ALD8 ManualIncludes Design calculations, Installation, Anolyte flow calculations,

Current density calculations, and MaintenanceUsed in Conveyor and Hoist systems.

The ThinCell is a fully submersible- pressurized cell.

WWW.ANOLYTE-CELL-RESOURCES.COMSUPPORT AND CUSTOMER SERVICE:931-854-9383

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Thank you for purchasing the latest technology in electrocoating anolyte cells covering the world. The ThinCell is designed to be a maintenance free, plug & play and disposable chambered membrane anode. Usually without any system modifications.

ThinCells are rated at 10 amps/sqft of effective anode area.Please do not exceed this rating.

Anolyte inlet pressure not to exceed 6 PSI with paint tank full.

Please follow the instructions following to ensure a successful start up. Including the common trouble shooting guide, to assist that your cells perform

as designed.

Current Density:All anodes wear down depending on the current that is distributed off the electrically active area of the anode. This area is named the Effective Anode Area (EAA) The ThinCell uses 100% of the calculated Effective Anode Area (EAA). Tubular cells use up to 45% of the calculated EAA. Knowing this the ThinCell can operate at 10 amps/sqft vs. the Tubular cell which is rated at 5 amps/sqft.

HOW TO CALCULATE CURRENT DENSITY:First you must know the sqft of anode area of the ThinCell.

To do this we must look at the part # ALD8-A-B-C-x-SSA = the vertical length in inchesConstant width of effective = 8"And the type of return port (X)

EXAMPLE A: See page #4 for part number breakdown

ALD8-72-83-9-1-SS

Sqft of EAA= (72 x 8)/144(sq inches/sqf)t= 4 sqft

Alternative method 72” x 0.0556 = 4.00 sqft

Max current density per cell = 4 sqft/cell x 10 amps/sqft = 40 amps per cell.

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Number of cells required for painting:1) You will need the sqft of painted throughput per minute.

PTP = (jobs/hour) x (sqft/job) x (1 hr./60 min) x 2 Minutes dwell time

2) Then divide that number by 4. The common 4-1 Ratio from paint suppliers.

Thus, if your painting 240 sqft PTP / 4 sqft (4-1 RULE) = 60 sqft of anode area.

Using: ALD8-78-83-9-1-SS

Sqft of EAA= (78 x 8)/144= 4.4 sqft

60 sqft EAA required /4.4 sqft/cell = 13.6 cells rounded up to 14 ThinCells

Note: A Tubular cell would have 1.82 sqft of EAA and require 60/1.82= 34 cell to compete, using the same EAA. Keep in mind that membrane area does not weight in on any elecrocoating calculations and having more membrane than anode area does not improve the Tubular cells performance.

INSTALLATION FORMATS:There are 2 basic installation formats.1) Conveyor systems2) Hoist systems

CONVEYOR SYSTEMS:Anolyte supply and return specifications and connections.ThinCell Spacing requirements are located on page #9

1) Gravity return format:Typically, the anolyte solution return path is designed to be gravity feed. This means that the 1/2” or 5/8” return port(s) located on the top of the effective membrane chamber, are routed directly into a return manifold which feeds back to the anolyte circulation tank. This method typically requires a siphon breaker located at the apex of the return tubing arch (see drawing #SB3).ACR recommends that the tubing should be attached to the fitting using Herbie clamps, or Stainless-steel hose clamps.

The return port (1/2” or 5/8” polypropylene fitting) is located next to the power cable feed on the top of the cell. (See photos PAGE 10 later in this manual)

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The return tubing is recommended to be a flexible, reinforced, chemical resistant PVC variety. Use of standard flexible PVC tubing may kink or restrict the flow from the cell and is not recommended for use.

2) Anolyte supply:The 3/8” port (Polypropylene fitting) is located next to the left side frame rail. The anolyte supply is directed into this port.

*It is recommended that a flow meter with a control valve should be installed prior to the cell to regulate the flow to the cell and assist diagnosis, if trouble shooting is required to be performed.ACR manufactures a calibrated flow meter assembly. Part # FM1 (1 gpm max) or FM2 (2 gpm max) ordered separately.

