Electrostatic Technology, Inc

®

Electrostatic Technology, Inc. A Subsidiary of Nordson Corporation 4 Pin Oak Drive, Branford, CT 06405 USA

MODEL 800 ARMATURE COATING SYSTEM

INSTALLATION & OPERATING MANUAL

FOR

BLACK & DECKER, EASTON, MD

SERIAL NUMBER 15278

REV. A

December 1997 (Rev. A February 1998)

Electrostatic Technology, Inc Model 800 Operation Manual

- 2 - Black & Decker, Easton, MD Serial # 15278 DATE 12/97

TABLE OF CONTENTS

1 INTRODUCTION .................................................................................................................. 6

2 SHIPPING............................................................................................................................... 6

3 OPERATING PRINCIPLES................................................................................................. 7

3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER..............................7 3.2 PROCESS DESCRIPTION ...........................................................................................8

4 GENERAL SAFETY.............................................................................................................. 9

4.1 INTRODUCTION..........................................................................................................9 4.2 SAFETY SYMBOLS...................................................................................................10 4.3 QUALIFIED PERSONNEL ........................................................................................11 4.4 INTENDED USE .........................................................................................................11 4.5 INSTALLATION.........................................................................................................12 4.6 OPERATION ...............................................................................................................13 4.7 LESS-OBVIOUS DANGERS .....................................................................................15 4.8 IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION .................15 4.9 MAINTENANCE & REPAIR .....................................................................................16 4.10 DISPOSAL...................................................................................................................17

5 AIR, ELECTRICAL AND WATER REQUIREMENTS................................................. 18

5.1 POWDER COATING MACHINE ..............................................................................18 5.1.1 AIR............................................................................................................................18 5.1.2 ELECTRICAL ..........................................................................................................18 5.1.3 WATER.....................................................................................................................18

5.2 INDUCTION HEATER...............................................................................................18 5.3 STEAM DEGREASER................................................................................................18

6 MECHANICAL FUNCTION: SEQUENCE & DESCRIPTION .................................... 19

6.1 LOAD/RELOAD STATION .......................................................................................19 6.2 STEAM DEGREASER MODULE..............................................................................19 6.3 PRE-COOLING STATION .........................................................................................19 6.4 COATING STATION..................................................................................................19 6.5 CLEANING STATION ...............................................................................................20

6.5.1 AIR KNIVES ............................................................................................................20 6.5.2 O.D. CLEANING......................................................................................................20 6.5.3 CONVEYOR CLEANER .........................................................................................20 6.5.4 SHAFT CLEANING.................................................................................................21 6.5.5 DOUBLE SIDED SHAFT CLEANER SET-UP ......................................................21

6.6 POWDER MANAGEMENT SYSTEM ......................................................................24 6.7 INDUCTION HEATING STATION...........................................................................24 6.8 CURE STATION .........................................................................................................25 6.9 FINAL COOL STATION ............................................................................................25 6.10 REFRIGERANT AIR DRYER....................................................................................25 6.11 DEIONIZED WATER SYSTEM ................................................................................25 6.12 PARTS COUNTER .....................................................................................................26 6.13 MAIN CONTROL CABINET.....................................................................................26

7 DESCRIPTION OF CONTROLS....................................................................................... 27



7.1 MAIN CONTROL CABINET.....................................................................................27 7.1.1 MODEL 800 ELECTRICAL CONTROLS ..............................................................27 7.1.2 STATION BEACON ................................................................................................29

7.2 CLEANING STATION PNEUMATIC CONTROLS.................................................30 7.3 AIR KNIVES PNEUMATIC CONTROLS.................................................................32 7.4 POWDER MANAGEMENT SYSTEM CONTROLS ................................................33 7.5 STEAM DEGREASER CONTROLS/INDICATORS ................................................35

7.5.1 PRE-WASH STEAM SECTION..............................................................................37 7.5.2 PRE-WASH WATER SECTION .............................................................................37

8 PREPARATION FOR OPERATION ................................................................................ 38

8.1 GENERAL ...................................................................................................................38 8.2 INITIAL SYSTEM INSTALLATION ........................................................................38 8.3 LOAD / RELOAD STATION .....................................................................................40 8.4 STEAM DEGREASER................................................................................................40 8.5 POWDER MANAGEMENT SYSTEM ......................................................................41

8.5.1 LOADING POWDER...............................................................................................41 8.5.2 POWDER MAINTENANCE....................................................................................41

8.6 COATER......................................................................................................................41 8.6.1 COATING BED........................................................................................................41 8.6.2 POWDER DEPOSITION .........................................................................................41 8.6.3 HIGH VOLTAGE.....................................................................................................42

8.7 CLEANERS .................................................................................................................42 8.7.1 O.D. ADJUSTING ....................................................................................................42 8.7.2 AIR KNIVES ADJUSTING .....................................................................................42 8.7.3 CONVEYOR CLEANERS ADJUSTING................................................................42 8.7.4 SHAFT CLEANING POSITION ADJUSTING ......................................................42

8.8 INDUCTION HEATER...............................................................................................43 8.9 CURE STATION .........................................................................................................43 8.10 FINAL COOL STATION ............................................................................................43

9 SPECIFIC EQUIPMENT SAFETY ................................................................................... 44

9.1 GENERAL ...................................................................................................................44 9.2 POWDER.....................................................................................................................44

9.2.1 EMPLOYEE HEALTH ............................................................................................44 9.2.2 FIRST AID PROCEDURES.....................................................................................45 9.2.3 SPECIAL PROTECTION.........................................................................................45 9.2.4 PRECAUTIONS .......................................................................................................45 9.2.5 MATERIAL SAFETY DATA SHEETS (MSDS)....................................................45

9.3 STEAM DEGREASER................................................................................................46 9.3.1 EMPLOYEE CONTACT..........................................................................................46 9.3.2 EMERGENCY MAINTENANCE............................................................................46

10 PANELVIEW SCREENS .................................................................................................... 47

10.1 MACHINE STARTUP SCREEN ................................................................................56 10.2 AUTO MODE START/STOP SCREEN.....................................................................56 10.3 MANUAL SETUP SCREEN.......................................................................................56 10.4 MACHINE STATUS SCREEN...................................................................................56 10.5 DEGREASER STATUS SCREEN..............................................................................56 10.6 ALARM HISTORY SCREEN....................................................................................56 10.7 ALARM BANNER SCREEN......................................................................................56



11 STATION STARTUP PROCEDURE ................................................................................ 57

11.1 OVERVIEW ................................................................................................................57 11.2 MANUAL MODE - COATING MACHINE ..............................................................58

11.2.1 STEAM DEGREASER............................................................................................58 11.2.2 INDUCTION HEATER............................................................................................58

11.3 AUTO MODE - COATING.........................................................................................60 12 STATION SHUTDOWN PROCEDURE ........................................................................... 62

12.1 AUTO MODE SHUTDOWN - COATING MACHINE .............................................62 12.2 MANUAL MODE SHUTDOWN - COATING MACHINE.......................................62 12.3 POWDER HANDLING AT SHUTDOWN.................................................................63 12.4 LOCKOUT...................................................................................................................64

13. MAINTENANCE.................................................................................................................. 66

13.1 GENERAL ...................................................................................................................66 13.2 COMPRESSED AIR SYSTEM...................................................................................66

13.2.1 AIR LINE..................................................................................................................66 13.2.2 REFRIGERANT AIR DRYER.................................................................................66 13.2.3 STEAM DEGREASER.............................................................................................66

13.3 FLUIDIC BED .............................................................................................................67 13.3.1 INSTALLATION OF POROUS PLATE .................................................................68

13.4 POWDER MANAGEMENT SYSTEM ......................................................................69 13.5 POWDER LEVEL SENSOR.......................................................................................70 13.6 O.D. CLEANER...........................................................................................................70 13.7 INDUCTION HEATER...............................................................................................70 13.8 COOLING FANS.........................................................................................................70 13.9 PROGRAMMABLE CONTROLLER.........................................................................70 13.10 ROTO-FLO CONVEYOR...........................................................................................71 13.11 MOTORS AND GEARS .............................................................................................71

14. PREVENTATIVE MAINTENANCE SCHEDULE.......................................................... 72

14.1 DAILY .........................................................................................................................72 14.2 WEEKLY.....................................................................................................................72 14.3 MISCELLANEOUS ....................................................................................................73 14.4 LUBRICATION CHART ............................................................................................74 14.5 LUBRICATION DIAGRAM.......................................................................................75

15 TROUBLE SHOOTING...................................................................................................... 76

16 PATENT INFORMATION ................................................................................................. 95

17 SPARE PARTS LIST........................................................................................................... 96

18 MANUFACTURER’S MANUALS..................................................................................... 97

19 FLOOR PLAN ...................................................................................................................... 99

20 ELECTRICAL SCHEMATICS........................................................................................ 100



TABLE OF FIGURES

Figure 1 Schematic of an Electrostatic Coater................................................................................7

Figure 2 Main Control Panel.........................................................................................................28

Figure 3 Cleaning and Pneumatic Controls ..................................................................................31

Figure 4 Air Knives Pneumatic Controls......................................................................................34

Figure 5 Main Screen Menu .........................................................................................................48

Figure 6 Machine Start-up Screen ................................................................................................49

Figure 7 Machine Auto Start/Stop Screen ....................................................................................50

Figure 8 Manual Setup Screen......................................................................................................51

Figure 9 Machine Status Screen ...................................................................................................52

Figure 10 Degreaser Status Screen ...............................................................................................53

Figure 11 Alarm History Screen ...................................................................................................54

Figure 12 Alarm Banner Screen ...................................................................................................55

Figure 13 Lockout Provisions........................................................................................................64



1 INTRODUCTION

This Installation and Operating Manual should be thoroughly reviewed before locating and installing the Model 800 Armature Coating System. It should be studied by operating personnel to achieve maximum safety and efficiency.

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 (800) and Serial Number 15278 of the Armature Coating System.

2 SHIPPING

Sometimes equipment can be damaged in transit. An inspection of the shipping containers should be made upon delivery. When equipment is removed from the shipping container(s), it should be carefully inspected for damage. 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.



3 OPERATING PRINCIPLES

3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER

Figure 1 Schematic of an Electrostatic Coater



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 or conveyed through the cloud, the charged 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 the voltage applied to the charging media and the exposure time to the cloud. Because of the High Voltage capability of the charging media, a sufficiently great potential exists between it and object in the cloud to permit even insulators to be coated. Unlike equipment with exposed electrodes, Electrostatic Technology, Inc.'s unique air ionization process charges the powder without permitting it, the object, or the operator to come in contact with the charging media.



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.



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 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 or 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 or death CAUTION: Failure to observe may result in equipment damage.



4.3 QUALIFIED PERSONNEL

"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.

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.

• failing 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 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. • 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 grounded 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

conditions. • 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, install 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. 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.

• 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.



4.6 OPERATION (continued) • 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. • 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 leak 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 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.



4.9 MAINTENANCE & REPAIR Allow only qualified personnel to perform maintenance, troubleshooting, and

repair tasks. • Always wear appropriate protective devices and use safety devices when

working on this equipment • Follow the recommended maintenance procedures in your equipment

manuals. • Do not service or adjust any equipment unless another person trained in

first aid and CPR is present. • Use only genuine ETI replacement parts. Using unapproved parts or

making unapproved modifications to equipment may void agency approvals and create safety hazards.

• Disconnect, lock out, and tag electrical power at a disconnect or breaker in

the service line ahead of electrical equipment before servicing. • Do not attempt to service electrical equipment if there is standing water

present. Do not service electrical equipment in a high-humidity environment.

• Use tools with insulated handles when working with electrical equipment. • Do not attempt to service a moving piece of equipment. Shut off the

equipment and lock out power. Secure equipment to prevent uncontrolled movement.

• Relieve air pressures before servicing equipment. Follow the specific

instructions in this manual. • Make sure that the room where you are working is sufficiently ventilated. • If a "power on" test is required, perform the test carefully and then shut off

and lock out power as soon as the test is over. • Connect all disconnected equipment ground cables and wires after

servicing the equipment. Ground all conductive equipment. • Check interlock systems periodically to ensure their effectiveness. WARNING: Operating faulty electrostatic equipment is hazardous

and can cause electrocution, fire, or explosion. Make resistance checks part of your periodic maintenance program.



4.9 MAINTAINENCE & REPAIR (continued) • Do not store flammable materials in the coating area or room. Keep

containers of flammable materials far enough away from the coater to prevent their inclusion in a fire. If a fire or explosion occurs, flammable materials in the area will increase the chances of and the extent of personal injuries and property damage.

• Practice good housekeeping procedures. Do not allow dust or powder

coatings to accumulate in the coating area or on electrical equipment. Read this information carefully and follow instruction.

4.10 DISPOSAL Dispose of equipment and materials used in operation and cleaning according to

your local regulations.



5 AIR, ELECTRICAL AND WATER REQUIREMENTS

5.1 POWDER COATING MACHINE 5.1.1 Air

A clean, oil free, dry supply of compressed air must be provided using 1 inch I.D. line capable of supplying 85 cubic feet/minute (2.832 cubic meters/minute) @ 60-90 pounds per square inch minimum.

5.1.2 Electrical

460 Volts, 60 Hertz, 3-Phase Plant Power from a 200 Amp fused disconnect must be supplied to the Operator Station Control Cabinet.

