WAGNER PEA-C4XL-S Operational manual

0102 II 2 D EEx 2mJ 85 °C
P_02330
Automatic Powder Spray Gun
PEA-C4XL-S
Version 03 / 2014
Translation of the
Original Operating
Manual

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PEA-C4XL-S
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
Table of Contents
1 GENERAL INFORMATION 6
1.1 Preface 6
1.2 Warnings, Notices, and Symbols in this Operating Manual 6
1.3 Languages 7
1.4 Abbreviations 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
2.5 Processible Working 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 Feature Identication 11
4 GENERAL SAFETY INSTRUCTIONS 12
4.1 Safety Instructions for the Operator 12
4.1.1 Electrical Devices and Equipment 12
4.1.2 Sta Qualications 12
4.1.3 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 Lacquers 14
4.3 Note on Safe Discharges 15
4.4 Protective and Monitoring Equipment 16
4.4.1 Release Guns (High-voltage/Pneumatic System) 16
5 DESCRIPTION 17
5.1 Spray Gun Design 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 Handling of the Hose Coupling 25
6.6 Assembling the Spray Gun 26

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6.7 Grounding 28
6.7.1 Grounding the Powder Coating System 29
7 OPERATION 30
7.1 Training the Operating Sta 30
7.2 Safety Instructions 30
7.3 Switching on the Spray Gun 31
7.4 Switching O the Spray Gun 31
7.5 Switching O the Spray Gun in the Event of Faults or Emergencies 31
7.6 Optimizing the Powder Cloud for Your Coating 32
7.7 Performing a Paint Change 33
7.7.1 Impulse Flushing 34
7.8 Reproducible Setting of the Nozzle Position 35
8 CLEANING AND MAINTENANCE 36
8.1 Cleaning 36
8.1.1 Cleaning Sta 36
8.1.2 Safety Instructions 36
8.1.3 Cleaning Procedures 37
8.2 Maintenance 38
8.2.1 Maintenance Sta 38
8.2.2 Safety Instructions 38
8.2.3 Maintenance Procedures 39
8.2.4 Replacing the Spray Gun 40
8.3 Cleaning the Gun and Dismantling the Flat Spray Nozzle 42
8.4 Replacing the Protective Wedge 43
8.5 Fitting the Round Spray Nozzle 45
8.6 Assembling the Angle Adapter 47
8.6.1 Removing the Nozzle and Electrode Holder 47
8.6.2 Fitting the Angle Adapter 48
8.6.3 Replacement of the Wearing Parts 48
8.7 Assembling the Corona-Star 50
8.8 Corona-Star for Angle Adapter 51
8.8.1 Assembling the Corona-Star 51
9
INSPECTIONS IN ACCORDANCE WITH DIN EN 50177: 201004 52
9.1 Overview of Inspections 53
10 DISASSEMBLY AND DISPOSAL 56
10.1 Disassembly 56
10.2 Disposal 57
11 TROUBLESHOOTING AND RECTIFICATION 58
12 ACCESSORIES 60
12.1 Flat Spray Nozzles 60
12.2 Deector Cone for Round Spray Nozzle 60
12.3 Corona-Star Retrot Set 61
12.4 Corona-Star WA C4 61
12.5 Wedge Tool 62
12.6 Electric Cables and Hoses 62
12.7 Angle Adapter 63
12.8 Powder Measuring Bag 64
Table of Contents

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13 SPARE PARTS 65
13.1 How Can Spare Parts Be Ordered? 65
13.2 PEA-C4XL-S Corona Automatic Gun 66
13.3 C4 R Electrode Holder with Nozzles 67
13.4 WA90 C4 Angle Adapter 68
13.5 WA60 C4 Angle Adapter 69
13.6 WA30 C4 Angle Adapter 70
14 DECLARATION OF WARRANTY AND CONFORMITY 71
14.1 Important Notes Regarding Product Liability 71
14.2 Warranty Claim 71
14.3 Declaration of Conformity 72
Table of Contents

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OPERATING MANUAL
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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.
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 instructions in this
operating manual.
1.1 PREFACE
1.2 WARNINGS, NOTICES, AND SYMBOLS IN THIS OPERATING MANUAL
Warning instructions in this operating 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 - 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 material damage.
This notice 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 notice 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 notice 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 notice 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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1.3 LANGUAGES
The operating manual is available in the following languages:
Language: Order No. Language: Order No.
German 2345333 English 2345334
Italian 2345335
1.4 ABBREVIATIONS
Number of pieces
Position
Marking in the spare parts lists
Order No. Order number
Spare part

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OPERATING MANUAL
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2 CORRECT USE
2.1 DEVICE TYPE
Automatic spray gun for automatic coating
2.2 TYPE OF USE
The PEA-C4XL-S spray gun 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
areas (zone 22). (See Chapter 3.1 Explosion Protection Identication).
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 standards 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 products,
and 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 material damage:
use of damp powder paint,
incorrectly set values for powder discharge,
and incorrectly set electrostatic values.
2.5 PROCESSIBLE WORKING 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 lacquers
and cleaning agents
Handling powder
lacquers and
cleaning agents
Skin irritations, Wear protective
clothing,
Operation,
Allergies Observe safety data
sheets
Maintenance,
Disassembly
Powder lacquer
in air outside the
dened working
area
Lacquering outside
the dened working
area
Inhalation of
substances
hazardous to health
Observe work and
operation instructions
Operation,
Maintenance
Falling down of
spray guns
Loosening of the
securing nuts
Injuries Regular check of
fastenings
Operation,
Maintenance
Residual voltage on
live parts
Decient grounding Electrical shock Indication of danger, Operation,
Instruction by trainer Maintenance

