Envirocoat Series Powder Coating System

Transcription

1 Envirocoat Series Powder Coating System Customer Product Manual Issued 2/11 For parts and technical support, contact your local Nordson representative This document is subject to change without notice. Check for the latest version. NORDSON CORPORATION AMHERST, OHIO USA

2 Contact Us Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information about Nordson can be found on the Internet using the following address: Address all correspondence to: Nordson Corporation Attn: Customer Service 555 Jackson Street Amherst, OH Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks Nordson and the Nordson logo are registered trademarks of Nordson Corporation.

3 Table of Contents i Table of Contents General... Congraduations on the Purchase of Your Nordson Product... Your Safety is Important to Nordson... Manufacturer Location... Internet... Nordson Product Manuals... Nordson Asia... v v v v v v vi Safety Introduction Qualified Personnel Intended Use Regulations and Approvals Personal Safety Fire Safety Grounding Action in the Event of a Malfunction Disposal System Description and Specifications Introduction System Components Powder Application Equipment Powder Recovery and Reclaim Powder Conditioning System Optional Box Unloader Electrical and Pneumatic Controls Power and Fan Control Functions Cartridge Pulse Function Control Panel Settings Electrical Schematics Pneumatic Diagram Specifications Booth Electrical Requirements Compressed Air Requirements Powder Conditioning System Requirements

4 ii Table of Contents Operation New System Startup System Startup Rotary Sieve Settings Rotary Sieve Vent-Assist Air Pressure Setting Feed Hopper Level Sensor Calibration Daily Startup Procedure Daily Shutdown Procedure Color Change Procedure Removing the Color Module Installing a New Color Module and Feed Hopper Startup After Color Change Maintenance System Cleaning With System On With System Off Daily Equipment Maintenance Weekly Maintenance Periodic Maintenance Maintenance Check List Cartridge Filter Maintenance General Maintenance Troubleshooting Control Panel Switches Troubleshooting Tables Reversing Motor Direction Exhaust Fan Motor Sieve Motor Repair Final Filter Replacement Cartridge Filter Replacement Color Module Fluidizing Plate Replacement Preparation Replacement Feed Hopper Fluidizing Plate Replacement Preparation Replacement Vibratory Sieve Repair Pulse Valve Replacement

5 Table of Contents iii Parts Introduction Generation I System Parts Model-Specific Parts Generation I Common Parts for Modules Generation I Generation II System Parts Model-Specific Parts Generation II Common Parts for 10, 12, 15, and 18C Modules Generation II Common Parts for 2, 4, 6, and 8C Modules Generation II. 7-6 Common Part for 8, 10, and 12C Modules Generation II Common Parts for All Modules Generation II Powder Conditioning Systems Powder Conditioning Equipment Common Parts for Powder Conditioning Systems

6 iv Table of Contents

7 General Information v General Information Congraduations on the Purchase of Your Nordson Product Nordson equipment is engineered and manufactured in accordance with strict specifications, using high quality components and state-of-the-art technologies that assure reliable, long-term performance. Your Product was thoroughly tested for proper operation prior to shipment. Before unpacking and installing your new equipment, please read this manual. It is your guide to safe installation, productive operation and effective maintenance. We recommend that you keep the manual available for future reference. Your Safety is Important to Nordson Carefully read the Safety section. Your product is designed for safe operation when used according to the published instructions. Potential hazards exist when operating instructions are not followed. Manufacturer Location Nordson (China) Co., Ltd #137 Guoshoujing Road, Zhangjiang Hi Tech Park,Pudong,Shanghai,China Telephone: Fax: For a list of Nordson organizations in Asia, refer to the list on the following page. Internet For information on Nordson products and contacts, go to Nordson Product Manuals To download electronic copies of Nordson product manuals, go to

8 vi General Information Nordson Asia Location Contact Phone Fax Hong Kong Nordson Application Equipment Taiwan Nordson Da Korea Nordson Sang San Philippines, Thailand, Nordson South East Indonesia, Vietnam Asia Australia Nordson Australia New Zealand Nordson New Zealand Malaysia Nordson Malaysia Japan Nordson Japan India Nordson India to Nordson America USA

9 Safety 1-1 Section 1 Safety Introduction Read and follow these safety instructions. Task- and equipment-specific warnings, cautions, and instructions are included in equipment documentation where appropriate. Make sure all equipment documentation, including these instructions, is accessible to all persons operating or servicing equipment. Qualified Personnel Equipment owners are responsible for making sure that Nordson equipment is installed, operated, and serviced by qualified personnel. Qualified personnel are those employees or contractors who are trained to safely perform their assigned tasks. They are familiar with all relevant safety rules and regulations and are physically capable of performing their assigned tasks. Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment may result in injury to persons or damage to property. Regulations and Approvals Some examples of unintended use of equipment include using incompatible materials making unauthorized modifications removing or bypassing safety guards or interlocks using incompatible or damaged parts using unapproved auxiliary equipment operating equipment in excess of maximum ratings Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed. All phases of equipment installation must comply with all federal, state, and local codes.

