WAGNER PEM-T3 Operating Manual

Page 1
Operating Manual
Tribo Manual Spray Gun
http://www.wagner-group.com
DANGER
Turn power off
before servicing!
CAUTION
Read rules for safe
operation and
instructions
carefully!
pemt3_0000
O
S
9
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0351967
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PEM-T3
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03/2008 0351709
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Introduction
Tribo manual spray gun Article No. 0351019
00_Pemt3_Aufbau.doc
F
E
pemt3_0001
G H
D
C
B
A
A Deflector cone B Nozzle body C Outer nut D Spray gun body
The Tribo manual spray gun PEM-T3 is used for powders suitable for friction loading. The PEM-T3 powder spray gun is used for industrial powder coating. This spray gun can be operated with the following control units:
E Trigger F Tribo air connection G Powder hose connection H Power supply
EPG 2008 with powder injector PI-P1
EPG-D1 with powder injector PI-F1
Control unit Bravo with powder injector PI-FM1
The powder feed and the Tribo air supply to the spray gun are activated by pressing the trigger.
Caution
The user must ensure, that the spray gun is only connected to Wagner equipment! High ambient temperatures must be avoided; in particular, the hoses must not be
routed through factory areas exposed to direct sunlight! To provide a safeguard against unintentional use of the spray gun, the control unit must
be turned off!
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Introduction
Table of contents Page
1. Safety regulations.......................................................................................................5
1.1 Safety hints....................................................................................................................5
1.2 EC Declaration of conformity.........................................................................................6
2. Preparing the spray gun.............................................................................................7
2.1 Select the suitable nozzle system.................................................................................7
2.2 Connecting the spray gun .............................................................................................7
2.3 Grounding......................................................................................................................8
3. Working with the spray guns.....................................................................................9
3.1 Start up the spray gun...................................................................................................9
3.2 Switching off the spray gun...........................................................................................9
3.3 Carrying out a change of color....................................................................................10
4. Maintenance and cleaning........................................................................................11
4.1 Replacing the spray gun..............................................................................................11
4.2 Cleaning the spray gun and replace the wear parts....................................................12
4.3 Mounting the gun extension........................................................................................13
4.4 Disposal.......................................................................................................................15
5. Rectification of malfunctions...................................................................................16
6. Technical data ...........................................................................................................17
7. Warranty.....................................................................................................................18
8. Scope of delivery and spare parts lists...................................................................19
8.1 How to order................................................................................................................19
8.2 Scope of delivery and spare parts list of PEM-T3.......................................................19
8.3 Charging body (complete)...........................................................................................20
8.4 Wide fan spray nozzle.................................................................................................20
8.5 Gun extension.............................................................................................................21
8.6 Charging body of PEM-T3 300....................................................................................22
8.7 Outer tube ...................................................................................................................23
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Introduction
00_..doc
This manual contains information and hints for the service, repair and maintenance of the equipment. The user must obey all the rules of operation found in this manual; failure to do so will render the warranty invalid.
Wagner 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.
Please pay particular attention to the parts marked by the following symbols. Follow the instructions exactly, in the interests of both your own safety and the correct functioning of the unit.
Warning
This symbol draws attention to the fact that if the operating instructions, working instructions, prescribed working sequences etc. are not followed exactly, this can lead to injury or even fatal accidents.
Caution
This symbol indicates that failure to follow the operating instructions, working instruc­tions, prescribed working sequences etc. exactly can lead to material damage.
Hint
This symbol draws your attention to useful additional information and tips. Failure to observe these instructions can cause malfunctions.
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Page 5
Safety regulations
1. Safety regulations
1.1 Safety hints
010101_ .doc
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
!
Warning
Under no circumstance may persons with a cardiac pacemaker come close to the area between the tip of the spray gun and the work piece to be coated!
The following rules must be observed in order to ensure a safe and efficient use of the equipment:
The user has to observe particularly the safety guidelines of the VdS, the local professional and security institutions.
