Manual Powder System
 High
voltage! Turn power off before servicing! Read rules for safe operation
and instructions carefully! |
back
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2007 - 70LR Manual Powder System |
09/96 | |
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| Operating Manual | |||
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2. Description of the manual powder system
2.2. What powder materials can be used?
2.4. Manual powder system 2007 - 70LR operation
2.4.1. Manual powder system (Corona): 2007/C - 70LR
2.4.2. Manual powder system (Tribo): 2007/T - 70LR
2.5.1. Manual powder system (Corona): 2007/C - 70LR
2.5.2. Manual powder system (Tribo): 2007/T - 70LR
3.1.1. Course order when starting up for the first time: Airmatic spraygun PEM-C2
3.1.2. Course order when starting up for the first time: Tribo spraygun PEM-T1
3.2. Assembling and connecting
3.4. Connection diagram with an Airmatic spraygun PEM-C2
3.5. Connection diagram with a Tribo spraygun PEM-T1
4.1. Adjusting the powder cloud
4.4.1. Changing powder when using one powder tank
4.4.2. Changing powder when using several powder tanks
5.1. Cleaning the manual powder system
5.2. Cleaning the powder spraygun
5.2.1. Cleaning the PEM-C2 powder nozzle
5.2.2. Cleaning the PEM-T1 powder nozzle
7. Spare parts list with accessories
| Back plate of the control unit EPG 2007 |  |
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Caution |
Mode 2: for gun type: PEM-T1
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Setting codes of the mode switch see paragraph 3.1. in the operating manual BAL-No. 0263 830 USA/UK !
1. IntroductionThis technical manual contains informations and hints for the servicing, repairing and maintenance of the equipment. The observation of this manual is element of the warranty agreements.
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.
This manual contains information which must be read and unterstood before using the equipment. When you come to an area which has one of the following symbols, pay particular attention and make certain to heed the safeguard.
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"Warning" |
Important safety information indicates a hazard which may cause serious injury or loss of life.
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"Caution" |
Important information that tells how to prevent damage to equipment or how to avoid causes of minor injuries.
"Recommendation"
Gives important information which should be given special attention.
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Declaration of ConformityKonformitätsbescheinigung |
herewith declares
that the equipment described in this manual has been developed and manufactured
in agreement with the demands according to paragraph 5.1.2 of the European Norm
EN 50014.
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Warning |
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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.
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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 electri-city 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.
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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.
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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
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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. |
1.1
Safety regulations
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Warning |
This equipment can be dangerous if it is not operated in accordance with this Operating Manual!
The following rules must be observed in order to ensure safe and efficient use of the equipment:
powder equipments must be electrically interlocked with the exhaust system
of the powder control
unit must be installed outside the hazard area. 2) 3)* ) UEG: Low explosion limit, i.e. maximum allowed concentration of powder in air.
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Warning |
Powders containing metal pigments may only be processed in compliance with the powder manufacturer's instructions.
Applicable Safety Regulations and List of Sources
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1) |
EN 50050/ |
Manual electrostatic spraying equipment |
(published by |
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2) |
EN 50053 Part 2 |
Selection, installation and use of electrostatic spraying equipment, manual electrostatic equipment for powder |
(published by |
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3) |
ZH 1/443 (1993) |
Electrostatic powder coating using manual spraying equipment |
(published by |
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4) |
EX-RL / ZH 1/10 |
Guidelines for explosion protection |
(published by |
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5) |
VDE 0165 |
Installation of electrical equipment in explosion-hazard areas |
(published by |
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6) |
VDMA 24371 Part 1 |
Guidelines for electrostatic coating using synthetic resin powders |
(published by |
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7) |
ELEX V |
Regulation for electrical systems in explosion-hazard areas |
(published by |
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8) |
VDE 0134 |
Instructions for first aid in case of accident |
(published by |
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9) |
VDS 2093 |
Association of insurance companies |
(Riehlerstr. 36 |
General Safety Rules
Keep your workplace well organized
A disorganized
workplace creates a hazard.
Take the environmental influences into consideration
Do not expose
the manual system to rain. Do not use the manual system in a damp or wet environment.
Ensure good illumination. Do not use power tools near flammable liquids or gases.
Store your tools carefully
Unused tools should
be stored in a dry, locked room and out of the reach of not authorized persons.
Do not use the cable for purposes other than those intended
Do not carry
the spraygun by the cable and do not use it to pull the plug out of the socket.
Protect the cable from heat, oil and sharp objects.
Do not over-reach your standing position
Avoid abnormal body
positions. Ensure stable footing and always keep your balance.
