e-mw50 series - spray painting equipment2 high voltage generation built-in high voltage booster...

Instruction Manual

Electrostatic air hand gun E-spraySeries

E-MW50 series

KEMA 0344 EN50050 BVS 06 ATEX E 049

GroupⅡ category 2 gas atmosphere equipment Suitable for use in Zone 1

This instruction manual contains IMPORTANT WARNINGS, CAUTIONS and

instructions for safe operation. Before operation, be sure to read this

instruction manual thoroughly and understand the equipment so that you can use

it safely and effectively for a long time.

Keep this booklet in an appropriate place for immediate reference.

Important information - Safety Precautions This electrostatic air hand spray gun is exclusively used for electrostatic painting (we call it

electrostatic spray gun from now on). Be sure to read and understand this instruction manual. Both the supervisor and operator shall be fully knowledgeable about the requirements stated

within this instruction manual, including important warnings, cautions and proper method of operation.

Wrong operation (mishandling) can cause serious bodily injury, death, fire or explosion.

This electrostatic spray gun is used along with related electrostatic controller (E-SC24L-EX)

series: option) and paint pump (e.g. DPS-90), etc. When using related equipment, also read instruction manuals for those products.


1. About safety Pay special attention to items which are shown by below marks and symbols.

Symbols and marks have the following meanings.

Indication of warnings and cautions

WARNING Indicates a potentially hazardous situation which, if not avoided, will result in serious injury or loss of life.

CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property damage.

Examples of warnings and cautions

Indicates [You must be careful]. We will explain briefly in or near the symbol. (The example on the left is [Be careful about electric shock]).

Indicates [You must not do]. We will explain briefly in or near the symbol. (The example on the left is [Do not touch]).

Indicates [You must do]. We will explain briefly in or near the symbol. (The example on the left is [Be sure to ground it]).

We shall not be responsible for any injury or damage caused by disregard of warnings, cautions or instructions.

Indicates notes which we ask you to observe. They are helpful to fully achieve performance and functions of the equipment. Important

①

Warnings and cautions for safe operation

WARNING

Fire and Explosion

Avoidance of fire and explosion at painting site

Never install it at a site with flammable goods or bring flammable goods like lighters. Paints and organic solvents are flammable, able to cause fire. Never use the following Halogenated Hydrocarbon solvents which can chemically react with spray gun parts (aluminum parts) etc., crack and melt them. Improper solvents: methyl chloride, dichloromethane, 1,2-dichloroethane, carbon

tetrachloride, trichloroethylene, 1.1.1.-trichloroethane (Be sure that all fluids and solvents are compatible with gun parts. We are ready to supply a material list used in the gun on request.)

Avoidance of fire caused by grounding failure

Be sure to keep hanger or conveyor clean without paint stuck on it and keep them conductive. Incomplete grounding, dirty hanger or conveyor cannot conduct electricity, and static electricity accumulates, resulting in fire accident by spark discharge.

Store paint and solvent in a metallic container which is grounded. Poorly grounded conductor can accumulate static electricity, causing fire accident by spark discharge. If you are forced to place conductive goods such as fluid container and fluid supply pump within 3m from the gun, be sure to ground them without fail.

Securely ground electrostatic controller (A class grounding： less than 10Ω). As you ground the electrostatic spray gun by contacting electrostatic controller through low voltage cable, incomplete grounding can accumulate static electricity on spray gun, causing fire accident by spark discharge or bodily injury by electric shock.

A class grounding

(Good!) ×(Bad!)

Be sure to contact metallic points by makingcontact points knife-edged or sharp-pointed.

②

Avoidance of fire by ignition of paints and solvents

Be sure to turn off electric source of electrostatic controller (E-SC24L-EX) series: option) before cleaning inside of fluid passages. As paints and solvents are flammable and have low flash points, they can catch fire if there is spark discharge in and around painting site.

Spray distance between work-piece and painting equipment must be over 10cm. If the distance is less than 10cm, spark discharge can occur and paint can catch fire.

Never use lacquer paints. Lacquer paints have low flash points and can catch fire.

Do not cover electrostatic spray gun with anti-dust sheet. Static electricity accumulated on sheet can discharge and solvent gas can catch fire.

Wrong operation

Avoidance of wrong use

Never point toward human or animal during spraying. If done, it can cause inflammation of eye or skin and bodily injury. Never use gas other than compressed air. If done, it can cause fire or poisoning accident. Never use at higher than max. operating pressure (refer to specifications on page 2). Tip of fluid needle has a sharp point. Do not touch the tip of fluid needle during maintenance for the protection of the human body.

Avoidance of wrong operation

Before inspecting, cleaning, disassembling or assembling electrostatic spray gun, be sure to turn off electric source of electrostatic controller (E-SC24L-EX) series: option), interlocked equipment and equipment and fully release air and fluid pressure in the following procedure. If not, it can cause bodily injury by wrong operation.

Job 1) Turn off electric source of electrostatic controller (E-SC24L-EX) series: option) . Job 2) Stop supply of compressed air, paint and solvent to spray equipment.

Job 3) Turn electrostatic spray gun downwards, pull trigger, operate fluid needle and fully

release air pressure and fluid pressure.

③

Bodily protection

Protection from solvents, air and fluid pressure

Use spray booth and do the painting job in a well-ventilated place. Painting and cleaning jobs in a poorly ventilated site can cause organic solvent poisoning and ignition. Always wear protective tool such as protective goggles and mask. If not, cleaning liquid can touch eyes and skin, causing inflammation. If you feel something wrong with eyes or skin, immediately consult with a doctor. We recommend you to wear earplugs for your safety. Noise level can reach over 85dB(A) depending on operating and working conditions. Be sure to turn off electric source of electrostatic controller or multi-gun control system and release fluid and air pressure before cleaning, disassembling or doing maintenance job or during stoppage of job. If not, remaining pressure can cause bodily injury through wrong operation and spattering of cleaning liquid. Be sure to follow [Avoidance of wrong operation ] on page ③ in order to turn off electric source, and release air and fluid pressure.

Protection from static electricity

Be sure to wear electrostatic shoes（resistance figure 105～10

8Ω、JIS T 8103） and anti-charge

working clothes（JIS T 8118）. If not, static electricity can accumulate on human body and cause bodily accidents by electric shock.

Operators must not wear metallic things such as watch or key holders during operation. If done, static electricity can accumulate on them and you will get an electric shock. If you wear glasses with metallic frame and approach

the gun, you can get an electric shock. Before approaching spray equipment, turn off electric source of electrostatic controller or multi-gun control system.

Operator must always hold electrostatic spray gun with bare hand or glove having a large hole at palm position. As human body is grounded through the handle of electrostatic spray gun, static electricity can accumulate on human body and cause bodily harm by electric shock if operator holds the gun handle with normal glove.

When you turn off main electric source switch in order to stop the gun operation in an emergency, it takes about 5 seconds till the electric potential of electrostatic spray gun goes down to a safe level. Don’t try to touch the pin electrode at tip of gun during that period.

Anti-charge workingclothes

Electrostatic shoes

Protection of human body If operators pull the trigger many times during operation, it may cause repetitive strain injury. Be sure to take a rest if you feel tired.

④

Others

Never use altered parts or other than genuine parts when parts are damaged or worn out. If done, it can cause failure of the gun, accidents or bodily injury.

Be sure to install a fire extinguisher at painting site.

Make sure that the equipment has stopped before you enter the working range of other painting equipment (robot, reciprocator, etc.). If not, moving robot or reciprocator can injure you.

Never use for food or chemicals. If done, erosion in paint passages can cause accidents, and foreign matter can enter.

extinguisher

CAUTION

Maintain safety and functions of electrostatic spray gun

Be sure to observe the following in order to maintain safety and functions of electrostatic gun: 1) Be sure to inspect and do the maintenance in accordance with 5. “Inspection and maintenance”(P.12). 2) Never immerse electrostatic gun body in cleaning thinner when cleaning gun. Clean electrostatic gun in accordance with 4.5 “Job-3 clean electrostatic air hand gun body and low voltage cable”(P.10). 3) Be sure to install and handle low voltage cable in accordance with 4.1 ”precautions on installation and handling of low voltage cable” (P.5). 4) Handle electrostatic gun with care in order not to give it a jolt. Especially take care not to drop, hit or trample on it or move work piece or hanger by tip of gun. If done, it can fail electrostatic spray gun.

⑤

Contents

1. Specifications··············································· P. 2

2. Check the product········································ P. 3

3. Names and functions of each section········ P. 4

4. Connection and setting ······························· P. 5

5. Inspection and maintenance······················· P. 12

6. Disassembling and assembling·················· P. 16

7. Parts list ························································ P. 23

8. Problems and remedies (troubleshooting)············· P. 24

Note:

The operator and the supervisor of this electrostatic gun must fully read and understand Chapters

from 1 to 3 and 4.3 to 4.5.

Only the supervisor and / or other equally qualified personnel, having fully read and understood

the contents of this instruction manual, can take care of matters related to Chapter 4 to 8.

‐1‐

1 Specifications < For Operator and Supervisor >

1.1 Important specifications

Ambient temperature range 5～40

Ambient humidity range Less than 70%RH

Max. operating pressure Air：0.68 MPa, Paint：0.35MPa

85dB(A) : at 1m backward from gun, 1.6m height Noise level (LAeqT) inlet air pressure 0.35MPa (recommended air pressure)、 GroupⅡ, category 2 gas atmosphere equipment Suitable for use in zone1

EX Spec. (CE ATEX regulation)

Ⅱ2G 0.24mJ EN50050

BVS 06 ATEX E 049 KEMA 0344

1.2 Main specifications

Items Specifications Remarks No.

1 External charging system Electrostatic Charging method 2 Built-in high voltage booster Cartridge system High voltage generation 3 Max. operating voltage During no-load -50kV

4 Max. operating current Initial setting 150μA

5 Not including external electrode Dimensions L×W×H 186×64.6×226.9

6 Mass Without low voltage cable and fluid tube 530g

7 Electrostatic controller E-SC24L-EX Applicable electrostatic controller Not included in this model

8 Air nipple / fluid nipple thread size G1/4 (air nipple)G3/8 (fluid nipple) Air hose and paint hose are not included

10 Applicable paint*1) Water based paint

W L

H

1.3 Specification of atomization Model code

mark indicates cable length ⇒ “X” :10m, “Y” : 15m, “Z” : 20m

Atomization No.

option E-MW50-11C5

Air cap model code 1 C5

Fluid nozzle dia. 2 Φ1.1

< How the Electrostatic Air Spray Gun Works > The air hose supplies air to the spray gun. The air atomizes the fluid being sprayed. The Electrostatic controller supplies low

voltages to power booster cartridge in the Electrostatic Air Spray guns. Electricity supplied by the electrostatic controller is converted to high voltage by a cartridge (booster circuit) inside the gun. The

high voltage is supplied to tip of the external electrode. The pump supplies fluid to the hose and gun, where the fluid is electrostatically charged as it passes the external electrode. The charged fluid is attracted to the grounded work piece, wrapping around and evenly coating all surfaces.

