SCHNIER AIR Flocker PRO User manual

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Art.Nr.:
810489
80 kV
300 µA

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1. Product and manufacturer 4
1.1. Product description 4
1.2. Specs 4
1.3. Product identification 4
1.4. Warranty and service notice 4
1.5. Manufacturer 5
1.6. Legal notice 5
1.7. Means of representation used 5
2. Guide to this manual 6
2.1. Persons to whom this manual is addressed 6
2.2. Accessibility of the operating instructions / storage 6
2.3. Work safety symbols and expressions 7
3. Instructions for avoiding hazards 7
4. Intended use of the AFP 9
4.1. Fields of application 9
4.2. Proper and professional operation 9
5. Protective equipment for persons operating the AFP 10
5.1. Dissipative footwear and gloves 10
5.2. Ear protection 10
5.3. Eye, nose and mouth protection 10
6. Structure of the AFP 11
6.1. Control with display and membrane keypad 12
6.2. Flocking hopper and motor for dosing brush 13
6.3. Flock reservoir container with dosing brush, brush bearing and sieve 14
6.4. Flock hopper with eccentric axes and sieve 15
6.5. Flocking Gun 16
7. Operating modes of the AIR Flocker PRO 17
7.1. Operation electrostatic-pneumatic 17
7.2. Operation electrostatic 17
7.3. Flocking 18
8. Site of installation 18
8.1. Conditions for a suitable installation site 18
9. Commissioning of the AIR Flocker PRO 19
9.1. Commissioning of the AIR Flocker PRO 19
10. Flocking 20
10.1. Types of flock 20
10.2. Quality of flocking 20
10.3. Process of flocking 20
11. Menu and settings via the membrane keypad 22
11.1. LED indicators 22
11.2. Keys and functions 22
11.3. Settings 22
11.4. Advanced settings 23
12. Working steps 24

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12.1. Changing the sieve 24
12.2. Change contact pressure between dosing brush and sieve 26
12.3. Changing the dosing brush 27
13. Malfunctions and their correction 31
14. Service and maintenance 33
14.1. Maintenance 33
14.2. Cleaning 33
15. Accessories and spare parts 34
16. Type plate 34
17. Declaration of Conformity 35
On our Youtube channel www.youtube.com/schnierelektrostatik,
we have produced interesting videos around flocking for you:
The following instruction videos are available for AIR Flocker PRO:
Tutorial about the AIR Flocker PRO settings
https://youtu.be/RX5fOEvLvAg
Tutorial about the advanced menu
https://youtu.be/EDyS4dn4yjc
AIR Flocker PRO - Basic setup tutorial
https://youtu.be/qBoItLUUOQk
AIR Flocker PRO - changing dosing brush
https://youtu.be/F3G13ckcRj4
AIR Flocker PRO - Changing and adjusting dosing sieve
https://youtu.be/SYApGtzZ3sU

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1. Product and manufacturer
Congratulations on the purchase of your AIR Flocker PRO!
1.1.Product description
The AIR Flocker PRO is the electrostatic-pneumatic flocking unit for professional use.
Sophisticated mechanics in combination with a modern control system is a guarantee for
sophisticated flocking with consistent quality. The parameters for high voltage, blower and
metering can be set quickly and easily via the convenient operating unit. In addition,
parameter sets can be stored and recalled just as quickly.
Made in Germany" is particularly important for the metering unit and the powerful blower
motor. The high-voltage supply is based on a modular system from SCHNIER Elektrostatik
that has been perfected over many years.
The innovative hand-held flocking gun uses the latest 3D manufacturing technology, which
makes previously unattainable geometries possible. Special attention was paid to the
ergonomics of the handle and the durability of the switch unit. The aim was to make working
as comfortable as possible, even over a longer period of time.
1.2.Specs
Variation
230 V
115 V
Input voltage
230 V +/-10%
115 V +/-10V
Input current
Max. 4 A
Max. 8 A
Output voltage
80 kV negative
Output current
Max 300 µA
Surroundings
+15°C to 40°C max. 70% rel. humidity, non-condensing.
Size
Approx. 885x500x865 mm
Weight
Approx. 120 kg
1.3. Product identification
Product: Electrostatic-pneumatic flocking machine
Type: AIR Flocker PRO
Part number: 810489
1.4. Warranty and service notice
The warranty is 24 months after delivery.
Any kind of warranty is void if the device has been opened, modified, parts have been
replaced with non-original parts or this operating manual has not been observed.
parts have been replaced with non-original parts or these operating instructions have not
been observed.
Repairs to the AFP can be carried out by SCHNIER Elektrostatik GmbH or an expert
authorized by SCHNIER Elektrostatik GmbH.
When repairs are carried out by authorized experts, only original spare parts may be used.
These can be obtained from SCHNIER Elektrostatik GmbH.
If you send an AFP to SCHNIER Elektrostatik GmbH, use only the original packaging for
transport.

