1 Prodigy ColorMax Powder Coating System Customer Product Manual Issued 6/09 For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) or contact your local Nordson representative. This document is subject to change without notice. Check for the latest version. NORDSON CORPORATION AMHERST, OHIO USA
2 Table of Contents Safety Startup Introduction Booth Moving (Optional) Qualified Personnel Color Changing Intended Use Shutdown Regulations and Approvals Personal Safety Maintenance Fire Safety Initial Canopy Conditioning Grounding Daily Maintenance Action in the Event of a Malfunction System Cleaning Disposal Daily Equipment Maintenance Weekly Maintenance Description Weekly Equipment Maintenance Introduction Booth Canopy Conditioning System Components Monthly Maintenance Booth Enclosure Monthly Equipment Maintenance Gun Positioners/Gun Blow-Off System (Optional) Cyclone Cleaning Cyclones and Reclaim System Emptying the Afterfilter Waste Hoppers Afterfilter Initial Setup and Operation Afterfilter Operation Changing Waste Containers Powder Feed Center Roll-On/Roll-Off System (Optional) Maintenance Check List Control Panels Troubleshooting Powder Feed Center Control Panel Introduction System Control Panel Afterfilter Panel Troubleshooting Chart Typical System Options Exhaust Fan Rotation Operation Repair Introduction Introduction Typical Operating Settings Cartridge Filter Replacement Operating Air Pressures Removing the Cartridge Filter Afterfilter Cartridge Filter Pulsing Installing the Cartridge Filter System Controls Setup Seasoning the Cartridge Filters AeroWash Operation Final Filter Replacement Timed Operation Pulse Valve Replacement On Operation Selection Switch Overrides Parts Feed Center Cartridge Filter Pulse Operation 3-3 Continuous Pulsing Introduction Timed Pulsing Afterfilter Parts Selection Switch Overrides Gun Blow-Off Parts Feed Center Waste Powder Canopy and Base Parts Cyclone Cleaning Media Transfer Operation... Switch Selection Overrides Oscillator/Reciprocator Operation Programmable Relay Setup System Diagram Changing Function Values Diagram 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 Apogee, ColorMax, HDLV, icontrol, Prodigy, Nordson, and the Nordson logo are registered trademarks of Nordson Corporation. AeroDeck, AeroWash, and Powder Port are trademarks of Nordson Corporation.
3 Change Record i Revision Date Change Change Record A03 6/09 Noted that air dryer interlock not used after April 2009 in Troubleshooting problems 4 and 5. Added cyclone cleaning procedure using cyclone cleaning media in Maintenance. Added Apogee conditioning procedure in Maintenance. Added notes in Operation about conditioning and using gloves.
4 ii Change Record
5 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.
6 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.
7 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.
8 1-4 Safety
9 Description 2-1 Section 2 Description Introduction This manual covers Colormax powder coating booths used with Prodigy Automatic Systems. A complete system includes Prodigy Powder Port feed centers, Prodigy automatic powder spray guns, and Prodigy icontrol integrated control systems. Options include Prodigy manual spray guns and controllers, and automatic gun positioners, oscillators, or reciprocators. This manual includes a description of the major system components and their operation; daily system operation procedures; and booth maintenance, troubleshooting, and repair procedures and normal wear parts. 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. For information on other system components, refer to the following manuals: Prodigy Powder Port Feed Center: Lance Assembly: Prodigy II High-Capacity Pump (Transfer) Prodigy II Automatic System Pump Panel: Prodigy III HDLV Pump Prodigy icontrol Console: icontrol Operator Interface: icontrol Operator Card: Prodigy Automatic Spray Gun: Prodigy Automatic Gun Clamp: Prodigy II Manual Spray Gun: Prodigy III Manual System: Prodigy II System Troubleshooting: Color Change Procedures Flip Chart NOTE: This manual covers the standard cfm Colormax powder coating system. Other cfm sizes can be custom configured, but are not covered in this manual.
10 2-2 Description System Components Table 2-1 Systems Components (See Figure 2-1) Item Component Function 1 After Filter Filters unusable powder from the air before returning the air to the spray area. 2 Cyclones Reclaim usable powder and return it to the powder feed center. 3 Cyclone Inlet Duct Routes oversprayed powder entrained in air flow to the cyclones. 4 Booth Enclosure Contains oversprayed powder while parts are being coated. 5 Manual Operator Openings with Platforms 6 Powder Port Feed Center 7 Gun Positioners/Gun Blow-Off System (Optional) NS Roll-On/Roll-Off System (Optional) Allow operators to manually touch up parts either entering or exiting the booth enclosure. Supplies powder to the Prodigy spray guns and recycles reclaimed powder. Blows powder off the spray guns while moving the spray guns out of the booth enclosure. Moves the system offline for cleaning, color change, or repair.
