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A electrode |
E atomizing air supply |
| B deflector cone | F powder supply |
| C outer nut | G electric supply |
| D spraygun body | H Corona Star supply |
The spraygun PEA-C2A is used for industrial powder coating.
It can be operated with individual control units or with control cabinet modules.
The high voltage is activated in the spraygun by switching on the high voltage generator and the powder release. At the same time, the powder and compressed air supplies to the gun are turned on.
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This spraygun may only be used for the above described application! The user must ensure, that the spraygun PEA-C2A is only connected to Wagner equipment. High ambient temperatures must be avoided; in particular, the hoses must not be routed through factory areas exposed to direct sunlight! To provide a safeguard against unintentional use of the spraygun, the control unit for the guns must be turned off! |
What type of coating powder can be used?
Basically, all coating powders can be used with the PEA-C2A. e.g.: epoxy resin, polyester, blended powder EP / PES, PUR.
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Powders containing metal pigments may only be processed in compliance with the powder manufacturer’s instructions. |
This technical manual contains information and hints for the service, repair and maintenance of the equipment. The observation of this manual is element of the warranty agreements.
Wagner powder systems are designed to meet the most stringent safety requirements. They can be operated in compliance with generally applicable safety codes and applicable national safety regulations.
Please pay particular attention to the parts marked by the following symbols. Follow the instructions exactly, in the interests of both your own safety and the correct functioning of the unit.
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This symbol draws attention to the fact that if the operating instructions, working instructions, prescribed working sequences etc. are not followed exactly, this can lead to injury or even fatal accidents. |
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This warning indicates that if the operating instructions, working instructions, prescribed working sequences etc. are not followed exactly, this can lead to damage to the unit. |
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This symbol draws your attention to useful additional information and tips. |
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Wagner hereby declares that the unit described in these operating instructions has been designed and manufactured according to the provisions of EU Directive 89/392/EEC. The following European standards have been applied: EN 50014 The following German standards or guidelines have been applied: ZH 1/444VDMA 2371 Part 1 VDE 0165 |
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This equipment can be dangerous if it is not operated in accordance with this operating manual! There might be additional regulations to be observed, put into effect by governmental, state or other official agencies or local security (fire) departments! |
The following rules must be observed in order to ensure a safe and efficient use of the equipment:
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· Under no circumstance may persons with a cardiac pacemaker come close to the area between the tip of the spraygun and the workpiece to be coated. The user has to observe particularly the safety guidelines of the VdS or the local professional and security institutions. 2) 3) 6) 9) · The spraygun may only be operated in the hazard zone created by operation of the manual spraying equipment itself. 2) 3) 6) · The spraygun may only be operated in powder spray booths or powder spray benches equipped with industrial ventilation. 2) 3) 6 · The user has to ensure that the medium value of the powder/air concentration does not exceed 50% of the LEL u ) (maximum allowed concentration of powder in air). If the LEL is not known, the user should assume a value of 20 g/m³. 2) 3) 6) · The main power connection for operation of the Wagner powder equipment must be electrically interlocked with the exhaust system of the powder coating booth. 2) 3) 6) · The Wagner control unit must be installed outside the hazard area. 2) 3) · The user must conduct periodic checks of the powder spray equipment (at least every year) with regard to explosion-protection. 5) 7) |
· In the event of faults or defects, repair work is to be performed at the user's discretion. 7) · The user must keep a test certificate of the device type on file at the installation site. 7) · The execution of repairs must not lead to an alteration in the explosion-protection. 5) 7) · Repairs may only be carried out by specially trained personnel. 7) · Repairs must never be performed in an explosion-hazard area. 7) · The work area must have an electrostatically conductive floor (measured in accordance with DIN 51953) 2) 3) 6) · All conductive parts in the work area must be electrostatically grounded (work area = 1.5 m at the sides, 2.5 m to the front and rear of every spray location or opening in the booth). 3) · All persons inside the work area must wear electrostatically conductive footwear. 2) 3) · If gloves are used, they must be of antistatic material or have cut-out palm areas. 2) 3) |
x) see paragraph 8.1 "Applicable Safety Regulations and List of Sources"
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Keep your workplace well organized Store your tools carefully Wear suitable work clothing Use breathing protection Take good care of the system |
Always remain alert Check your equipment for damage All parts must be properly assembled in order to ensure proper operation of the unit. Damaged parts should be repaired or replaced by a Wagner customer service |
