Electrostatic Flux Coating System

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1 Electrostatic Flux Coating System Customer Product Manual Part NORDSON CORPORATION AMHERST, OHIO USA

2 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 Blue Box, Can Works, Century, CleanSleeve, CleanSpray, Control Coat, Cross-Cut, Easy Coat, Econo-Coat, Excel 2000, Flow Sentry, FoamMix, Horizon, Hot Shot, Isocoil, Isocore, Iso-Flo, MEG, Nordson, the Nordson logo, Package of Values, PowderGrid, Pro-Flo, PRX, RBX, Ready Coat, Rhino, SCF, Select Coat, Select Cure, Shur-Lok, Smart-Coat, System Sentry, Tribomatic, Versa-Coat, Versa-Screen, and Versa-Spray are registered trademarks of Nordson Corporation. Accu-Jet, Auto-Flo, CanNeck, Clean Coat, CPX, EasyClean, Ink-Dot, OptiMix, PowderGrid, Pulse-Spray, Sure Coat, Swirlcoat and Walcom are trademarks of Nordson Corporation.

3 Table of Contents i Table of Contents Section 1 Safety 1. Introduction Qualified Personnel Intended Use Regulations and Approvals Personal Safety Fire Safety Action in the Event of a Malfunction Disposal Section 2 Description 1. Introduction System Operation Pump Operation System Components and Functions Specifications Section 3 Operation 1. New System Startup Fan Motor Rotation Check Sieve Motor Rotation Check System Settings Gun Adjustments Vent-Assist Air Pressure Adjustment Feed-Hopper Level Sensor Calibration Daily Startup and Shutdown Procedures Daily Startup Shutdown System Settings

4 ii Table of Contents Section 4 Maintenance 1. Daily Maintenance Enclosure Cleaning Daily Equipment Maintenance Weekly Maintenance Periodic Maintenance Maintenance Check List Section 5 Troubleshooting 1. Introduction Troubleshooting Chart Section 6 Repair 1. Final Filter Replacement Cartridge Filter Replacement Removal Installation Collector Fluidizing Plate Replacement Feed Hopper Fluidizing Plate Replacement Removal Installation Reclaim Hopper Fluidizing Plate Replacement Removal Installation Pulse Valve Replacement Motor and Fan Replacement Fan Replacement Motor Replacement Section 7 Parts 1. Introduction Using the Illustrated Parts List Final Filters and Mounting Hardware Cartridge Filters and Mounting Hardware Pulse Valves and Solenoids Collector Fluidizing Plate and Hardware Fan and Fan Drive

5 Section 1 Safety S1EN 03 [SF Powder] 6

6 1-0 Safety S1EN 03 [SF Powder] 6

7 Safety 1-1 Section 1 Safety 1. 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. 2. 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. 3. 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. 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 4. Regulations and Approvals 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. S1EN 03 [SF Powder] 6

8 1-2 Safety 5. Personal 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. 6. Fire Safety 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. S1EN 03 [SF Powder] 6

9 Safety 1-3 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. Grounding All work conducted inside the spray booth or within 1 m (3 ft) of booth openings is considered within a Class 2, Division 1 or 2 Hazardous location and must comply with NFPA 33, NFPA 70 (NEC articles 500, 502, and 516), and NFPA 77, latest conditions. 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 s platform, hoppers, photoeye supports, and metal 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 the 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-metal 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. S1EN 03 [SF Powder] 6

10 1-4 Safety 7. Grounding (contd) 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. 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. 8. Action in the Event of a Malfunction 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. 9. Disposal Dispose of equipment and materials used in operation and servicing according to local codes. S1EN 03 [SF Powder] 6

11 Section 2 Description

12 2-0 Description

13 Description 2-1 Section 2 Description 1. Introduction This manual covers general operation, maintenance, troubleshooting, and repair of your Nordson Electrostatic Flux Coating System. Components such as spray guns, control units, sieves, and fire detection systems are covered by separate manuals. For information on system components not covered by the manuals furnished with your system, contact your Nordson Corporation representative. 2. System Operation See Figure 2-1. A porous fluidizing plate in the feed hopper (20) plenum diffuses low-pressure compressed air into the powdered flux supply. The air fluidizes the flux so it can be pumped to the spray guns (16). Air-operated agitators (14) stir the flux to help keep it fluidized. The feed pumps (19) draw the flux out of the feed hopper and mix it with a high velocity stream of air. This air conveys the flux through the feed hoses (18) to the spray guns. The guns electrostatically charge the flux and spray it on the workpieces passing through the booth. The exhaust fan (1) pulls air into the booth enclosure (17) and through the cartridge filters (4). The oversprayed flux suspended in the air flow collects on the outside of the cartridge filters. The final filters (2) remove any remaining flux from the air. On a signal from a timer, the pulse valves (3) release large volumes of air through the center of the cartridge filters, blowing off the accumulated flux. The flux falls into the bottom of the collector (5), where it is fluidized. The reclaimed flux is then pumped by transfer pumps (6) through large-diameter transfer hoses (7) to an accumulator (15) mounted on a rotary sieve (13). The rotary sieve screens the flux. Particles too large to pass through the screen are discharged into a scrap container (11). The screened flux falls into the reclaim hopper (12), where it is stored and fluidized. A load chute on the reclaim hopper allows new flux to be added when system supplies run low. Flux is pumped by transfer pumps (10) through large diameter transfer hoses (8) to the feed hopper accumulator (21) on a signal from a level sensor. Conveying air, fluidizing air, and dust are vented into the collector through vent hoses (9, 22).

