ITW Gema PG 1-R1 Guide

17PG 1-R1
Issued 05/01
Operating Instructions and Spare Parts List
PG 1-R1 Robot Powder Gun
E

18 PG 1-R1
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19PG 1-R1
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Table of Content
PG 1-R1 Robot Powder Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Technical data of the PG 1-R1 Robot Powder Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. High-Voltage generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Powder flow and supplementary air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Flat jet nozzle with vented centre electrode . . . . . . . . . . . . . . . . . . . . . . . . 3
Preparatory steps for initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
a) Connecting the PG 1-R1 Powder gun . . . . . . . . . . . . . . . . . . . . . . . . 4
b) Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
a) Adjusting the powder output and powder cloud . . . . . . . . . . . . . . . . 6
b) Powder coating - Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
c) Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
d) Rinsing the powder hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
a) Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
b) Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PG 1-R1 Powder Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
a) Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
b) Gun dismantling: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
c) Gun assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
e) Cleaning the Spray nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Trouble shooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
PG 1-R1 Robot Powder Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

20 PG 1-R1
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1PG 1-R1
Issued 05/01
PG 1-R1 Robot Powder Gun
The PG 1-R1 Robot Powder Gun with integrated High-voltage generation is especially suited
for operation on a freely programmable Robot (up to 7 axes) for coating complex contours
and difficult to reach workpiece positions. The gun has very good penetration capability, and
a high, constant Transfer efficiency. The gun is easily dismantled, making it maintenance and
repair-friendly.
For fitting the gun on the Robot, the customer must supply the necessary Adapter for the
corresponding Robot type, by means of a pin for the exact positioning of the gun and also a
carrier for the gun cable and hoses.
8
3
4
7
9
6
1
2
16
10
11
12
15
8 Support
9 Flange plate
10 Locking screw
11 Gun cable connection
12 Gun cable
15 Powder hose connection
16 Rinsing air connection
1 Atomizing system
2 Threaded sleeve
3 Shaft
4 HV cascade
5 End plate
6 LED window
7 Plastic bolt
Technical data of the PG 1-R1 Robot Powder Gun
Rated input voltage: 10 V eff.
Frequency: 17 kHz
Rated output voltage: 98 kV
Polarity: negative
Maximum output current: 140 µA
HV indication: LED
Polarity: Negative
Approval: EN 50050
PTB test No. Ex-91.C.9102
Date PTB tested Oct. 1991
Figure 1
5

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Functional description
1. High-Voltage generation
The voltage generation module (Control module) supplies high-frequency low-voltage.
This voltage is conducted by the gun cable (12) and the gun connector (11) in the Support to
the high-voltage cascade (4).
This low voltage is stepped up (c) in the cascade (4). This primary high-voltage is subse-
quently rectified and multiplied in several stages in the cascade (d) until the required high-
voltage is attained.
The high-voltage is then fed from the spray nozzle to the electrode (e). See Figure 3.
When the high-voltage is adjusted on the control module, the intensity of the LED (6) also
changes. The user has the assurance that high-voltage is present and has control over this
function.
Figure 2
2. Powder flow and supplementary air
The supplementary air, serving as rinsing air, is connected to the gun, shown in Figure 4,
when air-cleaned nozzles are used.
The function of the nozzles are described in the applicable sections (see page 3).
4
11
12
cd
6
e

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3. Flat jet nozzle with vented centre electrode
The air-cleaned flat jet nozzle atomizes and charges the powder. The slotted opening forms
the powder cloud in such a way that an oval spray pattern is achieved.
The powder is charged by means of a central electrode. The high-voltage, generated inside
the gun, is conducted via the black contact ring of the nozzle holder to the centre electrode.
High-Voltage + Rinsing air
Rinsing air
e
Figure 3
In order to prevent powder from sintering on the electrode, the latter is cleaned by com-
pressed air during the spraying process. For this purpose rinsing air is fed via the small hole
in the black contact ring in the nozzle holder into the hole in the electrode holder.
Rinsing air control is described in the corresponding Gun Control Operating Instructions.

