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3.1 Connecting the System

1

The Energiser should be connected to an appropriate 3 phase power
supply by a competent qualified electrician in accordance with the
following recommendations:

Position  the  Energiser to allow unrestricted airflow into / out of the unit and
connect  to  a  mains  isolator  fuse  box  ensuring  each  phase  carries  suitable
fuses.

Remove the top panel and connect a suitable Power Cable to terminals 1, 2,
3 and Earth.

Check  that  the  input  voltage  is  correct  for  the  unit  (Refer  to  Energiser
Maintenance Manual).

Connect suitable size hose to the air supply. It is strongly recommended that
a filter unit be installed at the mains outlet point. A capacity of 1.5m³ /min @
5 bar (53cfm @ 72.5 psi) is usually adequate.

2

3

Remove any packing materials and ensure that all items are present and the equipment has suffered no damage whilst in transit
(see conditions of sale).

NB:

if using long supplies with a powered extension trolley also refer to Section 3.2.

A.

S500-PLC Energiser.

B.

Drive Unit Assembly.

C.

Power Cable / Air Hose Assembly.

D.

Wire Feed Conduits.

E.

Flexible Drive Cable.

F.

ARC150 Pistol and Tool Case.

Switch  on Power Supply and turn the Mains
Switch on.

Cooling  Airflow  should  pass  from  front  to
back. If air passes from the back to the front
of  the  Energiser,  the  fan  is  running  in
reverse.

If this is allowed to continue damage to the
Energiser may occur.

Isolate the Power

Supply and reverse two phases of the
input 3 phase.

Once airflow is passing through correctly,
turn the Mains Switch off and refit all panels.

AIRFLOW

Rear of Energiser

A

B

F

E

C

D

Power Terminals

Feed Power

Cable through

opening using a

suitable Gland

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Содержание ARC150-2310D

Страница 1: ...Page 1 of 48 ssue 21 11 11 ...

Страница 2: ...lar refer to the Safety Warnings Risk Assessments in Section 1 Under no circumstances should any modifications be made to the equipment without prior written approval from Metallisation MAN ARC150 OP For Pistols ARC150 CG23 ARC150 CG25 For Energiser S500 PLC Related Manuals Pistol Maintenance Manual MAN ARC150 MA Energiser Maintenance Manual MAN ENE S500 150 ...

Страница 3: ...T WIDTH WEIGHT 900mm 35 4 800mm 31 5 875mm 34 5 To Handle 485mm 19 1 670mm 26 4 Wheel to Wheel 291 6kg 644lb S500 PLC Energiser Specification DESCRIPTION CHARACTERISTICS Input Power Requirements 380 415 460 Vac 50 60Hz 3 Phase Optional Input Power 220V 50 60Hz 3 Phase Fusing Required 37A 460 Vac 40A 415 Vac 44A 380 Vac 76A 220 Vac 84A 200 Vac Max Power Consumption 29 KVA 46Vdc 500A output Typical ...

Страница 4: ...l 13 1 3 9 Summary 13 SECTION 2 THE EQUIPMENT 14 2 1 System Configurations 15 SECTION 3 OPERATING THE EQUIPMENT 17 3 1 Connecting the System 18 3 2 Connecting using a Powered Extension Trolley 20 3 3 Preparing to Spray 22 3 4 Spraying 24 3 5 Shutting Down 26 3 6 Remote Pendant 26 3 7 Using Optional Arc Extension 27 3 8 Closed Loop and Open Loop Modes 27 SECTION 4 BASIC MAINTENANCE 28 4 1 Routine M...

Страница 5: ...es Manifold Maintenance 39 4 9 Wire Condition 40 SECTION 5 FAULT FINDING 41 5 1 Operational Troubleshooting 42 SECTION 6 ILLUSTRATED PARTS LIST 43 6 1 Main Components 44 6 2 CG Spray Head 45 SECTION 7 INFORMATION TABLES 46 7 1 Typical Performance Figures 47 ...

