Heiche HEIS01 KTL system Surface Treatment

Manufacturer: Heiche

Model:HEIS01 KTL system

Year of manufacture: 1982

Major overhaul: 2008 to 2013

Status: Fully operational

Control system: Siemens S7-300

Operating software: Ditec

Operating modes: Manual, jog, and fully automatic

Technical Specifications

- Max. workpiece window: 1,240 x 800 x 600 mm
- Max. workpiece carrier weight: 160 kg
- Coating material: KTL paint (cathodic electrodeposition)
- Coating thickness: 10 to 45 micrometers
- Cycle time / throughput: 190 seconds per cycle (18 workpiece carriers per hour)
- Noise level: below 85 dB(A)
- Overall dimensions (L x W x H): 9,000 x 12,000 x 7,000 mm
- Number of baths: 15
- Number of loading and unloading stations: 6
- Conveyor system: Chain conveyor by KEWESTA
- Dip system: Lifting station by Klaus Sessler
- Drying: Curing oven by Rippert

Electrical and Utilities Data

- Supply voltage: 3-phase 230/400 V / 50 Hz
- Control voltage: 24 V DC
- Total installed power: 270 kW
- KTL control cabinet fuse: 160 A and 100 A
- KTL rectifier fuse: 300 A
- Pneumatic pressure: 7.5 bar
- City water consumption: 800 l/h
- Demineralised water consumption: 600 l/h at 2.5 bar
- Hot water supply: 85 degrees C, 120 kW, 1.5 bar

Curing Oven

- Manufacturer: Rippert
- Year of Manufacture : 2011
- Max. drying temperature: 220 degrees C
- Heating output: 240 kW
- Heating medium: Natural gas
- Recirculating air volume: 40,000 m3/h
- Fresh air volume: 1,000 m3/h
- Pre-heat zone max. temperature: 120 degrees C
- Heating zone max. temperature: 220 degrees C
- Exit zone max. temperature: 120 degrees C
- Pre-heat zone stations: 4
- Heating zone stations: 11
- Exit zone stations: 4

Complete Package Includes

- Chain conveyor with 64 stations
- 18 lifting stations at the baths
- 11 pre-treatment and cleaning baths plus double spray station
- 1 KTL process bath
- 3 post-treatment and finishing baths
- 1 curing oven with pre-heat zone, heating zone, and cooling zone
- 1 rectifier 0 to 400 V / 400 A including current density control
- Control cabinets and operator panel
- 360-degree part rotation system
- 4 supply tanks (3 m3 each) for process bath
- 1 chamber filter press for zinc phosphate bath
- 1 exhaust air scrubber with supply tank (0.4 m3)
- 2 oil separators
- Various pumps, filters, and pipework
- Biofilter system
- 40 rack trolleys
- 250 fixed product racks
- 250 movable product racks
- Various hook strips

Major Overhaul Works Carried Out 2008 to 2013

- New curing oven installed
- KTL paint bath including all peripherals renewed (paint pump, ultrafiltration, heating/cooling
- circuit, round dialysis cells)
- Bath circulation system renewed
- Lifting motors renewed
- Chain and chain track completely replaced
- Control system renewed
- Rotating rack technology added
- Spray degreasing station added
- Frequency converter technology added
- Pre-treatment dryer added
- Zinc phosphate filtration via chamber filter press added

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