TABLE OF CONTENTS · 2020. 9. 25. · serial #17121 i table of contents 1 introduction.....1 2 shipping ... 5 4.3 qualified personal

Electrostatic Technology, Inc Coating Bed with FlexiCoat™ Powder Management System

Serial #17121 i

TABLE OF CONTENTS

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

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

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

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

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

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

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

5.1 ELECTROSTATIC FLUIDIZED BED ........................................................................................................... 12 5.1.1 Air ........................................................................................................................................................... 12 5.1.2 Electrical ................................................................................................................................................ 12

5.2 REFRIGERANT AIR DRYER........................................................................................................................ 12 5.2.1 Air ........................................................................................................................................................... 12 5.2.2 Electrical ................................................................................................................................................ 12

6 DESCRIPTION OF COMPONENTS............................................................................................................... 13

6.1 ELECTROSTATIC FLUIDIZED BED ........................................................................................................... 13 6.1.1 Powder Level Sensor .............................................................................................................................. 13

6.2 REFRIGERANT AIR DRYER........................................................................................................................ 13 6.3 FLEXICOAT™ POWDER MANAGEMENT SYSTEM .............................................................................. 14

6.3.1 500 CFM Collector Module.................................................................................................................... 14 6.3.2 Proximity Level Sensors ......................................................................................................................... 14 6.3.3 Fluidizing Hopper................................................................................................................................... 14 6.3.4 Powder Fill Wand................................................................................................................................... 15

7 INSTALLATION................................................................................................................................................ 16

7.1 LOCATION ..................................................................................................................................................... 16 7.2 AIR CONNECTIONS...................................................................................................................................... 16 7.3 ELECTRICAL CONNECTION ...................................................................................................................... 17 7.4 VACUUM HOSES .......................................................................................................................................... 18 7.5 CONTROLS..................................................................................................................................................... 18

7.5.1 Settings.................................................................................................................................................... 18 7.6 POWDER LEVEL SENSOR........................................................................................................................... 18 7.7 POWDER MAINTENANCE........................................................................................................................... 19 7.8 REFRIGERANT AIR DRYER........................................................................................................................ 19

8 DESCRIPTION OF CONTROLS..................................................................................................................... 20

8.1 ELECTRICAL CONTROL PANEL................................................................................................................ 20 8.2 ELECTRICAL CONTROLS ........................................................................................................................... 20 8.3 COATING BED CONTROL PANEL ............................................................................................................. 21 8.4 COATING BED CONTROLS......................................................................................................................... 22 8.5 PNEUMATIC CONTROLS ON POWDER MANAGEMENT SYSTEM .............................................. 23


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9 START-UP AND OPERATION PROCEDURE.............................................................................................. 24

9.1 COATING STATION SET-UP ....................................................................................................................... 24 9.2 COATING OPERATION ................................................................................................................................ 25

10 SHUT-DOWN PROCEDURE ........................................................................................................................... 26

10.1 COATING & CLEANING OPERATION.................................................................................................. 26 10.2 RE-START PROCEDURE ......................................................................................................................... 26 10.3 EXTENDED SHUT-DOWN PROCEDURE.............................................................................................. 26

10.3.1 Coating & Cleaning................................................................................................................................ 26 10.3.2 Collector Module .................................................................................................................................... 27

10.4 POWDER/COLOR CHANGE.................................................................................................................... 27

11 TROUBLE SHOOTING .................................................................................................................................... 28

12 MAINTENANCE................................................................................................................................................ 31

12.1 GENERAL .................................................................................................................................................. 31 12.2 AIR SYSTEM ............................................................................................................................................. 31 12.3 COATING BED .......................................................................................................................................... 32

12.3.1 Porous Plate Replacement...................................................................................................................... 32 12.3.2 Powder Level Sensor .............................................................................................................................. 33

12.4 COLLECTOR MODULE ........................................................................................................................... 34 12.4.1 Fluidizing Hopper................................................................................................................................... 34 12.4.2 Porous Plate Replacement...................................................................................................................... 34

12.5 MAINTENANCE CAUTION..................................................................................................................... 35 12.5.1 Cartridge Filters..................................................................................................................................... 35 12.5.2 Final Filter ............................................................................................................................................. 35 12.5.3 Fan Motor............................................................................................................................................... 35

13 PATENTS ............................................................................................................................................................ 36

14 SPARE PARTS LIST ......................................................................................................................................... 37

15 FLOOR PLAN .................................................................................................................................................... 38

16 PNEUMATIC SCHEMATIC ............................................................................................................................ 38

17 ELECTRICAL DRAWING............................................................................................................................... 38

18 MANUFACTURER'S MANUALS ................................................................................................................... 38


Serial #17121 1

1 INTRODUCTION

This Instruction Manual must be studied and followed for the safe and efficient operation of the "Electrostatic Fluidized (Coating) Bed with FlexiCoat™ Powder Management System". Study this manual before locating and installing the equipment. ELECTROSTATIC TECHNOLOGY, INC. A SUBSIDIARY OF NORDSON CORPORATION 4 PIN OAK DRIVE BRANFORD, CT 06405 TELEPHONE: 203-488-8112 FAX: 203-483-8777 In future correspondence, please refer to the MODEL (Electrostatic Fluidized Coating Bed with FlexiCoat™ Powder Management System) and SERIAL NUMBER (17121) of the equipment.

2 SHIPPING Sometimes equipment can be damaged in transit. An inspection of the shipping crate should be

made upon delivery, and when equipment is removed, it should be carefully inspected to make sure the unit is in good condition. If the equipment is damaged, the carrier's claim agent should be requested to prepare a report, a copy of which should be sent to:

ELECTROSTATIC TECHNOLOGY, INC A SUBSIDIARY OF NORDSON CORPORATION 4 PIN OAK DRIVE BRANFORD, CT 06405 Electrostatic Technology, Inc will then advise concerning repairs and replacements.


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3 OPERATING PRINCIPLES

3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER


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3.2 PROCESS DESCRIPTION

Powder particles are aerated in a fluidizing chamber and are electrostatically charged by ionized air forced through a porous plate at the base of the chamber. As the powder particles become charged, they repel each other to such a degree that they rise above the chamber forming a cloud or veil of charged particles. When 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.