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0102
OPERATING MANUAL
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3 IDENTIFICATION
3.1 EXPLOSION PROTECTION IDENTIFICATION
3.2 PERMISSIBLE DEVICE COMBINATIONS
The PEA-C4XL-S powder spray gun may only be connected to the control devices listed
below:
EPG-S2 EPG-Sprint X
Gun type: PEA-C4XL-S
Manufacturer: J. Wagner AG
CH - 9450 Altstätten
II 2 D EEx 2mJ 85 °C
CE: European Communities
0102: Number of notied 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: Maximum ignition energy 2 mJ
85 °C: Maximum surface temperature
Incorrect use of the spray gun!
Risk of injury and damage to the device.
Only connect original Wagner devices to the PEA-C4XL-S HiCoat
spray gun.
WARNING

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3.3 SAFETY FEATURE IDENTIFICATION
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 system) 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 tanks 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
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4 GENERAL SAFETY INSTRUCTIONS
4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR
4.1.1 ELECTRICAL DEVICES AND EQUIPMENT
4.1.2 STAFF QUALIFICATIONS
4.1.3 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 decommissioned 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, maintained 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 megohms.
The protective clothing, including gloves, must comply with the requirements of
EN ISO 1149-5. The measured insulation resistance must not exceed 100 megohms.
The powder release must be electrically interlocked with the powder spray system's
exhaust air equipment.
Excess coating product (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.
Maintain sucient quantities of suitable re extinguishers and ensure that they are
serviceable.
The operating company must ensure that an 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 may not exceed 10 g/m³.

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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 this manual, 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.
- Secure the spray gun against actuation.
- Relieve pressure on spray guns and device.
-
In case of functional faults: Identify and correct the problem, proceed as described
in the "Fault Rectication" chapter.
The electrostatic charge may, in certain cases, give rise to electrostatic charges on the
device. This may result in the formation of sparks or ames when discharging.
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 functionality of grounding cables must be checked regularly (see EN 60204).
Only use an original Wagner powder hose.

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4.2.5 HANDLING POWDER LACQUERS
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 compressed air supply and decompress the system.
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-ammable cleaning uids.
Flammable cleaning liquids may only be used if, after switching o the high-voltage,
all high-voltage conducting parts are discharged to a discharge energy of less than
0.24 mJ before they can be accessed.
Most ammable 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.
Only mobile industrial vacuum cleaners of design 1 (see EN 60335-2) may be used to
remove dust deposits.
When preparing or processing the powder and cleaning the device, take note of the
processing regulations, laid down by the manufacturer of the powder lacquers, being
used.
Take note of the manufacturer’s instructions and the relevant environmental protection
regulations when disposing of powder lacquers.
Take the prescribed safety measures, in particular the wearing of safety glasses and
safety clothing as well as the use of protective hand cream.
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 on a spray wall with activated ventilation (exhaust air).

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OPERATING MANUAL
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4.3 NOTE ON SAFE 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
ignition energy 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 ignition energy.
Work piece
Luminous discharge
Nozzle
Electrode

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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 for perfect functioning.
If defects are detected on protective and monitoring equipment,
the system must not be operated until these defects are
remedied.
WARNING

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PEA-C4XL-S
B
C
A
F
G
H
X
X
P_02331
G
K
I
L
D
E
A
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
5 DESCRIPTION
5.1 SPRAY GUN DESIGN
Designation
A Fan spray nozzle or round spray nozzle
BDeector cone for round spray nozzle
C Round spray nozzle electrode
D Union nut
E Interlocking
F Spray gun body
G Powder hose connection
H Supporting tube
I Electrical connection
K Atomizing air connection
L Grounding screw
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 round spray nozzle with deector cone, the
depth control must be adjusted!

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OPERATING MANUAL
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Dimensions:
Length/width/height see Chapter 5.3.1
Weight
Electrical:
Input voltage maximum 22 Vpp
Input current maximum 0.9 A
Frequency 19 - 30 kHz
Output voltage maximum 100 kV DC
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 output quantity maximum 450 g/min;
maximum 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 and
1.013 bar is called norm cubic meter.

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PEA-C4XL-S
E
D
X
X
A*
P_02332
B
C
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
5.3.1 DIMENSIONS
Measurement mm inch
A* 30 1.18
B 400 15.75
C 1,100 43.31
D 60 2.36
E 72 2.83
Measurement for installation dimension C calculation when utilizing a round spray
nozzle with deector cone

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OPERATING MANUAL
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Quantity Order No. Designation
1 2344249 PEA-C4XL-S automatic gun
1 --- Nozzle set
The standard equipment includes:
1 2347535 Conformity certicate
1 2345333 Operating manual, German
1 see Chapter 1.3 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-C4XL-S
powder spray gun.
The accessories listed in Chapter 12 were included in the EC type examination and are
approved for use with the gun.