Manual M 700 Hopper

MITSUBA SYSTEMS (INDIA) PVT. LTD.
SERIES 700 HOPPER SYSTEM
PRODUCT MANUAL
SERIES-700 HOPPER SYSTEM

SAFETY
SAFETY
1. Introduction
READ THIS CAREFULLY BEFORE OPERATING ANY EQUPMENTS.
Read and follow these safety instructions, Task-and equipment-specific warnings,

cautions, and instructions are included in equipment documentation where
appropriate.
Make sure all equipment documentation, including these instructions, is accessible

to all persons operating or servicing equipment.
2. Qualified Personnel
Equipment owners are responsible for making sure that Mitsuba Systems’
equipment is installed, operated, and serviced by qualified personnel.
Qualified personnel are those employees or contractors who are trained to safely
perform their assigned tasks. They are familiar with all relevant safely rules and
regulations and are capable of performing their assigned tasks.
3. Intended Use
Use of Mitsuba Systems’ equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to persons or
damage to property.
Some examples of unintended use of equipment include
• using incompatible materials
• making unauthorized modifications
• removing or bypassing safety guards or interlocks
• using incompatible or damaged parts
• using unapproved auxiliary equipment
• operating equipment in excess of maximum ratings
4. Regulations and Approvals

Make sure all equipment is rated and approved for the environment in which it is
used. Any approvals obtained for Mitsuba Systems equipment will be voided if it
instructions for installation, operation, and service are not followed.
The equipment shall be considered dangerous if not operated according to the
standards EN 50050, EN 50053 Part 2 and EN 1953.
SAFETY
5. Personal Safety
WARNING
• Do not operate or service equipment unless you are Qualified.
• Do not operate equipment unless safety guards, doors, or covers are intact
and automatic interlocks are operating properly. Do not bypass or disarm any
safety devices.
• Keep clear of moving equipment. Before adjusting or servicing any moving

equipment, shut off the power supply and wait until the equipment comes to a
complete stop. Lock out power and secure the equipment to prevent
unexpected movement.
• Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or

servicing pressurized systems or components. Disconnected, lock out, and
tag switches before servicing electrical equipment.
• While operating manual electrostatic spray guns, make sure you are
grounded. Wear electrically conductive gloves or a grounding strap connected
to the gun handle or other true earth ground. Do not wear or carry metallic
objects such as tools.
• If you receive even a slight electrical shock, shut down all electrical or
electrostatic equipment immediately. Do not restart the equipment until the
problem has been identified and corrected.
• Follow the manufacturer’s instructions for safe handling and use of materials,
and use recommended personal protection devices.
To prevent injury, be aware of less-obvious dangers in the workplace that often

cannot be completely eliminated, such as hot surfaces, sharp edges, energized
electrical circuits, and moving parts that cannot be enclosed or otherwise guarded
for practical reasons. Care to be taken to especially avoid any repetitive strain
injury due to any recoil forces while operating the trigger of the gun.
SAFETY
6. Fire Safety
TO AVOID A FIRE OR EXPLOSION, FOLLOW THESE INSTRUCTIONS.
WARNING
• Ground all conductive equipment in the spray area. Check equipment and
work piece grounding devices regularly. Resistance to ground must not
exceed one mega ohm.
• Shut down all equipment immediately if you notice static sparking or arcing.
Do not restart the equipment until the cause has been identified and corrected
• Do not smoke, weld, grind, or use open flames where flammable materials
are being used or stored.
• Provide adequate ventilation to prevent dangerous concentrations of volatile

materials or vapors. Refer to local codes for guidance.
• Do not disconnect live electrical circuits while working with flammable

materials. Shut off power at disconnect switch first to prevent sparking.
• Know where emergency stop buttons, shutoff valves, and fire extinguishers
are located. If a fire starts in a spray booth, immediately shut off the spray
system and exhaust fans.
• Shut off electrostatic power and ground the charging system before adjusting,
cleaning, or repairing electrostatic equipment.
• Clean, maintain, test, and repair equipment according to the instructions in

your equipment documentation.
Use only replacement parts that are designed for use with original equipment.
Contact your local Mitsuba Systems representative for parts information and
advice.
SAFETY
7. Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system

immediately and perform the following steps:
• Disconnect and lock out electrical power. Close pneumatic shutoff valves
and relieve pressure.
• Identify the reason for the malfunction and correct it before restarting the
equipment.
8. Disposal
Dispose of equipment and materials used in operation and servicing

according to local codes that govern your area.
SAFETY
9. Caution List – for Operating Safety of the Equipment

• Your system can take normal voltage fluctuations. For extreme &
constant fluctuations, it is advisable to install a voltage stabilizer and
spike suppressor. This will ensure peak performance over long periods.
• Do not use excessive force on the muzzle of the electrostatic gun when
pulling out, otherwise the H.V. contact area of the gun will be damaged.
Pull out very gently after cleaning area with high pressure air.
• You may wash strongly fouled parts with Nitro-Thinner.
• Do not use Acetone.
• Do not damage electrodes while cleaning. Be careful while cleaning

these sharp electrodes so as to avoid being pierced.
Similarly insert back the muzzle after carefully aligning the black mark on the gun
body and muzzle. This ensures contact holes are aligned with contact pin. Insert
carefully without use of strength.
• Do not remove multiplier/cascade of reset gun unnecessarily. During

color change cascade need not be removed. Compressed air should be
simply blown through the gun. If cascade is removed, ensure that
adaptor Bush is in place and mark on cascade is carefully matched with
mark on gun body. Only then tighten the barrel holding nut.
• The Powder Spray system must be grounded solid and separate from
other system earths. This means that the Powder Spray Earth must not
be looped to Main Earth via the Booth, Oven etc., but it should be
connected to Main Earth separately.
• Maintain polarity of the Phase, Neutral and Earth at the Mains Power
Inlet.
• Switch OFF the ball valve at the main air inlet to prevent constant
operation of fluidizing air and accidental powder flow.
Install an air dryer to ensure that the main air into the Powder Spray System is
maintained at the specifications for compressed air as mentioned in this manual.
SAFETY
10. Basic Safety Care for Automatic and Manual Systems
CAUTION
• Properly ground all equipments within 5m of the powder spray area to an
earth ground.
• The floor of the powder spray area must be electro statically conductive.
• Powder should be removed from the skin with soap and water only.
DO NOT USE SOLVENTS.
• Do not tape the trigger in ‘ON’ position.
• Before cleaning or maintaining the gun, disconnect the main power

supply to the control panel.
• The operator should wear electro statically conductive footwear e.g.

leather soled shoes or chappals. He should hold the gun in his bare
hands to ensure skin to handle-metal contact.
• The electronic control unit is designed to cut out the high voltage system
in case of overloads. This is a safety precaution in-built into the system.
In case the system has cut-out (the Red LED on the Performance
Monitor is lit up), switch off the system and restart.
• A ground cable must be connected to the ground terminal of the

electrostatic sprayer. This cable must have proper metallic connection
with the coating booth, recovery unit, conveyor & jigs. The earth for the
electrostatic sprayer should not be looped to ground through the booth
etc.
• The power to the sprayer must be available only if the booth is switched
on. If the booth is switched off, the sprayer must also shut off.
• All ground connection must be checked daily or at least weekly.

