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Safety

Think and act in a safe manner. Always disconnect power and use a lockout before you work on the E-coat system, or any of the related subsystems. Observe any confined space conditions. Use the appropriate safety equipment and clothing for the task. Please carefully read all the instructions listed below to familiarize yourself with the project before attempting to perform any of the work.

Introduction

This manual provides the user with general information needed to install, operate, and maintain the Standard Cell Circulation System (SCCS). For experienced end users you may refer to the SCCS Quick Start Guide. The Description and Function and Installation Sections describe the function of the SCCS and the various system input requirements. Installation and operation of the SCCS are discussed in the following sections. Finally, the remaining sections describe the servicing of the SCCS. It is recommended that the user also carefully review the TECTRONTM Membrane Electrode (ME) Cell or One+ C Cell "Getting Started Manual", as well as the major component manuals that are supplied with each product. While every SCCS contains the same basic components and embodies a similar design, the physical dimensions and component selection depend upon the user's paint system. This particular model has been designed to operate efficiently with ME Cells. The user will find at the end of this manual drawings and specifications that apply to their particular system.

Description and Function

The function of the SCCS is to provide a flow of electrolyte to each Cell, which automatically purges excess neutralyzer (for cathodic ED Paint – its acid and for anodic ED Paint – its amine) from the system and also cooling the electrode. The former is achieved by adding deionized (DI) water to the SCCS tank when the conductivity level rises above a preset level. This dilutes the electrolyte concentration in the SCCS tank and causes the tank to overflow to drain, thereby removing the excess electrolyte from the system. The Pump Discharge Design Flow Rate (refer to appendix for these charts) is designed to provide adequate cooling for the electrodes. Flow rates below the Pump Discharge Design Flow Rate will most likely result in faster electrode corrosion rates. Generally the more flow there is, the longer the electrodes will perform satisfactorily.

Refer to the SCCS Flow Diagram (refer to appendix for drawing 997127). After leaving the discharge of the pump, the electrolyte then flows through a check valve. From this point the electrolyte flows through local piping to the electrolyte supply manifold on the sides of the paint tank.

Each ME Cell has an individual supply valve. The electrolyte fluid is delivered to the bottom of the ME Cell by the electrolyte supply tubing attached to the electrode. Electrolyte overflows by gravity back into the electrolyte return manifold through the overflow nozzle and electrolyte return tubing. There should be an air gap between the overflow tubing and the hole in the electrolyte return manifold or a vent in the return manifold to let air escape. The electrolyte then returns by local piping back to the SCCS. The electrolyte conductivity is monitored by a sensor that is located in the SCCS tank.

Whenever the conductivity level in the tank rises above the preset level, relay contacts in the conductivity monitor/controller send a signal to a Solenoid valve to open and let DI water into the electrolyte tank. The tank level is maintained by an overflow and thus the conductivity level is reduced by the addition of the DI water. When the conductivity level has fallen below the set point, the DI water turns off. A bottom tank drain valve is provided when manual draining of the tank is required. A low liquid level alarm switch in the tank provides a means to detect a loss of electrolyte fluid.

The DI water circuit includes a solenoid valve that has a manual over-ride (i.e. can open the valve with use of electrical power). The other valve is used to isolate the Solenoid valve, in the event servicing is required.

The composition of the electrolyte is mostly neutralizer and water. This is so because the ion-selective membrane that is part of the ME Cell allows the charged ions to pass from the paint bath into the electrolyte solution, thus removing the excess neutralizer or solubilizer from the paint bath.

Included in the Shipment

Included in the shipment are the following items: skid with the system; loose items (by-pass piping leg, conductivity controller, DI Water Assembly, low level sensor; Certification & Inspection Report for PN 221010 and System (i.e. CCS1), and Getting Started CD that contains the PDF files.

Unpacking Instructions

Use a phillps head screw driver to remove screws. Do not use a crow bar to pry wood pieces apart. The first step is to remove the cellophane from the unit. Step 2 is the unscrew the top wood cross members and set aside. Cut the banding that secures the tank. Next is to remove any loose items from inside the tank and set aside. Next remove the wood uprights at each corner. The unit can now be gently removed from its wooden skid. Remove any packaging that is protecting open pipes, or pressure gages (if orderd), etc. Use the match mark drawing shown on the tank cover to re-assemble as required. Lastly review all the steps and make sure the unit is fully unpacked and ready for the connection of services.

System Requirements

The necessary requirements that enable the SCCS to function properly are: DI water, electrical power (motor and starter, conductivity monitor/controller, and Solenoid Valve), proper drain, suitable location, and siphon breaker. Most of these items are the responsibility of the user.

DI Water

The incoming flow rate of the deionized (DI) water should be in the range of 40-60% of the electrolyte pump capacity. This will ensure an orderly mixing of the DI water and the electrolyte solution, such that the conductivity can be lowered at a predictable rate. The incoming pressure of the DI water should not exceed 50-60 psi which is the upper limit for the Solenoid Valve. It is also possible to use Reverse Osmosis water for make-up purposes too.

