EIC INSA MG801 User manual

!INSA Trading GMBH
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! !Instruction Manual
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Manual Guns Types MG801, MG801S and MG850
!Automatic Gun AG800
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This manual is supplied by INSA Trading GmbH, Switzerland
PHONE!214*477*134!!FAX972*317*6889!!
!!!!!!!!!!!!!WWW.EICGROUPUSA.COM!

Table of Contents
Foreword .............................................................................................................................................4
Version Information ...........................................................................................................................4
Safety-regulations concerning Electrostatic Powder Coating ..........................................................5
General notes applying to all guns.....................................................................................................7
!Introduction..........................................................................................................................................7
!Generation of high tension...................................................................................................................8
!Technical specifications of the manual and automatic guns...............................................................9
The Manual Guns Type MG801 and MG801S................................................................................10
!Introduction........................................................................................................................................10
!Differences between the MG801 and the MG801S...........................................................................10
The Manual Gun Type 850...............................................................................................................11
!Introduction........................................................................................................................................11
!Settings at the gun..............................................................................................................................12
! !High voltage adjustment.................................................................................................................... 12
! !Adjustment of the powder output...................................................................................................... 12
The Automatic Gun AG800..............................................................................................................13
!Generalities.........................................................................................................................................13
Gun Compatibility Chart ..................................................................................................................14
!Manual Guns......................................................................................................................................14
!Automatic Gun...................................................................................................................................14
Recommended voltage settings for typical applications..................................................................15
Using Muzzles ...................................................................................................................................16
!The use of different muzzles..............................................................................................................16
!Function of a deflector muzzle...........................................................................................................17
!Function of a flat spray muzzle..........................................................................................................18
Options available with INSA Guns ..................................................................................................19
!Triboelectric Versions........................................................................................................................19
!Muzzle Prolongations.........................................................................................................................19
!Low Ion Adaptor................................................................................................................................20
!Cup Gun Attachment .........................................................................................................................21
Maintenance......................................................................................................................................22
!Generalities.........................................................................................................................................22
!Daily Check........................................................................................................................................23
!Weekly check.....................................................................................................................................24
Troubleshooting................................................................................................................................25
Parts listing........................................................................................................................................26
!Muzzles and wearable parts...............................................................................................................26
!Parts of the manual guns ....................................................................................................................28
!Special buttons for the MG850..........................................................................................................30
!Parts of the Automatic Gun AG800...................................................................................................31
! !External view..................................................................................................................................... 31
! !Internal View..................................................................................................................................... 32
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Illustration Index
Basic operation of the gun ...................................................................................................................8
The Manual Gun MG801...................................................................................................................10
The MG850 Gun, companion of the Smarcoat Series.......................................................................11
Settings at the gun..............................................................................................................................12
Different types of muzzles available..................................................................................................16
Function of a deflector muzzle ..........................................................................................................17
Function of a flat spray muzzle..........................................................................................................18
An MG801 with a low ion adaptor....................................................................................................20
Cup gun Attachment for INSA manual units....................................................................................21
Electrode holder position at gun reassembly.....................................................................................23
Overview of the muzzles and other wearable parts...........................................................................26
Overview of a disassembled manual gun ..........................................................................................28
Special buttons of the MG850 ...........................................................................................................30
The Automatic Gun AG800...............................................................................................................31
Internal view of an automatic gun type AG800.................................................................................32

Versionofthedocument 2
Dateoflastmodification 2003-07-16
Foreword
Thank you for choosing an INSA Powder Coating System. It is a very efficient system with a low
consumption of spare parts. In order to gain the most profit from your equipment, please review the
different functions and maintenance required as described in this manual.
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!Important
Please note that INSA Trading GMBH or its representative take no responsibility if the equipment
is used outside its specification, or for uses other than those described in this manual.
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Version Information
4

Safety-regulations concerning Electrostatic Powder Coating
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1. The equipment can be dangerous when not used in
!!!! accordance with the requirements of the following standards:
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!!! !EN 50 050 (resp. VDE 0745 chapter 100)
!!!! !EN 50 053 (resp. VDE 0745 chapter 102)
!!!! !Instructions for electrostatic powder coating ZH 1/444
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2. All electrostatically conductive parts within a reach of 5 m from the
!!spray area must be grounded.
