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Electrostatic Technology 18028, Manual

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Electrostatic Technology 18028 Manual Download Page 23

Electrostatic Technology, Inc. 

 

Trickle Impregnation System 

Serial #18028 

19 

 

7.3 STATION 

BEACON 

 

RED 

Light 
 

Indicates an ALARM condition exists. 

AMBER 

Light 

Indicates the machine is in the MANUAL MODE. 
 
 

GREEN 

Light 

Indicates the Machine is operating in the 
AUTOMATIC MODE. 
 
 

BLUE 

Light 

Indicates the machine is low on material. 
 
 

 
 

7.4 

INDUCTION HEATER CONTROLS 

 

Please refer to the Heuttinger Operating Instructions; Section 6 – Operation, Control 
of TIG/BIG RF Generators for detailed information on the Controls and the 
operation of the Controls for the Induction Heater. 
 
This information is located in a separate Binder included with this Manual. 
 
Please make sure to completely understand this information before trying to operate 
the equipment. 
 

 

Summary of Contents for 18028

Page 1: ...Inhalation 11 4 2 2 2 Skin Contact 11 4 2 2 3 Eye Contact 11 4 2 2 4 Ingestion 11 4 2 3 Special Protection 11 4 2 4 Precautions 11 4 2 5 Material Safety Data Sheets MSDS 12 5 AIR AND ELECTRICAL REQUIR...

Page 2: ...HISTORY SCREEN 33 8 8 MACHINE I D SCREEN 34 8 9 ALARM BANNER SCREEN 35 9 PREPARATION FOR OPERATION 38 9 1 INITIAL SYSTEM INSTALLATION 38 9 2 INDUCTION HEATER 39 10 START UP AND OPERATION PROCEDURE 40...

Page 3: ...System Serial 18028 iii 14 1 2 Lifting Rails 49 15 TROUBLE SHOOTING 50 15 1 CONVEYOR CLUTCH 50 15 2 BAD PART 50 16 PATENTS 52 17 SPARE PARTS LIST 53 18 FLOOR PLAN 62 19 PNEUMATIC SCHEMATIC 62 20 ELEC...

Page 4: ......

Page 5: ...Trickle Impregnation System and SERIAL NUMBER 18028 located on the Main Electrical Enclosure of the TRICKLE IMPREGNATION SYSTEM 2 SHIPPING Sometimes equipment can be damaged in transit An inspection o...

Page 6: ...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...

Page 7: ...sk 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 WARN...

Page 8: ...val 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 perso...

Page 9: ...h 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 reins...

Page 10: ...ssociated with these and exercise appropriate caution Do not wear or carry metallic objects jewelry or tools while working with or around the induction heating unit Keep parts of the body or loose clo...

Page 11: ...hut 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 m...

Page 12: ...ment 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...

Page 13: ...Electrostatic Technology Inc Trickle Impregnation System Serial 18028 9 3 10 DISPOSAL Dispose of equipment and materials used in operation and cleaning according to your local regulations...

Page 14: ...al ordinances There is potential vapor explosion hazard Resin should be kept away from sparks or open flames Personnel should not be permitted to smoke in the trickle impregnation area 4 2 1 Employee...

Page 15: ...Consult a physician if required 4 2 2 3 Eye Contact Flush eye gently with plenty of clean water for 15 minutes If irritation persists contact a physician 4 2 2 4 Ingestion If swallowed consult a phys...

Page 16: ...2 5 Material Safety Data Sheets MSDS For every powder which is used in the coating equipment a Material Safety Data Sheet should be obtained from the powder manufacturer Personnel should be aware of...

Page 17: ...he Induction Heaters is supplied from the main power input specified in Section 6 1 2 above 5 2 2 Water 5 2 2 1 Closed Loop Induction Heater Cooling System Distilled water is required for the Closed L...

