3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER .................................................................. 2 3.2 PROCESS DESCRIPTION................................................................................................................................ 2
4 GENERAL SAFETY ............................................................................................................................................ 3
4.1 INTRODUCTION.............................................................................................................................................. 3 4.2 SAFETY SYMBOLS......................................................................................................................................... 4 4.3 QUALIFIED PERSONAL................................................................................................................................. 4 4.4 INTENDED USE............................................................................................................................................... 5 4.5 INSTALLATION............................................................................................................................................... 5 4.6 OPERATION ..................................................................................................................................................... 6 4.7 LESS OBVIOUS DANGERS............................................................................................................................ 8 4.8 ACTION IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION........................................ 8 4.9 MAINTENANCE & REPAIR ........................................................................................................................... 9 4.10 DISPOSAL.................................................................................................................................................. 10
5 AIR AND ELECTRICAL REQUIREMENTS ................................................................................................ 11
12.1 GENERAL .................................................................................................................................................. 29 12.1.1 High Voltage Multiplier.......................................................................................................................... 29
12.2 COMPRESSED AIR SYSTEM .................................................................................................................. 29 12.2.1 Air Lines ................................................................................................................................................. 29 12.2.2 Particle Air Filter ................................................................................................................................... 29 12.2.3 Refrigerant Air Dryer ............................................................................................................................. 30 12.2.4 Coalescing Filter .................................................................................................................................... 30
12.3 COATING BED .......................................................................................................................................... 30 12.3.1 Porous Plate Replacement...................................................................................................................... 31
12.4.1.1 Filter Cartridge Replacement ..........................................................................................................................32 12.4.2 Final Filter ............................................................................................................................................. 33
12.4.2.1 Final Filter Replacement.................................................................................................................................33 12.4.3 Fan Motor............................................................................................................................................... 34
14 SPARE PARTS LIST ......................................................................................................................................... 36
15 FLOOR PLAN .................................................................................................................................................... 38
Electrostatic Technology, Inc. FlexiCoat® M-300 Powder Application System
Serial #20229 1
1 INTRODUCTION
This Instruction Manual must be studied and followed for the safe and efficient operation of the "FlexiCoat® M-300 Powder Application System". Study this manual before locating and installing the equipment. ELECTROSTATIC TECHNOLOGY, INC. A SUBSIDIARY OF NORDSON CORPORATION 4 PIN OAK DRIVE BRANFORD, CT 06405 TELEPHONE: 203-488-8112 FAX: 203-483-8777 In future correspondence, please refer to the MODEL (FlexiCoat® M-300 Powder Application System) and SERIAL NUMBER (20229) and MODEL NUMBER (F21M-1-3-0-0-0-0-2-1) of the "POWDER COATING MACHINE".
2 SHIPPING Sometimes equipment can be damaged in transit. An inspection of the shipping crate should be
made upon delivery, and when equipment is removed, it should be carefully inspected to make sure the unit is in good condition. If the equipment is damaged, the carrier's claim agent should be requested to prepare a report, a copy of which should be sent to:
ELECTROSTATIC TECHNOLOGY, INC A SUBSIDIARY OF NORDSON CORPORATION 4 PIN OAK DRIVE BRANFORD, CT 06405 Electrostatic Technology, Inc will then advise concerning repairs and replacements.
Electrostatic Technology, Inc. FlexiCoat® M-300 Powder Application System
2 Serial #20229
3 OPERATING PRINCIPLES
3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER
3.2 PROCESS DESCRIPTION
Powder particles are aerated in a fluidizing chamber and are electrostatically charged by ionized air forced through a porous plate at the base of the chamber. As the powder particles become charged, they repel each other to such a degree that they rise above the chamber forming a cloud or veil of charged particles. When a grounded object is placed in this cloud, or conveyed through this cloud, the charged powder particles, because of their opposite potential, are attracted to it. As the particles become attached to the object, they form a uniform coating, being more attracted to exposed areas than to those already insulated. The longer the object is exposed to the cloud, the thicker the coating becomes, until saturation eventually takes place.
Coating thickness is controlled by applied voltage to the charging media and exposure time to the cloud. Because of the high voltage capability of the charging media, a sufficiently great potential exists between it and most substrates to permit even natural insulators to be coated. Unlike equipment with exposed electrodes, Electrostatic Technology, Inc.'s unique air ionization process charges the powder without permitting the powder, the object, or the operator to come in contact with the charging media.
Electrostatic Technology, Inc. FlexiCoat® M-300 Powder Application System
Serial #20229 3
4 GENERAL SAFETY
4.1 INTRODUCTION
This section contains general study instructions for using your Electrostatic Technology, Inc. (ETI) equipment. Task-and-equipment-specific warnings are included in other sections of this manual where appropriate. Note all warnings and follow all instructions carefully. Failure to do so may result in personal injury, death, or property damage.
To use this equipment safely:
• Read and become familiar with the general safety instructions provided in this section of the manual before installing, operating, maintaining, or repairing this equipment.
• Read and carefully follow the instructions given throughout this manual for
performing specific tasks and working with specific equipment. • Store this manual within easy reach of personnel installing, operating,
maintaining, or repairing this equipment. • Follow all applicable procedures required by your company, industry standards,
and government or regulatory agencies. Refer to the National Fire Protection Association (NFPA) standard 33 and to federal, state, regulatory agency, and local codes for rules and regulations covering installation and operation of powder coating systems.
• Obtain and read Material Safety Data Sheets (MSDS) for all materials used.
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4.2 SAFETY SYMBOLS
Become familiar with the safety symbols presented in this section. These symbols
will alert you to safety hazards and conditions that may result in personal injury, death, or property and equipment damage.
