E Automatic Powder System An ITW Company 17
Table of Contents Automatic Powder System 1. Fields of application........................................... 1 2. Scope of delivery............................................. 1 3. Designation................................................. 2 General information.................................................... 3 Mains supply.................................................. 3 Compressed air................................................ 3 Setting up the Automatic Powder System............................. 4 Possibilities................................................... 4 Assembly instructions........................................... 5 Spare Parts List Ordering Spare Parts............................................ 7 - Switch cabinet.......................................... 8 - Input plate (complete)................................... 10 - Frequence converter.................................... 11 - Cabinet rear wall - complete............................... 12 - Mounting plate......................................... 13 15
Automatic Powder System 1. Fields of application The automatic powder system with PG 1-A automatic powder guns is especially designed to meet the demands of production line applications in both manufacturing, and custom electrostatic coating installations, where reliability in automated working, comfortable operation, and safety are the outstanding advantages to the user. The flexible, modular structure of the is readily adaptable to any changes in your installation. Interlocking PMC PGC 1 PGC 1 PGC 1 PGC 1 PGC 1 PGC 1 PGC 1 PGC 1 HRC FPC PRC ADU 2 Power supply Reciprocator PG 1-A Control modules Powder hopper Reciprocator Guns with level sensor 2. Scope of delivery The scope of delivery depends on the number and composition of the modules (see above). It is extremely important to follow the "assembly instructions" in this manual, and the operating instructions supplied with every control unit, when setting up and operating the System. 1
3. Designation: Automatic Powder System -. Number of guns Atomizer PG 1-A PG 1-AE Enamel PG 1-AT Tribo Controls PMC 1 Powder Master Control (for fluidized powder hoppers) PMC 2 Powder Master Control (for powder hoppers with stirrer) PGC 1 Powder Gun Control PRC 1, 2 or 3 Powder Reciprocator Control ADU 2 Pneumatic / Fluidizing Unit HRC 1 Hose Rinsing Control (Individual rinsing) HRC 2 Hose Rinsing Control (Group rinsing) HRC 3 Hose Rinsing Control (Simultaneous rinsing of all hoses) FPC 1 Fresh Powder Control Injectors PI 3-V PI 3-H PI 4-V EI 1-V EI 1-H Powder Injector - Vertical connections Powder Injector - Horizontal connections Powder Injector - Vertical connections with a rinsing air connection Enamel Injector - Vertical connections Enamel Injector - Horizontal connections 2 Powder hoppers PH 4-1 PH 50-2/4/8 PH 100-12 PH 150-24 PH 200-32 FPS.-V Number of injectors Capacity in litres Number of guns
General information This is general information, for more detailed information see corresponding Operating Instructions Mains supply - The Mains supply is foreseen as 3 x 380V + N + E. - The mains frequency can be 50 or 60 Hz. - Adding the connected load of the individual units together gives the total connected load for the complete system. - All electrical components correspond to the IP 54 type of protection. - When the PRC unit is used, a power supply for reciprocator is also to be fitted in the base cabinet. Compressed air - The equipment only requires a compressed air supply on the main compressed air network (Main air input and compressed air distributor) - An ADU 2 unit is always fitted to monitor the fluidizating air. - The following values for compressed air must be maintained : Input pressure : 7-10 bar Max. water vapour : 1.3 g/m 3 Max. oil vapour : 0.1 ppm 3
