table of contents - nordson

Electrostatic Technology, Inc Filter End Coating System

Serial #15754 i

TABLE OF CONTENTS

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

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

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

3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER................................2 3.2 PROCESS DESCRIPTION .............................................................................................3

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

4.1 INTRODUCTION ...........................................................................................................4 4.2 SAFETY SYMBOLS.......................................................................................................5 4.3 QUALIFIED PERSONAL...............................................................................................5 4.4 INTENDED USE.............................................................................................................6 4.5 INSTALLATION.............................................................................................................6 4.6 OPERATION...................................................................................................................7 4.7 LESS OBVIOUS DANGERS..........................................................................................9 4.8 ACTION IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION .9 4.9 MAINTENANCE & REPAIR.......................................................................................10 4.10 DISPOSAL.................................................................................................................11

5 AIR AND ELECTRICAL REQUIREMENTS ............................................................ 12

5.1 POWDER COATING EQUIPMENT............................................................................12 5.1.1 Air ..........................................................................................................................12 5.1.2 Electrical ................................................................................................................12

6 MECHANICAL FUNCTION: SEQUENCE & DESCRIPTION............................... 13

6.1 COATING MODULE....................................................................................................13 6.2 CLEANING MODULES...............................................................................................13

6.2.1 Air Knives ..............................................................................................................13 6.2.2 O.D. Cleaning Module ...........................................................................................14

6.3 POWDER MANAGEMENT SYSTEM ........................................................................15 6.4 REFRIGERANT AIR DRYER......................................................................................18 6.5 MAIN CONTROL CABINET.......................................................................................18

7 DESCRIPTION OF CONTROLS................................................................................. 19

7.1 MAIN CONTROL CABINET.......................................................................................19 7.1.1 Electrical Controls .................................................................................................19 7.1.2 Remote H.V. Adjust Station ..................................................................................19

7.2 MAIN CONTROL CABINET PANEL.........................................................................20 7.2.1 Station Beacon .......................................................................................................21

7.3 COATING MODULE PNEUMATIC CONTROLS .....................................................21 7.4 COATING MODULE PNEUMATIC CONTROLS PANEL .......................................22 7.5 BULK CLEANING MODULE PNEUMATIC CONTROLS.......................................23 7.6 BULK CLEANING MODULE PNEUMATIC CONTROL PANEL ...........................26 7.7 O.D. CLEANING MODULE ........................................................................................27 7.8 O.D. CLEANING MODULE PNEUMATIC CONTROLS..........................................29 7.9 POWDER MANAGEMENT SYSTEM CONTROLS ..................................................30 7.10 POWDER MANAGEMENT SYSTEM PNEUMATIC CONTROLS......................32


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8 PREPARATION FOR OPERATION ...........................................................................33

8.1 GENERAL.....................................................................................................................33 8.2 INITIAL SYSTEM INSTALLATION..........................................................................33 8.3 POWDER MANAGEMENT SYSTEM........................................................................35

8.3.1 Loading Powder.....................................................................................................35 8.3.2 Powder Maintenance .............................................................................................35

8.4 COATER .......................................................................................................................35 8.4.1 Coating Bed ...........................................................................................................35 8.4.2 Powder Deposition.................................................................................................36

8.4.2.1 Fluidizing Air.....................................................................................................36 8.4.2.2 Powder Level .....................................................................................................36

8.4.3 High Voltage..........................................................................................................36 8.5 CLEANER ADJUSTING ..............................................................................................37

8.5.1 Air Knives Adjusting.............................................................................................37 8.5.2 O.D. Adjusting.......................................................................................................37

9 SPECIFIC EQUIPMENT SAFETY ..............................................................................38

9.1 GENERAL.....................................................................................................................38 9.2 POWDER.......................................................................................................................38

9.2.1 Employee Health....................................................................................................38 9.2.1.1 Inhalation ...........................................................................................................38 9.2.1.2 Skin Contact.......................................................................................................39 9.2.1.3 Eye Contact........................................................................................................39

9.2.2 First Aid Procedures ..............................................................................................39 9.2.2.1 Inhalation ...........................................................................................................39 9.2.2.2 Skin Contact.......................................................................................................39 9.2.2.3 Eye Contact........................................................................................................39

9.2.3 Special Protection ..................................................................................................39 9.2.4 Precautions.............................................................................................................40 9.2.5 Material Safety Data Sheets (MSDS) ....................................................................40

10 PANELVIEW SCREENS ...............................................................................................41

10.1 MAIN MENU SCREEN............................................................................................42 10.2 COATING –START-UP SCREEN ...........................................................................43 10.3 COATING START-UP PANELVIEW SCREEN.....................................................43 10.4 COATING - AUTO START/STOP SCREEN ..........................................................44 10.5 COATING-AUTO START/STOP PANELVIEW SCREEN....................................44 10.6 COATING - MANUAL SET-UP SCREEN..............................................................45 10.7 COATING-MANUAL SET-UP PANELVIEW SCREEN .......................................45 10.8 COATING - POWDER SYSTEM GRAPHICS........................................................46 10.9 COATING-POWDER SYSTEM GRAPHICS PANELVIEW SCREEN .................46 10.10 ALARM HISTORY SCREEN ..................................................................................47 10.11 ALARM BANNER SCREEN ...................................................................................48

11 STATION STARTUP PROCEDURE............................................................................49

11.1 OVERVIEW ..............................................................................................................49 11.2 MANUAL MODE – COATING EQUIPMENT .......................................................49 11.3 AUTO MODE – COATING......................................................................................51 11.4 LOCKOUT ................................................................................................................52

12 STATION SHUTDOWN PROCEDURE ......................................................................53


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12.1 AUTO MODE SHUTDOWN – COATING EQUIPMENT......................................53 12.2 MANUAL MODE SHUTDOWN – COATING EQUIPMENT ...............................53 12.3 POWDER HANDLING AT SHUTDOWN...............................................................53

13 MAINTENANCE............................................................................................................ 54

13.1 GENERAL.................................................................................................................54 13.2 COMPRESSED AIR SYSTEM.................................................................................54

13.2.1 Air Line..................................................................................................................54 13.2.2 Refrigerant Air Dryer.............................................................................................54

13.3 FLUIDIC BED...........................................................................................................55 13.4 INSTALLATION OF POROUS PLATE ..................................................................56 13.5 POWDER MANAGEMENT SYSTEM ....................................................................57 13.6 POWDER LEVEL SENSOR.....................................................................................57 13.7 O.D. CLEANER ........................................................................................................57 13.8 PROGRAMMABLE CONTROLLER ......................................................................57 13.9 MOTORS AND GEARS ...........................................................................................57

14 PREVENTATIVE MAINTENANCE SCHEDULE .................................................... 58

14.1 DAILY .......................................................................................................................58 14.2 WEEKLY...................................................................................................................58 14.3 MISCELLANEOUS ..................................................................................................58 14.4 LUBRICATION CHART..........................................................................................59 14.5 LUBRICATION DIAGRAM ....................................................................................59

15 TROUBLE SHOOTING ................................................................................................ 60

16 PATENT INFORMATION............................................................................................ 68

17 FLOOR PLAN................................................................................................................. 69

18 PNEUMATIC SCHEMATIC ........................................................................................ 69

19 ELECTRICAL SCHEMATIC....................................................................................... 69

20 SPARE PARTS LIST ..................................................................................................... 70

21 MANUFACTURER'S MANUALS ............................................................................... 74


Serial #15754 1

1 INTRODUCTION

This Instruction Manual must be studied and followed for the safe and efficient operation of the "Filter End Coating 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 Filter End Coating System and Serial Number 15754.