WARNING: Failure to observe this warning may result in personal in
personal injury, death, or equipment damage. WARNING: Risk of electrical shock. Failure to observe this warning
may result in personal injury, death, or equipment damage. WARNING: Disconnect equipment from line voltage. Failure to
observe this warning may result in personal injury, death, or equipment damage.
WARNING: Risk of explosion of fire. Fire, open flames and smoking
prohibited. WARNING Wear protective clothing, safety goggles, and approved
respiratory protection. Failure to observe may result in serious injury. WARNING: System or material pressurized. Release pressure. Failure
to observe this warning may result in serious injury of death. CAUTION: Failure to observe may result in equipment damage.
4.3 QUALIFIED PERSONAL
"Qualified Personnel" is defined here as individuals who thoroughly understand the equipment and its safe operation, maintenance, and repair. Qualified personnel are physically capable of performing the required tasks, familiar with all relevant safety rules and regulations, and have been trained to safely install, operate, maintain, and repair the equipment. It is the responsibility of the company operating the equipment to see that its personnel meet these requirements.
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4.4 INTENDED USE
WARNING: Use of this equipment in ways other than described in this manual
may result in personal injury, death, or property and equipment damage. Use this equipment only as described in this manual.
ETI cannot be responsible for injuries or damages resulting from nonstandard,
unintended applications of its equipment. This equipment is designed and intended only for the purpose described in this manual. Uses not described in this manual are considered unintended uses and may result in serious personal injury, death, or property damage. Unintended uses may result from taking the following actions:
• Making changes to equipment that have not been recommended or described in
this manual or using parts that are not genuine ETI replacement parts.
• Failure to make sure that auxiliary equipment complies with approval agency requirements, local codes, and all applicable safety standards.
• Using materials or auxiliary equipment that are inappropriate or incompatible
with your ETI equipment.
• Allowing unqualified personnel to perform any task.
4.5 INSTALLATION
Read the installation section of all system components manuals before installing your equipment. A thorough understanding of the system components and their requirements will help you install the system safely and efficiently.
• Allow only qualified personnel to install ETI and auxiliary equipment. • Use only approved equipment. Using unapproved equipment in an approved
system may void agency approvals. • Make sure all equipment is rated and approved for the environment in which you are using it. • Follow all instructions for installing components and accessories. • Install locking, manual, shutoff valves in the air supply lines to the system.
This allows you to relieve air pressure and lock out the pneumatic system before undertaking maintenance and repairs.
• Install a locking disconnect switch or breaker in the service line ahead of any
electrical equipment (if applicable).
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4.5 INSTALLATION (continued)
• Use only electrical wire of sufficient gauge and insulation to handle the rated current
demand. All wiring must meet local codes.
• Ground all electrically conductive equipment within 10 feet (3 meters) of the coating area. Ungrounded conductive equipment can store a static charge which could ignite a fire or cause an explosion if a hot spark is discharged.
• Install safety interlocks which shut down the coating system if the exhaust fan fails, a
fire is detected, or other emergency situation develops.
• Make sure the coating area floor is conductive to ground and that the operator's platform is grounded.
• Use only designated lifting points or lugs to lift and move heavy equipment. Always
balance and block loads when lifting to prevent shifting. Lifting devices must be inspected, certified, and rated for a greater weight than the equipment being lifted.
• Protect components from damage, wear, and harsh environmental condition.
• Allow ample room for maintenance, material supply container drop-off and loading,
panel accessibility, and cover removal.
• If safety devices must be removed for installation, reinstall them immediately after the work is completed and check them for proper functioning.
4.6 OPERATION
Only qualified personnel, physically capable of operating the equipment and with no impairments to their judgement or reaction times, should operate this equipment. Read all component manuals before operating a powder coating system. A thorough understanding of all components and their operations will help you operate the system safely and efficiently.
• Use this equipment only in the environments for which it is rated. Do not
operate this equipment in humid, flammable, or explosive environments unless it has been rated for safe operation in these environments.
• Before starting this equipment, check all safety interlocks, fire detection systems,
and protective devices such as panels and covers (if applicable). Make sure all devices are fully functional. Do not operate the system if these devices are not working properly. Do not deactivate or bypass automatic safety interlocks or locked-out electrical disconnects or pneumatic valves.
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4.6 OPERATION (continued)
• Know where EMERGENCY STOP buttons, shutoff valves, and fire
extinguishers are located. Make sure they work. If a component malfunctions, shut down and lock out the equipment immediately.
• Before operating, make sure all conductive equipment in the coating area is
connected to a true earth ground. • Never operate equipment with a known malfunction or leak. • Do not attempt to operate electrical equipment if standing water is present. • Never touch exposed electrical connections on equipment while the power is
ON. • Do not operate the equipment at pressures higher than the rated maximum
working pressure of any component in the system. • Know the pinch points, temperatures, and pressures for all equipment that you
are working with. Recognize potential hazards associated with these and exercise appropriate caution.
• Wear shoes with conductive soles, such as leather, or use grounding straps to
maintain a connection to ground when working with or around electrostatic equipment.
• Do not wear or carry metallic objects (jewelry or tools) while working with or
around electrostatic equipment. Ungrounded metal can store a static charge and cause harmful shocks.
• Keep parts of the body or loose clothing away from moving equipment or parts.
Remove personal jewelry and cover or tie back long hair. • Wear National Institute of Occupational Safety and Health (NIOSH) approved
respirators, safety glasses or goggles, and gloves while handling powder containers, filling hoppers, operating coating equipment, and performing maintenance or cleaning tasks. Avoid getting powder coatings on your skin.
• Do not smoke in the coating area. A lit cigarette could ignite a fire or cause an
explosion. • If you notice electrical arcing in the coating equipment, shut down the system
immediately. An arc can cause a fire or explosion. • Shut off electrostatic power supplies before making adjustments to powder
coating fluidized bed.
