2007 Airfluid Manual Powder System

2007 Airfluid
Manual Powder System 09/96

Danger!

High voltage! Turn power off before servicing! Read rules for safe operation and instructions carefully!

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Operating Manual

Table of contents

1. Introduction

1.1. Safety regulations

1.2. Warranty

2. Description of the manual powder system

2.1. Application

2.2. What powder materials can be used?

2.3. Specification

2.4. Manual powder system 2007 - Airfluid operation

2.4.1. Manual powder system (Corona): 2007/C - Airfluid

2.4.2. Manual powder system (Tribo): 2007/T - Airfluid

2.5. Part numbers

2.5.1. Manual powder system (Corona): 2007/C - Airfluid

2.5.2. Manual powder system (Tribo): 2007/T - Airfluid

3. Start up

3.1. Preparation

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

3.3. Grounding

3.4. Connection diagram with an Airmatic spraygun PEM-C2

3.5. Connection diagram with a Tribo spraygun PEM-T1

3.6. Basic adjustments

4. Operation

4.1. Adjusting the powder cloud

4.2. Practical notes

4.3. Work interruption

4.4. Changing powder

5. Maintenance and cleaning

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

6. Trouble shooting

7. Spare parts list with accessories

Back plate of the control unit
EPG 2007

Caution

Before start up the mode switch (18) at the back plate of the control unit must be adjusted depending on the application mode!
The control unit is factory-set for operation with the PEM-C2 Corona spraygun.
When using the control unit in conncetion with the Tribo spraygun PEM-T1 the mode switch must be set to mode 2!

Mode 2: for gun type: PEM-T1

When using the control unit together with other sprayguns the mode switch must be adjusted according to the respective operating modes!

Setting codes of the mode switch see paragraph 3.1. in the operating manual BAL-No. 0263 830 USA/UK !

1. Introduction

This technical manual contains information 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.

"Warning"

Important safety information indicates a hazard which may cause serious injury or loss of life.

"Caution"

Important information that tells how to prevent damage to equipment or how to avoid causes of minor injuries.

"Hint"

Gives important information which should be given special attention.

Declaration of Conformity

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.

Warning

HAZARD

PREVENTION

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.

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 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.

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.

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.

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.

1.1 Safety regulations

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:

The spraygun may only be operated in the hazard zone created by operation of the manual spraying equipment itself. 3)
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 observe particularly the safety guidelines of the VdS and the professional associations. 2) 3) 6) 9)
The user has to ensure that the medium value of the powder/air concentration does not exceed 50% of the UEG* ⁾ (lower explosion limit). If the UEG*⁾ is not known, the user should assume a value of 20 g/m³.
If the powder concentration at high total powder output is higher than the allowed values, the user should consult the powder manufacturer. In most cases an exact measurement of the lower explosion limit (UEG) will allow a higher maximum powder/air concentration.
The mains power connection for operation of the powder equipment must be electrically interlocked with the exhaust system of the powder
coating booth. 2) 3) 6)
The 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 users 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 experts who are specially qualified for this work. 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 (1.5 m at the sides, 2.5 m to the front and rear of every spray location or opening in the booth, as specified by EN 50053). 2) 3)
Electrostatically conductive footwear must be worn by all persons inside the work area. 2) 3)
If gloves are worn, they must be of antistatic material or have cut-out palm areas. 2) 3)

^{* )} UEG: Low explosion limit, i.e. maximum allowed concentration of powder in air.

Warning

Powders containing metal pigments may only be processed in compliance with the powder manufacturer's instructions.

Applicable Safety Regulations and List of Sources

1)

EN 50050/
DIN VDE 0745
Part 100

Manual electrostatic spraying equipment

(published by
VDE-Verlag, Berlin)

2)

EN 50053 Part 2
DIN VDE 0745
Part 200

Selection, installation and use of electrostatic spraying equipment, manual electrostatic equipment for powder

(published by
VDE-Verlag, Berlin)

3)

ZH 1/443 (1993)

Electrostatic powder coating using manual spraying equipment

(published by
C. Heymanns-Verlag, Cologne)

4)

EX-RL / ZH 1/10

Guidelines for explosion protection

(published by
C. Heymanns-Verlag, Cologne)

5)

VDE 0165

Installation of electrical equipment in explosion-hazard areas

(published by
VDE-Verlag, Berlin)

6)

VDMA 24371 Part 1

Guidelines for electrostatic coating using synthetic resin powders

(published by
Beuth-Verlag, Berlin)

7)

ELEX V

Regulation for electrical systems in explosion-hazard areas

(published by
VDE-Verlag, Berlin)

8)

VDE 0134

Instructions for first aid in case of accident

(published by
VDE-Verlag, Berlin)

9)

VDS 2093

Association of insurance companies

(Riehlerstr. 36
50668 Cologne)

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.

