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Sulzer Metco ECO ARC 600 Manual

Wire arc spray system
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ECO ARC 600
WIRE ARC SPRAY SYSTEM
Manual
NOTICE
All personnel reponsible for the proper and safe use of this equipment must read and
understand this instruction manual.
In addition, the operator of this equipment must receive personal instructions in its use.
A thorough understanding of the operation, maintenance, and safety requirements of
this equipment is essential.
© 2006 Sulzer Metco

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Summary of Contents for Sulzer Metco ECO ARC 600

  • Page 1 ECO ARC 600 WIRE ARC SPRAY SYSTEM Manual NOTICE All personnel reponsible for the proper and safe use of this equipment must read and understand this instruction manual. In addition, the operator of this equipment must receive personal instructions in its use.
  • Page 2 Manufacturer of this unit: Sulzer Metco OSU GmbH Weseler Str. 1 47169 Duisburg Telefon +49 203 54411-0 Telefax +49 203 54411-49 Sulzer Metco distribution: http://www.sulzermetco.com Protective note according to ISO 16016 The reproduction, distribution and utilization of this document as well as the communi- cation of its contents to others without explicit authorization is prohibited.

  • Page 3: Table Of Contents

    Contents General safety instructions Safety pictograms....................1 Operating and safety regulations...............3 Authorized use....................4 Unauthorized use ....................4 Measures concerning personnel and organization..........5 Ventilation and exhaust ..................6 Emissions, caused by the system ..............7 1.7.1 Metallic dust and fumes..................7 1.7.2 Spray jet, comprising molten metal particles and compressed atomizer air..8 1.7.3 Electric arc - UV radiation / Infrared radiation............9 1.7.4 Noise .......................10 1.7.5 Electrical energy ....................11...
  • Page 4 Energy supply....................3 3.2.1 Electrical supply....................3 3.2.2 Compressed air supply..................4 Installation of system Installation instructions ..................1 Installation schema....................2 Connecting hose package to power supply............2 Connecting power supply to plant mains............2 Installation of decoiling device................3 4.5.1 Hasp spool decoiling device ................3 4.5.2 Drum decoiling device ..................4 Important notes to follow: ..................4 4.6.1 Hasp / dorn spools.....................4 4.6.2 Drum decoiling device ..................4...
  • Page 5 8.2.1 Front and back side power supply..............10 8.2.2 Electrical system, pneumatics and control ............12 8.2.3 Wire feed drive Push 4 ..................16 Wearing parts recommended for stockkeeping ..........18 Appendix Recommended spray parameters for Sulzer Metco wire arc spray systems ..1 Circuit diagram ....................2...

  • Page 7: General Safety Instructions

    General Safety Instructions General safety instructions 1.1 Safety pictograms Attention! Special instructions, safety instructions, etc. Caution! Explosive material Caution! Hot surface Caution! Inflammable materials Danger! Risk of electric shock Caution! Magnetic fields from high currents can effect pacemaker operation Danger! Potentially dangers causing serious injury or death Attention! Additional information of general importance...
  • Page 8 General Safety Instructions Attention! Safety gloves must be worn Attention! Eye protection must be worn Attention! Safety overalls must be worn Caution! Moving parts (Risk of injury) Revision 1/10/08...

  • Page 9: Operating And Safety Regulations

    General Safety Instructions 1.2 Operating and safety regulations Thermal coating is a safe process. However, it is paramount that the operating crew is sufficiently familiar with the individual components, knows the safety regulations, and is competent in working with the system.

  • Page 10: Authorized Use

    - Use of wrong operation modes - Reconfiguration of control program - Installation of additional or alternative displaying and measuring devices without coordination with Sulzer Metco Spray device - Use of atomizer gas for cooling or cleaning any objects Spare parts...

  • Page 11: Measures Concerning Personnel And Organization

    Knowledge of hazardous materials • Appropriate handling of hazardous materials Sulzer Metco offers training courses, which provide both theoretical background and practical experience for safe operation of the system. This enables the operating crew to refuse following third party instructions not complying with the safety regulations.

