WDJ2-400

Brief Introduction 

Early in the 1950s, the electric arc spray painting equipment had already been developed and successfully applied to the repair and anti-corrosion territory by our native expert, Mr. Wu Jianchun, the founder of the spray painting. With the development of the science and technology innovation and industry, the high-performance electric arc spray painting equipment had gradually come into being. This electric arc spray machine was developed and accomplished based on summarizing the domestic varieties of electric arc spray painting equipments. It features advanced standards, superior performance, reliable quality and convenient operation, as well as cheap price.

 

Characteristics of the Equipment 

In comparison with other electric arc spray machine, this machine possesses the following main characteristics.

（1）It has a vertical frame structure and appropriate channel for air inlet and outlet, as well as the layout for the components.

（2）The control system has adopted a small logic programmer that has an accurate setting and reliable running, which make the power supply manufacturing technology seem more reasonable.

（3）It has multiple functions for protection.

a. It has a voltage loss protection. Even though the fault has already been eliminated, the system will not start by itself automatically.

b. It has an overheating protection. When the fault of the cooling fan emerges so that the rectifier overheats, the system will exit its running state and give an alarm.

c. The main transformer has an overload protection.

d. The whole equipment is under the protection of overload and short circuit.

e. It has an air voltage protection device, allowing the equipment to exit its running state and give an alarm with the lack of air.

f. Every time the three-phase 380 V power supply is switched on, the control system will identify the position where the spraying switch stays. If any spraying switch is set on the switch-on position (The wire feed switch is not included), the system will give an alarm and prompt so as to ensure the security of the delivery of current.

g. The inspection device for spraying current can be added and installed. When the wire is jammed or broken, the system will immediately stop its work and give an alarm to prompt (Which has to be appointed by the user, as this device is not installed for conventional products).

（4）In general, the rear wheel diameter of the power supply for electric arc spray painting is 200 mm, and the rear wheel diameter for this power supply reaches up to 250 mm, which makes it convenient to climb over the obstacles.

（5）In addition to the wire feed voltmeter, the wire feed ampere meter is additionally included. The spraying current can be preset via the wire feed voltmeter. In the process of spraying, whether the wire feed of the spray gun is smooth can be reflected via the wire feed ampere meter. When the spray gun is being maintained, the mechanical and electric status of the spray gun can be inspected via the wire feed ampere meter.

（6）The output of the DC and high-current part is half hidden. The M8-12 mm pin can be used as a fixing thread rod. The cable connector is a flat plate contact, which prevents the output pile head from generating heat so that the insulation plate gets burned out. And the output pile head will not be damaged due to the fact that the cable connector generates heat. All of the low-voltage and high-current connections inside the power supply adopt the copper block, which is covered with conductive cream so that the tinning technology is replaced.

 

Technical Parameters 

（1）WDJ2 Spray machine (Power Supply)

 

No.	Item	Parameter
1	Input Power Supply	Three-phase AC 380V 50Hz
2	Input Power	18.8KVA
3	Input Current	AC 22A
4	Output Floating Voltage	DC 21—45 V
5	Voltage Regulation Grade	3 grades respectively for coarse and fine regulation, 9 grades total
6	Power Supply Property	Flat Property
7	Output Current	DC 400A
8	Load Rate	60% （400A）
9	Insulation Level	Level B
10	Boundary Dimension (mm)	700(L) ×500(W) ×1010(H)
11	Weight	225 KGS
12	Available Spraying Methods	Pull and push type spray gun (Both of them need the wire feeder allocation)
13	Voltage of Compressed Air	≧0.6 MPa

 

（2）Configurable Spray Gun

Spray Gun	Item	Parameter
Pull Type Spray Gun	Wire feed Motor	Permanently Magnetic DC Motor
	Voltage	DC 24V
	Motor Power	75W
	Current	DC 3.2A
	Wire feed Rate  m/min	1-6.1 m/min
	Speed Regulation for Wire feed	Stepless
	Wire feed Method	Double wires symmetric to each other, constant rate
	Wire Rod Diameter	ф1.6、ф2、ф3 (Only zinc and aluminum wire)
	Voltage of The Compressed Air	≥0.5 MPa
	Consumption of The Compressed Air	φ6 Hole 1.8 M3/min   φ7Hole2.4 M3/min
	Wire feed Tension of The Spray Gun	≥8 KGS
The Push Type Spray Gun and Wire Feeder	Wire feed Motor	Permanently Magnetic DC Printing Motor
	Motor Power	85W
	Voltage	DC 24V
	Current	DC 4.5A
	Wire feed Rate m/min	1-7 m/min
	Wire feed rate Regulation	Stepless
	Wire feed Method	Double Wires Symmetric to Each Other, Constant Rate
	Wire Rod Diameter	ф2、ф3 (Only Zinc and Aluminum Wire)
	Voltage of The Compressed Air	≥0.5 MPa
	Consumption of The Compressed Air	φ7Hole2.4M3/min   φ9Hole3.8 M3/min
	Weight of The Wire Feeder	20 KGS
	Capacity of The Wire feed Tray	ф300×50×103mm 20 KGS Per Tray
	Volume of The Wire Feeder	580×360×280mm