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.

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 Warranty

What 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:

caused by use or installation of repair or replacement parts or accessories not manufactured by Wagner,
caused by repair performed by anyone other than a Wagner authorized service center, or
caused by or related to abrasion, corrosion, abuse, misuse, negligence, accident, normal wear, faulty installation or tampering in a manner which impairs normal operation.

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. Description of the manual powder system

2.1 Application

The manual powder system 2007 - Airfluid is designed for use in laboratories and low volume production in industry and trade.

The major advantages are:

Powder supply from the original container
Recoating in addition to prior automatic coating
Quick and easy cleaning

2.2 What powder materials can be used?

All powder paints can be processed with the manual powder system 2007 - Airfluid.

i.e.: Epoxy, Polyester, blended powder EP / PES, PUR.

2.3 Specification

Dimensions:

Width: 466 mm

Height: 1182 mm

Depth: 770 mm

Weight: approx. 39 kg

Electrical:

Mains power: *
220 V ... 240 V
110 V ... 120 V
100V

Frequency: 50...60 Hz

Input power: max. 120 W

EMI filter: EN 55022 Klasse B
VDE 0878 PT3 Klasse B

*see paragraph 2.5. "Part numbers" (for corresponding countries)

Displays:

High voltage: 0 - 100KV Resolution: 5KV

Corona current: 0 - 200µA Resolution: 10µA

Tribo current: 0 - 4 µA Resolution: 0,2µA

Pneumatic:

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:

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:

Working temperatur range: 5 to 45°C

If low temperature powders are used the ambient temperature may have to be lower than 30°C.

2.4 Manual powder system 2007 - Airfluid operation

The feed unit (A) is inserted directly into the powder sack of the container. The powder is fed to the powder gun (C) via the powder injector (B). Due to the special arrangement of the fluid hoses in front of the suction tube and the vibration of the entire container, 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 feed system.

2.4.1 Manual powder system (Corona): 2007/C - Airfluid

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 - Airfluid

Each 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.

2.5 Part numbers

2.5.1 Manual powder system (Corona): 2007/C - Airfluid

Standard

Japan

USA

(shaker motor version)

(230 V/ 50 Hz)

(100 V/ 50-60 Hz)

(120 V/ 60 Hz)

Part No.

0265 001

0265 011

0265 021

Item

Part No.

Quantity

Description

1

0264 188
0264 189
0264 190

1
1
1

Equipment trolley 2010 Airfluid (Standard)
Equipment trolley 2010 Airfluid (Japan)
Equipment trolley 2010 Airfluid (USA)

2

0265 100
0265 102
0265 101

1
1
1

Control unit EPG 2007 (Standard)
Control unit EPG 2007 (Japan)
Control unit EPG 2007 (USA)

3

0351 021

1

Airmatic spraygun PEM-C2

4

0264 193

1

Feed unit Integral ME 1

5

0241 294

1

Powder injector PJ 2020 PRS

6

0264 326

1

Airfluid connecting parts consisting of: Item. 6/1 ... 6/6

6/1

9982 077

1,5 m

Hose green (5,5 x 8)

6/2

9982 062

1,5 m

Hose blue (5,5 x 8)

6/3

9982 063

1,5 m

Hose red (5,5 x 8)

6/4

9992 200

1

Fitting plug-in nipple

6/5

9992 711

1

Coupling joint

6/6

9982 078

0,35 m

Hose black (5,5 x 8)

7

0264 417

1

Powder hose-Set 2020 consisting of: Item 7/1 ... 7/2

7/1

9982 079

6 m

Hose black (4 x 6)

7/2

9998 259

6 m

Powder hose transparent

8

0264 191

1

Set 2010 consisting of: Item 8/1 ... 8/3

8/1

9990 149

1

Y-piece

8/2

9998 132

1

One-way valve

8/3

9998 133

1

Double hose socket

9

0264 329

1

Retaining strap

(Extras see delivery note)

2.5.2 Manual powder system (Tribo): 2007/T - Airfluid

Standard

Japan

USA

(shaker motor version)

(230 V/ 50 Hz)

(100 V/ 50-60 Hz)

(120 V/ 60 Hz)

Part No.

