Electrostatic Technology MR240 Manual

Coating system

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Electrostatic Technology, Inc.

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

SHIPPING............................................................................................................................... 1

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

3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER .................................. 2

3.2 PROCESS DESCRIPTION ................................................................................................ 3

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

4.1 INTRODUCTION .............................................................................................................. 4

4.2 SAFETY SYMBOLS.......................................................................................................... 5

4.3 QUALIFIED PERSONNEL ............................................................................................... 6

4.4 INTENDED USE................................................................................................................ 6

4.5 INSTALLATION ............................................................................................................... 6

4.6 OPERATION...................................................................................................................... 8

4.7 LESS OBVIOUS DANGERS............................................................................................. 9

4.8 ACTION IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION ...... 10

4.9 MAINTENANCE & REPAIR.......................................................................................... 10

4.10

DISPOSAL ................................................................................................................... 11

AIR, ELECTRICAL AND WATER REQUIREMENTS .................................................... 12

5.1 POWDER COATING MACHINE ................................................................................... 12

5.1.1 Air ............................................................................................................................. 12

5.1.2 Electrical ................................................................................................................... 12

5.1.3 Water......................................................................................................................... 12

5.1.3.1 Closed Loop Induction Heater and Induction Heater Cooling System................. 12

5.1.3.2 Deionized Water Requirements: ........................................................................... 12

5.2 INDUCTION HEATER.................................................................................................... 12

MECHANICAL FUNCTION: SEQUENCE & DESCRIPTION........................................ 13

6.1 LOAD STATION ............................................................................................................. 13

6.2 COATING STATION ...................................................................................................... 13

6.3 O.D. CLEANING STATION ........................................................................................... 14

6.4 I.D. CLEANING STATION............................................................................................. 14

6.5 INDUCTION HEATING STATION ............................................................................... 14

6.6 CURE TRANSFER STATION ........................................................................................ 15

6.7 TIP CLEANING STATION ............................................................................................. 15

6.8 POWDER MANAGEMENT SYSTEM ........................................................................... 15

6.9 REFRIGERANT AIR DRYER......................................................................................... 16

6.10

DEIONIZED WATER SYSTEM ................................................................................. 16

6.11

CURE OVEN/FINAL COOL CONVEYOR SYSTEM ............................................... 16

DESCRIPTION OF CONTROLS ........................................................................................ 17

7.1 MAIN CONTROL CABINET.......................................................................................... 17

7.1.1 Electrical Control ...................................................................................................... 17

7.2 OPERATOR CONTROL PANEL.................................................................................... 17

7.2.1 Electrical Controls .................................................................................................... 18

7.3 STATION BEACON ........................................................................................................ 20

7.4 PNEUMATIC CONTROLS ............................................................................................. 21

7.5 PNEUMATIC CONTROLS PANEL ............................................................................... 24

7.6 POWDER MANAGEMENT SYSTEM CONTROLS.................................................... 25

PREPARATION FOR OPERATION................................................................................... 26

Serial #15784

MR240 Coating System

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Summary of Contents for Electrostatic Technology MR240

