Sulzer Metco ECO ARC 600 User manual

© 2006 Sulzer Metco
ECO ARC 600
WIRE ARC SPRAY SYSTEM
Manual
NOTICE
All personnel reponsible for the proper and safe use of this equipment must read and
understand this instruction manual.
In addition, the operator of this equipment must receive personal instructions in its use.
A thorough understanding of the operation, maintenance, and safety requirements of
this equipment is essential.

Manufacturer of this unit:
Sulzer Metco OSU GmbH
Weseler Str. 1
47169 Duisburg
Telefon [phone]
Telefax [phone]
Sulzer Metco distribution:
http://www.sulzermetco.com
Protective note according to ISO 16016
The reproduction, distribution and utilization of this document as well as the communi-
cation of its contents to others without explicit authorization is prohibited. Offenders will
be held liable for the payment of damages. All rights reserved in the event of the grant
of a patent, utility model or design.

Contents
1 General safety instructions
1.1 Safety pictograms..............................................................................................1
1.2 Operating and safety regulations.......................................................................3
1.3 Authorized use...................................................................................................4
1.4 Unauthorized use ..............................................................................................4
1.5 Measures concerning personnel and organization............................................5
1.6 Ventilation and exhaust.....................................................................................6
1.7 Emissions, caused by the system .....................................................................7
1.7.1 Metallic dust and fumes.....................................................................................7
1.7.2 Spray jet, comprising molten metal particles and compressed atomizer air......8
1.7.3 Electric arc - UV radiation / Infrared radiation....................................................9
1.7.4 Noise ...............................................................................................................10
1.7.5 Electrical energy..............................................................................................11
1.7.6 Compressed air energy...................................................................................12
1.7.7 Dust combustion and dust explosion hazard...................................................13
1.7.8 Hot surface......................................................................................................14
1.7.9 Danger of tripping / falling................................................................................14
1.7.10 Moving Parts..................................................................................................14
1.7.11 Oily compressed air (only at systems with air motor)....................................15
1.8 Other instructions ............................................................................................16
1.8.1 Protective equipment, protective and work clothing........................................16
1.8.2 Spray dust disposal.........................................................................................16
1.8.3 Solvents used for degreasing..........................................................................17
1.9 Hazardous materials........................................................................................18
1.10 Europe - Laws, Regulations, Standards and Directives................................21
1.11 German Laws, Instructions, Standards and Directives..................................22
1.12 DIN-Standards...............................................................................................24
1.13 Professional Insurance Association Accident Prevention Regulation ...........26
1.14 TRGS - Technical Regulations on Hazardous Substances...........................28
2 System-dependent Informations
2.1 What you need to know about this wire arc spray unit......................................1
2.1.1 General Informations.........................................................................................1
2.1.2 Authorization procedure ....................................................................................2
2.1.3 Spray wire..........................................................................................................2
2.2 Transport and Positioning..................................................................................3
2.2.1 Transport...........................................................................................................3
2.2.2 Positioning.........................................................................................................3
2.3 Further Instructions............................................................................................4
3 Technical Data und energy supply
3.1 Technical Data...................................................................................................1

3.2 Energy supply....................................................................................................3
3.2.1 Electrical supply.................................................................................................3
3.2.2 Compressed air supply......................................................................................4
4 Installation of system
4.1 Installation instructions......................................................................................1
4.2 Installation schema............................................................................................2
4.3 Connecting hose package to power supply.......................................................2
4.4 Connecting power supply to plant mains...........................................................2
4.5 Installation of decoiling device...........................................................................3
4.5.1 Hasp spool decoiling device..............................................................................3
4.5.2 Drum decoiling device.......................................................................................4
4.6 Important notes to follow: ..................................................................................4
4.6.1 Hasp / dorn spools.............................................................................................4
4.6.2 Drum decoiling device.......................................................................................4
5 Operation of system
5.1 Operating devices and indicators......................................................................2
5.2 Setting-up system..............................................................................................4
5.2.1 Introducing spray wire .......................................................................................4
5.2.2 Changing spray wire..........................................................................................4
5.3 Starting the system............................................................................................5
5.4 Setting-up spray parameters.............................................................................7
5.4.1 Setting-up spray voltage....................................................................................7
5.4.2 Setting-up spray capacity..................................................................................7
5.4.3 Changing spray capacity...................................................................................8
5.4.4 Setting-up atomizer air pressure .......................................................................8
5.4.5 Setting-up the oiler............................................................................................9
5.5 Further instructions..........................................................................................10
6 Troubleshooting
6.1 System does not start........................................................................................2
6.2 System does not start, system cuts out.............................................................4
6.3 System cuts out.................................................................................................5
6.4 Spray wires are not pushed forward, not melted down, electric arc breaks off, chatters
9
6.5 Electric arc shuts off, spray wires not feeding, push gear running..................11
6.6 Electric arc cuts out, coarse particles in spray coat, spray wires feeding, not melted
12
7 Maintenance
7.1 Spray device LD/U3...........................................................................................1
7.1.1 Control intervals.................................................................................................1
7.1.2 Changing contact nozzlesl.................................................................................2