TECHNICAL DATA
TECHNICAL DATA
Electrical Data
System Control Panel
Input Voltage 230V or 110V Single phase AC

selectable voltages
Frequency 50 / 60 Hz.
Connected loads 65VA
Safety class IP 54
Temperature Range -2 °C to +50 °C
Nominal Output Voltage to 10 V AC eff. @17000 Hz @ 0.9 Amps

Gun
Powder Gun (with integrated high voltage generator)
Nominal Input Voltage 10 V AC eff. @17000 Hz
Frequency 17000 Hz
Rated Output Voltage 100 KV DC
Polarity Negative ( Positive on Request)
Nominal Output Current 100 µA.
Pneumatic Data
Maximum input pressure 7 bar
Optimum input pressure 6 bar
Maximum water vapour content in compressed 1.3 g/m3

air
Maximum oil vapour content in compressed air 0.1 ppm
Maximum Compressed air consumption 13.2 m3 / h
GO TOP
FUNCTIONAL DESCRIPTION
The unit consists of a drawer (control panel), powder sprayer, Powder

Hopper, injector (powder pump) and trolley.
SERIES 700 PANEL
TROLLEY PILLAR
POWDER SPRAY CORONA GUN
POWDER SPRAY TRIBO GUN
POWDER HOPPER
POWDER PIPE
BASE TROLLEY
CASTERS
FIGURE NO 1
The fluidizing air is fed to the plenum chamber of the bed, the air passes
from the plenum through the porous tile into the powder. The air from the
plenum mixes with the powder causing fluidization i.e. a mixture of air and
powder that has characteristics of a liquid, and yet remains a dry powder.
The conveying air pulls the fluidized powder from the bed and propels it
through the hose to the gun. It is the conveying air which controls the
powder quantity being sprayed.
The dosing air is fed into the pump simultaneously with the powder
conveying air. The dosing air mixes with the powder and regulates the
powder-to-air ratio and hence controls the powder cloud density emitted
from the gun.
By balancing these two regulators the desired powder volume and

penetration can be achieved without any puffing or surging of powder.
Each gun can be set differently to suit the spray pattern required.
The concentration of the powder air mixture and therefore of the powder
output depends on the conveying-air pressure, the quality of the powder,
the length of the powder hose, the difference of the height between gun
and injector and the type of the gun. The manometer indicates the
dynamic pressure.
To decrease the powder output without reducing the conveying speed, the
vacuum in the hollow has to be decreased. For that purpose the dosing-air
is blown into the cavity as secondary air. By increasing the dosing air, the
powder output decreases.
To obtain a regular pulsating free powder output, the adjusting of

conveying-air and dosing have to be chosen in such a way, that the whole
compressed air consumption per gun does not fall below 2.5m3/hr. To
avoid an eventual blow-off the consumption should not exceed 7m3/hr. A
regular and pulsating free powder output depends also on the length of
the powder hose
The precise adjustment has to be carried out in every case.
In general, increasing the conveying air pressure increases powder output

and increasing dosing air reduces powder output.
The fluidization pressure depends on the type, specific gravity and

quantity of powder in the powder hopper. Fluidization pressure must be
set so that the powder is well agitated and free flowing in the powder
hopper. Without good fluidization, the flow of the powder will not be
uniform. Fluidization must never be excessive. When the powder appears
to “boil” it is a sign of good fluidization.
The KV control is connected to a potentiometer which controls the high

voltage generated in the gun. Higher the voltage; thinner the film and
greater the deposition efficiency.
The “Smart Tracker” is connected to the motherboard to ensure constant

monitoring of the performance of various components of the control panel.
Simultaneously, one must note that at higher voltages it is difficult to coat

complex shapes and cavities. Thus one must reduce the voltage to coat
cavities. In general, the Corona Sprayer is used for increased deposition
efficiencies; & the Tribo Sprayer for penetrating awkward shapes and
obtaining ultra high quality finishes.
The Indicator LED system shall display the Corona electrostatic charge in
the Corona Mode and with a Corona Gun and the Tribo Electrostatic
charge in the Tribo Mode with a Tribo Gun.
PCB (Printed Circuit Board): - THE PCB CONTAINS THE FOLLWING

COMPONANTS.
BLUE CERMET
PRINTED CIRCUIT BOARD VER
POTENTIOMETER
JUMPER SET ON PCB

(FOR’A’ & ‘B’ POSITION
PT 3
PT 1
LED’S ON PCB
FIGURE NO 2
Function of Three Blue Cermet Potentiometers

PT1 - Turning this clockwise decreases the K.V. indicator reading only
and does not affect the actual output K.V.
Turning this anti-clockwise increases the K.V. indicator reading

only and does not affect the actual output K.V.
This reading is not important for the TRIBO gun and does not indicate the
charging of the TRIBO gun whatsoever.
PT3 - Turning this anti-clockwise increases the maximum Output

voltage to the gun.
Turning this clockwise decreases the maximum output voltage to

the gun
This affects the actual K.V. output of the Corona gun.
In reality the maximum K.V. is about 105 K.V. and the min. K.V. is about 50-60 K.V.
Function of Three LED’s on the PCB

LED 1 Green led. This switches on the moment the panel is switched
on with the PCB inserted. This indicates that the PCB is
switched on ok.
LED 2 Amber led. This switches on when the spray gun is triggered.
This indicates that the solenoid valve is triggered on.
LED 3 Red led. This switches on upon overload. This led is normally
not on. In case of an overload, the gun H.V. is cutout and this
led switches on. The panel then needs to be switched off, PT2
readjusted and switched on again.
Function of Jumper set JP1 on the PCB
Factory set position. Do not change this position. Altering this

POSIITION‘A’ can affect the functioning of the powder spray equipment.
This position is to be used only when this PCB is replaced in a

POSITION ‘B’ earlier MITSUBA SYSTEMS equipment.
Special Note on the Function of the Tribo Super Charger
Suitable for Epoxy, Polyurethane, Polyamide (Nylon), Acrylic, PVC, Polyester.
Hybrid Epoxy Polyesters have to be specially formulated for use with the Tribo
Super Charger. Many powder manufacturers now make hybrids which are
compatible to Tribo guns. The standard Hybrid "Epoxy - Polyester" may or may
not get charged in a Tribo gun. It has to be tried out and confirmed prior to
production use. In case you must use the hybrid powder on the Tribo gun.
Inform your powder supplier to give you a Tribo compatible hybrid powder.
Flow Control:
The flow control in the Tribo should be set such that the output is between 5 to 8
kgs /hr . The output of the Tribo will never exceed 10-12 kg/hr as against the
output of a corona gun which is about 30 Kg/hr.
Tribo guns achieve better charging at higher speeds of powder flowing through
the gun. To achieve the best charging, increase conveying to a maximum
pressure of 5-6 bars & then increase the dosing. This will reduce the flow &
increase speeds on the powder. Increase the dosing air till the Tribo achieves
best charging and a good flow pattern.
BASIC INFORMATION
The Tribo gun uses a different principle than the traditional electrostatic gun for
charging the powder. The built in self-exciting charger gives an internal charging
to each individual powder particle without ionizing air. This takes place in the gun
itself and that means it is independent of the work piece and its surroundings.
There is no longer a straight field between the gun electrodes and work piece but
a diffused powder cloud with thousands of single carriers.
This type of charging technique has three extremely important advantages: -
1) As there is no corona, no faraday cage results and the most complex work
piece can be perfectly coated inside - out. Bends, hollows, Corners and
interiors which are not reachable with a corona gun can be perfectly coated
by Tribo
For example:
Proton Principle High Voltage Princ iple
2) Since air is not charged, dust particles do not get charged and so dust does
not deposit on the work piece. Also back-ionization and the resultant effects
like pin holing, orang peeling and moon craters is retarded. The powder
coating is thus optically brilliant as never Before
3) No high-tension generators exist and hence no sparks can flash over

between gun and work piece. Hence the gun can even be touched to the
earthed work piece without fear of ignition. Hollows, bends and interiors can
be well coated due to this phenomenon also.
ASSEMBLY, INSTALLATION & SETUP
WARNING: Allow only qualified personnel to perform the following

Tasks. Follow the safety instructions in this document and all other
related documentation.
WARNING: All electrically conductive equipment in the spray area must be

grounded. Ungrounded or poorly grounded equipment can Store an
electrostatic charge which can give personnel a severe Shock or
arc and cause a fire or explosion.
1. Assembly & Installation (Hopper System)
SERIES 700 CONTROL PANEL
TROLLEY PILLAR
POWDER SPRAY CORONA GUN
POWDER SPRAY TRIBO GUN
POWDER HOPPER
POWDER PIPE
TROLLEY BASE
CASTORS
• Remove the Dual Control Panel, Trolley Pillar, Trolley Base, Powder
Hopper, Corona Gun and accessories carefully from the Box. (The entire
system is packed in one box.)
• Bolt the Trolley Pillar on the Trolley Base using the 4 Bolts provided. Also
Bolt the Dual Control Panel on the Trolley Pillar using the 2 knobs
provided.
• Place the hopper on trolley base and connect the pneumatic hoses.
Blue tube for Powder/ Conveying Air
And Yellow tube for Carrier Air/ Dosing.
MAIN AIR IN CONNECTOR
SERIES 700 PANEL
FUSE HOLDER
GUN IN CONNECTOR “CORONA”
GUN IN CONNECTOR “TRIBO”
EARTHING SCREW
INTERLOCK GUN CONNECTOR
MAINS IN CONNECTOR
CONVEYING AIR OUT
DOSING AIR OUT
POWDER CONVEYING TUBE
CARRIER AIR
SERIES 700 PANEL
POWDER PUMP SET
POWDER HOPPER
• Connect gun plug to panel. Connect mains inlet cable to panel. Confirm
phase, Neutral + Earth polarity are correct on the mains plug.
GUN PLUG
MAINS IN
Confirm that earth connection is given to a proper ground.

