TABLE OF CONTENTSSystem) and SERIAL NUMBER (20940) of the "POWDER COATING MACHINE". 2 SHIPPING Sometimes equipment can be damaged in transit. An inspection of the shipping crate should

Electrostatic Technology, Inc FlexiCoat® 300 Powder Application System

Serial #20940 i

TABLE OF CONTENTS

1 INTRODUCTION................................................................................................................................................. 1

2 SHIPPING ............................................................................................................................................................. 1

3 OPERATING PRINCIPLES ............................................................................................................................... 2

3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER .................................................................. 2 3.2 PROCESS DESCRIPTION................................................................................................................................ 2

4 GENERAL SAFETY ............................................................................................................................................ 3

4.1 INTRODUCTION.............................................................................................................................................. 3 4.2 SAFETY SYMBOLS......................................................................................................................................... 4 4.3 QUALIFIED PERSONAL................................................................................................................................. 4 4.4 INTENDED USE............................................................................................................................................... 5 4.5 INSTALLATION............................................................................................................................................... 5 4.6 OPERATION ..................................................................................................................................................... 6 4.7 LESS OBVIOUS DANGERS............................................................................................................................ 8 4.8 ACTION IN THE EVENT OF A SYSTEM OR COMPONENT MALFUNCTION........................................ 8 4.9 MAINTENANCE & REPAIR ........................................................................................................................... 9 4.10 DISPOSAL.................................................................................................................................................. 10

5 AIR, ELECTRICAL AND WATER REQUIREMENTS ............................................................................... 11

5.1 FLEXICOAT® 300 .......................................................................................................................................... 11 5.1.1 Air ........................................................................................................................................................... 11 5.1.2 Electrical ................................................................................................................................................ 11

5.2 REFRIGERANT AIR DRYER........................................................................................................................ 11 5.2.1 Air ........................................................................................................................................................... 11 5.2.2 Electrical ................................................................................................................................................ 11

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

6.1 FLEXICOAT® 300 COATING STATION .................................................................................................... 12 6.2 REFRIGERANT AIR DRYER........................................................................................................................ 12 6.3 FLEXICOAT® 300 COLLECTOR.................................................................................................................. 12

6.3.1 500 CFM Collector Module.................................................................................................................... 12

7 INSTALLATION................................................................................................................................................ 13

7.1 LOCATION ..................................................................................................................................................... 13 7.2 AIR CONNECTIONS...................................................................................................................................... 13 7.3 ELECTRICAL CONNECTION ...................................................................................................................... 13 7.4 CONTROLS..................................................................................................................................................... 15

7.4.1 Settings.................................................................................................................................................... 15 7.4.2 Footswitch .............................................................................................................................................. 15

7.5 POWDER MAINTENANCE........................................................................................................................... 15 7.6 REFRIGERANT AIR DRYER........................................................................................................................ 15

8 DESCRIPTION OF CONTROLS..................................................................................................................... 16

8.1 MAIN ELECTICAL CABINET ...................................................................................................................... 16 8.2 ELECTRICAL CONTROL PANEL ILLUSTRATION.................................................................................. 16 8.3 ELECTRICAL CONTROL PANEL CONTROLS.......................................................................................... 17 8.4 PNEUMATIC CONTROL PANEL ILLUSTRATION ................................................................................... 18 8.5 PNEUMATIC CONTROL PANEL CONTROLS........................................................................................... 18 8.6 MISCELLANEOUS CONTROLS .................................................................................................................. 19 8.7 FLEXICOAT® POWDER COLLECTOR CONTROLS.................................................................................. 19

9 START-UP AND OPERATION PROCEDURE.............................................................................................. 20

9.1 COATING STATION SET-UP ....................................................................................................................... 20 9.2 ELECTROSTATIC COATING OPERATION ............................................................................................... 21


ii Serial #20940

9.3 POWDER REMOVAL OPERATION............................................................................................................. 21

10 SHUT-DOWN PROCEDURE ........................................................................................................................... 22

10.1 COATING BED OPERATION .................................................................................................................. 22 10.2 RE-START PROCEDURE ......................................................................................................................... 22 10.3 EXTENDED SHUT-DOWN PROCEDURE.............................................................................................. 22

10.3.1 Coating Bed Cleaning............................................................................................................................. 23 10.3.2 Powder Collector Module Cleaning ....................................................................................................... 23

10.4 POWDER/COLOR CHANGE.................................................................................................................... 24

11 TROUBLE SHOOTING .................................................................................................................................... 25

11.1 TROUBLE SHOOTING – COATER ......................................................................................................... 25 11.2 TROUBLE SHOOTING – POWDER COLLECTOR................................................................................ 26

12 MAINTENANCE................................................................................................................................................ 28

12.1 GENERAL .................................................................................................................................................. 28 12.2 MAINTENANCE CAUTION..................................................................................................................... 28 12.3 HIGH VOLTAGE MULTIPLIER .............................................................................................................. 28 12.4 COMPRESSED AIR SYSTEM .................................................................................................................. 28

12.4.1 Air Lines ................................................................................................................................................. 28 12.4.2 Particle Air Filter ................................................................................................................................... 28 12.4.3 Refrigerant Air Dryer ............................................................................................................................. 29 12.4.4 Coalescing Filter .................................................................................................................................... 29

