GTV Verschleißschutz GmbH Gewerbegebiet 57629 Luckenbach Tel. +49(0)2662/9576-0 Fax. + 49 (0) 2662 956-30 www.gtv-mbh.de office@gtv-mbh.de

Operators manual

HVOF GLC 720

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TABLE OF CONTENT

PAGE 1. DECLARATION OF CONFORMITY 4

2. DESCRIPTION 5 2.1. FRAME OF DELIVERY 5 2.2. HVOF PROCESS 5 3. SYMBOLS 7 4. HEALTH AND SAFETY 7 4.1 CHECKING FOR GAS LEAKS 8 4.2 SAFETY DEVICES 8 4.2.1 EMERGENCY STOP 8 5. PLANT INSTALLATION 9 GAS AND AIR PRESSURES 9 5.1 CONTROL PANEL (USER FUNCTIONS 9 5.2 START UP 10 5.2.1 START MENU 10 5.3 MENU „PROCESS “ 11

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TABLE OF CONTENT

PAGE 5.4 POWDER FEED RATE 12 5.5 MENU „SETUP“ 13 5.6 MENU „PROCESS GRAPHIC“ 14 5.7 SAVE;LOAD;DELETE A PROGRAM 15 5.8 RUN HVOF PROCESS 17 6. SERVICE AND MAINTENANCE 18 7. TROUBLE SHOUTING 18 Attachment 1: GLC Torch 19 Attachment 2: Powder feeder 21

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GTV Verschleißschutz GmbH Gewerbegebiet 57629 Luckenbach Tel. +49(0)2662/9576-0 Fax. + 49 (0) 2662 956-30 www.gtv-mbh.de office@gtv-mbh.de

EG- DECLARATION OF CONFORMITY

According to EG- Maschine Guideline 98/37/EG, Annex II A

EG-Guideline Electrical Magnetical Amicability 89/336/EWG EG- Guideline „Low Voltage“ 73/23/EWG

Machine: PLANT: HVOF COATING EQUIPMENT TYPE: MF-HVOF-GLC PRODUCTION DATE: May 2006 Project NO: IS DEVELOPED AND DESIGNED ACCORDING THE ABOVE MENTIONED NORMS IN FULL RESPONSIBILITY OF Incorporation:

GTV Verschleißschutz GmbH Gewerbegebiet, 57629 Luckenbach FOLLOWING STANDARDS:

• DIN EN 292 Safety of equipment, components and machine units • DIN EN 1050 Guidance for risk assessment • DIN EN 60204-1 Electrical setup for equipment and machines • VBG 61 Gases

THIS DECLARATION LOSE VALIDITY, IF CHANGES TO THE EQUIPMENT WILL BE DONE WITHOUT GTV AGREEMENT.

Luckenbach, 15.05.2006 Directoring Manager

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2. PLANT DESCRIPTION 2.1 FRAIM OF DELIVERY - 1 PIECE CONTROL BOX HVOF-GLC

- ELECTRICAL CONTROL PLC SIEMENS S7

- GAS MASSFLOW CONTROL BOX

- 1 PIECE HVOF GLC TORCH; SERIAL NO. (SPECIFIC MANUAL)

- 1 SET HOSES

- 1 PIECE POWDER FEEDER -PF-1/1 (SPECIFIC MANUAL)

Gas Control Box

Gas warning sensor Massflow controller

Powder Feeder

WINGAS Controller

PLC Box

HVOF GLC Torch

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Introduction HVOF HVOF Since it’s first application 20 years ago, High Velocity Oxygen Fuel (HVOF) spraying has

gained increasing importance in the thermal spray market.

The special feature on this technique, as compared to other TS techniques, is that the

coating material are less heated and with remarkably higher velocities impact on the

components which are to be coated.

In HVOF Systems a flame stream is formed by combustion under high pressure, resulting in

gas velocities of more than 2000 m/s. The spray powder is injected into this stream.

Physical Comparisation

Fuel Max. Flame-

temperature [C°]

Heat value [MJ/m3]

Oxygen/Fuel Ratio For a max. Temperature

Oxygen/Fuel Ratio for a neutral flame

Propane 2800 93 4,5 5,0 Hydrogen 2900 11 0,42 0,5 Ethen 3000 60 2,4 3,0 Acetylen 3160 60 1,5 2,5 Kerosene 2800 38 MJ/l 2,9 1) 3,4 1)

1) Mass mixture Oxygen /Kerosene

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3. SYMBOL DESCRIBTION

IM

4. HEALTH AND SA For operating equipment w

regulations specified by the

The operating area of the e

also serves as personal pr

Only authorized and

functions of the equ

trained personnel a

MAINTENANCE.