  • Page 12: Ventilation And Exhaust

    General Safety Instructions 1.6 Ventilation and exhaust All thermal spray processes produce fumes and dust particles from the materials being sprayed. To avoid the effects of dust and fumes generated by spraying, a suitable spray booth and sufficient exhaust system are required. Proper installation, operation and maintenance are important for system performance and maintaining a safe working environment.

  • Page 13: Emissions, Caused By The System

    General Safety Instructions 1.7 Emissions, caused by the system 1.7.1 Metallic dust and fumes Caution! Metallic dust and fumes can be toxic and harmful to your health! • Use extraction and filtering! - Ensure extraction and filtering systems of adequate capacity. - Arrange extraction walls/hoods to promote the flow.

  • Page 14: Spray Jet, Comprising Molten Metal Particles And Compressed Atomizer Air

    General Safety Instructions 1.7.2 Spray jet, comprising molten metal particles and compressed atomizer air Caution! Risk of combustion and fire. • Do not direct at people. • Do not direct at combustible substances. • Remove combustible substances from the spraying area (room). •...

  • Page 15: Electric Arc - Uv Radiation / Infrared Radiation

    General Safety Instructions 1.7.3 Electric arc - UV radiation / Infrared radiation Caution! Danger to the eyes! • Inflammation of the cornea or conjunctivitis. (Flashing before the eyes) • Damage to the retina from infrared radiation! • The radiation is more harmful than over-exposure to the sun. •...

  • Page 16: Noise

    General Safety Instructions 1.7.4 Noise Caution! A high level of noise can lead to hearing damage! • The sound pressure level is 104 - 118 dB (A) measured at 1m from the electric arc. As the current and arc voltage increase, so does the noise level.

  • Page 17: Electrical Energy

    General Safety Instructions 1.7.5 Electrical energy Caution! Bodily contact with electricity can be fatal! • Magnetic fields from high currents can effect Pacemaker operation. • Electrical systems and equipment should only be set up, repaired or tested by an electrical engineer or under the supervision of one. •...

  • Page 18: Compressed Air Energy

    General Safety Instructions 1.7.6 Compressed air energy Caution! Compressed air can be a hazard if used carelessly. • Protect the eyes. Compressed air can carry solid matter that may cause injury. • It is prohibited to clean clothing being worn on the body with compressed air that is still at full pressure.

  • Page 19: Dust Combustion And Dust Explosion Hazard

    General Safety Instructions 1.7.7 Dust combustion and dust explosion hazard Caution! Proper protection from dust combustion and dust explosions is only possible with sufficient knowledge of the hazards and the measures to be taken to prevent these. • The safest method of protection is to prevent any accumulation of dust at the workplace and within the extraction system and also in the pipe system of the filter.

  • Page 20: Hot Surface

    General Safety Instructions 1.7.8 Hot surface Caution! While spraying radial nozzle nut can reach temperatures of 75° C (167° F). Do not touch! • Do not touch with bare hands • Risk of burning the skin • The temperature of the radial nozzle nut depends on: - Spray capacity - Length of spray process - Used wire material...

  • Page 21: Oily Compressed Air (Only At Systems With Air Motor)

    General Safety Instructions 1.7.11 Oily compressed air (only at systems with air motor) Caution! An incorrect setting of the oiler can lead to a danger of fire and explosion! • Oil mist emerging from the manual spraying apparatus can generate a combustible or explosive mixture. •...

  • Page 22: Other Instructions

    General Safety Instructions 1.8 Other instructions 1.8.1 Protective equipment, protective and work clothing Caution! Use of personal protective equipment is mandatory. Failure to use all or part of the PPE will necessarily result in damage to health. • EU Directive 89/656/EEC lays down the minimum rules on health and safety when an employee is using personal protective equipment at work.

  • Page 23: Solvents Used For Degreasing

    General Safety Instructions 1.8.3 Solvents used for degreasing Parts to be coated must be cleaned and degreased. This is not possible without hazards and is officially regulated. • Degreasing by means of high-temperature steam spraying is subject to the conditions of the waste water act. (Federal Water Act - WHG).