Page 1: Table Of Contents
Electrostatic Technology, Inc. MR240 Coating System TABLE OF CONTENTS INTRODUCTION ........................1 SHIPPING..........................1 OPERATING PRINCIPLES ....................2 3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER ........2 3.2 PROCESS DESCRIPTION ....................3 GENERAL SAFETY......................4 4.1 INTRODUCTION ......................4 4.2 SAFETY SYMBOLS......................5 4.3 QUALIFIED PERSONNEL ....................
Page 2 Electrostatic Technology, Inc. MR240 Coating System 8.1 GENERAL........................26 8.2 INITIAL SYSTEM INSTALLATION ................26 8.3 LOAD STATION ......................28 8.4 COATER........................... 28 8.4.1 Coating Bed ......................28 8.4.2 Powder Deposition....................28 8.4.2.1 Fluidizing Air......................28 8.4.2.2 Powder Level ......................28 8.4.3 High Voltage......................
Page 3 Electrostatic Technology, Inc. MR240 Coating System 11.2.3 #1 O.D. CLEANING STATION ................50 11.2.4 I.D. CLEANING STATION..................50 11.2.5 INDUCTION HEATER STATION ................. 50 11.2.6 UNLOADING STATION ..................51 11.2.7 FIXTURE CLEANING STATION ................51 11.2.8 CURE OVEN SCREEN ................... 51 11.3...
Page 5: Introduction
MR240 Coating System 1 INTRODUCTION This Instruction Manual must be studied and followed for the safe and efficient operation of the " MR240 Coating System". Study this manual before locating and installing the equipment. ELECTROSTATIC TECHNOLOGY, INC. A SUBSIDIARY OF NORDSON CORPORATION...
Page 6: Operating Principles
Electrostatic Technology, Inc. MR240 Coating System 3 OPERATING PRINCIPLES SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER Serial #15784...
Page 7: Process Description
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.
Page 8: General Safety
Electrostatic Technology, Inc. MR240 Coating System 4 GENERAL SAFETY 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.
Page 9: Safety Symbols
Electrostatic Technology, Inc. MR240 Coating System 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.
Page 10: Qualified Personnel
Electrostatic Technology, Inc. MR240 Coating System QUALIFIED PERSONNEL "Qualified Personnel" is defined here as individuals who thoroughly understand the equipment and its safe operation, maintenance, and repair. Qualified personnel are physically capable of performing the required tasks, familiar with all relevant safety rules and regulations, and have been trained to safely install, operate, maintain, and repair the equipment.
Page 11 Electrostatic Technology, Inc. MR240 Coating System INSTALLATION (continued) • 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.
Page 12: Operation
Electrostatic Technology, Inc. MR240 Coating System 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.
Page 13: Less Obvious Dangers
Electrostatic Technology, Inc. MR240 Coating System OPERATION (continued) • 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...
Page 14: Action In The Event Of A System Or Component Malfunction
Electrostatic Technology, Inc. MR240 Coating System 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.
Page 15: Disposal
Electrostatic Technology, Inc. MR240 Coating System MAINTENANCE & REPAIR (continued) • 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.
Page 16: Air, Electrical And Water Requirements
Electrostatic Technology, Inc. MR240 Coating System 5 AIR, ELECTRICAL AND WATER REQUIREMENTS POWDER COATING MACHINE 5.1.1 Air A clean, oil free, dry supply of compressed air must be provided using 1 inch I.D. line capable of supplying 75 cubic feet/minute @ 60-90 pounds per square inch minimum.
Page 17: Mechanical Function: Sequence & Description
Electrostatic Technology, Inc. MR240 Coating System 6 MECHANICAL FUNCTION: SEQUENCE & DESCRIPTION LOAD STATION Stators are loaded into a V-block by customer loader assembly. The V-block carries and loads the stators onto the slide assemblies, which indexes them to each station.
Page 18: Cleaning Station
Electrostatic Technology, Inc. MR240 Coating System O.D. CLEANING STATION Powder removal from the outside diameter is done in the O.D. Cleaning Station. Parts are indexed into this station and extended out where a dual roller O.D. Cleaner/Flapper Assembly is raised from below by a pneumatic cylinder. The drive motor is engaged after the rollers come in contact with the parts, causing them to turn.
Page 19: Cure Transfer Station