12.5 COATING BED .......................................................................................................................................... 29 12.5.1 Porous Plate Replacement...................................................................................................................... 30

12.6 POWDER COLLECTOR MODULE.......................................................................................................... 31 12.6.1 Cartridge Filters..................................................................................................................................... 31

12.6.1.1 Cartridge Filter Replacement ..........................................................................................................................31 12.6.2 Final Filter ............................................................................................................................................. 32

12.6.2.1 Final Filter Replacement.................................................................................................................................32 12.6.3 Fan Motor............................................................................................................................................... 33

13 PATENTS ............................................................................................................................................................ 34

14 SPARE PARTS LIST ......................................................................................................................................... 35

15 FLOOR PLAN .................................................................................................................................................... 37

16 PNEUMATIC SCHEMATIC ............................................................................................................................ 37

17 ELECTRICAL DRAWING............................................................................................................................... 37

18 PLC PROGRAM ................................................................................................................................................ 37

19 MANUFACTURER'S MANUALS ................................................................................................................... 37


Serial #20940 1

1 INTRODUCTION

This Instruction Manual must be studied and followed for the safe and efficient operation of the "FlexiCoat® 300 Powder Application System" with optional Conventional Fluid Bed adapter. 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 (FlexiCoat® 300 Powder Application System) and SERIAL NUMBER (20940) of the "POWDER COATING MACHINE".

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.


2 Serial #20940

3 OPERATING PRINCIPLES

3.1 SCHEMATIC DIAGRAM OF AN ELECTROSTATIC COATER

3.2 PROCESS DESCRIPTION

Powder particles are aerated in a fluidizing chamber and are electrostatically charged by ionized air forced through a porous plate at the base of the chamber. As the powder particles become charged, they repel each other to such a degree that they rise above the chamber forming a cloud or veil of charged particles. When a grounded object is placed in this cloud, or conveyed through this cloud, the charged powder particles, because of their opposite potential, are attracted to it. As the particles become attached to the object, they form a uniform coating, being more attracted to exposed areas than to those already insulated. The longer the object is exposed to the cloud, the thicker the coating becomes, until saturation eventually takes place.

Coating thickness is controlled by applied voltage to the charging media and exposure time to the cloud. Because of the high voltage capability of the charging media, a sufficiently great potential exists between it and most substrates to permit even natural insulators to be coated. Unlike equipment with exposed electrodes, Electrostatic Technology, Inc.'s unique air ionization process charges the powder without permitting the powder, the object, or the operator to come in contact with the charging media.


Serial #20940 3

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.


4 Serial #20940

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.


Serial #20940 5

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.


6 Serial #20940

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.


Serial #20940 7

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.


8 Serial #20940

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 which may be hot or have sharp edges and

cannot be practically safeguarded.

• Electrical equipment which 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.


Serial #20940 9

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.


10 Serial #20940

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.


Serial #20940 11

IMPORTANT: Provide a proper ground connection for the plugequipment ground wire. Polarity of the receptaclemust be according to code.

IMPORTANT: Provide a proper ground connection for the plugequipment ground wire. Polarity of the receptaclemust be according to code.

5 AIR, ELECTRICAL AND WATER REQUIREMENTS

5.1 FLEXICOAT® 300

5.1.1 Air 30 scfm (0.850 m3/min.) @ 80 psi (5.5 bar) minimum/100 psi (6.9 bar)

maximum. A 1/2 inch minimum air line should be connected between the Coalescent Filter (outlet side of the Refrigerant Air Dryer) and the FlexiCoat® 300 Coating Machine.

5.1.2 Electrical

240 Volts, 50 Hertz, 1-Phase, 20 Amp circuit is required (an eight foot cord

with a three wire duplex plug is provided).

5.2 REFRIGERANT AIR DRYER

5.2.1 Air A Refrigerant Air Dryer capable of conditioning 30 scfm (0.850 m3/min.) @

80 psi (5.5 bar) minimum/100 psi (6.9 bar) maximum of clean air is required. Customer must connect a 1/2 inch air hose to the Particle Filter (inlet side of Refrigerant Air Dryer).

5.2.2 Electrical

240 Volts, 50 Hertz, 1-Phase. Customer must plug the attached plug into the proper receptacle. Refer to the Refrigerant Air Dryer information in the Appendix of this manual.


12 Serial #20940

6 DESCRIPTION OF COMPONENTS

6.1 FLEXICOAT® 300 COATING STATION The coating machine is complete with Coating Bed, High Voltage Multiplier, Air

Flow Meter, Vibrator (to ensure proper fluidization), and cloud containing Hood. The coating chamber is of a patented design that insures that neither powder, substrate being processed, nor foreign objects can contact the charging media.


A Refrigerant Air Dryer accepts in-plant compressed air and supplies moisture free

coating/cleaning air to the FlexiCoat® 300 Powder Application System. A Particle Filter is installed on the inlet of the Refrigerant Air Dryer to remove foreign particles

from the inlet air. A Coalescing Filter is installed on the outlet of the Refrigerant Air Dryer to remove any oils from entering the system.

