Operating Manual. Automatic spray gun AGR-08-E for electrostatic atomization for solventborne paint

Transcription

1 Operating Manual Automatic spray gun AGR-08-E for electrostatic atomization for solventborne paint Product No.: S-AGR08E-GB (Original) Issue: 07/18-4 REITER GmbH + Co. KG Oberflächentechnik Phone: +49 (0) / Berglenstraße Fax: +49 (0) / D Winnenden Internet:

2 Contents of the Operating Manual Chapter 1 General Chapter 2 Safety Regulations Chapter 3 Technical Data Chapter 4 Transport (not assigned) Chapter 5 Function Description (not assigned) Chapter 6 Installation (not assigned) Chapter 7 Commissioning and Operation Chapter 8 Maintenance Chapter 9 Spare Parts Chapter 10 Appendix (not assigned) S-AGR08-EgbDB 07/18-4

3 1 General Table of Contents 1.1 About this instruction manual Automatic gun AGR-08-E Components Guarantee Copyright About this instruction manual This instruction manual only applies the electrostatic automatic gun AGR-08-E in the processing of solvent-based paints. The information contained in this manual are only intended to learn about the components and their use in typical operating conditions. This is not a guide to commissioning, as each system is designed differently. To start the training by authorized personnel from REITER GmbH + Co. KG surface technology is essential. This manual provides information for the operation, maintenance and care of this electrostatic device from REITER GmbH + Co. KG Oberflächentechnik in a typical system configuration. The values and procedures given herein are to be regarded as standard and may vary slightly from the different installations. For a better understanding of this product and to achieve an optimal, error-free operation over a long period, the instructions must be read carefully. The specified tests and checks should be carried out at a troubleshooting section before a service technician is required. In any case, with such a requirement, a person should be in charge, who is familiar with the device and holds the operating instructions. For the various adapters and accessories separate manuals are available. 1.2 Automatic gun AGR-08-E The automatic gun AGR-08-E is an air atomizing electrostatic automatic pistol. The gun can be a set screw in the machine adapter removed quickly from same. The machine adapter receives all material, air, and power lines. AGR-08-E is suitable for use on industrial robots, automatic machines (reciprocators) or supports. The AGR-08-E automatic spray gun creates a voltage of up to 85 kv at the atomising point for the coating material. The particles charged here are transported to the workpiece by compressed air, where they are electrostatically attracted and held. The electrostatic field between the charged particles and the earthed workpiece also enables a high proportion of the overspray to reach the sides and back of the workpiece being coated. This guarantees that a high percentage of the atomised spray is deposited on the workpiece. The guns in this series are suitable for coatings, solvent-or water-based. S-AGR08-Egb01 07/18-4 Page 1 of 2

4 1 General Attention! This manual only deals with the dangers of the use of solvent-based paints. When processing water dilutable coatings use the corresponding operating instructions. The automatic spray gun AGR-08-E as such and also the latter together with its high voltage generator and cable must be seen only as components of a system they do not as such constitute a functional system overall. No declaration of conformity is therefore applicable, only a declaration of incorporation. A functional system is created only in combination with further equipment (air supply/exhaust air system, materials handling etc.). 1.3 Components The system AGR-08-E consists of a gun AGR-08-E, the machine adapter, the high voltage cable, the high voltage generator (REMO HSE HE k-100), the control board (SMI m (DC)) as well as the high-voltage distributor (HVE06/01). 1.4 Guarantee Therefore, it is recommended to read this operating manual carefully before start-up, as we cannot be held liable for damage or malfunctions resulting from the non-observance of this operating manual. During the guarantee period repair work and changes only may be carried out by our assemblers or with our consent. The system is designed only for the use according to the operating area described in chapter 2 Operating Area. Any other use is considered improper and REITER can not be held liable for any possible damage. 1.5 Copyright The copyright for this operating manual is retained by REITER GmbH + Co. KG Oberflächentechnik. This operating manual is intended for personnel involved in installation, operation and supervision. The operating manual include regulations and technical drawings which may not be copied, distributed, used for commercial purpose or given to others, either in full or in part. REITER GmbH + Co. KG Oberflächentechnik Phone: +49 (0) / Berglenstraße Fax: +49 (0) / D Winnenden info@reiter-oft.de S-AGR08-Egb01 07/18-4 Page 2 of 2

