Metallisation ARC150-CG23 User manual

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ssue: 21/11-11

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Issue: 23-10-2014
This maintenance manual must be read and understood before
any attempt is made to disassemble the equipment described
herein.
Under no circumstances should any modifications be made to
the equipment without prior written approval from Metallisation.
MAN-ARC150-MA
For Pistols: ARC150-CG23
ARC150-CG25
For Energiser: S500-PLC
Related Manuals:
Operation Manuals:
MAN-ARC150-OP
Energiser Maintenance Manual:
MAN-ENE-S500(150)

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CONTENTS
SECTION 1
SUPPLIES PACKAGES...........................................................................................................................4
1.1 Standard Supplies.......................................................................................................................................5
1.2 Manifold......................................................................................................................................................6
1.3 Extended Supplies......................................................................................................................................6
SECTION 2
MAINTENANCE........................................................................................................................................7
2.1 Routine Maintenance..................................................................................................................................8
2.2 Disconnecting the Pistol..............................................................................................................................9
2.3 CG Spray Head –Checking Contact Tips.................................................................................................10
2.4 CG Spray Head –Complete Disassembly ................................................................................................12
2.5 CG Spray Head Reassembly....................................................................................................................14
2.6 Advanced Disassembly.............................................................................................................................16
2.7 Drive Unit Maintenance.............................................................................................................................22
SECTION 3
FAULT FINDING.....................................................................................................................................23
3.1 Pistol Troubleshooting ..............................................................................................................................24
3.2 Drive Unit Troubleshooting –Inverter Messages.......................................................................................26
SECTION 4
ILLUSTRATED PARTS LIST .................................................................................................................28
4.1 Pistol Overview.........................................................................................................................................29
4.2 CG Spray Head.........................................................................................................................................30
4.3 Gearbox & Terminal Blocks ......................................................................................................................32
4.4 Cover Plates & Wire Guides .....................................................................................................................33
4.5 Tensioning Components...........................................................................................................................34
4.6 Trigger Assembly......................................................................................................................................35
4.7 The Flywheel ............................................................................................................................................35
4.8 Push / Pull Wire Drive and Motor Assembly - Overview............................................................................36
4.9 Push / Pull Wire Drive and Motor Assembly –Explosion...........................................................................38
4.10 Recommended Spares Holding ................................................................................................................40

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SECTION 1
SUPPLIES PACKAGES
1.1 Standard Supplies
1.2 Manifold
1.3 Extended Supplies

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1.1 Standard Supplies
The standard Supplies Package is 10 and 20 metres in length with all fittings appropriate to
connect to the ARC150 Pistol and S500-PLC Energiser. The table below highlights the
consumable parts available for these Supplies.
PART NUMBER
CONSISTING
QTY
SUP150-10M
Arcspray150,
10m supplies
package for
electric drive,
S500
5530
500A Cooled Conductor Assembly (2.5 Mtr)
2
6616
70mm Sq Power Cable *cable only
30
21181
Air Hose Black (3/4”) (M) *hose only
7.5
5515
6 Core + E 0.5mm Grey Control Cable
10.5
7601
Arc140 / Arc150 Flexible Drive Shaft 10 Mtr
1
7549/10
Arc140 / Arc150 Conduit 10M
2
5548/7.5
Energizer to manifold block supplies cover 7.5 Mtr
1
5549/2.5
Pistol to manifold block supplies cover 2.5 Mtr
1
5544A-ASSY
Manifold Block Assembly with terminals and covers
1
SUP150-20M
Arcspray150,
20m supplies
package for
electric drive,
S500
5530
500A Cooled Conductor Assembly (2.5 Mtr)
2
6616
70mm Sq Power Cable *cable only
70
21181
Air Hose Black (3/4”) (M) *hose only
17.5
5515
6 Core + E 0.5mm Grey Control Cable
20.5
7601/20
Arc140 / Arc150 Flexible Drive Shaft 20 Mtr
1
7549/10
Arc140 / Arc150 Conduit 10M
4
5544A-ASSY
Manifold Block Assembly with terminals and covers
1
5548/17.5
Energizer to manifold block supplies cover 17.5 Mtr
1
5549/2.5
Pistol to manifold block supplies cover 2.5 Mtr
1
7595
Arc140 / Arc150 Fde Conduit Ext Adaptor
2
Power, Air and Control Cables
5530 / *6616 / *21181 / 5515
Flexible Drive
Shaft
7601 or 7601/20
Wire Conduits
7549/10
SUP150-20M
ONLY
7595
Manifold Block Assembly and Covers
5549/2.5 / 5548/7.5 or 5548/17.5 / 5544A-ASSY