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3. The floor of the room containing the spray area must be
!!!! electrostatically conductive.
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4. The personnel must to wear shoes with conductive soles.
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5. The personnel that will handle the gun must use it with either bare hands or with
!!!electrostatically conductive gloves.
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6. The ground wire (green/yellow) has to be connected to the ground
!!!! screw on the back of the electrostatic control module.
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7. The ground wire must have a solid metallic connection with the booth, the recovery
!!system, and the conveyor chain as well as the objects to be coated.
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8. The electric cables as well as the powder hoses leading to the guns
!!!must be handled in such a way that they are protected against mechanical damage.
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9. Only after the recovery system has been put into operation may the powder coating unit
!!be switched on.
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11.
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12.
Electric wires as well as powder hoses have to be examined at least once a week.
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The grounding of all the electrostatically conductive parts and
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equipment within the reach of 5m from the spray area must be examined at least
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once a week.
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The control panel must be switched off when cleaning the gun or when changing
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nozzles or extensions.
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General notes applying to all guns
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Introduction
The manual powder guns with the integrated high voltage generator are designed to apply
electrostatically chargeable powder on grounded work-pieces. The guns are designed with state of
the art of technology. The parts are assembled in a simple manner which assures easy maintenance
and repair. The guns produce high voltage and it is therefore absolutely necessary to read the
instruction manual carefully before starting to operate.
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All guns are built in accordance with the CE-regulations. They have been tested together with the
electronic control board ECB, and have been found to comply with the European Regulation EN 50
050/54 regulation.
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!Important
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The guns and the electronic control board ECB 110 have been used in accordance with the
european regulation EN 50 050 as components of a configuration, they can only be used in this
combination. Any change or manipulation of the components will automatically void the warranty
and any implicated liability. Use of any parts other than original spare parts will void the warranty.
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Generation of high tension
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!!Illustration 1Basic operation of the gun
The powder gun with the integrated high voltage generator (Pos.1 in Illustration 1 above) is
supplied from the central drawer by the cable (pos.2) with low voltage of
16 kHz frequency. This voltage is transformed to high AC tension and afterwards multiplied up to
110 kV at the electrode (pos.3). The powder hose is connected to the hose connector (pos.4).
When the gun trigger (Pos. 5) is pressed, the magnetic valve will activate (for compressed air) along
with the voltage supply to the gun. The grounded plate (Pos. 6) at the handle will ensure the
operator is not charged.
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Inputvoltage: 10,5Veff
Frequency: 17kHz
OutputVoltage: 110kV-10%
Max.Outputcurrent: 140µA
Polarity: negative
Licence: EN50050
ExaminationNo: BVS97.D.2048
Technical specifications of the manual and automatic guns
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The Manual Guns Type MG801 and MG801S
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Introduction
The Manual Gun Series MG801 is a very rugged, well balanced, and light unit, designed to
withstand day-to-day powder coating operations. This gun is delivered as standard with all units of
Type 5100, but it may be used on any of the many INSA units.
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!Illustration 2: The Manual Gun MG801
Differences between the MG801 and the MG801S
The MG801 was constructed and is optimized for the use with a Series 5100 Manual Unit.
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The MG801S was built to operate on the Series 5300 'Suitcase' Unit. This Unit is ideal for coating
small batches of different parts, or to do powder tests. The MG801S is delivered with a cup
attachment as standard.
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The Manual Gun Type 850
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Introduction
The INSA Manual Gun MG850 was specially designed to be used with the INSA Series 5800
Smartcoat Drawer Type 5800. With this drawer, it can offer special functionality, as described
below.
The Series 850 Manual gun will operate on any INSA Drawer. The drawer may limit its
functionality though, and not allow the use of all the push button functions at the gun.
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!Illustration 3The MG850 Gun, companion of the Smarcoat Series
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Settings at the gun
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!!Illustration 4Settings at the gun
High voltage adjustment
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The gun has a switch (Position 1 in Illustration 4) which allows the adaptation of the voltage to
difficult coating situations (Faraday corners).
When the button is pushed, it will be locked in place. This will result in a reduction of the voltage,
and yield more uniform results and easier coating of corners and hard to coat areas.
When the button is pushed again, the voltage will return to the level it was before.
