EPG 2020 CG Powder Cup Gun Portable Set

EPG 2020 CG
Powder Cup Gun
Portable Set 04/97

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

2.1. Application

2.2. What powder materials can be used?

2.3. Specification

2.3.1. Control unit

2.3.2. Powder cup gun

2.4. Operation of powder cup gun portable set

2.5. Part numbers of powder cup gun portable set

2.6. Control functions

2.6.1. Control unit

2.6.2. Powder cup gun

2.7. Corona-Star Retrofit-Set

2.7.1. Description

2.7.2. Part numbers Corona-Star Retrofit-Set

2.7.3. Assembling instructions

3. Start up

3.1. Preparation

3.1.1. Mounting the powder cup

3.1.2. Adjusting the control unit

3.2. Connecting the powder cup gun to the control unit

3.3. Grounding

4. Operation

4.1. Adjusting the powder cloud

4.2. Practical notes

4.3. Application-related description of nozzle systems

4.4. Work interruption

4.5. Changing powder

5. Maintenance and cleaning

5.1 Cleaning the powder nozzle

5.2 Replacing the distribution rod

5.3. Standard adjustments of the spraygun

6. Trouble shooting

6.1. Control unit

6.2. Powder cup gun

7. Spare parts list with accessories

1. Introduction

This 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.

"Warning"

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

"Caution"

Important information for preventing damage to equipment or how to avoid causes of minor injuries.

"Hint"

Gives important information which deserves 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! 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 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. 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 observe particularly the safety guidelines of the VdS or the local professional and security institutions. 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 for having the powder tested for that concentration.
The mains power connection for operation of the powder spray 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. 7)
Repairs may only be carried out by experts who are specially trained 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 (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, as specified by EN 50053). 2) 3)

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

Electrostatically conductive footwear must be worn by all persons inside the work area. 2) 3)
If gloves are used, they must be of antistatic material or have cut-out palm areas. 2) 3)

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

Electrical equipment for explosion-hazard areas

Manual electrostatic spraying equipment

(published by
VDE-Verlag,
Berlin)

2)

EN 50053 - 2
DIN VDE 0745
Part 102

Requirements for selection, installation and use of electrostatic spraying equipment for flammable materials

(published by
VDE-Verlag,
Berlin)

3)

ZH 1/443

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
Beuth-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.

Wear suitable work clothing

Use breathing protection

Use breathing protection for work which produces dust.

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 alway keep your balance.

Take good care of the manual system

Keep the manual system clean to ensure that it works well and safely. Check the plug and line cord regularly and have them replace 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.

Caution

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 (socalled 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

2.1 Application

The control unit EPG 2020 CG in connection with the Airmatic-Powder cup gun PEM-CG2 is used for spraying of coating powders. Above all the gun is suitable for laboratory experiments, for coating of samples and low volume production.

Caution

The equipment may only be used for the above described application.

2.2 What powder materials can be used?

Basically, all coating powders can be used with the powder cup gun PEM-CG2 e.g.epoxy resin, polyester, blended powder EP / PES, PUR.

Caution

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

2.3 SpecificationsTechnische Daten

2.3.1 Control unit

Dimensions:

Width:

438mm

Height: 138 mm

Depth: 300 mm

Weight: ca. 11 kg (with powder cup gun)

Electrical:

Mains power:*
100/120/230 V

Frequency:
50...60 Hz

Input power:
max. 30 W

Output voltage: max. 22 Vpp

Output current:
max. 0,9 A

Solenoid valve control voltage:
24 V DC

Protection class:
IP 54

Radio interference level:

FN

Pneumatic:

Input air pressure:
86.5-115.3 psi (6 - 8 bar)

Output air pressure: 0...86.5 psi (0...6 bar)

Compressed air quality 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

* Selector switch on the front (see paragraph 2.6.)

