Translation of the Original Operating Manual

Transcription

1 Translation of the Original Operating Manual Cyclone Version 12 / 2016 P_03128 II 1/- D c IIIB T85 C

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3 Table of Contents 1 GENERAL Preface Warnings, Notices and Symbols in these Instructions Languages Accessories/Peristaltic Pump Operating Manual Abbreviations Terminology for the Purpose of this Manual 7 2 CORRECT USE Device Type Type of Use Use in an Explosion Hazard Area Safety Parameters Processible Working Materials Reasonably Foreseeable Misuse Residual Risks 9 3 IDENTIFICATION Explosion Protection Identification Type Plate Permissible Device Combinations 11 4 GENERAL SAFETY INSTRUCTIONS Safety Instructions for the Operator Electrical Devices and Equipment Personnel Qualifications Safe Work Environment Safety Instructions for Staff Safe Handling of WAGNER Powder Spray Devices Grounding the Device Product Hoses Cleaning Handling Powder Lacquers Protective and Monitoring Equipment 14 5 DESCRIPTION Components Mode of Operation Cyclone Separator Screening Unit Protective and Monitoring Equipment Two-hand Circuit Scope of Delivery Design Variants Powder Discharge Pneumatic Connection Technical Data 21 3

4 6 ASSEMBLY AND COMMISSIONING Training Assembly/Commissioning Staff Storage Conditions Installation Conditions Transportation Assembly and Installation Set-up Process for Variants 1, 2 and Set-up Process for Variant Grounding Safety Checks Commissioning 30 7 OPERATION Training the Operating Staff Safety Instructions Work After Commissioning Measuring Cyclone Efficiency Reducing Powder Loss 34 8 CLEANING AND MAINTENANCE Cleaning Cleaning Staff Safety Instructions Cleaning Procedures Maintenance Maintenance Staff Safety Instructions Maintenance Procedures Safety Checks Hoses, Tubes and Couplings 40 9 MALFUNCTION AND RECTIFICATION REPAIRS Repair Staff Safety Instructions FUNCTION TEST AFTER THE REPAIR INSPECTIONS ACCORDING TO DIN EN 50177: DISASSEMBLY AND DISPOSAL ACCESSORIES SPARE PARTS How Can Spare Parts Be Ordered? Explosion Drawing Spare Parts List DECLARATION OF WARRANTY AND CONFORMITY Important Notes Regarding Product Liability Warranty Claim Declaration of Conformity 54 4

5 1 GENERAL 1.1 PREFACE The operating manual contains information about safely operating, maintaining, cleaning and repairing the device. The operating manual is part of the device and must be available to the operating and service personnel. Operating and service personnel should be instructed according to the safety instructions. The device may only be operated in compliance with this operating manual. This equipment can be dangerous if it is not operated according to the instructions in this operating manual. 1.2 WARNINGS, NOTICES AND SYMBOLS IN THESE INSTRUCTIONS Warning instructions in this operating manual highlight particular dangers to users and to the device and state measures for avoiding the hazard. These warning instructions fall into the following categories: Danger - immediate risk of danger. Non-observance will result in death or serious injury. DANGER This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level. The measures for preventing the hazard and its consequences. Warning - possible imminent danger. Non-observance may result in death or serious injury. WARNING This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level. The measures for preventing the hazard and its consequences. Caution - a possibly hazardous situation. Non-observance may result in minor injury. CAUTION This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level. The measures for preventing the hazard and its consequences. Notice - a possibly hazardous situation. Non-observance may result in damage to property. NOTICE This notice warns you of a hazard! Possible consequences of not observing the warning instructions. The signal word indicates the hazard level. The measures for preventing the hazard and its consequences. Note - provides information about particular characteristics and how to proceed. 5

6 1.3 LANGUAGES The operating manual is available in the following languages: Language Order No. Language Order No. German English French Italian Spanish Russian Chinese Additional languages on request or at: ACCESSORIES/PERISTALTIC PUMP The operating manual for the peristaltic pump (models: PP25S, PP25C, PP40S, PP40C, PP25Y, PP25Y-FL and PP40Y) is available in the following languages: Language Order No. Language Order No. English English French Italian Spanish Additional languages on request or at: 1.4 ABBREVIATIONS Pos Order No. Designation Number of pieces Position Marking in the spare parts lists Order number Spare part 6

7 1.5 TERMINOLOGY FOR THE PURPOSE OF THIS MANUAL Cleaning Cleaning Flushing Staff qualifications Trained person Electrically trained person Electrician Skilled person in accordance with TRBS 1203 (2010/Revision 2012) Manual cleaning of devices and device parts with cleaning agent Internal flushing with compressed air of parts carrying paint Is instructed in the tasks assigned to him/her, the potential risks associated with improper behavior as well as the necessary protective devices and measures. Is instructed by an electrician about the tasks assigned to him/ her, the potential risks associated with improper behavior as well as the necessary protective devices and measures. Can assess the work assigned to him/her and detect possible hazards based on his/her technical training, knowledge and experience in relevant provisions. A person, who, based on his/her technical training, experience and recent vocational experience, has sufficient technical knowledge in the areas of explosion protection, protection from pressure hazards and electric hazards (if applicable) and is familiar with the relevant and generally accepted rules of technology so that he/she can inspect and assess the status of devices and coating systems based on workplace safety. 7

8 2 CORRECT USE 2.1 DEVICE TYPE cyclone 2.2 TYPE OF USE The is used to separate and recover powder lacquers (overspray) from a powder coating booth. 2.3 USE IN AN EXPLOSION HAZARD AREA The may not be placed in dust explosion zones. The device generates a potentially explosive area inside (Zone 20). 2.4 SAFETY PARAMETERS WAGNER accepts no liability for any damage arising from incorrect use. Use the device only to work with the products recommended by WAGNER. Only operate the device as a whole. Do not deactivate safety fixtures. Use only WAGNER original spare parts and accessories. The device may only be operated under the following conditions: The operating personnel must be trained on the basis of this operating manual. The safety regulations listed in this operating manual must be observed. The operating, maintenance and repair information in this operating manual must be observed. The statutory requirements and accident prevention regulation standards in the country of use must be observed. The may only be used once all parameters are set and all measurements/ safety checks are carried out correctly. 2.5 PROCESSIBLE WORKING MATERIALS Types of powder which can be charged electrostatically Metallic powder Not suitable for metal dusts 8

