Sames Inocoat Inocenter Instruction Manual Download Page 1

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Instruction manual

DRT7142

B - 2023/06

Inocenter

Summary of Contents for Inocoat Inocenter

Page 1: ...Instruction manual DRT7142 B 2023 06 Inocenter ...

Page 2: ...n any form whatsoever and all use or communication of its contents are forbidden without express written authorisation from Sames The descriptions and characteristics mentioned in this document are subject to change without prior notice Sames 2021 Translation of the original instruction manual ...

Page 3: ...duction tool Our network of experts is continuously trained and qualified to provide our customers with technical expertise on the liquid or powder installations in which our equipment is integrated The global environment of the production lines is taken into account during this technical audit A brochure is available for download www sames com france fr services service contract html Maintenance ...

Page 4: ...nk production phase 16 2 5 5 Recycled powder supply to th box powder powder recovery phase before a change of colour or end of production 17 2 5 6 Blowing of the recycled powder supply circuit 17 2 5 7 Draining the powder tank 18 2 5 8 Powder supply for sprayers powder hose 18 2 5 9 Blowing out powder feed pipes for sprayers 19 2 5 10 Tank blowing 19 2 5 11 Blowing out the dense phase powder pump ...

Page 5: ...k lid seal 32 5 2 3 Procedure A3 Checking the condition of the sleeve valves 32 5 3 Replacement 32 5 3 1 Procedure B1 Replacement of the vacuum generator 32 5 3 2 Procedure C1 Replacement of a powder pump 32 5 3 3 Procedure C2 Replacement of the ejector injector porous tube and sleeve valve of the powder pump 33 5 3 4 Procedure D1 Replacement of the porous plate and flat seal on the tank bottom 34...

Page 6: ...re 1 2 Compliance with the ATEX directives According to Directives 1999 92 EC and Dangerous Substances and Explosive Atmospheres Regulations 2002 the responsibility for defining ATEX zones lies with the user In accordance with the EN 16985 Standard Sames has designed the Inocenter considering the following zones Zone 20 for the inner volume of the powder fluidized tank Zone 22 for the inner volume...

Page 7: ...spheres Warning Flammable material Warning Corrosive subtance Warning Toxic material Warning Harmful products No access for people with active implanted cardiac devices Wear ear protection Wear a face shield Wear respiratory protection Wear safety footwear Wear protective clothing Wear protective gloves Wear head protection Opaque eye protection must be worn General mandatory action sign Connect a...

Page 8: ...ors have read and understood the user manuals for any peripheral electrical equipment present in the powdering area 1 5 Warnings It is imperative that anyone wearing a pacemaker does not use the equipment and does not enter the projection area High voltage can cause the pacemaker to malfunction This equipment may be hazardous if it is not used disassembled and reassembled in accordance with the ru...

Page 9: ...ent 8 Turn off all electrical or electrostatic equipment immediately even if the operator is exposed to a slight electric shock Do not restart the equipment until the problem has been diagnosed and resolved 9 The powder station especially the vibrating table and all conductive structures placed in or near the work place must be electrically connected to the protective grounding system of the power...

Page 10: ...tation 1 6 2 Ambient temperature The Inocenter powder station is designed to normally operate at an ambient temperature comprised between 0 C and 40 C The storage temperature must never exceed 60 C This powder distribution plant Inocenter is usually connected to a filter unit via a ventilation duct A filter explosion protection system in accordance with the ATEX Directive 2014 34 EU is required Sa...

Page 11: ... control system not designed by Sames or a Sames control system modified by a third party without written permission from an authorized Sames technical agent accidents such as collision with external objects or similar events flooding earthquake fire or similar events the use of seals that do not comply with those recommended by Sames pollution of pneumatic circuits by fluids or substances other t...

Page 12: ...eted return the table to its initial position When you have finished cleaning return the table to its original position 2 2 2 Powder transfer pump This pump equipped with 4 sleeves allows the transport of new powder from the box to the fluidized tank During the production phase the operation of the pump is managed by the level sensors of the tank The transport capacity of this pump with a new powd...