The 3/8” supply tubing specifications are that the flexible supply tubing must be chemical resistant. It is up to the end user to determine if the need of a reinforced tubing is required. Typically, the requirements are to verify that the tubing does not kink or crush causing resistance in the flow.

Securing the tubing to the 3/8” inlet port (fitting) should be accomplished as the return port using Herbie clamps or a Stainless-steel hose clamp.

ANOLYTE FLOW SPECIFICATIONS:

Please calculate and follow the methods for the proper anolyte flow of the cell.Following are the equations and flow rates for the ThinCell.

1) The part numbers. This number is produced to allow a quick and understandable method of determining the important variables of ThinCell.

Part number ALD8-A-B-C-1-SS

ALD8 = Vertical 8” wide effective length (8”)

“A” = The vertical height of the effective length in inches.

“B” = The vertical height of the entire cell in inches.

“C” = The length of the power lead from the fitting frame in feet.

“1” = ½” single return port “2” = dual ½” return ports “3”= single 5/8” return port

“SS” = Stainless steel anode material

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Knowing this we can continue onto the anolyte cell effective area in square feet (sqft)

Example #1 ALD8-70-80-3-1-SS

Single ½” outlet portSqft will be 8” wide x 70” (A) length of the effective area vertically.(8” x 70”) = 560 square inches560sqin/144= 3.89 sqft3.89 sqft x 0.2 gpm/sqft (see below) = 0.78 gpm anolyte flow

Example #2 ALD8-70-80-3-1-SS

Single ½” outlet port70 (A) x 0.0556 = 3.89 sqft This is the quick method3.89 sqft x 0.2 gpm/sqft = 0.78 gpm anolyte flow

Example #3 ALD8-66-78-3-3-SS

5/8” return port66 (A) x 0.0556= 3.67 sqft3.67 sqft x 0.3 gpm/sqft= 1.01 gpm

ANOLYTE FLOW LIMITATIONS: CONVEYOR SYSTEMS

Gravity returns: 1/2" single return, -1 In the part#. Anolyte flow 0.2 gpm/sqft per sqft minimum calculated anode area. A siphon breaker is recommended at the apex of the return tubing to prevent siphoning. 0.4 gpm/sqft per sqft recommended peak flow

Dual 1/2" return, -2 In the part#. 0.3 gpm/sqft minimum gpm per sqft of calculated anode area. 0.6 gpm/sqft maximum gpm per sqft of calc anode area. A siphon breaker is recommended on all gravity return systems

5/8" return, -3 In the part#. 0.3 gpm/sqft minimum gpm per sqft of calculated anode area. 0.7 recommended maximum gpm per sqft of calc anode area.A siphon breaker is recommended on all gravity return systems.

Do not exceed 6 PSI anolyte supply pressure with paint tank full

Important note:

If the anolyte solution cascades over the vent tube of the siphon breaker, reduce the anolyte flow back to a flow volume that keeps the solution in the vent tube.

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2) HOIST SYSTEMS:ThinCell Spacing requirements are located on page #9

Hoist systems generally use an anolyte return design that incorporates long runs of return tubing. Inherently, this method produces a high level of back pressure to the anolyte chamber internally of the cell. It is utmost important that the proper anolyte flow is maintained. The connections a hoist system utilize are one 3/8” inlet port and one 1/2” outlet port.

*It is recommended that a flow meter with a control valve should be installed prior to the cell to regulate the flow to the cell and assist diagnosis, if trouble shooting is required to be performed.ACR manufactures a calibrated flow meter assembly. Part # FM1 (1 gpm max) or FM2 (2 gpm max) ordered separately.

1) Anolyte supply:The 3/8” chemically resistant PVC supply line can be split between two cells using one flow meter rated at the proper flow calibration scale to supply the flow rating of both cells without exceeding the flow meters scale. It is always better to use one flow meter per cell to allow an accurate distribution of the anolyte solution. A reinforced anolyte supply line will prevent the tubing crushing or kinking with weight of a bundle of supply and return tubing routed together.

2) Anolyte return:The ½” chemically resistant PVC return tubing is required for each ThinCell. This prevents cross contamination and ease of trouble shooting. The return tubing can be reinforced flexible PVC tubing to avoid crushing and kinking. If the return tube is restricted from crushing or kinks the internal pressure of the membrane chamber can exceed the limitations and damage the cell.

