powder management system retrofit - nordsonpowder management system retrofit installation &...

POWDER MANAGEMENT SYSTEM RETROFIT

INSTALLATION & OPERATION MANUAL

FOR

GGDDCC WWOORRLLDDWWIIDDEE

HANOVER, PA

SERIAL # 18235

APRIL 2001

® Electrostatic Technology, Inc. A Subsidiary of Nordson Corporation 4 Pin Oak Drive, Branford, CT 06405 USA

Electrostatic Technology, Inc GDC Powder Management System

Serial #18235 i

TABLE OF CONTENTS

1 INTRODUCTION................................................................................................................................................. 2

2 SHIPPING ............................................................................................................................................................. 2

3 PROCESS DESCRIPTION ................................................................................................................................. 3

4 GENERAL SAFETY ............................................................................................................................................ 5

4.1 INTRODUCTION.............................................................................................................................................. 5 4.2 SAFETY SYMBOLS......................................................................................................................................... 6 4.3 QUALIFIED PERSONAL................................................................................................................................. 6 4.4 INTENDED USE............................................................................................................................................... 7 4.5 INSTALLATION............................................................................................................................................... 7 4.6 OPERATION ..................................................................................................................................................... 8 4.7 LESS OBVIOUS DANGERS.......................................................................................................................... 10 4.8 ACTION IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION...................................... 10 4.9 MAINTENANCE & REPAIR ......................................................................................................................... 11 4.10 DISPOSAL.................................................................................................................................................. 12

5 AIR AND ELECTRICAL REQUIREMENTS ................................................................................................ 12

5.1 AIR................................................................................................................................................................... 12 5.2 ELECTRICAL ................................................................................................................................................. 12

6 DESCRIPTION OF COMPONENTS............................................................................................................... 12

6.1 POWDER MANAGEMENT SYSTEM........................................................................................................... 12 6.2 PHOTOHELIC LEVEL SENSOR SYSTEM .................................................................................................. 13 6.3 PNEUMATIC CONTROLS ............................................................................................................................ 14 6.4 ELECTRICAL CONTROLS ........................................................................................................................... 14 6.5 HOPPER .......................................................................................................................................................... 14 6.6 VIBRATORY BOX FEEDER......................................................................................................................... 14 6.7 POWDER COLLECTION SYSTEM .............................................................................................................. 15

7 INSTALLATION................................................................................................................................................ 17

7.1 LOCATION ..................................................................................................................................................... 16 7.2 AIR CONNECTIONS...................................................................................................................................... 16 7.3 ELECTRICAL CONNECTION ...................................................................................................................... 17 7.4 VACUUM HOSES .......................................................................................................................................... 18 7.5 VACUUM HOSE GROUND WIRES ............................................................................................................. 18 7.6 POWDER LEVEL SENSOR........................................................................................................................... 18 7.7 POWDER MAINTENANCE........................................................................................................................... 19

8 START-UP AND OPERATION PROCEDURE.............................................................................................. 19

9 SHUT-DOWN PROCEDURE ........................................................................................................................... 21

9.1 POWDER HANDLING .............................................................................................................................. 21 9.2 POWDER/COLOR CHANGE.................................................................................................................... 21

10 MAINTENANCE................................................................................................................................................ 21

10.1 GENERAL...................................................................................................................................................... 21 10.2 AIR SYSTEM ............................................................................................................................................. 22 10.3 HOPPER POROUS PLATE REPLACEMENT.......................................................................................... 22 10.4 POWDER LEVEL SENSOR .............................................................................................................................. 23 10.5 POWDER COLLECTION SYSTEM ......................................................................................................... 23


Serial #18235 ii

11 PATENTS ............................................................................................................................................................ 24

12 SPARE PARTS LIST ......................................................................................................................................... 25

FLOOR PLAN

PNEUMATIC SCHEMATIC

ELECTRICAL DRAWING

MANUFACTURER'S MANUALS


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1 INTRODUCTION

This Instruction Manual must be studied and followed for the safe and efficient operation of the Powder Management System. Study this manual before locating and installing the equipment. ELECTROSTATIC TECHNOLOGY, INC. A SUBSIDIARY OF NORDSON CORPORATION 4 PIN OAK DRIVE BRANFORD, CT 06405 TELEPHONE: 203-488-8112 FAX: 203-483-8777 In future correspondence, please refer to the MODEL (Powder Management System and SERIAL NUMBER (18235) of the equipment.