11 Description 2-3 System Components (contd) Figure 2-1 Colormax System Components Note: Typical Colormax system shown. Equipment and locations may vary.
12 2-4 Description Booth Enclosure Table 2-2 Booth Enclosure Components Item Component Description 1 Canopy Contains the oversprayed powder. Air flow through the canopy openings carries overspray (powder not deposited on the parts being coated) suspended in the air through the AeroDeck and into the horizontal duct leading to the cyclones. 2 Floor Collects oversprayed powder until it is drawn under the AeroDeck and into the cyclones. The floor s stainless steel construction ensures that the operator is grounded while he or she is cleaning the booth enclosure. 3 AeroDeck Evenly distributes the air draw from the cyclones through the enclosure. 4 AeroWash System Periodically sends pulses of air down the sloped areas of the canopy walls to reduce powder buildup on the floor Figure 2-2 Booth Enclosure Components Note: Half of canopy removed for clarity.
13 Description 2-5 Gun Positioners/Gun Blow-Off System (Optional) Table 2-3 Gun Movers/Gun Blow-Off System Components Item Component Description 1 Air Manifolds Supply air to the blow-off nozzles. 2 Blow-Off Nozzles Blow off oversprayed powder from the spray guns as the spray guns are being pulled out of the booth enclosure. 3 In/Out Gun Positioners Move the spray guns into or out of the booth enclosure. 4 Oscillators or Reciprocators (Optional) Move the spray guns in repetitive or programmed patterns for thorough part coverage; position spray guns in between blow-off nozzles during color change Figure 2-3 Gun Movers/Gun Blow-Off Assist System
14 2-6 Description Cyclones and Reclaim System Table 2-4 Cyclones and Reclaim System Item Component Description 1 Cyclones Separate the usable powder from the air flow through the recovery system. Twin tapered cylinders, connected to the inlet air ducts, transfer pan, and banjo housing at the top which connects to the afterfilter through ductwork. 2 Transfer Pan Collects reclaimed powder and fluidizes it for the HDLV transfer pump. 3 HDLV Transfer System Transports the fluidized reclaimed powder from the transfer pan to the feed center Fludizing Air Powder Tubing Suction Powder Tubing Delivery to Feed Center Figure 2-4 Cyclones and HDLV Transfer System
15 Description 2-7 Afterfilter Table 2-5 After Filter Components Item Component Description 1 Final Filters Remove any remaining fine powder particles from the air before returning the air to the spray room. 2 Fan/Motor Assembly Draws powder-laden air out of the booth enclosure; through the cyclones and ductwork; into the afterfilter; and back into the spray room. 3 Waste Hoppers Collect powder particles that are blown off the cartridge filters. 4 Fluidizing Plates Fluidize the powder in the waste hoppers, allowing the powder to be pumped out of the waste hoppers. 5 Intake Duct Brings powder-laden air from the cyclones to the after filter. 6 Afterfilter Panel Contains pulse timer panel, PULSE ON DEMAND switch, and differential pressure switches and gauges. Refer to After Filter Panel for more information. 7 Cartridge Filters Filter powder particles out of the air before the air is drawn into the fan section. 8 Pulse Valves Periodically send pulses of air through the cartridge filters to blow off powder collected on the cartridges. 9 Pulse Air Manifolds Distribute compressed air to the pulse valves. 10 Pulse Valve Solenoids Signal the pulse valves to open based on pulse valve timer settings. NOTE: The afterfilter may have either deflagration vents or an explosion suppression system. Contact your Nordson representative for information about the explosion venting or suppression equipment Figure 2-5 AfterFilter Front and Side Views
16 2-8 Description Afterfilter Operation See Figure 2-5. Powder is conveyed through the intake duct (5) into the collector section, where powder collects on the external surfaces of the cartridge filters (7). The air passes through the cartridge filters and flows up into the final filter section, through the fan (2) and final filters (1) back into the spray room. The pulse valves (8) periodically release large volumes of compressed air into the centers of the cartridge filters, blowing the accumulated powder off the filters. Pulsing is controlled by the pulse valve timer in the after filter panel (6), which allows you to set both the time between pulses (delay) and the length (duration) of the pulse. The PULSE ON DEMAND switch on the afterfilter panel allows the operator to set cartridge pulsing to be either continuous or on-demand: CONTINUOUS: Cartridges are pulsed at operator-specified intervals set at the pulse valve timer. ON-DEMAND: Cartridges are pulsed only when the cartridge filter differential pressure switch detects a pressure drop across the cartridge filters of 6.5-in. water column (wc). The powder falls into the waste hoppers (3) in the bottom of the collector section. The waste hoppers are equipped with fluidizing plates (4), which diffuse air into the powder so that it will flow easily when the waste hoppers are emptied. The final filter differential pressure switch monitors the pressure drop across the final filters. At 2.5-in. wc, a red warning light on the system control panel lights. At 3-in. wc, the entire system shuts down. A safety gate in the duct between the booth and the afterfilter is retracted during normal operation. When the system is shut down the gate is closed. If a fire is detected in the booth, the fire detection system will shut down the exhaust fan and the gate will close to isolate the afterfilter from the booth.
