Electrostatic Technology 802 Manuel utilisateur

Electrostatic Technology, Inc. Model 802 Armature Coater

Serial #15681 i

TABLE OF CONTENTS

1 INTRODUCTION.............................................................................................................................1

2 SHIPPING .........................................................................................................................................1

3 OPERATING PRINCIPLES ...........................................................................................................2

3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER..........................................2

3.2 PROCESS DESCRIPTION .......................................................................................................3

4 GENERAL SAFETY ........................................................................................................................4

4.1 INTRODUCTION .....................................................................................................................4

4.2 SAFETY SYMBOLS.................................................................................................................5

4.3 QUALIFIED PERSONNEL ......................................................................................................5

4.4 INTENDED USE.......................................................................................................................6

4.5 INSTALLATION ......................................................................................................................6

4.6 OPERATION.............................................................................................................................8

4.7 LESS-OBVIOUS DANGERS .................................................................................................10

4.8 IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION .............................10

4.9 MAINTENANCE & REPAIR.................................................................................................11

4.10 DISPOSAL ..............................................................................................................................12

5 AIR, ELECTRICAL, AND WATER REQUIREMENTS ..........................................................13

5.1 POWDER COATING MACHINE ..........................................................................................13

5.1.1 Air ................................................................................................................................13

5.1.2 Electrical ......................................................................................................................13

5.1.3 Water............................................................................................................................13

5.1.3.1 Closed Loop Induction Heater Cooling System............................................13

5.1.3.2 Tower Water Requirements For Induction Heater Cooling .........................13

5.2 INDUCTION HEATER...........................................................................................................13

5.2.1 Electrical........................................................................................................................13

6 MECHANICAL FUNCTION: SEQUENCE AND DESCRIPTION ........................................14

6.1 LOAD/RELOAD AREA .........................................................................................................14

6.2 INDUCTION HEATER DEGREASER MODULE ................................................................14

6.3 COATING MODULE .............................................................................................................14

6.3.1 Coating Bed .................................................................................................................14

6.3.2 Powder Level Sensor ...................................................................................................15

6.4 CLEANING STATION ...........................................................................................................15

6.4.1 Bulk Box ......................................................................................................................15

6.4.2 O.D. Belt Cleaner.........................................................................................................15

6.4.3 Air Knives....................................................................................................................16

6.4.4 Screw Cleaner ..............................................................................................................16

Electrostatic Technology, Inc. Model 802 Armature Coater

ii Serial #15681

6.5 POWDER MANAGEMENT SYSTEM ..................................................................................17

6.6 INDUCTION HEATING MODULE.......................................................................................19

6.7 CURE MODULE.....................................................................................................................19

6.8 FINAL COOL MODULE........................................................................................................19

6.9 REFRIGERANT AIR DRYER................................................................................................19

6.10 DEIONIZED WATER SYSTEM ............................................................................................19

6.11 INDUCTION HEATER COOLING WATER ........................................................................20

6.12 MAIN CONTROL CABINET.................................................................................................20

7 DESCRIPTION OF CONTROLS.................................................................................................21

7.1 OPERATOR MAIN CONTROL PANEL ...............................................................................21

7.2 OPERATOR MAIN CONTROLS...........................................................................................22

7.3 COATER CONTROL PANEL................................................................................................25

7.4 COATER CONTROLS ...........................................................................................................25

7.5 CLEANING CONTROL PANEL ...........................................................................................26

7.6 CLEANING CONTROLS .......................................................................................................27

7.7 POWDER MANAGEMENT SYSTEM CONTROLS ............................................................28

8 SPECIFICE EQUIPMENT SAFETY...........................................................................................29

8.1 GENERAL...............................................................................................................................29

8.2 POWDER.................................................................................................................................29

8.2.1 Employee Health..........................................................................................................29

8.2.1.1 Inhalation......................................................................................................29

8.2.1.2 Skin Contact..................................................................................................29

8.2.1.3 Eye Contact...................................................................................................30

8.2.1.4 First Aid Procedures.....................................................................................30

8.2.2 Special Protection ........................................................................................................30