2 SHIPPING Sometimes equipment can be damaged in transit. An inspection of the shipping crate should be

made upon delivery, and when equipment is removed, it should be carefully inspected to make sure the unit 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, Inc will then advise concerning repairs and replacements.


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3 PROCESS DESCRIPTION 1) Turn on the air supply and electrical power to the PMS

a) Set the PMS pressure regulator for 80 PSIG b) Be sure that the air supply is free of oil, moisture, and other contaminants. A poor or

marginal air supply will negatively impact the performance of the PMS. c) Be sure to follow sound compressed air piping procedures so that high quality air is

delivered to the PMS. 2) Turn on the air supply to the Hopper fluidizer and adjust to the desired setting (usually not

exceeding 10 PSIG) It is important to turn this valve off when the System is not in use! a) Powder contained in the Hopper is continuously fluidized to help break down agglomerates

and help remove moisture in the powder. b) The Hopper conditions the powder so that it can be pneumatically conveyed to the Coater. c) Be sure that the existing compressed air dryer is working satisfactorily so that the full

benefit of the Hopper is realized. 3) The new photohelic-style level sensing system operates on a principle of differential pressure.

Powder fluidized in the coating chamber bed exerts pressure on the end of the sensing tube. As the powder level falls less pressure is exerted on the tube. When the pressure reaches a low limit a switch is activated that calls for powder to be fed to the coating chamber beds. The powder level in the bed increases until the high limit is reached, which de-activates the feeding cycle. a) Normal settings for the photohelic gage are 20 for low limit and 40 for high limit. b) The level sensor tube can also be adjusted to provide the desired feed characteristics. It is

important to adjust the system so that the bed does not run low on powder before refilling. c) It is also important to adjust the system so that the time between powder feeds is not

excessively long. This can be accomplished by moving the low and high limit needles closer together (for example 25 for low limit and 35 for high limit).

4) The photohelic output (low limit) signal turns on Solenoids #1 & #2, which activate the powder

transfer pumps #1- #4 located at the bottom of the PMS Hopper. Solenoid #1 operates Pumps #1 & #2 and Solenoid #2 operates Pumps #3 & #4.

5) Powder is pneumatically pumped from the Hopper through the special powder feed hose to the

Accumulators located on the side of each bed. a) Adjusting the pump air supply regulator (#9) varies each pump's output. b) The feed rate will effect how quickly each bed is replenished with powder. c) Adjust each pump to achieve a common delivery rate. Note that a longer hose may require

slightly higher pump pressure to achieve a common delivery rate. 6) The Accumulator acts as a mini-cyclone to receive the in-coming powder and then to lower the

powder into each side of each bed a) Excess air and powder within the Accumulator is directed out the top-mounted vent port and

is then directed to the main powder collection line via the Vent Manifolds. This powder is carried back to the PMS for re-use.


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7) The Hopper low level sensor actuates the Vibratory Box Feeder.

a) The red signal light mounted on the Photohelic Control Enclosure illuminates on low powder level.

b) The Vibratory Box Feeder delivers powder to the PMS until the high/normal level is attained and the green light is illuminated.

c) It may be necessary to replenish the powder supply box during a powder feeding cycle. d) If desired, the Vibratory Box Feeder can be operated manually by disconnecting the air line

supplied by the #3 Solenoid and supplying a direct air source to the Feeder. e) The Feeder, by virtue of its wheeled cart, can be used to transport powder from storage. Be

sure to disconnect the air supply and powder feed lines before moving the wheeled cart. f) A green light indicates normal operation. The PMS Hopper should hold 100 lbs to 150 lbs

of powder under normal conditions. When the Hopper is empty add only enough powder to reach a normal (green light) condition. Excessive filling could damage the powder collector filters.

8) The powder collection intensity can be adjusted by using the blast gate mounted on the 4"

powder return line. A spare 4" Connection with blast gate is provided.


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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.


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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 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 of 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 of death. CAUTION: Failure to observe may result in equipment damage.

