Operators Manual GTV-Powder feeder PF 2/2

Transcription

1 GTV Verschleißschutz GmbH Gewerbegebiet D Luckenbach Germany Phone: + 49 (0) 2662/95760 Fax: +49 (0)02662/ office@gtv-mbh.de Operators Manual GTV-Powder feeder PF 2/2 Table of content GTV Operators Manual: GTV Powder Feeder Series PF 2/X 1/17

2 A 1: Declaration of Conformity 1.1 Scope of usage GTV Powder Feeder Options EG - DECLARATION OF CONFORMITY DESCRIPTION FEATURES AND BENEFITS OPERATION MODE AND CONTROL SPECIFICATION GAS SUPPLY SYMBOL DESCRIBTION HEALTH AND SAFETY PREPARATION FOR FEEDING, START UP CLEANING AND MAINTENANCE SAFETY STANDARDS FOR CLEANING AND MAINTENANCE EMPTY POWDER CANISTER STEP STEP WEAR PARTS PARTS LIST OPERATING PANEL TP170A: ADJUST PARAMETERS Setup Options TROUBLE SHOOTING Diagnostic One or more motors are not operating Both feeder do not start operating...17 GTV Operators Manual: GTV Powder Feeder Series PF 2/X 2/17

3 1.1 SCOPE OF USAGE The machine is a powder feeder designed for thermal Spray as well as for laser cladding or PTA welding process. The machine must be used exclusively for feeding of powder shaped materials only. Regarding gases the use of argon, nitrogen or helium is allowed only. Oxygen as well as hydrogen or other burnable gases is in no circumstances allowed. If the machine shall be used for other purposes GTV has to be consultant! 1.2 GTV POWDER FEEDER OPTIONS - MF-PF 2/2 (2 Canister, 2 Drive) - MF-PF 2/1 (2 Canister, 1 Drive) - MF-PF 4/2 (4 Canister, 2 Drive) - MF-PF x/x Massflow controlled - H-PF x/x with Heater jacket - MFH-PF x/x Massflow controlled with Heater jacket 1.3 EG - DECLARATION OF CONFORMITY See next page. GTV Operators Manual: GTV Powder Feeder Series PF 2/X 3/17

4 GTV Verschleißschutz GmbH Gewerbegebiet Luckenbach Tel. +49(0)2662/ Fax (0) EG - DECLARATION OF CONFORMITY Machine: According to EG- Maschine Guideline 98/37/EG, Annex II A EG-Guideline Electrical Magnetical Amicability 89/336/EWG EG- Guideline Low Voltage 73/23/EWG PLANT: Powder Feeder TYPE: PF 2/2 PRODUCTION DATE: October 2006 SERIAL NO: Project No. IS DEVELOPED AND DESIGNED ACCORDING THE ABOVE MENTIONED NORMS IN FULL RESPONSIBILITY OF Incorporation: Company Location: GTV Verschleißschutz GmbH Gewerbegebiet, D Luckenbach, Germany FOLLOWING STANDARDS: DIN EN 292 Safety of equipment, components and machine units DIN EN 1050 Guidance for risk assessment DIN EN Electrical setup for equipment and machines VBG 61 Gases THIS DECLARATION LOSE VALIDITY, IF CHANGES TO THE EQUIPMENT WILL BE DONE WITHOUT GTV AGREEMENT. Luckenbach, Directoring Manager

5 2 DESCRIPTION The GTV Model MF-PF-X/X is an electronically controlled pressurised unit that produced accurate, repeatable powder feed rates. The feeder is designed for Plasma and HVOF Thermal Spray Systems as well as Laser Cladding up to an operating pressure of 4.5 bar. The GTV powder hopper is the container used to hold and feed the powder. In operation it is fitted into a drive housing which supports and provides motion to the powder disc which feeds the powder. The powder hopper can be mounted in every type of GTV powder feeder. Each size of powder hopper is designed by Bi-Cone construction. In this design, the upper powder container is fabricated with a conical lower section to help support the weight of powder in the hopper. Directly below this cone the powder hopper contains a suspended inverted cone in order to convey the powder further. The design maintains constant loading in the feed disc regardless of the mass of powder in the hopper. This ensures a consistent an repeatable feed rate at a constant powder disc RPM: Each powder hopper contains a powder stirrer mechanism driven by a motor fitted on the hopper lid. The design of the stirrer is similar to a wire whisk an maintains powder flowability and prevents packing without causing powder segregation. Spreader an exhauster units are used to meter the powder flow into the powder disc and into the powder pickup area. These are available in a L design of Liquid (free-flowing) powder types and a NL design for Non-Liquid (non free-flowing) powder types. Special spreader and exhauster units are available for aluminum/polyester powders and applications involving very low feed-rates or highly abrasive powders. Further information are available upon request. GTV Operators Manual: GTV Powder Feeder Series PF 2/X 5/17