9 2.6 REASONABLY FORESEEABLE MISUSE Assembly, installation and grounding not in accordance with the operating manual Performing unauthorized conversions or modifications to the device Use of damp powder lacquer Working with liquid coating products Use of defective components, spare parts or accessories other than those described in this operating manual Continuing work with a defective or kinked product hose Working with incorrect values for the machine parameters Use for foodstuffs 2.7 RESIDUAL RISKS Residual risks are risks which cannot be ruled out even in the event of correct use. If necessary, warning and prohibition signs at the relevant points of risk indicate residual risks. Residual risk Source Consequences Specific measures Lifecycle phase Skin contact with Handling powder Skin irritations, Wear protective Operation, powder lacquers and cleaning agents lacquers and cleaning agents allergies clothing Observe safety data sheets maintenance, Disassembly Powder lacquer Lacquering outside Inhalation of Observe work and Operation, in air outside the the defined working substances which operation instructions Maintenance defined working area area are hazardous to health Noise Exhaust system Hearing damage Wear ear protection Operation Blowing-out system Cleaning 9

10 3 IDENTIFICATION 3.1 EXPLOSION PROTECTION IDENTIFICATION Device type: Manufacturer: J. Wagner GmbH D Markdorf II 1/- D c IIIB T85 C CE: European Communities Symbol for explosion protection II Other areas (not mining) 1/- Category 1: Device generates Zone 20 inside Category - Device not suitable for use in explosion zone D Dust C Ignition protection: Protection provided by constructional safety IIIB Device group IIIB (non-conductive dusts) T85 C Maximum surface temperature 85 C; 185 F 3.2 TYPE PLATE Pos Designation 1 Manufacturer 2 Device type 3 Serial number 4 Year of manufacture 5 Nominal volume flow 6 Protection class 7 Two-hand circuit 8 CE identification J. Wagner GmbH D Markdorf Gerätetyp type Fabrikationsnummer serial number Baujahr year of production Nenn-Volumenstrom nominal air flow volume II 1/- D c IIIB T85 C m3/h 8 6 Schutzart proof class IP 54 7 Zweihandschaltung two hand control EN 574: Type I MADE IN GERMANY P_

11 3.3 PERMISSIBLE DEVICE COMBINATIONS The is part of a powder coating system that is comprised of the following parts: Booth Powder center Application Pipe Final filter Controller For powder recovery from the powder discharge, the following components can be used: Peristaltic feed pump 11

12 4 GENERAL SAFETY INSTRUCTIONS 4.1 SAFETY INSTRUCTIONS FOR THE OPERATOR Keep this operating manual at hand near the device at all times. Always follow local regulations concerning occupational safety and accident prevention ELECTRICAL DEVICES AND EQUIPMENT To be provided in accordance with the local safety requirements with regard to the operating mode and ambient influences. May only be maintained by skilled electricians. Must be operated in accordance with the safety regulations and electrotechnical regulations. Must be repaired immediately in the event of problems. Must be decommissioned if they pose a hazard. Must be de-energized before work is commenced on active parts. Secure the device against being switched back on without authorization. Inform staff about planned work. Observe electrical safety regulations PERSONNEL QUALIFICATIONS Ensure that the device is operated, maintained and repaired only by trained persons SAFE WORK ENVIRONMENT The floor in the working area must be electrostatically conductive (measurements according to EN 1081 and EN ). The footwear worn by the operators must comply with the requirements of EN ISO The measured insulation resistance must not exceed 100 megohms. The protective clothing, including gloves, must comply with the requirements of EN ISO The measured insulation resistance must not exceed 100 megohms. The powder release must be electrically interlocked with the powder spray system's exhaust air equipment. Excess coating product (overspray) must be collected up safely. Ensure that there are no ignition sources such as naked flames, sparks, glowing wires, or hot surfaces in the vicinity. No smoking. Maintain sufficient quantities of suitable fire extinguishers and ensure that they are serviceable. The operating company must ensure that an average concentration of powder lacquer in the air does not exceed 50% of the lower explosion limit (LEL = max. permitted concentration of powder to air). If no reliable LEL value is available, the average concentration must not exceed 10 g/m³. 12

13 4.2 SAFETY INSTRUCTIONS FOR STAFF Always follow the information in this manual, particularly the general safety instructions and the warning instructions. Always follow local regulations concerning occupational safety and accident prevention. Under no circumstances may people with pacemakers enter the area where the highvoltage field between the spray gun and the work piece to be coated builds up! SAFE HANDLING OF WAGNER POWDER SPRAY DEVICES Do not point spray guns at people. Before all work on the device, in the event of work interruptions and functional faults: - Switch off the energy/compressed air supply. - Secure the spray gun against actuation. - Relieve pressure on spray gun and device. - In the event of functional faults, rectify the fault as described in chapter 9 Malfunctions and rectification GROUNDING THE DEVICE The electrostatic charge may, in certain cases, give rise to electrostatic charges on the device. This may result in the formation of sparks or flames when discharging. Ensure that the device is grounded before each coating process. All of the system's conductive elements, such as floors, walls, ceilings, protective grating, transport equipment, work pieces, powder tanks, automatic moving devices or construction parts etc. in the spray area, with the exception of parts which carry high voltage during operation, must be connected to the grounding system. Parts of the booth must be grounded in accordance with EN Ensure that all persons inside the working area are grounded, e.g. that they are wearing electrostatically conductive shoes. The functionality of grounding cables must be checked regularly (see EN 60204) PRODUCT HOSES Use only an original WAGNER powder hose. Make sure that the hoses are laid only in suitable places. Hoses should not be laid in the following places under any circumstances: - in high-traffic areas, - on sharp edges, - on moving parts or - on hot surfaces. Ensure that the hoses are never run over by vehicles (e.g., fork lifts), or that the hoses are never put under pressure from the outside in any other way. Ensure that the hoses are never kinked. Observe maximum bending radii. 13

