EPG 2007 Universal Control Unit for Powder Sprayguns

EPG 2007
Universal Control Unit for
Powder Sprayguns 05/96

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

2.5. Special accessories

2.6. Operating elements

2.6.1. Front

2.6.2. Back plate

2.6.3. Description of the mode switch

3. Start up

3.1. Setting codes of the mode switch

3.1.1. Setting codes for stand alone system

3.1.2. Setting codes for ECOTECH

3.1.3. Special adjustments

3.2. Preparation for start up

3.2.1. Course order when starting up for the first time outside zone 11

3.2.2. Course order when starting up for the first time inside zone 11

3.3. Connection diagram

3.4. Adjusting the current limitation

3.5. Adjusting the automatic shut-off

4. Operation

4.1. Adjusting the powder cloud

4.2. Practical notes

5. Trouble shooting

Caution

Before start up the mode switch (18) at the back plate of the control unit must be adjusted depending on the application mode!

Setting codes of the mode switch see paragraph 3.1. in this operating manual!

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.

"Recommendation"
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 user has to observe particularly the safety guidelines of the VdS and the professional associations. 2) 3) 6) 15)
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 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. 2) 3) 6)
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)
When used inside the zone 11 the control unit may only be operated with the protection cover mounted to the back-side. (see paragraph 3.2.).

Caution

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

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

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 or
ZH 1/444

Electrostatic powder coating using manual and stationary 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 0100

VDE guidelines for the construction of
power plants with a nominal voltage up to 1000 V

(published by
VDE-Verlag,
Berlin)

9)

VDE 0113

VDE guidelines for the electrical equipment of machines

(published by
Beuth-Verlag,
Berlin)

10)

VDE 0147
Part 1

Guidelines for the construction of stationary electrostatic spraying equipment

(published by
Beuth-Verlag,
Berlin)

11)

VDE 0105
Part 1

Guidelines for the operation of high power plants

(published by
Beuth-Verlag,
Berlin)

12)

VDE 0105
Part 4

Operation of high power plants (additional regulation for stationary electrostatic spraying equipment)

(published by
Beuth-Verlag,
Berlin)

13)

VDE 0132

Instructions for fire fighting in electric equipment and nearby

(published by
Beuth-Verlag,
Berlin)

14)

VDE 0134

Instructions for first aid in case of accident

(published by
Beuth-Verlag,
Berlin)

15)

VDS 2093

Association of insurance companies

(Riehlerstr. 36
50668 Cologne)

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 2007 can be used as stand alone equipment in manual powder coating systems or in combination with other equipment in the ECOTECH Automatic Control System.

The following sprayguns can be connected to the control unit EPG 2007:

Manual sprayguns:

Airmatic manual sprayguns: PEM-C1, PEM-C2
Powder cup guns: PEM-CG1, PEM-CG2
Metallic manual spraygun: PEM-M2
TriboPLUS manual spraygun: PEM-TP1
Tribo manual spraygun: PEM-T1
Powder manual spraygun: GM 2000 EPA

Automatic sprayguns:

Airmatic automatic sprayguns: PEA-C1, PEA-C2
Airmatic Metallic automatic sprayguns: PEA-M1, PEA-M2
TriboPLUS automatic spraygun: PEA-TP1
Tribo automatic spraygun: PEA-T1
Powder automatic spraygun: GA 2000 EPA

Caution

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

2.2 Specification

Dimensions:

Width: 270 mm

Height: 136 mm

Depth: 370 mm (with cover 420 mm)

Weight: approx. 6,4 kg (with cover 7,2 kg)

Electrical:

Mains power: ( AC ) 85 VAC to 264 VAC

Frequency: 47 Hz to 440 Hz

Input power: max. 40 W

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

Output voltage: max. 22Vpp

Output current: max: 0,9A

Corona current limitation: 40µA to 160µA (adjustable)

Solenoid valve control voltage: 24 V DC

Protection class: IP 64

Radio interference level: FN

Displays:

High voltage: 0 to 100KV Resolution: 5KV

Corona current: 0 to 200µA Resolution: 10µA

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

Pneumatic:

Input air pressure: 6-8 bar

Output air pressures:

Feeding air: 0...6 bar

Dosage air: 0...2,5 bar

Gun air: 0...2,5 bar

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 40°C (see powder specification).