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.


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3 OPERATING PRINCIPLES

3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER


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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 an oil filter can at ground potential is conveyed through the cloud, the charged particles are attracted to it because of their opposite potential. The characteristics of the cloud are controlled by baffles to provide the required coverage on the filter can. 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 the filter can to permit it to be coated. Unlike equipment with exposed electrodes, Electrostatic Technology, Inc.'s unique air ionization process charges the powder without permitting the powder, the filter can, or the operator to come in contact with the charging media.


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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.

• 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.


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4.5 INSTALLATION (continued)

• 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.

• 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. 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.


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4.6 OPERATION (continued)

• 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. • Shut off moving equipment before taking measurements or inspecting workpieces.


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4.6 OPERATION (continued)

• 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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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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5 AIR AND ELECTRICAL REQUIREMENTS

5.1 POWDER COATING EQUIPMENT

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 300 scfm @ 80 pounds per square inch minimum to 100 pound per square inch maximum.

5.1.2 Electrical

480 Volts, 60 Hertz, 3-Phase Y Plant Power from a 35 Amp fused disconnect must be supplied to the Main Control Cabinet.


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6 MECHANICAL FUNCTION: SEQUENCE & DESCRIPTION

6.1 COATING MODULE

The oil filters are conveyed through the coating beds where they pass through controlled clouds of charged particles which coat the required area on each filter can.

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

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 Module.

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).

6.2 CLEANING MODULES

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

6.2.1 Air Knives

There are 6 sets of Air Knives located in the Bulk Cleaning Module. These Air Knives are controlled and adjusted by air flowmeters on the Main Pneumatic Panel.


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6.2.2 O.D. Cleaning Module

The O.D. Cleaning Module is located just after the Bulk Cleaning Module. It consists of two stations. Each utilizes moving belts to remove powder from the O.D. Each station is easily adjusted up or down, front or back for desired positioning

Adjustments can be made by turning the hand wheels located on the Front of the O.D. Cleaning module. The position of each belt can be raised or lowered as needed. Generally the belt should run very close to the O.D., just barely touching it.


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6.3 POWDER MANAGEMENT SYSTEM

The Powder Management System consists of the 5 HP Powder Collector (See Figure 1) with an HEPA afterfilter, Lower Fluidizing Hopper, Powder Level Sensor, Powder Dryer and Powder Pumps.

The powder management system collects powder in ducts located throughout the Machine and conveys it back to the 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 hopper by dry air which removes any remaining moisture from the powder. The powder is then fed by means of four Powder Pumps to the two feed hoppers located on the back of the Coating Module. From there the powder is allowed to trickle down into the coating bed. There is a magnet located in the Powder Feeder Hoppers 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 6 filter cartridges which retain powder within the system. Electric and pneumatic circuitry provides a reverse pulse of air to clean the filter cartridges.

A specially designed cloud-containing hood on the Coater with connecting duct-work completely controls the powder cloud during coating operation and transports undeposited good powder to the Powder Collector via flexible hose. Once this powder enters the Collector, it is mixed with virgin powder and collects in the lower Fluidizing Hopper.

As re-claimed powder enters the Powder Collector, it passes through the Powder Collector Filters. The (6) Filters are automatically and sequentially cleaned continuously during operation by pulses of compressed air through the Filter Element (from the inside outward). This removes collected powder from the outside surfaces of each Filter Element. Clean air exits the Powder Collector and passes through an afterfilter while the collected powder falls into the storage container at the base of the unit: the lower Fluidizing Hopper. Reclaimed powder released from the filters falls into the hopper (located beneath the filters). This lower hopper acts as a Powder Drying Chamber. As the powder accumulates in the lower hopper, it is fluidized with dry air prior to being fed into the Coating Bed. This fluidization removes any residual moisture from the powder.The Powder Pump then recycles the powder by pumping it back to the Coater Feed Hoppers as needed.

The pneumatic Powder Pumps are mounted to the outside wall of the Fluidizing Hopper. These pneumatic Powder Pumps pump a mixture of air and powder from the Fluidizing Hopper to the Feed Hoppers on the rear of the Coater hood.


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6.3 POWDER MANAGEMENT SYSTEM (continued)

Once in the Feed Hoppers, the powder settles and the air exits to the exhaust outlet. The powder is fed into the Coater Bed as needed, keeping the powder level at a constant height. When the Level Sensor detects that the powder level in the feed hoppers has dropped below the sensor tip, the Powder Pumps will turn "ON" and pump powder to the Feed Hoppers. The Powder Pump turns "OFF" when the Level Sensor detects enough powder. The pneumatic controls for the Powder Pumps feed rate are located on the Powder Collector. When the coating bed Level sensor detects that the powder level has dropped below the sensor tip, the rotary valves on the feed hopper turn on and add powder to the coating bed. The rotary valves turn “OFF” when the Level Sensor detects that there is enough powder in the coating bed. A Differential Pressure Gauge (Minihelic II Gauge) is located on the side of the Powder Collector. This provides an indication of how clean the filter cartridges are. A normal reading would be between 0 and 6. A reading above 6 would indicate that the filter cartridges are not being cleaned well enough. This would require re-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 extremely clean, or there is a hole in a filter or leakage past the filters. Refer to the Maintenance section (13.5) of this Manual for maintenance requirements for this filter.

A Differential Pressure Gauge (Minihelic Gauge) is located on the side of the collector/feeder assembly. This provides an indication of how clean the HEPA afterfilter cartridges are. A normal reading is between 0 and 3. A reading above 3 indicates that the afterfilter cartridges are clogged. To correct this requires replacing the HEPA afterfilters. 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. All powder must be added/supplied to the system through the 150 lb. Feeder Hopper located adjacent to the powder Collector. During continuous coating operation, additional powder can be added to the system through the 150 lb. Feeder Hopper. The 150 lb. Feeder Hopper is utilized to add virgin powder to the system without spillage. The pneumatic Powder Pumps are mounted on the top of the 150 lb. Feeder Hopper. These Powder Pumps pump a mixture of air and powder from the 150 lb. Fluidized Hopper to the Powder Collector Fluidized Hopper. When the Powder Collector Fluidized Hopper level sensor detects that the powder level has dropped below the sensor tip, the 150 lb. Feeder Hopper powder pumps will turn "ON" and pump powder to the Powder Collector. The powder pumps turn "OFF" when the level sensor detects enough powder. The pneumatic controls for the 150 lb. Feeder Hopper and powder pumps are located on the Powder Collector. Refer to Section 8.3.1 for instructions on loading powder into the system.


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Figure 1

POWDER MANAGEMENT SYSTEM


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6.4 REFRIGERANT AIR DRYER

A 300 SCFM Refrigerant Air Dryer accepts in-plant compressed air and supplies moisture-free Coating/Cleaning air to the entire Coating Equipment. 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 Equipment.