Before carrying out

guns the equipmen

for each componen

There must be no c

WARNING SIGN AS A POINTER FOR POSSIBLE DANGERS/HAZARDS !

PORTANT INFORMATION CONCERNING THE SYSTEM

FETY

here pressurized gases are present, the local laws and

Country are to be followed totally.

quipment must be protected by an acoustical enclosure which

otection against the movement of components.

trained personnel familiar with all specific

ipment are allowed to operate the system. Fully

re only allowed to carry out the SERVICE and

MAINTENANCE and SERVICE especially to the

t must be shut down by the main power switch

t.

urrent or voltage on the total equipment.

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4.1 CHECKING F Every system is che

But anyway for safe

spraying, using the

- Open all gas

- Note all inpu

them for two

- Is there a si

be found an

4.2 SAFETY DEV 4.2.1. EMERGENC For protection to pe

stop switch, which i

Gas warning dev A gas sensor is in

low quantities. In

and an error mess

Pb P(

Caution! Danger to life ! Operating the system is only allowed by closed door of the acoustical cabin !

Use always EYE-, EAR- and Respiratory Protection

Operating the HVOF torch manually with handle is allowed only with an emergency stop switch close to the operator !

OR GAS LEAKS

cked for gas leaks by GTV.

ty reasons a daily check is necessary. Please make a short check before

following procedures:

supply valves and close it again 15 sec. later.

t pressures at the pressure manometers and carefully monitor

minutes.

gnificant loss during this period there must be a leak which must

d sealed.

ICES

Y STOP

rsonnel and machines the control panel is equipped with an emergency

mmediately shuts down the system when depressed.

ice WINGAS

stalled in the gas control box, which detects gas concentrations in

case of a gas leak the warning unit gives a signal to the plc control

age appears on the screen.

lease read and understand the manual of the Wingas unit efore operation!

ress the “Reset Button” on the Wingas unit first after installation If the system was removed from Voltage) !

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5. PLANT INSTALLATION GAS AND AIR PRESSURES REQUIRED TO THE SYSTEM: OXYGEN: 145 PSI (10 BAR) NITROGEN: 87 PSI ( 6 BAR) PROPANE: 80 PSI (5-6 BAR) ATTENTION: AVOID LIQUID PHASE !NATURAL GAS: 100 PSI (7 BAR) AIR: 87 PSI ( 6 BAR)

5.1 CONTROL PA 1 Emergenc2 Light „Pilo3 Push Butt4 Light „Pro5 Push Butt6 Push Butt7 Push Butt8 Push Butt

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Liquid Propane or Propylen in the fuel gas line probably cause massflow controller problems! In adversarial cases the massflow controller is contaminated and has to be replaced by GTV, without warranty claim.

NEL (USER FUNCTIONS) y Stop t Flame“

on „Ignition“„ cess on“ on „Process Start“ on „Process Stop“ on „Powder Feeder Start on „Powder Feeder Stop“

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2 3 4

5 6 8 7

Preheating the Propane or Propylen lines and bottles will avoid liquefaction. Asked your gas supplier for help!

TP 170 Touch Screen

5.2 START UP

• Switch on the system with the main switch at the control box.

The Siemens screen shows the 5.2.1 „START MENU“

Select the language (English or German) Pushing the “Start” button the screen will change to the HVOF Menu

Press the “Reset Button” on the Wingas unit first after installation, if a gas warning message appears. (If the system was removed from Voltage) !

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5.3 MENU „Process“ (2. LEVEL) In that menu all parameters such as:

- Propane, Oxygen, Air, Powder feed rate (Disc Speed) are displayed

Change HVOF Parameter • Touch the button of your choice (Oxygen, Propane, Air (Luft), Dis

• A numerical pop up window appears

• Set the value with the numerical buttons

• confirm with „ENTER“

Mixer on/off

Disc speed feeder

c (Teller))

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5.4 Powder feed rate To set up the powder feed rate it is necessary to select the speed (RPM) of the feeder disc.

The powder feed rate is linear, means that for example 4 RPM gives the double feed rate of

2 RPM. The feeder disc speed can be choosed from 1 to10 RPM and depends on the

specific weight of the powder.

To support the flow of the powder, it is possible to switch on/off the mixer.

The powder gas has to be regulated manually at the hand wheel of the flow meter.

