Table of Contents
Summary of Contents for EIC INSA MG801
- Page 1 I NSA Trading GMBH I nstruction Manual Manual Guns Types MG801, MG801S and MG850 A utomatic Gun AG800 This manual is supplied by INSA Trading GmbH, Switzerland PHONE ...
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Page 2: Table Of Contents
Table of Contents Foreword .............................4 Version Information ...........................4 Safety-regulations concerning Electrostatic Powder Coating ............5 General notes applying to all guns.....................7 I ntroduction............................7 G eneration of high tension........................8 T echnical specifications of the manual and automatic guns...............9 The Manual Guns Type MG801 and MG801S................10 ... - Page 3 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...
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Page 4: Foreword
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. ... -
Page 5: Safety-Regulations Concerning Electrostatic Powder Coating
Safety-regulations concerning Electrostatic Powder Coating 1. The equipment can be dangerous when not used in a ccordance with the requirements of the following standards: E N 50 050 (resp. - Page 6 7. The ground wire must have a solid metallic connection with the booth, the recovery s ystem, 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 ...
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Page 7: General Notes Applying To All Guns
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. -
Page 8: Generation Of High Tension
Generation of high tension I llustration 1 Basic 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. -
Page 9: Technical Specifications Of The Manual And Automatic Guns
Technical specifications of the manual and automatic guns Inputvoltage: 10,5V Frequency: 17kHz OutputVoltage: 110kV-10% Max.Outputcurrent: 140µA Polarity: negative Licence: EN50050 ExaminationNo: BVS97.D.2048... -
Page 10: The Manual Guns Type Mg801 And Mg801S
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. -
Page 11: The Manual Gun Type 850
The Manual Gun Type 850 Introduction The INSA Manual Gun MG850 was specially designed to be used with the INSA Series 5800 Smartcoat 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. -
Page 12: Settings At The Gun
Settings at the gun I llustration 4 Settings at the gun High voltage adjustment The gun has a switch (Position 1 in Illustration 4) which allows the adaptation of the voltage to difficult coating situations (Faraday corners). -
Page 13: The Automatic Gun Ag800
The Automatic Gun AG800 Generalities The automatic gun AG800 is available in different variants, which are different in their polatity, and input voltage. Those differences have been color coded: Color Variant Green Standardvariant,negativepolarity Positivepolarity Grey Negativepolarity,9Vinputvoltage 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. -
Page 14: Gun Compatibility Chart
Gun Compatibility Chart Manual Guns GunModel Series5300Suitcase Series5100Manual Series5800Smartcoat MG801S MG801 MG850 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 ... -
Page 15: Recommended Voltage Settings For Typical Applications
Recommended voltage settings for typical applications The adjustment of the voltage can be done at the control drawer type 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 •... -
Page 16: Using Muzzles
Using Muzzles The use of different muzzles As described below, muzzles can be used to adapt the powder cloud to different situations. 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. -
Page 17: Function Of A Deflector Muzzle
Function of a deflector muzzle I llustration 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) -
Page 18: Function Of A Flat Spray Muzzle
Illustration 7 Function of a flat spray muzzle Function of a flat spray muzzle As can 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). -
Page 19: Options Available With Insa Guns
Options available with INSA Guns Various options are available with INSA guns: Triboelectric Versions instead of electrostatic versions • Muzzle extensions • Low Ion Adaptor • Cup Gun Attachment • Triboelectric Versions INSA guns are available for both triboelectric charging as well as electrostatic charging. ... -
Page 20: Low Ion Adaptor