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

6.5 MAIN CONTROL CABINET

The Main Control Cabinet holds all of the electric connections, fuses and circuit breakers for the system. Mounted on the machine frame is the pendant arm holding the control panel containing the View Panel and controls for equipment operation.


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7 DESCRIPTION OF CONTROLS

7.1 MAIN CONTROL CABINET

The following controls are located on the Main Control Panel:

7.1.1 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.

PANELVIEW screen

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

EMERGENCY STOP pushbutton

Will completely shut down the coating system.

7.1.2 Remote H.V. Adjust Station

HIGH VOLTAGE ADJUST up and down switch

Adjusts the output of the High Voltage Power Supply.

KILOVOLTS digital readout

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

EMERGENCY STOP pushbutton

Will completely shut down the coating system.


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7.2 MAIN CONTROL CABINET PANEL


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7.2.1 Station Beacon

A three-color stack light, located on top of the Control Panel pendant arm, provides a visual indication of the current status of Coating Equipment operation.

RED Light

When illuminated, indicates an Alarm condition.

AMBER Light

When illuminated, indicates the Coating Equipment is in Manual Mode

GREEN Light

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

7.3 COATING MODULE PNEUMATIC CONTROLS

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

FLUIDIC BED FLOW Air Flowmeter

Indicates the amount of fluidizing air being supplied to the Coating Bed.

FLUIDIC BED FLOW ADJUST Air Pressure Regulator

Adjusts the amount of Fluidizing being supplied to the coating bed.

FLUIDIC BED PRESSURE ADJUST Air Pressure Regulator

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

FLUIDIC BED PRESSURE Air Pressure Gauge (psi)

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

FEEDER AMPLIFIERS Pressure Adjustment

Adjusts and regulates the air pressure available to the air transducers for the Feed Hoppers at the rear of the Coating Module

FEEDER AMPLIFIERS Air Pressure Gauge (psi)

Indicates the amount of air pressure available to the air transducers for the Feed Hoppers


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7.4 COATING MODULE PNEUMATIC CONTROLS PANEL


Serial #15754 23

7.5 BULK CLEANING MODULE PNEUMATIC CONTROLS

AIR KNIFE #1 FLOW ADJUST Air Pressure Regulator

Adjust the amount of air flow to the Air Knife #1 in the Bulk Cleaning Module.

AIR KNIFE #1 FLOW Air Flowmeter

Indicates the amount of air flow to the Air Knife #1 in the Bulk Cleaning Module.

AIR KNIFE #1 PRESSURE ADJUST Air Pressure Regulator

Adjust and regulates the air pressure available to Air Knife #1.

AIR KNIFE #1 PRESSURE Air Pressure Gauge (psi)

Indicates the air pressure available to Air Knife #1.

AIR KNIFE #2 LEFT FLOW ADJUST Air Pressure Regulator

Adjust the amount of air flow to the Air Knife #2 Left Flow in the Bulk Cleaning Module.

AIR KNIFE #2 LEFT FLOW Air Flowmeter

Indicates the amount of air flow to the Air Knife #2 Left Flow in the Bulk Cleaning Module.

AIR KNIFE #2 LEFT PRESSURE ADJUST Air Pressure Regulator

Adjust and regulates the air pressure available to Air Knife #2 Left.

AIR KNIFE #2 LEFT PRESSUREAir Pressure Gauge (psi)

Indicates the air pressure available to Air Knife #2 Left.

AIR KNIFE #2 RIGHT FLOW ADJUST Air Pressure Regulator

Adjust the amount of air flow to the Air Knife #2 Right Flow in the Bulk Cleaning Module.

AIR KNIFE #2 RIGHT FLOW Air Flowmeter

Indicates the amount of air flow to the Air Knife #2 Right Flow in the Bulk Cleaning Module.

AIR KNIFE #2 RIGHT PRESSURE ADJUST Air Pressure Regulator

Adjust and regulates the air pressure available to Air Knife #2 Right.

AIR KNIFE #2 RIGHT PRESSURE Air Pressure Gauge (psi)

Indicates the air pressure available to Air Knife #2 Right.

7.5 BULK CLEANING MODULE PNEUMATIC CONTROLS (continued)

AIR KNIFE #3 FLOW ADJUST Adjust the amount of air flow to the Air Knife


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Air Pressure Regulator

#3 in the Bulk Cleaning Module.








Adjust the amount of air flow to the Air Knife #4 in the Bulk cleaning Module.







AIR KNIFE #5 LEFT FLOW ADJUST Air Pressure Regulator

Adjust the amount of air flow to the Air Knife #5 Left Flow in the Bulk Cleaning Module.

AIR KNIFE #5 LEFT FLOW Air Flowmeter

Indicates the amount of air flow to the Air Knife #5 Left Flow in the Bulk Cleaning Module.

AIR KNIFE #5 LEFT PRESSURE ADJUST Air Pressure Regulator

Adjust and regulates the air pressure available to Air Knife Left #5.

AIR KNIFE #5 LEFT PRESSUREAir Pressure Gauge (psi)

Indicates the air pressure available to Air Knife Left #5.


Serial #15754 25

7.5 BULK CLEANING MODULE PNEUMATIC CONTROLS (continued)

AIR KNIFE #5 RIGHT FLOW ADJUST Air Pressure Regulator

Adjust the amount of air flow to the Air Knife #5 Right Flow in the Bulk Cleaning Module.

AIR KNIFE #5 RIGHT FLOW Air Flowmeter

Indicates the amount of air flow to the Air Knife #5 Right Flow in the Bulk Cleaning Module.

AIR KNIFE #5 RIGHT PRESSURE ADJUST Air Pressure Regulator

Adjust and regulates the air pressure available to Air Knife Right #5.

AIR KNIFE #5 RIGHT PRESSURE Air Pressure Gauge (psi)

Indicates the air pressure available to Air Knife Right #5.


Adjust the amount of air flow to the Air Knife #6 in the Bulk Cleaning Module.




Adjust and regulates the air pressure available to the Air Knives #6.

AIR KNIFE #6 PRESSURE ADJUST Air Pressure Gauge

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


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7.6 BULK CLEANING MODULE PNEUMATIC CONTROL PANEL


Serial #15754 27

7.7 O.D. CLEANING MODULE

BELT CLEANER #1 AIR KNIFE FLOW ADJUST Air Flowmeter and Control

Adjust and indicates level of air flow to Belt Cleaner Air Knife #1 located in O.D. Cleaning Module.

BELT CLEANER #1 AIR KNIFE PRESSURE ADJUST Air Pressure Regulator

Adjusts and regulates air pressure available to Belt Cleaner #1 Air Knife.

BELT CLEANER #1 AIR KNIFE PRESSURE Air Pressure Gauge (psi)

Indicates air pressure available to Belt Cleaner #1 Air Knife.

BELT CLEANER #1 AIR AMPLIFIER PRESSURE ADJUST Air Pressure Regulator

Adjusts and regulates air pressure available to Belt Cleaner #1 Air Amplifier.

BELT CLEANER #1 AIR AMPLIFIER PRESSURE Air Pressure Gauge (psi)

Indicates air pressure available to Belt Cleaner #1 Air Amplifier.