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Adjustment of the powder output
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The operator can adjust the level of powder output directly at the gun by pushing the buttons
labeled '-' or '+' (Positions 2 and 3 in Illustration 4). When the button is pressed, the output will
change in the indicated direction. As soon as the button is released the change stops.
Please note that the adjustment as described above requires a drawer of the Smartcoat type (Series
5800)
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Color Variant
Green Standardvariant,negativepolarity
Red Positivepolarity
Grey Negativepolarity,9Vinputvoltage
The Automatic Gun AG800
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Generalities
The automatic gun AG800 is available in different variants, which are different in their polatity, and
input voltage. Those differences have been color coded:
The muzzles and other accessories are compatible with the automatic gun, so please consult the
respective sections to find a muzzle suitable for your application.
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!Distances in the powder booth
To reach near optimal coating performance, the minimal distance from the front part of the
automatic gun AG800 to the grounded part should be at least 100mm. Using distances lower than
this may lead to a charging of the cascade, which may cause damage to it.
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GunModel Series5300Suitcase Series5100Manual Series5800Smartcoat
MG801S O O N
MG801 O O N
MG850 X X O
GunModel Series5500Standard
Automatic
Series5800Advanced
Automatic'MerlinSystem'
AG800 O O
Gun Compatibility Chart
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Manual Guns
O = Fully Compatible
N = Gun is usable and works fine, but does not use the full potential of the drawer
X = Gun is usable and works fine, but the drawer can not support all the functionality of the gun
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Automatic Gun
O = Fully Compatible
N = Gun is usable and works fine, but does not use the full potential of the drawer
X = Gun is usable and works fine, but the drawer can not support all the functionality of the gun
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Voltage TypicalApplication
100kV Largeflatparts,filmthickness60micron
80kV Generalapplication
60kV Profilecoating
50kV Applicationofmetallicpowder
Recommended voltage settings for typical applications
The adjustment of the voltage can be done at the control drawer type 5100 or 5800, or the panel of
the 5300 Series 'Suitcase' Unit.
The powder application is variable, and depends on several external factors:
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Type of powder used
Desired thickness of the powder film
Range of different parts to be coated
The table below is provided as a starting point.
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We recommend the following settings for a typical application:
Please note that the MG801S type gun delivered with the Series 5300 Suitcase unit is limited to an
output voltage of about 80kV.
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Using Muzzles
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The use of different muzzles
As described below, muzzles can be used to adapt the powder cloud to different situations. There
are two different types of muzzles available, as shown in Illustration 5. Position 1 on the left hand
side depicts a deflector muzzle, Position 2 on the right shows a flat spray muzzle. Both types exist
in variations, to achieve gradual differences in the desired effect.
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!Illustration 5Different types of muzzles available
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Function of adeflector muzzle
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!!Illustration 6Function of adeflector muzzle
Position 1 in Illustration 6 shows the powder flow. The deflector cleaning air prevents a powder
buildup at the deflector (Pos. 2)
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Illustration 7Function of aflat spray muzzle
Function of aflat spray muzzle
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As can be seen in Illustration 7, the powder exits through the slot of the muzzle and creates a flat
cloud (Pos. 1). The speed at the exit can be adjusted through the pressure of the cleaning air (Pos.
2). There are different variants of this muzzle which will create different shapes of clouds.
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Options available with INSA Guns
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Various options are available with INSA guns:
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Triboelectric Versions instead of electrostatic versions
Muzzle extensions
Low Ion Adaptor
Cup Gun Attachment
Triboelectric Versions
INSA guns are available for both triboelectric charging as well as electrostatic charging.
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All INSA Units can be used with triboelectric versions and electrostatic versions.
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Muzzle Prolongations
The distance between the gun and the parts to be coated may be too far, or there are other special
cases requiring a longer length of the muzzle. Please contact your local representative, or INSA in
Switzerland if you need more information and pricing.
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Low Ion Adaptor
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All INSA guns can be equipped with a low ion adaptor. Illustration 8 shows an MG801 with such
an adaptor. The adaptor reduces the number of free ions. Its use will result in the following:
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More uniform coating, esp. less variation in the depth of the powder covering
Less 'orange peel'
Better penetration in faraday corners
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!!Illustration 8An MG801 with alow ion adaptor
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