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1.5. Manufacturer
SCHNIER Elektrostatik GmbH
Bayernstr. 13
72768 Reutlingen
Deutschland
Phone: [phone] / 90 973 - 60
Fax: [phone] / 90 973 - 99
www.schnier.de
www.schnier-flock.de
[email protected]
Head office: Reutlingen HBR 354 531
USt.-IdNr.: DE 146 481 986
General Manager: Olav Schnier
1.6. Legal notice
This manual may not be reproduced in part or in whole in any form, e.g. print, photocopy,
etc., or processed, duplicated or distributed using electronic systems.
The reproduction of trade names, common names, product designations, etc. in this manual,
even without special identification, does not justify the assumption that such names are to be
considered free in the sense of trademark and brand protection legislation and may therefore
be used by anyone.
1.7. Means of representation used
The following means of representation are used in these operating instructions to identify
hazards, notes and tips:
Symbol
Impact
This symbol warns of potentially hazardous situations which, if not
avoided, could result in death or injury.
This symbol warns of potentially dangerous electric shocks that
can result in death or injury if not avoided.
Warning of damage to the equipment or malfunctions
Note for simple, rational procedure

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2. Guide to this manual
These operating instructions must be read, understood and observed in all points by all
persons who are responsible for the devices and electrostatic systems. Only with knowledge
of these operating instructions can errors be avoided and safe and trouble-free operation be
guaranteed. SCHNIER Elektrostatik GmbH accepts no liability for damage resulting from
non-observance of these operating instructions!
This guide will allow you to:
- The safe handling of the AIR Flocker PRO.
For this purpose, you must be aware of the omnipresent and possible dangers
emanating from the AIR Flocker PRO. The hazards with the corresponding
instructions for hazard avoidance are listed from page 8 in this manual.
- The proper and professional operation of the AFP. This is described in these
instructions.
Please read these instructions carefully and act in accordance with the descriptions,
instructions and work procedures listed therein.
2.1. Persons to whom this manual is addressed
The AFP may only be operated by persons who have been instructed in its operation and
who have read these instructions carefully.
This operating manual applies to:
Persons who assemble, commission, perform flocking operations, maintain, service,
assemble, disassemble, repair, dispose of, and/or recycle the AFP.
Installation and maintenance personnel (e.g. machine setters, electrically qualified persons)
who have been trained by the manufacturer or operator with regard to the manual and
corresponding safety regulations.
Operating personnel (e.g. machine setters, persons with electrical qualifications) who have
been trained by the manufacturer or operator with regard to the manual and corresponding
safety regulations.
2.2. Accessibility of the operating instructions / storage
The operating manual must always be available at the plant for the responsible qualified
personnel (operating, maintenance, repair personnel, etc.) and must be ready to hand.
The manual must be kept by the operator for the entire service life of the plant. In case of
resale of the plant or parts of the plant, the manual must be handed over to the new owner,
as it is part of the plant.

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2.3. Work safety symbols and expressions
Notice:
In this operating manual, the expressions "live parts" or "active parts" refer to parts that have
a high-voltage potential during normal operation.
Symbol
Impact
This symbol warns of potentially hazardous situations which, if not
avoided, could result in death or injury.
This symbol warns of potentially dangerous electric shocks that
can result in death or injury if not avoided.
Warning of damage to the equipment or malfunctions
Note for simple, rational procedure
3. Instructions for avoiding hazards
Omnipresent and possible dangers emanate from the AFP.
There is also a risk that the AFP will be damaged and/or destroyed by improper operation.
The basic prerequisite for avoiding these dangers is that you read these operating
instructions carefully, especially this chapter. Act in accordance with the descriptions, notes
and operating procedures.
Risk of cuts and/or eye injuries
When cutting the outer and inner tensioning straps, you may suffer cuts and/or eye injuries
as well as cuts when lifting the AFP down or up on its transport pallet.
Injury prevention:
Only cut the outer and inner tensioning straps from the left or right narrow side of the AFP.
Never cut the outer and inner tensioning straps when facing them head-on.
Wear suitable gloves when lifting or lowering the AFP from the transport pallet.