14 4.2.4 CLEANING Before starting cleaning or any other manual work, the high voltage in the spray area must be shut down and locked to prevent it from being switched back on. Lock the compressed air supply and decompress the device. Secure the device against being switched back on without authorization. Use only electrically conducting and grounded tanks for cleaning fluids. Preference should be given to non-flammable cleaning fluids. Flammable cleaning liquids may only be used if, after switching off the high voltage, all high-voltage conducting parts are discharged to a discharge energy of less than 0.24 mj before they can be accessed. Most flammable solvents have an ignition energy of around 0.24 mj or 60 nc. The cleaning agent's flash point must be at least 15 K above the ambient temperature. Only mobile industrial vacuum cleaners of design 1 (see EN ) may be used to remove dust deposits HANDLING POWDER LACQUERS When preparing or processing the powder and cleaning the device, take note of the processing regulations, laid down by the manufacturer of the powder lacquers, being used. Take note of the manufacturer s instructions and the relevant environmental protection regulations when disposing of powder lacquers. Implement the prescribed safety measures, in particular the wearing of safety glasses and safety clothing as well as the use of protective hand cream if needed. Use a mask or breathing apparatus if necessary. To ensure sufficient protection of health and the environment, only operate the device in a powder booth or on a spray wall with activated ventilation (exhaust air). 4.3 PROTECTIVE AND MONITORING EQUIPMENT Protective and monitoring equipment must not be removed, modified or rendered unusable. Regularly check for perfect functioning. If defects are detected on protective and monitoring equipment, the system must not be operated until these defects are remedied. 14

15 5 DESCRIPTION 5.1 COMPONENTS Powder/air mixture Air containing fine grains P_03129 Pos Description Pos Description 1 Clean gas 6 Peristaltic pump (accessories) 2 Immersion pipe 7 Funnel 3 8 Turbine vibrator 4 Powder discharge 9 Sieve 5 Connection for peristaltic pump 10 Raw gas 5.2 MODE OF OPERATION CYCLONE SEPARATOR Paint powder can be separated from a carrier gas (air) with the cyclone separator. For this, the dust-laden air passes through the inlet screw in the and is set into rotation. The rotational flow operates helically on the, downwards. If the powder discharge is braked and moves upwards as a second vortex, where the air containing fine grains leaves the cyclone through the immersion pipe. 15

16 5.2.2 SCREENING UNIT The coating powder, separated in the, arrives at the sieve with the rotational flow. There, coarse impurities are held back while the coating powder passes through the sieve and slides along the funnel to the reclaimed powder. The turbine vibrator that is flange-mounted to the funnel, aids the screening and, at the same time, avoids the creation of powder clumps inside the funnel. The separated powder can either be... collected in a powder transport container (A), emptied into a fluid powder container (B), conveyed further with a peristaltic pump (C), or filled into a container. A B C P_ PROTECTIVE AND MONITORING EQUIPMENT Protective and monitoring equipment must not be removed, modified or rendered unusable. Regularly check for perfect functioning. If defects are detected on protective and monitoring equipment, the system must not be operated until these defects are remedied. Safety Device Differential pressure monitor on the filtering device Key switch on the controller Fire Extinguishing System Effect Powder feed blocked Linear motion unit blocked Fluidization and turbine vibrator deactivated 16

17 5.3.1 TWO-HAND CIRCUIT The two-hand circuit controls the lifting and sinking of the powder funnel. The powder funnel is connected to the swivel frames via three pneumatic cylinders (see Chapter 5.4.2). Lifting So that the powder funnel can be lifted and thus a closed inner space between the cyclone housing and powder funnel can be created, the rotary switch 3/2 WV ST-01 must be turned clockwise up to stop. The two-hand circuit is activated with rotary switch 3/2 WV ST-01. Then, push button 3/2 WV DT_1 and push button 3/2 WV DT_2 must be simultaneously activated with both hands until the powder funnel has reached its end position. If the activation of a pressure switch or of both pressure switches is interrupted during the lifting procedure, the lifting procedure is aborted and the powder funnel sinks back down to its starting position. The lifting procedure is not completed until one of the two end positions has been reached. The first end position is reached when the sieve frame is swiveled in (middle axis of the swivel frame is aligned with the middle axis of the cyclone housing). The first end position is locked with the limit switch SMPO-1-H-B-01. The second end position is reached when the sieve frame is completely swiveled out. This end position is locked with limit switch SMPO-1-H-B-02. Lowering To lower the powder funnel, the rotary switch 3/2 WV ST-01 must be turned counterclockwise. The powder funnel automatically lowers into its starting position. 17

18 Rotary switch 3/2 WV ST-01 Limit switch SMPO-1-H-B-02 Limit switch SMPO-1-H-B-01 Push button 3/2 WV DT-02 Push button 3/2 WV DT-01 P_

19 5.4 SCOPE OF DELIVERY Order No. Designation See Chapter variants The standard equipment includes: Declaration of Conformity Operating manual, German see Chapter 1.3 Operating manual in local language DESIGN VARIANTS Order No. Designation complete, 12,000 m 3 /h left complete, 12,000 m 3 /h right complete, 16,000 m 3 /h left complete, 16,000 m 3 /h right complete, 20,000 m 3 /h left complete, 20,000 m 3 /h right complete, 24,000 m 3 /h left complete, 24,000 m 3 /h right POWDER DISCHARGE 1 Pos Designation 1 Center of rotation for swiveling the sieve and the complete powder discharge 2 Powder funnel 3 Pneumatic cylinder for lifting the powder funnel P_

20 5.4.3 PNEUMATIC CONNECTION Dimensions Height 250 mm; 9.84 inches Width 300 mm; inches Depth 380 mm; inches P_ Pressure indication for the vibrator motor on the sieve (set to a max. of 2 bar; 29.1 psi). Display range: 0 to 4 bar; 0 to 58.1 psi 2 Pressure indication for the clamping cylinder (3 to 4 bar; 43.6 to 58.1 psi sufficient) Display range: 0 to 10 bar; 0 to psi 3 Pressure regulator for the air pressure of the three clamping cylinders for lifting and sinking the discharge funnel 4 Pressure regulator for the air pressure to the vibrator motor on the sieve The complete connection plate (Order No ) is usually mounted (on site during assembly) on the cyclone frame or on the final filter. 20