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For your own safety, use only accessories and equipment listed in the operating manual. The use of individual parts other than those recommended in the operating manual may create a hazard to personal safety. Use only original Wagner replacement parts! |
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HAZARD |
PREVENTION |
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Electrostatic arcing may cause an explosion or fire. Mixtures of powder and air can explode or ignite causing property damage and/or severe injury. |
Operator must be grounded. Grounding straps must be used when wearing rubber soled shoes. Operator must be in contact with the spraygun handle; cut out palm section and trigger fingers of any work gloves to be used. Operator must remove all metal objects from his or her person, which are not grounded. The object being sprayed must be grounded. All metal objects within the spray area must be grounded (including spray booth, part hangers, fire extinguishers, etc.) Grounded conductive floor must be provided in spray area. Turn off the Power Pack and unplug from outlet before flushing out the gun, cleaning or replacing parts on the gun such as changing tips. |
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Explosion or fire. Mixtures of powder and air can explode or ignite causing property damage and/or severe injury. |
Exhaust and fresh air introduction must be provided to keep the air within the spray area free of accumulation of flammable atmosphere. Smoking must not be allowed in spray area. Fire extinguishing equipment must be present and in working order. Electrostatic arcing must be prevented. (See Electrostatic arcing) When cleaning the system, use only materials recommended by the coatings manufacturer. Be sure Power Pack is turned off and unplugged. Avoid all ignition sources such as static electricity sparks, open flames such as pilot lights, hot objects such as cigarettes and sparks from connecting and disconnecting power cords and working light switches. |
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Explosion or fire. Mixtures of powder and air can explode or ignite causing property damage and/or severe injury. |
To prevent hazardous concentrations of flammable atmospheres, spray only in a properly ventilated spray booth. Never operate spraygun unless ventilation fans are operating properly. Check and follow all National, State and Local codes regarding air exhaust velocity requirements. Ventilation must be maintained during the cleaning operation. |
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Toxic Substances: Some materials may be harmful if swallowed or come in contact with the skin. |
Follow the requirements of the Material Safety Data Sheet supplied by the coatings manufacturer. Exhaust and fresh air introduction must be provided within the spray area to keep the air free of high powder accumulations. Wear a mask or respirator. Read all instructions for the mask to insure that it will provide the necessary protection against the inhalation of powder. |
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General |
Read all instructions and safety precautions before operating. Comply with all appropriate local, state and national codes governing ventilation, fire prevention, and operation of Electrostatic equipment usage. The United States Government Safety Standards have been adopted under the Occupational Safety and Health Act. These standards, particularly the General Standards, Part 1910 and the Construction Standard, Part 1926, should be consulted. NFPA Standard No. 33 is to be followed when setting up your spray area. Contact the National Fire Protection Association, Batterymarch Park, Quincy, Massachusetts, 02269 for more information. Check with insurance company for additional requirements. Use only identical replacement parts. Personnel must be given training in accordance with the requirements of NFPA Standard No. 33 chapter 15. It is the duty of all personnel responsible for the spray equipment operation and maintenance to read and understand all safety information furnished with this equipment. |
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When the high voltage is turned on, a glow or Corona discharge, that is only visible in a dark environment, occurs at the electrode tip. When the electrode approaches the grounded workpiece, this physical phenomenon can be observed. This glow discharge does not provide any ignition power and does not have any influence on the handling of the installation. When the electrode approaches the workpiece, the control device automatically reduces the high voltage to a safe level or turns off the high voltage, depending on the setting. |
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If the finger comes in contact with the plastic parts of the spraygun, harmless discharges (so-called brush discharges) can occur. The charging of the plastic parts is caused by the high voltage electrostatic field of the gun. However, these discharges do not provide any ignition power. |
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Nozzle |
Workpiece |
Spray cloud |
Coating distance |
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deflector cone
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wire goods gratings aluminum cross |
round spray cloud: |
100 ... 160 mm |
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fan spray nozzle
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difficult workpieces: undercuts broken edges |
widely-spread fan spray |
120 ... 180 mm |
You will find the part numbers in section 6.3 "Accessories"
The Corona-Star is a retrofit-set for the spraygun which helps to achieve a better surface quality. The development of "orange peel" can be avoided for most powder types.