Electrostatic Technology, Inc. MR240 Coating System CURE TRANSFER STATION The Cure Transfer Station, located just after the Induction Heating Station, removes the parts from the slide assembly and transfers them onto the Cure Oven Conveyor. Parts are indexed into the Cure Transfer Station and the slide is extended out to a position below the Offload Stripper Assembly.
Page 20: Refrigerant Air Dryer
Electrostatic Technology, Inc. MR240 Coating System POWDER MANAGEMENT SYSTEM (continued) A differential pressure gauge is located on the side of the collector/feeder assembly. This provides an indication of how clean the filter cartridges are. A normal reading is between 1 and 5. A reading above 5 indicates that the filter cartridges are not being cleaned well enough.
Page 21: Description Of Controls
Electrostatic Technology, Inc. MR240 Coating System 7 DESCRIPTION OF CONTROLS MAIN CONTROL CABINET The Main Control Cabinet holds all of the electric connections and switch gear for the system with the exception of the Induction Heater, which receives its power from a separate source.
Page 22: Electrical Controls
Electrostatic Technology, Inc. MR240 Coating System 7.2.1 Electrical Controls The following controls are located on the Main Control Panel: MAIN POWER ON Energizes all control circuits from the Pushbutton Main Control Cabinet. MAIN POWER OFF De-energizes all control circuits from the Pushbutton Main Control Cabinet.
Page 23 Electrostatic Technology, Inc. MR240 Coating System 7.2.1 Electrical Controls (continued) PARTS COUNTER In Automatic Operation, loaded parts are tracked through the PLC program and are counted by twos once they have indexed into the Unloading Station. The number of counted parts can be read on...
Page 24: Station Beacon
Electrostatic Technology, Inc. MR240 Coating System STATION BEACON A three-color stack light, located on top of the Main Electrical Enclosure, provides a visual indication of the current status of machine operation. The flash patterns are a 50% duty cycle with a slow flash having a period of 1 second, and a fast flash with a period of 0.5 seconds.
Page 25: Pneumatic Controls
Electrostatic Technology, Inc. MR240 Coating System PNEUMATIC CONTROLS The following controls are located on the front of the Load Station panel. The air flow values (SCFH) indicated with the controls are recommended settings under ideal operating conditions. They should be adjusted as needed during coating operation.
Page 26 Electrostatic Technology, Inc. MR240 Coating System PNEUMATIC CONTROLS (continued) AIR KNIFE FIXTURE CLEANER Adjusts and regulates the air pressure to LEFT PRESSURE ADJUST the Left Tip Cleaner Air Knife. Air pressure regulator AIR KNIFE FIXTURE CLEANER Indicates the air pressure available to the Left Tip Cleaner Air Knife.
Page 27 Electrostatic Technology, Inc. MR240 Coating System PNEUMATIC CONTROLS (continued) AIR KNIFE I.D. CLEANER Adjusts and indicates the amount of air FRONT ADJUST being supplied to the Front (outer) I.D. Air flowmeter & control Cleaner Knives. Adjusts and regulates the air pressure AIR KNIFE I.D.
Page 28: Pneumatic Controls Panel
Electrostatic Technology, Inc. MR240 Coating System PNEUMATIC CONTROLS PANEL Serial #15784...
Page 29: Powder Management System Controls
Electrostatic Technology, Inc. MR240 Coating System POWDER MANAGEMENT SYSTEM CONTROLS The following controls are located on the Powder Management System to the left of the glove box ports. Adjusts and regulates the air pressure POWDER FILTER BLOWDOWN (55 psi min./ 100 psi max.)
Page 30: Preparation For Operation
MR240 Coating System 8 PREPARATION FOR OPERATION These instructions for installing, operating, and maintaining the Model MR240 Rotary Coater must be followed for safe and efficient operation. In particular, precautions should be most carefully observed whenever the unit is operated. Study this manual before installing or operating the equipment.
Page 31 Electrostatic Technology, Inc. MR240 Coating System INITIAL SYSTEM INSTALLATION (continued) 7. Install the Powder Collector Filters in the Powder Collector. Start at the back of the cabinet and work towards the door. Place the Hanger Rod through the center of the Filter Element. Secure the Filter Element to the Hanger Rod by installing the special Rubber Washer Gasket, Wing Nut, and Protective Cap to the threads on the end of the Hanger Rod.
Page 32: Load Station
Electrostatic Technology, Inc. MR240 Coating System LOAD STATION The Load Station is designed to automatically accept parts from the customer’s part loader. In the event a mis-loaded part occurs at the v-block portion of this station, the proximity switches will detect the problem and display an error message on the Panel View display.