10 1-2 Safety Personal Safety Fire Safety To prevent injury follow these instructions. Do not operate or service equipment unless you are qualified. Do not operate equipment unless safety guards, doors, or covers are intact and automatic interlocks are operating properly. Do not bypass or disarm any safety devices. Keep clear of moving equipment. Before adjusting or servicing any moving equipment, shut off the power supply and wait until the equipment comes to a complete stop. Lock out power and secure the equipment to prevent unexpected movement. Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or servicing pressurized systems or components. Disconnect, lock out, and tag switches before servicing electrical equipment. Obtain and read Material Safety Data Sheets (MSDS) for all materials used. Follow the manufacturer s instructions for safe handling and use of materials, and use recommended personal protection devices. To prevent injury, be aware of less-obvious dangers in the workplace that often cannot be completely eliminated, such as hot surfaces, sharp edges, energized electrical circuits, and moving parts that cannot be enclosed or otherwise guarded for practical reasons. To avoid a fire or explosion, follow these instructions. Do not smoke, weld, grind, or use open flames where flammable materials are being used or stored. Provide adequate ventilation to prevent dangerous concentrations of volatile materials or vapors. Refer to local codes or your material MSDS for guidance. Do not disconnect live electrical circuits while working with flammable materials. Shut off power at a disconnect switch first to prevent sparking. Know where emergency stop buttons, shutoff valves, and fire extinguishers are located. If a fire starts in a spray booth, immediately shut off the spray system and exhaust fans. Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice.

11 Safety 1-3 Grounding WARNING: Operating faulty electrostatic equipment is hazardous and can cause electrocution, fire, or explosion. Make resistance checks part of your periodic maintenance program. If you receive even a slight electrical shock or notice static sparking or arcing, shut down all electrical or electrostatic equipment immediately. Do not restart the equipment until the problem has been identified and corrected. Grounding inside and around the booth openings must comply with NFPA requirements for Class II, Division 1 or 2 Hazardous Locations. Refer to NFPA 33, NFPA 70 (NEC articles 500, 502, and 516), and NFPA 77, latest conditions. Action in the Event of a Malfunction All electrically conductive objects in the spray areas shall be electrically connected to ground with a resistance of not more than 1 megohm as measured with an instrument that applies at least 500 volts to the circuit being evaluated. Equipment to be grounded includes, but is not limited to, the floor of the spray area, operator platforms, hoppers, photoeye supports, and blow-off nozzles. Personnel working in the spray area must be grounded. There is a possible ignition potential from the charged human body. Personnel standing on a painted surface, such as an operator platform, or wearing non-conductive shoes, are not grounded. Personnel must wear shoes with conductive soles or use a ground strap to maintain a connection to ground when working with or around electrostatic equipment. Operators must maintain skin-to-handle contact between their hand and the gun handle to prevent shocks while operating manual electrostatic spray guns. If gloves must be worn, cut away the palm or fingers, wear electrically conductive gloves, or wear a grounding strap connected to the gun handle or other true earth ground. Shut off electrostatic power supplies and ground gun electrodes before making adjustments or cleaning powder spray guns. Connect all disconnected equipment, ground cables, and wires after servicing equipment. If a system or any equipment in a system malfunctions, shut off the system immediately and perform the following steps: Disconnect and lock out electrical power. Close pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the equipment. Disposal Dispose of equipment and materials used in operation and servicing according to local codes.

12 1-4 Safety

13 System Description and Specifications 2-1 Section 2 System Description and Specifications Introduction This manual covers standard Envirocoat Generation II Series powder coating systems. It includes a description of the major system components and their operation; daily operation procedures; maintenance, troubleshooting, and repair procedures; and part numbers for normal wear items. System Components The Envirocoat system is available with a cartridge booth or a cyclone booth. The system consists of powder recovery and reclaim equipment and powder conditioning equipment. The powder application equipment is optional and its configuration depends on the products and powder being used. The powder recovery and reclaim equipment contains the sprayed powder within the booth and recovers the oversprayed powder so that it can be used again. The powder conditioning system sieves the reclaimed and virgin powder and fluidizes the powder so it can be sprayed. Because powder coating systems are customized to meet customer requirements, your system may have controls and equipment not described in this manual or located in different positions. Your Nordson representative can provide you with additional information and training to supplement this manual. This manual describes a basic manually operated system. Before operating your system please read the manuals for all equipment not covered in this manual. Figures 2-4, 2-1, 2-3, and 2-2 illustrate the operation and components of a typical system. WARNING: All components of the powder coating system must be connected to a true earth ground. Failure to observe this warning may result in personal injury or property damage.

14 2-2 System Description and Specifications Powder Application Equipment See Figure 2-1. The powder feed pumps (14) mounted on the feed hopper (15) draw powder out of the hopper through pickup tubes, mix it with a high-velocity stream of air, and force it through the feed hoses to the powder spray guns (10). The spray guns electrostatically charge the powder and spray it onto the grounded workpieces passing through the booth. The charged powder sticks to the grounded workpieces. Powder Recovery and Reclaim Cartridge Booth See Figure 2-1. The exhaust fan (4) pulls spray-room air into the booth canopy (1), through the color module (16) and cartridge filters (7), and into the fan section (2). The air is returned to the spray room through the final filters (5), free of all powder. Most of the oversprayed powder remains suspended in the air pulled through the system by the exhaust fan. The powder collects on the external surfaces of the cartridge filters. At timed intervals, the pulse valves (6) release large volumes of air through the centers of the cartridge filters. The pulse air blows the powder off the filters. The powder falls into the hoppers in the bottom of the color module, where it is fluidized and then pumped to the powder conditioning system by the transfer pumps (9). The transfer pumps can be controlled manually or by a timer in the system control panel.

