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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.

Required Materials

• Kraft Paper or Newspaper
• Scissors
• Graduated Cylinder
• Side Cutters
• Saw Horses

  Required Tools

• Membrane Shell Repair Kit (PN 164023)

  General

  It may occasionally become necessary to repair the TECTRON Membrane Electrode (ME) Shell due to parts or other foreign matter puncturing the Membrane. There are currently two designs of ME Shells you may be repairing: Non-Guarded and Guarded. Keep in mind that the repair procedure is intended for smaller punctures, not large tears or a great amount of Membrane damage. If there are any questions about whether your damaged ME Shell can be repaired, please call UFSc at the number below.

  Procedure

  • Safety First
  1. Turn off the system power and lockout the DC rectifier with your own lock.
  2. Remove the ME Electrode from the ME Shell. Rinse the ME Electrode and allow it to dry.
  • Repairing Non-Guarded Shells
  1. Carefully cut back the Wrap about 12 mm (1/2”) from the Membrane puncture. The wrap is the spiral looking material that covers the Membrane.
  2. Clean off all the dirt or dried paint solids from the uncovered area. Wind the patch (P/N 100002 - same material as wrap) around the circumference of the ME Shell. Cut the patch so that it overlaps itself by 25-50 mm (1” - 2”).
  3. Mix the two part epoxy (one part P/N Z07001 Hardener - two parts P/N Z070002 resin) and allow it to sit for 15 minutes.
  4. Pour a generous amount of epoxy on the punctured Membrane area and spread around with the wooden sticks (P/N Z121013). Pour a bead of epoxy 100 mm (4”) long line with the axis of the ME Shell about 50 mm (2”) from either side of the punctured area. 
  5. Place the edge of the patch over one of the beads of epoxy. Allow the epoxy to thoroughly penetrate the patch before proceeding.
  6. Wind the patch around the ME Shell. Pour more epoxy on the patch covering the punctured areas.
  7. Pour another bead of epoxy on the inside edge of the patch and attach it to the ME Shell. Use your hands to gently work the epoxy through all layers of the patch, making sure the patch is firmly attached to the ME Shell.
  8. Begin applying the yellow PVC tape (P/N Z110005) to the center of the patch. Continue to wrap the tape tightly and remove all air bubbles. Repeat this step with the other side of the patch.
  9. Place the ME Shell in a temperature controlled room (75° - 80°F). Place the ME Shell on saw-horses so that the punctured area faces the floor. Allow the epoxy to cure for 24 hours.
  10. After 24 hours remove the tape and apply the wire ties (P/N 245002) to the patched areas for added support.
  11. Stand the ME Shell up on end in a bucket and fill to the overflow nozzle with D.I. water. Wait for 30 minutes to allow the membrane to absorb the water. Monitor the leak rate. If the ME Shell is leaking less than 200 ml/hour, then the ME Shell is acceptable for use in an e-coat tank.
  • Repairing Guarded ME Shells
  1. Carefully cut and remove the guard about 90 mm (3-1/2”) above and below the center of the punctured area of Membrane.
  2. Complete steps 1 through 10 in above.
  3. Open the replacement guard (If repairing 1-1/2” model, use P/N 080013 for replacement guard. If repairing 2” model, use P/N 080016 for replacement guard.) and center it over the punctured area. Use the small wire ties (P/N 245002) to secure the guard to the ME Shell.

  Complete step 11 above.

• Video Procedure

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  Media:Abatron.pdf

  BULLETIN 990128