WAGNER PEA-C4-HiCoat FM Operational manual

0102 II 2 D EEx 2mJ 85 °C
P_01610
Automatic Powder Spray Gun
PEA-C4-HiCoat
Version 05 / 2012
Translation of the Original
Operating Manual

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PEA-C4-HiCoat
OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
Contents
1 GENERAL INFORMATION 6
1.1 Preface 6
1.2 Warnings, Notes and Symbols in these Instructions 6
1.3 Copyright 7
1.4 Contact Details 7
1.5 Languages 7
2 CORRECT USE 8
2.1 Device Type 8
2.2 Type of Use 8
2.3 Use in Potentially Explosive Areas 8
2.4 Safety Parameters 8
2.6 Processing Materials 9
2.6 Reasonably Foreseeable Misuse 9
2.7 Residual Risks 9
3 IDENTIFICATION 10
3.1 Explosion Protection Identication 10
3.2 Permissible Device Combinations 10
3.3 Safety Identications 11
4 GENERAL SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Operating Equipment 12
4.1.2 Personnel Qualications 12
4.1.3 A safe Work Environment 12
4.2 Safety Instructions for Sta 13
4.2.1 Safe Handling of WAGNER Powder Spray Devices 13
4.2.2 Grounding the Device 13
4.2.3 Accessories and Spare Parts 13
4.2.4 Cleaning and Maintenance 14
4.2.5 Handling Powder Paints 14
4.3 Note on Harmless Discharges 15
4.4 Protective and Monitoring Equipment 16
4.4.1 Release Guns (High-Voltage/Pneumatic System) 16
5 DESCRIPTION 17
5.1 Design of Spray Gun 17
5.2 Functioning of the Spray Gun 17
5.3 Technical Data 18
5.3.1 Dimensions 19
5.4 Permitted Accessories 20
5.5 Scope of Delivery 20
6 ASSEMBLY AND COMMISSIONING 21
6.1 Training Assembly/Commissioning Sta 21
6.2 Storage Conditions 21
6.3 Installation Conditions 21
6.4 Preparing the Spray Gun 22
6.4.1 Selection of the Suitable Nozzle System 22
6.5 Mounting the Spray Gun 24

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Contents
6.6 Grounding 25
6.6.1 Grounding the Powder Coating System 26
7 OPERATION 27
7.1 Training the Operating Sta 27
7.2 Safety Instructions 27
7.3 Switching on the Spray Gun 28
7.4 Switching o the Spray Gun 28
7.5 Switching o the Spray Gun in the Event of Faults or Emergencies 28
7.6 Optimizing the Powder Cloud for your Coating 29
7.7 Performing a Color Change 30
7.8 Reproducible Setting of the Nozzle Position 31
8 CLEANING AND MAINTENANCE 32
8.1 Cleaning 32
8.1.1 Cleaning Sta 32
8.1.2 Safety Instructions 32
8.1.3 Cleaning Procedures 33
8.2 Maintenance 34
8.2.1 Maintenance Sta 34
8.2.2 Safety Instructions 34
8.2.3 Maintenance Procedures 35
8.2.4 Replacing the Spray Gun 36
8.3 Cleaning the Spray Gun and Dismantling the Flat Spray Nozzle 37
8.4 Replacing the Protective Wedge 38
8.5 Fitting the Round Spray Nozzle 40
8.6 Fitting the Angle Adapter 42
8.6.1 Removing the Nozzle and Electrode Holder 42
8.6.2 Fitting the Angle Adapter 43
8.6.3 Replacement of the Wearing Parts 43
8.7 Mounting the Corona-Star 45
8.8 Corona-Star for Angle Adapter 46
8.8.1 Mounting the Corona-Star 46
9 INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 201004 47
9.1 Overview of Inspections 48
10 DISASSEMBLY AND DISPOSAL 50
10.1 Disassembly 50
10.2 Disposal 50
11 TROUBLESHOOTING AND RECTIFICATION 51
12 ACCESSORIES 53
12.1 Flat Spray Nozzles 53
12.2 Deector Cone 53
12.3 Retrot Set Corona-Star 54
12.4 Corona-Star WA C4 54
12.5 Wedge Tool 55
12.6 Gun Support and Fixation 55
12.7 Electric Cables and Hoses 55
12.8 Angle Adapter 56
12.9 Powder Measuring Bag 57

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OPERATING MANUAL
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13 SPARE PARTS 58
13.1 How can Spare Parts be ordered? 58
13.2 PEA-C4-HiCoat Corona Automatic Gun 59
13.3 Electrode Holder C4 R with Nozzles 60
13.4 Angle Adapter WA90 C4 61
13.5 Angle Adapter WA60 C4 62
13.6 Angle Adapter WA30 C4 63
14 DECLARATION OF WARRANTY AND CONFORMITY 64
14.1 Important Notes on Product Liability 64
14.2 Warranty Claim 64
14.3 Declaration of Conformity 65
14.4 EC Type Examination Certicate 66