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4 GENERAL SAFETY

4.1 INTRODUCTION

This section contains general study instructions for using your Electrostatic Technology, Inc. (ETI) equipment. Task-and-equipment-specific warnings are included in other sections of this manual where appropriate. Note all warnings and follow all instructions carefully. Failure to do so may result in personal injury, death, or property damage.

To use this equipment safely:

• Read and become familiar with the general safety instructions provided in this section of the manual before installing, operating, maintaining, or repairing this equipment.

• Read and carefully follow the instructions given throughout this manual for

performing specific tasks and working with specific equipment. • Store this manual within easy reach of personnel installing, operating,

maintaining, or repairing this equipment. • Follow all applicable procedures required by your company, industry standards,

and government or regulatory agencies. Refer to the National Fire Protection Association (NFPA) standard 33 and to federal, state, regulatory agency, and local codes for rules and regulations covering installation and operation of powder coating systems.

• Obtain and read Material Safety Data Sheets (MSDS) for all materials used.


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4.2 SAFETY SYMBOLS

Become familiar with the safety symbols presented in this section. These symbols

will alert you to safety hazards and conditions that may result in personal injury, death, or property and equipment damage.

WARNING: Failure to observe this warning may result in personal in

personal injury, death, or equipment damage. WARNING: Risk of electrical shock. Failure to observe this warning

may result in personal injury, death, or equipment damage. WARNING: Disconnect equipment from line voltage. Failure to

observe this warning may result in personal injury, death, or equipment damage.

WARNING: Risk of explosion of fire. Fire, open flames and smoking

prohibited. WARNING Wear protective clothing, safety goggles, and approved

respiratory protection. Failure to observe may result in serious injury. WARNING: System or material pressurized. Release pressure. Failure

to observe this warning may result in serious injury of death. CAUTION: Failure to observe may result in equipment damage.

4.3 QUALIFIED PERSONAL

"Qualified Personnel" is defined here as individuals who thoroughly understand the equipment and its safe operation, maintenance, and repair. Qualified personnel are physically capable of performing the required tasks, familiar with all relevant safety rules and regulations, and have been trained to safely install, operate, maintain, and repair the equipment. It is the responsibility of the company operating the equipment to see that its personnel meet these requirements.


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4.4 INTENDED USE

WARNING: Use of this equipment in ways other than described in this manual

may result in personal injury, death, or property and equipment damage. Use this equipment only as described in this manual.

ETI cannot be responsible for injuries or damages resulting from nonstandard,

unintended applications of its equipment. This equipment is designed and intended only for the purpose described in this manual. Uses not described in this manual are considered unintended uses and may result in serious personal injury, death, or property damage. Unintended uses may result from taking the following actions:

• Making changes to equipment that have not been recommended or described in

this manual or using parts that are not genuine ETI replacement parts.

• Failure to make sure that auxiliary equipment complies with approval agency requirements, local codes, and all applicable safety standards.

• Using materials or auxiliary equipment that are inappropriate or incompatible

with your ETI equipment.

• Allowing unqualified personnel to perform any task.

4.5 INSTALLATION

Read the installation section of all system components manuals before installing your equipment. A thorough understanding of the system components and their requirements will help you install the system safely and efficiently.

• Allow only qualified personnel to install ETI and auxiliary equipment. • 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.


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4.5 INSTALLATION (continued)

• 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 conductive to ground and that the operator's platform is grounded.

• Use only designated lifting points or lugs to lift and move heavy equipment. Always

balance and block loads when lifting to prevent shifting. Lifting devices must be inspected, certified, and rated for a greater weight than the equipment being lifted.

• Protect components from damage, wear, and harsh environmental condition.

• Allow ample room for maintenance, material supply container drop-off and loading,

panel accessibility, and cover removal.

• If safety devices must be removed for installation, reinstall them immediately after the work is completed and check them for proper functioning.

4.6 OPERATION

Only qualified personnel, physically capable of operating the equipment and with no impairments to their judgement or reaction times, should operate this equipment. Read all component manuals before operating a powder coating system. A thorough understanding of all components and their operations will help you operate the system safely and efficiently.

• Use this equipment only in the environments for which it is rated. Do not

operate this equipment in humid, flammable, or explosive environments unless it has been rated for safe operation in these environments.

• Before starting this equipment, check all safety interlocks, fire detection systems,

and protective devices such as panels and covers. Make sure all devices are fully functional. Do not operate the system if these devices are not working properly. Do not deactivate or bypass automatic safety interlocks or locked-out electrical disconnects or pneumatic valves.


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4.6 OPERATION (continued)

• 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.

• 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.


Serial #17121 9

4.6 OPERATION (continued)

• 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 lead and cause injury.

4.7 LESS OBVIOUS DANGERS

Operators should also be aware of less obvious dangers in the workplace that often cannot be completely eliminated:

• Exposed surfaces on the equipment which may be hot or have sharp edges and

cannot be practically safeguarded.

• Electrical equipment which may remain energized for a period of time after the equipment has been shut off.

• Vapors and materials which may cause allergic reactions or other health

problems. • Automatic hydraulic, pneumatic, or mechanical equipment or parts that may

move without warning. • Unguarded, moving mechanical assemblies.

4.8 ACTION IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION

Do not operate a system that contains malfunctioning components. If a component

malfunctions, turn the system OFF immediately.

• Disconnect and lock out electrical power. Close and lock out hydraulic and pneumatic shutoff valves and relieve pressures.

• Allow only qualified personnel to make repairs. Repair or replace the

malfunctioning component.


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4.9 MAINTENANCE & REPAIR

Allow only qualified personnel to perform maintenance, troubleshooting, and repair tasks. • Always wear appropriate protective devices and use safety devices when

working on this equipment • Follow the recommended maintenance procedures in your equipment manuals. • Do not service or adjust any equipment unless another person trained in first

aid and CPR is present. • Use only genuine ETI replacement parts. Using unapproved parts or making

unapproved modifications to equipment may void agency approvals and create safety hazards.

• Disconnect, lock out, and tag electrical power at a disconnect or breaker in the service line ahead of electrical equipment before servicing. • Do not attempt to service electrical equipment if there is standing water

present. Do not service electrical equipment in a high-humidity environment. • Use tools with insulated handles when working with electrical equipment. • Do not attempt to service a moving piece of equipment. Shut off the

equipment and lock out power. Secure equipment to prevent uncontrolled movement.

