VFC-5 to VFC-500 FLO-COATER

Transcription

1 VFC-5 to VFC-500 FLO-COATER INSTALLATION - MAINTENANCE INSTRUCTIONS

2 Page 1 CONTENTS Reference Documents... 2 Basic Room Layout... 3 Service Connections... 3 Electrical... 3 Compressed Air... 4 Steam Usage... 5 Installation Requirements... 6 Initial Flo-Coater Setup... 7 Component Installation Expansion Chamber Product Containers Inlet Air Seal Inlet Duct Assembly Explosion Venting Grounding Hydraulic Lift Cylinders/Pump Wash-in-Place System Cartridge Filters Pulse Air Reservoir - Max. Air Pressure Cartridge Filters 2 BAR Cartridge Filter Lifting Cables Snap Hook Connection Bayonet Clasp Connection Cartridge Filters 12 BAR Cartridge Filters 12 BAR with Filter Cylinders Spotlight System Maintenance Exterior/Interior Product Container Grounding Connections Wash-in-Place System (WIP) Cartridge Filter System Troubleshooting... 61

3 Page 2 REFERENCE DOCUMENTS Prior to the installation of this equipment, it is highly recommended that copies of the following Standards, Codes and other documents be obtained. These documents, along with the preliminary drawing package and a familiarity of local safety regulations, will assist you in determining that the completed installation meets all acceptable regulations. United States! United States National Fire Protection Association (NFPA) 68, Guide for Venting of Deflagrations! NFPA 69, Standard on Explosion Prevention Systems! NFPA 70, National Electrical Code (NEC)! Occupational Safety and Health Administration International! International Electrotechnical Commission (IEC)! Canadian Standards Association (CSA)! European/German Standard VDI3673! European/German Standard VDI2263! European Standard EN60204 cl. 20 (International Electrotechnical Commission (IEC) 204-1)

4 Page 3 BASIC ROOM LAYOUT Prior to receipt of the equipment, it is important that a proper facilities layout be performed. Properly planned, location and installation of the basic unit will maximize the efficiency of production during operation. Proper clearances must be allowed to perform routine maintenance, inspection and service. SERVICE CONNECTIONS ELECTRICAL WARNING! Electrical installation of this equipment must be in accordance with all state and local electrical codes as well as in compliance with the International Electric Code (IEC ) and applicable EC directives. Installation should be conducted by qualified electricians ONLY. Failure to install this equipment properly could result in damage to equipment, property and loss of life. The electrical components of a Vector Flo-Coater System are chosen to properly operate with the power source of the facility. Each system is built to customer specifications. Please refer to the appropriate electrical drawings in the Assembly Drawing section of this manual. Specific requirements will be given for:! Electrical Voltage/Phase/Hertz! System Amperage

5 Page 4 SERVICE CONNECTIONS COMPRESSED AIR A compressed air source is required for this equipment. It must be capable of producing:! Instrument Grade Air! 90 PSI (620kPa, 6.2 Bar) minimum Compressed air volume requirements are dependent upon the specific Flo- Coater system. Specific requirements for this system can be found on the Piping and Instrumentation Drawing found in the Assembly Drawings section of this text. In general, spray gun air requirements are approximately 15 SCFM (425 L/min) per nozzle. Filter pulsing requirements are approximately 18 SCFM (510 L/min). Additional requirements are approximately 6 SCFM (170 L/min). Noted below is a suggested configuration of equipment used to condition compressed air supplying the system. COMPRESSOR º FILTER º DEHUMIDIFIER º FILTER º OIL REMOVER + DEODORIZER = CLEAN AIR

6 Page 5 SERVICE CONNECTIONS STEAM USAGE If a steam air handler is used to heat the Flo-Coater process air, please refer to the Pneumatic Interconnect and Piping and Instrumentation Drawing in the Assembly Drawing section of this manual for steam coil requirements. Shut-off valves, strainers, and dirt traps must be installed according to manufacturer's requirements. If a steam humidifier has been supplied with the equipment, a clean steam source must be provided.

7 Page 6 For shipment, the Flo-Coater Unit is mounted to a wooden skid, braced and blocked for extra support, and covered with heavy plastic sheeting. It is then placed in a shipping container for transport. Upon arrival of equipment, immediately check shipping container for shipping damages. Report all damage to the carrier. Inspect all invoicing and material lists to ensure all parts are accounted for. Report all shortages immediately. Check for items that may be boxed separately. Remove the Flo-Coater pallet from the shipping container. Vector recommends using a fork truck with a minimum load rating of 6000 lbs. (2700 kg). Vector also recommends using 8 foot (2.4 m) extenders on the forks. The following components of the Flo-Coater are removed from the main unit for shipping. These components will have to be reinstalled on the unit prior to startup of the machine. Instructions for the installation of these components are included in this text.! Product Container(s)! Expansion Chamber(s) (Multi)! Explosion Venting (2-Bar Models)

8 Page 7 INITIAL FLO-COATER SETUP Prior to moving the Flo-Coater unit to the installation site, the following precautions must be taken: WARNING! Failure to observe the following precautions can result in injury to personnel and/or damage to equipment. 1. SAFETY FIRST! Observe all safety rules associated with the lifting equipment as provided by the manufacturer. 2. All lifting devices, straps, clamps, etc. must be rated to handle the weight of the Flo-Coater Unit. Typical weights range from 2000 lbs. (900 kg) to 5000 lbs. (2250 kg). Check the shipping invoice to determine the appropriate lift rating required. 3. All lifting equipment should be in good working condition. Double check to ensure proper placement of equipment BEFORE lifting the machine. 4. The top and bottom of the unit should be lifted simultaneously, keeping the unit balanced. This will help to avoid excessive shifting of the equipment during transport to the installation site. Transport the Flo-Coater Unit to the installation site using properly rated lifting equipment, fork lift or overhead crane.