2.3 Operation

In the control unit EPG 2007 a low voltage is produced, which is transformed inside the spraygun to high voltage (Corona and TriboPLUS). For protection against sparking and overheating an adjustable current limitation is provided.

Additionally the control unit EPG 2007 is equipped with the following air regulators:

For adjusting the powder output.
For adjusting the shape of the powder cloud.

At the control unit EPG 2007 the voltage presetting and actual high voltage values and the Corona or Tribo current are indicated. Operation status and fault messages are indicated as well.

The control unit EPG 2007 provides numerous additional functions, which guarantee optimum operation under a wide range of working-conditions.

2.4 Part numbers

Design: for ECOTECH
Part No. 0263 112
Design: for manual powder coating systems
Part No. 0265 100

2.5 Special accessories

Safety device (A): for operation inside zone 11

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).

Part No. 0265 902

2.6 Operating elements

2.6.1 Front

Voltage regulator
· Off-position (turn counterclockwise to the stop):
High voltage and powder delivery are switched-off
Voltage display is dark
Reset position: reset of a fault message
· Presetting of the high voltage (turn clockwise),
Regulation range: 15 ¸ 100 kV (single LED display)
Indicator "High voltage"
· lights up green
· Display range: 0 ¸ 100 kV, resolution 5 kV
· Single LED display: preset value of high voltage (HV + powder turned off)
· Bar graph LED display: actual high voltage (HV + powder turned on)
· "Dark": HV + powder release is blocked
High voltage scale
· Range: 0 ¸ 100 kV,
Indicator "Fault"
· lights up red in case of a fault:
"Ground monitoring" or "proximity shut-off"
Indicator "current"
· Lights up green
· Display range: 0 ¸ 200 µ A, resolution 10 µ A
Single LED display: current limitation
Bar graph LED display: Corona current
· Display range: 0 ¸ 4 µ A, resolution 0,2 µ A
Bar graph LED display: Tribo current
Indicator "Corona current scale is activ"
· Lights up green
Indicator "Tribo current scale is activ"
· Lights up green
Corona current scale
· Range: 0 ¸ 200 µ A (used when Corona mode is activ)
Tribo current scale
· Range: 0 ¸ 4 µ A (used when Tribo mode is activ)
Compressed air regulator "Spraygun"
· Adjusting the atomizing air pressure
· Regulation range: 0 - 2,5 ±0,3 bar
Pressure gauge "Spraygun"
· Atomizing air indicator
· Display range: 0 - 2,5 bar
Compressed air regulator "Powder injector"
· Adjusting the feeding air pressure for the powder injector
· Regulation range: 0 - 6 ±0,5 bar
Pressure gauge "Powder injector"
· Feeding air pressure indicator for the powder injector
· Display range: 0 - 6 bar
Compressed air regulator "Powder injector"
· Adjusting the dosage air pressure for the powder injector
· Regulation range: 0 - 2,5 ±0,3 bar
Pressure gauge "Powder injector"
· Dosage air pressure indicator for the powder injector
· Display range: 0 - 2,5 bar

2.6.2 Back plate

Main switch
0 = Control unit turned off
1 = Control unit turned on
· The indicator of Corona (6) or Tribo (7) lights up (depending on the type of equipment used and the setting of the mode switch (18))
Cover
· Protection of the function selector switch
Mode switch (toggle switch)
· Selection of the different operating modes
(see paragraph 2.6.3. "Description of the mode switch)
Primary fuse
· 1 AT (slow blow)
Mains power input
Mains power output
· for the shaker motor:
Powered only, if the mains switch is turned on. Voltage
corresponds to the mains power input voltage at terminal no. 20.
Direct mains power output
· To feed the mains power input of the next control unit
EPG 2007 when used in an ECOTECH-Automatic
Control System:
Whenever there is power connected to the mains power input, there is power for the following control units on the power output socket. The output voltage corresponds to the mains power input voltage at terminal no. 20.
Fastening thread
· for back plate cover, necessary in zone 11
Warranty lable

Caution

Each warranty claim against vanishes if warranty lable (24) is damaged.