8.2.3 Precautions...................................................................................................................30

8.2.4 Material Safety Data Sheets (MSDS) ..........................................................................30

9 PREPARATION FOR OPERATION...........................................................................................31

9.1 INITIAL SYSTEM INSTALLATION ....................................................................................31

9.2 GENERAL...............................................................................................................................33

9.3 COATER..................................................................................................................................34

9.3.1 Coating Bed .................................................................................................................34

9.3.2 Powder Deposition.......................................................................................................34

9.3.3 High Voltage Adjustment ............................................................................................35

9.4 POWDER MANAGEMENT SYSTEM ..................................................................................35

9.4.1 Loading Powder...........................................................................................................35

9.4.2 Powder Maintenance....................................................................................................35

9.5 CLEANERS.............................................................................................................................35

9.5.1 O.D. Cleaner ................................................................................................................35

9.5.2 Air Knives....................................................................................................................36

9.5.3 Screw Cleaners ............................................................................................................36

9.6 INDUCTION HEATERS ........................................................................................................36

Electrostatic Technology, Inc. Model 802 Armature Coater

Serial #15681 iii

10 OPERATION ......................................................................................................................................37

11 START-UP & OPERATION PROCEDURE...................................................................................38

11.1 LOCAL MODE-COATING MACHINE.....................................................................................38

11.2 EXTERNAL MODE-COATING ................................................................................................39

12 SHUTDOWN PROCEDURE ............................................................................................................40

12.1 LOCAL MODE SHUTDOWN-COATER ..................................................................................40

12.2 EXTERNAL MODE SHUTDOWN-COATER...........................................................................40

12.3 POWDER HANDLING...............................................................................................................40

12.3.1 Powder Management System...........................................................................................41

12.4 POWDER/COLOR CHANGE ....................................................................................................41

13 MAINTENANCE................................................................................................................................42

13.1 GENERAL...................................................................................................................................42

13.2 COMPRESSED AIR SYSTEM...................................................................................................42

13.2.1 Air Line ...........................................................................................................................42

13.2.2 Refrigerant Air Dryer.......................................................................................................42

13.3 FLUIDIC BED.............................................................................................................................43

13.3.1 Installation of Porous Plate ..............................................................................................43

13.3.2 Powder Level Sensor .......................................................................................................44

13.4 POWDER COLLECTOR ............................................................................................................44

13.4.1 Lower Fluidizing Hopper.................................................................................................45

13.4.2 Installation of Porous Plate ..............................................................................................45

13.4.3 Filter Cartridges ...............................................................................................................46

13.4.4 Differential Pressure Gauge.............................................................................................46

13.5 O.D. CLEANER ..........................................................................................................................46

13.6 INDUCTION HEATER...............................................................................................................47

13.7 COOLING BLOWERS................................................................................................................47

13.8 ROTO-FLO CONVEYOR...........................................................................................................47

13.9 MOTORS & GEARS...................................................................................................................47

14 PREVENTATIVE MAINTENANCE SCHEDULE ........................................................................48

14.1 DAILY .........................................................................................................................................48

14.2 WEEKLY.....................................................................................................................................48

14.3 MISCELLANEOUS ....................................................................................................................49

15 PART CHANGEOVER......................................................................................................................50

15.1 CHANGEOVER PROCEDURE .................................................................................................50

15.1.1 Changing From Smaller To Larger Parts........................................................................50

15.1.2 Changing From Larger To Smaller Parts.........................................................................50

Electrostatic Technology, Inc. Model 802 Armature Coater

iv Serial #15681

16 TROUBLESHOOTING .....................................................................................................................51

16.1 COATER......................................................................................................................................51

16.2 POWDER COLLECTOR ............................................................................................................55

16.3 CONVEYOR CLUTCH ..............................................................................................................55

16.4 BAD PARTS................................................................................................................................56

17 PATENT INFORMATION................................................................................................................58

18 MANUFACTURER'S MANUALS ...................................................................................................59

19 FLOOR PLAN ....................................................................................................................................60

20 PNEUMATIC SCHEMATIC ............................................................................................................60