9 Page 8 INITIAL FLO-COATER SETUP (Continued) Prepare to remove the Flo-Coater Unit from the shipping pallet. Attach appropriate lifting straps to the lift lugs on top of the Flo-Coater frame. Attach appropriate lifting straps around each leg at the bottom front of the frame. Position the lifting equipment and slowly lift both ends of the Flo-Coater at the same time, maintaining a balance. Remove the shipping pallet. Slowly lower the bottom section of the unit while slowly raising the top section of the unit. Position the Flo-Coater in preparation for final installation. WARNING! The Flo-Coater IS UNSTABLE until permanently anchored to the floor. DO NOT REMOVE the lifting equipment straps from the machine until the unit is bolted to the floor. Failure to keep machine stabilized until installed may result in the equipment tipping over and causing damage to equipment and/or injury to personnel. Use grade B8M Strain-Hardened stainless steel anchor bolts and associated hardware to anchor the Flo-Coater to the floor. Because each installation varies the following anchor bolt sizes are suggested. The customer is ultimately responsible for the safe installation of the Flo-Coater to the permanent structure.

10 Page 9 INITIAL FLO-COATER SETUP (Continued) RECOMMENDED ANCHOR BOLT SIZING MODEL ANCHOR BOLT SIZE QTY. VFC-5 - VFC-5M 5/8" (16 mm) - ½" (12 mm) 4-4 VFC-15 - VFC-15M ½" (12 mm) 12 VFC-30 - VFC-30M 3/4" (20 mm) - ½" (12 mm) 8-4 VFC-60 - VFC-60M 3/4" (20 mm) 16 VFC VFC-120M 3/4" (20 mm) 16 VFC VFC-200M 1" (25 mm) - 3/4" (20 mm) 8-8 VFC VFC-300M 1" (25 mm) - 3/4" (20 mm) 8-8 VFC VFC-500M 1" (25 mm) - 3/4" (20 mm) 8-8 VFC-5MX 5/8" (16 mm) 8 VFC-15MX 3/4" (20 mm) 4 VFC-30X - VFC-30MX 1" (25 mm) 4 VFC-60X - VFC-60MX 1" (25 mm) 4 VFC-120X - VFC-120MX 1" (25 mm) 4 VFC-200X - VFC-200MX 1 1/4" (32 mm) 4 VFC-300X - VFC-300MX 1 1/4" (32 mm) 4 VFC-500X - VFC-500MX 1 1/4" (32 mm) 4 NOTE: Each installation varies. It is ultimately the customers responsibility to safely install the Flo-Coater equipment according to facility structural requirements.

11 Page 10 COMPONENT INSTALLATION After the Flo-Coater is permanently installed, the remaining components should be installed. WARNING! The Flo-Coater components range in weight. It will be necessary to use adequate lifting devices to position some of the components. Failure to use the proper lifting equipment could result in injury to personnel and damage to the equipment. EXPANSION CHAMBER (Multi) The expansion chamber is a separate chamber on the Multi Flo-Coater. The expansion chamber uses a ball/cup and pin/yoke hinge design (Figure 1). This hinge design supports the chamber and allows the expansion chamber to swing away from the Flo-Coater for cleaning and inspection. To install the expansion chamber, use a lift device rated for the weight of the component to lift the expansion chamber until the hinge halves are aligned with each other. The expansion chamber hinge must be slightly higher than the frame hinge half, so that the ball can be lowered into the cup. It helps to tilt the expansion chamber slightly toward the frame so that the ball can be lowered into the cup before the yoke makes contact with the pin.

12 Page 11 COMPONENT INSTALLATION EXPANSION CHAMBER (Continued) The hinge assembly is adjusted at the factory. DO NOT attempt to disassemble or adjust the hinge assembly. Figure 1. Hinge Assembly - Expansion Chamber

13 Page 12 COMPONENT INSTALLATION (Continued) PRODUCT CONTAINERS Most product containers (Granulator, Wurster, Rotor) are set on a portable cart. Installation of the product container consists simply of lifting the container (using the properly weigh-rated lift device) and setting it on the cart. Roll the cart to the processing position and allow the hydraulic cylinders to lift the container into place. Some product containers are designed with the same yoke/pin hinge design that is used on the expansion chambers. Install the product container using the expansion chamber instructions. INLET AIR SEAL - FOR 2 BAR UNITS The inlet air seal is to be installed along with the inlet duct assembly. Instructions for the installation of the seal and assembly are on the following pages. A pressure regulator for this seal is located in the electrical control panel for this unit. An air pressure setting of 25 PSI should be set on the regulator before installation of the air seal into the inlet duct. 12-BAR units are not equipped with an inlet air seal.

14 Page 13 COMPONENT INSTALLATION (Continued) INLET DUCT ASSEMBLY The following instructions apply to 2-BAR units only. Refer to Inlet Duct Assembly Drawing and Figure 2 Figure 2. Inlet Duct Placement 1. The INLET DUCT BRACKET (HCB-1018) will still be bolted to the rear frame cross member. Do not move this bracket as it has been properly located at the factory. 2. Place the INLET DUCT SEAL (HCC ) inside the SEAL RING WELDMENT (HCD-1613). Make sure that the air stem on the seal is in line with the hole in the face of the SEAL RING WELDMENT.

15 Page 14 COMPONENT INSTALLATION INLET DUCT ASSEMBLY (Continued) 3. Slide the SEAL RING WELDMENT over the INLET DUCT WELDMENT (HCD-2602) so that the tangs on the ring straddle the block on top of the duct. 4. Position the product container into the processing position. 5. Connect the hydraulic pump unit to the main unit with the quick disconnect couplings. 6. Apply air pressure to the hydraulic pump connection labeled UP. This will cause the Inlet Air Plenum to rise to the upper-most position. Make sure all parts of the main unit are in proper alignment. 7. Place the inlet duct in position. Make sure that the lower half of the SEAL RING WELDMENT is inside the flange of the retaining ring (located in the flange connection of the Inlet Air Plenum). The top half of the SEAL RING WELDMENT must overlap the flange of the Inlet Air Plenum. 8. Center the front rim of the INLET DUCT WELDMENT to the flange connection for the inlet air plenum. There should be a 1/2" (12.7 mm) gap between the two parts all the way around. Bolt the INLET DUCT WELDMENT to the INLET DUCT BRACKET to maintain this position. Make sure the duct is square to the inlet air plenum flange connection. CAUTION! To provide a more accurate fit and to maintain the 1/2" (12.7 mm) clearance between the inlet duct weldment and the flange connection of the air seal flange, bring the customer supplied duct work to the already installed machine. The duct work should be the correct height, level and self-supporting. Do not distort the inlet duct location when making connection.

