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Sulzer Metco ECO ARC 600, Manual

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General Safety Instructions

1-26

Revision 1/10/08

1.13 Professional Insurance Association Accident 

Prevention Regulation

Regulations - VBG, BGV, BGI, BGR

VBG 4

Electrical systems and equipment

VBG 15

Welding, cutting and related methods

VBG 16

Compressors

VBG 101

Use of respiratory protective devices

VBG 113

Protective measures when using carcinogenic working materials

BGV A4

Industrial medicine precautions

BGV A5

First aid

BGV B3

Noise

BGI 503

First aid in the event of accidents

BGI 504-26

Policy G26: Respiratory equipment

BGI 504-20

Policy G20: Noise

BGI 593

Harmful substances by welding and related methods

BGI 553

Arc welding

BGI 594

Use of electrical equipment by increased electrical dangers

BGI 616

Evaluation of danger by welding fumes

Summary of Contents for ECO ARC 600

Page 1: ...for the proper and safe use of this equipment must read and understand this instruction manual In addition the operator of this equipment must receive personal instructions in its use A thorough under...

Page 2: ...sulzermetco com Protective note according to ISO 16016 The reproduction distribution and utilization of this document as well as the communi cation of its contents to others without explicit authoriz...

Page 3: ...1 7 11 Oily compressed air only at systems with air motor 15 1 8 Other instructions 16 1 8 1 Protective equipment protective and work clothing 16 1 8 2 Spray dust disposal 16 1 8 3 Solvents used for...

Page 4: ...re 4 5 2 2 Changing spray wire 4 5 3 Starting the system 5 5 4 Setting up spray parameters 7 5 4 1 Setting up spray voltage 7 5 4 2 Setting up spray capacity 7 5 4 3 Changing spray capacity 8 5 4 4 Se...

Page 5: ...sed nozzle system 2 8 1 2 Gear housing LD U3 4 8 1 3 Wire feeding LD U3 5 8 1 4 Wire pressure LD U3 6 8 1 5 Air motor LD U3 7 8 1 6 ON OFF swtich LD U3 8 8 1 7 Hose package LD U3 8 m 9 8 2 Power suppl...

Page 6: ......

Page 7: ...osive material Caution Hot surface Caution Inflammable materials Danger Risk of electric shock Caution Magnetic fields from high currents can effect pacemaker operation Danger Potentially dangers caus...

Page 8: ...General Safety Instructions 1 2 Revision 1 10 08 Attention Safety gloves must be worn Attention Eye protection must be worn Attention Safety overalls must be worn Caution Moving parts Risk of injury...

Page 9: ...eration of the system In addition to work specific information it contains also general safety regulations which the operating crew must have read and understood Failure to comply with the operating i...

Page 10: ...tem be used for the following unauthorized purposes This listing is not comprehensive System and components Unauthorized use System Use without previous instruction Use beyond the operational limits U...

Page 11: ...ience for safe operation of the system This enables the operating crew to refuse following third party instructions not complying with the safety regulations It is vital to comply with mandatory local...

Page 12: ...lectors should be provided with blow out or relief panels in case of explosion All local state and national fire codes must be complied with when determining the location of the exhaust system The arc...

Page 13: ...he work area you will require additional filters and official approval Activate the extraction system before the metal spraying system is started up Comply with critical values at the workplace AGW Us...

Page 14: ...m the spraying area room Avoid all risks of fire Never spray in explosion hazard areas Take care when handling gas bottles Leaking flammable gases can ignite in an explosive manner Use personal protec...

Page 15: ...accordance with DIN EN 169 or other comparable relevant national standard Skin and body protection All body parts that are exposed to the arc UV radiation must be covered Persons who are in the immed...

Page 16: ...d soundproofed booths Fit soundproofed capsules Use personal hearing equipment Persons who are in the immediate vicinity of the supply of the noise must also wear personal hearing protection If the no...

Page 17: ...equipment must be checked to ensure they are in a proper condition before being used for the first time following repair or at the set inspection intervals Live parts of an electrical system must not...

Page 18: ...tect the eyes Compressed air can carry solid matter that may cause injury It is prohibited to clean clothing being worn on the body with compressed air that is still at full pressure There is a danger...