Wear suitable work clothing
Use breathing protection
Use breathing protection
for work which produces dust.
Take good care of the manual system
Keep the system
clean to ensure that it works well and safety. Check the plug and line cord
regularly and have them replaced by customer service if damaged. Check the extension
cord regularly and replace it when damaged.
Always remain alert
Watch your work.
Proceed in a reasonable manner. Do not use tools when you lack concentration.
Check your equipment for damage
Before using the
manual system, carefully inspect slightly worn parts for proper operation. Check
whether the moving parts operate properly, whether they jam and whether parts
are damaged.
All parts must be properly mounted in order to ensure proper operation
of the unit. Damaged parts should be repaired or replaced by a
customer service.
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Warning |
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
replacement parts!
Safety-related information concerning harmless discharge
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.
1.2
WarrantyWhat is covered by this warranty:
Faulty and useless parts are replaced according to our general delivery
conditions.
Within the applicable warrant period, Wagner will repair or replace, at our option, 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, at our option, 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.
2.1
ApplicationThe manual powder system 2010 - 70LR is designed for use in laboratories and low volume production in industry and trade.
The major advantages are:
All powder paints can be processed with the manual powder system 2007 - 70LR. i.e.: Epoxy, Polyester, blended powder EP / PES, PUR.
2.3
Specifications
| Dimensions: | ||
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Width: 400 mm |
400 mm |
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| Height: |
1040 mm | |
| Depth: 560 mm | 560 mm | |
| Weight: | approx. 33 kg | |
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Mains power: |
85 V ... 266 | |
| Frequency: |
47...440 Hz | |
| Input power: |
max. 30 W | |
| EMI filter: | EN 55022 class B VDE 0878 PT3 class B |
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High voltage: |
0 to 100KV | Resolution: 5KV |
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Corona current: |
0 to 200µA | Resolution: 10µA |
| Tribo current: | 0 to 4 µA | Resolution: 0,2µA |
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Input air pressure: |
6 ... 8 bar | |
| Feeding air pressure: | 0-6 bar | |
| Dosage air pressure: | 0...2,5 bar | |
| Gun air pressure: | 0...2,5 bar | |
| Air throughput: | max. 19 Nm3/h | |
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 | |
| Residual oil content in compressed air: | max. 0,01 mg oil/Nm3 | |
| Residual dust content in compressed air: | max. 1 mg dust/Nm3 | |
Ambient conditions: |
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| Working temperatur range: 5 to 45°C | 5 to 45°C | |
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If low temperature powders are used the ambient temperature may have to be lower than 30°C. |
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2.4
Manual powder system 2007 - 70LR operationThe powder is fed to the powder gun (C) via the powder injector (B). Through supplying of fluid air into the fluid base of the powder tank (A), a homogeneous powder/air mixture is ensured during the entire feed operation.
The electrostatics and the powder quantity are controlled by means of the control unit (D).
The fluid air quantity can be adjusted with the one-way valve (E), attached to the equipment trolley.
A high DC voltage (up to 100 KV), applied across the grounded component and the electrode fitted to the gun body generates an electric field and applies a negative charge to the powder particles. The particles repel each other as they move from gun to workpiece and so distribute evenly through the fine powder cloud and then uniformly deposit on the grounded surface. Particles shooting past the component remain trapped in the electric field and deposit on the backside of the work object.
2.4.2
Manual powder system (Tribo): 2007/T - 70LREach individual powder particle is charged by a tribo-electric charge separation.
Every particle obtaines its own powder-specific maximum positive charge. The
particles
repel each other as they move from gun to workpiece and so distribute evenly
through the fine powder cloud and then uniformly deposit on the grounded surface.
Particles shooting past the component remain trapped in the electric field and
deposit on the backside of the work object.