Setting up the Automatic Powder System 1900 1 2 3 4 5 6 7 8 9 10 610 11 12 13 Compressed air input Exhaust air (out) Main valve Air distributor 100 Cooling air (in) 600 Front view min. 500 650 Free space for ventilation and access to the control cabinet Side view Possibilities - Up to 13 gun control module units can be fitted. - When the PRC unit are used, up to 2 power supply units can be fitted in the base cabinet. Enough space must be left at the rear of the unit for proper ventilation. - APS cabinets can only be mounted side by side (without a gap) or with one side against a wall. - Openings which are not used should be sealed with a coverplate. When the APS system is extended the coverplate can easily be unscrewed. 4
Assembly instructions - After unpacking and assembling the APS System the control cabinet must be fitted to the floor with the steel bolts supplied. The fixing holes are found in the base at the rear of the cabinet. - Internal connections have already been made at the factory, connections to control units of external plant must, however, be made before starting up. The connection possibilities for individual control units are found in the accompanying operating instructions. - When connecting the pneumatic hoses in the control cabinet their lengths, and radii should be specially taken into account! 5
Notes : 6
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 : Serial no : XXXX XXXX 2. Order no : 234 265 1 piece, Sealing gasket When ordering cable or hose material the length required must also be given. The spare part numbers of this yard/metre ware is always marked with an *. The spare part number of yard/metre ware always begins with 1...... All wear parts are marked with a #. All dimensions of plastic hoses are given as external and internal diameters : e.g. ø 8 / 6 mm = 8 mm outside diameter (o/d) / 6 mm inside diameter (I/d). 7
- Switch Cabinet 1 Drawer holder (left) 342 009 2 Roller guide (left) 342 041 3 Escutcheon plate 341 991 4 Door lock 244 660 5 Square key (for item 4 and 9) 206 008 6 Main switch 241 210 7 Drawer holder (right) 342 017 8 Roller guide (right) 342 050 9 Door lock 239 887 10 Rubber frame grommet 342 262 11 Rear wall door 341 606 12 Rubber cover plate 343 692 13 Bolt 302 198 14 Pressure gauge (0-10 bar) 203 289 15 Pressure regulator/filter unit 240 133 16 Double adapter - 1/2" 343 170 17 Clamp nut - 1/2" 239 844 18 Solenoid valve - 24 VAC 240 125 Valve coil with membrane - 24 VDC 243 990 19 Double adapter - 1/2" 202 436 20 Distributor block - 10x ø 8 mm 343 250 21 Air connection ring - 3/8" 241 970 22 Double adapter - 3/8" 242 020 23 Cap nut - 3/8" 203 157 24 Hose nipple - ø 10 mm 203 165 25 Solaflex hose - ø 16/10 100 498* 26 Hose clamp ring 203 386 27 Air connection adapter - 3/8" 241 997 28 Air connection ring - ø 8 mm 241 989 29 Air connection adapter - 3/8" 242 004 * Indicate length required 8
- Switch Cabinet 9, 5 1, 2 7, 8 10 11 12 16, 17 18 19 20 3 6 4, 5 13 14 15 21 29 28 27 22 23 24 25 26 9
- Input plate (complete) 1 Base board 345 490 2 Stop plate 238 368 3 Thermostat 238 171 4 Fuse element 227 420 5 Fuse - F 1.25 A (Slow) 201 618# 6 Relay 203 955 7 Contact rail - complete 345 571 8 Main switch 241 210 1 8 2 3 4, 5 6 7 # Wear Part 10
- Frequency converter mounting plate 1 Base plate 345 504 2 Frequency converter 248 231 2 1 11
- Cabinet rear wall - complete 1 Cabinet rear wall 342 157 2 Socket housing - 16 pole (Frequency converter version) 230 049 Socket housing - 16 pole (PRP version) 241 385 3 Socket base 202 150 4 Studding - M6x50 mm 301 159 5 Nut 200 417 6 Washer - M6 200 476 7 Shakeproof washer 200 450 8 Grounding cable 301 140 9 Milled nut 200 433 10 Grommet - PG16 204 366 11 Lead-through nut - PG16 204 412 12 Filter ventilator (incl. item 16) 234 257 13 Sealing frame 234 265 14 Fine filter 234 273# 15 Exhaust filter (incl. item 16) 238 112 16 Coarse filter 234 311# 1 15 13 2 3 14 16 4 5 6 7 5 8 7 9 10, 11 14 16 12 13 # Wear Part 12
- Mounting plate (PRP version) A PRP Mounting plate - complete 346 284 1 Mounting plate 346 276 2 PRP - complete 343 196 A 1 2 13
Documentation Copyright 1991 GEMA-VOLSTATIC LTD, CH-9015 St. Gall All technical products from GEMA-VOLSTATIC LTD are constantly being developed based on our continuing research and applications. The data found in this publication may therefore change at any time without prior notification. Printed in Switzerland 14