Electrostatic Technology, Inc. A Subsidiary of Nordson Corporation

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1 . A Subsidiary of Nordson Corporation 4 Pin Oak Drive, Branford, CT USA MODEL 800 ARMATURE COATING SYSTEM INSTALLATION & OPERATING MANUAL FOR BLACK & DECKER, EASTON, MD SERIAL NUMBER REV. A December 1997 (Rev. A February 1998)

2 TABLE OF CONTENTS 1 INTRODUCTION SHIPPING OPERATING PRINCIPLES SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER PROCESS DESCRIPTION GENERAL SAFETY INTRODUCTION SAFETY SYMBOLS QUALIFIED PERSONNEL INTENDED USE INSTALLATION OPERATION LESS-OBVIOUS DANGERS IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION MAINTENANCE & REPAIR DISPOSAL AIR, ELECTRICAL AND WATER REQUIREMENTS POWDER COATING MACHINE AIR ELECTRICAL WATER INDUCTION HEATER STEAM DEGREASER MECHANICAL FUNCTION: SEQUENCE & DESCRIPTION LOAD/RELOAD STATION STEAM DEGREASER MODULE PRE-COOLING STATION COATING STATION CLEANING STATION AIR KNIVES O.D. CLEANING CONVEYOR CLEANER SHAFT CLEANING DOUBLE SIDED SHAFT CLEANER SET-UP POWDER MANAGEMENT SYSTEM INDUCTION HEATING STATION CURE STATION FINAL COOL STATION REFRIGERANT AIR DRYER DEIONIZED WATER SYSTEM PARTS COUNTER MAIN CONTROL CABINET DESCRIPTION OF CONTROLS

3 7.1 MAIN CONTROL CABINET MODEL 800 ELECTRICAL CONTROLS STATION BEACON CLEANING STATION PNEUMATIC CONTROLS AIR KNIVES PNEUMATIC CONTROLS POWDER MANAGEMENT SYSTEM CONTROLS STEAM DEGREASER CONTROLS/INDICATORS PRE-WASH STEAM SECTION PRE-WASH WATER SECTION PREPARATION FOR OPERATION GENERAL INITIAL SYSTEM INSTALLATION LOAD / RELOAD STATION STEAM DEGREASER POWDER MANAGEMENT SYSTEM LOADING POWDER POWDER MAINTENANCE COATER COATING BED POWDER DEPOSITION HIGH VOLTAGE CLEANERS O.D. ADJUSTING AIR KNIVES ADJUSTING CONVEYOR CLEANERS ADJUSTING SHAFT CLEANING POSITION ADJUSTING INDUCTION HEATER CURE STATION FINAL COOL STATION SPECIFIC EQUIPMENT SAFETY GENERAL POWDER EMPLOYEE HEALTH FIRST AID PROCEDURES SPECIAL PROTECTION PRECAUTIONS MATERIAL SAFETY DATA SHEETS (MSDS) STEAM DEGREASER EMPLOYEE CONTACT EMERGENCY MAINTENANCE PANELVIEW SCREENS MACHINE STARTUP SCREEN AUTO MODE START/STOP SCREEN MANUAL SETUP SCREEN MACHINE STATUS SCREEN DEGREASER STATUS SCREEN ALARM HISTORY SCREEN ALARM BANNER SCREEN

4 11 STATION STARTUP PROCEDURE OVERVIEW MANUAL MODE - COATING MACHINE STEAM DEGREASER INDUCTION HEATER AUTO MODE - COATING STATION SHUTDOWN PROCEDURE AUTO MODE SHUTDOWN - COATING MACHINE MANUAL MODE SHUTDOWN - COATING MACHINE POWDER HANDLING AT SHUTDOWN LOCKOUT MAINTENANCE GENERAL COMPRESSED AIR SYSTEM AIR LINE REFRIGERANT AIR DRYER STEAM DEGREASER FLUIDIC BED INSTALLATION OF POROUS PLATE POWDER MANAGEMENT SYSTEM POWDER LEVEL SENSOR O.D. CLEANER INDUCTION HEATER COOLING FANS PROGRAMMABLE CONTROLLER ROTO-FLO CONVEYOR MOTORS AND GEARS PREVENTATIVE MAINTENANCE SCHEDULE DAILY WEEKLY MISCELLANEOUS LUBRICATION CHART LUBRICATION DIAGRAM TROUBLE SHOOTING PATENT INFORMATION SPARE PARTS LIST MANUFACTURER S MANUALS FLOOR PLAN ELECTRICAL SCHEMATICS

5 TABLE OF FIGURES Figure 1 Schematic of an Electrostatic Coater...7 Figure 2 Main Control Panel...28 Figure 3 Cleaning and Pneumatic Controls...31 Figure 4 Air Knives Pneumatic Controls...34 Figure 5 Main Screen Menu...48 Figure 6 Machine Start-up Screen...49 Figure 7 Machine Auto Start/Stop Screen...50 Figure 8 Manual Setup Screen...51 Figure 9 Machine Status Screen...52 Figure 10 Degreaser Status Screen...53 Figure 11 Alarm History Screen...54 Figure 12 Alarm Banner Screen...55 Figure 13 Lockout Provisions

6 1 INTRODUCTION This Installation and Operating Manual should be thoroughly reviewed before locating and installing the Model 800 Armature Coating System. It should be studied by operating personnel to achieve maximum safety and efficiency. If there are any questions, please call: ELECTROSTATIC TECHNOLOGY, INC. A Subsidiary of Nordson Corporation 4 PIN OAK DRIVE BRANFORD, CT TELEPHONE: FAX: In future correspondence, please refer to the Model (800) and Serial Number of the Armature Coating System. 2 SHIPPING Sometimes equipment can be damaged in transit. An inspection of the shipping containers should be made upon delivery. When equipment is removed from the shipping container(s), it should be carefully inspected for damage. If the equipment is damaged, the carrier's claim agent should be requested to prepare a report, a copy of which should be sent to: ELECTROSTATIC TECHNOLOGY, INC. A Subsidiary of Nordson Corporation 4 PIN OAK DRIVE BRANFORD, CT Electrostatic Technology Incorporated will then advise concerning repairs and replacements