14 2-2 Description 2. System Operation (contd) Clean air Vent air and dust Powder A Fig. 2-1 System Operation 1. Exhaust fan 2. Final filters 3. Pulse valves 4. Cartridge filters 5. Collector 6. Transfer pumps 7. Transfer hoses 8. Transfer hoses 9. Vent hose 10. Transfer pumps 11. Scrap container 12. Reclaim hopper 13. Rotary sieve 14. Agitators 15. Accumulator 16. Spray gun 17. Enclosure 18. Feed hose 19. Feed pumps 20. Feed hopper 21. Accumulator 22. Vent hose

15 Description 2-3 Pump Operation See Figure 2-2. The feed pump (1) has three air inlets in the pump body and an in-line inlet fitting installed at the outlet. When a spray gun is triggered, flow-rate air (A), atomizing air (B) and pulse air (C, C1) are turned on. Flow-rate air draws the powdered flux into the pump and conveys it to the spray guns. Pulse air breaks up any clumps of flux. Atomizing air distributes the flux evenly in the air stream and increases its velocity. When the spray gun is turned off, flow-rate, atomizing, and pulse air are turned off and reverse air (D, D1) is turned on. Reverse air prevents the flux from clogging the pumps, hoses, and guns. The transfer pumps (2) work on the same principle, but are equipped only with flow-rate air (A) and pulse air (B) inlets. To prevent flux from contaminating the solenoid valves that control air flow, all air lines are equipped with one-way check valves (3).

16 2-4 Description Pump Operation (contd) 1 3 C1 D1 B C D A 2 B A A Fig. 2-2 Feed and Transfer Pump Operation 1. Feed pump 2. Transfer pump 3. Check valves

17 Description System Components and Functions See Table 2-1 for a description of major system components. The numbers in the Item columns are references to Figure 2-3. Table 2-1 Containment and Recovery System Components and Functions Item Equipment Function 1 Solenoid panel Houses solenoid valves that control pump pulse air and reverse air. 2 Pneumatic panel Houses air pressure regulators and gauges used to control system pneumatic equipment. 3 Vent-assist pumps Help vent fluidizing air and dust out of the feed and reclaim hoppers into the collector. In the collector, the dust is filtered out of the air before it is returned to the spray room. 4 Accumulators Provides a connection point for multiple transfer hoses. Collects powdered flux pumped from the collector to the reclaim hopper and from the reclaim hopper to the feed hopper. 5 Agitator Stirs the flux to help keep it fluidized. Air-operated. 6 Feed hopper Stores and fluidizes the flux supply for the spray guns. 7 Feed pumps Pump flux from the feed hopper to the spray guns, through feed hoses. 8 Fan section Houses the exhaust fan and final filters. The exhaust fan pulls spray room air through the cartridge filters and pushes it through the final filters. The air flow contains the powdered flux within the system. 9 Pulse valve timer Controls the time between cartridge filter pulsing and the duration of each pulse. During a pulse, air is blown through the center of the cartridge filters to clean them. 10 Differential pressure gauge Monitors the pressure drop across the cartridge filters. A high reading indicates filter clogging. 11 Vent-assist plate Provides a connection point for hopper and accumulator vent hoses. 12 Versa-Screen workstation Houses system controls. Touch screen display allows operator to set up, monitor, and control most system components. 13 Collector Houses the cartridge filters, stores, and fluidizes reclaimed powder. 14 Booth enclosure Helps contain the sprayed powder within the system. 15 Spray guns Electrostatically charge and spray flux onto parts moving through the booth. 16 Oscillators Move the spray guns in a repetitive pattern. 17 Reclaim hopper Stores and fluidizes oversprayed flux. 18 Transfer pumps Pump reclaimed flux from the collector to the reclaim hopper, and from the reclaim hopper to the feed hopper, through transfer hoses. 19 Rotary sieve Screens reclaimed flux pumped from the collector. 20 Oscillator drive panel Houses the dc controls for the oscillators. 21 Fire detection system panel Houses the controls for the fire detection system. Sensors monitor the system and shut it down if an electrical arc or fire is detected. 22 System electrical panel Houses the system electrical controls, transformer, motor starters, overload protectors, and terminal blocks. Distributes conditioned power to the system devices. Also houses the transfer pump delay timer. 23 Gun control cabinet Houses the spray gun control units, and a master control unit that distributes power to the gun control units. A pilot valve and pneumatic manifold in the cabinet distributes compressed air to the gun control units.

