MGC 1 Multi Gun Control

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1 E Operating instructions and Spare Parts List Multi Gun Control GUNS kv µa GEMA VOLSTATIC 0 An ITW Company 3

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3 Table of contents Multi Gun Control Fields of application Description of control module Technical data for the Multi Gun Control Installation of the Preparatory steps for initial start-up a) Connecting the PG 2-A / PG -A powder guns b) Functional check c) Shut-down Repairing electrical parts a) Replacing the bulb in the main switch b) Replacing the fuse - F c) Replacing a potentiometer d) Replacing the electronics board (PCB) Trouble shooting guide Control module - Spare Parts

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5 Multi Gun Control Fields of application The electrostatic powder gun control is designed to control up to eight (8) PG 2-A or PG -A powder guns simultaneously. Description of control module The corona voltage can be optionally regulated on the front panel with the regulating knob (3). This knob serves two functions, when it is in the depressed mode (pushed in) the kv setting/ reading (2a - output voltage) of the guns can be made using the LED (Light Emitting Diode) high voltage scale (2) to the left of this knob. When the knob is pulled out the µa (2b - output current) setting/reading can also be made on the LED high voltage meter (2). When the knob is turned fully counter clockwise to the stop no voltage/current is measured at the guns. The gun voltage/corona discharge is identical on all guns. Beside the LED meter display for the gun voltage, and corona discharge, on the front panel are also 8 LEDs () for the operation of each gun. The green main ON/OFF switch (4) is located on the right-hand side. When the control module is switched off the switch centre grip is pointing to the zero (upwards). The powder gun control can be easily adapted to suit all available voltages. The power loss inside of control module is cooled by a heat sink with blower. The conveying air, and supplementary air to the injectors, and rinsing air to the gun is controlled (regulated) on the ADC Air Distribution Control. (See Op. Manual ADC ) GUNS kv µa GEMA VOLSTATIC 0 2 2a 2b 3 4 Front panel. Operation gun display 2. High voltage/corona current meter. 2a. Guns ON and kv setting/ reading. 2b. Guns ON and µa setting/ reading. 3. HV/corona current control knob. 4. Power switch. Figure

6 Technical data for the Multi Gun Control Electrical data Single-phase AC Selectable voltage : 0 V or 220 V Voltage selection is made on the inside of the electrical unit by reconnecting the wires on the transformer. The value of the fuse for 0 V is 6,30 AT and for 220 V is 3,5 AT. The equipment is delivered for operation at 220 V from the factory. Tolerance: +0% / -5%, Frequency : 50/60 Hz Connected load : 240 VA Rated output voltage (to each gun) : 0 V Rated output current (to each gun) :,2 VA Type of protection : IP 54 Temperature range : +0 o C to +40 o C (+50 o F to +04 o F) Dimensions Width : Depth : Height : 435 mm 300 mm 96 mm 2

7 Installation of the The Multi Gun Control is preassembled in the factory to a point where only certain cables must be connected at the rear of the control module. - Connect the solenoid valve cable from the ADC Air Distribution Control to the connection 2 - Connect the 6-pin-cable from the distribution box to the connection 4 - (Optionally) Connect the external signal cable to the connection 3 - Connect the mains cable to the connection Rear panel. Mains connection 5. Fuse F 2. ADC solenoid valve connection 6. Heat sink 3. External signal input 7. Blower 4. 6-pin-plug Figure 2 3

8 bar Preparatory steps for initial start-up a) Connecting the PG 2-A / PG -A powder guns. Connect the cables (7) with the 7-pin connector to the distribution box (8). 2. Connect the hoses for conveying air to the booster conveying air (3) and to the guns. 3. Connect the hoses for supplementary air to the booster supplementary air (4) and to the guns. 4. Connect the hoses for rinsing air to the booster rinsing air (5) and to the guns. 5. Connect the powder hoses to the guns and to the injectors (6) bar bar GUNS GEMA 0 00 VOLSTATIC kv µa Multi Gun Control 5 Booster rinsing air 2 ADC Air Distribution Control 6 PI injectors 3 Booster conveying air 7 Gun cable 4 Booster supplementary air 8 Distribution box Figure 3 4

9 b) Functional check See trouble shooting guide on page 8 for malfunctions.. Switch on the main switch (4) of the control module. The is under power when the lamp inside the green main switch illuminates. The PG 2-A / PG -A guns begin to spray. 2. Depress the high-voltage control knob (3) on the control module, if not already in this position, and turn to the left-hand stop. 3. The lowest left-hand LED (2a) on the high voltage/corona current meter (2) should illuminate. The equipment is active. 4. Set the high-voltage (or corona current) by turning the control knob (3) until the desired value is achieved. GUNS kv µa GEMA VOLSTATIC 0 2 2a 2b 3 4 Figure 4 When all the above checks have been successfully completed, the gun is ready for use. If it fails to function correctly, consult the trouble shooting guide on page 8. c) Shut-down - Switch off the control module. The adjustment for high-voltage must not be changed. 5