7.2 Hose package LD/U3 ........................................................................................4
7.3 Power supply with Push 4 drive.........................................................................4
7.4 Oiler (back side power supply)..........................................................................4
7.5 Filter (back side power supply)..........................................................................5
7.6 Drum decoiling device.......................................................................................5
7.7 Spool decoiling device.......................................................................................5
7.8 Table of lubricants.............................................................................................5
8 Spare part lists
8.1 Spray device LD/U3...........................................................................................2
8.1.1 Spray head LD/U3 (closed nozzle system) .......................................................2
8.1.2 Gear housing LD/U3..........................................................................................4
8.1.3 Wire feeding LD/U3...........................................................................................5
8.1.4 Wire pressure LD/U3.........................................................................................6
8.1.5 Air motor LD/U3.................................................................................................7
8.1.6 ON / OFF swtich LD/U3.....................................................................................8
8.1.7 Hose package LD/U3 (8 m)...............................................................................9
8.2 Power supply...................................................................................................10
8.2.1 Front and back side power supply...................................................................10
8.2.2 Electrical system, pneumatics and control ......................................................12
8.2.3 Wire feed drive Push 4....................................................................................16
8.3 Wearing parts recommended for stockkeeping...............................................18
9 Appendix
9.1 Recommended spray parameters for Sulzer Metco wire arc spray systems ....1
9.2 Circuit diagram ..................................................................................................2

General Safety Instructions
1-1
Revision 1/10/08
1 General safety instructions
1.1 Safety pictograms
Attention!
Special instructions, safety instructions, etc.
Caution!
Explosive material
Caution!
Hot surface
Caution!
Inflammable materials
Danger!
Risk of electric shock
Caution!
Magnetic fields from high currents can effect pacemaker
operation
Danger!
Potentially dangers causing serious injury or death
Attention!
Additional information of general importance
Attention!
Respiratory equipment must be worn
Attention!
Ear protection must be worn
i

General Safety Instructions
1-2 Revision 1/10/08
Attention!
Safety gloves must be worn
Attention!
Eye protection must be worn
Attention!
Safety overalls must be worn
Caution!
Moving parts (Risk of injury)

General Safety Instructions
1-3
Revision 1/10/08
1.2 Operating and safety regulations
Thermal coating is a safe process. However, it is paramount that the
operating crew is sufficiently familiar with the individual components,
knows the safety regulations, and is competent in working with the
system.
Our manual contains all necessary safety regulations and pointers for
the safe operation of the system.
In addition to work specific information it contains also general safety
regulations, which the operating crew must have read and understood.
Failure to comply with the operating instructions or the use of
unsuitable equipment may damage the system or even present a
danger to life and limb.
It is therefore vital that you read the operating and safety regulations
carefully, and note the additional operational risks described here.
Never use the installation and its components unless everything is in
perfect working order. Eliminate malfunctions immediately!

General Safety Instructions
1-4 Revision 1/10/08
1.3 Authorized use
This system is intended for the sole use of thermal coating of
workpieces in atmosphere. The system may be used solely in its
configuration as delivered, using the components as supplied.
Any other use of the system or its components is considered illegal.
Authorized use also includes the reading of the manuals and
compliance with all regulations.
1.4 Unauthorized use
The system has been manufactured in accordance with the current
level of technology and accepted safety regulations. However,
unauthorized use may result in bodily harm or death of the operator or
third parties, or in harm to the product itself or other material assets.
Under no circumstances should the system be used for the following
unauthorized purposes:
This listing is not comprehensive.
System and components Unauthorized use
System - Use without previous instruction
- Use beyond the operational limits
- Use in an atmosphere at risk for explosions
- Disabling safety devices, e.g. emergency shut-down
devices
- Use as control for other processes, e.g. for arc welding
- Use for incineration of articles or waste
- Installation of third-party components without coordination
with Sulzer Metco
- Installation of alternative or additional equipment for
displaying, measuring, controlling or setting of coating
parameters
Control electronics - Use of wrong operation modes
- Reconfiguration of control program
- Installation of additional or alternative displaying and
measuring devices without coordination with Sulzer Metco
Spray device - Use of atomizer gas for cooling or cleaning any objects
Spare parts - Installation of spare parts other than those from Sulzer
Metco