18 2-6 Description 3. System Components and Functions (contd) Fig. 2-3 System Components A

19 Description Specifications Overall Base Dimensions: Height Width Length 2.6 m (8.5 ft) 2.4 m (8.0 ft) 2.1 m (7.0 ft) Supply Air Pressure and Exhaust Fan Capacity: Maximum air pressure 6.9 bar (100 psi) Air flow at 4-in. w.c. 70 m 3 /min (2500 cfm) Air flow at 6-in. w.c. 56 m 3 /min (2000 cfm) System Equipment Capacities: Spray guns Cartridge filters Pulse valves Final filters six (automatic only) four, 66.0 cm (26 in.) four two, 61.0 x 50.8 cm (24 x 20 in.)

20 2-8 Description

21 Section 3 Operation

22 3-0 Operation

23 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. 1. New System Startup Use these procedures to prepare your Nordson flux coating system for production. Your Nordson representative will help you set up your application equipment and adjust your system control settings before you start production. Fan Motor Rotation Check Start the exhaust fan (refer to Daily Startup) and make sure the fan is pulling air into the booth enclosure and forcing air out through final filters. If the air flow is reversed, perform the following steps: WARNING: Shut off power at a disconnect ahead of the electrical panel before opening the panel door. Failure to observe this warning could result in serious injury or death. 1. Open the electrical panel door and reverse any 2 wires (L1, L2, or L3) connected to the fan motor starter (M110). 2. Close the panel door, turn on electrical power and the exhaust fan, and make sure air is flowing through the booth enclosure in the correct direction. Sieve Motor Rotation Check Make sure the sieve motor is rotating in the direction indicated by the arrow on the motor housing (clockwise as viewed from the motor end). If it is not, perform steps 1 and 2 of the Fan Motor Rotation Check procedure, reversing the sieve motor starter (M120) wires instead. System Settings NOTE: The settings given in this procedure are suggested initial startup settings. Make adjustments as needed for optimum performance. All the settings listed here are included in the System Settings chart at the end of this section, along with space for you to write in your adjusted settings. Copy this chart and post it on your system.

24 3-2 Operation System Settings (contd) WARNING: Shut off power at a disconnect ahead of the electrical panel before opening the panel door. Failure to observe this warning could result in serious injury or death. 1. Open the electrical panel door. Set the transfer-pump delay timer to 60 seconds, then close the panel door. 2. Turn on the system electrical power. 3. Open the pulse-valve timer panel. Make the following settings: Delay (OFF) Duration (ON) 15 seconds 0.07 seconds Close the timer panel. 4. Set all air pressure regulators on the pneumatic panels to zero. 5. Turn on the compressed air supply. Adjust the system air pressure to 6.9 bar (100 psi). 6. Turn on the exhaust fan (refer to Daily Startup). WARNING: Wear an approved respirator or dust mask and goggles when handling powders. Avoid getting powders on your skin. Wash powder off with soap and water only. 7. Fill the feed hopper 2 / 3 full of flux. 8. Calibrate the feed hopper level sensor. Refer to Feed Hopper Level Sensor Calibration in this section. 9. Set the reclaim and feed hopper fluidizing air pressures to 2.1 bar (30 psi). Adjust the pressures until you see the flux gently boiling. Allow minutes for the flux to fluidize before spraying. 10. Set the reclaim and feed hopper vent-assist pump air pressure to 0.7 bar (10 psi). 11. Set the collector module fluidizing air pressure to 2.1 bar (30 psi). When flux covers the fluidizing plate in the bottom of the collector module, adjust the pressure. You should see the surface of the flux boil gently. 12. At the rotary sieve control panel, make the following settings: Seal air pressure Flowmeters 1.7 bar (25 psi) 100 SCFH