3) Anolyte inlet pressure not to exceed 8 PSI

ANOLYTE FLOW SPECIFICATIONS FOR A HOIST SYSTEM

TTX systems and other hoist systems, Maximum 6 PSI anolyte inlet pressure.Anolyte flow is rated at, 0.2 gpm minimum per sqft of calculated anode area. For 1/2" tubing runs up to 25' long and up to 3 feet of vertical.  0.25 gpm would be the recommended max required flow rate. These numbers are based on using a single 1/2" fitting for a pressurized return. No siphon breaker required.If longer return lengths are required, hold the anolyte flow to 0.2 gpm per sqft of EAA.

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Example # 4

ALD8-66-78-20-1-SS (refer to the previous part # break down on page 4 )

66” * 0.0556 in/sqft = 3.67sqft3.67sqft x 0.2 gpm/sqft = 0.7 gpm

Example #5

ALD8-58-68-20-SS Anolyte flow rate = 0.6 gpm

Quick Start ProcessPLEASE READ THESE IMPORTANT MESSAGES ABOUT YOUR NEW CELLS

Care has been taken in packaging your equipment, please look over the cells and inspect the units for damage. Call ACR if you need assistance 931-854-9383.

Remove the ThinCell units from the crate and lay on a clean flat surface. It is not recommended to stand the cells upright leaning against a structure. If the cell falls from its position it will typically damage the cell rendering the unit useless.

NOTE: All ThinCell anodes are factory tested prior to shipping. There is no need to leak test the ThinCell. Improper testing methods may damage the cell.

MOUNTING THE THINCELL:The ThinCell is designed to be fully Submersible. The paint level can cover the entire frame in which the fittings and electrical cable are located.

Cell Spacing;The ThinCell can be mounted side by side and against the wall for maximum performance that allows a greater capacity to produce painted product. The maximum separation between cells is 16” frame to frame. See page 9 for further information.

A photo simulation is located later in this manual Page 10.

1) Unistrut using strut nuts is the most common. Place the ¼” strut nuts into the channel about 9” apart.

2) Place the cell onto the studs and secure with stainless steel hardware.

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3) Route the supply and return tubing to avoid kinks and crushing of the tubing.

4) Secure the tubing as described above on Conveyor or Hoist systems.

POWER CABLE CONNECTION:1) Route the power cable to where it is to be terminated. Most cells have a #6-gauge wire to power the cell.

2) If required, cut the power lead to the length desired and terminate with a lug, Power pole connection, or any other suitable electrical connector rated at 75 amps or higher.

3) It is important to keep the termination in a dry location and not exposed to the anolyte solution or paint bath.

IMPORTANT MEMBRANE INSTRUCTIONSThese methods have been determined over 12 years of field study and allow for a trouble free start up.

Method 1. NEW TANK Start up

The membrane needs to wet out prior to exposing the cell to full hydrostatic pressure of the anolyte circulation system with the paint tank empty. This can be done by spraying the outside with DI water once the cell is installed on the side of the tank, then fill up the cell about 1/3 of the effective length prior to filling the paint bath, then once the bath is ½ full start the anolyte circ system using the flow meter calculations.

Method #2 REPLACEMENT CELL Start up

Use this replacement method once the paint tank has been in operation. Spray the cell with DI water fill ¼ with DI, let sit for 10 minutes to wick the membrane. Dump out the water and install into the full paint bath. Terminate the cells anolyte system and power cable.Fill up with anolyte solution at the proper flow rate calculated.

Method #3 DRAINING THE PAINT BATH

When draining the paint bath, SHUT OFF the anolyte circulation system first.Allow the anolyte solution to remain in the cells. The anolyte solution will keep the membrane wetted out. NOTE: you may notice some anolyte solution dripping from the cells. This is normal. A damaged cell will dump the anolyte solution out quickly and will need replaced or repaired using repair kit part# RK1. Instructions for the repair are included with the RK1 product.

Once the paint is returned to the tank, follow normal slow start of the anolyte system and adjust the flow meters to the calculated flow.