460 Volts, 60 Hertz, 3-Phase, 100 Amps is required for the Induction Heater drops.

480 Volts, 60 Hertz, 3-Phase, 4 Amps fuse size disconnect is recommended. Ref: Steam Generator instruction manual.

5.1.3 Water

5.1.3.1 Closed Loop Induction Heater and Induction Heater Cooling System

Deionized water is required for the closed loop Induction Heater cooling system. Approximately 30 gallons (113.6 liters) of deionized water are required to fill the system.

5.1.3.2 Deionized Water Requirements: pH between 7.0 and 9.0 Chloride Content - 20 PPM Max. Nitrate Content - 10 PPM Max. Sulphate Content - 1000 PPM Max. Total Solids - 250 PPM Max. Hardness - 250 PPM CACO Max. Resistivity - 2500 OHM-CM Min.

5.2 INDUCTION HEATER

The Induction Heater is wired through the Main Electrical Control Cabinet. The power level is controlled by the Induction Heater Power Adjust control on the Main Control Panel (See Figure 2).

5.3 STEAM DEGREASER

Soft water is required at 0-10 gallon/minute (0-37 liter/minute) maximum at 50 psig. minimum for the wet steam water injection in the first stage (Pre-Wash) of the Steam Degreaser Chamber. Typical usage is approximately 0.5 - 1.0 gallons/minute (1.9 - 3.8 liter/minute).

The Steam Degreaser requires Saturated Vapor (Dry Steam) at 149°C at 70 psig and requires 500 -1000 pounds of steam per hour maximum.



6 MECHANICAL FUNCTION: SEQUENCE & DESCRIPTION

6.1 LOAD/RELOAD STATION

Armatures are loaded onto a roller chain conveyer by a gravity fed load ramp. The conveyor carries and loads the armatures onto the Twin Screw Roto-Flo Conveyer and transports them to each station.

6.2 STEAM DEGREASER MODULE

The parts traverse through a wet steam pre-wash and a cloud of superheated steam which is directed by nozzles at the armature core and shafts to provide cleaning action.

An exhaust blower draws the steam towards the bottom of the Degreaser and maintains a negative pressure to keep the steam inside the unit. The blower should be ducted outside the plant. Specially designed profile plates have been installed at both the entrance and exit of the Degreaser to reduce the open area through which the steam might escape.

6.3 PRE-COOLING STATION

The parts are then transported through the cooling station, where they are cooled to 37.8°C (100 F) or less. The cooling is achieved by a blower located behind the pre-cool station, to draw air past the hot armatures. This cooling is required for the parts to be properly coated.

6.4 COATING STATION

The armatures are next conveyed through the coating bed. As the armatures enter the bed area they pass through the cloud of charged particles which coat each armature.

A Suction Powder Pick-up hose is supplied to pick up spilled powder in this area. The suction is available continuously when the Machine is powered.

NOTE: This Pick-up hose should be used only for clean uncontaminated powder. Do not use it for general cleanup of dirt and trash.

A powder level sensing unit (Photohelic Gauge/Switch) controls the Powder Feeder to assure the correct level of powder in the coating bed at all times. The Powder Level Sensor consists of a control sensor with two inputs. The sensor reads the difference between the air pressure at the powder level in the Coating Bed and the ambient atmospheric pressure. The system logic requires that there be a difference between the two pressure readings. As the readings come together, additional powder is fed into the coating bed.



6.4 COATING STATION (continued)

The range of the control sensor has been pre-set at the E.T.I. factory and should not be touched or changed without consulting E.T.I. personnel. The Photohelic Gauge Meter which shows the pressure range is located on the front of the Machine at the entrance to the Coating Bed.

On this gauge, when the needle comes in contact with the Left Set-Point, the Powder Feeder goes "ON". It stays on until the needle makes contact with the Right Set-Point. This shuts off the powder feed.

Refer to the Dwyer Photohelic Gauge Manual in the Manufacturer's Manuals (Section 18) for more specific information on this unit).

6.5 CLEANING STATION

Bulk powder removal from the O.D. and Shafts is done in the First Cleaning Station.

6.5.1 Air Knives

There are 5 sets of Air Knives located in the Cleaning Station. A set includes a front and a rear Air Knife. These Air Knives are controlled and adjusted by air flowmeters on the Main Pneumatic Panel. • Air Knives #1 and #2 are located at the Bulk Box. • Air Knives #3, #4 ,and #5 are located after the O.D. Cleaner

6.5.2 O.D. Cleaning

The O.D. Cleaner is located just after the Bulk Cleaning Station. It utilizes a moving belt to pick powder off the core O.D. The O.D. Cleaner is easily adjusted up or down, front or back, and can swivel for desired positioning

Adjustments can be made by turning a small black knob located on the O.D. Cleaner. The position of the belt can be raised or lowered as needed. Generally the belt should run very close to the O.D., just barely touching it.

6.5.3 Conveyor Cleaner

There are Roto-Flo Cleaner Vacuums on the front and rear Roto-Flo Screws in the Belt Type O.D. Cleaner Section of the Machine. The Shaft Cleaner Vacuums on the front and rear Roto-Flo Screws in the Bulk Cleaning section of the Coating Bed also act as Roto-Flo Screw Cleaners.

All these Roto-Flo Screw Cleaner Vacuums are controlled and adjusted by air flowmeters on the Main Pneumatic Panel.



6.5.4 Shaft Cleaning

The shaft cleaning Air Knives are located just after the O.D. Cleaner. The function of the Air Knives is to clean the armature shafts. These knives use a thin stream of air to clean the shafts of excess powder and remove powder speckles prior to induction heating.

The knives are generally adjusted to be 1/8" from the armature shaft and will not interfere with the part. They should be adjusted on an angle in relation to the Machine center to allow the knife to clean the entire length of the shaft.

The volume of air available to each air knife is adjusted by air flowmeters located on the front of the Machine. Air flow should be adjusted so that there is sufficient air to clean the part without disturbing powder in the surrounding area.

6.5.5 Double Sided Shaft Cleaner Set-up (See appendix DWG E15278-6700)

1. Bring both the front and rear guide blocks (items 4 and 5) in toward the center of the Machine by rotating the respective guide rods (items 2 and 3).

2. Remove the O.D. friction assembly (items 34, 47 and 55) by removing the four button head screws (item 60) from the belt hanger mounts (item 33). If not installed yet, proceed to step 3.

3. Align the guide blocks so that they are parallel to the Machine Roto-Flo screws and set the digital indicators (item 38) to have an initial reading of 100.

4. Install the rear shaft cleaner assembly on the rear guide blocks (item 5).

5. Move the shaft cleaning assembly away from the center of the Machine by means of the guide rods.

6. Place two production dimension armatures in the Roto-Flo screw so that the armature shafts will be directly under the leading and trailing compression shoes (item 16).

7. By means of the guide rods, move the shaft cleaning assembly toward the center of the Machine and position the edge of the cleaning belt (item 41) approximately at the desired cut-off distance.

8. Turn on the motor (item 42) for the installed shaft cleaner assembly.

9. Lower the shaft cleaner assembly by using the micrometer slide unit (item 22) so that the shaft cleaning belt (item 41) is just barely touching the shaft of the armature at the center of the trailing compression shoe (item 16). This is confirmed if the armature under the trailing compression shoe spins smoothly and evenly. The spinning armature should be able to be stopped by simply laying the O.D. friction belt (item 55) on the armature O.D. If stopping of the spinning is not attainable, the shaft cleaner assembly is too low and exerting excessive force on the armature shaft. To correct this, raise the shaft cleaner assembly with the micrometer slide (item 22) until the desired condition is reached.



6.5.5 Double Sided Shaft Cleaner Set-up (continued)

10. Loosen the 3 leading socket head cap screws (item 51) which secure the compression shoe mount (item 18) keeping the fourth and final socket head cap screw snug to act as a pivot point.

11. Pivot the compression shoe mount (18) so that the shaft cleaning belt ( item 41) just barely makes contact with the armature shaft at the leading compression shoe. (item 16). Again, this is indicated in the same manner as in step 9.

12. Back off the compression shoe mount (item 18) slightly so that the armature under the leading compression shoe (item 16) stops spinning by itself when the armature under the trailing compression shoe (item 16) continues to spin smoothly. It may be necessary to readjust the belt tensioning idler (item 36) several times in order to complete steps 9 through 12.

Note: Correct adjustment of the belt tensioning idler (item 36) is of extreme importance. Adjustment of the belt tensioning idler (item 36) should not cause the compression shoe springs (item 48) to be compressed beyond their installed height. Overtensioning of the shaft cleaning belt is indicated by the compression shoe retaining rings (item 54) not resting on the back of the compression shoe mount (item 18) .

13. Tighten all 4 of the socket head cap screws (item 51) which secure the compression shoe mount.

14. Turn off the motor and remove the shaft cleaning assembly.

15. Install the front shaft cleaning assembly in the front guide blocks (item 4).

16. Perform steps 5 through 14 above on the front shaft cleaner assembly.

17. Install the O.D. friction assembly (items 34, 47 and 55) on to the belt hanger mounts. (item 33) by finger tightening the 4 button head cap screws (item 60) to allow vertical movement of the belt hangers (item 34).

18. Place 2 production dimension armature s in the Roto-Flow screw so that one each is directly under the lowest point of the two belt hangers (item 34).

19. Using the two hex head screws (item 61) adjust the height of the belt hangers (item 34) so that the O.D. friction belt (item 55) is resting against the O.D. of the armature. The O.D. friction belt should not exert any force on the armature O.D.

20. Lock the hex head screws (item 61) using the hex nuts (item 62).

21. Tighten the button head cap screws (item 60) which secure the belt hanger (item 34) to the belt hanger mount (item 33).

22. Loosen the button head cap screws and nuts (items 60 and 62)which secure the spring plunger mount (item 47) to the belt hangers (item 34) ,

23. Move the 2 sample armatures so that each one is under the leading and trailing spring plungers (item 56).

24. Adjust the spring plunger mount (item 47) so that the 2 spring plungers are compressed equally: approximately l/32”.



6.5.5 Double Sided Shaft Cleaner Set-up (continued)

25. Tighten the button head cap screws and their nuts (items 60 and 62) which secure the spring plunger mount (item 47) to the belt hangers (items 34).

26. Run the Roto-Flow screw conveyor with production dimension armatures, making sure that the armatures do not bind or cause excessive deflection of the O.D. friction assembly.

27. Also, make sure that the O.D. spring plunger assembly is not causing the armatures to bounce or jump.

If the armatures are jumping as they leave the trailing spring plunger, only that spring plunger needs to be backed out one full turn.

If the armatures are jumping after each and every spring plunger, the entire spring plunger mount is too low. Return to step 24.

NOTE: A too low condition must be corrected so that excessive force is not being exerted on the O.D. of the armatures.

28. Install both the front and rear shaft cleaner assemblies.

29. Turn on the motors for the shaft cleaning assemblies (item 42).

30. Run the Roto-Flow screw conveyor with production dimension armatures. Make sure that the armatures are moving smoothly through the shaft cleaning station and are not spinning excessively due to the cleaning belt force overriding the O.D. friction belt. If excessive armature spinning is observed, return to step 2 above.



6.6 POWDER MANAGEMENT SYSTEM

Powder management is accomplished by a vacuum system which collects powder in ducts located throughout the Machine and conveys it back to the lower hopper of the powder collector. In this hopper, the collected powder is mixed with virgin powder. The level of the powder mix is monitored by the level sensor in the hopper.

The powder is fluidized in this lower hopper by dry air which removes any remaining moisture from the powder. This lower hopper acts as a Powder Drying Chamber. The powder is then fed by means of a screw conveyor up to a Transition Weldment located just above the bed. From there the powder is allowed to trickle down into the coating bed. There is a magnet located in the Powder Feeder Transition Weldment to collect any metallic iron contamination in the powder.

Vacuum is supplied to the system through an assembly which consists of a fan and motor to generate the vacuum and 9 filter cartridges which retain powder within the system. Electric and pneumatic circuitry provides a reverse pulse of air to clean the filter cartridges. Reclaimed powder released from the filters falls into a hopper (located beneath the filters) and then through a rotary air lock into the lower hopper to be mixed with virgin powder.

A loading chamber at the rear of the collector/feeder allows virgin powder to be added to the system without spillage. Refer to Section 8.5.1 for instructions on loading powder into the system.

A differential pressure gauge is located on the side of the collector/feeder assembly. This provides an indication of how clean the filter cartridges are. A normal reading is between 1 and 5. A reading above 5 indicates that the filter cartridges are not being cleaned well enough. To correct this requires setting the unit so that the reverse cleaning pulses are more frequent and/or increasing the air pressure to the pulse circuit. A reading below 1 would indicate the filters are too clean, or that there is a hole in a filter or there is leakage past the filters. Refer to Maintenance (Section 13 of this manual) for a more complete discussion.

6.7 INDUCTION HEATING STATION

This Induction Heater is a 20 kW, 50 kHz unit. The purpose of the Induction Heating Station is to heat each armature to the proper temperature to allow the powder to flow and eventually cure. The Hood (yellow) for this station is interlocked and must be closed or you can not turn "ON" the Induction Heater.

The Induction Heater Power Adjust and the Induction Heater Power meter are located on the Main Electrical Control Panel. For information on the Induction Heater, refer to the Pillar Induction Heater Manual in the Manufacturer's Manuals (Section 18 of this manual).



6.7 INDUCTION HEATING STATION (continued)

The power control of the Induction Heater should be set as required to heat armatures to the proper temperature as read on the Optical Pyrometer at the exit of the Induction Heating Station. This reading is shown as the Heated Part Temperature on the Machine Status Screen.

The powder on the armatures should melt and have a wet look when the part is approximately 1/3 of the way through the Induction Coil.