25 Operation Set the accumulator vent-assist air pressure. Refer to Accumulator Vent-Assist Air Pressure Adjustment in this section. 14. Set the transfer-pump selector switch to AUTO. This will allow the level sensors to control the transfer pumps. Set the transfer pump air pressures: Flow-rate air pressure 1.7 bar (25 psi) Pulse air pressure 0.7 bar (10 psi) 15. Adjust the pulse-valve air pressure and volume: a. Open the left-hand slide gate on the front of the fan section to access the pulse valve air controls. Set the pulse valve regulator to bar (50 60 psi). Watch the pressure gauge. The pressure will drop when the valves open. b. Adjust the gate valve so the air pressure returns to bar (50 60 psi) just before the next pulse. This adjustment will prevent the powder pumps from being deprived of air during pulses. Gun Adjustments 1. Set gun triggering to the Manual mode: a. From the Main Menu, press F2 (Gun Control screen). b. Press F7 to toggle from Automatic to Manual mode. Changing to Manual mode will trigger the guns. 2. Trigger the spray guns and make the following settings: Flow-rate air 0.8 bar (12 psi) Atomizing air 1.7 bar (25 psi) Pulse air 1.4 bar (20 psi) Reverse air1.7 bar (25 psi) kv a 40 NOTE: These are suggested starting pressures. To fine-tune your film build, watch the guns spray while adjusting the flow-rate and atomizing air pressures on the gun control panels. Flow-rate air pressure is controlled by the left regulator, while atomizing air pressure is controlled by the right regulator.

26 3-4 Operation Gun Adjustments (contd) 3. Return gun triggering to the Automatic mode: a. Press F10 Previous Screen (Main Menu screen). b. Press F13 Gun Movers screen. Use F14 or F16 to move the guns to their fully extended positions, as needed. c. Press F10 Previous Screen (Main Menu screen). d. Press F2 Gun Control screen. e. Press F7 to toggle from Manual to Automatic mode. Vent-Assist Air Pressure Adjustment Use the following procedure to adjust the vent-assist air pressure. 1. Disconnect the scrap hose from the sieve scrap port. 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. Perform this procedure when you start up a new system or replace a sensor. 1. See Figure 3-1. Insert the level sensor into the plastic mounting well in the side of the feed hopper until it bottoms out, then pull it back about mm (0.125 in.). 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 2.1 bar (30 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.

27 Operation If the sensor LED (2) is on, slowly turn the sensor potentiometer (3) 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. Count the number of turns you make until the LED lights. 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. NOTE: Replacement sensors are shipped configured as normally closed (N.C.) switches mm (0.125 in.) 4 N.O. N.C. Fig. 3-1 Level Sensor Installation and Configuration 1. Cover 3. LED 2. Potentiometer 4. Jumper wire L1 (Vac) + (Vdc) L2 (Vac) (Vdc) A

28 3-6 Operation 2. Daily Startup and Shutdown Procedures Daily Startup Use these procedures for routine operation of your system. 1. Walk around the booth. Make sure the transfer, feed, and vent hoses are connected correctly, and that all equipment ground connections are secure. WARNING: An ungrounded or poorly grounded workpiece, conveyor, or equipment ground can cause electrical arcing. If arcing is observed, shut down the system immediately. Correct the cause before restarting the system. Failure to observe this warning could result in a fire or explosion, causing property damage, and possible injury or death. 2. Turn on the system electrical power and compressed air supply. 3. Turn on the master control unit and gun control units in the gun control cabinet, if not already on. 4. Push the SYSTEM START button on the electrical panel. This energizes the system. 5. Make sure the flame detector(s) and relay/indicator panel are functioning correctly. 6. Go to the Versa-Screen workstation and start the system: a. Press F3 Booth Control. b. Press F3 Manual Motors (Booth Status screen). c. Press F2 System Start (Motor Controls screen). This activates the exhaust fan motor and turns on air to all system devices. Through this screen, you can also change fan speed. Press the Home button to change the fan speed. Normal operation: Set fan speed at 3. Clean-up: Set fan speed at 10. d. Press F4 Sieve Start (Motor Controls screen).

29 Operation 3-7 e. Press F10 Previous Screen (Booth Status screen). f. Press F15 Gunmover Status. g. Press F7 Mover Mode (Gunmover Status screen). Select Automatic mode for normal operation. If the gun movers are not in the Home position, you will not be able to select Automatic mode. If so, select Manual mode and then Home. Once the gun movers are in the Home position, select Automatic. 7. Start the conveyor and move workpieces through the booth. With the system in Automatic mode, the guns will start spraying automatically as the workpieces pass beneath them. 8. Adjust pump air pressures and gun voltages as needed. NOTE: To fine-tune your film build, watch the guns spray while adjusting the flow-rate and atomizing air pressures on the gun control panels. Flow-rate air pressure is controlled by the left regulator, while atomizing air pressure is controlled by the right regulator. 9. Measure the air flow velocity at the enclosure entry and exit vestibules with a velometer. The velocity should be m/min ( ft/min). Make sure the sprayed flux is not being pulled from the guns and workpieces, and that the flux is not escaping from the enclosure openings. NOTE: Keep the air dryer running continuously. This will prevent moisture from accumulating in the compressed air system. Shutdown 1. Start the transfer pumps and sieves. Pump the reclaimed flux from the collector module back into the reclaim hopper. 2. Turn off the spray-gun master control unit. 3. Perform the daily maintenance procedures described in the Maintenance section. Perform daily maintenance procedures for other system equipment as described in their manuals. 4. Turn off the exhaust fan. Shut off the system electrical power and compressed air supply.