4.3 QUALIFIED PERSONAL

"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.


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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.

• Failure 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 the 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.

• Install a locking disconnect switch or breaker in the service line ahead of any

electrical equipment.


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4.5 INSTALLATION (continued)

• 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 conductive to ground 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 condition.

• 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, reinstall them immediately after the work is completed and check them for proper functioning.

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.


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4.6 OPERATION (continued)

• 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.

• 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.


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4.6 OPERATION (continued)

• Shut off moving equipment before taking measurements or inspecting work

pieces. • 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 they could lead and cause injury.

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 that may be hot or have sharp edges and

cannot be practically safeguarded.

• Electrical equipment that 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 ACTION 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.


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4.9 MAINTENANCE & REPAIR

Allow only qualified personnel to perform maintenance, troubleshooting, 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 area or 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.


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4.9 MAINTENANCE & REPAIR (continued)

WARNING: Operating faulty electrostatic equipment is hazardous and can

cause electrocution, fire, or explosion. Make resistance checks part of your periodic maintenance program.

• 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. 5 AIR AND ELECTRICAL REQUIREMENTS

5.1 AIR A clean, dry supply of compressed air must be provided to the Powder Management

System. 30 scfm (1.4 m3/min) of oil free air @ 80 psi (5.6 bar) minimum/100 psi (6.9 bar) maximum is required. A 3/4 inch minimum airline should be connected to the fitting on the rear of the PMS. Please Note that E.T.I. strongly recommends the air supply be connected to the PMS through a Coalescent Filter, a Refrigerant Air Dryer and a Particle Filter.

5.2 ELECTRICAL

480 Volts, 60 Hertz, 3-phase must be supplied to the Electrical Disconnect.

6 DESCRIPTION OF COMPONENTS

6.1 POWDER MANAGEMENT SYSTEM The Powder Management System embodies all the equipment and components that

condition, feed, distribute, and reclaim powder. Each major component is described below:


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6.2 PHOTOHELIC LEVEL SENSOR SYSTEM A Photohelic Level Sensor system monitors the powder level in the coating beds

to maintain an optimum level of powder, which helps maintain the repeatability and uniformity on the substrate. As the powder level drops, the level sensor tube in the beds experiences a pressure drop. The drop in pressure corresponds to an electronic message that activates a solenoid valve, and in turn, the powder pumps then feed powder to the Accumulator.

The Powder Level Sensor consists of a control sensor and two inputs that read

the difference between the pressure at the powder level in the Coating Bed and atmospheric pressure outside the Coating Bed area. The range of the control sensor has been pre-set at the ETI factory and should not be touched or changed without consulting ETI personnel. The Photohelic® Gauge/Switch that indicates the pressure range is located on the front of the machine at the entrance to the coating bed. When the Indicator needle comes in contact with the Left Set-Point Indicator, the powder feeding mechanism should turn "ON" and stay "ON" until the Indicator Needle comes in contact with the Right Set-Point Indicator, at which time it shuts "OFF". The powder feeding mechanism stays “OFF” until the Indicator Needle makes contact with the Left Set-Point Indicator again. Refer to the Photohelic® Gauge/Switch Section in the Appendix of this manual for more specific information on this unit.

NOTE: The range of the control sensor has been pre-set at the ETI factory and should touched or changed without consulting ETI personnel.


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6.3 PNEUMATIC CONTROLS

The Pneumatic Panel contains five pressure regulators and five corresponding pressure gages. From the left of the panel proceeding to the right, the functions are as follows: Position 1: Pressure regulator and gage for PMS Hopper. Do not exceed 10 psig. Position 2: Pressure regulator and gage for Powder Pump #1; adjust as needed Position 3: Pressure regulator and gage for Powder Pump #2; adjust as needed Position 4: Pressure regulator and gage for Powder Pump #3; adjust as needed Position 5: Pressure regulator and gage for Powder Pump #4; adjust as needed

6.4 ELECTRICAL CONTROLS

A central Electrical Disconnect is provided for the Powder Management System. Secondary electrical panels are contained within the upper access door of the PMS and the Photohelic Control Enclosure.