15 System Description and Specifications Figure 2-1 System Components and Operation Cartridge Booth 1. Canopy 7. Cartridge (primary) filters 2. Fan section 8. Vent hose 3. Fan motor 9. Transfer pumps 4. Fan 10. Powder spray gun 5. Final filters 11. Spray gun controller 6. Purge manifold and valves 12. Sieve 13. Accumulator 14. Powder feed pumps 15. Feed hopper 16. Color module Powder Recovery and Reclaim Cyclone Booth See Figure 2-2. The exhaust fan (4) pulls spray-room air into the booth canopy (1), through the cyclone (16), and into the afterfilter (2). The air is returned to the spray room through the final filters (5), free of all powder. The cyclone (16) separates the powder from the air flowing through the system. The powder falls into the transfer pan in the bottom of the cyclone and is pumped back to the sieve accumulator (13) by a transfer pump (9). The fine powder that remains in the air as it flows into the afterfilter (2) collects on the external surfaces of the cartridge filters (7). At timed intervals, the pulse valves (6) release large volumes of air through the centers of the cartridge filters, blowing the powder off the filters.

16 2-4 System Description and Specifications The recovered powder falls into the hoppers in the bottom of the afterfilter, where it is periodically pumped into a waste container, as it is typically too fine to be re-used Figure 2-2 System Components and Operation Cyclone Booth 1. Canopy 7. Cartridge (primary) filters 2. Afterfilter 8. Vent hose 3. Fan motor 9. Transfer pumps 4. Fan 10. Powder spray gun 5. Final filters 11. Spray gun controller 6. Purge manifold and valves 12. Sieve 13. Accumulator 14. Powder feed pumps 15. Feed hopper 16. Cyclone Powder Conditioning System See Figures 2-2 and 2-3. A typical powder conditioning system (PCS) consists of two main parts, the powder sieve (12) and the feed hopper (15). The PCS receives virgin and reclaimed powders, sieves out any impurities which may affect the finish, and stores the powder in the feed hopper.

17 System Description and Specifications 2-5 A porous fluidizing plate in the bottom of the feed hopper diffuses low-pressure air into the powder supply. The air fluidizes (aerates) the powder so that it can be pumped to the spray guns. To maintain a slight negative pressure in the feed hopper and prevent spray room contamination, a vent hose (8) allows the fluidizing air and transfer pump conveying air to flow into the color module or afterfilter, carrying fine powder dust with it. Typical systems may use an AZO Rotary Sieve or a Nordson Easy-Screen vibratory sieve. Optional Box Unloader See Figure 2-3. An optional box unloader (17) can be added to pump new powder from a box into the powder conditioning system to replenish the powder supply. The box unloader can be operated manually or automatically, on a signal from a level sensor in the feed hopper. Refer to Section 7, Parts, for Powder Conditioning System component part numbers. Typical Cartridge Booth Configuration Figure 2-3 Typical Cartridge Booth Configuration 1. Canopy 8. Vent hose 2. Fan section 9. Transfer pumps 5. Final filters 12. Sieve 15. Feed hopper 16. Color module 17. Box unloader

18 2-6 System Description and Specifications Figure 2-4 Typical Booth Configuration 10. Automatic spray guns 18. Reciprocator or oscillator 19. Booth air controls 20. Automatic spray gun controls 21. Booth control panel 22. Manual gun controller 23. Manual spray gun

19 System Description and Specifications 2-7 Electrical and Pneumatic Controls The controls consist of the following components, housed in one or more panels. Controls are configured depending on the application and the system options. Control Flame detector indicator Motor starters Pneumatic control Pulse air controls Pulse valve timer Differential pressure gauge(s) Table 2-1 Controls Description Optional equipment. Provides a visible signal If the detector senses a flame. If a fire is detected within the booth, the exhaust fan and powder application system must be shut down immediately. The system can be interlocked to accomplish this. Starts and stops down the exhaust fan motor, along with motors for optional equipment such as oscillators and rotary or vibratory sieves. Houses air pressure regulators and gauges for the feed hopper, color module, transfer pumps, and other pneumatic equipment. Regulate the pulse air pressure and volume. Controls include a regulator, pressure gauge, and gate valve. Consists of the pulse valve timer circuit board. Trim potentiometers on the board adjust pulse delay (time between pulses) and duration (time pulse valve is open). LEDs on the board light as each valve is triggered. Monitors the air pressure drop across the cartridge filters and final filters. When the critical level of pressure is reached it indicates that the filters are clogged. When this happens shut down the system and replace the filters. Power and Fan Control Functions The main isolator disconnects the three (3) phase input power to the control panel. It is generally interlocked with the cabinet door so that power must be switched off to gain access to the cabinet. A green START push button energizes the exhaust fan motor contactor and pulse sequence timer board (board mounted in a separate enclosure). WARNING: The START button should not be pressed when the color module is removed from under the fan section. Pressing the START button will start the exhaust fan, which may result in contamination of the final filters with foreign material. Without the color module installed, a running fan is a safety hazard for personnel working around the booth. A red STOP push button performs the opposite function of the green push button and deactivates the circuits. (The customer may wire additional remote emergency stop buttons in parallel).