Страница 6: ... Equipment Dos Don ts 1 1 2 Handling of the Energiser 1 1 3 The Energiser Mains Supply 1 2 Risk Assessment 1 3 Key Hazards 1 3 1 Noise 1 3 2 Radiant Energy 1 3 3 Fume Dust 1 3 4 Mechanical Hazards 1 3 5 Electrical Hazards 1 3 6 OZONE 1 3 7 Material Handling 1 3 8 The Pistol 1 3 9 Summary ...

Страница 7: ... carried out before using this equipment Ensure the equipment is properly set up as per Section 3 1 of this Manual NEVER point the pistol towards other personnel or combustible material NEVER spray onto hoses cables or instruments NEVER operate the pistol without using ear defenders and the appropriate eye protection NEVER look into the arc zone without first ensuring that the power switch is in t...

Страница 8: ... of effectiveness of measures Hazard Elimination Use of alternative work methods design improvements or change of process Substitution Replacement of material substance with another of less risk Use of Barriers Isolation or segregation Use of Documented Procedure Limiting exposure times dilution of exposure Safe systems of work that depend on human response Use of Warning Signs Signs instructions ...

Страница 9: ...e for conducting their own noise assessments which must be based on the exposure of the persons in the workplace and of which a noise survey is only part Key Hazards Stress difficulty in communication long term hearing loss Tinnitus NEVER operate the system without adequate hearing protection ALWAYS ensure that ALL personnel likely to be exposed are adequately protected including those not directl...

Страница 10: ...al commonly sprayed substances are subject to statutory exposure limits The assessment must take into account these exposure limits When a substance or preparation has an occupational exposure standard control of exposure is adequate if levels are maintained below that standard Below are the most commonly sprayed materials However other materials may also be toxic It is essential that users consul...

Страница 11: ...use allergis contact dermatitis It is a suspect human carcinogen and exposure must be kept as far below the maximum exposure limit MEL as is reasonably practicable Tin Tin powder may cause irritation Inhalation over a long period may cause scarring of the lungs without physiological symptoms Titanium Occupational ill health from exposure to titanium is unlikely Tungsten Ingestion of soluble tungst...

Страница 12: ...electrostatic discharges can ignite explosive mixtures additionally they can cause a fire which with gases present could be dangerous Key Hazards Electric shock explosion fire burns 1 3 6 OZONE Arc systems with much brighter arc intensity operate between 280 and 220 nm also called the UV C region Arc systems operating in this range also generate ozone Ozone is formed from dioxygen by the action of...

Страница 13: ...or or the surrounding environment In the case of the automated operation it is the responsibility of the client to risk assess the automatic installation and ensure all safety criteria are met 1 3 9 Summary Below is an approximate rating of the hazards in typical circumstances while using the ARC150 Arc Spray System It must be stressed that the hazard ratings may change in individual circumstances...

Страница 14: ...Page 14 of 48 SECTION 2 THE EQUIPMENT 2 1 System Configurations ...

Страница 15: ...RS PART NO DESCRIPTION ARC150 2310D ARC150 System 2 3mm 10m supplies drum dispense ARC150 2320D ARC150 System 2 3mm 20m supplies drum dispense ARC150 2510D ARC150 System 2 5mm 10m supplies drum dispense ARC150 2520D ARC150 System 2 5mm 20m supplies drum dispense STANDARD MIG SYSTEM PART NUMBERS PART NO DESCRIPTION ARC150 2310M ARC150 System 2 3mm 10m supplies MIG dispense ARC150 2320M ARC150 Syste...

Страница 16: ...ONFIGURATION EXTENDED SUPPLIES PISTOL SUPPLIES TOTAL MAX 10M 10 20M 50M 20M 30M 40M 10M Energiser Pistol Extension Supplies Pistol Energiser Wire in drums 3m max 2m std wire to drive Extension Supplies Push pull drive unit and MIG reels on power extension trolley with quick release connections Push pull drive unit on power extension trolley with quick release connections Supplies from wire drive t...