7 3 OPERATING PRINCIPLES 3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER Figure 1 Schematic of an Electrostatic Coater - 7 -

8 3.2 PROCESS DESCRIPTION Powder particles are aerated in a fluidizing chamber and are electrostatically charged by ionizing air forced through a porous plate at the base of the chamber. As the powder particles become charged, they repel each other to such a degree that they rise above the chamber forming a cloud or veil of charged particles. When a grounded object is placed or conveyed through the cloud, the charged particles, because of their opposite potential, are attracted to it. As the particles become attached to the object, they form a uniform coating, being more attracted to exposed areas than to those already insulated. The longer the object is exposed to the cloud, the thicker the coating becomes, until saturation eventually takes place. Coating thickness is controlled by the voltage applied to the charging media and the exposure time to the cloud. Because of the High Voltage capability of the charging media, a sufficiently great potential exists between it and object in the cloud to permit even insulators to be coated. Unlike equipment with exposed electrodes, Electrostatic Technology, Inc.'s unique air ionization process charges the powder without permitting it, the object, or the operator to come in contact with the charging media

9 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

10 4.2 SAFETY SYMBOLS Become familiar with the safety symbols presented in this section. These symbols will alert you to safety hazards and conditions that may result in personal injury, death, or property and equipment damage. WARNING: Failure to observe this warning may result in personal injury, death, or equipment damage. WARNING: Risk of electrical shock. Failure to observe this warning may result in personal injury, death, or equipment damage. WARNING: Disconnect equipment from line voltage. Failure to observe this warning may result in personal injury, death, or equipment damage. WARNING: Risk of explosion or fire. Fire, open flames and smoking prohibited. WARNING: Wear protective clothing, safety goggles, and approved respiratory protection. Failure to observe may result in serious injury.. WARNING: System or material pressurized. Release pressure. Failure to observe this warning may result in serious injury or death CAUTION: Failure to observe may result in equipment damage

11 4.3 QUALIFIED PERSONNEL "Qualified personnel" is defined here as individuals who thoroughly understand the equipment and its safe operation, maintenance, and repair. Qualified personnel are physically capable of performing the required tasks, familiar with all relevant safety rules and regulations, and have been trained to safely install, operate, maintain, and repair the equipment. It is the responsibility of the company operating the equipment to see that its personnel meet these requirements. 4.4 INTENDED USE WARNING: Use of this equipment in ways other than described in this manual may result in personal injury, death, or property and equipment damage. Use this equipment only as described in this manual. ETI cannot be responsible for injuries or damages resulting from nonstandard, unintended applications of its equipment. This equipment is designed and intended only for the purpose described in this manual. Uses not described in this manual are considered unintended uses and may result in serious personal injury, death, or property damage. Unintended uses may result from taking the following actions: making changes to equipment that have not been recommended or described in this manual or using parts that are not genuine ETI replacement parts. failing to make sure that auxiliary equipment complies with approval agency requirements, local codes, and all applicable safety standards. using materials or auxiliary equipment that are inappropriate or incompatible with your ETI equipment. allowing unqualified personnel to perform any task

12 4.5 INSTALLATION Read the installation section of all system components manuals before installing your equipment. A thorough understanding of system components and their requirements will help you install the system safely and efficiently. Allow only qualified personnel to install ETI and auxiliary equipment. Use only approved equipment. Using unapproved equipment in an approved system may void agency approvals. Make sure all equipment is rated and approved for the environment in which you are using it. Follow all instructions for installing components and accessories. Install locking, manual, shutoff valves in the air supply lines to the system. This allows you to relieve air pressure and lock out the pneumatic system before undertaking maintenance and repairs. Install a locking disconnect switch or breaker in the service line ahead of any electrical equipment. Use only electrical wire of sufficient gauge and insulation to handle the rated current demand. All wiring must meet local codes. Ground all electrically conductive equipment within 10 feet (3 meters) of the coating area. Ungrounded conductive equipment can store a static charge which could ignite a fire or cause an explosion if a hot spark is discharged. Install safety interlocks which shut down the coating system if the exhaust fan fails, a fire is detected, or other emergency situation develops. Make sure the coating area floor is grounded and that the operator's platform is grounded. Use only designated lifting points or lugs to lift and move heavy equipment. Always balance and block loads when lifting to prevent shifting. Lifting devices must be inspected, certified, and rated for a greater weight than the equipment being lifted. Protect components from damage, wear, and harsh environmental conditions. Allow ample room for maintenance, material supply container drop-off and loading, panel accessibility, and cover removal. If safety devices must be removed for installation, install them immediately after the work is completed and check them for proper functioning