5 2 Safety Regulations Table of Contents 2.1 Explanation of symbols and special directions Symbol of working safety Directions for Attention Operating area Electrostatic automatic spray gun Forced ventilation General demands for safe operation Instruction Use of electrostatic spraying systems in potentially explosive areas Work stations Interior coating of hollowware Cleaning Prerequisites to accessing spray booths Personal protective gear Working with ignition risk Explosion protection document Directives Explosion hazardous areas Checks Normative references Demands of design and quality for facilities used for electrostatic coating...10 S-AGR08-Egb02 07/18-4 Page 1 of 10

6 2 Safety Regulations 2.1 Explanation of symbols and special directions Symbol of working safety! This symbol accompanies all special directions for working safety given in this operating manual. Non-observance of this passages marked with this symbol may endanger life and limbs. Observe these directions and take special care in the cases described. Ensure all other operators are informed of these special directions. In addition to the special directions given in this operating manual, the generally valid regulations for safety and prevention of accidents have also to be observed Directions for Attention Attention! This warning is shown at points where special attention needs to be given in order that guidelines, regulations, special directions, and proper work procedures are observed and to prevent damage or destruction of the machine and/or other parts of the plant. 2.2 Operating area! This equipment can be dangerous if it is not operated in accordance with the instructions of this manual! The electrostatic gun AGR-08-E, hereinafter called device, is designed and built for the use in a stationary electrostatic application equipment designed for flammable liquid coating materials. The apparatus may only be used in an explosive atmosphere if this is created by the spray cloud of the applied coating material itself. Applied standards: EN 12215:2005 Coating plants Spray booths for application of organic liquid coating materials - Safety requirements EN 50176:2009 Stationary electrostatic application equipment for ignitable liquid coating material Safety requirements EN ISO :2004 Safety of machinery - Basic concepts, general principles for design - Part 1: Basic terminology, methodology EN ISO :2004 Safety of machinery - Basic concepts, general principles for design - Part 2: Technical principles BGI 764:2009 Electrostatic coating (valid only in Germany) S-AGR08-Egb02 07/18-4 Page 2 of 10

7 2 Safety Regulations Paragraph 0, Point 01 of EN 50176:2009 is applicable to the fields of application of the apparatus. This Standard also defines the design requirements for safe operation of the apparatus and the electrical installation, including the forced ventilation. The constructional requirements for the spray booth, defined in Standard EN 12215:2005, are also applicable. This applies particularly to the identification of explosion hazardous areas. This stipulates that the apparatus may only be used in areas where forced ventilation ensures that during the application of flammable liquid coating materials, the average concentration of solvents in the form of flammable vapour remains below 50% of the lower explosion limit (LEL) (EN 50176:2009, Para. 5.2). Pursuant to EN 50176:2009, Para /5.1.3, the apparatus is classified as a spraying system type C-L or D-L when operated with electrostatic application equipment. This depends on the type of installation and the local conditions. In accordance with Para of EN 50176:2009, type C-L or D-L spraying systems must be fitted with a locally applied extinguishing system which may also be operated manually. Section 5.2 of EN 50176:2009 must be observed. The requirements under 5.3 of EN 50176:2009 must be observed, in addition, if the apparatus is used as a 2G apparatus. 2.3 Electrostatic automatic spray gun This electrostatic automatic spray gun meets the requirements of EN 50176:2009 Stationary electrostatic application equipment for ignitable liquid coating material Safety requirements. This Operating Manual deals only with the dangers typically associated with the automatic coating process when electrostatic spray guns in the described form are used under the conditions as specified by the manufacturer. These electrostatic spray guns are classified as Group II, Category 2 equipment pursuant to Directive 94/9/EC, intended for use in explosive atmospheres generated by their own spray cloud. Equipment in this category is intended for use in areas where an explosive atmosphere comprising of gases, vapours, mist or dust/air mixtures may on occasion be expected. S-AGR08-Egb02 07/18-4 Page 3 of 10