Page 18: ...ding on a pair of shafts with ball bushings The trickle plate is driven by a ball screw servo motor arrangement so that it exactly follows the speed of the rotating armatures for 7 5 inches 3 pitches...

Page 19: ...tem provided to spray CO Carbon Dioxide in various stations on the machine in the case of fire The unit and Operating Controls is located behind the machine in the Cure Section There are two 2 Heat Se...

Page 20: ...heat exchanger Locate the view hole in the front panel of the machine at the Cure Module This view hole has a label marked Distilled Water Level A distilled water temperature gauge is located on the...

Page 21: ...olding the Operator Control Panel The following control is located on the Main Control Cabinet 7 1 1 Main Electrical Control MAIN DISCONNECT Turns on power to the Machine 7 2 OPERATOR CONTROL PANEL Th...

Page 22: ...Controller PanelView and PLC Input Modules OFF position turns OFF all control power to the machine including the PLC Programmable Logic Controller PanelView and PLC Input Modules EMERGENCY STOP Pushb...

Page 23: ...BLUE Light Indicates the machine is low on material 7 4 INDUCTION HEATER CONTROLS Please refer to the Heuttinger Operating Instructions Section 6 Operation Control of TIG BIG RF Generators for detail...

Page 24: ...THIS CONTROL IS NOT BEING USED AT THIS TIME UNLOAD AIR CYLINDER PRESSURE ADJUST Air Pressure Regulator located on Front Panel at Cure Station Adjusts and indicates the amount of air being supplied to...

Page 25: ...ressure available to the Rotary Mixer ROTARY MIXER PRESSURE ADJUST Air Pressure Regulator located on Rear of Trickle Station Adjusts and indicates the amount of air being supplied to the Rotary Mixer...

Page 26: ...the selection indicator boxes there are also additional indicators and messages present on each screen The Machine includes the following PanelView screens The MAIN MENU SCREEN displays the following...

Page 27: ...ecting touching the UP DOWN and ENTER buttons or using the PREVIOUS SCREEN and NEXT SCREEN buttons The ALARM SILENCE button silences the audible alarm The following screen buttons are located at the b...

Page 28: ...ushbutton Supplies Main Electrical Power to the Induction Heater Cabinet IND HEATER SUPPLY POWER OFF Screen Pushbutton Removes Main Electrical Power from the Induction Heater Cabinet INDUCTION HEATER...

Page 29: ...Electrostatic Technology Inc Trickle Impregnation System Serial 18028 25 8 2 MACHINE MANUAL CONTROL SETUP SCREEN continued Figure 2 MACHINE START UP SCREEN...

Page 30: ...reens and silence alarm button SELECT AUTO MODE Screen Pushbutton Set the machine for Automatic operation SELECT MANUAL MODE Screen Pushbutton Set the machine for Manual operation AUTO START Screen Pu...

Page 31: ...Electrostatic Technology Inc Trickle Impregnation System Serial 18028 27 8 3 MACHINE AUTO START STOP MACHINE STATUS SCREEN cont Figure 3 MACHINE AUTO START STOP MACHINE STATUS SCREEN...

Page 32: ...ESS Screen Message Displays oven Temperature SELECT RUN MODE Screen Pushbutton Places the Trickle Slide Station in Run Mode Normal Operation SELECT TEST MODE Screen Pushbutton Places the Trickle Slide...

Page 33: ...Electrostatic Technology Inc Trickle Impregnation System Serial 18028 29 8 4 MACHINE MANUAL CONTROL SETUP SCREEN continued Figure 4 MANUAL FUNCTION SCREEN...

Page 34: ...UMP STOP Screen Pushbutton Stops the Trickle Pump in manual mode INCREASE SPEED Screen Pushbutton Increases the output control signal of the Trickle Pump Note The Trickle Pump Auto Manual Switch locat...

Page 35: ...Electrostatic Technology Inc Trickle Impregnation System Serial 18028 31 8 5 MACHINE TRICKLE PUMP CALIBRATION SCREEN continued Figure 5 MACHINE TRICKLE PUMP CALIBRATION SCREEN...