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Risk of spinal injuries
You may suffer spinal injuries when lifting the AFP down or up on its transport pallet.
Injury prevention:
Before lifting down or up, assume the squatting position and straighten the spine. From the
squatting position, lift the AFP onto or off the transport pallet.
Risk of burns
You can suffer burns by touching the ball electrode (44).
Injury prevention:
Do not touch the ball electrode after the AFP has been connected to the power supply.
Danger of electric shocks
Avoid electric shocks:
The AFP must not be connected to the mains before and during assembly or disassembly.
For cleaning, maintenance or repair purposes, disconnect the AFP from the mains.
Disconnect the AFP from the power supply before removing the control and high-voltage
plug-in unit (13).
Disconnect the AFP from the power supply before replacing the cup electrode (45).
The ball electrode (44) must not be touched after the AFP has been connected to the power
supply.
Damage due to improper storage
Improper storage of the AFP can damage and/or destroy the unit.
Damage prevention:
Only store the AFP in its original packaging.
Avoid storage locations and installation sites with:
- high humidity
- strong solar radiation
- humidity and/or moisture
- strong temperature fluctuations
- extreme heat or extreme cold
- For information on the installation site and substrate, refer to chapter 8.

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Transport damage due to improper transport
Improper transport of the AFP can damage and/or destroy the device.
Damage prevention:
Only transport the AFP in its original packaging.
During operation, interference may occur due to emitted interference at the devices that are
in the immediate vicinity.
4. Intended use of the AFP
This chapter describes the purposes for which the AFP may be operated.
It also describes the conditions under which the AFP must not be operated.
The AFP may only be used and operated for the purposes described in this chapter.
4.1. Fields of application
The AFP can be used for electrostatic-pneumatic flocking of moldings, surfaces or cavities.
The AFP is particularly suitable for flocking complex moldings and cavities, such as those
found in automotive glove boxes and profiles with undercuts.
4.2. Proper and professional operation
There is a risk of explosion if adhesives containing solvents accumulate to form an
explosive gas atmosphere. This is particularly the case if there is no or insufficient technical
ventilation. An explosion can be triggered by an electric arc, as can occur at the ball
electrode (44) of the Flocking Gun (10).
Fire hazard exists with ignitable surfaces. An ignitable surface can be, for example, the
surface of an object to be flocked and grounded. The absence or inadequate technical
ventilation is conducive to the formation of ignitable surfaces. A fire can be triggered by an
electric arc, as can occur at the ball electrode (44) of the Flocking Gun (10).
In the event of structural modifications or optimizations to the unit by the customer without
prior consultation with SCHNIER Elektrostatik, all warranty claims will be voided.

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5. Protective equipment for persons operating the AFP
To maintain your health when handling the AFP, you should have the protective equipment
described below.
5.1. Dissipative footwear and gloves
By wearing dissipative footwear and dissipative gloves, you prevent the accumulation of
electrostatic charges that can lead to electric shocks.
5.2. Ear protection
During continuous operation of the AFP, its sound emission can possibly contribute to
hearing damage.
Therefore, use suitable hearing protection that reduces the sound emissions to a level that is
not harmful to health.
5.3. Eye, nose and mouth protection
To prevent flying flock from entering the eyes and/or entering the body through the nose or
mouth, wear eye protection in the form of suitable goggles and a suitable nose and mouth
guard.

