EIC INSA MG801 User manual

!INSA Trading GMBH

! !Instruction Manual

Manual Guns Types MG801, MG801S and MG850

!Automatic Gun AG800

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

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.

!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.

Version Information

Safety-regulations concerning Electrostatic Powder Coating

1. The equipment can be dangerous when not used in

!!!! accordance with the requirements of the following standards:

!!! !EN 50 050 (resp. VDE 0745 chapter 100)

!!!! !EN 50 053 (resp. VDE 0745 chapter 102)

!!!! !Instructions for electrostatic powder coating ZH 1/444

2. All electrostatically conductive parts within a reach of 5 m from the

!!spray area must be grounded.

3. The floor of the room containing the spray area must be

!!!! electrostatically conductive.

4. The personnel must to wear shoes with conductive soles.

5. The personnel that will handle the gun must use it with either bare hands or with

!!!electrostatically conductive gloves.

6. The ground wire (green/yellow) has to be connected to the ground

!!!! screw on the back of the electrostatic control module.

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.

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.

9. Only after the recovery system has been put into operation may the powder coating unit

!!be switched on.

10.

11.

12.

Electric wires as well as powder hoses have to be examined at least once a week.

The grounding of all the electrostatically conductive parts and

equipment within the reach of 5m from the spray area must be examined at least

once a week.

The control panel must be switched off when cleaning the gun or when changing

nozzles or extensions.

General notes applying to all guns

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.

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.

!Important

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.

Generation of high tension

!!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.

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

The Manual Guns Type MG801 and MG801S

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.

!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.

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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