Page 33: High Voltage
Electrostatic Technology, Inc. MR240 Coating System Level Sensor Probe COATER (continued) 8.4.3 High Voltage Set the High Voltage Adjust to get the kilovolt reading on the High Voltage Kilovolt Meter required for production line condition. CLEANERS 8.5.1 O.D. Cleaner Adjusting All adjustments for this station have been pre-set at the E.T.I.
Page 34: Tip Cleaner Adjusting
Electrostatic Technology, Inc. MR240 Coating System 8.5.3 Tip Cleaner Adjusting All adjustments for this station have been preset at the E.T.I. factory for optimum running conditions for your particular parts and powder. However, adjustments can be made as follows: Air Knife Fixture Cleaner (Air Knives) for this station, Left and Right, can be adjusted at the Main Pneumatic Panel.
Page 35: Powder Maintenance
Electrostatic Technology, Inc. MR240 Coating System POWDER MANAGEMENT SYSTEM (continued) 8.8.1 Loading Powder (continued) Step 6 - Shake the bag so that all the powder falls into the hopper below. NOTE: Do not allow foreign items (such as tie wraps) to fall in the Hopper.
Page 36: Specific Equipment Safety
Electrostatic Technology, Inc. MR240 Coating System 9 SPECIFIC EQUIPMENT SAFETY GENERAL SOME VOLTAGES EMPLOYED IN PARTS OF THIS COATING SYSTEM ARE HIGH. REMEMBER THAT ANY SOURCE OF VOLTAGE CAN BE HAZARDOUS. ONLY RELIABLE,DEPENDABLE, TRAINED EMPLOYEES SHOULD BE GIVEN THE RESPONSIBILITY OF OPERATION AND MAINTENANCE OF THIS SYSTEM.
Page 37: Eye Contact
Electrostatic Technology, Inc. MR240 Coating System POWDER (continued) 9.2.1 Employee Health (continued) 9.2.1.3 Eye Contact Powder may cause eye irritation. 9.2.2 First Aid Procedures 9.2.2.1 Inhalation Remove individual from exposure and call physician if breathing continues to be impaired. 9.2.2.2 Skin Contact Wash skin thoroughly with soap and water.
Page 38: Panelview Screens
SYSTEM ON is displayed. In addition to the selection/indicator boxes, there are also additional indicators and messages present on each screen to allow the operator to access station information efficiently. The Model MR240 Stator Coating Machine includes the following PanelView screens: SCREEN LIST SELECTOR SCREEN The Screen List Selector Screen lists the available screens for operating the Model MR240 Stator Coating Machine.
Page 39 Electrostatic Technology, Inc. MR240 Coating System 10 PANELVIEW SCREENS (continued) PARTS UNLOADER SCREEN Brings up the Parts Unloader Screen (allows Manual Operation of the Parts Unloader Station. CURE OVER SCREEN Brings up the Cure Oven Screen (allows Manual Operation of the Cure Oven).
Page 40: Machine Operation Screen
Electrostatic Technology, Inc. MR240 Coating System 10.1 MACHINE OPERATION SCREEN Along with access to Screen Select of Next Screen, the following screen includes controls for: SYSTEM START-UP & AUTO OPERATION SYSTEM START & STOP INDUCTION HEATER START & STOP AUTO RUN MODE SELECTION HOME MODE RESET COATER CYCLE START &...
Page 41: Parts Loader Screen
Electrostatic Technology, Inc. MR240 Coating System 10.3 PARTS LOADER SCREEN Along with access to Screen Select or Next Screen, the following screen includes controls for: MANUAL OPERATION OF THE PARTS LOADER STATION LOADER SETUP MODE & HOME MODE RESET TABLE LOAD INDEX & INDEX TABLE ONLY STEP LOADER CYCLE FULL LOADER CYCLE &...
Page 42: Parts Coating Screen
Electrostatic Technology, Inc. MR240 Coating System 10.4 PARTS COATING SCREEN Along with access to Screen Select or Next Screen, the following screen includes controls for: MANUAL OPERATION OF THE PARTS COATING STATION COATER SETUP MODE & HOME MODE RESET TABLE LOAD INDEX & INDEX TABLE ONLY COATER ON &...
Page 43: Cleaning Screen
Electrostatic Technology, Inc. MR240 Coating System 10.5 O.D. CLEANING SCREEN Along with access to Screen Select or Next Screen, the following screen includes controls for: MANUAL OPERATION OF THE O.D. CLEANING SCREEN O.D. CLEAN SETUP & HOME MODE RESET TABLE LOAD INDEX & INDEX TABLE ONLY CLEANER BELT UP &...
Page 44: Cleaning Screen
Electrostatic Technology, Inc. MR240 Coating System 10.6 I.D. CLEANING SCREEN Along with access to Screen Select or Next Screen, the following screen includes controls for: Manual Operation of the O.D. Cleaning Screen I.D. CLEAN SETUP & HOME MODE RESET TABLE LOAD INDEX & INDEX TABLE ONLY CLEANER CYCLE FORWARD &...
Page 45: Induction Heating Screen
Electrostatic Technology, Inc. MR240 Coating System 10.7 INDUCTION HEATING SCREEN Along with access to Screen Select or Next Screen, the following screen includes controls for: MANUAL OPERATION OF THE INDUCTION HEATING STATION INDUCTION HEAT SETUP & HOME MODE RESET TABLE LOAD INDEX & INDEX TABLE ONLY MOVE PART FORWARD &...