• Relieve air pressures before servicing equipment. Follow the specific

instructions in this manual. • Make sure that the area or room where you are working is sufficiently

ventilated. • If a "power on" test is required, perform the test carefully and then shut off and

lock out power as soon as the test is over. • Connect all disconnected equipment ground cables and wires after servicing

the equipment. Ground all conductive equipment. • Check interlock systems periodically to ensure their effectiveness.


Serial #17121 11

4.9 MAINTENANCE & REPAIR (continued)

WARNING: Operating faulty electrostatic equipment is hazardous and can cause

electrocution, fire, or explosion. Make resistance checks part of your periodic maintenance program.

• Do not store flammable materials in the coating area or room. Keep

containers or flammable materials far enough away from the Coater to prevent their inclusion in a fire. If a fire or explosion occurs, flammable materials in the area will increase the chances and the extent of personal injuries and property damage.

• Practice good housekeeping procedures. Do not allow dust or powder

coatings to accumulate in the coating area or on electrical equipment. Read this information carefully and follow instruction.

4.10 DISPOSAL

Dispose of equipment and materials used in operation and cleaning according to your

local regulations.


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IMPORTANT: Provide a proper ground connection for the plugequipment ground wire. Polarity of the receptaclemust be according to code.

5 AIR AND ELECTRICAL REQUIREMENTS

5.1 ELECTROSTATIC FLUIDIZED BED

5.1.1 Air 30 scfm (0.85 m3/min) @ 80 psi (5.6 bar) minimum/100 psi (6.9 bar)

maximum is supplied for both the coating bed and FlexiCoat™ Powder Management System, however, actual usage by the coating bed will be lower. A ½ in. (12.7 mm) minimum air line should be connected between the Coalescent Filter (outlet side of the Refrigerant Air Dryer) and the Electrostatic Fluidized Bed.

5.1.2 Electrical

The coating bed operates at 110 Volts (transformed down from 380 volts, 50

hertz, 3-phase as supplied to the main control box mounted on the side of the FlexiCoat™ Powder Management System.

5.2 REFRIGERANT AIR DRYER

5.2.1 Air A Refrigerant Air Dryer capable of conditioning 30 scfm (0.85 m3/min) @ 80

psi (5.6 bar) minimum/100 psi (6.9 bar) maximum of clean air is required. Customer must connect a ½ in. (12.7 mm) air hose to the Particle Filter (inlet side of Refrigerant Air Dryer).

5.2.2 Electrical

240 Volts, 50 Hertz, 1-phase. Customer must plug the attached wire into the proper receptacle on the main control box mounted on the side of the FlexiCoat™ Powder Management System. Refer to the Refrigerant Air Dryer information in the Appendix of this manual.

IMPORTANT: Provide a proper ground connection for the plug equipment ground wire. Polarity of the receptacle must be according to code.


Serial #17121 13

6 DESCRIPTION OF COMPONENTS

6.1 ELECTROSTATIC FLUIDIZED BED The coating bed is complete with a Powder Level Sensor, Powder Feed Tube, High

Voltage Multiplier, Vibrator (to ensure proper fluidization), and cloud containing Hood. The coating chamber is of a patented design which insures that neither powder, substrate being processed, nor foreign objects can contact the charging media.

6.1.1 Powder Level Sensor

A powder level-sensing unit (Dwyer Photohelic® Gauge/Switch) monitors the

powder level to maintain an optimum level of powder in the coating bed to ensure coating repeatability and uniformity from part to part. As the powder level drops, the level sensor sends an electronic message to activate the Powder Pump Solenoid. The Powder Pump replenishes the powder into the Coating Bed. When the proper level is obtained, the Powder Pump shuts off.

The Powder Level Sensor consists of a control sensor and two inputs which read

the difference between the pressure at the powder level in the Coating Bed and atmospheric pressure outside the Coating Bed area. The range of the control sensor has been pre-set at the ETI factory and should not be touched or changed without consulting ETI personnel. The Photohelic® Gauge/Switch which indicates the pressure range is located on the right side of the remote coater pneumatic panel. When the Indicator needle comes in contact with the Left Set-Point Indicator, the Powder Pump goes "ON" and stays "ON" until the Indicator Needle comes in contact with the Right Set-Point Indicator, at which time it shuts "OFF", until the Indicator Needle makes contact with the Left Set-Point Indicator again. Refer to the Dwyer Photohelic® Gauge/Switch Section in the Appendix of this manual for more specific information on this unit.

NOTE: The range of the control sensor has been pre-set at the ETI factory and should not be touched or changed without consulting ETI personnel.

6.2 REFRIGERANT AIR DRYER A Refrigerant Air Dryer (with Particle and Coalescing Filter) is installed with the

Electrostatic Fluidized (Coating) Bed with FlexiCoat™ Powder Management System to ensure clean, dry (moisture free), oil free air is supplied to the system.


14 Serial 17121

6.3 FLEXICOAT™ POWDER MANAGEMENT SYSTEM

The FlexiCoat™ Powder Management System consists of the following:

6.3.1 500 CFM Collector Module

The 500 CFM Collector Module uses a 1 HP motor to drive the Exhaust Fan. The Exhaust Fan pulls air from Powder Application Hood (Canopy) and into the (2) Cartridge Filters. The air passes through the Cartridge Filters and is forced through the Final Filter. The clean, powder free air is returned to the surroundings. Excess powder (not adhering to the parts) is carried by the air flowing through the Hood to the Cartridge Filters, where it collects on the outer surfaces. When activated, the pulse valves force air from the Pulse Valve Air Manifold through the Cartridge Filter in the opposite direction of normal flow. The pulse airflow cleans accumulated powder from the Cartridge Filter media. The powder falls to the bottom of the Collector Module and into the storage container where it can be recovered and recycled or discarded. A Differential Pressure Gauge is located on the side of the Collector Module. This gauge provides an indication of cleanliness of the Filter Cartridges. A normal reading would be between 0 and 3.5. A reading above 3.5 would indicate the Filter Cartridges are not being cleaned well enough. This would require resetting the unit so the reverse cleaning pulses are more frequent and/or increasing the air pressure to the pulse circuit.