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6. Structure of the AFP
1. Main switch
2. High Voltage connection
3. Powercon connection for power cable
4. Srew for grounding cable
5. Grounding connection for grounding air hose
6. Jack socket 6,3 mm for remote control
7. Connection for air hose
8. Air hose
9. High Voltage cable
10. Flocking Gun
11. Flock reservoir
12. Service flap
13. High Voltage module with control
14. Control with display and membrane keypad
15. Castor wheels with brake
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

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6.1. Control with display and membrane keypad
16. High Voltage Up/Down
17. Blower Up/Down
18. Dosing Up/Down
19. Preset Up/Down
20. Menu
21. Enter
22. LED operation
23. LED grounding
24. LED malfunction
25. LED high voltage
26. Active preset
27. Actual value high voltage
28. Actual value operation current
29. Target value high voltage
30. Target value blower
31. Target value dosing
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

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6.2. Flocking hopper and motor for dosing brush
32. Quick release left
33. Quick release right
34. Flock hopper
35. Locking screws for the eccentric axles located inside the flock hopper.
36. Air hose
32
36
33
34
35

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6.3. Flock reservoir container with dosing brush, brush bearing and sieve
37. Brush bearings
38. Dosing brush
39. Sieve
14. Flock reservoir container
40. Protective grid
37
38
39
14
40

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6.4. Flock hopper with eccentric axes and sieve
The flock hopper (34) is located behind the service flap (12).
34. Flock hopper
35. Locking screws for the eccentric axes located inside the flock hopper.
39. Sieve
41. Eccentric axe
35
34
39
41

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6.5. Flocking Gun
42. Handle
43. Push button
9. High voltage cable
44. Ball electrode Ø 33,5 mm
45. Cup electrode
46. Magnetic holder
36. Air hose
43
42
44
45
46
9
36

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7. Operating modes of the AIR Flocker PRO
The AFP can be operated not only electrostatically-pneumatically, but also exclusively
electrostatically. These two application possibilities are described in this chapter.
7.1. Operation electrostatic-pneumatic
Characteristic of this operating state is that the AFP functions as an electrostatic-pneumatic
flocking device.
For this purpose, the flock in the flock supply container (14) is metered out by the rotating
metering brush (38) through a perforated plate screen insert (39) arranged under the metering
brush into the flock hopper hanging below.
The amount of flock to be dosed out can be varied by changing the speed of the dosing brush.
The speed can be changed with the Dosing Up/Down keys (18). A low speed means a
correspondingly low flock quantity to be dosed out, a high speed means a correspondingly
large flock quantity to be dosed out.
The flock metered into the flock hopper is drawn off by the blower and transported on an air
stream through the PU air hose (36) connected to the blower connection piece to the flocking
gun (10).
The amount of air sucked in and thus the speed of the flock to be transported can be varied.
The air volume sucked in can be changed with the Blower Up/Down keys (17). The air volume
must be set in such a way that the transport of the flock to the flocking gun is guaranteed.
The flock transported through the air hose (36) is blown through the handle (42) and the cup
electrode (42) of the Flocking Gun past the ball electrode (45) onto the object to be flocked.
During this process, the ball electrode is under high voltage. As a result, the flock flowing
past is electrostatically charged and aligned in one direction. The strength of the charge can
be changed with the High voltage up/down keys (16). Depending on the set dosage, the flock
used and the distance between the flocking gun and the object to be flocked
to the flocking object, a higher high voltage can achieve a higher flock density, and a lower
high voltage can achieve a lower flock density.
7.2. Operation electrostatic
For purely electrostatic operation, the HV cable of the flocking gun must be completely
disconnected from the AIR Flocker PRO and pulled out of the HV connection.
For this purpose, the "EASY Flocker hand cable" (Art. No. 810471) is connected to the HV
connector.
The blower motor is set to the value 0 using the "Blower down" key (17) and the dosing is set
to the value 0 using the "Dosing down" key (18).
The flock fibers are now no longer applied to the workpiece with air assistance, but purely
electrostatically. For this purpose, the flock fibers are first filled into the applicator of the hand
cable and a corresponding sieve is put on.