Electrical

An electrical line of the proper voltage and number of phases should be brought to the SCCS. The user must supply the appropriate motor starter, start switch, and disconnect switch at a location of their choosing and in compliance with national & local electrical codes. Likewise, line power must be supplied to the conductivity monitor/controller and to its relay contacts. The Solenoid valve cable harness has been attached, but must be connected to the conductivity monitor/controller after the unit has been installed at the site. Lastly, the grounding stud on the tank should be connected to a local ground.

Proper Drain

There is a Tee fitting that combines the gravity overflow and the bottom tank drain. This should be connected to a suitable local drain. It is important that there be no reduction in pipe size of the overflow drain line to avoid unnecessary piping restrictions that could cause the tank to overflow out the top of the tank.

Suitable Location

A close and level location should be identified near the ED paint tank. The SCCS should be placed as close as possible to the paint tank to minimize the friction loss in the local piping. It is important to note that the liquid level in the electrolyte tank should be at least 8-18" below the bottom of the return manifolds (measured at the last Cell on the low end of the return manifold). This differential is necessary because the electrolyte return flow depends on gravity to propel it back to the tank. Also, the SCCS must be located so that the SCCS tank level is no more than 10 feet below the ED paint tank level. This is usually the maximum level differential allowed for in the SCCS pump design.

Siphon Breaker.

A siphon breaker must be provided to ensure that the ME Cells are not drained of their electrolyte fluid because the fluid inside them has been siphoned if the pump is turned off. If the Cells are drained, it is likely that the draw-down inside the electrolyte tank will trip the low level alarm switch after the pump is restarted and then more DI water and acid will have to be added to refill the tank. If UFS Corporation supplied the Supply and Return Manifold, these siphon breakers are already included in the kit. See Drawing Number 997149 in the Appendix.

Installation

This section details the sequence of installation steps to be taken to ensure a good working installation. The installation sequence consists of setting the tank, re-assembly of the PVC piping and electrical installation.

Setting the Tank

1. Carefully remove the crating, making sure to locate any items that may have shipped loose. Remove all exposed nails from the packing crate.
2. Set the tank on a flat, level concrete floor no more than 3 M (10') below ED tank rim.
3. Place the conductivity controller at eye level no farther than 1.5 M (60') from the pump/motor.

PVC Piping Re-assembly

1. Follow installation match mark locations for Piping Re-assembly. (see appendix for match mark drawing)
2. The PVC strainer does not have to pointing down to function properly.

Electrical Installation

Think and act in a safe manner. Always disconnect power and use a lockout before you work on the E-coat system or any of the related sub systems. Observe any confined space conditions. Use the appropriate safety equipment and clothing for the task.

1. Install per local and national electrical/safety codes.
2. Bring three phase, 460V line power to pump motor through an appropriate sized motor starter and disconnect switch.
3. Connect the DI Water Solenoid to the conductivity controller. Be sure to connect the to the terminal strip points. (see attached drawing 221010)
4. UFS has set the conductivity set point prior to shipping for each customer. Please see the included Inspection & Certification Report.
5. NOTE: If the conductivity sensor cable needs to be extended, Call UFS to exchange the existing sensor for one with a longer cable (there will be a modest charge due to the longer cable length). UFS does not recommend that the cable be spliced to make it longer.
6. Connect the low tank switch to an appropriate alarm circuit. . (see attached drawing 221010) NOTE: This switch as a 20 VA rating.
7. Attach ground wire from each location shown in attached drawing to an appropriate earth ground . (refer to attached drawing in appendix)

Installation Checklist

Start-up and commissioning is comprised of flushing the entire electrolyte system, checkout, and initialization of all equipment and components.

System Check-Out Checklist

• Remove any hold-downs, packing materials or restraints used to protect equipment during shipment.
• Compare all connections to and from the SCCS with the general arrangement shown on the Product data, flow schematic, and electrical wiring diagrams for accuracy.
• Bump motor and observe rotation. Motor rotation should be same as arrow on motor housing.
• Fully rotate all control valves to ensure proper operation. Turn all valves OFF.
• The ME Cells should already be checked out and filled with DI water.