0265 003

0265 013

0265 023

Item

Part No.

Quantity

Description

1

0264 188
0264 189
0264 190

1
1
1

Equipment trolley 2010 Airfluid (Standard)
Equipment trolley 2010 Airfluid (Japan)
Equipment trolley 2010 Airfluid (USA)

2

0265 100
0265 102
0265 101

1
1
1

Control unit EPG 2007 (Standard)
Control unit EPG 2007 (Japan)
Control unit EPG 2007 (USA)

3

0259 003

1

Tribo spraygun PEM-T1

4

0264 193

1

Feed unit Integral ME 1

5

0241 294

1

Powder injector PJ 2020 PRS

6

0264 326

1

Airfluid connecting parts consisting of: Item 6/1 ... 6/6

6/1

9982 077

1,5 m

Hose green (5,5 x 8)

6/2

9982 062

1,5 m

Hose blue (5,5 x 8)

6/3

9982 063

1,5 m

Hose red (5,5 x 8)

6/4

9992 200

1

Fitting plug-in nipple

6/5

9992 711

1

Coupling joint

6/6

9982 078

0,35 m

Hose black (5,5 x 8)

7

0264 417

1

Powder hose-Set 2020 consisting of: Item 7/1 ... 7/2

7/1

9982 079

6 m

Hose black (4 x 6)

7/2

9998 259

6 m

Powder hose transparent

8

0264 191

1

Set 2010 consisting of: Pos 8/1 ... 8/3

8/1

9990 149

1

Y-piece

8/2

9998 132

1

One-way valve

8/3

9998 133

1

Double hose socket

9

0264 329

1

Retaining strap

(Extras see delivery note)

3. Start up

Recommendation

Before installing and starting up the manual powder system, become familiar with the corresponding operating manual.

3.1 Preparation

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 - Airfluid.

Preconditions:

Operating modes must be defined according to the operating manual of the control unit EPG 2007.

3.1.1 Course order when starting up for the first time: Airmatic spraygun PEM-C2

Turn off the control unit EPG 2007 by switching the main switch (16) to the "0" position.
The mode switch at the back plate of the control unit is factory-set for this application mode.
For further procedure see paragraph 3.2. "Assembling and connecting".

Warning

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).

3.1.2 Course order when starting up for the first time: Tribo spraygun PEM-T1

Turn off the control unit EPG 2007 by switching the main switch (16) to the "0" position.
Unscrew cover (17) of the mode switch (18) and adjust switch positions to mode 2 acc. to "Setting codes of the mode switch" (see operating manual of the control unit EPG 2007).

Mode 2: for gun type: PEM-T1

For further procedure see paragraph 3.2. "Assembling and connecting".

Warning

3.2 Assembling and connecting

See paragraph 3.4. and 3.5. "Connection diagrams" on the following pages.

Course order:

Connect the double hose socket (8/3) at the mount (A) of the feed unit (4).
Connect the one-way valve (8/2) at the double hose socket (8/3).
Connect Y-piece (8/1) and fitting (B) on the equipment trolley (C) with a short (» 40 mm) black hose (6/6).
Connect the socket (D) and the control unit (2) with a black hose (6/6).
Connect powder injector (5) and powder spraygun (3) with the transparent powder hose (7/2).
Connect powder injector (5) and control unit (2) with the red feeding air hose (6/3).
Connect powder injector (5) and control unit (2) with the blue dosage air hose (6/2).
Connect control unit (2) and powder spraygun (3) with the black atomizing air hose resp. tribo air hose (7/1).
Connect the Y-piece (8/1) and the one-way valve (8/2) with the green fluid air hose (6/1).
Adjust the fluid air at the one-way valve (8/2) - see paragraph 3.6. "Basic adjustments".
Connect the manual powder system 2007 - Airfluid to the control unit as shown at paragraph 3.4. and 3.5. "Connection diagrams" on the following pages.
Connect compressed air system (E) to the manual powder system 2007 - Airfluid (1/4" coupling of the fitting (B) at the equipment trolley (C) available).
Connect gun cable to the corresponding socket at the back plate of the control unit.
Connect shaker motor cable to the corresponding socket at the back plate of the control unit and secure with bracket.
Connect power cable to the corresponding socket on the back plate of the control unit and secure with bracket.