8 2 Safety Regulations Forced ventilation Pursuant to EN 50176:2009, Section 5.4, the AGR-08-E electrostatic spray gun may only be used in spraying areas with forced or equivalent conditions of ventilation. This means that the maximum concentration of 50% of the lower explosion limit (LEL) of the coating material to be applied may not be exceeded in the spraying areas. The effectiveness of forced ventilation must be assured using special measures. 2.4 General demands for safe operation To guarantee safe operation of the spraying equipment and its accessories, the operating company must compile operating instructions, taking into account this Operating Manual. These operating instructions must be available in the appropriate language and at the appropriate location at the workplace. Such operating instructions must point out that the electrostatic spraying equipment may only be operated by trained persons. A warning sign must be affixed in an obvious location near the spraying area, in a language the user understands. This warning sign must explain the most important types of operation and protective measures which the operators should comply with. The dangers involved in the cleaning of spray guns must furthermore be clearly highlighted. The first start-up of the equipment by the operator is allowed only after the initial test run by an authorised specialist before the risk passes to the operator (BetrSichV [Ordinance on Industrial Safety and Health] 14). 2.5 Instruction It must be ensured that persons working with the electrostatic spraying system are instructed on the inherent dangers and the measures necessary for prevention of these, before starting to operate the electrostatic coating equipment and accessories. These instructions should be repeated at least once a year. 2.6 Use of electrostatic spraying systems in potentially explosive areas The type AGR-08-E electrostatic spraying systems (spray guns) may only be operated in areas in which the explosive conditions are caused exclusively by own electrostatic spraying of flammable liquid coating materials. Electrostatic spraying systems may only be operated provided protective measures are taken to protect from typical hazards of the tasks. Protective measures against electrical shock must furthermore be taken by: avoiding unnecessary work on live parts of the plant disconnecting from mains suitable working clothing securing against accidental switch-on ensuring that power is off earthing and shorting access control (vehicle permission) S-AGR08-Egb02 07/18-4 Page 4 of 10

9 2 Safety Regulations 2.7 Work stations Ensure all sources of ignition are avoided. Smoking and open flames are prohibited in fire and explosion hazardous areas. Ensure that coating material deposits are kept to a minimum in spray booths, spray stands and in the entire work area. Instruct and check that access doors to spray booths are kept closed during spraying. 2.8 Interior coating of hollowware Interior coating of hollowware inside of which hazardous conditions may arise due to gases, mist or dust produced by coating materials is prohibited unless special safety measures are taken. 2.9 Cleaning Coating material deposits must be removed at appropriate intervals. Special attention must to this end be given to the cleaning of spray booths and their ventilation equipment, spray-paint mist separators (if used), and their surroundings. The workpiece supports must be cleaned regularly to ensure good earthing of the workpieces. Ensure that the forced ventilation is operational during cleaning. Use only electrically conducting vessels for cleaning fluids. These vessels must also be earthed. Use only solvents with flash points at least 5K higher than ambient. Ensure that the discharge energy is < 0.24 mj before starting with cleaning work using flammable solvents on live components. In practice this means that the system must be securely earthed (see also 2.9) Prerequisites to accessing spray booths Ensure that solvent concentrations in the air which these persons may inhale are below health hazardous limits. Ensure that the floor of the spray booth is electrically conducting. Ensure that no persons are present in the spray booth during painting. Ensure that the discharge energy is < 350 mj if contact with high voltage circuit components is possible. The safe time between switching off the high voltage and possible contact with live components must be stipulated in due consideration of the operational and local conditions. Ensure that the discharge energy of the high voltage circuit is < 0.24 mj if flammable liquids are used (see also 2.8.5) for cleaning. S-AGR08-Egb02 07/18-4 Page 5 of 10

