Metallisation MK 73 Mode d’emploi

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ssue: 21/11-11

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Issue: 07-10-2013

This operating manual must be read and understood before any

attempt is made to operate the equipment described herein. In

particular, refer to the Safety Warnings / Risk Assessments in

Section 1.

Under no circumstances should any modifications be made to

the equipment without prior written approval from Metallisation.

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SPECIFICATIONS

The Metallisation MK73 is an Oxygen –Propane fuelled flame spray system typically used for

the application of anti-corrosion coatings. The following specifications are for a standard Pistol

system with 1/4" hoses.

Weight - Complete, excluding supply hoses 2.27Kg (5lb)

Pistol Dimensions

LENGTH

HEIGHT

WIDTH

25.7cm (10 1/8”)

28.6cm (11 1/4”)

9.5cm (3 3/4”)

Typical Performance Figures

MATERIAL

WIRE SIZE**

THROUGH -PUT

(kgs/Hr)

THROUGH -PUT

(lbs/Hr)

01E Aluminium

3/16” Fast

3/16”

1/8”

2mm

12.5

8.0

3.6

2.3

27.00

16.5

8.0

5.0

02E Zinc

3/16” Fast

3/16”

1/8”

2mm

50.0

32.0

16.0

8.2

110.0

70.0

35.0

18.0

07E/08E/09E Tin/Zinc

1/8”

2mm

21.3

9.1

47.0

20.0

05E, 10E & 15E Copper &

Bronzes

1/8”

2mm

5.9

4.1

13.0

9.0

30E, 35E, 45E, 55E, 57E

60E, 65E, 80E & 85E

Steels & Nichrome

1/8”

2mm

4.3

2.7

9.0

6.0

21E Zinc/Aluminium 85/15

3/16” Fast

3/16”

1/8”

2mm

38.0

25.0

12.5

7.5

84.0

55.0

27.0

16.0

06E Nickel

1/8”

3.6

8.0

** Stop/start unless otherwise specified in bold.

Services Required

The following air, gas and oxygen pressure and consumption figures cover the full range of

possible nozzle assemblies:

Compressed Air

Gases

Oxygen

Propane

30 cfm @ 80psi

50m³/hr @ 5.5 bar

48-280 cfh @ 22-70 psi

1.36-7.9 m³/hr @ 1.5-4.8 bar

22-56 cfh @ 25-60 psi

0.62-1.59m³/hr @ 1.7-4.1 bar

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CONTENTS

SECTION 2

SAFETY PRECAUTIONS & RISK ASSESSMENTS................................................................................6

1.1 Safety Precautions......................................................................................................................................7

1.1.1 Equipment Dos and Don’ts.......................................................................................................................7

1.1.2 Leak Test Procedures..............................................................................................................................8

1.1.3 Flashback.................................................................................................................................................9

1.2 Risk Assessment......................................................................................................................................10

1.3 Key Hazards.............................................................................................................................................11

1.3.1 Noise......................................................................................................................................................11

1.3.2 Flame.....................................................................................................................................................11

1.3.3 Particles.................................................................................................................................................11

1.3.4 Mechanical Hazards...............................................................................................................................12

1.3.5 Fume & Dust..........................................................................................................................................12

1.3.6 Summary................................................................................................................................................14

SECTION 2

THE EQUIPMENT ..................................................................................................................................15

2.1 Introduction to the MK73...........................................................................................................................16

2.2 Breakdown................................................................................................................................................17

2.2.1 The Pistol...............................................................................................................................................18

2.2.2 Flowmeter..............................................................................................................................................19

2.2.3 Air Filtration & Regulation Unit (ARF).....................................................................................................19

2.2.4 Pressure Regulators & Flashback Arrestors...........................................................................................19

2.2.5 Freestanding Flamespray Control Board................................................................................................19

2.2.6 Supplies Packages.................................................................................................................................20

SECTION 3

OPERATING THE EQUIPMENT ............................................................................................................22

3.1 Preparing the System ...............................................................................................................................23

3.2 Starting to Spray.......................................................................................................................................23

3.3 Spraying ...................................................................................................................................................25

3.4 Extinguishing the Pistol.............................................................................................................................26

3.5 Emergency Shut-Off Valve........................................................................................................................26

SECTION 4

MAINTENANCE & REPAIR....................................................................................................................27

4.1 Recommended Spares .............................................................................................................................28