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4.6 OPERATION (continued)
• Shut off moving equipment before taking measurements or inspecting work
pieces. • Wash exposed skin frequently with soap and water, especially before eating or
drinking. Do not use solvents to remove coating materials from your skin. • Do not use high-pressure compressed air to blow powder off your skin or
clothes. High-pressure compressed air can be injected under the skin and cause serious illness or death. Treat all high-pressure fittings and hoses as if they could lead and cause injury.
4.7 LESS OBVIOUS DANGERS
Operators should also be aware of less obvious dangers in the workplace that often cannot be completely eliminated:
• Exposed surfaces on the equipment which may be hot or have sharp edges and
cannot be practically safeguarded.
• Electrical equipment which may remain energized for a period of time after the equipment has been shut off.
• Vapors and materials which may cause allergic reactions or other health
problems. • Automatic hydraulic, pneumatic, or mechanical equipment or parts that may
move without warning. • Unguarded, moving mechanical assemblies.
4.8 ACTION IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION
Do not operate a system that contains malfunctioning components. If a component
malfunctions, turn the system OFF immediately.
• Disconnect and lock out electrical power. Close and lock out hydraulic and pneumatic shutoff valves and relieve pressures.
• Allow only qualified personnel to make repairs. Repair or replace the
malfunctioning component.
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Serial #20229 9
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 area or 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.
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4.9 MAINTENANCE & REPAIR (continued)
WARNING: Operating faulty electrostatic equipment is hazardous and can cause
electrocution, fire, or explosion. Make resistance checks part of your periodic maintenance program.
• Do not store flammable materials in the coating area or room. Keep
containers or 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 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.
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Serial #20229 11
IMPORTANT: Provide a proper ground connection for the plugequipment ground wire. Polarity of the receptaclemust be according to code.
5 AIR AND ELECTRICAL REQUIREMENTS
5.1 FLEXICOAT®
5.1.1 Air 10 scfm @ 80 psi minimum/100 psi maximum. A 1/2 inch air line (E.T.I.
provided) should be connected between the Coalescent Filter (outlet side of the Refrigerant Air Dryer) and the FlexiCoat® Coating Machine. The Polypro tubing is connected to the fitting mounted on the leg of the Powder Collector. The loose end should be pressed into the fitting on the Coalescent Filter.
5.2.1 Air A Refrigerant Air Dryer capable of conditioning 10 scfm @ 80 psi
minimum/100 psi maximum of clean air is required. Customer must connect a 1/2 inch air supply hose to the Particle Filter (inlet side of Refrigerant Air Dryer).
5.2.2 Electrical
115 Volts, 60 Hertz, 1-Phase. Customer must plug the attached three wire duplex plug into the proper receptacle. Refer to the Refrigerant Air Dryer information in the Appendix of this manual.
IMPORTANT: Provide a proper ground connection for the plug equipment ground wire. Polarity of the receptacle must be according to code.
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6 DESCRIPTION OF COMPONENTS
6.1 FLEXICOAT® COATING STATION The coating machine is complete with Coating Bed, High Voltage Multiplier, Air
Flow Meter, and cloud containing Hood. The coating chamber is of a patented design that insures that neither powder, substrate being processed, nor foreign objects can contact the charging media.
6.1.1 Optional Conventional Fluid Bed
The Conventional Fluid Bed (C.F.B.) is a non-electrostatic fluidizing dipping bed that mounts over the electrostatic fluidized bed. There is an operator control switch to run the High Voltage "OFF", and allow the C.F.B. to be used. The C.F.B. has 8 inch deep side walls which holds the powder in a lightly fluidized condition for the dipping of a pre-heated part.
The C.F.B. option is intended for heavy powder build applications on a hot part.
NOTE: CARE MUST BE TAKEN DURING DIPPING APPLICATIONS
TO NEVER TOUCH THE POROUS PLATE LOCATED AT THE BOTTOM OF THE FLUIDIZING BED WITH A HOT PART OR IT WILL MELT.
6.2 REFRIGERANT AIR DRYER
A Refrigerant Air Dryer accepts in-plant compressed air and supplies moisture free
coating/cleaning air to the FlexiCoat® M-300 Powder Application System. A Particle Filter is installed on the inlet of the Refrigerant Air Dryer to remove foreign particles from the inlet air. A Coalescing Filter is installed on the outlet of the Refrigerant Air Dryer to remove any oils from entering the system.
6.3 FLEXICOAT® POWDER COLLECTOR
The FlexiCoat® Powder Collector consists of the following:
6.3.1 500 CFM Collector Module
The 500 CFM Collector Module uses a ¾ HP motor to drive the Exhaust Fan. The Exhaust Fan pulls air from Powder Application Hood (Canopy) and into the (2) Cartridge Filters. The air passes through the Cartridge Filters and is forced through the Final Filter. The clean, powder free air is returned to the surroundings. Excess powder (not adhering to the parts) is carried by the air flowing through the Hood to the Cartridge Filters, where it collects on the outer surfaces. When activated, the pulse valves force air from the Pulse Valve Air Manifold through
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Serial #20229 13
6.3.1 500 CFM Collector Module (continued)
the Cartridge Filter in the opposite direction of normal flow. The pulse airflow cleans accumulated powder from the Cartridge Filter media. The powder falls to the bottom of the Collector Module and into the storage container (5 Gallon Pail) where it can be recovered and recycled or discarded. A Differential Pressure Gauge is located on the side of the Collector Module. This gauge provides an indication of cleanliness of the Filter Cartridges. A normal reading would be between 0 and 3.5. A reading above 3.5 would indicate the Filter Cartridges are not being cleaned well enough.
If this is the case, increase the number of times during the day that the filter cartridges are cleaned by pressing the Filter Pulse Manual Valve. Or slightly increase the air pressure to the pulse circuit (air regulator/gauge on the right front leg of the Powder Collector) so the reverse cleaning pulses are more intense.