17 Description 2-9 Powder Feed Center The powder feed center sieves reclaimed and virgin powder and delivers it to the spray guns. It includes an exhaust fan, cartridge filters, and final filters to collect and contain the powder within the enclosure during cleaning and handling operations. The feed center can accommodate up to 32 HDLV powder pumps, to supply powder to automatic spray guns. The pumps are housed in pump panels on each side of the feed center, eight pumps per panel. NOTE: Refer to the Prodigy Powder Port manual for a detailed description of the powder feed center and its functions Figure 2-6 Prodigy Powder Port Feed Center 1. HDLV powder pumps 2. Feed center controls 3. Powder lance 4. Feed hopper 5. Sieve 6. Cartridge filters Roll-On/Roll-Off System (Optional) Roll-on/roll-off systems move the booth offline for color change, cleaning, and maintenance. In roll-on/roll-off systems, the booth base and all related components are equipped with casters and motor drives. The casters ride on rails installed in the spray room floor. The motor drives move the platform online and offline. Booth movement is controlled by online and offline end-of-travel limit switches and operator controls on the system control panel.
18 2-10 Description Control Panels Refer to the following tables for a description of typical system controls. The contents and locations of the control panels vary depending on the system configuration and options installed. Powder Feed Center Control Panel For more information on the feed center controls and operation, refer to the feed center manual Control Emergency Stop Reclaim Transfer On/Off Virgin Transfer On/Off Color Change Start Color Change Stop Reclaim/Virgin Transfer Purge Start Reclaim/Virgin Transfer Purge Stop Sieve On/Off Description Shuts down the entire powder coating system. Rotate the button in the direction of the arrow to reset. Turns on and off the reclaim transfer pump. The pump runs continuously when turned on. Lights amber when on. Enables and disables the virgin transfer pump. When enabled, the pump is controlled by the level sensor and a delay timer. The delay timer prevents the pump from starting until the delay runs out, to prevent pump chattering (rapid on/off cycles). Lights amber when on. Starts the color change process. The spray guns, pumps, and lances are automatically purged. Lights green when on. Used by the feed center operator to notify the system that all feed center color change tasks are complete. Stops process if pressed before complete. Starts the reclaim and virgin transfer pump purge process. Lights green when on, flashes during purge cycle. Stops the reclaim and virgin transfer pump purge process. Starts and stops the vibratory sieve.
19 Description 2-11 System Control Panel Standard Controls Disconnect Switch System Start System Stop System Ready Afterfilter Fan Start Afterfilter Fan Stop Final Filter Warning AeroWash Selector Switch Feed Center Fan Start Feed Center Fan Stop Optional Controls Booth Lights Switch Oscillator #1, 2 Start Oscillator #1, 2 Stop Oscillator #1, 2 Speed Booth Mover Enable Cyclone Disconnect Duct Dampers Description Turns on and off system power and power to the powder feed center control panel. Pushbutton/Green Indicator. Turns on power to the system control panel, if all interlocks (fire detection system, explosion suppression system) and limit switches are closed. Turns off power to the system control panel. Green Indicator. Lights when the SYSTEM START button is pressed and the duct safety gate is fully open. Pushbutton/Amber Indicator. Turns on afterfilter exhaust fan. Turns off afterfilter fan. Spray guns are interlocked with the fan, if the fan is shut off the spray guns shut off. Red Indicator. Lights if the final filter differential pressure exceeds 2.5 in. wc. If the pressure exceeds 3 in. wc the system will be shut down. 3-Position Switch, Off/On/Timed Use to control AeroWash functions. Select continuous on, timed on, or off. Pushbutton/Amber Indicator. Turns on feed center exhaust fan. Turns off feed center exhaust fan. Description Turns on and off booth lights (customer installed). Pushbutton/Amber Indicator. Turns on oscillators. Turns off oscillators. Rotary switch, controls oscillator stroke speed. Enables booth mover system (Roll On/Off booths only) 2-Position Switch, Open/Close. Open to move booth, close after move. Open disconnects duct work from cyclone. 2-Position Switch, Online/Offline. Routes airflow through ductwork. Select online when booth in production position; offline when booth moved offline. Afterfilter Panel Control Pulse On Demand Switch Differential Pressure Gauges and Switches Pulse Valve Timer Description CONTINUOUS: Cartridges are pulsed at operator-specified intervals set at the pulse valve timer. ON-DEMAND: Cartridges are pulsed continuously, but only when the cartridge filter differential pressure switch detects a pressure drop across the cartridge filters of 6.5-in. wc. Detect the pressure drop across the cartridge and final filters to indicate degree of clogging of the filter media. The final filter differential pressure switch is set to light a red warning light at 2.5-in. wc and shut down the entire system at 3-in. wc. (Inside Panel) Use to set the duration (on time) and delay (off time) of continuous cartridge pulsing.