Trained and qualified personnel may only oper­ate the electrostatic coating equipment.
The spray gun may only be operated in powder coating booths or on powder coating stands that are equipped with a ventilation system.
The user has to make sure, that the average powder/air concentration does not exceed 50% of the LEL (maximum allowed concentration of powder in air). If a reliable LEL value is not available, the average powder/air concentration may not exceed 10 g/m³.
Over sprayed powder must be reliably collected.
Adhere to the instructions given by the manufac-
turers and to the prevalent local laws on the environment when disposing of waste coating powder.
The main power connection for operation of the Wagner powder equipment must be electrically interlocked with the exhaust system of the powder coating booth.
In the event of faults or defects, repair work is to be performed at the user's discretion.
The user must conduct periodic checks of the powder spray equipment (at least every year) with regard to explosion-protection.
Repairs may only be carried out by trained tech­nicians and may never be carried out in an explosion hazardous area. Protective measures against explosions must still be installed.
The work area must have an electrostatically conductive floor (measured in accordance with EN 1081).
All conductive parts in the work area must be electrostatically grounded (work area = 1 m around every spray location or opening in the booth).
All persons inside the work area must wear electrostatically conductive footwear.
Spray guns should be operated with bare hands! If gloves are used they must be made of conductive material.
Guideline 94/9/EC: The device is suited for the applications it was designed for, even in explosion-hazard areas.
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Safety regulations
Wear suitable work clothing
Use breathing protection or a vizard for work
which produces powder and when developing solvent steams:
Avoid health dangers by inhalation and skin contacts of solvent steams and lacquer aerosols; Cornea injuries by splashes in the eye.
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 Wagner replacement parts!
Alteration or repair of Wagner original spare parts may cause fatal accidents or explosions in the coating system!
010102_ .doc
Check the equipment for damage
Before operating the system, check if slightly damaged parts still function correctly. Check whether the moving parts operate properly, whether they jam and whether parts are damaged.
Damaged parts should be repaired or replaced by a Wagner customer service.
1.2 EC Declaration of conformity
Wagner hereby declares that the unit described in these operating instructions has been designed and manufactured according to the provisions of EU Directives 98/37/EC, 94/9/EC, 73/23 EEC and 89/336 EEC.
The following European standards were applied:
EN 12100-1/-2 EN 50281-1-1/-1-2 EN 61000-6-1 EN 61000-6-2 EN 61000-6-3 EN 60204-1 EN 50053-2 EN 50050 EN 50177
The following German standards and/or Guidelines were applied:
BGI 764
The product includes an EC declaration of conformity. This can be ordered again if necessary from your WAGNER dealer by giving details of the product and serial number involved.
0103_Konformitaet.doc
The number of the EC Declaration of Conformity is 0351967.
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Page 7
Preparing the spray gun
2. Preparing the spray gun
2.1 Select the suitable nozzle system
0201_Duesenauswahl_tribo.doc
Nozzle Overview Application Spray pattern
Oval powder cloud:
Deflector cone
Wire goods
Grid designs
Size is dependent on the deflector cone diameter.
For powder quantities from: 50 ... 300 g/min
Fan spray nozzle
Difficult workpieces:
Undercuts
Profiles
Wide fan spray
nozzle
Difficult workpieces:
Undercuts
Profiles
The part numbers are listed in chapter 8 "Scope of delivery and spare parts lists".
2.2 Connecting the spray gun
Before you start making connections, switch off the powder feeding. Refer to the operating instructions of the corresponding control unit for this.
Widely spread flat powder cloud. For powder quantities:
from 50 ... 150 g/min
Widely spread flat powder cloud. For powder quantities:
from 100 ... 250 g/min
Tribo air
from the control unit Powder feed
to the electrical connection at the control unit
from the powder injector
pemt3_0003
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Preparing the spray gun
Connect the spray gun to the Tribo current measuring or display module with the electrical
cable.
Connect the powder hose to the spray gun and to the powder injector.