Page 13: ... air blower Allows the cleaning of the powder station Vibrating table Moving support of the powder box New powder supply plunger New powder suction rod Plunger support Quick plunger locking system in cleaning position Powder level sensors Indicate high and low levels of powder in the tank Connection for cleaning hopper under cyclone Evacuation of cleaning hopper under cyclone Compressed air blower...

Page 14: ...enoid valves optional Clean the Inobooth floor Air tank equipped with solenoid valves for cleaning and blowing Used for cleaning the distribution and recycling cycles Distribution terminal board sleeve valve and blowing management All the distribution terminals which allow the control the man agement of the sleeve valves and the blowing Roof plates for distribution management Plates equipped with ...

Page 15: ...e supply of new powder starts when the tank is filled for the first time and in the production phase when the high level sensor is lost followed by an adjustable delay The pump transfers the powder from the container to the tank Sleeve valve QR11 open and sleeve valve QR23 closed DES09280 KK511 KK523 QR23 QR11 KK23 N225 Powder tank Air tank Powder pump Powder box Powder flow ...

Page 16: ... of the cyclone or is then transported by the flip flop system of the sleeve valves to the tank Recycling of the powder starts when the high level sensor in the tank tempo is lost Airs T21A and T22A are transport airs to evacuate the powder to the tank DES09281 KK511 KK523 QR23 QR11 KK23 N225 Powder tank Air tank Powder box Air flow Powder pump DES09282 KK24 KK548 KK510 KK524 QR48 QR24 QR10 N225 E...

Page 17: ... 6 Blowing of the recycled powder supply circuit The powder ducts are cleaned alternately from the air tank to the tank EVM21 and QR 48 closed from the air tank to the ventilation QR10 EVM21 closed from the air tank to the cyclone QR10 QR48 closed DES09283 KK24 KK548 KK510 KK524 QR48 QR24 QR10 N225 EVM22 Air T21A Air T22A EVM21 Powder tank Air tank Evacuation smoke ventilation Powder box Powder fl...

Page 18: ...ply to the projectors is managed by the venturi pump The injection air acts on the powder flow and the dilution air on the transport air to bring the air powder mixture to the projector in a homogeneous manner DES09285 QR11 Powder tank Powder box Powder flow Tank drain valve DES09286 QRPL01 12 QRPR01 12 KK20L01 L12 KK20R01 R12 Powder tank Powder flow Up to 24 projectors Injection air Dilution air ...

Page 19: ...k when the QRPLXX sleeve valves for the air streams are opened 2 5 10 Tank blowing The tank has its own air supply via two air inlets on the rear panel Valves QR45 and QR44 are closed during cleaning air trains The tank is also cleaned by the new and recycled powder supply pipes during the cleaning phases DES09287 QRPL01 12 QRPR01 12 KK20L01 L12 KK20R01 R12 Powder tank Air flow Up to 24 projectors...

Page 20: ...der into the ventilation system through the draw pipe 2 Valves QR 23 and KK 23 send air streams to the pump s chambers A B depending on the opening of valves PV1 PV4 DES09289 KK23 KK523 KK8 KK7 KK5 KK6 KK9 PV2 CHB CHA PV4 PV1 PV3 QR23 QR11 N225 KH24 KKCHA KKCHB Powder tank Air network Air flow Aspiration blowing Aspiration blowing Evacuation to ventilation Powder supply plunger in its housing alon...

Page 21: ...ed during the recovery phase of the powder contained in the cyclone by QR48 QR10 EVM21 closed 4 Blowing via QR23 and KK 23 to the reservoir PAP sleeve valves closed 5 Blowing towards the PAP QR11 closed DES09290 KK24 KK23 KK548 KK523 KK524 KK510 QR48 QR24 QR10 QR11 N225 EVM22 Air T21A Air T22A EVM21 QR23 Powder tank Air flow Evacuation to ventilation Powder supply plunger in its housing along the ...