 

Structure and Characteristics of the Latter Wire Feeder

This wire feeder has double wire feed, its main advantages are：

• The printing motor is used as driving power, it has the advantages of steady running, big torque, low inertia and small noise.

• It has a long service life and can continuously be running for more than 4,000 hours.

• It is free of maintenance. And its main motor and reduction box do not need the maintenance for refueling and replacement of the carbon brush.

• Strict wire feed synchronization provides the quality arc intersection of spraying electric arc with stable external conditions.

The left and right part of wire feed mechanism, which is equipped with a dual drive wire feeding device with dust cover , are symmetrical to each other. This mechanism is fixed on the motor reducer with a fixed plate, and the motor output shaft is equipped with a driving wheel, which drives the two driven gears, each of them located at the left and right side of the upper part respectively, with the same number of teeth. There are two wire feeding wheels, each of them located at the left and right side of the coaxial line respectively. Under the action of the knurled screw and the copper spacer, the wire feeding wheel is fixed on its shaft. The two wire feeding wheels are respectively stressed by the arm for voltage regulation to control the front and rear rolling bearings and the handle can be regulated by the voltage. The left and right stressing lever and locating pin of the lever around the left and the right side can be driven to rotate reversely with a small angle through the compression spring, steel bowl and stressing handle so as to achieve the purpose of changing the situation where the voltage is uniformly distributed.

Due to the fact that the dual drive mechanism with its left part symmetrical to its right part is on the same driving shaft, the strictly synchronized wire feed occurs, generating the steadiness of the arc intersection of the electric arc. Mostly, the wire feed mechanism does not stay together with the spraying power supply so that it is convenient to choose to operate either on the wire feeder or on the spray gun.

The control system is made up of the optional switch on the control panel’s work of the wire feeder, the inching button and the indicator light for wire feed, as well as the spraying voltage and ampere meter.

 

（3）The Spraying Parameters of Each Material (For Reference)

Wire rod Category	Wire Rod Diameter	Air Cap Hole Diameter	Wire Feed Voltage	No-load Spraying Voltage	Spraying Current	Air Voltage
Zinc,Zinc,Tin,and Lead Tin Alloy	Ф1.6	Ф5~Ф6	14~20V	14~20V	30~70A	0.35~ 0.45Mpa
Aluminum	Ф1.6	Ф5~Ф6	14~20V	20~24V	40~70A	0.4~ 0.45Mpa
Zinc,Zinc,Tin,and Lead tin alloy	Ф2 Ф3	Ф7 Ф9	14~24V	21~30V 21~32V	100~200A 140~300A	0.35~ 0.55Mpa
Aluminum	Ф2 Ф3	Ф7 Ф9	14~24V	24~32V	100~200A 150~400A	0.4~ 0.6Mpa
Copper	Ф1.6 Ф2	Ф5~Ф6	14~20V	30~40V	100~200A	0.4~ 0.6Mpa
Carbon Steel And Stainless Steel	Ф1.6Ф2	Ф7	10~18V	35~42V	100~200A	0.4~ 0.6Mpa

 

Descriptions

(1)The selection of each parameter is appropriate

The spraying parameter of each kind of wire rod has already been listed in the instruction book. While the spraying is being implemented, multiple parameters are all set on a piece of parameter strip, which is not wide, other than definitely a certain parameter point (For example, as for the zinc spraying, the spraying voltage is set at 21-28 V). And there are some parameters that can affect other data. For example, on the condition that the spraying voltage is determined, the wire feed pressure (rate) is positively proportional to the spraying current. If the parameter setting is different, so is the spraying effect. Therefore, the users can make their choices according to the requirement of their own so as to make the quality of spraying coating satisfying.