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7.3. Flocking
Flocking processes can be performed or terminated by pressing or releasing the button (13)
of the flocking gun.
When the switch is pressed, the Operation LED (22) starts to light up in green. This lights up
as long as the button remains pressed. The blower is then briefly ramped up to maximum
speed. Afterwards, the speed is reduced to the value set with the Blower Up/Down keys (17).
Due to the ramp-up to the maximum speed, a stronger sound emission is generated for a short
time than is the case in continuous operation of the AFP. Any flock in the air hose (36) is blown
out when the blower is ramped up. The metering brush (38) is then rotated and flock is metered
out. The high voltage set with the HS Up/Down keys (16) is then generated.
When the button is released, the blower is shut down, the dosing brush is stopped and the
high voltage is discharged. The LED flashes until the voltage is completely discharged. The
LED then goes out.
8. Site of installation
This chapter describes the conditions that must be met by a suitable installation site so that
the AFP can be operated properly and professionally. The overall view of the AFP with the
part markings can be found on the last page of these operating instructions.
8.1. Conditions for a suitable installation site
A suitable installation site for the AIR Flocker PRO must meet the following conditions:
- The installation site must be covered and dry. This prevents damage to the AFP due
to humidity and moisture.
- The base must be firm and level. This ensures that the AFP stands firmly and
securely and cannot be displaced by vibrations.
- The base must be free of impurities such as dust, etc., so that these cannot be
sucked in by the blower via the suction port and block the air hose if necessary.
- An unobstructed air supply must be ensured so that the blower does not overheat.
To this end, a minimum distance of 10 cm must be maintained from boundary
surfaces.
- The unimpeded opening of the lid of the flock reservoir container (14) must be
ensured.
- The unimpeded opening of the service flap (12) must be ensured.

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9. Commissioning of the AIR Flocker PRO
This chapter describes how the AIR Flocker PRO can be put into operation after proper and
professional installation.
Commissioning is understood to mean connecting the AFP to the power supply and testing
the AFP for function.
The following description of commissioning refers to the use of the AFP in conjunction with
the associated electrostatic manual spraying device (Flocking Gun).
The initial start-up is carried out without flock in the flock storage container.
- To avoid electric shocks and burns, do not touch the ball
electrode (44) after making the power connection.
- To avoid high-voltage flashovers to flocking objects or machine parts, a minimum
distance of 10 cm from the ball electrode (44) to flocking objects or machine parts
must be maintained.
9.1. Commissioning of the AIR Flocker PRO
1. Establish the power connection. To do this, plug the Powercon connector into the
connector (2) on the front of the AFP. The mains plug is plugged into the mains socket
provided.
2. Insert the HV connector plug of the flocking gun into the HV connector socket of the
AFP. It is essential to ensure that the entire plug is dry and clean.
3. Screw the union nut only slightly tight.
4. Push the air hose over the connection on the AFP and secure it with the clamp. Insert
the end of the hose wire into the ground socket and screw it tight.
5. Connect the ground wire for grounding your workpiece to the screw with the wing nut
and screw it tight. Also connect the ground wire for grounding the AFP here.
6. Turn the main switch (1) clockwise to the I ON position.
7. The display shows the last preset called up (preset 1 is preset during initial start-up).
8. Now the AIR Flocker PRO is ready for operation. When the switch of the flocking gun
is actuated, the fan,the dosing and the high voltage are started with the set parameters.
9. The blower is briefly brought up to maximum speed to blow out any excess flock still in
the hose. Afterwards, the blower will ramp down to the set value. The duration of the
blow-out process can be set in the advanced menu.

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10. Flocking
10.1. Types of flock
The following types can be processed with the AFP:
- Cotton
- Viscose
- Polyamide (Nylon, Perlon)
- Polyester
10.2. Quality of flocking
The quality of flocking can be influenced by the following parameters:
Flock
The moisture and flowability of the flock used is decisive for the flocking quality. Basically,
the use of dry and free-flowing flock leads to better flocking results.
Flock quantity
Basically, a larger flock quantity means a higher flock density. The decisive factor here is the
type of flock used.
Strength of charging the flock
Basically, a stronger charge on the flock means better alignment of the flock on the object to
be flocked.
Distance of the Flocking Gun to the object to be flocked
In principle, a smaller distance from the Electrostatic Hand Spray Unit to the flocking object
results in a higher flock density.
Adhesive
The flocking quality depends largely on the adhesive used and its opening time.
10.3. Process of flocking
1. Place the object to be flocked on the grid bottom of the flocking booth. (Art.No.
810477).
2. Ground the object to be flocked. To do this, clamp the alligator clip of the grounding
cable to the object to be flocked. Make sure that the alligator clip has sufficient
contact with the adhesive.
3. Switch on the suction unit (Art. No. 810495).
4. Switch on the AFP. To do this, turn the main switch (1) clockwise to the I ON position.
5. If necessary, set the settings of dosing, blower and high voltage to medium values.
6. Take the Flocking Gun.
7. To blow out residual flock from the air hose and to set a continuous flock flow, direct
the Flocking Gun in the flocking booth next to the object to be flocked.