20 2-8 System Description and Specifications Cartridge Pulse Function The pulse sequence timer board controls cartridge filter cleaning pulsing. The time interval between pulses (the delay) and the duration of each cleaning pulse is selected by the miniature potentiometers mounted on the timer circuit board. There is one (1) clearly marked potentiometer for each timing function. Typical timer settings are 9 45 seconds between pulses and 40 milliseconds for the duration of the pulse. Experience has equated a setting of 40 milliseconds to a short sharp bang noise when the pulse occurs. In each case the delay and duration times are dependent upon the powder loading and cartridge cleaning pressure with good cleaning being the result of the proper settings. The filter cartridges are being cleaned properly when a differential pressure reading of approximately 0.7 Kpa (2.8 inches wc) is obtained. Readings between approximately 0.25 and 0.75 Kpa would be acceptable for typical new installations. These initial readings will rise progressively during the life of the cartridge up to about 1.1 Kpa (4.4 inches wc), then more rapidly until the maximum differential pressure is reached. (Some installations with high powder loading may run at more than 0.75 Kpa (3 inches wc). NOTE: Pressure switches PS1, PS2, and PS3 may be located elsewhere or may not be included in the system, depending on the configuration. Control Panel Settings Control Function Recommended Setting PS1 Final filter differential pressure 10 millibar (~ 4 in. wc) PS2 Cartridge filter differential pressure 10 millibar (~ 4 in. wc) PS3 Slugging relay timer 10 seconds T1 Dual hopper recycle timer as needed Differential pressure gauge Cartridge filter pressure kpa or in. wc Pulse timer Cartridge filter cleaning Frequency depends upon number of cartridges Duration = 40 ms Delay = 9 45 seconds

21 System Description and Specifications 2-9 Electrical Schematics TO CUSTOMER SUPPLY 3 PHASE 380V 50HZ K3M E N L1 L2 L3 KM1 CONTROL STATION ISOLATOR 63 AMP C1B 1L1 KM2 U1 CB CB U2 1L2 1L3 V1 W1 CB CB M1 CB CB V2 W2 U4SQ.MM T/OL RANGE: AMPS SETTING 22 AMPS EXHAUST FAN 11 KW, 380V, 3 PHASE, 50 HZ C2B 2L1 KM4 U3 CB 2L2 2L3 V3 W3 CB CB M2 OSCILLATOR NO KW, 380V, 3 PHASE, 50 HZ 1.5SQ.MM T/OL RANGE: AMPS SETTING 2.2 AMPS C3B 3L1 KM5 U4 CB 3L2 3L3 V4 W4 CB CB M3 OSCILLATOR NO KW, 380V, 3 PHASE, 50 HZ 1.5SQ.MM T/OL RANGE: AMPS SETTING 2.2 AMPS CB4 4L1 KM6 U5 CB 4L2 4L3 V5 W5 CB CB M4 EASYSCREEN 0.18 KW, 380V, 3 PHASE, 50 HZ 1.5SQ.MM T/OL RANGE: AMPS SETTING 0.35 AMPS To Schematic 2 of 2 Figure 2-5 Electrical Schematics Typical (1 of 2)

22 2-10 System Description and Specifications TO CONTROL STATION ISOLATOR CB5 20 KM7 21 TO MANUAL GUN/19 IN. RACK CB CB 2 240V, 1 PHASE, 50HZ CB6 16 AMPS PUSHBUTTON EMERGENCYAUXILIARY INTERLOCK CB1/1 CB4/1 STOP START 27 1 CB CB 22 CB CB 23 TO/L 24 TO/L MS1TDR/ KM3/1 11 KM1 2 6 AMPS EXHAUST FAN /1 2 MK 7 /1 1 MK MS1TDR/2 12 KM1/2 13 KM3 2 7 PUSHLIGHT 2 7 KM2 2 7 OSCILLATOR #1 STOP 16 START KM KM4/1 2 OSCILLATOR #2 STOP 7 18 START 19 KM5 2 KM5/1 2 EASYSCREEN 7 KM6 2 GUN POWER 7 KM TMR 2 7 1TMR/1 30 SV1 (220V, 50HZ, 6.5W) CB CB 2 7 CB7 31 CARTRIDGE PULSING CB CB 2 SELECTION Figure 2-6 Electrical Schematics Typical (2 of 2)

23 System Description and Specifications 2-11 Pneumatic Diagram AIR IN EP MANUAL GUN EP TRANSFER PUMP VENT COLOR MODULE FLUIDIZING HOPPER FLUIDIZING AUXILIARY (PLUGGED) 4 5 TO PULSE MANIFOLD 2 Figure 2-7 Pneumatic Diagram Typical 1. Ball valves 2. Air manifold (pneumatic panel) 3. Pulse air regulator and gauge 4. Solenoid valve (optional) 5. Box unloader (optional)

24 2-12 System Description and Specifications Specifications Booth Electrical Requirements Electrical requirements are for standard powder coating system configurations. Special installations may have larger requirements. Nordson representatives will notify the customer of any non-standard electrical requirements before the system is installed. It is the responsibility of the customer to supply power to the incoming terminals of the disconnect switch (isolator) inside the panel along with other minor associated wiring. Table 2-2 Cartridge Booth Electrical Requirements System Electrical Requirement Fan Motor Load 2 Cartridge Color Module 1600/1800 cfm 4 Cartridge Module 3400 cfm 6 Cartridge Module 4800 cfm 8 Cartridge Module 6800 cfm 10 Cartridge Module 8500 cfm 12 Cartridge module cfm 15 Cartridge Module cfm 18 Cartridge Module cfm , , phase neutral and earth , , phase neutral and earth , , phase neutral and earth , , phase neutral and earth , , phase neutral and earth , , phase neutral and earth , , phase neutral and earth , , phase neutral and earth 4 kw 3.0 amp 4 kw 4.0 amp 7.5 kw 5.5 amp 11 kw 11.0 amp 11 kw amp 15 kw 15.0 amp 18.5 kw amp 18.5 kw amp NOTE: Fan motor loads are based on 6 inch w.c. The accessories load will vary with each installation. Your Nordson Representative can confirm total electrical loads after the system is configured. Compressed Air Requirements It is responsibility of the customer to supply clean, dry, compressed air to the system air drop. Compressed air requirements will be provided prior to the system installation but may also be estimated using the tables below. A refrigerator-type compressed air dryer with a coalescing-type micro-filter for removing water and oil from the air supply is vital to the operation of any powder booth.