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5544
7287
8237
5547
5545
5546
5570
1.2 Manifold
Each Standard size Supplies Pack incorporates a Manifold which allows the transfer of air and
current to the conductors. The below illustration shows the parts that comprise the Manifold
Assembly.
1.3 Extended Supplies
The following extended supplies are available for connection to the optional Power Extension
Trolley (ARC150-PET):
Please contact Metallisation if you require any consumable parts for the above Supplies
Packs.
NB: Extended supplies pack covers are not available for configurations longer than 20m as
the cables become too heavy to package together.
PART
NUMBER
CONSISTING
DESCRIPTION
QTY
5544A-ASSY
Manifold Block
Assembly with
terminals and
covers
5570
Manifold Terminal Block (700A)
2
7287
3/8" Plug (Int'Hex)
1
8237
3/4"BSP x 1/2"BSP Coned Coupler
1
5544
ARC150 /
ARC170AC
Manifold
Block
5545
ARC150 / ARC170AC Manifold Block End Cap
1
5546
ARC150 / ARC170AC Manifold Block Cover
1
5547
ARC150 / ARC170AC Manifold Block Body
1
PART NUMBER
DESCRIPTION
SUP150-10EX
10m Supplies pack for power extension trolley (ARC150-PET)
SUP150-20EX
20m Supplies pack for power extension trolley (ARC150-PET)
SUP150-30EX
30m Supplies pack for power extension trolley (ARC150-PET)
SUP150-40EX
40m Supplies pack for power extension trolley (ARC150-PET)
To Energiser
To Pistol

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SECTION 2
MAINTENANCE
2.1 Routine Maintenance
2.2 Disconnecting the Pistol
2.3 CG Spray –Checking Contact Tips
2.4 CG Spray Head –Complete Disassembly
2.5 CG Spray Head Reassembly
2.6 Advanced Disassembly
2.7Drive Unit Maintenance

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2.1 Routine Maintenance
The following table gives a routine maintenance schedule for the ARC150 Arcspray Pistol.
NB: Before commencing repairs or maintenance on any part of the Pistol, ensure that the power supply
has been isolated. If possible, work should be carried out in a clean environment, if the system has not
been used for a period of time it is strongly recommended that all connections are checked before
commencing operation. Failure to do this could result in damage to the equipment.
MAINTENANCE
SCHEDULE
MAINTENANCE OPERATION
EVERY 8 HOURS
Remove the Hood and Shroud.
Clean any dust and debris from the Wire Roller Assy and surrounding areas on the Pistol.
Clean any dust and debris from the Drive Unit.
Ensure that the inside of the Air Cap is clean.
Clean and refit the Hood and Shroud.
Clean Wire Guides.
Check all cables and hoses for damage and dust –clean / replace as necessary.
Check the electrical connections at the Manifold for damage. Replace if necessary. Ensure electrical
connections are tight.
Blow clean dry air through the Wire Conduits / PTFE Tubing for approximately 2 minutes.
Blow clean dry air over the wire being used to remove any dust residue.
Clean and / or replace the Contact Tip and Contact Tip Support Tubes to ensure smooth wire feed.
Change wire cleaner cloths and re-lubricate.
EVERY 20
HOURS
In addition to the above, carry out the following:
Dismantle the CG Spray Head –Section 2.4. Clean all components and re-fit or replace as necessary.
Lubricate the Pinch Release Cam.
Generally look for signs of overheating on wire insulation.
EVERY
40 HOURS
In addition to the above, carry out the following:
Check and ensure that all mechanical and electrical connections are secure.
Inspect the Supplies package and Manifold for any signs of damage, wear or perishing due to age.
Remove Rollers Tyres and reverse or if needed clean using a wire brush.
Inspect Wire Guides for wear.
NB: Solvent based cleaners MUST NOT BE USED when cleaning the ARC150 Pistol as
they can have a detrimental effect on the pistol’s drive box.
NB: Power to the Energiser MUST be isolated before performing any maintenance
work. Failure to do so may result in serious injury.