2.6.3 Description of the mode switch

Switch Description:

8 High voltage and powder release for manual spraygun through gun trigger, for automatic sprayguns through internal bridge

8 High voltage and powder release through control unit
CCM 2028 / CCM 2007 or potential free contact

7 Recuced high voltage in gaps between workpieces in connection with the gap control module (GCM 2007)

7 No high voltage in gaps between workpieces (voltage is switched to 0 KV)

6 Optional function is turned on (not used in standard configuration)

6 Optional function is turned off

5 Maximum high voltage limited to 80 kV

5 Maximum high voltage automatically optimized between 80 kV and 100 kV

4 Proximity shut-off and fault message storing at cable break disabled

4
Proximity shut-off and fault message storing enabled (only for Corona and TriboPLUS sprayguns)

3 High voltage generation turned off (for Tribo guns)

3 High voltage generation turned on

2 Current display: Tribo current

2 Current display: Corona current

1 Tribo current measuring line enabled for all Tribo manual / automatic sprayguns and TriboPLUS manual sprayguns (PEA-TP1 with additional adapter)

1 Tribo current measuring line disabled

3. Start up

Recommendation
Before installing and starting up the control unit, become familiar with the corresponding operating manual.

3.1 Setting codes of the mode switch

Gun type

Stand alone systems

Ecotech - Systems

Standard
setting

Special
setting

Standard
setting

Special
setting

Manual spraygun

PEM-C1, -C2
PEM-CG1, -CG2
PEM-M2
PEM-TP1
PEM-T1
GM 2000 EPA

1
1
1
4
2
3

A, B
A, B
A, B
A

A

7
7
7
10
8
9

A, B
A, B
A, B
A

A

Automatic spraygun

PEA-C1, -C2
PEA-M1, -M2
PEA-TP1
PEA-T1
GA 2000 EPA

1
1
6
5
1

A, B, C
A, B, C
A, C
C
A, B, C

7
7
12
11
7

A, B, D
A, B, D
A, D

A, B, D

1 = factory setting

3.1.1 Setting codes for stand alone system

Code 1: (factory setting) for gun type:

PEM-C1, PEM-C2 PEA-C1, PEA-C2

PEM-CG1, PEM-CG2 PEA-M1, PEA-M2

PEM-M2 GA 2000 EPA

Code 2: for gun type: PEM-T1

Code 3: for gun type: GM 2000 EPA

Code 4a:
for gun type: PEM-TP1
Code 4b:
for gun type: PEM-TP1

with high voltage
current display: CORONA
Corona- and Tribo-charging

with high voltage
current display: TRIBO
Corona- and Tribo-charging

Code 4c:
for gun type: PEM-TP1

Code 5: for gun type: PEA-T1

without high voltage
current display: TRIBO
only Tribo-charging

Code 6: for gun type: PEA-TP1 without adapter box EPG 2020 TP
Part No. 0260 624

6a 6b

with high voltage
current display: CORONA
Corona- and Tribo-charging

without high voltage
current display: no
only Tribo charging

with adapter box EPG 2020 TP Part No. 0260 624

6c 6d

with high voltage
current display: CORONA
Corona- and Tribo-charging

with high voltage
current display: TRIBO
Corona- and Tribo-charging

6e

without high voltage
current display: TRIBO
only Tribo-charging

3.1.2 Setting codes for ECOTECH

Code 7: for gun type:

PEM-C1, PEM-C2 PEA-C1, PEA-C2

PEM-CG1, PEM-CG2 PEA-M1, PEA-M2

PEM-M2 GA 2000 EPA

Code 8: for gun type: PEM-T1

Code 9: for gun type: GM 2000 EPA

Code10a
for gun type: PEM-TP1
Code 10b
for gun type: PEM-TP1

with high voltage
current display: CORONA
Corona- and Tribo-charging

with high voltage
current display: TRIBO
Corona- and Tribo-charging

Code 10c
for gun type: PEM-TP1

Code 11: for gun type: PEA-T1

without high voltage
current display: TRIBO
only Tribo-charging

Code 12: for gun type: PEA-TP1
without adapter box EPG 2020 TP Part No. 0260 624

12a 12b

with high voltage
current display: CORONA
Corona- and Tribo-charging

without high voltage
current display: no
only Tribo charging

with adapter box EPG 2020 TP Part No. 0260 624

12c 12d

with high voltage
current display: CORONA
Corona- and Tribo-charging

with high voltage
current display: TRIBO
Corona- and Tribo-charging

12e

without high voltage
current display: TRIBO
only Tribo-charging

3.1.3 Special adjustments

Special setting A:

Proximity shut-off disabled for all Corona and Tribo-PLUS manual and automatic sprayguns.

Special setting B:

The automatic switching of the maximum high voltage 80 or 100 kV is disabled:
The maximum high voltage is set to 80 kV.
This adjustment is recommended for the sprayguns: PEM-TP1, PEA-TP1 and GM 2000 EPA.

Caution

When using a Corona Star the configuration B must be selected.

Special setting C (stand alone system):

This configuration provides the possibility (when using an automatic spraygun with a stand alone control unit) to remote control the high voltage and/or powder release via an external, potential-free relay contact.

Special setting D:
Function:

Reduced high voltage during gaps between workpieces ECOTECH Automatic Control System:

CCM 2007
Gap control GCM 2007
Corona - Automatic sprayguns PEA - C1 / C2
or PEA - M1 / M2
or PEA - TP1
or Ga 2000 EPA

In this switch configuration the high voltage is reduced to one half during a gap between two adjacent workpieces. The powder delivery is turned off, if this function is programmed at the GCM 2007.
At longer gaps (resp. coating interruptions) the high voltage will be completely turned off by the gap control.

Advantages of this feature:

Fast return of the high voltage after the gap
Protection of the cascade (lifetime)
No pin-hole formation.

Special setting E:

Switch setting: mixed operation between Corona and Tribo manual guns:
Advantage:
When using a Corona or a Tribo manual gun alternately no switching of the Dip-Switch is required.

Restrictions:

When using a Tribo manual gun the LED bar graph display for the high voltage lights up for several seconds.
The display "Tribo" lights up all the time, even when using a Corona manual gun with high voltage.
The Corona current display is disabled.
not usable for PEA-C1.

3.2 Preparation for start up

Preconditions:

The safety rules (paragraph 1) must be observed when setting up a powder coating system.
Operating modes must be defined, see paragraph 3.1.

Caution

When used inside the zone 11 the control unit may only be operated with the protection cover mounted to the back-side.

Hint

There is a special operating manual available for using the control unit EPG 2007 in the ECOTECH 2007 - Automatic Control System.
Operating manual No. 0263 826E

3.2.1 Course order when starting up for the first time outside zone 11

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 set switches depending on operating mode (see paragraph 2.6.3. "Description of the mode switch").
Connect a powder gun according to the paragraph 3.3. "Connection diagram" to the control unit EPG 2007.

3.2.2 Course order when starting up for the first time inside zone 11

Warning

When used inside the zone 11 the control unit may only be operated with the protection cover (A) mounted to the back-side.

Section X -X

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 set switches depending on operating mode (see paragraph 2.6.3. "Description of the mode switch").

Connect dosage air hose (B), feeding air hose (C) and atomizing air hose (D) at the control unit EPG 2007.

Connect mains power cable (F) and (if applicable) shaker motor cable (G) at the control unit EPG 2007.

Connect spraygun cable (E) at the control unit EPG 2007.