25 System Description and Specifications 2-13 The procurement and installation of the air dryer, coalescing filter, and timer/solenoid air valve are normally the responsibility of the customer. Some installations will have the compressed air conditioning equipment supplied and installed by Nordson personnel if agreed during negotiations. Depending upon the degree of automation desired, the dryer and booth may be interlocked to prevent the operation of the booth without a supply of conditioned air, or the correct operation and start sequence may be specified in the operating instructions. With either manual or automatic control of the dryer, it should be impossible to spray powder into the booth without a conditioned air supply. Table 2-3 Typical Compressed Air Requirements Air Flow Powder feed pumps Feed hopper fluidizing Transfer pumps Cartridge filter pulsing U.V. flame detector system (If applicable) Oscillator, variable stroke (If applicable) Color module hopper fluidizing Compressed Air Requirement 10 scfm (each pump) CH80 CH120 CH scfm (each pump) 4 scfm/1000 cfm of collector capacity at 410 kpa (60 psi) 3 scfm each detector head 6 scfm (normal operation) up to 20 cfm 20 scfm per fluidizing bed Powder Conditioning System Requirements Table 2-4 Powder Conditioning System Requirements Operating Air Pressure kpa (psi) Component Max. Air Flow (cfm) Voltage (AC) Phase Feed Hopper (80 Kg) (15) Feed Hopper (120 Kg) (15) Feed Hopper (200 Kg) (15) Rotary Sieve AZO (60) Rotary Sieve Nordson (60) Power (kw) Pancake or Box Sieve 110 or Easy-Screen Sieve Vent Assist (40)

26 2-14 System Description and Specifications

27 Operation 3-1 Section 3 Operation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. New System Startup Use these procedures to prepare your Envirocoat Generation II powder coating system for production. Refer to the appropriate manuals for instructions if your system is equipped with an automatic triggering system. Your Nordson representative will help you set up your application equipment and adjust your system control settings before you start powder coating your products. Record the system settings on the charts provided at the end of this section. Make extra copies of the charts as needed. NOTE: Since powder coating systems are custom-designed to each customer s requirements, each system will have a different combination of equipment. Your system may have equipment not described in this manual, such as automatic gun triggering and air management systems. Before starting the system: Make sure that all tube fittings, hose clamps and electrical plugs are properly and securely installed. Make sure that all installation guidelines have been completed for the other subsystems in your powder system such as the powder booth reclaim section, new powder feeders such as box unloaders, and other accessories. Follow the instructions in the manuals supplied with the equipment. Set all air pressure regulators supplying the main powder conditioning system components to zero before supplying compressed air to the system. System Startup 1. Turn ON the system compressed air supply. Adjust supply pressure to 700 kpa (100 psi). 2. Turn ON the system electrical power. 3. Press the START push button to start the exhaust fan. Set the pulse air pressure to 415 kpa (60 psi) (recommended setting). 4. Make sure the feed hopper is correctly grounded to a true earth ground.

28 3-2 Operation System Startup (contd) WARNING: Wear a NIOSH-approved respirator or dust mask and safety glasses or goggles when handling powder. Avoid getting powder on your skin. Wash powder off with soap and water only. 5. Fill the feed hopper approximately 2/3 full with powder. 6. Calibrate the powder level sensor (if installed) on the feed hopper, following the instructions in this section or the instructions supplied with the level sensor. 7. Set the feed hopper fluidizing air pressure to kPa (10 15 psi). Adjust the pressure until the powder in the hopper appears to be gently boiling. Allow minutes before spraying, to make sure the powder is properly conditioned. 8. Prepare the powder sieve following the guidelines in the sieve manual. Typically the sieve will start with the exhaust fan. 9. Set the transfer pump air pressure to 70 kpa (10 psi). Adjust the pressure to a higher level if necessary. The transfer pumps pump reclaimed powder from the color module to the sieve. 10. Systems with more than one reclaim hopper may be fitted with a pump timer to shut off the pumps automatically. Make sure that the timer is adjusted as shown in the timer manual. 11. If vent assist is installed on the feed hopper vent stub, adjust the vent assist air after the system and sieve have been running for a few minutes, as follows: Lift the access lid on the top of the feed hopper. If the top surface of the fluidized layer of powder is not visible, then adjust the vent assist air flow control valve to increase the air flow to the vent assist nozzle. The vent assist air should create a slight negative pressure within the hopper, drawing the cloud of suspended powder above the fluidized powder into the vent hose and color module. 12. After make sure all other subsystems are prepared for production according to their manuals, turn on the oscillators, if used, and the conveyor. Rotary Sieve Settings NOTE: Sieve operation depends on system configuration. In some systems, the sieve turns on when the exhaust fan is started. In other systems the feed hopper level sensor signal turns on the sieve. If your system uses a rotary sieve equipped with a pneumatic panel, set the bearing air seal air pressure to 1.7 bar (25 psi) and the flowmeters to 100 SCFH. If your system uses a air-operated vibratory sieve, set the air pressure to 3.5 bar (50 psi). Adjust the pressure up or down to maintain the flow of powder through the sieve.