Ambient conditions:

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

2.3.2 Powder cup gun

Weight: 890 g (without supply lines)

Electrical:

Input voltage: max. 22 Vpp

Input current: max. 0,9 A

Frequency: 19...30 kHz

Output voltage: max. 100 kV DC

Output current: max. 160 µ A DC

Polarity: negative

Design: accord. to EN 50050

Protection class: IP 54

Pneumatic:

Input air pressure: 29 psi (2 bar - standard adjustment)

Powder output: max. 200 g/min at 29 psi 2 bar (max. 300 g/min at 58 psi 4 bar)

2.4 Operation of powder cup gun portable set

When the trigger (E, see paragraph 2.6.) is pulled (control unit is turned on), the high voltage is activated in the PEM-CG2. At the same time the supply air (F) to the powder cup gun is opened at the control unit.

The air supply is used:

For the central air to ventilate the deflector cone.
For fluidization of the powder in the powder cup (H).
For feeding air (L) and dosage air of the built-in injector in the gun body (J). This injector pumps the fluidized powder from the powder cup (H) to the nozzle.

A high DC voltage (up to 100 kV), applied across the grounded workpiece and the electrode fitted to the gun body generates an electric field and applies a negative charge to the powder particles. These repel each other as they move from gun to workpiece and so distribute evenly through the fine spray 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. Effective material yield, time savings, markedly improved quality of finish, less cleaning and a healthier environment are the principal properties of the process.

Caution

To provide a safeguard against unintentional use of the spraygun, the control unit must be turned off.

2.5 Part numbers of powder cup gun portable set

Standard

USA

Japan

(set up voltage)

(230 V/ 50 Hz)

(120 V / 60 Hz)

(100 V / 50-60 Hz)

Part No.

0264 016

0264 052

0264 051

Part No.

Standard

USA

Japan

Quantity

Description

0264614

0264285
0264611
0264612

0264614

0264285
0264611
0264612

0264614

0264285
0264611
0264612

1

1
1
1

EPG 2020 CG control unit,
consisting of:

Module HVM 2072-H
Module PSM 2216
Module PSM 2014

0241270
0130215
-

0264626
0130215
-

0264625
0130215
0236219

1
1
1

Power cable
Grounding cable
Grounding cable (mains power)

035023

0351023

0351023

1

Powder cup gun Airmatic PEM-CG2
with round spray nozzle, externally charged, Deflector cone Ø 17 mm and powder cup 500 cm³

0351225

0351225

0351225

1

Deflector cone Ø 17

0351226

0351226

0351226

1

Deflector cone Ø 25

0351227

0351227

0351227

1

Deflector cone Ø 32

9982079

9982079

9982079

4 m

Hose black AD6x1

9992195

9992195

9992195

1

Fitting

9992711

9992711

9992711

1

Coupling joint

0264960

9951115

0264960

9951115

0264960

9951115

1

2

Set of replacement parts EPG 2020 CG consisting of:
Fuse 0,5 A

(Options see delivery note)

2.6 Control functions

2.6.1 Control unit

1 Voltage regulator (HVM 2072-H)

The voltage regulator HVM 2072-H is turned off when the knob is turned counterclockwise beyond the switch point
Select level of the desired high voltage (maximum 100 kV)

2 LED bar graph display (HVM 2072-H)

Indication of desired high voltage in kV when the spraygun is not triggered
( single LED display)
Indication of the actual high voltage in kV when the spraygun is turned on
( bar graph LED display)

3 LED bar graph display (HVM 2072-H)

Spraying current limit when the gun is turned off
( single LED display)
Actual spraying current in µA when gun is triggered
( bar graph LED display)

4 Green indicator (HVM 2072-H)

Lights up green when system is operational

5 Red indicator (HVM 2072-H)

Lights up red in event of a malfunction

there are turned off:

the high voltage
the supply air

6 Pressure gauge (PSM 2216)

Supply air pressure indicator for the powder cup gun PEM-CG2
Range: 0 - 6 bar

7 Control knob (PSM 2216)

Adjusting the supply air pressure for the powder cup gun PEM-CG2
Range: 0 - 6 bar