Page 46: Parts Unloader Screen
Electrostatic Technology, Inc. MR240 Coating System 10.8 PARTS UNLOADER SCREEN Along with access to Screen Select or Next Screen, the following screen includes controls for: MANUAL OPERATION OF THE PARTS UNLOADER STATION UNLOAD SETUP MODE & HOME MODE RESET TABLE LOAD INDEX & INDEX TABLE ONLY STEP UNLOADER FULL UNLOAD CYCLE &...
Page 47: Cure Oven Screen
Electrostatic Technology, Inc. MR240 Coating System 10.9 CURE OVEN SCREEN Along with access to Screen Select or Next Screen, the following screen includes controls for: MANUAL OPERATION OF THE CURE OVEN STATION OVEN SETUP MODE & HOME MODE RESET TABLE LOAD INDEX & INDEX TABLE ONLY UNLOAD OVEN CONVEYOR FULL OVEN CYCLE &...
Page 48: Part Fixture Cleaner Screen
Electrostatic Technology, Inc. MR240 Coating System 10.10 PART FIXTURE CLEANER SCREEN Along with access to Screen Select or Next Screen, the following screen includes controls for: MANUAL OPERATION OF THE PART FIXTURE CLEANER STATION FIX CLEAN SETUP & HOME MODE RESET TABLE LOAD INDEX &...
Page 49: Alarm History Screen
Electrostatic Technology, Inc. MR240 Coating System 10.11 ALARM HISTORY SCREEN Emergency Stop is Active, Fault. Coater High Voltage Overload, Fault. Plant Air is Off Pressure or is Low, etc. 10.12 ALARM BANNER SCREEN An Alarm Banner, which pops up over the current screen when an alarm is triggered, allows an operator to immediately and appropriately respond to a given situation.
Page 50: Startup Procedure
Electrostatic Technology, Inc. MR240 Coating System 11 STARTUP PROCEDURE 11.1 OVERVIEW There are two modes for operating the Stator Coating Machine, Automatic and Manual. This section will provide the operating personnel with a thorough understanding of start-up and shutdown procedures. Supervisory personnel should...
Page 51 Electrostatic Technology, Inc. MR240 Coating System 11.1 OVERVIEW (continued) Assuming that all of the air, electrical and water requirements have been connected and supplied to the Coating Machine, the following can be performed: Step 1 Make sure the Disconnect Switch at the Main Electrical Enclosure, the Induction Heater and Motor Armature Oven Panel are in the "ON"...
Page 52: Manual Operation
Electrostatic Technology, Inc. MR240 Coating System 11.1 OVERVIEW (continued) Step 10 Select MACHINE STATUS SCREEN from the SCREEN LIST SELECTOR SCREEN. On the MACHINE STATUS SCREEN, select SETUP 4.2DIA STATOR or SETUP 3.6DIA STATOR. The selected stator is displayed at the top of the screen.
Page 53: Loading Station
Electrostatic Technology, Inc. MR240 Coating System 11.2 MANUAL OPERATION (continued) There are seven individual stations, each with a dedicated operating screen. Any of these stations can be selected from the SCREEN LIST SELECTOR SCREEN, along with the MACHINE OPERATION, CURE OVEN, MACHINE STATUS, ALARM history and ALARM ACTIVE SCREENS.
Page 54: O.d. Cleaning Station
Electrostatic Technology, Inc. MR240 Coating System 11.2 MANUAL OPERATION (continued) 11.2.3 #1 O.D. CLEANING STATION Select the #1 O.D. CLEANING SCREEN from the SCREEN LIST SELECTOR SCREEN. Then select the O.D. CLEANING SETUP, which indexes parts into the station. Press the CLEANER BELT UP and BELT MOTOR ON.
Page 55: Unloading Station
Electrostatic Technology, Inc. MR240 Coating System 11.2 MANUAL OPERATION (continued) 11.2.6 UNLOADING STATION Select the PARTS UNLOAD SCREEN from the SCREEN LIST SELECTOR SCREEN. Then select the UNLOAD SETUP MODE. Press the FULL UNLOAD CYCLE, which unloads the parts onto the oven conveyor. Pressing the STOP LOADER CYCLE may stop the Full Unload Cycle.
Page 56: Automatic Operation
Electrostatic Technology, Inc. MR240 Coating System 11.3 AUTOMATIC OPERATION The Automatic Operation is intended to be used primarily under production line situations after all settings have been determined during Manual Operation. Step 1 Be sure all aspects of the Coating Machine operation are understood.
Page 57 Electrostatic Technology, Inc. MR240 Coating System 11.3 AUTOMATIC OPERATION (continued) NOTE: If a problem occurs, a warning message will appear on the PanelView Screen and the buzzer will be turned on along with the red light of the Station Beacon.
Page 58 Electrostatic Technology, Inc. MR240 Coating System 11.3 AUTOMATIC OPERATION (continued) Step 4 Select MACHINE STATUS SCREEN from the SCREEN LIST SELECTOR SCREEN and Press TABLE FAULT RESET. Step 5 Select MACHINE OPERATION SCREEN from the SCREEN LIST SELECTOR SCREEN and Press START COATER CYCLE.
Page 59: Station Shutdown Procedure