6.3 FLEXICOAT® 300 COLLECTOR

The FlexiCoat® Collector consists of the following:

6.3.1 500 CFM Collector Module

The 500 CFM Collector Module uses a 1 HP motor to drive the Exhaust Fan. The Exhaust Fan pulls air from Powder Application Hood (Canopy) and into the (2) Cartridge Filters. The air passes through the Cartridge Filters and is forced through the Final Filter. The clean, powder free air is returned to the surroundings. Excess powder (not adhering to the parts) is carried by the air flowing through the Hood to the Cartridge Filters, where it collects on the outer surfaces. When activated, the pulse valves force air from the Pulse Valve Air Manifold through the Cartridge Filter in the opposite direction of normal flow. The pulse airflow cleans accumulated powder from the Cartridge Filter media. The powder falls to the bottom of the Collector Module and into the storage container where it can be recovered and recycled or discarded. A Differential Pressure Gauge is located on the side of the Collector Module. This gauge provides an indication of cleanliness of the Filter Cartridges. A normal reading would be between 0 and 3.5. A reading above 3.5 would indicate the Filter Cartridges are not being cleaned well enough. This would require resetting the unit so the reverse cleaning pulses are more frequent and/or increasing the air pressure to the pulse circuit.


Serial #20940 13

7 INSTALLATION

These instructions for installing, operating and maintaining the FlexiCoat® 300 Powder Application 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 "FlexiCoat®" and ancillary equipment on a level surface at the desired

location. Refer to Floor Plan Drawing in the Appendix of this manual.

2. Look over the entire Powder coating Machine and Powder Collector Module to make sure there has been no damage during shipping. Although your machine may be shipped pre-assembled, please read through this manual before installing.

7.2 AIR CONNECTIONS

E.T.I. supplies the Poly-Flo tubing for all air connections. Refer to the Pneumatic Schematic in the Appendix of this manual. 1. Check that all pneumatic hoses are connected securely throughout the

machine. 2. Connect the hose from the Coalescing Filter (on the Refrigerant Air Dryer) to

the main air inlet of the FlexiCoat® 300.

NOTE: If Dry inert gas is used, consult the E.T.I. factory.

3. Connect the ½ inch air supply hose to the inlet of the Particle Filter (on the Refrigerant Air Dryer).

7.3 ELECTRICAL CONNECTION

1. Connect the Booth and Electrical Panel to a true earth ground.

2. Connect the electrical cord from the Refrigerant Air Dryer to a receptacle outlet rated: 240 Volts, 50 Hz, 1-Phase.

3. Connect the FlexiCoat® 300 Powder Application System electrical cord to a

receptacle rated: 240 Volts, 50 Hz, 1-Phase, 20 Amp.

CAUTION: ALL RECEPTACLES MUST HAVE A PROPER GROUND CONNECTION.


14 Serial #20940


Serial #20940 15

7.4 CONTROLS

7.4.1 Settings

1. Turn "ON" the system electrical power and open the air supply shutoff

valve. 2. Make sure the System air pressure is between 80 psi - 100 psi (5.5 bar -

6.9 bar).

3. Press the COLLECTOR START push button. 4. Turn the AUTO PULSE (Filter Pulse) Selector Switch to the "ON"

position.

5. Turn the COATER BED Selector Switch to the "ON" position.

6. Adjust the Filter Pulser air pressure to 45 psi (3 bar).

7. Adjust the Coater Bed air pressure to 45 psi (3 bar).

7.4.2 Footswitch

1. Locate the Coater Footswitch and position in front of the Coater Station. The Footswitch is already pre-wired to the electrical controls.

7.5 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 Bed and the Powder Collector Pail. All powder containers (bags, barrels, hoppers, etc.) should be kept tightly closed.

NOTE: Do not mix different types of powder.


Plug the Refrigerant Air Dryer into proper electrical receptacle. Make sure that the Refrigerant Air Dryer ON/OFF Switch is in the "ON" position.


16 Serial #20940

8 DESCRIPTION OF CONTROLS

8.1 MAIN ELECTICAL CABINET

The following control is located on the Main Electrical Cabinet:

MAIN DISCONNECT ON/OFF Switch

Turns the System electrical power "ON/OFF".

8.2 ELECTRICAL CONTROL PANEL ILLUSTRATION


Serial #20940 17

8.3 ELECTRICAL CONTROL PANEL CONTROLS

EMERGENCY STOP Pushbutton

Shuts off the exhaust fan. Shuts off power to system electrical and pneumatic devices.

COLLECTOR START Pushbutton

Turns ON the Powder Collector exhaust fan. Turns on power to system electrical and pneumatic devices.

COLLECTOR STOP Pushbutton

Turns OFF the Powder Collector exhaust fan. Turns off power to system electrical and pneumatic devices.

AUTO PULSER OFF/ON Switch

Activates the Powder Collector Filter pulser (shakedown) sequence. When the Filter Pulser is left on "ON" during processing, the filter cartridges are continuously cleaned by a back pulse of air as controlled by the pulse timer. When the Filter Pulser is turned "OFF" during processing there is no filter cleaning being done. Operator must remember to turn the Filter Pulser Selector Switch to "ON" and let the filters be pulsed clean for a few minutes before turning the System "OFF".

COATER BED OFF/ON Selector Switch

Turns Coater Bed "ON". Enables High Voltage and Fluidizing air to be supplied when Footswitch is pressed.

VIBRATOR OFF/ON Selector Switch

Turns Coater Bed Vibrator "ON". Applies slight vibration to the Coating Bed. Generally, materials that fluidize well require no vibration assistance. Vibration assistance is only required for materials which are hard to fluidize.