Connect compressed air (A) from the equipment trolley terminal to the air inlet terminal of the control unit EPG 2007.

For use inside the zone 11 connect a grounding cable from the cover terminal (J) to the grounding screw (K). Mount the cover terminal (J) with the fastening screws (L) at the housing back plate (M) of the control unit EPG 2007.

Connect the powder spraygun to the control unit EPG 2007 according to the connection diagram (see paragraph 3.3.).
For further procedure see operating manuals of the manual powder equipment:
2007 - Airfluid and/or 2007 - 70LR

3.3 Connection diagram

Pneumatic hose: Polyamid PA Ø8±0,1
Polyurethan PUR Ø8 ±0,15

3.4 Adjusting the current limitation

Recommendation
When a gun approaches the workpiece, the spraying current increases while the high voltage is reduced correspondingly. If the spraygun gets to close to the workpiece, the spraying current remains constant (current limitation) while the high voltage is now decreased automatically by the EPG 2007.

When using very easily chargeable powder types and small distances to the workpiece, overcharging effects may accur mainly around edges (pin-hole formation).

In this case it is possible to readjust the current limitation from 160 µA (= factory setting) to any value between 40 µA and 160 µA.

Course order:

Turn off high voltage (stand-by)

By turning the trimming potentiometer RT2 (screwdriver size 1 to 2) the desired currrent limitation set-point can be adjusted in the range from 40 ¸ 160 µ A. Watch the single LED-indication at the current display for correct setting.

3.5 Adjusting the automatic shut-off

Recommendation

The EPG 2007 is factory-set for no automatic shut-off in case of workpiece contact. The enabling of the automatic shut-off feature and the adjustment of a certain shut-off distance depends on the gun type used and must therefore be carried out locally.

Course order:

Turn potentiometer (RT3) counterclockwise to the stop (screwdriver size 1 to 2).

Turn voltage regulator counterclockwise to the stop:
The high voltage turns off.

Hold manual or automatic spraygun at distance of approx. 1 cm from the grounded workpiece.

Turn voltage regulator clockwise to maximum setting. Press trigger on manual gun (current display is higher than voltage display).

Slowly turn potentiometer (RT3) clockwise until the high voltage switches off:
The automatic shut-off feature is now adjusted for automatic switch-off at approx. 1 cm distance.

Caution

If the current limitation is adjusted to another value, the shut-off feature must also be readjusted.

4. Operation

4.1 Adjusting the powder cloud

Recommendation

The spraygun and the control unit EPG 2007 are connected as shown in the connection diagram in paragraph 3.3.
Compressed air supply must be within 6 - 8 bar.

Course order:

Turn voltage regulator (1) counterclockwise to stop position.
Turn on the control unit by switching the main switch (16) on the back plate to the "1" position:
the indicator (6 or 7) lights up.
Turn the voltage regulator (1) clockwise until the minimum high voltage (2) is indicated. (Pull the trigger for manual sprayguns). The voltage display (2) changes from preset to actual value.
(Single LED display bar graph LED display)
Adjust atomizing air pressure (10) 0.5 - 1* bar (11)
Adjust feeding air pressure (12) 0.5 - 4* bar (13)
Adjust dosage air pressure (14) ~ 0.8* bar (15)
* Recommended values.
Adjust the powder cloud:
If necessary, readjust the airs (10,12,14).
See operating manual of the spraygun.
Turn off again the control unit by switching the main switch (16) on the back plate to the "0" position.

4.2 Practical notes

High ambient 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 (baking).

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.

5. 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.

At a malfunction first check the toggle switch setting at the mode selector switch for correct setting (see paragraph 3.1. "Setting codes of the mode switch") if neccessary readjust.

Malfunction

Cause

Remedy

Powder indicator does not light up

- Mains power not turned on

- Fuse 1 AT slow blow defective

- Turn on mains power

- Replace fuse

No tribo current reading

- Unsuitable powder

- The display is adjusted for Corona current

- No powder delivery to the spraygun

- Electrical cable between spraygun and control unit defective

- Use suitable powder

- Adjust for correct mode selection (see paragraph 3.1.)