‐2‐

2 Check the product < For Operator and Supervisor >

This product consists of an electrostatic gun including the following accessories. Before use, be sure to confirm that there is no shortage or damage. If there is any shortage or damage, please contact the shop which sold it to you.

Name Contents

Electrostatic gun

Low voltage cable

(1) Special screwdriver to tighten needle packing set

(2) Binding tube to bind air hose and low voltage cable

(3) Cleaning brush to clean

electrostatic gun exclusively (to clean surface)

(4) Cleaning brush to clean electrostatic gun exclusively (to clean small holes)

Acce

ssor

ies

(5) Instruction manual (this one)

‐3‐

3 Names and functions of each section < For Operator and Supervisor >

3.1 E-MW100 series

Fluid adj. set Adjusts fluid output.

Atomizing head（air cap, fluid nozzle） Atomizes paint with air.

Fluid nipple Connects to fluid hose (G3/8).

Low voltage connector Supplies electricity from low voltage cable

(AC24Vpp).

Handle Releases charged electricity on human body. Be sure to hold with bare hand.

Air nipple Connects to air hose (G1/4).

Pattern adj. set with lock Adjusts pattern width.

External electrode Charging electrostatic to atomized fluid Quick removable to change 2 kinds of electrode depending on painting

process.

‐4‐

4 Connection and setting < For Supervisor >

4.1 Connection of electrostatic gun Before connecting electrostatic gun, be sure to read and observe the below chart.

WARNING Before connection, be sure to turn off primary side electric source, release primary side air source and turn off all electric source switches. (Refer to P.④ ”avoidance of wrong operation”)

Be sure to check that all products are grounded. If not done, it can cause fire by spark discharge through leakage or charge and bodily injury by electric shock.

(1) Be sure to use designated primary side electric source for electrostatic controller (E-SC24L-EX) series：option). Input of different voltage other than designated one can cause damage to the product or fire (refer to instruction manual of electrostatic controller or multi-gun control system as for details).

(2) Max. air pressure of primary side air source must be less than 0.68MPa. If higher, it can cause damage to the product or accident since the product is not for high pressure.

CAUTION

(1) Be sure to clean air filtered through air dryer, air filter (3～5μm) and oil mist separator (0.03～0.01μm). When using lubricator in air supply piping, take air from separate supply piping or filter through over two-stage oil mist separators. Dirty air for painting can fail painting.

(2) When using for the first time after purchase, spray thinner into the inside of fluid passage and remove anti-rust oil. Remaining anti-rust oil can fail painting such as fish eyes.

(3) Before connecting air hose to electrostatic gun, fully blow air. Dust in piping can fail painting. (4) Before use, filter paint to remove dust or foreign matter from paint. If not, it can cause leak from seated

section and make initial fluid output unstable.

(5) Electrically connect electrostatic controller (E-SC24L-EX) series：option) and other equipment in accordance with this instruction manual and instruction manuals of other related products.

(6) Bind low voltage cable, air hose and fluid hose so that there is no partial tension or bend. Refer to (4.2 “Precautions on installation and handling of low voltage cable” (P.6)

‐5‐

4.2 Precautions on installation and handling of low voltage cable

Be sure to read and observe the below cautions before connection, installing and handling low voltage cable.

CAUTION

(1) Tighten cap nut of low voltage cable and securely connect low voltage cable. If tightening is incomplete, paint and solvent can enter inside of connector causing failure of electrostatic gun and electrostatic controller.

(2) Be sure to observe the following about binding low voltage cable of electrostatic gun in order to maintain its

strength and durability. ① Never bind cable within about 50cm from gun handle of electrostatic gun. ② When pointing electrostatic gun upwards, downwards, left and right, carefully bind low voltage cable with air

hose and fluid hose so that there is no strong bend or tension on low voltage cable. ③ When binding over 50cm from gun handle, bind with attached spiral tube or vinyl tape at over 5cm intervals,

and do not bind too tightly. Especially do not bind continuously with vinyl tape or wide spiral tube. If done, bound section becomes like a hard bar, and it is broken at both ends, then it can cause disconnection or damage of cable and hose.

(3) Do not bind low voltage cable, air hose or fluid hose, or handle electrostatic gun so that there is forced bend or

strong tension during painting.. If done, it can reduce strength and cause disconnection. (4) Pay attention not to trample on low voltage cable. It can disconnect when you trample on it especially on grid floor

of the spray booth. (5) Do not continuously bind low voltage cable itself (especially near electrostatic gun connector) with vinyl tape etc., to

increase strength or avoid dirt. If done, it can conversely reduce strength and cause disconnection. (6) Do not immerse low voltage cable in solvent or paint for a long time. If done, it can greatly reduce strength and

lifetime of low voltage cable. (7) After cleaning low voltage cable, be sure to remove solvent attached to surface, or blow with air. (8) Do not use metallic binding band. Metallic one can accumulate static electricity and cause electric shock.

Low voltage cable

Bind low voltage cable lighterthan air hose and fluid hose sothat there is no strong tensionon low voltage cable wheninclining gun up or down

Over 5cm intervals from 50cm distance

Tension can causebend (can bedisconnected)

Low voltage cable

Do not bind continuously withvinyl tape or with spiral tubelike this.

‐6‐

(1) Standard connecting example of E-M15B series spray gun

Necessary equipment

Electric source AC-240V

Air hose ex.) AHU-8 5m

Electrostatic controller E-SC24L-EX (option)

First class grounding less than

10Ω ground resistance

G3/8

G1/4

G1/4

Air source

Compressor

Air filter

Air to operate paint pump

Air regulator

Paint pump ex.) DPS-90 : (option)

Low voltage cable

(option)

Air regulator

G3/8

Air hose set ex.) AHU-8 10m

Fluid hose set ex.) PHN-6 10m

‐7‐

4.3 Check grounding < For Operator and Supervisor > Job-1 Ground all conductive objects within 3 m from electrostatic hand gun.

WARNING Ground all conductive objects within 3m from electrostatic gun to avoid electrostatic electric accidents (electric shock and fire).

Job-2 Turn on electric source of electrostatic controller (E-SC24L-EX series : option) and check that ground failure does not display. (Regarding turning on electric source and failure display, refer to instruction manual of electrostatic controller).

4.4 Setting spray conditions < For Supervisor >

Important

This gun is only use of vertical pattern. If this spray gun is used with horizontal

pattern use, the external electrode will be dirt with paint and will cause paint

defects.

Use of horizontal pattern Use of vertical pattern

(1) Air pressure

Adjust air regulator

(2) Fluid output / pattern width

Adjust fluid output by fluid pressure adjustment and locked fluid adj. knob and adjust pattern width by

pattern adj. set.

(3) Check spray distance

Set spray distance at about 200～300mm in order to get proper electrostatic effect.

‐8‐

Hints about electrostatic painting

Bad penetration into recessed section Too much bounce back and paint buildup on protruded section

Spray pressure Increase Spray pressure Increase

Spray distance Closer Spray distance Closer Pattern width Smaller Pattern width Smaller Voltage Decrease Voltage Decrease

Spray recessed section first

4.5 Cleaning after painting job is finished < For Operator and Supervisor >

WARNING

(1)After painting job is finished, be sure to fully release air pressure and fluid pressure and turn off electrostatic controller (E-SC24L-EX series : option) (2)Before cleaning fluid passage (spraying thinner), be sure to turn off electrostatic controller (E-SC24L-EX series：option). If not, it can cause ignition and great danger

Job-1 Clean fluid passage (spray thinner) Spray till cleaning thinner becomes transparent.

Job-2 Clean atomizing head

Remove and clean air cap cover and air cap (As for details, refer to 6. “Disassembly and assembly” on page 17

Spraying Spray recessed section first Spraying

OK if it becomes transparent

By hand By hand

Air cap cover

Air cap

‐9‐

Job-3 Clean electrostatic air hand gun and low voltage cable

In order to use electrostatic gun for a long time, wipe off surface of electrostatic gun and low voltage cable with soft cloth soaked with cleaning thinner and cleaning brush (to clean surface). After cleaning is finished, be sure to blow surface of gun and low voltage cable with air and dry up attached thinner.

‐10‐

CAUTION

(1) When the situation forces you to clean electrostatic gun with thinner gun, be sure to observe the following. If not, it can fail electrostatic gun.

a) After cleaning with thinner gun, be sure to blow with air and dry up thinner attached to surface of electrostatic gun and low voltage cable. As thinner can enter air passage of electrostatic gun during cleaning with thinner gun, be sure to spray air through electrostatic gun (dry air) and blow remaining thinner out.

b) Do not spray thinner gun for a long time. Especially do not focus on one spot.

c) Do not spray thinner gun directly to the following spots.

① Connector of low voltage cable

② Nail of trigger

③ Air hole of air cap ④ Inside of air nipple

(2) What you must never do Never immerse electrostatic gun body or low voltage cable in cleaning thinner. If done, thinner can enter air

passage and high voltage generator in gun, failing electrostatic gun and electrostatic controller or disconnecting low voltage cable for a short time due to its deterioration.

①

②

③

④

Low voltage cable

‐11‐

5 Inspection and maintenance < For Supervisor > Only the supervisor and / or other equally qualified personnel, having fully read and understood

the contents of this instruction manual, can take care of matters related to Chapters 5.

Be sure to observe the following inspection standards to achieve functions safely and fully.

WARNING Before inspection and maintenance, be sure to turn off electric source of electrostatic controller (E-SC24L-EX series：option) and fully release air pressure and fluid pressure. (Refer to P.④ ”avoidance of wrong operation”).

CAUTION Never immerse electrostatic gun or low voltage cable in cleaning thinner. Clean them in accordance with 4.5 ”Job-3Clean electrostatic gun and low voltage cable” (P.10, 11). If not, it can affect safety and performance of the products.

5.1 Daily inspection and maintenance 1) Daily inspection items

Where to inspect Part name Contents Purpose Remedies No

External electrode

Tip external Visually check for bend or breakage

Avoid painting failure and low transfer efficiency 1 Replace part electrode

Visually check 2 Fluid nozzle Tip section Avoid painting failure Replace part deformation and damage

Center and horn holes

Visually check 3 Air cap Avoid painting failure Replace part deformation and damage

Avoid painting failure, electrostatic accident by failing to stop charge

Electrostatic gun

Check for air leakage Refer to 8.1”Painting equipment” (P.24) 4 Each section (by leaking sound)

Visually check for fluid leakage from tip of fluid nozzle

Refer to 8.1 ”Painting equipment” (P.24) 5 Fluid nozzle Tip section Avoid painting failure

Visually check if charge lamp lights up and gun is charged

Avoids painting failure and low transfer efficiency

Refer to 8.2 ”Electrical problems” (P.25) Charge lamp

Electrostatic controller 6

Display lamp of electric current figure for painting

Refer to 5.1 2) ”daily inspection” Visually check if current figure

exceeds normal figure. Avoids painting failure and low transfer efficiency Clean fluid passage of

gun (P12).