6 3 FEATURES AND BENEFITS - suitable for use with all GTV powders - visual monitoring of the feed mechanism during operation - selection of powder hoppers with different sizes (0.3, 1.5 or 5 Liter) - easy cleaning few wear parts, low maintenance - insensitive to any type of external disturbance - powder segregation is avoided when using blended powder - easy handling when refilling powder - a proven system over a long periods of operation 4 OPERATION MODE AND CONTROL The powder hopper consist of a rotating powder disc with an annular groove of rectangular cross section. The powder is conveyed from the powder container into the groove of the powder disc where is deposited by the spreader unit in a precisely defined height across the entire with of the groove. Diametrically opposite the spreader unit is the exhauster unit. With this nozzle-shaped part the powder is sucked out of the groove of the powder disc and conveyed in the carrier gas inside an anti-static special hose to the plasma gun where it melts an is sprayed into the surface of the work piece. The powder feed rate is proportional to the speed of the dispensing disk and can be set by infinite variation to any desired value within the feed range. During operation the gas-tight powder hopper is subjected to a slight overpressure. The gas is able to exit into the powder hose only at the exhauster unit. As it does so, the powder in the slot of the powder disc is entrained and conveyed by the gas flowing in the hose. The same volume of gas which exits at the end of the hose is referred to the powder container. GTV Operators Manual: GTV Powder Feeder Series PF 2/X 6/17

7 4.1 SPECIFICATION Installation Voltage: 230 V/50 Hz or 110 V/60 Hz Feeder gas pressure: 4 bar Canister Capacity: 1.5 Litre (Option 5 Litre and 0,3 Litre for Laser) Dimensions PF 2/X: 600 mm x 350 mm x 1400 mm (W x D x H) PF 4/2: 600 mm x 600 mm x 1400 mm (W x D x H) Heater jacket Temp: 0-50 C The disk and mixer motor is controlled electronically by a Siemens S7 controller. The adjustment of the feeding parameters will be done with the Operator Panel of the HVOF or Plasma unit or for stand alone feeders with the Operator Panel TP170A (see separate description). 4.2 GAS SUPPLY The powder feed gas (Argon or Nitrogen or Helium) will be supplied by the gas cabinet of the Plasma, HVOF, Laser unit or of an independent gas supply. The optional gas massflow controller is responsible for the accurate gas flow. The valve of the flow meter at the housing side (left and right) of the feeder must be opened completely. If the feeder is used as a stand alone feeder and not delivered with massflow controller, the adjustment of the feeder gas has to be done using the flow meter. A safety valve prevent a canister pressure of more than 4,5 bar. 5 SYMBOL DESCRIBTION Warning sign as a pointer for possible dangers/hazards Important information concerning the system GTV Operators Manual: GTV Powder Feeder Series PF 2/X 7/17

8 6 HEALTH AND SAFETY Never use burnable gases as well as Oxygen for feeding! Only Argon, Nitrogen or Helium are allowed! Only authorised and trained personnel familiar with all specific functions of the equipment are allowed to operate the system. Fully trained personnel are only allowed to carry out SERVICE and MAINTENANCE!!Read and understand the manual before using the system! 7 PREPARATION FOR FEEDING, START UP Make sure that power and gas is connected. Remove the connector of the mixer and remove canister lid. Use a funnel to fill up the canister with the powder of your choice. Close the canister and plug in the connector of the mixer. Switch on the system with the main power switch. Set up the parameters for: Disk (RPM) Mixer (RPM) Feeder gas Start the Plasma or HVOF process. Start powder feeding at: The Plasma or HVOF console if remote cable is connected. Or with the Start button of the powder feeder. GTV Operators Manual: GTV Powder Feeder Series PF 2/X 8/17

9 8 CLEANING AND MAINTENANCE 8.1 SAFETY STANDARDS FOR CLEANING AND MAINTENANCE The powder feeder GTV MF-PF-X/X has less wear parts and needs therefor less maintenance. It is important to keep the whole system clean, remove dust every day after operation. Most powders are toxic. Cleaning the feeder accordance to the specific country safety standards concerning working in toxic areas Read the material reminder of the powder and follow their safety instructions Do not clean the area with compressed air. Use always a vacuum cleaner or soft brushes to remove dust and dirt. Use always Eye- and Respiratory Protection! 8.2 EMPTY POWDER CANISTER There are two way s to empty the powder canister: STEP 1 Remove the powder hose from the torch and put it into the powder bottle. Make sure that powder feed gas is on. Set up maximum disk speed = 12 RPM. Start feeding the powder back to the powder bottle STEP 2 Remove the mixer motor connector and the lid. Pull off the complete powder canister from the feeder. GTV Operators Manual: GTV Powder Feeder Series PF 2/X 9/17