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Figure 4
Preparatory steps for initial start-up
For operating the PG 1-R1 Robot Powder Gun observe absolutely
the relevant Safety Notice, and the Safety Instructions of the Robot
manufacturer!
a) Connecting the PG 1-R1 Powder Gun
1. Fit the gun on the adapter on the Robot arm .
Make sure that the pin on the adapter sits exactly in the slot in gun flange.
2. Tighten the fixing screw (also take note of the assembly instructions of the Robot
manufacturer).
3. Position the gun cable, powder, and rinsing air hoses on the inside the arm so that
neither kinks nor twists can form.
4. Connect the gun cable to the gun control (See the Gun Control Operating Instructions)
5. Connect the rinsing air hose from the corresponding connection to the gun.
6. Connect the powder hose from the gun to the corresponding Injector.
CAUTION
Powder hose - PI Injector
Rinsing air - Gun Control
Gun cable - Gun Control

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b) Functional check
For malfunctions see Troubleshooting Guide, page 11.
(Please also take note of the Gun Control Operating Instructions)
1. Switch on the Control module.
2. Set the High-voltage with the corresponding Regulating knob on the Control unit
The LED (kV) of the High-voltage display lights up. High-voltage is present in the PG 1-
R1 Robot Powder Gun.
3. Slowly increase the High-Voltage:
The high-voltage reading should slowly increase. At the same time the LED on the back
of the gun lights up. The intensity of the LED increases as the voltage rises.
4. Conveying, Supplementary, and Rinsing air pressure are set accordingly, dependent on
the application, by the higher hierarchy Plant control and displayed on the respective
pressure gauge (Display).
5. The maximum Rated output current can be monitored on the Gun Control (Please take
note of the Gun Control Operating Instructions).
When all these checks have been successfully completed, the gun is ready for use. If it fails
to function correctly, consult the Troubleshooting Guide, page 11.

6PG 1-R1
Issued 05/01
Start-up
a) Adjusting the powder output and powder cloud
The powder output is dependent on the type of powder, the powder hose length, the pow-
der hose diameter, the conveying air pressure, and the Supplementary air.
The operating principle of the injector, and the influence of Supplementary air are explained
in the PI Injector Operating Manual.
1. Switch the control module on
The gun sprays powder
2. Adjust the Conveying air according to the instructions of the control module.
3. Adjust the Supplementary air according to the instructions of the control module.
4. Adjust the powder cloud
5. Adjust the rinsing air pressure, so that the desired shape the powder cloud is not
affected
b) Start-up - Powder coating
First check that all electrically conducting parts within 5 m of the
coating booth are grounded.
1. Switch on the control module
2. Adjust the High-Voltage:
Check by observing the LED (6).
c) Shut-down
1. Switch off the control module
The settings for High-Voltage, rinsing air, and powder output can be left as they are.
2. For interruptions in working, such as lunchbreaks, overnight, etc. it is necessary to
switch off the control module, and also to disconnect the compressed air supply or to
close the input pressure reducing valve.
d) Rinsing the powder hose
Residual powder must be removed from the powder hose before long idle periods as fol-
lows:
1. Unfasten the clamping nut of the injector and pull off the hose connection.
2. Blow out the hose manually with the compressed air gun.
3. Insert the hose connection into the clamping nut again and tighten the nut.
CAUTION

7PG 1-R1
Issued 05/01
Maintenance schedule
Conscientious maintenance at regular intervals increases the service life of the PG 1-R1
powder gun and will result in uniform coating quality over a longer period!
a) Daily maintenance
1a Clean gun, see below
b) Weekly maintenance
1b Clean powder hopper, injector, and gun. Do not refill the powder hopper until coating is
to be resumed!
2b Check ground connections between control module, coating booth, suspension device
of workpieces or the conveyor chain.
Cleaning and repairs
PG 1-R1 Powder Gun
a) Cleaning
Frequent cleaning of the gun is recommended to assure good coating quality.
Before cleaning the gun, switch off the control module and detach
the gun connector.
The compressed air used for cleaning should be free of oil and
water.
Daily:
1. Clean the outside of the gun.
Weekly:
2. Detach the powder hose at the connector.
3. Detach the nozzle from the gun and clean it.
4. Blow out the gun through the powder inlet in the direction of flow.
5. Clean the gun tube (19) with the spiral brush supplied.
6. Blow out the gun with compressed air again.
7. Reassemble and reconnect the gun.
8. Blow the Powder hose through and clean.
IMPORTANT

8PG 1-R1
Issued 05/01
b) Gun dismantling:
The gun should only be dismantled if this is necessary due to a
defect or contamination.
Disassemble the gun only to the point where access to the corre-
sponding part is achieved.
Before cleaning the gun, switch off the control module and detach.
The cascade must not be removed because it has been installed
according to a special process. If the cascade is defect, send the
entire shaft (3) to an authorized ITW Gema service centre.
Figure 5
8.1
75 3
20
16
9
20
15
25
26
12
23
23
22
22
22
10
8
21
1
2
28
19
IMPORTANT