13 4.6 OPERATION Only qualified personnel, physically capable of operating the equipment and with no impairments to their judgement or reaction times, should operate this equipment. Read all component manuals before operating a powder coating system. A thorough understanding of all components and their operations will help you operate the system safely and efficiently. Use this equipment only in the environments for which it is rated. Do not operate this equipment in humid, flammable, or explosive environments unless it has been rated for safe operation in these environments. Before starting this equipment, check all safety interlocks, fire-detection systems, and protective devices such as panels and covers. Make sure all devices are fully functional. Do not operate the system if these devices are not working properly. Do not deactivate or bypass automatic safety interlocks or locked-out electrical disconnects or pneumatic valves. Know where EMERGENCY STOP buttons, shutoff valves, and fire extinguishers are located. Make sure they work. If a component malfunctions, shut down and lock out the equipment immediately. Before operating, make sure all conductive equipment in the coating area is connected to a true earth ground. Never operate equipment with a known malfunction or leak. Do not attempt to operate electrical equipment if standing water is present. Never touch exposed electrical connections on equipment while the power is ON. Do not operate the equipment at pressures higher than the rated maximum working pressure of any component in the system. Know the pinch points, temperatures, and pressures for all equipment that you are working with. Recognize potential hazards associated with these and exercise appropriate caution. Wear shoes with conductive soles, such as leather, or use grounding straps to maintain a connection to ground when working with or around electrostatic equipment

14 4.6 OPERATION (continued) Do not wear or carry metallic objects (jewelry or tools) while working with or around electrostatic equipment. Ungrounded metal can store a static charge and cause harmful shocks. Keep parts of the body or loose clothing away from moving equipment or parts. Remove personal jewelry and cover or tie back long hair. Wear National Institute of Occupational Safety and Health (NIOSH) approved respirators, safety glasses or goggles, and gloves, while handling powder containers, filling hoppers, operating coating equipment, and performing maintenance or cleaning tasks. Avoid getting powder coatings on your skin. Do not smoke in the coating area. A lit cigarette could ignite a fire or cause an explosion. If you notice electrical arcing in the coating equipment, shut down the system immediately. An arc can cause a fire or explosion. Shut off electrostatic power supplies before making adjustments to powder coating fluidized bed. Shut off moving equipment before taking measurements or inspecting work pieces. Wash exposed skin frequently with soap and water, especially before eating or drinking. Do not use solvents to remove coating materials from your skin. Do not use high-pressure compressed air to blow powder off your skin or clothes. High-pressure compressed air can be injected under the skin and cause serious illness or death. Treat all high-pressure fittings and hoses as if they could leak and cause injury

15 4.7 LESS-OBVIOUS DANGERS Operators should also be aware of less obvious dangers in the workplace that often cannot be completely eliminated: exposed surfaces on the equipment which may be hot or have sharp edges and cannot be practically safeguarded. electrical equipment which may remain energized for a period of time after the equipment has been shut off. vapors and materials which may cause allergic reactions or other health problems. automatic hydraulic, pneumatic, or mechanical equipment or parts that may move without warning. unguarded, moving mechanical assemblies. 4.8 IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION Do not operate a system that contains malfunctioning components. If a component malfunctions, turn the system OFF immediately. Disconnect and lock out electrical power. Close and lock out hydraulic and pneumatic shutoff valves and relieve pressures. Allow only qualified personnel to make repairs. Repair or replace the malfunctioning component

16 4.9 MAINTENANCE & REPAIR Allow only qualified personnel to perform maintenance, troubleshooting, and repair tasks. Always wear appropriate protective devices and use safety devices when working on this equipment Follow the recommended maintenance procedures in your equipment manuals. Do not service or adjust any equipment unless another person trained in first aid and CPR is present. Use only genuine ETI replacement parts. Using unapproved parts or making unapproved modifications to equipment may void agency approvals and create safety hazards. Disconnect, lock out, and tag electrical power at a disconnect or breaker in the service line ahead of electrical equipment before servicing. Do not attempt to service electrical equipment if there is standing water present. Do not service electrical equipment in a high-humidity environment. Use tools with insulated handles when working with electrical equipment. Do not attempt to service a moving piece of equipment. Shut off the equipment and lock out power. Secure equipment to prevent uncontrolled movement. Relieve air pressures before servicing equipment. Follow the specific instructions in this manual. Make sure that the room where you are working is sufficiently ventilated. If a "power on" test is required, perform the test carefully and then shut off and lock out power as soon as the test is over. Connect all disconnected equipment ground cables and wires after servicing the equipment. Ground all conductive equipment. Check interlock systems periodically to ensure their effectiveness. WARNING: Operating faulty electrostatic equipment is hazardous and can cause electrocution, fire, or explosion. Make resistance checks part of your periodic maintenance program

17 4.9 MAINTAINENCE & REPAIR (continued) Do not store flammable materials in the coating area or room. Keep containers of flammable materials far enough away from the coater to prevent their inclusion in a fire. If a fire or explosion occurs, flammable materials in the area will increase the chances of and the extent of personal injuries and property damage. Practice good housekeeping procedures. Do not allow dust or powder coatings to accumulate in the coating area or on electrical equipment. Read this information carefully and follow instruction DISPOSAL Dispose of equipment and materials used in operation and cleaning according to your local regulations

18 5 AIR, ELECTRICAL AND WATER REQUIREMENTS 5.1 POWDER COATING MACHINE Air A clean, oil free, dry supply of compressed air must be provided using 1 inch I.D. line capable of supplying 85 cubic feet/minute (2.832 cubic pounds per square inch minimum Electrical 460 Volts, 60 Hertz, 3-Phase Plant Power from a 200 Amp fused disconnect must be supplied to the Operator Station Control Cabinet. 460 Volts, 60 Hertz, 3-Phase, 100 Amps is required for the Induction Heater drops. 480 Volts, 60 Hertz, 3-Phase, 4 Amps fuse size disconnect is recommended. Ref: Steam Generator instruction manual Water Closed Loop Induction Heater and Induction Heater Cooling System Deionized water is required for the closed loop Induction Heater cooling system. Approximately 30 gallons (113.6 liters) of deionized water are required to fill the system Deionized Water Requirements: ph between 7.0 and 9.0 Chloride Content - 20 PPM Max. Nitrate Content - 10 PPM Max. Sulphate Content PPM Max. Total Solids PPM Max. Hardness PPM CACO Max. Resistivity OHM-CM Min. 5.2 INDUCTION HEATER The Induction Heater is wired through the Main Electrical Control Cabinet. The power level is controlled by the Induction Heater Power Adjust control on the Main Control Panel (See Figure 2). 5.3 STEAM DEGREASER Soft water is required at 0-10 gallon/minute (0-37 liter/minute) maximum at 50 psig. minimum for the wet steam water injection in the first stage (Pre-Wash) of the Steam Degreaser Chamber. Typical usage is approximately gallons/minute ( liter/minute). The Steam Degreaser requires Saturated Vapor (Dry Steam) at 149 C at 70 psig and requires pounds of steam per hour maximum