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2.2 Disconnecting the Pistol
Release roller tension
by pushing the Pinch
Release Cam in the
direction shown.
Remove the wire
conduits and wire
from the rear of the
pistol by hand.
Uncouple the Pistol
Control Cable. This
connection is found on
the rear of the pistol.
2
NOTE: Before attempting to disconnect the Pistol always be sure to isolate the Mains Supply.
1
Using a Spanner, hold steady the Terminal Block (A). Using a second Spanner unscrew the Cooled Conductor (B). Repeat the step
for the opposite side and remove the second Cooled Conductor.
Unscrew and remove the Flexible Drive Cable (C).In order to prevent dust ingress wrap up the square end of the cable.
NB: Before attempting to reconnect the Pistol, always ensure that the Mains Power is isolated and that all connections are clean and
free from damage. Also ensure that all connections are tight as a poor connection or contamination can cause overheating.
3
4
Loosen the Pointed Shroud Screw and remove the Shroud by
pulling forward.
Loosen the Thumb Screw and remove the Hood.
A
B
C

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2.3 CG Spray Head –Checking Contact Tips
Remove the Air Cover by unscrewing in the direction shown.
3
Remove the Air Cap by pulling forward.
4
If not already
removed, loosen
the Pointed Shroud
Screw and remove
the Shroud by
pulling forward.
1
NOTE: Before attempting to remove the Contact Tips always ensure that the mains power supply is isolated and the wire has been
removed from the pistol.
Loosen the Thumb Screw
and remove the Hood.
2

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Continue to remove the Contact Tips using the following technique:
Once satisfied, reassembly of the CG Spray Head, from the point of the Contact Tip removal
is a reverse of the above procedure. All components must be cleaned in an appropriate de-
greasing agent and blow dried before replacing.
For complete disassembly instruction of the CG Spray Head please see Section 2.4.
Remove the Air Concentrator by pulling forward.
5
At this point the Spray Head will look as shown and the
Contact Tips will be accessible.
6
7
Using a suitable
spanner, remove the
Contact Tips and
check for damage and
clean / replace as
necessary.

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2.4 CG Spray Head –Complete Disassembly
Loosen the Air Cover by turning in the direction shown. DO
NOT unscrew completely. Now the complete Spray Head
Assembly can be pulled forward from the pistol.
4
Using an appropriate Hex Key remove the Screws and
Clamp Pads from the left and right hand Terminals.
3
If not already removed, loosen the Pointed Shroud Screw
and remove the Shroud by pulling forward.
1
NOTE: Before attempting to disassemble the Spray
Head always ensure that the mains power supply is isolated
and the wire has been removed from the pistol.
5
Contact Tip Support Tubes will need to be replaced
periodically. The frequency of replacement will depend upon
the wire used and adherence to maintenance schedule.
At this point the Contact Tips Support Tubes can be removed and cleaned / replaced as necessary. The Contact Tip Support Tubes
can be removed by hand as shown above. If experiencing difficulty in removing, use soft jaws.
NB: Drills should NOT be used to clean tubes as they are likely to increase the size of the Contact Tube, potentially reducing its life.
Loosen the Thumb Screw and remove the Hood. Check the
‘O’ Ring on the Air Cover for damage and replace as
necessary.
2

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Taking care not to drop any of the parts, continue to inspect the Spray Head parts using the
following technique:
The Transfer Plug
should have come
away with the Spray
Head Assembly. Pull
it out.
If it remained in the
Pistol, pull it out from
there.
9
Taking care not to drop the any of
the Spray Head parts, unscrew
and remove the Air Cover.
The Air Cover should be easy to
unscrew having loosened it whilst
attached to the pistol.
6
7
Lift out the Air Cap
and check for
damage.
This is an example of wear to an
Air Cap –the central orifice is no
longer perfectly round.
Inspect the Transfer
Plug and the two ‘O’
Rings for wear /
damage.
Wash all components
in an appropriate de-
greasing agent, blow
dry and if any parts
are damaged renew
as required.
10
8
Lift out the Air
Concentrator and
check for damage.
This is an example of damage to
an Air Concentrator –we can see
the wear on either side of the
central orifice.