Page 36: ...regnation System 32 Serial 18028 8 6 ALARM ACTIVE SCREEN The ALARM ACTIVE SCREEN figure 6 screen provides a list of active machine faults and selections to access different screens and silence the aud...

Page 37: ...Impregnation System Serial 18028 33 8 7 ALARM HISTORY SCREEN The ALARM HISTORY SCREEN figure 7 provides a history of machine faults and selections to access different screens and silence the audible...

Page 38: ...rickle Impregnation System 34 Serial 18028 8 8 MACHINE I D SCREEN The MACHINE I D SCREEN provides manufacturer information along with selections to access different screens and silence the audible ala...

Page 39: ...t Part Cooling Blower Motor Safety Switch Is Off alarm_18 Fault Part Cooling Blower Motor Overload Tripped alarm_19 Fault Induction Heater H2O Pump Motor Overload Tripped alarm_20 Fault Spare Motor Ov...

Page 40: ..._46 Fault Servo Drive Follower Overtravel Detected alarm_47 Fault Servo Drive Retracting Overtravel Detected alarm_48 Servo Drive Home Position Not Registered alarm_49 Spare alarm_50 Spare alarm_51 Au...

Page 41: ...Electrostatic Technology Inc Trickle Impregnation System Serial 18028 37 8 9 ALARM BANNER SCREEN continued Figure 9 ALARM BANNER SCREEN...

Page 42: ...hine in the desired location 3 Adjust the height and level the Main Machine 4 Locate peripheral equipment such as the Induction Heater and Fire Extinguisher System in proper places with respect to the...

Page 43: ...r Tank has been filled DO NOT TRY TO OPERATE THE SYSTEM AT THIS TIME 12 At this point contact and E T I serviceman for Start Up Service 9 2 INDUCTION HEATER To Enable the Induction Heater Select the M...

Page 44: ...load and unload stations Step 4 Place the Control Switch in the START position to turns on control power to the machine The trickle station should automatically find its home position Step 5 The MAIN...

Page 45: ...ep 5 Press the CONVEYOR START screen pushbutton Step 6 Select the NEXT SCREEN or go to the MAIN MENU SCREEN and select the MACHINE TRICKLE PUMP CALIBRATION SCREEN Step 7 Place the Data Edit Enable key...

Page 46: ...on Heater coil 10 2 1 Induction Heater To operate the Induction Heater CONVEYOR START must be selected on the MACHINE MANUAL CONTROL SETUP SCREEN The IND HEATER SUPPLY ON and the INDUCTION HEATER STAR...

Page 47: ...ow the oven to come up to the desire temperature Step 4 Press the following screen pushbuttons MACHINE SYSTEM START IND HEATER SUPPLY ON IND HTR FAULT RESET INDUCTION HEATER START Step 5 Go to the MAI...

Page 48: ...INDUCTION HEATER STOP and IND HEATER SUPPLY OFF This will turn off the Induction Heater cabinet Press MACHINE SYSTEM STOP This will stop the Induction Heater Water Pump and Part Cooling Blower Exhaust...

Page 49: ...re that the contacting surfaces are disconnected using gauge or by visual investigation Try to restart the system The system must not start Pneumatic P1 Main pneumatic valve Near the Air Drier Push In...

Page 50: ...rs the System should be kept clean and free of a particles water and oil 12 2 2 Air Filters and Lubricator Particle Filter Clean and check for proper functioning Change filter element if dirty See the...

Page 51: ...g during repair or replacement of damaged hoses Step 7 Restring new hoses back through to the tips of the idle lines 12 4 INDUCTION HEATER Observe the Water Tank Sight Glass located on the front of th...

Page 52: ...2 WEEKLY 1 Check and lubricate all motors pumps and bearings on the machine if required 2 Check the Induction Heater Cooling Water System for any restrictions which could cause a clog in the pump or...