16 Page 15 COMPONENT INSTALLATION INLET DUCT ASSEMBLY (Continued) 9. With the Inlet Air Plenum in the upper-most position (steps 4, 5, 6 and 7 above), apply 25 PSI of air pressure to the INLET DUCT SEAL (HCC ). This will make the inlet duct assembly rigid. CAUTION! Make the connection with the customer supplied duct work. The Inlet Air Plenum must be in the upper-most position with the air seal inflated when this connection is made. For the seal to inflate properly, the inlet duct work must be self-supporting and level. Do not support the duct work with the inlet duct assembly on this unit. Do not distort the inlet duct location when making connection. INLET DUCT ASSEMBLY - 12-BAR UNITS Connection to the inlet air plenum of a 12-bar unit is the sole responsibility of the customer. Ductwork and piping should be installed according to local, national and international regulations for containment of deflagrations. Suppression systems should be taken into consideration when installing supply and exhaust ductwork.

17 Page 16 EXPLOSION VENTING On Vector 12-BAR Flo-Coater systems, explosion venting is not required because the Flo-Coater is designed to contain the pressure increase that is associated with the ignition of explosive dusts and/or flammable solvents. Explosion venting is standard equipment on all Vector 2-BAR Flo-Coaters. Two different types of explosion vents are available: top vent and wall vent. On either type of vent, ducting MUST be installed between the vent and the outside atmosphere in the shortest distance possible. The duct must be made with the same geometrical cross section (round, square, rectangle) as determined by the mating flange shipped with the equipment, and the duct must be constructed in such a manner as to withstand a 2-bar overpressure. The open end of the duct must be covered with a vent cap to prevent dirt, snow, rain etc., from entering the duct and depositing on top of the explosion relief dampers. The cap may have a maximum force of Bar (1.5 kpa) to open. Please refer to U.S. standard NFPA 68 and European standard VDI3673; both provide criteria for venting of deflagrations. Explosion relief ducts should include an access door to be used for cleaning and inspection of the explosion vent assembly and/or duct. This door must be constructed to withstand a 2-bar overpressure, and securely fastened to the duct to prevent leaking. If the door is hinged, it should open into the duct.

18 Page 17 EXPLOSION VENTING (Continued) All duct seams should be continuously welded and installed to protect operators from injury, should a mishap occur. NOTE K Installation will vary with each application; therefore, design MUST comply with U.S. standard NFPA 68, European standard VDI3673 and local safety codes, ensuring proper venting of equipment. If explosion venting is a problem, another option that is highly recommended is utilization of an explosion suppression device. Explosion suppression is based on the fact that a deflagration takes a definable period of time to generate into an explosion. In short, an explosion suppression system utilizes a pressure sensor that can pick up the generation of less than 1 PSI (6.9 kpa). Upon sensing a positive pressure the sensor instantly activates the release of a special gas, powder or water and extinguishes the deflagration before it generates to the point of an explosion. It is ultimately the customer s responsibility to ensure that suppression systems are installed correctly. EXPLOSION VENT INSTALLATION Once the Flo-Coater is permanently installed, the explosion relief duct weldment needs to be installed to the top or back of the filter chamber. To install, proceed as follows (Figure 3): 1. Position the Explosion Vent Cover flange against the mating Flo-Coater Flange on the filter chamber.

19 Page 18 EXPLOSION VENT INSTALLATION (Continued) 2. Align mounting holes on the filter chamber with the mounting holes on the duct weldment, with the access door located in the desired orientations. 3. Bolt the two pieces together. 4. Install the fracture release clamps (Figure 3) to the explosion duct weldment as follows: Figure 3. Fracture Release Clamp a. Insert the threaded rod through the Flo-Coater Flange. b. Install a flat washer and hex nut on the bottom of the threaded rod, under the Flo-Coater Flange. c. Install another hex nut and flat washer on threaded rod, on top of the Explosion Duct Flange. Tighten the hex nut to the flange. d. Place a hex nut and flat washer on the top of the threaded rod.

20 Page 19 EXPLOSION VENT INSTALLATION (Continued) e. Place the fracture bar on top of the washer. Position the fracture bar so the bumper is resting on the flange of the Explosion Vent Cover or hinged door at the top of the filter chamber. f. Install another flat washer and hex nut on top of the fracture bar. g. Adjust double nuts on the upper half of the threaded rod until the split fingers of the fracture bar bottom out against the bumper. This pre-loads the fracture release clamp to 60% of the fracture rating. To double check for proper tension, measurements from the top of the fracture clamp to the bottom of the bumper should be ½" (12.7 mm). Please refer to Figure 4 and 5 below. Figure 4. Unloaded Fracture Clamp Figure 5. Loaded Fracture Clamp

21 Page 20 EXPLOSION VENT INSTALLATION (Continued) There are several fracture clamps to be installed around the flange. Repeat Step 4 for every clamp until the explosion relief cover or hinged door(s) have been installed. All remaining holes use standard ½ (13 mm) hex head capscrews and nuts. The final installation step of the Explosion Vent is to cable or attach the explosion vent cap to the duct assembly. As each installation varies, the customer is responsible for selecting the proper equipment to accomplish this. The cable is used to prevent the explosion vent cap from becoming an airborne hazard in the event of a deflagration. EQUIPMENT GROUNDING Fluidization equipment can create a static hazard if not properly designed and installed. During the process, free electrons in the product and the airstream collect within the machine and duct work. Depending upon environmental conditions, once the potential electron buildup becomes great enough, a static discharge can occur, creating an explosive hazard. To remove this risk, every part of the Flo-Coater equipment must be electrically bonded in such a way to prevent static buildup. WARNING! Removal of grounding straps or improper grounding of this equipment could cause an explosive hazard due to static discharge, causing severe injury or death to personnel.