19 6 MECHANICAL FUNCTION: SEQUENCE & DESCRIPTION 6.1 LOAD/RELOAD STATION Armatures are loaded onto a roller chain conveyer by a gravity fed load ramp. The conveyor carries and loads the armatures onto the Twin Screw Roto-Flo Conveyer and transports them to each station. 6.2 STEAM DEGREASER MODULE The parts traverse through a wet steam pre-wash and a cloud of superheated steam which is directed by nozzles at the armature core and shafts to provide cleaning action. An exhaust blower draws the steam towards the bottom of the Degreaser and maintains a negative pressure to keep the steam inside the unit. The blower should be ducted outside the plant. Specially designed profile plates have been installed at both the entrance and exit of the Degreaser to reduce the open area through which the steam might escape. 6.3 PRE-COOLING STATION The parts are then transported through the cooling station, where they are cooled to 37.8 C (100 F) or less. The cooling is achieved by a blower located behind the pre-cool station, to draw air past the hot armatures. This cooling is required for the parts to be properly coated. 6.4 COATING STATION The armatures are next conveyed through the coating bed. As the armatures enter the bed area they pass through the cloud of charged particles which coat each armature. A Suction Powder Pick-up hose is supplied to pick up spilled powder in this area. The suction is available continuously when the Machine is powered. NOTE: This Pick-up hose should be used only for clean uncontaminated powder. Do not use it for general cleanup of dirt and trash. A powder level sensing unit (Photohelic Gauge/Switch) controls the Powder Feeder to assure the correct level of powder in the coating bed at all times. The Powder Level Sensor consists of a control sensor with two inputs. The sensor reads the difference between the air pressure at the powder level in the Coating Bed and the ambient atmospheric pressure. The system logic requires that there be a difference between the two pressure readings. As the readings come together, additional powder is fed into the coating bed

20 6.4 COATING STATION (continued) The range of the control sensor has been pre-set at the E.T.I. factory and should not be touched or changed without consulting E.T.I. personnel. The Photohelic Gauge Meter which shows the pressure range is located on the front of the Machine at the entrance to the Coating Bed. On this gauge, when the needle comes in contact with the Left Set-Point, the Powder Feeder goes "ON". It stays on until the needle makes contact with the Right Set-Point. This shuts off the powder feed. Refer to the Dwyer Photohelic Gauge Manual in the Manufacturer's Manuals (Section 18) for more specific information on this unit). 6.5 CLEANING STATION Bulk powder removal from the O.D. and Shafts is done in the First Cleaning Station Air Knives There are 5 sets of Air Knives located in the Cleaning Station. A set includes a front and a rear Air Knife. These Air Knives are controlled and adjusted by air flowmeters on the Main Pneumatic Panel. Air Knives #1 and #2 are located at the Bulk Box. Air Knives #3, #4,and #5 are located after the O.D. Cleaner O.D. Cleaning The O.D. Cleaner is located just after the Bulk Cleaning Station. It utilizes a moving belt to pick powder off the core O.D. The O.D. Cleaner is easily adjusted up or down, front or back, and can swivel for desired positioning Adjustments can be made by turning a small black knob located on the O.D. Cleaner. The position of the belt can be raised or lowered as needed. Generally the belt should run very close to the O.D., just barely touching it Conveyor Cleaner There are Roto-Flo Cleaner Vacuums on the front and rear Roto-Flo Screws in the Belt Type O.D. Cleaner Section of the Machine. The Shaft Cleaner Vacuums on the front and rear Roto-Flo Screws in the Bulk Cleaning section of the Coating Bed also act as Roto-Flo Screw Cleaners. All these Roto-Flo Screw Cleaner Vacuums are controlled and adjusted by air flowmeters on the Main Pneumatic Panel

21 6.5.4 Shaft Cleaning The shaft cleaning Air Knives are located just after the O.D. Cleaner. The function of the Air Knives is to clean the armature shafts. These knives use a thin stream of air to clean the shafts of excess powder and remove powder speckles prior to induction heating. The knives are generally adjusted to be 1/8" from the armature shaft and will not interfere with the part. They should be adjusted on an angle in relation to the Machine center to allow the knife to clean the entire length of the shaft. The volume of air available to each air knife is adjusted by air flowmeters located on the front of the Machine. Air flow should be adjusted so that there is sufficient air to clean the part without disturbing powder in the surrounding area Double Sided Shaft Cleaner Set-up (See appendix DWG E ) 1. Bring both the front and rear guide blocks (items 4 and 5) in toward the center of the Machine by rotating the respective guide rods (items 2 and 3). 2. Remove the O.D. friction assembly (items 34, 47 and 55) by removing the four button head screws (item 60) from the belt hanger mounts (item 33). If not installed yet, proceed to step Align the guide blocks so that they are parallel to the Machine Roto-Flo screws and set the digital indicators (item 38) to have an initial reading of Install the rear shaft cleaner assembly on the rear guide blocks (item 5). 5. Move the shaft cleaning assembly away from the center of the Machine by means of the guide rods. 6. Place two production dimension armatures in the Roto-Flo screw so that the armature shafts will be directly under the leading and trailing compression shoes (item 16). 7. By means of the guide rods, move the shaft cleaning assembly toward the center of the Machine and position the edge of the cleaning belt (item 41) approximately at the desired cut-off distance. 8. Turn on the motor (item 42) for the installed shaft cleaner assembly. 9. Lower the shaft cleaner assembly by using the micrometer slide unit (item 22) so that the shaft cleaning belt (item 41) is just barely touching the shaft of the armature at the center of the trailing compression shoe (item 16). This is confirmed if the armature under the trailing compression shoe spins smoothly and evenly. The spinning armature should be able to be stopped by simply laying the O.D. friction belt (item 55) on the armature O.D. If stopping of the spinning is not attainable, the shaft cleaner assembly is too low and exerting excessive force on the armature shaft. To correct this, raise the shaft cleaner assembly with the micrometer slide (item 22) until the desired condition is reached

