PJ 2020 PRS
Powder Injector 		09/98

Danger!

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

 


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Operating Manual

Index

1. Introduction

1.1. Warranty

2. Description

2.1. Part number

2.2. Specification

2.3. Application

2.4. Processable Powders

2.5. Operation of the powder injector

2.6. Mechanical design of the powder injector

3. Start up

3.1. Connecting the powder hose

3.2. Grounding

3.3. Mounting to the injector plate

4. Operation

4.1. Adjusting the powder injector PJ 2020 PRS

4.2. Air volume and powder output

4.3. Changing powder

5. Maintenance and cleaning

5.1. Daily maintenance and changing powder

5.2. Replacing or cleaning the injector nozzle

6. Trouble Shooting

7. Spare parts list

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.

1.1 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 Part number

Powder injector PJ 2020 PRS Part No. 0241 294

2.2 Specification

Width

30 mm

 

Length overall

110 mm

Weight 300 g   Height overall 100 mm

2.3 Application

The powder injector PJ 2020 PRS is used for powder feeding in Manual and Automatic-powder coating systems.

The powder injector PJ 2020 PRS can be used for the switched air mode (see 2.5.).

2.4 Processable Powders

All powder paints can be processed with the powder injector PJ 2020 PRS.

2.5 Operation of the powder injector

With the feeding air (F) the fluidized powder (A) will be sucked in from the powder container. By adjusting a higher feeding air quantity, the fed powder quantity (S) is also increased.
The supply of the dosage air (D) increases the flow rate at almost constant powder quantity in the powder feed hose.

When the feeding air is turned off and at the same time the dosage air quantity is increased to maximum then the injector (powder feeding) is "switched off"; i.e. no powder is fed to the gun while the hose is still constantly flushed by the dosage air. As soon as the feeding air is switched on again and the dosage air is turned to normal quantity the powder flow will start immediately (switched air mode).

2.6 Mechanical design of the powder injector

A Powder supply from powder container
F Feeding air inlet
D Dosage air inlet
S Powder/air mixture to gun

3. Start up

3.1 Connecting the powder hose

Push the powder hose (A) onto the injector nozzle (B) until it is firmly fixed.

3.2 Grounding

The powder injector must be grounded by means of a grounding cable. The grounding cable must be connected at the back plate of the control unit or to the system ground.

Grounding hole Ø 4 mm
for the grounding cable see
special accessories

 
 

 

 

Use only conductive
O-ring

Caution

The powder injector must be grounded to prevent static charging.

3.3 Mounting to the injector plate

The powder injector (1) can be screwed on to an injector plate (2) as shown with a M6 filister head screw (DIN 912). The injector plate must be grounded.

 Fastening hole M6

4. Operation

4.1 Adjusting the powder injector PJ 2020 PRS

Rule of thumb for setting the PJ 2020 PRS:

4.2 Air volume and powder output

The table is valid under the following conditions:

Powder feed hose

Material

PUR

 

length

7,5 m

 

inner Diameter

11 mm

Powder-Automatic gun

PEA-C1

 

Powder type

blue, Polyflex,

PES-120 Tribo

 

Particle size

< 32 µm 47%

   

< 96 µm 98%

Feeding air (Nm3/h)

Dosage air (Nm3/h)

Powder output (g/min) [± 20%]

4

0

342

3

1

245

2

2

123

1

3

9

01.)

>41.)

01.)

1.) Set values for switching operation
Note to air volume and powder output

4.3 Changing powder

Course order:

  1. Turn off high voltage.
  2. Turn off feeding air, turn off dosage air.
  3. Disconnect powder feed hose (S), feeding air hose (F) and dosage air hose (D) from the powder injector.
  4. Blow bursts of compressed air through the powder injector from the injector powder inlet (A) and clean completely from powder deposits.
  5. Mount again powder feed hose (S), feeding air hose (F) and dosage air hose (D).
  6. Before re-starting check the grounding.

5. Maintenance and cleaning

Caution

Always turn off the high voltage before starting any maintenance work and ensure that they cannot start up again!

5.1 Daily maintenance and changing powder

Course order:

  1. Turn off high voltage and ensure that they cannot start up again.
  2. Further procedure see paragraph 4.3. "Changing powder".

The nozzle (2) and the o-rings (3/4) are wear parts which must be checked frequently (at least every week) and replaced if the powder output decreases.

5.2. Replacing or cleaning the injector nozzle

Course order:

  1. Turn off high voltage and ensure that they cannot start up again.
  2. Disconnect all air and powder hoses (F/D/S) from the powder injector and remove the powder injector from the injector socket at the powder container (see paragraph 4.3. "Changing powder").
  3. Unscrew the outer nut (1) and remove the injector nozzle (2) from the injector housing.
  4. Clean the injector housing (5) (blow out).
  5. Clean or replace the injector nozzle (2).
  6. Slide the new injector nozzle (2) into the housing (5) as far as it will go.
  7. Slide the outer nut (1) over the injector nozzle and tighten it securely.
  8. Mount again all air and powder hoses (F/D/S) (see paragraph 3.1. "Connecting the powder hose").

6. Trouble Shooting

Malfunction

Cause

Remedy

Insufficient powder delivery

- Nozzle clogged

- Injector nozzle worn

- Leak between container and injector

- Replace and clean nozzle

- Replace as described in paragraph 5.2.

- Replace o-Ring

Pulsed powder delivery

- Too little dosage air

- Injector nozzle not mounted correctly

- Increase dosage air quantity

- Clean thread of the outer nut

- Tighten nut securely