6.8 CURE STATION

The Cure Station, located just after the Induction Heating Station, allows time for the epoxy on each armature to cure. To retain the heat, the 2 insulated hoods should always be closed while the Machine is running.

There are PLC controlled heating elements installed within the Cure zone to maintain the proper curing temperature.

6.9 FINAL COOL STATION

In this station the armature passes through an aerodynamically designed directional vane, directing air over and through each coated armature. The air is pulled through using an exhaust fan. When the armature leaves this station, it is cool enough to be handled by hand.

Within this station is the radiator for cooling the deionized water that flows through the induction coils. This radiator uses the same air flow that cools the armatures.

6.10 REFRIGERANT AIR DRYER

A 100 SCFM Refrigerant Air Dryer accepts in-plant compressed air and supplies moisture-free Coating/Cleaning air to the entire Coating Machine. Having moisture-free air is important for fluidization of the powder.

A particle air filter is installed on the inlet of the Refrigerant Air Dryer to remove foreign particles from the inlet air.

A coalescing air filter is installed on the outlet of the Refrigerant Air Dryer to remove any oils from entering the Coating Machine.

For specific information, on the Refrigerant Air Dryer refer to the Manufacturer's Manuals (Section 18).

6.11 DEIONIZED WATER SYSTEM

The water that flows through the coils of the Induction Heaters is contained in a closed loop system. This system should be filled with about 30 gallons (113.6 liters) of deionized water.

The water is maintained in a deionized condition by a replaceable cartridge element. An indicator light signals when the element needs changing. This indicator light can be seen through a peep hole in the front panel of the Cure Station. The peep hole is marked with the label "Deionized Water Filter Change When Light Is Red".

Heat in the deionized water system is removed as the deionized water flows through a radiator in the final cool station.



6.12 PARTS COUNTER

A proximity Switch located under the Roto-Flo Screw Conveyer in the Final Cooling Station acts as a Parts Counter. The count of parts can be read on the Panel View Display.

6.13 MAIN CONTROL CABINET

The Main Control Cabinet holds all of the electric connections and switch gear for the system. Mounted on this cabinet is the pendant arm holding the control panel containing the Panel View and controls for equipment operation and High Voltage adjustment. Refer to Main Control Panel drawing, Figure 2.



7 DESCRIPTION OF CONTROLS

7.1 MAIN CONTROL CABINET

The following controls are located on the Main Control Panel: 7.1.1 Model 800 Electrical Controls

MAIN DISCONNECT switch

Turns on power for the system.

MASTER START pushbutton

Energizes all control circuits.

MASTER STOP pushbutton

De-energizes all control circuits.

MASTER ON Panel light. When ON indicates power is on for the system.

PANEL VIEW screen

Used for operating the Coating Machine. See Section 10 in this Manual for a description of controls located on the Panel View screen.

EMERGENCY STOP pushbutton

Will completely shutdown the system.

HIGH VOLTAGE ADJUST adjustable pot

Adjusts the output of the High Voltage Power Supply.

KILOVOLTS digital readout

Indicates the voltage being supplied by the 80 kV D.C. High Voltage Power Supply.

MICROAMPS digital readout

Indicates the current being drawn from the 80 kV D.C. High Voltage Power Supply.

INDUCTION HEATER POWER ADJUST adjustable pot

Adjusts the output power of the Induction Heater

INDUCTION HEATER POWER Indicates power supplied to the induction heater coil.



Figure 2 Main Control Panel



7.1.2 Station Beacon

A three-color stack light, located on top of the Main Control Cabinet, provides a visual indication of the current status of Coating Machine operation.

RED light

When illuminated, indicates an Alarm condition and/or the loader is starved for parts

AMBER light

When illuminated, indicates the Coating Machine is in Manual Mode

GREEN light

When illuminated, indicates the Coating Machine is in Automatic Mode and cycling (running without any faults).



7.2 CLEANING STATION PNEUMATIC CONTROLS

The following controls are located on the front of the Cleaning Station panel. The air flow values (SCFH) indicated with the controls are recommended settings under ideal operating conditions. They should be adjusted as needed during coating operation.

FLUIDIC BED ADJUST air flowmeter and control

Adjusts and indicates the amount of fluidizing air being supplied to the Coating Bed.

FLUIDIC BED PRESSURE ADJUSTair pressure regulator

Adjusts and regulates the air pressure available to the Coating Bed air flowmeter and control.

FLUIDIC BED PRESSURE (psi) air pressure gauge

Indicates the amount of air pressure available to the Coating Bed air flowmeter and control.

POWDER DRY CHAMBER ADJUST air flowmeter and control

Adjusts and indicates the amount of fluidizing air supplied to the Coating Bed.

POWDER DRY CHAMBER PRESSURE air regulator

Adjusts and regulates the air pressure available to the Powder Drying Chamber air flow meter.

POWDER DRY CHAMBER PRESSURE air pressure gauge

Indicates the air pressure available to the Powder Drying Chamber air flow meter and control.

CONVEYOR CLEANER FRONT ADJUST air flowmeter and control

Adjusts and indicates the amount of air flow to the air transducer for the Front Roto-Flo Conveyor vacuum located in the Bulk Cleaning section of the Coater Station Hood.

CONVEYOR CLEANER REAR ADJUST air flowmeter and control

Adjusts and indicates the amount of air flow to the air transducer for the Rear Roto-Flo Conveyor vacuum located in the Bulk Cleaning section of the Coater Station Hood.

O.D. CLEANER ADJUST air flowmeter and control

Adjusts and indicates the amount of air flow to the O.D. Cleaner Belt vacuum air transducer which adjusts the amount of vacuum suction.

SHAFT CLEANER FRONT ADJUST air flowmeter and control

Adjusts and indicates the amount of air flow to the air transducer for the Front Armature Shaft vacuum located in the O.D. Cleaner station.

SHAFT CLEANER REAR ADJUST air flowmeter and control

Adjusts and indicates the amount of air flow to the air transducer for the rear Armature Shaft vacuum located in the O.D. Cleaner station.

CONVEYOR, O.D. & SHAFT CLEANERS PRESSURE ADJUST air pressure regulator

Adjusts and regulates the air pressure available to the Conveyor cleaners, O.D. Cleaner Belt & all Shaft Cleaners.



Figure 3 Cleaning and Pneumatic Controls

7.2 CLEANING STATION PNEUMATIC CONTROLS (continued)

CONVEYOR, O.D & SHAFT CLEANERS PRESSURE air pressure gauge

Indicates the air pressure available to the Conveyor cleaners, O.D. Cleaner Belt & all Shaft Cleaners.

I.R. DETECTOR ADJUST (20 SCFM) Adjusts and indicates the air flow available for air which continuously blows across the lens of the Infrared Temperature Detector to keep it clean.



7.3 AIR KNIVES PNEUMATIC CONTROLS

AIR KNIFE 1 FRONT ADJUST air flowmeter and control

Adjusts and indicates the amount of air flow to the Air Knife #1 FRONT which is located in the Bulk Cleaning Section of the Coater Station Hood.

AIR KNIFE 1 REAR ADJUST air flowmeter and control

Adjusts and indicates the amount of air flow to the Air Knife #1 REAR which is located in the Bulk Cleaning section of the Coater Station Hood.


Adjusts and indicates the amount of air flow to Air Knife #2 FRONT which is located in the Bulk Cleaning section of the Coater Station Hood.


Adjusts and indicates the amount of air flow to Air Knife #2 REAR which is located in the Bulk Cleaning section of the Coater Station Hood.


Adjusts and indicates the amount of air flow to Air Knife #3 FRONT which is located in the Bulk Cleaning station.


Adjusts and indicates the amount of air flow to Air Knife #4 FRONT which is located in the Bulk Cleaning station.


Adjusts and indicates the amount of air flow to Air Knife #4 REAR which is located after the O.D. Cleaning station.


Adjusts and indicates the amount of air flow to Air Knife #5 FRONT which is located in the O.D. Cleaning station.


Adjusts and indicates the amount of air flow to Air Knife #5 REAR which is located in the O.D. Cleaning station.


Adjusts and indicates the amount of air flow to Air Knife #6 FRONT which is located after the O.D. Cleaning station.


Adjusts and indicates the amount of air flow to Air Knife #6 REAR which is located after the O.D. Cleaning station.

AIR KNIFE #1-6 PRESSURE ADJUST air pressure regulator

Adjusts and regulates the air pressure available to the Air Knives #1 through 6.

AIR KNIFE #1-6 PRESSURE air pressure gauge

Indicates the air pressure available to the Air Knives #1 through 6.



7.4 POWDER MANAGEMENT SYSTEM CONTROLS

POWDER FILTER BLOWDOWN (55 psi min./ 100 psi max.) air pressure regulator

Adjusts and regulates the air pressure available for the automatic blowdown of the Powder Collector Cartridges.

POWDER MAN. SYS. FILTER (0-5 NORMAL READING) differential pressure gauge

Indicates the difference in pressure across the Powder Management System Filter from the clean side to the dirty side which indicates the level of cleanliness of the Cartridges.

Black & Decker, Easton, MD - 34 - Serial # 15278 DATE 12/97

Figure 4 Air Knives Pneumatic Controls



7.5 STEAM DEGREASER CONTROLS/INDICATORS

INCOMING STEAM GATE VALVE (STM 1)

Should be turned off if service is required to the system. Turns off incoming steam. The Degreaser will not operate if this valve is closed because there will not be enough pressure to trip the pressure switch.

STRAINER (STM 2) Removes foreign particles from the steam system

SEPARATOR Removes foreign particles from the steam.

REGULATOR (STM 18) Reduces the incoming steam pressure. The steam pressure gauge after the regulator will read the required pressure

STM. PREHEAT AIR SOLENOID (25 psi)

First stage solenoid that feeds a small amount of steam through the Superheater and through the system. to pre-heat the system and to avoid pipe banging before the second stage solenoid

STM. PREHEAT AIR SOLENOID (45 psi)

Second stage solenoid that feeds steam and through the Superheater and through the system.

HI TEMP VALVE

Allows steam to go into the Superheater and throughout the system.

INCOMING STEAM PRESSURE SWITCH (STM 13)

Does not allow the Superheater to turn on without sufficient steam pressure. The steam pressure must be at least 30 psi for the system to operate and is indicated on the Pressure Gauge. NOTE: THIS SWITCH IS ADJUSTABLE, BUT SHOULD NEVER BE SET BELOW 30 PSI

PRESSURE GAUGE (STM 8) Indicates the pressure of incoming steam entering the Superheater. Should read approximately 50 psi

INCOMING STEAM TEMPERATURE. GAUGE (STM 14)

Indicates the temperature of incoming steam. Should read approximately 300°F.



INCOMING STEAM THERMOCOUPLE (TC #1)

Provides a reading of the incoming steam temperature to show on the Degreaser Status Screen

SUPERHEATER HEATING ELEMENT THERMOCOUPLES (TC #3-5)

Provides a temperature reading of the Heating Element in the Superheater temperature to show on the Degreaser Status Screen. TC #3 - HTRS 1-3, TC #4 - HTRS 4-6, TC #5 – HTRS 7-9

SUPERHEATER Superheats the steam to the required temperature.

OUTLET STEAM THERMOCOUPLE (TC #2)

Provides a temperature reading of the superheated steam at the outlet of the Superheater to show on the Degreaser Status Screen

SUPERHEATER STEAM TEMPERATURE GAUGE (STM 22)

Reads the temperature of steam coming out of the Superheater

PRESSURE RELIEF VALVE (STM 18)

Factory pre-set @ 80 psi. The valve vents steam when excessive pressures are reached.

HI TEMP VALVE AIR SOLENOID

Operates the main pneumatic HI TEMP VALVE. This allows superheated steam to go into the Degreaser Tank.

SUPERHEATED STEAM GLOBE VALVE

Used primarily for maintenance. Also Allows throttling of the superheated steam.

SUPERHEATED STEAM PRESSURE GAUGE

Indicates the pressure of the steam entering the Degreaser Tank. This gauge should read approximately 50psi.

EMERGENCY STOP red pushbutton

When Emergency Stop is pushed, the Superheater power will turn "OFF", the solenoids will close, the exhaust blower will stop, and any residual steam pressure will be exhausted through the Pressure Relief Valve.



7.5.1 PRE-WASH STEAM SECTION GLOBE VALVE (STS 10)

Used primarily for maintenance. Also controls the steam flow to the Pre-Wash

7.5.2 PRE-WASH WATER SECTION

WATER HAMMER

Prevents hammering of air in the water supply.

FLOWMETER

Reads the flow of water to the Pre-Wash.

INCOMING WATER PRESSURE SWITCH

Does not allow the system to operate without sufficient water pressure. The water pressure must be at least 30 psi for the system to operate. NOTE: This switch is adjustable, but should never be set below 5 psi.

BACK FLOW PREVENTOR

Prevents water or steam from getting into the water supply line.

SOLENOID VALVE

Allows water to enter the Pre-Wash system

GLOBE VALVE

Regulates the water/steam mixture to the Pre-Wash. Adjusts the water flow of GPM.



8 PREPARATION FOR OPERATION

These instructions for installing, operating, and maintaining the Model 800 Coating Machine must be followed for safe and efficient operation. In particular, precautions should be most carefully observed whenever the unit is operated. Study this manual before installing or operating the equipment. Some voltages employed in this equipment are high. Remember that any source of voltage can be hazardous.

