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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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 Identication 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 Qualications 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 Deector 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 Retrot Set CoronaStar 48
12.7 CoronaStar WA C4 49
12.8 CoronaStar PEA-C4 F5 Retrot 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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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 qualications
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 sucient 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 TRBS1203(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 Identication, 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 Notied 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 Digiow

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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 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 inuences.
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. Secure the device against being
switched back on without authorization. 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.

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4.1.2 A SAFE WORK ENVIRONMENT
Danger due to dust formation!
Severe or fatal injuries due to explosion hazard or inhalation, swallowing or contact with
the skin or eyes.
The oor in the working area must be electrostatically conductive
(measurements according to EN 1081 and EN 61340-4-1).
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 personal protective equipment (see Chapter 4.2.1) is available and is used.
Ensure that all persons within the working 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. No smoking.
Maintain sucient quantities of suitable re extinguishers and ensure that they are
serviceable.
The powder release must be electronically interlocked with the powder spray system
exhaust equipment.
Excess coating product (overspray) must be collected up safely.
The operating company must ensure that an average concentration of powder lacquer
in the air does not exceed 50% of the lower explosion limit (LEL = max. permitted
concentration of powder to air). If no reliable LEL value is available, the average
concentration must not exceed 10 g/m³.
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 qualications.

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4.2 SAFETY INSTRUCTIONS FOR THE PERSONNEL
Always follow the information in this manual, particularly the safety instructions and
the warning instructions.
Always follow local regulations concerning accident prevention regulations.
In electrostatics applications: Persons belonging to a risk group according to
EMF guideline 2013/35/EU (e.g., carriers of active implants), must not enter the
high-voltage area.
4.2.1 PERSONAL SAFETY EQUIPMENT
Danger due to dust formation!
Serious or fatal injuries due to inhalation, swallowing or contact with the skin or eyes.
Observe the processing regulations laid down by the manufacturer of the powder
lacquer being used, when preparing or processing the powder.
Take note of the manufacturer’s notication and the relevant environmental protection
regulations when disposing of powder lacquers.
Take the specied 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 sucient health and environmental safety: Operate the device in a powder coating
booth or on a spraying wall with the ventilation (extraction) switched on.
4.2.2 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
Danger due to dust formation!
Do not point spray guns at people.
Do not spray device parts using electrostatic equipment.
Before any work on the device, in the event of work interruptions and malfunctions:
– Switch o the energy/compressed air supply.
– Relieve pressure on powder spray gun and device.
– Secure the powder spray gun against actuation.
– Disconnect the control unit from the mains.
– In the event of functional faults: remedy the fault as described in the
"Troubleshooting" chapter.

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4.2.3 GROUNDING THE DEVICE
Danger due to electrostatic charge!
Explosion hazard and damage to the device.
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the device.
Flames or sparks can form during discharge.
Correct grounding of the entire coating system prevents electrostatic charges:
Ensure that all devices and tanks are grounded before each coating process.
All of the system's conductive elements, such as oors, walls, ceilings, protective
grating, transport equipment, work pieces, powder tanks, automatic moving devices
or construction parts etc. in the spray area, with the exception of parts which carry high
voltage during operation, must be connected to the grounding system.
Parts of the booth must be grounded in accordance with EN 12981.
Ensure that all persons inside the working area are grounded, e.g., that they are wearing
static dissipative shoes.
Grounding cables must be checked regularly to ensure that they are serviceable
(see EN 60204).
4.2.4 PRODUCT HOSES
Danger due to damaged product hoses!
The product hose may cause dangerous injuries.
Use only an original WAGNER powder hose.
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.

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4.2.5 ELECTRICAL CONNECTION CABLES
Risk caused by improperly laid cables!
Risk of injury and damage to the device.
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.
4.2.6 CLEANING AND FLUSHING
Danger due to cleaning and ushing!
Explosion hazard and damage to the device.
Before starting cleaning or any other manual work, the high voltage in the spray
area must be shut down and locked to prevent it from being switched back on.
Lock the compressed air supply and decompress the device.
Secure the device against being switched back on without authorization.
Use only electrically conducting and grounded tanks for cleaning uids.
Preference should be given to non-ignitable cleaning uids.
If ignitable cleaning uids are used, all parts carrying high voltage must be discharged
to a discharge energy of less than 0.24 mJ, once the high voltage has been switched
o, before they can be reached. Most ignitable solvents have an ignition energy of
around 0.24 mJ or 60 nC.
The cleaning agent's ash point must be at least 15 K above the ambient temperature.
Note the details provided by the powder lacquer manufacturer.
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used
for getting rid of dust build-up.
Take measures for workplace safety (see Chapter 4.1.2).

