PEA - T1 Tribo Automatic Powder Spraygun	01/98
Danger! High voltage! Turn power off before servicing! Read rules for safe operation and instructions carefully!
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	Operating Manual

Sommaire

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

2.4. Operation

2.5. Part numbers

2.6. Design

3. Start up

3.1. Connecting the spraygun

3.1.1. Connecting to the control unit EPG 2007

3.1.2. Connecting to the control unit EPG 2010 T

3.1.3. Connecting to the control modules

3.2. Grounding

4. Operation

4.1. Adjusting the powder cloud

4.2. Application-related description of nozzle systems

4.3. Work interruption

4.4. Changing powder

5. Maintenance and cleaning

5.1. Cleaning the charging body

5.2. Replacement of the wear parts

6. Trouble shooting

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 instruction 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 the safety regulations given in 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 user has to observe particularly the safety guidelines of the VdS and the professional associations. 3) 6) 9)
• The spraygun may only be operated in powder spray booths or powder spray benches equipped with industrial ventilation. 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.
• If the powder concentration at high total powder output is higher than the allowed value, 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. 3) 6)
• In the event of faults or defects, repair work is to be performed at the users discretion. 7)
• The control unit must be installed outside the hazard area. 3)
• The work area must have an electrostatically conductive floor (measured in accordance with DIN 51953). 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. 3)
• Electrostatically conductive footwear must be worn by all persons inside the work area. 3)
• If gloves are worn, they must be of antistatic material or have cut-out palm areas. 3)

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

Applicable Safety Regulations and List of Sources

1)	EN 50177	Stationary electrostatic spraying equipment	(published by VDE-Verlag, Berlin)
3)	ZH 1/444	Electrostatic powder coating using 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)	EN 60204 Part 1 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:

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 Tribo-Automatic spraygun PEA-T1 is used for industrial powder
coating.

The spraygun may be operated with the following control units:

EPG 2007:
This control unit is integrated part of the ECOTECH Automatic
Control System.

EPG 2010 T.
or may be operated with the following module combination in customized control
cabinets:

Module PM 400:
- Adjusting and displaying feeding air and dosage air
- Adjusting and displaying atomizing air
- Adjusting and displaying tribo air

Module TAM 2011:
Displaying tribo current

Selection module TSM 2011:
Change the tribo current indicator to an other Tribo-Spraygun (is required, to
display tribo current from several Tribo-Sprayguns: for more information - ask service center).

Caution

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

2.2 What powder materials can be used?

The Tribo-Automatic spraygun PEA - T1 is used to process all coating powders which are suitable for frictional charging. Appropriate coating powders are, for example:

Epoxy resin powder, PUR, powder prepared for a frictional charging (Tribo powder), and limited, coating powders on a polyester resin basis.

For your special application, the suitability of the many different powders using the Tribo-Automatic spraygun PEA - T1, should be determined by practical tests.

2.3 Specification

Electrical:

Pneumatic:

Compressed air quality acc. to ISO 8573.1:

Ambient conditions:

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

2.4 Operation

When the control is turned on, the pneumatic module is activated. The appropriate powder and compressed-air supplies to the gun is switched on.

Each individual powder particle is charged by a tribo-electric charge separation. Every particle obtaines its own powder-specific maximum positive charge. 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.

2.5 Part numbers

Tribo-Automatic spraygun PEA-T1 Part No. 0260 004

Standard version:
with deflector cone Ø25 mm
and mounting accessories for the gun mounting bracket

Accessories: see paragraph 7.

2.6 Design

A Deflector cone	F Powder supply
B Nozzle body	G Tribo-current measuring connection
C Outer nut	H Atomizing air
D Spraygun body	J System ground
E Tribo air connection	Z = Assembly dimensions 325 mm (i.e. for mounting to reciprocators)

3. Start up

Recommendation

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

3.1 Connecting the spraygun

Hint

The user must ensure, that the spraygun is only connected to equipment.

• Connecting the Tribo-Automatic spraygun PEA-T1:
• to EPG 2007:
  in connection with a Turbo Module TCM 2007
  see paragraph 3.1.1.
• to EPG 2010 T:
  in connection with a Turbo Module TCM 2007
  see paragraph 3.1.2.
• to the control modules:
  for control cabinets
  see paragraph 3.1.3.

Caution

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

3.1.1 Connecting to the control unit EPG 2007

Electrical connection:

• Leave the control unit turned off. See operating manual of the control unit
  EPG 2007, paragraph "Start up".
• Connect electrical cable (Tribo current measuring lead 4) to Tribo-spraygun and control unit EPG 2007.