21 5.5 TECHNICAL DATA Dimensions and operating points: Rated air flow m 3 /h ft 3 /s m 3 /h ft 3 /s m 3 /h ft 3 /s m 3 /h ft 3 /s Length 1550 mm inch 1550 mm inch 1550 mm inch 1550 mm inch Width 2221 mm inch 2142 mm mm mm inch Height 5940 mm inch 5840 mm inch 4975 mm inch 4680 mm inch Weight Approx kg approx lbs Approx kg approx lbs Approx kg approx lbs Approx. 850 kg approx lbs Pressure loss approx bar; 1,200 Pa (valid for all models) Pneumatic connection Compressed air connection bar; psi Compressed air quality according to ISO , 2010 (Class 6.5.2) Residual water content in compressed air max. 1.3 g H 2 O/Nm 3 at a dew point of 7 C and 700 kpa Residual oil content in compressed air max. 0.1 mg oil/nm 3 Residual dust content in compressed air max. 5 mg dust/nm 3 Particle size in the compressed air max. 5 μm (micrometer) WARNING Exhaust air containing oil! Risk of poisoning if inhaled. Insufficient paint application quality. Provide compressed air free from oil and water. (Quality standard according to ISO , 2010) = Particle density 5 mg/m3; pressure dew point +7 C; Oil content 0.1 mg/ m3 Ambient conditions: If low-melting powders are used, the ambient temperature may have to be lower than 30 C; 86 F. Volume measures: For volumes specified in Nm³ (standard cubic meters). One cubic meter of a gas at 0 C and bar is called norm cubic meter. Ambient conditions Operating temperature range 5-40 C; F Noise development < 80 db (mains pressure 0.6 MPa ; 6 bar; 87 psi) 21

22 6 ASSEMBLY AND COMMISSIONING 6.1 TRAINING ASSEMBLY/COMMISSIONING STAFF WARNING Incorrect installation/operation! Risk of injury and damage to the device. The commissioning staff must have the technical skills to safely undertake commissioning. When commissioning and for all work, read and follow the operating manual and safety regulations for the additionally required system components. A skilled person must check to ensure that the device is in a reliable state after it is installed and commissioned. 6.2 STORAGE CONDITIONS Until the point of assembly, the must be stored in a dry location, free from vibrations and with a minimum of dust. The must be stored in closed rooms. The air temperature at the storage location must be between -20 C and +60 C (-4 F and +140 F). The relative air humidity at the storage location must be between 20 and 70% (without condensation). 6.3 INSTALLATION CONDITIONS The air temperature at the installation site must be in a range between +5 C and +40 C; +41 F and +104 F. The relative air humidity at the installation site must be between 20 and 70% (without condensation). Observe the specific processing temperatures of the powder manufacturer. The surface on which the reciprocator stands must have the following characteristics: Vibration-free Horizontal (permissible slant 1 ) Load bearing capacity (2000 kg/m²; 4409 lbs/m²) 22

23 6.4 TRANSPORTATION WARNING Parts have high weights and centers of gravity! Risk of injury and damage to the device. Only use appropriate lifting tackle (fork lift) for assembly. Secure the parts against tipping during transport. Cordon off assembly area to keep out unauthorized persons. The is delivered completely mounted to the installation site. Final assembly is performed on-site. Transportation and warehouse operations may only be performed by qualified personnel, especially in the use of industrial trucks, ladders and cranes. The selected means of transport must be suitable and permissible for the respective component weights (minimum carrying capacity 1200 kg; 2646 lbs). For the insertion of parts at the installation site, an opening width of at least 2000 mm (6.56 ft.) must exist, and an opening height of 2500 mm (8.20 ft.). The is delivered flat. 23

24 6.5 ASSEMBLY AND INSTALLATION The is delivered flat and must be set up on-site. DANGER Parts have high weights and centers of gravity! Death or serious injury. Given the mass and high centre of gravity of the parts, installing the monocyclone can be a dangerous process! Proceed extremely carefully during assembly and installation. Cordon off danger area to keep out unauthorized persons. Heavy weight! Device and material damage. NOTICE To set up the monocyclone, a weight-bearing lifting device (hook, belt etc.) with a load capacity of at least 1,200 kg; 2,646 lbs must be available! A P_03140 The monocyclone housing has holes (A) with d = 30 mm; 1.20 inches, added in the factory, for attaching the sling gear. 24

25 CAUTION Inadequate lifting gear! Risk of injury and damage to the device. The monocyclone may only be lifted using ropes on the frame capable of bearing load! DANGER Unforeseeable proper motion when erecting! Death or serious injury. Since the center of gravity of the monocyclone is not on the middle axis due to the spiral inflow and the possibly already mounted discharge funnel, the monocyclone tries to turn away towards the spiral inflow when setting it up on the side! There are four ways of installing the cyclone: 1. Lifting with ropes/chains using a suitable overhead crane 2. Lifting with ropes/chains using a large forklift truck with a long fork 3. Lifting with ropes/chains using a suitable rope and block and tackle 4. Lifting with two suitable forklift trucks Since the frame's feet always slide over the floor during installation and the paintwork on the frame and/or feet base is thereby damaged, a support (wooden pallets, wooden boards, plastic supports etc.) must be placed underneath them. Ideally the feet are placed on a forklift truck so that the cyclone cannot swing out in a vertical position. 25

26 6.5.1 SET-UP PROCESS FOR VARIANTS 1, 2 AND 3 DANGER Unforeseeable proper motion when erecting! Death or serious injury. While lifting the unit upright, it is imperative to pay attention to the offset center of gravity! Use additional ropes to prevent the unit from falling over. Raise the monocyclone with extreme care. Permissible lifting gear: overhead crane/crane runway large forklift truck or block and tackle with overhead gantry crane. In doing so, the following steps must be noted: 1. Attach ropes/chains with the permissible load capacity on the provided drilled holes A and secure them against loosening. 2. Remove belts from. 3. Slowly lift the into the vertical position with the overhead crane, forklift truck or block and tackle. When doing so, ensure that a suitable support is used under the monocyclone's feet (wooden pallets, wooden boards, plastic supports etc.), so that the floor is not damaged. 4. Due to the offset center of gravity of the, it can begin to rotate during lifting. This rotational movement around a vertical axis is intercepted by a second forklift truck, as the forklift truck, with help of a wooden beam, forms a stop surface for the monocyclone s feet. P_

