1. Partially fill the tank with water and add 25 liters (for spray) or 30 litres (for dip) of TRIPHOS-TCP1100M, 2.5 Litters of BOOSTER and 2.2 Litters of ADDITIVE-A3 for every 1000 liters of bath.
2. Fill the bath up to its operating level with water and stir the solution thoroughly.
3. To increase iron build up in the bath solution add clean steel wool, at the rate of 1kg per 1000 Ltrs. of bath solution. Let the steel wool be in the solution   over night.  In the morning, remove as much of the undissolved steel wool as possible.
4. Immediately before commencing production add 1litter of Toner (L) every 100 liters of bath.

Bath control : The TRIPHOS-TCP1100, Toner and ferrous iron concentrations can be determined more accurately by titration methods.  (Refer Terminology: T4)

Replenishment for Phosphate Chemical strength : Add 200 ml of TRIPHOS–TCP1100R per 100liters bath for each total Acid point below 20.

Bath Maintenance :

1. It is important to have the correct amount of Toner in TRIPHOS–TCP1100 bath and if required small additions should be made at regular intervals.  Too much Toner or large in frequent additions, causes excessive sludge formation and wastage of TRIPHOS-TCP1100, too little can result in an accumulation of iron salts which throws the bath out of balance.
2. Such a bath often has brown colour and although is still gives a slightly produce normal coatings.  The brown colour can be raising the temperature of the bath as much as possible and making successive additions of Toner (L) solution in small quantities at a time.  While clearing the colour, brown fumes will be given off and heavy sludge will form.  The bath should be de-slued before bringing into use.
3. Sludge accumulates in the bottom of the tank and when it begins to interfere with the processing, the bath should be cleaned out. Sludge content should not exceed 3000 ppm.  To do this allow the sludge to settles, decant the clear solution into the emptied rinse tank and discard the sludge.  Wash out the TRIPHOS–TCP1100 tank and return the solution.  Restore the bath to its operating level by adding water and the same proportion of chemicals used in the original bath.
4. When phosphate coating powdery, we should add ADDITIVE-A3 to correct free acid and to get dark coating.

Adjusting the Free Acid

If the free acid content exceeds the highest permissible value, it should be adjusted by adding small amounts of NEUTRALIZER PT with the circulation pump switched on.

Per 0.1 point free acid to be neutralized and per 1.000 l bath liquid add :

NEUTRALIZER PT …………………………………..  1.5 kg

Under normal operating conditions the free acid content does usually not fall below the minimum permitted value so that adjustment to a higher level generally is not necessary.

Note: The initial charge and replenishment data contained herein are normal for most installations.  Your AST representative may suggest a deviation from this data to meet specification requirement or local conditions.

FOLLOWING POINTS TO BE KEPT TO DISCARD THE TANK SOLUTION.

Discard the bath when the iron content reaches 0.4%.

HANDLING PRECAUTIONS

TRIPHOS–TCP1100 is slightly acidic and clothing should be protected if there is any possibility of continuous or frequent splashing with the solution.  Wash off any splashes on the skin at once with cold water.  If the solution gets in the eyes, wash out with liberal quantities of water and obtain immediate medical attention.