Electrostatic Technology FlexiCoat 300 Manuel utilisateur

Electrostatic Technology, Inc FlexiCoat® Model 300 Coater

Serial #20158 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................................................................................................................................ 2

4 GENERAL SAFETY ............................................................................................................................................ 3

4.1 INTRODUCTION.............................................................................................................................................. 3

4.2 SAFETY SYMBOLS......................................................................................................................................... 4

4.3 QUALIFIED PERSONAL................................................................................................................................. 4

4.4 INTENDED USE ............................................................................................................................................... 5

4.5 INSTALLATION............................................................................................................................................... 5

4.6 OPERATION ..................................................................................................................................................... 6

4.7 LESS OBVIOUS DANGERS............................................................................................................................ 8

4.8 ACTION IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION........................................ 8

4.9 MAINTENANCE & REPAIR ........................................................................................................................... 9

4.10 DISPOSAL.................................................................................................................................................. 10

5 AIR AND ELECTRICAL REQUIREMENTS ................................................................................................ 11

5.1 FLEXICOAT®.................................................................................................................................................. 11

5.1.1 Air ........................................................................................................................................................... 11

5.1.2 Electrical ................................................................................................................................................ 11

6 DESCRIPTION OF COMPONENTS............................................................................................................... 12

6.1 FLEXICOAT®300 COATING STATION...................................................................................................... 12

6.1.1 Tooling Plate .......................................................................................................................................... 12

6.1.1.1 Low Velocity Plume (cover)................................................................................................................................12

6.1.2 Powder Level Sensor .............................................................................................................................. 12

6.1.3 Powder Feed Chamber........................................................................................................................... 13

6.1.4 Optional Conventional Fluid Bed........................................................................................................... 13

6.2 FLEXICOAT®COLLECTOR ......................................................................................................................... 13

6.3 FLUIDIZING HOPPER/POWDER FEED PUMP .......................................................................................... 14

7 INSTALLATION................................................................................................................................................ 15

7.1 LOCATION ..................................................................................................................................................... 15

7.2 AIR CONNECTIONS...................................................................................................................................... 15

7.3 ELECTRICAL CONNECTION ...................................................................................................................... 15

7.4 CONTROLS..................................................................................................................................................... 16

7.4.1 Footswitch .............................................................................................................................................. 16

7.4.2 Settings.................................................................................................................................................... 16

7.5 FLUIDIZING HOPPER/POWDER FEED PUMP .......................................................................................... 16

7.6 POWDER MAINTENANCE........................................................................................................................... 17

8 DESCRIPTION OF CONTROLS..................................................................................................................... 18

8.1 POWDER COLLECTOR AND COATER CONTROL PANEL ILLUSTRATION ...................................... 18

8.2 POWDER COLLECTOR AND COATER CONTROLS................................................................................ 19

8.3 COATING BED PNEUMATIC CONTROL PANEL ILLUSTRATION ....................................................... 21

8.4 COATING BED PNEUMATIC CONTROLS................................................................................................. 21

8.5 POWDER FEED PNEUMATIC CONTROL PANEL ILLUSTRATION ...................................................... 22

8.6 POWDER FEED PNEUMATIC CONTROLS................................................................................................ 23

8.7 FLEXICOAT® COLLECTOR AND COATER CONTROLS ......................................................................... 24

9 START-UP AND OPERATION PROCEDURE.............................................................................................. 25

9.1 COATING STATION SET-UP ....................................................................................................................... 25

Electrostatic Technology, Inc FlexiCoat® Model 300 Coater

ii Serial #20158

9.2 ELECTROSTATIC COATING OPERATION ............................................................................................... 25

9.3 CONVENTIONAL FLUID BED COATING OPERATION .......................................................................... 26

9.4 POWDER REMOVAL OPERATION (ELECTROSTATIC COATING ONLY) .......................................... 27

9.5 FLUIDIZING HOPPER/POWDER FEED PUMP .......................................................................................... 27

9.5.1 Powder Level .......................................................................................................................................... 27

10 SHUT-DOWN PROCEDURE ........................................................................................................................... 28

10.1 COATING MACHINE ............................................................................................................................... 28

10.2 RE-START PROCEDURE ......................................................................................................................... 28

10.3 EXTENDED SHUT-DOWN PROCEDURE.............................................................................................. 28

10.3.1 Coating Bed Cleaning............................................................................................................................. 28

10.3.2 Powder Collector Cleaning .................................................................................................................... 29

10.4 POWDER/COLOR CHANGE.................................................................................................................... 29

11 TROUBLE SHOOTING .................................................................................................................................... 30

11.1 TROUBLE SHOOTING – COATER ......................................................................................................... 30

11.2 TROUBLE SHOOTING – POWDER COLLECTOR................................................................................ 31

12 MAINTENANCE................................................................................................................................................ 33

12.1 GENERAL .................................................................................................................................................. 33

12.1.1 High Voltage Multiplier.......................................................................................................................... 33

12.2 AIR SYSTEM ............................................................................................................................................. 33