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The assembling of the Corona-Star may only be carried out by trained personnel! |
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When assembling the Corona Star, make sure that the ground rod is always mounted first! |
Before beginning making connections, switch off the high voltage generator. Refer to the corresponding operating instructions for the control units or control modules for this.
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Please use the parts listed in section 6.3 "Accessories" when connecting and fastening the spraygun. |
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By using a Wagner PJ-D1 powder injector and a suitable control unit, it is possible to blow out or flush the spraygun automatically each time before it is switched off. |
In order to achieve a good powder coating and for security reasons the spraygun must be properly grounded. This is made via the gun holder.
A poorly grounded workpiece causes:
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Sparks between workpiece and conveyor hooks (hangers) can occur if hooks or other hanger parts are not completely cleaned! These sparks can cause heavy radio frequency interferences. |
Switch on the high voltage generation and the powder delivery.
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To reduce wear, the total of feeding air and dosage air must be in between 4 - 6 Nm3/! |
The following illustration provides information on the effects of the feeding air and dosage air on the volume being fed or the rate of feed.
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An exact description of how to set the air flows can be found in the operating instructions for the corresponding control units.
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Recommended powder output volumes depending on the internal diameter of the hose
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powder hose [mm] |
feeding air [Nm3 / h] |
powder output [g / min] |
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10 |
approx. 2.8 ... 4.8 |
... 100 |
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11 |
approx. 3.3 ... 5.8 |
50 ... 250 |
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12 |
approx. 3.7 ... 6.8 |
100 ... 350 |
The spraygun is switched off in different ways, depending on the type of powder injector. In most cases this procedure is undertaken by a control system, if the coating system is equipped for this.
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The spraygun should be blown through (flushed) and cleaned from powder deposits with every interruption of work. In this way powder deposits and surges on switching on again are to a great extent avoided. |
If you want to switch the spraygun off manually and the powder injector is not designed for automatic flushing, proceed as follows:
All parts carrying powder in the entire coating system must be thoroughly cleaned of powder deposits on a change of color. In the following, only the procedure for the spraygun is described. Instructions on cleaning the other components can be found in the appropriate operating instructions.
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Take care that the nozzle insert is not damaged when removing and replacing it! |
| Warning | Caution |
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WHEN CLEANING THE ELECTROSTATIC SYSTEM, THESE SAFETY PROCEDURES MUST BE FOLLOWED. FAILURE TO FOLLOW THESE PROCEDURES MAY RESULT IN AN EXPLOSION/FIRE. Turn power pack to the "OFF" position and unplug from power source before starting to clean. Exhaust and fresh air introduction must be maintained during the clean up operation. Keep cleaning materials in approved safety containers. All personnel and cleaning equipment, including container used in cleaning operation, must be grounded. DO NOT turn on the POWER PACK until the cleaning operation has been completed, all cleaning materials have been removed from spray area, and spray area is free of any mixtures of powder and air produced by the cleaning operation. |
If defects in the equipment are found, DO NOT use until repairs are completed. Clean equipment immediately after use. NEVER IMMERSE SPRAYGUN OR PARTS OF IT IN ANY FLUID AT ANY TIME. Be sure the Power Pack is turned off and unplugged from the power source. NOTE The powder passages of the spraygun should be cleaned while cleaning the powder hose and powder pump, following instructions, provided with the powder pump (injector). (See document No. PJ - D1) Clean the spray tip by removing from spraygun, flushing with air and replacing on spraygun. |
Before beginning replacing the spraygun, free it of powder deposits in accordance with section 3.3.
