瓦格纳尔静电喷涂机EPG3000静电发电机使用说明书

1、瓦格纳尔高压无气喷涂机网站地址：Electrostatic Power Generator静电发电机EPG- 3000操作说明书OPERATING MANUAL部件号0 3 8 1 8 2 0PART NO. 0 3 8 1 8 2 0版本 04 2002Edition 04 2002中文译文仅供参考，请以英文原版为准目录页号1.1使用本操作说明书USING THE MANUAL51.2安全建议ADVICE ABOUT SAFETY51.3生产责任书及保修PRODUCT LIABILITY AND WARRANTY92.说明DESCRIPTION112.1供货范围

2、SCOPE OF SUPPLY112.2技术数据TECHNICAL DATA112.3用途APPLICATION122.4功能说明FUNCTIONAL DESCRIPTION122.5操作控制OPERATING CONTROL132.5.1EPG 3000的前面板FRONT PLATE OF THE EPG3000132.5.2EPG 3000的后面板BACK PLATE OF THE EPG3000153.准备和安装PREPARATION AND INSTALLATION173.1设备的安装/定位INSTALLATION / POSITIONING OF THE UNIT173.2接地EAR

3、THING173.2.1在模块化喷涂系统中的使用USING IN MODULAR PAINTING SYSTEM183.2.2作为单机装置使用USE AS A STAND-ALONE UNIT193.2.3电缆的最小截面积MINIMUM CABLE CROSSSECTION203.3将EPG 3000装在机架中FIXING THE EPG3000 IN THE RACK204.启动和运行START-UP AND OPERATION214.1控制装置/喷枪的启动STARTING-UP THE CONTROL UNIT / SPRAY GUN215.故障排除和维修保养TROUBLESHOOTING

4、 AND MAINTENANCE236.维修作业REPAIR WORK256.1打开模块OPEN THE UNIT256.2更换选择开关和灯管REPLACING SELECTOR SWITCH AND FILAMENT BULPS266.3更换高压模块HVM CHANGING HIGH VOLTAGE MODULE HVM.266.4更换气动模块的部件CHANGING PARTS OF THE PNEUMATIC UNIT276.5更换PCB EPG 3000后面板组件CHANGING PCB EPG3000 REAR PANEL ASSY.276.6更换电源REPLACING THE POW

5、ER SUPPLY286.7更换灯保险丝REPLACING LIGTH FUSES287.附件ACCESSORIES298.零备件目录SPARE PARTS CATALOGUE308.1如何订购零备件HOW TO ORDER SPAREPARTS?308.2零备件清单中的特殊标记SPECIAL MARKS IN SPARE PARTS LISTS308.3EPG 3000零备件SPARE PARTS EPG3000318.4电路图ELECTRICAL DIAGRAM348.5PCB后面板连接电路图CONNECTION DIAGRAM PCB REAR PANEL358.6使用外部控制装置的连接

6、（例）USING THE EXTERNAL CONTROLCONNECTION(EXAMPLE)368.7外部控制电缆连线EXTERNAL CONTROL CABLE CONNECTIONS378.8EPG 3000- GA2005气路连接图PNEUMATIC CONNECTION EPG3000 - GA200538本技术手册包括与本设备的使用、维修和保养有关的说明和线索。若不按照本说明说明的说明操作本设备，可能产生危险。遵守本说明书的说明是担保协议生效的重要条件。本说明书有以下语言版本：语言 部件号德语/英语0381 820法语/德语0381 821意大利语/西班牙语0381 822丹麦语

7、/瑞士语0381 8231.1 使用本操作说明书“当心”本警示符表示，假如不严格遵守操作说明、工作说明和规定的工作程序等，可能导致人员受伤或严重事故。“注意”本警示符表示，假如不严格遵守操作说明、工作说明和规定的工作程序等，可能导致设备受损。“留意”本符号提醒您注意有用的附加信息和建议。1.2 安全建议“当心”下面各点必须特别注意以确保喷涂设备的安全使用：This manual contains information andinstructions for the operation, repairand maintenance of the control unit.This equipm