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2.5 CG Spray Head Reassembly
Screw the Air
Cover over the Air
Cap. Hand tighten
firmly but NOT
excessively.
5
With both ‘O’ Rings fitted to the Transfer Plug,
lubricate the larger ‘O’ Ring lightly with silicon
grease.
Press the Transfer Plug
into the Contact Tube
Support Block until the
largest diameter
touches the rear of the
block.
1
Once all Spray Head parts have been cleaned and any damaged parts have been renewed, the Spray Head can be reassembled
using the following technique:
Select the correct Contact Tips for the wire being sprayed –
see Section 4.2.Push the Contact Tubes through the Contact
Tube Support Block until they bottom out and they protrude
from the front face of the seat of the block.
2
Place the Air Concentrator in the seat of the Contact Tube
Support Block with the Contact Tubes passing through the
Air Concentrator.
3
Place the Air Cap over the Air Concentrator.
4

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NB: Before refitting the Spray Head onto the pistol, ensure that the contact areas on the
Terminals and Clamp Pads are clean and undamaged. Poor contact in these
areas can cause overheating.
Slide the Hood over the front of the pistol and tighten the
Thumb Screw.
8
Fit the Shroud onto the Air Cover and
tighten the Pointed Shroud Screw in the
direction shown.
9
NB: The Rear Wire Guides and Roller
Guide Assy can be removed for cleaning
/ replacing at any point as per the
ARC150 Operating Manual. They will
however be removed as a matter of
course during the Advanced Dissasembly
procedure that now follows.
7
Re-fit the Clamp Pads, by pressing the CG Spray Head
against the Pistol. Fit the first Clamp Pad loosely and then fit
the second Clamp Pad. Tighten both by screwing in firmly but
NOT excessively. Excessive force will result in damage to the
Clamp Pads / Terminals.
Place the Spray Head against the front of the pistol. Ensure the Transfer Plug locates in the Contact Tube Support Block and the Contact
Tubes locate in the left and right hand Terminals.
It is important that the Contact Tubes are pushed fully through the Air Concentrator and that they are level with each other. If uncertain,
check this is the case by removing the Air Cover and Air Cap.
6

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2.6 Advanced Disassembly
The reduction gearing has been factory lubricated for long life. Disassembly may be required if any faults are experienced but it is
recommended that when a major overhaul is required or accidental damage occurs that the Pistol is returned to the nearest
Metallisation Factory, Distributor or Agent for repair. If however further disassembly is necessary, the following procedure should be
followed but only performed by experienced fully competent maintenance personnel.
Disconnect the Pistol as per Section 2.2
Remove the CG Spray Head as per Section 2.4
Unscrew the 6 x Button Head Cap Screws holding the ARC150
Cover Plate in place.
Beneath the Cover Plate the ARC150 Cover Plate Gasket will
then need to be removed.
Using an appropriate Hex Key unscrew the 2 x Socket Head
Cap Screws connecting the wires to the left and right hand
Terminals.
1
2
4
5
Unscrew the 2 x Socket Head Cap Screws holding the right and
left hand Terminals to the ARC150 Pistol Body. The left and
right hand Terminals can now be cleaned / replaced as
required. Using a suitable ‘O’ Ring tool remove the ‘O’ Ring
found on the underside of the Terminals and replace as
necessary.
The wire should be pulled through the hole in order to free it
completely from the Side Plate.
3

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If removing the Side Plates for inspection / replacing of the Front Wire Guides, continue with
the following disassembly procedure:
This is how the Pistol appears at this point. For maintenance of
the Front and Rear Wire Guides go to point 9/10. To continue
stripping the pistol, go to point 11.
6
7
9
8
Using an appropriate Hex Key unscrew the 4 x Socket Head
Cap Screws holding the ARC150 Side Plates in place.
Before the Side Plates can be removed, the Switch must be released from the Side Plates. Using suitable pliers pull the Side Plate Switch
Clip upwards until it is freed from the Side Plate. Carefully pull the switch out.
Periodically Wire guides will
need to be removed for
cleaning and replacement.
Taking each side plate, use
an adjustable spanner to
unscrew the Rear Wire
Guides and remove for
inspection.
Clean or renew as
necessary.
NB: Rear Wire Guides can
be removed for inspection
without removing the side
plate.
The Front Wire Guide in each side plate is held in place by a
Circlip. Circlip pliers are required to remove the circlip, then the
front wire guide can be pulled out easily by hand.
10