System Flushing and Cleaning Checklis

• Fill tank by using the DI Water switch located on the Conductivity Controller Panel until water fills Tank to ~¾” full.
• Open Pump Suction Valve and bump motor. (do not bump motor without having primed the pump with DI Water.
• Open bottom tank drain valve and empty the tank. Use a DI water hose to empty the tank of any sediment left on the bottom of the tank. Close bottom tank drain valve and refill tank with DI water.
• Close all the electrolyte supply manifold valves controlling flow to the ME Cells.
• Remove the electrolyte supply (at the supply valve Hose barb) and at the return tubing (at the return manifold connection) of the Cell furthest away from the SCCS on both sides of the tank. Take two scrap pieces of 3/8" ID PVC tubing. Create a temporary jumper by placing one end over the supply valve hose barb and place the other end into the return manifold opening. Repeat for other side. Now crack open the supply valves just enough to let air escape.
• Use the DI Water switch located on the Conductivity Controller Panel to fill tank again to ~3/4 full. Turn on pump. Slightly open the pump discharge control valve to approximate the incoming DI water flow rate. Turn off the manual DI water control valve when the return manifold begins to overflow back into the tank. Fully open the two supply valves only after all the air has escaped. Open the pump discharge valve to increase the flushing of the manifolds. Flush for 5-10 minutes. Turn pump off.
• Open bottom tank drain valve and empty tank. Use a DI water hose to empty the tank of any sediment left on the bottom of the tank. Close drain valve.
• Repeat the steps to flush the manifolds a second time. Before turning off pump for the second time, turn all supply valves OFF (except for siphon breaker valves) and check all the supply manifolds for leaks.

System Start-up Checklist

• Use the DI Water switch located on the Conductivity Controller Panel to fill tank again to ~3/4 full. Turn on pump. As tank level decreases use the DI Water switch to replenish the tank until DI Water fluid begins to overflow into the tank from the return manifold.
• Add enough acid (for cathodic paints, as specified by paint supplier) to the electrolyte tank to increase the conductivity to 80-90% of the paint manufacturer's recommended level.
• Open all the individual ME Cell supply valves and adjust the flow rate according to the minimum established by UFS. If using UFS flowmeter 225010 or 225042 then adjust the flow so the ball is below the upper black line.
• Use a PVC Pipe to gently push the Low Level Float to its full down position. Check to make sure the customer supplied alarm is working. UFS recommends this signal also be used to shut down the pump via the customer supplied starter.

Maintenance

Periodically inspections of the SCCS should include checking the pump suction strainer to make sure it is clean, ensuring that there are no obstructions blocking either the supply or the return pipes to the electrolyte tank, and confirming that the conductivity set point is adjusted properly. For further information on normal operation and maintenance procedures, the user should read the component operation manuals supplied in the Appendix.

Trouble Shooting

Please see the trouble shooting section in the Appendix

Spare Parts and Accessories

The Major Component List is shown below. This list includes the user serviceable items in your SCCS system.

Safety

• A safe work environment is of utmost importance to UFS Corporation; therefore, we recommend that our customers:
• Design and implement a comprehensive health and safety program that includes training on working with electrical and chemical equipment.
• Design and implement a lockout, tagout program for maintaining ED equipment.
• Conduct on going training for ED employees that encompasses system installation, operation, and maintenance for UFSc components and other ED equipment.
• Post adequate warnings at the job site including labels and tags on energized circuits.
• Use proper techniques to lift heavy objects and wear the appropriate clothes and safety equipment for the task at hand.
• Upon request, MSDS sheets for appropriate chemicals are available from UFS Corporation.

Warranty

We warrant all equipment manufactured by UFSc to be free from defects in material and manufacture at the time of shipment for a period of one (1) year from the date of shipment. We will furnish without charge, but not install, replacements for such parts as we find to have been defective. This warranty shall not apply to any equipment which has been subjected to misuse, neglect or accident, or has been altered or tampered with, or if corrective work has been done thereon without our specific written consent. No allowances will be made for such corrective work done without such consent. Improper maintenance, deterioration by chemical action, and wear, do not constitute defects.

Equipment manufactured by others, and included in our offering, is not warranted in any way by us but carries only the manufacturer’s warranty, if any. All ME Electrodes (and or cathodes), of any material, are not warranted by us in any way since they by nature are sacrificial and will erode or corrode away with time.

All warranty claims must be submitted within ten (10) days of discovery of defects or shall be deemed waived. All parts returned for inspection must be sent prepaid. No representative of our company has any authority to waive, alter, vary or add to the terms hereof without prior approval in writing. The foregoing is in lieu of all other warranties (including that of merchantability), whether express or implied.

Liability

It is expressly understood that our liability, including that for breach of contract, negligence, strict liability in term, or otherwise for our products is limited to the furnishing of such replacement parts, and that UFSc will not be liable for any expense, injury, loss or damage, whether direct or consequential, including but not limited to loss of profits, production, increased cost of operation, or spoilage of material, arising in connection with the sale or use of, or inability to use, our equipment or products for any purpose, except as herein provided.

Appendix

• Trouble Shooting, Bulletin 990171
• Electrolyte Flow Schematic
• ME Cell Flow Rates
• Typical SCCS Product Drawings
• Field Re-Assembly Installation (using match mark) Guide
• Conductivity Controller Wiring Drawing
• Solenoid Valve Drawing
• Siphon Breaker
• Typical Spare Parts List
• Manufacturer’s Manuals

BULLETIN 994105