6.3.2 Proximity Level Sensors

There is a low level and high level proximity sensor. Each proximity sensor monitors the powder level inside the collector module and sends an electronic signal to the light bar located atop the collector. When the low level sensor does not see any powder, the red light will be blinking on/off. Once powder is added and the level reaches the high level proximity sensor the red light goes off and the amber light stays on. Eventually, when the powder level goes below the low level proximity sensor, the amber light turns off and the red light begins blinking on/off again.

6.3.3 Fluidizing Hopper

The Fluidizing Hopper is located at the bottom of the Collector Module. The powder is fluidized in this Hopper by dry air to remove any moisture from the powder. The powder is recycled by the Powder Pump(s). The pneumatically controlled Powder Pump(s) are mounted on the side of the Fluidizing Hopper. The Powder Pump(s) feed powder to the Coating Bed via flexible hose(s).


Serial #17121 15

6.3.4 Powder Fill Wand

The Powder Fill Wand is a hand-held device connected to the side of the FlexiCoat™ Powder Management System. It provides a method to vacuum fill/add powder to the Coating Bed. The assembly consists of a Nozzle, ON/OFF Control Lever, Air Pressure Regulator/Gauge and Hose. By placing the Nozzle in a bag/container of powder and squeezing the Lever, powder is sucked into the Collector Module. There are Level Sensors in the Collector Module to read the powder level at all times.


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7 INSTALLATION

These instructions for installing, operating and maintaining the Electrostatic Fluidized (Coating) Bed with FlexiCoat™ Powder Management System must be followed for its safe and efficient operation. In particular, precautions should be observed whenever the unit is operated. Study this manual before installing or operating equipment. Some voltages employed in this equipment are high. Remember that any source of voltage can be hazardous.

7.1 LOCATION

1. Place "FlexiCoat™ Powder Management System" and ancillary equipment

on a level surface at the desired location. Refer to Floor Plan Drawing in the Appendix of this manual.

2. Look over the entire Powder Management System and refer to the Customer Product Manual #303 867A (located in the Appendix) for installation information not specified in this manual. Although your machine may be shipped pre-assembled, please read through this manual before installing.

7.2 AIR CONNECTIONS

E.T.I. supplies the Poly-Flo tubing for all air connections. Refer to the Pneumatic Schematic in the Appendix of this manual. 1. Connect the Particle Filter to the inlet fitting of the Refrigerant Air Dryer.

NOTE: If Dry inert gas is used, consult the E.T.I. factory.

2. Connect the Coalescing Filter to the outlet fitting of the Refrigerant Air Dryer. 3. Connect the hose from the Coalescing Filter (on the outlet of the Refrigerant

Air Dryer) to the main air inlet fitting on the FlexiCoat™ Powder Management System.

4. Connect the hose from the “T” fitting on the FlexiCoat™ Powder

Management System to the Remote Coating Bed Pneumatic Panel.

5. Check that all pneumatic hoses are connected securely throughout the machine.

6. Connect ½” main air supply hose to the inlet of the Particle Filter (on the

Refrigerant Air Dryer).


Serial #17121 17

7.3 ELECTRICAL CONNECTION

Please refer to the Electrical Drawings included with this Operating Manual for information on proper electrical connections. 1. Connect the Electrical Panel to a true earth ground. 2. Connect the electrical cord from the Refrigerant Air Dryer to the receptacle

mounted on the Powder Management System Electrical Control Box.

3. Mount the remote Coating Bed Electrical Control enclosure in a preferred location. Connect wire leads from the enclosure to the following: Coating Bed Vibrator; Powder Management System Electrical Control Box; Coating Bed High Voltage Multiplier; Customer’s own On/Off Control.

IMPORTANT NOTE:

If the Customer wishes to connect his own On/Off Control, make the remote (external) mode electrical connections between the E.T.I. equipment and the Customer’s equipment. Refer to Electrical Schematic Drawing #C101957. Note that wires #7 and #8 are to be used as connections for Customer’s On/Off Control. If the Customer will not connect his own On/Off Control then wires #7 and #8 must be connected together in order for the E.T.I. equipment to operate.

4. Mount the remote Coating Bed Pneumatic Control Panel in a preferred location. Connect wire leads from the Pneumatic Control Panel to the Electrical Control enclosure.

5. Connect the Customer’s plant electrical supply of 380 volts, 50 hertz, 3-

phase to the Main Electrical Control Box mounted on the FlexiCoat™ Powder Management System.

CAUTION: ALL RECEPTACLES MUST HAVE A PROPER GROUND CONNECTION.


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7.4 VACUUM HOSES

E.T.I. supplies the flexible vacuum hose required. Refer to the Floor Plan Drawing in

the Appendix of this manual.

NOTE: The vacuum hose(s) can build up a static charge when the Powder Collector is "ON" and running. To prevent this static charge build-up, ground wires must be installed with the vacuum hose(s).

All vacuum hose connections must be grounded to equipment frame, metal surface to metal surface and must be checked for continuity. To do this: Connect a ground wire from the internal wire of the vacuum hose and the opposite end to a metal surface. Note: If the internal wire is not exposed, strip away the hose material to expose a 1” section of bare wire.

7.5 CONTROLS

7.5.1 Settings

1. Ensure that the pulse selector switch is in the “ON” position.

2. Turn “ON” the system electrical power and open the air supply shutoff valve.

3. Adjust the plant air supply to 80 – 100 psi (5.6 – 6.9 bar).

4. Adjust the Coating Bed air pressure to 45 psi (3 bar).

5. Adjust the Fluidizing Hopper air pressure to 10 psi (0.67 bar).

6. Adjust the Filter Pulser air pressure to approximately 40 psi (2.76 bar).

7. Press the Exhauster “START” push button.

7.6 POWDER LEVEL SENSOR

These instructions should be followed to achieve the optimum level in the Coating

Bed which has a Photohelic® Powder Level Sensor. Adjust the Level Sensor Probe (tube) approximately 1 inch above the Porous Plate

surface. Loosen the lock nut/fitting and slide the tube (up or down) to this position. DO NOT USE THE WHITE PLASTIC HOSE TO PULL THE TUBE, PULL BY


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THE CLEAR PLASTIC TUBE ITSELF (if the hose becomes damaged or improperly

sealed, the Level Sensor will become inoperable). The Powder Level Sensor will only indicate that there is sufficient powder in the

Coating Bed. When the powder level is below the bottom of the Level Sensor Probe, the Powder Pump will then activate.