Avoid output failure, electric shock or fire due to disconnection of low voltage cable

Low voltage cable

Visually check for excessive strain on low voltage cable

Refer to 4.1”Low voltage cable installation” (P.6). 7 The whole cable

2) Daily inspection items

Where to inspect Part name Contents Purpose

Fluid passage

Avoids painting failure and low transfer efficiency due to electric leakage from paint buildup 1 Clean fluid passage of gun with thinner Electrostatic gun

Avoids low transfer efficiency due to electric leakage 2 Electrostatic gun Surface Remove paint attached to surface

3 Low voltage cable Surface Remove paint attached to surface Avoids short cable lifetime

4 Fluid hose/air hose Surface Remove paint attached to surface Avoids short hose lifetime

‐12‐

5.2 Periodical inspection items 1) Weekly periodical inspection（appearance）（*handle : handle、barrel tip body of gun［plastic］）

Part name

Where to inspect

How to inspect Contents Standards Purpose Remedies No

1 Avoids failure of electric parts in gun and electrostatic controller due to paint and thinner inside.

connection between handle

Electro- static gun

Contact the shop which sold it to you and ask for repair.

Check for clearance No clearance Visually check and ※

barrel※

2 connection between electro-static gun and local connector

Tighten low voltage cable nut. Refer to Check for

looseness No looseness

Tighten and check

Avoids failure of electrostatic controller 6.4「Remove and fit low

voltage cable」(P.22). Low voltage cable 3 Replace low voltage

cable. Refer to Avoids failure of output and electric shock or fire due to disconnection of cable

Check for crack or swelling.

outer cover of cable None Visually check 6.4「Remove and fit low

voltage cable」(P.22). 4 Electro-

static controller

Under charged condition, bring tip of gun close to grounded metal.

Contact the shop which sold it to you and ask for repair.

Check if OCR

operates

OCR must operate

Checks function of safeguard. OCR lamp

2) Periodical inspection（inspect electrostatic gun and cable individually） Part

name Where to inspect Cycle Contents Purpose Remedies No

1 Avoids electric shock and fire due to disconnection of cable

Replace low voltage cable Refer to 6.3「Remove and fit low voltage cable」(P.22)

Low voltage cable

500Hr Conductivity and isolation of each section

Check as per 5.4 ”Periodical inspection” 1) (P.14)

2 Maintain performance of gun Contact the shop which sold it to you and ask for repair.

Check as per 5.4”Periodical inspection” 2) (P.15)

Gun body 500Hr Conductivity and isolation of each section

5.3 Periodical parts replacement (when parts are used without damage) Replace-

ment cycle Part name If not done Remarks No

1 Needle packing set 1000Hr Paint leakage

2 Fluid needle set 1000Hr Paint leakage

3 Fluid nozzle 1000Hr Paint leakage (check at 500Hr)

4 Air valve set 2000Hr Air leakage (check at 1000Hr)

5 Low voltage cable 500Hr Charge failure, electric shock, fire (check at 500Hr)

Regarding maintenance inside electrostatic gun which is not described in instruction manual, contact the shop which sold it to you since it can fail safety factor and performance.

‐13‐

5.4 Periodical inspection method 1) Inspect conductivity and isolation of low voltage cable

Connector on controller side

Connector on electrostatic

gun side

Connector case

① Conductivity inspection Where to inspect conductivity

Inspection Connector terminal No. on controller side

Connector terminal No. on electrostatic gun side Normal condition No.

1 1 A

2 2 F

3 3 E

4 4 D

Must be conductive by tester

5 5 C

6 7 Connector case

② Isolation inspection Where to inspect isolation

Inspection Connector terminal No. on controller side

Connector terminal No. on electrostatic gun Normal figure No.

1 1 F, E, D, C

2 2 E, D, C

3 3 D, C

4 4 C

Over 1000MΩ by insulation resistance

tester (500V)*1)

5 7 A, F, E, D, C

*1) 1000V insulation resistance tester is available.

‐14‐

2) Conductivity and isolation of electrostatic gun body

① Measure resistance between electrode at gun tip and connector terminal A on gun side Normal resistance ＝In the range of 240～340MΩ

Measuring condition： Measured by insulation resistance tester (500V*1))


Normal resistance 200～280MΩ

② Measure resistance between electrode at gun tip and handle Normal resistance ＝Over 2000MΩ

*1) Measuring condition: Measured by insulation resistance tester (500V )


Normal resistance over 2000MΩ

‐15‐

6 Disassembling and assembling < For Supervisor > Only the supervisor and / or other equally qualified personnel, having fully read and understood

the contents of this instruction manual, can take care of matters related to Chapters 6.

WARNING

Before disassembling, be sure to turn off electric source of electrostatic controller (E-SC24L-EX series: option), and fully release air pressure and fluid pressure.

CAUTION Precautions when disassembling and assembling electrostatic gun

(1) First fully remove attached dust on each part before assembling. (2) After assembling, be sure to check that there is no leakage of air or fluid. (3) Over-tightening air cap, fluid nozzle and plastic screw at gun tip can damage screw or seated section.

Pay attention not to tighten with more than necessary strength. (4) Be sure to fit or remove fluid nozzle while pulling trigger. If not, it can damage seat of set.

6.1 How to replace fluid needle set and fluid needle packing (1) Remove air cap and fluid nozzle

Job-1 Manually turn air cap cover and remove air cap cover and air cap.

By hand

Cap cover

Air cap

Job-2 Apply monkey wrench to hex. Surface of fluid nozzle while pulling trigger, and loosen screw and

remove.

(2) Remove fluid needle bar

Spanner Keep trigger pulled

Fluid

Job-1 Remove locked fluid adj. knob.

Fluid adj. knob

‐16‐

Job-2 Pull out fluid needle spring and fluid needle bar set.

Fluid needle bar set Fluid needle spring

(3) Replace fluid needle packing set.

Job－1 Fully loosen fluid needle packing set with attached special screwdriver and remove it.

Special driver Fluid needle packing set

Job-2 Point gun downwards, clean inside of barrel, and blow solvent with air.

Cleaning barrel with its headpointing upwards can makedirty thinner enter airpassage, failing air valve andfluid needle.

Job-3 Screw lightly new fluid needle packing set with special screwdriver.

Special driver New fluid needle packing set

(5) Fit fluid needle bar set Job-1 Insert fluid needle bar set from rear section of gun and fit fluid needle spring and fluid adj. knob.

Fluid needle bar set Fluid needle bar

‐17‐

Job-2 Screw lightly fluid needle packing set with special screwdriver and tighten further by about 30°

after screw stops. Special driver

(6) Fit fluid nozzle

Job-1 Pull trigger（Keep on pulling trigger till job-3 is finished）

Job-2 Lightly screw fluid nozzle by hand.

Fluid nozzle

Keep trigger pulled

Job-3 Tighten further about 10°～ 20°after fluid nozzle is stopped by hand tightening.

CAUTION Be sure to observe the above 10°～20°tightening. Further additional tightening can damage plastic screw or seated section.

‐18‐

(7) Fit air cap

Job-1 Fit air cap to air cap cover and lightly screw air cap cover into gun body.

Job-2 Adjust cap direction and tighten cap cover. Further tighten about 20°after it is stopped by hand tightening. (Tighten air cap to the extent that air cap does not turn)

‐19‐

6.2 How to replace air valve seat set and fluid adj. guide (1) Remove air cap cover, air cap, fluid nozzle and fluid needle bar set in accordance with 6.1 (1)～(2).

(2) Remove fluid adj. guide, spacer, air valve spring and air valve.

Job-1 Remove fluid adj. guide.

Fluid adj. guide

Job-2 Remove air valve spring and air valve.

Air valve Air valve spring

(3) Replace air valve seat set

Job-1 Remove air valve seat by hex. bar spanner (wrench flat 10mm).

Air valve seat set Hex. bar spanner

Job-2 Tighten new air valve seat set by hex. bar spanner (wrench flat 10mm).

Hex. bar spanner

(4) Fit air valve, air valve spring, spacer and fluid adj. guide.

Job-1 Fit air valve, air valve spring and spacer into handle in this order.

Air valve spring Air valve Hint

Job becomes easier if youpoint gun downwards.

Job-2 Insert convex at tip of fluid adj. guide into concave of air valve spring and screw fluid adj.

guide. (*Further additional tightening can damage plastic screw.)

Fluid adj. guide Hint

Job becomes easier if youpoint gun downwards.

(5) Fit needle bar set, fluid nozzle and air cap in accordance with 6.1 (5)～(7).

‐20‐

6.3 How to replace fluid tube set <In case of E-M15B series>

(1) Replace fluid tube set

Remove joint nuts (2 places) and then fluid tube set.

(2) Clean fluid joint and fluid nipple

Wipe off paint stuck on fluid joint and fluid nipple by attached cleaning brush.

(3) Fit fluid tube set

Fit joint nut and sleeve to fluid tube set, fit it to gun, tighten joint nut and fix fluid tube set.

6.4 How to replace external electrode set

CAUTION When removing external electrode set, pay attention not to enter dust, paint and solvent into

both part of connection. If it is dirt with dust, paint and solvent, clean and dry by air blowing

completely before assembling

Job-2 Job-1 Turn the external electrode setthe arrow direction

Push the external electrode set

Job-3 Pull the external electrode set

External electrode

‐21‐

6.5 Fit or remove low voltage cable

CAUTION

(1) Do not remove low voltage cable so often except when replacing or inspecting low voltage cable. (2) Turn cap nut of low voltage cable in order to fit or remove low voltage cable (loosen / tighten). Loose

tightening of cap nut can make paint and solvent enter connector, failing electrostatic gun and electrostatic controller.

Cap nut to fix low voltage

‐22‐

7 Parts list < For Supervisor > 7.1 E-MW50 series

No. 部品名個数 No. 部品名個数

Air cap Screw(+) 1 1 21 2

Cap cover Hex. nut 2 1 22 1

Fluid nozzle Gun hook 3 1 23 1

Needle packing set Screw (+) 4 1 24 1

Air valve bar Pattern adjust set 5 1 25 1

Air valve seat set External electrode set 6 1 26 1

Air valve 7 1 27

Air valve spring O ring 8 1 28 1

Fluid adj. guide set O ring 9 1 29 1

Needle bar set Sleeve 10 1 31 2

Needle bar spring Joint nut 11 1 32 2

Fluid adj. knob Fluid tube 12 1 33 1

E stopper O ring 13 2 34 1

Trigger stud Pattern adj. guide 14 2 35 1

Fluid hose joint Pattern adj. valve 15 1 36 1

Fluid tube set O ring 16 1 37 1

Trigger O ring 17 1 39 1

Fix nut Terminal spring 18 1 40 1

19 Fluid nipple stay 1 50 Low voltage cable※3)

1

Fluid nipple 20 1

※ 1) This part name(No.1) is depending on model code.

No. 1 ⇒E-MW50-C5～：Air cap C5、E-MW50-C1～：Air cap(2)

※ 2) This part name（No.3） is depending on model code

No. 3 ⇒E-MW50-11～：Fluid nozzle(2)-1.1、 E-MW50-13～：Fluid nozzle(2)

※ 3) This part name(No.50) is depending on model code

No.50 ⇒E-MW50-X ：10m length、E-MW50-Y ：15mlength、E-MW50-Z ：20mlength、

※No.50 Low voltage cable is not indicated above.