Page 19: ...itional ignition supplies The electric arc and the spray jet with the molten metal particles is an unavoidable ignition supply You can mitigate this by never directing the spray jet at an accumulation...

Page 20: ...falling Caution There is a danger of tripping falling Lay connecting pipe and hose bundles as well as cables in a safe position and if necessary protect them 1 7 10Moving Parts Caution There is danger...

Page 21: ...sion Avoid ignition sources As far as possible do not align the exhaust flow of the manual spraying apparatus in the direction of ignition sources Do not extinguish fires with water Use powder extingu...

Page 22: ...the event of combustion these can cause additional injury Wear close fitting clothes especially in the sleeves because you will be working with moving parts The national accident prevention rules must...

Page 23: ...d cleaning with chlorinated hydrocarbon solvents has been subject to new regulations and thus heavily restricted In no event should solvents be used without taking suitable protective measures Parts m...

Page 24: ...in the Material Safety Data Sheet which comes with the material being used be consulted Complete and current information should be obtained from national and local agencies The Federal Ministry for La...

Page 25: ...In general chromium compounds are caustic and irritating to the skin the mucous membrane of the nose and the deep respiratory tract These three chromates are carcinogenic Cobalt and its compounds Co 0...

Page 26: ...A substance will generally not harm your health if the concentration in the breathable air at the workplace does not exceed this value Nickel as Metal Nickel carbonate Nickel oxide Nickel compounds in...

Page 27: ...t at the workplace to source by Vertretung der Europ ischen Kommission in Deutschland Unter den Linden 78 10117 Berlin Germany Tel 49 0 30 2280 2000 Fax 49 0 30 2280 2222 E Mail eu de kommission ec eu...

Page 28: ...tion against emissions TA Luft Technical Instruction Air TA L rm Technical Instruction Noise WHG Federal water act ArbStoffV Hazardous working materials act ArbSt ttV Work places act ASR Work places d...

Page 29: ...lame spraying DVS 2308 Issue 2000 07 Regulations on design of components and parts for spraying DVS 2310 1 Issue 1999 10 Instructions for producing metallographic sections and evaluation of thermally...

Page 30: ...g Terminology classification DIN EN ISO 17834 Issue 2004 02 Thermal spraying Coatings for protection against corrosion and oxidation at elevated temperatures Respiratory equipment DIN 3179 1 Issue 198...

Page 31: ...d contact electrical equipment DIN EN 1127 1 Issue 1997 10 Explosive atmospheres Explosion prevention and protection Part 1 Basic concepts and methodology DIN EN 60204 1 Issue 1998 11 Safety of machin...

Page 32: ...atory protective devices VBG 113 Protective measures when using carcinogenic working materials BGV A4 Industrial medicine precautions BGV A5 First aid BGV B3 Noise BGI 503 First aid in the event of ac...

Page 33: ...k place with ventilation and exhaust BGR 133 Equip workplaces with fire extinguisher Safety regulations BGR 189 Use of protective clothing BGR 190 Use of respiratory equipment BGR 192 Use of eye and f...

Page 34: ...all lists TRGS Regulations TRGS 101 Technical Regulation on Hazardous Substances TRGS 402 Measuring and assessing the concentration of hazardous substances in the air in breathing areas TRGS 507 Surfa...

Page 35: ...sformer rectifier and AC motor and electrical protective circuits to guard against uncontrolled reactivation following faults Nevertheless for your own safety always observe the safety regulati ons an...

Page 36: ...ticle 4 BlmSchG It does not fall under the approval pro cess of Article 10 however but the simplified process according to Article 19 Extract from the 4 Federal Immission Control Ordinance Systems for...

Page 37: ...ion will occur If due to lack of space there are restrictions on the positioning of the power supply other arrangements must be made to ensure an adequate supply of cooling air The power supply should...

Page 38: ...starting work Check the production parameters For coating larger joined surfaces it is an advantage to exchange the standard round stream system for a flat spray system Please seek our advice Perform...

Page 39: ...Secondary nominal DC 600 A at 100 duty cycle Operating voltage 22 34 V Off load voltage 26 39 V Cooling passive convection Wire feed drive Push 4 on power supply Weight ca 12 kg AC motor 230 V Nominal...