Page 22: ...1 Electrical Characteristics Vibrator for the vibrating table and tank Protection class ATEX II 3 D Ex tc IIIC T100 C Dc Classification group II category 3D Supply voltage 230 V 240 V single phase earth Frequency 50 60 Hz Power 45 W Protection class IP 65 Insulation class F DES07421 2338 2255 1330 1803 ...

Page 23: ...turi pump 100 NL min in operation 160 NL min in cleaning Fluidization 60 NL min Inotransfer pump 450 NL min in operation 650 NL min in cleaning Recycling 250 NL min in recycling 650 NL min in cleaning External blowing projector 330 NL min projector Max compressed air consumption for an installation of 24 projectors Operation phase 170 Nm3 h Powder internal circuit cleaning phase 400 Nm3 h on avera...

Page 24: ...o move the powder station It is imperative to respect the position given in the diagram below for gripping the powder station Powder station Weight approx 550 kg Width 1800 mm Depth 1353 mm Height 2255 mm Tank Length 865 mm Width 414 mm Height excluding sleeve valve 581mm Useful volume 33 l Box from the powder supplier Min length 390 mm Min Width 320 mm Height max 420 mm Powder pumps Maximum numbe...

Page 25: ...t The weighted equivalent sound pressure level of 79 dB A is in LEQ value measured over observation periods of at least 30 seconds 3 3 2 Inocenter in cleaning phase The weighted equivalent continuous sound pressure level is 99 dB A under the specified operating conditions Measuring conditions the equipment was put into operation at maximum characteristics the measurements were carried out at diffe...

Page 26: ...the electrical connections of the following equipment Solenoid valves for blowing out the tank Transfer pump control board Roof lighting Inductive detector of the guillotine 2 terminal boxes vibrating table and tank vibrators Solenoid valves of the distribution terminal board control and blowing Note for electrical and pneumatic wiring of the various components please refer to the associated diagr...

Page 27: ...owder station requiring grounding are connected to the grounding bars located on the frame at the back of the powder station It is imperative to connect the grounding bars of the control unit to the grounding bar of the control cabinet or to a factory or building earth 4 2 6 Sensitivity adjustment of powder level sensors Raise the powder level above the sensor and adjust the setting screw with a s...

Page 28: ...2 9 Installation of solenoid valves for booth floor blower option Step 1 Screw the mounting plate to the profile at the rear of the Inocenter under the tank blowing solenoid valve assembly using two M8x20 screws 1 Step 2 clip the solenoid valve assembly onto the rail of the mounting plate Connect the hoses to the solenoid valves Regulator number Designation Type of regulator Factory setting KH20 R...

Page 29: ...panel of the booth Step 2 screw the quick connector onto the inside the booth Connect the hose equipped with a quick fit coupling according to the customer s configuration Step 3 screw the sleeve valve assembly onto the bulkhead at the rear of the booth Connect the external powder feed hose to the ring socket Step 4 Remove the end cap from the supply plunger ...

Page 30: ... bead of DP460 glue P N H2CPAL062 to the contour of the tube 3 and press on fully by turning the adaptor fitting 2 Step 6 fit the quick connector 1 onto the adapter 2 Step 7 fit the Inocenter recovery tank 5 P N 900022095 and its lid P N 900022096 2 5 3 1 4 ...

Page 31: ...e The user will have to create his own maintenance range as he uses the Sames equipment Procedure Detail Duration Frequency Cleaning A A1 Checking the condition of the powder pumps injector porous tube ejector and sleeve valves 10 min Every 40 hours of use A2 Checking the condition of the cover seal of the tank 1 min 1 time per month A3 Checking the condition of the sleeve valves 30 min Every 3 mo...