  • Page 24: Hazardous Materials

    General Safety Instructions 1.9 Hazardous materials All Sulzer Metco materials are supplied with a Material Safety Data Sheet. Never spray a material without reading and following the precautions contained in the Material Safety Data Sheet. Some Materials (e.g. beryllium, tellurium and their oxides) are very...
  • Page 25 General Safety Instructions Substance Formula MAC-value TRC-Value Hazards to health if MAC or TRC- (mg / m³) (mg / m³) values are exceeded Aluminum (as metal) 1,5 A Inhaling or swallowing may lead to Aluminum hydroxide Al(OH)3 coughing fit, shortness of breath and Aluminum oxide Al2O3 inflammation of the respiratory tract.
  • Page 26 General Safety Instructions Substance Formula MAC-value TRC-Value Hazards to health if MAC or TRC- (mg / m³) (mg / m³) values are exceeded Nickel as Nickel and virtually all nickel - Metal compounds are deemed carcinogenic. - Nickel carbonate Fumes and dust containing nickel can - Nickel oxide cause sensitization of the skin.

  • Page 27: Europe - Laws, Regulations, Standards And Directives

    General Safety Instructions 1.10 Europe - Laws, Regulations, Standards and Directives EC-Directives 89/391/EEC Council directive on the introduction of measures to encourage Issue 1989-06 improvements in the safety and health of workers at work 98/37/EC Council directive for alignment of statutory provisions and administrative Issue 1998-06 regulation of the member states for machines 95/63/EC...

  • Page 28: German Laws, Instructions, Standards And Directives

    General Safety Instructions 1.11 German Laws, Instructions, Standards and Directives Laws, Directions, Regulations and Directives BImSchG Federal law for the protection against emissions TA-Luft Technical Instruction - Air TA-Lärm Technical Instruction - Noise Federal water act ArbStoffV Hazardous working materials act ArbStättV Work places act Work places directive...
  • Page 29 General Safety Instructions DVS-Information sheets - Thermal Spraying DVS 2302 Corrosion protection of steel and cast iron materials by thermally sprayed Issue 2003-11 coatings in zinc and aluminum DVS 2303-1 Non-destructive testing of thermally sprayed coating; layer thickness Issue 2003-12 measurement DVS 2304 Quality assurance in thermal spraying...

  • Page 30: Din-Standards

    General Safety Instructions 1.12 DIN-Standards Thermal Spraying DIN EN 169 Personal eye protection - Filters for welding and related techniques - Issue 2003-02 Transmittance requirements and recommended use DIN EN ISO 14919 Thermal spraying - Wires, rods and cords for flame and arc spraying - Issue 2001-10 Classification;...
  • Page 31 General Safety Instructions other DIN-Standards DIN 1946 Ventilation and air conditioning, 7 parts DIN 14406-4 Portable fire extinguishers; Maintenance; information for application Issue 1986-08 DIN 40050-9 Degrees of protection (IP-code); protection against foreign objects; water Issue 1993-05 and contact; electrical equipment DIN EN 1127-1 Explosive atmospheres - Explosion prevention and protection - Issue 1997-10...

  • Page 32: Professional Insurance Association Accident Prevention Regulation

    General Safety Instructions 1.13 Professional Insurance Association Accident Prevention Regulation Regulations - VBG, BGV, BGI, BGR VBG 4 Electrical systems and equipment VBG 15 Welding, cutting and related methods VBG 16 Compressors VBG 101 Use of respiratory protective devices VBG 113 Protective measures when using carcinogenic working materials BGV A4 Industrial medicine precautions...
  • Page 33 General Safety Instructions Regulations - VBG, BGV, BGI, BGR BGR A3 Working on energized parts of electrical equipment BGR B11 Safety and health at work „electromagnetic fields“ BGR 104 Explosion protection guidelines BGR 109 Aluminum-dust-explosions BGR 117-1 Working in tanks and confined spaces BGR 121 Safety and health protection at work place with ventilation and exhaust BGR 133...

