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Electrostatic Technology FlexiCoat 300 Manual

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Electrostatic Technology, Inc
1
INTRODUCTION................................................................................................................................................. 1
2
SHIPPING ............................................................................................................................................................. 1
3
OPERATING PRINCIPLES ............................................................................................................................... 2
3.1
SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER .................................................................. 2
3.2
PROCESS DESCRIPTION................................................................................................................................ 2
4
GENERAL SAFETY ............................................................................................................................................ 3
4.1
INTRODUCTION.............................................................................................................................................. 3
4.2
SAFETY SYMBOLS......................................................................................................................................... 4
4.3
QUALIFIED PERSONAL................................................................................................................................. 4
4.4
INTENDED USE ............................................................................................................................................... 5
4.5
INSTALLATION............................................................................................................................................... 5
4.6
OPERATION ..................................................................................................................................................... 6
4.7
LESS OBVIOUS DANGERS............................................................................................................................ 8
4.8
ACTION IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION........................................ 8
4.9
MAINTENANCE & REPAIR ........................................................................................................................... 9
4.10
DISPOSAL.................................................................................................................................................. 10
5
AIR AND ELECTRICAL REQUIREMENTS ................................................................................................ 11
®
5.1
.................................................................................................................................................. 11
5.1.1
Air ........................................................................................................................................................... 11
5.1.2
Electrical ................................................................................................................................................ 11
6
DESCRIPTION OF COMPONENTS............................................................................................................... 12
®
6.1
300 COATING STATION...................................................................................................... 12
6.1.1
Tooling Plate .......................................................................................................................................... 12
6.1.1.1
Low Velocity Plume (cover) ................................................................................................................................12
6.1.2
Powder Level Sensor .............................................................................................................................. 12
6.1.3
Powder Feed Chamber ........................................................................................................................... 13
6.1.4
Optional Conventional Fluid Bed........................................................................................................... 13
®
6.2
COLLECTOR ......................................................................................................................... 13
6.3
FLUIDIZING HOPPER/POWDER FEED PUMP .......................................................................................... 14
7
INSTALLATION ................................................................................................................................................ 15
7.1
LOCATION ..................................................................................................................................................... 15
7.2
AIR CONNECTIONS...................................................................................................................................... 15
7.3
ELECTRICAL CONNECTION ...................................................................................................................... 15
7.4
CONTROLS..................................................................................................................................................... 16
7.4.1
Footswitch .............................................................................................................................................. 16
7.4.2
Settings.................................................................................................................................................... 16
7.5
FLUIDIZING HOPPER/POWDER FEED PUMP .......................................................................................... 16
7.6
POWDER MAINTENANCE........................................................................................................................... 17
8
DESCRIPTION OF CONTROLS ..................................................................................................................... 18
8.1
POWDER COLLECTOR AND COATER CONTROL PANEL ILLUSTRATION ...................................... 18
8.2
POWDER COLLECTOR AND COATER CONTROLS................................................................................ 19
8.3
COATING BED PNEUMATIC CONTROL PANEL ILLUSTRATION ....................................................... 21
8.4
COATING BED PNEUMATIC CONTROLS................................................................................................. 21
8.5
POWDER FEED PNEUMATIC CONTROL PANEL ILLUSTRATION ...................................................... 22
8.6
POWDER FEED PNEUMATIC CONTROLS................................................................................................ 23
®
8.7
9
START-UP AND OPERATION PROCEDURE.............................................................................................. 25
9.1
COATING STATION SET-UP ....................................................................................................................... 25
Serial #20158

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®
FlexiCoat
Model 300 Coater
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  • Page 1: Table Of Contents

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater TABLE OF CONTENTS INTRODUCTION..............................1 SHIPPING ................................1 OPERATING PRINCIPLES ..........................2 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER ..............2 PROCESS DESCRIPTION..........................2 GENERAL SAFETY ............................3 INTRODUCTION.............................. 3 SAFETY SYMBOLS............................4 QUALIFIED PERSONAL..........................
  • Page 2 ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater ELECTROSTATIC COATING OPERATION ....................25 CONVENTIONAL FLUID BED COATING OPERATION ................26 POWDER REMOVAL OPERATION (ELECTROSTATIC COATING ONLY) .......... 27 FLUIDIZING HOPPER/POWDER FEED PUMP ..................27 9.5.1 Powder Level ............................27 SHUT-DOWN PROCEDURE ........................... 28 10.1...