Страница 17: ...NG THE EQUIPMENT 3 1 Connecting the System 3 2 Connecting using a Powered Extension Trolley 3 3 Preparing to Spray 3 4 Spraying 3 5 Shutting Down 3 6 Remote Pendant 3 7 Using Optional Arc Extension 3 8 Closed Loop and Open Loop Modes ...

Страница 18: ...ly adequate 2 3 Remove any packing materials and ensure that all items are present and the equipment has suffered no damage whilst in transit see conditions of sale NB if using long supplies with a powered extension trolley also refer to Section 3 2 A S500 PLC Energiser B Drive Unit Assembly C Power Cable Air Hose Assembly D Wire Feed Conduits E Flexible Drive Cable F ARC150 Pistol and Tool Case S...

Страница 19: ...Terminal Blocks G and firmly tighten Use one spanner to hold the Terminal Block whilst tightening the conductor with another to prevent damage to the Terminal Blocks This joint will carry up to 500 amperes so ensure they are securely tightened and check periodically 4 Replace the Hood D and Shroud B 5 Connect the Control Cable from the supplies pack to the rear of the Pistol I Connect the Control ...

Страница 20: ... a Powered Extension Trolley allows the Energiser to be sited further away from the spray job whilst still maintaining the power air and control couplings quick release feature PART NO DESCRIPTION ARC150 PET ARC150 powered extension trolley for ARC150 system FRONT BACK ...

Страница 21: ...ack to the appropriate connections on the front of the Powered Extension Trolley Now the supplies can be fitted to the Pistol as per Section 3 1 Point 5 Ensure that power to the Energiser is isolated Connect the Extension Supplies Pack comprising Power Cables Motor Drive Cable and Nozzle Air Hose to the appropriate connections on the front of the Energiser and connect the Control Cables from the D...

Страница 22: ...This will dramatically improve the performance and life of the Wire Conduits and aid feeding the wire into the pistol Ensure that the drive roller tension is released by pulling the Fixing Arm Tensioners down on both sides of the unit Allow 50mm to protrude through the Unit Then pull down the Bearing Pressure Arms and close with the Fixing Arm Tensioners 50mm Attach an absorbent strip for wire lub...

Страница 23: ...g a pair of side cutters trim the wires flush to the Air Cap Face The wire ends MUST NOT touch each other or the Air Cap OR 6 7 8 9 If using Drum Dispensers Ensure there is a gap between the feed cones to avoid a short circuit A Remove the lid of the drum and pull out the wire Feed the wire end through the top of the feed cone and place the cone on top of the drum Tighten up the 3 retaining screws...

Страница 24: ...will now be displayed on the voltmeter F This will drop to the DURING SPRAYING figure when the pistol is in operation 9 When in Closed Loop Mode factory set you can pre set the desired Spray Current via the Potentiometer G For example setting the potentiometer to 2 00 will pre set the Energiser to spray at 200 Amps The Spraying current is only displayed on the Ammeter H when the pistol is spraying...

Страница 25: ...e reading and makes redundant the need to make allowances for differing length supplies when setting voltage NB The Voltages given are approximate minimums The correct voltage is the minimum voltage that will maintain a stable arc Voltages higher than required can result in a reduction of spray efficiency Air pressures can be adjusted to suit application Reduced pressures will result in a rougher ...

Страница 26: ...the Pistol NB Pressing the STOP button before releasing the trigger on the pistol can result in damage to the Spray Head due to wire overrun 5 Turn the Energiser Mains switch D to OFF 6 If not spraying for an extended period turn off the power and air supplies to the Energiser 7 Once the environment has been cleared turn off the Dust Extraction System 3 6 Remote Pendant An optional Remote Pendant ...