8 Socket for the gun cable (PSM 2216)

9 Supply air pressure connection (PSM 2216)

10 Compressed air connection (PSM 2216)

11 Grounding connection (PSM 2216)

12 Voltage selector switch (PSM 2216)

To switch the input voltage of the control unit from 115 V (100 - 120 V) to 230 V (220 - 240 V)

13 Cover (PSM 2216)

Protection of front panel

14 Primary Fuse (PSM 2216)

0.5 AT (slow blow)

15 Main switch (PSM 2014)

OFF = Control unit turned off
ON = Control unit turned on

The control unit is turned on, the modules HVM 2072-H and PSM 2216 are operational and can be preset as described in paragraph 4.1. "Adjusting the powder cloud".

16 Mains power input socket (PSM 2014)

2.6.2 Powder cup gun

A Electrode G Electric supply

B Deflector cone H Powder cup 1)

C Outer nut J Cup socket with integrated powder injector

D Spraygun body K Adjust feeding air (red)

E Trigger L Adjust fluid air (green)

F Supply air

1) Container with fluidization

Hint

The spraygun has a factory setting for generating an optimum powder cloud with any standard powder. See also paragraph 5.3. "Standard adjustments of the spraygun"

2.7 Corona-Star Retrofit-Set

2.7.1 Description

The Corona-Star is a Retrofit-Set for the Powder-spraygun PEM-CG2, which helps to achieve a better surface quality.

The development of the "orange peel" can be avoided for most powder types.

Caution

The gun cable must be connected via the adapter cable (1) to the control unit, when the Corona-Star Retrofit-Set is used.

2.7.2 Part numbers Corona-Star Retrofit-Set

Part No. 0351 110

Item

Part No.

Quantity

Description

1

0259 608

1

Adapter cable

2

0351 111

1

Corona-Star cpl.

3*

0260 296

1

Electrode Corona-Star (included in pos. 2)

* Wear part

2.7.3 Assembling instructions

Caution

The assembling of the Corona-Star may only be carried out by trained personnel!

Course order:

Switch off control unit.
Detach the gun cable (A) from the control unit.
Connect the cable with the knurled screw (B) at the air manifold (C).
Attach the Corona-Star (D) to the outer nut (E).
Connect the gun cable (A) and the adapter cable (F).
Connect the adapter cable (F) at the control unit.
The spraygun is ready to operate.

Connect adapter cable (F) at the control unit

Connect gun cable (A) and adapter cable (F)

3. Start up

Recommendation

Before installing and start up, become familiar with the corresponding operating manuals.

3.1 Preparation

3.1.1 Mounting the powder cup

The powder cup gun is dismantled in two parts packaged in the case:

Spraygun (J)
Powder cup (H)

Before operating the gun:

Screw the powder cup (H) onto the spraygun (J)

3.1.2 Adjusting the control unit

Turn off control unit EPG 2020 CG by switching the main switch (15) to the "0" position.

Caution

Is the correct voltage set?

Unscrew the cover (13) and check at the voltage selector switch (12) the correct input voltage 115 V (100 - 120 V) or 230 V (220 - 240 V), if necessary adjust.
The safety rules (paragraph 1) must be observed when setting up a manual powder system.

3.2 Connecting the powder cup gun to the control unit

Hint

The user must ensure, that the spraygun is only connected to equipments.
Before connecting the electrical cables remove the cover at the front of the EPG 2020 CG.

Electrical connections:

Turn off control unit.
Connect electrical cable (8) of the powder cup gun at the control unit.

Pneumatic connection:

Route the air hose (S) (AD6x2 black) from the air output (10) of the control unit to the air input terminal of the gun handle.