22 6.5.5 Double Sided Shaft Cleaner Set-up (continued) 10. Loosen the 3 leading socket head cap screws (item 51) which secure the compression shoe mount (item 18) keeping the fourth and final socket head cap screw snug to act as a pivot point. 11. Pivot the compression shoe mount (18) so that the shaft cleaning belt ( item 41) just barely makes contact with the armature shaft at the leading compression shoe. (item 16). Again, this is indicated in the same manner as in step Back off the compression shoe mount (item 18) slightly so that the armature under the leading compression shoe (item 16) stops spinning by itself when the armature under the trailing compression shoe (item 16) continues to spin smoothly. It may be necessary to readjust the belt tensioning idler (item 36) several times in order to complete steps 9 through 12. Note: Correct adjustment of the belt tensioning idler (item 36) is of extreme importance. Adjustment of the belt tensioning idler (item 36) should not cause the compression shoe springs (item 48) to be compressed beyond their installed height. Overtensioning of the shaft cleaning belt is indicated by the compression shoe retaining rings (item 54) not resting on the back of the compression shoe mount (item 18). 13. Tighten all 4 of the socket head cap screws (item 51) which secure the compression shoe mount. 14. Turn off the motor and remove the shaft cleaning assembly. 15. Install the front shaft cleaning assembly in the front guide blocks (item 4). 16. Perform steps 5 through 14 above on the front shaft cleaner assembly. 17. Install the O.D. friction assembly (items 34, 47 and 55) on to the belt hanger mounts. (item 33) by finger tightening the 4 button head cap screws (item 60) to allow vertical movement of the belt hangers (item 34). 18. Place 2 production dimension armature s in the Roto-Flow screw so that one each is directly under the lowest point of the two belt hangers (item 34). 19. Using the two hex head screws (item 61) adjust the height of the belt hangers (item 34) so that the O.D. friction belt (item 55) is resting against the O.D. of the armature. The O.D. friction belt should not exert any force on the armature O.D. 20. Lock the hex head screws (item 61) using the hex nuts (item 62). 21. Tighten the button head cap screws (item 60) which secure the belt hanger (item 34) to the belt hanger mount (item 33). 22. Loosen the button head cap screws and nuts (items 60 and 62)which secure the spring plunger mount (item 47) to the belt hangers (item 34), 23. Move the 2 sample armatures so that each one is under the leading and trailing spring plungers (item 56). 24. Adjust the spring plunger mount (item 47) so that the 2 spring plungers are compressed equally: approximately l/

23 6.5.5 Double Sided Shaft Cleaner Set-up (continued) 25. Tighten the button head cap screws and their nuts (items 60 and 62) which secure the spring plunger mount (item 47) to the belt hangers (items 34). 26. Run the Roto-Flow screw conveyor with production dimension armatures, making sure that the armatures do not bind or cause excessive deflection of the O.D. friction assembly. 27. Also, make sure that the O.D. spring plunger assembly is not causing the armatures to bounce or jump. If the armatures are jumping as they leave the trailing spring plunger, only that spring plunger needs to be backed out one full turn. If the armatures are jumping after each and every spring plunger, the entire spring plunger mount is too low. Return to step 24. NOTE: A too low condition must be corrected so that excessive force is not being exerted on the O.D. of the armatures. 28. Install both the front and rear shaft cleaner assemblies. 29. Turn on the motors for the shaft cleaning assemblies (item 42). 30. Run the Roto-Flow screw conveyor with production dimension armatures. Make sure that the armatures are moving smoothly through the shaft cleaning station and are not spinning excessively due to the cleaning belt force overriding the O.D. friction belt. If excessive armature spinning is observed, return to step 2 above