10 Empty the canister into the powder bottle (use a funnel). Remove the screws of the red ring. Pull of the plastic part from the base housing. Take off the rest powder with a soft brush or a vacuum cleaner. 9 WEAR PARTS During cleaning and maintenance the condition of all wear parts shall be checked regularly and discard if necessary. The minimum stock of all wear parts are listed following. 9.1 PARTS LIST Pos. GTV-No. Designation Recommended Spares Quantity plug for mixer/stirrer motor cover for mixer/stirrer motor hollow set screw mixer/stirrer motor cover for hopper with motor locking cover Woodruff-Key spring washer M fillister head screw A+P radial seal ring Form AS, NBR AP O-Ring special screw filler pipe coupling 2-parts, consisting of: coupling bore hole hollow set screw gear bore hollow Set Screw holder complete O-Ring Powder canister bearing bushing damper fillister stifts stirrer/mixer pressure levelling pipe feeding cone O-Ring fillister-screw (14) aluminium ring for support Holder for suction GTV Operators Manual: GTV Powder Feeder Series PF 2/X 10/17

11 O-Ring cover plate set spreader NL, consisting of: suction NL spreader NL set spreader L, consisting of: suction L spreader L set spreader Laser, consisting of: suction Laser spreader Laser suction intermediate NL spreader intermediate NL feed plate intermediate 0,6 x 11 mm hollow set screw shaft for feed plate feed plate Standard feed plate Laser 0,6 x 5 mm spring special O-Ring main housing A+P radial seal ring Form AS, NBR AP bearing bushing O-Ring extension to main housing bearing Locking ring drive shaft Key 4x4x O-Ring A+P radial seal ring Form AS, NBR AP bearing cover fillister screw coupling 2-parts with screws gear bore Dia-10-h O-Ring (Gas-Injector) O-Ring Set cpl. (9 piece) 1 GTV Operators Manual: GTV Powder Feeder Series PF 2/X 11/17

12 GTV Operators Manual: GTV Powder Feeder Series PF 2/X 12/17

13 GTV Operators Manual: GTV Powder Feeder Series PF 2/X 13/17

14 GTV Operators Manual: GTV Powder Feeder Series PF 2/X 14/17

15 10 OPERATING PANEL TP170A: ADJUST PARAMETERS Switch on the equipment with the main power switch. Push Start button You see the main picture of the TP170A: To set the parameters of Disk 1 (Left Feeder) or Disk 2 (Right Feeder): Touch inputbox set and input a value with the softkeys to set up the disc speed or the mixer speed. GTV Operators Manual: GTV Powder Feeder Series PF 2/X 15/17

16 Softkey Input Input Range: Disc Speed 0 10 RPM Mixer Speed % Pushing the Start button on the panel will open the valve for carrier gas and the stirrer motor rotates. After a few seconds the disk will rotate. The actual speed of the disk will be shown in the output filed act Pushing the Stop button the disk motor stops immediately and the carrier gas flow as well as the stirrer will stop after a few seconds. In order to adjust carrier gas flow use needle of flow meter left and right side of the feeder located SETUP OPTIONS The feeder can be external controlled e.g. GTV Plasma/HVOF Equipment or Robot system or any other suitable device. GTV Operators Manual: GTV Powder Feeder Series PF 2/X 16/17

17 Push the button stand alone/remote to switch between internal and external control. stand alone for internal control. remote for remote control. The disk speed can be set external e.g. GTV Plasma/HVOF Equipment or intern on the main picture. Push the button rpm to select the disk speed source. rpm intern : Analogue Signals for disk speed internal set rpm extern : Analogue Signals for disk speed external set Operatin of the solenoid valve for carrier gas. Push the button valve to select the behavior of the solenoid valve. valve open : input solenoid valve for carrier gas is always opened valve auto : input solenoid valve for carrier gas will be opened by remote control device/command, by Stand Alone or Start button powder feeder 11 TROUBLE SHOOTING 11.1 DIAGNOSTIC Push the button fault on the main picture to show an error list. On this list all currently present errors will be shown ONE OR MORE MOTORS ARE NOT OPERATING Possible reason: Overload current of motor board Turn off the feeder, wait while and then turn on the feeder BOTH FEEDER DO NOT START OPERATING Possible reasons: Feeder gas missing Feeder gas pressure too low Couplings not plugged in GTV Operators Manual: GTV Powder Feeder Series PF 2/X 17/17