22 Page 21 EQUIPMENT GROUNDING (Continued) Vector installs the following ground devices at the factory:! Grounding strap between the Flo-Coater inlet plenum and frame! Grounding pin between the inlet plenum and the product container. On Multi models, a grounding pin is provided between the expansion chamber and the filter chamber. When the product container is in the UP position, the grounding pin connections are made. The customer is responsible for installing the following ground devices during installation:! Grounding strap across all ductwork connections.! Earth ground from the Flo-Coater. Minimum wire size is #8 AWG stranded (i10.65mm). Install a ground lug on the frame of the Flo- Coater and connect the wire to the lug. Terminate the connection at an earth ground. After installation, the grounded system should be checked using methods outlined in European Standard EN60204 cl. 20 (International Electrotechnical Commission (IEC) 204-1). Subsequent results from this procedure will verify the adequacy of the grounded system.

23 Page 22 HYDRAULIC LIFT CYLINDERS/PUMP 12-BAR Flo-Coater units are not equipped with hydraulic lift cylinders. On standard 2-BAR Flo-Coaters, the hydraulic pump unit is used to power the hydraulic lift cylinders. These cylinders, positioned on each side of the inlet air plenum, raise the sealing ring against the bottom of the product container. The pump contains an oil reservoir and a pneumatic pump. It is recommended the hydraulic pump be located out of the processing area or room. Connect the hydraulic hoses to the supply and return connections on the hydraulic pump, then to the Flo-Coater unit. On the frame crosspiece at the rear of the unit, a shield covers the hydraulic lines. Connect the hydraulic hoses at the appropriate connection points. recommends using ISO Vg 32 grade oil for lubrication of the hydraulic pump. Maintenance procedures can be found in the vendor information located in this manual. Connect an airline to the pump. The following table lists the required air pressure regulator setting for the hydraulic pump unit to maintain 2-bar (200 kpa) integrity of the Flo-Coater unit. Check this table to determine the proper air pressure setting for your specific unit.

24 Page 23 RECOMMENDED AIR PRESSURE FOR HYDRAULIC PUMP MODEL VFC-30 - VFC-30M VFC-60 - VFC60M VFC VFC-120M VFC VFC-200M VFC VFC-300M VFC VFC-500M REQUIRED AIR PRESSURE PSI ( kpa) PSI ( kpa) PSI ( kpa) PSI ( kpa) PSI ( kpa) PSI ( kpa)

25 Page 24 EMERGENCY STOP Once a Flo-Coater has been closed, ready for processing, there are no moving parts exposed on the Flo-Coater in the process room. Consequently, an emergency stop is not required. However, some local regulations may still require an emergency stop. To install an emergency stop, mount the supplied box (containing the e-stop) in a location as dictated by local regulations. Connect the pneumatic lines to points as indicated on the Pneumatic and Piping and Instrumentation drawing, included in the Assembly Drawings section of this manual. WASH-IN-PLACE SYSTEM (WIP) The Wash-in-Place (WIP) system provides the operator with an easy method of cleaning the Flo-Coater. A WIP system may consist of one or more of the following components:! One or more spray gun assemblies that are installed at various points on the Flo-Coater! A cleaning solution delivery system! A wash recirculation system Each of the above items are options that can be provided by Vector with the purchase of the Flo-Coater. Otherwise these items are customer supplied.

26 Page 25 WASH-IN-PLACE SYSTEM (Continued) Installation of the WIP system consists of the following:! Installation of a cleaning solution delivery system! Installing a drain hose from the drain located in the bottom of the inlet plenum to the customer selected drainage site.! Interconnection of all hoses, valves and pneumatic lines between each WIP spray gun assembly and the cleaning solution delivery system. Ferrules are located on the end of each WIP tube for attachment of hose. If Vector is not providing the cleaning solution system, the following nozzle specifications will assist you in determining proper solution delivery system for the WIP nozzles. NOZZLE SPECIFICATIONS Maximum Pressure PSI Flow Range Gallons per minute

27 Page 26 WASH-IN-PLACE SYSTEM (Continued) INSTALLING WIP ASSEMBLIES The CIP assemblies are mounted in several locations on the Flo-Coater unit, including but not limited to: S One (1) at the top of the filter chamber (WIP port - the longest straight tube) S One in the middle of the filter chamber (Spray gun port - This tube has the larger flange and cutouts for the hand knobs.) S One (1) on the inlet plenum CAUTION! When installing the WIP assemblies, care should be taken to avoid hitting or banging the filter racks or hanger assemblies. Distortion of the filter racks or hanger assemblies can cause damage to filter media necessitating premature replacement of racks and filters. WIP PORTS To mount the clean-in-place assemblies in the locations where sanitary ports are used, a clamp and gasket are provided. Place gasket against assembly flange and insert nozzle and tube through the port. Position so nozzle head is aimed for maximum spray pattern coverage. Place sanitary clamp around the assembly and port flange and tighten. a. For the assembly at the top of the filter chamber, the nozzle should be aimed downwards. b. For the assembly in the inlet plenum, the nozzle should be aimed upwards.