28 Serial #15754

7.7 O.D. CLEANING MODULE (continued)






















Serial #15754 29

7.8 O.D. CLEANING MODULE PNEUMATIC CONTROLS


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7.9 POWDER MANAGEMENT SYSTEM CONTROLS

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

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

POWDER MAN. SYS.FILTER (0-6) 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.

FINAL FILTER GAUGE (0-3 Normal Reading) Differential pressure gauge

Indicates the difference in pressure across the Final Filter from the clean side to the dirty side which indicates the level of cleanliness of the Cartridges

COLLECTOR BED PRESSURE ADJUST Air pressure regulator

Adjusts and regulates the air pressure for the collector fluidized bed.

COLLECTOR BED PRESSURE Air pressure gauge (psi)

Indicates the amount of air pressure available to the collector fluidized bed.

POWDER PUMP #1 PRESSURE ADJUST Air pressure regulator

Adjusts and regulates the air pressure for Powder Pump #1.

POWDER PUMP #1 PRESSURE Air pressure gauge (psi)

Indicates the amount of air pressure available for Powder pump #1.














Serial #15754 31

7.9 POWDER MANAGEMENT SYSTEM CONTROLS (continued)

FEED HOPPER BED PRESSURE ADJUST Air pressure regulator

Adjusts and regulates the air pressure for the Feed Hopper Fluidized Bed.

FEED HOPPER BED PRESSURE Air pressure gauge (psi)

Indicates the amount of air pressure available to the Feed Hopper Fluidized Bed.

HOPPER AGITATOR PRESSURE ADJUST Air pressure adjust

Adjusts and regulates the air pressure for the Feed Hopper Agitator.

HOPPER AGITATOR PRESSURE Air pressure gauge (psi)

Indicates the amount of air pressure available to the he Feed Hopper Agitator.




Indicates the amount of air pressure available to Powder Pump #5.




Indicates the amount of air pressure available to Powder Pump #6.


32 Serial #15754

7.10 POWDER MANAGEMENT SYSTEM PNEUMATIC CONTROLS


Serial #15754 33

8 PREPARATION FOR OPERATION

These instructions for installing, operating, and maintaining the Filter End Coating System 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 Equipment 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 Modules in the desired location within the customer supplied conveyor. 3. The Modules may have been shipped in two or three sections. These sections

should be connected to the conveyor system with the bolts and vibration isolator pads provided.

4. Locate peripheral equipment such as the Powder Management System and the Air

Dryer in proper places with respect to the coating equipment. Refer to the Layout Drawing of the system.

5. Level all the peripheral equipment and make all necessary mechanical

connections to attach peripheral equipment to the Modules.

6. 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.


34 Serial #15754

8.2 INITIAL SYSTEM INSTALLATION (continued)

NOTE: Some of the pipes may require connecting during the assembly operation.

7. 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.

8. Prepare ducts from the coating and cleaning areas for the Powder Collector. Connect

ducts to the System as required. These ducts are used to vent the modules and to reduce noise in the Machine area.

9. Prior to connecting the plant air supply to the Equipment, blow the lines out to make

sure nothing is in them which could cause a clog in the Equipment Air Supply System. Make sure that the Main Equipment Air Shut Off valve (Red handle by the Air Dryer) is closed (in) at this time. Connect plant air supply to the Main Equipment Air Connection (bluepipe) located on the rear of the Air Dryer. Pull up the Red Air Supply Valve handle to allow the air to circulate through the Air Dryer. Check for air leaks by listening for escaping air.

10. At this time connect the main electrical power to the E.T.I. Equipment. Make sure air

connections have been properly made in the equipment. DO NOT TRY TO OPERATE THE SYSTEM AT THIS TIME

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


Serial #15754 35


8.3.1 Loading Powder Follow this procedure: Step 1 – Remove tie-wrap from powder bag and open loading door on the

top of the 150 lb. Feeder Hopper. Step 2 – Load only one bag of powder at a time; do not overfill the Feeder

Hopper. Leave about one foot of clear space to the loading door. Step 3 – Empty the bag into the Feeder Hopper through the loading door. Step 4 – Shake the bag so that all the powder falls into the Feeder Hopper. Step 5 – Close the loading door. NOTE: Do not allow foreign items (such as bag tie wraps) to fall in the

Feeder Hopper. They may plug the powder pumps.

8.3.2 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 powders.

8.4 COATER

8.4.1 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.


36 Serial #15754

8.4.2 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 controlling the fluidizing air or by controlling the powder level:

8.4.2.1 Fluidizing Air

Increasing the fluidizing air will increase the cloud density and the resultant 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.

8.4.2.2 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 compression nut on the fitting clamping the level sensor probe tube. Next, gently pull the sensor probe tube and retighten the nut.

8.4.3 High Voltage

Set the High Voltage Adjust to give the Kilovolt reading on the High Voltage Kilovolt Meter required for production line condition. The High Voltage Adjust "UP" and "DOWN" push buttons are located on the manual setup screen and Auto Start/Stop screen. A High Voltage Adjust switch is located at the Remote High Voltage Adjust Station.


Serial #15754 37

8.5 CLEANER ADJUSTING

8.5.1 Air Knives Adjusting

Press COATER ON the Manual Setup Screen. Run powder coated parts and adjust the Air Knives positions and the Air Control Valves for adequate cleaning of the filter O.D.’s under production line conditions.

8.5.2 O.D. Adjusting

Press COATER ON the Manual Setup Screen. Run powder coated parts and adjust the position of the O.D. Cleaner Belts and air control valves meters on the Module Pneumatic Panel. for adequate cleaning of the Filter O.D.'s under production line conditions.


38 Serial #15754

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 DO MAINTENANCE WORK ALONE

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.


Serial #15754 39

9.2.1 Employee Health (continuted)

9.2.1.2 Skin Contact

Powder may cause skin irritation such a 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.


40 Serial #15754

WASH THOROUGHLY BEFORE EATING OR SMOKING. DO NOT SMOKE IN THE VICINITY OF THE COATING AREA. AVOID INHALATION OF DUST AND/OR FUMES.

9.2.4 Precautions

Personnel should observe the following when working with powdered materials:

9.2.5 Material Safety Data Sheets (MSDS)

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.


Serial #15754 41

10 PANELVIEW SCREENS

The Allen-Bradley PanelView 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 AUTO MODE is chosen, the box changes to AUTO 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 following PanelView screens are provided:

Main Menu Screen Lists the available screens for operating the Coating Equipment and an alarm silence pushbutton. Also provided is a configuration screen button which should be accessed by qualified personnel only.

Coating Start-up Screen Displays the COATING START-UP SCREEN.

Coating-Auto Start/Stop Screen Displays the COATING AUTO START/STOP SCREEN.

Coating-Manual Set-up Screen Displays the COATING-MANUAL SET-UP SCREEN.

Coating-Powder System Graphics Displays the COATING-POWDER SYSTEM GRAPHICS.

Alarm History Screen Displays the ALARM HISTORY SCREEN.