  • Page 34: Trgs - Technical Regulations On Hazardous Substances

    General Safety Instructions 1.14 TRGS - Technical Regulations on Hazardous Substances TRGS-Regulations TRGS 101 Technical Regulation on Hazardous Substances TRGS 402 Measuring and assessing the concentration of hazardous substances in the air in breathing areas TRGS 507 Surface treatment in rooms and tanks TRGS 900 AGW - Critical values at the workplace to source by:...

  • Page 35: System-Dependent Informations

    1x Spray device LD/U3 (with hose pakage) • 1x Wire feed drive Push 4 The Sulzer Metco OSU - wire arc spray unit is designed for coating work pieces of all kind with metal layer Sulzer Metco OSU GmbH has incorporated safety devices into the...

  • Page 36: Authorization Procedure

    The ECO ARC 600 wire arc spray system requires approval in accor- dance with Article 4 BlmSchG. It does not fall under the approval pro- cess of Article 10, however, but the simplified process according to Article 19.

  • Page 37: Transport And Positioning

    ECO ARC 600 2.2 Transport and Positioning 2.2.1 Transport • The power supply must be exposed to shocks or strong vibrations. • The power supply can be transported using a fork lift truck or by hoist / crane using suspension hooks and screwed-on lugs.

  • Page 38: Further Instructions

    ECO ARC 600 2.3 Further Instructions • Before starting work each day check that all safety measures and precautions for thermal spraying have been taken! • Check personal protective equipment each day before starting work! • Check the production parameters! •...

  • Page 39: Technical Data Und Energy Supply

    ECO ARC 600 Technical Data und energy supply 3.1 Technical Data Power supply ECO ARC 600 (without decoiling device) Weight 405 kg Dimensions 1450 x 690 x 1000 [mm] (LxWxH) Electrical connections 400 V / 50 - 60 Hz / < 38 A...
  • Page 40 ECO ARC 600 Hose package Weight Length Standard length 15,6 kg Spray capacity ECO ARC 600 max. melting capacity at 100% duty cycle • 60,0 kg / h • ZnAl15 53,0 kg / h • 18,0 kg / h •...

  • Page 41: Energy Supply

    ECO ARC 600 3.2 Energy supply Caution! Work on electrical systems and equipment should only be performed by a qualified electrician. 3.2.1 Electrical supply 4 - wire mains connection 3 Phases black, brown, grey 1 Earth yellow-green Mains voltage 400 V, 50 - 60 Hz Nominal current <...

  • Page 42: Compressed Air Supply

    ECO ARC 600 3.2.2 Compressed air supply Note • Conditioned, dry and oil-free compressed air is a condition for good quality of the sprayed coating. (in accordance with ISO 8573 Class 1). Caution! Max. compressed air supply of 10 bar •...

  • Page 43: Installation Of System

    ECO ARC 600 Installation of system 4.1 Installation instructions • Make sure that all energy connections are fixed properly Loose connections will lead to charring of cables! • Consider the preconditions for place of positioning. (see chapter 2) Revision 1/10/08...

  • Page 44: Installation Schema

    ECO ARC 600 4.2 Installation schema 2.2, 3.4 1.2, 3.2 1.3, 3.3 1.1, 3.1 4.3 Connecting hose package to power supply • Lay straight hose package without loops and bends. • Connect atomizer air hose (3.1) to coupling (1.1). •...

  • Page 45: Installation Of Decoiling Device

    ECO ARC 600 4.5 Installation of decoiling device The ECO ARC 600 can be operated with hasp spools decoiling device as well as drum decoiling device. 4.5.1 Hasp spool decoiling device • Take off caps from both screws located at the back (on top of power supply) and unscrew them.

  • Page 46: Drum Decoiling Device

    ECO ARC 600 4.5.2 Drum decoiling device • Assemble all components of drum decoiling device as shown below.. 4.6 Important notes to follow: 4.6.1 Hasp / dorn spools • The wire must be fed from the top of the spool into the wire guide tubes.
  • Page 47 ECO ARC 600 Revision 1/10/08...