30 3-8 Operation 3. System Settings Equipment Primary Air Pressure (plant supply) Collector Module Fluidizing Transfer pump flow rate Transfer pump pulse Feed Hopper Fluidizing Vent-assist Reclaim Hopper Fluidizing Vent-assist pump Transfer pump flow rate Transfer pump pulse Pulse Manifold Air pressure Rotary Sieve Flowmeter #1 Flowmeter #2 Seal air pressure Vent-assist air pressure Pulse Timer Delay (OFF) time Duration (ON) time Filter Pressure Drop Maximum Readings Cartridge filters Final filters Spray guns Recommended Initial Settings Final Setting Changes 6.9 bar (100 psi) 2.1 bar (30 psi) 1.7 bar (25 psi) 0.7 bar (10 psi) 2.1 bar (30 psi) 0.7 bar (10 psi) 2.1 bar (30 psi) 0.7 bar (10 psi) 1.7 bar (25 psi) 0.7 bar (10 psi) bar (50 60 psi) 100 SCFH 100 SCFH 1.7 bar (25 psi) 2.8 bar (40 psi) 15.0 sec sec. 4 6-in. w.c. 2-in. w.c. #1 Flow-rate 0.8 bar (12 psi) Atomizing Pulse Reverse Voltage AFC 1.7 bar (25 psi) 1.4 bar (20 psi) 1.7 bar (25 psi) kv 40 A

31 Operation 3-9 Spray guns (contd) Equipment #2 Flow-rate 0.8 bar (12 psi) Atomizing Pulse Reverse Voltage AFC Recommended Initial Settings Final Settings Changes 1.7 bar (25 psi) 1.4 bar (20 psi) 1.7 bar (25 psi) kv 40 A #3 Flow-rate 0.8 bar (12 psi) Atomizing Pulse Reverse Voltage AFC 1.7 bar (25 psi) 1.4 bar (20 psi) 1.7 bar (25 psi) kv 40 A #4 Flow-rate 0.8 bar (12 psi) Atomizing Pulse Reverse Voltage AFC 1.7 bar (25 psi) 1.4 bar (20 psi) 1.7 bar (25 psi) kv 40 A #5 Flow-rate 0.8 bar (12 psi) Atomizing Pulse Reverse Voltage AFC 1.7 bar (25 psi) 1.4 bar (20 psi) 1.7 bar (25 psi) kv 40 A #6 Flow-rate 0.8 bar (12 psi) Atomizing Pulse Reverse Voltage AFC 1.7 bar (25 psi) 1.4 bar (20 psi) 1.7 bar (25 psi) kv 40 A

32 3-10 Operation

33 Section 4 Maintenance

34 4-0 Maintenance

35 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. 1. Daily Maintenance Perform these procedures daily to keep your system clean and functioning properly. WARNING: Wear an approved respirator and safety glasses or goggles when handling flux, operating the system, or performing maintenance or cleaning operations. Enclosure Cleaning 1. Turn off the automatic-gun master-control unit. 2. Turn on the exhaust fan (refer to Daily Startup in the Operation section). Set the motor speed to Clean the enclosure roof, walls, and floor with a rubber squeegee. Push the collected flux into the color module. 4. Clean the booth enclosure with a rubber squeegee, pushing the flux into the collector hopper. 5. Remove the remaining residue from the enclosure 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). 6. Turn off the exhaust fan. 7. Clean the operator s platform and the floor around the booth.