8.1 GENERAL

Properly coated and cured parts are subject to several variables such as: size of part, conveyor speed, type of powder, ambient temperature and humidity conditions. Care must be taken at all times when setting up the Machine for a particular product under specific conditions in order to obtain the desired results. This section contains a general explanation of the adjustments that can be made. Once specific settings have been determined for each product, they should be charted and made a set-up requirement prior to a production run.

8.2 INITIAL SYSTEM INSTALLATION

The following procedure should be used for the initial installation of the Coating System:

1. Uncrate all equipment from the shipping containers and crates. An inspection of the shipping containers should be made on delivery in accordance with Section 2.

2. Place the Main Machine in the desired location. 3. The Main Machine may have been shipped in two or three sections. These

sections should be connected together with the bolts provided at one or both of the following points: at the Induction Heater Station/Cure Tunnel entrance (if two sections) plus at the Coating Station (if shipped in three sections).

4. Adjust the height of the entire system and level the system. 5. Locate peripheral equipment such as the Powder Management System,

Regenerative Air Dryer, Induction Heater, Superheater and Cooling Blowers in proper places with respect to the Main Machine. Refer to the Layout Drawing of the system. Note that the Powder Collector Loading Station sight window and Rubber Gloves face the Induction Heater. Also, the Loading Door faces the rear of the Induction Heater.

6. Level all the peripheral equipment and make all necessary mechanical connections to attach peripheral equipment to the Main Machine.

7. Reconnect all wiring, piping, and hoses for electrical and pneumatic operation. All have been clearly marked numerically or alphabetically so that like numbers or letters will be connected together. All water piping for the Steam Degreaser has also been clearly marked for reconnection. NOTE: Some of the pipes may require connecting during the assembly operation. This is particularly true of the superheater plumbing and its exhaust.



8.2 INITIAL SYSTEM INSTALLATION (continued)

8. Re-connect the Roto-Flo Transport Screws and the Lifting Rails at the point they have been separated (Induction Heater exit).

9. Install the Powder Collector Filters in the Powder Collector. Start at the back of the cabinet and work towards the door. Place the Hanger Rod through the center of the Filter Element. Secure the Filter Element to the Hanger Rod by installing the special rubber washer Gasket, Wing Nut, and Protective Cap to the threads on the end of the Hanger Rod. Do not tighten at this time. Hang this Filter Element Assembly from the Venturi Bracket in the top of the Cabinet. Turn the Wing Nut clockwise until the Filter Element bottoms out on the stops. The Filter Element must be tightened until it can not be twisted by hand.

10. Prepare ducts from the coating area for the Powder Collector, Steam Degreaser Blower, Pre-Cooling Blower, Cooling Blower, Steam Degreaser Overpressure Valve, Induction Heater Hood, and Cure Tunnel. These ducts are used to vent steam, ovens, etc. and to reduce noise in the Machine area. Connect ducts to the System as required.

11. Fill with deionized water the Induction Heater Cooling Water Tank located under the Cure Tunnel. The Fill Tube is located on the rear of the Machine behind the Cure Tunnel. Check for leaks. NOTE: If the unit was shipped with anti-freeze , it must be flushed prior to filling.

12. Install the Deionizer Filter (Element) Cartridge into the Deionizer case. The Filter Cartridge has been shipped in a box taped to the side of the Deionizer case.

13. Prior to connecting the plant air supply to the Machine, blow the lines out to make sure nothing is in them which could cause a clog in the Machine Air Supply System. Make sure that the Main Machine Air Shut Off valve (Red handle back by the Air Dryer) is closed (in) at this time. Connect plant air supply to the Main Machine Air Connection (blue pipe) located on the rear of the E.T.I. Machine behind the Air Dryer. Pull up the Red Air Supply Valve handle on the Machine to allow the air to circulate through the Coating Machine. Check for air leaks by listening for escaping air.

14. Provide an incoming water pipe for the supply of 6 gpm min. @ 50 PSI min. of soft water to the Steam Degreaser Pre-Wash.

15. Turn "ON" plant steam supply, but do not connect it to the Machine. Run low pressure (less than 30 pounds/square inch) through the piping to a drain and allow it to clean out the interior of the piping before connecting to the E.T.I. Machine. This will avoid plugging the steam nozzles in the Degreaser with material which may have collected inside the piping. Once this is done, connect the steam supply to the E.T.I. Machine and check for leaks on incoming lines. DO NOT TURN "ON" THE SUPERHEATER AT THIS TIME.



8.2 INITIAL SYSTEM INSTALLATION (continued)

16. At this time connect the main electrical power to the E.T.I. Machine. Make sure air connections have been properly made in the equipment and the De-Ionized Water Tank has been filled. DO NOT TRY TO OPERATE THE SYSTEM AT THIS TIME

17. At this point, contact an E.T.I. serviceman for Start-up service.

8.3 LOAD / RELOAD STATION

The Operating Principles, Section 3 of this Manual describes the two different modes of operation: Automatic and Manual. When armatures are loaded onto the Roto-Flo Conveyor System in either mode of coating operation and an armature is misloaded, the Proximity Switch detects the misloaded part and the chain will stop. The Alarm Message, MISLOADED PART ON LOADER CHAIN, will appear on the Panel View Display and the operator will then have to correct the problem by doing the following:

Step 1 Go to the LOAD / RELOAD STATION Step 2 Open the Guard Door Step 3 Remove the misloaded armature(s) and the armatures at

the roto-flow loading point. Step 4 Close the Guard Door. This will reset the fault.

8.4 STEAM DEGREASER

Once the Steam Degreaser is running and DEGREASER START has been pressed, wait for approximately 20 minutes for the degreasing system to come up to temperature before attempting to run the machine.



8.5 POWDER MANAGEMENT SYSTEM 8.5.1 Loading Powder

Follow this procedure: Step 1. Remove tie-wrap from powder bag and open loading door. Step 2. Load only one bag of powder at a time; do not over-fill hopper. Leave about one foot of clear space to the screen in the loading chamber. Step 3. Close loading door. Step 4. Place hands in the rubber gloves. Step 5. Empty bag inside loading chamber. Step 6. Shake the bag so that all the powder falls into the hopper below.

NOTE: Do not allow foreign items (such as Bag Tie Wraps) to fall in the Hopper. They may jam the Powder Feeder Screw.

Step 7. Open the loading door, remove the empty bag, and close the loading door.

8.5.2 Powder Maintenance

Most powders are hygroscopic. An attempt should be made to finish the days run with a minimum amount of powder left in the Collector Hopper. The Hopper should be filled at the beginning of the day and be left almost empty at the end of the day. All powder containers (bags, barrels, hoppers, etc.) should be kept tightly closed.

NOTE: Do not mix different types of powder

8.6 COATER 8.6.1 Coating Bed

Press COATER ON button on MANUAL SETUP SCREEN. If the bed has been cleaned out and is empty, the automatic feature of the Powder Level Sensor will fill the bed with powder. Adjust the Coating Bed Air Flow Meter until the powder is uniformly fluidized (bubbling evenly) over the entire surface. Adjust the Gate Valves on the Powder Collector/Coater exhaust ducts so that no powder is spilling out of the Coater Hood.

8.6.2 Powder Deposition

Powder deposition on the part can be controlled by the density of the cloud and/or the High Voltage. Increasing the cloud density beyond a certain point reduces the effectiveness of the High Voltage and makes the Coater over-sensitive so that small variations in line voltage or atmospheric conditions will affect coating from part to part.



Cloud density can be varied by two methods:

8.6.2.1 Fluidizing Air

Increasing the fluidizing air will increase the cloud density (deposition). Decreasing the fluidizing air will decrease the cloud density. Increasing the air pressure beyond the uniformly fluidized point (bubbling) should never be done. Coating will become uncontrollable with uneven deposition and undue stress will be placed on the porous plate.

8.6.2.2 Powder Level

The powder level height in the fluidizing bed can be changed. Raising the level will bring an increasingly denser portion of the cloud closer to the part. It is not recommended to increase (or decrease) the height more than 1/2 in. (12.7 mm) beyond that set at installation. Consult E.T.I. personnel for any changes beyond this point. To raise the level, loosen the nut. clamping the level sensor probe tube. Next, gently pull the sensor probe tube and retighten the screw. Do not rotate the probe tube as it has a flat spot on it which must remain under the cap screw.

8.6.3 High Voltage

Set the High Voltage Adjust to give the Kilovolt reading on the High Voltage Kilovolt Meter required for production line condition.

8.7 CLEANERS 8.7.1 O.D. Adjusting

Press COATER ON on the Manual Setup Screen. Run powder coated parts and adjust the O.D. Cleaner Belt position for adequate cleaning of the armature O.D.'s under production line conditions.

8.7.2 Air Knives Adjusting

Press COATER ON on the Manual Setup Screen. Run powder coated armatures and adjust the Air Knives positions and the Air Control Valves for adequate cleaning of the armature shafts under production line conditions.

8.7.3 Conveyor Cleaners Adjusting

Press COATER ON on the Manual Setup Screen. When coating armatures, the Roto-Flo Screw Vacuums will automatically clean the Roto-Flow Screws as they revolve inside the Vacuum. The Conveyor Cleaner Vacuums are controlled by the Air Flow Meters on the Main Pneumatic Panel.

8.7.4 Shaft Cleaning Position Adjusting

Reference Section 6.5.5



8.8 INDUCTION HEATER

To operate the Induction Heater, the CONVEYOR START must be selected on the Manual Setup Screen. Then the IND HTR START must be selected on the Machine Startup Screen(wait 1 min. to allow the water pump to increase water pressure in the Induction Heater before pressing IND. HTR START on the Machine Startup Screen). Next, select the INDUCTION HEAT POWER ON located at the end of the Cleaning Station. The unit will be "ready", but will not generate heat until the armatures pass the Proximity Switch at the entrance to the Induction Coil. The INDUCTION HEATER POWER METER on the pendant control panel will show the level of heat power being generated

8.9 CURE STATION

Be sure to keep the hood closed while armatures are passing through the Cure Station. Operating with the hood open could have the following results:

• Interference with the temperature control preventing proper curing of the coating. • Burning out the heating units.

8.10 FINAL COOL STATION

The radiator for cooling the Induction Heater Cooling Water is mounted in this station. The station covers must be closed during operation to insure that the blower air removes heat from the radiator to keep the Induction Heater Cooling Water at the proper temperature.



9 SPECIFIC EQUIPMENT SAFETY

9.1 GENERAL

SOME VOLTAGES EMPLOYED IN PARTS OF THIS COATING SYSTEM ARE HIGH. REMEMBER THAT ANY SOURCE OF VOLTAGE CAN BE HAZARDOUS.

ONLY RELIABLE, DEPENDABLE, TRAINED EMPLOYEES SHOULD BE GIVEN THE RESPONSIBILITY OF OPERATION AND MAINTENANCE OF THIS SYSTEM.

ALL SECTIONS OF THIS MANUAL SHOULD BE STUDIED AND ALL POTENTIAL SAFETY HAZARDS IDENTIFIED AND UNDERSTOOD PRIOR TO INSTALLATION AND OPERATION OF THIS EQUIPMENT.

NEVER WORK ALONE, THERE MUST ALWAYS BE AT LEAST 2 PEOPLE INVOLVED IN MAINTENANCE WORK INSIDE THE DEGREASING TANK.

9.2 POWDER

As with all powder and finely ground materials, there is a potential dust

hazard. Powder recovery equipment must be kept in good working order for maximum safety. In the case of a powder spill; shovel, sweep, or vacuum the material up and dispose of it in accordance with applicable Local, State and Federal Ordinances. Blowing powder with air hoses is specifically NOT recommended.

There is a potential dust explosion hazard. Powder should be kept away from sparks or open flames. Personnel should not be permitted to smoke in the Powder Coating Area.

9.2.1 Employee Health

Personnel may be susceptible to the following effects of overexposure to powdered material:

9.2.1.1 Inhalation

Dust may cause irritation of the respiratory tract. Massive overexposure may produce pulmonary sensitization similar to a simple cold. Further exposure may lead to some type of asthmatic response.

9.2.1.2 Skin Contact

Powder may cause skin irritation such as Dermatitis or skin sensitization. Strict attention to proper personal hygiene practice is recommended.



9.2.1.3 Eye Contact

Powder may cause eye irritation.

9.2.2 First Aid Procedures

9.2.2.1 Inhalation

Remove individual from exposure and call physician if breathing continues to be impaired.

9.2.2.2 Skin Contact

Wash skin thoroughly with soap and water.

9.2.2.3 Eye Contact

Flush eye gently with plenty of clean water for 15 minutes. If irritation persists, get medical attention.

9.2.3 Special Protection

Protective equipment may be worn in order to minimize contact with skin, eyes or clothing. Masks, rubber gloves, eye goggles and some type of coveralls may be suitable.

9.2.4 Precautions

Personnel should observe the following when working with powdered materials:

WASH THOROUGHLY BEFORE EATING OR SMOKING.

NO SMOKING IN THE VICINITY OF THE COATING AREA.

AVOID INHALATION OF DUST AND/OR FUMES. 9.2.5 Material Safety Data Sheets (MSDS)

9.2.5.1 For every powder which is used in the coating equipment, a Material Safety Data Sheet and/or toxicity sheet should be obtained. Personnel should be aware of potential health hazards, as well as proper methods of handling powdered materials.



9.3 STEAM DEGREASER 9.3.1 Employee Contact

An employee assigned as the Steam Degreaser operator must be familiar with and follow all safety precautions involved in working with steam. They should be instructed in the safeguards necessary for safe Steam Degreaser operation and maintenance. This instruction should involve at least the following areas:

-The correct method to promptly take the unit out of service.