Connect the hose for Tribo air to the spray gun and to the control unit.
2.3 Grounding
For safety reasons, the spray gun must be properly grounded. This occurs through the electrical cable.
Good grounding of the workpiece is also necessary for optimum powder coating. A poorly grounded workpiece causes:
dangerous electric charging of the workpiece
back-spray onto spray gun and user
uneven coating
very bad wrap around
0203_ .doc
Warning
Sparks between workpiece and conveyor hooks (hangers) can occur if hooks or other hanger parts are not completely cleaned!
These sparks can cause heavy radio frequency interference.
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Page 9
Working with the spray guns
3. Working with the spray guns
3.1 Start up the spray gun
Switch on the control unit.
Select the type of gun Manual and charging Tribo on the control unit.
Refer to the operating instructions of the control unit for this.
Caution
To reduce wear, the total of feed air and dosage air must range between
3.5 - 6 Nm3/h!
The total of feed air, dosage air and Tribo air should not exceed a maximum of
7.5 Nm3/h!
Hold the manual gun in the spray booth, press the trigger and set the powder volume and
the powder speed to a test piece by adjusting the volume of feed air and dosage air.
Only open the Tribo air until a Tribo current reading of 3 µA is attained.
Caution
The Tribo air must be reduced or shut off if the Tribo current (charging current) exceeds
μA!
3.5
The charging current depends on the type of powder used and should ideally lie between
2.5 and 3.5
3.2 Switching off the spray gun
The spray gun is switched off in different ways, depending on the type of powder injector.
Hint
The spray gun should be blown through (flushed) and cleaned from powder deposits with every interruption of work. In this way on again are to a great extent avoided.
The flushing procedure can be set on the control unit if the spray gun is connected to an
EPG-D1 or a Control unit Bravo in conjunction with the PI-F1 powder injector. In this case the
spray gun is blown free of powder as soon as the trigger is released.
μA.
powder deposits and surges on switching
0302_.doc
If the spray gun is operated with an proceed as follows:
Release the trigger on the spray gun so that the powder feed and high voltage generator
are switched off.
Set the knob for the overall air quantity on the control unit EPG 2008 to maximu m. No more
powder will be delivered when switching on again.
Press the trigger on the spray gun so that the spray gun is blown free of powder.
Switch off the control unit and secure against inadvertent switch on.
03/2008 0351709 - PEM-T3 9
EPG 2008 control unit and a PI-P1 powder injector,
Page 10
Working with the spray guns
3.3 Carrying out a change of color
All parts carrying powder in the entire coating system must be thoroughly cleaned of powder deposits on a change of color. In the following, only the procedure for the spray gun is described. Instructions on cleaning the other components can be found in the appropriate operating instructions.
Switch off the control unit and secure it against being switched on again.
4
2
1
Pemt3_0005
Pull off the deflector cone 1 from the charging body 5.
Unscrew the outer nut 2 from the gun housing 3.
Carefully draw the nozzle body 4 out of the gun housing 3.
Carefully extract the charging body 5.
If you do not use automatic flushing:
Release the trigger on the spray gun so that the powder supply and high voltage generation are switched off.
Pull the powder injector out of the powder container’s injector connection so that no powder can be delivered
5
3
during flushing. Press the trigger on the spray gun so
that the spray gun is blown free of powder.
Switch the control unit off and secure it against being switched on unintentionally.
Caution
Ensure in particular that none of the charging body’s components are damaged when removing and replacing the wear parts!
Clean the parts, which have been dismantled, and the spray gun from powder deposits.
Carefully re-fit the charging body 5 a nd the nozzle body 4 in the gun housing 3 and tighten
it up with the outer nut
Slide the deflector cone 1 onto the charging body 5 again.
The spray gun is again ready for operation.
2.
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Maintenance and cleaning
4. Maintenance and cleaning
4.1 Replacing the spray gun
0401_ .doc
Before you commence the replacement of the spray gun any powder residue must be removed
thoroughly.