7.7 POWDER MAINTENANCE

Most powders are hygroscopic. An attempt should be made to finish the day's run

with a minimum amount of powder left in the Collector Fluidizing Hopper. All powder containers (bags, barrels, hoppers, etc.) should be kept tightly closed.

NOTE: Do not mix different types of powder.

7.8 REFRIGERANT AIR DRYER

Plug the Refrigerant Air Dryer into the receptacle mounted on the Powder Management System Electrical Control Box. When Main Power is "ON", Refrigerant Air Dryer will operate.


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8 DESCRIPTION OF CONTROLS

8.1 ELECTRICAL CONTROL PANEL

8.2 ELECTRICAL CONTROLS

MAIN DISCONNECT ON/OFF Switch

Turns the System electrical power “ON/OFF”.

STOP Pushbutton

Shuts off the exhaust fan. Shuts off power to system electrical and pneumatic devices

EXAHUSTER #1 START Pushbutton

Turns on the exhaust fan. Turns on power to system electrical and pneumatic devices.

FILTER PULSER ON/OFF Switch

Activates automatic filter pulser (shake-down) sequence.


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8.3 COATING BED CONTROL PANEL


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8.4 COATING BED CONTROLS

COATER BED LEVEL SENSOR Photohelic Gauge

This Photohelic Gauge indicates set points for activation and deactivation of the Powder Feeder. This unit is factory set. If reset to raise or lower powder level, always maintain a spacing of 10 between indicators.

COATER BED FLUIDIZING ADJUST Flowmeter

Adjusts and indicates the amount of fluidizing air supplied to the coating bed.

FEED CHAMBER EXHAUST AIR PRESSURE Air Pressure Regulator & Gauge

Indicates and adjusts the amount of regulated air pressure supplied to the air pump located on the Feed Box exhaust outlet.

COATER FEED PUMP AIR PRESSURE Air Pressure Regulator & Gauge

Indicates and adjusts the amount of regulated air pressure supplied to the powder pump attached to the Fluidizing Hopper.

KILOVOLT Digital Meter

Indicates the voltage being supplied by the High Voltage Multiplier when the Footswitch is pressed.

HIGH VOLTAGE ADJUSTMENT Adjustable Potentiometer

Adjusts the output of the High Voltage Multiplier (0-80 kV)

VIBRATOR ADJUSTMENT Adjustable Potentiometer

Adjusts the intensity of vibration delivered to the Coating Bed. Generally, materials which fluidize well require no vibration assistance; vibration assistance is only required for materials which are hard to fluidize.


Serial #17121 23

8.5 PNEUMATIC CONTROLS ON POWDER MANAGEMENT SYSTEM

POWDER MANAGEMENT SYSTEM FILTER DIFFERENTIAL PRESSURE (1 – 3.5 Normal Reading) Magnahelic Gauge

Indicates the difference in pressure across the Powder Management System Filter Cartridges from the clean side to the dirty side which indicates the level of cleanliness of the filter cartridges. When the cartridges are dirty and should be replaced, the reading is above the normal reading level.

FILTER PULSER AIR ADJUSTMENT Air Pressure Regulator & Gauge

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

POWDER FILL HOSE AIR PRESSURE Air Pressure Regulator & Gauge

Adjusts and indicates the amount of regulated air pressure supplied to the hand-held Powder Fill Wand. Increased air pressure increases powder suction.

COLLECTOR HOPPER AIR PRESSURE Air Pressure Regulator & Gauge

Adjusts and indicates the amount of regulated air pressure supplied to the Fluidizing Hopper located at the bottom of the Collector Module.


24 Serial 17121

9 START-UP AND OPERATION PROCEDURE

9.1 COATING STATION SET-UP

Step 1 - Make sure the Refrigerant Air Dryer is plugged into the electrical supply and is “ON”. Wait 15 minutes for the High Temperature Warning Light on the Refrigerant Air Dryer to turn “OFF”. If there is no light, check to make sure the “ON/OFF” switch is set to the “ON” position.

Step 2 - Press the Exhauster “START” pushbutton, located on the electrical

box. Check the cartridge filter differential pressure gauge on the Collector Module. During normal operation, the pressure should remain under 3.5 inches water column. If the reading reaches 3.5 or higher, the cartridge filters are clogged and should be pulsed. If the differential pressure gauge still reads 3.5 or higher after pulsing, replace the cartridge filters.

Step 3 - Adjust the Pulser regulator for the Collector Module Pulse Valves to

approximately 60 psi (4 bar). Step 4 - Adjust the Powder Fill Hose regulator to approximately 40 psi (2.76

bar). Use the fill wand to add powder to the Collector Module. It will take approximately (3) bags (approximately 50 pounds each) of powder to reach a full level of powder. This is indicated by the light bar atop the Collector Module, the red light stops blinking and the amber light goes on.

Step 5 - Adjust the Fluidizing Hopper air pressure to 10 psi (0.67 bar). The

normal operation range is 5-15 psi (0.35 – 1.03 bar). Step 6 - Adjust the Coating Bed air pressure to 45 psi (3 bar). This

regulator/gauge is located on the Coating Bed Control Panel. Step 7 - Turn the High Voltage Control to zero. Step 8 - Adjust the Coating Bed flow adjust flowmeter to approximately 30%

of the meter capability. Step 9 - Adjust the Powder Pump air pressure to 10 psi (0.67 bar). The

normal operating range is 5-20 psi (0.35 – 1.38 bar). NOTE: The Coating Bed must be “ON”. Step 10 - Set the Coating Bed level sensor gauge so the left-set point needle

reads 20 Pa and the right-set needle reads 30 Pa. At this point, the Coating Bed level sensor will be signaling to the Powder Feed Pump, and powder will begin filling the Coating Bed. Raising the set-points will increase the powder level in the Coating Bed.


Serial #17121 25

9.2 COATING OPERATION

Step 1 - Adjust the Coating Bed Fluidizing Adjust if necessary. There should

be adequate fluidization of the powder in the Bed so a cloud forms.