29 Operation 3-3 Rotary Sieve Vent-Assist Air Pressure Setting To maintain a neutral air pressure in the rotary sieve so it can function properly, the compressed air used to convey the reclaimed powder to the sieve accumulator is vented into the color module. Vent-assist air is directed through the vent tube, toward the color module, to create low pressure in the tube and increase the air flow. Use the following procedure to adjust the vent-assist air pressure. 1. Disconnect the scrap hose from the sieve. 2. Secure a paper or plastic bag to the scrap port with a worm clamp, cable tie, or rubber band. 3. Start the exhaust fan, sieve, and transfer pumps. 4. Watch the bag. If it inflates, increase the vent-assist air pressure. If it deflates, decrease the vent assist air pressure. NOTE: Depending on the sieve used, the vent-assist air pressure regulator is located either on the sieve pneumatic panel or on the system pneumatic panel. Feed Hopper Level Sensor Calibration The level sensor is a capacitive proximity switch. For it to function properly, you must calibrate it. This procedure must be done when you start up a new system and also when you replace a sensor. 1. See Figure 3-1. Insert the level sensor into the plastic mounting well (1) in the side of the feed hopper until it bottoms out, then tighten the plastic screws on the side of the well to hold the sensor securely. 2. Make sure system power is on and the exhaust fan is running. 3. Open the feed hopper lid and fill the hopper 2 / 3 full of powder. 4. Increase the hopper fluidizing air pressure to bar (8 10 psi). The powder level should rise above the top of the mounting well as the powder fluidizes. Add powder to the hopper if it does not. 5. Shut off the fluidizing air. The mounting well should now be coated with a film of powder. 6. If the sensor LED (3) is on, slowly turn the sensor potentiometer (2) clockwise until it goes off. If the LED is off, slowly turn the potentiometer counterclockwise until it lights, then clockwise until it goes off. 7. Increase the fluidizing pressure until the powder level rises above the mounting well. The LED should be off. 8. Turn the potentiometer counterclockwise, counting the number of turns you make, until the LED lights. NOTE: Replacement sensors are shipped configured as normally closed (N.C.) switches. 9. Turn the potentiometer clockwise for 1 / 2 the number of turns you counted in step 8. The LED will go off. The sensor is now set in the midpoint of its sensitivity range.

30 3-4 Operation Feed Hopper Level Sensor Calibration (contd) mm (0.125 in.) 4 N.O. N.C. 1 3 L1 (Vac) +(Vdc) 2 4 L2 (Vac) (Vdc) Figure 3-1 Feed Hopper Level Sensor Calibration 1. Mounting well 2. Potentiometer 3. LED 4. Bridge jumper wire Daily Startup Procedure 1. Turn on the air compressor or make sure compressed air is being supplied to the air dryer. 2. Turn on the air dryer, either locally or at the main booth control panel. NOTE: Approximately fifteen (15) minutes after the air dryer is turned on, compressed air will be available at the powder coating system. 3. Turn the main isolator on the control panel to ON. Push the green START button to turn on the exhaust fan 4. Turn ON the cartridge filter pulsing switch (where used). 5. Turn ON the booth lights (where used). 6. When compressed air is available at the booth, start loading the conveyor with workpieces, or, if the conveyor is already loaded, turn on the oscillator/reciprocators.

31 Operation 3-5 Daily Shutdown Procedure 1. Turn OFF the spray guns and oscillators/reciprocators. If workpieces are still within the booth, move them out or unload the conveyor, to provide clear access inside the booth. 2. Turn OFF the cartridge pulsing switch (where used). 3. Start the transfer pumps and sieves. Clean the booth interior completely and pump the reclaimed powder from the color module hoppers or cyclone into the feed hopper. If used, pump the waste powder out of the afterfilter hopper into a waste drum. NOTE: It is important that the reclaimed powder be stored in the feed hopper when the system is shut down. This ensures that the powder can be effectively conditioned before startup. 4. Disconnect the transfer hoses from the powder transfer pumps and blow out the hoses with compressed air. Always blow out hoses from the pump end of the hose. Reconnect the hoses. 5. Remove the powder transfer pumps from the pickup tubes. Disassemble the pumps and clean them with compressed air. Replace any worn parts. 6. Remove the feed pumps from the pickup tubes. Disassemble the pumps and clean them with compressed air. Replace worn parts as necessary. 7. Replace any feed or transfer hoses that are clogged with impact-fused powder. 8. Clean rotary sieves: Turn off the sieve and empty the scrap bucket. Open the sieve housing and clean the rotor and filter screen with a soft brush. Inspect the screen for damage and replace if necessary. 9. Clean vibratory sieves: Turn off the sieve, then unclamp and remove the upper housing. Remove and clean the screen. Replace it if damaged. 10. Blow off the powder spray guns. Perform cleaning and maintenance according to the instructions in their manuals. Replace worn or damaged parts as necessary. 11. Push the red button STOP button to stop the booth exhaust fan. 12. Turn off the compressed air and shut down the air dryer. 13. Shut OFF the system electrical powder and the compressed air supply. 14. Clean the booth interior and exterior, booth and application equipment, and spray room. 15. Inspect the cartridge filters in the afterfilter. Make sure the filters are seated properly up against the top of the filter section. Make sure the filters are not leaking powder into the fan section. Correct as necessary, replace filters as necessary. 16. If electro-pneumatic oscillators are used, drain the oscillator air filter/separator and refill the air lubricator.