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Maintenance, repair or replacement of the spraygun may only be performed by trained personnel in a suitable location outside the hazard area! |
The wear parts marked with (*) in the spare parts list of the spraygun PEA-C2A, must be regularly checked and replaced if necessary.
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Never place the spraygun or parts of it into any wet cleaning agent! |
The powder tube is comprised of many parts which from time to time have to be dismantled, cleaned and where necessary, replaced by new parts.
1. Remove the nozzle system:
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2. Remove the upper powder tube:
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3. Remove the lower powder tube:
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4. Cleaning and assembly the spraygun
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Malfunction |
Cause |
Remedy |
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No electrostatic charge (e.g. no wrap-around or no powder adhesion). |
- Fault at high voltage generator. - Electrical cable between spraygun and control unit defective. - Cascade in spraygun is defective |
- Inform Wagner service center. - Replace electrical cable. - Inform Wagner service center. |
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Poor wrap-around. Back-spray. |
- Bad or no grounding. |
- See paragraph 2.4. |
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Powder output |
- Impurities. - Powder sintering. - Impurities in delivery system. - Feeding air / dosage air proportion not correct. - Wear to powder injector nozzle. |
- Blow through powder feeding parts. - Clean powder feeding parts - See operating instructions of connected devices. - Readjust at the control unit. - Change worn out parts of the powder injector. 1.). |
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Spray cloud is |
- Nozzle system worn out. |
- Replace nozzle system. |
1.) The wear and spare parts can be found in the operating instructions for the powder injector.
Faulty and useless parts are replaced according to our general delivery conditions.
To ensure a correct spare part order and delivery, the following information is required:
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Item |
Part No. |
Description |
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0351 004 |
angled powder-spraygun PEA-C2A |
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1 |
0351 309 |
outer nut |
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2 |
0351 900 * |
nozzle insert, assembly ** |
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2/1 |
0351 339 * |
wedge |
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3 |
0351 524 * |
powder tube short |
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4 |
9971 316 * |
O-ring 13x1 |
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5 |
0351 201 |
nozzle body, assembly |
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6 |
0351 527 |
clamping screw |
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7 |
0351 523 * |
powder tube |
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8 |
0351 521 * |
bend |
* wear part ** only available as a set
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Part-No. |
Description |
Application |
Material |
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0351 216 |
electric cable 5 m |
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0351 217 |
electric cable 10 m |
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0351 215 |
electric cable 20 m |
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0700 341 |
hose 18x3 |
powder feeding |
PUR |
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9982 058 |
hose 17x3 |
powder feeding |
PUR |
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9981 939 |
hose 6x1 |
atomizing air |
Polyamide |
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Item |
Part No. |
Description |
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0351 916 |
Corona Star assembly: |
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1 |
0351 209 |
Corona Star |
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1/1 |
0260 296 * |
electrode Corona Star (included in Position 1) |
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2 |
0351 529 |
ground rod |
* wear part
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Item |
Part No. |
Description |
Application |
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1 |
0260 328 |
hanger |
to fasten the angled powder-spraygun |
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2 |
0260 215 |
gun support |
to fasten the hanger to the reciprocator |
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2
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Item |
Part No. |
Description |
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1 |
0351 901 * |
fan spray nozzle (gap) assembly |
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1/1 |
0351 232 * |
fan spray nozzle (gap) |
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1/2 |
0351 346 * |
air nozzle |
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2 |
0351 225 * |
deflector cone Ø 17 mm |
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2 |
0351 226 * |
deflector cone Ø 25 mm |
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2 |