‐23‐

‐24‐

8 Problems and remedies (Troubleshooting) < For Supervisor >

Check all troubleshooting solutions before disassembling gun. Some problems result from improper balance of air and fluid.

When you cannot solve problem even if you consult the following, contact the shop which sold it to you.

8.1 Painting equipment

Prob

lem

Place Place(s) to be checked

Part No.

Cause Check・Confirm

Tigh

ten

Rep

air

Adj

ust

Cle

an

Rep

lace

Insufficient tightening Joint Each air joint

Scratches on seat Dirt on seat Scratches on seat Weak spring Can not move A

ir le

akag

e

Tip of electro-static gun

Air valve seat set Air valve,

6 7

Damaged Insufficient tightening

Joint Each fluid joint Scratches on seat Insufficient tightening Dirt on seat Screw of air cap

cover Fluid nozzle and seat of gun body

3 10

Scratches on seat 4 Dirt on seat Needle bar set,

Fluid nozzle 10 Scratches and wear on seat

Gun air passage Back flow of thinner Fluid adj. set 12 Open too wide

Tip of fluid nozzle

Fluid needle spring 11 Spring failure 4 Insufficient tightening

Flui

d le

akag

e

From lower side of barrel

Needle packing setNeedle bar set 10 Scratches, wear

Set pressure is low Fluid regulator fails Fluid pressure Leakage from tank Smashed, bent Fluid tube 23 Clogged Insufficient tightening Dirt on seat

Paint supply

Leakage from each fluid joint

Scratches on seat 12 Fluid adj. knob Travel of fluid

needle 10 Fluid needle is loose Fluid nozzle 3 Clogged Air cap 1,2 Loose

Electrostatic gun

Fluid hose joint 15 Orifice is clogged Paint Paint viscosity Too high Pa

int o

utpu

t is

decr

ease

d or

uns

tabl

e

Paint remained Paint shortage

Pr

oble

m

Rep

lace

Tigh

ten

Adj

ust

Rep

air

Cle

an

Part Cause Place(s) to be checked No. Place Check・Confirm

Fluid nozzle 3 Air is mixed Fluttering

Needle packing set 4 Insufficient tightening

Crescent Air cap 1 Hole is clogged or deformed

Air cap 1 Hole is clogged or Inclined

Fluid nozzle 3 Deformed

Splitting Fluid viscosity Too low

Heavy center Fluid viscosity Too high

Infe

rior p

atte

rn

Fluid nozzle 3 Seat fails Spitting

Needle bar set 10 Paint leaks

8.2 Electrical problems

spec

ial s

pec.

Prob

lem

Rep

lace

Adj

ust

Cle

an

Cause Place(s) to be checked Place Check・Confirm

Low voltage cable Connector is not connected Electrostatic gun

Barrel Inside is dirty

Paint Paint resistance less than 30MΩ･cm

Hig

h vo

ltage

is n

ot c

harg

ed

E-SC24L-EX Refer to Electrostatic controller instruction manual.

‐25‐

8.3 Check and remedy painting problems Pr

oble

m

Rep

lace

Adj

ust

Cle

an

Place(s) to be checked

Part Cause Place No. Check・Confirm

Spray air pressure Too low

Paint viscosity Too high Poor atomization Air cap set 1 Clogged, dirty,

Fluid nozzle 3 damaged

Spray air pressure Low Orange peel

Fluid viscosity High

Haze・blushing Solvent boiling point Low

Fluid output Too much

Infe

rior f

inis

h

Spray distance Too close Runs・sags

Solvent boiling point Too high

Spray air pressure Too low

Paint resistance Too low

Pattern width Too wide

Intake of spray booth Insufficient intake Too

muc

h

boun

ce b

ack

Terribly dirty

Too far Spray distance

‐26‐

Warranty

All ANEST IWATA s.r.l. products have a one-year guarantee from the invoice date, unless otherwise stated in writing. The warranty covers all manufacturing faults and material defects. Any spare part replacement or repair operations are covered only if they are carried out by our technicians at servicing shops.

The faulty parts must be sent CARRIAGE PAID. Once the components have been repaired, they will be sent CARRIAGE FORWARD to the customer.

The warranty covers no intervention of our technicians during installation or dismantling operations. If for practical purposes one of our technicians is sent on site, a charge will be made for the time plus extra for traveling and expenses.

Our warranty dose not cover direct or indirect damage to people or property caused by our equipment. It covers no repair operations carried out by the customer or by a third party, either.

THE WARRANTY DOES NOT COVER

Damage or breakdown caused by improper use or assembly

Damage or breakdown caused by the use of spare parts that are different form the original or recommended ones.

Damage or breakdown caused by a bad preservation.

Components subject to wear (described in the spare part list.)

WARRANTY FORFEITURE:

In case of delayed payment or other contractual defaults.

Whenever changes or repairs are carried out on our equipment without prior authorization.

Whenever the serial number is damaged or removed.

When the damage is caused by improper use or functioning, or if the equipment falls, is bumped or by other causes not due to the normal working conditions.

Whenever the unit is disassembled, tampered with or repaired without the authorization of ANEST IWATA s.r.l.

All repair interventions carried out under warranty do not interrupt its duration.

All disputed will be settled in the court of justice of Turin.

Service contact

3176, Shinyoshida-cho, kouhoku-ku,

Yokohama-shi, Kanagawa-ken, 223-8501 Japan

Instruction manual No．T076-00

Code No. 03700000

Instruction manual

Electrostatic Controller E-spraySeries

E-SC24 -EX series E-SC24L-EX series


E-SC24-EX series is only for E-MW100 series. E-SC24L-EX series is only for E-MW50 series. To be installed only safe area

This instruction manual contains IMPORTANT WARNINGS, CAUTIONS and

instructions for safe operation. Before operation, be sure to read this

instruction manual thoroughly and understand the equipment so that you can use

it safely and effectively for a long time.


Important information - Safety Precautions This electrostatic controller is exclusively used for electrostatic painting. Be sure to read and

understand this instruction manual. Both the supervisor and operator shall be fully knowledgeable about the requirements stated

within this instruction manual, including important warnings, cautions and proper method of operation.

Wrong operation (mishandling) can cause serious bodily injury, death, fire or explosion.

This electrostatic controller is used along with related electrostatic spray guns (E-MW100, [for

E-SC24-EX] / E-MW50 [for E-SC24L-EX]): options) and paint pump (e.g. DPS-90), etc. When using related equipment, also read instruction manuals for those products.


1. About safety Pay special attention to items which are shown by below marks and symbols.

Symbols and marks have the following meanings.

Indication of warnings and cautions

WARNING Indicates a potentially hazardous situation which, if not avoided, will result in serious injury or loss of life.

CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property damage.

Examples of warnings and cautions

Indicates [You must be careful]. We will explain briefly in or near the symbol. (The example on the left is [Be careful about electric shock]).

Indicates [You must not do]. We will explain briefly in or near the symbol. (The example on the left is [Do not touch]).

Indicates [You must do]. We will explain briefly in or near the symbol. (The example on the left is [Be sure to ground it]).

We shall not be responsible for any injury or damage caused by disregard of warnings, cautions or instructions.

Indicates notes which we ask you to observe. They are helpful to fully achieve performance and functions of the equipment. Important

①

Warnings and cautions for safe operation

WARNING

Fire and Explosion

Avoidance of fire and explosion at painting site

Never install it at a site with flammable goods or bring flammable goods like lighters. Paints and organic solvents are flammable, able to cause fire. Never use the following Halogenated Hydrocarbon solvents which can chemically react with spray gun parts (aluminum parts) etc., crack and melt them. Improper solvents: methyl chloride, dichloromethane, 1,2-dichloroethane, carbon

tetrachloride, trichloroethylene, 1.1.1.-trichloroethane (Be sure that all fluids and solvents are compatible with gun parts. We are ready to supply a material list used in the gun on request.)

Avoidance of fire caused by grounding failure

Be sure to keep hanger or conveyor clean without paint stuck on it and keep them conductive. Incomplete grounding, dirty hanger or conveyor cannot conduct electricity, and static electricity accumulates, resulting in fire accident by spark discharge.

Store paint and solvent in a metallic container which is grounded. Poorly grounded conductor can accumulate static electricity, causing fire accident by spark discharge. If you are forced to place conductive goods such as fluid container and fluid supply pump within 3m from the gun, be sure to ground them without fail.

Securely ground electrostatic controller (A class grounding： less than 10Ω). As you ground the electrostatic spray gun by contacting electrostatic controller through low voltage cable, incomplete grounding can accumulate static electricity on spray gun, causing fire accident by spark discharge or bodily injury by electric shock.

A class grounding

(Good!) ×(Bad!)

Be sure to contact metallic points by makingcontact points knife-edged or sharp-pointed.

②

Avoidance of fire by ignition of paints and solvents

Be sure to turn off electric source of electrostatic controller (E-SC24-EX / E-SC24L-EX series) before cleaning inside of fluid passages. As paints and solvents are flammable and have low flash points, they can catch fire if there is spark discharge in and around painting site.

Spray distance between work-piece and painting equipment must be over 10cm. If the distance is less than 10cm, spark discharge can occur and paint can catch fire.

Never use lacquer paints. Lacquer paints have low flash points and can catch fire.

Do not cover electrostatic spray gun with anti-dust sheet. Static electricity accumulated on sheet can discharge and solvent gas can catch fire.

Wrong operation

Avoidance of wrong use

Never point toward human or animal during spraying. If done, it can cause inflammation of eye or skin and bodily injury. Never use gas other than compressed air. If done, it can cause fire or poisoning accident. Never use at higher than max. operating pressure (refer to specifications on page 2). Tip of fluid needle has a sharp point. Do not touch the tip of fluid needle during maintenance for the protection of the human body.

Avoidance of wrong operation

Before inspecting, cleaning, disassembling or assembling electrostatic spray gun, be sure to turn off electric source of electrostatic controller (E-SC24-EX / E-SC24L-EX series), interlocked equipment and equipment and fully release air and fluid pressure in the following procedure. If not, it can cause bodily injury by wrong operation.

Job 1) Turn off electric source of electrostatic controller (E-SC24-EX / E-SC24L-EX series). Job 2) Stop supply of compressed air, paint and solvent to spray equipment.

Job 3) Turn electrostatic spray gun downwards, pull trigger, operate fluid needle and fully

release air pressure and fluid pressure.

③

Bodily protection

Protection from solvents, air and fluid pressure

Use spray booth and do the painting job in a well-ventilated place. Painting and cleaning jobs in a poorly ventilated site can cause organic solvent poisoning and ignition. Always wear protective tool such as protective goggles and mask. If not, cleaning liquid can touch eyes and skin, causing inflammation. If you feel something wrong with eyes or skin, immediately consult with a doctor. We recommend you to wear earplugs for your safety. Noise level can reach over 85dB(A) depending on operating and working conditions. Be sure to turn off electric source of electrostatic controller or multi-gun control system and release fluid and air pressure before cleaning, disassembling or doing maintenance job or during stoppage of job. If not, remaining pressure can cause bodily injury through wrong operation and spattering of cleaning liquid. Be sure to follow [Avoidance of wrong operation ] on page ③ in order to turn off electric source, and release air and fluid pressure.