42 Serial #15754

. 10.1 MAIN MENU SCREEN


Serial #15754 43

10.2 COATING –START-UP SCREEN Along with access to different screens, the start-up screen includes controls for: POWDER COLLECTOR START & STOP CONVEYOR MAIN POWER ON & OFF AUTOMODE SELECTION MANUAL MODE SELECTION

10.3 COATING START-UP PANELVIEW SCREEN


44 Serial #15754

10.4 COATING - AUTO START/STOP SCREEN Along with access to different screens, the Auto Start/Stop screen includes

controls for: AUTO START & STOP CONVEYOR SPEED NORMAL/SLOW SELECTION H.V. µA METER (High Voltage Micro Amp Reading) H.V. kV METER (High Voltage Kilo Volt Reading) HIGH VOLTAGE NORMAL & SLOW SPEED SETPOINTS ENTRIES HIGH VOLTAGE RAISE & LOWER

10.5 COATING-AUTO START/STOP PANELVIEW SCREEN


Serial #15754 45

10.6 COATING - MANUAL SET-UP SCREEN Along with access to different screens, the Manual Set-up screen includes controls

for: O.D. CLEANER START & STOP COATER ON & OFF CONVEYOR MODE RUN/ JOG SELECTION CONVEYOR SPEED NORMAL /SLOW SELECTION H.V. µa METER (High Voltage Micro Amp Reading) H.V. kV METER (High Voltage Kilo Volt Reading) HIGH VOLTAGE NORMAL & SLOW SPEED SETPOINTS ENTRIES HIGH VOLTAGE RAISE & LOWER

10.7 COATING-MANUAL SET-UP PANELVIEW SCREEN


46 Serial #15754

10.8 COATING - POWDER SYSTEM GRAPHICS The Powder System Graphic screen provides an overview monitoring of the

Powder Collection and Pumping systems.

10.9 COATING-POWDER SYSTEM GRAPHICS PANELVIEW SCREEN


Serial #15754 47

10.10 ALARM HISTORY SCREEN The Alarm History provides a history of machine faults and warnings.


48 Serial #15754

10.10 ALARM HISTORY SCREEN (continued) Emergency Stop is Active, Fault. Coater High Voltage Overload, Fault. Plant Air

is Off Pressure or is Low, etc.

10.11 ALARM BANNER SCREEN

An Alarm Banner, which pops up over the current screen when an alarm is triggered, allows an operator to immediately and appropriately respond to a given situation. The banner contains a message describing the alarm condition along with its date and time. It also provides alarm buttons for acknowledging and clearing the alarm history.


Serial #15754 49

11 STATION STARTUP PROCEDURE

11.1 OVERVIEW

There are two modes for operating the Coating and Cleaning Equipment: 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 Cleaning Equipment operation and make adjustments as required to ensure that proper coating of filters is maintained.

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

Step 1 Make sure the Main Disconnects 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 all

hoods and doors are closed. Step 5 Press the Coating Machine MASTER START pushbutton. Step 6 Call up the Coating Start-Up Screen. Step 7 The Refrigerant Air Dryer 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: POWDER COLLECTOR START, CONVEYOR MAIN POWER ON.

NOTE: Fault and warning messages 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 Alarm Message from the Banner Screen and turns off the audible alarm. (If the audible alarm is still present, there is a "silence alarm" button on the main menu and alarm history screens. To help clear the fault, a fault history of all previous faults can always be called up on the Alarm History Screen. An alarm message display which scrolls through all active alarms is present at the top of the alarm history screen as well as the Start-Up, Auto Start/Stop, and Manual Set-Up screens.

11.2 MANUAL MODE – COATING EQUIPMENT


50 Serial #15754

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).

When used for Experimentation, the Conveyor speed, 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 module 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 Equipment Operation are understood. Step 2 Follow Step 1 through 8 in the Station Start-up Procedure on the

preceding page. Step 3 Select the MAIN SCREEN MENU, then select MANUAL SET-UP

SCREEN. Step 4 Select O.D. CLEANER START, COATER ON AND CONVEYOR

START/JOG. Step 5 Use the High Voltage RAISE & LOWER Buttons to change the high

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

KEEP IN MIND THE PRIORITY FUNCTIONS. The O.D. CLEANER AND COATER can not turn "ON" unless the Powder Collector is "ON". The conveyor will not start unless the conveyor main power is "ON". NOTE: The conveyor has a "NORMAL" or "SLOW" speed selection and a "RUN" or "JOG" mode selection. The "RUN" or "JOG" mode can only be changed while the conveyor is "STOPPED".


Serial #15754 51

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 operation are understood. Step 2 Follow the entire Equipment Start-up Procedure (Section 11.1 in this

manual) Step 3 On the PanelView Screen, select the MAIN SCREEN MENU. Step 4 Select AUTO START/STOP SCREEN Step 5 The following buttons on the Start-up Screen should already have been

selected: • POWDER COLLECTOR START • CONVEYOR MAIN POWER ON NOTE: If a problem occurs, a warning message will appear on the PanelView 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 SHUTDOWN PROCEDURE (Section 12 in this manual) and correct the problem.

Step 6 Select the AUTO START button. If there is an alarm, the Banner Alarm Screen should come up on the PanelView Screen. Select ACKNOWLEDGE to silence the alarm. Check and respond to the error messages and correct the fault. NOTE: Reference Note in section 11.1.

Step 7 If no faults are present, "AUTO MODE IS READY" will appear on the Auto Start/Stop Screen.


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11.4 LOCKOUT

Type of Energy Place of Lockout Method of Lockout and

Releasing of Stored Energy

Checking the Result of Lockout

Electric 480 v E1 Disconnect switch on ETI main electric cabinet

Turn the disconnect switch into "OFF" position, and place the multiple lock and a name tag on it. Danger: Voltage may be present at PLC chassic slots 6, 9, 10, 11, and 12. Reference adjacent equipment & operating manual.

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

Pneumatic 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.


Serial #15754 53

12 STATION SHUTDOWN PROCEDURE

12.1 AUTO MODE SHUTDOWN – COATING EQUIPMENT

Step 1 Run all parts off the System. Step 2 From AUTO START/STOP Screen, press Auto Stop "OFF". This will

turn off the Coater, High Voltage, Conveyor, and O.D. Cleaner. Wait at least 1 minute before pressing any other functions "OFF".

Step 3 From the START-UP Screen, press CONVEYOR MAIN POWER OFF. Step 4 Press POWDER COLLECTOR "STOP". Step 5 Press the MASTER "STOP" pushbutton. It is recommended that the

daily cleaning procedure be performed at this time.

12.2 MANUAL MODE SHUTDOWN – COATING EQUIPMENT

Step 1 Run all parts off the System. Step 2 There is no required sequence for turning "OFF" functions in the Setup

Mode; however, generally the functions would be shut "OFF" in reverse order of turning them "ON"

Step 3 It is recommended that the daily cleaning procedure be performed at this time.

12.3 POWDER HANDLING AT SHUTDOWN

Only a minimum amount of powder should be left in the Powder Management System when is shutdown over an 8-hour period. When the Equipment is to be shut off for more than 24 hours, the powder should be removed from the Coating Bed in order to prevent clogging of the porous plate. The Powder Feeder Hopper should be emptied and the powder stored in an airtight container when the Equipment 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.


54 Serial #15754

13 MAINTENANCE

13.1 GENERAL

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

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

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, resulting in a clogged Porous Plate in the Coater and dirty, spotty 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.

WARNING: ELECTRICAL VOLTAGE USED IN THIS EQUIPMENTCAN BE HAZARDOUS. MAINTENANCE SHOULD BEHANDLED BY QUALIFIED PERSONNEL.