  • Page 48: Operation Of System

    ECO ARC 600 Operation of system 5.1 Operating devices and indicators I> 14 13 ECO ARC 600 Arc Spray Unit Sulzer Metco Revision 1/10/08...
  • Page 49 ECO ARC 600 Pos. Description Function Permant = System ON Signal lamp white Blinking = Emergency stop Signal lamp green System ready Reset-button Signal lamp yellow Permanent = Error Overload Blinking = Error Temp. or Air Wire feed button Wire feed without spray voltage, without atomizing air...

  • Page 50: Setting-Up System

    ECO ARC 600 5.2 Setting-up system 5.2.1 Introducing spray wire • Put wire spool on its decoiling device. The wire must run off the spool from the top. Tighten spring breaks slightly so the spool is not running. Alternatively: Guide wire from drums over the deflection rollers.

  • Page 51: Starting The System

    ECO ARC 600 5.3 Starting the system Before you can operate the ECO ARC 600, please note the following: • Check level of oil in the oiler (13). The level has to comply with the marks at the oiler. For refilling push down the retainer at the oiler and take out the protective grid including the glass plunger.
  • Page 52 ECO ARC 600 • Caution! Atomizer air blows! Do not direct spray device at people. • After approx. 2 seconds spray process starts! • Set-up desired pressure of atomizing air. (s. Setting-up atomizing air pressure) • If the spray voltage has to be modified, first press the OFF-button (A) at the spray device, then use the spray voltage step switch (8).

  • Page 53: Setting-Up Spray Parameters

    The adhesive tensile strength of Al-coatings will be enhanced using higher voltage (step 5). 5.4.2 Setting-up spray capacity • The ECO ARC 600 is preset to a spray capacity of 600 A. • The wire feed speed is regulated accordingly. Wire feed speed <=> Spray capacity •...

  • Page 54: Changing Spray Capacity

    ECO ARC 600 • Coating smaller workpieces e.g. small profiles too much spray material is lost. In this case the amperage should be reduced to an adequate level. 5.4.3 Changing spray capacity • Turn regulation screw (C) at spray device, until throttle valve is half way opened.

  • Page 55: Setting-Up The Oiler

    ECO ARC 600 • Aluminum and aluminum alloys used as corrosion protection coa- tings should always be sprayed at the maximum voltage (step 5) and with the highest atomizer air pressure. These coatings are finer grained and more dense and have a higher anticorrosion value.

  • Page 56: Further Instructions

    ECO ARC 600 5.5 Further instructions • Before starting work each day check that all safety measures and precautions for thermal spraying have been taken. • Check personal protective equipment each day before starting work. • Check the production parameters.

  • Page 57: Troubleshooting

    ECO ARC 600 Troubleshooting This wire arc spray system is equiped with a PLC. The PLC is located behind the right panel of the power supply. The PLC has a small dis- play for status information and error messages. Anlage •...

  • Page 58: System Does Not Start

    ECO ARC 600 6.1 System does not start Indication Cause Remedy Three phase System is not switch ON Switch ON system with main current switch Three phase power supply of Check fuse in three phase system current supply system Wrong mains power supply...
  • Page 59 ECO ARC 600 Indication Cause Remedy Power supply Fuse Check fuses at the power supply. If red LED is shining fuse -F4 on -A10 is defective. Power supply Control cable towards spray Check control cable and Spray device device is faulty...

  • Page 60: System Does Not Start, System Cuts Out

    ECO ARC 600 6.2 System does not start, system cuts out Indication Cause Remedy Hose package Short-circuit between both Measure resistance (short- current-air-cables: circuit) between current-air- Insulation damaged cables Power supply - Turn main switch OFF System OFF - demount hose package...