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4.2.7 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 12 and Chapter 13 that are
assigned to the device.
Do not use any defective components.
Before all work on the device and in the event of work interruptions:
– Switch o the energy and compressed air supply.
– Relieve pressure on powder spray gun and device.
– Secure the powder spray gun against actuation.
Observe the operating and service manual for all work.
4.2.8 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, modied 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.
4.2.8.1 RELEASING GUNS HIGH VOLTAGE/PNEUMATIC SYSTEM
Enabling high voltage depends on:
– Exhaust air is OK
– Fire extinguishing system/re detection signal OK (external signal)
– No EMERGENCY STOP
– Control voltage ON
As soon as one of these conditions is not fullled, the high voltage is switched o
immediately. After the fault has been eliminated and acknowledged, the enabling
mechanism can be selected again. An automatic switch on is prevented by the hardware
locking.

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4.3 INFORMATION ABOUT SAFE DISCHARGES
1
2
3
4
P_03925
Designation
1 Nozzle
2 Electrode
3 Luminous discharge
4 Work piece
With the high voltage switched on, a luminous or corona discharge occurs at the electrode
tip; this can only be seen in the dark. This physical eect can be seen when the electrode
is brought near the grounded work piece. This luminous discharge does not involve any
ignition energy and has no eect on system handling. When the electrode approaches the
work piece, the control unit automatically reduces the high voltage to a safe value. If you
touch plastic parts of the spray gun with your nger, harmless discharges may occur due to
the high-voltage eld around the spray gun (so-called brush discharges). However, these
do not contain any ignition energy.

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5 DESCRIPTION
5.1 CONSTRUCTION OF THE AUTOMATIC GUN
5
X
7
2
3
6
1
P_03904
4
9
5
8
X
Designation
1 Electrode
2 Deector cone
3 Union nut
4 Type plate
5 Powder hose connection
6 Spray gun body
7 Flat jet nozzle
8 Electrical connection
9 Atomizer air connection
5.2 MODE OF OPERATION OF THE AUTOMATIC GUN
The spray gun is switched on and o via the superordinated control unit.
At the same time the air supply and high voltage are activated.
The distance of the installed spray guns to each other must be at least 300 mm; 11.81 inches
for functional reasons.
The gun control cabinet must be switched o in order to lock the automatic gun!
If changing from the at jet nozzle to the deector cone, the depth control must be adjusted.

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5.3 SCOPE OF DELIVERY
Order no. Designation
1 390004 Automatic gun, PEA-C4 HiCoat
-- Nozzle set
The standard equipment includes:
1 390893 Declaration of Conformity
1 390822 Operating manual, in German
1 see Chapter 1.3 Operating manual in local language
5.4 DATA
5.4.1 TECHNICAL DATA
Dimensions:
Length/width/height see Chapter 5.4.2
Weight 555 g; 1.22 lbs
Electrical:
Input voltage maximum 22 Vpp
Input current maximum 0.9A
Frequency 19–30 kHz
Output voltage maximum 100 kV DC
maximum Corona current 120 µA
Polarity negative
Construction type in accordance with DIN EN 50177 types A-P
Protection class IP 54
Pneumatic:
Input air pressure (atomizing air volume) maximum 3 bar; 0.3 MPa, 43.51 psi
Powder discharge quantity maximum 450 g/min;
maximum 0.99 lbs/min
WARNING
Exhaust air containing oil!
Risk of poisoning if inhaled.
Insucient paint application quality
Provide compressed air free from oil and water
(Quality Standard 6.5.2 according to ISO 8573.1, 2010)
6.5.2 = particle density ≤ 5 mg/m; pressure dew point ≤ +7 °C; oil content ≤ 0.1mg/m

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Ambient conditions:
If low-melting powders are used, the ambient temperature may have to be lower than 30 °C;
86 °F.
Volume measures for volumes specied in Nm³ (standard cubic meters). One cubic meter
of a gas at 0 °C and 1.013 bar is called norm cubic meter.
Ambient conditions:
Operating temperature range 5–40 °C; 41–104 °F
Relative humidity < 75%
5.4.2 DIMENSIONS
A
C
B
P_01611
X
E
D
X
Measurement mm inch
A 395 133.66
B* 30 1.18
C 310 12.20
D 76 2.99
E 82 3.23
* Measurement for installation dimension C calculation when utilizing a deector cone
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