Serial #15754 55

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.

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.

CAUTION: THE UNIFORM POROSITY OF THE POROUS PLATE ISVERY IMPORTANT TO PROPER COATING. DO NOTSCRAPE OR EVEN TOUCH IT WITH A HARD ORSHARP OBJECT. NEVER POINT AN AIR GUNDIRECTLY AT THE PLATE.


56 Serial #15754

13.4 INSTALLATION OF POROUS PLATE

Step 1 Turn Equipment "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 module from the conveyor.

Step 5 When powder has been cleaned out disconnect both the High Voltage Cable and Air Line from the Ionization Chamber.

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 four vibration isolators which mount the coating bed onto the frame.

Step 8 Lift off the coating bed.

Step 9 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 10 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 11 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 12 Reverse steps 1 through 7 to re-install the Ionization Chamber and operate the Coating Bed.

NOTE: Care must be taken when working around the level sensor probe(tube) so that the probe is not damaged. Damage to the probe tube may cause the level sensor to cease functioning or to functionimproperly.


Serial #15754 57


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 6 which would indicate that the cartridges are not being cleaned. If the reading is above 6, 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.

13.6 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 on Powder Level Sensor Gauge.

13.7 O.D. CLEANER

The O.D. Cleaner Belts and Belt Cleaner Brushes may become worn with time. Refer to the Spare Parts List (Section 17) in this manual for the correct spare part numbers.

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

13.9 MOTORS AND GEARS

Oil and lubricate as required. Refer to the Lubrication Chart (Section 14.4 of this manual).


58 Serial #15754

14 PREVENTATIVE MAINTENANCE SCHEDULE

14.1 DAILY

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

2. Check the Porous Plates for proper fluidization and replace if required. The Porous Plates should be replaced every 6 months, unless required earlier. Refer to Section 13.4 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, red - replace. 3. Check and lubricate all motors, pumps, and bearings on the Equipment if

required. Refer to the Lubrication Chart (Section 14.4) of this manual.

4 Check the magnets located in the Powder Feed Hoppers on the rear of the Coating Bed. Remove chips and replace magnets.

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 6 by adjusting the air pressure in the timer, then the Filter Cartridges need replacement.

2 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.

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

Belt should be changed every 6 months.


Serial #15754 59

14.4 LUBRICATION CHART

# LUBE COMPONENTS

LUBRICATION COMPONENT

TO BE SERVICED

MACHINE COMPONENT

TO BE SERVICED

LOCATION LUBRICATION FREQUENCY

RECM'D OIL VISCOSITY OR

GREASE NO.

8 Bearing Jack O.D. Cleaning Module Yearly EP#1

4 Bearing Drive O.D. Cleaning Module Yearly EP#1

1 In-Line Air Lubricator

Feeder Hopper Agitator Air

Motor

Powder Collector Weekly SAE 10

2 Bearing Blower Inside Powder Collector Yearly Texaco Starplex

#2

14.5 LUBRICATION DIAGRAM Grease yearly 2 pumps per fitting. Texaco Starplex #2 Oil check every week. Fill to level SAE 10 COATING BULK CLEANING O.D. CLEANING MODULE MODULE MODULE Grease yearly 2 pumps per fitting EP#1


60 Serial #15754

15 TROUBLE SHOOTING

ALARM MESSAGES AND TROUBLE SHOOTING GUIDE

MESSAGES CAUSES SOLUTIONS EMERGENCY STOP IS ACTIVE

One of the Emergency Stop buttons has been pressed. The Nordson Fire System has been activated. The filament string inside the coating bed is broken.

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 starting the machine will create no danger. Reset the Emergency Stop push button. Carefully check Coater for fire. If a fire has occurred, determine the cause and correct. Replace the filament string and reset the Nordson Fire System. Notify ETI if a fire has occurred.

CYCLE STOP PUSHBUTTON IS ACTIVATED

The machine was running and the conveyor was stopped by the Cycle Stop pushbutton.

Check the machine and conveyor, then pull out the Cycle Stop pushbutton. Press the Start pushbutton or restart the machine from the operator panel.

POWDER COLLECTOR NOT TURNED ON

An attempt was made to start the O.D. Cleaner or Coater before turning on the Powder Collector.

Turn on the Powder Collector.

CONVEYOR MAIN POWER NOT TURNED ON

An attempt was made to start the Conveyor before turning on the Conveyor Main Power.

Turn on the Conveyor Main Power.

AUTO MODE NOT SELECTED

An attempt was made to run the machine in Auto Mode while the machine is in Manual Mode.

Place the machine in Auto Mode.

MANUAL MODE NOT SELECTED

An attempt was made to run the machine in Manual Mode while the machine is in Auto Mode.

Place the machine in Manual Mode.


Serial #15754 61

15 TROUBLE SHOOTING (Continued)


MESSAGES CAUSES SOLUTIONS WARNING: NORDSON FIRE SYSTEM FAULT ALARM

The Nordson Fire System has detected an Alarm Fault.

Record the error message on the Nordson Fire System display panel and reference the Nordson Fire System Manual for corrective action.

WARNING: COATING BED IS LOW ON POWDER

The Coating Bed powder level is low. The Powder Feeder has been trying to fill the Coating Bed for 4 minutes. The Powder Collector Powder Hopper is empty. The powder sensing tube inside the Coating Bed is set improperly. The Powder Hopper motor speed is turned down. The level sensor/gauge has malfunctioned.

Check for “Warning - Left or Right Powder Hopper Low On Powder" alarm. 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.

WARNING: POWDER COLLECTOR VACUUM IS LOW

Collector vacuum is low. This warning will be given 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 pulsar off time thus increasing the pulsing frequency. Check the Powder Collector blower for normal operation. Check and replace plastic film over 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, then the filter cartridge will need to be changed.


62 Serial #15754



MESSAGES CAUSES SOLUTIONS WARNING: O.D. CLEANER #1 BELT NOT DETECTED

O.D. Cleaner #1 Belt is Broken. The Proximity Switch located on the O.D. cleaner is not responding.

Check for broken O.D. Cleaner #1 Belt. Verify that the Proximity Switch located on the O.D. Cleaner is aligned correctly and responding.

WARNING: O.D. CLEANER #2 BELT NOT DETECTED

O.D. Cleaner #2 Belt is Broken. The Proximity Switch located on the O.D. Cleaner is not responding.

Check for broken O.D. Cleaner #2 Belt. Verify that the Proximity Switch located on the O.D. cleaner is align correctly and responding.

WARNING: O.D. CLEANER #4 BELT NOT DETECTED

O.D. Cleaner #4 Belt is Broken. The Proximity Switch located on the O.D. Cleaner is not responding.

Check for broken O.D. Cleaner #4 Belt. Verify that the Proximity Switch located on the O.D. Cleaner is aligned correctly and responding.

WARNING: POWDER COLLECTOR IS LOW ON POWDER

The Powder Collector level is low. The Powder Collector Hopper feeder has been trying to fill the Powder Collector. The Collector Powder Hopper is empty.

Check for powder inside the Powder Collector Hopper. Verify that the two powder pumps for this hopper are working correctly.

WARNING: LEFT POWDER HOPPER IS LOW ON POWDER

Left Powder Hopper Lower level sensor has detected a low level of powder.