HIGH KVA METER Digital Meter

Indicates the voltage being supplied by the High Voltage Multiplier when the Footswitch is pressed.

HIGH VOLTAGE ADJUST Adjustable Potentiometer

Adjusts the output of the High Voltage Multiplier (0-80 kV).


18 Serial #20940

8.4 PNEUMATIC CONTROL PANEL ILLUSTRATION

8.5 PNEUMATIC CONTROL PANEL CONTROLS

FLEXICOAT BED ADJUSTMENT Air Flowmeter

Adjusts and indicates the amount of fluidizing air supplied to the Coating Bed.

FLEXICOAT BED PRESSURE Air Pressure Gauge

Indicates the amount of regulated air pressure supplied to the Coating Bed.

FLEXICOAT BED PRESSURE ADJUSTMENT Air Pressure Regulator

Adjusts the amount of regulated air pressure supplied to the Coating Bed.


Serial #20940 19

8.6 MISCELLANEOUS CONTROLS

The following control is not located on the Electrical Control Panel:

FOOTSWITCH Activates the Coating Bed when pressed.

The Coating Bed will only operate while the Footswitch is pressed and cease to operate when the Footswitch is released.

8.7 FLEXICOAT® POWDER COLLECTOR CONTROLS

Note that these controls are not shown on a drawing, they are found on the Enclosure or Frame of the FlexiCoat® Powder Collector. FILTER PULSER AIR PRESSURE Air Pressure Regulator & Gauge

Indicates and adjusts amount of regulated air pressure supplied to the Powder Collector Cartridge Cleaning Pulser.

DIFFERENTIAL PRESSURE GAUGE Magnahelic Gauge

Indicates the difference in pressure across the Powder Collector filters from the clean side to the dirty side, which indicates the level of cleanliness of the filter cartridges.


20 Serial #20940

9 START-UP AND OPERATION PROCEDURE

9.1 COATING STATION SET-UP

Step 1 - Make sure the Refrigerant Air Dryer is plugged into the electrical supply and is "ON". Wait 5 minutes before operation to allow the Dryer to achieve a pressure compensation within the refrigeration system. Check to make sure the “ON/OFF” switch is set to the “ON” position.

Step 2 - Press the COLLECTOR START pushbutton, located on the Electrical

Control Panel. Check the cartridge filter differential pressure gauge on the Collector Module. During normal operation, the pressure should remain under 3.5 inches water column. If the reading reaches 3.5 or higher, the cartridge filters are clogged and should be pulsed. If the differential pressure gauge still reads 3.5 or higher after pulsing, replace the cartridge filters.

Step 3 - Make sure the AUTO PULSE (Filter Pulse) Selector Switch is in the

"ON" position. Step 4 - Make sure that the Filter Pulser regulator for the Powder Collector

Pulse Valves is set to approximately 45 psi (3 bar). Step 5 - Turn the COATER BED Selector Switch to the "ON" position. Step 6 - Add a suitable Electrostatic Fluidized Bed coating powder to the

Coating Bed. The un-fluidized powder depth in the Coating Bed should measure approximately 1 to 1.5 inches deep.

Step 7 - Adjust the FLEXICOAT BED PRESSURE (Coating Bed air

pressure) to 45 psi (3 bar). This regulator/gauge is located on the Pneumatic Control Panel.

Step 8 - Turn the High Voltage Control to zero. Step 9 - Adjust the FLEXICOAT BED ADJUSTMENT (Coating Bed Air

Flowmeter) to approximately 30% of the meter capability.

NOTE: The Coater footswitch must be pressed.


Serial #20940 21

9.2 ELECTROSTATIC COATING OPERATION

Step 1 - Adjust the FLEXICOAT BED ADJUSTMENT (Air Flowmeter) if

necessary. There should be adequate fluidization of the powder in the Bed so a cloud forms.

Step 2 - Ground the part to be coated using the ground clip. Hold the part just

above the Coating Bed. Step 3 - Press the Coater Footswitch and activate the Coating Bed.

Step 4 - Turn the HIGH VOLTAGE ADJUST up to a starting point of 55 kV.

Allow the part to be coated (in the powder cloud) for the duration of the coating cycle. Rotate the part around as required to get uniform powder deposition.

Step 5 - Release the Coater Footswitch and remove the part to inspect after

coating. Adjust the FLEXICOAT BED ADJUSTMENT Air Flowmeter, High Voltage setting and/or length of coating cycle in order to obtain the optimum coating.

Step 6 - Repeat these steps as required to obtain a satisfactorily coated part.

9.3 POWDER REMOVAL OPERATION

Step 1 - Once a part has been satisfactorily coated, powder may be removed

from unwanted surfaces by vacuum, manual wiping or brushing, or by the use of a stream of compressed air.

Step 2 - Once parts are satisfactorily coated and cleaned, place them onto a

rack or hanger for oven cure.


22 Serial #20940

10 SHUT-DOWN PROCEDURE

10.1 COATING BED OPERATION Note: you should leave the Auto Pulser (Filter Pulser) Selector Switch in the "ON" position which will enable continuous automatic filter pulsing to occur whenever the system is "ON" and running. You may elect to leave the Filter Pulser set on "OFF" which means it will not pulse the cartridges while it is "ON" and running. However, if you elect to operate the machine with the automatic pulsing feature turned "OFF" then you must remember to shake the cartridges down every time you shut the unit "OFF" by following the procedure below. Step 1 - Whenever you shut the machine "OFF" you should shake down the

filter cartridges. Turn AUTO PULSER Selector Switch to "ON" to pulse the Filter Cartridges. This should be done every time the machine is going to be shut "OFF". You may find that it is necessary to do this several times a day. However, the system must be "ON" for this feature to work.

