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

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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

Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 1
1 INTRODUCTION
This Operating Manual must be studied and followed for the safe and efficient operation of the Model
802 Coating System. Study this manual before locating and installing the equipment.
If there are any questions, please call:
ELECTROSTATIC TECHNOLOGY, INC.
A SUBSIDIARY OF NORDSON CORPORATION
4 PIN OAK DRIVE
BRANFORD, CT 06405
TELEPHONE: [phone]
FAX: [phone]
In future correspondence, please refer to the Model (802) and Serial Number (15681) of the Coating
System.
2 SHIPPING
Sometimes equipment can be damaged in transit. An inspection of the shipping crates should be made
upon delivery. When the equipment is removed, it should be carefully inspected to make sure the
equipment is in good condition. If the equipment is damaged, the carrier's claim agent should be
requested to prepare a report, a copy of which should be sent to:
ELECTROSTATIC TECHNOLOGY, INC.
A SUBSIDIARY OF NORDSON CORPORATION
4 PIN OAK DRIVE
BRANFORD, CT 06405
Electrostatic Technology Incorporated will then advise concerning repairs and replacements.

Electrostatic Technology, Inc. Model 802 Armature Coater
2 Serial #15681
3 OPERATING PRINCIPLES
3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER

Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 3
3.2 PROCESS DESCRIPTION
Powder particles are aerated in a fluidizing chamber and are electrostatically charged by
ionizing air forced through a porous plate at the base of the chamber. As the powder particles
become charged, they repel each other to such a degree that they rise above the chamber
forming a cloud or veil of charged particles. When a grounded object is placed in this cloud or
conveyed through this cloud, the charged powder particles, because of their opposite potential,
are attracted to it. As the particles become attached to the object, they form a uniform coating,
being more attracted to exposed areas than to those already insulated. The longer the object is
exposed to the cloud, the thicker the coating becomes, until saturation eventually takes place.
Coating thickness is controlled by applied voltage to the charging media and exposure time to
the cloud. Because of the high voltage capability of the charging media, a sufficiently great
potential exists between it and most substrates to permit even natural insulators to be coated.
Unlike equipment with exposed electrodes, Electrostatic Technology, Inc.'s unique air
ionization process charges the powder without permitting the powder, the object, or the
operator to come in contact with the charging media.

Electrostatic Technology, Inc. Model 802 Armature Coater
4 Serial #15681
4 GENERAL SAFETY
4.1 INTRODUCTION
This section contains general study instructions for using your Electrostatic Technology, Inc.
(ETI) equipment. Task-and equipment-specific warnings are included in other sections of this
manual where appropriate. Note all warnings and follow all instructions carefully. Failure to
do so may result in personal injury, death, or property damage.
To use this equipment safely,
• Read and become familiar with the general safety instructions provided in this section
of the manual before installing, operating, maintaining, or repairing this equipment.
• Read and carefully follow the instructions given throughout this manual for performing
specific tasks and working with specific equipment.
• Store this manual within easy reach of personnel installing, operating, maintaining, or
repairing this equipment.
• Follow all applicable procedures required by your company, industry standards, and
government or regulatory agencies. Refer to the National Fire Protection Association
(NFPA) standard 33 and to federal, state, regulatory agency, and local codes for rules
and regulations covering installation and operation of powder coating systems.
• Obtain and read Material Safety Data Sheets (MSDS) for all materials used.

Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 5
4.2 SAFETY SYMBOLS
Become familiar with the safety symbols presented in this section. These symbols will alert
you to safety hazards and conditions that may result in personal injury, death, or property and
equipment damage.
WARNING: Failure to observe this warning may result in personal injury,
death, or equipment damage.
WARNING: Risk of electrical shock. Failure to observe this warning may
result in personal injury, death, or equipment damage.
WARNING: Disconnect equipment from line voltage. Failure to observe this
warning may result in personal injury, death, or equipment damage.
WARNING: Risk of explosion or fire. Fire, open flames and smoking
prohibited.
WARNING: Wear protective clothing, safety goggles, and approved
respiratory protection. Failure to observe may result in serious injury.
WARNING: System or material pressurized. Release pressure.
Failure to observe this warning may result in serious injury or death.
CAUTION: Failure to observe may result in equipment damage.
4.3 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. It is the
responsibility of the company operating the equipment to see that its personnel meet these
requirements.