8、ent can be dangerous if itis not operated in accordance withthis manuall.Compliance with this manual constitutesan integral component of theguarantee agreement.The manual is available in variouslanguages:Language Part No.German/ English 0381 820French/ Dutch 0381 821Italian/ Spanish 0381 822Danish/

9、Swedish 0381 8231.1 USING THE MANUAL"Caution"This heading is used wherever noncompliancewith operating instructions,working instructions, specifiedworking sequences etc. may result ininjury or fatal accident."Attention"This heading is used wherever noncompliancewith operating ins

10、tructions,working instructions, specifiedworking sequences etc. may result indamage to the unit."Note"This heading is used to draw attentionto a particular passage in thetext.1.2 ADVICE ABOUT SAFETY"Caution"The following points should receivespecial attention to ensure the safeus

11、e of spraying equipment:喷射伤危险要保证工间休息时以及在喷嘴安装和拆除之前，务必先要将喷枪泄压。千万不要将喷枪对准自己或他人，喷射会造成伤害。千万不要将自己的手或手指靠在喷射处。一旦被涂料和清洗剂伤害到皮肤后，要立即由医护人员进行处理，要对医生说明涂料或清洗剂的种类。清洗剂及工具只能使用闪点比周围温度至少高5开氏绝对温度的清洗剂。外部的清洗，只能使用刷子或用清洗剂浸湿的刷子或者布来擦拭，不要使用硬物或溶剂喷枪。清洗在清洗喷枪时，千万不要对着一个密闭的容器内开枪（形成的溶剂/空气混合气体会引起爆炸）。健康与安全为有利于人身健康和保护环境，在喷房内或对着墙面进行喷涂时，通风

12、要充分（抽气），以确保喷涂安全。为避免职业病，必须始终遵照执行油漆及清洗剂制造商所制定的安全规则。无论是油漆准备阶段、喷涂阶段还是设备清洗时。必须遵守当地的各种健康与安全规定，尤其是应穿戴防护服和呼吸道护具，以保护皮肤和呼吸系统。呼吸道护具尽管在喷涂过程中只会产生很少的漆雾，但毕竟不是绝对的没有。因此，应向操作员提供呼吸道护具（见行业协会呼吸道保护设备说明表BGI 572和BGVD25）。Danger of injury by injectionThe pressure should be releasedfrom the spray gun and the gun securedduring

13、 breaks in work or beforeassembling and dismantling the nozzle.Never point the gun at yourself or anyother person, the spray jet can causeinjury by injection.Never put your finger or hand in thespray jet.In case of injury to skin by paint orcleaning agents consult a doctor immediately.Inform the doc

14、tor of thetype of paint or cleaning agent used.Cleaning agents and toolsOnly cleaning agents whose flashpoint is at least 5 kelvin higher thanthe ambient temperature should beused. External cleaning should onlybe carried out using a brush or acloth dampened with cleaning agentand never with hard obj

15、ects or solventguns.CleaningWhen cleaning the gun it shouldnever be sprayed into a "closed" container(formation of an explosive gasair/ mixture.Health and SafetySpraying can only be carried outsafely, both for people and the environment,if it is done in a spray boothor in front of a sprayi

16、ng wall with sufficientventilation (air extraction).In orderto avoid occupational illness thesafety regulations laid down by themanufacturer of the paint or cleaningagent used must be adhered to duringpreparation and application of thepaint and while cleaning the equipment.All local health and safet

17、y regulationsmust be complied with, particularlythe wearing of protective clothing,gloves and breathing apparatus toprotect the skin and the respiratorysystem.Protective breathing masksAlthough the spraying procedure producesvery little mist, it is not completelymist free. The operator mustbe provid