This is very IMPORTANT.
Operating faulty electrostatic equipment is hazardous and can

cause Electrocution, fire, or explosion Make resistance checks
part of your Periodic maintenance program. If you receive even
a slight Electrical Shock or notice static sparking or arcing, shut
down all Electrical Electrostatic equipment immediately. Do not
restart the Equipments Until the problem has been identified
WARNING and corrected.
• Put an air relief hose from the powder hopper into the powder spray
booth if you have a relief vent with the system.
2. Commencement of Operations (Hopper System)
• Ensure proper Earthing ( ) to the equipment.
• Put powder into the hopper.
POWDE FILLED IN HOPPER
POWDER HOPPER
• Connect the equipment to the main air supply. Turn on the Ball Valve at
the main Air inlet.
M 700 PILLAR
VALVE BALL
EARTHING
POTENTIOMETER 4 BAR PRESSURE

KNOB SERIES 700 GUAGE
3 WAY SWITCH REGULATOR

PERFORMANCE 7BAR PRESSURE
MOINTER GUAGE
• Switch on the power supply.
• Check the gun to connect in the right socket at the back of the control
panel. If using corona gun place the gun connector in “C” connector & if
Tribo then use “T” connector on the back.
REAR SIDE OF SERIES 700 PANEL
GUN IN CONNECTOR “CORONA”
GUN IN CONNECTOR “TRIBO”
EARTHING SCREW
INTERLOCK GUN CONNECTOR

• To switch the gun supply on rotate the 3 way switch to “T” for Tribo & “C”
for corona.
FRONT SIDE OF SERIES 700 PANEL
POTENTIOMETER
3 WAY SWITCH
• Direct the gun into the spray booth and trigger the gun.
• Adjust the fluid bed air pressure to 0.2 to 1.5 kg/cm2 till the powder in the
hopper appears to "boil". Do not keep higher pressure than necessary
otherwise powder may "puff" out the gun. (Maintain pressure within green
zone of pressure gauge.)
• Adjust the dosing air pressure to about 0.5 to 1 bar (generally this is
always less than 2.0 bar, maintain pressure within green zone of pressure
gauge.)
• Adjust the conveying air pressure to about 2.5 kg/cm2 to 3 kg/cm2 for
electrostatic gun & upwards of 4 kg/cm2 for Tribo gun. (Maintain pressure
within green zone of pressure gauge.)
• By increasing conveying air, you will increase powder density. By reducing

conveying air, you will decrease powder density.
• By increasing dosing air, you will increase powder speeds and reduce
cloud density. By reducing dosing air, you will reduce powder speeds and
increase cloud density.
• Set the H.V. control to desired level. By increasing H.V. the -ve KV &
charging level increases.
• For the Tribo Gun just plug in the gun at the Gun In 'T' plug at the rear of
the panel and switch on.
3. Important Compressor Air Data

MAXIMUM MOISTURE CONTENT 1.3 gms / m³
MAXIMUM OIL CONTENT 0.1 ppm

IMPORTANT
Most high technology powder application systems require good quality
compressed air, free of oil and moisture. This is because powders are
hygroscopic in nature and would quickly absorb oil and moisture. This would
deteriorate powder quality in terms of its resistively (charging efficiency) and
flow properties.
Air emerging from a compressor is saturated with moisture, condensed

water, oil droplets and oil vapor. This must be removed or else powder
could get bad and its charging and deposition efficiency be affected
adversely.
We recommend you to install an excellent oil and moisture trap. A

refrigerated air dryer or heatless air dryer provides excellent results for
water vapour removal. Activated carbon driers should be used for oil
removal.
COLOUR CHANGE & MAINTENANCE SCHEDULE

1. Colour Change
It is important to note that a black and white powder mix in powder coating
does not give gray. It gives a black finish with white spots and vice versa. So
the Colour change operation is very critical.
PROCEDURE
1. Drain and clean powder hopper.
2. Blow out powder hose with compressed air, squeeze powder hose if
necessary.
3. Disassemble and clean the gun, with high-pressure air and soft brush.
4. Prepare sprayer for operation with the new powder.
5. Before starting with the coating operation, "flush" powder hose and gun
with the new powder.
CAUTION
1. Do not use excessive force on the muzzle of the electrostatic gun when
pulling out, otherwise the H.V. contact area of the gun will be damaged.
Pull out very gently after cleaning area with high pressure air.
2. Wash strongly fouled parts with nitro thinner. Do not use acetone. Do not
damage the electrodes when cleaning the nozzle.
3. The mark on the cascade & gun handle must be aligned before fitting
back the cascade.
2. Basic Safety Care for Automatic and Manual Systems
WARNING
1. Properly ground all equipments within 5m of the powder spray area

to an earth ground.
2. The floor of the powder spray area must be electrostatic ally

conductive.
3. Powder should be removed from the skin with soap and water
only. DO NOT USE SOLVENTS.
4. Do not tape the trigger in ‘ON’ position.
5. Before cleaning or maintaining the gun, disconnect the main power

supply to the control panel.
6. The operator should wear electro statically conductive footwear e.g.

leather soled shoes or chappals. He should hold the gun in his bare
hands to ensure skin to handle-metal contact.
7. The electronic control unit is designed to cut out the high voltage
system in case of overloads. This is a safety precaution in-built into
the system. In case the system has cut-out (the Red LED on the
Performance Monitor is lit up), switch off the system and restart.
8. A ground cable must be connected to the ground terminal of the

electrostatic sprayer. This cable must have proper metallic
connection with the coating booth, recovery unit, conveyor & jigs. The
earth for the electrostatic sprayer should not be looped to ground
through the booth etc.
9. The power to the sprayer must be available only if the booth is

switched on. If the booth is switched off, the sprayer must also shut
off.
All ground connection must be checked daily or at least weekly.

3. Servicing and Routine Maintenance
1. Clean the powder feed pump every day at least. If the pump is fitted
with a brass powder hose connector + venture, this must be cleaned
every day to ensure it is powder blockage free.
2. Blow air through the powder hose to clean it once a day.
3. Blow air through the spray gun to clean it once everyday.
4. Check (and replace if necessary) the outlet Teflon sleeve of the

powder feed pump once a week at least. Time for wear out of the
venturi is varied and depends a lot on the abrasivity of the powder
used, amount of powder sprayed and various other factors.
5. Check (and replace if necessary) the deflector.
6. Once a year the equipment should be overhauled by a maintenance

engineer.
7. Oil and water must be discharged every day. Oil content of

compressed air must not exceed 0.1 PPM. Water content of
compressed air must not exceed 1.3 g/m3
8. Check your air purifying unit every week.

TROUBLE SHOOTING
TROUBLE-SHOOTING
Introduction
This section contains troubleshooting procedures. These procedures cover only
the most Common problems that you may encounter.
If you cannot solve the problem with the Information given here, contact
your Mitsuba System representative.
Note that the Mitsuba System is not responsible for any damages done to
the system while handling or trouble-shooting the equipment.
PERFORMANCE MONITOR
TROUBLE SHOOTING
Troubleshooting Chart
FAULT CAUSE REMEDY

0.5 Amps Led Not No Mains Input Rectify Situation
Glowing
Check 0.5 A Fuse Replace Fuse With 0.5A
Check I/P Voltage Slow Blow Fuse only
Mains Cord Is Defective Check Continuity And
Replace
Repeated Blowing Of Check Mains Line. Phase And
0.5a Fuse Neutral Polarity.
H-Pot Filter Open/ Rectify Loose Connection.