9PG 1-R1
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b) Gun dismantling (cont.)
1. Detach the powder hose from the corresponding connection (15)
2. Detach the rinsing air hose from the corresponding connection (16)
3. Remove the nozzle.
4. Unscrew the locking screw (10) so that it stands out approximately 3 mm from the
flange plate. Do not unscrew completely as the screw can easily get lost.
5. Give the cable connector (12) a 1/4 turn clockwise (align the marks) and pull out in a
straight line.
6. Unscrew the plastic bolt (7) and remove the end plate (5).
7. Remove the Support (8) with the Flange plate (9) and the Powder tube (19) from the
Shaft (3).
8. Check the O-Ring (21) and if damaged, replace.
9. Remove the Powder tube (19) from the Support (8).
The connections for the powder hose (15) and the rinsing air (16) should not be unscrewed if
they are not defect.
c) Gun assembly
- The gun is reassembled by performing the previously described dismantling steps in
the reverse order.
- Careful handling is recommended.
- If the gun cable connector cannot be inserted properly without applying force, disas-
semble the gun again and reassemble it.
- The Powder hose connection (15) should always be screwed in up to the stop.
If the Support does not fit into the Shaft again without force, because the Powder tube
(19) is touching the Shaft, then the Powder hose connection (15) must be turned back
one turn and the Powder tube pressed further onto the Powder hose connection.
After the gun has been reassembled, check that:
- the gun cable connector (12) is properly seated: it should be possible to turn the locking
screw (10) all the way into the countersink.
- there are no gaps between the joints.

10 PG 1-R1
Issued 05/01
e) Cleaning the Spray nozzles
Please handle the Nozzle electrode with care when cleaning or at
maintenance – Danger of injury!
Never bend or pull on the electrode!
Daily or after each shift:
- Clean the outside of the spray nozzles with compressed air.
Solvents or other liquids can be used.
Clean only with a damped cloth, never submerse the parts in solvent!
- Check the seating of the spray nozzle.
Make sure that the threaded sleeve is always tightened correctly.
If the flat jet nozzle is loosely fitted, high-voltage from the gun can
“flash over” and damage the gun!
Weekly:
- Remove the spray nozzles and clean the inside with compressed air
Sintered powder accumulations should also be removed.
Monthly:
- Check the spray nozzles for wear.
Replace the flat jet nozzle if:
- the spray pattern is no longer a perfect oval.
- deep grooves are present in the nozzle slot, or if the wall thickness has decreased.
- the wedge at the rear of the electrode holder is worn.
NOTICE
CAUTION

11PG 1-R1
Issued 05/01
Troubleshooting Guide
(Bold numbers in the text refer to Figure 5.)
Causes
In the gun:
– Gun cable defective
– High-voltage part defective
– O-ring (21) defect or miss-
ing
- Injector,checkvalveorthrot-
tlingatinjector,powderhose
or gun clogged
- Insert sleeve in injector is
worn
No conveying air:
- Reducing valve defective
- Solenoid valve defective
- Electronics board (PCB)
defective
- High-Voltage too low
- Gun connector, gun cable
or gun cable connector is
defect
- High-Voltage cascade is
defect
- Electronics board (PCB)
defect
- Workpiece not properly
grounded
Faults
High-voltage display does not
show any value even though
theControlmoduleis switched
on.
During the spraying process
air escapes from the gun shaft
Gun does not spray powder
although the Control module
is switched on
Gun sprays powder, LED at
the rear of the cascade is
not lit, powder does not ad-
here to the workpiece
Gun sprays powder, High-
Voltage present, powder
does not adhere to the
workpiece
Remedies
Replace or mail in for repair
Mail in the gun for possible
repair
Replace or insert
Clean corresponding part
Replace
Replace
Replace
Mail in for repair
IncreasetheHigh-voltageon
the control module
Replace defect item or mail
it in for repair
Mail in the shaft of the
gun for repair
Mail in for repair
Check the ground connec-
tion, also refer to "Safety
regulations"