Electrostatic Technology, Inc. Model 802 Armature Coater
6 Serial #15681
4.4 INTENDED USE
WARNING: Use of this equipment in ways other than described in this manual may result in
personal injury, death, or property and equipment damage. Use this equipment only as
described in this manual.
ETI cannot be responsible for injuries or damages resulting from nonstandard, unintended
applications of its equipment. This equipment is designed and intended only for the purpose
described in this manual. Uses not described in this manual are considered unintended uses
and may result in serious personal injury, death, or property damage. Unintended uses may
result from taking the following actions:
• Making changes to equipment that have not been recommended or described in this
manual or using parts that are not genuine ETI replacement parts.
• Failing to make sure that auxiliary equipment complies with approval agency
requirements, local codes, and all applicable safety standards.
• Using materials or auxiliary equipment that are inappropriate or incompatible with your
ETI equipment.
• Allowing unqualified personnel to perform any task.
4.5 INSTALLATION
Read the installation section of all system components manuals before installing your
equipment. A thorough understanding of system components and their requirements will help
you install the system safely and efficiently.
• Allow only qualified personnel to install ETI and auxiliary equipment.
• Use only approved equipment. Using unapproved equipment in an approved system
may void agency approvals.
• Make sure all equipment is rated and approved for the environment in which you are
using it.
• Follow all instructions for installing components and accessories.
• Install locking, manual, shutoff valves in the air supply lines to the system. This allows
you to relieve air pressure and lock out the pneumatic system before undertaking
maintenance and repairs.

Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 7
4.5 INSTALLATION (continued)
• Install a locking disconnect switch or breaker in the service line ahead of any electrical
equipment.
• Use only electrical wire of sufficient gauge and insulation to handle the rated current
demand. All wiring must meet local codes.
• Ground all electrically conductive equipment within 10 feet (3 meters) of the coating
area. Ungrounded conductive equipment can store a static charge which could ignite a
fire or cause an explosion if a hot spark is discharged.
• Install safety interlocks which shut down the coating system if the exhaust fan fails, a
fire is detected, or other emergency situation develops.
• Make sure the coating area floor is grounded and that the operator's platform is
grounded.
• Use only designated lifting points or lugs to lift and move heavy equipment. Always
balance and block loads when lifting to prevent shifting. Lifting devices must be
inspected, certified, and rated for a greater weight than the equipment being lifted.
• Protect components from damage, wear, and harsh environmental conditions.
• Allow ample room for maintenance, material supply, container drop-off and loading,
panel accessibility, and cover removal.
• If safety devices must be removed for installation, install them immediately after the
work is completed and check them for proper functioning.

Electrostatic Technology, Inc. Model 802 Armature Coater
8 Serial #15681
4.6 OPERATION
Only qualified personnel, physically capable of operating the equipment and with no
impairments to their judgement or reaction times, should operate this equipment.
Read all component manuals before operating a powder coating system. A thorough
understanding of all components and their operations will help you operate the system safely
and efficiently.
• Use this equipment only in the environments for which it is rated. Do not operate this
equipment in humid, flammable, or explosive environments unless it has been rated for
safe operation in these environments.
• Before starting this equipment, check all safety interlocks, fire-detection systems, and
protective devices such as panels and covers. Make sure all devices are fully
functional. Do not operate the system if these devices are not working properly. Do
not deactivate or bypass automatic safety interlocks or locked-out electrical disconnects
or pneumatic valves.
• Know where EMERGENCY STOP buttons, shutoff valves, and fire extinguishers are
located. Make sure they work. If a component malfunctions, shut down and lock out
the equipment immediately.
• Before operating, make sure all conductive equipment in the coating area is connected
to a true earth ground.
• Never operate equipment with a known malfunction or leak.
• Do not attempt to operate electrical equipment if standing water is present.
• Never touch exposed electrical connections on equipment while the power is “ON”.
• Do not operate the equipment at pressures higher than the rated maximum working
pressure of any component in the system.
• Know the pinch points, temperatures, and pressures for all equipment that you are
working with. Recognize potential hazards associated with these and exercise
appropriate caution.
• Wear shoes with conductive soles, such as leather, or use grounding straps to maintain
a connection to ground when working with or around electrostatic equipment.

Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 9
4.6 OPERATION (continued)
• Do not wear or carry metallic objects (jewelry or tools) while working with or around
electrostatic equipment. Ungrounded metal can store a static charge and cause harmful
shocks.
• Keep parts of the body or loose clothing away from moving equipment or parts.
Remove personal jewelry and cover or tie back long hair.
• Wear National Institute of Occupational Safety and Health (NIOSH) approved
respirators, safety glasses or goggles, and gloves, while handling powder containers,
filling hoppers, operating coating equipment, and performing maintenance or cleaning
tasks. Avoid getting powder coatings on your skin.
• Do not smoke in the coating area. A lit cigarette could ignite a fire or cause an
explosion.
• If you notice electrical arcing in the coating equipment, shut down the system
immediately. An arc can cause a fire or explosion.
• Shut off electrostatic power supplies before making adjustments to powder coating
fluidized bed.
• Shut off moving equipment before taking measurements or inspecting workpieces.
• Wash exposed skin frequently with soap and water, especially before eating or
drinking. Do not use solvents to remove coating materials from your skin.
• Do not use high-pressure compressed air to blow powder off your skin or clothes.
High-pressure compressed air can be injected under the skin and cause serious illness
or death. Treat all high-pressure fittings and hoses as if the could leak and cause injury.

Electrostatic Technology, Inc. Model 802 Armature Coater
10 Serial #15681
4.7 LESS-OBVIOUS DANGERS
Operators should also be aware of less-obvious dangers in the workplace that often cannot be
completely eliminated:
• Exposed surfaces on the equipment which may be hot or have sharp edges and cannot
be practically safeguarded.
• Electrical equipment which may remain energized for a period of time after the
equipment has been shut off.
• Vapors and materials which may cause allergic reactions or other health problems.
• Automatic hydraulic, pneumatic, or mechanical equipment or parts that may move
without warning.
• Unguarded, moving mechanical assemblies.
4.8 IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION
Do not operate a system that contains malfunctioning components. If a component
malfunctions, turn the system off immediately.
• Disconnect and lock out electrical power. Close and lock out hydraulic and pneumatic
shutoff valves and relieve pressures.
• Allow only qualified personnel to make repairs. Repair or replace the malfunctioning
component.

Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 11
4.9 MAINTENANCE & REPAIR
Allow only qualified personnel to perform maintenance, trouble-shooting, and repair
tasks.
• Always wear appropriate protective devices and use safety devices when working on
this equipment
• Follow the recommended maintenance procedures in your equipment manuals.
• Do not service or adjust any equipment unless another person trained in first aid and
CPR is present.
• Use only genuine ETI replacement parts. Using unapproved parts or making
unapproved modifications to equipment may void agency approvals and create safety
hazards.
• Disconnect, lock out, and tag electrical power at a disconnect or breaker in the service
line ahead of electrical equipment before servicing.
• Do not attempt to service electrical equipment if there is standing water present. Do
not service electrical equipment in a high-humidity environment.
• Use tools with insulated handles when working with electrical equipment.
• Do not attempt to service a moving piece of equipment. Shut off the equipment and
lock out power. Secure equipment to prevent uncontrolled movement.
• Relieve air pressures before servicing equipment. Follow the specific instructions in
this manual.
• Make sure that the room where you are working is sufficiently ventilated.
• If a "power on" test is required, perform the test carefully and then shut off and lock out
power as soon as the test is over.
• Connect all disconnected equipment ground cables and wires after servicing the
equipment. Ground all conductive equipment.
• Check interlock systems periodically to ensure their effectiveness.
WARNING: Operating faulty electrostatic equipment is hazardous and can
cause electrocution, fire, or explosion. Make resistance checks part of your
periodic maintenance program.