Check for "Warning - Powder Collector Is Low On Powder" alarm. Verify that the two powder pumps for this hopper are working correctly.


Serial #15754 63



MESSAGES CAUSES SOLUTIONS WARNING: RIGHT POWDER HOPPER IS LOW ON POWDER.

Right Powder Hopper Lower level sensor has detected a low level of powder.

Check for "Warning - Powder Collector Is Low On Powder" alarm. Verify that the two powder pumps for this hopper are working correctly.

WARNING: CONVEYOR ROTATION SENSOR ALARM

The Receiver and Emitter Photo Sensors are too far apart (Low Gain) in order to detect a passing object effectively.

Bring the Receiver and Emitter Photo Sensors closer together.

WARNING: PART ENTER COATING BED SENSOR ALARM



WARNING: PLC BATTERY IS LOW

The PLC Battery has a low charge. READ THE ALLEN BRADLEY SLC500 MANUAL BEFORE ATTEMPTING TO REPLACE THE PLC CPU BATTERY! The Allen Bradley SLC500 Modular Hardware Style installation and operation manual has a specific replacement procedure. The PLC CPU could be damaged if the battery replacement procedure is not followed.


64 Serial #15754



MESSAGES CAUSES SOLUTIONS WARNING: PARTS FELL IN COATING BED MODULE

The parts have not exited the end of the Coater Module. Someone has removed parts from the conveyor. The parts have fallen off the conveyor. The parts detector photo sensor has malfunctioned.

Stop Conveyor and turn off the Coater. Remove any parts, which may have fallen off the conveyor.

WARNING: PARTS FELL IN BULK CLEANING OR O.D. CLEANING MODULE

The parts have not exited the end of the O.D. Cleaning Module. Someone has removed parts from the conveyor. The parts have fallen off the conveyor. The parts detector photo sensor has malfunctioned.

Stop Conveyor and the O.D. Cleaning Module. Remove any parts, which may have fallen off the conveyor.

WARNING: PART EXIT COATING BED SENSOR ALARM



WARNING: PART EXIT O.D. CLEANING SENSOR ALARM



WARNING: LOW COATING HIGH VOLTAGE SETTING

The Coater High Voltage setting is set to low to allow sufficient powder coating.

Raise the Coater High Voltage setting above 10 Kilo Volts.


Serial #15754 65



MESSAGES CAUSES SOLUTIONS FAULT: POWDER COLLECTOR BLOWER MOTOR OVERLOADED

The Powder Collector Blower Motor overload tripped. The Blower Motor has a bad bearing or winding. The Powder Collector Blower has a bad bearing.

Make a visual inspection of all of the components involved in this fault. Check the running amperage draw of the motor using a clamp-on ammeter. Replace any worn out bearing or the motor if needed. Reset motor overload Note: This type of work is to be performed by qualified maintenance personnel only.

FAULT: COATING BED VIBRATOR MOTOR OVERLOADED

The Coating Bed Vibrator Motor overload tripped.

Make a visual inspection of all of the components involved in this fault. Check the running amperage draw of the motor using a clamp-on ammeter. Replace any worn out bearing or the motor if needed. Reset motor overload. Note: This type of work is to be performed by qualified maintenance personnel only.

FAULT: 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.


66 Serial #15754



MESSAGES CAUSES SOLUTIONS FAULT: 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.

FAULT: COATING BED 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 slivers from oil filters or conveyor have fallen in. The high voltage overload unit is malfunctioning.

Remove any filters 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.


Serial #15754 67



MESSAGES CAUSES SOLUTIONS FAULT: CONVEYOR DRIVE UNIT FAULT ALARM

A fault has been detected at the Conveyor Drive Unit.

Record the Error Code Number on the Conveyor Drive Unit display panel. Reference the troubleshooting section in the Conveyor Drive Unit Manual for corrective action.

FAULT: MACHINE STOPPED BY EXTERNAL SIGNAL

The Start/Stop Signal has been activated. This signal must be present in order for the machine (conveyor system) to operate. The signal is a permissive signal (interlock) and is available for use by the equipment receiving the coated parts from the machine.

Resume sending the Start Signal, this will start the machine.


68 Serial #15754

16 PATENT INFORMATION The Filter End Coating System is manufactured under one or more of the following United States patents:

3,575,344 3,607,998 3,698,847

3,828,729 3,865,610 3,881,763

3,889,015 3,901,185 3,914,461

3,916,826 3,921,574 3,937,179

3,951,099 4,030,446 4,053,661

4,084,018 4,101,687 4,120,070

4,123,175 4,297,386 4,325,982

4,330,567 4,332,835 4,368,214

4,418,642 4,472,452 4,517,219

4,606,928 4,808,497 4,950,497

5,052,332 5,092,267 5,116,636

5,213,847 5,275,849 5,639,307


Serial #15754 69

17 FLOOR PLAN

See Appendix for Floor Plan. 18 PNEUMATIC SCHEMATIC

See Appendix for Pneumatic Schematic. 19 ELECTRICAL SCHEMATIC

See Appendix for Electrical Schematic.


70 Serial #15754

20 SPARE PARTS LIST

PART DESCRIPTION ETI PART NO. ASSEMBLY RECM'D

SPARE PRICE EACH

Belt Cleaner Spare D15754-6100 Belt Cleaning Module 1

Belt B15754-6113 Belt Cleaning Module 2

Timing Belt, Berg, #20TP-100 Belt Cleaning Module 2

80 K.V. DCI, 100 UA Power Supply 5050010 Coating Module 1

High Voltage Output Lead 6' 5061012 Coating Module 1

Porous Plate E15754-1009 Coating Module 1

Ball Bearing, Fafnir, 304PP Coating

Module 2

Transfer Pump, Nordson, 165633 Powder

Collector 1

Sol. Valve 2-W/way, w/DIN Conn., 3/8"NPT, ASCO, SC8210G1-24VDC Powder

Collector 1

Minihelic II, Differential Pressure Gauge, 0-10" W.C., Dwyer, 2-5010 Powder

Collector 1

Pressure Regulator, 0-125 psig, w/mtg nut, Watts, R10-04CP Pneumatic 1

Pressure Regulator Norgren #R07-200-RNKA 3013004 Pneumatic 1

Pressure Regulator, 0-60 psig, w/mtg nut, Watts, R10-03BP Pneumatic 2

Pressure Switch/Gauge Dwyer #3000-60PA 3018015 Pneumatic 1

Particulate Filter, Kaeser, KPF-375 Pneumatic 2

Oil Removal Filter, Kaeser, KOR-375 Pneumatic 2

Flanged Bearing 3/8" x 5/8" nominal, Oilite, FF-607-2 Cleaning

Modules 2

Jack, Machine Screw, Upright, Standard Gear, 4" Rise, JF Shaw, ¼ MSJ-U-20 O.D. Cleaning

Module 2

Low Torque Journal Bearing, RH, 1:1, Tol-o-matic, 01080000 O.D. Cleaning

Module 1

120V Power Module, 2 Across, AB #800E-2TL5 Electrical 1

Push Button, No Head, AB #3800T-FXP16XA1 Electrical 1

Push Button, ILL., Amber, AB #800T-FXP16AA1 Electrical 1

Push Button, MOM., Black, 1N.O., 3-Way, MOM. AB #800T-J91B SW Electrical 1

Push Button, MOM., Black, 1N.O., PB., ILL., Maint AB #800T-JFXP16RA1 Electrical 1