Burnt
Replace Motherboard
On/Off Switch Led Not Check On/Off Switch On Rectify Loose Connection
Glowing Panel
Check Middle Block Of

The Switch
Check Middle Crimping

Of Red Wire Through
The On-Off Switch Block

Check Point ‘L’ On M.B. Rectify Loose Connection.
Replace N/O Contact/ Switch
Replace Motherboard
K.V. Indicator Led Not K.V. Indicator Supply 12v Rectify Loose Connection
Glowing From Control
Transformer Not Proper. Replace Control Transformer

Check Supply At Point ‘N’ Rectify Loose Connection.
& Point ‘E2’ Of
Motherboard Replace Motherboard
PCB Faulty Replace PCB

TROUBLE SHOOTING
Fault Cause Remedy

2.5 Amps Led Not Check 2.5 Amps Fuse Replace Fuse With 2.5 Amps
Glowing Slow Blow Fuse Only
Repeated Blowing Of Rectify Loose Connection /
2.5 Amp Fuse Shorting
Replace PCB
Replace Motherboard / Vertical

Connector.
Check O/P Voltage Of Replace Transformer
Transformer
Control PCB Led Not PCB Loose Connection Fit In PCB Properly
Glowing
Replace Motherboard
Check Vertical PCB Replace Vertical PCB
PCB Is Defective Mail In For Possible Repairs
H.V. Gun Led Not Gun Plug Loose Plug In Properly

Glowing Connection
K.V. Potentiometer Set Turn Potentiometer On Fully /
To Zero Replace
Ensure That PCB Jumper

Position Set At ‘A’(If The Pot Is
Of 10k)
Micro Switch On Gun Check And Replace
Defective
Gun Cable Defective Check For Continuity & Replace
Gun Wrongly Put Into Put Corona Gun Into At The Back
‘T’ Position Of Panel Position
Check Point ‘B’ At Rectify Loose Connection
Motherboard
Replace Motherboard
Check Varistor At Gun Replace
In Plug
H.V. Gun Not Working Mail In For Possible Repairs
Check Power Cartridge Replace Power Cartridge

(If Corona Infinity)
TROUBLE SHOOTING
Fault Cause Remedy

H.V. Gun Led Glows K.V. Potentiometer Not Turn Potentiometer On Fully /
Dimly Set To Full Replace
Ensure That PCB Jumper

Position Set At ‘A’
H.V. Low Clean Cascade Points / Replace
Cascade Pins
Replace Power Cartridge
Rotate Cermet Pt3 On PCB

Clockwise
Mail In For Possible Repairs
Sol. Valve Trigger PCB Defective Mail In For Possible Repairs

Led Not Glowing
0.75 Amps Led Not Check Fuse Replace Fuse With 0.75 Amps
Glowing Slow Blow Fuse Only
Check Solenoid Valve Jammed Valve
Replace Solenoid Valve

Check Point ‘M’ & ‘M1’ Rectify Loose Connection
At Motherboard
Replace Motherboard
Overload Red Led System Overloaded Switch Off And Restart After 2
Glowing Min
Switch Off-Rotate Pt2 On PCB

Clockwise-Restart.
PCB Faulty Replace PCB

TROUBLE SHOOTING
Fault Cause Remedy

Powder Does Not Air Supply Pressure Check And Rectify By
Flow While Air Flows Incorrect Increasing Conveying Or
Out Of The Gun Reducing Dosing
Teflon Sleeve Worn Out Replace Teflon Sleeve

Blocked Pump/Injector Clean Out / Fit
Or Dipstick Or Blocked Properly
Check Valve (Non
Return Valves) Or
Improperly Fitted Pump
Conveying Regulator Clean/Rectify By

Checked/Leaked Situation
Blocked Powder Hose Clean / Replace
Blocked Gun Clean Carefully

( Very Carefully With Drill Of
Same Size If Necessary )
Powder Pipe Blocked Clean / Replace

Fluidization Is Poor Increase Fluidization Air;
Replace Clogged Tile
Check For Bad Moist
Powder
Conveying + Dosing Ensure Proper Connection.

Pipe Into Charged
Powder Does Not Solenoid Valve Replace/Mail For Repairs

Flow And Air Does Defective Clean Sol. Valve
Not Flow Out Of The Sol. Valve Checked.
Gun Pneumatic Tubing Clean / Replace
Blocked / Leaked
Regulator Chocked / Clean Out / Replace
Defective
Gun Cable Is Broken Check For Continuity And

Replace
Gun Micro Switch Is Check With Multi-meter And

Defective Replace
TROUBLE SHOOTING
Fault Cause Remedy

Powder Does Not PCB Defective Mail In For Possible Repairs
Flow And Air Does
Not Flow Out Of The Sol. Valve Fuse Blow Replace 0.75 Fuse
Gun Main Inlet Ball Valve Turn On Ball Valve
Turned Off
Main Air Inlet Ball Valve Clean / Replace

Faulty
Gun Charging Ok But KV Meter Defective Replace IC On K.V. Meter

No Indication On
Meter Replace K.V. Meter
PCB Defective. Replace PCB

Poor Deposition Or HV Low Increase Potentiometer
Wrap Around Potentiometer On Full Rotate Cermet Pt3 On PCB
But H.V. Indication Is Anti-Clockwise / Replace
Low Potentiometer / Ensure PCB
Jumpers Set At Position ‘A’
/Gun Defective Mail In For
Possible Repairs
Check Earthing / Correct / Clean Jigs If
Grounding Of Necessary
Workpieces / System
Powder Moist / Bad As Change Powder
One Can Feel Full
Charging On The Hand /
Hair
Electrodes At Gun Tip Clean / Replace Muzzle
Dirty Or Broken
TROUBLE SHOOTING
Fault Cause Remedy

Poor Deposition Gun Contact Pins Broken Replace Barrel
Or Wrap Around
Mail In Gun For Possible
Repairs.
3 Core Cable Badly Fitted In Correct By Separating
Gun Handle / Wires Of Cable Wires
Touching Each Other In
Handle
Handle / Barrel Pin Dirty Clean Contacts By Using

CTC / Thinner / After Shave
/ Replace Barrel Pins
Barrel Loose In Handle Fit Barrel Properly In

Handle
Barrel Is Defective Replace Power Cartridge /

Gun Gives Check Grounding Of Gun, Rectify

Shock / Operator , Work pieces &
Sparking- Panel To Main Earth
Crackling Noise 3 Core Cable Of Gun Badly Correct By Separating
Fitted In Handle / Touching Wires
Each Other In Handle
Check Gun Body For Spark Mail In For Possible Repairs

Leakage At Full HV Or Seal With Araldite.
Uneven Pattern Deflector Not Fitted Properly Fit Properly

(Heavy Spots)
Deflector Is Damaged Replace
Dosing Air Too Low. Adjust Dosing Pressure To

Minimum 0.5 bar.
Teflon Sleeve Warn Out Replace

Dosing NRV Checked.
Clean / Replace
Powder Pipe Beut Or Of
Low Quality.
No Or Low Fluidization Rectify.

Pressure.
TROUBLE SHOOTING
TROUBLESHOOTING DIRECTIONS
REPLACING FUSE
CLEANING SOL. VALVE
REPLACING SOL. VALVE

TROUBLE SHOOTING
REPLACING MOTHER
BOARD
REPLACING PRINTED
CIRCUIT BOARD (PCB)
REPLACING CONTROL
TRANSFORMER
REPLACING
POTENTIOMETER
TROUBLE SHOOTING
REPLACING PRESSURE
REGULATOR
REPLACING SWITCH
ROTATING CERMETS
TROUBLE SHOOTING
REPLACING DPM
REPLACING PERFORMANCE
MONITOR
REPLACE TEFLON SLEEVE

(VENTURI)
REPLACING POWER
CARTRIDGE
REPLACE CLOGGED TILE
CLEANING NRV
TROUBLE SHOOTING
INSTRUCTION TO REPLAC FUSE: -

This document demo shows how to change the fuse.
It is recommended to first identify the situation and the blown up fuse
for that troubleshooting chart may help and then attempt to replace
the fuse.
THE THREE FUSES ARE