Connection diagram with the control unit EPG 2020 CG

3.3 Grounding

In order to achieve a good powder coating and for security reasons (see 1.1. "Safety regulations"), the Portable set EPG 2020 CG must be properly grounded.

Good grounding of the workpiece is necessary for optimum powder coating. A poorly grounded workpiece causes:

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

Vorsicht

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 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).
For connection of the ground strap at the control unit, see paragraph 3.2. "Connection diagram".

4. Operation

4.1 Adjusting the powder cloud

Preconditions:

The control unit EPG 2020 CG must be connected to electrical mains power (16), but not turned on (15).
The compressed air (10) must be connected.
Connect the powder cup gun PEM-CG2 electrically (8) and pneumatically (9) to the control unit EPG 2020 CG as shown in the connection diagram, see paragraph 3.2. and 3.3. .

Course order:

Turn the voltage control (1) counterclockwise beyond the switch point. This will prevent the high voltage turning on.
Fill up the powder cup with powder material (max. 75%), don't close the cover.

Turn on the control unit EPG 2020 CG by switching the main switch (15) to the "ON" position:
· operating lamp (4) lights up.
Adjust supply air pressure (6,7) at the control unit EPG 2020 CG to 2 bar.
Turn on the high voltage and turn the voltage regulator (1) clockwise to the required value (2).
· The indicator lights up with a single LED at the preset value.
Hold the powder cup gun in the spray booth and pull the trigger:
· The voltage display (2) changes from preset to actual value.
(single LED display bar graph LED)
Adjust powder cloud on test object:

Fluid air

Feeeding air

Slowly turn the grenn regulating knob (L) for fluid air until the powder in the cup is fluidized:
· The powder must be slightly "boiling".
Put the lid onto the cup.
Turn the red regulating knob (K) for feeding air to desired powder flow rate.
Turn off the control unit EPG 2020 CG by switching the main switch (15) to the "OFF" position.

4.2 Practical notes

High room temperatures must be avoided; in particular, the hoses must not be routed through 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 deposits from building up.

4.3 Application-related description of nozzle systems

Nozzle

Workpieces

Spray cloud

Air adjustments

Coating distance

Round spray nozzle, externally charged

Wire goods, Gratings, Aluminum cross sections

Round spray cloud depending on the size of the deflector cone

Feeding air: with the regulating knob at the cup gun

100-160 mm

depending on the chargeability of the powder

Fan spray nozzle, externally charged

difficult workpieces, undercuts, broken edges

fan spray

Feeding air: with the regulating knob at the cup gun

120-180 mm

depending on the chargeability of the powder

4.4 Work interruption

Hint:

The powder cup gun should be blown through and cleaned from powder deposits with every interruption of work.

fluid air

feeding air

Course order:

Unscrew powder cup (H) from gun body (J).
Close the fluid air with the green regulating knob (L).
Open up further the feeding air with the red regulating knob (K).
Hold the powder cup gun in the spray booth, pull the trigger and blow free from powder deposits.
Turn off high voltage at the control unit.
Turn off control unit.

4.5 Changing powder

Course order:

Clean the powder cup gun, see paragraph 4.3. "Work interruption".
Remove deflector cone (1) from the nozzle insert (3).
Unscrew outer nut (2) from the gun housing (4).
Carefully extract nozzle insert (3) from the gun housing (4).
Clean dismantled parts and powder cup gun from powder deposits (assembling in reverse order).

For re-starting operation, see paragraph 4.1. "Adjusting the powder cloud".

Hint

Use a separate powder cup (5) for each individual color.
The positions in the pictures are not the same as in the spare parts list.

5. Maintenance and cleaning

Preconditions:

Turn off control unit.
Remove the mains power plug!

Hint

The wear parts marked with (*) in the spare parts list of the powder cup gun PEM-CG2, must be regularily checked and replaced if necessary.