Electrostatic Technology, Inc. MR240 Coating System 12 STATION SHUTDOWN PROCEDURE 12.1 AUTOMATIC OPERATION SHUTDOWN Step 1 After the last parts have unloaded onto the Oven Conveyor, select MACHINE OPERATION SCREEN from the SCREEN LIST SELECTOR SCREEN and Press STOP COATER CYCLE.
Page 60: Powder Handling At Shutdown
Electrostatic Technology, Inc. MR240 Coating System 12.3 POWDER HANDLING AT SHUTDOWN Only a minimum amount of powder should be left in the Powder Management System when it is shutdown over an 8-hour period. When the machine is not used in...
Page 61: Lockout
Electrostatic Technology, Inc. MR240 Coating System 12.4 LOCKOUT SPECIFIC CHARACTERISTICS Make sure the Disconnect Switch at the Main Electrical Enclosure, the Induction Heater and Motor Armature Oven Panel are in the "ON" position. Method of Lockout Checking the Result Type of Energy...
Page 62: Maintenance
Electrostatic Technology, Inc. MR240 Coating System 13 MAINTENANCE 13.1 GENERAL A systematic 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.
Page 63: Fluidic Bed
Electrostatic Technology, Inc. MR240 Coating System 13.3 FLUIDIC BED 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.
Page 64 Electrostatic Technology, Inc. MR240 Coating System 13.3.1 Installation of Porous Plate (continued) NOTE: CARE MUST BE TAKEN WHEN WORKING AROUND THE LEVEL SENSOR PROBE SO THAT THE PROBE IS NOT BENT OR DAMAGED. DAMAGE TO A PROBE MAY CAUSE THE LEVEL...
Page 65: Powder Management System
Electrostatic Technology, Inc. MR240 Coating System 13.4 POWDER MANAGEMENT SYSTEM The Powder Collector Filter Cartridge cleaning is done automatically by the unit. At the end of every shift, the Differential Pressure Gauge should be checked to make sure that it is not reading above 5, which would indicate that the cartridges are not being cleaned.
Page 66: Induction Heater
Electrostatic Technology, Inc. MR240 Coating System 13.7 INDUCTION HEATER Observe the water tank site glass labeled “Distilled Water Level” (located on the side of the water tank) to make sure the deionized water level is correct. Observe the deionizer indicator light (located on the front of the Cure Station) to make sure the distilled water in the Induction Heater cooling system is within specifications.
Page 67: Preventative Maintenance Schedule
Electrostatic Technology, Inc. MR240 Coating System 14 PREVENTATIVE MAINTENANCE SCHEDULE 14.1 DAILY 1. Look over entire coater system and remove any powder or foreign objects. 2. Remove the magnet located on the front of the Powder Feeder Transition Weldment above the Coating Bed and inspect for metal chips. Remove chips and replace magnet.
Page 68: Lubrication Chart
Electrostatic Technology, Inc. MR240 Coating System 14.3 MISCELLANEOUS (continued) 2. Replace the Deionizer Filter Cartridge approximately every 5 to 6 months, even if the Deionizer Filter Indicator Light is still green which indicates that a change is not required. 3. Powder should not be allowed to remain in the Coating Bed when the system is not in use.
Page 69: Alarm Messages
Electrostatic Technology, Inc. MR240 Coating System 15 ALARM MESSAGES ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS EMERGENCY STOP One or more of the three Determine who and why the ACTIVATED Emergency Stop buttons has Emergency Stop Button was been pressed.
Page 70 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS FIRE IN COATER A fire in the Coater has been Carefully check coater for fire. detected. The filament string If a fire has occurred, holding the Coater Fire...
Page 71 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS POWDER COLLECTOR The Powder Collector vacuum Increase the Powder Collector VACUUM LOW is low. This warning will filter pulse air pressure. transpire if the Powder...
Page 72 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS POWDER FEEDER MOTOR The powder feeder motor Make a visual inspection of all OVERLOAD overload tripped. of the components involved in this fault. The powder feeder motor has a bad bearing or winding.
Page 73 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS INDUCTION HEATER The Induction Heater guard is Close the Induction Heater GUARD OPEN not closed. The guard must be guard. closed in order to operate the Induction Heater.
Page 74 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS #1 SPINDLE NOT #1 spindle (slide assembly) Correct any problems with the RETRACTED did not retract (detected by #1 Operating Station that would spindle retracted proximity...
Page 75 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS #4 SPINDLE NOT #4 spindle (slide assembly) Correct any problems with the RETRACTED did not retract (detected by #4 Operating Station that would spindle retracted proximity...