28 Page 27 WASH-IN-PLACE SYSTEM (Continued) INSTALLING WIP ASSEMBLIES (Continued) Proper installation of the WIP assemblies is important. Spray pattern of the nozzles is affected by the alignment and placement of the nozzles in each port. Failure to install properly will result in inadequate spray pattern and inadequate cleaning of the Flo-Coater unit. All of the WIP assemblies are removable. Port plugs are provided to seal the WIP ports and spray gun port when the nozzles have been removed. FOR MAXIMUM PERFORMANCE, IT IS RECOMMENDED THAT ALL WIP ASSEMBLIES ARE REMOVED PRIOR TO PROCESSING OR DISCHARGING OF PRODUCT. INSTALLING SPRAY GUN ASSEMBLIES To mount the spray gun assembly in the spray gun port location, remove the gun port plug by loosening the hand knobs. Place o-ring in the groove of the assembly and insert nozzle and tube through the spray gun port. Tighten the hand knobs.

29 Page 28 CARTRIDGE FILTER WARNING! A Vector engineered cartridge filter should always be used with the Vector Flo-Coater. Use of other filters can result in poor process performance, shorter filter life, and loss of product and production throughput. The Vector cartridge filters are a critical engineered component of the Vector Flo- Coater System that makes a difference in the granulating, coating and drying processes that are performed in these units. After years of testing development, the Vector cartridge filter combines the right filter media, inner support, end cap adhesive, gaskets and seals, pleat design and configuration into a quality controlled and certified filter designed to provide the best possible performance. The Cartridge filter is comprised of a cylindrical metal frame supporting pleated filter material. Exhaust air passes through the Cartridge Filter before being discharged into the exhaust plenum. The Filter Pulse is designed to periodically expel accumulated product that adheres to the filter material that may eventually plugging the filter. The pulse function is accomplished by a blast of compressed air from the exhaust plenum side of the cartridge filter into the expansion chamber.

30 Page 29 PULSE AIR RESERVOIR RECOMMENDED MAXIMUM AIR PRESSURE Flo-Coater Model CAUTION! The cartridge pulse function MUST NEVER be initiated under the following conditions: 1. When the exhaust damper is fully closed or the explosion vent may blow out 2. If pulse air reservoir pressures exceed recommended maximums as defined in the following table. Excessive pressure may damage the filter. Regulator Part Number Diaphragm Valve Part Number Recommended Max. Pressure VFC-30 - VFC-30M HCA HCA PSIG VFC-60 - VFC-60M HCA HCA PSIG VFC VFC-120M HCA HCA PSIG VFC VFC-200M HCA HCA PSIG VFC VFC-300M HCA HCA PSIG VFC VFC-500M HCA HCA PSIG VFC-5MX HCA HCA PSIG VFC-15MX HCA HCA PSIG VFC-30X - VFC-30MX HCA HCA PSIG VFC-60X - VFC-60MX HCA HCA PSIG VFC-120X - VFC-120MX HCA HCA PSIG VFC-200X - VFC-200MX HCA HCA PSIG VFC-300X - VFC-300MX HCA HCA PSIG VFC-500X - VFC-500MX HCA HCA PSIG

31 Page 30 TO INSTALL CARTRIDGE FILTER(S) - 2-BAR UNITS The following procedures are for installing standard cartridge filters on 2-Bar Flo- Coaters. Please refer to Figure 6 (Single Inline Filter) or Figure 7 (Dual Inline Filters) NOTE K ALWAYS wear protective gloves prior to handling cartridge filters. Oils from skin can contaminate the filter, soiling the material and product being processed. Gloves will also protect the hands from scrapes and cuts. 1. Shut off all electrical power and air supply to the Flo-Coater. 2. Access filter mount assembly inside Flo-Coater. For inclined mounted filters, access by opening filter access doors on filter chamber. For vertically mounted filters, access by removing product container, swinging expansion chamber out of the way, and reaching up into machine. 3. Remove hand knob on end of filter support frame. 4. Insert filter through access passage. NOTE K For cartridge filters equipped with bands, it is important that bands around filter remain in the same position as shipped from the factory. Shortened filter life may result if filters are pulsed with bands out of position. 5. Position the grounding spring nut on the threaded tip of the support frame.

32 Page 31 TO INSTALL CARTRIDGE FILTER(S) (Continued) Figure 6. Single Inline Cartridge Filter Assembly Figure 7. Dual Inline Cartridge Filter Assembly

33 Page 32 TO INSTALL CARTRIDGE FILTER(S) (Continued) NOTE K For proper grounding, check the position of the grounding spring nut in this manner: 1. Without the filter installed, measure distance (A) from end of spring in its relaxed state to end of threaded tip on frame. 2. With filter pushed into position on support frame, measure distance (B) from end cap surface of hole to end of threaded tip of frame. 3. If distances B - A = 1/4" (6.35 mm) or more, the spring is properly positioned. Adjustments to the grounding spring nut are made by turning the nut in or out on the threaded tip as needed. 6. A. (Dual Inline Filters) Slide filter with two open end caps on frame first. Gently push filter up until gasket makes contact with duct. The filter should contact the upper grounding spring at the gasket and end cap edge. B. (Single Inline Filter) Slide filter onto support frame with gasketed end first. Gently push filter up until gasket makes contact with duct. The grounding spring nut should be slightly compressed against the end cap of the filter. 7. Hold filter in place and install hand knob on threaded tip. Turn hand knob while rotating filter. Continue until filter no longer rotates easily. Tighten hand knob an additional 1-1/2 to 2 turns.