Protection from static electricity

Be sure to wear electrostatic shoes（resistance figure 105～10

8Ω、JIS T 8103） and anti-charge

working clothes（JIS T 8118）. If not, static electricity can accumulate on human body and cause bodily accidents by electric shock.

Operators must not wear metallic things such as watch or key holders during operation. If done, static electricity can accumulate on them and you will get an electric shock. If you wear glasses with metallic frame and approach

the gun, you can get an electric shock. Before approaching spray equipment, turn off electric source of electrostatic controller or multi-gun control system.

Operator must always hold electrostatic spray gun with bare hand or glove having a large hole at palm position. As human body is grounded through the handle of electrostatic spray gun, static electricity can accumulate on human body and cause bodily harm by electric shock if operator holds the gun handle with normal glove.

When you turn off main electric source switch in order to stop the gun operation in an emergency, it takes about 5 seconds till the electric potential of electrostatic spray gun goes down to a safe level. Don’t try to touch the pin electrode at tip of gun during that period.

Anti-charge workingclothes

Electrostatic shoes

Protection of human body If operators pull the trigger many times during operation, it may cause repetitive strain injury. Be sure to take a rest if you feel tired.

④

Others

Never use altered parts or other than genuine parts when parts are damaged or worn out. If done, it can cause failure of the gun, accidents or bodily injury.

Be sure to install a fire extinguisher at painting site.

Make sure that the equipment has stopped before you enter the working range of other painting equipment (robot, reciprocator, etc.). If not, moving robot or reciprocator can injure you.

Never use for food or chemicals. If done, erosion in paint passages can cause accidents, and foreign matter can enter.

extinguisher

⑤

Contents

for a Operator

1. Specifications ············································P. 3 2. Names and functions of each section ·····P. 4 3. Operation····················································P. 5 4. Safeguards ·················································P. 7 5. Daily maintenance and inspection···········P. 10 6. Problems and remedies (troubleshooting)P. 11

for a Supervisor

7. Specifications ············································P. 13

8. Check the products ···································P. 13

9. Names and functions of each section ·····P. 14

10. Setup of electrostatic controller ···············P. 16

11. Operation·····················································P. 21

12. Safeguards··················································P. 24

13. Daily maintenance and inspection ···········P. 27

14. Parts List ···················································P. 28

15. Problems and remedies (troubleshooting) ···········P. 29

The operator and the supervisor of this electrostatic controller must fully read and understand from P.2 to P.9 (for a Operator).

Only the supervisor and / or other equally qualified personnel, having fully read and understood the contents of this instruction manual, can take care of matters related to P.10 to P.26

Note:

【for a operator】

Electrostatic Controller E-SC24 -EX series E-SC24L-EX series

Instruction manual

< for a operator>

‐2‐ 【for a operator】


1 Specifications

1.1 Specifications Items Contents

Input voltage AC200～240V 50/60Hz single-phase

Output voltage (Electrostatic Controller) MAX AC24Vpp

Output current (discharge current of electrostatic spray gun) MAX 150μA (C.P 200μA )

Electric consumption ≒75W

Ambient temperature range 5～40

Ambient humidity range Less than 70%RH

Safeguards Detection of over-current, LV cable failure, spray set time failure

Dimensions L×W×H 245mmX150mmX130mm

Mass 3.4kg

Charge ON/OFF mechanism Air flow switch（air joint IN/OUT size: G1/4 male）

Max. operating air pressure (when air flow switch is used) MAX 0.68MPa

Applicable electrostatic spray gun

E-SC24-EX series. ⇒ E-MW100 series E-SC24L-EX series ⇒ E-MW50 series

< Outline of electrostatic controller >

This electrostatic controller is for supplying electricity to the booster circuit built into the electrostatic spray gun. It converts AC200-240V electricity to AC24Vpp and supplies the electricity to the electrostatic spray gun via a low voltage cable. (LV cable) It has built-in safeguards (detection of over current, disconnection of LV cable failure and self-diagnostic function to detect failure)



2 Names and functions of each section

2.1 Front panel of Electrostatic Controller 1) Operation section

Voltage 1～3 key have pre-set voltages for each keys.To change the voltage key, see

“supervisor’s instructions”

Power switch

Reset key

Scroll key Changes content of 7 seg.

Display lamp. (refer to 3.2)

2) Display section

Power lamp (green)

Charge lamp (yellow)

LED bar (green) Displays spray current

7seg. Display lamp for various information

Display mode lamp (yellow)

Failure display lamp (red)



3 Operation

3.1 Normal operation

WARNING

(１) When charging electrically, be sure to ground all surrounding metallic things. If not it can cause fire

or injury of electric shock.

CAUTION

(１) During charging (when high voltage is generated), do not put electrostatic spray gun within about 50cm of Electrostatic Controller. If done, Electrostatic Controller can fail if it sparks, as Electrostatic Controller is electrical equipment.

After setup is finished, start painting according to the following procedure. Job-1 Turn on power switch.

Power lamp lights up and the gun is ready to charge (voltage key lamp, display mode lamp, 7 seg. Display lamp lights up and displays.)

Job-2 In case of hand spray

gun: if the spray gun starts to spray, air flow switch operates and gun is charged*1）

When high voltage is charged, charge lamp lights up and spray current is displayed in spray current *2） *1）Max. Voltage –60kV ( for E-SC24-EX), -50kV ( for E-SC24L-EX) is set when shipped form factory (it is set on voltage1) *2）It normally lights up about in the range of 80 ~ 130μA. But display differs according to other conditions

Job-3 In the case of spray hand

gun: if the connected spray gun ends air spray, air flow switch stops, charge stops and returns to Job-1 condition.

Job-4 If spray job is finished,

turn off power of Electrostatic Controller.

Power OFF

Power lamp goes out

Charge lamp goes out, gun charge

OFF

Display mode lamp light up (refer to 3.2)

7 seg. Display lamp (refer to 3.2)

Power lamp lights up

Power switch ON

Charge lamp lights up Gun charge ON

Gun sprays Air flow switch ON

The guns spray ends, Air flow switch OFF

Voltage key lamp lights up Default :Voltage 1selected

Display lamp goes out.

Spray current display

LED bar display



3.2 How to change 7 seg. LED display items Information of “setting voltage” or “spray current” is displayed on 7 seg. display lamp. This section

describes how to change display items hereunder.

*1)“charge gun No.” or “failure gun No.” are option

Job-1 push scroll key on the right side of 7seg. display lamp and change to the item you wand

to display.

Job-2 Lamp lights up in selected display mode and present current of selected mode is displayed on 7 seg.

display lamp.

Display mode lamp 7 seg. LED display lamp

Scroll key

Figure is displayed on 7 seg. display lamp in accordance with light up display mode lamp.

Display item Unit on 7 seg. display

lamp Displayed

Voltage -kV Setting Voltage current μA Present Current



4 Safeguards Safeguards (failure detection functions) to monitor safety about electrostatic coating system of

electrostatic controller are explained below. 4.1 Safeguards to be monitored Contents of safeguards

Detection items Contents to be detected Safeguards

over current failure 1 When over 150μA coating current occurs and continues for over 30sec.

Immediately shutting off HV charging and sounding failure buzzer. Warning mode is kept until reset key is pushed.

over current failure 2 In case the current flows over 200μA. (Hard wear circuit protection: CP)

Immediately shutting off HV charging and sounding failure buzzer. The warning mode is kept until turning off the power switch.

LV cable failure When LV cable is damaged. Immediately shutting off charge and sounding failure buzzer. Warning mode is kept till reset key is pushed.

spray set time over When detecting continuous charge signal for over 2 minutes.

Immediately shutting off charge and sounding failure buzzer. Warning mode is kept till reset key is pushed.

high voltage

generator failure When the current supplied to high voltage generator, is in abnormal condition


Indication lamp Detection name

7seg. display Power Charge Ground Over current LV cable Time

over 2 guns charge Alarm

Power on while charging signal on Periodical beep sound

Over current failure1 Beep sound


LV cable failure Current detecting line Beep sound

Primary line of transformer Beep sound

Shielding wire Beep sound

Spray set time over Beep sound

High voltage generator

failure E01 Beep sound

：lighting, ：flickering (normal interval: 1sec)、：flickering (slow interval 2sec)、：flickering (fast interval 0.5sec)



4.2 Measures when warning mode appears by safeguards When electrostatic controller detects failure, buzzer sounds and warning mode appears. Follow the

following procedure, check the contents of failure and remedy. Before taking any measures, be sure to read the following warning items.

Beep！Suppose that electrostatic controller detects failure, warning buzzer sounds and charge is stopped (=warning mode)

Job-1 Suspend coating job and check failure item by lit-up position of failure display lamp.

First check failure item by failuredisplay lamp although warningbuzzer continues sounding.



Job-2 If you have checked failure item, push reset key and cancel warning mode. But if failure condition is continuously detected (for example, disconnection of shield wire), warning mode cannot be cancelled since failure is detected again and warning mode appears. In that case, turn power switch OFF.

If failure item is checked, push resetkey and reset warning mode. But as for disconnection of shieldwire, warning mode continues evenif reset till grounding is reconnected. Turn power OFF.

Job-3 After canceling warning mode, proceed confirmation about checked failure items according to below

chart. When failure is still detected, equipment may have failed. Check again ”6. Problems and remedies”

WARNING

(１) Before checking failure of electrostatic spray gun, be sure to turn off power of electrostatic controller and fully release air pressure and fluid pressure (refer to P.③ “avoidance of wrong operation”) in order to avoid bodily injury by wrong operation.

Failure items Check and remedy

Over current failure

Charge again and check if over current failure is detected. When over current failure is detected even if charged, check the following item. Check if spray distance is continuously short or other grounded thing comes nearer tip of gun.

⇒When spray distance is continuously short (grounded thing is near tip of electrostatic spray gun) this detection can work. If so, make spray distance longer.

LV cable failure

Note the lighting mode of LV cable lamp (see Table in sec.4) and check cable connection on electrostatic spray gun side and electrostatic controller side of low voltage cable. If connection of low voltage cable has no problem, LV cable was snapped. ⇒Replace low voltage cable.

Spray set time Charge again and check if charge is turned ON/OFF normally. If it is detected again, refer to 6 “Problems and remedies”, chart 7.



5 Daily inspection and maintenance

Refer to the below chart and periodically inspect Electrostatic Controller (weekly).

WARNING

(１) Before inspection, be sure to turn off power of Electrostatic Controller and fully release

air pressure (refer to P.③ “avoidance of wrong operation”).

Where to inspect

1. Grounding connection of Electrostatic Controller Is grounding wire off or worn out?

2. Remove dirt from Electrostatic Controller body Is dust accumulated?

3. Low voltage cable 1) Remove dirt. 2) Check outer damage. 3) Check for loose connector.

Is dust jammed? Is outer cover (sheath) damaged or disconnected? Is connector out of place?

4. Air hose 1) Remove dirtiness. 2) Check for outer damage. 3) Check for looseness of joint (air leak).

Is dust accumulated? Is air hose damaged or scratched? Is air leaking from loose joint?



