6 MECHANICAL FUNCTION: SEQUENCE & DESCRIPTION
9.2 POWDER
9.2.5 MATERIAL SAFETY DATA SHEETS (MSDS)
9.2.5.1 For every powder which is used in the coating equipment, a Material Safety Data Sheet and/or toxicity sheet should be obtained. Personnel should be aware of potential health hazards, as well as proper methods of handling powdered materials.
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9.3 STEAM DEGREASER 9.3.1 Employee Contact
An employee assigned as the Steam Degreaser operator must be familiar with and follow all safety precautions involved in working with steam. They should be instructed in the safeguards necessary for safe Steam Degreaser operation and maintenance. This instruction should involve at least the following areas:
-The correct method to promptly take the unit out of service.
-To whom the employee should report suspected leaks or failure of equipment.
-To never bypass safety interlocks.
-To never rely on interlocks to shut down equipment.
-To use proper eye protection.
-To never open the Steam Degreaser Cover while the unit is running.
-To avoid reaching into the Steam Degreaser while it is operating because the steam is invisible and will cause severe burns.
9.3.2 Emergency Maintenance
In the event of a jam in the Degreaser Conveyor or a situation where the operator will have to open the Degreaser Tank Cover and work inside the Tank, please follow the information below:
1.NEVER WORK ALONE. THERE MUST BE AT LEAST 2 PEOPLE
INVOLVED IN MAINTENANCE WORK INSIDE THE DEGREASER TANK.
2.PRESS THE DEGREASER "OFF" PUSHBUTTON. DO NOT PULL THE EMERGENCY STOP CORD OR PRESS "MASTER STOP" UNLESS IT IS ABSOLUTELY NECESSARY, BECAUSE HOT STEAM WILL REMAIN INSIDE THE TANK, DELAYING ENTRY INTO THE TANK. WHEN THE DEGREASER "OFF" PUSH BUTTON IS PRESSED, THERE IS A DELAY BEFORE THE EXHAUST FAN IS SHUT-DOWN. THIS DELAY WILL ALLOW THE EXHAUST FAN TO EVACUATE STEAM FROM THE DEGREASER TANK.
3.STAY CLEAR OF THE STEAM TANK AND WAIT APPROXIMATELY ONE HOUR. TURN THE MESSAGE DISPLAY SELECTOR SWITCH TO
"OUTLET STEAM" AND OBSERVE THE TEMPERATURE. WHEN THE INDICATED TEMPERATURE IS LESS THAN 38°C (100°F), OPEN THE TOP OF THE DEGREASER TANK.
CAUTION: SOME AREAS OF THE TANK AND ARMATURES WILL BE HOT. USE APPROVED GLOVES TO HANDLE ANYTHING INSIDE THE STEAM TANK.
4.BEFORE PROCEEDING MAKE SURE THE CONVEYOR IS STOPPED.
5.AFTER CORRECTING THE PROBLEM, CLOSE THE TANK COVER BEFORE RESTARTING THE DEGREASER.
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10 PANELVIEW SCREENS
The Allen-Bradley Panel View screens are designed with a touch-sensitive surface overlaying the monitor. Selections are made by touching the display directly. When a selection is made, the selection/indicator box changes to display a new message. For example, when
AUTOMATIC MODE is chosen, the box changes to AUTOMATIC MODE SELECTED. In addition to the selection/indicator boxes, there are also additional indicators and messages present on each screen to allow the operator to access station information efficiently.
The Model 800 Coating Machine includes the following Panel View screens:
MAIN MENU SCREEN
The Main Menu Screen (Figure 5) lists the available screens for operating the Model 800 Coating Machine. The operator can access the desired screen by selecting (touching) its button on the Main Menu Screen.
Machine Start-up Screen Displays the MACHINE START-UP SCREEN.
Machine Auto Start/Stop Screen Displays the AUTO START/STOP SCREEN.
Manual Setup Screen Displays the SETUP SCREEN
Machine Status Screen Displays the MACHINE STATUS SCREEN
Degreaser Status Screen Displays the DEGREASER STATUS SCREEN
Alarm History Screen Displays the ALARM HISTORY SCREEN
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Figure 5 Main Screen Menu
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Figure 6 Machine Start-up Screen
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Figure 7 Machine Auto Start/Stop Screen
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Figure 8 Manual Setup Screen
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Figure 9 Machine Status Screen
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Figure 10 Degreaser Status Screen
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Figure 11 Alarm History Screen
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Figure 12 Alarm Banner Screen
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10.1 MACHINE STARTUP SCREEN
The Machine Start-Up screen includes DEGREASER START & STOP, SYSTEM START
& STOP, IND HTR START & STOP, AUTO MODE, MANUAL MODE, GO TO NEXT SCREEN, and GO TO MAIN MENU.