34 Page 33 TO INSTALL CARTRIDGE FILTER (Continued) 8. Ensure that filter is sealed properly by placing hands on outside diameter of end cap and attempting to turn filter on frame. If filter turns, it is not properly sealed. Tighten hand knob ½ turn and recheck. CAUTION Overtightening hand knob may result in distortion of filter end cap. Figure 8. Single Inline Cartridge Filter Installed Figure 9. Dual Inline Cartridge Filter Installed

35 Page 34 CARTRIDGE FILTER LIFTING CABLES The 12-BAR units are the only Flo-Coaters equipped with the filter lifting cables. The lifting cables allow the operator to lower the filters for maintenance and then raise them again into processing position. Ordinarily the unit is shipped with the filter lifting cables in position. Some installations require removal of these cables, with the need for their installation once the machine has been permanently placed (Figure 10). The following procedure describes how to thread the wire rope from the winch assembly to the cartridge filter pivot shaft. Figure 10. Flo-Coater with Filter Lifting Cables Installed

36 Page 35 CARTRIDGE FILTER LIFTING CABLES (Continued) 1. Consult the vendor information manual for the winch (supplied in the manuals) for proper winding of the wire rope inside the winch. 2. Pull end of wire rope up to the top of the Flo-Coater frame to sheave assembly (HCA-9556). Thread wire rope through the assembly so that the wire rope lies within the pulley groove. 3. Pull wire rope through the sheave assembly toward the sheaves (HCA- 9553) on top of the Flo-Coater. 4. Thread the wire rope through the sheave assembly (HCA-9553), again making sure the wire rope lies within the pulley groove. 5. Insert the end of the wire rope into the tube at the base of the sheave assembly. (See Figure 11). Figure 11. Sheave Assy with Tube 6. Push the wire rope through this tube until it can be seen inside the filter chamber.

37 Page 36 CARTRIDGE FILTER LIFTING CABLES (Continued) There are two types of connections to the wire rope lifting cables. One connection is to the trigger snap hook. Another connection is to the bayonet clasp. S S The trigger snap hook connection is used on cartridge filter assemblies that can ONLY be raised and lowered. The bayonet clasp connection is used on cartridge filter assemblies that can spin for the WIP cleaning system. TRIGGER SNAP HOOK CONNECTION - RAISING AND LOWERING OF FILTERS ONLY 1. Pull wire rope down to the trigger snap hook on the filter hanger assembly. Strip nylon coating from end of wire rope and loop through the trigger snap hook as shown. (Figure 12) Figure 12. Trigger Snap Hook

38 Page 37 CARTRIDGE FILTER LIFTING CABLES (Continued) TRIGGER SNAP HOOK CONNECTION - RAISING AND LOWERING OF FILTERS ONLY (Continued) 2. Crimp compression sleeve once using a compression tool. 3. Trim end of wire rope close to sleeve. 4. Remove knob from end of filter hanger assembly. 5. Install cartridge filter on hanger assembly. 6. Replace knob. 7. Repeat procedure for each filter.

39 Page 38 CARTRIDGE FILTER LIFTING CABLES (Continued) BAYONET CLASP CONNECTION - FOR RAISING AND LOWERING OF SPINNING FILTERS 1. Pull wire rope down to the bayonet clasp on the filter pivot assembly. 2. Press the pin out of the pivot shaft. 3. Strip nylon coating from wire rope and thread rope through the pivot shaft bore. 4. Crimp compression once using a compression tool. 5. Trim end of wire rope close to sleeve. 6. Pull wire rope loop into pivot shaft bore. 7. Press pin into pivot shaft through wire loop. 8. Wire rope should look like example in Figure 13. Figure 13. Filter Pivot Assembly

40 Page 39 TO INSTALL CARTRIDGE FILTER(S) - 12-BAR UNITS The following procedures are for installing cartridge filters on 12-Bar Flo-Coaters. NOTE K ALWAYS wear protective gloves prior to handling cartridge filters. Oils from skin can contaminate the filter, soiling the material and product being processed. Gloves will also protect the hands from scrapes and cuts. 1. Lower each cartridge filter assembly by accessing the Filter Control function key on the Operator Interface Panel. 2. Access filter mount assembly inside Flo-Coater. For vertically mounted filters, access by removing product container, swinging expansion chamber out of the way, and reaching up into machine. 3. Release snap hook or bayonet clasp. Remove hangar assembly from machine. 4. Remove hand knob on end of filter hanger assembly. 5. Insert hanger assembly into filter so that threaded end protrudes through the small hole in the closed end of filter. NOTE K For cartridge filters equipped with bands, it is important that bands around filter remain in the same position as shipped from the factory. Shortened filter life may result if filters are pulsed with bands out of position. 6. Replace hand knob on threaded tip. Turn hand knob until tightened. 7. Place filter and hangar assembly into machine. Reconnect snap hook or bayonet clasp.

41 Page 40 TO INSTALL CARTRIDGE FILTER(S) - 12-BAR UNITS 8. Raise the filter by accessing the Filter Control function key on the Operator Interface Panel. The winch will draw the filter lifting cable up through the exhaust duct until the wire sensor senses the preprogrammed distance has been reached. A timer is initiated to keep the winch motor running an additional five seconds to ensure that the filter is completely seated into the exhaust duct. (Figure 14) Figure 14. Cartridge Filter Installed 9. Repeat the above procedure for each cartridge filter.

42 Page 41 TO REMOVE STANDARD CARTRIDGE FILTER 1. Shut off all electrical power and air supply to the Flo-Coater. 2. Access filter mount assembly inside the Flo-Coater. For inclined mounted filters, access by opening the filter access doors on the filter chamber. For vertically mounted filters, access by removing the product container, swinging the expansion chamber out of the way, and reaching up into the machine. 3. Hold filter(s) in place and remove hand knob. 4. Slide filter(s) from support frame. 5. Grounding spring nuts should remain on the filter support rack to maintain adjustments made earlier. 6. Remove filter(s) from machine through access. TO REMOVE 12-BAR CARTRIDGE FILTERS 1. Lower each cartridge filter assembly by accessing the Filter Control function key on the Operator Interface Panel. 2. Swing expansion chamber out of processing position to access filters. 3. Remove hand knob from bottom of hanger assembly. 4. Slide the hanger assembly out of the cartridge filter. 5. Replace hand knob on hanger assembly to avoid misplacing the hand knob.

