Putting into operation FLEXI ARC 300

Arc spraying
System manual
MAN 96983 EN 02

© Oerlikon Metco 7/2014

Oerlikon Metco AG Switzerland
Rigackerstrasse 16
CH-5610 Wohlen
+41 56 618 81 81
+41 56 618 81 00

www.oerlikon.com/metco
Putting into operation FLEXI ARC 300

Information about the manual

This manual describes the control software for the thermal coating Operation
system. The manual supports the user in the safe and efficient opera-
tion of the plant.

Description Characteristics

Putting into operation FLEXI ARC 300 Description of putting the system into operation

Please keep this manual in a safe place close to your installation.

i
Orientation help

• Table of contents at the beginning of the manual

• Index in the back of the manual INFO
Specific safety instruc-
Additional documents tions for the relevant
components of the
• Safety for arc spraying installation are con-
tained in the corre-
sponding manuals

Copyright regulations
Reprinting of this manual without prior written permission from
Oerlikon Metco is strictly prohibited. No parts may be reproduced, cop-
ied or distributed by any means, including through the use of elec-
tronic systems.

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 Putting into operation FLEXI ARC 300

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Putting into operation FLEXI ARC 300

Table of contents
Operation
1 Putting the installation into operation
1.1 Preparatory work steps..................................................................................... 7
1.2 Adjusting the spraying parameters ................................................................... 8
1.2.1 Adjusting the spray voltage .............................................................................. 8
1.2.2 Adjusting the atomizer air ................................................................................. 9
1.2.3 Adjusting the spraying current ........................................................................ 10
1.3 Activation of the wire feed .............................................................................. 12
1.4 Synchronising the feed speed (LD/U2 - Push 1) ............................................ 14
1.5 Starting the spraying mode............................................................................. 16

Index .............................................................................................................. 19

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 Putting into operation FLEXI ARC 300

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Putting into operation FLEXI ARC 300

1 Putting the installation into operation

Operation

1.1 Preparatory work steps

• Caution!
The (customer-side) electrical power supply must be configured as
i
a clockwise rotating field. INFO
Non-observance of
• Check the cables and cable connections for damage. these instructions can
• Check the hoses for damage and wear. result in damage to the
installation
• Check the wire guidance for damage and wear.
• Check the oiler.
The fill level must correspond to the marking on the oiler.
To refill, press the locking lever on the oiler downwards and
remove the protective grille, complete with glass chamber, by
unscrewing. After filling, lock both components again.
• Check the compressed air filter.
The filter element must not be heavily soiled or clogged, otherwise
the installation's compressed air supply cannot be ensured.
• Maintain the quality of the compressed air:
Use compressed air exclusively in accordance with ISO 8573,
Class 1.
Contaminated compressed air degrades the spraying characteris-
tics and can result in damage to the air motor.
• Check the extraction.
A filter/extraction unit must always be switched on while spraying.

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 Putting into operation FLEXI ARC 300

1.2 Adjusting the spraying parameters

Suitable parameters for the spray voltage, spraying current and atom-
izer air can be obtained from the manual "Recommended spraying
parameters".

1.2.1 Adjusting the spray voltage

• The spray voltage controls the melting temperature of the wire.
The higher (lower) the spray voltage, the higher (lower) the melting
temperature of the wire.
• The spray voltage is adjusted with the step switches (-S1.1 & -S1.2)

i and can be read off on the voltmeter (-P2) when the installation is
running.
INFO • The spray voltage must be set high enough to provide a continu-
Never operate the step ously burning arc that will ensure trouble-free operation.
switches while spraying
• You can recognise incorrectly set voltages as follows:
Changing the spray - Spray voltage too high:
voltage while spraying The noise of the arc is steady, but loud.
can damage the instal- - Spray voltage too low:
lation The wire melts off unevenly, with stuttering.
(The spraying device "spits")

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Putting into operation FLEXI ARC 300

1.2.2 Adjusting the atomizer air

• The atomizer air controls the size of the spray particles.
The higher (lower) the pressure of the atomizer air, the smaller Operation
(larger) the spray particles.
• The atomizer air is adjusted with the pressure regulator (2) and the
pressure can be read off on the pressure gauge (1) when the
installation is running.
• The atomizer air can be adjusted between 1 and 6 bar. To adjust
the air pressure, pull out the pressure regulator slightly, adjust the
desired pressure and press the regulator back in again.

-P2 -P1

I>
1

U U P

-S1.1 -S1.2 -S1.3

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 Putting into operation FLEXI ARC 300

1.2.3 Adjusting the spraying current

• The spraying current controls the quantity of the sprayed wire.
The higher (lower) the spraying current, the higher (lower) the
quantity of the sprayed wire.