Step 2 - Adjust the blastgates for the 1.5 inch vacuum duct located on the Hood of the Coating Bed. Slowly close the blastgates until the cloud drifts upward from the center of the Coating Bed with a minimum of turbulence.

Step 3 - Adjust Customer’s vacuum line located above the Coating Bed

opening so that the cloud is pulled upward with a minimum of turbulence.

Step 4 - Turn the High Voltage adjustment up to a starting point of 55 kV.

Step 5 - Repeat these steps as required to obtain a satisfactorily coated

substrate.


26 Serial 17121

10 SHUT-DOWN PROCEDURE

10.1 COATING & CLEANING OPERATION

Step 1 - Press the Exhauster STOP push button located on the electrical control panel.

NOTE: If the Refrigerant Air Dryer has been running and is shut "OFF" then re-started, you must wait 5 minutes before turning the unit back "ON" to allow the Refrigerant Air Dryer to equalize and prevent it from short cycling.

10.2 RE-START PROCEDURE When re-starting press the Exhauster START push button. High Voltage settings and

air settings should not need to be re-adjusted. They will remain set as before shutdown.

10.3 EXTENDED SHUT-DOWN PROCEDURE

When shutting the machine down for more than an overnight period, the following

should be noted:

When not in use, the coating material in the unit should be removed from the Couture Bed and Collector to prevent clogging of the Porous Plate. As most coating materials are hygroscopic, storage of the powder in the Powder Feeder for extended periods of time is not recommended. It is advisable that the powder be removed and stored in an airtight container. Observe the following procedure:

10.3.1 Coating & Cleaning

Step 1 - Turn the fan motor “ON”. Leave the pulse selector switch in the

“OFF” position. Step 2 - Clean the inside of the canopy with a rubber squeegee or other

grounded, nonmetallic device. Open the hinged baffle door and scrape the powder into the Collector Module.

Step 3 - Adjust the High Voltage Control to zero. Step 4 - Carefully vacuum the remaining powder from the Bed. Use a

shop vacuum with a soft plastic nozzle on the end of its hose or remove the hose from the top of the Coating Bed.


Serial #17121 27

10.3.1 Coating & Cleaning (continued)

Step 5 - Press the Exhauster STOP push button to shut off the fan motor. Step 6 - Turn the electrical panel’s disconnect switch to the “OFF”

position.

10.3.2 Collector Module

Step 1 - Turn the electrical panel’s disconnect switch to the “OFF” position.

Step 2 - Remove the hex head bolts and flat washers securing the Filter

Access Panel to the Collector Module. Remove the Filter Access Panel.

Step 3 - Clean the inside of the Collector Module with a rubber squeegee

or other grounded nonmetallic device. Remove the powder from the lower section of the Collector Module and Lower Fluidizing Hopper using a scoop or shop vacuum with a soft plastic nozzle on the end.

NOTE: It is not necessary to remove the Fluidizing Hopper unless changing

color or replacing the Fluidizing Hopper Porous Plate.

10.4 POWDER/COLOR CHANGE When changing powder from one color to another, it is very important that the

Coating Bed be thoroughly cleaned to prevent contamination. The same bed cleaning procedure as above should be used. Also, the Powder Collector cartridge should be changed if powder is being saved and re-used. It is also necessary to thoroughly clean the Powder Collector Hopper to avoid color contamination.


28 Serial 17121

11 TROUBLE SHOOTING

COATER-SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Coating Bed High Voltage control set too low.

Increase (turn knob) High Voltage control.

No High Voltage indicated to Coating Bed

DC Power Supply in control box is bad.

Contact your ETI representative for further instructions

High Voltage control is set too low.

Increase (turn knob) High Voltage control.

High Voltage Multiplier is bad. Replace Multiplier.

No or low coating

If cable is disconnected or loose. Check plug connection. NOTE: Do not twist Multiplier connection it will damage internal connections.

Air flowmeter control is set too low.

Increase air flow (turn knob) on flowmeter. Tighten screws of porous plate ring.

Air Leaking by gasket at porous plate.

Check gasket – replace if necessary.

Porous Plate is clogged. Install new porous plate. Air solenoid is not operating. Replace the defective solenoid. Particle Air filter is clogged. Replace the filter element. Air shut-off valve partially closed.

Check valve and open if required.

Insufficient air to fluidize power.

Ice blocking air lines. Repair or adjust Air Dryer (refer to manufacturer's maintenance information in appendix).

Moisture in Coater fluidizing air. Check analysis gauge on the Air Dryer-if applicable.

Refrigerant Air Dryer malfunctioning.

Refer to the maintenance (section 12.2) information of this manual.

Particle Air Filter is dirty. Replace filter element. Refer to the Spare Parts List of this manual for part number.

Coalescing Filter needs to be drained.

Drain Coalescing Filter and replace the filter element if damaged. Refer to the Spare Parts List of this manual for part number.

Coating powder is wet or damp.

Powder is hygroscopic and has absorbed moisture from the humid air around it.

Aerate powder in Coating Bed at low fluidization air setting for 20 minutes w/High Voltage turned "OFF".


Serial #17121 29

11 TROUBLE SHOOTING - continued

COATER-SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Substrate not properly grounded Faulty ground to substrate Check ground clip to substrate to

make sure it is secure or insure that the conveyor or tooling provides a good ground.

COLLECTOR - SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) No suction on Powder Collector. Powder Collector filter

cartridge(s) not being cleaned – infrequent filter cartridge blow-off.

Refer to the Powder Collector manufacturer's manual, located in the Appendix of this manual.

Cartridge filters clogged due to: Failure to pulse filters Pulse the filters several times. Inadequate pulse pressure Increase the manifold pressure to

60-90 psi (4.14-6.20 bar). Powder too fine or contaminated If using reclaimed powder,

reduce the ratio of reclaimed-to-virgin powder. Check powder particle size, if necessary.

Pulse valve malfunction The pulse valve diaphragm is ruptured. If you hear a hissing sound inside of the fan section, check for constant air flow from the valve. Replace the damaged valve.

Cross drafts Check for cross drafts across the booth face and correct as necessary.

Exhaust fan rotation reversed causing less vacuum generated by Powder Collector

Reverse the rotation of the motor by switching the wiring.