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2.5.1
Manual powder system (Corona): 2007/C - 70LR
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Standard |
Japan |
USA |
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Part No. |
0265 002 |
0265 012 |
0265 022 |
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Item |
Part No. |
Quantity |
Description |
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1 |
0264 214 |
1 |
Equipment trolley 2001 |
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2 |
0265 100 |
1 |
Control unit EPG 2007 (Standard) |
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3 |
0351 021 |
1 |
Airmatic spraygun PEM-C2 |
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4 |
0264 005 |
1 |
Powder tank 70LR |
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5 |
0264 410 |
1 |
2020 connecting parts consisting of: Item. 5/1 ... 5/6 |
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5/1 |
9982 077 |
1,5 m |
Hose green (5,5 x 8) |
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5/2 |
9982 062 |
1,5 m |
Hose blue (5,5 x 8) |
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5/3 |
9982 063 |
1,5 m |
Hose red (5,5 x 8) |
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/4 |
9992 200 |
1 |
Fitting plug-in nipple |
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5/5 |
9992 711 |
1 |
Coupling joint |
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5/6 |
9982 078 |
0,35 m |
Hose black (5,5 x 8) |
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6 |
0264 417 |
1 |
Powder hose-Set 2020 consisting of: Item 6/1 ... 6/2 |
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6/1 |
9982 079 |
6 m |
Hose black (4 x 6) |
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6/2 |
9998 259 |
6 m |
Powder hose transparent |
(Extras see delivery note)
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2.5.2
Manual powder system (Tribo): 2007/T - 70LR
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Standard |
Japan |
USA |
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Part No. |
0265 004 |
0265 014 |
0265 024 |
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Item |
Part No. |
Quantity |
Description |
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1 |
0264214 |
1 |
Equipment trolley 2001 |
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2 |
0265100 |
1 |
Control unit EPG 2007 (Standard) |
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3 |
0259 003 |
1 |
Tribo spraygun PEM-T1 |
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4 |
0264 005 |
1 |
Powder tank |
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5 |
0264 410 |
1 |
2020 connecting parts consisting of: Item 5/1 ... 5/6 |
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5/1 |
9982 077 |
1,5 m |
Hose green (5,5 x 8) |
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5/2 |
9982 062 |
1,5 m |
Hose blue (5,5 x 8) |
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5/3 |
9982 063 |
1,5 m |
Hose red (5,5 x 8) |
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5/4 |
9992 200 |
1 |
Fitting plug-in nipple |
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5/5 |
9992 711 |
1 |
Coupling joint |
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5/6 |
9982 078 |
0,35 m |
Hose black (5,5 x 8) |
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6 |
0264 417 |
1 |
Powder hose-Set 2020 consisting of: Item 6/1 ... 6/2 |
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6/1 |
9982 079 |
6 m |
Hose black (4 x 6) |
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6/2 |
9998 259 |
6 m |
Powder hose transparent |
(Extras see delivery note)
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Recommendation
Before installing and starting up the manual powder system, become familiar
with the corresponding operating manual.
3.1 Preparation
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Caution |
The mode switch of the control unit EPG 2007 is factory-set
for
Corona spraygun PEM-C2.
When using a Tribo spraygun PEM-T1 the mode switch at the back plate of the control unit EPG 2007 must be readjusted. (see operating manual of the conrol unit EPG 2007 paragraph 3.1. "Setting codes of the mode switch" BAL-No. 0263 830 USA/UK).
The safety rules (paragraph 1) must be observed when setting up the manual powder system 2007 - 70LR.
Preconditions:
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Warning |
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When used inside the zone 11 the manual powder system may only be operated with the protection cover (A) mounted at the back-side of the control unit, see operating manual of the control unit EPG 2007 paragraph 3. "Start up". In several countries there are country-specific regulations, according to which the control unit of the manual powder system must be installed outside the dust explosion-hazard zone (Zone 11 according to ZH 1/443 and ZH 1/444 - see paragraph 1.1. "Safety regulations"). With the safety device (A) mounted to the control unit it is allowed to install the equipment inside zone 11 according to the certificate PTB No. Ex-92.C.9102 (see appendix). |
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3.1.2
Course order when starting up for the first time: Tribo spraygun PEM-T1
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Mode 2: for gun type: PEM-T1
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Warning |
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When used inside the zone 11 the manual powder system may only be operated with the protection cover (A) mounted at the back-side of the control unit, see operating manual of the control unit EPG 2007 paragraph 3. "Start up". In several countries there are country-specific regulations, according to which the control unit of the manual powder system must be installed outside the dust explosion-hazard zone (Zone 11 according to ZH 1/443 and ZH 1/444 - see paragraph 1.1. "Safety regulations"). With the safety device (A) mounted to the control unit it is allowed to install the equipment inside zone 11 according to the certificate PTB No. Ex-92.C.9102 (see appendix). |
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3.2 Assembling and connectingSee paragraph 3.4. and 3.5. "Connection diagrams" on the following pages.
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Course order:
3.3 GroundingIn order to achieve a good powder coating and for security reasons (see 1.1., safety regulations), the manual powder system 2007-Airfluid must be properly grounded.
Good grounding of the workpiece is necessary for optimum powder coating. A poorly grounded workpiece causes:
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Warning |
In installation with a mains cable without separate protective ground terminals
it is absolutely necessary to connect the control unit via grounding screw at
the back plate to
the system ground by a separate grounding cable!
Sparks between workpiece and conveyor hooks (hangers)
can occur if hooks or other hanger parts are not completely
cleaned!