Step 2 - Turn the COATER BED Selector Switch to the "OFF" position. Step 3 - Press the COLLECTOR STOP push button located on the electrical

control panel. Step 4 - At this time you may wish to re-claim powder from the Powder

Collector. Re-claimed powder may be mixed with virgin material at a rate of no more than 20% re-claim and re-used in the Coating Machine. Remove the bucket from under the Powder Collector Hopper to access the re-claimed powder.

10.2 RE-START PROCEDURE

When re-starting press the COLLECTOR START push button and turn the COATER

BED Selector Switch to the "ON" position. High Voltage settings and air settings should not need to be re-adjusted. They will remain set as before shutdown.

10.3 EXTENDED SHUT-DOWN PROCEDURE

When shutting the machine down for more than an overnight period, the following

should be noted:

When not in use, the coating material in the unit should be removed from the Coating Bed to prevent clogging of the Porous Plate. As most coating materials are hygroscopic, storage of the powder in the Powder Collector Re-claim Pail for extended periods of time is not recommended. It is advisable that the powder be removed and stored in an air tight container. Observe the following procedure:


Serial #20940 23

10.3.1 Coating Bed Cleaning

Step 1 - Turn the Powder Collector Fan Motor "ON" (COLLECTOR

START). Put the AUTO PULSE Selector Switch in the "OFF" position. Note; if the unit has been oiprating with the Powder Collector Filter Pulse (AUTO PULSE) in the "OFF" position then you must turn it "ON" and allow the Filters to be pulsed clean a few times. Then turn the Auto Pulse feature "OFF".

Step 2 - Clean the inside of the canopy with a rubber squeegee or other

grounded, nonmetallic device. Open the hinged baffle door and scrape the powder into the Powder Collector Module.

Step 3 - Make sure to turn the COATER BED Selector Switch to the

"OFF" position. Step 4 - Carefully vacuum the remaining powder from the Bed. Use a

shop vacuum with a soft plastic nozzle on the end of its hose. Any residual powder not vacuumed out from inside the canopy can be blown with compressed air into the Powder Collector Module.

Step 5 - Press the COLLECTOR STOP pushbutton to shut off the Powder

Collector Fan Motor. Step 6 - Turn the electrical panel’s disconnect switch to the "OFF"

position.

10.3.2 Powder Collector Module Cleaning

Step 1 - Turn the electrical panel’s DISCONNECT SWITCH to the "OFF" position.

Step 2 - Remove the hex head bolts and flat washers securing the Filter

Access Panel to the Powder Collector Module. Remove the Filter Access Panel.

Step 3 - Clean the inside of the Powder Collector Module with a rubber

squeegee or other grounded nonmetallic device. Brush the powder from the lower section of the Powder Collector Module into the Powder Re-claim Pail.


24 Serial #20940

10.4 POWDER/COLOR CHANGE

When changing powder from one color to another, it is very important that the

Coating Bed be thoroughly cleaned to prevent contamination. The same bed cleaning procedure as above should be used. Also, the Powder Collector Filter Cartridges should be changed if powder is being saved and re-used. It is also necessary to thoroughly clean the Powder Collector Hopper and Powder Re-claim Pail to avoid color contamination.


Serial #20940 25

11 TROUBLE SHOOTING

11.1 TROUBLE SHOOTING – COATER

COATER-SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Coating Bed High Voltage control set too low.

Increase (turn knob) High Voltage control.

No High Voltage indicated to Coating Bed

DC Power Supply in control box is bad.

Contact your ETI representative for further instructions

High Voltage control is set too low.

Increase (turn knob) High Voltage control.

High Voltage Multiplier is bad. Replace Multiplier.

No or low coating

If cable is disconnected or loose. Check plug connection. NOTE: Do not twist Multiplier connection it will damage internal connections.

Air flowmeter control is set too low.

Increase air flow (turn knob) on flowmeter. Tighten screws of porous plate ring.

Air Leaking by gasket at porous plate.

Check gasket – replace if necessary.

Porous Plate is clogged. Install new porous plate. Air solenoid is not operating. Replace the defective solenoid. Particle Air filter is clogged. Replace the filter element. Air shut-off valve partially closed.

Check valve and open if required.

Insufficient air to fluidize power.

Ice blocking air lines. Repair or adjust Air Dryer (refer to manufacturer's maintenance information in appendix).

Moisture in Coater fluidizing air. Check analysis gauge on the Air Dryer-if applicable.

Refrigerant Air Dryer malfunctioning.

Refer to the maintenance section of this manual.

Particle Air Filter is dirty. Replace filter element. Refer to the Spare Parts List of this manual for part number.

Coalescing Filter needs to be drained.

Drain Coalescing Filter and replace the filter element if damaged. Refer to the Spare Parts List of this manual for part number.

Coating powder is wet or damp.

Powder is hygroscopic and has absorbed moisture from the humid air around it.