10.2 AUTO MODE START/STOP SCREEN
The Auto Mode Start/Stop screen includes controls for AUTO START & STOP along with selections to access different screens.
10.3 MANUAL SETUP SCREEN
The Manual Setup screen includes controls for CONVEYOR START & STOP, COATER ON & OFF, CLEANER START & STOP along with selections to access different screens.
10.4 MACHINE STATUS SCREEN
The Machine Status screen presents reports from the monitoring system along with COOLING WATER TEMPERATURE, CURE OVEN TEMPERATURE, HEATED PARTS TEMPERATURE and PROCESSED PARTS COUNTER plus controls to RESET COUNTER & ACK RESET along with selections to access different screens..
10.5 DEGREASER STATUS SCREEN
The Degreaser Status Screen (Figure 10) lists temperature information about the Steam Degreaser along with selections to access different screens.
10.6 ALARM HISTORY SCREEN
The Alarm History provides a history of machine faults:
Emergency Stop is Active Coater High Voltage Overload Plant Air is Off
Pressure is Low
10.7 ALARM BANNER SCREEN
The Alarm Banner screen provides reports on machine faults along with the date and time. It also provides controls for ALARM ACK & CLEAR HISTORY
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11 STATION STARTUP PROCEDURE 11.1 OVERVIEW
There are two modes for operating the Coating Machine; Automatic and Manual. This section will provide the operating personnel with a thorough understanding of start-up and shut-down procedures. Supervisory personnel should occasionally check the Coating and Induction Heater operation and make adjustments as required to ensure that proper coating, cleaning, and curing of armatures is maintained.
Assuming that all of the air, electrical, and water requirements have been connected and supplied to the Coating Machine, the following can be performed:
Step 1 Make sure the Main Disconnects and the disconnects for the Cooling Blowers are in the "ON" (up) position.
Step 2 MAIN Screen Menu should appear. If not, call it up.
Step 3 Make sure that the TEE handle for the main air supply is pulled out (on).
Step 4 Make sure that all Emergency Stop Buttons are pulled out and that the Pull Cord button is Reset.
Step 5 Press the Coating Machine MASTER START pushbutton.
Step 6 Call up the Machine Start-Up Screen.
Step 7 The Refrigerant Air Dryer and Cure Tunnel oven will turn “on”. There will be a delay of up to 5 minutes for the Refrigerant Air Dryer to cool and become “ready”. The Coating Machine will not operate until the Refrigerant Air Dryer is “ready”
Step 8 Wait until the AIR DRYER IS NOT READY message no longer appears on the screen.. Proceed to the AUTO MODE OR MANUAL MODE.
NOTE: For initial startup, after installation, proceed to MANUAL MODE.
Step 9 On the MACHINE STARTUP SCREEN, select in the following order:
DEGREASER ON, SYSTEM START, IND. HTR. START.
NOTE:
Faults will be reported on the Banner Screen (along with an audible alarm and the Red light on the Station Beacon). Acknowledging the fault by pressing the Acknowledge button on the Banner Screen removes the Fault Message from the Banner Screen.
To help clear the fault, a fault history of all previous faults can always be called up on the Alarm History Screen.
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11.2 MANUAL MODE - COATING MACHINE
The Manual Mode is used for Set-up, Experimentation, Maintenance, and Cleaning (for example, when it is desired to have the Powder Management System "ON" and not the Coating Bed). This Mode is also used when re-setting the Conveyor Clutch and re-setting the Proximity Switches in case parts are coming off the Conveyor in the Coating Bed.
When used for Experimentation, the various Conveyor speeds, High Voltage settings, and Air Pressure settings should be recorded under several production line situations in order to chart and fix these settings for future use. Each individual system can be turned "ON" and
"OFF" within the limits of the priority circuitry for setting-up or troubleshooting.
Step 1 Be sure all aspects of the Machine Operation are understood.
Step 2 Follow step 1 through 9 in the Station Startup Procedure on the preceding page.
Step 3 Select the MAIN SCREEN MENU, then select MANUAL SETUP SCREEN
Step 4 Select CONVEYOR START and COATER ON
Step 5 Use the High Voltage Adjust dial to change the high voltage setting or the coating (fluidic) bed. The Fluidic Bed air flowmeter may also be used to control powder fluidization.
Step 6 CLEANERS: Select CLEANER START to turn on the O.D. and shaft cleaner.
KEEP IN MIND THE PRIORITY FUNCTIONS. The Air Knives, Coater, O.D.
Cleaner, Roto-Flo Screw Vacuums, and High Voltage can not turn "ON" unless the Powder Collector is "ON". The Induction Heater will not operate unless the Conveyor is "ON". and there are parts in the Induction Heater coil.