4.2 Routine Maintenance................................................................................................................................28

4.3 Disconnecting the Pistol............................................................................................................................29

4.4 The Nozzle Assembly...............................................................................................................................30

4.4.1 Removal & Dismantling..........................................................................................................................30

4.4.2 Nozzle Re-Assembly..............................................................................................................................31

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4.5 The Gas Head & Main Valve.....................................................................................................................32

4.5.1 Removal & Dismantling..........................................................................................................................32

4.5.2 Gas Head & Valve Re-Assembly............................................................................................................33

4.6 The Drive Box...........................................................................................................................................34

4.6.1 Dismantling the Wire Drive Assembly ....................................................................................................35

4.6.2 Dismantling the Air Shield Valve ............................................................................................................36

4.6.3 Dismantling the Speed Control...............................................................................................................37

4.6.4 Re-Assembling the Speed Control .........................................................................................................37

4.6.5 Re-Assembling the Air Shield Valve.......................................................................................................38

4.5.6 Re-Assembling the Wire Feed Drive......................................................................................................38

4.7 The Drive Motor........................................................................................................................................41

4.7.1 Dismantling the Drive Motor...................................................................................................................41

4.7.2 Re-Assembling the Drive Motor..............................................................................................................41

4.8 Feed Roller Tension..................................................................................................................................42

4.8.1 Checking Feed Roller Tension ...............................................................................................................42

4.8.2 Adjusting Feed Roller Tension ...............................................................................................................42

SECTION 5

FAULT FINDING.....................................................................................................................................43

5.1 Troubleshooting........................................................................................................................................44

5.1.2 Flowmeter Troubleshooting:...................................................................................................................46

SECTION 6

WIRE DISPENSING................................................................................................................................48

6.1 Wire Swift .................................................................................................................................................49

6.1.1 Operating Instructions............................................................................................................................49

6.1.2 Wire Straightener...................................................................................................................................50

SECTION 7

ILLUSTRATED PARTS LIST .................................................................................................................51

7.1 Gas Head & Spreader Nozzle...................................................................................................................52

7.2 Diaphragm Valve ......................................................................................................................................54

7.3 Power Unit / Drive Motor...........................................................................................................................54

7.4 Wire Drive Unit & Feed Control.................................................................................................................56

SECTION 8

INFORMATION TABLES .......................................................................................................................58

8.1 Flowmeter Settings...................................................................................................................................59

8.2 Nozzle Selection Chart..............................................................................................................................60

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SECTION 1

SAFETY PRECAUTIONS & RISK ASSESSMENTS

1.1 Safety Precautions

1.1.1 Equipment Dos & Don’ts

1.1.2 Leak Test Procedure

1.1.3 Flashback

1.2 Risk Assessments

1.3 Key Hazards

1.3.1 Noise

1.3.2 Flame

1.3.3 Particles

1.3.4 Mechanical Hazards

1.3.5 Fume & Dust

1.3.6 Summary

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1.1 Safety Precautions

Provided that the equipment is properly set up, regularly maintained and used correctly, metal

spraying does not present any great danger. However, like most industrial processes, misuse

and careless practices can create hazards for personnel and damage to the equipment.

The equipment detailed in this manual will produce levels of noise and dust that require safety

measures to be taken by personnel using the equipment. It uses pressurized and flammable

gases. Careful consideration should be taken when positioning this equipment.

It is the responsibility of the user to ensure that all appropriate measures are in place for safe

operation, before the equipment is used. Metallisation will be pleased to assist and advise as

appropriate.

1.1.1 Equipment Dos and Don’ts

Check all hoses regularly. Damaged hoses must be replaced immediately.

Ensure that all hose connections are properly tightened and do not leak.

Ensure that proper extraction is available and is turned on before the gas supplies

are tuned on and turned off after the gas supplies are turned off.

NEVER point the pistol towards other personnel or combustible material.

NEVER spray onto hoses, regulators or flowmeters.

NEVER operate the pistol without using ear defenders and the appropriate eye protection.

NEVER apply grease to any thread or connection which is to carry oxygen.

NEVER operate the pistol without using regulators fitted with flashback arrestors.

NEVER release gases into an un-extracted area.

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1.1.2 Leak Test Procedures

Leak Test Procedure - to be carried out before the pistol is used:

Make sure all the hoses are connected correctly and gauges are in good working

order.