18、ed with a protective breathing mask. (see respiratory equipmentinstruction sheet BGI 572 and BGVD25 from the professional trade association)漆管喷枪和泵与喷枪间的高压管的质量必须能够承受泵压力。软管必须能够抗涂料的化学腐蚀。抽吸系统必须根据当地要求，在现场安装漆雾抽吸系统。附件和零备件制造商的担保和生产责任书只对由瓦格纳尔生产的附件和零备件有效。地线根据静电充电和喷涂时的流速，设备可能会带上静电。放电时可能会产生打火或者火焰。为了避免此情况的发生，设备必须

19、始终保持接地状态。在涂料容器和设备之间必须要有一个导电的连接（等电位结合线）。所有在生产区域工作的人员必须穿具有导电性的鞋（例如带有皮革底的鞋）。工作区域的地板必须是防静电的（见EN 50053 part 1， par. 7.2）。无害静电放电的有关安全信息如果用手接触喷枪的塑料部分，会造成无危害的静电放电（所谓的电刷放电）。塑料部件上的带电是由喷枪（静电）高压场引起的。此放电是绝对安全的。使用喷枪时，其电极针末端或许会产生电晕弧光（仅在黑暗的情况才可看到）。当电极针（喷枪）距离待喷物体4-10毫米时，会出现电晕放电的现象。电晕发光安全是无害的。固定静电系统的安装模块化喷涂系统是固定喷涂系统的

20、一个组件。安装固定喷涂系统时，应严格遵守EN 50176。其要求之一是只能用一把钥匙接通高压，但可以不用钥匙将高压关闭，如用紧急设停按钮。Paint hosesThe spray gun and the high pressurehose between the pump and thespray gun must be adequately ratedfor the pressure produced by thepump.The hose material must be chemicallyresistant to the effects of the sprayedmaterial.E

21、xtraction systemsPaint mist extraction systems must befitted on site according to the localregulations.Accessories and spare partsThe manufacturer's warranty andproduct liability are only valid if originalWagner accessories and spareparts are usedEarthingDepending on the electrostaticcharge and

22、the flow speed of thespray, an electrostatic charge mayoccur in the equipment. This couldcause a spark or flame on discharging.In order to avoid this, the equipmentmust always be earthed.There must be a conductive connection(equipotential bonding cable) betweenthe material container and theequipment

23、.All persons inside the working areamust wear conductive shoes (e.g.shoes with leather soles).The floor of the working area must beanti-electrostatic.(see part 1, par. 7.2)Safety information aboutharmless electrostatic dischagesIf the plastic parts of the spray gunare touched with the hand, this can

24、result in a harmless electrostatic discharge(known as brush discharge). The charge on the plastic parts iscaused by the high-voltage field ofthe gun. The discharging is completelysafe.A corona glow may occur at the electrodeend of the gun when it is in use(only visible under dark conditions). Acoron

25、a discharge can occur if theelectrode (spray gun) comes withinapprox. 4-10 mm of the object beingsprayed. The corona glow is totallyharmless.Setting up stationary electrostaticsystems.The Modular Painting System is acomponent of a stationary sprayingsystem. When setting up stationaryspraying systems

26、 comply strictly withEN 50176.One of the requirements is that it isonly possible to switch on the highvoltage with a key. But it must be possibleto switch off the high voltagewithout a key, for instance with anemergency stop button.德国规则及标准a) BGV A2Electrical installations and equipmentb) BGV D15Work

27、ing with liquid ejection devicesc) BGV D25Using coating materialsd) CHV 9Regulations on flammable liquidse) CHV 11Regulations on electrical equipmentin Ex areas.f) BGR 104Explosion protection rulesg) BGR 132Avoiding ignition risksh) BGR 180Setting up for cleaning with solventsfor liquid ejection dev

28、icesi) ZH 1/406Guidelines for liquid ejection devices.j) BGI 740Painting rooms and equipmentk) BGI 764Electrostatic coating.留意：以上规则及标准可向cologne的Heymanns出版社订购。German regulations and guidelinesa) BGV A2Electrical installations and equipmentb) BGV D15Working with liquid ejection devicesc) BGV D25Using