General Safety Instructions
1-5
Revision 1/10/08
1.5 Measures concerning personnel and
organization
Only trained and well instructed authorized personnel may operate the
system. Responsibility and accountability must be ensured.
Requirements:
• Medical check of aptitude
• Training and advanced training for wire arc spraying
• Safety thinking
• Basic knowledge of electricity
• Knowledge of hazardous materials
• Appropriate handling of hazardous materials
Sulzer Metco offers training courses, which provide both theoretical
background and practical experience for safe operation of the system.
This enables the operating crew to refuse following third party
instructions not complying with the safety regulations.
It is vital to comply with mandatory local rules and regulations:
• laws / ordinances
• regulations pertaining to accident prevention
• trade union directives, safety rules, instructional leaflets, and other
professional documentations
• standards
Keeping a cleaning / servicing / repair log is frequently required by law.
A log book is also useful for other reasons, such as:
• accident prevention
• preservation of value
• environmental protection
Work on the electrical equipment of the installation may be carried out
solely by professional personnel and in compliance with the
electrotechnical regulations.

General Safety Instructions
1-6 Revision 1/10/08
1.6 Ventilation and exhaust
All thermal spray processes produce fumes and dust particles from the
materials being sprayed. To avoid the effects of dust and fumes
generated by spraying, a suitable spray booth and sufficient exhaust
system are required. Proper installation, operation and maintenance
are important for system performance and maintaining a safe working
environment. For additional safety, dust collectors should be provided
with blow-out or relief panels in case of explosion. All local, state, and
national fire codes must be complied with when determining the
location of the exhaust system.
The arc spray process generates ozone, NOx, dust, and fumes that
can damage the respiratory system. An adequate exhaust and
ventilation system is required. A minimum air velocity of 90 m/min.
(300 ft./min.) is recommended in the areas adjacent to the spray gun
and the object being coated.
In addition to proper booth ventilation, appropriate personal respiratory
equipment must always be used. An industrial hygienist should be
consulted for recommendations on type and fit.

General Safety Instructions
1-7
Revision 1/10/08
1.7 Emissions, caused by the system
1.7.1 Metallic dust and fumes
Caution!
Metallic dust and fumes can be toxic and harmful to your health!
• Use extraction and filtering!
- Ensure extraction and filtering systems of adequate capacity.
- Arrange extraction walls/hoods to promote the flow.
- Seek our advice.
• Ensure that ventilation of spraying areas is sufficient and that it
promotes the flow.
Do not ventilate with oxygen!
• If filtered air is fed back into the work area, you will require
additional filters and official approval.
• Activate the extraction system before the metal spraying system is
started up.
• Comply with critical values at the workplace (AGW).
• Use personal respiratory equipment.
- A clean air helmet has proven itself in practice.
- Check the quality of the breathing air supplied to the clean air
helmet.
- Further information are provided in chapter "DIN Norms".
• During meal breaks ensure that toxic metallic dust does not enter
the digestive tract. Before eating, drinking, smoking or taking snuff,
wash hands and face thoroughly.
• Dispose of metallic dust!
- The relevant national laws or regulations must be observed.
- See also chapter "spray dust disposal".

General Safety Instructions
1-8 Revision 1/10/08
1.7.2 Spray jet, comprising molten metal particles and
compressed atomizer air
Caution!
Risk of combustion and fire.
• Do not direct at people.
• Do not direct at combustible substances.
• Remove combustible substances from the spraying area (room).
• Avoid all risks of fire.
• Never spray in explosion hazard areas.
• Take care when handling gas bottles. Leaking flammable gases
can ignite in an explosive manner.
• Use personal protective equipment:
- Breathing protection
- Eye protection
- Hearing protection
- Body protection
- Hand protection
• Hardly flammable protective clothing must be worn.
• If easily flammable substrates have to be coated, take appropriate
measures to prevent spontaneous combustion.

General Safety Instructions
1-9
Revision 1/10/08
1.7.3 Electric arc - UV radiation / Infrared radiation
Caution!
Danger to the eyes!
• Inflammation of the cornea or conjunctivitis.
(Flashing before the eyes)
• Damage to the retina from infrared radiation!
• The radiation is more harmful than over-exposure to the sun.
• Use personal protective equipment:
- Eye protection
Use only eye protection lenses with a filtering effect in
accordance with DIN EN 169 or other comparable relevant
national standard.
- Skin and body protection
All body parts that are exposed to the arc UV radiation must be
covered.
• Persons who are in the immediate vicinity of the radiation supply
must also wear personal protection or be protected from the
radiation by effective vision protection.
• Eyes must be protected from
- rays reflected from bright walls or objects,
- bright spray jet, e.g. in the case of spraying of aluminum.
- Use eye protection lenses in accordance with DIN EN 169 or with
other comparable relevant national standard.
- Use goggles with side protection.

