Electrostatic Technology 802 Manuale utente
Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 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 PERSONNEL ......................................................................................................5
4.4 INTENDED USE.......................................................................................................................6
4.5 INSTALLATION ......................................................................................................................6
4.6 OPERATION.............................................................................................................................8
4.7 LESS-OBVIOUS DANGERS .................................................................................................10
4.8 IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION .............................10
4.9 MAINTENANCE & REPAIR.................................................................................................11
4.10 DISPOSAL ..............................................................................................................................12
5 AIR, ELECTRICAL, AND WATER REQUIREMENTS ..........................................................13
5.1 POWDER COATING MACHINE ..........................................................................................13
5.1.1 Air ................................................................................................................................13
5.1.2 Electrical ......................................................................................................................13
5.1.3 Water............................................................................................................................13
5.1.3.1 Closed Loop Induction Heater Cooling System............................................13
5.1.3.2 Tower Water Requirements For Induction Heater Cooling .........................13
5.2 INDUCTION HEATER...........................................................................................................13
5.2.1 Electrical........................................................................................................................13
6 MECHANICAL FUNCTION: SEQUENCE AND DESCRIPTION ........................................14
6.1 LOAD/RELOAD AREA .........................................................................................................14
6.2 INDUCTION HEATER DEGREASER MODULE ................................................................14
6.3 COATING MODULE .............................................................................................................14
6.3.1 Coating Bed .................................................................................................................14
6.3.2 Powder Level Sensor ...................................................................................................15
6.4 CLEANING STATION ...........................................................................................................15
6.4.1 Bulk Box ......................................................................................................................15
6.4.2 O.D. Belt Cleaner.........................................................................................................15
6.4.3 Air Knives....................................................................................................................16
6.4.4 Screw Cleaner ..............................................................................................................16
Electrostatic Technology, Inc. Model 802 Armature Coater
ii Serial #15681
6.5 POWDER MANAGEMENT SYSTEM ..................................................................................17
6.6 INDUCTION HEATING MODULE.......................................................................................19
6.7 CURE MODULE.....................................................................................................................19
6.8 FINAL COOL MODULE........................................................................................................19
6.9 REFRIGERANT AIR DRYER................................................................................................19
6.10 DEIONIZED WATER SYSTEM ............................................................................................19
6.11 INDUCTION HEATER COOLING WATER ........................................................................20
6.12 MAIN CONTROL CABINET.................................................................................................20
7 DESCRIPTION OF CONTROLS.................................................................................................21
7.1 OPERATOR MAIN CONTROL PANEL ...............................................................................21
7.2 OPERATOR MAIN CONTROLS...........................................................................................22
7.3 COATER CONTROL PANEL................................................................................................25
7.4 COATER CONTROLS ...........................................................................................................25
7.5 CLEANING CONTROL PANEL ...........................................................................................26
7.6 CLEANING CONTROLS .......................................................................................................27
7.7 POWDER MANAGEMENT SYSTEM CONTROLS ............................................................28
8 SPECIFICE EQUIPMENT SAFETY...........................................................................................29
8.1 GENERAL...............................................................................................................................29
8.2 POWDER.................................................................................................................................29
8.2.1 Employee Health..........................................................................................................29
8.2.1.1 Inhalation......................................................................................................29
8.2.1.2 Skin Contact..................................................................................................29
8.2.1.3 Eye Contact...................................................................................................30
8.2.1.4 First Aid Procedures.....................................................................................30
8.2.2 Special Protection ........................................................................................................30
8.2.3 Precautions...................................................................................................................30
8.2.4 Material Safety Data Sheets (MSDS) ..........................................................................30
9 PREPARATION FOR OPERATION...........................................................................................31
9.1 INITIAL SYSTEM INSTALLATION ....................................................................................31
9.2 GENERAL...............................................................................................................................33
9.3 COATER..................................................................................................................................34
9.3.1 Coating Bed .................................................................................................................34
9.3.2 Powder Deposition.......................................................................................................34
9.3.3 High Voltage Adjustment ............................................................................................35
9.4 POWDER MANAGEMENT SYSTEM ..................................................................................35
9.4.1 Loading Powder...........................................................................................................35
9.4.2 Powder Maintenance....................................................................................................35
9.5 CLEANERS.............................................................................................................................35
9.5.1 O.D. Cleaner ................................................................................................................35
9.5.2 Air Knives....................................................................................................................36
9.5.3 Screw Cleaners ............................................................................................................36
9.6 INDUCTION HEATERS ........................................................................................................36
Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 iii
10 OPERATION ......................................................................................................................................37
11 START-UP & OPERATION PROCEDURE...................................................................................38