PLACED AT THE BACK OF
THE CONTROL PANEL.
TO REPLACE THE FUSE: -

PRESS THE FUSE CAP WITH THE HELP OF SCREW DRIVER AND ROTATE
IT IN ANTI-CLOCK VISE DIRECTION. AT ONE POINT THE CAP WILL GET
PUSHED OUT.
THEN TAKE OUT THE FUSE CAP WHICH CONTAINS FUSE AS WELL.
REPLACE THE FUSE WITH RECOMMENDED VALUE AND SLOW BLOW
TYPE.
AND SIMILARLY BY APPLYING A SMALL PUSH INSERT THE FUSE INTO
CAP AND PLACE THE CAP IN SOCKET AND ROTATE CLOCKWISE
DIRECTION KEEPING THE CAP PRESSED.
TROUBLE SHOOTING
INSTRUCTIONS TO CLEAN SOLENOID VALVE
1) Open the nut with 15

no. spanner.
TROUBLE SHOOTING
2) Remove the coil of the

solenoid valve by
simply pulling it out as
shown in the figure.
3) Open the solenoid

plunger block with
22no. spanner.
TROUBLE SHOOTING
The plunger block comes out and the plunger can be seen. Remove the plunger
cautioning the plunger spring should not lost.
Blow the high pressure air into the solnoid base, plunger block and plunger to clean.
TROUBLE SHOOTING
Note: make sure that the plunger spring is placed

properly as it was originally placed.
The loose part has to be at upper side
The tight part has to be at lower side
Place the plunger on the

solenoid base.
TROUBLE SHOOTING
Fit the plunger block on

the solenoid base & tight
the assembly.
2) Place the coil of the

solenoid valve by
simply pushing it in as
shown in the figure.
TROUBLE SHOOTING
1) Tight the nut with 15

no. spanner.
Solenoid valve is cleaned succesfully and ready for the operation

TROUBLE SHOOTING
INSTRUCTIONS TO REPLACING SOLENOID VALVE
Before opening the solenoid

valve remove all the pneumatic
connection from the solenoid
valve.
Also Before opening the

solenoid valve; remove the
electrical connections from the
4-way strip.
Open the nuts with M3 box

spanner and remove the
covering sheet.
TROUBLE SHOOTING
Then open the screws with

help of the star-head screw
driver and open the connecting
wires.
To replace the solenoid valve open all 4 nuts using

M5 box spanner.
The solenoid valve gets free and can be easily
removed from the system panel.
TROUBLE SHOOTING
Take a fresh solenoid valve and place it on the panel

place provided for the solenoid valve.
TROUBLE SHOOTING
Connect the wire as per the

diagram.
And then bolt the solenoid valve.

The solenoid valve assembly is
ready for use.
TROUBLE SHOOTING
INSTRUCTION TO REPLACE MOTHER-BOARD

To replace the mother board it is important to take out the Printed circuit board.
Then only the mother board can be replaced safely.
2) To loose the nut rotate

bolt in clock wise
direction. Remove the
nut and bolt assembly.
By doing this; the PCB
be comes free and
easy to remove.
2) Just pull up the PCB

in vertical direction
with even but not
much force.
TROUBLE SHOOTING
3) Remove all the

connector safely.
4) Remove the bolt form

the four nuts holding
the mother board.
The mother board comes out. Take a fresh mother-board an dplace it on the base plate
provided in side of the panel. Then insert the screws and tight them well. The mother board is
replaced sucessfully.
Then insert the PCB with the vertical card in the socket provided for the PCB on the mother-
board.
The Mother-board has been replaced sucessfully and ready to use.

TROUBLE SHOOTING
INSTRUCTIONS TO REPLACE PRINTED CIRCUIT BOARD: -
1) To loose the nut rotate

bolt in clock wise
direction. Remove the
nut and bolt assembly.
By doing this; the PCB
be comes free and easy
to remove.
2) Just pull up the PCB

in vertical direction
with even but not
much force.
3) Then push the new PCB

in to the socket and
press it evenly in the
vertical card slots.
TROUBLE SHOOTING
INSTRUCTIONS TO REPLACE CONTROL TRANSFORMER: -

Transformer is very important part of the panel as it provides the power to
the system. Non proper wiring can lead to the malfunctioning of the system
1) Identify the pri. & sec.
PRIMARY
SECONDARY
2) Open the nuts using

M5 box spanner
3) Open the nuts of 8-way using

M3 box spanner
TROUBLE SHOOTING
Secondary Primary
8- Way connecting strip
To Motherboard
Open the screws of the 8 way connecting strip which are coming from the
transformer using star-screw driver.
Then replace the new transformer properly.
Cautioning the circuit connections should be as per the speciation required.
(i.e. 110V or 230V) provided in the “wiring diagram” at motherboard wiring
TROUBLE SHOOTING
INSTRUCTIONS TO REPLACE POTENTIOMETER: -

Front top view of the potentiometer
1) To open the potentiometer, first open

the knob with 1mm Allen-key
KNOB
2) The knob will come out, then open
nut with 14/15 spanner.
TROUBLE SHOOTING
Rear view of the potentiometer
3) Then pull the potentiometer from the

inside of the panel.
4) Remove the connection between

potentiometer and the mother board.
The potentiometer can be changed
and a new pot can be placed in the
similar way proceeding from step 4 to
1 in reverse order.
TROUBLE SHOOTING
INSTRUCTION TO REPLACING PRESSURE REGULATOR
To open the regulator open the

front nut provided for the fitting
of the nut.
TROUBLE SHOOTING
Then open regulator remove all the pneumatic connections and pull the solenoid valve
out of the panel.
TROUBLE SHOOTING
Take a fresh regulator and put

it in to the panel.
Then rotate the nut in the

clockwise direction.
The regulator is replaced
successfully.
TROUBLE SHOOTING
INSTRUCTION TO REPLACING SWITCH
Open the lid of the panel.

The switch is present below
the potentiometer.
To open the n/o blocks

insert a screw driver in the
gap between n/o block and
the switch. The n/o block
comes out remove all three
blocks.
The precaution has to be taken for removing the n/o bolcks as the execive force may
lead to the breaking of the n/o blocks lock in clips.
TROUBLE SHOOTING
Lose the screws with metal

connector.
To remove the switch, hold the knob

and twist. It will get detached from the
body of the switch. The knob comes
out from the front of the panel and the
body comes from inside of the panel.
Take a fresh switch. And

insert the trust caps in
the place provided for it
on the bottom side of the
switch knob.
Place the switch body in side of the panel, where the place is provided for the switch.
TROUBLE SHOOTING
And inset the switch knob from

the front of the panel.
To fit the knob perfectly in the
switch body insert it in the body
and rotate it.
It will automatically fits in the
panel.
Fit the switch by tightening

the screws one by one.
The switch has been

replaced successfully.
TROUBLE SHOOTING
After replacing the switch

place the N/O blocks back
in the position.
Note: The N/O block for Tribo should be
at the lower side of the blocks.
The sequence is as follows from
the top to bottom
The sequence is as follows from the

top to bottom.
1>N/O for Corona gun
2>N/O for mains
3>N/O for Tribo gun
The switch is replaced and

ready to use.
TROUBLE SHOOTING
INSTRUCTIONS TO ROTATE THE CERMETS
PT3
PT1
THE CERMET PROVIDED ARE FOR THE PURPOSE OF MANUAL ADJUSTMENTS
PT 1: - Turning this cermet clockwise decreases the K.V. indicator reading only and
does not affect the actual output K.V.
PT 3:-Turning this cermet anti-clockwise increases the maximum Output voltage to the
gun.
TROUBLE SHOOTING
First it is very important to identify which cermet to be rotated.

Then only proceed to adjust the cermet.
Insert the screw driver in the screw set of the cermet then rotate
as per the requirement. Do not use intensive force to rotate the
screw, as it may damage the material of the cermet and lead to
malfunctioning of the system.
TROUBLE SHOOTING
INSTRUCTIONS TO REPLACE DPM: -
(DPM)
PERFORMANCE
MONITOR (PM)
upper view of the panel

the DPM is placed at the front side near the potentiometer.
DPM
POTENTIOMETER
MOTHER-BOARD
TROUBLE SHOOTING
1) To open DPM open the

2 screws with a star
head screw driver.
2) Remove the connector

plugs.
4) Then the DPM comes

out then it can be
replaced.
5) Take a fresh DPM and

the fit it on the place
provided for it inside of
the panel.
TROUBLE SHOOTING
It is important to note that the DPM should be placed properly in the position.
It should look straight from the front of the panel.
6) Tight the screws with

firstly inserting the
washer.
7) Connect the cable

Rellemec 2pin & 3pin
connector
The DPM Is Replaced Successfully.
MAIN PAGE
TROUBLE SHOOTING
INSTRUCTIONS TO REPLACE PERFORMANCE MONITOR
DIGITAL PERFORMANCE
MONITOR (DPM)
PERFORMANCE
MONITOR (PM)
To open the performance monitor it is necessary to open the digital performance

monitor first
1) To open DPM open the
2 screws with a star
head screw driver.
2) Remove the connector

plugs.
TROUBLE SHOOTING
INSTRUCTIONS TO REPLACE TEFLON SLEEVE: -
1) The venturi is placed in the

pump powder nozzle
POWDER PUMP BODY
2) To open the nozzle just

hold the nozzle tightly and
pull it out of the assembly it
will easily come out without
much effort.
POWDER PUMP
OUTLET NOZZLE
TROUBLE SHOOTING
3) To take out venturi from

the nozzle just hold the
nozzle tightly and pull it
out of the assembly.
You may need to push
the venturi from the rear
side of the nozzle with
the help of multi nut
holder.
4) The new venturi is

placed in the nozzle
and just pushed in. It
will get fitted in side the
nozzle tightly. Then this
is placed in the
assembly by pushing
SLEEVE
with even force.
The Teflon sleeve has been

replaced successfully.
TROUBLE SHOOTING
Then the DPM comes out then it can be replaced if defective.
After opening the DPM to open the performance monitor open the 4 screws with star-head
screw driver.
Then the PM comes out then it can be replaced if defective.