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SLOW START PROCESS FOR THE ANOLYTE SYSTEM

1) Once installed and paint is in the tank. Check the position of the flow valves and verify they are in the off position.

2) Bypass anolyte flow with the bypass valve by the pump, if equipped. Open bypass valve slightly to allow pressure to the flow meters.

3) Adjust 1 flow meter at a time the calculated value. You may have to increase the bypass position to gain more flow as flow meters are opened. Check balance to verify.

4) Check return lines for flow. It takes some time to fill the cells, verify return flow before continuing onto the next cell.

5) The flow meters may require an adjustment for more flow once running. A steady return stream of anolyte solution is required for proper flow. Do not exceed maximum flow to cells without consulting ACR.

4) Start production.

Review of installation:

SPACING OF CELLS: The Thincell can be placed as close as side by side with 0” clearance, up to 16” frame to frame. Mounting against the wall is allowed

CELL PLACEMENT:Hoist: Every corner of the tank should have at least one ThinCell per side, then evenly spaced.Conveyor: After full immersion of part, start installation of the first ThinCell a minimum 3 feet from this point (dead zone). The front of the tank then receives at least 2 Thincells per side mounted side by side and at least 2 Thincells side by side at the rear typically at the same dead zone spacing of 3 feet minimum as above with the part fully removed as the point. The remaining cells evenly spaced.

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PICTORAL INSTALL PROCESSPlease Note other methods may be used to install the ThinCell into your system. This instruction

portion is just to aid into the basic strut installation methods and the cells anolyte and power terminations. Your installation may vary.

1) Install Strut nuts. They are placed 9” on center.

Insert strut nut into channel. Rotate the nut 90 degrees clockwise.

Your installation method may use Strut studs instead of Strut nuts. The process is the same basically.

Measure 9” from stud #1 and repeat installation with nut #2

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The following pictures are for instruction only. Cell in the Photos is a demonstration prototype. The cell that is purchased is cosmetically different.

Remember to wet out the cell prior to installingHanging the ThinCell

.

Hold the cell and install the ¼” bolt assembly through the cell and into the strut nut.

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Repeat with the #2 bolt assembly into the #2 nut.

Install Anolyte supply tubing.

Install Anolyte return tubing.Some ALD Series will have (2) ½” or (1) 5/8”return port(s) connect in the same

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manner.

Attach Power.Shown with optional 75 amp quick disconnects.

Installation complete…..

START UP REVIEWOnce installed and wetted out properly with paint is in the tank to full level. Check the position of the flow valves and verify they are in the off position. Bypass anolyte flow with the bypass valve by the pump. Open bypass valve slightly to allow pressure to the flow meters. Start the pump and adjust 1 flow meter at a time to calculated gpm. You may have to increase the bypass position to gain more flow as flow meters are opened. Check balance to verify calculated gpm per cell. Check return lines for flow. It takes some time to fill the cells, verify return flow before continuing onto the next cell. DO NOT OVER PRESSURIZE THE CELL. Adjust all the flow meters until you have a good steady flow through the return line. No pulsing (conveyor systems) of solution should be seen.

MAXIMUM CALCULATED FLOW RATE SHOULD NOT BE EXCEEDED.DO NOT OPERATE ANOLYTE INLET PRESSURE OVER 6 PSI WITH PAINT TANK FULL..IF YOU EXPERIENCE WHAT APPEARS TO BE SURGING OR PULSING OF THE RETURN SOLUTION CALL ACR. With a gravity return system, a siphon breaker is required to solve this issue. SEE PAGE 16

If you don’t see any solution returning from the return line, check the return line for kinks. Check the supply line for kinks.

The Thincell will take up to 2 minutes to fill do not rush this process.

Periodically check the flow meters and return lines for flow and color.Normal anolyte solution color is a mild yellow.

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If you noticed a darkening of the solution it is the color of paint and the cell should be isolated, by closing of the flow meter to keep from contaminating the anolyte system and the other cells. Then removed for inspection.

If the color is a tea to coffee color an over current density issue is present or insufficient anolyte flow This requires further investigation to determine if there is a dead cell in the tank, causing the current draw to another cell and pushing the current density too high for that cell. An improper flow meter adjustment, not enough calculated flow or not enough anode area present.

