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

3
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

4
PEA-C4XL-S
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
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

5
PEA-C4XL-S
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
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

6
PEA-C4XL-S
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
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

7
PEA-C4XL-S
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
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

8
PEA-C4XL-S
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
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.

9
PEA-C4XL-S
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
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

10
PEA-C4XL-S
0102
OPERATING MANUAL
VERSION 03/2014 ORDER NUMBER DOC2345334
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