  • Page 3: Introduction

    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. Serial #20158...

  • Page 4: Operating Principles

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 3 OPERATING PRINCIPLES SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER 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.

  • Page 5: General Safety

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 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 6: Safety Symbols

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 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 7: Intended Use

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 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.

  • Page 8: Operation

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 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.
  • Page 9 ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 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. •...

  • Page 10: Less Obvious Dangers

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 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.

  • Page 11: Maintenance & Repair

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 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.

  • Page 12: Disposal

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 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.

  • Page 13: Air And Electrical Requirements

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 5 AIR AND ELECTRICAL REQUIREMENTS ® FLEXICOAT 5.1.1 10 scfm @ 80 psi minimum/100 psi maximum. A 1/2 inch minimum air line ® should be connected to the FlexiCoat Coating Machine. It is strongly recommended that the air supply to be connected to the ®...

  • Page 14: Description Of Components

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 6 DESCRIPTION OF COMPONENTS ® FLEXICOAT 300 COATING STATION The coating machine is complete with Coating Bed, Powder Feed Chamber, High Voltage Multiplier, Air Flow Meter, Vibrator (to insure proper fluidization), and Tooling Plate with Low Velocity Plume (cover).

  • Page 15: Powder Feed Chamber

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 6.1.2 Powder Level Sensor (continued) ® 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.

  • Page 16: Fluidizing Hopper/Powder Feed Pump

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater ® FLEXICOAT COLLECTOR (continued) 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.

  • Page 17: Installation

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 7 INSTALLATION ® These instructions for installing, operating and maintaining the FlexiCoat Model 300 Coater 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.

  • Page 18: Controls

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater CONTROLS 7.4.1 Footswitch Locate the Coater Footswitch and position in front of the Coater Station. The Footswitch is already pre-wired to the electrical controls. 7.4.2 Settings Press COLLECTOR START pushbutton on the Control Panel. This will turn the Blower Motor "ON".

  • Page 19: Powder Maintenance

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 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 Fluidizing Hopper. All powder containers (bags, barrels, hoppers, etc.) should be kept tightly closed.

  • Page 20: Description Of Controls

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 8 DESCRIPTION OF CONTROLS POWDER COLLECTOR AND COATER CONTROL PANEL ILLUSTRATION Serial #20158...

  • Page 21: Powder Collector And Coater Controls

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater POWDER COLLECTOR AND COATER CONTROLS COLLECTOR START Turns the Powder Collector "ON". Pushbutton Turns the Powder Collector "OFF". COLLECTOR STOP Pushbutton AUTO PULSER Activates Powder Collector Filter pulser ON/OFF Selector Switch (shakedown) sequence.
  • Page 22 ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater POWDER COLLECTOR AND COATER CONTROLS (continued) Enables the High Voltage to be turned HIGH VOLTAGE ON/OFF Selector Switch "ON" when using the Electrostatic Fluid Bed. Should be in the "OFF" position when using the Optional Conventional Fluid Bed.

  • Page 23: Coating Bed Pneumatic Control Panel Illustration

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater COATING BED PNEUMATIC CONTROL PANEL ILLUSTRATION COATING BED PNEUMATIC CONTROLS FLEXICOAT BED Adjusts and indicates the amount of fluidizing air supplied to the coating bed. ADJUSTMENT Air Flowmeter FLEXICOAT BED Adjusts the amount of regulated air pressure supplied to the coating bed.

  • Page 24: Powder Feed Pneumatic Control Panel Illustration

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater POWDER FEED PNEUMATIC CONTROL PANEL ILLUSTRATION Serial #20158...

  • Page 25: Powder Feed Pneumatic Controls

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater POWDER FEED PNEUMATIC CONTROLS COATING BED This Photohelic Gauge indicates set points for activation and deactivation of the LEVEL SENSOR Photohelic Gauge Powder Feeder. This unit is factory set. If reset to raise or lower powder level, always maintain a spacing of 10 between indicators.

  • Page 26: Flexicoat ® Collector And Coater Controls

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater ® FLEXICOAT COLLECTOR AND COATER CONTROLS Note that these controls are not shown on a drawing, they are found on the Electrical ® Cabinet, Enclosure or Frame of the FlexiCoat Powder Collector.