-To whom the employee should report suspected leaks or failure of equipment.

-To never bypass safety interlocks.

-To never rely on interlocks to shut down equipment.

-To use proper eye protection.

-To never open the Steam Degreaser Cover while the unit is running.

-To avoid reaching into the Steam Degreaser while it is operating because the steam is invisible and will cause severe burns.

9.3.2 Emergency Maintenance

In the event of a jam in the Degreaser Conveyor or a situation where the operator will have to open the Degreaser Tank Cover and work inside the Tank, please follow the information below:

1.NEVER WORK ALONE. THERE MUST BE AT LEAST 2 PEOPLE INVOLVED IN MAINTENANCE WORK INSIDE THE DEGREASER TANK. 2.PRESS THE DEGREASER "OFF" PUSHBUTTON. DO NOT PULL THE EMERGENCY STOP CORD OR PRESS "MASTER STOP" UNLESS IT IS ABSOLUTELY NECESSARY, BECAUSE HOT STEAM WILL REMAIN INSIDE THE TANK, DELAYING ENTRY INTO THE TANK. WHEN THE DEGREASER "OFF" PUSH BUTTON IS PRESSED, THERE IS A DELAY BEFORE THE EXHAUST FAN IS SHUT-DOWN. THIS DELAY WILL ALLOW THE EXHAUST FAN TO EVACUATE STEAM FROM THE DEGREASER TANK. 3.STAY CLEAR OF THE STEAM TANK AND WAIT APPROXIMATELY ONE HOUR. TURN THE MESSAGE DISPLAY SELECTOR SWITCH TO "OUTLET STEAM" AND OBSERVE THE TEMPERATURE. WHEN THE INDICATED TEMPERATURE IS LESS THAN 38°C (100°F), OPEN THE TOP OF THE DEGREASER TANK. CAUTION: SOME AREAS OF THE TANK AND ARMATURES WILL BE HOT. USE APPROVED GLOVES TO HANDLE ANYTHING INSIDE THE STEAM TANK. 4.BEFORE PROCEEDING MAKE SURE THE CONVEYOR IS STOPPED. 5.AFTER CORRECTING THE PROBLEM, CLOSE THE TANK COVER BEFORE RESTARTING THE DEGREASER.



10 PANELVIEW SCREENS

The Allen-Bradley Panel View screens are designed with a touch-sensitive surface overlaying the monitor. Selections are made by touching the display directly. When a selection is made, the selection/indicator box changes to display a new message. For example, when AUTOMATIC MODE is chosen, the box changes to AUTOMATIC MODE SELECTED. In addition to the selection/indicator boxes, there are also additional indicators and messages present on each screen to allow the operator to access station information efficiently.

The Model 800 Coating Machine includes the following Panel View screens: MAIN MENU SCREEN

The Main Menu Screen (Figure 5) lists the available screens for operating the Model 800 Coating Machine. The operator can access the desired screen by selecting (touching) its button on the Main Menu Screen.

Machine Start-up Screen Displays the MACHINE START-UP SCREEN.

Machine Auto Start/Stop Screen Displays the AUTO START/STOP SCREEN.

Manual Setup Screen Displays the SETUP SCREEN

Machine Status Screen Displays the MACHINE STATUS SCREEN

Degreaser Status Screen Displays the DEGREASER STATUS SCREEN

Alarm History Screen Displays the ALARM HISTORY SCREEN



Figure 5 Main Screen Menu



Figure 6 Machine Start-up Screen



Figure 7 Machine Auto Start/Stop Screen



Figure 8 Manual Setup Screen



Figure 9 Machine Status Screen



Figure 10 Degreaser Status Screen



Figure 11 Alarm History Screen



Figure 12 Alarm Banner Screen



10.1 MACHINE STARTUP SCREEN

The Machine Start-Up screen includes DEGREASER START & STOP, SYSTEM START & STOP, IND HTR START & STOP, AUTO MODE, MANUAL MODE, GO TO NEXT SCREEN, and GO TO MAIN MENU.

10.2 AUTO MODE START/STOP SCREEN

The Auto Mode Start/Stop screen includes controls for AUTO START & STOP along with selections to access different screens.

10.3 MANUAL SETUP SCREEN

The Manual Setup screen includes controls for CONVEYOR START & STOP, COATER ON & OFF, CLEANER START & STOP along with selections to access different screens.

10.4 MACHINE STATUS SCREEN

The Machine Status screen presents reports from the monitoring system along with COOLING WATER TEMPERATURE, CURE OVEN TEMPERATURE, HEATED PARTS TEMPERATURE and PROCESSED PARTS COUNTER plus controls to RESET COUNTER & ACK RESET along with selections to access different screens..

10.5 DEGREASER STATUS SCREEN

The Degreaser Status Screen (Figure 10) lists temperature information about the Steam Degreaser along with selections to access different screens.

10.6 ALARM HISTORY SCREEN

The Alarm History provides a history of machine faults:

Emergency Stop is Active Coater High Voltage Overload Plant Air is Off Pressure is Low

10.7 ALARM BANNER SCREEN

The Alarm Banner screen provides reports on machine faults along with the date and time. It also provides controls for ALARM ACK & CLEAR HISTORY



11 STATION STARTUP PROCEDURE

11.1 OVERVIEW

There are two modes for operating the Coating Machine; Automatic and Manual. This section will provide the operating personnel with a thorough understanding of start-up and shut-down procedures. Supervisory personnel should occasionally check the Coating and Induction Heater operation and make adjustments as required to ensure that proper coating, cleaning, and curing of armatures is maintained.

Assuming that all of the air, electrical, and water requirements have been connected and supplied to the Coating Machine, the following can be performed:

Step 1 Make sure the Main Disconnects and the disconnects for the Cooling Blowers are in the "ON" (up) position.

Step 2 MAIN Screen Menu should appear. If not, call it up. Step 3 Make sure that the TEE handle for the main air supply is pulled out (on). Step 4 Make sure that all Emergency Stop Buttons are pulled out and that the

Pull Cord button is Reset. Step 5 Press the Coating Machine MASTER START pushbutton. Step 6 Call up the Machine Start-Up Screen. Step 7 The Refrigerant Air Dryer and Cure Tunnel oven will turn “on”. There

will be a delay of up to 5 minutes for the Refrigerant Air Dryer to cool and become “ready”. The Coating Machine will not operate until the Refrigerant Air Dryer is “ready”

Step 8 Wait until the AIR DRYER IS NOT READY message no longer appears on the screen.. Proceed to the AUTO MODE OR MANUAL MODE. NOTE: For initial startup, after installation, proceed to MANUAL MODE.

Step 9 On the MACHINE STARTUP SCREEN, select in the following order: DEGREASER ON, SYSTEM START, IND. HTR. START.

NOTE: Faults will be reported on the Banner Screen (along with an audible alarm and the Red light on the Station Beacon). Acknowledging the fault by pressing the Acknowledge button on the Banner Screen removes the Fault Message from the Banner Screen. To help clear the fault, a fault history of all previous faults can always be called up on the Alarm History Screen.



11.2 MANUAL MODE - COATING MACHINE

The Manual Mode is used for Set-up, Experimentation, Maintenance, and Cleaning (for example, when it is desired to have the Powder Management System "ON" and not the Coating Bed). This Mode is also used when re-setting the Conveyor Clutch and re-setting the Proximity Switches in case parts are coming off the Conveyor in the Coating Bed.

When used for Experimentation, the various Conveyor speeds, High Voltage settings, and Air Pressure settings should be recorded under several production line situations in order to chart and fix these settings for future use. Each individual system can be turned "ON" and "OFF" within the limits of the priority circuitry for setting-up or troubleshooting.

Step 1 Be sure all aspects of the Machine Operation are understood. Step 2 Follow step 1 through 9 in the Station Startup Procedure on the

preceding page. Step 3 Select the MAIN SCREEN MENU, then select MANUAL SETUP

SCREEN Step 4 Select CONVEYOR START and COATER ON Step 5 Use the High Voltage Adjust dial to change the high voltage setting or

the coating (fluidic) bed. The Fluidic Bed air flowmeter may also be used to control powder fluidization.

Step 6 CLEANERS: Select CLEANER START to turn on the O.D. and shaft cleaner.

KEEP IN MIND THE PRIORITY FUNCTIONS. The Air Knives, Coater, O.D. Cleaner, Roto-Flo Screw Vacuums, and High Voltage can not turn "ON" unless the Powder Collector is "ON". The Induction Heater will not operate unless the Conveyor is "ON". and there are parts in the Induction Heater coil.

11.2.1 STEAM DEGREASER

To operate the Steam Degreaser, select the DEGREASER ON BUTTON. Wait until the DEGREASER NOT READY message goes away. This will take as much as 30 minutes to allow the Degreaser to come up to the proper operating temperature.

11.2.2 INDUCTION HEATER

To operate the Induction Heater, CONVEYOR START must be selected on the Manual Setup Screen. Then the IND HTR START must be selected on the Machine Startup Screen. The Induction Heater will be "ready", but will not generate heat unless the following conditions are met: • armatures pass the Proximity Switch at the entrance to the Induction Coil • the hood is closed



11.2.2 INDUCTION HEATER

The INDUCTION HEATER POWER METER on the pendant control panel will show the level of heat power being generated.

If the Conveyor Clutch trips in Manual Mode, a message will be displayed which says "MAIN CONVEYOR DRIVE CLUTCH HAS TRIPPED and the Conveyor will stop running. If this happens, the operator should turn the conveyor off and check for jammed parts or other problems which would prevent Conveyor operation. Then select the CONVEYOR START button to reset the Clutch. The Conveyor should begin to run.



11.3 AUTO MODE - COATING

The Auto Mode is intended to be used primarily under production line situations after all settings have been determined in Manual Mode.

Step 1 Be sure all aspects of the Coating Machine operation are understood Step 2 Follow step 1 through 9 in the Station Startup Procedure (Section 11 in

this Manual). Step 3 On the Panel View Screen, select the MAIN SCREEN MENU. Step 4 Select MACHINE AUTO START/STOP SCREEN Step 5 The following buttons on the Manual Setup Screen should already have

been selected in the order listed: DEGREASER ON SYSTEM START IND HTR START

NOTE: If a problem occurs, a warning message will appear on the Panel View Screen and the buzzer will be turned on along with the red light of the Station Beacon. To correct any faults, it is not always necessary to shut the equipment down. But if it seems to be required, follow the STATION SHUT DOWN PROCEDURE (Section 12 in this manual) and correct the problem

Step 6

Once the DEGREASER IS NOT READY message goes away, the degreaser is ready. Select the AUTO START button. If there is an alarm, the Banner Alarm Screen should come up on the Panel View Screen. Select ACKNOWLEDGE to silence the alarm. Check and respond to the error messages and correct the fault. NOTE: Faults will be reported on the Banner Screen (along with an audible alarm and the Red light on the Station Beacon). Acknowledging the fault by pressing the Acknowledge button on the Banner Screen removes the Fault Message from the Banner Screen and turns off the audible alarm To help clear the fault, a fault history of all previous faults can always be called up on the Alarm History Screen.

Step 7 If no faults occur, "AUTO MODE IS ON " will appear on the Auto Mode Start/Stop Screen.



11.3 AUTO MODE – COATING (continued)

There is a Pyrometer that reads the temperature of the armatures to check if they are at the correct operating temperature for cure (TBD). In case the armatures are not at the correct temperature, there will be a Alarm Status Screen message displayed on the Panel View Screen. If the temperature is shown as too low, the coating of the parts may not be fully cured. The operator should then use the following procedure to correct the problem:

• Increase the Induction Heater Power until the HEATED PARTS TEMPERATURE is reading at the proper level..

• Mark the parts whose coating may not be fully cured and set them aside for testing.

In case a fault occurs and the conveyor stops, leaving armatures in the Induction Heating Station, there will be automatic cycling of the Induction Heater which will serve to complete the cure process. A message will come up IND HTR CYCLING.



12 STATION SHUTDOWN PROCEDURE

12.1 AUTO MODE SHUTDOWN - COATING MACHINE Step 1 Run all parts off the System Step 2 Press Automatic Mode "OFF". This will turn off the Coater, High Voltage,

Conveyor, and O.D. Cleaner. Once the Conveyor is "OFF", the Air Knives and Roto-Flo Screw Vacuums will cease to operate. Wait at least 1 minute before pressing any other functions "OFF".

Step 3 Press BLOWERS "OFF Step 4 Press INDUCTION Heater Water PUMP "STOP". Step 5 Press POWDER COLLECTOR "STOP". Step 6 Press DEGREASER "STOP". Step 7 Leave the MASTER START "ON" for at least 5 minutes because the Steam

Degreaser Exhaust Blower will continue to run, which will keep steam from coming out of the Degreasing Tank, and also start to cool down the inside of the Degreasing Tank.

Step 8 After 1 minutes the Steam Degreaser Exhaust Blower will automatically turn "OFF". Once the Blower has shut off, press the MASTER "STOP" pushbutton. It is recommended that the daily cleaning procedure be started while waiting.

12.2 MANUAL MODE SHUTDOWN - COATING MACHINE Step 1 Run all armatures off the System. Step 2 There is no required sequence for tuning "OFF" functions in the Setup Mode,

However, generally the functions would be shut "OFF" in reverse order of turning them ON.

Step 3 If you have run the Steam Degreaser; leave the MASTER START "ON" for at least 5 minutes because the Steam Degreaser Exhaust Blower will continue to run, which will keep steam from coming out of the Degreasing Tank, and also start to cool down the inside of the Degreasing Tank.