10 2 Safety Regulations 2.11 Personal protective gear Ensure that persons working with electrostatic spraying systems and any persons present on the electrically conducting floor wear antistatic shoes. Where protective gloves are required, these must be antistatic or have similar properties Working with ignition risk The operating company shall ensure that no work involving risk of ignition is carried out in fire and explosion hazardous areas. Exceptions are possible, provided special protective measures (e.g. removing coating material, solvents and other flammable goods, cleaning equipment and building sections beforehand, ensuring adequate ventilation etc.) are taken. Ensure that work involving risk of ignition which is carried out near openings to explosion hazardous rooms and areas is only performed if it can be assured that sources of ignition cannot enter such rooms and areas. S-AGR08-Egb02 07/18-4 Page 6 of 10

11 2 Safety Regulations 2.13 Explosion protection document Directives DIRECTIVE 1999/92/EC OF THE EUROPEAN PARLIAMENT AND THE COUNCIL (ATEX 137), dated 16 December 1999, on minimum requirements for improvement of safety and health protection of workers potentially at risk from explosive atmospheres (fifteenth individual Directive relevant to Article 16 (1) of Directive 89/391/EEC), the company, in this case the operator of electrostatic spraying equipment, is required, pursuant to Article 8, to compile an explosion protection document identifying explosion hazardous areas (zones). In the Federal Republic of Germany, the aforementioned Directive 1999/92/EC has been enshrined in national legislation by the Ordinance on Industrial Safety and Health (BetrSichV) dated 27 September, These requirements must additionally be observed if the plant is operated in Germany. The following requirements are based on the 1999/92/EC Directive. The operating company has the following obligations in this respect: As from 3 October, 2002, and before starting any work, an explosion protection document must be drawn up for all newly created workstations and plant with explosion hazardous atmospheres. This document must be at hand prior to initial start-up of a plant. Should any changes or extensions occur and/or the working materials and/or the working procedure be changed during the operating time of the plant, the explosion protection document must be revised accordingly. Document content: Determination and assessment of the hazards Measures taken to achieve the objectives Classification into zones Observance of minimum requirements set out in Annex 4 Coordination of measures taken by the employer responsible for the provision and use of working equipment It is possible to combine existing risk assessments, documents or other equivalent reports (BetrSichV 5, Explosion hazardous areas) Explosion hazardous areas Example of the application of solvent-based coating materials in spray booths with no operator inside the booth (pursuant to EN 12215:2005). Note: With automatic electrostatic coating equipment pursuant to EN 50176:2009, the maximum concentration of flammable solvents must be limited to < 50% LEL. This also applies to a recirculating air system. Spray booths with flammable solvent concentrations > 25%, but < 50% LEL pursuant to EN 12215:2005 (irrespective of solvent flash points!). S-AGR08-Egb02 07/18-4 Page 7 of 10

12 2 Safety Regulations Type of ventilation Area classification in zones Stand and booth interiors Forced ventilation Zone 1: interior Around stand openings (permanent openings, but no doors) Forced ventilation Zone 2: 1m S-AGR08-Egb02 07/18-4 Page 8 of 10

13 2 Safety Regulations Checks An automatic (fixed) spray plant for electrostatic spraying of coating materials must be checked by an expert prior to first start-up. Type, extent and frequency of the checks must in individual cases be stipulated by the operating company in due consideration of operational and local conditions. The trade association may in individual cases demand written proof in the form of test records, EDP protocols or similar. It must be ensured that electrostatic spraying systems / plant and their accessories are checked for safe operation by an expert as required, but at least once a year. These checks must be documented in writing. The following checks must be performed by an electrician 1 : Test cycle daily Test cycle weekly Exhaust air ducting systems for efficacy Proper functionality of overcurrent protection X X Protection against high discharge energy Protection against ignition of flammable cleaning agents Efficacy of measures for protection against direct contact X X X Efficacy of earthing arrangements X Insulation of all live plant components > 1 kv under normal operating conditions Interlocking, access control X X Ensure that sufficient fire extinguishers are installed. Fire extinguishers must be checked regularly, but at least every 2 years. Staff must be instructed on use of the fire extinguishers. A project-related, up to date alarm plan must be available, explaining the alarm system and controls (manual/automatic). 1 Electrician An electrician is a person who, based on his technical training, knowledge, experience and knowledge of pertinent regulations, is capable of assessing the tasks assigned to him and detecting possible dangers (see 2 Para. 3 UVV [Accident Prevention Regulations] VBG [Institution for Statutory Accident Insurance and Prevention in the Administrative Sector] 4). An electrician furthermore has the following qualifications: Academic knowledge in the field of explosion protection and the specialised field of electrostatic process technology, knowledge on the local conditions including the electrical system and awareness of the loading of the electrical system. S-AGR08-Egb02 07/18-4 Page 9 of 10