10 Repairing electrical parts The following repairs may be carried out by the user. a) Replacing the bulb in the main switch. Turn the main switch off and disconnect the mains cable of the control module. 2. Unscrew the black retaining ring () of the main switch on the front of the control module and remove the green switch grip. 3. Push the special extractor (supplied) against the defect bulb and turn counter-clockwise to the stop. The bulb can now be removed easily. 4. Replace the new bulb so that the pins on the bulb fit into the slots of the bulb holder. Push the bulb carefully down as far as it will go and turn clockwise. 5. Check that the bulb is seated correctly. 6. Replace the green switch grip and screw on the retaining ring. Make sure that the white stripe is pointing upwards. 7. Reconnect the Mains cable of the control module. b) Replacing the fuse - F. Unscrew the cap of the fuse holder with a wide bladed screwdriver or a small coin. 2. Remove the defective fuse from the control module and replace with a new fuse for the correct line voltage (F= 3.5 AT for V / 6.30 AT for 00-20V). 3. Replace the cap of the fuse holder. c) Replacing a potentiometer. Remove all electrical connections on the rear of the control module. (2.) Unscrew the retaining screw at the lower rear of the control module 3. Slide out the module from the housing and place on a clean, flat surface. ATTENTION Do not pull out by the control knobs. Push the module out from behind. 4. Unscrew the screws of the cover plate and carefully remove the cover. 5. Unscrew the grub screw of the potentiometer knob with an Allen key and pull the knob off the spindle. 6. Remove the locking nut (with a correct sized spanner) and washer, pull the potentiometer out (to the inside of the housing). 7. Replace the new potentiometer and carefully reassemble the unit in the reverse order to which it was dismantled. Do not cross the locking nut threads. ATTENTION The contacts are not numbered, therefore, the potentiometer should only be replaced by a specialist! When replacing the cover care should be taken that the gasket is not displaced. 6

11 d) Replacing the electronics board (PCB). Remove all electrical connections on the rear of the control module. (2.) Unscrew the retaining screw at the lower rear of the control module 3. Slide out the module from the housing and place on a clean flat surface. ATTENTION Do not pull out by the control knobs. Push the module out from behind. 4. Unscrew the quick-release screws and carefully remove the cover. 5. Loosen the two nuts (2) and remove the screws completely from the board. 6. Lift the board out carefully, making sure that the LED scale is not damaged in the process. 7. Carefully remove plugs A and B (Never pull on the cables). The plugs should not be connected to the wrong socket on assembly. Reassemble in the reverse order. When replacing the cover care should be taken that the gasket is not displaced B A Figure 5 7

12 Trouble shooting guide Faults Green lamp does not illuminate although control module has been switched on. Gun does not spray powder although the control module is switched on Gun sprays powder, powder does not adhere to the workpiece Causes Operating error: Module is not switched on No power: Control unit is not connected to Mains Fuse F defective External power line fuse defective In equipment: Lamp defective Electronics board (PCB) defective In the gun: Gun cable defective High voltage section defective - No conveying air - Electronics board (PCB) defective - High voltage too low - Gun connector, gun cable or gun cable connector is defective - High voltage cascade is defective - Electronics board (PCB) defective Remedies Switch on Connect sprayer with power cord to Mains Replace Replace or reset Replace Mail in for repair Replace, eventual mail in for repairs Mail in gun for possible repairs See ADC or Booster Mail in for repair Increase the high voltage on the control module Replace defective item or mail it in for repair Mail in the shaft of the gun for repair Mail in for repair Gun sprays powder, high voltage present, powder does not adhere to the work piece. - Work piece not properly grounded Check the ground connection, also refer to "Safety rules" 8

13 Spare Parts List Ordering Spare Parts When ordering spare parts for your powder coating booth, please indicate the following specifications:. Type, and serial number of your powder coating booth 2. Order number, quantity, and description of each spare part Example:. Type Serial no: Order no: , piece, T-Piece - /8"-ø 8-ø 8 mm When ordering cable or hose material the length required must 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 xx xxx. 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). 9

14 Control module - Spare Parts 2 Main board (complete) Heat sink Printed circuit board CB Switch Adapter fixture Contact unit Lamp unit Bulb 24 V/2W Regulating knob Clamp nut Washer Rubber seal Potentiometer - complete Fixed plug, with gasket (for Mains connection) Socket - 4 pin Socket - 7 pin Fuse holder Fine wire fuse (slow blow) V, 3,5 AT V, 6,30 AT Blower 240 V 2 W Plug grommet Printed circuit board CB Quick-release screw Plug insert Plug housing Protective grating

15 Control module ; ; Figure 6

16 Documentation Edition - July 992 Copyright ITW Gema AG, CH-905 St. Gall All technical products from ITW Gema AG 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 2

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