Step 4 After 1 minutes, the Steam Degreaser Exhaust Blower will automatically turn "OFF". It is recommended that the daily cleaning procedure be started while waiting for the Degreaser Exhaust Blower to turn off Once the Blower has shut off, press the MASTER STOP BUTTON.

NOTE: Do not press MASTER STOP until all the blowers have stopped



12.3 POWDER HANDLING AT SHUTDOWN

Only a minimum amount of powder should be left in the Powder Management System when it is shutdown over an 8 hour period. When the Machine is not used in excess of 24 hours, the powder should be removed from the Coating Bed in order to prevent clogging of the porous plate due to ambient temperature and humidity conditions. The Powder Feeder Hopper should be emptied and the powder stored in an air tight container when the Machine will not be used for more than 48 hours.

When changing the type or color of powder, the Powder Management System must be thoroughly cleaned out in order to prevent contamination of the new powder



12.4 LOCKOUT Figure 13 Lockout Provisions



LOCKOUT (continued) Specific Characteristics Type of energy Place of lockout Method of lockout and

releasing of stored energy Checking the result of lockout

Electric 480 v E1 Master switch on cell electric cabinet

Turn the master switch into OFF position, and place the multiple lock and a name tag on it. Danger: the network side of the main switch, the interior lighting, the receptacles, and the PLC is under voltage

Make sure that the contacting surfaces are disconnected using gauge or by visual investigation. Try to restart the system. The system must not start

Pneumatic 6 bar P1 Main pneumatic valve

Push the valve handle in, and make the lockout and place a name tag.

Listen to whether the valve has released the air. Make sure that the valve is closed and the lock is properly placed

Steam S1 Main steam inlet valve

Turn the main steam valve fully clockwise to the closed position. Place red cover over the main steam valve handle. Lock and tag the red cover. DANGER: the steam pipe may be very hot.

Read the pressure on steam inlet gauge (STMB) and steam outlet gauge . They must both read “0” (zero) pressure. Make sure the valve is closed and the lock is properly placed.

Water W1 Turn the main water valve into the OFF position and place a lock and tag on it.

See that the valve has released water out of the valve drain and that the lock is properly placed

Steam Generator Ref: Steam Generator instruction manual for lockout procedures.



13. MAINTENANCE

13.1 GENERAL A systematic maintenance schedule should be set up and adhered to in order to

insure optimum machine operation. Daily, weekly, and monthly schedules should be established as applicable for each part of the coating system.

WARNING: ELECTRICAL VOLTAGES USED IN THIS EQUIPMENT CAN BE HAZARDOUS. MAINTENANCE SHOULD BE HANDLED BY QUALIFIED PERSONNEL

13.2 COMPRESSED AIR SYSTEM The importance of keeping the compressed air clean, dry and oil free cannot be

over-emphasized. More coating problems can be traced to failure to maintain the air filters and air dryers than any other cause.

13.2.1 Air Line

The air line which enters the coater should be kept clean and free of all

particles, water and oil.

13.2.2 Refrigerant Air Dryer Check the Refrigerant Air Dryer auto-drain for proper functioning. NOTE:

The drain can become clogged by oil or dirt. This will allow wet compressed air to enter the machine, resulting in a clogged Porous Plate in the Coater and dirty, epoxy spotted shafts on the parts. Refer to the Refrigerant Air Dryer manufacturer’s information for more specific maintenance instructions.

Particle Filter Clean and check for proper functioning. Change

filter element if dirty. Coalescing Filter Check and drain if necessary. Note: a wet filter

element is normal. Refer to the Coalescing information in the manufacturer’s manual supplied. Change the filter element if dirty. See the Spare Parts List (Section 17) for the correct filter number.

13.2.3 STEAM DEGREASER Follow the Steam Degreaser Preventive maintenance instructions listed in the

Preventative Maintenance (Section 14 of this manual).



DAILY CHECK AT START-UP: Check the Pressure Gauges on the Steam Degreaser and compare against previously

recorded settings to make sure there are no drastic changes which may indicate some type of problem (such as clogged nozzles).

13.3 FLUIDIC BED

The porous plate is the key factor in controlling the powder cloud in the fluidic bed. Under normal operation, the powder on the plate will be uniformly fluidized (lightly bubbling) over the entire surface of the plate. If the fluidization is not uniform, the porous plate has become clogged and will have to be replaced. The porous plate will require periodic replacement depending upon hours of use, contaminants in the compressed air, and conditions of operation and cleaning.

CAUTION: THE UNIFORM POROSITY OF THE PLATE IS VERY IMPORTANT FOR PROPER COATING. DO NOT SCRAPE OR EVEN TOUCH IT WITH A HARD OR SHARP OBJECT. NEVER POINT AN AIR GUN DIRECTLY AT THE PLATE Clogging of the pores of the porous plate is the most common cause of failure. Once the porous plate has been removed, inspect it to determine the reason for clogging. Possible causes are:

-Leaving powder unused in the bed for an extended period of time during humid conditions.

-Oil or water in air supply system.

-Damage from scratching, gouging or denting the plate.

-Blowing compressed air directly at the surface of the plate.

Correct the cause of plate failure and avoid conditions in the future which may lead to it. Order a new porous plate and gasket material from ETI and carefully install.



13.3.1 Installation of Porous Plate

Step 1 Turn machine "OFF" and make sure Main Disconnect is "OFF".

Step 2 Open the Hood of the Coating Bed.

Step 3 Vacuum all the powder out from the Coating area. Use a soft brush or a soft plastic fitting on the end of the vacuum hose.

Step 4 Remove the panel in front of the Coating Bed.

NOTE: CARE MUST BE TAKEN WHEN WORKING AROUND THE LEVEL SENSOR PROBE SO THAT THE PROBE IS NOT BENT OR DAMAGED. DAMAGE TO A PROBE MAY CAUSE THE LEVEL SENSOR TO CEASE FUNCTIONING OR TO FUNCTION IMPROPERLY

ALSO, CARE MUST BE TAKEN WHEN WORKING AROUND THE FIRE SENSOR BURN STRING. IF THIS IS BROKEN IT MUST BE REPLACED IMMEDIATELY OR THERE WILL BE NO SENSOR IN CASE OF FIRE.

Step 5 When powder has been cleaned out, remove the Vibrator bolted to the Ionization Chamber. Disconnect both the High Voltage Cable and Air Line from the center tube extending down from the Ionization Chamber.(The air line is connected to the tee coming off the side of the tube and the High Voltage Cable. The High Voltage Cable is connected to the bottom of the tee.)

Step 6 Place a rigid support under the Coater Ionization Chamber (lower section of Coating Bed). Remove the plastic hex head nuts, located along the Bed flange of Coater Ionization Chamber and let the Ionization Chamber rest on the rigid support

Step 7 Remove the Ionization Chamber.

Step 8 The old Porous Plate will now be exposed. The old Porous Plate and Gasket should come out with the chamber. Make sure all the Gasket material is removed from the upper flange inside the chamber.

Step 9 Replace with the new Porous Plate and Gasket. Gasket material should be placed along the outer edge and both the top and bottom of the Porous Plate before it is re-installed. Note that when installing the Porous Plate, either side may face up.

Step 10 Clean any powder out of the charging media chamber and off the charging media if required. Note that the Bolts securing the Upper Coating Bed and the Lower Ionization Chamber may not have been tightened enough or the gasket was worn or not seated properly if there is powder in the charging media chamber.

Step 11 Reverse steps 1 through 7 to re-install the Ionization Chamber and operate the Coating Bed.



13.4 POWDER MANAGEMENT SYSTEM The Powder Collector Filter Cartridge cleaning is done automatically by the unit.

At the end of every shift, the Differential Pressure Gauge should be checked to make sure that it is not reading above 4 which would indicate that the cartridges are not being cleaned. If the reading is above 4, the pulse frequency or duration should be increased. To increase the pulse frequency: decrease the setting on the "OFF TIME" timer which is located in the small electrical enclosure on the side of the Powder Management System. Note that the "ON TIME" timer has been set at the ETI factory for a minimum pulse cycle time. To increase the duration of the pulse cycle: increase the "ON TIME" timer.

The intensity of the pulse may be increased or decreased by raising or lowering the

air pressure to the shakers in the Powder Collector using the Air Regulator which is located near the top of the Powder Management System. Typical air pressure is 60 psi.

Under normal operation, the filter cartridges should be replaced approximately

every 6 to 12 months. When circumstances require that they be changed, care must be taken to ensure proper air sealing is maintained. Care must also be taken to avoid damaging the thin metal edges on the ends of the filters. These are easily dented which may result in improper fit and poor air sealing. Refer to the manufacturer’s manual for recommended procedure and other maintenance information.



13.5 POWDER LEVEL SENSOR Make sure that powder is not packed inside the probe tube or it will affect accurate

sensing. Refer to the Dwyer information included in the Manufacturer's Manuals section for

maintenance information.

13.6 O.D. CLEANER The O.D. Cleaner Belt and Belt Cleaner Brush may become worn with time. Refer

to the Spare Parts List (Section 17) in this manual for the correct spare part numbers.

13.7 INDUCTION HEATER Observe the water tank site glass labeled "Distilled Water Level" (located on the

front of the Cure Station Panel) to make sure the deionized water level is correct. Observe the deionizer indicator light (located on the front of the Cure Station) to

make sure the distilled water in the Induction Heater cooling system is within specifications. If the Indicator Light is green, this means the filter element is good. Red means the filter element must be changed.

For the Manufacturer's recommended Maintenance Schedule, please refer to the

Pillar Manufacturer's Manuals section of this manual.

13.8 COOLING FANS Refer to the Buffalo Forge manual in the Manufacturer's Manuals section of this

manual

13.9 PROGRAMMABLE CONTROLLER Refer to the Allen-Bradley Manual for specific maintenance information.



13.10 ROTO-FLO CONVEYOR Vacuum out any accumulated powder. CAUTION: DO NOT GREASE OR OIL CONVEYOR. ROTO-FLO SCREWS

AND COMPONENTS MUST BE KEPT COMPLETELY CLEAN AND DRY IN ORDER TO KEEP PRODUCTION PARTS CLEAN.

13.11 MOTORS AND GEARS Oil and lubricate as required. Refer to the Lubrication Chart (Section 14.4 of this

manual).



14. PREVENTATIVE MAINTENANCE SCHEDULE

14.1 DAILY 1. Look over entire Conveyor system and remove any powder or foreign

objects. 2. Remove the magnet located on the front of the Powder Feeder Transition

Weldment above the Coating Bed an inspect for metal chips. Remove chips and replace magnet.

3. Check the lens on the Infrared Temperature Detector for cleanliness and

clean as required. Refer to Manufacturer's Manuals section of this manual for instructions and cleaning solvent recommended. Do not just wipe the lens with a rag or it may be scratched.

4. Check the site glass for the Induction Heater Deionized Water TANK

level(look through the hole in the front panel at the Cure Station). Note that the Induction Heater Pump must be running in order to get a proper reading on the Indicator Light. (If the Pump is not running, the Indicator Light will always be red.) If the light is green, the filter cartridge is good. Red means the filter cartridge must be changed. Refer to the Barnstead manual for information on replacing the filter cartridge. The panel on front of the Machine at the Cure Station must be removed in order to have access to the Deionizer Filter.

5. Check the Porous Plate for proper fluidization and replace if required. The

Porous Plate should be replaced every 6 months, unless required earlier. Refer to Section 3.3.1 for instructions on installing a Porous Plate.

14.2 WEEKLY 1. Check the Automatic Drain on the Refrigerant Air Dryer. 2. Check the Air Particle and Coalescing Filter Indicator Lens and replace the

Filter Elements if required. Note: green - clear, yellow - change, red - replace.

3. Check and lubricate all motors, pumps, and bearings on the machine if

required. Refer to the Lubrication Chart (Section 14.4) of this manual. 4. The Induction Heater Cooling Water Inlet Pipe Strainer should be checked

for sediment and cleared as required. Insure the System is OFF when conducting this check and subsequent maintenance.



14.2 WEEKLY (continued) 5. Check all float controls for oil or sediment which may have collected and

cause them to operate incorrectly. Refer to pneumatic schematic for locations of float controls.

14.3 MISCELLANEOUS 1. Under favorable conditions the Powder Collector Filter Cartridges should

only need to be replaced approximately every 6 to 12 months. However, if the reading on the Differential Pressure Gauge (located on the Powder Management System) can not be brought down below 4 by adjusting the air pressure in the timer, then the Filter Cartridges need replacement. Refer to Section 13.3 for procedures to remove/install the Cartridges.

2. Replace the Deionizer Filter Cartridge approximately every 5 to 6 months,

even if the Deionizer Filter Indicator Light is still green which indicates that a change is not required.

3. Powder should not be allowed to remain in the Coating Bed when the

System is not in use. It should be removed to prevent clogging of the Porous Plate. Note: Do not scrape or even touch the porous plate with a hard or sharp object. Never point an air gun directly at the porous plate. As most coating materials are hygroscopic, storage of powder in the Powder Load Hopper and Powder Management System is also not recommended.

4. Check all of the Steam Degreaser dumps monthly to make sure there are no

restrictions. 5. Open all Steam Strainers on the Steam Degreaser and remove any sediment

which may have accumulated in the Inlet Strainer screens on a monthly basis. Insure that the System is "OFF" when conducting this check and subsequent maintenance.

6. Clean the Steam Degreaser Nozzles on a monthly basis to avoid build-up

which will clog the nozzles. Note that dirty nozzles indicate dirty Strainer Screens as well.