21 ELECTRICAL SCHEMATIC ..........................................................................................................60

22 SPARE PARTS ...................................................................................................................................61

Electrostatic Technology, Inc. Model 802 Armature Coater

Serial #15681 v

TABLE OF FIGURES

FIGURE 1A: 5HP POWDER COLLECTOR................................................................................................18

FIGURE 1B: SCRAP POWDER COLLECTOR ..........................................................................................18

FIGURE 2: PIPING DIAGRAM ................................................................................................................32

FIGURE 3: LEVEL SENSOR PROBE TUBE...........................................................................................34

Electrostatic Technology, Inc. Model 802 Armature Coater

Serial #15681 1

1 INTRODUCTION

This Operating Manual must be studied and followed for the safe and efficient operation of the Model

802 Coating System. Study this manual before locating and installing the equipment.

If there are any questions, please call:

ELECTROSTATIC TECHNOLOGY, INC.

A SUBSIDIARY OF NORDSON CORPORATION

4 PIN OAK DRIVE

BRANFORD, CT 06405

TELEPHONE: 203-488-8112

FAX: 203-483-8777

In future correspondence, please refer to the Model (802) and Serial Number (15681) of the Coating

System.

2 SHIPPING

Sometimes equipment can be damaged in transit. An inspection of the shipping crates should be made

upon delivery. When the equipment is removed, it should be carefully inspected to make sure the

equipment is in good condition. If the equipment is damaged, the carrier's claim agent should be

requested to prepare a report, a copy of which should be sent to:

ELECTROSTATIC TECHNOLOGY, INC.

A SUBSIDIARY OF NORDSON CORPORATION

4 PIN OAK DRIVE

BRANFORD, CT 06405

Electrostatic Technology Incorporated will then advise concerning repairs and replacements.

Electrostatic Technology, Inc. Model 802 Armature Coater

2 Serial #15681

3 OPERATING PRINCIPLES

3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER

Electrostatic Technology, Inc. Model 802 Armature Coater

Serial #15681 3

3.2 PROCESS DESCRIPTION

Powder particles are aerated in a fluidizing chamber and are electrostatically charged by

ionizing air forced through a porous plate at the base of the chamber. As the powder particles

become charged, they repel each other to such a degree that they rise above the chamber

forming a cloud or veil of charged particles. When a grounded object is placed in this cloud or

conveyed through this cloud, the charged powder particles, because of their opposite potential,

are attracted to it. As the particles become attached to the object, they form a uniform coating,

being more attracted to exposed areas than to those already insulated. The longer the object is

exposed to the cloud, the thicker the coating becomes, until saturation eventually takes place.

Coating thickness is controlled by applied voltage to the charging media and exposure time to

the cloud. Because of the high voltage capability of the charging media, a sufficiently great

potential exists between it and most substrates to permit even natural insulators to be coated.

Unlike equipment with exposed electrodes, Electrostatic Technology, Inc.'s unique air

ionization process charges the powder without permitting the powder, the object, or the

operator to come in contact with the charging media.

Electrostatic Technology, Inc. Model 802 Armature Coater

4 Serial #15681

4 GENERAL SAFETY

4.1 INTRODUCTION

This section contains general study instructions for using your Electrostatic Technology, Inc.

(ETI) equipment. Task-and equipment-specific warnings are included in other sections of this

manual where appropriate. Note all warnings and follow all instructions carefully. Failure to

do so may result in personal injury, death, or property damage.

To use this equipment safely,

• Read and become familiar with the general safety instructions provided in this section

of the manual before installing, operating, maintaining, or repairing this equipment.

• Read and carefully follow the instructions given throughout this manual for performing

specific tasks and working with specific equipment.

• Store this manual within easy reach of personnel installing, operating, maintaining, or

repairing this equipment.

• Follow all applicable procedures required by your company, industry standards, and

government or regulatory agencies. Refer to the National Fire Protection Association

(NFPA) standard 33 and to federal, state, regulatory agency, and local codes for rules

and regulations covering installation and operation of powder coating systems.

• Obtain and read Material Safety Data Sheets (MSDS) for all materials used.

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