WAGNER PEM-TG3 Operating Manual
http://www.wagner-group.com
Operating Manual
Tribo Cup Gun
DANGER
High Voltage!
Turn power off
before servicing!
Read rules for safe
operation and
instructions
carefully!
CAUTION
pemtg3_0000
0351967
PEM-TG3
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04/2006 0351717
Introduction
Tribo Cup Gun PEM-TG3 Article No. 0351036
00_Pemtg3_Aufbau.doc
570
m
m
X
A
B
F
G
J
E
C
D
H
Pemtg3_0001a
X
K L
Pemtg3_0001b
A Deflector cone
B Nozzle body
C Outer nut
D Spray gun body
E Trigger
F Air supply (input air)
G Electrical connection
H Powder container with fluidization
J Adapter with integrated powder injector
K Setting knob red for setting the feed air
L Setting knob black for setting the Tribo air
The Tribo cup gun PEM-TG3 is used for processing all coating powders suitable for friction
charging.
The Tribo cup gun is mainly suitable for laboratory tests, sample coating and/or low volume
production.
By actuating the trigger the compressed air supplies to the gun is turned on. This compressed
air is required for Tribo, feed, dosing and fluid air applications.
This cup gun can be operated with the control unit EPG 2008.
The cup gun is equipped with a powder container with a capacity of 500 cm
3
. You can also
mounted different powder containers on the cup gun.
You will find the article numbers in chapter 10
"Accessories".
Caution
The operator must ensure that the spray gun PEM-TG3 s only connected to Wagner
devices!
High room temperatures and, in particular, laying hoses in areas exposed to sunlight in
factory buildings must be avoided!
To secure the spray guns, the control unit must be switched off!
2 0351717 - PEM-TG3 04/2006
Introduction
Table of contents Page
1. Safety regulations.......................................................................................................5
1.1 Safety hints....................................................................................................................5
1.2 EU Declaration of conformity.........................................................................................8
2. Preparing the spray gun.............................................................................................9
2.1 Selection of the suitable equipment ..............................................................................9
2.2 Mounting the powder container...................................................................................10
2.3 Connecting the spray gun ...........................................................................................10
2.4 Grounding....................................................................................................................11
3. Working with the spray guns...................................................................................12
3.1 Starting up the spray gun and adjusting Tribo air........................................................12
3.2 Switching off the spray gun.........................................................................................12
3.3 Performing a color change..........................................................................................13
4. Maintenance and cleaning........................................................................................15
4.1 Replacing the spray gun..............................................................................................15
4.2 Cleaning the spray gun and replacing the wear parts.................................................17
4.3 Check the standard settings........................................................................................18
4.4 Disposal.......................................................................................................................19
5. Rectification of malfunctions...................................................................................20
6. Technical data ...........................................................................................................21
7. Applicable safety regulations ..................................................................................22
8. Warranty.....................................................................................................................23
9. Scope of delivery and spare parts lists...................................................................24
9.1 How to order spare parts.............................................................................................24
9.2 Scope of delivery and spare parts list PEM-TG3 ........................................................25
10. Accessories...............................................................................................................27
10.1 Powder container ........................................................................................................27
10.2 Special accessory .......................................................................................................28
04/2006 0351717 - PEM-TG3 3
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.
4 0351717 - PEM-TG3 04/2006
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/EG: The device is suited for the
applications it was designed for, even in
explosion-hazard areas.
Also refer to chapter 7
"Applicable safety regulations".
04/2006 0351717 - PEM-TG3 5
Safety regulations
010102_ .doc
• 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.
• 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.
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!
6 0351717 - PEM-TG3 04/2006
Safety regulations
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 remove all metallic objects from his or her
person, which are not grounded.
• The object being sprayed must be grounded.
• All metallic 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 electricity sparks, open
flames such as pilot lights, hot objects such as cigarettes and
sparks from connecting and disconnecting power cords and
working light switches.
• To prevent hazardous concentrations of flammable
atmospheres, spray only in a properly ventilated spray booth.
• Never operate spray gun 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 18.
• 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.
04/2006 0351717 - PEM-TG3 7
Safety regulations
1.2 EU Declaration of conformity
0103_ .doc
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 EU declaration of conformity. This can be ordered again if
necessary from your WAGNER dealer by giving details of the product and serial number
involved.
The EU declaration of conformity has the number 0351967.
8 0351717 - PEM-TG3 04/2006
Preparing the spray gun
04/2006 0351717 - PEM-TG3 9
2. Preparing the spray gun
2.1 Selection of the suitable equipment
0201_Duesenauswahl_tribo.doc
Nozzle Overview Application Spray pattern
Deflector cone
• Wire goods
• Grid designs
Oval powder cloud:
Size is dependent on the deflector
cone diameter.
For powder quantities from:
50 ... 300 g/min
Fan spray nozzle
Difficult workpieces:
•
Undercuts
• Profiles
Widely spread flat powder cloud.
For powder quantities:
from 50 ... 150 g/min
Wide fan spray
nozzle
Difficult workpieces:
• Undercuts
• Profiles
Widely spread flat powder cloud.
For powder quantities:
from 100 ... 250 g/min
Powder container Comments
500 cm3 900 cm3 220 cm
3
Select the powder container size dependently
of the powder volume required for coating.
You will find the article numbers in chapter 10
"Accessories".
Preparing the spray gun
10 0351717 - PEM-TG3 04/2006
2.2 M ounting the powder container
H
J
pemcg4_0002a
The cup gun is delivered in two dismantled parts:
• spray gun and
• powder container (500 cm
3
)
Screw the powder container H onto the adapter J,
turning the powder container simultaneously right up to
the limit, thus ensuring that it is securely closed.
2.3 Connecting the spray gun
Pemtg3_0003
• Connect the spray gun to the
control unit
A with the electrical
cable.
• Connect the black hose (external
∅ 6x2) for the air supply to the spray
gun.
Air supply
B from the control unit
to the electrical connection
A at the control unit
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