6 Problems and remedies (troubleshooting)

WARNING

Before inspection, be sure to turn off power of electrostatic controller and fully release air pressure. (refer to P.③ ”avoidance of wrong operation”)

If you refer to below chart and cannot solve problem, be sure to contact the shop which sold it to you.

Important

Problems Causes Remedies Main power is not turned on. Power cable has been unplugged.

Turn on main power. Plug the power cable.

1 Power lamp does not light up even if electric source is turned on. Fuse is disconnected. Replace with fuse (5.2x20mm 250V2.5A). refer to 7.2.in

supervisor instructions.

2

Soon after turning on power switch, the buzzer sounds and charging lamp flashes.

The controller detected abnormal situation, which high-voltage signal has already been on before power switch on.

Check if spraying has started before power switch on, or air leakage from air passages, or jamming by dust in flow switch. In jamming case, disconnect air hoses and apply air flushing directly into air inlet/outlet of controller

3

Power lamp lights up but charge lamp does not light up even if spraying correctly.

Flow switch is not working. Jamming by dust in air flow switch. Disconnect air hoses and apply air flushing directly into air inlet/outlet of controller

Electrostatic spray gun failure. Consult our contacts 4

Power lamp and charge lamp light up. but the high voltage is not impressed. Electrostatic Controller failure. Consult our contacts

Grounded object or spray distance is constantly too short. Secure proper spray distance.

Low voltage cable failure. (Inside of cable broke down ) Replace low voltage cable. 5 Over-current is detected.

Electrostatic spray gun failure. Consult our contacts

Low voltage cable is disconnected. Reconnect low voltage cable. 6 Shielding wire

disconnection is detected. Low voltage cable failure (Shielding wire broke down) Replace low voltage cable.

Spraying continually over 2min. Check how to spraying. If you need special setting, consult our contacts

Air leaks from air hose joint. Tighten air hose joint to stop air leaking.

Air leaks from spray gun. Replace the gun’s air valve seat set 7

Spray set time is detected even if electrostatic spray gun is not sprayed over 2 min..

Dust jamming in air flow switch Disconnect air hoses and apply air flushing directly into air inlet/outlet of controller


【for a supervisor】

- 12 - 【for a supervisor】

Electrostatic Controller E-SC24 -EX series E-SC24L-EX series

Instruction manual

< ｆor a supervisor >



7 Specifications

7.1 Specifications Items Contents

Input voltage AC200～240V 50/60Hz single-phase Output voltage (Electrostatic Controller) MAX AC24Vpp Output current (discharge current of electrostatic spray gun) MAX 150μA (C.P 200μA )

Electric consumption ≒75W

Ambient temperature range 5～40 Ambient humidity range Less than 70%RH Safeguards Detection of over-current, LV cable failure, spray set time failure Dimensions L×W×H 245mmX150mmX130mm

Mass 3.4kg Charge ON/OFF mechanism Air flow switch（air joint IN/OUT size: G1/4 male） Max. operating air pressure (when air flow switch is used) MAX 0.68MPa

Applicable electrostatic spray gun E-SC24-EX series. ⇒ E-MW100 series E-SC24L-EX series ⇒ E-MW50 series

< Outline of electrostatic controller > This electrostatic controller is for supplying electricity to the booster circuit built into the electrostatic spray gun. It converts AC200-240V electricity to AC24Vpp and supplies the electricity to the electrostatic spray gun via a low voltage cable. (LV cable) It has built-in safeguards (detection of over current, disconnection of LV cable failure and self-diagnostic function to detect failure)

8 Check the products

This unit consists of the following accessories including electrostatic controller. Before use, be sure to check that all the products are included without any damage. If you find some products are missing or damaged, contact the shop which sold it to you.

Name of products Contents

Electrostatic Controller

(1) Grounding wire (5m)

Acce

ssor

ies

(2) Instruction manual （this one）

R1.25-4 R1.25-6



9 Names and functions of each section

9.1 Outer appearance of electrostatic controller

Rear

Electric source cord （5m）200 ~ 240V

Front

Fuse box

Low voltage cableconnector

Air joint IN/OUT size：G1/4

Front panelSignal output

(Option) Ground terminal

9.2 Position of screw (M4) to fix electrostatic controller

140mm

100mm

15mm

15mm

Sid

top

bottom

10mm

M4 screw ×4pcs. （）

245mm 10mm



9.3 Front panel of Electrostatic Controller

1) Operation section

Reset key

Power switch

A～C key Used to change voltagesetting (refer to 5.3) Only A key is used.

Voltage 1～3 key Changes voltage setting. (refer to 5.3) Default set; voltage 1

Enter key Changes voltage setting.

(refer to 5.3)

Scroll key Changes content of 7

seg. Display lamp. (refer to 5.2)

2) Display section

Failure display lamp (red)

LED bar (green) Displays spray current

7seg. Display lamp for various information

Display mode lamp (yellow)

Charge lamp (yellow)

Electric source lamp (green)



10 Setup of Electrostatic Controller

This section explains how to set up electrostatic controller about standard connection as shown below. Before setup, be sure to observe the below warning.

WARNING

A) Before connection, be sure to turn off power switch, release pressure of primary side air

source and turn off all power switches of related equipment.

A) Securely connect grounding. Insufficient grounding can cause failure by charging of electrostatic controller, fire by spark discharge through leak, charge, or injury by electric shock.

B) Be sure to connect surrounding metallic things to ground before charging electrically. If not, it can cause fire or injury by electric shock.

A) Never use primary side electric source other than designated AC 200 ~ 240V. B) Input of different voltage than set specifications can cause damage to equipment or fire.

Ground A class

Electric source AC200 ~ 240V

Air source

Compressor

⇒ air filter ⇒ air regulator

Connect customer’s equipment

Electrostatic spray gun

E-spray series (option)

Air hose （option）

Low voltage cable（option）

Air hose (option)

Grounding wire （accessory）

Electric source cord*）

(accessory)

Standard setup

Air joint connection IN/OUT size G 1/4

Connector for low voltage cable

Caution: The earth pin of AC plug isn’t PE. It’s necessary to connect grounding wire.



10.1 Connection of electric cable

WARNING

A) Before connection, be sure to turn off power switch, release pressure of primary side air

source and turn off all power switches of related equipment.

A) Securely connect grounding. Insufficient grounding can cause failure by charging of Electrostatic Controller, fire by spark discharge through leak, charge, or injury by electric shock.

B) When charging electrically, be sure to ground all surrounding metallic things. If not, it can cause fire or injury of electric shock.

A) Never use primary side electric source other than designated AC 200 ~ 240V）. B) Input of different voltage then set specifications can cause damage to equipment or fire.

Job-1 Fit attached grounding wire to grounding terminal block at back

of Electrostatic Controller. Connect the other terminal to grounding terminal of customer (we recommend A class grounding)

Job-2 Insert power cord into AC 200 ~ 240V power receptacle of customer.

Job-3 Connect low voltage cable attached to electrostatic gun to

low voltage cable connector (output) of front panel.

Ground terminal

To customer’s ground terminal (we recommend A class grounding)

Caution: The earth pin of AC plug isn’t PE(protection earth). It’s necessary to connect ground.

Low voltage cable connector

To electrostatic gun of customer

Refer to instruction manual ofElectrostatic gun about how tofit to Electrostatic gun.



10.2 Connection of air hose As hand spray gun type is charged ON/OFF by air flow switch (air flow sensor) in electrostatic controller, you must connect air hose to electrostatic controller.

CAUTION

A) When connecting air hose, pay attention so that dust does not enter air hose. If not, it can fail painting.

B) Use clean and dry compressed air which is filtered near at inlet to controller through air filter (less than 5μm) and dried through air dryer. Dirty air can fail painting.

Job－１ Connect air hose to joint (lower side) for G1/4 air inlet of front panel of electrostatic controller and the other side to air source of customer. As for customer’s air source, be sure to read the above caution.

Job－２ Connect air hose for electrostatic gun to air joint for G1/4 air outlet at front panel of electrostatic controller and the other side Electrostatic spray gun of customers.

10.3 Connection of external output signal ( for Model : E-SC24-EXS1, E-SC24L-EXS1) It can output signal of “power”, “charge”, “current flow caution “and “failure” to the outside of the electrostatic controller. Refer to next page for an explanation of how to set up the connection of cable for output.

Connect to joint (lower side) of air inlet

Size G1/4 To primary side air source

Connect to joint (upper side) of air outlet

Size G1/4 To Electrostatic

Spray Gun

Refer to instruction manual ofElectrostatic Spray Gun about how tofit Electrostatic Spray Gun.

Plug (Accessories)

e.g.) Signal tower

Receptacle cover (Accessories) Connection cable*

*) A user needs to prepare.

Receptacle of output signal



< Construction >

Receptacle Plug

Electrostatic controller rear panel

1 2 3

4 5 6 7

8 9 10

11 12

Receptacle Plug

(Accessories)

1 2 3 4 5 6 7

9 1112

8 10

Items Signal 1 1 ON (close) 2 2 Power OFF (open) 3 3 ON (close) 4 4 Charge OFF (open) 5 5 ON (close) 6 6 Failure OFF (open) 7 7 ON (close) 8 8 Current flow caution OFF (open) 9 9 No use - 10 10 No use - 11 11 No use - 12 12 No use -

Specification (Charge input contact point) No-voltage contact point output Normal open Contact point capacity Below

250V 1A (Resistance load)

< How to connect Plug and Cable > <Job-1> Disassemble the Plug



<Job-2> Solder and connect cable. (Pay attention not to get burnt) <Job-3> Assemble the Plug <Job-4> Tighten the screw.

Connection cable

Screw Screwdriver

Soldering iron

Be careful of a burn.



11 Operation

11.1 Normal operation

WARNING

A) When charging electrically, be sure to ground all surrounding metallic things. If not it can cause fire or injury of electric shock.

CAUTION

A) During charging (when high voltage is generated), do not put electrostatic spray gun within about 50cm of Electrostatic Controller. If done, Electrostatic Controller can fail if it sparks, as Electrostatic Controller is electrical equipment.

After setup of 4 is finished, start painting according to the following procedure. Job-1 Turn on power switch.

Power lamp lights up and the gun is ready to charge (voltage key lamp, display mode lamp, 7 seg. Display lamp lights up and displays.)

Job-2 In case of hand spray

gun: if the spray gun starts to spray, air flow switch operates and gun is charged*1）

When high voltage is charged, charge lamp lights up and spray current is displayed in spray current *2） *1）Max. Voltage –60kV ( for E-SC24-EX), -50kV ( for E-SC24L-EX) is set when shipped form factory (it is set on voltage1) *2）It normally lights up about in the range of 80 ~ 130μA. But display differs according to other conditions

Job-3 In the case of spray hand

gun: if the connected spray gun ends air spray, air flow switch stops, charge stops and returns to Job-1 condition.

Job-4 If spray job is finished,

turn off power of Electrostatic Controller.

Gun sprays Air flow switch ON

Display mode lamp light up (refer to 5.2)

7 seg. Display lamp (refer to 5.2)

Voltage key lamp lights up

Default :Voltage 3 (refer to 5.3)

Electric source lamp lights up

Electric source switch ON

Charge lamp lights up Gun charge ON

Spray current display

LED bar display

Electric source OFF

Electric source lamp goes out

Display lampgoes out.