29、coating materialsd) CHV 9Regulations on flammable liquidse) CHV 11Regulations on electrical equipmentin Ex areas.f) BGR 104Explosion protection rulesg) BGR 132Avoiding ignition risksh) BGR 180Setting up for cleaning with solventsfor liquid ejection devicesi) ZH 1/406Guidelines for liquid ejection de

30、vices.j) BGI 740Painting rooms and equipmentk) BGI 764Electrostatic coating.Note:All titles can be ordered with HeymannsPublishing House in cologne.1.3 生产责任书及保修生产责任方面的重要说明由于EC规定已于1990年1月1日起开始实行，制造商只对由他们生产的或是得到他们批准的部件负责，并且是在设备被正确地安装、操作、以及保养的前提之下负责。如果用户使用由其他厂商提供的附件或零备件，那么我们将部分地或完全不负有关责任。所使用的瓦格纳尔原装附件和零

31、备件保证都符合全部安全规定。设备具有以下的生产担保：12个月， 6个月多班操作所有部件在收到货物6到12个月以内经过我们证明不能使用或是被严重损害时，可以进行免费的维修和退换，但仅限于由于不完善的设计、有缺陷的材料、不良工艺而损坏的部件。因以下原因的损坏不在保修范围内：不适合或不正确的使用，用户或第三方错误的安装或启动，自然磨损损害，以及磨损件（零件清单中以w标出）不正确的操作或保养。在收到货物后要立即进行检查，如有明显的问题，应以书面形式，在收到货物的14天之内通知供货商或通知我们，以避免失去申诉的权利。我们保留由契约伙伴履行担保的权利。担保的履行只能在用户将保修卡和/或带有日期及销售者签章

32、的发票连同设备一同返还之后才实施。如果发现不符合保修条件，那么所有的维修费用都应由买方承担。1.3 PRODUCT LIABILITY ANDWARRANTYImportant notes on product liabilityAs a result of an EC regulation, effective asfrom January 1, 1990, the manufacturer shallonly be liable for his product if all parts comefrom him or are approved by him, and if thedevic

33、es are properly fitted , operated andmaintained.If other makes of accessory and spare partsare used, the manufacturer's liability could befully or partially null and void.The usage of original WAGNER accessoriesand spare parts guarantees that all safety regulationsare observed.This equipment is

34、covered by the followingmanufacturing warranty:12 months,6 months for multi-shift operationAll parts which prove unusable or theuse of which is seriously impairedwithin 12 months or 6 months of receiptby the purchaser due to circumstancespredating receipt, such asfaulty design, defective materials o

35、rpoor workmanship, shall be repairedor replaced at our discretion and freeof charge.No liability will be accepted for damageattributable to the following factors:Inappropriate or incorrect use,faulty installation or startup by thepurchaser or third parties, naturalwear and tear, as well as wear part

36、s"w" (marked in the list of spare parts),incorrect handling or maintenance.The equipment must be checked immediatelyupon receipt. Obvious defectsmust be reported to the supplieror to us in writing within 14 days of receiptin order to avoid losing the rightof complaint.We reserve the right

37、to assign warrantywork to a contractual partner.Warranty shall only apply if the purchaserreturns the warranty card and/or sales invoice bearing the date ofsale and seller's signature togetherwith the equipment.Any repair costs will be charged tothe purchaser if it is found that thewarranty does

38、 not apply.CE证书缩略语CE = Communautés Européennes:标有CE标志的产品是按照欧盟的标准进行生产和检验的。这就表示使用的材料，制造过程及操作方面，本产品完全符合欧盟的安全与卫生要求，并因此而符合欧盟的规定与标准。这种适用于特定产品的规定与标准可以在CE证书中找到。证书与产品包装在一起或者也可以向生产厂商索取。在欧洲生产的产品从1995年1月1日起就必须通过CE认证，并且只有通过了CE认证的产品才能进行销售。EMC检验：电磁兼容性检验是CE认证的必不可少的一部分，经过电磁兼容检验的产品的干扰辐射在规定的限度内不会影响其它部件。此外，产品