Page 32: ... Checking the condition of the sleeve valves Every 3 months Check the flexibility of the sleeve and replace it if necessary 5 3 Replacement Before any intervention on the powder station switch off the electrical and pneumatic power supplies Bleed the compressed air circuit by activating the air blower 5 3 1 Procedure B1 Replacement of the vacuum generator Disconnect the compressed air hoses Uncoup...

Page 33: ...roceed in reverse order for reassembly Replace the injector Unscrew the elbow fitting 1 remove the injector 2 from the pump body and replace it Proceed in reverse order for reassembly Replace the porous tube Unscrew the pump holder 7 from the upper flange 11 Remove the seal 8 the porous tube 9 and the seal 10 and replace them Proceed in reverse order for reassembly Replace the sleeve valve Unscrew...

Page 34: ...s by slightly loosening the 4 lock nuts 5 unscrewing the 4 M6x25 screws 4 and removing the 4 pins 3 Step 4 disconnect the powder hoses from the venturi pumps at the bottom of the tank Unclip the venturi pumps from the tank and temporarily tie the venturi pumps and their hoses together on each side of the tank to make it easier to move the tank Step 5 on the roof of the Inocenter next to the light ...

Page 35: ...and around the cylinder at the rear of the tank Step 11 lift the tank a little approx 6 cm using the straps and a lifting goat or cart to avoid damaging the cylinder Step 12 unscrew the 20 M6x40 screws 13 from the base plate 12 and remove it Step 13 Remove flat seal 11 and porous plate 10 Reassembling Before reassembling degrease the base plate and any tank surfaces in contact with it with isoprop...

Page 36: ... Inocenter The powder transport hose is clogged or bent Clean the powder transport hose with com pressed air The powder pump is not correctly connected on its support Replace the powder pump by pushing it fully on its support Insufficient powder comes out The powder pump ejector is worn Replace the ejector The powder transport hose is clogged or bent Clean the powder transport hose with com presse...

Page 37: ... not necessary On the other hand if the stop is not possible the 1st emergency parts will be kept in stock Wearing parts Wearing parts are consumable components such as O rings that undergo regular degradation over time during normal operation of the installation It is therefore advisable to replace them according to a defined frequency and adapted to the operating time of the installation The wea...

Page 38: ...38 Member of Exel group DRT7142 B 2023 06 7 1 Inocenter Powder Station 1 2 3 4 5 6 9 8 7 10 11 12 ...

Page 39: ...fer pump management board see 7 1 2 page 41 1 1 5 910027665 Ventilation duct assembly see 7 1 3 page 42 1 1 6 910023986 Inotransfer pump see DRT6454 1 1 7 910028081 New powder supply sleeve valve assembly see 7 1 4 page 43 1 1 8 910028082 Recycling sleeve valve assembly see 7 1 4 page 43 1 1 9 910035654 Booth floor solenoid valve assembly see 7 1 5 page 44 option 1 10 910028125 Solenoid valve asse...

Page 40: ...erminal boards 1 1 1 220000585 Distributor terminal control 1 1 2 220000673 Distributor 2x3 2 type K 1 1 3 220000584 Distributor terminal blowing 1 1 4 220000670 Distributor 2x3 2 type K 1 1 5 220000671 Distributor 3 2 type VX 1 1 6 220000672 Distributor 2x3 2 type VH 1 1 Part Number Description 220000584 4 220000585 4 Units up to 6 projectors 220000584 8 220000585 8 Units up to 8 projectors 22000...

Page 41: ...level for spare parts 910028861 Transfer pump management board 1 1 1 220000570 Distributor terminal 1 1 2 220000672 Distributor 2x3 2 type VH 1 1 3 220000671 Distributor 3 2 type VX 1 1 4 220000670 Distributor 2x3 2 type K 1 1 5 130001279 Cell 1 1 6 220000607 Distributor 3 2 2 1 7 160000249 Filter Dia 10 2 1 8 160000248 Filter Dia 8 4 1 9 130001927 Vacuum generator 1 1 1 2 3 4 5 6 7 8 9 ...