Caution
Repair or replacement of the spray gun or parts of the spray gun are only allowed to be performed outside the hazard area and in a suitable place by specialist personnel!
The wearing parts in the spray gun, marked in the spare parts list with *, must be regularly checked and, if necessary replaced.
0401_Pemt3_Ausbauen.doc
D
F
Switch off the control unit and/or high
voltage generator.
H
G
Disconnect the electrical cable H from
the control unit
J.
Disconnect the powder feed hose G
and Tribo air hose
D.
gun
F from the spray
J
Pemt3_0004
Exchange the spray gun for a new one and assemble it in reverse order.
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Maintenance and cleaning
4.2 Cleaning the spray gun and replace the wear parts
Caution
Never place the spray gun or parts of it into any wet cleaning agent!
Caution
While pulling out and replacing the wearing parts make sure that the parts of the charging body are not damaged.
4
0402_Pemt3_Verschlaustausch.doc
2
1
Pull the deflector cone 1 from the
charging body
5.
Unscrew the outer nut 2 from the gun
housing
3.
Carefully pull out the nozzle body 4
from the gun housing
5
Carefully pull out the charging body 5.
3.
Check the removed parts for wear.
The
entire charging body can be
3
Pemt3_0005
replaced with a procedure.
new one during this
It is also possible to dismantle the charging body and merely replace the parts affected by wear.
14
7
Carefully unscrew the tip 6 from the
13
threaded bar charging body.
Unscrew the air nozzle 14 from the
deflector cone rod replace it with a
7 and dismantle the
13 if worn and
new one.
Complete clean residual powder from
all parts.
6
Replace worn parts with new ones.
8
Reassembly of the charging body.
Carefully push the charging body back
9
into gun and reassemble the gun.
10
Pemt3_0006
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Maintenance and cleaning
4.3 Mounting the gun extension
Caution
In order to install a gun extension, the spray gun must always be thoroughly clean! It is even better to use a new spray gun.
3
2
1
P_00715
Pull the deflector cone/fan spray nozzle 1 from the nozzle body 3.
Unscrew the outer nut 2 from the gun housing.
Pull the nozzle body 3 from the gun housing.
4
P_00716
Pull out the charging body 4 from the gun housing.
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Maintenance and cleaning
5
2
P_00717
Insert outer tube 5 into the gun housing and secure it with outer nut 2.
6
7
1
P_00718
Insert charging body 6 into the outer tube 5 and push it in as far as it will go.
Push adapter 7 onto outer tube 5 as far as it will go.
Locate deflector cone / column nozzle 1 onto adapter 7.
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Maintenance and cleaning
4.4 Disposal
04_Entsorgung.doc
Only for EU countries
Do not dispose of electric tools together with household waste material!
In observance of the European Directive 2002/96/EC on waste electrical and electronic equipment and implementation in accordance with national law, this product is not to be disposed of together with household waste material but must be recycled in an environmentally friendly way!
Wagner or one of our dealers will take back your used Wagner waste electrical or electronic equipment and will dispose of it for you in an environmentally friendly way. Please ask your local Wagner service center or dealer for details or contact us direct.
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Rectification of malfunctions
5. Rectification of malfunctions
Malfunction Cause
No Tribo current (e.g. no wraparound or no powder adhe­sion)
Poor wrap-around Back-spray Powder outlet
uneven or inadequate
- Inadequate or no powder charging
- Electrical cable from spray gun to control unit faulty
- Tribo current measuring or display module defective
- Powder-conveying parts in spray gun worn
- Inadequate or no ground - See chapter
- Soiling
- Powder sintering or powder­conveying parts in spray gun worn
- Blow through parts carrying powder
Rectification
- Contact Wagner Service
-Replace worn parts
"
Grounding"
- Blow through parts carrying powder
- Clean parts carrying powder and replace if necessary
- See operating instructions for the related devices connected
- Feed air / dosage air ratio incorrect
- Wear on powder injector nozzle
Spray pattern is uneven
1.) You will find the wearing parts and spare parts in the operating instructions for the powder injector.