Powder escaping from Coating Bed opening


30 Serial 17121

11 TROUBLE SHOOTING - continued

COLLECTOR - SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Fuse(s) blown Check for the reason fuse(s) blew

and correct it. Replace the blown fuse(s).

Fan motor overload shutdown Correct one of the following possible motor, contactor, fuse or operational problem as needed: • Check the exhaust fan for

proper rotation direction. • Check for mechanical binding

of the motor/fan assembly. • Check for contact corrosion

at the motor starters (M108, M110, M112, or M114 in the electrical panel).

• Check the overload protectors for failure (OL108, OL112, or OL114 in the electrical panel).

System will not start

Incorrect, shorted, or open electrical wiring

Check the electrical circuits.

Cartridge pulsing will not start No air supply to pulse manifold Check the air supply.


Serial #17121 31

12 MAINTENANCE

12.1 GENERAL A systemic maintenance schedule should be set up and adhered to in order to insure

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

WARNING: ELECTRICAL VOLTAGE USED IN THIS EQUIPMENT CAN BE HAZARDOUS. MAINTENANCE SHOULD BE HANDLED BY QUALIFIED PERSONNEL.

12.2 AIR SYSTEM The importance of keeping the compressed air clean, dry and oil free cannot be over-

emphasized. More coating problems can be traced to failure to maintain the air filters and air dryers than any other cause. Consult manufacturer's maintenance sections in the Appendix of this manual.

Particle Air Filter – Clean and check for proper functioning. Change filter element

if it's dirty. Refrigerant Air Dryer – Once the Refrigerant Air Dryer is "ON" and operating,

after 15 minutes and periodically thereafter the following procedures should be implemented:

Step 1 - Make sure that the green "Power On" light is lit. Step 2 - Make sure that the indicator pointer is in the green area (normal

dew point temperature) and not in the red area (dew point temperature too high).

Step 3 - Make sure that condensate drains are draining; drains can very easily become clogged by oil or dirt. This will allow wet compressed air to enter the machine, resulting in a clogged porous plate in the Coating Bed and poor fluidization.

Coalescing Filter - Check and drain. Note that a wet filter element is normal. Air Line – The air line which enters the Coating Bed should be kept clean and free of

all particles, water, and oil.


32 Serial 17121

12.3 COATING BED

The screws holding down the retaining ring should be checked periodically for

tightness. Loose bolts may cause geysers of rising powder and non-uniform fluidization.

The Porous Plate is the key factor in controlling the powder cloud in the fluidic bed.

Under normal operation, the powder on the plate will be uniformly fluidized (lightly bubbling) over the entire surface of the plate. If the fluidization is not uniform, the Porous Plate has become clogged and will have to be replaced. The Porous Plate will require periodic replacement depending upon hours of use, contaminants in the compressed air, and conditions of operation and cleaning.

CAUTION: THE UNIFORM POROSITY OF THE POROUS PLATE IS VERY IMPORTANT TO PROPER COATING. DO NOT SCRAPE OR EVEN TOUCH IT WITH A HARD OR SHARP OBJECT. NEVER POINT AN AIR GUN DIRECTLY AT THE PLATE.

Clogging of the pores of the plate is the most common cause of failure. Once the

Porous Plate has been removed, inspect it to determine which of the following reasons caused clogging:

• Leaving powder unused in the bed for an extended period of time during humid

conditions.

• Oil or water in air supply system.

• Damage from scratching, gouging or denting the plate.

• Blowing compressed air directly at the surface of the plate.

• Correct the cause of plate failure and avoid conditions in the future which may have lead to it. Order a new Porous Plate and gasket material from ETI and carefully install.

12.3.1 Porous Plate Replacement

Step 1 - Turn the Coating Bed "OFF"

Step 2 - Unplug the Coating Bed from all electrical power sources.

Step 3 - Disconnect the air hose connection from the Level Sensor Tube. Step 4 - Disconnect the Powder Pump Hose from the Coating Bed Hood. Step 5 - Vacuum all the powder from the bed.


Serial #17121 33

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

12.3.1 Porous Plate Replacement (continued)

Step 6 - Remove the plastic hex head screws from the Coating Bed Hood

Flange and remove the Hood. Vacuum the remaining powder from the Coating Bed using a soft brush fitting or rubber nozzle on the end of a vacuum hose.

Step 7 - Remove the old Porous Plate and gasket material.

Step 8 - Use the old Porous Plate as a template for positioning and making

the mounting holes in the new Plate.

Step 9 - Clean electrostatic powder out of the charging media and off the charging media if required. Note that the Porous Plate retaining ring must not have been tightened down enough or that the gasket was worn or not seated properly if there is powder in the charging media chamber.

Step 10 - Place the new Porous Plate onto the flange in the fluidic chamber.

Place new gasket material around the outside edge of the plate and position the Porous Plate Retaining Ring. MAKE SURE TO INSTALL THE NEW POROUS PLATE WITH THE SMOOTH SIDE FACING UP.

Step 11 - Replace the plastic screws and tighten down evenly so that the

retaining ring is snug against the Porous Plate to prevent ionized air leakage around edges of the Porous Plate.

12.3.2 Powder Level Sensor

Make sure that powder is not packed inside the probe tube or it will affect

accurate sensing. Refer to the Dwyer (Photohelic Gauge) information included in the Appendix of this manual for specific maintenance instructions.


34 Serial 17121

12.4 COLLECTOR MODULE

Refer to Appendix of this manual for maintenance information on the Powder Collector.

12.4.1 Fluidizing Hopper

Under normal operation, powder inside the Powder Collector collects in the Lower Hopper where it is fluidized and pre-dried by a Porous Plate. This fluidizing powder can then be pumped from the Lower Hopper by the Powder Pump. The Porous Plate requires the same maintenance and care as the Coater Bed Porous Plate (Section 12.3). Powder should be emptied when there will be a powder type, color change, and/or extended shut-down of coating operation. This will ensure the Porous Plate inside the Lower Hopper will perform properly. Whenever the Lower Hopper is removed, use a soft plastic nozzle attachment and vacuum the Porous Plate. Inspect the Porous Plate and replace as necessary.

12.4.2 Porous Plate Replacement

Step 1 - Turn "OFF" the machine according to the shut-down procedure.

