operators manual - gtv verschleißschutz€¦ · gained increasing importance in the thermal spray...

Postfach 311 Firmensitz: D-57503 Gewerbegebiet

www.gtv-mbh.de D- 57629 [email protected]

GmbH Tel.: +49 2662 9576-0 Fax: +49 2662 9576 30

Plasma & Flame Spray Engineering

Operators manual

HVOF MF-K2

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TABLE OF CONTENT

Seite 1. DECLARATION OF CONFORMITY 4

2. DESCRIPTION 5 2.1. FRAIM OF DELIVERY 5 2.2. HVOF PROCESS 5 3. SYMBOLS 7 4. HEALTH AND SAFETY 7 4.1 CHECKING FOR GAS LEAKS 8 4.2 SAFETY DEVICES 9 4.2.1 EMERGENCY STOP 9 5. PLANT INSTALLATION 10 GAS AND WATER PRESSURES 10 5.1 CONTROL PANEL (USER FUNCTIONS 10 5.2 START UP 11 5.2.1 START MENU 11 5.2.2 MP 270 SCREEN 11 5.3 MENU „HVOF K2“ 12

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TABLE OF CONTENT

Seite 5.4 MENU „INPUT PRESSURES“ 13 5.5 MENU „WATER“ 14 5.6 MENU „PROCESS GRAPHIC“ 15 5.7 SAVE;LOAD;DELETE A PROGRAM 16 5.8 RUN HVOF PROCESS IN AUTOMATIC MODE 17 6. SERVICE AND MAINTENANCE 18 7. TROUBLE SHOUTING 18

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EG- DECLARATION OF CONFORMITY

According to EG-Richtlinie Maschinen 98/37/EG, Anhang II A EG-Richtlinie Elektromagnetische Verträglichkeit 89/336/EWG

EG-Richtlinie „Niederspannung“ 73/23/EWG Machine: PLANT: HVOF COATING EQUIPMENT TYPE: MF-HVOF-K2 PRODUCTION YEAR: 2001 SERIAL NO: IS DEVELOPPED AND DESIGNED ACCORDING THE ABOVE MENTIONED

NORMS IN FULL RESPONSIBILITY OF

Firma GTV Verschleißschutz GmbH, Gewerbegebiet, 57629 Luckenbach FOLLOWING NORMS:

• DIN EN 292 Sicherheit von Maschinen, Geräten und Anlagen • DIN EN 1050 Leitsätze zur Risikobeurteilung • DIN EN 60204-1 Elektrische Ausrüstung von Maschinen • VBG 61 Gase

THIS DECLARATION LOSE VALITY, IF CHANGEMENTS TO THE EQUIPMENT WILL BE DONE WITHOUT GTV AGREEMENT. Luckenbach, 05.04.01

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2. PLANT DESCRIPTION 2.1 FRAIM OF DELIVERY - 1 PIECE CONTROL BOX HVOF-K2

- ELECTRICAL CONTROL PLC SIEMENS S7

- GAS MASSFLOW CONTROL

- LIQUID FUEL PUMP TYPE PROMINENT HP2A

- 1 PIECE HVOF K2 TORCH; SERIAL NO. (SPECIFIC MANUAL)

- 1 SET HOSES

- 1 PIECE WATER COOLER PC 800 Ser:no.N-0102-800 (SPECIFIC MANUAL)

- 1 PIECE POWDER FEEDER MF-PF-2/2 (SPECIFIC MANUAL)

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Introduction HVOF HVOF Since it’s first application 20 years ago, High Velocity Oxygen Fuel (HVOF) spraying has

gained increasing importance in the thermal spray market.

The special feature on this technique, as compared to other TS techniques, is that the

coating material are less heated and with remarkably higher velocities impact on the

components which are to be coated.

In HVOF Systems a flame stream is formed by combustion under high pressure, resulting in

gas velocities of more than 2000 m/s. The spray powder is injected into this stream.

HVOF K2 System

The HVOF K2 System is an HVOF System of the 3. generation. Instead of a fuel gas this

system use a liquid fuel (Kerosene).

The system operates at a higher combustion chamber pressure of up to 10 bar. The powder

is injected radially into the gas stream, just behind the point of divergence.