32 3-6 Operation Color Change Procedure Cartridge Booth These instructions describe color change procedures for reclaim systems that use a separate color module, feed hopper, and sieve for each color. Removing the Color Module 1. Clean the booth interior as described in the Daily Maintenance procedures in the Maintenance section. Clean the spray guns and feed hoses as described. 2. Shut off the system electrical power and compressed air supply. Relieve the system air pressure. 3. If there are quick-disconnect plates on the color module disconnect them. Uncouple the tube connectors from the feed hopper receptacles. 4. If a rotary sieve is used, disconnect the sieve electrical cables from the junction boxes. 5. Remove the level sensor from the feed hopper and store it on one of the fan supports. 6. Disconnect the feed hoses from the powder pumps. 7. Disconnect the transfer hoses from the transfer pumps. 8. Remove the ground strap from the color module. 9. Unclamp the color module from the fan section seal (six clamps), then unclamp the color module from the booth inlet(four clamps). 10. Roll the color module and feed hopper away from the booth. Leave the baffles in place on the color module. 11. Hang the canvas storage cover on the color module so that it covers the top and side openings. Installing a New Color Module and Feed Hopper 1. Thoroughly clean the powder off the inlet frame (interface between booth and the module) and surrounding area. NOTE: If you find large amounts of powder in the fan section, the cartridge filters are leaking. Fix the problem before proceeding. Refer to the Troubleshooting and Repair sections for instructions. 2. Inspect and clean the interior of the fan section (1). Check the fan section seal, and replace it if it is damaged. 3. Remove the canvas storage cover from the new color module. 4. Position the new color module under the fan section, against the inlet frame stops. 5. Secure color module to the inlet frame with the four (4) side clamps. Pull down and clamp the module seal frame to the color module.

33 Operation Connect air lines to the color module. 7. Roll the feed hopper in place and connect the transfer hoses to the transfer pumps. 8. Connect the quick-disconnect plates (if used) to the color module. 9. Connect the tube connectors to the receptacles on the feed hopper. 10. Install the level sensor into the mounting well on the feed hopper. 11. Make sure the accumulator vent hose is connected to the color module vent stub, and the vent-assist air line is connected to the vent assist fitting. 12. Connect the sieve electrical cables to the junction boxes. 13. Disconnect the old feed hoses from the guns. Install new feed hoses between the feed pumps and the guns, or use hoses that have already been used with the new color. 14. Make sure the transfer hoses are connected to the accumulator. 15. Connect all equipment ground straps and wiring. Startup After Color Change 1. Before starting the system, make sure all tubing, hoses, electrical cables, and ground straps have been reconnected. 2. Turn on the system electrical power and compressed air supply. 3. Push the green START button on the control panel to start the exhaust fan. 4. Fill the feed hopper 2/3 full of powder. Adjust the hopper fluidizing air pressure until the powder boils gently. Wait 5 10 minutes for the powder to fluidize. 5. Turn ON the pulsing air switch (where used). 6. Purge each gun individually while holding a bag over the gun nozzle, inside the booth, to remove any color contamination from the guns and hoses. 7. Start the conveyor and start spraying parts. 8. Adjust the feed pump air pressures and gun voltages, if necessary (different colors or powders may require different settings).

34 3-8 Operation Color Change Procedure Cyclone Booth These instructions describe color change procedures for powder coating systems that use a cyclone and afterfilter to recover the sprayed powder. 1. Disconnect the powder feed hoses from the feed pumps and blow out the hoses and spray guns with compressed air. Disassemble and clean the feed pumps. 2. Blow off the spray gun exteriors. 3. Clean the booth interior as described in the Daily Maintenance procedures in the Maintenance section. 4. Pump the powder in the cyclone transfer pan back to the feed hopper. 5. Open the transfer pan with the exhaust fan running and blow out the transfer pan. Close the transfer pan. 6. Open the cyclone doors and blow out the cyclone, first with a short lance, then with a long lance. Close the cyclone doors when complete. 7. Disconnect the transfer hose from the transfer pan and blow out the transfer hoses. Disassemble and clean the transfer pump. 8. Disconnect the transfer hoses, fluidizing air tubing, vent tubing, powder feed hoses, and pump air tubing from the feed hopper. 9. If used, remove the level sensor from the feed hopper. 10. If used, disconnect the rotary sieve electrical cables and air supply tubing. 11. Disconnect the feed hopper ground strap. 12. Roll the feed hopper out of the way and install a feed hopper with the new powder, connecting the air and powder hoses and tubing to the pumps, accumulator, and plenum. Install the level sensor, if used. 13. Make sure the transfer pump is installed on the transfer pan and the transfer hose is connected to the pump and the accumulator. 14. Make sure the accumulator vent hose is connected to the color module vent stub, and the vent-assist air line is connected to the vent assist fitting. 15. Connect the sieve electrical cables and air supply tubing. 16. Disconnect the old feed hoses from the guns. Install new feed hoses between the feed pumps and the guns, or use hoses that have already been used with the new color. 17. Connect all equipment ground straps and wiring. Startup After Color Change 1. Before starting the system, make sure all tubing, hoses, electrical cables, and ground straps have been reconnected. 2. Turn on the system electrical power and compressed air supply. 3. Push the green START button on the control panel to start the exhaust fan.