6.5 HOPPER

The Hopper is located beneath the main cabinet and consists of a fluidizing plenum, level sensors and Hopper compartment. Virgin powder supplied by the Vibratory Box Feeder and reclaim powder dislodged from the collector filters is continuously fluidized by compressed air in the Hopper. This action helps to remove moisture from the powder and breaks down agglomerates so that the powder transported to the Coater is optimized for coating performance. The Hopper Level Sensors are located inside the Hopper access door. The upper sensor is the High/normal level sensor and activates a green indicating light at the Photohelic Control Enclosure. The lower sensor is the Low Level sensor and is activated when the Hopper is running low on powder. When the sensor is activated a red light will illuminate at the Photohelic Control Enclosure and the #3 Solenoid will engage the Feeder. Remember to keep the Hopper air supply pressure below 10 psig or damage to the collector filters may result.

6.6 VIBRATORY BOX FEEDER

The Vibratory Box Feeder takes powder from the manufacturer's 50 pound box container and pneumatically feeds it to the PMS Hopper. The Feeder receives its operational signal from the Low Level Hopper sensor, which is located inside the Hopper access door. The Feeder Cart has separate pneumatic controls to adjust air settings for the Feeder powder pump and the Box Vibrator. Both controls should be set as required for proper operation. Be sure to use the Box Vibrator at all times.


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6.7 POWDER COLLECTION SYSTEM

The Powder Collector uses a 10 HP Fan Motor to create a rated 1,800 CFM at 6" external static pressure. The vacuum created within the cabinet draws fugitive powder from the Coater to the PMS for reuse. The Collector employs six pleated cartridge filters to trap powder particles for reuse. Reverse air pulses serve to keep the powder from accumulating on the filters and decreasing collection efficiency. The air pressure for pulsing is adjustable. It is suggested to use approximately 55 psig for normal operation. Located atop the PMS is a HEPA After filter to provide enhanced air quality at the discharge. A magnehlic gage is located at the top of the PMS cabinet to indicate filter and collection efficiency. Under normal conditions the gage reading should between 0 and 4. If the gage moves past 4 it may be necessary to increase the pulse pressure or replace the filters.


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7 INSTALLATION

These instructions for installing, operating and maintaining the Powder Management System must be followed for its safe and efficient operation. In particular, precautions should be observed whenever the unit is operated. Study this manual before installing or operating equipment. Some voltages employed in this equipment are high. Remember that any source of voltage can be hazardous.

7.1 LOCATION

1. Place "Powder Management System" and ancillary equipment on a level

surface at the desired location. Lag or affix as required.

7.2 AIR CONNECTIONS

Refer to the Pneumatic Schematic in the Appendix of this manual. 1. Check to make sure all pneumatic hoses are connected securely throughout

the system. 2. Connect the GDC air supply line from the Customer supplied Air Filters and

Refrigerant Air Dryer to the inlet fitting of the PMS.

3. Refer to the Pneumatic Schematic in the appendix of the Manual.


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CAUTION: ALL RECEPTACLES MUST HAVE A PROPER GROUND CONNECTION.

7.3 ELECTRICAL CONNECTION

Please refer to the Electrical Drawings included with this Operating Manual for information on proper electrical connections. Connect main electrical power from the Customer supplied 240 Volt, 60 hertz, 3-Phase source to the Electrical Control Cabinet. Refer to the Electrical Schematic Drawing # D103447.

1) Connect 480VAV/3∅/60Hz power to the fused disconnect mounted to the side of the PMS

2) With ETI-supplied Photohelic Control Enclosure previously mounted; make wire interconnections from the PMS to the Photohelic Control Enclosure

3) Install the ETI-supplied wire bundle into a GDC-supplied electrical conduit from the PMS Electrical Panel (located within the top mounted door) to the Photohelic Control Enclosure. Use supplied connection information

4) Install four-conductor wiring from the GDC Main Panel to the supplied Photohelic Control Enclosure. Terminations are made per Item 5.