Page 42: ...sembly Level 1 1st emergency parts Level 2 Wearing parts Item Part Number Description Qty Unit of sale Maintenance level for spare parts 910027665 Ventilation duct assembly 1 1 1 110002655 Inductive sensor 1 1 2 2 900016064 Flexible sleeve for sheath Dia 150 2 1 2 1 2 ...

Page 43: ...s 910028082 Recycling sleeve valve assembly 1 1 1 220000532 Sleeve valve 3 1 2 2 900018417 Annular connection Dia 13 3 1 3 900018416 Annular connection Dia 19 1 1 910028081 New powder supply sleeve valve assembly 1 1 1 220000532 Sleeve valve 2 1 2 2 900018417 Annular connection Dia 13 2 1 3 900018416 Annular connection Dia 19 1 1 New powder supply sleeve valve assembly Recycling sleeve valve assem...

Page 44: ...parts 910028124 Solenoid valve assembly for distribution cleaning 1 1 1 1 F1SSRL020 Safety valve 1 1 2 2 1300001792 Cleaning solenoid valve 2 1 1 2 3 220000431 Pressure gauge 0 12 bar 1 1 4 220000430 Regulator filter 1 1 910028125 Solenoid valve assembly for blowing out the tank 1 1 5 220000538 Solenoid valve 2 1 1 2 910035654 Booth floor solenoid valve assembly Option 1 6 220000673 Distributor 2x...

Page 45: ...cy parts Level 2 Wearing parts Item Part Number Description Qty Unit of sale Mainte nance level for spare parts 910034100 Rotary vibrating table EU version 1 1 910034803 Rotary vibrating table US version 1 1 1 200000474 Silent block 4 1 2 910030011 Vibrator EU version 1 1 1 2 910030896 Vibrator US version 1 1 1 2 1 2 ...

Page 46: ...ption Qty Unit of sale Maintenance level for spare parts 910033995 Rotary vibrating table EU version with weighing system 1 1 910034804 Rotary vibrating table US version with weighing system 1 1 1 220000693AT Sensor 1 1 1 2 2 900021472 Sensor spacer 2 1 3 200000474 Silent block 4 1 4 910030011 Vibrator UE version 1 1 1 2 910030896 Vibrator US version 1 1 1 2 4 2 1 3 ...

Page 47: ...8786 Powder pump 24 max 1 2 910028325 Plunger supply sleeve valve 24 max 1 3 130001649 1 Antistatic powder tube 24 max 1 2 4 900022841 Flat seal 1 1 2 5 900021745 Porous bottom plate 1 1 6 J2FTCF029 O ring 24 max 1 1 2 7 110001075AT Capacitive sensor 2 1 8 900020250 Tank cap 1 1 9 220000539 Sleeve valve 1 1 2 10 J2CTPB364 O ring 1 1 1 2 11 160000121 O ring 1 1 1 2 12 J2FTDF341 O ring 1 1 1 2 1 2 3...

Page 48: ...ance level for spare parts 910033637 Tank 1 1 1 900019767 Porous cover plate 1 1 2 900022754 Cover seal 1 1 2 3 900019765 Nipple 2 1 4 J2FTDF239 O ring 2 1 2 5 130001802 Non return valve 2 1 6 220000531 Sleeve valve 2 1 2 7 J2CTPB660 O ring 1 1 2 8 130001929AT Position switch 1 1 9 900018554 Flat seal 1 1 2 10 180000522AT Cylinder 1 1 1 2 3 4 5 6 10 7 9 8 ...

Page 49: ...l 1 1st emergency parts Level 2 Wearing parts Item Part Number Description Qty Unit of sale Maintenance level for spare parts 1 110002495AT Vibrator EU version 1 1 1 2 110002765AT Vibrator US version 1 1 1 2 2 X3AVSY226 Screw CHC M6x20 4 1 3 X3CDSP783 Washer M6 4 1 1 2 3 ...