- Check powder delivery

- Inform service center

No Corona current reading

- High voltage generator is turned off

- The display is adjusted for Tribo current

- High voltage generator defective

- Turn on and adjust the high voltage

- Adjust for correct mode selection (see paragraph 3.1.)

- Inform service center

No high voltage

- High voltage generator is turned off

- High voltage generator defective

- Turn on and adjust the high voltage

- Inform service center

Fault indicator lights up

- No spraygun is connected at the control unit

- Spraygun too close to workpiece (Wrong adjustment of the proximity shut-off)

- Break in interconnect cable to spraygun, that means no grounding between control unit and spraygun

- Connect spraygun

- New adjustment of the proximity shut-off (see paragraph 3.5.)

- Please inform customer services for replacement of the interconnect cable

No powder delivery
and / or no high voltage

- High voltage potentiometer on position "OFF"

- High voltage generator defective

- powder delivery is blocked

- Turn high voltage potentiometer clockwise

- Inform service center

- Clean hoses, injectors and all powder leading components or replace if necessary

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 or ZH 1/444	Electrostatic powder coating using manual and stationary 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 0100	VDE guidelines for the construction of power plants with a nominal voltage up to 1000 V	(published by VDE-Verlag, Berlin)
9)	VDE 0113	VDE guidelines for the electrical equipment of machines	(published by Beuth-Verlag, Berlin)
10)	VDE 0147 Part 1	Guidelines for the construction of stationary electrostatic spraying equipment	(published by Beuth-Verlag, Berlin)
11)	VDE 0105 Part 1	Guidelines for the operation of high power plants	(published by Beuth-Verlag, Berlin)
12)	VDE 0105 Part 4	Operation of high power plants (additional regulation for stationary electrostatic spraying equipment)	(published by Beuth-Verlag, Berlin)
13)	VDE 0132	Instructions for fire fighting in electric equipment and nearby	(published by Beuth-Verlag, Berlin)
14)	VDE 0134	Instructions for first aid in case of accident	(published by Beuth-Verlag, Berlin)
15)	VDS 2093	Association of insurance companies	(Riehlerstr. 36 50668 Cologne)

Dimensions:
Width:	270 mm
Height:	136 mm
Depth:	370 mm (with cover 420 mm)
Weight:	approx. 6,4 kg (with cover 7,2 kg)
Electrical:
Mains power:	( AC ) 85 VAC to 264 VAC
Frequency:	47 Hz to 440 Hz
Input power:	max. 40 W
EMI filter:	EN 55022 class B VDE 0878 PT3 class B
Output voltage:	max. 22Vpp
Output current:	max: 0,9A
Corona current limitation:	40µA to 160µA (adjustable)
Solenoid valve control voltage:	24 V DC
Protection class:	IP 64
Radio interference level:	FN
Displays:
High voltage:	0 to 100KV Resolution: 5KV
Corona current:	0 to 200µA Resolution: 10µA
Tribo current:	0 to 4 µA Resolution: 0,2µA
Pneumatic:
Input air pressure:	6-8 bar
Output air pressures:
Feeding air:	0...6 bar
Dosage air:	0...2,5 bar
Gun air:	0...2,5 bar
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

Switch		Description:
	8	High voltage and powder release for manual spraygun through gun trigger, for automatic sprayguns through internal bridge
	8	High voltage and powder release through control unit CCM 2028 / CCM 2007 or potential free contact
	7	Recuced high voltage in gaps between workpieces in connection with the gap control module (GCM 2007)
	7	No high voltage in gaps between workpieces (voltage is switched to 0 KV)
	6	Optional function is turned on (not used in standard configuration)
	6	Optional function is turned off
	5	Maximum high voltage limited to 80 kV
	5	Maximum high voltage automatically optimized between 80 kV and 100 kV
	4	Proximity shut-off and fault message storing at cable break disabled
	4	Proximity shut-off and fault message storing enabled (only for Corona and TriboPLUS sprayguns)
	3	High voltage generation turned off (for Tribo guns)
	3	High voltage generation turned on
	2	Current display: Tribo current
	2	Current display: Corona current
	1	Tribo current measuring line enabled for all Tribo manual / automatic sprayguns and TriboPLUS manual sprayguns (PEA-TP1 with additional adapter)
	1	Tribo current measuring line disabled