12.3 COATING BED .......................................................................................................................................... 33

12.3.1 Porous Plate Replacement...................................................................................................................... 34

12.3.2 Powder Level Sensor .............................................................................................................................. 35

12.4 COLLECTOR MODULE ........................................................................................................................... 35

12.4.1 Cartridge Filters..................................................................................................................................... 35

12.4.2 Final Filter ............................................................................................................................................. 36

12.4.3 Fan Motor............................................................................................................................................... 36

12.5 FLUIDIZING HOPPER/POWDER FEED PUMP ..................................................................................... 36

13 PATENTS ............................................................................................................................................................ 37

14 SPARE PARTS LIST ......................................................................................................................................... 38

15 FLOOR PLAN .................................................................................................................................................... 40

16 PNEUMATIC SCHEMATIC ............................................................................................................................ 40

17 ELECTRICAL DRAWING ............................................................................................................................... 40

18 PROGRAMMABLE CONTROLLER.............................................................................................................. 40

19 MANUFACTURER'S MANUALS ................................................................................................................... 40

Electrostatic Technology, Inc FlexiCoat® Model 300 Coater

Serial #20158 1

1 INTRODUCTION

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

"FlexiCoat®Model 300 Coater". Study this manual before locating and installing the equipment.

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 (FlexiCoat®Model 300 Coater), SERIAL

NUMBER (20158) and MODEL NUMBER (S28A-0-3-1-0-0-0-0-2) of the "POWDER

COATING MACHINE".

2 SHIPPING

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

made upon delivery, and when equipment is removed, it should be carefully inspected to make

sure the unit 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, Inc will then advise concerning repairs and replacements.

Electrostatic Technology, Inc FlexiCoat®Model 300 Coater

2 Serial #20158

3 OPERATING PRINCIPLES

3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER

3.2 PROCESS DESCRIPTION

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

by ionized 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 FlexiCoat® Model 300 Coater

Serial #20158 3

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.

Electrostatic Technology, Inc FlexiCoat®Model 300 Coater

4 Serial #20158

4.2 SAFETY SYMBOLS

Become familiar with the safety symbols presented in this section. These symbols

will alert you to safety hazards and conditions that may result in personal injury,

death, or property and equipment damage.

WARNING: Failure to observe this warning may result in personal in

personal injury, death, or equipment damage.

WARNING: Risk of electrical shock. Failure to observe this warning

may result in personal injury, death, or equipment damage.

WARNING: Disconnect equipment from line voltage. Failure to

observe this warning may result in personal injury, death, or equipment

damage.

WARNING: Risk of explosion of fire. Fire, open flames and smoking

prohibited.

WARNING Wear protective clothing, safety goggles, and approved

respiratory protection. Failure to observe may result in serious injury.

WARNING: System or material pressurized. Release pressure. Failure

to observe this warning may result in serious injury of death.

CAUTION: Failure to observe may result in equipment damage.

4.3 QUALIFIED PERSONAL

"Qualified Personnel" is defined here as individuals who thoroughly understand the

equipment and its safe operation, maintenance, and repair. Qualified personnel are

physically capable of performing the required tasks, familiar with all relevant safety

rules and regulations, and have been trained to safely install, operate, maintain, and

repair the equipment. It is the responsibility of the company operating the

equipment to see that its personnel meet these requirements.

Electrostatic Technology, Inc FlexiCoat® Model 300 Coater

Serial #20158 5

4.4 INTENDED USE

WARNING: Use of this equipment in ways other than described in this manual

may result in personal injury, death, or property and equipment damage. Use

this equipment only as described in this manual.

ETI cannot be responsible for injuries or damages resulting from nonstandard,

unintended applications of its equipment. This equipment is designed and

intended only for the purpose described in this manual. Uses not described in

this manual are considered unintended uses and may result in serious personal

injury, death, or property damage. Unintended uses may result from taking the

following actions:

• Making changes to equipment that have not been recommended or described in

this manual or using parts that are not genuine ETI replacement parts.

• Failure to make sure that auxiliary equipment complies with approval agency

requirements, local codes, and all applicable safety standards.

• Using materials or auxiliary equipment that are inappropriate or incompatible

with your ETI equipment.

• Allowing unqualified personnel to perform any task.

4.5 INSTALLATION

Read the installation section of all system components manuals before installing your

equipment. A thorough understanding of the system components and their

requirements will help you install the system safely and efficiently.

• Allow only qualified personnel to install ETI and auxiliary equipment.

• Use only approved equipment. Using unapproved equipment in an approved

system may void agency approvals.

• Make sure all equipment is rated and approved for the environment in

which you are using it.

• Follow all instructions for installing components and accessories.

• Install locking, manual, shutoff valves in the air supply lines to the system.

This allows you to relieve air pressure and lock out the pneumatic system

before undertaking maintenance and repairs.

• Install a locking disconnect switch or breaker in the service line ahead of any

electrical equipment (if applicable).