24 6.6 POWDER MANAGEMENT SYSTEM Powder management is accomplished by a vacuum system which collects powder in ducts located throughout the Machine and conveys it back to the lower hopper of the powder collector. In this hopper, the collected powder is mixed with virgin powder. The level of the powder mix is monitored by the level sensor in the hopper. The powder is fluidized in this lower hopper by dry air which removes any remaining moisture from the powder. This lower hopper acts as a Powder Drying Chamber. The powder is then fed by means of a screw conveyor up to a Transition Weldment located just above the bed. From there the powder is allowed to trickle down into the coating bed. There is a magnet located in the Powder Feeder Transition Weldment to collect any metallic iron contamination in the powder. Vacuum is supplied to the system through an assembly which consists of a fan and motor to generate the vacuum and 9 filter cartridges which retain powder within the system. Electric and pneumatic circuitry provides a reverse pulse of air to clean the filter cartridges. Reclaimed powder released from the filters falls into a hopper (located beneath the filters) and then through a rotary air lock into the lower hopper to be mixed with virgin powder. A loading chamber at the rear of the collector/feeder allows virgin powder to be added to the system without spillage. Refer to Section for instructions on loading powder into the system. A differential pressure gauge is located on the side of the collector/feeder assembly. This provides an indication of how clean the filter cartridges are. A normal reading is between 1 and 5. A reading above 5 indicates that the filter cartridges are not being cleaned well enough. To correct this requires setting the unit so that the reverse cleaning pulses are more frequent and/or increasing the air pressure to the pulse circuit. A reading below 1 would indicate the filters are too clean, or that there is a hole in a filter or there is leakage past the filters. Refer to Maintenance (Section 13 of this manual) for a more complete discussion. 6.7 INDUCTION HEATING STATION This Induction Heater is a 20 kw, 50 khz unit. The purpose of the Induction Heating Station is to heat each armature to the proper temperature to allow the powder to flow and eventually cure. The Hood (yellow) for this station is interlocked and must be closed or you can not turn "ON" the Induction Heater. The Induction Heater Power Adjust and the Induction Heater Power meter are located on the Main Electrical Control Panel. For information on the Induction Heater, refer to the Pillar Induction Heater Manual in the Manufacturer's Manuals (Section 18 of this manual)

25 6.7 INDUCTION HEATING STATION (continued) The power control of the Induction Heater should be set as required to heat armatures to the proper temperature as read on the Optical Pyrometer at the exit of the Induction Heating Station. This reading is shown as the Heated Part Temperature on the Machine Status Screen. The powder on the armatures should melt and have a wet look when the part is approximately 1/3 of the way through the Induction Coil. 6.8 CURE STATION The Cure Station, located just after the Induction Heating Station, allows time for the epoxy on each armature to cure. To retain the heat, the 2 insulated hoods should always be closed while the Machine is running. There are PLC controlled heating elements installed within the Cure zone to maintain the proper curing temperature. 6.9 FINAL COOL STATION In this station the armature passes through an aerodynamically designed directional vane, directing air over and through each coated armature. The air is pulled through using an exhaust fan. When the armature leaves this station, it is cool enough to be handled by hand. Within this station is the radiator for cooling the deionized water that flows through the induction coils. This radiator uses the same air flow that cools the armatures REFRIGERANT AIR DRYER A 100 SCFM Refrigerant Air Dryer accepts in-plant compressed air and supplies moisturefree Coating/Cleaning air to the entire Coating Machine. Having moisture-free air is important for fluidization of the powder. A particle air filter is installed on the inlet of the Refrigerant Air Dryer to remove foreign particles from the inlet air. A coalescing air filter is installed on the outlet of the Refrigerant Air Dryer to remove any oils from entering the Coating Machine. For specific information, on the Refrigerant Air Dryer refer to the Manufacturer's Manuals (Section 18) DEIONIZED WATER SYSTEM The water that flows through the coils of the Induction Heaters is contained in a closed loop system. This system should be filled with about 30 gallons (113.6 liters) of deionized water. The water is maintained in a deionized condition by a replaceable cartridge element. An indicator light signals when the element needs changing. This indicator light can be seen through a peep hole in the front panel of the Cure Station. The peep hole is marked with the label "Deionized Water Filter Change When Light Is Red". Heat in the deionized water system is removed as the deionized water flows through a radiator in the final cool station

26 6.12 PARTS COUNTER A proximity Switch located under the Roto-Flo Screw Conveyer in the Final Cooling Station acts as a Parts Counter. The count of parts can be read on the Panel View Display MAIN CONTROL CABINET The Main Control Cabinet holds all of the electric connections and switch gear for the system. Mounted on this cabinet is the pendant arm holding the control panel containing the Panel View and controls for equipment operation and High Voltage adjustment. Refer to Main Control Panel drawing, Figure

27 7 DESCRIPTION OF CONTROLS 7.1 MAIN CONTROL CABINET The following controls are located on the Main Control Panel: Model 800 Electrical Controls MAIN DISCONNECT switch MASTER START pushbutton MASTER STOP pushbutton MASTER ON PANEL VIEW screen EMERGENCY STOP pushbutton HIGH VOLTAGE ADJUST adjustable pot KILOVOLTS digital readout MICROAMPS digital readout INDUCTION HEATER POWER ADJUST adjustable pot INDUCTION HEATER POWER Turns on power for the system. Energizes all control circuits. De-energizes all control circuits. Panel light. When ON indicates power is on for the system. Used for operating the Coating Machine. See Section 10 in this Manual for a description of controls located on the Panel View screen. Will completely shutdown the system. Adjusts the output of the High Voltage Power Supply. Indicates the voltage being supplied by the 80 kv D.C. High Voltage Power Supply. Indicates the current being drawn from the 80 kv D.C. High Voltage Power Supply. Adjusts the output power of the Induction Heater Indicates power supplied to the induction heater coil

28 Figure 2 Main Control Panel

29 7.1.2 Station Beacon A three-color stack light, located on top of the Main Control Cabinet, provides a visual indication of the current status of Coating Machine operation. RED light AMBER light GREEN light When illuminated, indicates an Alarm condition and/or the loader is starved for parts When illuminated, indicates the Coating Machine is in Manual Mode When illuminated, indicates the Coating Machine is in Automatic Mode and cycling (running without any faults)