27 5. As soon as the stands vertically on its feet, it can be moved to the end position with the help of a forklift truck. Thereby, it's frame is picked up by the forks. The attachment points are, seen from the feet, the two first parallel frame struts. In order to avoid damage to the frame, suitable anti-slip supports (rubber mats, wooden boards) must be used. Additionally secure the with straps to prevent it from slipping or tipping over. 6. Carefully lift the Monocyclon EEP cm off the floor with the fork lift. Maneuvering with the fork lift truck must take place slowly and jerk-free. Avoid longer transport routes in this position. 7. As soon as the final position is reached, the supplied support plates are laid under the feet of the. Align the support plates with help of the brackets (never align the support plates with bare hands - risk of crushing). 8. After aligning the support plates, the Monocyclone EEP-1 can be lowered onto the support plates. 9. Screw the supplied M16 leveling screws on the feet of the. Level the Monocyclone with the help of a spirit level. 10. If the is correctly aligned and leveled, it must be firmly attached to the floor. Drill two holes per Monocyclone foot into the floor. The drilling takes place through the existing drilled holes of the monocyclone foot. 11. Pound the dowel through the drilled holes of the Monocyclone foot, into the floor, with the help of a hammer and then screw them tight. P_

28 6.5.2 SET-UP PROCESS FOR VARIANT 4 CAUTION Incorrect stop position! Never lift using the monocyclone's funnel! Risk of injury and damage to the device. Lifting with two suitable forklift trucks In doing so, the following steps must be noted: The monocyclone may only be lifted using the frame pillars capable of bearing load! 1. Remove belts from. 2. To avoid damage to the floor and to the monocyclone, use suitable supports (wooden boards, rubber mats etc.). 3. The first forklift truck lifts the monocyclone in the middle (upper end of the frame) and, in the driving direction, towards the cyclone outlet. During the set-up process, the second forklift truck drives in the opposite direction of the set-up direction. 4. Ensure that the monocyclone is lifted by the first forklift truck and that the second forklift truck drives in the opposite direction in an alternating and slow manner until all four of the monocyclone's feet rest vertically on the support area. 5. Further assembly steps are to be performed as described in Chapter NOTICE Incorrect position of the discharge funnel! Avoid rotation! P_03139 If the connection of the discharge funnel is not in the correct position, the discharge funnel can be mounted afterwards on each frame leg. When dismounting the discharge funnel, use suitable lifting gear (e.g. forklift truck with pallet). After the remounting of the discharge funnel, connect the grounding cable with the signal ground. 28

29 6.6 GROUNDING For safety reasons the system must be properly grounded. WAGNER recommends the use of a copper cable of at least 16 mm² with sufficient mechanical resistance for connection to the signal ground. Good grounding of the work piece is also necessary for optimum powder coating. A poorly grounded work piece causes: dangerous electric charging of the work piece, very poor wrap-around, uneven coating, back spraying to the spray gun, i.e., contamination. Prerequisites for perfect grounding and coating are: Conducting suspension for the work piece that is to be coated. Grounding of the powder coating booth, transport and suspension equipment to be provided on site in accordance with the corresponding operating manuals or the definitions laid down by the manufacturer. Regular cleaning of hangers from powder residues. Grounding resistance for the work piece of a maximum of 1 MΩ (megaohm). Grounding cable connected to the control module or control cabinet. NOTICE Risk of ignition and electromagnetic malfunctions! Sparks between work piece and conveyor hooks (hangers) can occur if hooks or other hanger parts are not completely cleaned! These sparks can cause heavy radio frequency interference. 6.7 SAFETY CHECKS Carry out safety checks in accordance with Chapter

30 6.8 COMMISSIONING NOTICE Defective seals can significantly reduce the separation efficiency! Before each commissioning, check whether all seals are in flawless condition. The is part of a coating system and will be commissioned and turned on/off in connection with this. DANGER Risk of fire! Death or serious injury. The monocyclone may only be operated together with a quickreacting fire suppression system! The works after proper commissioning without manual operation. The two-hand circuit serves solely to perform maintenance, cleaning, repairs and to rectify malfunctions. 30

31 7 OPERATION 7.1 TRAINING THE OPERATING STAFF WARNING Incorrect operation! Risk of injury and damage to the device. The operating staff must be qualified to operate the entire system. The operating staff must be familiar with the potential risks associated with improper behavior as well as the necessary protective devices and measures. Before work commences, the operating staff must receive appropriate system training. 7.2 SAFETY INSTRUCTIONS WARNING Incorrect operation! Risk of injury and damage to the device. If contact with powder products or cleaning agents causes skin irritation, appropriate precautionary measures must be taken, e.g., wearing protective clothing. The footwear worn by operating staff must comply with EN ISO The measured insulation resistance must not exceed 100 megohms. The protective clothing, including gloves, must comply with EN ISO The measured insulation resistance must not exceed 100 megohms. 7.3 WORK AFTER COMMISSIONING The works after proper commissioning without manual operation. The two-hand circuit serves solely to perform maintenance, cleaning, repairs and to rectify malfunctions. 31

32 7.4 MEASURING CYCLONE EFFICIENCY Cyclone efficiency, application efficiency, system efficiency and powder loss: The cyclone efficiency describes the efficiency of the powder separation from the powder/ air mixture that is guided through the cyclone. It can be determined by a certain amount of powder being introduced via the recovery system (see procedure below). The cyclone efficiency is strongly influenced by the powder's spectrum of grains. Therefore, each entry of a cyclone efficiency is to be seen as an average value for a powder with normal grain spectrum distribution. Fine grain < 10 μm and other light particles are generally separated with more difficulty. The amount of powder caught in the final filter is called powder loss. This is often seen in regards to the cyclone efficiency. It is true however, that the amount of loss also depends on how high the application efficiency of the coating system is (application efficiency). This is significantly influenced by the type and size of the workpiece and its suspension. In this context, the smaller the work pieces and the larger the gap between individual work pieces, the lower the application efficiency is, due to a greater amount of overspray. The influence between the cyclone efficiency and the application efficiency on the powder loss is shown in the following table. Powder loss table Effective application Cyclone efficiency efficiency 99% 98% 97% 96% 95% 94% 93% 92% 90% 0.11% 0.22% 0.33% 0.44% 0.55% 0.66% 0.77% 0.88% 80% 0.25% 0.50% 0.74% 0.99% 1.23% 1.48% 1.72% 1.96% 70% 0.43% 0.85% 1.27% 1.69% 2.10% 2.51% 2.91% 3.31% 60% 0.66% 1.32% 1.96% 2.60% 3.23% 3.85% 4.46% 5.06% 50% 0.99% 1.96% 2.91% 3.85% 4.76% 5.66% 6.54% 7.41% 45% 1.21% 2.39% 3.54% 4.66% 5.76% 6.83% 7.88% 8.91% 40% 1.48% 2.91% 4.31% 5.66% 6.98% 8.26% 9.50% 10.71% 35% 1.82% 3.58% 5.28% 6.91% 8.50% 10.03% 11.50% 12.94% 30% 2.28% 4.46% 6.54% 8.54% 10.45% 12.28% 14.04% 15.73% 25% 2.91% 5.66% 8.26% 10.71% 13.04% 15.25% 17.36% 19.35% 20% 3.85% 7.41% 10.71% 13.79% 16.67% 19.35% 21.88% 24.24% 15% 5.36% 10.18% 14.53% 18.48% 22.08% 25.37% 28.40% 31.19% 10% 8.26% 15.25% 21.26% 26.47% 31.03% 35.06% 38.65% 41.86% 5% 15.97% 27.54% 36.31% 43.18% 48.72% 53.27% 57.08% 60.32% 32