3.3 Grounding

In 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:

very bad wrap-around
uneven coating
back-spray onto spraygun and user
dangerous electric charging of the workpiece

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:

Good grounding the workpiece to be coated of conveyors and hangers.
Grounding of the powder spray booth and the transport and mounting equipment with the installation of a > 16 mm² copper conductor to system ground.
Regular cleaning of hangers from powder deposits.
The grounding resistance of the workpiece must not exceed 1 MOhm (Mega Ohm).
Connect a ground strap to the control unit - see paragraphs

3.4 Connection diagram with an Airmatic spraygun PEM-C2

Pneumatic hose:
Polyamid PA Ø 8 ± 0,1
Polyurethan PUR Ø 8 ± 0,15 (preferably Legris)

3.5 Connection diagram with a Tribo spraygun PEM-T1

Pneumatic hose:
Polyamid PA Ø 8 ± 0,1
Polyurethan PUR Ø 8 ± 0,15 (preferably Legris)

3.6 Basic adjustments

Preconditions:

Connect the powder spraygun to the control unit as shown in the conntection diagram, see paragraph 3.4. or 3.5..
The compressed air (6 - 8 bar) must be connected.
The control unit must be turned off.

Course order:

Connect power cable of the manual powder system to (electrical) mains power.

Caution

The mains power connection must be eletrically interlocked with the exhaust air system of the powder spray booth.

Turn on control unit.
Turn the voltage regulator at the control unit counterclockwise beyond the switch point. This will prevent the high voltage and the powder delivery from turning on.
The fluid air pressure can be closed with the one-way valve, attached to the feed system.
Turn dosage air, feeding air and atomizing air at the control unit to 0 setting.
Turn off the control unit.
For further procedure see paragraph 4.1. "Adjusting the powder cloud".

4. Operation

Caution

In order to prevent damage of the container due to vibration (scrub through), a minimum distance of ¾ inch must be maintained between the feed unit and the container bottom.

The fluid air must be set as soon as the control unit is turned on (possible blockage).

The feed unit should only sink into the powder driven by its own weight.

Before turning off the manual powder system, you must first pull the feed unit out of the powder container (danger of blockage of the fluid air hoses).

4.1 Adjusting the powder cloud

Preconditions:

The basic adjustments must be carried out acc. to paragraph 3.6. .

Course order:

Open powder container (25 - 30 kg), place on shaker table and fix into position with the retaining strap provided.
Turn on control unit:
· The shaker motor starts running.
Drop down the feed unit to the powder surface.
Adjust the fluid air pressure with the one-way valve (1 bis 2 bar) until the feed unit starts sinking into powder through its own weight:
· The necessary fluid air quantity depends on the powder quality.
· The powder should be slightly "boiling" around the fluid hoses.

Caution

Avoid to much dust development.

Hold the spraygun into the spray booth, pull the trigger and adjust the powder cloud.
Adjust feeding air, dosage air and atomizing air at the control unit:

For further information see operating manuals of control unit and spraygun
respectively.

4.2 Practical notes

High room temperatures must be avoided; in particular, the hoses must not be routed through factory areas exposed to direct sunlight.
Powders with a gelling tendency should be processed at low temperatures and the hoses flushed with compressed air every day in order to prevent powder from sintering.

4.3 Work interruption

Hint

The spraygun and the powder feeding parts should be blown through and cleaned from powder deposits with every interruption of work.

Course order:

Release trigger on spraygun:
· The high voltage is turned off.
· The Powder feed is turned off.
Remove feed unit from the container, to prevent further powder delivery.
Hold the spraygun into the spray booth, pull the trigger and blow through to remove powder deposits.

Caution

Before turning off the manual powder system, you must first pull the feed unit out of the powder container (danger of blockage of the fluid air hoses).

Turn off control unit:
· The fluid air keeps on running.
Turn off compressed air supply:
· The fluid air is turned off.

It is recommended, not to turn off the fluid air via the one-way valve. When reusing the same coating powder you don’t have to readjust the fluid air quantity.

4.4 Changing powder

Hint

When changing colors, all powder-transporting components must be cleaned thoroughly.

Course order: Cleaning

Turn off the control unit and clean manual powder system according to paragraph 4.3. "Work interruption".
Clean thoroughly the powder spraygun from powder deposits, see operating manual of the powder spraygun.
Undo powder hose from powder injector and blow through to remove powder deposits.
Undo powder injector from the feed unit and clean thoroughly from powder deposits.
Clean thoroughly the feed unit from powder deposits.

