WAGNER PEM-T3 User manual

03/2008 0351709

http://www.wagner-group.com

Operating Manual

Tribo Manual Spray Gun

DANGER

High Voltage!

Turn power off

before servicing!

CAUTION

Read rules for safe

operation and

instructions

carefully! pemt3_0000

0351967 PEM-T3

Introduction

20351709 - PEM-T3 03/2008

Tribo manual spray gun Article No. 0351019

00_Pemt3_Aufbau.doc

pemt3_0001

A Deflector cone

B Nozzle body

C Outer nut

D Spray gun body

E Trigger

F Tribo air connection

G Powder hose connection

H Power supply

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:

•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!

Introduction

03/2008 0351709 - PEM-T3 3

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

Introduction

40351709 - PEM-T3 03/2008

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 instruc-

tions, 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.

Safety regulations

03/2008 0351709 - PEM-T3 5

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 oper-

ate 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 tech-

nicians 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.

Safety regulations

60351709 - PEM-T3 03/2008

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!

1.2 EC Declaration of conformity

0103_Konformitaet.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 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.

The number of the EC Declaration of Conformity is 0351967.

Preparing the spray gun

03/2008 0351709 - PEM-T3 7

2. Preparing the spray gun

2.1 Select the suitable nozzle system

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

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.

to the electrical connection Powder feed

Tribo air

from the powder injector

at the control unit

from the control unit

pemt3_0003

Preparing the spray gun

80351709 - PEM-T3 03/2008

• 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.

0203_ .doc

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

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.

Working with the spray guns

03/2008 0351709 - PEM-T3 9

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

3.5 μA!

The charging current depends on the type of powder used and should ideally lie between

2.5 and 3.5 μA.

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 powder deposits and surges on switching

on again are to a great extent avoided.

0302_.doc

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.

If the spray gun is operated with an EPG 2008 control unit and a PI-P1 powder injector,

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 maximum. 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.

Working with the spray guns

10 0351709 - PEM-T3 03/2008

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.

Pemt3_0005

• 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

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.

• Pull off the deflector cone 1from the charging body 5.

• Unscrew the outer nut 2from the gun housing 3.

• Carefully draw the nozzle body 4out of the gun housing 3.

• Carefully extract the charging body 5.

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 5and the nozzle body 4in the gun housing 3and tighten

it up with the outer nut 2.

• Slide the deflector cone 1onto the charging body 5again.

The spray gun is again ready for operation.

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