35 Operation Fill the feed hopper 2/3 full of powder. Adjust the hopper fluidizing air pressure until the powder boils gently. Wait 5 10 minutes for the powder to fluidize. 5. Turn ON the pulsing air switch (where used). 6. Purge each gun individually while holding a bag over the gun nozzle, inside the booth, to remove any color contamination from the guns and hoses. 7. Start the conveyor and start spraying parts. 8. Adjust the feed pump air pressures and gun voltages, if necessary (different colors or powders may require different settings).

36 3-10 Operation

37 Maintenance 4-1 Section 4 Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: Wear an approved respirator and safety glasses or goggles when handling powder, operating spray equipment, or performing maintenance or cleaning operations. Obtain and read Material Safety Data Sheets for each powder used. System Cleaning With System On 1. Turn off the automatic gun master control unit(s) and manual gun control units. 2. Disconnect the powder feed hoses from the powder pumps. Blow the powder out of the hoses and spray guns with compressed air. 3. Ground the spray gun electrodes and clean the spray guns according to the instructions in the gun manuals. 4. With the exhaust fan on and the color module in place, use a squeegee to clean all powder off the booth ceiling, walls, and floor. Push the powder into the color module. 5. Remove the remaining powder residue from the enclosure with an air-powered vacuum and a soft brush attachment. Wipe down all surfaces with damp, lint-free cloth (do not use tack cloths). If you remove the color module, clean the inlet frame and surrounding area.

38 4-2 Maintenance With System Off 1. Turn off the exhaust fan. 2. Clean all transfer pumps. on color modules on bulk feed systems 3. Clean sieve screens. 4. Clean feed hopper and bulk hopper vents (if applicable). 5. Clean bulk hopper cyclone (if applicable). 6. Turn off all fluidizing air and transfer pumps. 7. Clean spray guns, feed hoses, and feed pumps. 8. Clean fire detector heads (if applicable). 9. Clean outside of booth (walls, hoses, oscillators, gun positioners, and other spray room equipment. 10. Check spray gun voltages as described in the spray gun manuals. 11. Check feed hopper fluidizing pan and plate for small parts or foreign items. Daily Equipment Maintenance Equipment Procedure Filters Check the differential pressure gauges. 1. Check the final filter differential pressure gauge. It should read between 1 and 2.5 in. of water (wc). Make sure no powder is leaking from around the filter gasket or face. 2. Check the cartridge filter differential pressure gauge. It should read between 4 and 6 in. of water (wc). Check the pulse valve timing. Vibratory Sieve Remove the screen from the sieve. Clean the screen and replace it if it is damaged. Rotary Sieves Clean 1. Empty the scrap pail. 2. Open the sieve housing and clean the rotor and screen with a soft brush. Replace the screen if it is damaged. 3. Check the bearing seal air pressure and flow rate. Check the vent-assist air pressure. Refer to your sieve manual for more information. Transfer Pumps 1. Disconnect the transfer hoses from the pumps. Blow the powder out of the hoses with compressed air. 2. If the pumps are installed horizontally, place a small container under the transfer pumps to catch spilled powder. Remove the pumps from the adapters. Blow out the adapters. 3. Disassemble the pumps. Clean the parts with a low-pressure air gun and a clean cloth. Replace any worn or damaged parts. Continued...

39 Maintenance 4-3 Equipment Procedure Fan Section 1. Remove the final filters and inspect the fan compartment. Vacuum out any powder. 2. Inspect the pulse valve compartment. Vacuum out any powder. If significant amounts of powder have accumulated in the fan or pulse valve compartment, the cartridge filters may be leaking. Refer to the Troubleshooting section for instructions. 3. Inspect the V-belts. Replace cracked or worn belts. Powder Spray Guns Disassemble and clean the spray guns according to the instructions in their manuals. Powder Pumps Disassemble and clean the pumps according to the instructions in their manuals. Replace worn parts. Flame Detector System Check the detector sensors every four hours and clean the lenses, if necessary. Make sure air is being supplied to the sensors. Make sure the detector system is operating properly. Compressed Air Supply Hold a clean, white cloth under the drop leg and open the drop-leg drain valve. Water, oil, or other contaminants will stain the cloth. Eliminate any source of contamination. Drain the filters and separators and check the filter elements. Check all air pressure regulator settings. NOTE: The air dryer should remain on at all times to prevent moisture from accumulating in the compressed air system. Air Dryers Refer to your air dryer manual for maintenance procedures and schedules. Gun Movers (Positioners, Oscillators and Reciprocators) Accumulators and Vent Hoses Workpiece and Conveyor Grounds Each shift, make sure the gun movers are moving smoothly and at the proper speed. Make repairs and adjustments if necessary. Lubricate the gun movers as described in their manuals. Vacuum out the accumulators and blow the powder out of the vent hoses with compressed air. WARNING: An ungrounded or poorly grounded workpiece, hanger, or conveyor can cause electrical arcing. If arcing is observed, shut down the system immediately. Correct the cause before resuming operations. Failure to observe this warning could result in a fire or explosion, causing property damage and possible personal injury or death. Make sure all workpieces are grounded through the hangers and conveyor. The resistance between the workpieces and the hangers, and the hangers and ground, must be less than 1 megohm. You will get better transfer efficiency and workpiece coverage at 500 ohms or less. Clean or strip the hangers regularly.