43 Page 42 FILTER CARTRIDGES - 12-BAR UNITS WITH FILTER CYLINDERS The following procedures are for installing cartridge filters using filter cylinders for 12-Bar Flo-Coaters. NOTE K ALWAYS wear protective gloves prior to handling cartridge filters. Oils from skin can contaminate the filter, soiling the material and product being processed. Gloves will also protect the hands from scrapes and cuts. 1. Remove the product container. K Make sure filter cylinders are in the lifted position before opening or closing the Expansion Chamber. 2. Swing expansion chamber out of processing position to access filter cylinder. 3. Lower the filter cylinders by accessing the Filter Control function key on the Operator Interface Panel (Figure 15). Figure 15. Filter Cylinder

44 Page 43 FILTER CARTRIDGES - 12-BAR UNITS WITH FILTER CYLINDERS (Continued) 4. Insert filter rack into the top of the filter (Figure 16). 5. Screw hand knob to the bottom of the filter (Figure 17). 6. Insert pin hair cotter through hole on the rack (Figure 17). Figure 16. Inserting Rack Figure 17. Hand Knob with Pin Hair Cotter

45 Page 44 FILTER CARTRIDGES - 12-BAR UNITS WITH FILTER CYLINDERS (Continued) 7. Connect top of filter rack to filter cylinder by inserting the pin safety snap through the filter cylinder shaft (Figure 18). Figure 18. Pin Safety Snap Connection 8. Lift filters into place by accessing the Filter Control function key on the Operator Interface Panel (Figure 19). Figure 19. Filter in Place

46 Page 45 TO REMOVE 12-BAR FILTERS WITH FILTER CYLINDERS NOTE K ALWAYS wear protective gloves prior to handling cartridge filters. Oils from skin can contaminate the filter, soiling the material and product being processed. Gloves will also protect the hands from scrapes and cuts. K Make sure filter cylinders are in the lifted position before opening or closing the Expansion Chamber. 1. Swing expansion chamber out of processing position to access filters. 2. Lower the filters by accessing the Filter Control function key on the Operator Interface Panel. 3. Remove filter by removing pin safety snap from filter cylinder shaft. 4. Replace pin safety snap to filter rack to avoid misplacing it.

47 Page 46 SURFACE TEMPERATURE/NOISE LEVELS It is recommended that after installation, a check for surface temperatures and noise levels be conducted. Variances in air circulation, process temperatures, and installation from one environment to another may increase/decrease surface temperatures and noise. If excessive temperatures or noise levels are found, the customer is responsible for marking the equipment and notifying personnel in the appropriate manner. SPOTLIGHT An optional accessory available with the Flo-Coater equipment is a hand held spotlight. The spotlight is a 12 volt, high intensity, 50 watt, 100,000 candlepower sealed beam lamp. The aluminum, lightweight guard is cast from high impact, non-sparking alloy. The spotlight is used for illuminating the interior of the Flo- Coater through the viewing windows. Because installations vary, Vector does not supply the power cord for the spotlight. The customer must determine the acceptable length of the power cord needed and make the connection between the selected power cord and the spotlight. Vector recommends a 16/3 SOW (S=Service cord, 0=Oil resistant, W=weather and water resistant) power cord. Figure 20. Spotlight

48 Page 47 SPOTLIGHT (Continued) To install power cord follow these steps : 1. Unscrew the bottom section of the light from the top section. 2. Remove the boot from bottom of the top section. 3. Using needle-nose pliers reach into the bottom of the top section and pull the plug out. 4. Loosen the two screws on the bottom section. 5. Unscrew the end piece from the bottom section and remove the tube. 6. Feed cord through the end piece, tube and bottom section. 7. Attach cord leads to terminals on plug. 8. Reinsert the plug into top section. 9. Reinsert the boot to the bottom of the plug. 10. Screw bottom section back onto the top section. 11. Screw end piece back onto the bottom section. 12. Tighten the two screws on the bottom section. Figure 21. Spotlight Parts Call-out

49 Page 48 SYSTEM MAINTENANCE Scheduled maintenance outlined in this section should be used only as a guideline. Maintenance histories and protocol assigned by the customer should ultimately be used to determine scheduling of maintenance. FLO-COATER - EXTERIOR The exterior of the Flo-Coater can be cleaned using a soft cloth with a mild detergent. The exterior should be cleaned weekly to avoid build up of residue. Careful inspection of all window gaskets, and port assemblies should be made. Replacement of gaskets should be made periodically to maintain good seals. FLO-COATER - INTERIOR The interior of the Flo-Coater should be inspected with every product change. Product residue can cause cross-contamination. Although a clean-in-place system is effective when cleaning the interior, product can invade small places around the gun ports and windows. SUPPRESSION SYSTEMS - 2 Bar Units The Suppression system should be checked as recommended by the manufacturer of the system. Please refer to the vendor information provided with this manual or contact the manufacturer directly.

50 Page 49 SYSTEM MAINTENANCE PRODUCT CONTAINER Reference the Product Container and Cart Assembly Drawings when removing the product container from the Flo-Coater. The product container should be cleaned daily. Careful inspection of the plate conidur during cleaning is advised. Any build-up of material will restrict process air and produce undesirable characteristics during fluidizing. DISASSEMBLY INSTRUCTIONS FOR 2-BAR UNITS: 1. Lower the product container by accessing the Container Control function key on the Operator Interface Panel. 2. Unlatch the clamps between the filter chamber (or the expansion chamber on the multi units) and the product container. 3. Pull the cart away from the Flo-Coater. 4. Remove the gasket form the bottom of the filter chamber. (For multi units, remove the gasket from bottom of expansion chamber and filter chamber.) 5. Install screen support rods into the (4) four holes on the cart. 6. Release screen support latches and flip the latches up. CAUTION To avoid scraping and damaging the conidur plate on the metal static pin always pull plate out from the handle end of cart. 7. Remove conidur plate from the handle end of the cart. 8. Remove screen support. 9. Remove the gasket from the screen support. 10. Remove gasket from the bottom of the product container. 11. Proceed to cleaning instructions.