39、必须通过抗干扰能力的EMC测试。这表明它们可不受外部干扰的影响。家用、商用、和工业用途的电磁兼容性标准各不相同。本装置是根据EMC工业标准检测的。它也符合于家用和商用标准。EC合格证书标有部件号：0381 891的证书与产品包装在一起。你可以向瓦格纳代理商订购这些证书，订购时请提供产品及其序列号。1.4 CE-CONFORMITYShort explanationCE = Communautés Européennes:Products identified with the CE markhave been manufactured andchecked accordin

40、g to EU guidelines.This means that, in terms of materialsused, manufacturing process and operation,they are in accordance withthe EU safety and health requirementsand therefore the EU regulationsand standards. The regulationsand standards applying to a particularproduct can be found in the CECertifi

41、cate of Conformity. This is enclosedwith the product or can be requestedfrom the manufacturer. TheCE marking has been compulsory inEurope since 1st January 1995, andonly products bearing CE identificationmay be released into circulation.EMC test:The electromagnetic compatibilitytest forms an integra

42、l part of the CEconformity. EMC tested products arebuilt such that their interference radiationdoes not influence other deviceswithin the stipulated limits.Moreover products must be EMCtested for their interference immunity.This means they are protected fromthe influence of external interference.The

43、 EMC standard differentiates betweendomestic, business, commercialand industrial use.The present device is checked accordingto the standards for industrialuse. The limits for domestic, businessand commercial use are also compliedwith.EC Certificate of ConformityThe certificate, Part No.: 0381 891is

44、enclosed with this product. If required,this can be reordered from yourWAGNER representative, quoting theproduct and serial number.2. 说明2.1 供货范围2.0 DESCRIPTION2.1 SCOPE OF SUPPLY数量Qty.部件号Part No.说明Description10381 020EPG 3000 静电控制模块Electrostatic control unit EPG3000标准设备包括：The standard equipment incl

45、udes:29922 101带齿垫圈Serrated washer29903 328椭圆头螺丝Oval head screw10264 900零备件组件*Spare parts set *10381 891CE合格证CE-Declaration of Conformity10381 820操作说明书德证/英语Operating manual German/ English1in Kap. 1see 1.0当地语言的操作说明书An operating manual in the locallanguage29951 116*零备件组件包括：延迟熔化保险丝2.0A* The spare parts

46、 set comprises:Delay-action fuses 2.0A29951 117延迟熔化保险丝1.0ADelay-action fuses 1.0A特殊型号见发货说明。备注：基本设备中不包括连接电缆。见第7章附件。2.2 技术数据电路：输入电压：85 VAC - 264 VDC47 Hz - 440 Hz.输入功率：最大 40 W输出电压：最大 19 Vpp输出电流最大 1.0 A阀门控制电压：24 V DC高压极限：80 kV喷枪电流极限：100 µA DC干扰等级：FN封闭等级 IP 64气路：输入空气压力：6 - 8 bar输出空气压力：0 - 6 bar压缩气质

47、量符合 ISO8573.1 5.5.4尺寸：宽度：270 mm高度：136 mm深度：315 mm重量：approx. 7.5 kg工作温度范围： 0 - 43°CFor special versions the delivery noteapplies.Note:The connection cables are not includedin the basic equipment.See accessories in chapter 7.2.2 TECHNICAL DATAElectrical:Input voltage: 85 VAC - 264 VDC47 Hz - 440

48、Hz.Input power: max. 40 WOutput voltage: max. 19 VppOutput current max. 1.0 AValve controlvoltage: 24 V DCHigh voltagelimit: 80 kVSpray gun currentlimit: 100 µA DCInterferenceclass: FNEnclosure class IP 64Pneumatics:Input air pressure: 6 - 8 barOutput airpressure: 0 - 6 barCompr.air qualityto I