14 2 Safety Regulations 2.14 Normative references Demands of design and quality for facilities used for electrostatic coating EN 12215:2005 Spray booths for application of organic liquid coating materials - Safety requirements BGI 764:2009 Electrostatic coating (valid only in Germany) EN 50176:2009 Stationary electrostatic application equipment for ignitable liquid coating material - Safety requirements EN /-2:2004 Safety of machinery S-AGR08-Egb02 07/18-4 Page 10 of 10

15 3 Technical Data Table of Contents 3.1 Designs Technical data Automatic gun AGR-08-E Designs The automatic spray gun AGR-08-E is available in different designs. They differ in the use of a variety of components and/or in the material flow. Note! There are two versions of spray heads possible dead end or circulation. The spray heads with circulation have two material lines, allowing coating material to circulate through the head so a colour change can be performed while the gun is closed. Only the nozzle area must be flushed on the gun itself. S-AGR08-Egb03 07/18-4 Page 1 of 2

16 3 Technical Data 3.2 Technical data Automatic gun AGR-08-E Spray system: AGR-08-E AGR-08-EN Max. pressures: Switching times: Weight: Conventional air atomization Low pressure air atomization 0 to 14 bar material (MAT) 6 bar control air (CYL) 9 bar atomiser air (ATOM) and fan air (FAN) < 60 msec. at 5,8 bar control air 610 g Materials: Spray head: Stainless steel Paint needle (standard): Stainless steel Nozzle (standard): Stainless steel incl. plastic insert (POM) Needle pack: UHMPE Piston: POM Head holder: AlZnMgCu1,5 blue anodized End plate: AlZnMgCu1,5 blue anodized Cover: AlZnMgCu1,5 blue anodized Air distribution ring: Brass, chemically nickel-plated Air cap: Brass, chemically nickel-plated Air cap retaining ring: Brass, chemically nickel-plated Material-contacting seals: VITON EX for solvent-based coatings Dimensions: AGR-08-E with intermediate plate S-AGR08-Egb03 07/18-4 Page 2 of 2

17 7 Commissioning and Operation Table of Contents 7.1 Commissioning Usage conditions Tools and other materials required Fastening onto intermediate plates (if available) Intermediate plate AGR Adjusting the jet geometry Distance to workpiece Commissioning Supply line (VL) Return line (RL) Fan air (HL) Atomizer air (ZL) Main needle (HN) The automatic spray gun AGR-08-E, depending on the built-in version, is attached on a intermediate plate, which serves as an adapter to be able to use the gun as diverse as possible. This plate is mounted on an adapter to which the material and the air can be connected. Depending on the version, the gun sits directly on an adapter without an intermediate plate is required. The adapter is attached to the movement device (robot or hoisting device) or to a tripod. All compressed air and material lines are connected to the adapter. S-AGR08-Egb07 07/18-4 Page 1 of 3

18 7 Commissioning and Operation 7.2 Usage conditions Operating temperature: max. 80 C Ambient temperature: max. 40 C 7.3 Tools and other materials required The following tools are required for installing and removing the automatic spray gun AGR-08-E: Hexagon socket head wrench, size 4 Gun grease (part no ) for the o-ring-wetting while placing the gun. 7.4 Fastening onto intermediate plates (if available) Intermediate plate AGR Note! For the intermediate plate (part no ) the automatic gun AGR-08-E is fitted with the locking device (part no ). 1. Fixing gun on the intermediate plate. 2. Fixing automatic gun AGR-08-E and the stud with tip with a hexagon socket head wrench, size 4. S-AGR08-Egb07 07/18-4 Page 2 of 3