36 4-2 Maintenance Daily Equipment Maintenance Equipment Procedure Filters 1. Check the final filter differential pressure gauge. It should read between 1- and 2-in. w.c. A pressure greater than 2-in. w.c. will shut down the system automatically. Make sure no flux is leaking from around the filter gasket or face. Rotary Sieve 1. Empty the scrap container. 2. Check the cartridge filter differential pressure gauge. It should read between 4- and 6-in. w.c. A reading higher than 6-in. w.c. indicates that the filters are clogged and should be replaced. Check the pulse valve timing. 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 seal air pressure and flow rate. Check the sieve accumulator vent-assist air pressure. Refer to your AZO sieve manual for more information. Feed and Transfer Pumps 1. Disconnect the hoses from the pumps. Blow out the hoses with compressed air. 2. Place a small container under the pumps to catch spilled flux. Depress the spring clips on the pumps and pull them off 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. 4. Check the pump adapters and pickup tubes. If they are clogged with flux, use a wooden dowel or plastic rod to clean them out, working from the inside of the hopper. Fan Section 1. Remove the final filters and inspect the fan compartment. Vacuum out any flux. 2. Inspect the pulse-valve compartment. Vacuum out any flux. If significant amounts of flux have accumulated in the fan or pulse-valve compartment, the cartridge filters may be leaking. Refer to the Troubleshooting and Repair sections for instructions.

37 Maintenance 4-3 Spray Guns Equipment Fire Detection System Compressed Air Supply and Air Dryer Gun Movers Accumulators and Vent Hoses Workpiece and Conveyor Grounds Procedure Disassemble and clean the guns according to the instructions in their manuals. 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. 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. Refer to your air dryer manual for maintenance procedures and schedules. Each shift, make sure the gun movers are stroking 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 flux out of the vent hoses with compressed air. WARNING: An ungrounded or poorly grounded workpiece 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 conveyor. The resistance between the workpieces 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 workpiece hangers regularly.

38 4-4 Maintenance 2. Weekly Maintenance Equipment Procedure Booth Spray Guns Reclaim and Feed Hoppers Collector Clean the booth enclosure interior as described in Enclosure Cleaning, and the exterior, all attached equipment, and the spray room. Perform resistance checks on the spray guns and cables as described in the gun manuals. Remove the flux from the hoppers. Vacuum the interiors. Check the fluidizing plates. If the plates are stained, the air supply could be contaminated by oil or moisture. Check the air dryer and air filters. Replace the fluidizing plates if they are contaminated. Lubricate the hopper casters with a lithium grease. Start the exhaust fan and activate the pulse valves to blow off as much flux as possible off the cartridge filters. Do not vacuum the cartridge filters. Remove the cartridge filters and inspect the filter media and gaskets. Replace the filters if they are damaged. Pump the flux out of the collector. Vacuum the interior. Check the fluidizing plate. If it is stained, the air supply could be contaminated by oil or moisture. Check the air dryer and air filters. Replace the fluidizing plate if it is contaminated. 3. Periodic Maintenance Equipment Electrical Connections Air Dryer Gaskets Bearings AZO Rotary Sieve Procedure Check all terminal blocks, and junction boxes for loose wires. Tighten any loose connections and inspect all wiring for damaged insulation. Replace the wiring if the insulation is damaged. Check the air dryer operation. Refer to your air dryer manual for maintenance procedures and schedules. Inspect all gaskets and seals for damage. Replace them if they are damaged. Every six months, lubricate the motor bearings with two shots of lithium or polyurea grease from a grease gun. Lubricate the AZO rotary-sieve lip seals every three months with a white lithium grease. Refer to your sieve manual for more information.

39 Maintenance Maintenance Check List Activity Each Shift Daily Weekly Monthly Cleaning Accumulator Booth enclosure Color module Fan and pulse-valve compartments Feed hoses and transfer hoses Fire detector sensor lenses* Feed and transfer pumps Guns Rotary sieve Vent hoses Resistance Checks Guns and Cables Visual Checks Air supply drop leg Air dryer Cartridge filter differential-pressure gauge Electrical connections Final filter differential-pressure gauge Fire detector sensors Gaskets Gun movers Workpiece clearance** Workpiece grounding Flux levels Lubrication AZO rotary-sieve lip seals*** Fan bearings Motor bearings * Every 4 hours. ** Clearance should be monitored continuously. *** Every 3 months.

40 4-6 Maintenance

41 Section 5 Troubleshooting

42 5-0 Troubleshooting

43 Troubleshooting 5-1 Section 5 Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. 1. Introduction This section contains troubleshooting procedures. These procedures cover only the most common problems that you may encounter. If you cannot solve the problem with the information given here, contact your local Nordson representative for help. Problem 1. Guns are surging or spitting; flux flow is inadequate or intermittent 2. Problems with coating uniformity, edge coverage, film build, wrap, or penetration into recesses 3. Flux not transferring between collector, reclaim hopper, and feed hopper Page 4. Flux not fluidizing, or clouds of flux erupting from surface Final filters clogged, flux in fan compartment Cartridge filters clogged System shuts down or will not start Sieve not screening flux Sieve scrap bucket filling up with flux Flux escaping from booth openings