Warning

Do not disassemble gun cable for cleaning. It could lead to malfunction of the powder cup gun.
No guarantee for the safety of the user can be accepted.

5.1 Cleaning the powder nozzle

Clean the powder cup gun, see paragraph 4.4. "Work interruption".
Remove the nozzle system from the powder cup gun and clean it as described in paragraph 4.5. "Changing powder".

Caution

Never place the spraygun or parts of it into any cleaning agent!

5.2 Replacing the distribution rod

Course order: for example round spray nozzle:

Remove the deflector cone (1).
Unscrew the outer nut (2) from the gun housing (5).
Extract nozzle insert (3, 4).

Caution

When pulling out and inserting the new nozzle insert, take care that the contact points are thoroughly cleaned.

Disconnect protective wedge (4) from the nozzle insert (3):
· Should the protective wedge (4) be extensively worn, replace it.

The cleaning of the other nozzle systems is performed in the same manner.

Hint

The positions in the pictures are not the same as in the spare parts list.

5.3 Standard adjustments of the spraygun

Standard adjustments:

Supply air pressure: 2 bar.
Powder output: max. 200 g/min
Powder type: Standard powder with a particle size distribution of
35 ... 40% < 32 µ m *

* The standard values of the particle size distribution apply for the measuring in H₂O + ultrasonic, laser, flow.

Control elements:

K adjust feeding air 1) L adjust fluid air 1)

M adjust dosage air 1) N adjust central air 1)

1) When turning counterclockwise the value will be increased.

Adjustments at the spraygun:

Check supply air pressure and readjust if necessary.
The supply air must be at 2 bar.
Check fluidizing bed of the powder cup for damages and replace if necessary.

Special adjustments at the spraygun:

At a desired powder output of more than 200 g/min increase the supply air pressure at the control unit to max. 4 bar. The powder output can get to a maximum of 300 g/min.
In general the dosage air (M) and central air (N) have not to be adjusted.

Warning

The throttle-screws M and N should never be screwed in completely (danger of destruction!).

Hint

The spraygun has a factory setting for generating an optimum powder cloud with any standard powder.

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

Caution

Maintenance, repair or replacement of the powder spray unit or its components may only be performed by trained personnel outside the hazard area in a suitable location.

6.1 Control unit

Malfunction

Cause

Remedy

Powder indicator does not light up

- Mains power not turned on

- 0.5 A slow blow fuse defective

- Turn on mains power

- 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 customer services regarding the replacement of the interconnect cable

- Turn off HVM 2072-H; increase distance between spraygun and workpiece; then turn on again; inform customer services if error message reoccurs

- Inform service center

6.2 Powder cup gun

Malfunction

Cause

Remedy

No powder output No electrostatic charge

- Safety fuses at control unit are defective

- Replace safety fuses, see operating manual of the control unit

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 service center

- Inform service center

- Inform center

Poor wrap-around

Back-spray

- Bad grounding

- No grounding

- See paragraph 3.3.

- See paragraph 3.3.

Powder output irregular or insufficient

- Compressed air main supply insufficient

- Powder container not tight

- Feeding air / dosage air- proportion not correct

- Impurities

- Obstructions

- Wear

- Check air main supply

- Tighten powder container properly

- Readjust, see paragraph 5.3.

- Empty the container, blow off powder air channels

- Dismantle spraygun, clean the parts, see paragraph 4.4. and 4.5.

- Change worn out parts, see paragraph 5.