11.2.1 STEAM DEGREASER
To operate the Steam Degreaser, select the DEGREASER ON BUTTON. Wait until the DEGREASER NOT READY message goes away. This will take as much as 30 minutes to allow the Degreaser to come up to the proper operating temperature.
11.2.2 INDUCTION HEATER
To operate the Induction Heater, CONVEYOR START must be selected on the Manual Setup Screen. Then the IND HTR START must be selected on the Machine Startup Screen. The Induction Heater will be "ready", but will not generate heat unless the following conditions are met:
• armatures pass the Proximity Switch at the entrance to the Induction Coil
• the hood is closed
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11.2.2 INDUCTION HEATER
The INDUCTION HEATER POWER METER on the pendant control panel will show the level of heat power being generated.
If the Conveyor Clutch trips in Manual Mode, a message will be displayed which says
"MAIN CONVEYOR DRIVE CLUTCH HAS TRIPPED and the Conveyor will stop running. If this happens, the operator should turn the conveyor off and check for jammed parts or other problems which would prevent Conveyor operation. Then select the CONVEYOR START button to reset the Clutch. The Conveyor should begin to run.
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11.3 AUTO MODE - COATING
The Auto Mode is intended to be used primarily under production line situations after all settings have been determined in Manual Mode.
Step 1 Be sure all aspects of the Coating Machine operation are understood Step 2 Follow step 1 through 9 in the Station Startup Procedure (Section 11 in
this Manual).
Step 3 On the Panel View Screen, select the MAIN SCREEN MENU.
Step 4 Select MACHINE AUTO START/STOP SCREEN
Step 5 The following buttons on the Manual Setup Screen should already have been selected in the order listed:
DEGREASER ON SYSTEM START IND HTR START NOTE:
If a problem occurs, a warning message will appear on the Panel View Screen and the buzzer will be turned on along with the red light of the Station Beacon. To correct any faults, it is not always necessary to shut the equipment down. But if it seems to be required, follow the STATION SHUT DOWN PROCEDURE (Section 12 in this manual) and correct the problem Step 6 Once the DEGREASER IS NOT READY message goes away, the
degreaser is ready. Select the AUTO START button.
If there is an alarm, the Banner Alarm Screen should come up on the Panel View Screen. Select ACKNOWLEDGE to silence the alarm.
Check and respond to the error messages and correct the fault.
NOTE: Faults will be reported on the Banner Screen (along with an audible alarm and the Red light on the Station Beacon). Acknowledging the fault by pressing the Acknowledge button on the Banner Screen removes the Fault Message from the Banner Screen and turns off the audible alarm
To help clear the fault, a fault history of all previous faults can always be called up on the Alarm History Screen.
Step 7 If no faults occur, "AUTO MODE IS ON " will appear on the Auto Mode Start/Stop Screen.
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11.3 AUTO MODE – COATING (continued)
There is a Pyrometer that reads the temperature of the armatures to check if they are at the correct operating temperature for cure (TBD). In case the armatures are not at the correct temperature, there will be a Alarm Status Screen message displayed on the Panel View Screen. If the temperature is shown as too low, the coating of the parts may not be fully cured. The operator should then use the following procedure to correct the problem:
• Increase the Induction Heater Power until the HEATED PARTS TEMPERATURE is reading at the proper level..
• Mark the parts whose coating may not be fully cured and set them aside for testing.
In case a fault occurs and the conveyor stops, leaving armatures in the Induction Heating Station, there will be automatic cycling of the Induction Heater which will serve to complete the cure process. A message will come up IND HTR CYCLING.
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12 STATION SHUTDOWN PROCEDURE
12.1 AUTO MODE SHUTDOWN - COATING MACHINE Step 1 Run all parts off the System
Step 2 Press Automatic Mode "OFF". This will turn off the Coater, High Voltage, Conveyor, and O.D. Cleaner. Once the Conveyor is "OFF", the Air Knives and Roto-Flo Screw Vacuums will cease to operate. Wait at least 1 minute before pressing any other functions "OFF".
Step 3 Press BLOWERS "OFF
Step 4 Press INDUCTION Heater Water PUMP "STOP".
Step 5 Press POWDER COLLECTOR "STOP".
Step 6 Press DEGREASER "STOP".
Step 7 Leave the MASTER START "ON" for at least 5 minutes because the Steam Degreaser Exhaust Blower will continue to run, which will keep steam from coming out of the Degreasing Tank, and also start to cool down the inside of the Degreasing Tank.
Step 8 After 1 minutes the Steam Degreaser Exhaust Blower will automatically turn
"OFF". Once the Blower has shut off, press the MASTER "STOP" pushbutton.
