cloud for Coating 28
7.6 Reproducible Setting of the Nozzle Position 28
8 CLEANING AND MAINTENANCE 29
8.1 Cleaning 29
8.1.1 Cleaning Personnel 29
8.1.2 Cleaning Procedures 29
8.1.3 Performing a Paint Change 29
8.2 Maintenance 30
8.2.1 Maintenance Personnel 30
8.2.2 Maintenance Instructions 30
8.2.3 Safety Checks and Maintenance Intervals 30
8.2.4 Maintenance Procedures 30
8.3 Replacing the Automatic Gun 32
8.4 Removing the Flat Jet Nozzle 33
8.5 Replacing the Protective Wedge 34
8.5.1 Removing the Protective Wedge 34
8.5.2 Installing the Protective Wedge 35
8.6 Changing from Flat Jet Nozzle to Round Jet Nozzle 36
8.7 Assembling the Angle Adapter 37
8.7.1 Removing the Nozzle and Electrode Holder 37
8.7.2 Fitting the Angle Adapter 38
8.7.3 Replacing the Wearing Parts 39
8.8 Assembly of the CoronaStar 40
8.9 Assembly of the CoronaStar for Angle Adapter 41
9 TROUBLESHOOTING AND RECTIFICATION 42
10 INSPECTIONS 43
11 DISASSEMBLY AND DISPOSAL 46
11.1 Disassembly 46
11.2 Disposal 46
12 ACCESSORIES 47
12.1 Flat Jet nozzle 47
12.2 Deector Cone 47
12.3 Flat Jet Nozzle Set C4 F5 (Not FM Approved) 47
12.4 Flat Jet Nozzle C4 F5-X (Not FM Approved) 48
12.5 Flat Jet Nozzle F1-X (Not FM Approved) 48
12.6 Retrot Set CoronaStar 48
12.7 CoronaStar WA C4 49
12.8 CoronaStar PEA-C4 F5 Retrot Set 49

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12.9 Wedge Tool 49
12.10 Gun Mounting and Fixation 50
12.11 Angle Adapter 50
12.12 Hoses 50
12.13 Electrical Connection Cable 50
12.14 Powder Measuring adapter 51
12.14.1 Powder Measuring Adapter for Flat Jet Nozzle C4 51
12.14.2 Powder Measuring Adapter for Flat Jet Nozzle C4-F5/X1-F5 51
13 SPARE PARTS 52
13.1 How Can Spare Parts Be Ordered? 52
13.2 PEA-C4-HiCoat Corona Automatic Gun 53
13.3 Electrode Holder C4 R with Nozzles 54
13.4 Angle Adapter, WA90 C4 55
13.5 Angle Adapter, WA60 C4 56
13.6 Angle Adapter, WA30 C4 57
14 EU DECLARATION OF CONFORMITY 58
14.1 EU Declaration of Conformity - Automatic Gun 58

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VERSION 05/2019 ORDER NUMBER DOC390829 PEA-C4-HiCoat
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.
Note: 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 390822
Translation of the original operating manual
Language Order no. Language Order no.
English 390829 Portuguese 2315719
French 390836 Danish 390870
Italian 390840 Serbian 390871
Spanish 390851 Norwegian 390880
Russian 2335894 Slovenian 390863
Chinese -- Czech 390896
Dutch 390876 Polish 2320221
Swedish 2400205 Turkish 2400976
Hungarian 2338222 -- --
Additional languages on request or at: www.wagner-group.com
1.4 ABBREVIATIONS
Order no. Order number
Spare part
Marking in the spare parts lists
Position
Number of pieces
-- Item not available as spare part
/ Item does not exist

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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 compressed air
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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2 CORRECT USE
2.1 DEVICE TYPE
Automatic powder gun for the automatic coating of grounded workpieces.
2.2 TYPE OF USE
TheautomaticPEA-C4 HiCoatgunserves as stationaryequipmentforindustrial electrostatic
coating with ignitable powder in automatic systems. It can be operated either with single
control units or switch cabinet modules.
WAGNER explicitly prohibits any other use!
The automatic powder gun may only be operated in a temperature range from 5–40 °C;
41–104 °F.
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.
Follow the instructions in the operating manual.
2.3 FOR USE IN POTENTIALLY EXPLOSIVE AREAS
This type A-P electrostatic powder gun is suitable for processing industrial powder lacquers
for coating electrically conductive objects and can be used in potentially explosive areas
(zone 22) (see Explosion Protection Identication, Chapter 3.1).
In explosion hazard areas, only use approved explosion-proof electrical devices.
2.4 PROCESSIBLE WORKING MATERIALS
– types of powder that can be charged electrostatically;
– metallic powder.
Note:
Contact your localWAGNER 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:
liquid coating products, e.g., solvents or water-based lacquers are not processed;
no food, medicine or cosmetics are processed.

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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
Device type: Automatic powder gun, PEA-C4 HiCoat
Manufacturer: Wagner International AG
9450 Altstätten
Switzerland
0102 II 2D 2mJ
CE European Communities
0102 Notied body: PTB
Ex Symbol for explosion protection
II Device class II
2 Category 2
D Ex-atmosphere dust
2 mJ Maximum ignition energy 2 mJ
3.2 TYPE PLATE
P_03903
PEA-C4 Serial Number:
Made in Switzerland
0102 II 2 D 2mJ
PTB 05 ATEX 5008
3.3 PERMISSIBLE DEVICE COMBINATIONS
WARNING
Incorrect use!
Risk of injury and damage to the device.
Only connect the automatic powder gun to original WAGNER devices.
The automatic PEA-C4 HiCoat powder gun may only be used with the following control units:
Guns Control units
– PEA-C4-HiCoat – EPG-Sprint – EPG Prima – HVM-DP
– EPG-Sprint X – EPG 2008 – EPG-DP 5
– EPG-Sprint XE – EPG 2007 – EPG–SL 5
– EPG-D1 – HVM-D 1 – EPG 2025 Digiow