TROUBLE SHOOTING
INSTRUCTIONS TO REPLACE POWER CARTRIDGE: -
Coupling Nut
Barrel
1) The power cartridge is

Handle the important part of
the gun. To replace
power cartridge open
the coupling nut by
rotating it as shown.
2) Then pull out the

barrel cautioning the
connective inserts of
the cartridge
3) Hold the barrel such that

cartridge faces.
Open the screws of the
cartridge.
4) The cartridge comes

out easily and can be
replaced.
TROUBLE SHOOTING
It is important to note that male insert’s of the power cartridge must get inserted in the female
inserts of the barrel. Then screw up the power cartridge with the barrel. The barrel; assembly is
complete.
To assemble the barrel

with the handle the
marking at the bottom
side of the handle as well
as on the barrel is
provided. It is important to
match the markings.
TROUBLE SHOOTING
Then just push the barrel

in side of the handle the
barrel gets fitted with the
gun handle.
Put the coupling nut on

the barrel.
And rotate it to tight it as

shown.
The replacement
procedure of the power
cartridge is complete.
TROUBLE SHOOTING
INSTRUCTIONS TO REPLACE CLOGGED TILE: -
1) The tile is in side of

the hopper system. To
change the tile open
the base at a side by
opening the clamps
on the base
After opening all the clamps, top of the hopper can easily removed at a side.
And then pulling the tile up, it can be removed out of the base with little of
efforts. Cautioning the tile should not be handled with excessive pressure it
may lead to breaking of the tile. Proper bushing is necessary for the hopper
to perform efficiently.
TROUBLE SHOOTING
Hopper top
Fluidizing tile
Hopper base
Clamp
TROUBLE SHOOTING
2) Take new tile and

properly fit the gasket
on the tile.
3) Push the tile on the

hopper base; where
the place is provided.
It will fit perfectly on
the hopper base.
Then place the hopper top on the base. Clamp up the assembly properly.
The assembly is complete and ready to be used.
TROUBLE SHOOTING
INSTRUCTION TO CLEAN NRV

The NRV is used to protect the instrument from the damages occurring due to the
powder. The powder can damage the solenoid valve and also lead to blocking.
To open the NRV use 16/17 no. spanner
BLOW AIR
When the upper part opens, blow air with pressure and clean the filter inside.
TROUBLE SHOOTING
If still the problems persist then simply open the filter out.
Now blow air on the filter very well.

And again fix the filter by rotating the screw driver in anticlockwise directions.
And fit the top using 16/17 spanner
The assembly is complet and ready to use.

PART LIST
PART LIST
SERIES 700 CORONA PANEL
PART LIST
TRANSFORMER RELAY PRINTED CIRCUIT BOARD VER 2.5

PART LIST
SERIES 700 CORONA PANEL
SR. ITEM ITEM CODE QTY.

NO. NO.
1} POTENTIOMETER EL – 03 – 0019 ONE
1A} POTENTIOMETER KNOB EL – 03 – 5001 ONE
2} SWITCH 3 WAY EL – 02 – 0001 ONE
2A} SWITCH BLOCK 2 NO EL – 02 – 0021 THREE
2B} THRUST PAD ONE
3} DPM LED EL – 01 – 0201 ONE
3A} PERFORMANCE MONITOR EL – 01 – 0304 ONE
4} PRESSURE GAUGE 7 BAR 42 MM PN – 01 – 0312 ONE
5} GASKET PRESSURE GAUGE CN – 01 – 0151 TWO
6} REGULATOR DIA31 PN – 01 – 0101 TWO
7} GASKET REGULATOR CN – 01 – 0141 TWO
8} PRESSURE GAUGE 4 BAR 42 MM PN – 01 – 0302 ONE
9} FUSE HOLDER FH7 EL – 05 – 0101 THREE
9A} GLASS FUSE 0.5A SLOW BLOW EL – 05 – 0001 ONE
9B} GLASS FUSE 0.75A SLOW BLOW EL – 05 – 0011 ONE
9C} GLASS FUSE 2.5A SLOW BLOW EL – 05 – 0021 ONE
10} GASKET FUSE CN – 01 – 0111 THREE
11} CONNECTOR 3 PIN S.S. EL – 04 – 0001 TWO
12} GASKET GUN IN / INTERLOCK CN – 01 – 0131 THREE
13} CONNECTOR 4 PIN S.S. EL – 04 – 0011 ONE
14} EARTH SCREW SET CN – 02 – 0301 ONE
15} GASKET EARTH SCREW / POT EL – 01 – 0101 TWO
16} SOCKET MAINSIN WITH GASKET EL – 04 – 0101 ONE
17} PNU. BULKHEADS 6 OD TWO
18} GASKET PNEUMATIC CN – 01 – 0121 THREE
19} PNU. BULKHEADS 8 OD ONE
20} SOLENOID VALVE 24V AC PN – 01 – 0001 ONE
PART LIST

NO. NO.
21} PNU. STR. CONN. ¼”M 6 OD PN – 02 – 0141 ONE
21A} PNU.CONN. Y ¼”M 6 OD PN – 02 – 0141 ONE
22} PANEL SOL. VAL. CLAMP 2U SH – 01 – 0104 TWO
23} CONNECTOR STRIP 4 WAY EL – 04 – 0211 ONE
24} HI – POT FILTER EL – 01 – 0501 ONE
25} PNU. CONN. STR. 1/8”F 6 OD PN – 02 – 0101 TWO
25A} PNU. CONN. ELBOW. 1/8”F 6 OD PN – 02 – 0101 TWO
26} PNU. CONN. ELBOW ¼”M 6 OD PN – 02 – 0131 FOUR
27} PNU. CONN. ELBOW 1/8”M 6 OD PN – 02 – 0121 TWO
27A} PNU. PIPE 6 OD TWO
27B} PNU. PIPE 8 OD ONE
28} MOTHER BOARD VER. 1.2 EL – 01 – 0107 ONE
29} TRANSFORMER CONTROL EL – 06 – 0001 ONE
30} CONNECTOR STRIP 8 WAY EL – 04 – 0221 ONE
31} MASTER PCB VER 2.0 EL – 01 – 0010 ONE
32} MASTER PCB SCREW SET CN – 02 – 0101 ONE
33} GASKET GROMET LID CN – 01 – 0221 FOUR
34} GASKET PANEL LID – INNER CN – 01 – 0201 ONE
35} GASKET PANEL LID – OUTER CN – 01 – 0211 ONE
36} PANEL MOUNTING KNOB M6 CN – 01 – 1011 TWO
37} N.R.V. PN – 01 – 0201 TWO
PART LIST
TROLLEY PILLAR
SERIES 700 TROLLEY PILLAR
7 BAR PRESSURE
REGULATOR
BALL VALVE
SERIES 700 TROLLEY
CASTOR /WHEEL
PART LIST
TROLLEY PILLAR INTERNAL