33 Depending on the system concept, the powder loss is still influenced by the operating mode (recovery system or spray-to-waste mode), as well as losses during paint changes. If all of the losses are added up and compared with the amount of fresh powder used, the system efficiency is determined. The cyclone efficiency can be determined by the following procedures. Procedures: In three series of measurements, the fresh powder is passed through the cyclone. Then, the amount of powder that was collected after the first cycle is fed through the cyclone and then collected again. Finally the powder collected after the second cycle is fed through the cyclone again. The mean value of the resulting efficiency taken from the three measurements is used. The cyclone efficiency is thus, the mean value from a fresh powder cycle and two following cycles with the reclaimed powder. Powder quantity: An initial powder quantity of 10 to 20 kg (22.1 to 44.2 lbs) should be used. More powder increases the measurement precision. The powder should be added into the suction (e.g. of the booth) with a speed of 350 g/min (1lbs/min). To do so, a small scoop can be used. It is to be expected that the efficiency with fresh powder is worse by several percentage points than with measurements made with reclaimed powder. This is because the fine grain fraction of the fresh powder is not separated as easily and, in the first cycle, an increased amount of fine fraction lands as waste in the final filter. If large differences should occur in comparative measurements, the measurement should be repeated in order to rule out measuring errors. To be able to interpret measurement results better, knowledge of the spectrum of grains of the used powder is helpful. This can be requested from the powder supplier. 33

34 7.4.1 REDUCING POWDER LOSS If the powder loss is no longer in the desired range, the system can usually be optimized through different measures. Employee training Employees should know during which process steps, losses occur and how these can be reduced. Especially in paint change systems, powder loss can be greatly decreased as a result of work being carried out properly. Regular cleaning and maintenance work Cleaning and maintenance work (Chapter 8) should be undertaken regularly and carefully by qualified and trained staff. Gap and height control Automatic switching off of the guns in areas in which there are no workpieces can significantly reduce powder loss. Depth control Automatic movement of the guns, in order to maintain the same distance to the workpiece and to thereby achieve a higher efficiency despite variable workpiece dimensions. Optimization of workpiece hanging Workpieces hung as near together as possible, reduces empty spaces and increases the application efficiency. Automatic fresh powder supply Especially with single-paint systems, the continuous mixing of reclaimed powder with fresh powder improves not only the coating quality but also the application efficiency. In this way it can be avoided that, due to the segregation effect, entire containers of reclaimed powder must be disposed of because they can no longer be processed. Modern plastic booths with floor blow off If powder settles on the floor and walls, the composition changes such that it can no longer be used. As a result of floor blow off, virtually no powder settles. The powder is immediately returned into circulation. For individual consultation or the exact determination of the system efficiency, your contact persons at WAGNER Industrial Solutions will be happy to assist you. 34

35 8 CLEANING AND MAINTENANCE 8.1 CLEANING CLEANING STAFF Cleaning work should be undertaken regularly and carefully by qualified and trained staff. They should be informed of specific hazards during their training. The following hazards may arise during cleaning work: Health hazard from inhaling powder lacquer Eye injuries from escaping powder lacquer Hearing damage caused by noise during the cleaning procedure Use of unsuitable cleaning tools and aids SAFETY INSTRUCTIONS DANGER Explosive powder/air mixes! Danger to life and equipment damage. Before starting cleaning or other manual work, the high voltage must be shut down and locked to prevent it from being switched back on! The spray gun must be separated from the high-voltage supply and compressed air supply before any cleaning work is started! Use only electrically conductive tanks for cleaning liquids! Ground the tank! Preference should be given to non-flammable cleaning fluids. Flammable cleaning liquids may only be used if, after switching off the high voltage, all high-voltage conducting parts are discharged to a discharge energy of less than 0.24 mj before they can be accessed. Most flammable solvents have an ignition energy of around 0.24 mj or 60 nc. The cleaning agent's flash point must be at least 15 K above the ambient temperature. Only mobile industrial vacuum cleaners of design 1 (see EN ) may be used to remove dust deposits. 35

36 WARNING Incorrect maintenance! Risk of injury and damage to the device. If contact with powder products or cleaning agents causes skin irritation, appropriate precautionary measures must be taken, e.g., wearing protective clothing. The footwear worn by operating staff must comply with EN ISO The measured insulation resistance must not exceed 100 megohms. The protective clothing, including gloves, must comply with EN ISO The measured insulation resistance must not exceed 100 megohms CLEANING PROCEDURES The valid health and safety specifications and the safety instructions provided in Chapter 4 must be adhered to for all cleaning work. The cleaning intervals should be adapted by the operator depending on the level of use and if necessary the level of soiling. If in doubt, we recommend contacting J. Wagner GmbH's specialist personnel. The valid health and safety specifications and the safety instructions provided in Chapter 4 must be adhered to for all cleaning work. Outside cleaning: Outer deposits and soiling on the monocyclone and in the direct vicinity (floor) are to be removed regularly. Inside cleaning: The internal cleaning of the powder discharge can be performed with the help of a compressed air gun. When doing so, the suction of the entire system must remain switched on. This cleaning method helps to remove powder. Should heavy sintering be present in the powder discharge, spirits and a cleaning cloth, for example, can be used to remove the sintering. The suction of the entire system is to be switched off for this. In the process, it must always be observed that the powder funnel inside is damp wiped. If there is sintering and there are deposits on the entire monocyclone (inner cyclone casing), the system can be cleaned with cleaning pellets (see Chapter and Chapter 14). Further information regarding cleaning pellets can be obtained at the J. Wagner GmbH service center. Paint change: Paint change procedures can be found in the respective complete operating manual. 36