Page 40: ...ngth Standard length 15 6 kg 8 m Spray capacity ECO ARC 600 max melting capacity at 100 duty cycle Zn 60 0 kg h ZnAl15 53 0 kg h Al 18 0 kg h AlMg5 16 0 kg h Permissible current loading for silicon re...

Page 41: ...rents from major loads and other mains fluctuations interrupt spraying 400 V mains voltage should only be under overshot by a maxi mum of 5 4 wire mains connection 3 Phases 1 Earth black brown grey ye...

Page 42: ...ower supply bayonet coupling Note In order to achieve 6 bar atomizer pressure a minimum supply pressure of 8 bar is necessary The compressed air of job compressors must undergo special con ditioning I...

Page 43: ...08 4 Installation of system 4 1 Installation instructions Make sure that all energy connections are fixed properly Loose connections will lead to charring of cables Consider the preconditions for plac...

Page 44: ...rol cable 3 3 to connector 1 3 Loose knurled screws at push drive Insert wire guide tubes 3 4 into bore 2 2 and lock with knurled screws 4 4 Connecting power supply to plant mains Connect adequate com...

Page 45: ...s well as drum decoiling device 4 5 1 Hasp spool decoiling device Take off caps from both screws located at the back on top of power supply and unscrew them Position spool mounting on power supply and...

Page 46: ...wires must not touch each other There is danger of short circuit Check all wire guidings for smooth and easy running 4 6 2 Drum decoiling device Ensure sufficient clearance of steel drums There is a d...

Page 47: ...ECO ARC 600 5 1 Revision 1 10 08...

Page 48: ...ECO ARC 600 5 2 Revision 1 10 08 5 Operation of system 5 1 Operating devices and indicators 5 1 2 3 4 6 7 8 11 9 12 14 13 Sulzer Metco Zn P U I ECO ARC 600 Arc Spray Unit TM 10 A B C...

Page 49: ...feed s Changing spray capacity 8 Step switch for spray voltage Regulates spray voltage s Setting up spray voltage 9 Manometer Indicator pressure of atomizing air 10 Pressure regulator Regulates press...

Page 50: ...of with a file and straighten them Insert wire through the wire guide tubes up against the push drive Keep wire pressure levers 11 pushed successively and guide wire between the pressure rolls throug...

Page 51: ...ith main switch 6 White signal lamp 1 lights permanently yellow signal lamp 3 is blinking Push yellow button 3 once to acknowledge White 1 and green signal lamp 2 light permanently Push the wire feed...

Page 52: ...approx 2 seconds spray process starts Set up desired pressure of atomizing air s Setting up atomizing air pressure If the spray voltage has to be modified first press the OFF button A at the spray dev...

Page 53: ...a pre adjusted current limiter relay If this capacity is exceeded the system automatically shuts off It is thereby protected from over load In the event of overload the yellow button 3 lights The syst...

Page 54: ...Push the OFF button A at the spray device The system can be started again it is ready for operation 5 4 4 Setting up atomizer air pressure The atomizer air is adjustable via the pressure regulator 9...

Page 55: ...st atomizer air pressure These coatings are finer grained and more dense and have a higher anticorrosion value 5 4 5 Setting up the oiler The oiler is set to a frequency of 1 drop each 6 seconds at a...

Page 56: ...und stream system for a flat spray system Please seek our advice Perform functional monitoring of the machine each day The hose and cable set should not be kinked Lay out in large loops only Ensure sp...

Page 57: ...nces of the surrounding Electrical appliances and machines must be checked for their proper condition before putting into operation for the first time after their maintenance or passing a definite per...

Page 58: ...Check compressed air con nection Air compressor Malfunction or switched OFF Check air compressor Valve closed in compressed air mains Check ring mains and produ cer of compressed air Pressure is too l...

Page 59: ...tive Power supply Spray device Control cable towards spray device is faulty or ON OFF signal not ready Check control cable and signal Spray device No oil in the oiler Air motor deadlocked Check the oi...

Page 60: ...Spray device Clip off spray wire at the contact nozzles Wire tips must not touch each other Measure resistance short circuit between current air cables Wire tips must not touch each other Short circui...