Spray jet not correct

- Deflector cone (round spray) or nozzle cap (fan spray) clogged resp. worn out

- Clean the deflector cone resp. Nozzle cap; replace worn out and defective parts

Fluidizing bed insufficient or not at all

- Fluidizing air

- Powder container not tight

- Impurity or obstruction

- Wear

- Adjust with the green
regulation knob

- Tighten powder container properly

- Clean fluidizing bed connection and fluidizing disc

- Change parts (e.g. fuidizing disc)

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)	EN 50050 DIN VDE 0745 Part 100	Electrical equipment for explosion-hazard areas Manual electrostatic spraying equipment	(published by VDE-Verlag, Berlin)
2)	EN 50053 - 2 DIN VDE 0745 Part 102	Requirements for selection, installation and use of electrostatic spraying equipment for flammable materials	(published by VDE-Verlag, Berlin)
3)	ZH 1/443	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 Beuth-Verlag, Berlin)
9)	VDS 2093	Association of insurance companies	(Riehlerstr. 36 50668 Cologne)

Dimensions:
Width:	438mm
Height:	138 mm
Depth:	300 mm
Weight:	ca. 11 kg (with powder cup gun)
Electrical:
Mains power:*	100/120/230 V
Frequency:	50...60 Hz
Input power:	max. 30 W
Output voltage:	max. 22 Vpp
Output current:	max. 0,9 A
Solenoid valve control voltage:	24 V DC
Protection class:	IP 54
Radio interference level:	FN
Pneumatic:
Input air pressure:	86.5-115.3 psi (6 - 8 bar)
Output air pressure:	0...86.5 psi (0...6 bar)
Compressed air quality 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
* Selector switch on the front (see paragraph 2.6.)
Ambient conditions:
If low temperature powders are used the ambient temperature may have to be correspondingly lower than 30°C.

Weight:	890 g (without supply lines)
Electrical:
Input voltage:	max. 22 Vpp
Input current:	max. 0,9 A
Frequency:	19...30 kHz
Output voltage:	max. 100 kV DC
Output current:	max. 160 µ A DC
Polarity:	negative
Design:	accord. to EN 50050
Protection class:	IP 54
Pneumatic:
Input air pressure:	29 psi (2 bar - standard adjustment)
Powder output:	max. 200 g/min at 29 psi 2 bar (max. 300 g/min at 58 psi 4 bar)

	Standard	USA	Japan
(set up voltage)	(230 V/ 50 Hz)	(120 V / 60 Hz)	(100 V / 50-60 Hz)
Part No.	0264 016	0264 052	0264 051

A Electrode	G Electric supply
B Deflector cone	H Powder cup 1)
C Outer nut	J Cup socket with integrated powder injector
D Spraygun body	K Adjust feeding air (red)
E Trigger	L Adjust fluid air (green)
F Supply air

Item	Part No.	Quantity	Description
1	0259 608	1	Adapter cable
2	0351 111	1	Corona-Star cpl.
3*	0260 296	1	Electrode Corona-Star (included in pos. 2)

K adjust feeding air 1)	L adjust fluid air 1)
M adjust dosage air 1)	N adjust central air 1)

Malfunction	Cause	Remedy
No powder output No electrostatic charge	- Safety fuses at control unit are defective	- Replace safety fuses, see operating manual of the control unit
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 service center - Inform service center - Inform center
Poor wrap-around Back-spray	- Bad grounding - No grounding	- See paragraph 3.3. - See paragraph 3.3.
Powder output irregular or insufficient	- Compressed air main supply insufficient - Powder container not tight - Feeding air / dosage air- proportion not correct - Impurities - Obstructions - Wear	- Check air main supply - Tighten powder container properly - Readjust, see paragraph 5.3. - Empty the container, blow off powder air channels - Dismantle spraygun, clean the parts, see paragraph 4.4. and 4.5. - Change worn out parts, see paragraph 5.
Spray jet not correct	- Deflector cone (round spray) or nozzle cap (fan spray) clogged resp. worn out	- Clean the deflector cone resp. Nozzle cap; replace worn out and defective parts
Fluidizing bed insufficient or not at all	- Fluidizing air - Powder container not tight - Impurity or obstruction - Wear	- Adjust with the green regulation knob - Tighten powder container properly - Clean fluidizing bed connection and fluidizing disc - Change parts (e.g. fuidizing disc)