(2)The air voltage refers to the persistent voltage indicated on the barometer when the spraying is being implemented. Within a limited range of pipe diameter, this voltage is inversely proportional to the distance from the power supply to the gunpoint of the spray gun.

 

Operating Steps 

• Pull Type Spray Gun

When the equipment is ready, switch on the power supply and connect the cable and the air leather hose and so on. After nothing wrong is inspected

A:Running-in

For the operators who install and use this equipment for the first time, they should not feel anxious about the wire connection and spraying and be familiar with the equipment performance. Please operate according to the following steps. 

(1)When there is compressed air, close the main switch QF of the power supply on the control panel, and the “Electricity On” indicator light H1 lights up.

(2)Move the switch ST2 for a working condition of the spray gun of the control panel to “Wire Feed”, and inspect the running condition of the wire feed motor regulating the potentiometer RP for the wire feed rate regulation so as to keep the wire feed pressure at approximately 15 V.

(3)Turn the switch ST2 for a working condition of the spray gun of the control panel to “Spraying”. At that time, the three indicator lights for spraying indication light up one after another and the gunpoint of the spray gun sprays the compressed air. The required spraying voltage can be regulated through two pieces of triple-leveled switches for voltage regulation.

(4)Turn the switch ST2 for a working condition of the spray gun of the control panel to “Stop”, and the running is over.

Notes:  “Off” should correspond exactly to “On” of the same exact switch.

B:Normal Spraying

With the above running-in, the operators have their preliminary knowledge of this electric arc spraying power supply. For normal spraying, please refer to the following steps:

(1)Connect the metal wire required to be sprayed and regulate the voltage of the wire feed wheel well.As for the soft metal wire, the voltage of the wire feed wheel should not be too big to prevent the metal wire from being deformed. 

(2)Turn the switch ST2 for a working condition of the spray gun of the control panel or the switch on the handle of the spray gun to “Spraying”. When the spraying is being carried out for the first time, the various parameters that are previously set should be inspected one after another. 

• Push Type Spray Gun

A:Running-in

Fix the power unit for spraying and place the wire feeder on the trolley for wire feed. In accordance with the provisions, those components on the power unit for spraying, such as the three-phase power supply, the wire of the spray gun (regardless of the positive and negative pole), the control line of the spray gun and air leather hose, should be connected in place.

First of all, do not be anxious about connecting the metal wire well and quickly. The spraying program should be inspected so as to familiarize the operator with the different control switches.

(1)When there is compressed air, switch on the main power switch QF on the control panel and the “Electricity On” indicator light H1 lights up.

(2)Turn the switch ST2 for a working condition of the spray gun of the control panel (or the control switch ST3 on the wire feed panel) to “Wire Feed” and regulate the potentiometer RP for “Wire Feed Rate Regulation”.  Keep the wire feed pressure at approximately 15 V and press the inching button for “Wire Feed” to check whether the wire feed driving is normal. 

(3)Turn the switch ST2 for a working condition of the spray gun of the control panel (or the control switch ST3 on the wire feed panel) to “Spraying”. At that time, the three indicator lights for spraying indication light up one after another and the gunpoint of the spray gun sprays out the compressed air. The required spraying voltage can be regulated through two pieces of triple-leveled switch for voltage regulation .

(4)Turn the switch ST2 for a working condition of the spray gun of the control panel (or the control switch ST3 on the wire feeder panel) to “Stop”, and then the running is over.

Notes: “Off” should correspond exactly to “On” of the same exact switch. 

B:Normal Spraying

(1)Next, the wire can be connected. The plate rail pin can be straightened on the plate wire rail (left and right) to a horizontal position.The corresponding metal wire, together with the reset pin, can be loaded into the rail and reset the pin. Open the dust cover and make it unfold downwards by 90 degrees and lift the handle up in hand to allow the wire to be feeded into the wire leading mouth. After the metal wire goes through the V-shaped groove of the wire feed wheel, it is inserted into the middle wire leading mouth. Then it enters into the V-shaped groove until it stops at the wire outlet  of the wire feeder. Press the handle downwards so as to install the drive pipe at the wire outlet of the wire feeder.

(2)After both left and right wires are connected, turn the control switch ST3 (Figure 4) on the wire feed panel to “Wire Feed”, and then press the “Inching Wire Feed” button (or the switch at the middle of the spray gun handle) to move two pieces of metal wires through the wire feed drive pipe to the other end of it. After the two pieces of metal wires show up, screw them up onto the spray gun.