6.4 SURECOAT MANUAL SPRAY GUN WITH CUP FEED
Refer to Nordson Manufacturer's information in the Appendix of this Manual for information on Operation and Controls of the Sure Coat Manual Powder Spray Gun, Sure Coat Manual Gun Control Unit and the Cup Gun Kit.
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7 INSTALLATION
These instructions for installing, operating and maintaining the FlexiCoat® Powder Application System must be followed for its safe and efficient operation. In particular, precautions should be observed whenever the unit is operated. Study this manual before installing or operating equipment. Some voltages employed in this equipment are high. Remember that any source of voltage can be hazardous.
7.1 LOCATION
1. Place "FlexiCoat®" and ancillary equipment on a level surface at the desired
location. Refer to Floor Plan Drawing in the Appendix of this manual.
2. Look over the entire Powder Coating Machine and Powder Collector Module to make sure there has been no damage during shipping. Although your machine may be shipped pre-assembled, please read through this manual before installing.
7.2 AIR CONNECTIONS
E.T.I. supplies the Poly-Flo tubing for all air connections. Refer to the Pneumatic Schematic in the Appendix of this manual. 1. Check that all pneumatic hoses are connected securely throughout the
machine. 2. Connect the 1/2 inch air supply hose to the fitting on the Air Supply Valve
connected to the Particle Filter (inlet side of Refrigerant Air Dryer).
NOTE: If Dry inert gas is used, consult the E.T.I. factory.
7.3 ELECTRICAL CONNECTIONS
1. Connect the Booth and Electrical Panel to a true earth ground.
2. Connect the electrical cord from the Refrigerant Air Dryer to a receptacle outlet rated: 115 Volts, 60 Hz, 1-Phase.
3. Connect the FlexiCoat® M-300 Powder Application System electrical cord to
a receptacle rated: 115 Volts, 60 Hz, 1-Phase, 20 Amp.
CAUTION: ALL RECEPTACLES MUST HAVE A PROPER GROUND CONNECTION.
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7.4 CONTROLS
7.4.1 Footswitch
Locate the Coater Footswitch and position in front of the Coater Station. The Footswitch is already pre-wired to the electrical controls.
7.5 POWDER MAINTENANCE
Most powders are hygroscopic. An attempt should be made to finish the day's run
with a minimum amount of powder left in the Coating Bed and Powder Collector Hopper. All powder containers (bags, barrels, hoppers, etc.) should be kept tightly closed.
NOTE: Do not mix different types of powder.
7.6 REFRIGERANT AIR DRYER
After plugging the Refrigerant Air Dryer into proper electrical receptacle (see Section 7.3) make sure the ON\OFF switch is in the "ON" position. When power is "ON", the Refrigerant Air Dryer will operate.
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8 DESCRIPTION OF CONTROLS
8.1 COATER CONTROL PANEL ILLUSTRATION
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8.2 COATER CONTROLS
KILOVOLT Digital Meter
Indicates the voltage being supplied by the High Voltage Multiplier when the Footswitch is pressed.
HIGH VOLTAGE ADJUSTMENT Adjustable Potentiometer
Adjusts the output of the High Voltage Multiplier (0-80 kV)
COATER BED OFF/ON Selector Switch
Turns "ON" and "OFF" the Coating Bed. In the "ON" position, fluidizing air and High Voltage are enabled to the coating process (if the High Voltage has been turned "ON"). In the "OFF" position, fluidizing air and High Voltage are disabled and the Coating Bed will not operate.
HIGH VOLTAGE OFF/ON Selector Switch
Enables or disables the High Voltage during the coating process. In the "ON" position the High Voltage is enabled and will turn "ON" during the coating process. In the "OFF" position, the High Voltage is disabled and will not turn "ON" during the coating process. NOTE: The HIGH VOLTAGE Selector Switch must be in the "OFF" position prior to use of the Optional Conventional Fluid Bed (Hot Dip) Adapter. This disables the High Voltage and will only allow fluidizing air during the coating process.
COATER VIBRATOR OFF/ON Selector Switch
Turns the Coating Bed Vibrator "ON" and "OFF". The intensity of vibration is adjusted on the Vibrator itself.
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8.3 PNEUMATIC CONTROL PANEL ILLUSTRATION
8.4 PNEUMATIC CONTROL PANEL CONTROLS
FLEXICOAT BED ADJUSTMENT Air Flowmeter
Adjusts and indicates the amount of fluidizing air supplied to the Coating Bed.
FLEXICOAT BED PRESSURE Air Pressure Gauge
Indicates the amount of regulated air pressure supplied to the Coating Bed.
FLEXICOAT BED PRESSURE ADJUSTMENT Air Pressure Regulator
Adjusts the amount of regulated air pressure supplied to the Coating Bed.
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8.5 MISCELLANEOUS CONTROLS
The following items are not located on the Electrical Control Panel:
FOOTSWITCH Activates the Coating Bed when pressed.
The Coating Bed will only operate while the Footswitch is pressed and cease to operate when the Footswitch is released.
GROUND CLIP Alligator Clip Located on the front of the Coating Bed area
Provides a ground potential for parts to be coated. Operator should connect this Ground Clip to the part or the part holding fixture to allow for a good path to ground so that powder will be attracted uniformly.
8.6 FLEXICOAT® POWDER COLLECTOR CONTROLS
Note that these controls are not shown on a drawing, they are found on the Enclosure or Frame of the FlexiCoat® Powder Collector. POWDER COLLECTOR OFF/ON Switch
Turns the Powder Collector Exhauster ON/OFF.
FILTER PULSE MANUAL VALVES 2 Pushbuttons (one pushbutton for each Filter Cartridge)
Activates the filter pulser (shakedown) to blow powder off the Filter Cartridge. Note: Filter Cartridge blowdown only occurs while the button is being pressed.