- Parts of nozzle system worn - Replace worn parts
- Adjust at control unit
- Replace worn parts in the pow­der injector 1.)
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Technical data
6. Technical data
Adjusting
Weight: 500 g
06_Tribopistolendaten.doc
Electrical:
Design: as per EN 50177 and EN 50050 Protection class: IP 54
Pneumatic:
Input air pressure (Tribo air): max. 43.5 psi (3 bar) Powder output quantity: max. 300 g/min
06_ .doc
Required compressed air quality:
Quality class
Compressed air quality according to ISO 8573.1
Max. residual water:
5
(pressure dew point in °F at 100 psi
+44.6 °F / +7 °C
/ °C at 700 kPa)
2 3 3
Max. oil contents: 0.1 mg oil/m3 / 0.1 oz/ft3
Max. concentration: 5 mg/m3 / 5 oz/ft3
Max. particle size:
μm / 5 microns
5
Ambient conditions:
If low temperature powders are used, the ambient temperature may have to be lower than 86 °F (30 °C).
Volume measures:
For volumes, specified in Nm3 (standard cubic meters). One cubic meter of a gas at
32 °F (0 °C) and 1.013 bar is called norm cubic meter.
3
1 Nm
/h = 35.3 ft3/h; 1 bar = 14.504 psi
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Warranty
7. Warranty
What is covered by this warranty?
Faulty or defective 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.
08_ .doc
What is not covered by this warranty?
This warranty does not cover any of the following damages or defects:
1. Damages or defects caused by use or installation of repair or replacement parts or accessories not manufactured by Wagner,
2. Damages or defects caused by repair performed by anyone other than a Wagner authorized service center, or
3. Damages or defects 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 EXPRE SS 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 WA RRANTIES, 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; you may also be entitled to other rights, which vary from state to state.
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Page 19
Scope of delivery and spare parts lists
8. Scope of delivery and spare parts lists
8.1 How to order
0901_ .doc
Faulty and unserviceable parts are replaced in accordance with our General Terms and Conditions of Delivery.
In order to be able to guarantee safe and smooth spare parts delivery, the following informa­tion is necessary:
- Invoicing address
- Delivery address
- Name of contact persons for check back
- Type of delivery
- Quantity ordered, article number and designation
8.2 Scope of delivery and spare parts list of PEM-T3
0351019
Item Art. No. Designation
- - 0351019 Tribo manual gun
1 0259474 * 1 0259475 * 2 0351654 Outer nut Tribo ET 3 0351581 Nozzle body 4 0260928 * Fan spray nozzle ** 5 0260629 * Charging body (complete)
* Wearing part ** Only available as a set *** Special accessory
PEM-T3
Deflector cone ( Deflector cone (
22) 28) ***
0351019_et
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Scope of delivery and spare parts lists
8.3 Charging body (complete)
0260629
12
13
0260629_et
Item Art. No. Designation
- - 0260629 Charging body
(complete)
11
10
14
6 0260472 * Tip 7 0260473 Threaded bar 8 0260474 * Ring 9 0260471 * Charging tube
10 0260476 * Support ring
9
8
7
6
11 0260470 * Rod 12 0260463 * Central air supply 13 0260469 * Deflector cone rod 14 0260632 * Air nozzle (complete)
* Wearing part
8.4 Wide fan spray nozzle
1
4
3
2
0260926_et