Pneumatic connection:

• Tribo air (1): Turbo module TCM 2007 Tribo-spraygun
• Atomizing air (2): Control unit EPG 2007 Tribo-spraygun
• Feeding air (5): Control unit EPG 2007 Powder injector
• Dosage air (6): Control unit EPG 2007 Powder injector
• Powder delivery (3): Powder injector PJ 2020 PRS Tribo-spraygun
• Fluid air: Throttle valve Feed system /
  Fluid connection
• The spraygun is properly fastened and grounded to both stationary or mobile reciprocator gun support system - e.g. EBA 3 / EBA 1 - by means of the mounting-braket (7) (see paragraph 7. "Accessories").
• The adjustments powder quantity and powder fluidization are to be carried out at the appropriate control modules (see operating manual for the respective control units).

Connecting diagram with the control unit EPG 2007

3.1.2 Connecting to the control unit EPG 2010 T

Electrical connection:

• Leave the control unit turned off. See operating manual of the control unit
  EPG 2010 T, paragraph "Start up".
• Connect electrical cable (Tribo current measuring lead 4) to Tribo-spraygun and control unit EPG 2010 T.
• Pneumatic connection:
• Tribo air (1): Turbo module TCM 2007 Tribo-spraygun
• Atomizing air (2): Control unit EPG 2010 T Tribo-spraygun
• Feeding air (5): Control unit EPG 2010 T Powder injector
• Dosage air (6): Control unit EPG 2010 T Powder injector
• Powder delivery (3): Powder injector PJ 2020 PRS Tribo-spraygun
• Fluid air: Throttle valve Feed system /
  Fluid connection
• The spraygun is properly fastened and grounded to both stationary or mobile reciprocator gun support system - e.g. EBA 3 / EBA 1 - by means of the mounting-braket (7) (see paragraph 7. "Accessories").
• The adjustments powder quantity and powder fluidization are to be carried out at the appropriate control modules (see operating manual for the respective control units).

Connecting diagram with the control unit EPG 2010 T

3.1.3 Connecting to the control modules

Electrical connection:

• Connect electrical cable (Tribo current measuring lead 4) to Tribo-spraygun and display module TAM 2011.

Pneumatic connection:

• Tribo air (1): Module PM 400 Tribo-spraygun
• Atomizing air (2): Module PM 400 Tribo-spraygun
• Feeding air (5): Module PM 400 Powder injector
• Dosage air (6): Module PM 400 Powder injector
• Powder delivery (3): Powder injector PJ 2020 PRS Tribo-spraygun
• Fluid air: Throttle valve Feed system /
  Fluid connection
• The spraygun is properly fastened and grounded to both stationary or mobile reciprocator gun support system - e.g. EBA 3 / EBA 1 - by means of the mounting-braket (7) (see paragraph 7. "Accessories").
• The adjustments powder quantity and powder fluidization are to be carried out at the appropriate control modules (see operating manual for the respective control modules).

Connection diagram with the control modules

3.2 Grounding

In order to achieve a good powder coating and for security reasons (see 1.1., safety regulations), the Tribo-Automatic spraygun PEA-T1 must be properly grounded.

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

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

"Warning"

Sparks between workpiece and conveyor hooks (hangers)
can occur if hooks or other hanger parts are not completely
cleaned!

Preconditions for good grounding as well as coating are:

• Good grounding the workpiece to be coated, of conveyors and hangers.
• Grounding of the powder spray booth and the transport and mounting equipment with the installation of a > 16 mm² copper conductor to system ground.
• Regular cleaning of hangers from powder deposits.
• The grounding resistance of the workpiece must not exceed 1 MOhm (Mega Ohm).
• Grounding, see connection diagram paragraph 3.1.

4. Operation

4.1 Adjusting the powder cloud

Preconditions:

• The compressed air must be connected.
• Connect the Tribo-Automatic spraygun PEA-T1 electrically and pneumatically to the control unit resp. control module as shown in the connection diagram, see paragraph 3.1.

Course order:

1. Turn on the control cabinet.
2. Open Tribo air (settings, see following diagram):

"Caution "

The tribo air has to be opened before feeding air and dosage air, otherwise there is a risk of malfunction.

To reduce the wear of the wear parts, the air volume for the spraygun should be adjusted not higher than 7,5 Nm³/h. The total of
Tribo air, feeding air and dosage air must be < 7,5 Nm³/h (see following diagram).

Maximum air volume of feeding air + dosage air + tribo air 7,5 Nm³/h

Tribo current display at maximum air volume (feeding air + dosage air + tribo air):

minimum charging current: 2,0 - 2,5 µ A
ideal charging current: 2,5 - 3,5 µ A
charging current too large: > 3,5 µ A reduce tribo air

Feeding air + dosage air min. 4 Nm³/h max. 6 Nm³/h air
(according to hose diameter / length)

3. Open feeding air and dosage air.
4. Open up the atomizing air only so far, to still keep the deflector cone free of powder deposits.
5. Adjust powder cloud on test object.