37 8.2 MAINTENANCE MAINTENANCE STAFF Maintenance work should be undertaken regularly and carefully by qualified and trained staff. They should be informed of specific hazards during their training. The following hazards may arise during maintenance work: Health hazard from inhaling powder lacquer Use of unsuitable tools and aids Once the maintenance work is complete, the device must be checked by a qualified person to ensure a reliable condition. 37

38 8.2.2 SAFETY INSTRUCTIONS DANGER Incorrect maintenance/repair! Danger to life and equipment damage. Repair or replacement of devices or parts of devices are only allowed to be performed outside the hazard area by qualified personnel. Before starting maintenance or other manual work, the high voltage must be shut down and locked to prevent it from being switched back on! The spray gun must be separated from the high-voltage supply and compressed air supply before any maintenance work is started! DANGER Incorrect maintenance/repair! Risk of injury and damage to the device. Repairs and part replacement may only be carried out by specially trained staff or a WAGNER service center. Before all work on the device and in the event of work interruptions: - Secure the spray gun against actuation. - Switch off the energy/compressed air supply. - Relieve spray gun and device pressure. Observe the operating and service manual for all work. WARNING Incorrect maintenance! Risk of injury and damage to the device. If contact with powder products or cleaning agents causes skin irritation, appropriate precautionary measures must be taken, e.g., wearing protective clothing. The footwear worn by operating staff must comply with EN ISO The measured insulation resistance must not exceed 100 megohms. The protective clothing, including gloves, must comply with EN ISO The measured insulation resistance must not exceed 100 megohms. 38

39 8.2.3 MAINTENANCE PROCEDURES The maintenance intervals should be adapted by the operator depending on the level of use and, if necessary, the level of soiling (see also chapter 9 Malfunctions and rectification ). If in doubt, we recommend contacting WAGNER's specialist personnel. The valid health and safety specifications and safety instructions provided in Chapter 4 must be adhered to for all maintenance work. Maintenance work on the cyclone separator At the end of operation, check the cyclone separator for deposits and caking on the inside of the cyclone, especially in the immersion pipe. Remove existing deposits and caking. Check seals, sealing strips and closing mechanisms and replace and/or adjust them as necessary. Check for leaks in running condition. No false air can escape along the interfaces of the funnel/cyclone. Check all grounding connections on the monocyclone for damage and replace them if necessary. Pellet cleaning, to remove sintering, which could possible negatively effect the paint change quality and efficiency. Time stamp daily weekly X Depending on the degree of sintering every 3-6 months X X X Maintenance work on the powder discharge Time stamp daily weekly Check the sieve cloth for impurities and replace it in case of mechanical damage. X Check seals and replace them as necessary. X Check sealing forces of the quick-release fasteners (if present) and adjust them as necessary. X Maintenance work on the powder discharge (continued) Check pneumatic locking of the discharge funnel: - The discharge funnel must be able to be opened during the discharge operation. - If necessary, adjust the compressed air pressure for the cylinders. - Check for perfect functioning of the two-hand circuit. Time stamp daily weekly X 39

40 8.2.4 SAFETY CHECKS Inspection point Inspection interval Remarks Hoses, tubes, couplings daily Chapter Grounding weekly Chapter 4.2.2, Chapter 6.6 Inspection for damage weekly Chapter 10 The above recommended intervals are maximum values and can be modified by the operator depending on the local and operational conditions and the contamination. Damaged devices must be decommissioned and repaired immediately HOSES, TUBES AND COUPLINGS The service life of the complete hoses, for product and air, is reduced due to environmental influences even when handled correctly. Check hoses, pipes, and couplings every day and replace if necessary. Before every commissioning, check all connections for leaks. Additionally, the operator must regularly check the complete hoses for wear and tear as well as for damage at intervals that he/she has set. Undamaged complete hoses are to be replaced when the following intervals have been exceeded: Product hoses: a maximum of 6 years from the date of the hose imprinting. Air hoses: a maximum of 10 years from the date of the hose imprinting. 40

41 9 MALFUNCTION AND RECTIFICATION DANGER Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in chapter 15 Spare Parts and that are assigned to the unit. Before all work on the device and in the event of work interruptions: - Switch off the energy supply and the compressed air supply. - Relieve spray gun and device pressure. - Secure the spray gun against actuation. Observe the operating and service manual for all work. Malfunctions can only be detected and rectified if daily maintenance and cleaning work are performed (see Chapter 8). Malfunction Cause Remedy Removal efficiency is poor. - The seals, especially on the cyclone's dust extraction, are damaged or worn out. - Check the seals and replace them as necessary. - The exhaust air current is no longer sufficient. - Check pipings; If they are clogged clean them and, if necessary, repair them. - Check the final filter and replace the filter cartridges as necessary. - Check the final filter and, if necessary, replace the cleaning valves (solenoid valves). - Check throttle valve position (if throttle valve is present) and adjust it as necessary. - Check frequency converter settings (if frequency converter is present) and adjust them as necessary. - If the powder center is directly connected to the final filter, check the throttle valve position of the powder center in operating mode. 41