NO. NO.
1} PNEU. CONN. ELBOW 1/8" M 6 OD PN – 02 – 0121 ONE
2} PRESSURE REGULATOR PN – 01 – 0101 ONE
3} PNEU. CONN. ELBOW 1/4" M 6 OD PN – 02 – 0131 ONE
4} PNEU. CONN. STRAIGHT 1/8" F 6 OD PN – 02 – 0102 ONE
5} PRESSURE GUAGE 0 - 4 BAR PN – 01 – 0302 ONE
6} PNEU. CONN. T 1/4" M 8 OD PN – 02 – 0251 ONE
7} PNEU. CONN. STRAIGHT 1/4" F 8 OD PN – 02 – 0212 ONE
7A} BRASS CONN. 3/8”M X ¼”M ONE
8} BALL VALVE PN – 06 – 0221 ONE
9} MALE ¼” 6 OD ONE
10} FEMALE ¼” 6 OD ONE
11} GUN HOOK SH – 03 – 5101 ONE
12} COMPLETE PILLAR ONE
13} TROLLEY BASE ONE
14} ASSEMBLED TROLLEY ONE
PART LIST
POWDER HOPPER
PART LIST
POWDER HOPPER
NO. NO.
1} POWDER HOPPER COMPLETE ONE
2} PNEU. BULKHEAD CONN. 6 OD ONE
2A} EARTH SCREW SET CN – 02 – 0301 ONE
3} FLUIDIZING TILE ROUND PN – 05 – 0121 ONE
3A} FLUIDIZING TILE GASKET ONE
4} HOPPER CLAMPS CN – 13 – 2055 ONE
5} INJECTOR PUMP ASSY. FG – 20 – 0001 ONE
6} HOPPER TOP LID ONE
6A} HOPPER TOP LID GASKET ONE
7} HOPPER POURING LID ONE
PART LIST
HOPPER PUMP
POWDER PUMP SET
POWDER HOPPER
PART LIST
HOPPER PUMP

NO. NO.
1} ELBOW CONNECTOR 1/8" M PN – 02 – 0121 ONE
2} POWDER PUMP BRASS NOZZLE PN – 06 – 1021 ONE
2A} BRASS NOZZLE ‘O’ RING CN – 10 – 0101 TWO
3} POWDER PUMP BODY PN – 06 – 1001 ONE
3A} PUMP BODY ‘O’ RING GASKET CN – 10 – 0111 TWO
4} STRAIGHT CONNECTOR 1/8" M PN – 02 – 0111 ONE
5} INJECTOR SLEEVE (NEW) PN – 06 – 0121 ONE
5A} SLEEVE CIRCLIP CN – 10 – 0123 ONE
5B} SLEEVE 'O' RING GASKET CN – 10 – 0121 TWO
6} PUMP OUTLET NOZZLE PN – 06 – 0125 ONE
6A} OUTLET NOZZLE 'O' RING GASKET CN – 10 – 0125 TWO
7} POWDER PUMP BASE PN – 06 – 0130 ONE
8} PUMP BASE ‘O’ RING CN – 10 – 0130 TWO
9} PUMP BASE NUT PN – 06 – 0132 ONE
10} SUCTION TUBE PN – 06 – 0021 ONE
10A} SUCTION TUBE ‘O’ RING CN – 10 – 0135 ONE
PART LIST
INFINITI MANUAL CORONA GUN

PART LIST
INFINITI TM MANUAL CORONA GUN
SR. ITEM ITEM CODE

NO. NO. QTY.
1} DEFLECTOR & NOZZLE REFER MUZZLE
PAGE
2} UNION NUT FOR ELECTROSTATIC GUN GE – 03 – 0001 ONE
3} MUZZLE REFER MUZZLE
PAGE
4} DEFLECTOR ROD GE – 05 – 0041 ONE
5} CASCADE BARREL FG – 10 – 0220 ONE
6} COUPLING NUT FOR HOLDING GE – 04 – 3011 ONE
CASCADE BARELL TO HANDLE
7} VITON 'O' RINGS BARREL OUTER CN – 10 – 1001 TWO
8} VITON 'O' RINGS BARREL INNER CN – 10 – 1002 TWO
9} POWER CARTRIDGE GE – 01 – 3001 ONE
10} BARREL REPLACEABLE H.V. PINS GE – 01 – 1007 ONE
11} ADAPTOR PLUG GE – 02 – 0011 ONE
12} TRIGGER SCREW GE – 02 – 0051 ONE
13} TRIGGER FOR ELECTROSTATIC GUN GE – 05 – 0071 ONE
14} BRASS TRIGGER WASHER GE – 02 – 0053 ONE
15} MICRO SWITCH EL – 02 – 5001 ONE
16} GUN HOOK SCREW TWO
17} REPLACEABLE HOOK GE – 05 – 0051 ONE
18} SCREW SET WITH HOLDER FOR CN – 02 – 0004 ONE
ABOVE
19} HANDLE COVER PLATE ELECTRO GE – 03 – 0201 ONE
20} INLET NOZZLE FOR POWDER PN – 06 – 1001 ONE
21} STRAIN RELIEF ELECTRIC GE – 03 – 0105 ONE
CONNECTOR
22} POWDER PIPE ANTI FUSING TYPE PN – 03 – 0501 ONE
23} GUN CABLE 3 CORE X 5 MTR. WITH EL – 03 – 0117 ONE
PLUG
24} HANDLE WITH HIGH VOLTAGE FG – 10 – 0210 ONE
GENERATOR
25} ELECTROSTATIC GUN ASSEMBLY FG – 10 – 0201 ONE
COMPLETE
PART LIST
INFINITI AUTO CORONA GUN

PART LIST
INFINITI AUTO CORONA GUN

NO. NO.
1} DEFLECTOR REFER MUZZLE ONE
PAGE
2} NOZZLE REFER MUZZLE ONE
PAGE
3} UNION NUT FOR GUN GE – 03 – 0001 ONE
4} MUZZLE FOR GUN WITH SAFETY REFER MUZZLE ONE
SYSTEM PAGE
5} AUTO GUN CASCADE ASSEMBLY FG – 11 – 0220 ONE
6} COUPLING NUT FOR HOLDING GE – 04 – 3011 ONE
CASCADE TO HANDLE
7} BARREL 'O' RING CN – 10 – 1001 TWO
8} POWER CARTRIDGE 'O' RING CN – 10 – 1002 TWO
9} POWER CARTRIDGE FOR AUTO GUN GE – 01 – 3002 ONE
10} BARREL H.V. PINS GE – 01 – 1007 FOUR
11} ADAPTOR PLUG GE – 02 – 0011 ONE
12} AUTO HANDLE WITH HIGH VOLTAGE FG – 11 – 0210 ONE
GENERATOR
13} AIR INLET CONNECTOR ONE
15} GUN CLAMP HOLDER SCREW SET CN – 05 – 0001 ONE
16} GUN MOUNTING BOLTS CN – 05 – 0004 TWO
17} AUTO GUN CLAMP FG – 20 – 1001 ONE
18} CABLE 3CORE X 8 MTRS WITH PLUG EL – 03 – 0117 ONE
19} AUTO GUN OUTER SLEEVE SET ONE
(UNION NUT + SLEEVE + COUPLING)
20} AUTO ELECTROSTATIC GUN FG – 11 – 0201 ONE
ASSEMBLY COMPLETE
PART LIST
GUN MANUAL TRIBO

PART LIST
GUN MANUAL TRIBO

NO. NO.
1} DEFLECTOR CAP GT – 01 – 0007 ONE
2} DEFLECTOR TRIBO GT – 01 – 0001 ONE
3} FRONT TURBULATOR GT – 01 – 0004 ONE
4} DEFLECTOR BUSH GT – 01 – 6010 ONE
5} FRONT THREADED BUSH O RING TWO
6} FRONT THREADED BUSH GT – 01 – 0013 ONE
7} TURBULATOR GT – 01 – 0016 THREE
8} CENTRE BUSH GT – 01 – 0019 TWO
9} CENTRE ROD WITH EARTH SCREW GT – 01 – 0022 ONE
10} REAR BUSH CONICAL STRAIGHT GT – 01 – 0025 ONE
11} TURBULATOR TYPE TRIBO GUN COMPLETE FG – 12 – 0001 ONE
12} TRIGGER SCREW TRIBO GE – 02 – 0051 ONE
13} TRIGGER TRIBO GT – 03 – 0001 ONE
14} TRIGGER SCREW TRIBO WASHER GE – 02 – 0053 ONE
15} MICRO SWITCH EL – 02 – 5001 ONE
16} RUBBER WASHER GT – 01 – 0028 ONE
17} AL WASHER GT – 01 – 0028 ONE
18} EARTHING SPRING GT – 01 – 0028 ONE
19} EARTHING KNOB GT – 01 – 0028 ONE
20} METAL SCREW SET GT – 01 – 0021 ONE
21} HANDLE COVER PLATE TRIBO GT – 03 – 0011 ONE
22} STRAIN RELIEF ELECTRIC CONNECTOR GE – 03 – 0105 ONE
23} BRASS AIR NOZZLE ONE
25} POWDER PIPE ANTI FUSING TYPE PN – 03 – 0501 ONE
26} CABLE 3 CORE 5 MTR WITH PLUG EL – 03 – 0017 ONE
PART LIST
AUTO TRIBO GUN