Caution

Differences in quantity of air with PJ 2020 PRS with orifice without orifice

Dosage Air with 1.5 mm	Dosage Air without orifice

The PJ 2020 PRS is only supplied with an integral orifice for the dosage air!

4.2 Application-related description of nozzle system

Nozzle	Workpieces	Spray cloud	Air adjustments	Coating distance
Round spray nozzle	Wire goods, Grating, Aluminum profile	Round spray cloud dependent on the size of the deflector cone	Feeding air: 1- 4 bar Dosage air: 0 - 2.4 bar Atomizing air: 0 - 2.4 bar	100-160 mm dependent on the chargeability of the powder
Fan spray nozzle	difficult workpieces, undercuts, broken edges	widely-spread fan spray	Feeding air: 1- 4 bar Dosage air: 0 - 2.4 bar Atomizing air: 0 - 2.4 bar	120-180 mm dependent on the chargeability of the powder

4.3 Work interruption

Hint

The Tribo-Spraygun should be blown through and cleaned from powder deposits with every interruption of work.

Course order:

1. Remove powder injector from injector connection (no powder delivery).
2. Don't turn off feeding air and dosage air.
3. Don't turn off tribo air.

Caution

The tribo air must stay open!

4. Turn on the spraygun and blow through via powder injector.
5. Turn off control system and secure that they cannot start up again.

4.4 Changing powder

Course order:

1. Clean the Tribo-spraygun, see paragraph 4.3. "Work interruption".

2. Remove deflector cone (1).
3. Unscrew outer nut (2) from the gun housing (3).
4. Carefully extract nozzle body (4).
5. Carefully pull out the charging body (5) from the housing.

Hint

When pulling out and inserting the parts take care not to damage any parts of the charging body.

6. Clean dismantled parts and Tribo-spraygun from powder deposits (assembling in reversed order).
7. For re-starting operation, see paragraph 4.1. "Adjusting the powder cloud".

5. Maintenance and cleaning

Caution

Maintenance, repair or replacement of the powder spray unit (Tribo-Automatic spraygun PEA-T1) or its components may only be performed by trained personnel outside the hazard area in a suitable location.

Preconditions

• Turn off control cabinet and powder supply.
• Ensure that they cannot start up again!
  (see paragraph 4.3. "Work interruption")

Hint

The wear parts marked with (*) in the spare parts list of the Tribo-Automatic spraygun PEA-T1, must be regularily checked and replaced if necessary.

5.1 Cleaning the charging body

1. Clean the spraygun, see paragraph 4.3. "Work interruption".
2. Remove the charging body from the spraygun and clean it as described in paragraph 4.4. "Changing powder".

Caution

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

5.2 Replacement of the wear parts

1. Replacing the charging body

Course order:

Hint

When pulling out and inserting the parts take care not to damage any parts of the charging body.

1. Carefully turn the tip (1) from the threaded rod (2) and dismantle the charging body (3 ... 9) into its components.
2. Clean all parts from powder deposits.

Caution

Don't damage the parts, otherwise there is a risk of malfunction.

3. Change worn out parts (see paragraph 7. "spare parts list").

2. Replacing the air manifold

Course order:

1. Undo and remove hose socket (4).
2. Undo filister head screws (6) and disconnect carefully connecting piece (3) from the housing (1) and mounting part (2), slightly moving it backwards on the connecting tube (13) by approximately one inch.

Caution

Don’t damage the strand (A)

3. Pull off wire lug (A) from the grounding tube (7) and pull off connecting piece (3) completely from housing (1), mounting part (2) and connecting tube (13).
4. Push out carefully air manifold (12) with O-ring (11) and replace both with new parts (see paragraph 7. "Spare parts list").
5. To assemble, remount connecting piece (3) first and then the new parts
   (11, 12, 4).

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 (Tribo-Automatic spraygun PEA-T1) or its components may only be performed by trained personnel outside the hazard area in a suitable location.

Malfunction	Cause	Remedy
Air and powder don't turn on	No mains power Fuse at control cabinet is defective Gun cable defective	Turn on mains power Replace fuse, see operating manual of the control cabinet Replace gun cable
No tribo current reading	Unsuitable powder is used Gun cable defective Display module defective Wear	Use suitable powder Replace gun cable Inform service center Change worn out parts
Poor wrap-around	Bad grounding Bad powder charging	See paragraph 3.2.
Powder output irregular or insufficient	Compressed air main supply insufficient Powder sintering Feeding air / dosage air- proportion not correct Impurities in delivery system Obstructions Wear	Check connected equipment Blow off powder-feeding parts Readjust at the control unit See operating manual of connected devices Dismantle spraygun, clean the parts, see paragraph 5. Change worn out parts, see paragraph 5.
Spray jet not correct	Deflector cone clogged resp. worn out	Clean the deflector cone; replace worn out and defective parts