Serial #15754 71

20 SPARE PARTS LIST (continued)


SPARE PRICE EACH

Contact N.O., 2 Across, AB #800"E-2X10 Electrical 1

Contact N.C., 2 Across, AB #800E-2X01 Electrical 1

Incandescent Lamp, 6 Vac (ANSI#755/1866), AB #800E-N65 Electrical 1

Incandescent Lamp, 120V AC/DC (ANSI#949), AB #800T-169 Electrical 1

Light Pole Lamp, 24VDC, 6 Vac (ANSI#755/1866), AB #855T-L24 Electrical 1

Circuit Breaker, 1 Pole, 20 Amps, AB #1492-CB1G200 Electrical 1


Circuit Breaker, 1 Pole, 1 Amp, AB #1492-CB1G010 Electrical 1






Circuit Breaker, 1 Pole, 8 Amps, AB #1492-GH008 Electrical 1

Limit Switch with LT, AB #802T-ALPN Electrical 1

Fuse, 1 Amp, Bussman #ABC-1 Electrical 6

Fuse, 12 Amp, Bussman #ABC-12 Electrical 6

Fuse, 8/10 Amp, Bussman #FNM-8/10 Electrical 6

Fuse, 25 Amp, Gould #TRS25R Electrical 3

Fuse, 3 Amps, Gould #ATQR3 Electrical 2

Fuse, 10 Amps, Gould #ATQR10 Electrical 2 Contactor, 24 VDC Coil, 12 Amps, AB #100-A12NZ243 Electrical 1

Contactor, 24 VDC Coil, 9 Amps, AB #100-A09NZ243 Electrical 1

Contactor, 120 VAC Coil, 18 Amp Cont., AB #100-A18ND3 Electrical 1

Relay, 110 VAC Coil 4 N.O. Contacts, AB #700-F400A1 Electrical 1

Relay, 24 VDC, Contacts, 4 N.O., AB #700DC-MB400Z24 Electrical 1

Relay, 24 VDC contacts, 2 N.O., 2 N.C., AB #700DC-MB220Z24 Electrical 1


72 Serial #15754



SPARE PRICE EACH

Motor Overload, 6.3-10.0 Amp, AB #140-MN-1000 with Indicator Contact, Aux. Trip, AB #140-T10 Electrical 1

Motor Overload, 1.0-1.6 Amp, AB #140-MN-0160 with Aux. Trip Indicator Contact, AB #140-T10 Electrical 1

Diode Suppressor, AB #199-FSMZ1 Electrical 1

Diode Suppressor, AB #199-MSMD1 Electrical 1

R/C Suppressor, AB #199-FSMA1 Electrical 1

Aux. Contactor, 2 N.O., AB #195-FA20 Electrical 1

Aux. Contactor, 4 N.O., AB #195-FA40 Electrical 1

Power Supply, 120/22/VAC, AB #1746-P2 Electrical 1

Processor 5/05, SLC500, AB #1747-L551 Electrical 1

Input Module, 16 Point DC, AB #1746-IB16 Electrical 1 Relay Contact Output Module, AB #1746-OW16 Electrical 1

Analog Input/Output Module, AB #1746-F104V Electrical 1

Advance Interface Converter, AB #1761-NET-AIC Electrical 1

Cable, AB #1747-CP3 Electrical 1

Cable, 29.5 ft., AB #1761-CBL-AS-09 Electrical 1

PanelView PV900, AB #2711-T9A2 Electrical 1 Backlight Lamp, PanelView PV900, AB #2711-NL2 Electrical 1

Proximity Switch, Efector #KIE-2015-FB0A/LS100AK Electrical 1

Inductive Sensor, Turck #B12-M12-AP6X-H1141 Electrical 1

Photoelectric Sensor, Emitter, Banner #T186EQ Electrical 1

Photoelectric Sensor, Receiver, Banner #T18SP6RQ Electrical 1 Speed Control, DC Motor, KB Electronics #KBMM125 Electrical 1

Barrier Terminal, KB Electronics #9897 Electrical 1

H.P. Resistor, KB Electronics #9836 Electrical 1

Overload, Regent Controls #Resetter 32 Electrical 1 Voltage Transformer, 750VA, Computer Regulator Sola #63-23-175-8 Electrical 1

Transformer, 2KVA, Acme #T-2-53012-S Electrical 1 Power Supply, 12 Amp, 24 VDC, Power One #F24-12-A Electrical 1

Vibration Horn, 24 VDC, Weatherproof, Federal Signal Corp. #WB450 Electrical 1

Motorized Variable Variac, Staco #SD291 Electrical 1


Serial #15754 73



SPARE PRICE EACH

Digital Meter with Sensitivity Board #VF-0020V Installed Texmate #RP35U Electrical 1

Resistor, 51K OHMS, 2 Watts Electrical 1

Resistor, 100K OHMS, 2 Watts Electrical 1

Capacitor, 10 F, 150 Volts Electrical 1

Neon NE2 Lamp 5013004 Electrical 1

Please Note: Prices are valid for 90 days from the date of this document.


74 Serial #15754

21 MANUFACTURER'S MANUALS

ADVANCED INTERFACE CONVERTER (AIC+) (AB) DEVICE NET INTERFACE (DNI) (AB) AIR COALESCING FILTERS (KAESER) AIR PRESSURE REGULATOR, GENERAL (WATTS) AIR PRESSURE REGULATOR, MINIATURE (WATTS) CAPACITIVE PROXIMITY SWITCH (EFECTOR) COMPUTER REGULATOR VOLTAGE TRANSFORMER (SOLA) DC SELF-CONTAINED SENSOR (BANNER) DIGITAL METER #RP35U (TEXMATE) DISCRETE I/O MODULES (AB) DRUM AGITATOR (GRACO) FIRE DETECTION SYSTEM (NORDSON) GEARMOTOR (BODINE) MINIHELIC DIFFERENTIAL PRESSURE GAUGE (DWYER) MOTOR SPEED CONTROL (KB ELECTRONICS) PANELVIEW TERMINALS (AB) POWER SUPPLY (POWER ONE) POWDER FEEDER HOPPER (NORDSON) POWDER LEVEL SENSOR (DWYER) PRESSURE SWITCH (AB) PRESSURE SWITCH (DWYER) RS232-TO-ETHERNET® CHANNEL-TO-CHANNEL (AB) PASSTHRU FOR SLC 5/05™ PROCESSORS (AB) RATEMASTER® FLOWMETER (DWYER) REFRIGERANT AIR DRYER (KAESER) SLC 5/05™ MODULAR PROCESSORS (AB) SLC500 MODULAR HARDWARE STYLE (AB) SLC500 FAST ANALOG I/O MODULES (AB)


Serial #15754 75

21 MANUFACTURER'S MANUALS (continued)

SOLENOID VALVE, 8210 (ASCO) SOLENOID VALVE, 8316 (ASCO) TRANSFORMER (ACME) VARIABLE AUTOTRANSFORMER (STACO) VISI-FLOAT® FLOWMETER (DWYER)

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