20 2-12 Description Typical System Options Refer to the manuals shipped with optional equipment for more information, or contact your Nordson Corporation representative. Equipment Air Dryer Gun Positioners Oscillators Reciprocators Powder Drum Unloaders Fluidizing Hoppers Prodigy icontrol Part Identification and Spray Gun Triggering System Prodigy Manual Spray Guns and Controllers Description Removes moisture from the system air supply. Most systems use regenerative-desiccant or refrigerated air dryers. Move the spray guns horizontally or vertically toward or away from the workpieces. Move the spray guns in simple repetitive strokes. Move the spray guns in programmed patterns. Transfer powder from shipping drums to the powder feed center. Plastic boxes with a compartment and porous fluidizing plate in the bottom. Low pressure compressed air passing through the plate fluidizes the powder. Identifies and tracks parts on the conveyor and controls gun triggering, powder flow, and electrostatic voltage. Controls movement of gun positioners and reciprocators. Used along with automatic spray guns for final touch-up and coating of hard-to-reach locations.
21 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. Introduction The programmable relays in the powder feed center and system control panels control the automatic processes for the booth and feed center. The relays are typically programmed by your Nordson application engineer to suit your application requirements. NEW SYSTEMS: Before starting up your powder coating system for the first time, perform the Initial Canopy Conditioning procedure in Maintenance. The inside surfaces of the canopy must be clean, free of oils, and dry. A clean canopy prevents powder from sticking, and allows for fast color changes. Typical Operating Settings The settings listed here are approximate. You may need to adjust these settings to obtain the desired results. Operating Air Pressures Air Pressure Input (System) Cartridge Filter Pulse (Afterfilter) Waste Hopper Fluidizing (Afterfilter) AeroWash Setting 6 bar (90 psi) 4 bar (60 psi) 1 bar (15 psi) 5.5 bar (80 psi)
22 3-2 Operation Afterfilter Cartridge Filter Pulsing The cartridge filters in the afterfilter housing are pulsed with compressed air to knock off accumulated powder and maintain air flow through the booth. The pulse delay and duration are controlled by the timer board inside the afterfilter control panel. Pulsing starts when the exhaust fan is turned on and stops when it is turned off. Timer On Time (Duration) Off Time (Delay) Setting 0.07 seconds 90 seconds System Controls Setup The following describes the booth and feed center functions and settings controlled by the programmable relay in the system control panel, and the steps required to set the values in the relay. AeroWash Operation The AeroWash system consists of compressed air jets that clean powder from the sloping surfaces of the spray booth interior and the AeroDeck panels. Typically, three pilot-activated air valves control the flow of air to the left and right sides of the booth and the AeroDeck panels. The AeroWash system operation is controlled by the selector switch on the spray system control panel. The switch positions are OFF, ON, and TIMED. Timed Operation When TIMED is selected, the air valves are opened sequentially to move powder off the surfaces and into the collection system. The timed sequence is controlled by a delay and duration cycle. The delay value (B01:T) is the amount of time between a duration cycle. When the delay timer runs out, the duration cycle starts, during which each valve is opened for the duration value (B02:T), one after the other. When the duration cycle is completed the delay timer is restarted. On Operation When ON is selected, all three air valves are opened at the same time and stay open until another mode of operation is selected or the switch selection is overridden.
23 Operation 3-3 Selection Switch Overrides The color change cycle overrides the AeroWash switch selection. When the Color Change Start button is pressed the valves are closed. Once the guns are fully retracted from the booth, the valves are opened continuously to assist in the cleaning of the booth. When the Color Change Stop button is pressed the valves resume normal timed operation. The AeroWash system is interlocked with the spray booth exhaust fan (in the afterfilter) so if the fan is turned off the AeroWash system is also turned off. Feed Center Cartridge Filter Pulse Operation The feed center cartridge filters collect the waste powder contained inside the feed center. The filters must be cleaned periodically to remove the accumulated powder and maintain the air flow through the feed center. The filters are cleaned by directing pulses of compressed air into the interior of the filters, which knocks the powder off the external surfaces of the filters. The powder falls into the waste hopper under the filters, where it is held until the operator pumps it into a waste container. Filter pulsing is controlled by a selector switch on the feed center solenoid panel. The switch allows pulsing to be set to OFF, CONT (continuous), or TIMED operation. Continuous Pulsing If CONT is selected, each filter pulse valve is turned on for a short duration (B08:T) followed by a delay (B06:T), then the next filter is pulsed. This sequence is repeated continuously. Timed Pulsing If TIMED is selected, a pulse cycle delay (B05:T) separates each pulse cycle. When the cycle delay timer runs out, the pulse cycle starts. During the pulse cycle, each filter is pulsed in turn, using the B08:T and B06:T delay and duration timers. When the pulse cycle is completed the cycle delay timer is restarted. This sequence is repeated continuously. Selection Switch Overrides Filter pulsing is disabled during a color change cycle. Filter pulsing is interlocked with the feed center exhaust fan so if the fan is turned off then pulsing is also turned off.