The guns spray ends, Air flow switch OFF

Charge lamp goes out, gun charge

OFF



11.2 How to change 7 seg. LED display items Information of “set voltage”, “spray current” is displayed on 7 seg. display lamp. We explain how to

change display items hereunder.

*1)“charge gun No.” or “failure gun No.” are option.

Job-1 push scroll key on the right side of 7 seg. display lamp and change to the item you wand

to display.

Job-2 Lamp lights up in selected display mode and present current of selected mode is displayed on 7 seg.

display lamp.

Display mode lamp 7 seg. LED display lamp

Scroll key

Figure is displayed on 7 seg. display lamp in accordance with light up display mode lamp.

Display item Unit on 7 seg. display

lamp Displayed

Voltage -kV Set Voltage current μA Present Current



11.3 How to change set voltage This page must be worked only by trained, qualified personnel who understand the requirements in this manual.

Max. voltage; voltage 3 is set when shipped from our plant. When you want to change charge voltage of electrostatic gun, you can choose from the following 3 kinds of voltage.

Job-1 If you continue pushing “A” key while pushing “reset key” under normal conditions (charge stand-by

with only power ON for over 4 seconds, it becomes voltage selection mode. Voltage lamp of display mode lamp, gun No. lamp and voltage key lamp flash, and 7 seg. display lamp displays “1” and flashes.

Job-2 Chose newly set voltage key from “voltage 1～3 key” and push. (selected voltage key lamp flashes)

Job-3 If “ENTER key “ is pushed, voltage set mode returns to normal mode. Charge from next time is set

voltage by newly selected voltage key. (set voltage key lamp lights up)

Chart1. preset voltage key against each voltage key Voltage key

Model voltage 1 standard voltage 2 voltage 3

E-SC24-EX series

(for E-MW100) -40kV -50kV -60kV

E-SC24L-EX series (for E-MW50) -30kV -40kV -50kV

While pushing reset key Push “A” key over 4 seconds

Voltage selection modeNormal mode

Gun No. “1” displays andflashes

Voltage key lamp flashes

Select and push newly set voltage key

LED lamp of pushed voltage

key flashes and its setvoltage is displayed on 7seg. display lamp.

Gun No. lamp flashes

Voltage selection

Normal modeVoltage selection

LED lamp of newly set voltagekey flashes.

Push “ENTER” key Set change is renewed and returnsto normal mode.



12 Safeguards

Safeguards (failure detection functions) to monitor safety about electrostatic coating system of electrostatic controller are explained below.

1.1 Safeguards to be monitored Contents of safeguards

Detection items Contents to be detected Safeguards

over current failure 1 When over 150μA coating current occurs and continues for over 30sec.


over current failure 2 In case the current flows over 200μA. (Hard wear circuit protection: CP)


LV cable failure When LV cable is damaged. Immediately shutting off charge and sounding failure buzzer. Warning mode is kept till reset key is pushed.

spray set time over When detecting continuous charge signal for over 2 minutes.


high voltage

generator failure When the current supplied to high voltage generator, is in abnormal condition












High voltage generator

failure E01 Beep sound

：lighting, ：flickering (normal interval: 1sec)、：flickering (slow interval 2sec)、：flickering

(fast interval 0.5sec)



12.1 Measures when warning mode appears by safeguards When electrostatic controller detects failure, buzzer sounds and warning mode appears. Follow the

following procedure, check the contents of failure and remedy. Before taking any measures, be sure to read the following warning items.

Job-1 Suspend coating job and check failure item by lit-up position of failure display lamp.

Job-2 If you have checked failure item, push reset key and cancel warning mode.

But if failure condition is continuously detected (for example, disconnection of shield wire), warning mode cannot be cancelled since failure is detected again and warning mode appears. In that case, turn power switch OFF.

Beep！Suppose that electrostatic controller detects failure, warning buzzer sounds and charge is stopped (=warning mode)

First check failure item by failuredisplay lamp although warningbuzzer continues sounding.

If failure item is checked, push resetkey and reset warning mode. But as for disconnection of shieldwire, warning mode continues evenif reset till grounding is reconnected. Turn power OFF.



Job-3 After canceling warning mode, proceed confirmation about checked failure items according to below

chart. When failure is still detected, equipment may have failed. Check again ”8. Problems and remedies”

WARNING A) Before checking failure of electrostatic spray gun, be sure to turn off power of electrostatic

controller and fully release air pressure and fluid pressure (refer to P.③ “avoidance of wrong operation”) in order to avoid bodily injury by wrong operation.

Failure items Check and remedy

Charge again and check if over current failure is detected.

Over current failure

When over current failure is detected even if charged, check the following item. Check if spray distance is continuously short or other grounded thing comes nearer tip of gun.

⇒When spray distance is continuously short (grounded thing is near tip of electrostatic spray gun) this detection can work. If so, make spray distance longer.

LV cable failure

Note the lighting mode of LV cable lamp (see Sec.4) and check connector connection on electrostatic spray gun side and electrostatic controller side of low voltage cable. If connection of low voltage cable has no problem, LV cable was snapped. ⇒Replace low voltage cable.

Spray set time Charge again and check if charge is turned ON/OFF normally. If it is detected again, refer to 6 “Problems and remedies”, chart 7.



13 Daily inspection and maintenance

13.1 Daily inspection and maintenance Refer to the below chart and periodically inspect Electrostatic Controller (weekly).

WARNING A) Before inspection, be sure to turn off power of Electrostatic Controller and fully release

air pressure (refer to P.③ “avoidance of wrong operation”).

Where to inspect

1. Grounding connection of Electrostatic Controller Is grounding wire off or worn out? 2. Remove dirt from Electrostatic Controller body Is dust accumulated? 3. Low voltage cable

1) Remove dirt. 2) Check outer damage. 3) Check for loose connector.

Is dust accumulated? Is outer cover (sheath) damaged or disconnected? Is connector out of place?

4. Air hose 1) Remove dirtiness. 2) Check for outer damage. 3) Check for looseness of joint (air leak).

Is dust accumulated? Is air hose damaged or scratched? Is air leaking from loose joint?

13.2 How to replace fuse How to replace fuse when fuse is disconnected, is explained below. Job-1 Turn cover of fuse box counterclockwise at back of

Electrostatic Controller with minus screwdriver and remove cover.

Job-2 Replace fuse (5.2X20mm 250V2.5A) in fuse box. Job-3Turn cover of fuse box clockwise with minus drive and

fit cover.

Turn it counterclockwise andremove it.

Fuse box

Fuse box

Turn it clockwise and fit it.



14 Parts List

No. E-SC24(L)-EX E-SC24(L)-EX-S1 1

E-SC24(L)-EX 1 1

2 Fuse 1 1 3 Connector plug - 1

E-SC24(L)-EX

2

1 1

2

3 E-SC24(L)-EXS1



15 Problems and remedies (troubleshooting)

WARNING A) Before inspection, be sure to turn off power of electrostatic controller and fully release air

pressure. (refer to P.③ ”avoidance of wrong operation”)

A) If you refer to below chart and cannot solve problem, be sure to contact the shop which sold it to you. Important

Problems Causes Remedies Main power is not turned on. Power cable has been unplugged.

Turn on main power. Plug the power cable.

1 Power lamp does not light up even if electric source is turned on. Fuse is disconnected. Replace with fuse (5.2x20mm 250V2.5A). refer to 7.2.in

supervisor instructions.

2

Soon after turning on power switch, the buzzer sounds and charging lamp flashes.

The controller detected abnormal situation, which high-voltage signal has already been on before power switch on.

Check if spraying has started before power switch on, or air leakage from air passages, or jamming by dust in flow switch. In jamming case, disconnect air hoses and apply air flushing directly into air inlet/outlet of controller

3

Power lamp lights up but charge lamp does not light up even if spraying correctly.

Flow switch is not working. Jamming by dust in air flow switch. Disconnect air hoses and apply air flushing directly into air inlet/outlet of controller

Electrostatic spray gun failure. Consult our contacts 4

Power lamp and charge lamp light up. but the high voltage is not impressed. Electrostatic Controller failure. Consult our contacts

Grounded object or spray distance is constantly too short. Secure proper spray distance.

Low voltage cable failure. (Inside of cable broke down ) Replace low voltage cable. 5 Over-current is detected.

Electrostatic spray gun failure. Consult our contacts

Low voltage cable is disconnected. Reconnect low voltage cable. 6 Shielding wire

disconnection is detected. Low voltage cable failure (Shielding wire broke down) Replace low voltage cable.

Spraying continually over 2min. Check how to spraying. If you need special setting, consult our contacts

Air leaks from air hose joint. Tighten air hose joint to stop air leaking.

Air leaks from spray gun. Replace the gun’s air valve seat set 7

Spray set time is detected even if electrostatic spray gun is not sprayed over 2 min..

Dust jamming in air flow switch Disconnect air hoses and apply air flushing directly into air inlet/outlet of controller

Warranty

All ANEST IWATA s.r.l. products have a one-year guarantee from the invoice date, unless otherwise stated in writing. The warranty covers all manufacturing faults and material defects. Any spare part replacement or repair operations are covered only if they are carried out by our technicians at servicing shops.

The faulty parts must be sent CARRIAGE PAID. Once the components have been repaired, they will be sent CARRIAGE FORWARD to the customer.

The warranty covers no intervention of our technicians during installation or dismantling operations. If for practical purposes one of our technicians is sent on site, a charge will be made for the time plus extra for traveling and expenses.

Our warranty dose not cover direct or indirect damage to people or property caused by our equipment. It covers no repair operations carried out by the customer or by a third party, either.

THE WARRANTY DOES NOT COVER

Damage or breakdown caused by improper use or assembly

Damage or breakdown caused by the use of spare parts that are different form the original or recommended ones.

Damage or breakdown caused by a bad preservation.

Components subject to wear (described in the spare part list.)

WARRANTY FORFEITURE:

In case of delayed payment or other contractual defaults.

Whenever changes or repairs are carried out on our equipment without prior authorization.

Whenever the serial number is damaged or removed.

When the damage is caused by improper use or functioning, or if the equipment falls, is bumped or by other causes not due to the normal working conditions.

Whenever the unit is disassembled, tampered with or repaired without the authorization of ANEST IWATA s.r.l.

All repair interventions carried out under warranty do not interrupt its duration.

All disputed will be settled in the court of justice of Turin.

Service contact

3176, Shinyoshida-cho, kouhoku-ku,

Yokohama-shi, Kanagawa-ken, 223-8501 Japan

Instruction manual No．T078-00

Code No. 03538070

Instruction Manual

E-spray

Series

E-MW100/ 50 series E-SC24(L)-EX series Technical information V1.03


GroupⅡ category 2 gas atmosphere equipment Suitable for use in Zone 1

This instruction manual contains IMPORTANT WARNINGS,

CAUTIONS and instructions for safe operation. Before operation, be sure to

read this instruction manual thoroughly and understand the equipment so

that you can use it safely and effectively for a long time.