Aerate powder in Coating Bed at low fluidization air setting for 20 minutes w/High Voltage turned "OFF".


26 Serial #20940

11.1 TROUBLE SHOOTING – COATER (continued)

COATER-SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Substrate not properly grounded Faulty ground to substrate Check ground clip to substrate to

make sure it is secure or insure that the conveyor or tooling provides a good ground.

11.2 TROUBLE SHOOTING – POWDER COLLECTOR

COLLECTOR - SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) No suction on Powder Collector. Powder Collector filter

cartridge(s) not being cleaned – infrequent filter cartridge blow-off.

Make sure the Auto Filter Pulser is "ON" and operating properly.

Cartridge filters clogged due to: Failure to pulse filters Pulse the filters several times. Inadequate pulse pressure Increase the manifold pressure to

60-90 psi (4.14-6.20 bar). Powder too fine or contaminated If using reclaimed powder,

reduce the ratio of reclaimed-to-virgin powder. Check powder particle size, if necessary.

Pulse valve malfunction The pulse valve diaphragm is ruptured. If you hear a hissing sound inside of the fan section, check for constant air flow from the valve. Replace the damaged valve.

Cross drafts Check for cross drafts across the booth face and correct as necessary.

Parts too large, interrupting flow of air through booth

Contact your ETI representative.

Powder escaping from booth openings

Exhaust fan rotation reversed Reverse the rotation of the motor by switching the wiring.


Serial #20940 27

11.2 TROUBLE SHOOTING – COLLECTOR (continued)

COLLECTOR - SYMPTOM POSSIBLE CAUSE(S) REMEDY(S) Blown Fuses Check reason for Blown Fuses

and the and correct it. Replace the blown fuse(s).

Fan motor overload shutdown Correct one of the following possible motor, contactor, fuse or operational problem as needed: • Check the exhaust fan for

proper rotation direction. • Check for mechanical binding

of the motor/fan assembly. • Check for contact corrosion

at the motor starter (1M in the electrical panel).

• Check the overload protectors for failure (1OL in the electrical panel).

System will not start

Incorrect, shorted, or open electrical wiring

Check the electrical circuits.

Cartridge pulsing will not start No air supply to pulse manifold Check the air supply.


28 Serial #20940

12 MAINTENANCE

12.1 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.

12.2 MAINTENANCE CAUTION

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

12.3 HIGH VOLTAGE MULTIPLIER

Please Note: Do not twist the cord that plus into the High Voltage Multiplier, the pins are very fragile and will break off. This condition will cause irreparable damage to the High Voltage Multiplier.

12.4 COMPRESSED 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. If wet compressed air enters the machine, it may result in a clogged porous plate in the Coating Bed and poor fluidization.

12.4.1 Air Lines

The air lines which enter the Coating Machine and the Powder Collector Module should be kept clean and free of any particles, water, and oil.

12.4.2 Particle Air Filter

Clean and check for proper functioning. Check the Filter Indicator Lens and replace the Filter Element if required. Note: green – O.K., red – replace.

Refer to the Particle Filter information in the manufacturer’s manual supplied. Change the filter element if dirty. See the Spare Parts List (Section 14) for the correct filter number.


Serial #20940 29

12.4.3 Refrigerant Air Dryer

Once the Refrigerant Air Dryer is "ON" and operating, after 15 minutes and periodically thereafter the following procedures should be implemented:

Step 1 - Make sure that the "Power On" light is lit and the unit is

operating. Step 2 - Make sure that condensate drain is draining; drains can very

easily become clogged by oil or dirt. This will allow wet compressed air to enter the machine, resulting in a clogged porous plate in the Coater and poor fluidization.

Consult the enclosed AIR/TAK Manual included in the Appendix of this Manual for more specific Refrigerant Air Dryer maintenance and troubleshooting instructions.

12.4.4 Coalescing Filter

Check and drain. Note that a wet filter element is normal.

Check the Filter Indicator Lens and replace the Filter Element if required. Note: green – O.K., red – replace. Refer to the Coalescing Filter information in the manufacturer’s manual supplied. Change the filter element if dirty. See the Spare Parts List (Section 14) for the correct filter number.

12.5 COATING BED

CAUTION: THE UNIFORM POROSITY OF THE POROUS PLATE IS VERY IMPORTANT TO PROPER COATING. DO NOT SCRAPE OR EVEN TOUCH IT WITH A HARD OR SHARP OBJECT. NEVER POINT AN AIR GUN DIRECTLY AT THE PLATE.

The screws holding down the Porous Plate retaining ring should be checked

periodically for tightness. Loose bolts may cause geysers of rising powder and non-uniform fluidization.

The Porous Plate is the key factor in controlling the powder cloud in the fluidic bed.

Under normal operation, the powder on the plate will be uniformly fluidized (lightly bubbling) over the entire surface of the plate. If the fluidization is not uniform, the Porous Plate has become clogged and will have to be replaced. The Porous Plate will require periodic replacement depending upon hours of use, contaminants in the compressed air, and conditions of operation and cleaning.


30 Serial #20940

12.5 COATING BED (continued)

Clogging of the pores of the plate is the most common cause of failure. Once the Porous Plate has been removed, inspect it to determine which of the following reasons caused clogging:

• Leaving powder unused in the bed for an extended period of time during humid

conditions.

• Oil or water in air supply system.

• Damage from scratching, gouging or denting the plate.