FILTER PULSER AIR PRESSURE Air Pressure Regulator & Gauge
Indicates and adjusts amount of regulated air pressure supplied to the Powder Collector Cartridge Cleaning Pulser.
DIFFERENTIAL PRESSURE GAUGE Magnahelic Gauge
Indicates the difference in pressure across the Powder Collector filters from the clean side to the dirty side which indicates the level of cleanliness of the filter cartridges.
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9 START-UP AND OPERATION PROCEDURE
9.1 COATING STATION SET-UP
Step 1 - Make sure the Refrigerant Air Dryer is plugged into the electrical supply and is "ON". Wait 5 minutes before compressed air admission is possible. Open the air supply valve mounted on the inlet side of the Refrigerant Air Dryer.
Step 2 - Turn the POWDER COLLECTOR Switch "ON" (located on the left
side of the machine). Check the cartridge filter differential pressure gauge on the Collector Module. During normal operation, the pressure should remain under 3.5 inches water column. If the reading reaches 3.5 or higher, the cartridge filters are clogged and should be pulsed. If the differential pressure gauge still reads 3.5 or higher after pulsing, replace the cartridge filters.
Step 3 - Adjust the Filter Pulser Air Pressure (FILTER PULSE PRESSURE
ADJUST) to 40 psi (2.8 bar). Note that this should never be set lower than 40 psi (2.8 bar). This setting is for the Powder Collector Filter Cartridge Pulse Valves.
Step 4 - Add a suitable Electrostatic Fluidized Bed coating powder to the
Coating Bed. The un-fluidized powder depth in the Coating Bed should measure approximately 1 to 1.5 inches deep.
Step 5 - Turn the COATER BED OFF/ON Selector Switch to "ON". NOTE: The Coater footswitch must be pressed for Steps 6 - 7. Step 6 - Adjust the Coating Bed Air Pressure (FLEXICOAT BED
PRESSURE ADJUSTMENT) to 45 psi (3 bar). This regulator/gauge is located on the Coater Control Panel.
Step 7. Turn the High Voltage Control to zero. Step 8 - Refer to Section 9.2 for Electrostatic Fluid Bed operation. Refer to
Section 9.3 for Conventional Fluid Bed coating.
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9.2 ELECTROSTATIC COATING OPERATION
Step 1 - Adjust the Coating Bed air flowmeter (FLEXICOAT BED
ADJUSTMENT) to approximately 30% of the meter capacity. There should be adequate fluidization of the powder in the Bed so a cloud forms. Adjust further if required.
NOTE: The Coater footswitch must be pressed to do this. If the powder does not fluidize easily it may require slight vibration to the Coating Bed to assist the powder in fluidizing. To do this, turn the COATER VIBRATOR Selector Switch to the "ON" position. In normal operation with standard powders vibration is not typically needed but it can be applied if required.
Step 2 - Turn the HIGH VOLTAGE OFF/ON Switch to the "ON" position. Step 3 - Press the Coater Footswitch and turn the High Voltage adjustment up
to a starting point of 55 kV. Step 4 - Ground the part to be coated using the ground clip. Hold the part 3 –
5 inches above the Coating Bed and begin Electrostatic Fluid Bed coating.
Step 5 - Continue to press the Coater Footswitch and allow the part to be
coated (in the powder cloud) for the duration of the coating cycle. Rotate the part around as required to get uniform powder deposition.
Step 6 - Release the Coater Footswitch and remove part to inspect after
coating. Adjust Coating Bed Fluidizing Adjust, High Voltage setting and/or length of coating cycle in order to obtain the optimum coating.
Step 7 - Repeat these steps as required to obtain a satisfactorily coated part.
9.3 CONVENTIONAL FLUID BED (HOT DIP) COATING OPERATION
Step 1 - Place the Conventional Fluid Bed Adapter onto the deckplate surface
above the Electrostatic Fluid Bed. Mount to the deckplate with the screws supplied.
Step 2 - Turn the HIGH VOLTAGE OFF/ON Switch to the "OFF" position. Step 3 - Add a suitable Conventional Fluid Bed coating powder to the Coating
Bed. The un-fluidized powder depth in the Coating Bed should be deep enough to cover the part to be coated.
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9.3 CONVENTIONAL FLUID BED COATING OPERATION (continued)
Step 4 - Adjust the Coating Bed air flowmeter (FLEXICOAT BED
ADJUSTMENT) to approximately 30% of the meter capacity.
NOTE: The Coater footswitch must be pressed. The powder surface should not be fluidized (like in the Electrostatic Fluid Bed) but just slightly moving and acting like a liquid. Adjust the Coating Bed air flowmeter (FLEXICOAT BED ADJUSTMENT) as required to achieve this condition. If the powder does not fluidize easily it may require slight vibration to the Coating Bed to assist the powder in fluidizing. To do this, turn the COATER VIBRATOR Selector Switch to the "ON" position. In normal operation with standard powders vibration is not typically needed but it can be applied if required.
Step 5 - Preheat the part to be coated. Step 6 - Begin the dipping process. Be careful to never let the part touch
the Porous Plate at the bottom of the Coating Bed or it will melt the plate.
Step 1 - Once a part has been satisfactorily coated, powder may be removed
from unwanted surfaces by vacuum, manual wiping or brushing, or by the use of a stream of compressed air.
Step 2 - Once parts are satisfactorily coated and cleaned, place them onto a
rack or hanger for oven cure.
9.5 MANUAL SPRAY GUN OPERATION
Step 1 - Make sure to read and understand the Operation of the SureCoat Manual Spray Powder Spray Gun. Turn the unit "ON".
Step 2 - Open the Customer supplied air supply valve to allow air to enter the
FlexiCoat® Powder Application System.