2

A. How to set up

1. How to choose the voltage (voltage1, 2, 3)

1) Enter voltage setting mode by pushing ”reset + A” keys for 4sec

2) Number of the target gun will blink on 3 digits indicator. (Usually it shows from no.1 gun)

3) Choose target gun number by scroll keys. (in case of single use, you can choose only no.1 gun)

4) Push a voltage button which you want to set among voltage1-3 keys.

⇒the set voltage will be indicated on 3 digits.

5) Choose next target gun number by scroll keys. (in case of multi-gun use)

⇒the gun number which you chose will be indicated.

6) Push a voltage button which you want to set among voltage1-3 keys. (in case of multi-gun use)

⇒the set voltage will be indicated on 3 digits.

7) If you want to set other gun’s voltage, repeat the procedure from 5). (in case of multi-gun use)

8) After finishing to set voltage for each guns, push “enter” key to exit from this mode.

Chart1. Voltage keys initial setup

Model voltage 1

voltage 2

voltage 3 (initial setup)

Indicating Voltage -40kV -50kV -60kV E-SC24-EX series

(for E-MW100) (Non loaded voltage) (-70kV) (-80kV) (-90kV)

Indicating Voltage -30kV -40kV -50kV E-SC24L-EX series (for E-MW50) (Non loaded voltage) (-60kV) (-70kV) (-80kV)

2. How to change voltage on Voltage keys （Voltage 1 – 3 keys）

1) Enter the voltage setting mode by pushing “reset + enter + voltage 1 or 2 or 3 “keys for 4sec.

2) The setting voltage of pushed voltage key is indicated on 3digits.

The indicated voltage is “set voltage + 30kV” (ie: non loaded voltage)

3) Change the value by scroll keys, and push “enter” key.

4) The chose voltage key’s value is changed and exit from this mode.

3. How to change max current detection time

1) Enter max current detection time setting mode by pushing “reset+ B” keys for 10sec

2) Number of the target gun will blink on 3 digits indicator and the over current LED will blink.

3) Choose target gun number by scroll keys and push “enter” key.

(in case of single use, you can choose only no.1)

4) The max current detection time is indicated on 3 digits. (Initial setup: 30 sec. adjustable range 0 – 60 sec)

5) Change the value of max current by scroll key and push “enter” key.

6) The controller goes back to the gun number select mode.

7) If you need to change the value of other guns, repeat the procedure from 2). (in case of multi-gun use)

8) After finishing to set max current value for each guns, push “B” key to exit from this mode.

4. High level settings

1) Turn on the power switch pushing “A+C” keys and keep pushing for 4sec.

2) The setting code is indicated on 3digits.

3) Change the setting code by scroll keys, and push “enter” key.

4) Then 3degits show value of the setting code.

5) Change the value by scroll keys.

Setting code Setting subject Initial

value Range of

value unit

001 Max. limited voltage for “Voltage 1” 60 25 - 95 -kV 002 Max. limited voltage for “Voltage 2” 60 25 - 95 -kV 003 Max. limited voltage for “Voltage 3” 60 25 - 95 -kV 004 Continuous charging max time a) 120 10 - 600 sec 005 Max. current for “Voltage 1” 150 50 – 390 uA 006 Max. current for “Voltage 2” 150 50 – 390 uA 007 Max. current for “Voltage 3” 150 50 – 390 uA

010 Detection delay time of “LV cable failure” except shielding wire failure b) 10 0 - 20 1/10sec

011 Detection delay time of “2 guns charging failure” 10 5 – 20 1/10sec

012 Detection delay time of “LV cable failure” only shielding wire failure 10 5 – 20 1/10sec

013 Charge delay time (on delay time) 20 5 – 20 1/10sec 014 Power supply adj. depend on cable length for “Voltage 1” 10 10 -25 m 015 Power supply adj. depend on cable length for “Voltage 1” 10 10 -25 m 016 Power supply adj. depend on cable length for “Voltage 1” 10 10 -25 m

a) To disable “continuous charging failure function”, turn on dip no. 8 on main P.C.B b) “LV cable failure except shielding wire” means “current detection circuit failure” and “primary circuit of

the high-voltage trans former failure”

6) After finishing to set the value, push “enter “key, and go back code indication mode.

7) After backing to setting code indication mode, then push “A+C” key to exit from this mode.

3

Max limited voltage

Voltage of tip of electrode [-kV]

90

Current [uA]

200 150

60

Max Current

80

0 10050

Max. power potential line: E-MW100

Non loaded voltage: E-MW100

Max. power potential line: E-MW50

Non loaded voltage: E-MW50

Actual painting current

Actual max. power performance line: (red bold) E-MW50

Actual max. power performance line (black bold): E-MW100

Vo

i

4

Electrostatic hand gun E-MW50/100 Series

Handle

Electrostatic controller E-SC24(L)-EX Series

Grounded work piece

Low voltage cable

Electrical current

“i”

Grounding line

Primary line

Current detection line

5

B. Error detection 1. Contents of error detection

no Detection items Contents to be detected Safeguards

1 Grounding failure a) When the controller is not grounded. Immediately sounding failure buzzer. this warning mode is kept until “reset” key is pushed.

2 Over current failure 1 //software detection//

When over 150μA coating current occurs and continues for over 30sec.


3 Over current failure 2 In case the current flows over 200μA. (Hard wear circuit protection: CP)


4 Shielding wire failure The shielding wire circuit has been damaged. (particularly on LV cable) 〃

5 Current detecting wire failure

The current detecting circuit has been damaged. (particularly on LV cable and HV generator)

〃

6 Primary low voltage line failure

The primary low voltage circuit has been damaged. (Particularly on LV cable and HV generator)

〃

7 Spray set time over When detecting continuous charge signal for over 2 minutes. ※dip SW8 on: enable / off : disable


8 2 guns charging failure More than 2 guns have been charged at once. ※multi gun setup: enable / single use: disable 〃

9 HV generator failure The over current has been supplied to high voltage generator.


10 High voltage switch failure (Flow switch)

The high voltage switch has been on before power switch has been on.


a) Grounding failure mode is not applied on CE mark edition (E-SC24/L-EX series)




Grounding failure a) Beep sound








High voltage generator failure E01 Beep sound

High voltage switch failure Beep sound

：lighting, ：flickering (normal interval: 1sec)、：flickering (slow interval 2sec)、：flickering (fast interval 0.5sec)

a) Grounding failure mode is not applied on CE mark edition (E-SC24/L-EX series)

6

C. How to indicate the histories

1. Log data 1: Total running time (power on time) (MAX 9990Hr) 1) Enter the total running time indication mode by pushing “enter + A “keys for 4sec.

2) The total running time is shown on 3digits. (the unit x10 hours)

3) Automatically, this mode is cleared after 4 sec.

2. Log data 2: Total charging time (MAX. 9990Hr) 1) Enter the total charging time indication mode by pushing “enter + B “keys for 4sec.

2) After gun no. is flicked for 3 sec, the total running time is shown on 3digits. (the unit x10 hours)

3) The indication of the gun no. is able to be changed by the scroll keys, during flicking gun number.

4) Automatically, this mode is cleared after 5 sec after operations.

3. Log data 3: Total number of on/off triggering counter. (MAX 200,000,000 times) 1) Enter the total number of times indication mode by pushing “enter + C “keys for 4sec.

2) After gun no. is flicked for 3 sec, the total running time is shown on 3digits. (the unit x10,000 times)

3) The indication of the gun no. is able to be changed by the scroll keys,


4. Log data4 Error detection history (MAX 25 cases)

1) Enter the Error detection history mode by pushing “enter + A + B “keys for 4sec.

2) Choose the gun number by the scroll key, and push “enter” key.

3) The error history is indicated on 3 digits, and changeable to next history by the scroll keys.

First 2 digits shows the order of history (01-25, young number is later), and last 1 digit shows code of error. The code is as following table. ex) “ 012” Latest error(01) / Grounding failure(2). Error code. Detected Failure type Error code. Detected Failure type Error code Detected Failure type

1 Over current (hard detected) 4 LV cable failure

(Shielding wire failure) 7 LV cable failure (Primary line of transformer)

2 Grounding failure 5 2 guns charge failure 8 LV cable failure (Current detecting line)

3 Over current (soft detected) 6 Time over 9 High voltage generator failure

4) Back to gun select mode push “enter” key.


7

D. About the controller

1. How to reset to default setting

1) Turn on the power switch pushing “Voltage 1, 2 and 3” keys until sounding “pi” sound (about 2sec.).

2) And the code “001” is shown firstly in 3digits.

3) Change the code “001” or “002” or “003” for your purpose.

“001”: Initial setting data is cleared. (not including “002”, “003” data)

“002”: Error detection history is cleared.

“003”: Total running time, Total charging time, Total number of on/off triggering times data are cleared.

4) Push “enter” key to execute reset which you chose

5) After “pi” sound for 2 sec., the reset is finished.

2. How to check the software version. 1) Push “A+B+C” keys for 3 sec.

2) The version is shown in 3 digits. ex “103” is ver. 1.03

E. How to change the drive mode for E-MW50 or E-MW100

The hard ware is completely same, the difference is setting) １． How to change the mode to E-MW50 setting. (E-SC24L-EX)

１） Turn off.

２） Open the enclosure and change the dip-switch 9 on main P.C.B. to “on” side.

３） Close the enclosure carefully.

４） Turn on the power switch pushing “Voltage 1, 2 and 3” keys until sounding “pi” sound (about 2sec.)

５） Choose “001” mode and push “enter” key.

６） After “pi” sound for 2 sec., the reset is finished

７） Confirm the 3 digits and “B” button are flickering.

８） The controller has been set as E-MW50’s controller.

２． How to change the mode to E-MW100 setting. (E-SC24-EX) １） Turn off.

２） Open the enclosure and change the dip-switch 9 on main P.C.B. to “off” side.

３） Close the enclosure carefully.

４） Turn on the power switch pushing “Voltage 1, 2 and 3” keys until sounding “pi” sound (about 2sec.)

５） Choose “001” mode and push “enter” key.

６） After “pi” sound for 2 sec., the reset is finished

７） Confirm the 3 digits is not flickering and “A” button is lighting.

８） The controller has been set as E-MW100’s controller.

8

F. Dip switch setting

DIP-SW (※: initial setting) note Address Off (0) On (1)

External voltage control No.1 Disable※ Enable

Grounding detection No.2 Disable※ Enable

Data rate 1 No.3 (See table) (See table)※ See below tab.

Data rate 2 No.4 (See table) (See table)※ See below tab.

Parity No.5 Non※ Yes

Parity No.6 Odd number※ Even number

Initial setting No.7 Normal※ For special customer

Time over No.8 Enable※ Disable Since ver.2.02

Non No.9

For inspection No.10 Disable※ Enable

tab. combination of data rate 1 and 2

Data rate Address 3 Address 4 9600※ On On 4800 On Off 2400 Off On 1200 Off Off

3176, Shinyoshida-cho, kouhoku-ku, Yokohama-shi, Kanagawa-ken, 223-8501 Japan

e-mw50 series - spray painting equipment2 high voltage generation built-in high voltage booster...

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