19 7 Commissioning and Operation 7.5 Adjusting the jet geometry Note! The gun has a variable jet geometry to produce a round or flat spray pattern. You should only work with clean, dry, filtered, oil-free air. 1. Select a suitable air flap. 2. Position the air distributing ring to produce the desired jet geometry. 3. Make the appropriate setting for the atomiser air. 4. Make the appropriate setting for the horn air. Position for vertical spray pattern Position for horizontal spray pattern Distance to workpiece Positon the automatic gun AGR-08-E about 15 to 30 cm from the workpiece. S-AGR08-Egb07 07/18-4 Page 3 of 3

20 8 Maintenance Table of Contents 8.1 Required tools and lubricants Removing gun Dismantling of the automatic gun Reassembly of the automatic gun Possible sources of error for the reassembly Maintenance of needle set Assembly device for spraying system AGR-08 (option) Faults...14 Note: The air cap can be replaced on the automatic spray gun AGR-08-E without removing it from the system. For all other maintenance jobs, the automatic spray gun AGR-08-E must be removed from the intermediate plate/adapter and replaced by a reserve gun. 8.1 Required tools and lubricants The following are required for installation and removal: Socket wrench or nut, size 13 Hexagon socket head wrench, size 4 and size 6 Torx wrench TO40 Torque wrench Gun grease (part no ) for wetting of the o-ring when placing the gun Note: Needle, needle set and piston should only be exposed to gun grease (part no ). Other grease can lead to a malfunction of the automatic spray gun AGR-08-E (unsuitable grease could cause swelling of needle set and piston). 8.2 Removing gun! Caution! Danger of injury due to lines under pressure! When removing the automatic spray gun AGR-08-E, spray fluid may emerge under high pressure. Make certain no paint material gets into the air channels. Rinse and blow out the material lines, then depressurise them. Wear protective clothing and/or glasses. 1. Loosen stud on intermediate plate 2. Removing automatic gun AGR-08-E up. S-AGR08-Egb08 07/18-4 Page 1 of 15

21 8 Maintenance 8.3 Dismantling of the automatic gun Attention! Rinse the automatic gun Secure the gun against restarting Wear protection clothes (glases and gloves) Notice the generally applicable accident prevention regulations 1. Loosen and remove the gun with a hexagon socket head wrench, size 4 from the intermediate plate or the adapter. 2. Loosen and remove the cover (19). 3. Loosen and remove the three screws (18) and remove the end plate (17). S-AGR08-Egb08 07/18-4 Page 2 of 15

22 8 Maintenance 4. Sliding head holder (11) backwards from the spray head (8). Remove paint needle (13), small compression spring (16), big compression ring (15) and spring pin (14). Remove two Viton O-rings (10) from the spray head holder for fan air and atomizing air. Attention: Risk of injury! Needle can be very sharp. S-AGR08-Egb08 07/18-4 Page 3 of 15

23 8 Maintenance 5. Press piston (12) by hand or with a blunt tool from the head holder (11). 6. Loosen retaining ring (1) by hand and remove it together with the air cap (3) and the air cap gasket (2). 7. Loosen nozzle (4) with socket wrench or nut SW 13 and remove it together with the air distributing ring (7) and the two gaskets (6). S-AGR08-Egb08 07/18-4 Page 4 of 15

24 8 Maintenance 8. Unscrew the needle packing with a Torx wrench TO40. Attention: This applies only to the standard packing of plastic. Clean all individual parts with a suitable detergent and dry. Gaskets and packing should be changed fundamentally during disassembly. Check all parts for damage or wear, and replace them with new original spare parts from the company Reiter. S-AGR08-Egb08 07/18-4 Page 5 of 15

25 8 Maintenance 8.4 Reassembly of the automatic gun 1. Lay out all components and the required tools on a clean level surface. 2. Mount the spray head (8) into the greased standard needle set (9) with 0.8 Nm or mount the special package made in stainless steel with Kalrez o-rings into the spray head (8) and tighten with a suitable tool with 3.0 Nm. 3. Wet gaskets (6) with little fat and put it in the air distribution ring (7). Attention: The gaskets are different. The smaller diameter is in the air distributing ring. Too much grease can be carried away by the fan air and atomizing air and reflected in painting/coating on the workpiece. That the gaskets do not slip, it makes sense to hold the gun with the needle down vertically and insert the air distribution ring with the gaskets from below. Attention: Risk of injury! Needle can be very sharp. S-AGR08-Egb08 07/18-4 Page 6 of 15