Low Ion Adaptor All INSA guns can be equipped with a low ion adaptor. Illustration 8 shows 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. -
Page 21: Cup Gun Attachment
Cup Gun Attachment All manual units allow the mounting of a cup gun attachment. Such an attachment is shown in illustration 9 below. The attachment is usually mounted where the powder hose would be and has the following benefits: Allows small quantities of powder to be used •... -
Page 22: Maintenance
Maintenance Generalities A regular maintenance of the system is necessary in order to assure uniform results. It will also prolong the lifetime of the components of your system. P lease take note of the following points before doing ... -
Page 23: Daily Check
Daily Check C lean the outside of the gun. R emove the muzzle assembly including the electrode holder and clean it. P ull out the electrode holder and clean it carefully ... -
Page 24: Weekly Check
Weekly check c lean the injector c hange the insert sleeve, if necessary (wear part) c lean the gun with compressed air d isassemble and clean the gun carefully r eplace the deflectors if necessary (wear part) ... -
Page 25: Troubleshooting
Troubleshooting C aution Before opening the casing, switch off the electrical voltage and disconnect the electric cable. Failure Causesoffailure Howtofixthem Novoltagesupply -mainsupplynotconnected -brokencable -inputfusedefect -connectit -replaceit -replaceit Nolightonmainswitch -lampdefect -replaceit Nohightension -ECB100defect -replaceit -cascadedefect -replaceit -gunswitchdefect -replaceit -cablebroken -replaceit... -
Page 26: Parts Listing
Parts listing Muzzles and wearable parts I llustration 11 Overview of the muzzles and other wearable parts Different muzzles and wear parts are available to be used with the different INSA Guns. All spare parts can be used with all INSA Guns. - Page 27 Pos. OrderNo. Description 200.104.01 Muzzle100mm 200.101.01 Electrodeholder110mm 200.106.01 Flatspraynozzle 200.110.01 Deflectordia13mm 200.111.01 Deflectordia18mm 200.112.01 Deflectordia24mm 200.102.01 Airdeflectordia6mm 200.102.02 Airdeflectordia10mm 200.105.01 Unionnut Wear Parts are printed in italic type...
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Page 28: Parts Of The Manual Guns
Parts of the manual guns Please consult Illustration 12 and the table on the following page. I llustration 12 Overview of a disassembled manual gun... - Page 29 Pos. Order.No. Description 200.051.01 Powdertube 201.001.01 HT-Generatorgreennegative 201.001.02 HT-Generatorredpositive 201.001.03 HT-Generatorgrey9Vnegative 200.100.01 Rubber-sealing 200.001.01 Guncablewithplugtodrawer 200.058.01 Guntrigger 200.059.01 Cableclamp 200.060.01 Gunswitch 200.061.01 Powdertubewithhoseconnector 200.062.01 Handlescrew 200.063.01 Plasticcap 200.064.01 Handlescrew 200.065.01 Screwforcoverplate 200.066.01 Coverplate 200.067.01 Upperhandlebodywithpushbutton 200.068.01 Lowerhandlebodywithpushbutton 201.002.01 Coverplateforcascade 200.069.02 Powderdiverter Wear Parts are printed in italic type...
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Page 30: Special Buttons For The Mg850
Special buttons for the MG850 In addition to the parts outlined above, the MG850 also contains special buttons. I llustration 13 Special buttons of the MG850 Pos. OrderNo. Description 200.070.01 Button For Voltage 200.071.01 Button For Powder Output... -
Page 31: Parts Of The Automatic Gun Ag800
Parts of the Automatic Gun AG800 External view I llustration 14 The Automatic Gun AG800 Pos.in Illuastration OrderNo. Description Various Muzzle Please Consult Illustration 11On Page 26 210.000.01 Cascade With Negative Polarity 210.000.02 Cascade With Positive Polarity 210.000.07 Cascade 9V With Negative Polarity 210.012.01... -
Page 32: Internal View
Internal View Illustration 15 Internal view of an automatic gun type AG800 OrderNo Description Pos.in Illustration Various Cascade 20100201 CoverPlate 21000701 Peumatic Connector 20100801 Air Tube 20010001 Rubber Sealing 21000301 Cable With Plug 21000401 Cable Clamp 21000501 Powder Tube 21000601 Hose Connector 21000901 Air Hose... - Page 33 OrderNo Description Pos.in Illustration 21001201 Lower Gun Body 21001301 Fixation Screws 21001401 Plastic Caps...
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