Electrostatic Technology 802 User manual

Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 i
TABLE OF CONTENTS
1 INTRODUCTION.............................................................................................................................1
2 SHIPPING .........................................................................................................................................1
3 OPERATING PRINCIPLES ...........................................................................................................2
3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER..........................................2
3.2 PROCESS DESCRIPTION .......................................................................................................3
4 GENERAL SAFETY ........................................................................................................................4
4.1 INTRODUCTION .....................................................................................................................4
4.2 SAFETY SYMBOLS.................................................................................................................5
4.3 QUALIFIED PERSONNEL ......................................................................................................5
4.4 INTENDED USE.......................................................................................................................6
4.5 INSTALLATION ......................................................................................................................6
4.6 OPERATION.............................................................................................................................8
4.7 LESS-OBVIOUS DANGERS .................................................................................................10
4.8 IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION .............................10
4.9 MAINTENANCE & REPAIR.................................................................................................11
4.10 DISPOSAL ..............................................................................................................................12
5 AIR, ELECTRICAL, AND WATER REQUIREMENTS ..........................................................13
5.1 POWDER COATING MACHINE ..........................................................................................13
5.1.1 Air ................................................................................................................................13
5.1.2 Electrical ......................................................................................................................13
5.1.3 Water............................................................................................................................13
5.1.3.1 Closed Loop Induction Heater Cooling System............................................13
5.1.3.2 Tower Water Requirements For Induction Heater Cooling .........................13
5.2 INDUCTION HEATER...........................................................................................................13
5.2.1 Electrical........................................................................................................................13
6 MECHANICAL FUNCTION: SEQUENCE AND DESCRIPTION ........................................14
6.1 LOAD/RELOAD AREA .........................................................................................................14
6.2 INDUCTION HEATER DEGREASER MODULE ................................................................14
6.3 COATING MODULE .............................................................................................................14
6.3.1 Coating Bed .................................................................................................................14
6.3.2 Powder Level Sensor ...................................................................................................15
6.4 CLEANING STATION ...........................................................................................................15
6.4.1 Bulk Box ......................................................................................................................15
6.4.2 O.D. Belt Cleaner.........................................................................................................15
6.4.3 Air Knives....................................................................................................................16
6.4.4 Screw Cleaner ..............................................................................................................16

Electrostatic Technology, Inc. Model 802 Armature Coater
ii Serial #15681
6.5 POWDER MANAGEMENT SYSTEM ..................................................................................17
6.6 INDUCTION HEATING MODULE.......................................................................................19
6.7 CURE MODULE.....................................................................................................................19
6.8 FINAL COOL MODULE........................................................................................................19
6.9 REFRIGERANT AIR DRYER................................................................................................19
6.10 DEIONIZED WATER SYSTEM ............................................................................................19
6.11 INDUCTION HEATER COOLING WATER ........................................................................20
6.12 MAIN CONTROL CABINET.................................................................................................20
7 DESCRIPTION OF CONTROLS.................................................................................................21
7.1 OPERATOR MAIN CONTROL PANEL ...............................................................................21
7.2 OPERATOR MAIN CONTROLS...........................................................................................22
7.3 COATER CONTROL PANEL................................................................................................25
7.4 COATER CONTROLS ...........................................................................................................25
7.5 CLEANING CONTROL PANEL ...........................................................................................26
7.6 CLEANING CONTROLS .......................................................................................................27
7.7 POWDER MANAGEMENT SYSTEM CONTROLS ............................................................28
8 SPECIFICE EQUIPMENT SAFETY...........................................................................................29
8.1 GENERAL...............................................................................................................................29
8.2 POWDER.................................................................................................................................29
8.2.1 Employee Health..........................................................................................................29
8.2.1.1 Inhalation......................................................................................................29
8.2.1.2 Skin Contact..................................................................................................29
8.2.1.3 Eye Contact...................................................................................................30
8.2.1.4 First Aid Procedures.....................................................................................30
8.2.2 Special Protection ........................................................................................................30
8.2.3 Precautions...................................................................................................................30
8.2.4 Material Safety Data Sheets (MSDS) ..........................................................................30
9 PREPARATION FOR OPERATION...........................................................................................31
9.1 INITIAL SYSTEM INSTALLATION ....................................................................................31
9.2 GENERAL...............................................................................................................................33
9.3 COATER..................................................................................................................................34
9.3.1 Coating Bed .................................................................................................................34
9.3.2 Powder Deposition.......................................................................................................34
9.3.3 High Voltage Adjustment ............................................................................................35
9.4 POWDER MANAGEMENT SYSTEM ..................................................................................35
9.4.1 Loading Powder...........................................................................................................35
9.4.2 Powder Maintenance....................................................................................................35
9.5 CLEANERS.............................................................................................................................35
9.5.1 O.D. Cleaner ................................................................................................................35
9.5.2 Air Knives....................................................................................................................36
9.5.3 Screw Cleaners ............................................................................................................36
9.6 INDUCTION HEATERS ........................................................................................................36

Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 iii
10 OPERATION ......................................................................................................................................37
11 START-UP & OPERATION PROCEDURE...................................................................................38
11.1 LOCAL MODE-COATING MACHINE.....................................................................................38
11.2 EXTERNAL MODE-COATING ................................................................................................39
12 SHUTDOWN PROCEDURE ............................................................................................................40
12.1 LOCAL MODE SHUTDOWN-COATER ..................................................................................40
12.2 EXTERNAL MODE SHUTDOWN-COATER...........................................................................40
12.3 POWDER HANDLING...............................................................................................................40
12.3.1 Powder Management System...........................................................................................41
12.4 POWDER/COLOR CHANGE ....................................................................................................41
13 MAINTENANCE................................................................................................................................42
13.1 GENERAL...................................................................................................................................42
13.2 COMPRESSED AIR SYSTEM...................................................................................................42
13.2.1 Air Line ...........................................................................................................................42
13.2.2 Refrigerant Air Dryer.......................................................................................................42
13.3 FLUIDIC BED.............................................................................................................................43
13.3.1 Installation of Porous Plate ..............................................................................................43
13.3.2 Powder Level Sensor .......................................................................................................44
13.4 POWDER COLLECTOR ............................................................................................................44
13.4.1 Lower Fluidizing Hopper.................................................................................................45
13.4.2 Installation of Porous Plate ..............................................................................................45
13.4.3 Filter Cartridges ...............................................................................................................46
13.4.4 Differential Pressure Gauge.............................................................................................46
13.5 O.D. CLEANER ..........................................................................................................................46
13.6 INDUCTION HEATER...............................................................................................................47
13.7 COOLING BLOWERS................................................................................................................47
13.8 ROTO-FLO CONVEYOR...........................................................................................................47
13.9 MOTORS & GEARS...................................................................................................................47
14 PREVENTATIVE MAINTENANCE SCHEDULE ........................................................................48
14.1 DAILY .........................................................................................................................................48
14.2 WEEKLY.....................................................................................................................................48
14.3 MISCELLANEOUS ....................................................................................................................49
15 PART CHANGEOVER......................................................................................................................50
15.1 CHANGEOVER PROCEDURE .................................................................................................50
15.1.1 Changing From Smaller To Larger Parts........................................................................50
15.1.2 Changing From Larger To Smaller Parts.........................................................................50

Electrostatic Technology, Inc. Model 802 Armature Coater
iv Serial #15681
16 TROUBLESHOOTING .....................................................................................................................51
16.1 COATER......................................................................................................................................51
16.2 POWDER COLLECTOR ............................................................................................................55
16.3 CONVEYOR CLUTCH ..............................................................................................................55
16.4 BAD PARTS................................................................................................................................56
17 PATENT INFORMATION................................................................................................................58
18 MANUFACTURER'S MANUALS ...................................................................................................59
19 FLOOR PLAN ....................................................................................................................................60
20 PNEUMATIC SCHEMATIC ............................................................................................................60
21 ELECTRICAL SCHEMATIC ..........................................................................................................60
22 SPARE PARTS ...................................................................................................................................61

Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 v
TABLE OF FIGURES
FIGURE 1A: 5HP POWDER COLLECTOR................................................................................................18
FIGURE 1B: SCRAP POWDER COLLECTOR ..........................................................................................18
FIGURE 2: PIPING DIAGRAM ................................................................................................................32
FIGURE 3: LEVEL SENSOR PROBE TUBE...........................................................................................34