24 3-4 Operation Feed Center Waste Powder Transfer Operation The powder collected in the feed center waste hopper is transferred by a venturi-type transfer pump to a waste container. The transfer pump is controlled by START and STOP buttons on the feed center. When the START button is pressed, an off delay timer timer (B10:T) starts. The pump stops when the STOP button is pressed, or is automatically turned off when the off delay timer runs out. Switch Selection Overrides The transfer pump control is interlocked with the feed center exhaust fan. The transfer pump will not start if the feed center fan is not running. Oscillator/Reciprocator Operation If reciprocators are used, then starting a color change causes the reciprocators to move to the Park position for external blowoff. If oscillators are used, starting a color change causes the oscillators to move to the bottom-of-stroke position so that the spray guns are in the correct vertical location for the external gun blowoff cycle. The sequence of events is as follows: 1. Color change signal is received. 2. Bottom-of-stroke sensor detects oscillator crank arm and starts delay (B11:T, B12:T). While delay timer is running the sensor signal is ignored. 3. Oscillator slows to 20% speed. 4. Bottom-of-stroke sensor detects oscillator crank arm on next revolution and stops oscillator. 5. External blowoff starts. Bottom-of-stroke sensor must detect crank arm at all times during color change cycle. When the color change STOP button is pressed, the reciprocators or oscillators are released from Park or bottom-of-stroke and resume normal operation. Programmable Relay Setup Changing Function Values Open the system control panel door to access the programmable relay. NOTE: These instructions are also reproduced on a label on the inside of the control panel door.
25 Operation 3-5 Figure 3-7 System Control Panel Programmable Relay 1. Press the ESC and OK keys simultaneously. 2. Press the DOWN () key until the display pointer is on SET PARAM. 3. Press the OK key. The display shows B0x:T and register preset value. 4. Press the UP () key or DOWN () key to select the register preset value to change. 5. Press the OK key. The display highlights the first digit of the preset value. 6. Press the LEFT () or RIGHT () key to highlight the digit to change. 7. Press the UP () key or DOWN () key to change the digit value. 8. After each digit is changed to the desired value, press the OK key. 9. To change another value, go back to step 4. To exit, press the ESC key twice to return to the RUN display. Function Settings Parameter Description Setting B01:T AeroWash Output Cycle Delay (minutes) 5.00 B02:T AeroWash Output #1 Duration (seconds) 5.00 B03:T AeroWash Output #2 Duration (seconds) 5.00 B04:T AeroWash Output #3 Duration (seconds) 5.00 B05:T Feed Center Filter Pulse Cycle Delay (minutes) B06:T Feed Center Filter Pulse Off Duration (seconds) B08:T Feed Center Filter Pulse On Duration (seconds) B010:T Feed Center Waste Powder Off Delay (minutes) B011:T Oscillator #1 Bottom-of-Stroke Sensor Delay 3.00 (seconds) B012:T Oscillator #2 Bottom-of-Stroke Sensor Delay (seconds) 3.00
26 3-6 Operation Startup Use the following procedure to start up the system on a daily basis. NOTE: These procedures assume that the system was cleaned before it was shut down. 1. Make sure the disconnect switches on the system and afterfilter panel are turned on. 2. If applicable, move the system to the online position. Refer to Booth Moving in this section for more information. 3. Press the SYSTEM START button on the system control panel. The SYSTEM START indicator will light. The slide gate in the ductwork between the cyclones and the afterfilter opens. When the gate is fully open, the SYSTEM READY indicator lights and the system is ready to start. 4. Press the AFTERFILTER FAN START button to start the afterfilter exhaust fan. 5. Press the FEED CENTER FAN START button to start the feed center exhaust fan. 6. Prepare the bulk feed system (if used) for operation. 7. Prepare the feed center for operation. Refer to the Prodigy Powder Port feed center manual If used, press the OSCILLATOR #1 and #2 START buttons. Adjust the oscillator speed with the OSCILLATOR #1 and #2 SPEED dials if necessary. 9. Turn the AEROWASH switch to the TIMED position. The booth is now ready for production. For spray gun operation, refer to the following manuals: icontrol Operator Interface Prodigy Manual Gun Controller NOTE: It is important that the inside surface of the canopy is not touched by bare hands. Skin oils and other contaminants will affect the ability of the canopy to shed powder during blowoff. Operators should wear cotton gloves when working with the canopy.