Page 61: ...rent power supply Three phase current Fluctuations in mains power Check mains power if necessary install separate line Compressed air supply Cross section of pipe is too small Volumetric flow Nm h too...

Page 62: ...the inside Switching OFF by tempera ture sensitive switch Clean power supply from the inside s maintenance Let cool down until green signal lamp lights Cooling time Rectifier ca 5 min Transformer max...

Page 63: ...or Change blocked filter pad Operate system only with assembled filter pad If not solenoid valve will be damaged No oil in the oiler Air motor deadlocked Check the oiler Refill air motor oil Oil the a...

Page 64: ...sformer B10 is defective If the cur rent is below 50 mA inter face module A10 is defective Replace defective compo nent Spray device Air motor runs too fast Therefore spray capacity amp is too high Re...

Page 65: ...se in your three phase current system Three phase current supply Loose connection of plug cable Check plug cable connec tions Decoiling device Not smooth running Must run smoothly If not clean and gre...

Page 66: ...s soiled or worn out Clean or change wire feed rolls AC Motor does not run At push gear Check fuse and motor cable At power supply Check fuses s circuit dia gram Spray device Wire feed rolls soiled or...

Page 67: ...Push OFF button Unscrew compressed air hose of power supply Spray device Push ON button If no air is blowing at the compressed air hose con nection replace solenoid valve Spray device Air motor defec...

Page 68: ...maintenance or Atomizer gas pressure too low Regulate compressed air Set pressure 3 5 bar Spray wire melts down irre gularly Voltage too low Check voltage and set cor rectly Spray device Nozzle system...

Page 69: ...d outside Spray with Teflon spray W Clean fan spray nozzle inside and outside Spray with Teflon spray M Check wear of the wire feed rolls if neccessary replace M Check smooth running of pressure rolls...

Page 70: ...le adjusting device 1 14 in the toolkit and gently tighten the clamping screws 1 01 8 Then remove the nozzle adjusting device Ensure that the atomizer nozzles 1 07 sit in their recesses on the contact...

Page 71: ...r With the air pressure that is applied upon start up it is pushed forwards and it aligns itself automatically It pushes the two bottom halves of the con tact nozzle tips onto the advanced spray wires...

Page 72: ...n that numbers are corre sponding Check plugs Check transition see circuit diagram 7 3 Power supply with Push 4 drive M Check wire feed and pressure rolls of the push gear for wear The wire is fed via...

Page 73: ...leakage cur rent Position the two drum decoiling devices at a distance as there is a danger of short circuit M Check that reversing wheels run freely and grease as neces sary 7 7 Spool decoiling devi...

Page 74: ...ECO ARC 600 7 6 Revision 1 10 08...

Page 75: ...ECO ARC 600 8 1 Revision 1 10 08...

Page 76: ...ECO ARC 600 8 2 Revision 1 10 08 8 Spare part lists 8 1 Spray device LD U3 8 1 1 Spray head LD U3 closed nozzle system 1 13 1 12 1 14 1 1 2 1 1 5 1 2 1 1 7 1 1 1 11 1 10 1 9 1 8 1 1 1 1 7 1 1 6 1 1 7...

Page 77: ...setscrew M6x25 DIN913 45H 02002100625 1054788 1 2 Air nozzle tube LD U3 13408041 1053727 1 7 Atomizer nozzle 2 hole LD U3 13408065 1053737 1 8 Slot contact nozzle 2 5 mm for Zn ZnAl15 AlMg5 1340432 25...

Page 78: ...3x8 DIN964 0200302038 1054345 2 6 Contact plate LD U3 13408016 1053716 2 6 1 Fillister head screw M4x16 DIN84 A2 02000220416 1054725 2 6 2 Spring washer A4 DIN127 Zn 020009104 1053897 2 6 3 Spring was...

Page 79: ...2 1053462 3 2 Worm wheel LD U3 13408014 1053714 3 3 Circlip A10x1 02028 1051922 3 4 Distance ring LD U3 13408063 1053735 3 5 Deep groove ball bearing 609 2RS 0204335 4 1055413 3 6 Drive roll knurled p...