  • Page 61: System Cuts Out

    ECO ARC 600 6.3 System cuts out Indication Cause Remedy Three phase Plug / connections are loose. Check plug / connections current Check mains power Wrong power / power failure Fuse Check fuse at three phase current power supply Three phase...
  • Page 62 ECO ARC 600 Indication Cause Remedy Power supply Build-up of heat Leave cooling air slot (in / out) blank Power supply covered. Switching OFF by tempera- Let cool down until green BLINKING ture sensitive switch. signal lamp lights. Convection cooling not insu- System OFF red.
  • Page 63 ECO ARC 600 Indication Cause Remedy Power supply Control transformer Only specialist staff is allo- wed to work at electrical appliances. Before opening the power supply pull out the mains plug! Check control transformer. Power supply Condenser for pre cleaned...
  • Page 64 ECO ARC 600 Indication Cause Remedy If the current in terminals Replace defective compo- System OFF X2:1 and X2.3 (measured nent between contact and wire) is Error Underload above 50 mA, transformer B10 is defective. If the cur- rent is below 50 mA, inter- face module A10 is defective.

  • Page 65: Spray Wires Are Not Pushed Forward, Not Melted Down, Electric Arc Breaks Off, Chatters

    ECO ARC 600 6.4 Spray wires are not pushed forward, not melted down, electric arc breaks off, chatters Indication Cause Remedy Power supply Power supply Only specialist staff is allo- One phase is missing wed to work at electrical appliances.
  • Page 66 ECO ARC 600 Indication Cause Remedy Push-gear No tension at pressure rolls Check wire pressure lever Wire feed rolls and pressure Power supply rolls must be pressed together. System OFF Error Underload Pressure rolls not smooth Clean and grease pressure running rolls;...

  • Page 67: Electric Arc Shuts Off, Spray Wires Not Feeding, Push Gear Running

    ECO ARC 600 6.5 Electric arc shuts off, spray wires not feeding, push gear running Indication Cause Remedy Power supply Solenoid valve defective. Spray device: (Comp. air - air motor) Push OFF-button. Unscrew compressed air hose of power supply. Spray device: Push ON-button.

  • Page 68: Electric Arc Cuts Out, Coarse Particles In Spray Coat, Spray Wires Feeding, Not Melted

    ECO ARC 600 6.6 Electric arc cuts out, coarse particles in spray coat, spray wires feeding, not melted Indication Cause Remedy Power supply Rectifier, transformer, or Only specialist staff is allo- main relays wed to work at electrical appliances. Check rectifier, transformer and main relays.

  • Page 69: Maintenance

    ECO ARC 600 Maintenance Legend: daily weekly monthly annual 7.1 Spray device LD/U3 7.1.1 Control intervals Check contact nozzles for wear and centre alignment. Rub gra- phite powder or contact grease on to the inside of the new con- tact nozzles.

  • Page 70: Changing Contact Nozzlesl

    ECO ARC 600 7.1.2 Changing contact nozzlesl 1.10 1.11 1.08 1.07 1.01.7 1.01.8 1.09 1.02 1.14 1.01.7 1.13 1.12 Removal • Unscrew the radial air nozzle nut (1.11). Remove gas nozzle (1.10). • Remove cover ring (1.09). • Slide atomizer nozzle (1.07) downwards.
  • Page 71 ECO ARC 600 Use only the slotted contact nozzles. Un-slotted contact nozzles pre- vent the sliding contacts from working. The atomizer nozzle (1.07) is positioned in a floating manner. With the air pressure that is applied upon start-up it is pushed forwards and it aligns itself automatically.

  • Page 72: Hose Package Ld/U3

    ECO ARC 600 7.2 Hose package LD/U3 Perform a visual external check for damage Wire guide tubes: Check wire for smooth running through the tubes. Therefore loose wire guide tubes. Replace wire guide tubes if you meet with resistance when pushing the wire. Treat new wire guide tubes inside with graphite powder.