30 7.2 CLEANING STATION PNEUMATIC CONTROLS The following controls are located on the front of the Cleaning Station panel. The air flow values (SCFH) indicated with the controls are recommended settings under ideal operating conditions. They should be adjusted as needed during coating operation. FLUIDIC BED ADJUST air flowmeter and control Adjusts and indicates the amount of fluidizing air being supplied to the Coating Bed. FLUIDIC BED PRESSURE ADJUST air pressure regulator FLUIDIC BED PRESSURE (psi) air pressure gauge POWDER DRY CHAMBER ADJUST air flowmeter and control POWDER DRY CHAMBER PRESSURE air regulator POWDER DRY CHAMBER PRESSURE air pressure gauge CONVEYOR CLEANER FRONT ADJUST air flowmeter and control CONVEYOR CLEANER REAR ADJUST air flowmeter and control O.D. CLEANER ADJUST air flowmeter and control SHAFT CLEANER FRONT ADJUST air flowmeter and control SHAFT CLEANER REAR ADJUST air flowmeter and control CONVEYOR, O.D. & SHAFT CLEANERS PRESSURE ADJUST air pressure regulator Adjusts and regulates the air pressure available to the Coating Bed air flowmeter and control. Indicates the amount of air pressure available to the Coating Bed air flowmeter and control. Adjusts and indicates the amount of fluidizing air supplied to the Coating Bed. Adjusts and regulates the air pressure available to the Powder Drying Chamber air flow meter. Indicates the air pressure available to the Powder Drying Chamber air flow meter and control. Adjusts and indicates the amount of air flow to the air transducer for the Front Roto-Flo Conveyor vacuum located in the Bulk Cleaning section of the Coater Station Hood. Adjusts and indicates the amount of air flow to the air transducer for the Rear Roto-Flo Conveyor vacuum located in the Bulk Cleaning section of the Coater Station Hood. Adjusts and indicates the amount of air flow to the O.D. Cleaner Belt vacuum air transducer which adjusts the amount of vacuum suction. Adjusts and indicates the amount of air flow to the air transducer for the Front Armature Shaft vacuum located in the O.D. Cleaner station. Adjusts and indicates the amount of air flow to the air transducer for the rear Armature Shaft vacuum located in the O.D. Cleaner station. Adjusts and regulates the air pressure available to the Conveyor cleaners, O.D. Cleaner Belt & all Shaft Cleaners

31 Figure 3 Cleaning and Pneumatic Controls 7.2 CLEANING STATION PNEUMATIC CONTROLS (continued) CONVEYOR, O.D & SHAFT CLEANERS PRESSURE air pressure gauge I.R. DETECTOR ADJUST (20 SCFM) Indicates the air pressure available to the Conveyor cleaners, O.D. Cleaner Belt & all Shaft Cleaners. Adjusts and indicates the air flow available for air which continuously blows across the lens of the Infrared Temperature Detector to keep it clean

32 7.3 AIR KNIVES PNEUMATIC CONTROLS AIR KNIFE 1 FRONT ADJUST air flowmeter and control AIR KNIFE 1 REAR ADJUST air flowmeter and control AIR KNIFE 2 FRONT ADJUST air flowmeter and control AIR KNIFE 2 REAR ADJUST air flowmeter and control AIR KNIFE 3 FRONT ADJUST air flowmeter and control AIR KNIFE 4 FRONT ADJUST air flowmeter and control AIR KNIFE 4 REAR ADJUST air flowmeter and control AIR KNIFE 5 FRONT ADJUST air flowmeter and control AIR KNIFE 5 REAR ADJUST air flowmeter and control AIR KNIFE 6 FRONT ADJUST air flowmeter and control AIR KNIFE 6 REAR ADJUST air flowmeter and control AIR KNIFE #1-6 PRESSURE ADJUST air pressure regulator AIR KNIFE #1-6 PRESSURE air pressure gauge Adjusts and indicates the amount of air flow to the Air Knife #1 FRONT which is located in the Bulk Cleaning Section of the Coater Station Hood. Adjusts and indicates the amount of air flow to the Air Knife #1 REAR which is located in the Bulk Cleaning section of the Coater Station Hood. Adjusts and indicates the amount of air flow to Air Knife #2 FRONT which is located in the Bulk Cleaning section of the Coater Station Hood. Adjusts and indicates the amount of air flow to Air Knife #2 REAR which is located in the Bulk Cleaning section of the Coater Station Hood. Adjusts and indicates the amount of air flow to Air Knife #3 FRONT which is located in the Bulk Cleaning station. Adjusts and indicates the amount of air flow to Air Knife #4 FRONT which is located in the Bulk Cleaning station. Adjusts and indicates the amount of air flow to Air Knife #4 REAR which is located after the O.D. Cleaning station. Adjusts and indicates the amount of air flow to Air Knife #5 FRONT which is located in the O.D. Cleaning station. Adjusts and indicates the amount of air flow to Air Knife #5 REAR which is located in the O.D. Cleaning station. Adjusts and indicates the amount of air flow to Air Knife #6 FRONT which is located after the O.D. Cleaning station. Adjusts and indicates the amount of air flow to Air Knife #6 REAR which is located after the O.D. Cleaning station. Adjusts and regulates the air pressure available to the Air Knives #1 through 6. Indicates the air pressure available to the Air Knives #1 through

33 7.4 POWDER MANAGEMENT SYSTEM CONTROLS POWDER FILTER BLOWDOWN (55 psi min./ 100 psi max.) air pressure regulator POWDER MAN. SYS. FILTER (0-5 NORMAL READING) differential pressure gauge Adjusts and regulates the air pressure available for the automatic blowdown of the Powder Collector Cartridges. 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