Flow meter

Place for spare canister

Caution! Danger to life!! Before lighting the HVOF Gun it is absolutely necessary to make sure that feeder gas flows. Otherwise an explosive gas mixture in the powder tank is possible. A bypass line will reduce the feeder gas volume to a minimum to avoid ignition problems. Leave the flow meter needle valve fully open during ignition and process!

Read and understand the manual of the powder feeder before operating the system.

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Entering Level 3 with the function keys Graphics or Setup 5.5 Menu „ Setup “ (3. Ebene)

In this menu it is possible to set up the parameters for Ignition and ramp up. Typical Startup Parameters: Fuel Gas: 10 – 15 SLPM

Oxygen: 35 – 45 SLPM

No Air!

Typical Ramp Parameters: Fuel Gas: 35 – 45 SLPM

Oxygen: 100 – 120 SLPM

Air 45 PSI

Ignition values depending on diffent conditions of the system as:

• hose length • nozzle condition • pressures • fuel gas

With the function Rezept/Recipe you will enter Level 4

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5.6 MENU „PROCESS GRAPHIC“ (3.LEVEL)

In this menu the Oxygen and fuel gas values of the HVOF process are shown in a graph

form, which gives the possibility of an uncomplicated process monitoring.

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5.7 SAVE; LOAD;DELETE A PROGRAM 5.7.1 RECIPE EDIT

5.7To

-

-

-

-

SAVE

.2 SAVE P save the par

Write a new

Touch the ri

The parame

Touch the s

DELETE

ROGRAM: ameters of the H

program name i

ght Transfer sym

ter of the HVOF

ymbol „SAVE“.

Transfer symbols

VOF Menu it is necessary to:

n the field „Data record name / Datensatzname“

bol

Menu are listed now.

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5.7.3 LOAD AN EXISTING PROGRAM - Touch the field „Data record name / Datensatzname “

- All existing programmes will be listed.

- Choose a program.

- Touch the left Transfer symbol

- The data’s were sent to the plc and shown in the HVOF Menu. 5.7.4 DELETE PROGRAM - Touch the field „Data record name“.

- All existing programmes will be listed.

- Choose a program.

- Touch the “DELETE” symbol

- A message „Delete? 0/yes 1/no “ will be shown on the screen.

- Push 0 to delete

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5.8 Start HVOF Process - Adjust all Parameters to your choice or choose an existing program according 5.7.3 - Push “START“ button at the operator panel. - Check the powder gas flow at the flow meter ! - Ignite the gun

(Don`t wait too long, because air cooling is missing) - Push “START“ button a second time and the process runs up. - Push „Start Powder feeder“ after achieving the process parameters. 5.8.1 Stop the HVOF process - Press button „STOP“ at the operator panel or at the gun handle. The HVOF process stops automatically. - Air blows for 30sec. to protect the torch 5.8 Gun handle functions

At the gun handle is a stop switch installed.

1. Switch: Process Stop

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6. SERVICE AND MAINTENANCE It is recommended to make a service and maintenance contract which includes a technical service once per year. In addition to a function and safety check, this service includes a calibrate of massflow controllers to ensure reproducible coatings can be produced at all times. Please keep the whole equipment clean. Remove dust and dirt every day. There is no regular service and maintenance necessary for the control panel. Check and clean the filter insert of the air circulation.

Service and maintenance of the Powder Feeder and the HVOF torch is described in their separate manuals. Please read and understand carefully.

7. TROUBLESHOUTING: Warning Triangle

Most of the possible errors will be shown on the screen. But however, if the operator confirms an error message without solving the cause, the message is not longer on the screen. Therefore a Warning triangle shows an outstanding problem.

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Spare Parts List GLC-Burner

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Item No. Name of Item

720.001 Air Cap Body

720.002 Siphon

720.003 Air Cap

720.006 Nozzle Nut

720.007P 720.007E

Nozzle Propane Nozzle Ethen

720.014 Siphon O-ring (4)

720.021 Burning Gas Coupling-Pin

720.022 Oxygen Coupling-Pin

720.023 Air Coupling-Pin

720.024 Powder Connector

720.025 Powder Connector O-ring

720.108 Nozzle O-ring, large

720.109 Nozzle O-ring, small

720.141 Main Body

720.145 Mount

720.146 Screw (2)

720.190 Handhold

720.200 Siphon Unit

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GTV Powder Feeder HVOF GLC

Table of content

1. DESCRIBTION

2. SYMBOL DESCRIBTION

3. HEALTH AND SAFETY

4. PREPARATION FOR FEEDING

5. CLEANING AND MAINTENANCE

5.1 EMPTY

6. PART LIST

A 1: Drawings

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1 Description The GTV Powder feeder produces accurate, repeatable powder feed rates. The feeder is designed for HVOF Thermal Spray Systems up to an operating pressure of 87 psi (6 bars). • Feeder gas pressure: 87 psi (6 bar) • Canister Capacity: 1.5 Liter The disk and mixer motor is controlled electronically by a Siemens S7 controller.