Page 80: ...24 1053721 4 3 1 Washer M4 DIN125 Zn 020008104 1053875 4 3 2 Fillister head screw M4x8 DIN84 Zn 02000210408 1054699 4 4 Compression spring LD U3 13408042 1053728 4 4 1 Hex headl setscrew M6x16 DIN913...

Page 81: ...r motor MD Z 5300 13213 20 1056093 5 3 Swivel connector complete 13508012 1053786 5 3 1 Swivel connector R 1 4 0306811 1052956 5 3 2 O Ring NBR 13x1 5mm 0304130150 1054428 5 3 3 Double nipple LD U3 13...

Page 82: ...Switch on off 010004 1051957 6 1 3 Covering cap OFF with nobe 010003 1 1055135 6 1 4 Covering cap ON without nobe 010003 2 1055137 6 2 Name plate for switch LD U3 13408038 1053725 6 2 1 Fillister hea...

Page 83: ...0 1 1056697 15 2 2 Insulated wire guide hose 8 m 135107 80 2 1056698 15 2 3 Compressed air motor hose 8 m 135107 80 4 1056699 15 2 4 Control cable 8 m 135107 80 5 1056700 15 2 5 External hose 50x1 5mm...

Page 84: ...ECO ARC 600 8 10 Revision 1 10 08 8 2 Power supply 8 2 1 Front and back side power supply 1 16 1 15 H1 H2 S3 H3 S2 P1 S6 S1 Q1 1 18 1 17 X2 1 13 1 14 1 18 1...

Page 85: ...070 1 1055225 Fastening adapter BE3 01032110 1053142 LED element direct voltage 0103050 1 1055222 H2 Signal lamp green 0103030 1 1055219 Fastening adapter BE3 01032110 1053142 LED element direct volta...

Page 86: ...scription Article No SAP No B10 Current sensor w 400A calibrat checked 132010254 1061571 N2 Frequency converter 0 25 kW 1 5 A 01145 2 1055333 L1 1 L1 2 Throttle 350 A 010441 1052003 T1 Three phase tra...

Page 87: ...No SAP No 2 10 Pressure regulator wire feed air 030723 1052229 B1 Pressure sensing switch 2 5 bar 1 4 030900 1052241 Y1 Solenoid valve 24V 50Hz for atomizing air 031011 24 1055557 Y2 Solenoid valve 24...

Page 88: ...ECO ARC 600 8 14 Revision 1 10 08 T2 K1 A10 F4 D10 F2 1 F2 2 F3 K3 F21 F22 F23...

Page 89: ...2 1 F2 2 F2 3 Fuse 5x20mm 2A M 0113519 1052677 F4 Fuse 5x20mm 4A M integrated on A10 0113520 1052678 F21 F22 F23 Load disconnecting switch 63A 3 pol 01089630855 1054637 Fuse insert 63A type 1701 063 0...

Page 90: ...15 1 13 1 14 1 12 1 10 1 09 1 08 1 21 1 19 1 02 1 22 1 23 1 24 1 02 1 07 1 03 1 02 1 06 0304120100 1 05 1 03 1 01 1 06 1 02 1 18 1 16 1 15 1 13 1 14 1 21 1 19 1 04 1 02 1 22 1 24 1 23 1 02 1 07 1 03...

Page 91: ...7 1 13 Circlip A10x1 02028 1051922 1 14 Distance disc 10x22x0 3 0200430102203 1055073 1 15 O Ring NBR 10x1mm 0304100100 1054411 1 16 Pressure lever cpl right 13504090 1 1056471 1 17 Pressure lever cpl...

Page 92: ...508003 25 1056582 Wire feed drive Push 4 Drive slip roll spline profile 2 5 13504821 25 1056515 Pressure slip roll 1 6 3 2 hard knur 13504810 25 1056489 Wire guide helices 136127 4 1 1057234 Power sup...

Page 93: ...higher the amperage the higher the output You have to to care that a faultless melting behavior of the wire is guaranteed which means to adjust the operating voltage as needed Small and thin walled wo...

Page 94: ...ECO ARC 600 9 2 Revision 1 10 08 9 2 Circuit diagram...

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