  • Page 27: Start-Up And Operation Procedure

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 9 START-UP AND OPERATION PROCEDURE COATING STATION SET-UP Step 1 - Press COLLECTOR START pushbutton on the Control Panel. Check the cartridge filter differential pressure gauge on the Collector Module. During normal operation, the pressure should remain under 3.5 inches water column.

  • Page 28: Conventional Fluid Bed Coating Operation

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater ELECTROSTATIC COATING OPERATION (continued) Step 4 - Ground the part to be coated using the ground clip. Hold the part just above the Coating Bed and begin Electrostatic Fluid Bed coating. Step 5 - Continue to press the Coater Footswitch and allow the part to be coated (in the powder cloud) for the duration of the coating cycle.

  • Page 29: Powder Removal Operation (Electrostatic Coating Only)

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater POWDER REMOVAL OPERATION (ELECTROSTATIC COATING ONLY) Step 1 - Once a part has been satisfactorily coated, powder may be removed from unwanted surfaces by vacuum, manual wiping or brushing, or by the use of a stream of compressed air.

  • Page 30: Shut-Down Procedure

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 10 SHUT-DOWN PROCEDURE 10.1 COATING MACHINE Step 1 - If System has not been run with the Auto Pulser "ON", turn the Auto Pulser Selector Switch to "ON" and let the filters be pulsed clean for a few minutes before turning the system "OFF".

  • Page 31: Powder Collector Cleaning

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 10.3.1 Coating Bed Cleaning (continued) Step 4 - Disconnect the Powder Level Sensor Hose, and both the Powder Feed Hose and the Exhaust Hose from the Powder Feed Chamber above the Coating Bed.

  • Page 32: Trouble Shooting

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 11 TROUBLE SHOOTING 11.1 TROUBLE SHOOTING – COATER COATER-SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) No High Voltage indicated to Coater Bed ON/OFF Switch is Turn Coater Bed ON/OFF Switch Coating Bed set to "OFF".

  • Page 33: Trouble Shooting - Powder Collector

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 11.1 TROUBLE SHOOTING – COATER (continued) COATER-SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Coating powder is wet or damp. Moisture in Coater fluidizing air. Check analysis gauge on the Air Dryer-if applicable. Refrigerant Air Dryer Refer to the maintenance (section malfunctioning.
  • Page 34 ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 11.2 TROUBLE SHOOTING – COLLECTOR (continued) COLLECTOR - SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Powder escaping from booth Cartridge filters clogged due to: openings 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).

  • Page 35: Maintenance

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 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.

  • Page 36: Porous Plate Replacement

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 12.3 COATING BED (continued) 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.

  • Page 37: Powder Level Sensor

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 12.3.1 Porous Plate Replacement (continued) Step 7 - Make mounting holes in new Porous Plate if required (refer to old Porous Plate as a template. Step 8 - Apply gasket material along top and bottom edges of the new Porous Plate (refer to old plate for position) and make mounting holes in the gasket as required.

  • Page 38: Final Filter

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 12.4.1 Cartridge Filters (continued) Always 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...

  • Page 39: Patents

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 13 PATENTS ® The FlexiCoat Model 300 Coater is manufactured under one or more of the following United States Patents: 6,620,243 6,558,752 B2 6,458,427 6,240,873 6,068,702 5,773,097 5,639,307 5,275,849 5,213,847 5,116,636 5,092,267...

  • Page 40: Spare Parts List

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 14 SPARE PARTS LIST Refer to Nordson manual #303 867B, located in the Appendix, for additional information on Collector Module. PRICE ETI PART RECM'D PART DESCRIPTION ASSEMBLY QTY. EACH SPARE Coating Porous Plate...
  • Page 41 ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 14 SPARE PARTS LIST (continued) PRICE ETI PART RECM'D PART DESCRIPTION ASSEMBLY QTY. EACH SPARE Fuse, 3 Amp Electrical #FNQ-3 Fuse, 10 Amp " #FRN-R-10 Fuse, 8 Amp " #MDL-8 Programmable Logic Controller,...

  • Page 42: Floor Plan

    ® Electrostatic Technology, Inc FlexiCoat Model 300 Coater 15 FLOOR PLAN See the Appendix for the Floor Plan Drawing. 16 PNEUMATIC SCHEMATIC See the Appendix for the Pneumatic Schematic Drawing. 17 ELECTRICAL DRAWING See the Appendix for Elementary Electrical Drawing.

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