PART LIST
AUTO TRIBO GUN

NO. NO.
1} DEFLECTOR TRIBO AUTO GT – 02 – 0001 ONE
2} FRONT TURBULATOR AUTO GT – 02 – 0004 ONE
3} DEFLECTOR BUSH AUTO GT – 02 – 0007 ONE
4} FRONT THREADED BUSH 'O' RING GT – 02 – 0011 ONE
5} FRONT THREADED BUSH AUTO GT – 02 – 0014 ONE
6} TURBOLATOR AUTO GT – 02 – 0017 THREE
7} CENTRE BUSH AUTO GT – 02 – 0021 TWO
8} CENTRE ROD WITH EARTH SCREW GT – 02 – 0024 ONE
9} REAR CENTRE ROD BUSH GT – 02 – 0027 ONE
10} AUTO TRIBO HANDLE WITH INNER TUBE GT – 02 – 0030 ONE
11} ALUMINIUM DISTRIBUTOR BLOCK GT – 02 – 0034 ONE
12} ALU. DISTRIBUTOR BLOCK 'O' RING GT – 02 – 0037 ONE
13} ALU. DISTRIBUTOR BLOCK 'O' RING GT – 02 – 0041 TWO
14} REAR BUSH GT – 02 – 0044 ONE
15} POWDER IN NOZZLE GT – 02 – 0047 ONE
16} AUTO TRIBO CLAMP GT – 02 – 0051 ONE
17} EARTH SCREW GT – 02 – 0054 ONE
18} LOCKING THUMB SCREW GT – 02 – 0057 ONE
19} PNEU. CONNECTOR ELBOW PN – 02 – 0131 ONE
20} AUTO TRIBO GUN TURBULATOR TYPE FG – 13 – 0001 ONE
COMPLETE
PART LIST
MUZZLES & NOZZLES

PART LIST
MUZZLES & NOZZLES

SR. ITEM ITEM CODE
NO. NO. QTY.
MUZZLE 4 ELECTRODES WITH 9
DEFLECTORS
1} DEFLECTOR φ 15 MM TYPE 1 GE – 04 – 1001 ONE
10} 4 ELECTRODE MUZZLE FG – 14 – 0001 ONE
MUZZLE 32 ELECTRODES WITH 9

DEFLECTORS
10} MUZZLE 32 ELECTRODE FG – 14 – 0201 ONE
11} DEFLECTOR ROD BLACK GE – 05 – 0043 ONE
METALLIC MUZZLE WITH 9

DEFLECTORS
10} METALLIC MUZZLE FG – 14 – 0301 ONE
12} METALLIC MUZZLE UNION NUT ONE
PART LIST
MUZZLE CENTER ELECTRODE WITH

NOZZLES (AIR RINSE)
1} FLAT SPRAY NOZZLE SINGLE SLIT GE – 04 – 2001 ONE
1A-2} FLAT SPRAY NOZZLE SINGLE SLIT GE – 04 – 2002 ONE
(DIVIDER)
(MAIN)
1B-4} FLAT SPRAY NOZZLE SINGLE SLIT GE – 04 – 2004 ONE
(BASE)
(DIVIDER)
(MAIN)
2} FLAT SPRAY NOZZLE 4 SLIT GE – 04 – 2011 ONE
4} CUP TYPE INTERNAL CHARGING GE – 04 – 2031 ONE
NOZZLE
5} CENTRE ELECTRODE MUZZLE FOR FG – 14 – 0111 ONE
FLAT
SPRAY
MUZZLE CENTER ELECTRODE

WITHOUT AIR RINSE
1} FLAT SPRAY NOZZLE SINGLE SLIT GE – 04 – 2001 ONE
(DIVIDER)
(MAIN)
(BASE)
(DIVIDER)
(MAIN)
4} CUP TYPE INTERNAL CHARGING GE – 04 – 2031 ONE
NOZZLE
5} CENTRE ELECTRODE MUZZLE FOR FG – 14 – 0101 ONE
FLAT
SPRAY
4 ELECTRODE MUZZLE WITH AIR

RINSING
1} DEFLECTOR FOR AUTO GUN φ 15 GE – 04 – 1101 ONE
DEFLECTOR FOR AUTO GUN φ 30 GE – 04 – 1107 ONE
4} 4 ELECTRODE MUZZLE WITH AIR FG – 14 – 0011 ONE
RINSING DEFLECTOR MOUNTING
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM
WIRING DIAGRAM

Manual M 700 Hopper

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Manual M 700 Hopper

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MITSUBA SYSTEMS (INDIA) PVT. LTD.

SERIES 700 HOPPER SYSTEM

SERIES-700 HOPPER SYSTEM

READ THIS CAREFULLY BEFORE OPERATING ANY EQUPMENTS.

Read and follow these safety instructions, Task-and equipment-specific warnings,

Make sure all equipment documentation, including these instructions, is accessible

4. Regulations and Approvals

• Do not operate or service equipment unless you are Qualified.

• Keep clear of moving equipment. Before adjusting or servicing any moving

• Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or

To prevent injury, be aware of less-obvious dangers in the workplace that often

TO AVOID A FIRE OR EXPLOSION, FOLLOW THESE INSTRUCTIONS.

• Provide adequate ventilation to prevent dangerous concentrations of volatile

• Do not disconnect live electrical circuits while working with flammable

• Clean, maintain, test, and repair equipment according to the instructions in

7. Action in the Event of a Malfunction

If a system or any equipment in a system malfunctions, shut off the system

Dispose of equipment and materials used in operation and servicing

9. Caution List – for Operating Safety of the Equipment

• You may wash strongly fouled parts with Nitro-Thinner.

• Do not use Acetone.

• Do not damage electrodes while cleaning. Be careful while cleaning

• Do not remove multiplier/cascade of reset gun unnecessarily. During

10. Basic Safety Care for Automatic and Manual Systems

• Do not tape the trigger in ‘ON’ position.

• Before cleaning or maintaining the gun, disconnect the main power

• The operator should wear electro statically conductive footwear e.g.

• A ground cable must be connected to the ground terminal of the

• All ground connection must be checked daily or at least weekly.

Input Voltage 230V or 110V Single phase AC

Connected loads 65VA

Temperature Range -2 °C to +50 °C

Nominal Output Voltage to 10 V AC eff. @17000 Hz @ 0.9 Amps

Nominal Input Voltage 10 V AC eff. @17000 Hz

Rated Output Voltage 100 KV DC

Polarity Negative ( Positive on Request)

Nominal Output Current 100 µA.

Optimum input pressure 6 bar

Maximum water vapour content in compressed 1.3 g/m3

Maximum Compressed air consumption 13.2 m3 / h

The unit consists of a drawer (control panel), powder sprayer, Powder

SERIES 700 PANEL

POWDER SPRAY CORONA GUN

POWDER SPRAY TRIBO GUN

By balancing these two regulators the desired powder volume and

To obtain a regular pulsating free powder output, the adjusting of

In general, increasing the conveying air pressure increases powder output

The fluidization pressure depends on the type, specific gravity and

The KV control is connected to a potentiometer which controls the high

The “Smart Tracker” is connected to the motherboard to ensure constant

Simultaneously, one must note that at higher voltages it is difficult to coat

PCB (Printed Circuit Board): - THE PCB CONTAINS THE FOLLWING

JUMPER SET ON PCB

Function of Three Blue Cermet Potentiometers

Turning this anti-clockwise increases the K.V. indicator reading

PT3 - Turning this anti-clockwise increases the maximum Output

Turning this clockwise decreases the maximum output voltage to

Function of Three LED’s on the PCB

Function of Jumper set JP1 on the PCB

Factory set position. Do not change this position. Altering this

This position is to be used only when this PCB is replaced in a

This type of charging technique has three extremely important advantages: -