Maintenance:Once cells are in and operation, there is no need for maintenance except checking the anolyte circulation flows and color of the solution. A clear to slight yellow color is normal. Color changes to a tea or coffee color indicates poor anolyte flow, which should be increased to spec, or other previously mentioned issues. Paint colored solution indicates a leak in the cell and the cell requires replacement.

The cells are designed to operate until the anode is dissolved. If your system has a current monitoring system this will indicate 0 amps. The other cells will take up the load until a replacement arrives. Replacement units should be installed as soon as possible to relieve the load to the other cells. Do not exceed 10 amps/sqft of effective anode area. This will lower the life span and blind the membranes quickly.

Anode wear can be determined by pressing on the clear back of the cell. A sense of the anode flexing under finger pressure is a sign that the anode has dissolved about 2/3rds of the original thickness. Calculated from the install date and dividing by 3 for the given months will provide an estimated date of replacement.

If liquid is detected in the visible clear back space it is also time to think of replacing the cell within a month or so.

All cells are warranted for 2 year from date of installation. ACR warrants against defects in workmanship and materials. Labor, down time or other expenses are not covered under any warranty. The defective unit may be requested to be returned to ACR for examination at the end users’ expense with a RGA number, provided by ACR. If the unit is covered under our guidelines ACR will ship a repaired or replacement unit out in a timely manner. A purchase order may be required to repair, replace, and ship a unit to the end user, if warranty is not applicable. The end user must be in good standings with ACR accounting dept for warranty coverage to apply. Anode wear is not covered under any warranties. Please see the attached warranty sheet for further warranty information.

Contact us at:ACR217 Hub CircleCookeville, TN. 38506Phone 931-854-9383

www.anolyte-cell-resources.com

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TROUBLE SHOOTING

The Thincell is a high performance and high efficiency anolyte cell. Proper start up will insure a long life. However, if you are experiencing an issue please review the following.

Anolyte return issues:No solution returning through the return tubing: 1) Verify anolyte flow through flow meter and adjust to the calculated flow

a) On a start-up it will take up to 2 minutes to fill the cellb) Verify the flow- cell could be ruptured remove and inspect.

2) Verify that return line is not kinkeda) remove cell and inspect.

3) Verify paint level, has it risen.a) If paint level rises the cell is ruptured. Replace unit.

Anolyte solution looks as if it is surging in the tubing.1) Anolyte flow requires a siphon breaker. Do not exceed calculated GPM during this

adjustment.2) The anolyte solution will not completely fill the return tubing. Verify that the flow is at

calculated GPM. A little bubbling is normal from the electrolysis process internal of the cell.

3) Flow calculations (effective length(A) x 0.0556) = Cells sqft of anode area.

4) Surging is when the anolyte return path has a drop that will allow siphoning from the cell. You will see the tubing fill completely with solution, then the tube will be full of air, then back to full of solution. Install a siphon breaker to eliminate this issue. Surging will suck the anolyte solution out of the cell and will damage the cell as the membrane get too close to the anode.

5) You are recommended to call ACR if you believe you have surging, we will assist you in verifying system compliance prior to permitting higher flow rates.

Testing an ALD8 Model cell:

1) Remove the suspect cell from the Ecoat tank in the normal fashion.2) Hold cell upside down vertically to drain the contents of the cell’s anolyte chamber.

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3) Use a small 2x4x12” block of wood or like to elevate the top portion of the cell about 2” off the ground. The bottom of the cell is on the floor.

4) Connect the 3/8” anolyte supply to a regulated DI water source.5) Connect the ½” or 5/8" return line so that it drains away from the cell. 6) Supply the cell 0.5 gpm7) If no leaks are found the cell is OK for service. Allow to drain and return to tank.8) If a cell has a bad a leak, it will appear under this test and will be visually observed.

Note: The membrane will allow a small amount of beading up on the exterior. This is referred to as sweating and should not be confused as a leak. A leak will flow out quickly. Over time the outside will naturally become wet. A leak test should only require 30 seconds or so to evaluate.

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DRAWING SB3

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THINCELL SPEC SHEET

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