(3)When the 0.5-1 meter of metal wire is feeded in, observe and check if the wire feed is stable. Preset the pressure handle and take the stressing scale on the handle as a reference point of the wire feed pressure. In the process of wire feeding, as long as the metal wire does not slip in the groove of the wire feed wheel, the small scale of pressure is preferred.  If the metal wire bears too much pressure; as a result, the metal wire will be deformed. The appropriate pressure diminishes the wear of the transmission components and increase their service lives. In general, the adjustment is carried out on the 1-3 scale value.

(4)If everything is all right, cut off the redundant metal wire at the gunpoint of the spray gun to prevent them from intersecting with each other. When the control switch on the panel is turned to “Spraying”, the spraying operation can be carried out immediately. For some spray guns, the operation can also be carried out with the "Spraying" switch on the spray gun.

Notes: “Off” should correspond exactly to “On” of the same exact switch.

 

Protective Function of the Equipment 

The WDJ2-400 electric arc spray machine has multiple protective functions, which can safeguard the security of both the operator and the equipment as much as possible and shorten the time needed for personnel training and accumulation of experience. So operators can focus their attention on the spraying quality and mastering how to perfect the coating thickness when the spraying is conducted.

(1)Every time the equipment is energized, at that particular moment, the spraying switch should be detected at the position where it stays.

 The on-off switch is turned manually and it stays somehow at the “On” position. If the operator carelessly switches on the power supply, the control system will immediately start the spraying program, which brings risks to the equipment and person nearby. With this detection function, the condition of the spraying being carried out the first minute the equipment is energized does not exist. If the spraying switch stays at the “On” position, the indicator light for “Faults” lights up to remind you that certain component is not ready yet, so “please deal with it”. What you need to do is  just turn the switch at the position of “Spraying” to the position of “Stop”.

(2)The relay FQ for air pressure protection is used to make sure that the system can not carry out the task of spraying until there is compressed air. When there is no air pressure or the pressure is not enough, the control system will give an alarm. When the air pressure is restored, the alarm disappears by itself. It is unnecessary to press the reset button.

In general, the relay is installed at the position where there is air pressure protection when it leaves the factory. The start-up pressure is 0.38 Mpa.  The release pressure is approximately 0.2 Mpa. If the relay needs to be repaired when there is no air pressure, the lateral plate at the right side can be opened. Turn the switch S for air pressure protection upwards to configure the control system not to be protected by the air pressure.

Notes: please turn the switch for air pressure protection back when the spraying is carried out normally.

Since the spray gun is repaired or for other reasons, the “Wire Feed” switch is not protected by air pressure and under the control of the relay FQ. When there is no air pressure, the wire feed carries on.

(3)The temperature relay FS is designed to protect the rectifier tube against too high temperature.

When a fault of the cooling fan occurs, and the operator is not aware of it and proceeds with spraying, at that time, the temperature of the rectifier tube ascends. When the temperature reaches its set value, the control system will stop  spraying and give an alarm. The heated temperature relay FS needs a certain period of time to cool down until it recovers. It is unnecessary to press the reset button.

(4)The thermorelay ET is designed to protect the rectifier transformer from being overloaded.

When the operator overloads the rectifier transformer by violating the provisions or for other reasons, the control system will stop  spraying and give an alarm. The overloaded thermorelay needs a certain period of time to cool down until it recovers. At that time, turn the control switch for spraying back to “Stop” and press the reset button to make the control system stop producing the alarm, and then the spraying will proceed.

In a word, when the alarm indicator light for “Faults” lights up, it is necessary to analyze the causes instead of pressing the reset button aimlessly.

The alarm indicator light for “Faults” lights up the first minute the equipment is energized, which means that there is no air pressure and the  spraying switch position is incorrect. It is unnecessary to press the reset button in the above two circumstances.

 

Equipment Maintenance and Notes 

The routine maintenance and repair of the electric arc spraying system is greatly important. The accumulation of dirt and metal dust will bring about the accelerated wear of the equipment and shorten its service life. Therefore, the metal dust and dirt on the spray gun should be cleaned up every shift and the inner cavity of air cap and orifice clean should be kept clean. Besides, the following points should be noted.

(1)The spray machine should be placed in a location where there is little oscillation of temperature, little dust and flat ground, as well being dry and well ventilated.  It should also be protected against exposure to sunlight and rain and access of small animals. Besides, it should be covered up by dust cover when not used.

(2)The environment temperature range of application should be from -10 ℃ to +40 ℃, and the altitude height should not be more than 1,500 meters.