42 Malfunction Cause Remedy Removal efficiency is poor (continuation) - The exhaust air current is no longer sufficient (continuation) - If suctioned manual coating station is present, check the throttle valve position of the manual coating station. - The cyclone casing is worn by - Repair the cyclone casing. abrasive dusts. - Powder granularity is too fine. - Use coarser powder. - The connection of the pneumatic cylinder is not sufficient. - False air infiltration due to false or not optimally set powder pump (e.g. peristaltic pump). The sieve is clogged. - The properties of the coating powder The powder discharge does not remain in the extended position. - The amount of powder returned is too great (e.g. during booth cleaning). - The pneumatic turbine vibrator on the discharge funnel does not function in an optimal way. - The proximity switch is defective or not in the correct position. - Check pressure on the cylinders (3 to 4 bar; 43.5 to 58.1 psi ), and check whether the pneumatic cylinders are not fully extended in the closed position. - Set powder pump in an optimal way. - Check the coating powder for moisture and, if necessary, replace the coating powder with dry powder. - Use a sieve cloth with a larger mesh width. To do so, ask the WAGNER Service Department. - Switch on the pneumatic turbine vibrator. - Check the operating pressure for the pneumatic turbine vibrator and set it not higher than 1.5 bar; 21.8 psi. - Check exhaust throttle on pneumatic turbine vibrator and replace it as necessary. - Check pneumatic turbine vibrator and replace it as necessary. - Check the function of the proximity switch via the optical functions test. - Readjust the proximity switch on the pneumatic cylinder. 42

43 10 REPAIRS 10.1 REPAIR STAFF Repair work should be undertaken carefully by qualified and trained personnel. They should be informed of specific hazards during their training. The following hazards may arise during repair work: Health hazard from inhaling powder lacquer Danger due to residual pressure in compressed-air lines Eye injuries from escaping powder lacquer Use of unsuitable tools and aids A skilled person must check to ensure that the device is in a reliable state after it is repaired SAFETY INSTRUCTIONS Observe the safety instructions in Chapter 4 and Chapter Before a Repair - Flush cyclone casing and powder discharge with cleaning pellets and then clean them. Chapter After a Repair - Carry out a safety checks in accordance with Chapter DANGER Incorrect maintenance/repair! Danger to life and equipment damage. Only a WAGNER service center or a suitably trained person may carry out repairs and replace parts. Only repair and replace parts that are listed in chapter 15 Spare Parts and that are assigned to the unit. Before all work on the device and in the event of work interruptions: - Switch off the energy supply and the compressed air supply. - Relieve spray gun and device pressure. - Secure the spray gun against actuation. Observe the operating and service manual for all work. 43

44 11 FUNCTION TEST AFTER THE REPAIR All functions must be checked in manual and automatic mode. 12 INSPECTIONS ACCORDING TO DIN EN 50177: 2010 If the system is used for electrostatic coating with flammable coating powders, testing should be undertaken in accordance with DIN EN 50177: as per Table 3 and Table 4. 44

45 Section Type of inspection Requirements 1 Checking the effectiveness of technical ventilation 2 Link between technical ventilation equipment and high voltage, compressed air and coating material supply Checking the effectiveness of technical ventilation The technical ventilation should be interlocked such that the powder feed and high voltage cannot be switched on, while the technical ventilation is not working effectively. Inspection Type of inspection by TP/SP ME Measurements of air flow speed / air quantities Check the differential pressure indicator. SP FT Test whether the system is safely stopped and the product supply, supply air and high voltage are switched off when the ventilation is shut down. 3 Parts carrying high voltage outside the spray area Legend: MF = Manufacturer ER = Employer SP = Skilled person FPO = Fire prevention officer ELT = Electrician TP = Trained person Parts carrying high voltage outside the spray area must be routed such that discharges which put people at risk do not occur. FT = Function test ME = Measurement OC = Organization check VI = Visual inspection CM = Constant monitoring TT = Technical testing SP FT Inspect and test (e.g., by measurement) whether all parts carrying high voltage do not result in discharge which puts people at risk. Inspection interval continuously annually weekly 45

46 Section Type of inspection Requirements 4 Effectiveness of grounding All the system's conductive elements, such as floors, walls, ceilings, protective grating, transport equipment, work pieces, powder tanks, machines or construction parts etc. in the spray area, with the exception of parts which carry high voltage during operation, must be connected to the grounding system. Parts of the booth must be grounded in accordance with EN Measures to take if conductive components are insufficiently grounded 6 Ground leaking resistance from the work piece attachment point Legend: MF = Manufacturer ER = Employer SP = Skilled person FPO = Fire prevention officer ELT = Electrician TP = Trained person If sufficient grounding of conductive parts cannot be ensured, their discharge energy must not exceed the permissible value. The resistance to ground of every work piece's locating point must not exceed 1 megohm (measurement voltage must be 1000 V). The form of construction of the work piece mount must guarantee that the work pieces remain grounded during coating. FT = Function test ME = Measurement OC = Organization check VI = Visual inspection CM = Constant monitoring TT = Technical testing Inspection Type of inspection by SP VI/ME/CM Visual check of ground connections, perform function test on grounding switch, measurement of grounding resistors. SP ME/CM Measurement of discharge energy. SP ME/CM Measure resistance to ground (work piece receiver - ground potential) max V. Inspection interval weekly weekly weekly 46

47 13 DISASSEMBLY AND DISPOSAL We recommend having the WAGNER system disassembled by WAGNER or another specialist. Before starting disassembly, all supply media (electric current, compressed air) must be disconnected at the connection points. All powder lacquer lines must be completely emptied and then rinsed. Lacquer residues must be disposed of in line with statutory requirements. Before starting disassembly, check whether the supply lines have actually been interrupted and have been depressurized and/or de-energized if necessary. The empty system should be thoroughly cleaned. In particular fire loads such as unused lacquers in exhaust air pipes etc. should be removed to keep the risk of fire during disassembly as low as possible. We recommend reporting to the public authorities the fact that systems with mandatory approval requirements are decommissioned. Separate all materials encountered during disassembly as clearly as possible in line with statutory requirements. Take appropriate actions to ensure that no dangerous substances enter the system during disassembly. All waste produced must be separated and disposed of in line with local requirements. Used materials are: Steel PVC synthetic material Cable... 47

48 14 ACCESSORIES Peristaltic pump PP25S Order No.: Peristaltic pump PP25C Order no P_02873 Peristaltic pump PP40S Order No.: Peristaltic pump PP40C Order no P_02874 Peristaltic pump PP25Y Order No: Peristaltic pump PP25Y-FL Order no P_02875 Peristaltic pump PP40Y Order No.: Immersion pipe cleaner Order no (Monocyklon m3/h) (Monocyklon m3/h) (Monocyklon m3/h) (Monocyklon m3/h) P_03084 P_03137 Cleaning pellets 5 kg Order No.: kg Order No.: kg Order No.: B_