• Blowing compressed air directly at the surface of the plate.

• Correct the cause of plate failure and avoid conditions in the future which may have lead to it. Order a new Porous Plate and gasket material from E.T.I. and carefully install.

12.5.1 Porous Plate Replacement

Step 1 - Turn the FlexiCoat® 300 "OFF"

Step 2 - Unplug the FlexiCoat® 300 from all electrical power sources.

Step 3 - Vacuum all the powder from the bed using a soft brush fitting or

rubber nozzle on the end of a vacuum hose.

Step 4 - Remove the plastic hex head screws from the Porous Plate Retaining Ring and remove the Ring. Remove the old Porous Plate and gasket material.

Step 5 - Use the old Porous Plate as a template for positioning and making

the mounting holes in the new Plate.

Step 6 - Clean electrostatic powder out of the charging media and off the charging media if required. Note that the Porous Plate retaining ring must not have been tightened down enough or that the gasket was worn or not seated properly if there is powder in the charging media chamber.

Step 7 - Place the new Porous Plate onto the flange in the fluidic chamber.

Place new gasket material around the outside edge of the plate and position the Porous Plate Retaining Ring. MAKE SURE TO INSTALL THE NEW POROUS PLATE WITH THE SMOOTH SIDE FACING UP.


Serial #20940 31

12.3.1 Porous Plate Replacement (continued)

Step 8 - Replace the plastic screws and tighten down evenly so that the

retaining ring is snug against the Porous Plate to prevent ionized air leakage around edges of the Porous Plate.

Step 9 - Add a suitable Electrostatic Fluidized Bed coating powder to the

Coating Bed.

12.6 POWDER COLLECTOR MODULE

Refer to the Appendix of this Manual for maintenance information on the Powder Collector.

12.6.1 Cartridge Filters

Inspect the cartridge filters for damage to the filter media or gaskets. Remove the Final Filter and inspect the Collector Module for powder leaks. If powder is leaking past the cartridge filter gaskets, tighten the wing nuts on the cartridge filters to compress the gaskets and stop the leaks. Replace the cartridge filters if necessary. Check the differential pressure gauge. Under normal operation, the pressure should remain under 3.5 inches water column. If the reading reaches 3.5 or higher, the cartridge filters are clogged and must be pulsed. If the differential pressure gauge still reads 3.5 or higher after pulsing, replace the cartridge filters. 12.6.1.1 Cartridge Filter Replacement

All cartridge filters are accessible through the filter access panel. The filter closest to the filter access panel (outside filter) must be removed in order to access the filter that is furthest from the filter access panel. Step 1 - Remove the hex head bolts, lock washers and flat washers securing the filter access panel to the Powder Collector Module. Remove the filter access panel. Step 2 - Remove the protective cap from the threaded end of the hanger rod. Step 3 - While supporting the bottom of the outside cartridge filter with one hand, remove the wing nut and flat washer securing the cartridge filter to the hanger rod. Remove the cartridge filter (and discard it). Step 4 - Remove the hanger rod from the hook in the upper collector module.


32 Serial #20940

12.6.1.1 Cartridge Filter Replacement - continued Step 5 - repeat Step 2 to remove the inside cartridge filter, leaving its hanger rod in place on the hook. Step 6 - Remove the new cartridge filters form their cartons and inspect them for damage. Do not use damaged cartridge filters. Step 7 - Guide the installed hanger rod through the open end of the cartridge filter. Guide the threaded end of the hanger rod through the hole in the closed end of the cartridge filter. Step 8 - Secure the cartridge filter and hanger rod to the collector module using the flat washer and wing nut. Tighten the wing nut until the cartridge filter gasket is compressed evenly. Step 9 - Install a protective cap over the threads of the hanger rod. Step 10 - Hang the outside hanger rod on its hook and repeat Steps 2-4 to install the outside cartridge filter. Step 11 - Secure the filter access panel to the collector module using the flat washers and hex head bolts.

12.6.2 Final Filter

Visually inspect the Final Filter whenever replacing the cartridge filters. Replace the Final Filter when it becomes clogged and negatively affects performance of the exhaust fan.

12.6.2.1 Final Filter Replacement

Step 1 - Remove the hex nuts and lock washers securing the Z-brackets to the collector module. Step 2 - Remove the old final filter from the collector module.

Step 3 - Remove the new final filter from its carton and inspect it for

damage. Do not use a damaged final filter. Step 4 - Set the new final filter in place with the gasket facing the

collector module. Do not damage the gasket. Step 5 - Install the Z-brackets in place over the final filter. Install the

lock washers and hex nuts and finger-tighten the nuts. Step 6 - Check the position of the final filter to make sure that the

gasket will seal on all four sides. 12.6.2.1 Final Filter Replacement - continued


Serial #20940 33

Step 7 - Tighten the hex nuts until the gasket is compressed slightly.

Make sure the gasket is compressed equally on all four sides of the final filter.

12.6.3 Fan Motor

Lubricate the fan motor bearings every six months with one of the following greases or equivalent grease. Clean the motor grease fittings and apply two full strokes from a grease gun to each fitting. Do not over-grease the fan motor. • Dolium R (Shell Oil Co.) • SRI #2 (Chevron USA, Inc.)