27 Operation 3-7 Booth Moving (Optional) This procedure only applies to Roll On/Roll Off booths. 1. Move the CYCLONE DISCONNECT switch to the OPEN position. The cyclones disconnect from the afterfilter inlet duct. A limit switch prevents movement until the cyclones are fully disconnected. 2. Press the BOOTH MOVER ENABLE button. The booth mover buzzer sounds and the booth mover pendant button is enabled for three minutes. 3. Visually check the area around the booth for obstructions. Clear the area of all obstructions and personnel. 4. Press and hold the pendant button to move the booth to the desired position. The booth stops moving when either you release the button or the booth reaches either the online or offline position. 5. When the booth is in the online or offline position, move the CYCLONE DISCONNECT switch to the CLOSED position. The cyclones connect to the after filter inlet duct. 6. Move the DUCT DAMPERS switch to the ONLINE or OFFLINE position. Color Changing A color change sequence is started by pressing the Color Change START button on the Prodigy feed center control panel. The sequence is finished or aborted by pressing the Color Change STOP button. Refer to the Prodigy Powder Port feed center manual for detailed color change procedures. The following procedure describes the color change procedure and lists the booth cleaning steps. Pressing the Start button starts the spray gun purge and blowoff cycles. AeroWash air is turned off, and feed center cartridge filter pulsing is shut off. The gun movers move the guns to the blowoff position, then move all the way in. The guns are purged and blown off while they are moved out of the booth. When the spray gun purge and blowoff cycles are complete the AeroWash air is turned on continuously to assist in the manual cleaning of the booth.
28 3-8 Operation Color Changing (contd) Once the guns are retracted, you can start cleaning the booth: NOTE: It is important that the inside surface of the canopy is not touched by bare hands. Skin oils and other contaminants will affect the ability of the canopy to shed powder during blowoff. Operators should wear cotton gloves when working with the canopy. 1. At the entrance end of the booth, blow off the door sills, then close the entrance doors. 2. Blow off the exit door sills, then enter the booth and blow off the ceiling, walls, and floor, working towards the entrance end. 3. One at a time, blow off the tops of the AeroDeck panels, then flip them up and blow off the undersides. 4. Blow off the extraction duct door, then open it and blow out the extraction duct. 5. Set the AeroDeck panels back into operating position and exit the booth. Follow the rest of the color change steps in the Prodigy Powder Port feed center manual NOTE: Whenever it becomes difficult to blow powder off the canopy surface, perform the Booth Canopy Conditioning procedure on page 4-4. Conditioning keeps the canopy easy to clean and reduces the potential for contamination of reclaimed powder. Shutdown Use the following procedure to shut down the system. 1. Move the booth offline, if desired. 2. Clean the system by performing the color change process, but do not install a new powder source. 3. Press the SYSTEM STOP button on the system control panel. This will shut down all system motors and close all solenoid valves. 4. If you will be shutting down the system for maintenance, repair, or an extended period of time, turn the disconnect switches on the system and exhauster (if applicable) control panels to the off position.
29 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. Initial Canopy Conditioning Perform this procedure on new canopies before initial startup. This procedure removes oils or other contaminants from the canopy, making the canopy easy to clean and reducing the potential for contamination of reclaimed powder. Required: Acetone or 80%+ isopropyl alcohol, mild dishwashing detergent, clean water, 5 gallon buckets, pre-washed 100% cotton rags, clean hand sponges and sponge mop. NOTE: Rags used for cleaning must be washed before use to remove sizing and starches which would be transferred to the canopy surfaces, degrading the ability of the canopy to shed powder. 1. Wipe down entire canopy with acetone or isopropyl alcohol and pre-washed, 100% cotton rags. 2. Fill two clean buckets with water. 3. Put 2 3 drops of mild dish washing detergent into one of the buckets. This will be the soap bucket. 4. Soak and wring out a hand sponge or a sponge mop in the soap bucket. Wipe down the entire inside of the canopy, frequently wringing out the sponge in the rinse bucket and then re-soaping the sponge in the soap bucket. A continuous wet surface is not necessary, so do not be concerned if some surfaces air-dry prior to next step. You must make sure that the soap solution contacts all surfaces. 5. Empty the buckets, rinse them, and repeat steps 1 3, for a total of two wash cycles. 6. Empty the buckets and rinse them thoroughly. Fill the buckets with clean water and rinse the entire inside of the canopy, frequently wringing out the sponge in the rinse buckets. 7. Repeat step 5 two more times, for a total of three rinse cycles, then allow canopy to completely dry before resuming spray operations. NOTE: It is important that the inside surface of the canopy is not touched by bare hands. Skin oils and other contaminants will affect the ability of the canopy to shed powder during blowoff. Operators should wear cotton gloves when working with the canopy.