44 5-2 Troubleshooting 2. Troubleshooting Chart Problem Possible Cause Corrective Action 1. Guns are surging or spitting; flux flow is inadequate or intermittent Flux in feed hopper inadequately fluidized Low flux level in feed hopper Feed pump venturi nozzles or throats worn; adapter O-rings leaking; pump or pickup tube clogged Obstruction in feed hose Severe tribo-charging in feed hose Obstruction in gun Flow-rate or atomizing air pressure incorrect Adjust the fluidizing air pressure. The flux should be gently boiling. Refer to problem 4 for more troubleshooting procedures. Add flux to the feed hopper. Refer to problem 3 for more troubleshooting procedures. Clean the pump and pickup tube. Replace any worn parts. Replace the adapter O-rings, if they are damaged. Disconnect the feed hose from the pump. Blow the flux out of the hose with compressed air. Make sure the hose is clear. Eliminate kinks or severe bends in the hose. The hose should be no longer than 7.6 m (25 ft) with a maximum 2.7-m (9-ft) vertical rise. Contact your Nordson Corporation representative for a suitable hose material. Unclog the gun. To do this, put the guns in Manual mode (refer to Gun Adjustments in the Operation section) and increase the flow-rate air pressure to 2.8 bar (40 psi) or higher until the gun clears. Return the pressure setting to normal. If this does not work, open the solenoid panel and increase the air pressure on the purge air regulator (middle regulator) until the gun clears. If the gun is still clogged, stop production, shut down the system, and manually clean the gun. If you are using conical nozzles, make sure there is a 3-mm (0.125-in.) or larger gap between the deflector and the nozzle. Refer to the Operation section for recommended air pressures and ratios. Continued on next page

45 Troubleshooting 5-3 Problem Possible Cause Corrective Action 2. Problems with coating uniformity, edge coverage, film build, wrap, or penetration into recesses 3. Flux not transferring between collector, reclaim hopper, and feed hopper Poor workpiece grounding Gun placement incorrect Feed pump flow-rate and atomizing air pressure incorrect Electrostatic voltage (kv) or AFC setting incorrect for workpieces being coated Wrong nozzles being used Flux feed problems Transfer pump air pressure too low Transfer pump venturi nozzle clogged or throat worn Transfer hose plugged Sieve screens clogged, or motor running in wrong direction Resistance from workpiece to ground must be less than 1 megohm. For best results, resistance should not be more than 500 ohms. Clean the workpiece hangers if necessary. Check the conveyor ground. Position the guns cm (10 14 in.) from the workpieces. Stagger the guns 30.5-cm (12-in.) apart vertically and 38.1-cm (15-in.) apart horizontally to avoid fan pattern and electrostatic field overlap. Contact your Nordson Corporation representative for advice. Refer to the Operation section for the recommended air pressures and ratios. Adjust the voltage to kv for large flat surfaces and kv for recesses. Never set the voltage below 60 kv. Refer to the Operation section for the recommended voltage and AFC settings. Use flat spray nozzles for large, regular-shaped workpieces. Use conical nozzles for deep recesses and most manual touch-up. Refer to problem 1 for more troubleshooting procedures. Increase the air pressure. Clean the pump and replace worn parts. Blow the flux out of the hose with compressed air. Clean the sieve screens. Refer to the Sieve Motor Rotation Check procedure in the Operation section. Continued on next page

46 5-4 Troubleshooting 2. Troubleshooting Chart (contd) Problem Possible Cause Corrective Action 3. Flux not transferring between collector, reclaim hopper, and feed hopper (contd) 4. Flux not fluidizing, or clouds of flux erupting from surface Accumulator plugged Accumulator vent-assist air pressure too high Transfer pump delay too long, level sensor sensitivity adjusted incorrectly, or sensor failed Flux in collector not fluidized. Deep hole in flux around pickup tube Flux damp or contaminated; cannot be fluidized or pumped Fluidizing pressure too low or high Moist or oil-contaminated flux Air leaking from fluidizing pan gasket instead of diffusing through fluidizing plate, or contaminated air plugging pores in fluidizing plates Clean out the inlet ports. Clean the accumulator interior. Reduce the vent-assist air pressure. Decrease the transfer pump delay. Calibrate the level sensor as described in the Operation section. Replace the level sensor if the problem continues. Increase the fluidizing pressure. If the problem continues, go to the next cause. Refer to problem 4 for more troubleshooting procedures. Check the flux in the hoppers. Increase the fluidizing air pressure until the flux is gently boiling. Decrease the pressure if clouds of flux are erupting from the surface. Open the drain valve at the air-supply drop leg and check the air supply for water or oil. Check the filters, separators, and air dryer. Replace the flux in the hoppers, then go to the next cause. Check for air leaks around the fluidizing pan gaskets. If leaks are found, remove the pan and replace the gasket. If fluidizing air pressure increases or decreases abruptly, remove the flux from the hoppers and inspect the fluidizing plates for stains, discoloration, or polished surfaces. Replace the fluidizing plates if they are contaminated or plugged. Continued on next page

