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