EIC INSA AG800 Instruction Manual Download Page 1 | Manualshive

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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

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Summary of Contents for INSA AG800

Page 1: ...A 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 ...

Page 2: ...r 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 Gu...

Page 3: ...ction 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 ...

Page 4: ...f 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 4 ...

Page 5: ... 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 yello...

Page 6: ...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 ...

Page 7: ...nual 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 co...

Page 8: ...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...

Page 9: ...putvoltage 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 9 ...

Page 10: ...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...

Page 11: ...tcoat Drawer Type 5800 With this drawer it can offer special functionality as described below The Series 850 Manual gun will operate on any INSA Drawer The drawer may limit its functionality though and not allow the use of all the push button functions at the gun Illustration 3 The MG850 Gun companion of the Smarcoat Series 11 ...

Page 12: ...ults and easier coating of corners and hard to coat areas When the button is pushed again the voltage will return to the level it was before Adjustment of the powder output The operator can adjust the level of powder output directly at the gun by pushing the buttons labeled or Positions 2 and 3 in Illustration 4 When the button is pressed the output will change in the indicated direction As soon a...

Page 13: ...ences have been color coded The muzzles and other accessories are compatible with the automatic gun so please consult the respective sections to find a muzzle suitable for your application Distances in the powder booth To reach near optimal coating performance the minimal distance from the front part of the automatic gun AG800 to the grounded part should be at least 100mm Using distances lower tha...

Page 14: ...Manual Guns O Fully Compatible N Gun is usable and works fine but does not use the full potential of the drawer X Gun is usable and works fine but the drawer can not support all the functionality of the gun Automatic Gun O Fully Compatible N Gun is usable and works fine but does not use the full potential of the drawer X Gun is usable and works fine but the drawer can not support all the functiona...

Page 15: ... 5100 or 5800 or the panel of the 5300 Series Suitcase Unit The powder application is variable and depends on several external factors Type of powder used Desired thickness of the powder film Range of different parts to be coated The table below is provided as a starting point We recommend the following settings for a typical application Please note that the MG801S type gun delivered with the Seri...

Page 16: ...ons There are two different types of muzzles available as shown in Illustration 5 Position 1 on the left hand side depicts a deflector muzzle Position 2 on the right shows a flat spray muzzle Both types exist in variations to achieve gradual differences in the desired effect Illustration 5 Different types of muzzles available 16 ...

Page 17: ...nction of a deflector muzzle Illustration 6 Function of a deflector muzzle Position 1 in Illustration 6 shows the powder flow The deflector cleaning air prevents a powder buildup at the deflector Pos 2 17 ...

Page 18: ...an be seen in Illustration 7 the powder exits through the slot of the muzzle and creates a flat cloud Pos 1 The speed at the exit can be adjusted through the pressure of the cleaning air Pos 2 There are different variants of this muzzle which will create different shapes of clouds 18 ...

Page 19: ...ailable for both triboelectric charging as well as electrostatic charging All INSA Units can be used with triboelectric versions and electrostatic versions Muzzle Prolongations The distance between the gun and the parts to be coated may be too far or there are other special cases requiring a longer length of the muzzle Please contact your local representative or INSA in Switzerland if you need mor...

Page 20: ...an MG801 with such an adaptor The adaptor reduces the number of free ions Its use will result in the following More uniform coating esp less variation in the depth of the powder covering Less orange peel Better penetration in faraday corners Illustration 8 An MG801 with a low ion adaptor 20 ...

Page 21: ...the powder hose would be and has the following benefits Allows small quantities of powder to be used Container holds about 1 5 Litres Built in fluidization of the powder and powder injector Illustration 9 Cup gun Attachment for INSA manual units When the main application is coating small batches of parts a cup gun attachment may be more economical than a powder hopper 21 ...

