New Uses for TruIDL™ E-Coat Process Data Logger

We are discovering new uses for the TruIDL E-coat Process Data Logger. A recent run at a customer’s E-coat tank uncovered an issue with the DC Rectifier. The chart of Voltage Vs time showed evidence of very high AC ripple. Afterward an electrician measured the AC and DC voltage of the rectifier and confirmed the high level of AC ripple.

AC ripple is always going to be present in the DC output of the rectifier and should be under 5 %. Under 1% would be ideal. AC ripple is present because the DC power is made from AC current. Usually there is a filter bank, or equal, in the design of the rectifier that tries to minimize the amount of AC ripple. Sometimes these components fail and need to be replaced.

In an E-coat system with 5% or less AC ripple the curves of Voltage Vs time will look smooth and be generally upward trending, as shown below. Once the sensor moves past the last anode cell the voltages will begin to fall off.

On the other hand, if the AC ripple is not being suppressed because of some trouble in the rectifier, the curve of Voltage Vs time will look a lot different, as shown above. Note there is only one sensor curve being shown to improve clarity for this example.

In the situation above the AC ripple was measured at about 48%. The detrimental affects of AC ripple are:

• loss of efficiency – not all the time is being spent at the required voltage.
• paint film defects – if the voltage peaks get high enough, film defects may begin to occur.

With this information, the customer is empowered to take the appropriate steps to correct deficiencies with their E-coat electrical system.

Standard Anodic E-coat Element Cleaning Procedure Using Power Flux Concentrate

Please read all the instructions listed below carefully to familiarize yourself with the project before attempting to perform any of the work or unpacking any further.

Required Materials and Tools:

1. Paint Company Approved Cleaning Solution
2. Power Flux Concentrate

Although the mechanics of the cleaning procedure is generally the same for most systems, the following procedure is specific to the Power Flux Concentrate cleaner chemistry. The procedure is based on cleaning one eight inch or two six inch cartridges at a time with an individual cartridge cleaning system. You should feel free to modify the mechanics – not the chemistry – to accommodate your specific cleaning system.

1. Isolate the cartridge to be cleaned from the paint manifolds (feed, return, and permeate).
2. Initial Flush Procedure:  Drain paint from the cartridge and follow up with a D.I. water flush to drain. Cartridge should be flushed until water runs clear. If the flush is to be done using a tank and a pump, adjust the pH to the paint tank (or lower) is preferred.
3. Final Flush Procedure:

Fill: cleaning tank with D.I. water and adjust pH to approximately 11.0

Open: cleaning return

Open: permeate to cleaning tank

Close: cleaning feed

Start Pump: slowly open the cleaning feed valve

Circulate pH adjusted D.I. water at ambient temperature for about 5 minutes and drain. Close the cleaning inlet valve.

1. Preparation of Cleaning Solution:  Prepare a 200-liter cleaning solution by mixing the cleaner in the cleaning tank based on a 99:1 dilution. The 200-liter quantity is based on the cleaning of one eight or two six inch cartridge at a time.  NOTE:  Be sure to leave at least 20 cm of space at the top of the cleaning tank to accommodate foaming.

Example:  2 liter Power Flux Concentrate + 198 liter D.I. water = 200 liter solution

1. Cleaning Procedure:  Raise the temperature of the cleaning solution to 100-105 degrees Fahrenheit either by heating or closed loop circulation. When the solution reaches 100-105 degrees Fahrenheit, adjust the pH to 11.0 by adding 50% NaOH solution.

It is important to maintain the temperature between 100-105 degrees Fahrenheit and pH between 11.0. Do not allow the temperature to exceed 110 degrees Fahrenheit and pH to exceed 11.0. Once the temperature is stable, slowly open the inlet valve to avoid hydraulically shocking the element. Maintain circulation for 45 to 60 minutes at the specified temperature and pH. Make pH adjustments during the cleaning cycle if necessary.

1. After cleaning is complete, drain the cleaning system completely and flush the cartridge thoroughly with D.I. water at ambient temperature to drain.
2. Drain the cleaning system again. The cleaning procedure is now complete and the element may be returned to paint. Filter bags should be changed at this point.

For more information see the original manual that came with the equipment or call UFSc at the phone number shown above.

Standard Cathodic E-coat Element Cleaning Procedure Using Power Flux Concentrate

Please read all the instructions listed below carefully to familiarize yourself with the project before attempting to perform any of the work or unpacking any further.