26 8 Maintenance 4. Turn gun to 180 (needle up), place fluid nozzle and tighten it to 30 Nm. Place air cap and tighten it manually with retaining ring. Little gun grease on the threads facilitates subsequent removal. 5. Wet slightly two o-rings (10) from not solvent resistant Viton, for fan air and atomizing air with gun grease and insert into the head holder (11). Attention: Too much grease can be carried away by the fan air and atomizing air and reflected in painting/coating on the workpiece. 6. Lubricate piston (12) and push into the head holder (11) manually. 7. Fit spray head (8) and head holder (11) together. S-AGR08-Egb08 07/18-4 Page 7 of 15

27 8 Maintenance 8. Grease tip of the paint needle (13) with gun grease and insert through the piston (12) into the needle set. Push manually careful forwards towards the nozzle. 9. Place greased spring pin (14) and the two compression springs small (16), large (15) which are inserted into each other, on the paint needle (13). 10. Close housing with end plate (17). 11. Tighten the three screws with an Allen key with 4.5 Nm. S-AGR08-Egb08 07/18-4 Page 8 of 15

28 8 Maintenance 12. Grease necessarily cover (19) and end plate (17) in order to facilitate subsequent dismantling. 13. Grease solvent resistant Kalrez o-rings (20) on the gun bottom with gun grease. Place it on the adapter or left to see in the photo on the intermediate plate and tighten with an Allen key size 4. S-AGR08-Egb08 07/18-4 Page 9 of 15

29 8 Maintenance Possible sources of error for the reassembly Mount two gaskets (6) with air distributing ring (7). Essential to maintain correct position and seat! Insert the respective smaller diameter of the gaskets into the air distribution ring. Here the lower gasket is slipped! A visual check is necessary! Grease nozzle (4) and tighten with 30 Nm. Pay particular attention to the pretension of the gaskets (6). Place the paint nozzle manually. Then tighten with a torque wrench to 30 Nm. Use always a nut or socket wrench to tighten, otherwise the nozzle can be deformed. Under no circumstances use a wrench! Attention: Ensure correct fit! Place retaining ring and tighten by hand. Check annular gap between the paint nozzle (4) and air cap (3) visually on round consistent measure. As illustrated on the left, it may not look like! Check proper seating of the air cap visually! S-AGR08-Egb08 07/18-4 Page 10 of 15

30 8 Maintenance 8.5 Maintenance of needle set 1. Unscrew the cover on the back. Loosen and remove the three Allen screws with an Allen key 4 mm. At reassembly please lubricate with grease (part no ). 2. Remove back gun cover. 3. Remove the two springs and the spring pin and separate the spay head from the head holder by axial, manually carefully pulling. Attention: Risk of injury! Needle can be very sharp. S-AGR08-Egb08 07/18-4 Page 11 of 15

31 8 Maintenance 4. Unscrew the worn standard needle set with a Torx 40 with light, axial pressure. Clean the spray head carefully before the new set is used. Lubricate the standard set (part no , see image) with grease (part no ) and screw with a Torx 40 with 0,8 Nm. Push out the special needle set Kalrez cpl. (part no ) from the nozzle side with a plastic pin (part no ) after the retaining screw M12x1 and the paint nozzle was turned by using a Allen key 6 mm (the paint needle in the photo used here only for clarity. This is not to be used for installation). Clean the spray head carefully before the new set is used. Please make sure that all parts during initial installation and after cleaning wet with grease (part no ). A replacement of the O-rings in case of maintenance is needed only as required, but recommended. Special needle set Kalrez cpl. (part no ) consisting of: 1 off Set housing ( ) 3 off Cap-type gasket 3,3x9x3,1 ( ) 1 off Holding screw M12 x 1 ( ) 4 off O-ring Kalrez ( ) 5. The assembly of the package in the previously greased spray head is done manually, since the pack forms a circumferential gap to the housing and is sealed by the front, each O-ring. They therefore need not be pressed or hammered. A facilitate insertion provides the plastic mandrel (part no ). Tighten the previously greased screw plug with an Allen key 6 mm and 5-6 Nm S-AGR08-Egb08 07/18-4 Page 12 of 15

