Powder tank
90LR / 70LR / 35LR 		03/98

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 Page

1. Introduction

1.1. Safety regulations

1.2. Warranty

2. Description

2.1. Application

2.2. What powder materials can be used?

2.3. Part number of the powder tank

2.4. Specification of the powder tank

2.5. Operation of the powder tank

2.6. Mechanical assembly of the powder tank

3. Start up

3.1. Assembling and connecting

3.2. Grounding

3.3. Changing powder

4. Maintenance and cleaning

5. Trouble Shooting

5.1. Powder Injector

5.2. Powder Tank

6. Spare parts list and accessories

6.1. How to order

6.2. Powder tank

6.3. Powder injector PJ 2020 PRS

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! 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:

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

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 system to rain. Do not use the 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 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 system
Keep the system clean to ensure that it works well and safety.

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 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 Wagner 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!

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:

  1. caused by use or installation of repair or replacement parts or accessories not manufactured by Wagner,
  2. caused by repair performed by anyone other than a Wagner authorized service center, or
  3. 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 Wagner 90 LR, 70 LR and 35 LR powder tanks hold the powder and are accessories for the Integral 2020 - G, 2010 - 70 LR and 2007 - 70 LR manual powder systems. They are designed for use in small to medium-sized series production in industry and trade.

2.2 What powder materials can be used?

All powder paints can be processed with the powder tanks 90 LR, 70 LR and 35 LR.

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

2.3 Part number of the powder tank

Powder tank 90 LR Part No. 0263 089
Powder tank 70 LR Part No. 0264 005
Powder tank 35 LR Part No. 0264 006

2.4 Specification of the powder tank

Description

Tank 90 LR

Tank 70 LR

Tank 35 LR

Tank weight

approx. 10 kg

approx. 9.6 kg

approx. 7.5 kg

Effective volume

60 l

50 l

25 l

Max. filling capacity *

*

*

*

Fluid air pressure

1 ... 2 bar

1 ... 2 bar

1 ... 2 bar

Air consumption

5 ... 8 Nm3/h

5 ... 8 Nm3/h

5 ... 8 Nm3/h

* See paragraph 3. "Start up"

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:

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

2.5 Operation of the powder tank

In the powder tank (E), the powder is fluidized by pumping air through the air inlet (G) into the fluid base (F). The fluidized powder in pumped by means of the PJ 2020 PRS powder injector (A) via the powder suction system (B) to the powder spraygun.

2.6 Mechanical assembly of the powder tank

A Powder injector PJ 2020 PRS E Powder tank
B Suction system F Fluid base
C Exhaust air hose G Air inlet for fluidizing
D Lid  

3. Start up

Recommendation

Before installing and starting up of the powder tank 90 LR,
70 LR or 35 LR, become familiar with the corresponding operating manual.

3.1 Assembling and connecting

Course order:

  1. Read the safety precautions (paragraph 1) before using the powder tank 90 LR, 70 LR or 35 LR for the first time.
  2. Open spring clips (2) on lid (1).
  3. Remove lid (1) and pour powder into tank.

Caution

The 90 LR powder tank may be filled with a max. of 30 - 35 kg of powder.
The 70 LR powder tank may be filled with a max. of 20 - 25 kg of powder.
The 35 LR powder tank may be filled with a max. of 8 - 12 kg of powder.

  1. Close cover (1) and secure with spring clips (2).
  2. Connect grounding cable to grounding lug (3).
  3. Connect fluid air socket (4) to fluid air supply system.
  4. Connect powder injector (5) and control unit with feeding air hose (6) and dosage air hose (7).
  5. Connect powder injector (5) and powder spraygun with the powder hose (8).
  6. Place the exhaust air hose (9) into the powder booth.
  7. Air settings, see operating manual of the powder injector and the corresponding manual powder system.

3.2 Grounding

The grounding cable must be attached to the 2007 - 70 LR (2010 - 70 LR or Integral 2020 - G) equipment trolley. 2) 3).

Caution

Check for correct grounding of the equipment trolley. 2) 3).

3.3 Changing powder

Recommendation

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

It is recommended to use a separate powder tank for each color. This allows a color change to be carried out faster and reduces cleaning times to a minimum.

Course order: Cleaning

  1. Turn off high voltage and ensure that they cannot start up again.
  2. Disconnect grounding cable to grounding lug.
  3. Disconnect fluid air socket from the fluid air supply system.
  4. Disconnect feeding air hose and dosage air hose from the powder injector and control unit.
  5. Disconnect powder hose from powder injector and powder spraygun.
  6. Disconnect exhaust air hose from the powder tank.
  7. Remove lid from powder tank.
  8. Thoroughly blow out tank, fluid base and powder suction system with compressed air (vacuum off if necessary) and rub out with dry cloth.