Page 76 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS #7 SPINDLE NOT #7 spindle (slide assembly) Correct any problems with the RETRACTED did not retract (detected by #7 Operating Station that would spindle retracted proximity...
Page 77 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS MACHINE INDEX CYCLE Table did not index (rotate) Allow gearbox oil to warm up NOT COMPLETE within 3 seconds from one as the table indexes through a station to the next.
Page 78 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS PART UNLOAD CYCLE During the automatic coating Correct any problems that NOT COMPLETE cycle, the slide assembly at the would prevent the slide Unloading Station did not assembly from extending.
Page 79 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS FIXTURE CLEANER During the automatic coating Correct any problems that CYCLE NOT COMPLETE cycle, the slide assembly at the would prevent the slide Fixture Cleaning Station did assembly from extending.
Page 80 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS O.D. CLEANER IS NOT During the automatic coating Correct any problems that DOWN cycle, the dual roller O.D. would prevent the O.D. Cleaner/Flapper Assembly did...
Page 81 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS PARTS LOAD CYCLE NOT During the automatic coating Correct any problems that COMPLETE cycle, the slide assembly at the would prevent the slide Loading Station did not extend assembly from extending.
Page 82 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS PART TEMPERATURE IS The induction heated part Check the Induction Heater temperature is set too cool. power setting. Turn up the The Raytek Temperature power at 2% intervals and Sensor measures the surface check part temperature.
Page 83 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS PART TEMPERATURE IS The induction heated part Check the Induction Heater TOO HIGH temperature is set too hot. The power setting. Turn down the Raytek Temperature Sensor...
Page 84 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS FUME EXHAUST MOTOR The Fume Exhaust Fan motor Make a visual inspection of all OVERLOAD overload tripped. the components involved with this fault. The Fume Exhaust Fan motor has a bad bearing or winding.
Page 85 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS CURE OVEN IS NOT Oven Not Ready Alarm Check PLC input wires. READY detected at the Motor Correct any bad connections. Armature Oven Control Panel Let the Cure Oven (monitored on plc input I:4/4).
Page 86 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS WARNING-REMOVE ALL The Emergency Stop Reset the Emergency Stop PARTS BEFORE pushbutton was activated or pushbutton. Close all door STARTING AUTO CYCLE ! one of the door guards was...
Page 87 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS I.D. CLNR. LOWER RIGHT During the automatic coating Press TABLE FAULT RESET DEAD STOP NOT cycle, the I.D. Cleaner Lower display button located on the...
Page 88 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS PART IS MISSING AT At lease one part is missing Press TABLE FAULT RESET INDUCTION HEATER (detected by proximity switch display button located on the [I:2/10]) as the table indexed MACHINE STATUS SCREEN.
Page 89 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS PART IS MISSING AT Select MACHINE STATUS INDUCTION HEATER SCREEN from the SCREEN LIST SELECTOR SCREEN and Press (Continued) TABLE FAULT RESET. Select MACHINE OPERATION...
Page 90 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS PART LOADER FAULT During the automatic coating Press TABLE FAULT RESET cycle, the Part Loader V- display button located on the Block Assembly did not MACHINE STATUS SCREEN.
Page 91 Electrostatic Technology, Inc. MR240 Coating System ALARM MESSAGES AND TROUBLE SHOOTING GUIDE MESSAGES CAUSES SOLUTIONS PART UNLOADER FAULT During the automatic coating Press TABLE FAULT RESET cycle, the slide assembly had display button located on the retracted but the Offload MACHINE STATUS SCREEN.
Page 92: Trouble Shooting
Electrostatic Technology, Inc. MR240 Coating System 16 TROUBLE SHOOTING COATER-SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) No High Voltage to Coating Coating Bed High Voltage Increase (turn knob) High Bed. control set too low. Voltage control. Turn off and on Main Power to Overload tripped.
Page 93 Electrostatic Technology, Inc. MR240 Coating System 16 TROUBLE SHOOTING (continued) COATER-SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Insufficient air to fluidize Air flowmeter control is set too Increase air flow (turn knob) on power. low. flowmeter. Air leaking by gasket at porous Tighten screws of porous plate plate.