5) Make the necessary interconnections using the following instructions: (a) 14ga green wire: connect as ground wire from GDC Main Panel to Photohelic

Control Enclosure (b) 14ga white wire: connect as 110VAC/1∅ neutral wire from GDC Main Panel to

Photohelic Control Enclosure (c) 14ga red wire: connect as 110VAC/1∅ hot wire from GDC Main Panel to

Photohelic Control Enclosure. This wire connection should be a 110VAC/1∅ control signal that will onnect to ETI Connection #311 located on the terminal strip within the Photohelic Control Enclosure

(d) 14ga red wire: connect as 110VAC/1∅ switched wire from GDC Main Panel to Photohelic Control Enclosure. This wire connection will be controlled by the GDC Main Panel to turn on the PMS Collector blower motor and connects to the ETI Connection #304 located located on the terminal strip within the Photohelic Control Enclosure

6) Verify and test that all wiring and terminations are correct prior to power up.


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NOTE: The vacuum hose(s) can build up a static charge when the Customer supplied Powder Collection System is "ON" and running. To prevent this static charge build-up, ground wires must be installed with the vacuum hose(s).

7.4 VACUUM HOSES

E.T.I. supplies the flexible vacuum hoses required to connect the powder collection

manifold to the Powder Collector.

1. Connect the 4 inch I.D. hose from the powder collection manifold to the 4 inch duct on the Powder Collecter.

7.5 VACUUM HOSE GROUND WIRES All vacuum hose connections must be grounded to equipment frame, metal surface to

metal surface and must be checked for continuity. Take a ground wire and do the following at all vacuum hose connections:

Vacuum Hose to Vacuum Hose:

1. Locate the end of each vacuum hose and strip a 1 inch (25 mm) section of jacketing from the vacuum hose internal metal wires (vacuum hose I.D. must have a section of bare internal wire exposed for proper ground wire contact).

2. Connect a ground wire between the internal wires of each vacuum hose and

then connect entire hose assembly to a metal surface.

Vacuum Hose to Duct:

1. Locate the end of each vacuum hose and strip a 1 inch (25 mm) section of jacketing from the vacuum hose internal metal wires (vacuum hose I.D. must have a section of bare internal wire exposed for proper ground wire contact).

2. Connect a ground wire from the internal metal wire of a vacuum hose to a

ground at the duct (such as a bolt on the frame or Powder Collection System).

7.6 POWDER LEVEL SENSOR

Adjust as required during Machine set-up.


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7.7 POWDER MAINTENANCE

Most powders are hygroscopic. An attempt should be made to finish the day's run

with a minimum amount of powder left in the Coating System. All powder containers (bags, barrels, hoppers, etc.) should be kept tightly closed.

NOTE: Do not mix different types of powder.

8 START-UP AND OPERATION PROCEDURE 1) Turn on the air supply and electrical power to the PMS

a) Set the PMS pressure regulator for 80 PSIG b) Be sure that the air supply is free of oil, moisture, and other contaminants. A poor or

marginal air supply will negatively impact the performance of the PMS. c) Be sure to follow sound compressed air piping procedures so that high quality air is

delivered to the PMS. 2) Turn on the air supply to the Hopper fluidizer and adjust to the desired setting (usually not

exceeding 10 PSIG) It is important to turn this valve off when the System is not in use! a) Powder contained in the Hopper is continuously fluidized to help break down agglomerates

and help remove moisture in the powder. b) The Hopper conditions the powder so that it can be pneumatically conveyed to the Coater. c) Be sure that the existing compressed air dryer is working satisfactorily so that the full

benefit of the Hopper is realized. 3) The new photohelic-style level sensing system operates on a principle of differential pressure.

Powder fluidized in the coating chamber bed exerts pressure on the end of the sensing tube. As the powder level falls less pressure is exerted on the tube. When the pressure reaches a low limit a switch is activated that calls for powder to be fed to the coating chamber beds. The powder level in the bed increases until the high limit is reached, which de-activates the feeding cycle. a) Normal settings for the photohelic gage are 20 for low limit and 40 for high limit. b) The level sensor tube can also be adjusted to provide the desired feed characteristics. It is

important to adjust the system so that the bed does not run low on powder before refilling. c) It is also important to adjust the system so that the time between powder feeds is not

excessively long. This can be accomplished by moving the low and high limit needles closer together (for example 25 for low limit and 35 for high limit).