12 PG 1-R1
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NOTES:

13PG 1-R1
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Spare Parts List
Ordering Spare Parts
When ordering spare parts for powder coating equipment, please indicate the following
specifications:
1. Type, and serial number of your powder coating equipment
2. Order number, quantity, and description of each spare part
Example:
1. Type PG 1-R1, Serial no: xxxx xxxx
2. Order no: 232 670, 5 pieces, O-ring - ø 13.1 x 1.6 mm
When ordering cable or hose material the lengths required must also be given.
The spare part numbers of yard/metre ware always begins with 1.. ... and are always marked
with an * in the spare parts list.
Wear parts are always marked with a #.
All dimensions of plastic powder hoses are quoted as external (o/d), and internal (i/d) diam-
eters :
e.g. ø 8 / 6 mm = 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d).
For optimum coating quality, the necessary operating safety, the
requested Fire and Explosion protection and for maintaining your
claim to Guarantee, the exclusive use of original ITW Gema Spare
Parts is a must.
NOTICE

14 PG 1-R1
Issued 05/01
PG 1-R1 Robot Powder Gun
Notes:
1. Only those parts have been included in the spare parts list which can be replaced by
the user without difficulty.
2. If a part of the shaft (3) is broken or the High-Voltage cascade in the shaft is defect,
then the complete shaft must be returned to an ITW Gema service centre to be in-
spected and/or repaired. The High-Voltage cascade is fitted according to a special
process and therefore should not be dismantled by the user.
3. If the gun cable (12) is defect, the complete gun cable assembly should be returned for
repair.
Figure 6
8.1
75 3
20
16
9
20
15
25
26
12
23
23
22
22
22
10
8
21
1
2
28
19

15PG 1-R1
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*Please indicate length required
#Wear parts
PG 1-R1 Robot Powder Gun
PG 1-R1 Robot Powder Gun (without Items 1, 2, 12, 25-28) 650 129
1 FSD 21 Flat Jet Nozzle 358 215#
2 Threaded sleeve 328 774
3 Shaft assembly, complete with shaft, cascade,
O-Rings - Items 20 and 21
Negative polarity 338 249
Positive polarity 338 257
5 Cover 650 080
7 Plastic bolt - M 8 x 35 mm 328 847
8 Support 650 064
8.1 Air tube 650 072
9 Flange plate 650 110
9.1 Cylinder scew - M 5 x 30 mm (for Item 9) 216 372
10 Grub screw - M 4 x 30 mm 600 342
12 Gun cable, complete - 20 m 651 400
12.1 Cable only (for Item 12) 102 911*
15 Powder hose connector - Aluminium (with O-ring - Item 20) 653 136
16 Rinsing air connector 328 820
19 Powder tube 653 101#
20 O-Ring - ø 13.1 x 1.6 mm 600 326#
21 O-Ring - ø 6.1 x 1.6 mm 600 334#
22 O-Ring - ø 7.65 x 1.78 mm 232 564#
23 O-Ring - ø 10.82 x 1.78 mm 232 556#
25 Powder hose - No. 40 601 888#*
26 Rinsing air hose - ø 6 / 4 mm 600 709*
28 Special fitting tool (for Item 19) 362 026
Spiral brush (for Item 19) 333 514

16 PG 1-R1
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Documentation PG 1-R1
©Copyright 1995 ITW Gema AG.
All rights reserved.
This publication is protected by copyright. Unauthorized copying is prohibited by law. No part
of this publication may be reproduced, photocopied, translated, stored on a retrieval system
or transmitted in any form or by any means for any purpose, neither as a whole nor partially,
without the express written consent of ITW Gema AG.
OptiTronic, OptiGun, EasyTronic, EasySelect, EasyFlow and SuperCorona are registered
trademarks of ITW Gema AG.
OptiMatic, OptiMove, OptiMaster, OptiPlus, OptiMulti and Gematic are trademarks of ITW
Gema AG.
All other product names are trademarks or registered trademarks of their respective holders.
Reference is made in this manual to different trademarks or registered trademarks. Such
references do not mean that the manufacturers concerned approve of or are bound in any
form by this manual. We have endeavoured to retain the preferred spelling of the trade-
marks, and registered trademarks of the copyright holders.
To the best of our knowledge and belief, the information contained in this publication was
correct and valid on the date of issue. ITW Gema AG makes no representations or warran-
ties with respect to the contents or use of this publication, and reserves the right to revise
this publication and make changes to its content without prior notice.
Printed in Switzerland
ITW Gema AG
Mövenstrasse 17
9015 St. Gall
Switzerland
Phone: [phone]
Fax: [phone]
E-mail: [email protected]