For the case of WC-Co powder, this system allows a spray rate of up to 10 kg/h without

affecting the coating quality.

Physical Comparisation

Fuel Max. Flame-

temperature [C°]

Heat value [MJ/m3]

Oxygen/Fuel Ratio For a max. Temperature

Oxygen/Fuel Ratio for a neutral flame

Propane 2800 93 4,5 5,0 Hydrogen 2900 11 0,42 0,5 Ethen 3000 60 2,4 3,0 Acetylen 3160 60 1,5 2,5 Kerosene 2800 38 MJ/l 2,9 1) 3,4 1)

1) Massenmischungsverhältnis Sauerstoff/Kerosin

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3. SYMBOL DESCRIBTION

IM

4. HEALTH AND SA For operating equipment w

regulations specified by the

The operating area of the e

also serves as personal pr

Only authorized and train

equipment are allowed to

to carry out the SERVICE

Before carrying out MAIN

equipment must be shut

There must be no curren

WARNING SIGN AS A POINTER FOR POSSIBLE DANGERS/HAZARDS !

PORTANT INFORMATION CONCERNING THE SYSTEM

FETY

here pressurized gases are present, the local laws and

Country are to be followed totally.

quipment must be protected by an acoustical enclosure which

otection against the movement of components.

ed personnel familiar with all specific functions of the

operate the system. Fully trained personnel are only allowed

and MAINTENANCE.

TENANCE and SERVICE especially to the guns the

down by the main power switch for each component.

t or voltage on the total equipment.

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4.1 CHECKING F Every system is che

But however for saf

before spraying usi

- Open all gas

- Note all inpu

them for two

- Is there a si

be found an

Caution! Danger to life!! Operating the system is only allowed by closed door of the acoustical cabin !

Use always EYE-, EAR- and Respiratory Protection

OR GAS LEAKS

cked for gas leaks by GTV.

ety reasons a daily check is necessary. Please make a short check

ng the following procedures:

supply valves and close it again 15 sec. later.

t pressures at the pressure manometers and carefully monitor

minutes.

gnificant loss during this period there must be a leak which must

d sealed.

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4.2 SAFETY DEVICES 4.2.1. EMERGENCY STOP For protection to personnel and machines the control panel is equipped with an emergency

stop switch, which immediately shuts down the system when depressed.

After pushing the emergency stop during the process the equipment shuts down directly without running the automatic soft stop cycle. Because of possible KEROSENE inside the torch, the next ignition of the system may be impossible.

4.2.3 KEY SWITCH „POWER ON/OFF“ Only skilled personnel who are familiar with the specific functions of the equipment are

authorised to have the key. Make sure that an unauthorized usage of the equipment is

impossible.

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5. PLANT INSTALLATION GAS AND WATER PRESSURES REQUIRED TO THE SYSTEM: OXYGEN: 18 BAR NITROGEN: 5 BAR WATER: 16 BAR 5.1 CONTROL PANEL (USER FUNCTIONS)

9 Emergency Stop 10 Light Powder feeder 11 Push Button Powderförderer Start 12 Push Button Pulverförderer Stop

1 Light Process on 2 Push Button Process Start 3 Push Button Process Stop 4 Light Ignition 5 Push Button Ignition 7 Key Switch Power On 8 Light power Stand By

1 2 5 4 11 10

9 3 7 8 12

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5.2 START UP

• Switch on the system with the main switch at the control box.

• Switch on the power with the key switch (7) at the panel.

The Siemens screen shows the 5.2.1 „START MENU“

Bild 5.2

SCREEN BUTTOM LINE FUNCTION KEYS F13 – F20 5.2.2 CHANGE SCREEN Pushing the F13 button the screen will change to the HVOF K2 Menu

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5.3 F 13: MENU „HVOF K2“ (2. LEVEL) In that menu all parameters such as:

- kerosene, oxygen, powder feed gas, feeder disk speed, mixer RPM, combustion

pressure, water in and output temperature, water flow will be shown .