Course order: Re-starting

Open new powder container (25 - 30 kg), place on shaker table and fix into position with the retaining strap.
Perform basic adjustments, according to paragraph 3.6.
"Adjust the powder cloud", according to paragraph 4.1.

5. Maintenance and cleaning

Weekly 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.

5.1 Cleaning the manual powder system

Cleaning the manual powder system see paragraph 4.4. "Changing powder".

Remove powder injector (5) from the feed unit (4).

Disconnect transparent powder hose (7/2), red feeding air hose (6/3) and blue dosage air hose (6/2) from the powder injector (5).

Blow through powder injector with bursts of compressed air from the powder inlet.

Check powder injector and if necessary replace wear parts - see operating manual of the powder injector PJ 2020 PRS.

Blow bursts of compressed air in direction of delivery through powder hose and powder spraygun.

Disconnect powder hose and powder spraygun and blow through spraygun from powder inlet with bursts of compressed air.

Disconnect the feed unit (4) from the mount (A) by undoing of the quick coupling (E).

Thoroughly blow out suction tube of feed unit with compressed air in direction of delivery and rub off with dry cloth.

5.2 Cleaning the powder spraygun

Caution

Never place the spraygun or parts of it into any wet cleaning agent!
When changing the powder nozzle, take care that the electrical contact points are thoroughly cleaned.

5.2.1 Cleaning the PEM-C2 powder nozzle

Cleaning the powder nozzle see paragraph 5. "Maintenance and cleaning" in the operating manual of the powder spraygun PEM-C2 (No. 0351 801 USA/UK).

5.2.2 Cleaning the PEM-T1 powder nozzle

Cleaning the charging body see paragraph 5. "Maintenance and cleaning" in the operating manual of the powder spraygun PEM-T1 (No. 0259 846 USA/UK).
Replacing the wear parts see paragraph 5. "Maintenance and cleaning" in the operating manual of the powder spraygun PEM-T1 (No. 0259 846 USA/UK).

Warning / Caution

WARNING

CAUTION

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 2020 PRS)

Clean the spray tip by removing from spraygun, flushing with air and replacing on spraygun.

6. Trouble shooting

Malfunction

Cause

Remedy

Operation indicator does not light up

- Power supply turned off

- Fuse 1 AT defective

- Turn on power supply

- Replace fuse

Fault indicator lights up

- Break in interconnect cable to spraygun

- Spraygun too close to workpiece

- Grounding between control unit and spraygun interrupted

- Please notify
service center or trained personnel for the replacement of the interconnect cable

- Turn off high voltage. Increase distance between spraygun and workpiece. Turn on high voltage again. Inform service center if error message reoccurs

- Inform service center

Powder output bursts (spatters)

- Air speed in powder hose too low

- Reduced diameter of powder hose due to bending

- Compressed air fluctuations

- Increase feeding air and dosage air volumes

- Use higher quality powder hose with consistent inside diameter

- Install a reservoir tank for compressed air

Dust build-up in powder box

- Too much fluid air

- Reduce fluid air volume at throttle valve

Poor wrap-around

- Bad grounding

- See paragraph 3. "Start up"

Back-spray

- No grounding

- See paragraph 3. "Start up"

No powder output

- Powder container empty

- Spraygun blocked

- Powder hose blocked

- Powder suction system is plugged up in powder container

- Feeding air hose kinked

- Powder hose kinked

- Refill or replace powder container

- 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

Feed unit does not sink into powder

- Guide rod of the mount for the feed unit binds

- Improve guide rod smoothness

1)	EN 50050/ DIN VDE 0745 Part 100	Manual electrostatic spraying equipment	(published by VDE-Verlag, Berlin)
2)	EN 50053 Part 2 DIN VDE 0745 Part 200	Selection, installation and use of electrostatic spraying equipment, manual electrostatic equipment for powder	(published by VDE-Verlag, Berlin)
3)	ZH 1/443 (1993)	Electrostatic powder coating using manual spraying equipment	(published by C. Heymanns-Verlag, Cologne)
4)	EX-RL / ZH 1/10	Guidelines for explosion protection	(published by C. Heymanns-Verlag, Cologne)
5)	VDE 0165	Installation of electrical equipment in explosion-hazard areas	(published by VDE-Verlag, Berlin)
6)	VDMA 24371 Part 1	Guidelines for electrostatic coating using synthetic resin powders	(published by Beuth-Verlag, Berlin)
7)	ELEX V	Regulation for electrical systems in explosion-hazard areas	(published by VDE-Verlag, Berlin)
8)	VDE 0134	Instructions for first aid in case of accident	(published by VDE-Verlag, Berlin)
9)	VDS 2093	Association of insurance companies	(Riehlerstr. 36 50668 Cologne)