General Safety Instructions
1-10 Revision 1/10/08
1.7.4 Noise
Caution!
A high level of noise can lead to hearing damage!
• The sound pressure level is 104 - 118 dB (A) measured at 1m from
the electric arc. As the current and arc voltage increase, so does
the noise level.
• Take noise protection measures
- Provide soundproofed work areas
- Build soundproofed booths
- Fit soundproofed capsules
- Use personal hearing equipment.
• Persons who are in the immediate vicinity of the supply of the
noise must also wear personal hearing protection.
• If the noise level exceeds 85 dB (A), hearing protection must be
worn that is appropriate for the noise level.
- Ear plugs; to be worn in the ear
- Ear muffs; to be worn over the ear
• The level of noise that may reach the outside is laid down in the
TA-Lärm.
• In other countries the relevant national regulations that must be
observed are applicable.

General Safety Instructions
1-11
Revision 1/10/08
1.7.5 Electrical energy
Caution!
Bodily contact with electricity can be fatal!
• Magnetic fields from high currents can effect Pacemaker
operation.
• Electrical systems and equipment should only be set up, repaired
or tested by an electrical engineer or under the supervision of one.
• Electrical equipment should only be used if it complies with the
operational and local requirements on safety and any
environmental effects.
• Electrical systems or equipment must be checked to ensure they
are in a proper condition before being used for the first time,
following repair or at the set inspection intervals.
• Live parts of an electrical system must not be worked on.
• Work should only take place on active parts of electrical systems
and equipment if the five safety rules have been followed:
1. Insulate
2. Protect against reactivation
3. Verify safe isolation from the supply
4. Earth and short-circuit
5. Cover or safeguard live neighboring parts
• Take special care in humid areas.
• Do not clean power supply with water.
• Power supply should not be exposed to rain.
• Sweaty or damp clothing and shoes are a hazard as they are
electrically conductive.

General Safety Instructions
1-12 Revision 1/10/08
1.7.6 Compressed air energy
Caution!
Compressed air can be a hazard if used carelessly.
• Protect the eyes.
Compressed air can carry solid matter that may cause injury.
• It is prohibited to clean clothing being worn on the body with
compressed air that is still at full pressure. There is a danger of
injury. Apart from this, metallic dust, which can be toxic, is swirled
up and thereby can enter the blood stream via the respiratory
organs.

General Safety Instructions
1-13
Revision 1/10/08
1.7.7 Dust combustion and dust explosion hazard
Caution!
Proper protection from dust combustion and dust explosions is only
possible with sufficient knowledge of the hazards and the measures to
be taken to prevent these.
• The safest method of protection is to prevent any accumulation of
dust at the workplace and within the extraction system and also in
the pipe system of the filter.
(Primary Explosion Protection)
• For cleaning purposes it is best to use an industrial vacuum
cleaner according to category C.
• Dust must not be swirled up. In the right concentration with air
oxygen, an explosive dust/air mixture can form which through
initial combustion can lead to an explosion.
• Avoid additional ignition supplies.
• The electric arc and the spray jet with the molten metal particles is
an unavoidable ignition supply. You can mitigate this by never
directing the spray jet at an accumulation of dust.
• Do not extinguish burning dust with water.
• Use a powder extinguisher with metal fire extinguishing powder
according to fire class D. Take advance precautions by seeking the
advice of the fire service.
• Moist or wet dust from zinc, aluminum, magnesium and alloys of
these tend towards spontaneous combustion. A chemical reaction
with water leads to a build-up of hydrogen, especially with
aluminum. Suitable safety measures must be taken when filtering
and storing the dust.
• Aluminum and aluminum alloy dust and other rapidly reacting
metallic dusts should only be extracted using filter systems
designed for the purpose. These dust/air mixtures are easily
combustible and explosive.
• The relevant national regulations must be observed.

General Safety Instructions
1-14 Revision 1/10/08
1.7.8 Hot surface
Caution!
While spraying radial nozzle nut can reach temperatures of 75° C
(167° F). Do not touch!
• Do not touch with bare hands
• Risk of burning the skin
• The temperature of the radial nozzle nut depends on:
- Spray capacity
- Length of spray process
- Used wire material
1.7.9 Danger of tripping / falling
Caution!
There is a danger of tripping / falling.
• Lay connecting pipe and hose bundles as well as cables in a safe
position and if necessary protect them.
1.7.10Moving Parts
Caution!
There is danger of moving parts at the running system as follows:
• Spray wire decoiling device
• Wire feed unit (if existing)
Therefore consider the following hints:
•Risk of injury!
Never put your hands, fingers or any other object inside the
rotating wire feed rolls.
•Risk of injury by being pulled inside!
Long hair, loose clothing, etc. must not be close to any moving
parts.