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PEA-C4-HiCoat
OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
1 GENERAL INFORMATION
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 operating and service
sta.
The operating and service sta should be instructed according to the safety instructions.
The device may only be operated in compliance with this operating manual.
This equipment can be dangerous if it is not operated according to the denitions in this
operating manual.
1.1 PREFACE
1.2 WARNINGS, NOTES AND SYMBOLS IN THESE INSTRUCTIONS
Warning instructions in this operating manual highlight particular dangers to users and
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 - possible imminent danger.
Non-observance may result in death or serious injury.
Caution - a possibly hazardous situation.
Non-observance may result in minor injury.
Note - provides information about particular characteristics and how to proceed.
Notice - a possibly hazardous situation.
Non-observance may result in damage to property.
This information warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
DANGER
This information warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
WARNING
This information warns you of a hazard!
Possible consequences of not observing the warning instructions.
The signal word indicates the hazard level.
The measures for preventing the hazard and its consequences.
CAUTION
This information warns you of a hazard!
Possible consequences of not observing the warning instructions. The signal word
indicates the hazard level.
The measures for preventing the hazard and its consequences.
NOTICE

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OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
1.5 LANGUAGES
The copyright for this operating manual belongs to J. Wagner AG.
The information contained in this operating manual may only be used by the operator for
his own use, e.g. to produce operating instructions.
1.3 COPYRIGHT
J. Wagner AG Tel [phone]
Industriestrasse 22 Fax [phone]
Postfach 663 www.wagner-group.com
CH-9450 Altstätten [e-mail]
1.4 CONTACT DETAILS
The operating manual is available in the following languages:
Language: Order No. Language: Order No.
German 390822 English 390829
French 390836 Dutch 390876
Italian 390840 Spanish 390851
Danish 390870 Portuguese 2315719
Norwegian 390880 Polish 2320221
Czech 390896 Slovenian 390863
Serbian 390871

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OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
2 CORRECT USE
2.1 DEVICE TYPE
Automatic spray gun for automatic coating
2.2 TYPE OF USE
The spray gun PEA-C4-HiCoat serves as stationary equipment for industrial electrostatic
coating with ammable powder in automatic systems. It can be operated either with
single control units or switch cabinet modules.
2.3 USE IN POTENTIALLY EXPLOSIVE AREAS
This type A-P electrostatic powder spray gun is suitable for processing industrial powder
paints for coating electrically conductive objects and can be used in potentially explosive
atmospheres (zone 22). (See explosion protection identication Chap 3.1).
2.4 SAFETY PARAMETERS
The powder spray gun is only suited to the application of powder paint.
J. Wagner AG forbids any other use!
The powder spray gun may only be operated under the following conditions if:
the operating sta have previously been trained on the basis of this operating manual,
the safety regulations listed in this operating manual are observed,
the operating, maintenance and repair information in this operating manual is
observed,
and the statutory requirements and accident prevention regulations standard in the
country of use are observed.
The spray gun may only be used if all parameters are set and all measurements/safety
checks are carried out correctly.

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2.6 REASONABLY FORESEEABLE MISUSE
The following is prohibited:
coating work pieces which are not grounded
unauthorized conversions and modications to the spray gun
processing liquid or similar coating materials
using defective components, spare parts or accessories other than those described in
chapter 12 of this operating manual
The forms of misuse listed below may result in health issues and/or damage to property:
use of damp powder paint
incorrectly set values for powder discharge
incorrectly set electrostatic values
2.6 PROCESSING MATERIALS
Types of powder which can be charged electrostatically
Metallic powder
2.7 RESIDUAL RISKS
Residual risks are risks which cannot be excluded even in the event of correct use.
If necessary, warning and prohibition signs at the relevant points of risk indicate residual
risks.
Residual Risk Source Consequences Specic Measures Lifecycle Phase
Skin contact with
powder paints and
cleaning agents
Handling powder
paints and cleaning
agents
Skin irritation, Wear protective
clothing
Operation,
allergies Note safety data
sheets
maintenance,
disassembly
Powder paint in air
outside the dened
working area
Painting outside the
dened working
area
Inhalation of
substances
hazardous to health
Observe working
instructions and
operating
procedures
Operation,
maintenance
Falling down of
spray guns
Loosening of the
securing nuts
Injuries Regular check of
xations
Operation,
maintenance
Residual voltage on
live parts
Decient grounding Electrical shock Danger instruction, Operation,
instruction by
trainer
maintenance