Preconditions for good grounding as well as coating are:
3.4 Connection diagram with an Airmatic spraygun PEM-C2
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3.5 Connection diagram with a Tribo spraygun PEM-T1
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3.6 Basic adjustmentsPreconditions:
Course order:
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Caution |
The mains power connection must be eletrically interlocked with the exhaust air system of the powder spray booth.
4.1
Adjusting the powder cloudPreconditions:
Course order:
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Caution |
The powder tank may only be filled half way.
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Caution |
Avoid to much dust development.
For further information see operating manuals of control unit and spraygun
respectively.
Recommendation
The spraygun and the powder feeding parts should be blown through and cleaned from powder deposits with every interruption of work.
Course order:
1. Release trigger on spraygun:
2. Remove powder injector from the mount, to prevent further powder delivery.
3. Hold the spraygun into the spray booth, pull the trigger and blow through to remove powder deposits.
4. Turn off control unit:
5. Turn off compressed air supply:
It is recommended not to turn off the fluid air via the one-way valve. In this way you avoid having to readjust the fluid air when using the same powder paint.
Recommendation
When changing colors, all powder-transporting components must be cleaned thoroughly.
4.4.1
Changing powder when using one powder tankCourse order: Cleaning
Course order: Re-starting
Recommendation
It is recommended to use a separate powder tank for each color. This allows a color change to be carried out faster and reduces cleaning times to a minimum.
Course order: Cleaning
Course order: Re-starting
5.
Maintenance and cleaningWeekly cleaning of the manual powder system ensures trouble-free operation.
The control unit is maintenance-free, when used acc. to this operating manual.
The wearing parts of the powder spraygun and the powder injector must be checked and replaced if necessary.
The spare parts are marked in the corresponding listings in this operating manual and in the separate operating manuals of the individual components.
| 1. Cleaning the manual powder system see paragraph 4.4. "Changing powder". |  |
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2. Remove powder injector (B) from the powder tank (4). |
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| 3. Disconnect transparent powder hose (6/2), red feeding air hose (5/3) and blue dosage air hose (5/2) from the powder injector (B). | |
| 4. Blow through powder injector with bursts of compressed air from the powder inlet. | |
| 5. Check powder injector and if necessary replace wear parts - see operating manual of the powder injector PJ 2020 PRS. | |
| 6. Blow bursts of compressed air in direction of delivery through powder hose and powder spraygun. | |
| 7. Disconnect powder hose and powder spraygun and blow through spraygun from powder inlet with bursts of compressed air. | |
| 8. Undo green fluid air hose from the powder tank and remove powder tank from the equipment trolley for cleaning. | |
| 9. Remove lid from powder tank and blow out thoroughly with compressed air (vacuum off if necessary) to remove powder deposits. | |
| 10. Clean thoroughly the suction unit of the powder tank from powder deposits | |
| 11. Clean thoroughly the fluid base, check blockages and damages and if necessary replace - see operating manual of the powder tank 70LR. | |
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Caution |
The compressed air must meet the requirements in paragraph 2.3. (acc. to ISO 8573.1), to avoid blocking of the fluid base.
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Caution |
5.2.2
Cleaning
the PEM-T1 powder nozzle
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Warning / Caution |
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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.
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NOTE
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6.
Trouble shooting
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Malfunction |
Cause |
Remedy |
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Operation indicator does not light up |
- Mains power is not turned on - Fuse 1 AT defective |
- Turn on mains power - Replace fuse |
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Fault indicator lights up |
- Break in interconnect cable to spraygun |
- Please notify - Turn off high voltage. Increase distance between spraygun and workpiece.
Turn on high voltage again. Inform - Inform |
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Powder output bursts (spatters) |
- Air speed in powder hose too low - Reduced diameter of powder hose due to bending - Compressed air fluctuations caused by brief high consumption |
- Increase feeding air and dosage air volumes - Use higher quality powder hose with consistent inside diameter - Install a reservoir tank for compressed air directly in front of large consumption point |
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Dust build-up in area of manual powder system |
- Too much fluid air |
- Reduce fluid air volume at throttle valve |
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Poor wrap-around |
- Bad grounding |
- See paragraph 3. "Start up" |
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Back-spray |
- No grounding |
- See paragraph 3. "Start up" |
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No powder output |
- Powder container empty - Spraygun blocked - Powder hose blocked - Powder suction system is plugged up in powder tank - Feeding air hose kinked - Powder hose kinked |
- Refill or replace powder tank - Blow through spraygun with compressed air - Blow through powder hose with compressed air - Blow through powder suction system with compressed air - Straighten hose or replace - Straighten hose or replace |