51 Page 50 SYSTEM MAINTENANCE PRODUCT CONTAINER (Continued) DISASSEMBLY INSTRUCTIONS FOR 12-BAR UNITS: 1. Lower the product container by accessing the Container Control function key on the Operator Interface Panel. 2. Unlatch the clamps between the filter chamber (or the expansion chamber on the multi units) and the product container. 3. Pull the cart away from the Flo-Coater. 4. Remove the gasket form the bottom of the filter chamber. (For multi units, remove the gasket from bottom of expansion chamber and filter chamber.) 5. Install screen support rods into the (4) four holes on the cart CAUTION To avoid scraping and damaging the conidur plate on the metal static pin always pull plate out from the handle end of cart. 6. Unbolt the bolts from the bottom of the product container. 7. Remove conidur plate from the handle end of the cart. 8. Remove the gasket surrounding the conidur plate. 9. Remove screen support. K To easily remove gasket from inlet plenum, at the operator interface, inflate the seals. 10. Remove the gasket from the inlet plenum. 11. Remove gasket from the bottom of the product container. 12. Proceed to cleaning instructions.

52 Page 51 SYSTEM MAINTENANCE PRODUCT CONTAINER (Continued) CLEANING INSTRUCTIONS When cleaning between batches of the same product it is only necessary to clean conidur plate, screen and gaskets throughly. When a product change occurs clean ALL parts to avoid cross contamination. CAUTION NEVER use sandpaper, wire brushes or an abrasive cloth to clean the product container and/or product screens. Damage to the surfaces will result. Wipe the inside of the container free of residue using a soft cloth, mild detergent and warm water. Wash the conidur plate, gaskets and the screen support using a soft cloth, mild detergent and warm water. It may be necessary to soak the conidur plate to loosen product. Make sure the screen support, conidur plate and container are thoroughly dry before processing.

53 Page 52 SYSTEM MAINTENANCE PRODUCT CONTAINER (Continued) REASSEMBLY INSTRUCTIONS Follow disassembly instructions in reverse order to reassemble. When replacing the conidur plate make sure the side stamped UP is facing up (Figure 20). Figure 20. Stamp on product screen Also, if applicable, the cut-out notch should be lined up with the discharge port (Figure 21). Figure 21. Alignment of notch

54 Page 53 SYSTEM MAINTENANCE GROUNDING CONNECTIONS The grounding connections on the Flo-Coater should be checked periodically at weekly intervals. All debris should be removed from the connection and a continuity check should be performed. Good contact points are necessary to make a good ground connection. Check the grounding connections by using an ohmmeter to check each connection. An impedance measurement of less than 1 ohm is acceptable. If the ohm readings are greater than 1 ohm, reinstall the ground, or clean the connection. Check all ground points: Product Container to frame Cartridge Filter Grounding Spring All ductwork connections

55 Page 54 SYSTEM MAINTENANCE WASH-IN-PLACE SYSTEM The Wash-in-Place (WIP) system provides the operator with an easy method of cleaning the Flo-Coater. A WIP assembly consists of a tube equipped with a nozzle head. All surfaces of the Flo-Coater unit are within the spray pattern of the nozzle. Designed for either temporary or permanent placement, the WIP assemblies are easily removed for periodic cleaning and maintenance. Minimal maintenance is required for the WIP assemblies. Inspection of the flange gaskets and o-rings upon every installation of the assemblies will reveal cracked or brittle parts. Replace these parts as often as necessary to maintain the proper seal against the Flo-Coater. The nozzles and tubes separate for cleaning. These parts can be washed with a mild, soapy solution. The cartridge filters may be removed from the Flo-Coater for separate care and maintenance if desired. INLET AIR HANDLING UNITS Please refer to the vendor information for each component of the air handling unit for specific instructions on the maintenance of exhaust blowers, steam units, valves, etc.

56 Page 55 SYSTEM MAINTENANCE CARTRIDGE FILTER CARE AND MAINTENANCE A filter maintenance program should be initiated to prolong the life of the filter and to properly maintain a consistent filtering environment for the processing system. Some general maintenance procedures will help to accomplish this. DO NOT drop filter(s) on end caps or sides. S Bent end caps could cause seal failure. S A damaged inner core could prevent proper alignment on filter(s) support frame. DO NOT slide filter(s) over sharp or abrasive surfaces. S Media damage may result. S Band breakage or movement out of position may result. DO NOT overtighten hand knob. S Warping of filter(s) may occur. DO NOT pulse filter(s) with greater than recommended maximum pulse air reservoir pressure. ALWAYS clean filter(s) on a regular basis. Follow cleaning procedure guidelines outlined in the following pages. ALWAYS replace filter(s) if following conditions exist: S Tears in media have occurred. S Band is broken or will not stay in position. S Silicone adhesive or gasket is cracked, or beginning to deteriorate. S Particles become imbedded and are not removable. S Diminished airflow capacity and higher pressure drops are experienced.

57 Page 56 SYSTEM MAINTENANCE Removal of the cartridge filters from the Flo-Coater is not necessary when using a Wash-in-Place (WIP) system. Spray nozzles are directly aimed for cleaning filters mounted on a pivot assembly, spinning the filter as it is cleaned. As in all cleaning procedures, the customer is ultimately responsible for determining if the cartridge filters are thoroughly cleaned in order to prevent cross-contamination of product. Optional cleaning methods are offered in this text. REMOVAL OF STANDARD CARTRIDGE FILTER 1. Shut off all electrical power and air supply to the Flo-Coater. 2. Access filter mount assembly inside Flo-Coater. For inclined mounted filters, access by opening filter access doors on filter chamber. For vertically mounted filters, access by removing product container and reaching up into machine. 3. Hold filter(s) in place and remove hand knob. 4. Slide filter(s) from support frame. 5. Grounding spring nuts should remain on filter support rack to maintain adjustments made earlier. 6. Remove filter(s) from machine through access. TO REMOVE 12-BAR CARTRIDGE FILTER 1. Lower each cartridge filter assembly by accessing the Filter Control function key on the Operator Interface Panel. 2. Swing expansion chamber out of processing position to access filters. 3. Remove hand knob from bottom of hanger assembly. 4. Slide the hanger assembly out of the cartridge filter. 5. Replace hand knob on hanger assembly to avoid misplacing the hand knob.