The following applies: Wire transport speed <=> Current in

amperes
• The spraying current is adjusted steplessly with the control valve
(3) on the LD/U2 and can be read off on the ammeter (-P1) when
the installation is running.
By turning the control valve anticlockwise (clockwise), the spraying
current is increased (reduced).
• The LD/U2 has been adjusted on the test stand to the maximum
spraying current of 300 A.
• If the melting behaviour of the spray wire is unsatisfactory (the arc

i crackles) despite setting the recommended parameters (see man-

ual "Spraying parameters"), the electric choke should be switched
off with the choke switch (-S1.3) (switch position horizontal). If the
INFO the set spraying current is less than 80 A, the electric choke should
Never operate the also be switched off.
choke switch while As standard, the electric choke is switched on (switch position ver-
spraying tical).

Changing the choke

setting while spraying
can damage the instal-
lation

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Putting into operation FLEXI ARC 300

-P2 -P1
Operation

I>
1

U
U P

-S1.1 -S1.2 -S1.3

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 Putting into operation FLEXI ARC 300

1.3 Activation of the wire feed

1. Switch on the AC supply voltage.
2. Open the compressed air line.
3. Pull the wire guide tubes (7) out of the LD/U2 and lay them out
straight, without kinks.
4. On the air motor of the wire feed gearbox Push 1, open the control
valve (9) by turning fully anticlockwise.
5. On the air motor of the LD/U2, close the control valve (3) approx.
half way by turning clockwise.
6. Switch on the power supply FLEXI ARC 300 with the main switch
(-Q1).
White signal lamp (-H1) lights up,
yellow signal button (-H3, -S3) flashes.
7. Hold the dead man's switch (4) and the button (6) on the spraying
device LD/U2 pressed down until the spray wires come out of the
wire guide tubes.
8. Release the platen (10) on the wire feed gearbox Push 1 and wind
up the spray wires again until they project approx. 150 mm from
the wire guide tubes. Close the platen again on the wire feed gear-
box Push 1.
9. Open the platen (5) on the spraying device LD/U2.
10. Insert the wire guide tubes (7) up to the stop in the spraying device
LD/U2.
Ensure that the spray wires lie in the grooves of the feed rollers
and extend out of the contact nozzles.
Secure the wire guide tubes (7) with the knurled screws (8).
11. Close the platen (5) on the spraying device LD/U2.
12. Clip off the wire ends short, so that they do not touch.
13. The installation is now set up for the spraying mode.

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Putting into operation FLEXI ARC 300

-H3, -S3
Operation

I>

U U P

-Q1

-S1.1 -S1.2 -H1 -H2

6
5

10

3
(7)

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 Putting into operation FLEXI ARC 300

1.4 Synchronising the feed speed (LD/U2 - Push 1)

Both air motors must be synchronised with each other, as follows:

1. On the air motor of the wire feed gearbox Push 1, open the control
valve (9) by turning fully anticlockwise.
2. Start the spraying mode.
(See 1.5 Starting the spraying mode - page 16)
3. Adjust the required spraying current at the control vale (3) of the
LD/U2.
The spraying current is displayed on the ammeter (-P1).
4. Close the control valve (9) on the wire feed gearbox Push 1 by
turning until the spraying power reduces slightly (read off on the
ammeter (-P1)). Then, open the control valve again by one half
turn.
5. Both feeds are now synchronised with each other.
6. Stop the spraying mode.

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Putting into operation FLEXI ARC 300

-P2 -P1
Operation

I>
1

U
U P

-S1.1 -S1.2 -S1.3

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 Putting into operation FLEXI ARC 300

1.5 Starting the spraying mode

1. Switch on the filter/extraction unit.
2. Switch on the AC supply voltage.
WARNING
3. Open the compressed air line.
Danger from the spray-
ing process 4. Switch on the power supply FLEXI ARC 300 with the main switch
(-Q1).
Take personal protec- White signal lamp (-H1) lights up,
tion yellow signal button (-H3, -S3) flashes.
measures
5. Press the yellow signal button (-H3, -S3) once to acknowledge.
White (-H1) and green signal lamps (-H2) light up.
6. Aim the spraying device LD/U2 in the dust extractor intake.
7. Hold the dead man's switch (4) pressed down on the spraying
device LD/U2 and press the button (6).

Caution!
Do not aim the spraying device LD/U2 towards people!
Atomizer air will blast out immediately!
After a delay of 2 seconds, the spraying mode starts.
8. Depending on the application, the spraying parameters (spray volt-
Wear protective age, spraying current, atomizer air) can be adjusted to suit.
equipment 9. Switch off the spraying device LD/U2 by releasing the dead man's
switch (4).
The spraying mode can also be stopped on the power supply by
pressing the yellow signal button (-H3, -S3).

Note:
The oiler is adjusted in the factory to a frequency of 1 drop every
6 seconds (see sight glass (12) on the oiler).
If the oiler setting does not correspond to this frequency, it can be
readjusted with a screwdriver at the regulating screw (11).

11
12

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Putting into operation FLEXI ARC 300

-H3, -S3
Operation

I>

U U P

-Q1

-S1.1 -S1.2 -H1 -H2

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Index
Operation
A
Activation of wire feed ..................... 12
Adjusting spray voltage ..................... 8
Adjusting spraying capacity ............. 10
Adjusting atomizer air ........................ 9

R
Readjusting oiler ............................. 16

S
Starting spraying mode ................... 16
Synchronising feed speed ............... 14

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