Gun type	Stand alone systems		Ecotech - Systems
	Standard setting	Special setting	Standard setting	Special setting
Manual spraygun
PEM-C1, -C2 PEM-CG1, -CG2 PEM-M2 PEM-TP1 PEM-T1 GM 2000 EPA	1 1 1 4 2 3	A, B A, B A, B A A	7 7 7 10 8 9	A, B A, B A, B A A
Automatic spraygun
PEA-C1, -C2 PEA-M1, -M2 PEA-TP1 PEA-T1 GA 2000 EPA	1 1 6 5 1	A, B, C A, B, C A, C C A, B, C	7 7 12 11 7	A, B, D A, B, D A, D A, B, D

Code 1: (factory setting) for gun type:		PEM-C1, PEM-C2 PEA-C1, PEA-C2 PEM-CG1, PEM-CG2 PEA-M1, PEA-M2 PEM-M2 GA 2000 EPA

Code 2: for gun type: PEM-T1		Code 3: for gun type: GM 2000 EPA

Code 4a: for gun type: PEM-TP1		Code 4b: for gun type: PEM-TP1

with high voltage current display: CORONA Corona- and Tribo-charging		with high voltage current display: TRIBO Corona- and Tribo-charging
Code 4c: for gun type: PEM-TP1		Code 5: for gun type: PEA-T1

without high voltage current display: TRIBO only Tribo-charging
Code 6: for gun type: PEA-TP1 without adapter box EPG 2020 TP Part No. 0260 624
6a		6b

with high voltage current display: CORONA Corona- and Tribo-charging		without high voltage current display: no only Tribo charging
with adapter box EPG 2020 TP Part No. 0260 624
6c		6d

with high voltage current display: CORONA Corona- and Tribo-charging		with high voltage current display: TRIBO Corona- and Tribo-charging
6e

without high voltage current display: TRIBO only Tribo-charging

Code 7: for gun type:		PEM-C1, PEM-C2 PEA-C1, PEA-C2 PEM-CG1, PEM-CG2 PEA-M1, PEA-M2 PEM-M2 GA 2000 EPA

Code 8: for gun type: PEM-T1		Code 9: for gun type: GM 2000 EPA

Code10a for gun type: PEM-TP1		Code 10b for gun type: PEM-TP1

with high voltage current display: CORONA Corona- and Tribo-charging		with high voltage current display: TRIBO Corona- and Tribo-charging
Code 10c for gun type: PEM-TP1		Code 11: for gun type: PEA-T1

without high voltage current display: TRIBO only Tribo-charging
Code 12: for gun type: PEA-TP1 without adapter box EPG 2020 TP Part No. 0260 624
12a		12b

with high voltage current display: CORONA Corona- and Tribo-charging		without high voltage current display: no only Tribo charging
with adapter box EPG 2020 TP Part No. 0260 624
12c		12d

with high voltage current display: CORONA Corona- and Tribo-charging		with high voltage current display: TRIBO Corona- and Tribo-charging
12e

without high voltage current display: TRIBO only Tribo-charging

	Course order: Turn potentiometer (RT3) counterclockwise to the stop (screwdriver size 1 to 2).
	Turn voltage regulator counterclockwise to the stop: The high voltage turns off.
	Hold manual or automatic spraygun at distance of approx. 1 cm from the grounded workpiece.
	Turn voltage regulator clockwise to maximum setting. Press trigger on manual gun (current display is higher than voltage display).
	Slowly turn potentiometer (RT3) clockwise until the high voltage switches off: The automatic shut-off feature is now adjusted for automatic switch-off at approx. 1 cm distance.