Page 22: ...ur system Please take note of the following points before doing any maintenance work Before disassembling the gun the control drawer must be switched off The gun plug must to be disconnected The compressed air used for cleaning the gun must be free of oil and water It will only be necessary to remove the muzzle assembly There are no further user serviceable parts 22 ...

Page 23: ...leaned with compressed air Clean the powder hose Re assemble the gun and connect it with the drawer Please Note Illustration 10 Electrode holder position at gun reassembly When reassembling the electrode holder and the muzzle it has to be ascertained that the groove in the electrode holder pos 2 and the muzzle correspond with the guide pos 1 in the gun The contact hole in the electrode holder must...

Page 24: ...air disassemble and clean the gun carefully replace the deflectors if necessary wear part replace the muzzle if necessary wear part disassemble the injector completely and clean all parts ev Change the insert sleeve wear part Please Note Other than the muzzle the gun contains no other user serviceable parts 24 ...

Page 25: ...laceit Powderpoorlycharged nohightension electrodecoveredwith powder partsnotgrounded faultycascade followabovementioned advice cleanit connectthemtoground replaceit Nopowderflow examinetheinputpressure defectivemagneticvalve ECB110defect Replaceit replaceit Insufficientcoatinginthe corners Powderoutputspeedtoohigh voltagetoohigh reduceairpressure reduceit Troubleshooting Caution Before opening th...

Page 26: ...arts are available to be used with the different INSA Guns All spare parts can be used with all INSA Guns To get uniform reproducible results wear parts should be replaced as soon as a deterioration is apparent Please refer to Illustration 11 and to the table on the following page to determine which parts fit your application best 26 ...

Page 27: ...ectrodeholder110mm 3 200 106 01 Flatspraynozzle 4 200 110 01 Deflectordia13mm 5 200 111 01 Deflectordia18mm 6 200 112 01 Deflectordia24mm 7 200 102 01 Airdeflectordia6mm 8 200 102 02 Airdeflectordia10mm 9 200 105 01 Unionnut Wear Parts are printed in italic type 27 ...

Page 28: ...Parts of the manual guns Please consult Illustration 12 and the table on the following page Illustration 12 Overview of a disassembled manual gun 28 ...

Page 29: ...058 01 Guntrigger 8 200 059 01 Cableclamp 9 200 060 01 Gunswitch 10 200 061 01 Powdertubewithhoseconnector 11 200 062 01 Handlescrew 12 200 063 01 Plasticcap 13 200 064 01 Handlescrew 14 200 065 01 Screwforcoverplate 15 200 066 01 Coverplate 16 200 067 01 Upperhandlebodywithpushbutton 17 200 068 01 Lowerhandlebodywithpushbutton 18 201 002 01 Coverplateforcascade 19 200 069 02 Powderdiverter Wear P...

Page 30: ... 200 070 01 Button For Voltage 21 200 071 01 Button For Powder Output Special buttons for the MG850 In addition to the parts outlined above the MG850 also contains special buttons Illustration 13 Special buttons of the MG850 30 ...

Page 31: ... Page 26 2 210 000 01 Cascade With Negative Polarity 210 000 02 Cascade With Positive Polarity 210 000 07 Cascade 9V With Negative Polarity 3 210 012 01 Lower Gun Body 4 Air Connector 5 High Voltage Supply Parts of the Automatic Gun AG800 External view Illustration 14 The Automatic Gun AG800 31 ...

Page 32: ...nector 4 20100801 Air Tube 5 20010001 Rubber Sealing 6 21000301 Cable With Plug 7 21000401 Cable Clamp 8 21000501 Powder Tube 9 21000601 Hose Connector 10 21000901 Air Hose 11 21001001 Connection Screws 12 21001101 Upper Gun Body Internal View Illustration 15 Internal view of an automatic gun type AG800 32 ...

Page 33: ...Pos in Illustration 15 OrderNo Description 13 21001201 Lower Gun Body 14 21001301 Fixation Screws 15 21001401 Plastic Caps 33 ...

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