32 8 Maintenance 8.6 Assembly device for spraying system AGR-08 (option) Part no Simple handling of the spay gun and those items Fast nozzle change No damage/deformation by vice jaws on the housing of the spray gun Shortened maintenance times because atomizer need not be re-clamped for each operation Open and close the casing with a torque wrench Disassemble and reassemble paint nozzle Change the needle packing Insert piston S-AGR08-Egb08 07/18-4 Page 13 of 15

33 8 Maintenance 8.7 Faults Note! In case of faults, determine the cause before disassembling to eliminate the error with as little maintenance work as possible. Faults Possible causes Corrective action No uniform atomization or spray pattern is not symmetrical Nozzle stuck or damaged or deformed on the paint trailing edge Air cap holes are clogged in complete or in part, or deformed Clean nozzle/air cap with suitable cleaning material or replace it Insufficient atomization/fan air Fan air and atomizer air are not set correctly Air cap and/or air distribution ring have not enough throughput Cable cross-section capacity is too low or narrows by screwing, kinking points or similar Nozzle cross-section configured incorrectly Readjust fan air and atomizer air Replace air cap or/and air distributing ring Revise cable cross-section, replace screws, cut out kinking points and/or use new hose Replace nozzle Atomization/fan air can not be shut off completely Defective proportional valve or pressure regulating valve Replace defective component Atomization/fan air can not properly regulate Seals at air distributing ring not installed properly or not present Replace seals Material flow too low or nonexistent Clogged nozzle Main needle stiff/blocked Piston or needle set glued Clean nozzle Control pressure should not fall below 5.0 bar Clean piston or replace needle set Paint outlet at the gun Needle set or needle worn (paint outlet on housing) Maintain gun Replace needle set and/or needle S-AGR08-Egb08 07/18-4 Page 14 of 15

34 8 Maintenance Faults Possible causes Corrective action Paint outlet at the air cap or material outlet hole of the nozzle Nozzle not properly tightened or dirt on the sloping sealing surface Maintain gun Grease nozzle and tighten with 30 Nm Paint outlet between gun and intermediate plate or gun adapter Material seals (o-rings) damaged on gun bottom or missing/damaged or overstretched locking Replace o-rings or locking S-AGR08-Egb08 07/18-4 Page 15 of 15

35 9 Spare Parts Table of Contents 9.1 General Instructions Spare parts order Disposal Storage General Instructions A stock of the most important spare and wearing parts to wear at the place of installation is an important prerequisite for the constant proper function and availability. We provide a guarantee only for original spare parts delivered by us. In case of damage resulting from the use of non-original spare parts and accessories, any liability or guarantee provided by REITER GmbH + Co. KG Oberflächentechnik is excluded. The stock keeping of spare parts is provision for any the validity of agreements involving system availability, service times and guarantee or systems performance. 9.2 Spare parts order To order make use of the spare parts list in the part documentation and parts lists. All parts which are labelled with E are spare parts, all parts which are labelled with V are wearing parts. For the spare parts order the following data shall indicate: Order number (see acknowledgment) Part number (see parts list) Designation (see parts list) Parts lists designation S-AGR08-Egb09 07/18-4 Page 1 of 2

36 9 Spare Parts 9.3 Disposal For disposal clean the AGR-08-E thoroughly of all media (paint, solvent) Disposal of packaging and used parts must be made according to the rules and regulations of the country, in which the device was installed. 9.4 Storage The automatic gun AGR-08-E has to be stored in a dry and dust free area in its original packaging. Make sure to prevent extreme temperature fluctuations because otherwise condensation can occur, which can cause damages to the device. S-AGR08-Egb09 07/18-4 Page 2 of 2