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If inspecting the Trigger Assembly, continue with the following instruction. To inspect the
Flywheel go to point 14.
6295
Switches
If required the Handle can be removed from the Trigger Assembly. Using an appropriate Hex Key. Unscrew the Handle Screw on the
underside of the Handle then pull away from the Trigger Assembly.
The push button assembly is a singular unit and is not normally changed as individual parts. However, the switches can be replaced but
only by competent engineers with experience of soldering.
11
14
To remove the Trigger Assembly 6 x Socket Head Cap Screws
will first need to be unscrewed using an appropriate Hex Key.
Pistol Rear
Pistol Underside
Now, the Trigger Assembly must be released from the Tension
Assembly. Using an appropriate Roll Punch, tap out the Pinch
Roll Pivot Pin, keep this somewhere safe for reassembly later.
The complete Trigger Assembly can now be removed by
pulling it away from the Pistol over the Flex Drive Connector.
In order to remove the Flywheel, unscrew and remove 2 x Socket Head Cap Screws on the underside of the ARC150 Pistol Body using an
appropriate Hex Key. Now the Flywheel Support Mk2 can be pulled out.
Using an appropriate Hex Key, unscrew the Grubscrew located in the Flywheel Mk2. The complete Flywheel Assembly can now be pulled
out by hand.
12
13
Reassembly
Note:
The Pinch Roll
Pivot Pin MUST
be punched out
from the left to
right to prevent
scoring of the
internal bore.
Reassembly Note:
When replacing the
Grubscrew, it must be
aligned with the hole in
the Pistol Wormshaft.

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If inspecting the Tension Assembly, go to point 17 and continue the strip down procedure:
15
17
18
Removing the Flywheel will expose an ‘O’ ring on the underside
of the ARC150 Pistol Body. If damaged or worn, remove using
an appropriate ‘O’ Ring Tool and replace accordingly.
This is how the Pistol will appear at this point. If problems are
experienced with the Tension Assembly, continue to strip the
Pistol by continuing to point 17. Problems experienced with the
gears or Wormshaft, go to point 20.
Using an appropriate Hex Key, unscrew the Special Tension Screw. This is a long screw and will take a while to unscrew completely.
Be sure to retain the Spring Support (Threaded), 2 x Spring (stainless steel) and Spring Limiter as they fall from the assembly. Check these
parts for wear / damage and replace accordingly.
16
Reassembly Note:
Before replacing the ‘O’
Ring, grease with silicon
grease.
Spring Support
(Threaded)
Spring
(Stainless steel)
Spring Limiter
If necessary, remove the Shoulder Screw from the Tension
Assembly using a Flat Head Screwdriver and check the Pinch
Roll Bearing and Steel Washer (5mm Dia) for wear / damage.
Renew as required.
The Special Tension
Screw and Arm Pivot Pin
can be pulled away for
inspection and cleaning
or if appropriate,
replacement.
Pinch Roll
Bearing
Steel Washer
(5mm Dia)
Shoulder Screw
Special
Tension
Screw
Arm Pivot
Pin

Page 20 of 42
Continue to inspect the Tension Assembly following point 19. If problems are experienced with
the Wormshaft or gears, go to point 20 and continue the stip down procedure.
In order to remove the Pinch Release Cam for inspection or renewal, first remove the 6mm Ext Circlip using appropriate Circlip Pliers. Then
push out the Cam Pivot Pin. The Pinch Release Cam will now lift out.
Examine all parts for dirt, wear and damage. Clean all parts as needed. Where necessary replace the parts. Ensure all parts are properly
lubricated before reassembly.
19
Hold Still
Using two appropriate Hex Keys remove the Socket Head Cap Screws retaining the Roller End Cap, Pistol Roller Tyre End Cap and
Roller Roller Tyre to the ARC150 Pistol Body. One Hex key to hold one side in place while the other to unscrew the opposite side.
The Wire Roller parts can then be pulled away by hand, see assembly above right.
Using the appropriate Hex Key, loosen the Grubscrew in the
ARC150 Pistol Drive Box. This doesn’t need to be removed
completely.
Using Circlip Pliers, remove the 52mm Intl Circlip retaining the
gears in the Worm Drive Box.
20
21
22
Reassembly Note:
When replacing the
52mm Intl Circlip, ensure
the gap is aligned with
Grubscrew entry point.