Step 3 - Turn the POWDER COLLECTOR Switch "ON" (located on the left side of the machine).
Step 3 - Adjust the Filter Pulser Air Pressure to 40 psi (2.8 bar). Note that this
should never be set lower than 40 psi (2.8 bar). This setting is for the Powder Collector Filter Cartridge Pulse Valves.
Step 4 - Turn the COATER BED OFF/ON Selector Switch to "OFF".
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9.5 MANUAL SPRAY GUN APPLICATION (continued) Step 5 - Make sure that there is a good ground between the part hanger hook
and the hanger bar inside the FlexiCoat Hood. Step 6 - Process parts using the Spray Gun and make necessary adjustments to
obtain a satisfactory part. Once parts are satisfactorily coated place them onto a rack or hanger for oven cure.
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10 SHUT-DOWN PROCEDURE
10.1 COATING BED OPERATION Whenever you shut the machine "OFF" you should manually pulse (shake down) the filter cartridges. This should be done every time the machine is going to be shut "OFF". You may find that it is necessary to do this several times a day. However, the system must be "ON" for this feature to work. Step 1 - Press both FILTER PULSER MANUAL VALVES several times
before shutting the System "OFF". Step 2 - Turn the HIGH VOLTAGE OFF/ON Switch to the "OFF" position. Step 3 - Turn the COATER BED OFF/ON Switch to the "OFF" position. Step 4 - Turn the POWDER COLLECTOR Switch "OFF" " (located on the
left side of the machine). Step 5 - At this time you may wish to re-claim powder from the Powder
Collector. Re-claimed powder may be mixed with virgin material at a rate of no more than 20% re-claim and re-used in the Coating Machine. Remove the bucket from under the Powder Collector Hopper to access the re-claimed powder.
10.2 RE-START PROCEDURE
When re-starting turn the POWDER COLLECTOR Switch "ON". Turn the
COATER BED OFF/ON Selector Switch to the "ON" position. High Voltage settings and air settings should not need to be re-adjusted. They will remain set as before shutdown.
NOTE: If the Refrigerant Air Dryer has been running and is shut
"OFF" then re-started, you must wait 5 minutes before turning the unit back "ON" to allow the Refrigerant Air Dryer to equalize and prevent it from short cycling.
10.3 EXTENDED SHUT-DOWN PROCEDURE When shutting the machine down for more than an overnight period, the following
should be noted: When not in use, the coating material in the unit should be removed from the Coating Bed to prevent clogging of the Porous Plate. As most coating materials are hygroscopic, storage of the powder in the Powder Collector Re-claim Pail for extended periods of time is not recommended. It is advisable that the powder be removed and stored in an air tight container. Observe the following procedure:
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10.3.1 Coating Bed Cleaning
Step 1 - Turn the Powder Collector "ON". Press both FILTER PULSER
MANUAL VALVES several times. Step 2 - Clean the inside of the Coating Bed canopy with a rubber
squeegee or other grounded, nonmetallic device. Open the hinged baffle door and scrape the powder into the Powder Collector Module.
Step 3 - Make sure to turn the COATER BED OFF/ON Selector Switch to
the "OFF" position. Step 4 - Carefully vacuum the remaining powder from the Bed. Use a
shop vacuum with a soft plastic nozzle on the end of its hose. Any residual powder not vacuumed out from inside the canopy can be blown with compressed air into the Powder Collector Module.
Step 5 - Turn the Powder Collector "OFF".
10.3.2 Powder Collector Module Cleaning
Step 1 - Unplug the FlexiCoat® M-300 Powder Application System from the electrical source. Make sure System is "OFF".
Step 2 - Remove the hex head bolts and flat washers securing the Filter
Access Panel to the Powder Collector Module. Remove the Filter Access Panel.
Step 3 - Clean the inside of the Powder Collector Module with a rubber
squeegee or other grounded nonmetallic device. Brush the powder from the lower section of the Powder Collector Module into the Powder Re-claim Pail.
10.4 POWDER/COLOR CHANGE
When changing powder from one color to another, it is very important that the
Coating Bed be thoroughly cleaned to prevent contamination. The same bed cleaning procedure as above should be used. Also, the Powder Collector Filter Cartridges should be changed if powder is being saved and re-used. It is also necessary to thoroughly clean the Powder Collector Hopper and Powder Re-claim Pail to avoid color contamination.
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11 TROUBLE SHOOTING
11.1 TROUBLE SHOOTING – COATER
COATER-SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Coating Bed High Voltage control set too low.
Increase (turn knob) High Voltage control.
No High Voltage indicated to Coating Bed
DC Power Supply in control box is bad.
Contact your ETI representative for further instructions
High Voltage control is set too low.
Increase (turn knob) High Voltage control.
High Voltage Multiplier is bad. Replace Multiplier.
No or low coating
If cable is disconnected or loose. Check plug connection. NOTE: Do not twist Multiplier connection it will damage internal connections.
Air flowmeter control is set too low.
Increase air flow (turn knob) on flowmeter. Tighten screws of porous plate ring.
Air Leaking by gasket at porous plate.
Check gasket – replace if necessary.
Porous Plate is clogged. Install new porous plate. Air solenoid is not operating. Replace the defective solenoid. Particle Air filter is clogged. Replace the filter element. Air shut-off valve partially closed.
Check valve and open if required.
Insufficient air to fluidize power.
Ice blocking air lines. Repair or adjust Air Dryer (refer to manufacturer’s maintenance information in appendix).
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11.1 TROUBLE SHOOTING – COATER (continued)
COATER-SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Moisture in Coater fluidizing air. Check analysis gauge on the Air
Dryer-if applicable. Refrigerant Air Dryer malfunctioning.
Refer to the maintenance (section 12.2) information of this manual.