Electrostatic Technology, Inc FlexiCoat®Model 300 Coater

6 Serial #20158

4.5 INSTALLATION (continued)

• Use only electrical wire of sufficient gauge and insulation to handle the rated current

demand. All wiring must meet local codes.

• Ground all electrically conductive equipment within 10 feet (3 meters) of the coating

area. Ungrounded conductive equipment can store a static charge which could ignite

a fire or cause an explosion if a hot spark is discharged.

• Install safety interlocks which shut down the coating system if the exhaust fan fails, a

fire is detected, or other emergency situation develops.

• Make sure the coating area floor is conductive to ground and that the operator's

platform is grounded.

• Use only designated lifting points or lugs to lift and move heavy equipment. Always

balance and block loads when lifting to prevent shifting. Lifting devices must be

inspected, certified, and rated for a greater weight than the equipment being lifted.

• Protect components from damage, wear, and harsh environmental condition.

• Allow ample room for maintenance, material supply container drop-off and loading,

panel accessibility, and cover removal.

• If safety devices must be removed for installation, reinstall them immediately after

the work is completed and check them for proper functioning.

4.6 OPERATION

Only qualified personnel, physically capable of operating the equipment and with no

impairments to their judgement or reaction times, should operate this equipment.

Read all component manuals before operating a powder coating system. A thorough

understanding of all components and their operations will help you operate the

system safely and efficiently.

• Use this equipment only in the environments for which it is rated. Do not

operate this equipment in humid, flammable, or explosive environments unless it

has been rated for safe operation in these environments.

• Before starting this equipment, check all safety interlocks, fire detection systems,

and protective devices such as panels and covers (if applicable). Make sure all

devices are fully functional. Do not operate the system if these devices are not

working properly. Do not deactivate or bypass automatic safety interlocks or

locked-out electrical disconnects or pneumatic valves.

Electrostatic Technology, Inc FlexiCoat® Model 300 Coater

Serial #20158 7

4.6 OPERATION (continued)

• Know where EMERGENCY STOP buttons, shutoff valves, and fire

extinguishers are located. Make sure they work. If a component malfunctions,

shut down and lock out the equipment immediately.

• Before operating, make sure all conductive equipment in the coating area is

connected to a true earth ground.

• Never operate equipment with a known malfunction or leak.

• Do not attempt to operate electrical equipment if standing water is present.

• Never touch exposed electrical connections on equipment while the power is

ON.

• Do not operate the equipment at pressures higher than the rated maximum

working pressure of any component in the system.

• Know the pinch points, temperatures, and pressures for all equipment that you

are working with. Recognize potential hazards associated with these and

exercise appropriate caution.

• Wear shoes with conductive soles, such as leather, or use grounding straps to

maintain a connection to ground when working with or around electrostatic

equipment.

• Do not wear or carry metallic objects (jewelry or tools) while working with or

around electrostatic equipment. Ungrounded metal can store a static charge and

cause harmful shocks.

• Keep parts of the body or loose clothing away from moving equipment or parts.

Remove personal jewelry and cover or tie back long hair.

• Wear National Institute of Occupational Safety and Health (NIOSH) approved

respirators, safety glasses or goggles, and gloves while handling powder

containers, filling hoppers, operating coating equipment, and performing

maintenance or cleaning tasks. Avoid getting powder coatings on your skin.

• Do not smoke in the coating area. A lit cigarette could ignite a fire or cause an

explosion.

• If you notice electrical arcing in the coating equipment, shut down the system

immediately. An arc can cause a fire or explosion.

• Shut off electrostatic power supplies before making adjustments to powder

coating fluidized bed.

Electrostatic Technology, Inc FlexiCoat®Model 300 Coater

8 Serial #20158

4.6 OPERATION (continued)

• Shut off moving equipment before taking measurements or inspecting work

pieces.

• Wash exposed skin frequently with soap and water, especially before eating or

drinking. Do not use solvents to remove coating materials from your skin.

• Do not use high-pressure compressed air to blow powder off your skin or

clothes. High-pressure compressed air can be injected under the skin and cause

serious illness or death. Treat all high-pressure fittings and hoses as if they

could lead and cause injury.

4.7 LESS OBVIOUS DANGERS

Operators should also be aware of less obvious dangers in the workplace that often

cannot be completely eliminated:

• Exposed surfaces on the equipment which may be hot or have sharp edges and

cannot be practically safeguarded.

• Electrical equipment which may remain energized for a period of time after the

equipment has been shut off.

• Vapors and materials which may cause allergic reactions or other health

problems.

• Automatic hydraulic, pneumatic, or mechanical equipment or parts that may

move without warning.

• Unguarded, moving mechanical assemblies.

4.8 ACTION IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION

Do not operate a system that contains malfunctioning components. If a component

malfunctions, turn the system OFF immediately.

• Disconnect and lock out electrical power. Close and lock out hydraulic and

pneumatic shutoff valves and relieve pressures.

• Allow only qualified personnel to make repairs. Repair or replace the

malfunctioning component.

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