Course order: Re-starting

  1. The powder tank may only be filled half way.
  2. Assembling and connecting, according to paragraph 3.1. .

4. Maintenance and cleaning

Caution

The powder tank must be cleaned thoroughly after each color change.

The compressed air must meet the requirements in paragraph 2.4. (acc. to ISO 8573.1), to avoid blocking of the fluid base.

Course order:

  1. Turn off high voltage and ensure that they cannot start up again.
  2. Further procedure see paragraph 3.3. "Changing powder".
  3. Remove powder injector from the powder tank.
  4. Check powder injector and if necessary replace wear parts - see operating manual of the powder injector PJ 2020 PRS.
  5. Clean thoroughly the fluid base, check blockages and damages and if necessary replace.

5.Trouble Shooting

5.1 Powder Injector

Malfunction

Cause

Remedy

Insufficient powder delivery

  • Nozzle clogged
  • Injector nozzle worn
  • Leak between container and injector
  • see operating manual of the powder injector PJ 2020 PRS
  • see operating manual of the powder injector PJ 2020 PRS
  • see operating manual of the powder injector PJ 2020 PRS

Pulsed powder delivery

  • Too little dosage air
  • Increase dosage air quantity
  • see operating manual of the powder injector PJ 2020 PRS

5.2 Powder Tank

Malfunction

Cause

Remedy

No powder output

  • - Powder container empty
  • - Powder hose blocked
  • - Powder suction system is plugged up in powder tank
  • - Feeding air hose kinked
  • - Powder hose kinked
  • - Refill or replace powder tank
  • - Blow through powder hose with compressed air
  • - Blow through powder suction system with compressed air
  • - Straighten hose or replace
  • - Straighten hose or replace

6. Spare parts list and accessories

6.1 How to order

To ensure a correct spare part delivery, the following informations are necessary:

Numbers of pieces, Part No. and Description

The number of pieces does not have to be identical with the numbers in the columns "numbers" of the lists. The numbers give you only the information of how often a part is included in an assembly group.

Following informations are necessary for a correct order:

Caution

Please refer to the spare parts list if you wish to order any spare parts. Refer to the drawings mentioned in the spare parts list for further information.

We can only accept liability for original spare parts supplied by the factory.

We explicitly draw your attention to the fact that we have not checked or approved other spare parts which have not been supplied by the factory. It is therefore possible that the installation and/or use of such products may detrimentally affect the design characteristics of the equipment and may therefore jeopardize their active and/or passive safety. Any liability cannot be accepted for damage resulting from the use of other spare parts or accessories that have not been supplied by the factory.

Please bear in mind that manufacturing and engineering specifications often apply to factory and supply parts and that the spare parts that we offer are in accordance with the latest state of the art.

6.2 Powder tank

Powder tank 90 LR: Part No. 0263 089
Powder tank 70 LR: Part No. 0264 005
Powder tank 35 LR: Part No. 0264 006

Pos.

Artikel-Nr.

Menge

Benennung

1

0263 375

1

90 LR tank

1

0264 211

1

70 LR tank

1

0264 212

1

35 LR tank

2

0264 215

1

Base housing

3

0264 381

1

Lid

4

0264 382

1

Fluid base

5

9971 527

1,12 m

Seal (10x5)

6

9994 703

6

Spring clip (7.6 mm lift)

7

- **

12

Filister head screw (M3x5)

8

9992 270

1

Threaded connection (1/8")

9

0184 336

1

Hose nippel

10

- **

1

Hex nut (BM 16x1.5)

11

9982 058 *

3 m

Powder hose (AØ 17x3))

12

0241 294 *

1

Powder injector PJ 2020 PRS

13

0241 279 *

1

Injector connection assembly (with O-ring)

14

- **

1

Knurled nut (M6)

15

- **

2

Washer (A 6.4)

16

0241 276

1

Ground cable assembly

17

- **

12

Star washer

19

0241 376

1

Cable coupling

20

0263 357 *

1

Suction tube (Ø 22x1 Þ 90 LR)

20

0264 421 *

1

Suction tube (Ø 22x1 Þ 70 LR)

20

0264 420 *

1

Suction tube (Ø 22x1 Þ 35 LR)

21

8324 008

1.1 m

Seal (6x6)

24

9971 178

2

O ring (16x2) (included in item 13)

* Wear part
** no wear part (just for information); not available as spare part!

6.3 Powder injector PJ 2020 PRS

Part No. 0241 294
See separate operating manual: No. 0241 881 USA/UK