Particle Air Filter is dirty. Replace filter element. Refer to the Spare Parts List of this manual for part number.
Coalescing Filter needs to be drained.
Drain Coalescing Filter and replace the filter element if damaged. Refer to the Spare Parts List of this manual for part number.
Coating powder is wet or damp.
Powder is hygroscopic and has absorbed moisture from the humid air around it.
Aerate powder in Coating Bed at low fluidization air setting for 20 minutes w/High Voltage turned to zero (0).
Substrate not properly grounded Faulty ground to substrate Check ground clip to substrate to make sure it is secure or insure that the conveyor or tooling provides a good ground.
11.2 TROUBLE SHOOTING – POWDER COLLECTOR
COLLECTOR - SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) No suction on Powder Collector. Powder Collector filter
cartridge(s) not being cleaned – infrequent filter cartridge blow-off.
Increase the number of times during the day that the filter cartridges are cleaned by pressing the Filter Pulse Manual Valve. Refer to the Powder Collector manufacturer's manual, located in the Appendix of this manual.
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11.2 TROUBLE SHOOTING – COLLECTOR (continued)
COLLECTOR - SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Cartridge filters clogged due to: Failure to pulse filters Pulse the filters several times. Inadequate pulse pressure Increase the manifold pressure to
60 psi (4.14 bar). Powder too fine or contaminated If using reclaimed powder,
reduce the ratio of reclaimed-to-virgin powder. Check powder particle size, if necessary.
Pulse valve malfunction The pulse valve diaphragm is ruptured. If you hear a hissing sound inside of the fan section, check for constant air flow from the valve. Replace the damaged valve.
Cross drafts Check for cross drafts across the booth face and correct as necessary.
Parts too large, interrupting flow of air through booth
Contact your ETI representative.
Powder escaping from booth openings
Exhaust fan rotation reversed Reverse the rotation of the motor by switching the wiring.
No power to unit Check to make sure power connections are good and there is incoming electrical power.
Fan motor overload shutdown Correct one of the following possible motor, contactor, fuse or operational problem as needed: • Check the exhaust fan for
proper rotation direction. • Check for mechanical binding
of the motor/fan assembly. • Re-set Manual Motor Starter
and turn unit back ON. If problem persists, contact E.T.I.
System will not start
Incorrect, shorted, or open electrical wiring
Check the electrical circuits.
Cartridge pulsing will not start No air supply to pulse manifold Check the air supply and air supply connection.
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12 MAINTENANCE
12.1 GENERAL A systemic 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 VOLTAGE USED IN THIS EQUIPMENT CAN BE HAZARDOUS. MAINTENANCE SHOULD BE HANDLED BY QUALIFIED PERSONNEL.
12.1.1 High Voltage Multiplier
PLEASE NOTE: Do not twist the cord that plus into the High Voltage Multiplier, the pins are very fragile and will break off. This condition will cause irreparable damage to the High Voltage Multiplier.
12.2 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. If wet compressed air enters the machine, it may result in a clogged porous plate in the Coating Bed and poor fluidization.
12.2.1 Air Lines
The air lines which enter the Coating Machine and the Powder Collector Module should be kept clean and free of any particles, water, and oil.
12.2.2 Particle Air Filter
Clean and check for proper functioning. Check the Filter Indicator Lens and replace the Filter Element if required. Note: green – O.K., red – replace.
Refer to the Particle Filter information in the manufacturer’s manual supplied. Change the filter element if dirty. See the Spare Parts List (Section 14) for the correct filter number.
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12.2.3 Refrigerant Air Dryer
Once the Refrigerant Air Dryer is "ON" and operating, after 15 minutes and periodically thereafter the following procedures should be implemented:
Step 1 - Make sure that the "Power On" light is lit and the unit is
operating. Step 2 - Make sure that condensate drain is draining; drains can very
easily 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 poor fluidization.
Consult the enclosed AIR/TAK Manual included in the Appendix of this Manual for more specific Refrigerant Air Dryer maintenance and troubleshooting instructions.
12.2.4 Coalescing Filter
Check and drain. Note that a wet filter element is normal.
Check the Filter Indicator Lens and replace the Filter Element if required. Note: green – O.K., red – replace. Refer to the Coalescing Filter information in the manufacturer’s manual supplied. Change the filter element if dirty. See the Spare Parts List (Section 14) for the correct filter number.
12.3 COATING BED
The screws holding down the Coating Bed flange to the Ionization Chamber flange
should be checked periodically for tightness. Loose bolts may cause geysers of rising powder and non-uniform fluidization.
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 POROUS PLATE IS VERY IMPORTANT TO PROPER COATING. DO NOT SCRAPE OR EVEN TOUCH IT WITH A HARD OR SHARP OBJECT. NEVER POINT AN AIR GUN DIRECTLY AT THE PLATE.
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12.3 COATING BED (continued)
Clogging of the pores of the plate is the most common cause of failure. Once the
Porous Plate has been removed, inspect it to determine which of the following reasons caused clogging:
• 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 have lead to it. Order a new Porous Plate and gasket material from ETI and carefully install.
12.3.1 Porous Plate Replacement
Step 1 - Turn System "OFF" by turning the POWDER COLLECTOR
Switch to "OFF". Step 2 - Vacuum all the powder from the bed using a soft brush fitting or
rubber nozzle on the end of a vacuum hose.
Step 3 - Disconnect the electric plug from the voltage multiplier.
CAUTION: Pull the electrical plug straight down to disconnect it from the voltage multiplier. The plug will be damaged if it is twisted during removal.
Step 4 - Disconnect the poly-flo tubing from the air inlet elbow.
Step 5 - Remove the twenty (20) plastic hex head screws from the Porous
Plate Retaining Ring and remove the Ring. Remove the old Porous Plate and gasket material.
Step 6 - Use the old Porous Plate as a template for positioning and making
the mounting holes in the new Plate.