Страница 27: ...ension is being used 3 8 Closed Loop and Open Loop Modes The Energiser is factory set to run in Closed Loop Mode enabling the operator to set the spray current to a pre defined value via the potentiometer independent of wire type before starting the job enabling easier setup For example setting the potentiometer to 2 00 will pre set the Energiser to spray at 200 Amps This mode can be changed so th...

Страница 28: ...ce 4 2 CG Spray Head Checking Contact Tips 4 3 CG Spray Head Complete Disassembly 4 4 CG Spray Head Reassembly 4 5 Tension Adjustment of Rollers 4 6 Roller Guide Assembly Maintenance 4 7 Rear Wire Guides Checking 4 8 Supplies Manifold Maintenance 4 9 Wire Condition ...

Страница 29: ... the exterior of the Energiser with a DRY clean cloth Check all external power and control cable connections for security Re tighten as necessary EVERY 20 HOURS In addition to the above carry out the following on the pistol Dismantle the CG Spray Head Section 4 3 Clean all components and re fit or replace as necessary Lubricate the Pinch Release Cam Generally look for signs of overheating on wire ...

Страница 30: ... Air Cap by pulling forward 4 If not already removed loosen the Pointed Shroud Screw and remove the Shroud by pulling forward 1 NOTE Before attempting to disassemble the Spray Head always ensure that the mains power supply is isolated and the wire has been removed from the pistol Loosen the Thumb Screw and remove the Hood 2 ...

Страница 31: ...ents must be cleaned in an appropriate de greasing agent and blow dried before replacing For complete disassembly instruction of the CG Spray Head please see Section 4 3 Remove the Air Concentrator by pulling forward 5 At this point the Spray Head will look as shown and the Contact Tips will be accessible 6 7 Using a suitable spanner remove the Contact Tips and check for damage and clean replace a...

Страница 32: ... the mains power supply is isolated and the wire has been removed from the pistol 5 Contact Tip Support Tubes will need to be replaced periodically The frequency of replacement will depend upon the wire used and adherence to maintenance schedule At this point the Contact Tubes can be removed and cleaned replaced as necessary The Contact Tubes can be removed by hand as shown above If experiencing d...

Страница 33: ...ver should be easy to unscrew having loosened it whilst attached to the pistol 6 7 Lift out the Air Cap and check for damage This is an example of wear to an Air Cap the central orifice is no longer perfectly round 8 Lift out the Air Concentrator and check for damage This is an example of damage to an Air Concentrator we can see the wear on either side of the central orifice Inspect the Transfer P...

Страница 34: ...k 1 Once all Spray Head parts have been cleaned and any damaged parts have been renewed the Spray Head can be reassembled using the following technique Select the correct Contact Tips for the wire being sprayed Push the Contact Tubes through the Contact Tube Support Block until they bottom out and they protrude from the front face of the seat of the block 2 Place the Air Concentrator in the seat o...

Страница 35: ...4 6 and 4 7 respectively of this Manual 7 Re fit the Clamp Pads by pressing the CG Spray Head against the Pistol Fit the first Clamp Pad loosely and then fit the second Clamp Pad Tighten both by screwing in firmly but NOT excessively Excessive force will result in damage to the Clamp Pads Terminals Place the Spray Head against the front of the pistol Ensure the Transfer Plug locates in the Contact...

Страница 36: ...n the top of the Pistol in the slot in front of the Pinch Release Cam Using an appropriate Hex Key turn the Tension Screw CLOCKWISE to increase the tension ANTI CLOCKWISE to decrease the tension NB These issues should be addressed rather than increasing the tension which can create other problems For example excessive tension can deform the wire and make it out of round This will cause problems fe...

Страница 37: ...Roller Tyre Serrated V E can be pulled away by hand and if found to worn or damaged the Roller Tyre can be reversed or cleaned of any clogging At this point the assembly can be reassembled Be sure not to loose the Pistol Roller Tyre Drive Key F and ensure that it is in place If both grooves are damaged the Roller Tyre should be replaced NB New Roller Tyres can be pushed in by hand but ensure that ...