7. Check all belts monthly for wear and replace if required. The O.D. Cleaner

Belt should be changed every 6 months.



14.4 LUBRICATION CHART

# LUBE COMPONENTS

LUBR. COMPONENT TO

BE SERVICED

MACHINE COMPONENT TO

BE SERVICED

LOCATION LUBR. FREQ.

RECM'D OIL VISCOSITY OR

GREASE NO.

21 Bearing DRIVE LOAD STATION YRLY Texaco Starplex # 2

2 Bearing BLOWER SUPER HEATER frame

WKLY Dow Corning # 44

2 Bearing BLOWER PRE-COOL STATION

QRTLY Texaco Starplex # 2

2 Bearing BLOWER Inside POWDER COLLECTOR frame

MNTLY Texaco Starplex # 2

2 Bearing BLOWER FINAL COOL STATION

QTRLY Texaco Starplex # 2

1 Gear Reducer DRIVE LOAD STATION YRLY Mobil SHC 634

1 Gear Reducer POWDER MANAG. SYSTEM

Above COATING BED

YRLY Mobil SHC 634

1 Gear Reducer POWDER MANAG. SYSTEM

Left Side of POWDER FEEDER HOPPER

YRLY Mobil SHC 634

1 In-line Air Lubricator

PNEUMATIC PISTON

Under LOAD & DRIVE

STATION

MNTLY SAE 10

As Req'd

Thread(s) Bolt(s), Nut(s), any Threaded Component(s)

(Steam) DEGREASER TANK

Before Re-Installing

High Temp. 1800°F (982°C)

Anti-Seize Grease



14.5 LUBRICATION DIAGRAM

Electrostatic Technology INC. Model 800 Operation Manual


15 TROUBLE SHOOTING

ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS

AIR DRYER IS NOT READY

The Air Dryer has just been started up and is not cold enough to properly dry the main air supply

The air dryer will become “ready” by running and cooling its internal piping and opening up its temperature switch. Let the Air Dryer run by itself. The air dryer has to be at “ready” temperature before the machine will run.

STEAM DEGREASER IS NOT READY

Mode selector is in the Auto position and the Degreaser has been turned on, but is not up to “ready” temperature yet.

The Degreaser outlet temperature will rise above the ready set point as a function of normal operation.

CURE TUNNEL IS NOT READY

Mode selector is in the auto position and the Cure Tunnel is heating up, but is not up to “ready” temperature yet. Cure Tunnel Hood is open.

The Cure Tunnel temperature will rise above the ready set point as a function of normal operation. Close Hood.

PART LOADER IS STARVED FOR PARTS

The machine is operating in automatic mode and the chain conveyor has indexed 15 times without a part being sensed by Part Detector Proximity Switch. The Part Detector Proximity Switch is malfunctioning.

Check the equipment feeding the coating machine or the escapement loaded parts onto the chain conveyor. Check the chain conveyor for any jammed parts. Check the Misloaded Part Proximity Switch and its associated wiring.

EMERGENCY STOP CORD PULLED

The Emergency Stop cord located on the entire front length of the machine has been pulled.

The Emergency Stop Cable Switch must be reset. Check the machine and any personnel around the machine before resetting the switch.

A CYCLE STOP BUTTON STOPPED THE MACHINE

The machine was running and the conveyor was stopped by one of the three Cycle Stop push buttons.

Check the machine, Roto-Flo conveyor, chain conveyor, and Part Loader then pull out the Cycle Stop push button.

EXTERNAL SIGNAL HAS STOPPED CONVEYOR

The Start/Stop Signal at the Load or Unload End of Machine signal has been activated. This signal must be present in order for the conveyor system and Part Loader to operate. The signal is a permissive signal (interlock) and is used by the equipment receiving the coated parts from the machine.

Resume sending the Start Signal at Unload and Load ends of Machine, this will start the machine.

EXTERNAL SIGNAL HAS STOPPED PART LOADER

Start/Stop Loader Signal has been activated. This signal must be present in order for the Part Loader to operate. The signal is a permissive signal (interlock) to be used by the equipment feeding parts onto the chain conveyor. Remove the signal and the Part Loader and chain conveyor will stop after it finishes the current index. Remember this signal will not stop the Part Loader and chain conveyor immediately!

Resume sending the Start Loader signal to the machine.



ALARM MESSAGES AND TROUBLE SHOOTING GUIDE

MESSAGES CAUSES SOLUTIONS MAIN CONVEYOR IS RUNNING SLOW

The PLC has detected the Roto-Flo conveyor is too slow to meet the production rate of the machine. The DC motor drive speed setting has been altered. The conveyor drive system has some type of problem causing some type of binding. The DC motor drive is malfunctioning.

Time the speed of the Roto-Flo conveyor using a watch or stopwatch. Note: Production rate of the machine is based on 600 parts per hour or 10 parts per minute. Check operation of the drive system.

PART LOADER GUARD IS OPEN

The Part Loader guard is open. This guard has to be closed before the Part Loader and chain conveyor will operate again.

Check to see if someone is working on the Part Loader chain conveyor, or the Degreaser section. Close the Part Loader guard.

PARTS LOADER GUARD SWITCH IS BAD

The Parts Loader guard switch has two electrical switches which act together when the switch is activated and deactivated. Only one of the two redundant switches has been activated.

The Part Loader guard safety switch has malfunctioned, replace switch.

MISLOADED PART IN PART LOADER

A part has been loaded onto the chain conveyor at the wrong location. The correct location is between the chain tabs which are closest together.

Open up the Part Loader guard and remove any parts on the chain conveyor. Note: The fault is reset when the guard is opened and then closed. Close guard.

PARTS FELL OFF IN THE COATER

The parts have not exited the end of the coater. Someone has removed parts from the roto-flo conveyor between the precool blower section and the entrance to the coater. Note: Any parts removed from the roto-flo conveyor will give a false indication of “PARTS FELL OFF IN THE COATER” message. The parts have fallen off the roto-flo conveyor screw in the coater. The parts detector proximity switch has malfunctioned.

Turn off the coater and remove any parts which may have fallen off the roto-flo conveyor. Check spacing adjustment of the roto-flo screws and Check for bent roto-flo screws. Notice that the coater high voltage only comes on when there are parts in the coater which prevents overcoating the roto-flo screws with powder. If the coater was operated in Manual Mode and the high voltage was turned up, the roto-flo screws must be brushed off to remove excessive powder build-up before running parts through the coater.




MESSAGES CAUSES SOLUTIONS PRE-WASH NOZZLES ARE CLOGGED

STEAM DEGREASER FAULTS & WARNINGS The steam inlet temperature has not risen above 250° 10 minutes after the Degreaser Main Steam Valve was opened. This condition can be caused by the superheated prewash nozzles clogging which decreases steam flow.

Shut down the Degreaser by pressing the Degreaser Off push button. STAY CLEAR OF THE STEAM TANK AND WAIT APPROXIMATELY 5 MINUTES. OPEN THE GUARD AND HOOD BEING SURE TO STAY CLEAR OF THE ESCAPING STEAM VAPOR WHICH MAY STILL BE PRESENT. ALLOW THE STEAM TANK TO COOL BEFORE ATTEMPTING TO WORK IN THE STEAM TANK. CAUTION - SOME AREAS OF THE TANK AND ARMATURES WILL BE HOT. USE APPROVED GLOVES TO HANDLE ANYTHING INSIDE THE STEAM TANK. Remove each prewash nozzle and blow out dirt using compressed air. Important: When reassembling nozzles, place high temperature anti-seize compound (such as JOMAR Hi-Temp 1800° F rating) on threads. Note: This type of work is to be performed by qualified maintenance personnel only.




MESSAGES CAUSES SOLUTIONS SUPERHEATED STEAM VALVE DID NOT OPEN

The superheated steam valve air solenoid was turned on and the superheated steam valve did not open. The superheated steam valve is jammed closed. The superheated steam valve limit switch activating arm did not push up the “open” limit switch actuator arm. Insufficient air supply to the superheated steam solenoid. The superheated steam valve air solenoid malfunctioned because of a bad coil or a blown fuse.

The superheater steam valve must be disassembled. Refer to manufacturers instruction manual. Adjust the superheated steam valve activating arm so it will move both limit switch actuator arms. Check operation of the superheated steam valve air solenoid. Check the air supply to the solenoid. Check fuse.

SUPERHEATED STEAM VALVE DID NOT CLOSE

The superheated steam valve is jammed open. The superheated steam valve air solenoid was turned off and after a 20 second time delay the superheated steam valve did not open. The superheated steam valve limit switch activating arm did not push down the “closed” limit switch actuator arm. The superheated steam valve air solenoid is malfunctioning.

The superheated steam valve must be disassembled. Refer to manufacturers instruction manual. Adjust the superheated steam valve activating arm so it will move both limit switch actuator arms. Check operation of the superheated steam valve air solenoid.

FIRE IN THE POWDER COATER

COATING SECTION FAULTS AND WARNINGS A fire in the Coater has been detected. The filament string holding the Coater Fire Detector limit switch closed has burned away. This action causes the spring loaded limit switch actuator to return. All machine functions are turned off immediately.

Carefully check coater for fire. If a fire has occurred, determine the cause and correct. Replace the filament string. Notify E.T.I.




COATER IS LOW ON POWDER.

The coating bed powder level is low. The powder feeder has been trying to fill the coating bed for 45 seconds. The powder collector powder hopper is empty. The powder sensing tube inside the coating bed is set improperly. The powder feeder spring helix is broken. The level sensor/gauge has malfunctioned.

Load powder hopper with powder. Check and/or adjust the height of the level sensing tube inside the coating bed.

Check settings, vacuum lines, and operation of the level sensor (Photohelic gauge).

Check the powder feeder housing and/or the powder feeding tube for damage.

DEGREASER EXHAUST FAN IS NOT RUNNING

The Degreaser has been started but the Degreaser exhaust fan contactor has not energized.

Check operation of the Degreaser exhaust fan contactor. Replace if necessary.

Note: This type of work is to be performed by qualified maintenance personnel only.

DEGREASER EXHAUST FAN MOTOR OVERLOAD

The Degreaser exhaust fan motor overload tripped.

The Degreaser exhaust fan motor has a bad bearing or winding.

One of the Degreaser blower shaft bearings has worn out.

Make a visual inspection of all the components involved with this fault.

Check the running amperage draw of the motor using a clamp-on ammeter.

Replace any worn out bearings or the motor if needed.

Replace the motor overload if the motor is drawing under rated current and the overload continues to trip out. Reset motor overload.





COATER HIGH VOLTAGE OVERLOADED

The high voltage overload unit for the high voltage power supply has tripped.

Enough parts have fallen into the coating bed to short out the high voltage power supply.

The high voltage cable is shorting out or is malfunctioning.

The high voltage power supply is shorting out or is malfunctioning.

There is a crack in the coating bed ionization chamber causing a short to the machine frame.

Water or high humidity.

Metal nuts, bolts, etc. or metal slivers from armatures.

The high voltage overload unit is malfunctioning.

Remove any armatures that have fallen into the coating bed.

Clean the coating bed to remove metal slivers, wet powder, etc.

Check the operation of the high voltage cable. Visually inspect for short circuits and arc marks.

Check the operation of the high voltage overload unit.

Inspect the entire coating bed including the ionization chamber for cracks.

INDUCTION HEATER CYCLING ON/OFF

INDUCTION HEATER FAULTS & WARNINGS

The Induction Heater is cycling power to keep the armature hot while the conveyor is stopped.

When the conveyor starts, the Induction Heater will resume normal operation.




MESSAGES CAUSES SOLUTIONS

HEATED PART TEMPERATURE IS LOW

The induction heated part temperature is set too cool. The Infra Red Detector measures the surface temperature of each part as it passed by the detector infrared beam. If the measured temperature is not hot enough for curing the epoxy, the fault message appears.

The Infra Red Detector control board parameter settings are off. The emissivity setting is critical. If this setting is off, Infra Red Detector output will be incorrect.

The Infra Red Detector control board is turned off.

Check the Induction Heater power setting. Turn up the power and check part temperature.

Check the Infra Red Detector control board parameter settings.

INDUCTION HEATER COOLING WATER IS TOO HOT

The Induction Heater cooling water temperature is “too hot”.

Final coating blower air may be restricted.

The Induction Heater temperature switches have malfunctioned.

The cooling pump water supply reservoir is low on water.

Ambient air in the plant may be too hot to cool the water.

Check the cooling water supply reservoir. Fill to ¾ full with deionized water.

INDUCTION HEATER GUARD OPEN

The Induction Heater guard is not closed. The guard must be closed in order to operate the Induction Heater. Opening the guard will turn off the Induction Heater and prevent operating the machine in auto-mode

Close the Induction Heater guard.

INDUCTION HEATER IS NOT READY

Induction heater water pump failure.

Induction heater cooling water low

Check water pump motors, belts, etc.

Water reservoir with distilled water

.




INDUCTION HEATER IS NOT READY (continued)

Induction heater overload switch tripped (located on operators control panel).


Reset overload switch. If it continues to trip, check for arcing and shorts.

Refer to the Pillar instruction manual for trouble shooting instructions.

For further assistance call the Pillar Industries service department directly at:

800-558-7733 or 414-255-6470 (8 a.m. to 5:00 p.m. CST)

414-225-6040 for 24HR technical assistance.

POWDER COLLECTOR VACUUM IS LOW

SYSTEM FUNCTION FAULTS AND WARNINGS

The Powder Collector vacuum is low. This warning will transpire if the Powder Collector vacuum switch does not sense enough vacuum when the Powder Collector blower motor is on.