30 4-2 Maintenance Daily Maintenance Perform these procedures daily to keep your system clean and functioning properly. System Cleaning WARNING: Wear an approved respirator and safety glasses or goggles when performing maintenance or cleaning operations. Obtain and read Material Safety Data Sheets for each powder used. 1. Perform a color change, but do not load a new color powder into the feed center. 2. Clean the spray guns according to the instructions in their manuals. WARNING: Use only non-conductive tools to clean the booth interior. Do not use any tools that could create friction sparks. A hot spark could be pulled into the recovery system and ignite an explosion or fire. 3. Remove any powder residue from the booth interior with an air-powered vacuum and a soft brush attachment. Wipe down all surfaces with a damp, lint-free cloth (do not use tack cloths). 4. Clean the floor around the booth. 5. Check all equipment grounds, hoses, and cables for loose connections, wear, or breakage. Repair or replace as necessary.
31 Maintenance 4-3 Daily Equipment Maintenance Equipment Flame Detector System Air Dryers Air Velocity Compressed Air Supply Afterfilter Cartridge Filters and Housings Final Filter Housing and Fan Oscillators and In/Out Gun Positioners Powder Spray Guns Prodigy Powder Pumps Prodigy HDLV Transfer Pumps (Reclaim and Virgin Powder) Sieve Workpiece and Conveyor Grounds Procedure Check the detector heads every four hours and clean the lenses, if necessary. Make sure air is being supplied to the heads. Make sure the detector system is operating properly. Perform any required maintenance as described in your air dryer manual. Measure the air velocity at all booth openings with a velometer. Minimum velocity is 36 m/min (120 fpm). Hold a clean, white cloth under the supply line 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. The cartridge filter differential pressure gauge should read 4 6 in. wc. with the exhaust fan operating. If it is high, check the pulse valve timing. The cartridge filters should be pulsed often enough to prevent clogging. The final filter differential pressure gauge should read in. wc. with the exhaust fan operating. At 3 in. w.c. the system will shut down. Each shift, make sure the oscillators and in/out gun positioners are moving smoothly and at the proper speed. Make repairs and adjustments if necessary. Follow the lubrication instructions in the equipment manuals. Clean the spray guns according to the instructions in their manuals. Visually inspect the pump pinch valves (visible through the transparent pump bodies). If powder is visible inside the pinch valve cavities, the pinch valve is leaking. Disassemble and replace all pinch valves at the same time. Refer to the pump manual for instructions and pinch valve kit part number. Visually inspect the pump pinch valves (visible through the transparent pump body). If powder is visible inside the pinch valve cavities, the pinch valve is leaking. Disassemble and replace all pinch valves at the same time. Refer to the pump manual for instructions and pinch valve kit part number. Remove and clean the screen. Replace the screen if it is damaged. Check the rubber seals. Replace any damaged or worn parts. 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. Use a megohm meter to check resistances. You will get better transfer efficiency and workpiece coverage at 500 ohms or less. Clean the hangers regularly.
32 4-4 Maintenance Weekly Maintenance Weekly Equipment Maintenance Equipment Booth Enclosure Afterfilter Differential Pressure Gauges Powder Spray Guns and Cables HDLV Powder Pumps and Tubing (Gun and Transfer) Procedure Perform the Booth Canopy Conditioning procedure in this section. Clean the booth exterior, all attached equipment, and the spray room. Check the enclosure for cracks, damage, and dirt. Seal any cracks. Observe and record the differential pressure gauge readings. Cartridge Filters Pressure Drop: in. wc Final Filters Pressure Drop: in. wc The cartridge filters are clogged if the pressure drop across the filters exceeds 6.5-in. wc. The system is programmed so that at 2.5-in. wc, the final filter warning light on the control panel lights. At 3-in. wc the system shuts down. Clean the spray guns. Perform electrostatic resistance checks as described in the spray gun manuals. Purge the pumps. If powder is visible inside the pinch valve cavities, the pinch valve is leaking. Disassemble and replace all pinch valves at the same time. Refer to the pump manual for instructions and kit part numbers. Check the suction and delivery tubing for blockages or wear. Clear or replace tubing as necessary. Booth Canopy Conditioning Perform this procedure every six months or whenever it becomes difficult to blow powder off the canopy surface. Conditioning keeps the canopy easy to clean and reduces the potential for contamination of reclaimed powder. NOTE: To remove impact-fused powder, perform the initial canopy conditioning procedure on page Fill two clean buckets with water. 2. Put 2 3 drops of mild dish washing detergent into one of the buckets. This will be the soap bucket. 3. Soak and wring out a hand sponge or sponge mop in the soap bucket. Clean the entire inside of the canopy, frequently wringing out the sponge in the rinse bucket and then re-soaping the sponge in the soap bucket. 4. Empty the buckets, rinse them, and repeat steps 1 3, for a total of two wash cycles. 5. Empty the buckets and rinse them. Fill the buckets with clean water and rinse the entire inside of the canopy, frequently wringing out the sponge in the rinse buckets. 6. Repeat step 5 two more times, for a total of three rinse cycles. Allow the canopy to completely dry before resuming spray operations. NOTE: It is important that the inside surface of the canopy is not touched by bare hands. Skin oils and other contaminants will affect the ability of the canopy to shed powder during blowoff. Operators should wear cotton gloves when working with the canopy.