4) The photohelic output (low limit) signal turns on Solenoids #1 & #2, which activate the powder transfer pumps #1- #4 located at the bottom of the PMS Hopper. Solenoid #1 operates Pumps #1 & #2 and Solenoid #2 operates Pumps #3 & #4.

5) Powder is pneumatically pumped from the Hopper through the special powder feed hose to the Accumulators located on the side of each bed. a) Adjusting the pump air supply regulator (#9) varies each pump's output. b) The feed rate will effect how quickly each bed is replenished with powder. c) Adjust each pump to achieve a common delivery rate. Note that a longer hose may require

slightly higher pump pressure to achieve a common delivery rate.


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6) The Accumulator acts as a mini-cyclone to receive the in-coming powder and then to lower the powder into each side of each bed a) Excess air and powder within the Accumulator is directed out the top-mounted vent port and

is then directed to the main powder collection line via the Vent Manifolds. This powder is carried back to the PMS for re-use.

7) The Hopper low level sensor actuates the Vibratory Box Feeder. a) The red signal light mounted on the Photohelic Control Enclosure illuminates on low

powder level. b) The Vibratory Box Feeder delivers powder to the PMS until the high/normal level is

attained and the green light is illuminated. c) It may be necessary to replenish the powder supply box during a powder feeding cycle. d) If desired, the Vibratory Box Feeder can be operated manually by disconnecting the air line

supplied by the #3 Solenoid and supplying a direct air source to the Feeder. e) The Feeder, by virtue of its wheeled cart, can be used to transport powder from storage. Be

sure to disconnect the air supply and powder feed lines before moving the wheeled cart. f) A green light indicates normal operation. The PMS Hopper should hold 100 lbs to 150 lbs

of powder under normal conditions. When the Hopper is empty add only enough powder to reach a normal (green light) condition. Excessive filling could damage the powder collector filters.

8) The powder collection intensity can be adjusted by using the blast gate mounted on the 4" powder return line. A spare 4" Connection with blast gate is provided.


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9 SHUT-DOWN PROCEDURE

9.1 POWDER HANDLING

As most coating materials are hygroscopic, storage of powder in the system for

extended periods of time is not recommended. It is advisable that the powder be removed and stored in an airtight container.

Only a minimum of powder should be left in the Customer supplied Powder

Collection System when it is shut down over an 8 hour period. When the Coating Machine is not being used in excess of 24 hours, the powder should be removed from the Coating Bed in order to prevent clogging of the Porous Plate due to ambient temperature and humidity conditions. The Customer supplied Powder Feeding Mechanism should be emptied and the powder stored in and air tight container when the machine will not be used for more than 48 hours.

9.2 POWDER/COLOR CHANGE

When changing the type of powder, the Customer supplied Powder Collection System

must be thoroughly cleaned out to prevent contamination. When changing powder from one color to another, it is very important that the

Coating Bed, Coating Chamber, Vacuum Ducts, and Powder Feed Hoses be thoroughly cleaned to prevent contamination.

Also, the Powder Collector cartridges should be changed if powder is being saved

and re-used. It is also necessary to thoroughly clean the Powder Collector Hopper and Customer supplied Powder Feed Mechanism to avoid color contamination.

10 MAINTENANCE

10.1 GENERAL A systemic maintenance schedule should be set up and adhered to in order to insure

optimum machine operation. Daily, weekly, and monthly schedules should be established as applicable for each part of the coating system.

WARNING: ELECTRICAL VOLTAGE USED IN THIS EQUIPMENT CAN BE HAZARDOUS. MAINTENANCE SHOULD BE HANDLED BY QUALIFIED PERSONNEL.


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10.2 AIR SYSTEM

The importance of keeping the compressed air clean, dry and oil free cannot be over-

emphasized. More coating problems can be traced to failure to maintain the air filters and air dryers than any other cause. Consult manufacturer's maintenance information for Customer supplied Refrigerant Air Dryer, Particle Air Filter, and Coalescing Filter.

Check the Air Line which enters the Coating Bed and make sure it is kept clean and

free of all particles, water, and oil. Check the Refrigerant Air Dryer to make sure that condensate drains are draining,

they can very easily become clogged by oil or dirt. This will allow wet compressed air to enter the Coating Machine, resulting in clogged a Porous Plate and poor fluidization.