Required Materials and Tools:

1. Paint Company Approved Cleaning Solution
2. Power Flux Concentrate

Although the mechanics of the cleaning procedure is generally the same for most systems, the following procedure is specific to the Power Flux Concentrate cleaner chemistry. The procedure is based on cleaning one eight inch or two six inch cartridges at a time with an individual cartridge cleaning system. You should feel free to modify the mechanics – not the chemistry – to accommodate your specific cleaning system.

1. Isolate the cartridge to be cleaned from the paint manifolds (feed, return, and permeate).
2. Initial Flush Procedure:  Drain paint from the cartridge and follow up with a D.I. water flush to drain. Cartridge should be flushed until water runs clear. If the flush is to be done using a tank and a pump, adjust the pH to the paint tank (or lower) is preferred.
3. Final Flush Procedure:

Fill: cleaning tank with D.I. water and adjust pH to approximately 2.0 – 2.2

Open: cleaning return

Open: permeate to cleaning tank

Close: cleaning feed

Start Pump: slowly open the cleaning feed valve

Circulate pH adjusted D.I. water at ambient temperature for about 5 minutes and drain. Close the cleaning inlet valve.

1. Preparation of Cleaning Solution:  Prepare a 200-liter cleaning solution by mixing the cleaner in the cleaning tank based on a 99:1 dilution. The 200-liter quantity is based on the cleaning of one eight or two six inch cartridge at a time.  NOTE:  Be sure to leave at least 20 cm of space at the top of the cleaning tank to accommodate foaming.

Example:  2 liter Power Flux Concentrate + 198 liter D.I. water = 200 liter solution

1. Cleaning Procedure:  Raise the temperature of the cleaning solution to 100-105 degrees Fahrenheit either by heating or closed loop circulation. When the solution reaches 100-105 degrees Fahrenheit, adjust the pH to 2.0 – 2.2 by adding formic acid up to 3% or by adding muriatic acid.

It is important to maintain the temperature between 100-105 degrees Fahrenheit and pH between 2.0 – 2.2. Do not allow the temperature to exceed 110 degrees Fahrenheit and pH to drop below 2.0. Once the temperature is stable, slowly open the inlet valve to avoid hydraulically shocking the element. Maintain circulation for 45 to 60 minutes at the specified temperature and pH. Make pH adjustments during the cleaning cycle if necessary.

1. After cleaning is complete, drain the cleaning system completely and flush the cartridge thoroughly with D.I. water at ambient temperature to drain.
2. Drain the cleaning system again. The cleaning procedure is now complete and the element may be returned to paint. Filter bags should be changed at this point.

For more information see the original manual that came with the equipment or call UFSc at the phone number shown above.

Retro-fitting male Element into Female

Tools / equipment Required: 

1. Saw Horses O-Rings 
2. 1-9/32” Drill Bit PN 565024 (#122) 
3. Bow Saw or equivalent PN 565050 (#121)
4. Vacuum PN 565051 (#123)
5. Drill 

Step #1

Place element on saw horses.

Step #2

Take bow saw or something equivalent  to cut off top portion of permeate tube (with o-rings).  Tip: Make sure the permeate Tube is cut off flush with the ATD.  Also, keep the lip or cup seal on for protection so ATD will not crack.

Step #3

Take 1-9/32” drill bit and bore permeate tube 3-1/2” deep.  Make sure to go slow and keep a steady hand.   After drilling chamfer ID of pipe so the o-rings will not get cut.  Tip: Try to keep the element on the horses to prevent and shavings from running down the permeate tube.  After drilling, use vacuum to take out any shavings.  At this time it would be safe to take the cup seals off.

Step #4

Wrap spacer on outside of element to assure snug body fit inside UF housing.  Tip:  This may take a couple of times to get the proper body fit.  When done, use PVC tape to keep it in place as shown below.

Step #5

When placing male top cap in the permeate tube, use o-ring PN 565024 (#122).  If fit is loose, use o-ring PN 565051 (#123).  If fit is tight, use o-ring PN 565050 (#121).

Note:
Do not modify bottom permeate tube (pipe with plug or dome cap).  

UF Monitor System Panel

This guide can help identify and solve problems with UF Machines equipped with the UF Monitor System from UFS. It is meant to be a supplement  to the  Getting Started Guide Bulletin 994310.

For more information see the original manual that came with the equipment or call UFSc at the phone number shown above.