11.1 LOCAL MODE-COATING MACHINE.....................................................................................38
11.2 EXTERNAL MODE-COATING ................................................................................................39
12 SHUTDOWN PROCEDURE ............................................................................................................40
12.1 LOCAL MODE SHUTDOWN-COATER ..................................................................................40
12.2 EXTERNAL MODE SHUTDOWN-COATER...........................................................................40
12.3 POWDER HANDLING...............................................................................................................40
12.3.1 Powder Management System...........................................................................................41
12.4 POWDER/COLOR CHANGE ....................................................................................................41
13 MAINTENANCE................................................................................................................................42
13.1 GENERAL...................................................................................................................................42
13.2 COMPRESSED AIR SYSTEM...................................................................................................42
13.2.1 Air Line ...........................................................................................................................42
13.2.2 Refrigerant Air Dryer.......................................................................................................42
13.3 FLUIDIC BED.............................................................................................................................43
13.3.1 Installation of Porous Plate ..............................................................................................43
13.3.2 Powder Level Sensor .......................................................................................................44
13.4 POWDER COLLECTOR ............................................................................................................44
13.4.1 Lower Fluidizing Hopper.................................................................................................45
13.4.2 Installation of Porous Plate ..............................................................................................45
13.4.3 Filter Cartridges ...............................................................................................................46
13.4.4 Differential Pressure Gauge.............................................................................................46
13.5 O.D. CLEANER ..........................................................................................................................46
13.6 INDUCTION HEATER...............................................................................................................47
13.7 COOLING BLOWERS................................................................................................................47
13.8 ROTO-FLO CONVEYOR...........................................................................................................47
13.9 MOTORS & GEARS...................................................................................................................47
14 PREVENTATIVE MAINTENANCE SCHEDULE ........................................................................48
14.1 DAILY .........................................................................................................................................48
14.2 WEEKLY.....................................................................................................................................48
14.3 MISCELLANEOUS ....................................................................................................................49
15 PART CHANGEOVER......................................................................................................................50
15.1 CHANGEOVER PROCEDURE .................................................................................................50
15.1.1 Changing From Smaller To Larger Parts........................................................................50
15.1.2 Changing From Larger To Smaller Parts.........................................................................50
Electrostatic Technology, Inc. Model 802 Armature Coater
iv Serial #15681
16 TROUBLESHOOTING .....................................................................................................................51
16.1 COATER......................................................................................................................................51
16.2 POWDER COLLECTOR ............................................................................................................55
16.3 CONVEYOR CLUTCH ..............................................................................................................55
16.4 BAD PARTS................................................................................................................................56
17 PATENT INFORMATION................................................................................................................58
18 MANUFACTURER'S MANUALS ...................................................................................................59
19 FLOOR PLAN ....................................................................................................................................60
20 PNEUMATIC SCHEMATIC ............................................................................................................60
21 ELECTRICAL SCHEMATIC ..........................................................................................................60
22 SPARE PARTS ...................................................................................................................................61
Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 v
TABLE OF FIGURES
FIGURE 1A: 5HP POWDER COLLECTOR................................................................................................18
FIGURE 1B: SCRAP POWDER COLLECTOR ..........................................................................................18
FIGURE 2: PIPING DIAGRAM ................................................................................................................32
FIGURE 3: LEVEL SENSOR PROBE TUBE...........................................................................................34
Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 1
1 INTRODUCTION
This Operating Manual must be studied and followed for the safe and efficient operation of the Model
802 Coating System. Study this manual before locating and installing the equipment.
If there are any questions, please call:
ELECTROSTATIC TECHNOLOGY, INC.
A SUBSIDIARY OF NORDSON CORPORATION
4 PIN OAK DRIVE
BRANFORD, CT 06405
TELEPHONE: 203-488-8112
FAX: 203-483-8777
In future correspondence, please refer to the Model (802) and Serial Number (15681) of the Coating
System.
2 SHIPPING
Sometimes equipment can be damaged in transit. An inspection of the shipping crates should be made
upon delivery. When the equipment is removed, it should be carefully inspected to make sure the
equipment 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 Incorporated will then advise concerning repairs and replacements.
Electrostatic Technology, Inc. Model 802 Armature Coater
2 Serial #15681
3 OPERATING PRINCIPLES
3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER
Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 3
3.2 PROCESS DESCRIPTION
Powder particles are aerated in a fluidizing chamber and are electrostatically charged by
ionizing air forced through a porous plate at the base of the chamber. As the powder particles
become charged, they repel each other to such a degree that they rise above the chamber
forming a cloud or veil of charged particles. When a grounded object is placed in this cloud or
conveyed through this cloud, the charged powder particles, because of their opposite potential,
are attracted to it. As the particles become attached to the object, they form a uniform coating,
being more attracted to exposed areas than to those already insulated. The longer the object is
exposed to the cloud, the thicker the coating becomes, until saturation eventually takes place.
Coating thickness is controlled by applied voltage to the charging media and exposure time to
the cloud. Because of the high voltage capability of the charging media, a sufficiently great
potential exists between it and most substrates to permit even natural insulators to be coated.
Unlike equipment with exposed electrodes, Electrostatic Technology, Inc.'s unique air
ionization process charges the powder without permitting the powder, the object, or the
operator to come in contact with the charging media.
Electrostatic Technology, Inc. Model 802 Armature Coater
4 Serial #15681
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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