ITW Gema PG 1-R1 Leitfaden
17PG 1-R1
Issued 05/01
Operating Instructions and Spare Parts List
PG 1-R1 Robot Powder Gun
E
18 PG 1-R1
Issued 05/01
19PG 1-R1
Issued 05/01
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
Issued 05/01
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
2PG 1-R1
Issued 05/01
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
3PG 1-R1
Issued 05/01
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.
4PG 1-R1
Issued 05/01
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
5PG 1-R1
Issued 05/01
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
Inhaltsverzeichnis