34 Figure 4 Air Knives Pneumatic Controls Black & Decker, Easton, MD Serial # DATE 12/97

35 7.5 STEAM DEGREASER CONTROLS/INDICATORS INCOMING STEAM GATE VALVE (STM 1) STRAINER (STM 2) SEPARATOR REGULATOR (STM 18) STM. PREHEAT AIR SOLENOID (25 psi) STM. PREHEAT AIR SOLENOID (45 psi) HI TEMP VALVE INCOMING STEAM PRESSURE SWITCH (STM 13) PRESSURE GAUGE (STM 8) INCOMING STEAM TEMPERATURE. GAUGE (STM 14) Should be turned off if service is required to the system. Turns off incoming steam. The Degreaser will not operate if this valve is closed because there will not be enough pressure to trip the pressure switch. Removes foreign particles from the steam system Removes foreign particles from the steam. Reduces the incoming steam pressure. The steam pressure gauge after the regulator will read the required pressure First stage solenoid that feeds a small amount of steam through the Superheater and through the system. to pre-heat the system and to avoid pipe banging before the second stage solenoid Second stage solenoid that feeds steam and through the Superheater and through the system. Allows steam to go into the Superheater and throughout the system. Does not allow the Superheater to turn on without sufficient steam pressure. The steam pressure must be at least 30 psi for the system to operate and is indicated on the Pressure Gauge. NOTE: THIS SWITCH IS ADJUSTABLE, BUT SHOULD NEVER BE SET BELOW 30 PSI Indicates the pressure of incoming steam entering the Superheater. Should read approximately 50 psi Indicates the temperature of incoming steam. Should read approximately 300 F

36 INCOMING STEAM THERMOCOUPLE (TC #1) SUPERHEATER HEATING ELEMENT THERMOCOUPLES (TC #3-5) SUPERHEATER OUTLET STEAM THERMOCOUPLE (TC #2) SUPERHEATER STEAM TEMPERATURE GAUGE (STM 22) PRESSURE RELIEF VALVE (STM 18) HI TEMP VALVE AIR SOLENOID SUPERHEATED STEAM GLOBE VALVE SUPERHEATED STEAM PRESSURE GAUGE EMERGENCY STOP red pushbutton Provides a reading of the incoming steam temperature to show on the Degreaser Status Screen Provides a temperature reading of the Heating Element in the Superheater temperature to show on the Degreaser Status Screen. TC #3 - HTRS 1-3, TC #4 - HTRS 4-6, TC #5 HTRS 7-9 Superheats the steam to the required temperature. Provides a temperature reading of the superheated steam at the outlet of the Superheater to show on the Degreaser Status Screen Reads the temperature of steam coming out of the Superheater Factory 80 psi. The valve vents steam when excessive pressures are reached. Operates the main pneumatic HI TEMP VALVE. This allows superheated steam to go into the Degreaser Tank. Used primarily for maintenance. Also Allows throttling of the superheated steam. Indicates the pressure of the steam entering the Degreaser Tank. This gauge should read approximately 50psi. When Emergency Stop is pushed, the Superheater power will turn "OFF", the solenoids will close, the exhaust blower will stop, and any residual steam pressure will be exhausted through the Pressure Relief Valve

37 7.5.1 PRE-WASH STEAM SECTION GLOBE VALVE (STS 10) PRE-WASH WATER SECTION WATER HAMMER FLOWMETER INCOMING WATER PRESSURE SWITCH Used primarily for maintenance. Also controls the steam flow to the Pre-Wash Prevents hammering of air in the water supply. Reads the flow of water to the Pre-Wash. Does not allow the system to operate without sufficient water pressure. The water pressure must be at least 30 psi for the system to operate. NOTE: This switch is adjustable, but should never be set below 5 psi. BACK FLOW PREVENTOR SOLENOID VALVE GLOBE VALVE Prevents water or steam from getting into the water supply line. Allows water to enter the Pre-Wash system Regulates the water/steam mixture to the Pre- Wash. Adjusts the water flow of GPM

38 8 PREPARATION FOR OPERATION These instructions for installing, operating, and maintaining the Model 800 Coating Machine must be followed for safe and efficient operation. In particular, precautions should be most carefully observed whenever the unit is operated. Study this manual before installing or operating the equipment. Some voltages employed in this equipment are high. Remember that any source of voltage can be hazardous. 8.1 GENERAL Properly coated and cured parts are subject to several variables such as: size of part, conveyor speed, type of powder, ambient temperature and humidity conditions. Care must be taken at all times when setting up the Machine for a particular product under specific conditions in order to obtain the desired results. This section contains a general explanation of the adjustments that can be made. Once specific settings have been determined for each product, they should be charted and made a set-up requirement prior to a production run. 8.2 INITIAL SYSTEM INSTALLATION The following procedure should be used for the initial installation of the Coating System: 1. Uncrate all equipment from the shipping containers and crates. An inspection of the shipping containers should be made on delivery in accordance with Section Place the Main Machine in the desired location. 3. The Main Machine may have been shipped in two or three sections. These sections should be connected together with the bolts provided at one or both of the following points: at the Induction Heater Station/Cure Tunnel entrance (if two sections) plus at the Coating Station (if shipped in three sections). 4. Adjust the height of the entire system and level the system. 5. Locate peripheral equipment such as the Powder Management System, Regenerative Air Dryer, Induction Heater, Superheater and Cooling Blowers in proper places with respect to the Main Machine. Refer to the Layout Drawing of the system. Note that the Powder Collector Loading Station sight window and Rubber Gloves face the Induction Heater. Also, the Loading Door faces the rear of the Induction Heater. 6. Level all the peripheral equipment and make all necessary mechanical connections to attach peripheral equipment to the Main Machine. 7. Reconnect all wiring, piping, and hoses for electrical and pneumatic operation. All have been clearly marked numerically or alphabetically so that like numbers or letters will be connected together. All water piping for the Steam Degreaser has also been clearly marked for reconnection. NOTE: Some of the pipes may require connecting during the assembly operation. This is particularly true of the superheater plumbing and its exhaust

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