  • Page 73: Filter (Back Side Power Supply)

    Grease Worm gear M0S2 Installation grease 1000 operating hours (Spray device LD/U3) Acheson „Molydag 49“ Sulzer Metco OSU air motor oil Air motor Oiler setting alternatively (Oiler at power supply) each 6 seconds 1 drop Esso „Pneumatic oil 32, 100“...
  • Page 74 ECO ARC 600 Revision 1/10/08...
  • Page 75 ECO ARC 600 Revision 1/10/08...

  • Page 76: Spare Part Lists

    ECO ARC 600 Spare part lists 8.1 Spray device LD/U3 8.1.1 Spray head LD/U3 (closed nozzle system) 1.7 1.1.6 1.10 1.9 1.11 1.1.7 1.1.1 1.14 1.13 1.12 1.1.5 1.1.7 1.1.2 Revision 1/10/08...
  • Page 77 ECO ARC 600 Pos. Description Article No. SAP-No. Spray head compl. LD/U3 13508002/1 1056580 1.1.1 O-Ring NBR 9x2.5mm 0304090250 1054409 1.1.2 O-Ring NBR 11x1.5mm 0304110150 1054417 1.1.5 Fillister head screw M4x35 DIN84 Zn 02000210435 1054707 1.1.6 Fillister head screw M4x40 DIN84 Zn...

  • Page 78: Gear Housing Ld/U3

    ECO ARC 600 8.1.2 Gear housing LD/U3 2.7.1 2.8.1 2.6.1 2.6.2 2.6.3 2.6.3 2.6.2 2.6.1 2.4.1 2.4.1 2.5.1 2.5.1 Pos. Description Article No. SAP-No. Housing compl. LD/U3 13508001 1053781 Wire line LD/U3 13408037 1053724 Current / gas connection LD/U3 13408035...

  • Page 79: Wire Feeding Ld/U3

    ECO ARC 600 8.1.3 Wire feeding LD/U3 3.1.1 3.1.1 Pos. Description Article No. SAP-No. Wire feeding LD/U3 13508005 1053783 Wire feed shaft LD/U3 13408013 1053713 3.1.1 Feather key 3x3x9 DIN6885 02022802 1053462 Worm wheel LD/U3 13408014 1053714 Circlip A10x1 02028...

  • Page 80: Wire Pressure Ld/U3

    ECO ARC 600 8.1.4 Wire pressure LD/U3 4.0.01 4.0.02 4.6.1 Gehäuseteil - links Gehäuseteil - rechts 4.4.2 4.4.2 4.4.1 4.4.1 4.1.2 4.1.1 Einschraubbolzen 4.3.1 4.3.1 Art.Nr.: 13408022/1 4.3.2 4.3.2 4.0.1 4.0.1 Schraubenkopf mit Isolierscheibe abdecken (in Bohrung einpressen) 4.2.1 4.2.1 4.2.2...

  • Page 81: Air Motor Ld/U3

    ECO ARC 600 8.1.5 Air motor LD/U3 5.3.3.1 5.3.2 5.3.3 5.3.4 5.3.1 Pos. Description Article No. SAP-No. Drive compl. LD/U3 13508009 1053784 Worm shaft LD/U3 13408015 1053715 Air motor MD-Z-5300 13213-20 1056093 Swivel connector. complete 13508012 1053786 5.3.1 Swivel connector R 1/4''...

  • Page 82: On / Off Swtich Ld/U3

    ECO ARC 600 8.1.6 ON / OFF swtich LD/U3 6.2.1 6.2.1 6.2.1 6.1.3 6.1.4 6.1.2 6.1.1 Totmann-Schalter Pos. Description Article No. SAP-No. On/off switch compl. LD/U3 13508010 1053785 6.1.1 Switch ''on''+''off'' 010004 1051957 6.1.2 Switch ''on''+''off'' 010004 1051957 6.1.3 Covering cap OFF (with nobe)

  • Page 83: Hose Package Ld/U3 (8 M)

    ECO ARC 600 8.1.7 Hose package LD/U3 (8 m) 15.1 (15.2) 15.1.1 15.1.2 (15.2.1) (15.2.2) Anschluß Anschluß Handspritzapparat Stromquelle 15.1.3 15.1.4 15.1.5 (15.2.3) (15.2.4) (15.2.5) Artikel-Nr. in Klammern ( ) = 8m Schlauchpaket Pos. Description Article No. SAP-No. 15.2 Cable and hose set 8 m...