33 Maintenance 4-5 Monthly Maintenance Monthly Equipment Maintenance Equipment Feed Center and Afterfilter Venturi-Type Transfer Pumps Air Dryer Electrical Connections Gaskets Fan and Roll-On/Roll-Off System Bearings Roll-On/Roll-Off Wheels Procedure Disassemble and clean the pump blocks, venturi throats and throat holders. Replace worn parts. Check the air dryer operation. Refer to your air dryer manual for maintenance procedures and schedules. Check all terminal blocks and junction boxes for loose wires. Tighten any loose connections and inspect the system wiring. Replace any damaged wires. Inspect all gaskets and seals, replace any that are damaged. Every six months, lubricate the fan bearings and all motor bearings with two shots of No. 2 lithium grease from a grease gun. Lubricate the flanged wheel bearings with two shots of white lithium grease every six months. Cyclone Cleaning Use the cyclone cleaning media listed in Parts to clean the cyclones and remove impact-fused powder. Results may vary depending on the level of impact fusion. Cleaning durations can be reduced or increased to meet system requirements. 1. Disconnect the transfer hose and fluidizing air tubing from the transfer pan at the bottom of the cyclone. 2. Plug all the tubing and hose connectors in the transfer pan. 3. Close the cyclone access doors, if open. 4. With the exhaust fan running, dump 1 2 cups of cyclone cleaning media into the cyclone inlet duct. 5. Let media clean the cyclones for approximately one hour. This duration can be reduced or increased as needed. 6. Shut down the exhaust fan. 7. Open the transfer pan and remove the remaining cyclone cleaning media. 8. Close the transfer pan. 9. Load a new powder color and reclaim to waste for 1 2 minutes to cleanse the system of the cyclone cleaning media residue.
34 4-6 Maintenance Emptying the Afterfilter Waste Hoppers Waste powder transfer is a continuous operation controlled by two solenoid valves and a timer, located in the afterfilter panel. When the afterfilter exhaust fan is on the timer (TDR220) is enabled and the waste powder pump solenoid (SOL 219) is turned on for continuous operation. The fluidizing and vibrator motor solenoid (SOL 220) is turned on and off by the timer. Adjustment T1 on the timer sets the amount of time that the fluidizing and vibrator motor solenoid (SOL 220) is turned on. T1 is adjustable for seconds. Adjustment T2 on the timer sets the delay between cycles of SOL 220. T2 is adjustable for minutes. NOTE: The feed center also has a waste hopper that must be emptied as needed. Refer to the feed center manual for the procedure. Initial Setup and Operation See Figure Secure the waste lid (8) to an empty 55-gallon drum (5). 2. Connect the ground clamp (4) to a true earth ground. 3. Attach 3 / 4 -in. transfer hoses (9) between the transfer pumps (3) and the hose connectors (6) on the waste lid. Use hose clamps on both ends of the transfer hoses. NOTE: Make sure that all unused hose connectors on the waste lid are plugged. 4. Attach the vent hose (2) to the waste lid vent stub (7). Attach the other end of the vent hose to the afterfilter vent stub (1). 5. Open the ball valves on the afterfilter air drop to supply compressed air to the transfer pumps and fluidizing/vibrator air pilot valves. The air pilot valves are controlled by the solenoid valves SOL 219 and 220 in the afterfilter panel. NOTE: The normal operating air pressure for the transfer pump is 2 bar (30 psi). Increase the transfer pump air pressure if desired. Regulators are located on the afterfilter air drop. Changing Waste Containers 1. Close the air drop ball valves supplying compressed air to the transfer pumps. 2. Remove the waste lid (8), with hoses attached, from the waste container (5). 3. Install the waste lid on an empty waste container. 4. Open the air drop ball valves.
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