The Powder Collector filter cartridges are clogged up with powder thus reducing vacuum.

The Powder Collector blower fan belt is broken or is slipping.

The plastic film covering the explosion vent opening is torn or ruptured.

The Powder Collector vacuum switch setting is misadjusted.

Increase the Powder Collector filter pulse air pressure. Decrease the filter pulser off time thus increasing the pulsing frequency.

Check the Powder Collector blower for normal operation.

Check and replace plastic film cover the explosion venting opening.

Note the reading on the differential pressure gauge located on the Powder Collector; it should read between 1 and 5.

If the above instructions do not remedy the problem than the filter cartridge will need to be changed.





POWDER HOPPER IS LOW AND NEEDS TO BE FILLED

Powder hopper level sensor has detected a low level of powder; do not overfill the Hopper.

Fill the powder hopper with one bag of powder.

CURE TUNNEL CIRCUIT BREAKER IS TRIPPED

CURE TUNNEL FAULTS AND WARNINGS

The Cure Tunnel heater circuit breaker has tripped.

One of the heater sets or one of wires interconnecting a heater(s) has shorted out.

One of the heater elements has burnt out.

Reset the circuit breaker. Use a clamp-on ammeter to measure current draw on each 3 phase leg.

If one of the legs is measuring high, check for defective heating element by measuring resistance and Hipot to test for grounds.


CURE TUNNEL NOT READY

The machine was running in auto mode and the Cure Tunnel temperature has dropped below the minimum “ready” temperature.

The Cure Tunnel hoods are opened so the Cure Tunnel heaters, thermocouple and cure conveyor are exposed to ambient air. The Cure Tunnel will not heat up because the heat is escaping.

One or more of the Cure Tunnel heater elements is burnt out.

Close all the Cure Tunnel hoods to allow the Cure Tunnel to heat up. Use a clamp-on ammeter to measure current draw on each 3 phase leg.

If one of the legs is measuring high, check for defective heating element by measuring resistance and Hipot to test for grounds.


PLANT AIR IS OFF OR PRESSURE IS LOW

The operator was in the process of starting all functions of the machine and this fault occurred. The plant air supply is low which means that there is not enough air pressure or volume to start and run the machine.

The Main Air Shut-off Valve is closed.

The Plant Air Pressure Switch is misadjusted. The pressure setting is too close to the actual operating pressure of the machine

Open the Main Air Shut-off Valve.

Check the air supply pressure and volume.

Check the air pressure switch setting.





THERMOCOUPLE MODULE FAULT IN SLOT #6 FAULTED

THERMOCOUPLE MODULE FAULTS AND WARNINGS

The thermocouple module in PLC rack slot 6 has malfunctioned.

Use the Allen-Bradley thermocouple module manual to trouble shoot the thermocouple module.

Replace the thermocouple module.

THERMOCOUPLE MODULE IN SLOT #7 FAULTED

The thermocouple module in PLC rack slot 7 has malfunctioned.

Use the Allen-Bradley thermocouple module manual to trouble shoot the thermocouple module.

Replace the thermocouple module.

THERMOCOUPLE NO. 1 WIRE IS OPEN OR BAD

The thermocouple module has determined the inlet steam thermocouple (#1) has an open connection. The Degreaser will not run without this thermocouple.

The thermocouple wire is loose or disconnected at the thermocouple head, splice box, or the thermocouple module wiring arm.

The thermocouple itself is malfunctioning.

Check all connections and wires for this thermocouple. Correct any bad connections.

Replace the thermocouple if necessary.


The thermocouple module has determined the outlet steam thermocouple (#2) has an open connection. The Degreaser will not run without this thermocouple.




Replace the thermocouple if necessary,





The thermocouple module has determined the Superheater 1-3 heater high limit thermocouple (#3) has an open connection. The Degreaser will not run without this thermocouple.











.






Replace the thermocouple if necessary






The thermocouple module has determined the Induction Heater cooling water thermocouple (#6) has an open connection.






The thermocouple module has determined the Cure Tunnel (Oven) thermocouple (#7) has an open connection.






The thermocouple module has determined there is an open connection between the I.R. detector and the thermocouple module.

The thermocouple wire is loose or disconnected at the Infra Red Detector control board or the thermocouple module wiring arm.

The I.R. detector control board is turned off.

Check all thermocouple connections for the Infra Red Detector.

Turn on the Infra Red Detector control board.




PART LOADER CHAIN CONVEYOR IS STUCK

The chain conveyor tried to index forward but did not complete the index.

A part has wedged itself between the chain conveyor and a guide rail.

The Chain Conveyor Position Detector Proximity switch malfunctioned.

There is a problem with the conveyor drive system located underneath the part loader guard area.

If the chain conveyor was jammed, remove the jam. Close the loader guard..

Check operation and adjustment of the Chain Conveyor Position Detector Proximity Switch. Readjust if necessary.

MAIN CONVEYOR CLUTCH IS TRIPPED

The conveyor clutch (torque limiter) tripped. Part jammed in Roto-Flo bearing.

A Roto-Flo conveyor bearing is binding on the conveyor causing excessive torque.

The conveyor clutch limit switch is out of proper alignment with clutch.

Check the entire length of the Roto-Flo conveyor for any jams or pinching. Correct any jams or pinch points.

Manual Mode: Let the conveyor drive system continue to run until the Roto-Flo clutch resets itself.

Check the operation of the Roto-Flo clutch trip switch. The limit switch should go off when the clutch is tripped.

PLANT STEAM IS NOT HOT

The Degreaser was started and after five minutes, the incoming steam supply has not raised the Superheater outlet temperature above 100° C.

The incoming steam supply is low or is restricted.

Check the incoming steam supply pressure and temperature.

Check all the incoming steam supply valves. Open the valves if necessary.





PLANT STEAM PRESSURE LOW

The incoming steam supply is low or is restricted.

The steam supply to the Degreaser was turned off.

The steam pressure switch has malfunctioned.

Check the incoming steam supply pressure using the pressure gauge at the inlet side of the Superheater.

Check the steam pressure switch to insure it was set correctly and is operating properly. If the pressure switch is set too close to the steam line pressure setting, then a slight reduction in line pressure could open (activate) the switch.

Check the tubing connecting the steam pressure switch for clogging

STEAM PRESSURE SW. DID NOT TURN OFF

The steam regulator air solenoids were turned off and after a 30 second delay the steam pressure was still on.

Steam pressure switch is bad.

One of the steam regulator air solenoids did not turn off.

Check operation of the steam regulator and air solenoids.

Check pressure gauges for “0” pounds of steam. If switch is still on, it is defective or misadjusted.

DEGREASER GUARD IS OPEN

The Degreaser guard is not closed. The guard must be closed in order to operate the Degreaser. Opening the guard will shut down the Degreaser.

Check to see if someone is working on the Degreaser then close the Degreaser guard.

DEGREASER GUARD SWITCH IS BAD

The Degreaser guard switch is a dual switch. Only one of the dual switches activated when the guard was closed.

Close the Degreaser guard completely. Check operation of the safety switch and replace the safety switch and/or the switch key.

WATER IS STILL IN THE DEGREASER SUPERHEATER

The Superheater has been on for 15 minutes but is unable to raise the outlet steam temperature over 200° C. The Superheater vessel is filled with water which means the Superheater can’t completely boil out the water. Essentially the Superheater becomes a steam boiler.

Turn off the Degreaser and let the Superheater cool down completely. Refer to steam drawing sheet #15. Check strainers (Item 32) for dirt clogging and steam traps (Item 8) of proper operations. Replace if defective.




FUME EXHAUST FAN MOTOR OVERLOAD

The Fume Exhaust Fan motor overload (0:10/11O.L.) tripped.

The Fume Exhaust Fan motor has a bad bearing or winding.

The Fume Exhaust Blower has a bad bearing.

Make a visual inspection of all the components involved with this fault.



Reset motor overload.


PRECOOL BLOWERS MOTOR OVERLOAD

The precool fan motor overload (0:9/4 O.L.) tripped.

The cooling fan motor has a bad bearing or winding.

The precool blower has a bad bearing.

Make a visual inspection of all of the components involved with this fault.









FINAL COOLING BLOWER MOTOR OVERLOAD

The final cool fan motor overload (0:9/5 O.L.) tripped.


The final cool blower has a bad bearing.

Make a visual inspection of all of the components involved with this fault.





POWER COLLECTOR BLOWER MOTOR OVERLOAD

The powder collector fan motor overload (0:9/1 O.L.) tripped.


The powder collector blower has a bad bearing.

Make a visual inspection of all of the components involved in this fault.


Replace any worn out bearing or the motor if needed.

Reset motor overload





POWDER COLLECTOR AIR LOCK MOTOR OVERLOAD

The powder collector air lock motor overload (0:9/2 O.L.) tripped.

The motor has a bad bearing or winding.

The air lock or gear reducer has a bad bearing.






POWDER FEEDER MOTOR OVERLOAD

The powder feeder motor overload (0:9/3 O.L.) tripped.

The powder feeder motor has a bad bearing or winding.

The gear reducer has a bad bearing.

The powder feeder spring helix is jammed or broken.










INDUCTION HEATER WATER PUMP MOTOR OVERLOAD

The induction heater water pump motor overload (0:9/6 O.L.) tripped.

The water pump motor has a bad bearing or winding.

The water pump has a bad bearing.






PRECOOL BLOWER MOTOR SAFETY SWITCH IS OFF

The safety switch for precool blower motor (4 MTR) has been turned off which will prevent the machine from running in the Auto Mode.

Visually check that the safety switch is off. Important: Do not turn on the switch, as maintenance work may be in progress on the motor, belts, etc. The person who shut off the switch is the only one who can turn it back on.

FINAL COOL BLOWER MOTOR SAFETY SWITCH IS OFF

The safety switch for the final cool blower motor (5 MTR) has been turned off, which will prevent the machine from running in Auto Mode.


DEGREASER EXHAUST BLOWER MOTOR SAFETY SWITCH IS OFF

The safety switch for the degreaser exhaust blower (7 MTR) has been turned off, which will prevent the machine from running in Auto Mode.





FUME EXHAUST BLOWER IS NOT RUNNING

The fume exhaust blower motor contactor (0:10/1M) failed to energize when the programmable computer signaled it to turn on.

Check circuit breakers 402CB and 167CB, reset it tripped.

Check DC power supply (300PWR) for 24VDC output.

Check contactor (305M) for open coil.

EMERGENCY STOP BUTTON PRESSED

One or more of the three Emergency Stop buttons has been pressed. Determine who had pressed the Emergency Stop Button and why the Emergency Stop button was pressed before pulling out the button and restarting the machine. Correct the problem and make sure no danger will be created by starting the machine. Reset the Emergency Stop push-button.

Electrostatic Technology, Inc. Model 800 Operation Manual


16 PATENT INFORMATION The Model 800 Electrostatic Powder Coating Machine is manufactured under one or more of the following

United States Patents: 5,639,307 4,120,070 5,275,849 4,101,687 5,213,847 4,084,018 5,116,636 4,053,661 5,092,267 4,030,446 5,052,332 3,951,099 4,606,928 3,937,179 4,517,219 3,921,574 4,472,452 3,916,826 4,418,642 3,917,461 4,368,214 3,901,185 4,332,835 3,889,015 4,330,567 3,881,763 4,325,982 3,865,610 4,297,386 3,828,729 4,123,175 3,698,847



17 SPARE PARTS LIST (See Appendix)



18 MANUFACTURER’S MANUALS Backflow Preventer Watts Blower BL Buffalo Blower MW Buffalo B-Pure Pressure Cartridge System Barnstead Clutch w/Limit Switch Mayr Clutch Brake Power Supply/Control Regent Controls Clutch/Brake Warner Coalescing Filter F46 Norgren Constant Voltage Transformer SOLA DC Motor Speed Control KB Electronics Filter F17 Norgren Flowmeter Dwyer Flowmeter Insite Gear Reducer Sew/Euro Gearmotor Bodine Heat Exchanger ITT Heater Watlow High Temp Valve Leslie Input Module Allen Bradley Level Sensor Syntron Limit Switch w/Light Allen Bradley Line Separator Wright/Austin Magnahelic Differential Pressure Gauge Dwyer Motor Baldor Output Module Allen Bradley Panel View 500 Allen Bradley Photohelic Pressure Switch w/gage Dwyer Powder Collector Torit Power Supply Hipotronics Power Supply Pillar Power Supply Power One Power Supply SLC 500 Allen Bradley Pressure Blower Cincinnati Fan Pressure Reducing Valve Leslie Pressure Switch Square D Pressure Switch Dwyer Proximity Switch IFA Efector Proximity Switch IGA Efector Pump Eastern Centrichem Reducer 15:1 Hub City Reducer 60:1 Hub City Refrigerant Air Dryer Kaeser Regulator R100 Master Pneumatic Regulator R180 Master Pneumatic Resetter 32 Overload Regent Controls Right Angle Drive LH, RH Tol-o-matic Rotary Air Lock Meyer Safety Switch and Key Euchner SLC 500 Thermocouple Input Module Allen Bradley Solenoid Valve ASCO Steam Trap Spirax/Sarco



Transformer Hevi-Duty Vibrator FMC Water Hammer Arrest Watts



19 FLOOR PLAN



20 ELECTRICAL SCHEMATICS

The following schematics will be found in the Appendix:

ETI 15278-4000, Sheets 1 through 14

These include Electrical, Pneumatic, Lube, Water and Steam Drawings for the Fuel Pump Armature Coater.

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