Страница 38: ...st be isolated and the wire completely removed from the rear of the Pistol The Rear Wire Guides can then be removed by unscrewing them from the Left and Right Hand Side Plates Clean the Rear Wire Guide as necessary or replace if damaged NB For any further maintenance of the ARC150 Pistol please refer to the ARC150 Pistol Maintenance Manual Rear Wire Guide ...

Страница 39: ...cables should also be checked regularly and cleaned and replaced as necessary Below is a guide to separating the Manifold in order to carry out the Manifold Maintenance procedure The Manifold Block Cover can now be pulled away to reveal the Manifold Block Body and all power connections Using a 3mm Hex Key remove the 2 x screws on the Pistol side of the Manifold Separate the Manifold Block End Cap ...

Страница 40: ...een stored in an open state for a long period of time If this is allowed to enter the system it can become compacted and cause the wire to seize The most common solution when debris is a problem is to wet a lint free pad with approximately 5ml of Metallisation Wire Oil and fold it over the wire where it enters the wire conduit The pad may be held in place with a small spring clip and the pad remov...

Страница 41: ...Page 41 of 48 SECTION 5 FAULT FINDING 5 1 Operational Troubleshooting ...

Страница 42: ...ed check clean replace the wire conduits as necessary It is essential that the Metallisation ARC150 Arcspray System is properly maintained and operated Faults may occur due to incorrect operation lack of proper maintenance or incorrect component selection To avoid these issues follow these simple steps 1 Always follow the maintenance schedules as recommended in the relevant Operating and Maintenan...

Страница 43: ...Page 43 of 48 SECTION 6 ILLUSTRATED PARTS LIST 6 1 Main Components 6 2 CG Spray Head ...

Страница 44: ...elevant Maintenance Manual PART NO DESCRIPTION QTY 5503 Clamp Pad 2 5580 Pistol Roller Tyre Housing 2 5581 Pistol Roller Tyre End Cap 2 5582 Pistol Roller Tyre Drive Key 2 5583 Roller Tyre 2 3mm 2 5m Serrated V 2 or 5584 Roller Tyre 1 6mm 2 0mm Serrated V 2 6469 Screw 6 6471 Socket Head Screw 2 6713 Pointed Shroud Screw 1 6891A New Shroud 1 7528 Hood 1 7546 Thumb Screw 1 7548 Roller End Cap 2 6891...

Страница 45: ...eing sprayed and the appropriate part numbers are shown in Table 2 TABLE 1 Pistol Parts Standard PART NO DESCRIPTION QTY 1007 O Ring 1 6836AM Medium Air Cap AM 1 6844A Air Cover 1 7480 Contact Tube Support Block 1 7481 Air Concentrator 1 7490 Contact Tip Support Tube 2 7507 Support Block Seal Tube 1 7577 O Ring 1 9721 O Ring 1 TABLE 2 Contact Tip Variations WIRE SIZE PART NO DESCRIPTION QTY 1 6 74...

Страница 46: ...Page 46 of 48 SECTION 7 INFORMATION TABLES 7 1 Typical Performance Figures ...

Страница 47: ...UT KG HR 500A COVERAGE m kg 100 Metallisation Wire 01E Aluminium 2 3mm 12 2 88 Metallisation Wire 02E Zinc 2 3mm 51 0 82 Metallisation Wire 21E Zinc Aluminium 85 15 2 3mm 44 1 00 Metallisation Wire 28E Arctec 2 3mm 12 3 85 Metallisation Wire 72E Inconel 625 1 6mm 13 6 300A 1 02 ...

Страница 48: ...y have occurred Periodically changes are made to the information herein and Metallisation reserve the right to make improvements and or changes to the products described in this publication at any time without prior notice METALLISATION LIMITED Pear Tree Lane Dudley West Midlands DY2 0XH UK Tel 44 1384 252464 Fax 44 1384 237196 Email support metallisation com ...

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