  • Page 84: Power Supply

    ECO ARC 600 8.2 Power supply 8.2.1 Front and back side power supply -S3, -H3 -S2 1.18 1.18.1 1.17 1.16 1.15 1.14 1.13 Revision 1/10/08 8-10...
  • Page 85 ECO ARC 600 Pos. Description Article No. SAP-No. Current / air guide pin 134224 1052769 Insulating bush compl. 135222 1052811 Insulating disc 40x9 134223 1052768 1.13 Washer M16 DIN125 Ms 020008216 1053894 Tooth lock washer M16 DIN6798 AZ Zn 02005216...

  • Page 86: Electrical System, Pneumatics And Control

    -B10 Current sensor w. 400A-calibrat. checked 132010254 1061571 Frequency converter 0.25 kW / 1.5 A 01145/2 1055333 -L1.1 Throttle 350 A 010441 1052003 -L1.2 Three phase transformer ECO ARC 600 0104265 1052509 Rectifier 600 A 0105016 1052517 Revision 1/10/08 8-12...
  • Page 87 ECO ARC 600 2.10 Pos. Description Article No. SAP-No. 2.10 Pressure regulator (wire feed air) 030723 1052229 Pressure sensing switch 2.5 bar 1/4'' 030900 1052241 Solenoid valve 24V/50Hz (for atomizing air) 031011/24 1055557 Solenoid valve 24V/50Hz (for wire feeding air)
  • Page 88 ECO ARC 600 -F21; -F22; -F2.1; -F2.2; -D10 -F23 -A10 Revision 1/10/08 8-14...
  • Page 89 ECO ARC 600 Pos. Description Article No. SAP-No. -A10 Interface Module II 01015403 1053140 -D10 M3 Control and logic relay programmed CD 20 1064969 -F2.1 -F2.2 Fuse 5x20mm 2A M 0113519 1052677 -F2.3 Fuse 5x20mm 4A M (integrated on -A10)

  • Page 90: Wire Feed Drive Push 4

    ECO ARC 600 8.2.3 Wire feed drive Push 4 1.01 1.02 1.02 1.03 1.03 1.06 1.06 1.05 1.05 1.08 1.02 1.02 1.08 1.03 1.03 1.09 1.07 1.07 1.09 1.02 1.02 1.25.1 1.25.2 1.24 1.24 1.26 1.23 1.23 0304120100 0304120100 1.06 1.06...
  • Page 91 ECO ARC 600 Pos. Description Article No. SAP-No. Module Push4 (for ECO ARC 600) 1360410/540 1057045 1.01 Gear motor Push 4 12:1-lg. shaft 011601/100 1055346 (-M2) 1.02 Washer M6 DIN 125 Zn 020008106 1053877 1.03 Allen screw M6x20 DIN912 sw...

  • Page 92: Wearing Parts Recommended For Stockkeeping

    ECO ARC 600 8.3 Wearing parts recommended for stockkeeping Component / Description Article No. SAP-No. LD/U3 Slot contact nozzle Ø2.5 mm (for Zn, ZnAl15, AlMg5) 1340432/25 1056252 Contact nozzle Ø2.5 mm (for Al) 13401351/25 1056131 Gas nozzle Ø2.5 mm 1340434/25-2 1056257 Drive roll, knurled-prof., wire size 2.5 (for Zn, ZnAl15, AlMg5)

  • Page 93: Appendix

    ECO ARC 600 Appendix 9.1 Recommended spray parameters for Sulzer Metco wire arc spray systems Parameters for bond coat Parameters for top coat Wire Voltage [V] Air [bar] Voltage [V] Air [bar] OSU 001 18 - 20 3,0 - 5,0...

  • Page 94: Circuit Diagram

    ECO ARC 600 9.2 Circuit diagram Revision 1/10/08...

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