Fit the leak test nozzle 1260 on to the pistol.

Switch on extraction.

Open gas cylinder valves.

Open the regulators to the standard operating pressures.

Open fully the gas valve on the pistol.

Set the regulators to the required working pressures.

Close the cylinder valves and screw out the regulators.

Watch the cylinder pressure gauges on the oxygen and fuel gas for approximately 5

minutes.

If the cylinder input pressure gauge drops then there is a leak between the cylinder

and the regulator. Use a leak detection spray or liquid to identify, then rectify leak

before using the pistol.

If the cylinder output pressure gauge drops then there is a leak between the regulator

and the nozzle. Use a leak detection spray or liquid to identify, then rectify leak before

using the pistol.

If no movement of the pressure gauges is seen then the system has no identifiable

leak and is safe to use.

To release pressure, release the fittings on the exit of the flashback arrestors. Then

re-tighten.

Remove the leak test nozzle and replace with the standard nozzle assembly

Alternatively:

Carry out first 7 points, then:

Using a proprietary leak detection spray or liquid check all hose and accessory

connections and pistol valve assembly mating faces.

If a leak is detected however small it must be rectified before the system is put into

operation.

Turn off the gases and close the pistol valve. Carefully undo the gas fittings to release

gas. Ensure fittings are re-tightened.

Results:

Cylinder Input Pressure Gauge Drops –There is a leak between the cylinder and the regulator

Cylinder Output Pressure Gauge Drops –There is a leak between the regulator and the pistol.

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Under these circumstances, use a leak detection spray or liquid to identify, then rectify the

leak before using the Pistol. If there is no movement of pressure gauges, then there is no

identifiable leak and the pistol is safe to use.

NB: Leak Test Information is based on the assumption that all pressure gauges are in

good working order, with any visible defects having already been rectified e.g.

damaged hoses, broken flowmeters etc…

1.1.3 Flashback

Poorly maintained equipment may on occasion produce flashbacks If hose protection and

flashback arrestors are fitted, the risk of flames reaching the fuel gas and oxygen supplies is

virtually eliminated.

However, flashback, particularly if sustained, can seriously damage the nozzle assembly.

Therefore, if flashback occurs, the following procedure should always be carried out:

1) Immediately close the Pistol valve.

2) Shut off the Oxygen Supply Valve.

3) Shut off the Fuel Gas Supply Valve.

4) If fitted, operate the Safety Shut-Off Handle on the flowmeter.

5) Re-open the Pistol Valve and allow air to flush the nozzle parts for approximately 30

seconds.

6) Restart the system as identified in Section 3.2

7) If on re-lighting the flashback is repeated, shut off as above and ascertain the cause.

Page 10 of 64

1.2 Risk Assessment

Prior to commencing work with Thermal Spray equipment, a Risk Assessment should be

carried out on the equipment and the way in which that equipment is to be used.

The Risk Assessment should identify the hazards associated with the work and also the

control measures required. This will either eliminate the risk, or reduce it to an acceptable

level to prevent ill health or injury to the persons carrying out, or who could be affected by the

work.

The results of the Risk Assessment and the control measures necessary should be made

known to the persons carrying out, or those affected by the work.

Some control measures are better able to produce the desired result than others.

The safety precedence sequence shows the order of effectiveness of measures.

Hazard Elimination

Use of alternative work methods, design improvements or change of process.

Substitution

Replacement of material/substance with another of less risk.

Use of Barriers

Isolation or segregation.

Use of Documented Procedure

Limiting exposure times, dilution of exposure. Safe systems of work that depend on human

response.

Use of Warning Signs

Signs, instructions, labels that depend on human response.

Use of Personal Protective Equipment (PPE)

Depends on human response, used as a sole measure only when all other options have been

exhausted. PPE is the last resort.

It is the responsibility of the user of the equipment to ensure that all appropriate control

measures identified in the Risk Assessment are in place before using the equipment

To assist you in carrying out you Risk Assessment we have identified the Key Hazards in the

operation of Thermal Spray Equipment and this information can be found in Section 1.3.

In this section the key hazards associated with Thermal Spraying are described. It includes a

brief description of the hazards and their possible consequences. In any Risk Assessment for

a Thermal Spray Process, a consideration of all relevant hazards will need to be included.

Ancillary activities that are likely to be undertaken, such as grinding, grit blasting, solvent

cleaning, machining etc., are not included in this section.

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