Page 94 Electrostatic Technology, Inc. MR240 Coating System 16 TROUBLE SHOOTING (continued) COATER-SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Coater Unit in overload Coater High Voltage overload Consult ETI for condition. circuit is factory set to trip (shut recommendation and Coater off) at conservative value.
Page 95 Electrostatic Technology, Inc. MR240 Coating System 16 TROUBLE SHOOTING (continued) COATER-SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Coater Unit in overload High Voltage Power Supply may Remove High Voltage cable condition (continued) be defective. from High Voltage Power Supply. From PARTS COATING SCREEN, turn "ON"...
Page 96 Electrostatic Technology, Inc. MR240 Coating System 16 TROUBLE SHOOTING (continued) BAD PART - POSSIBLE CAUSE(S) REMEDY(S) SYMPTOM Powder coating too thin Low powder level in Coating Check height of Level Sensor Tube (Probe) and adjust if necessary. Refer to Section 8.4.2.2.
Page 97 Electrostatic Technology, Inc. MR240 Coating System 16 TROUBLE SHOOTING (continued) BAD PART - POSSIBLE CAUSE(S) REMEDY(S) SYMPTOM Powder left on part O.D. Parts not clean prior to coating; Degrease parts prior to coating. oil residue on parts. Parts not cooled prior to coating.
Page 98: Patent Information
Electrostatic Technology, Inc. MR240 Coating System 17 PATENT INFORMATION The Model MR240 Stator Coating System is manufactured under one or more of the following United States Patents: 3,575,344 3,607,998 3,698,847 3,828,729 3,865,610 3,881,763 3,889,015 3,901,185 3,914,461 3,916,826 3,921,574 3,937,179 3,951,099...
Page 99: Spare Parts
Electrostatic Technology, Inc. MR240 Coating System 18 SPARE PARTS RECM'D PRICE PART DESCRIPTION PART ASSEMBLY QTY. SPARE EACH Magnet (Rev D) Magnet #MAG-510, Reid Head Timing Pulley, Modified 100036 Slide Timing Belt Slide #TB20UP6-115, Berg Timing Pulley Slide #TP20A8W6-20, Berg Twin Pillow Block Slide &...
Page 100 Electrostatic Technology, Inc. MR240 Coating System RECM'D PRICE PART DESCRIPTION PART ASSEMBLY QTY. SPARE EACH Bushing Powder #H 15/16 Bore, Browning Management Regulator Powder #R100-4, Master Pneumatic Management Powder Magnet 100169 Management Outside Tube, 2 ¼ O.D. Powder 12FT 12FT...
Page 101 Electrostatic Technology, Inc. MR240 Coating System RECM'D PRICE PART DESCRIPTION PART ASSEMBLY QTY. SPARE EACH Offload Stripping Pin, Offload 100135 Stripper Linear Guide Unit, FEN-3/4-4 Offload #151722, Festo Stripper Cylinder, Double Acting Offload #DSN-3/4-4-P, Festo Stripper V-Block Assy Liner Race Rework, Load...
Page 102 Electrostatic Technology, Inc. MR240 Coating System RECM'D PRICE PART DESCRIPTION PART ASSEMBLY QTY. SPARE EACH Proximity Switch, 30 MM Dia Electrical #3RG1614-6AC00, Siemens High Flex Cable Electrical #804000B02M020, Brad Harrison High Voltage Power Supply 5050010 Electrical Pressure Sensor, Type #PEV-1/4-SC-OD...
Page 103 Electrostatic Technology, Inc. MR240 Coating System RECM'D PRICE PART DESCRIPTION PART ASSEMBLY QTY. SPARE EACH Fuse Electrical #FNM 10, Bussman Fuse Electrical #FRNR 15, Bussman Motor Speed Control Electrical #KBWD-13, KB Penta Power Control Relay, 3NO, 1NC Electrical #3TH2031-OBB4, Siemens...
Page 104 Electrostatic Technology, Inc. MR240 Coating System RECM'D PRICE PART DESCRIPTION PART ASSEMBLY QTY. SPARE EACH 2 Position Valve, Type #MFH-3-1/4NPT Electrical #10836, Festo 2 Position Solenoid Valve Type #MEH-5/2-4.0 Electrical #30619, Festo Serial #15784...
Page 105: Manufacturer's Manuals
Electrostatic Technology, Inc. MR240 Coating System 19 MANUFACTURER’S MANUALS All of the Manufacturer's Manuals listed below can be found in the Manufacturer's Manuals Binder: • Air Flow Interlocking Safety Switches (Antunes Controls) • B-Pure Pressure Cartridge System (Barnstead) • Circuit Breaker (Siemens) •...
Page 106 Electrostatic Technology, Inc. MR240 Coating System 18 MANUFACTURER’S MANUALS (continued) • Photohelic® Pressure Switch Gage (Dwyer) • Powder Collector (Torit®) • Power Supply (Power One) • Pressure Regulator (Festo) • Radial Blade Exhauster (Cincinnati Fan) • Ratemaster® Flowmeter (Dwyer) • Refrigerant Air Dryer (Kaeser) •...
Page 107: Floor Plan
Electrostatic Technology, Inc. MR240 Coating System 20 FLOOR PLAN See Mechanical Drawings section located in the back of this manual. 21 ELECTRICAL AND PNEUMATIC SCHEMATICS See Electrical Program binder for the Electrical and Pneumatic Schematics: ETI 15784-4000, Sheets 1 through 21...

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