(3)It is prohibited to change the voltage level when the spraying is carried out. The output end of direct current, together with the cable connector should be fixed firmly and no looseness is allowed. In order to avoid that the cable connector hits against the front stop plate due to its excessive slant in the process of installation, the cable connector should be installed on the surface engraved with groove to prevent the cable conductor surface and pile head from sliding.

(4)When the spraying is carried out, especially when the high current is output, the falling range of voltage should be around 10%, which is a normal phenomenon and does not mean that there is any fault within this machine.

(5)The short distance range (Within 10 meters) of the power unit incoming line with alternating current should not be less than 4 mm2. When the short distance goes beyond 10 meters, the range should not be less than 6 mm2.

(6)The equipment grounding and power unit incoming line, together with the  cable insulation should be kept in good condition.

(7)The faults that are found should be eliminated in time, and the control and protective circuit inside the power unit should not be changed.

(8)When the spraying is carried out, the wind direction should be taken into consideration to allow both equipment and people to stay at a windward position.

(9) Connecting and disconnecting of the connector assembly. The connector assembly should be connected and aligned with the groove and not be turned with forcible push and pull to avoid being damaged.

(10)As long as the gunpoint of spray gun sprays compressed air, one of the two cables must have direct current, at that time, please do not maintain the spray gun. Please turn the switch S2 for a working condition of the spray gun to “Wire Feed” when the spray gun is maintained or the wire feed voltage is set.

(11)Every time the wire is connected to the spray gun, the nozzle exit should be inspected. If the intersection of the two metal wire pieces is not good, the arcing is not good either.

(12)In the process of spraying, the two metal wire pieces definitely should not hit against each other behind the spray gun.

(13)Periodically clean and eliminate the accumulated dust on various components inside the power box with brush and dry compressed air. If the environment is poor, the cleaning cycle should be shortened.

(14)The qualified electric personnel shall be asked to maintain the equipment and be aware to cut off the power supply during maintenance.

 

Auxiliary Equipments for Spraying (It is optional for users to purchase) 

As the spraying power unit is relatively heavy, the wire feeder should not be placed on the spraying power unit. In order to flexibly go deep into the site and place the power unit in a good environment, it is necessary to install and place the wire feeder on the specially-made trolley.  Our company has already developed two models of wire feed trolleys, one is the totally-closed high position wire feed trolley , which is suitable for operating the plate with wire under poor conditions. The other is an open-type low position wire feed trolley, which is suitable for operation in low, short and narrow sites and can also be used to spray on a relatively high position after it is erected.

 

Schematic Adjustment Diagram of Push Type Spray Gun Conduit Pipe 

The pull type spray gun conduit pipe is assembled together with the connection mouth and the adjustment is not needed when the spraying is being carried out. On the condition that the spraying is unsatisfactory, and considering that the arc intersection point is not good, the conduit pipe should be repaired and adjusted, which means that the conduit pipe is forced to move forward and backward within the spray gun through the screw thread, so as to make the pipe meet the requirements of the arc intersection point.

The various electric and mechanical connectors on the spray gun should be firm and in good condition.

 

 Schematic Adjustment Diagram of Push Type Spray Gun Conduit Pipe

 

Geometric Arc Intersection Point

Forward And Backward Removable Air Cap

The conduit pipe can be forced to move forward and backward and adjusted with the jam nut.

Interval is approximately 2 mm.

3 mm

Connection Mouth

Conduit Pipe

 

Schematic Electric Diagram of the WDJ2-400 Spraying Power

Programmer

Fan

Electricity On

Air Passes

Current Passes

Wire Feed

Faults

Stop

Spraying

Wire Feed

Spraying

Stop

Wire Feed

Overload

Emergency Stop Reset

Fault Detection

Power Panel Control Spraying

Temperature And Air Pressure Detection

Remote Switch Control Spraying

Remarks: There is no fault detection for general products except if it is specified by users.

Circuit Board for Rate Regulation

The Pin No. of Connector Assembly XS1

Wire Lead No.

The Pin No. of Connector Assembly XS2

Wire Lead No.

Programming device

 

Schematic Electric Diagram of the WDJ3-S Wire Feeder 

 

Remarks: As for the spray gun without the “Spraying Switch on Spray Gun Handle”, it does not have to be used. At that time, the spraying control is operated on the wire feeder panel.

Wire Feed Switch on Spray Gun Handle

Wire Feed Inching Button on Panel

Wire Feed Motor

Spraying Switch on Spray Gun Handle

Spraying

Wire Feed

Spraying Switch on Panel