49、SO8573.1 5.5.4MeasurementsWidth: 270 mmHeight: 136 mmDepth: 315 mmWeight: approx. 7.5 kgWorking temperaturerange: 0 - 43°C2.3 用途用途静电控制模块EPG 3000只能用于自动喷枪GA2005EAC或GA2005EA或GA2805EA。留意：自动喷枪GA2000EAC或GA2000EA或GA2800EA同样也可用EPG 3000进行操作。用于上述喷枪时，EPG 3000中的成形气调节器必须关闭。EPG3000静电控制模块可作为模块化喷涂系统的一个组件运行或单机运

50、行。2.4 功能说明EPG 3000静电控制模块与相应的喷枪及其它组件一起组成静电喷涂系统。它可作为单机使用或通过一个外部控制器（如，可编程逻辑控制器，模块化喷涂系统）使用。可设置三种工作模式，即“喷涂”、“清洗”或者（无高压喷涂）。喷枪的高压和油漆阀通过EPG 3000接通和关闭。该高压具有以下特性：如果喷枪与所喷涂的工件（或地线）距离太近，电压会自动降低以防止意外的火花放电。与此同时，喷枪中的高压阀和油漆阀及预置雾化气阀门的气路打开。2.3 APPLICATIONAttentionThe electrostatic control unit EPG3000 may only be used

51、 with the automaticspray guns GA2005EAC or GA2005EA or GA2805EA.Note:The automatic guns GA 2000 EAC,GA 2000 EA or GA 2800 EA canlikewise be operated with theEPG3000. The shaping air regulator in the EPG3000 must remainclosed for this.The EPG3000 can be run as acomponent of the Modular PaintingSystem

52、 or as a stand-alone unit2.4 FUNCTIONAL DESCRIPTIONThe EPG3000 is made up into anelectrostatic spraying system with theappropriate spray gun and othercomponents.It can be used either as a stand-aloneunit or through an external controller.(e.g. PLC, Modular Painting System).Three operating modes can

53、be set, i.e. "Spray", "Clean", or (sprayingwithout high voltage).The high voltage and the paintmaterial valve of the spray gun isswitched on and off through the EPG3000. The high voltage characteristicshave the effect that if the spraygun gets too close to the objectbeing sprayed

54、 (or to earth), thevoltage is automatically reduced thuspreventing an unintentional sparkdischarge. At the same time as thehigh voltage and the paint materialvalve, the pre-set atomising air valvein the spray gun is pneumaticallyactuated.2.5 操作控制2.5.1 EPG 3000的前面板2.5 OPERATING CONTROLS2.5.1 FRONT PL

55、ATE OF THEEPG30001 高压调节钮l 逆时针方向旋转经过开关点，将高压模块关闭。l 顺时针方向旋转调节高压（最大80kV）。2 喷涂电流显示屏（绿色发光显示屏）以微安为单位以条形显示喷涂电流值。3 高压指示器（绿色发光显示屏）以千伏为单位以条形显示高压值（实际值）。4 接近关闭指示（指示灯- 红色），喷枪接近当喷枪与工件间距离太近时，该指示灯亮。HVM进入故障模式，例如：l 高压被关闭。l 喷枪上的油漆阀和雾化气阀被关闭。操作步骤：l 排除引起故障的原因，如，增大喷枪和工件间的距离。l 用高压调节钮将HVM关闭，并随后再将它接通。1 Voltage regulator Rotat

56、e anti-clockwise pastswitching point to turn off thehigh-voltage module. Rotate clockwise to adjust thehigh-voltage (max 80 kV)2Spraying current display(Luminousdisplay green). Shows thespraying current in µA as a bardisplay.3 High voltage indicator(Luminousdisplay green)Shows the high-voltage (actualvalue) in kV as a bar display.4 Proximity shut-off(LED - red) , gun proximityLights up when the distance betweenthe gun and object is toolow. HVM goes into fault mode,i.e.: High-voltage is turned off. Material valve and atom