Electrostatic Technology, Inc. Model 802 Armature Coater
12 Serial #15681
4.9 MAINTENANCE & REPAIR (continued)
• Do not store flammable materials in the coating area or room. Keep containers or
flammable materials far enough away from the coater to prevent their inclusion in a
fire. If a fire or explosion occurs, flammable materials in the area will increase the
chances and the extent of personal injuries and property damage.
• Practice good housekeeping procedures. Do not allow dust or powder coatings to
accumulate in the coating area or on electrical equipment. Read this information
carefully and follow instruction.
4.10 DISPOSAL
Dispose of equipment and materials used in operation and cleaning according to your local
regulations.

Electrostatic Technology, Inc. Model 802 Armature Coater
Serial #15681 13
5 AIR, ELECTRICAL, AND WATER REQUIREMENTS
5.1 POWDER COATING MACHINE
5.1.1 Air
A clean, oil free, dry supply of compressed air must be provided using 1 in.(25.4mm)
I.D. line capable of supplying 75 SCFM (2.12 m3min) @ 80 psi (5.6 bar) minimum to
100 psi(6.9 bar) maximum.
5.1.2 Electrical
380 Volts, 50 Hertz, 3-Phase, 100 Amp service plant power must be supplied to the
main disconnect on located on the rear of the machine.
5.1.3 Water
5.1.3.1 Closed Loop Induction Heater Cooling System
Distilled water is required for the closed loop Induction Heater cooling
system. Approximately 10 gallons (37.8 liters) of distilled water is
required to fill the system.
5.1.3.2 Tower Water Requirements for Induction Heater Cooling
Customer must supply 7.5 gal/min (28.4L/min) at 30 psi (2.1 bar) of
cooling water [85º F (29º C) max, 45º F (7º C) min] to the Heat
Exchanger for the Closed Loop Induction Heater Cooling System.
5.2 INDUCTION HEATER
5.2.1 Electrical
Power for the Induction Heaters is supplied from the main power input specified in
Section 5.1.2 above

Electrostatic Technology, Inc. Model 802 Armature Coater
14 Serial #15681
6 MECHANICAL FUNCTION: SEQUENCE AND DESCRIPTION
6.1 LOAD/RELOAD AREA
Parts are manually placed on the ETI Roto-Floconveyor. The conveyor moves parts
through each station of the Model 802.
NOTE: The drive system is located at this station.
6.2 INDUCTION HEATER DEGREASER MODULE
Degreasing is accomplished by heating the parts with the Induction Heater Degreaser module.
This Induction Heater is the first of two 400 kHz/5kW units. This induction heater raises the
temperature of each part to eliminate grease and oil from the part surfaces. The hood for this
module must be closed to allow the unit to operate.
Adjustment controls for the Induction Heaters are located on the Operator Control Panel. For
information on temperature adjustment, refer to the Pillar Induction Heater manual in the
Manufacturer’s Manual binder.
The power control of this Induction Heater should be set to achieve the minimum temperature
that removes oil and grease from the parts.
The degreased parts then enter the Pre-Cool station, where they are cooled to ambient
temperature or less. The cooling is achieved by using a blower, located under the cooling
station, to blow air past the hot parts.
NOTE: The blower exhaust should be ducted outside the plant.
The parts exit the Pre-Cool station at the proper temperature for powder coating.
6.3 COATING MODULE
6.3.1 Coating Bed
The parts are conveyed through the coating bed. As the parts enter the bed area they
pass through the cloud of charged particles and the parts are electrostatically powder
coated.