34 Serial #20940

13 PATENTS The FlexiCoat® M-300 is manufactured under one or more of the following United States

Patents:

6,856,052 B2 6,827,780 6,759,095 6,620,243 6,558,752 B2 6,458,427 6,240,873

6,068,702 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


Serial #20940 35

14 SPARE PARTS LIST

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

SPARE PRICE EACH

Porous Plate, 14" x 14" 300036 Coating Bed 1 2 $218

Gasket Material, 3/4" wide 6513018 " A/R 1 roll $60 Plastic Screws, 5/16-18 x 1 ½" Long " 20 50 $.90 High Voltage Multiplier 8000001 " 1 - - H.V. Multiplier Cable 8016001 " 1 - - Vibrator, V-2-B 5041001 " 1 - -

Cartridge Filter 7100018 Collector Module 2 2 $129

Final Filter 7100041 " 1 1 $110 Hanger Rod (22") 1020011 " 2 1 $30 Wing Nut 1020012 " 2 1 $3 Washer 1020016 " 2 1 $1 Protective Cap 1020014 " 2 1 $3 Cartridge Pulse Valve, 1" NPT 3016013 " 2 - - Cartridge Pulse Nozzle, #165726 3022010 " 2 - - Refrigerant Air Dryer, 30 scfm, 220V, 1-PH, 50 Hz. AIR/TAK #SD-30-A

Pneumatic 1 - -

Particle Filter Housing & Element AIR/TAK #F04-GP60 " 1 - -

Particle Filter Replacement Element AIR/TAK #GP60 " - 1 $112

Coalescing Filter Housing & Element AIR/TAK #F04-C60 " 1 - -

Coalescing Filter Replacement Element AIR/TAK #C60 " - 1 $112

Differential Pressure Gauge, 0 – 10", Minihelic 3018019 " 1 - - Air Pressure Gauge, 0-60 psi Norgren #18-013-202 3010002 " 1 - -

Air Pressure Gauge 3018002 " 1 - - Air Regulator 3013004 " 2 - - Air Flowmeter 3018012 " 1 - - Solenoid Valve, 3-way, 1/4" NPT 3016012 " 1 - - Solenoid Coil, 24 VDC 3016011 " 1 - - Solenoid Valve (Filter Pulser) 5046026 " 2 1 $81 Blower Motor, ¾ HP, 56C, 2850 RPM, 220V, 50Hz., 1-Phase Baldor #VL3506-50

Electrical 1 - -

Emergency Pushlock Turn Reset Switch, N.C. , Red 5011089 " 1 - -

Pushbutton, N.O., Green 5011091 " 1 - -


36 Serial #20940

14 SPARE PARTS LIST (continued)

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

SPARE PRICE EACH

Pushbutton, N.C., Red 5011090 Electrical 1 - - Programmable Logic Controller (Pre-Programmed) Allen-Bradley MicroLogix 1000

5211006 " 1 - -

Disconnect Switch 5011080 " 1 - - Motor Contactor 5020031 " 1 - - Motor Overload, 1.6 - 5.0 Amps 5020037 " 1 - - Contactor 5020030 " 1 - - Auxiliary Contact 5020040 " 1 - - Transformer, 500 VA w/Sec. Fuse Clip for 13/32" x 1 1/2" Fuse 5062008 " 1 - -

Digital Meter, 3 1/2 Digit 5039006 " 1 - - Potentiometer 5042008 " 1 - - Selector Switch 5011051 " 3 - - Footswitch 5011006 1 1 $52 DC Power Supply 8000003 " 1 - - Control Wiring Harness 8000004 1 - - Line Filter 8000005 1 - - Solid State Relay 5020018 " 1 - - Relay 5020002 " 1 - - Fuse, 0.8 Amp (Filter Pulser) Bussman #MDL-8/10 (or equal) " 2 2 $$

Fuse, 2 Amp Bussman #FRN-R-2 (or equal) " 1 1 $$

Fuse, 3 Amp Bussman #FNQ-3 (or equal) " 2 2 $$

Fuse, 10 Amp Bussman #FRN-R-10 (or equal) " 2 2 $$

Please Note: Prices are valid for 90 days from the date on this document. Items marked with $$ -

contact ETI for price.


Serial #20940 37

15 FLOOR PLAN

See the Appendix for the Floor Plan Drawing.

16 PNEUMATIC SCHEMATIC See the Appendix for the Pneumatic Schematic Drawing. 17 ELECTRICAL DRAWING

See the Appendix for the Elementary Electrical Drawing. 18 PLC PROGRAM

See the PLC Program located in the Appendix of this Manual. 19 MANUFACTURER'S MANUALS

All of the Manufacturer's Manuals listed below can be found in the Appendix of the manual:

• Air Flowmeter (Dwyer) • Air Filters - Particle & Coalescing (AIR/TAK)

• Air Regulator (Norgren) • Blower Motor (Baldor)

• Digital Meter (Summit) • High Voltage Multiplier (Nordson)

• Minihelic II Differential Pressure Gauge (Dwyer)

• Programmable Logic Controller (Allen-Bradley)

• Refrigerant Air Dryer (AIR/TAK)

• Transformer (Hammond)

• Vibrator (Syntron)

TABLE OF CONTENTSSystem) and SERIAL NUMBER (20940) of the "POWDER COATING MACHINE". 2 SHIPPING Sometimes equipment can be damaged in transit. An inspection of the shipping crate should

Documents