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PEA-C4-HiCoat
0102
OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
The EC type examination certicate PTB 05 ATEX 5008 can be found in chapter 14.4.
3.2 PERMISSIBLE DEVICE COMBINATIONS
The PEA-C4-HiCoat powder spray gun may only be connected to the control devices listed
below:
EPG-Sprint HVM-D 1
Bravo HVM-DP
EPG-D1 EPG-DP 5
EPG Prima EPG-SL 5
EPG 2008 EPG 2025 Digi.
EPG 2007
Gun type: PEA-C4-HiCoat
Manufacturer: J. Wagner AG
CH - 9450 Altstätten
II 2 D EEx 2mJ 85 °C
CE: Communautés Européennes
0102: Number of appointed body which is involved in the production
monitoring phase
E: according to European standard
Ex: Symbol for explosion protection
II: Device class II
2: Category 2
D: Ex-atmosphere dust
2mJ: Max. ring power 2 mJ
85 °C: Max. surface temperature
Incorrect use of the spray gun!
Risk of injury and damage to the device.
Only connect original Wagner devices to the PEA-C4-HiCoat
spray gun.
WARNING

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OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
3.3 SAFETY IDENTIFICATIONS
Plates bearing information for the user have been attached to the work openings of the
powder coating booth.
The plate size corresponds to the standard category Ø 100 mm; 3.94 inches.
The label plates, which must be attached, are shown below:
Explosive atmosphere!
Close to the spray area a warning sign (included in the delivery of the installation) has to be
placed with the following indications:
The equipment may only be operated by trained sta.
Before starting cleaning the spray gun or carrying out any other work in the spray
area, the high-voltage must be shut down in such a way that it cannot be activated
again by actuating the trigger of the spray gun.
Use only metallic containers for cleaning uids.
Preferably use solvents with the highest possible ash point, higher than the ambient
temperature if possible.
The electrostatic spraying unit must be maintained regularly according to the
manufacturer's instructions. Repairs may only be performed according to the
manufacturer's instructions.
Forbidden for unauthorized
persons!

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OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL DEVICES AND OPERATING EQUIPMENT
4.1.2 PERSONNEL QUALIFICATIONS
4.1.3 A SAFE WORK ENVIRONMENT
Keep this operating manual at hand near the device at all times.
Always follow local regulations concerning occupational safety and accident
prevention.
To be provided in accordance with the local safety requirements with regard to the
operating mode and ambient inuences.
May only be maintained by skilled electricians.
Must be operated in accordance with the safety regulations and electrotechnical
regulations.
Must be repaired immediately in the event of problems.
Must be put out of operation if they pose a hazard.
Must be de-energized before work is commenced on active parts.
Secure the device against being switched back on without authorization. Inform sta
about planned work.
Observe electrical safety regulations.
Ensure that the device is operated and repaired only by trained persons.
The oor in the working area must be electrostatically conductive (measurements
according to EN 1081 and EN 61340-4-1).
The footwear worn by the operators must comply with the requirements of
ENISO20344. The measured insulation resistance must not exceed 100 megaohms.
The protective clothing, including gloves, must comply with the requirements of
ENISO1149-5. The measured insulation resistance must not exceed 100 megaohms.
The powder release must be electrically interlocked with the powder spray system's
exhaust air equipment.
Excess coating material (overspray) must be collected up safely.
Ensure that there are no ignition sources such as naked ames, sparks, glowing wires or
hot surfaces in the vicinity. Do not smoke.
Provide sucient numbers of suitable re extinguishers and ensure that they are
serviceable.
The operating company must ensure that the average concentration of powder paint
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.

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OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
4.2.1 SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES
4.2.2 GROUNDING THE DEVICE
4.2.3 ACCESSORIES AND SPARE PARTS
4.2 SAFETY INSTRUCTIONS FOR STAFF
Always follow the information in these instructions, particularly the general safety
instructions and the warning instructions.
Always follow local regulations concerning occupational safety and accident
prevention.
Under no circumstances may people with pacemakers enter the area where the
high-voltage eld between the spray gun and the work piece to be coated builds up!
Do not point spray guns at people.
Before all work on the device, in the event of work interruptions and functional faults:
- Switch o the energy/compressed air supply.
- Lock spray guns to prevent them actuating.
- Relieve pressure on spray guns and device.
- In the event of functional faults: Identify and correct the problem, proceed as
described in chapter "Elimination of Faults".
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the
device. In the event of discharge, this may result in the formation of sparks or ames.
Ensure that the device is grounded before each coating process.
Ground the work pieces to be coated.
Ensure that all persons inside the working area are grounded, e.g. by wearing
electrostatically conductive shoes.
The function of grounding cables must be checked regularly (see EN 60204).
Only use original Wagner powder hose.