The adjustment of the feeding parameters will be done with the Operator Panel of the

HVOF unit. The gas flow has to be adjusted with the flow meter.

2 SYMBOL DESCRIBTION

Warning sign as a pointer for possible dangers/hazards

Important information concerning the system

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3 HEALTH AND SAFETY

Never use explosive gases for feeding ! Only Argon or Nitrogen are allowed!

Only authorised and trained personnel familiar with all specific functions of the

equipment are allowed to operate the system.

Fully trained personnel are only allowed to carry out SERVICE and

MAINTENANCE.

Read and understand the manual before using the system.

4 PREPARATION FOR FEEDING, START UP • Make sure that power and gas is connected.

• Remove the connector of the mixer and remove canister lid.

• Use a funnel to fill up the canister with the powder of your choice.

• Close the canister and plug in the connector of the mixer.

• Set up the parameters for:

• Disc (RPM)

• Mixer (RPM)

• Feeder gas

• Start the HVOF process.

• Start powder feeding at:

• The HVOF console.

• Or with the Start button at the gun handle.

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5. CLEANING AND MAINTENANCE 5.1 SAFETY STANDARDS FOR CLEANING AND MAINTENANCE The powder feeder 402.815 has less wear parts and needs therefor less

maintenance.

It is important to keep the whole system clean, remove dust every day after

operation.

Most powders are toxic. Cleaning the feeder accordance to the specific country safety standards concerning „working in toxic areas“ Read the material reminder of the powder and follow their safety instructions

Do not clean the area with compressed air. Use always a vacuum cleaner or soft brushes to remove dust and dirt.

Use always Eye- and Respiratory Protection !

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5.1 Empty powder canister

There are two way’s to empty the powder canister:

5.1.1

• Remove the powder hose from the torch and put it into the powder bottle.

• Make sure that powder feed gas is on.

• Set up maximum disk speed = 12 RPM.

• Start feeding the powder back to the powder bottle.

5.1.2

• Remove the mixer motor connector and the lid.

• Pull off the complete powder canister from the feeder.

• Empty the canister into the powder bottle (use a funnel).

• Remove the screws of the red ring.

• Pull of the plastic part from the base housing.

• Take off the rest powder with a soft brush or a vacuum cleaner.

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Attachment 2: PARTLIST

GTV Powder feeder Pos. GTV-

No. Description Recom.

1 402.511 Plug 2 402.530 Lid 2.1 402.602 Screw 3 402.508 Mixermotor 4 402.554 Lid 6 402.606 Woodruff wedge 7 402.607 Lock washer 8 402.608 Srew 9 402.524 Sealing 10 402.522 O-Ring 5 11 402.562 Screw 12 402.553 Filler plug 402.601 Clutch assy. 13 402.510 Clutch 14 402.614 Screw 15 402.615 Gear 17 402.617 Screw 16 402.559 Holder assy. 18 402.521 O-Ring 5 19 402.551 Tank 20 402.558 Bearing 21 402.552 Cone 21.1 402.621 Pin 22 402.610 Mixer 23 402.561 Tube 24 402.527 Funnel 25 402.520 O-Ring 2 26 402.626 Screw (14) 27 402.544 Cover ring 28 402.528 Holder for Exhauster 29 402.523 O-Ring 2

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30 402.550 Cover plate 31 402.566 Exhauster NL 3 33 402.565 Spreader NL 3 33 402.557 Exhauster L 3 31 402.556 Spreader L 3 402.580 31 Exhauster 601 33 Spreader 601 35 402.635 Screw 36 402.532 Disc shaft 37 402.533 Disc standard 1 38 39 402.517 Spring 40 402.519 O-Ring 5 41 402.526 Main housing 42 402.516 Sealing 44 402.513 Bearing 45 402.567 Spacer sleeve 46 402.569 O-Ring 2 47 402.529 Extension 48 402.648 Bearing 49 402.629 Locker ring 50 402.542 Shaft 51 402.651 Wedge 52 402.568 O-Ring 2 53 402.536 Sealing 54 402.543 Bearing lid 55 402.655 Screw 56 402.509 Clutch 56.1 402.656 Gear 57 402.564 O-Ring (Gas-Injector) 5 59 402.599 O-Ring kit (9 pcs) 2

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