Step 7 - Clean electrostatic powder out of the charging media chamber and off the charging media if required. Note that the Porous Plate must not have been properly sealed if there is powder in the charging media chamber.
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12.3.1 Porous Plate Replacement (continued)
Step 8 - Apply new gasket material along top and bottom edge of the new
Porous Plate. Make the new mounting holes in the gasket material. Place the new Porous Plate onto the flange in the fluidic chamber and re-position the Porous Plate Retaining Ring. MAKE SURE TO INSTALL THE NEW POROUS PLATE WITH THE SMOOTH SIDE FACING UP.
Step 9 - Replace the twenty (20) plastic hex head screws and tighten down
evenly so that the retaining ring is snug against the Porous Plate to prevent ionized air leakage around edges of the Porous Plate.
Step 10 - Connect the poly-flo tubing to the air inlet elbow. Step 11 - Connect the electrical plug to the voltage multiplier. Step 12 - Restore the system to normal position. Step 13 - Add a suitable Electrostatic Fluidized Bed coating powder to the
Coating Bed.
12.4 POWDER COLLECTOR MODULE
12.4.1 Cartridge Filters
Inspect the cartridge filters for damage to the filter media or gaskets. Remove the Final Filter and inspect the Collector Module for powder leaks. If powder is leaking past the cartridge filter gaskets, tighten the wing nuts on the cartridge filters to compress the gaskets and stop the leaks. Replace the cartridge filters if necessary. Check the differential pressure gauge. Under normal operation, the pressure should remain under 3.5 inches water column. If the reading reaches 3.5 or higher, the cartridge filters are clogged and must be pulsed. If the differential pressure gauge still reads 3.5 or higher after pulsing, replace the cartridge filters.
12.4.1.1 Filter Cartridge Replacement
All cartridge filters are accessible through the filter access panel. The filter closest to the filter access panel (outside filter) must be removed in order to access the filter that is furthest from the filter access panel. Step 1 - Remove the hex head bolts, lock washers and flat washers securing the filter access panel to the Powder Collector Module. Remove the filter access panel. Step 2 - Remove the protective cap from the threaded end of the hanger rod.
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12.4.1.1 Filter Cartridge Replacement (continued) Step 3 - While supporting the bottom of the outside cartridge filter with one hand, remove the wing nut and flat washer securing the cartridge filter to the hanger rod. Remove the cartridge filter (and discard it). Step 4 - Remove the hanger rod from the hook in the upper collector module. Step 5 - repeat Step 2 to remove the inside cartridge filter, leaving its hanger rod in place on the hook. Step 6 - Remove the new cartridge filters form their cartons and inspect them for damage. Do not use damaged cartridge filters. Step 7 - Guide the installed hanger rod through the open end of the cartridge filter. Guide the threaded end of the hanger rod through the hole in the closed end of the cartridge filter. Step 8 - Secure the cartridge filter and hanger rod to the collector module using the flat washer and wing nut. Tighten the wing nut until the cartridge filter gasket is compressed evenly. Step 9 - Install a protective cap over the threads of the hanger rod. Step 10 - Hang the outside hanger rod on its hook and repeat Steps 2-4 to install the outside cartridge filter. Step 11 - Secure the filter access panel to the collector module using the flat washers and hex head bolts.
12.4.2 Final Filter
Visually inspect the Final Filter whenever replacing the cartridge filters. Replace the Final Filter when it becomes clogged and negatively affects performance of the exhaust fan.
12.4.2.1 Final Filter Replacement
Step 1 - Remove the hex nuts and lock washers securing the Z-brackets to the collector module. Step 2 - Remove the old final filter from the collector module.
Step 3 - Remove the new final filter from its carton and inspect it for
damage. Do not use a damaged final filter.
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12.4.1.1 Filter Cartridge Replacement (continued)
Step 4 - Set the new final filter in place with the gasket facing the
collector module. Do not damage the gasket. Step 5 - Install the Z-brackets in place over the final filter. Install the
lock washers and hex nuts and finger-tighten the nuts. Step 6 - Check the position of the final filter to make sure that the
gasket will seal on all four sides. Step 7 - Tighten the hex nuts until the gasket is compressed slightly.
Make sure the gasket is compressed equally on all four sides of the final filter.
12.4.3 Fan Motor
Lubricate the fan motor bearings every six months with one of the following greases or equivalent grease. Clean the motor grease fittings and apply two full strokes from a grease gun to each fitting. Do not over-grease the fan motor. • Dolium R (Shell Oil Co.) • SRI #2 (Chevron USA, Inc.)
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13 PATENTS The FlexiCoat® M-300 Powder Application System is manufactured under one or more of the
Sure Coat Demonstration System Spray Gun Nordson #309480
Sure Coat Gun w/ Cup
Feed 1 - -
Please Note: Prices are valid for 90 days from the date on this document.
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15 FLOOR PLAN
See the Appendix for the Floor Plan Drawing.
16 PNEUMATIC SCHEMATIC See the Appendix for the Pneumatic Schematic Drawing. 17 ELECTRICAL DRAWING See the Appendix for Elementary Electrical Drawing. 18 MANUFACTURER'S MANUALS All of the Manufacturer's Manuals listed below can be found in the Appendix of this manual:
• Air Filters - Particle & Coalescing (AIR/TAK) • Air Flowmeter (Dwyer)
• Air Regulator (Norgren) • Blower Motor (Baldor)
• Differential Pressure Gauge (Dwyer)
• Digital Meter (Summit)
• High Voltage Multiplier (Nordson)
• Refrigerant Air Dryer (AIR/TAK)
• Sure Coat Manual Powder Spray Gun (Nordson)
• Sure Coat Manual Gun Control Unit (Nordson) • Cup Gun Kit (Nordson)