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OPERATING MANUAL
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4.2.5 HANDLING POWDER PAINTS
4.2.4 CLEANING AND MAINTENANCE
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 supply of compressed air and decompress the system.
Secure the device against being switched back on without authorization.
Use only electrically conducting and grounded containers for cleaning uids.
Preference should be given to non-ammable cleaning uids.
Flammable cleaning uids may only be used if, once the high-voltage has been
switched o and all parts carrying high-voltage are discharged to a discharge energy
of less than 0.24 mJ before they can be reached.
Most ammable solvents have a ring power of around 24 mJ or 60 nC.
The cleaning agent's ash point must be at least 15 K above the ambient temperature.
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used to
remove dust deposits.
Take note of the processing regulations laid down by the manufacturer of the powder
paint being used, when preparing or processing the powder.
Take note of the manufacturer’s advice and the relevant environmental protection
regulations when disposing of powder paints.
Take the prescribed safety measures, in particular wear of safety glasses and safety
clothing and use protective hand cream if required.
Use a mask or breathing apparatus if necessary.
To ensure sucient protection of health and the environment, only operate the device
in a powder booth or at a spray wall with activated ventilation (exhaust air).

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PEA-C4-HiCoat
P_01091
OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
4.3 NOTE ON HARMLESS DISCHARGES
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 eect can be seen when the electrode
is brought near the grounded work piece. This luminous discharge does not involve any
ring power and has no eect 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 ring power.
Work piece
Luminous discharge
Nozzle
Electrode

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OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
4.4 PROTECTIVE AND MONITORING EQUIPMENT
4.4.1 RELEASE GUNS HIGHVOLTAGE/PNEUMATIC SYSTEM
Enabling high-voltage depends on:
Exhaust air is OK
Fire extinguishing system/re detection system is OK (external signal)
No EMERGENCY STOP
Control voltage ON
As soon as one of these conditions is not fulfilled, the high-voltage is switched off
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.
Incorrect use!
Risk of injury and damage to the device.
Protective and monitoring equipment must not be removed,
modied or rendered unusable.
Regularly check that they are working perfectly.
If defects are detected on protective and monitoring equipment,
the system must not be operated until these defects are
remedied.
WARNING

17
PEA-C4-HiCoat
G
X
A
A
C
D
B
P_01612
H
F
G
E
X
OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
5 DESCRIPTION
5.1 DESIGN OF SPRAY GUN
Description
A Flat spray nozzle (deector cone)
B Electrode
C Cap nut
D Gun body
E Electrical connection
F Atomizing air connection
G Powder hose connection
H Type plate
5.2 FUNCTIONING OF THE SPRAY 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 spray gun!
If changing from the at spray nozzle to the deector cone, the depth control must be
adjusted.

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OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
Dimensions:
Length/width/height see chapter 5.3.1
Weight 555 g; 1.22 lbs
Electrical:
Input voltage max. 22 Vpp
Input current max. 0.9 A
Frequency 19 - 30 kHz
Output voltage max. 100 kV DC
Polarity negative
Construction type in accordance with DIN EN 50177
type A-P
Protection class IP 54
Pneumatic:
Input air pressure (atomizing air volume) max. 3 bar; 0.3 MPa, 43.51 psi
Powder output quantity max. 450 g/min; max. 0.99 lbs/min.
Ambient conditions:
Operating temperature range 5 - 45 °C; 41 - 113 °F
Relative humidity < 75 %
5.3 TECHNICAL DATA
Outgoing air containing oil!
Risk of poisoning if inhaled.
Provide compressed air free from oil and water (quality standard
3.5.2 according to ISO 8573.1) 3.5.2 = 5 μm / +7 °C; 44.6 °F /
0.1mg/m³.
WARNING
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 specied in Nm³ (standard cubic meters). One cubic meter of a gas at 0 °C;
32°F and 1.013 bar is called norm cubic meter.

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PEA-C4-HiCoat
A
C
B
P_01611
X
E
D
X
OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
5.3.1 DIMENSIONS
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 deector cone

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PEA-C4-HiCoat
OPERATING MANUAL
VERSION 05/2012 ORDER NUMBER DOC 390829
Quantity Order No. Description
1 390004 PEA-C4-HiCoat automatic gun
1 --- Nozzle set
The standard equipment includes:
1 390893 Declaration of conformity
1 390822 Operating manual German
1 see chap. 1.1 Operating manual in local language
5.5 SCOPE OF DELIVERY
5.4 PERMITTED ACCESSORIES
Only the accessories listed in this operating manual may be connected to the
PEA-C4-HiCoat powder spray gun.
The accessories listed in chapter 12 were included in the EC type examination and are
approved for use with the gun.