Bild 5.3

Change HVOF Parameter • move the „Blank“ with the cursor buttons to the parameter of your choice

• Changeable parameters are: Kerosene flow, oxygen flow, powder feed gas flow, feeder

disk speed, mixer RPM

• setup the value with the numerical buttons

• confirm with „ENTER“

With the function keys F13 - F20 you will get into Level 3

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5.4 F18: MENU „PRESSURE “ (3. LEVEL)

This Menu shows the input pressure of the gases Oxygen and Nitrogen as well as the Kerosene pressure of the pump and the combustion pressure in the torch.

If the pressure of one or more gases is too low, the equipment will not start or shuts down automatically.

Bild 5.4

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5.5 F 16 MENU „WATER“ (3. LEVEL)

Bild 5.5

This Menu shows the parameters of the cooling water such as: • actual in- and output temperature (°C) • actual flow (Litre/min) • maximum temperature which the equipment shuts down • minimum flow which the equipment shuts down An error message will be shown on the screen if the water temperature is too high or the flow is too low. To protect the system, the equipment will also shut off.

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5.6 MENU „PROCESS GRAPHIC“ (3.LEVEL)

Bild 5.10

In this mask some relevant parameters of the HVOF process are shown in a graph form,

which gives the possibility of an uncomplicated process monitoring.

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5.7 SAVE; LOAD;DELETE A PROGRAM 5.7.1 RECIPE EDIT

5.7.2 SAVETo save the p

- Write a ne

- Move the

- The param

- Move the

80.71.1

OXYGEN KEROSENE POWDERGAS 1 POWDERGAS 2 DISC 1 DISC 2

850 22 9 9 2,5 2,5

PROGRAM: arameters of the HVOF K2 Menu it is necessary to:

w program name in the field „Data record name“ and co

cursor to the right Transfer symbol and confirm with EN

eter of the HVOF K2 Menu are listed now.

cursor to the symbol „SAVE“ and confirm with ENTER.

1
SAVE DELETE
Transfer symbols

nfirm with ENT

TER

Bild 5.7

ER

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5.7.3 LOAD AN EXISTING PROGRAM - Move the cursor to the field „Data record name“ an push ENTER. All existing

programmes will be listed.

- Choose a program with the Cursor Up/Down buttons and confirm with ENTER.

- Move the cursor to the left Transfer symbol and confirm with ENTER

- The data’s were sent to the plc and shown in the HVOF K2 Menu. 5.7.4 DELETE PROGRAM - Move the cursor to the field „Data record name“ an push ENTER. All existing

programmes will be listed.

- Choose a program with the Cursor Up/Down buttons and confirm with ENTER.

- Move the cursor to the “DELETE” symbol and confirm with ENTER

- A message „Delete? 0/yes 1/no “ will be shown on the screen.

- Push 0 to delete

5.8 RUN HVOF K2 IN AUTOMATIC MODE - Switch to automatic mode in the Menu „HVOF K2 “

Adjust all Parameters to your choice or choose an existing program according 5.7.3 - Push “START“ button (2) at the operator panel. - Ignition and run up will be done automatically. - Push „Start Powder feeder“ (11) if the K2 gun achieve the process parameters. 5.8.1 Stop the HVOF process - Press button (3) „STOP“ at the operator panel The HVOF process stops automatically.

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6. SERVICE AND MAINTENANCE It is recommended to make a service and maintenance contract which includes a technical service once per year. In addition to a function and safety check, this service includes a calibrate of massflow controllers to ensure reproducible coatings can be produced at all times. Please keep the whole equipment clean. Remove dust and dirt every day. There is no regular service and maintenance necessary for the control panel. Check and clean the filter insert of the air circulation.

Service and maintenance of the Powder Feeder, the water cooler and the K2 torch is described in their separate manuals. Please read and understand carefully.

7. TROUBLESHOUTING K1 FUNKTION

Most of the possible errors will be shown on the screen. But however, if the operator confirms an error message without solving the cause, the message is not longer on the screen. Therefore a buffer memory is installed which can be opened with the K1 button of the MP 270 operator panel. As long as an error is valid it will be shown with K1.

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Equipment Description:

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operators manual - gtv verschleißschutz€¦ · gained increasing importance in the thermal spray...

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