Page 50: ...6RLCS411 Right angle connector 1 1 2 2 544808 Injector 1 1 1 2 3 F6RAJR025 Coupling fitting 1 8 BSP 1 1 4 EU9000854 Blue washer 1 8 BSP 1 1 5 910014388 Ejector 1 1 1 2 6 900008907 Powder exit nozzle 1 1 2 7 J2FTDF273 O ring 1 1 1 2 8 900008904 Powder tip nut 1 1 9 220000533 Sleeve 1 1 10 J2FTDF155 O ring 1 1 1 2 11 900017562 Porous tube 1 1 2 12 J2CTPB216 O ring 1 1 1 2 13 J2CTCN034 O ring 2 1 1 2...

Page 51: ...pply option Level 1 1st emergency parts Level 2 Wearing parts Item Part Number Description Qty Unitof sale Maintenance level for spare parts 910034325 External powder supply sleeve valve 1 1 1 220000532 Sleeve valve 1 1 2 2 900018417 Annular connection Dia 13 1 1 1 2 ...

Page 52: ...nge of identity and logo Updating graphic charter Removal of sleeve replacement procedure Add operating principles Add air regulator settings Added fluidization air setting for level sensors Add booth floor blowing solenoid valves optional Add external powder supply Added replacement of porous plate and flat seal on tank bottom Update rotary vibrating table and weighing version 2 5 4 2 7 4 2 8 4 2...

Page 53: ...53 Member of Exel group DRT7142 B 2023 06 9 Appendices 9 1 EU and UK Declarations of conformity ...

Page 54: ...ue to falling or ejected objects Risques dûs aux surfaces aux arêtes ou aux angles Risks due to surfaces edges or angles Risques liés aux éléments mobiles Risks related to moving parts Risques dus aux mouvements non commandés Risks of uncontrolled movements 1 5 1 5 1 1 5 2 1 5 3 1 5 4 1 5 5 1 5 6 1 5 7 1 5 8 1 5 9 Risques dûs à d autres dangers Risks due to other hazards Alimentation en énergie él...

Page 55: ...dyrektywy Toepasselijke richtlijnen Platné směrnice Tillämpliga direktiv Gældende direktiver Sovellettavat direktiivit Kohaldatavad direktiivid Piemērojamās direktīvas Taikomos direktyvos Приложими директиви Alkalmazandó irányelvek Directive aplicabile Ισχύουσες οδηγίες Primjenjive smjernice Uplatniteľné smernice Veljavne directive Применимые директивы 適用される指令适用的指令 4 Marquage Markierung Marcado M...

Page 56: ...s due to falling or ejected objects Risques dûs aux surfaces aux arêtes ou aux angles Risks due to surfaces edges or angles Risques liés aux éléments mobiles Risks related to moving parts Risques dus aux mouvements non commandés Risks of uncontrolled movements 1 5 1 5 1 1 5 2 1 5 3 1 5 4 1 5 5 1 5 6 1 5 7 1 5 8 1 5 9 Risques dûs à d autres dangers Risks due to other hazards Alimentation en énergie...

Page 57: ...Directivas aplicáveis Obowiązujące dyrektywy Toepasselijke richtlijnen Platné směrnice Tillämpliga direktiv Gældende direktiver Sovellettavat direktiivit Kohaldatavad direktiivid Piemērojamās direktīvas Taikomos direktyvos Приложими директиви Alkalmazandó irányelvek Directive aplicabile Ισχύουσες οδηγίες Primjenjive smjernice Uplatniteľné smernice Veljavne directive Применимые директивы 適用される指令适用...

Page 58: ...botic applicators pumps and dosing machines We offer solutions at the cutting edge of technological innovation serving industrial efficiency for the most challenging customers and environmentally friendly Sames bonds protects and beautifies all materials More than a supplier Sames is the partner of your performance We Simply Apply the Most Efficient Solutions Headquarter 13 Chemin de Malacher CS70...

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