0351 227 * |
deflector cone Ø 32 mm |
* wear part
| Weight: | 900 g |
| Electrical: | |
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input voltage: |
max. 22 Vpp |
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input current: |
max. 0.9 A |
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frequency: |
19 ... 30 kHz |
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output voltage: |
max. 100 kV DC |
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output current: |
max. 200 m A DC |
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polarity: |
negative |
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design: |
accord. to EN 50177 |
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protection class: |
IP 54 |
| Pneumatic: | |
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input air pressure (atomizing air): |
max. 4 bar |
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powder output: |
max. 350 g/min |
| Compressed air quality acc. to ISO 8573.1: | |
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residual water content in compressed air: |
max. 1.3 g H2O/Nm3 at a dew point of 7 °C |
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residual oil content in compressed air: |
max. 0.01 mg oil/Nm3 |
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residual dust content in compressed air: |
max. 1 mg dust/Nm3 |
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Volume measures: 1 Nm3/h = 35.3 ft3/h |
| Ambient conditions: |
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If low temperature powders are used, the ambient temperature may
have to be lower than |
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1) |
EN 50177 |
Stationary electrostatic spraying equipment |
(published by |
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3) |
ZH 1/444 |
Electrostatic powder coating using stationary spraying equipment |
(published by |
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4) |
EX-RL / ZH 1/10 |
Guidelines for explosion protection |
(published by Cologne) |
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5) |
VDE 0165 |
Installation of electrical equipment in explosion-hazard areas |
(published by |
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EN 50014 |
Electrical equipment for explosion-hazard areas |
(published by |
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6) |
VDMA 24371 |
Guidelines for electrostatic coating using synthetic resin powders |
(published by |
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7) |
ELEX V |
Regulation for electrical systems in |
(published by |
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8) |
VDE 0100 |
VDE guidelines for the construction of power converters with a nominal voltage up to 1000 V |
(published by |
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9) |
EN 60204 part 1 |
VDE guidelines for the electrical equipment of machines |
(published by |
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10) |
VDE 0147 |
Guidelines for the construction of stationary electrostatic spraying equipment |
(published by |
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11) |
VDE 0105 |
Guidelines for the operation of high power converters |
(published by |
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12) |
VDE 0105 |
Operation of high power converters (additional regulation for stationary electrostatic spraying equipment) |
(published by |
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13) |
VDE 0132 |
Instructions for fire fighting in electric equipment and nearby |
(published by |
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14) |
VDE 0134 |
Instructions for first aid in case of accident |
(published by |
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15) |
VDS 2093 |
Association of insurance companies |
(Riehlerstr. 36 |
What is covered by this warranty:
Faulty parts are replaced according to our general delivery conditions.
Within the applicable warrant period, Wagner will repair or replace, defective parts without charge if such parts are returned with transportation charges prepaid to the nearest authorized service center. If Wagner is unable to repair this product so as to conform to this limited warranty after a reasonable number of attempts, Wagner will provide, either a replacement for this product or a full refund of the purchase price of this product.
These remedies are the sole and exclusive remedies available for breach of express and implied warranties.
What is not covered by this warranty:
This warranty does not cover any damage or defects:
Limitation of remedies:
IN NO CASE SHALL WAGNER BE LIABLE FOR ANY INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES OR LOSS, INCLUDING TRANSPORTATION COSTS, WHETHER SUCH DAMAGES ARE BASED UPON A BREACH OF EXPRESS OR IMPLIED WARRANTIES, BREACH OF CONTRACT, NEGLIGENCE, STRICT TORT, OR ANY OTHER LEGAL THEORY.
Disclaimer of implied warranties:
THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
No ability to transfer:
This warranty is extended to the original purchaser only and is not transferable.
Your rights under state law:
Some states do not allow limitations on how long an implied warranty lasts or the exclusion of incidental or consequential damages, so the above limitation and exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.