Step 2 - Turn main power disconnect “OFF”. Step 3 - Remove the Proximity Sensor and air line connected to the

Fluidizing Hopper and Powder Pump. Step 4 - Loosen the (4) hex head bolts positioned upside down close to the

base of the Collector Module. Step 5 - Push the Fluidizing Hopper so it slides out from the Collector

Module. Step 6 - Release the (4) latches holding the bottom half of the Fluidizing

Hopper. The Porous Plate will now be exposed. Step 7 - Loosen and remove the hex head bolts located around the outer

edges of the Porous Plate. Step 8 - Lift out the Porous Plate and replace it with a new Porous Plate. Step 9 - Re-Install the screws. Make sure the Porous Plate has gasket

material around the outer edges for proper sealing. Step 10 - Reverse Steps #3 to #7 to re-assemble the Fluidizing Hopper to

the Collector Module.


Serial #17121 35

12.5 MAINTENANCE CAUTION

WARNING ELECTRICAL VOLTAGE USED IN THIS EQUIPMENT CAN BE HAZARDOUS. MAINTENANCE SHOULD BE HANDLED BY QUALIFIED PERSONNEL.

12.5.1 Cartridge Filters

Inspect the cartridge filters for damage to the filter media or gaskets. Remove the Final Filter and inspect the Collector Module for powder leaks. If powder is leaking past the cartridge filter gaskets, tighten the wing nuts on the cartridge filters to compress the gaskets and stop the leaks. Replace the cartridge filters if necessary. Check the differential pressure gauge. Under normal operation, the pressure should remain under 3.5 inches water column. If the reading reaches 3.5 or higher, the cartridge filters are clogged and must be pulsed. If the differential pressure gauge still reads 3.5 or higher after pulsing, replace the cartridge filters.

12.5.2 Final Filter

Visually inspect the Final Filter whenever replacing the cartridge filters. Replace the Final Filter when it becomes clogged and negatively affects performance of the exhaust fan.

12.5.3 Fan Motor

Lubricate the fan motor bearings every six months with one of the following greases or equivalent grease. Clean the motor grease fittings and apply two full strokes from a grease gun to each fitting. Don not over-grease the fan motor. • Dolium R (Shell Oil Co.) • SRI #2 (Chevron USA, Inc.)


36 Serial 17121

13 PATENTS The Electrostatic Fluidized (Coating) Bed with FlexiCoat™ Powder Management System is

manufactured under one or more of the following United States Patents:

5,773,097

5,639,307 5,275,849

5,213,847 5,116,636

5,092,267 5,052,332

4,606,928 4,517,219

4,472,452 4,418,642

4,368,214 4,332,835

4,330,567 4,325,982

4,297,386 4,123,175

4,120,070 4,101,687

4,084,018 4,053,661

4,030,446 3,951,099

3,937,179 3,921,574

3,916,826 3,917,461

3,901,185 3,889,015

3,881,763 3,865,610

3,828,729 3,698,847


Serial #17121 37

14 SPARE PARTS LIST Refer to Nordson manual #303 867A, located in the Appendix, for additional information on Powder Management System Module.

PART DESCRIPTION ETI PART NO. ASSEMBLY QTY. RECM'D SPARE

PRICE EACH

Porous Plate, 17.5” x 13.5” x 3/16” 101903 Coating Bed 1 2

Gasket Material, ½ x 1/8 6513018 " 1 roll 1 roll Plastic Screws, 5/16-18 x 1 ½” Long " 32 50 High Voltage Multiplier 8000001 " 1 Particle Filter, Ultrafilter FF0004 Pneumatic 1

Particle Filter Replacement Element, Ultrafilter FF 03/05 " 1

Coalescing Filter, Ultrafilter MF0004 " 1

Coalescing Filter Replacement Element, Ultrafilter MF 03/05 " 1

Refrigerant Air Dryer Ultrafilter Buran #SD 0050-60 " 1

Air Pressure Regulator 3013004 " 5 Air Pressure Gauge 3013005 " 5 Solenoid Coil (Coater Bed and Collector Fluidizing Hopper) 3016011 " 2

Photohelic Gauge 3018005 " 1 Air Flowmeter 3018012 " 1

Cartridge Filter 7100017 Collector Module 2 2

Final Filter 7100041 " 1 1 Porous Plate, Fluidizing Hopper C50094-5002 " 1 1 Proximity Sensor, High & Low Type KIE, #KI3513, Efector " 2 1

Powder Pump #631-401, Nordson " 1

Powder Level Warning Light Bulb, 120 VAC #8WD4348-1XX, Siemens " 2 2

DC Power Supply 8000003 Electrical 1 1 3 ½ Digit Meter 5039006 " 1 1 Relay, Solid State #Z120D10, OPTO22 " 1 1

Fuse, 4A; #FNQR-4, Bussman " 2 4 Fuse, 6A; #FNQR-6, Bussman " 2 4 Fuse, 7A; #FNQR-7, Bussman " 1 2 Fuse, 8A; #FNM-8, Bussman " 1 2 Fuse, 6A; #LPJ-6SP, Bussman " 3 6


38 Serial 17121

15 FLOOR PLAN

See the Appendix for the Floor Plan Drawing # B101979.

16 PNEUMATIC SCHEMATIC See the Appendix for the Pneumatic Schematic Drawing # D101978. 17 ELECTRICAL DRAWING See the Appendix for Elementary Electrical Drawings. 18 MANUFACTURER'S MANUALS All of the Manufacturer's Manuals listed below can be found in the Appendix of this manual:

• Blower Motor (Baldor) • Coalescing Filter (Ultrafilter)

• Differential Pressure Gauge (Dwyer)

• 3 ½ Digit Meter (Texmate)

• FlexiCoat™ Powder Application System (ETI)

• Flowmeter (Dwyer)

• LOGO! Manual (Siemens)

• Particle Filter (Ultrafilter)

• Powder Level Sensor (Dwyer)

• Proximity Switch (Efector)

• Refrigerant Air Dryer (Ultrafilter)

• Solenoid Valve (Norgren)

• Vibrator (Syntron)

Documents

TABLE OF CONTENTS · 2020. 9. 25. · serial #17121 i table of contents 1 introduction.....1 2 shipping ... 5 4.3 qualified personal