Clean and check the Particle Air Filter for proper functioning. Change filter

element if it's dirty. Check and drain the Coalescing Filter.

10.3 Hopper Porous Plate Replacement

Step 1 - Turn the entire system “OFF”. Follow the Shut-Down Procedure (Section 10).

Step 2 - Disconnect the air supply line to the Hopper Plenum

Step 3 - Release four (4) latches holding Hopper Plenum to the Hopper Step 4 - Remove all the bolts that secure the porous plate to the retention

frame Step 5 - Gently lift out the porous plate and gasket material from the

retention frame Step 8 - Clean powder out from inside the Plenum Chamber.

Step 9 - Place new gasket material around the edge of the Retention

Frame. Place the new Porous Plate onto the flange. Note that when installing the Porous Plate the smoothest side should face up.

Step 10 - Re-install the hex-head bolts. Tighten bolts down evenly. Step 11 - Activate the Hopper per normal Start-Up sequence.


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10.4 Powder Level Sensor

Make sure that powder is not packed inside the Probe (tube) or it will affect accurate sensing. Refer to the Manufacturer’s information included in the Appendix of the Manual.

10.5 POWDER COLLECTION SYSTEM

E.T.I. recommends that Customer refer to the manufacturer’s maintenance

information for proper maintenance of this equipment.


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11 PATENTS The Powder Management System is manufactured under one or more of the following United

States Patents:

5,773,097

5,639,307 5,275,849

5,213,847 5,116,636

5,092,267 5,052,332

4,606,928 4,517,219

4,472,452 4,418,642

4,368,214 4,332,835

4,330,567 4,325,982

4,297,386 4,123,175

4,120,070 4,101,687

4,084,018 4,053,661

4,030,446 3,951,099

3,937,179 3,921,574

3,916,826 3,917,461

3,901,185 3,889,015

3,881,763 3,865,610

3,828,729 3,698,847


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12 SPARE PARTS LIST

PART DESCRIPTION ETI PART NO. ASSEMBLY QTY. RECM'D SPARE

PRICE EACH

Hopper Porous Plate 103517 1 2 $158 Powder Collector Filters, Torit #8PP-46638-00 7100015 Collector 6 6 $158 Hopper Powder Pump, Nordson #165-633 Collector 4 4 $84.25Powder Feed Hose, Nordson # 900-651, 3/4" D Collector 50 ft $3.75/' Photohelic Gage 3018015 Coater Retro 2 - $398 Powder Accumulator 103435 Coater Retro 4 1 Call HEPA After-filter; Torit #8PP14818-00 Collector 1 1 $468 Vibratory Box Feeder Powder Pump; Nordson #165-633 Feeder 1 1 $84.25

Gasket Material, ¾" wide x 1/8" thick 6513018 " 1 roll 1 roll $50 Solenoid Valve 3016012 Collector 3 - $71 Solenoid Coil, 24 VDC 3016011 " 3 - $11.25Level Sensor Tube 103441 Coater Retro 2 2 $75 Air Pressure gage, 0 - 160 psig 3013005 Collector 4 $13 Air Presure Regulator 3013004 " 5 $25 Air Pressure gage, 0 - 60 psig 3013002 " 1 $14


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13 FLOOR PLAN

See the Appendix for the Floor Plan Drawing #103543

14 PNEUMATIC SCHEMATIC See the Appendix for the Pneumatic Schematic Drawing #103518 15 ELECTRICAL DRAWING See the Appendix for Electrical Schematic Drawings #103447-01 through 03

16 MANUFACTURER'S MANUALS All of the Manufacturer's Manuals listed below can be found in the Appendix of this manual:

• Photohelic Gage (Dwyer) • Hopper Level Sensor (ifm efector) • Powder Collector (Torit)


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POWDER COLLECTOR

MANUAL


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POWDER PUMPS

MANUAL


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PHOTOHELIC GAGES

MANUAL


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HOPPER LEVEL SENSORS

MANUAL


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ELECTRICAL DRAWINGS

&

SCHEMATICS


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FLOOR PLAN


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PNEUMATIC DRAWINGS

&

SCHEMATICS


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MISCELLANEOUS

MANUALS

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