It is recommended that the daily cleaning procedure be started while waiting.
12.2 MANUAL MODE SHUTDOWN - COATING MACHINE Step 1 Run all armatures off the System.
Step 2 There is no required sequence for tuning "OFF" functions in the Setup Mode, However, generally the functions would be shut "OFF" in reverse order of turning them ON.
Step 3 If you have run the Steam Degreaser; leave the MASTER START "ON" for at least 5 minutes because the Steam Degreaser Exhaust Blower will continue to run, which will keep steam from coming out of the Degreasing Tank, and also start to cool down the inside of the Degreasing Tank.
Step 4 After 1 minutes, the Steam Degreaser Exhaust Blower will automatically turn
"OFF". It is recommended that the daily cleaning procedure be started while waiting for the Degreaser Exhaust Blower to turn off
Once the Blower has shut off, press the MASTER STOP BUTTON.
NOTE: Do not press MASTER STOP until all the blowers have stopped
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12.3 POWDER HANDLING AT SHUTDOWN
Only a minimum amount of powder should be left in the Powder Management System when it is shutdown over an 8 hour period. When the Machine is not used in excess of 24 hours, the powder should be removed from the Coating Bed in order to prevent clogging of the porous plate due to ambient temperature and humidity conditions. The Powder Feeder Hopper should be emptied and the powder stored in an air tight container when the Machine will not be used for more than 48 hours.
When changing the type or color of powder, the Powder Management System must be thoroughly cleaned out in order to prevent contamination of the new powder
Black & Decker, Easton, MD - 64 - Serial # 15278 DATE 12/97
12.4 LOCKOUT
Figure 13 Lockout Provisions
Black & Decker, Easton, MD - 65 - Serial # 15278 DATE 12/97
LOCKOUT (continued) Specific Characteristics
Type of energy Place of lockout Method of lockout and releasing of stored energy
Checking the result of lockout
Electric 480 v E1
Master switch on cell electric cabinet
Turn the master switch into OFF position, and place the multiple lock and a name tag on it. Danger: the network side of the main switch, the interior lighting, the receptacles, and the PLC is under voltage
Make sure that the contacting surfaces are disconnected using gauge or by visual investigation.
Try to restart the system.
The system must not start
Pneumatic 6 bar P1
Main pneumatic valve
Push the valve handle in, and make the lockout and place a name tag.
Listen to whether the valve has released the air. Make sure that the valve is closed and the lock is properly placed
Steam S1
Main steam inlet valve Turn the main steam valve fully clockwise to the closed position. Place red cover over the main steam valve handle.
Lock and tag the red cover.
DANGER: the steam pipe may be very hot.
Read the pressure on steam inlet gauge (STMB) and steam outlet gauge . They must both read “0” (zero) pressure. Make sure the valve is closed and the lock is properly placed.
Water W1 Turn the main water valve
into the OFF position and place a lock and tag on it.
See that the valve has released water out of the valve drain and that the lock is properly placed Steam Generator Ref: Steam Generator
instruction manual for lockout procedures.
Black & Decker, Easton, MD - 66 - Serial # 15278 DATE 12/97
13. MAINTENANCE 13.1 GENERAL
A systematic 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.
WARNING: ELECTRICAL VOLTAGES USED IN THIS EQUIPMENT CAN BE HAZARDOUS. MAINTENANCE SHOULD BE HANDLED BY QUALIFIED PERSONNEL
13.2 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.
13.2.1 Air Line
The air line which enters the coater should be kept clean and free of all particles, water and oil.
13.2.2 Refrigerant Air Dryer
Check the Refrigerant Air Dryer auto-drain for proper functioning. NOTE:
The drain can 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 dirty, epoxy spotted shafts on the parts. Refer to the Refrigerant Air Dryer manufacturer’s information for more specific maintenance instructions.
Particle Filter Clean and check for proper functioning. Change filter element if dirty.
Coalescing Filter Check and drain if necessary. Note: a wet filter element is normal. Refer to the Coalescing information in the manufacturer’s manual supplied.
Change the filter element if dirty. See the Spare Parts List (Section 17) for the correct filter number.
13.2.3 STEAM DEGREASER
Follow the Steam Degreaser Preventive maintenance instructions listed in the Preventative Maintenance (Section 14 of this manual).
Black & Decker, Easton, MD - 67 - Serial # 15278 DATE 12/97
DAILY CHECK AT START-UP:
Check the Pressure Gauges on the Steam Degreaser and compare against previously recorded settings to make sure there are no drastic changes which may indicate some type of problem (such as clogged nozzles).
13.3 FLUIDIC BED
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
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