Item Art. No. Designation
1 0260926 * Wide fan spray nozzle **
0260280 * Wide fan spray nozzle
2
9971037 * O-ring 22x1,5
3
0260627 *
4
* Wearing part ** Only available as a set
Deflector cone
13
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Page 21
Scope of delivery and spare parts lists
8.5 Gun extension
4
3
1
P_00719
Item Art. No. Designation
-- 0260934 Gun extension 300 mm
1 0260935 * Charging body PEM-T3 ET 2 0260936 * Outer tube PEM-T3 ET 3 0259474 *
Deflector cone (
22)
4 0259479 Adapter
2
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Scope of delivery and spare parts lists
8.6 Charging body of PEM-T3 300
3
4
2
1
5
5
9
5
5
10
7
P_00720
8
5
6
Item Art. No. Designation
-- 0260935 Charging body PEM-T3 300
1 0260632 * Air nozzle (complete) 2 0260463 * Central air supply 3 0260469 * Deflector cone rod 4 0260470 * Rod 5 0260471 * Charging tube 6 0260472 * Tip 7 0260474 * Ring 8 0260476 * Support ring 9 0260657 * Charging tube
10 0260658 Threaded bar
* Wearing part
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Page 23
Scope of delivery and spare parts lists
8.7 Outer tube
2
1
P_00721
Item Art. No. Designation
-- 0260936 Outer tube T3 300 ET
1 0260655 Outer tube T300 2 0260656 Powder tube
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Notes
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Notes
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Page 26
Notes
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ADDRESSES
Germany Switzerland
J. WAGNER GmbH J. WAGNER AG Otto-Lilienthal-Str. 18 Postfach 109 D-88677 Markdorf Industriestrasse 22 CH-9450 Altstätten
Phone +49(0)7544/505-0 Phone +41(0)71/7572211 Fax +49(0)7544/505-200 Fax +41(0)71/7572222
Austria Netherlands
J. WAGNER GmbH Wagner Systemen Nederland B.V. Otto-Lilienthal-Str. 18 Proostwetering 105 C Postfach 1120 NL-3543 AC UTRECHT D- 88677 Markdorf
Phone: ++49/ (0)7544 / 5050 Phone +31(0)30/2410688 Fax: ++49/ (0)7544 / 505200 Fax +31(0)30/2410765
Belgium Denmark
Estee Industries WAGNER Powder Systems Scvandinavia Leenbeekstraat 9 Juupajokivej 8 B-9770 Kruishoutem DK-8850 Bjerringbro
Phone +32(0)9/3885410 Phone +45 7023 2052 Fax +32(0)9/3885440 Fax +45 8668 2052
Sweden
WAGNER Powder Systems Scandinavia AB Hedenstorpsvägen 4 Sverige - 55593 Jönköping
Phone +46(0)36/341590 Fax +46(0)36/368580
Great Britain USA
WAGNER Spraytech (UK) Ltd. WAGNER Systems Inc. Unit 3 Haslemere Way 300 Airport Road, Unit 1 Tramway Industrial Estate Elgin, IL 60123 UK-Banbury, Oxon OX 16 8TY
Phone +44-1295-265353 Phone +1(0)630/503-2378 Fax +44-1295-269861 Fax +1(0)630/503-2377
Page 28
ADDRESSES
Japan
WAGNER- HOSOKAWA Micron Ltd. No. 9, 1-Chome Shodal Tajka, Hirakata-Shi Osaka 673-1132
Phone +81(0)728/566751 Fax +81(0)728/573722
China
WAGNER SPRAYTECH SHANGHAI CO LDT.
th
4
Flr, No. 395 Jiangchangxi Road Shibei Industrial Zone Shanghai, 200436
Phone +86(0)2166521858 Fax +86(0)2166529819
France
J. Wagner France SARL B.P. 75, 5, Avenue du 1er Mai F-91122 Palaiseau-Cédex
Phone +33(0)825/011111 Fax +33(0)1/69817257
Italy Spain
WAGNER Itep S.p.A. WAGNER Spraytech Iberia S.A. Via Santa Vecchia, 109 P.O.Boc, 132, Crtra. N-340, Km. 1245,4 I-22049 Valmadrera - LC E-08750 Molins de Rei (Barcelona)
Phone +39/0341/212211 Phone +34(0)93/6800028 Fax +39/0341/210200 Fax +34(0)93/6800555
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