Dimensions:
Width:	466 mm
Height:	1182 mm
Depth:	770 mm
Weight:	approx. 39 kg
Electrical:
Mains power: *	220 V ... 240 V 110 V ... 120 V 100V
Frequency:	50...60 Hz
Input power:	max. 120 W
EMI filter:	EN 55022 Klasse B VDE 0878 PT3 Klasse B
*see paragraph 2.5. "Part numbers" (for corresponding countries)
Displays:
High voltage:	0 - 100KV	Resolution: 5KV
Corona current:	0 - 200µA	Resolution: 10µA
Tribo current:	0 - 4 µA	Resolution: 0,2µA
Pneumatic:
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:
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:
Working temperatur range:	5 to 45°C
If low temperature powders are used the ambient temperature may have to be lower than 30°C.

	Standard	Japan	USA
(shaker motor version)	(230 V/ 50 Hz)	(100 V/ 50-60 Hz)	(120 V/ 60 Hz)
Part No.	0265 001	0265 011	0265 021

Item	Part No.	Quantity	Description
1	0264 188 0264 189 0264 190	1 1 1	Equipment trolley 2010 Airfluid (Standard) Equipment trolley 2010 Airfluid (Japan) Equipment trolley 2010 Airfluid (USA)
2	0265 100 0265 102 0265 101	1 1 1	Control unit EPG 2007 (Standard) Control unit EPG 2007 (Japan) Control unit EPG 2007 (USA)
3	0351 021	1	Airmatic spraygun PEM-C2
4	0264 193	1	Feed unit Integral ME 1
5	0241 294	1	Powder injector PJ 2020 PRS
6	0264 326	1	Airfluid connecting parts consisting of: Item. 6/1 ... 6/6
6/1	9982 077	1,5 m	Hose green (5,5 x 8)
6/2	9982 062	1,5 m	Hose blue (5,5 x 8)
6/3	9982 063	1,5 m	Hose red (5,5 x 8)
6/4	9992 200	1	Fitting plug-in nipple
6/5	9992 711	1	Coupling joint
6/6	9982 078	0,35 m	Hose black (5,5 x 8)
7	0264 417	1	Powder hose-Set 2020 consisting of: Item 7/1 ... 7/2
7/1	9982 079	6 m	Hose black (4 x 6)
7/2	9998 259	6 m	Powder hose transparent
8	0264 191	1	Set 2010 consisting of: Item 8/1 ... 8/3
8/1	9990 149	1	Y-piece
8/2	9998 132	1	One-way valve
8/3	9998 133	1	Double hose socket
9	0264 329	1	Retaining strap

Malfunction	Cause	Remedy
Operation indicator does not light up	- Power supply turned off - Fuse 1 AT defective	- Turn on power supply - Replace fuse
Fault indicator lights up	- Break in interconnect cable to spraygun - Spraygun too close to workpiece - Grounding between control unit and spraygun interrupted	- Please notify service center or trained personnel for the replacement of the interconnect cable - Turn off high voltage. Increase distance between spraygun and workpiece. Turn on high voltage again. Inform service center if error message reoccurs - Inform service center
Powder output bursts (spatters)	- Air speed in powder hose too low - Reduced diameter of powder hose due to bending - Compressed air fluctuations	- Increase feeding air and dosage air volumes - Use higher quality powder hose with consistent inside diameter - Install a reservoir tank for compressed air
Dust build-up in powder box	- Too much fluid air	- Reduce fluid air volume at throttle valve
Poor wrap-around	- Bad grounding	- See paragraph 3. "Start up"
Back-spray	- No grounding	- See paragraph 3. "Start up"
No powder output	- Powder container empty - Spraygun blocked - Powder hose blocked - Powder suction system is plugged up in powder container - Feeding air hose kinked - Powder hose kinked	- Refill or replace powder container - 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
Feed unit does not sink into powder	- Guide rod of the mount for the feed unit binds	- Improve guide rod smoothness