Page 53: ...ER PROCEDURE 14 1 1 Bearing Blocks Loosen all Bearing Blocks front and or rear throughout the machine Start at the Drive End and move Bearing Blocks into proper position one at a time Tighten each one...

Page 54: ...torque Repair reason for binding or replace with new bearing Re set Clutch 15 2 BAD PART BAD PART SYMPTOM POSSIBLE CAUSE S REMEDY S Pump not running Check electrical connection Hose clogged Check for...

Page 55: ...part temperature entering Trickle area Turn Induction Heater setting up Cure Tunnel temperature set too low Turn Cure Tunnel temperature setting up Resin not cured Resin mixed incorrectly Correctly re...

Page 56: ...ng United States Patents 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...

Page 57: ...e Ball Screw 24 in long Dia Nom 50 x 2 Lead non preloaded Thomson 2DB 12OUB FL24 Trickle Station 1 Nozzle Tube 103158 8 8 75 Air Driven Mixer Midwest Mixing Inc 347K2SS 2 Pump Motor Dayton 2M167D Pump...

Page 58: ...4 4 1 055 Roto Flo Transport Screw 91 long S S 103643 2 2 To advise Roto Flo Bearing 102297 22 22 160 Lifting Rail Load 103100 1 1 309 Lifting Rail Induction 103101 1 1 538 Lifting Rail Impregnator 10...

Page 59: ...ECM D SPARE PRICE EACH Finger 103136 Conveyor 4 4 378 Chute 103135 Load Station 1 340 V Block 103339 1 707 Guide Load Chute 1 L H 1 R H 103537 2 2 309 Air Cylinder Bimba BF 171 DNR 4 1 126 Dura Scape...

Page 60: ...22 Indicator Insert MLF 110 Festo 10634 1 Air Regulator Wilkerson R16 03 000 2 1 50 Air Regulator Wilkerson R16 02 G00 1 1 64 Air Regulator Wilkerson R26 04 G00 1 1 90 Air Regulator Norgren R07 200 R...

Page 61: ...rter Allen Bradley 1761 NET AIC 2 1 184 Safety Relay Allen Bradley 440N C02070 1 1 752 Safety Relay Door Switches 10 M Cable Allen Bradley 440N S32033 4 1 101 Differential Pressure Switch 2 5 H20 Dwye...

Page 62: ...able Banner Mqdc 415RA 2 1 35 Ultrasonic Proximity Sensor NC Hyde Park SM900A 110000 2 1 718 Operator Control Screen Panelbuilder Type PV 1000 Allen Bradley 2711 T10C9L1 1 PanelView Back Light Lamp Al...

Page 63: ...LAPD 2R 1 1 4 Incandescent Bulb for Panel Switches White IDEC LAPD 2W 4 4 4 Incandescent Bulb for Panel Switches Amber IDEC LAPD 2A 1 1 4 Circuit Breaker 10 Amp 1 Pole Allen Bradley 1492 CB1G100 2 Cir...

Page 64: ...rammable Logic Controller SLC 5 05 Allen Bradley 1747 L551 Program Controller 1 1 3 111 Power Supply Allen Bradley 1747 P2 1 1 482 Input Module Allen Bradley 1746 IV16 5 1 257 Isolated Output Module A...

Page 65: ...Electrostatic Technology Inc Trickle Impregnation System Serial 18028 61 Please Note Prices are valid for 90 days from the date on this document...

Page 66: ...ls listed below can be found in the separate Manufacturer s Manuals Binder Advance Interface Convertor Allen Bradley Air Filters Particle Coalescing Wilkerson Air Regulator Wilkerson Blower Motor Bald...

Page 67: ...n Bradley SLC Processor Allen Bradley Analog I O Modules Allen Bradley Discrete I O Modules Allen Bradley High Speed Counter Module Allen Bradley Isolated I O Module Spectrum Controls Power Supply All...

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