47 Troubleshooting 5-5 Problem Possible Cause Corrective Action 4. Flux not fluidizing, or clouds of flux erupting from surface (contd) 5. Final filters clogged, flux in fan compartment Transfer pumps or hoses are plugged, or fluidizing plate is cracked Incorrect ratio of reclaimed-to-new flux Uneven distribution of flux in hopper Leaking cartridge filter gaskets, or hole in filter media Leak in cartridge filter mounting plate Clean the transfer pumps and replace worn parts. Blow the flux out of the transfer hoses with compressed air. Make sure the hoses are clear. Check the fluidizing plates and replace any plate that is cracked. Change the transfer-pump air pressure to increase or decrease the transfer rate. Add new flux to hopper. The flux supply should be no more than 3 parts reclaim-to-1 part new flux. Increase the fluidizing pressure. Check the flux and the fluidizing plate for contamination as previously described. Make sure the gaskets are sealing correctly. If you can slip a mm (0.015 in.) feeler gauge between the gasket and the sealing surface, tighten the tension screws to compress the gaskets. Refer to the Repair section for instructions. If the gaskets continue to leak, remove the cartridges. Clean and inspect the gaskets, sealing surfaces, and filter media. Replace the cartridges if the gaskets or filter media are damaged. Refer to the Repair section. Replace clogged final filters. Locate and seal any leaks with RTV sealant. 6. Cartridge filters clogged Pulse air pressure inadequate Increase the pulse air pressure or volume. Decrease the pulse timer delay (off time). Flux too fine or contaminated Reduce the ratio of reclaim-to-new flux. Check the flux particle size. Replace contaminated flux and fix the source of contamination. Continued on next page

48 5-6 Troubleshooting 2. Troubleshooting Chart (contd) Problem Possible Cause Corrective Action 6. Cartridge filters clogged (contd) 7. System shuts down or will not start Pulse valves out of position Timer board settings incorrect Pulse valve or solenoid valves clogged or malfunctioning Flux level in collector too high Fire detection system detects a flame or spark, or is malfunctioning Final filters clogged Final filter pressure switch failed Air dryer not operating, or interlock not activated Fuse(s) blown Electrical failure Position the valves so they are pointing straight down. The nozzles must direct the pulse air through the center of the filters. Adjust the timer board settings as described in the Operation section. Open the pulse-valve timer panel. If you do not hear a pulse each time a LED lights, the solenoid valve or the pulse valve connected to that LED may be clogged or failed. Check the wiring to the solenoid valve before opening the solenoid box and replacing the solenoid valve. Pump out excess flux. Check for a fire inside the enclosure or collector. Check the workpiece and conveyor grounds. Make sure the sensors are aimed properly. Follow the troubleshooting procedures in the flame detector system manual. Locate the source of flux leakage and correct the problem. Refer to problem 5 for more troubleshooting procedures. Replace the switch. Start the air dryer. Follow the troubleshooting procedures in the dryer manual. Check the interlock circuit. Check the fuses in the system electrical panel. Replace the blown fuse(s). If the fuses continue to blow, fix the electrical problem. Trace the circuits and correct the problem. Continued on next page

49 Troubleshooting 5-7 Problem Possible Cause Corrective Action 8. Sieve not screening flux Screen clogged or damaged Clean or replace screen. 9. Sieve scrap bucket filling up with flux 10. Flux escaping from booth openings Scrap bucket lid not sealed Screen clogged Hopper or accumulator vents clogged or hose kinked Vent-assist air pressure too low Cartridge filters clogged Cross drafts interfering with exhaust fan draw Workpieces entering booth are too hot Spray gun output exceeds booth containment capability Booth openings too large Fan section slide dampers open Workpieces too large for booth Guns too close to entrance and exit vestibules or openings Fan rotation backward Lid must be airtight. Tighten lid. Check scrap hose connections. Clean or replace screen. Clean vents, checks hoses. Increase vent-assist air pressure. Refer to Vent-Assist Air Pressure Adjustment in the Operation section. If the differential pressure gauge shows more than 6-in. w.c., refer to problem 6. Check for cross drafts at all enclosure openings. Eliminate or divert drafts. Cool the workpieces before moving them into the booth. The workpiece temperature should not exceed 49 C (120 F). Reduce the flux flow and/or the number of the guns. Close or decrease the size of the openings. Close the slide damper on the side of the fan section. Contact your Nordson Corporation representative. Move the guns farther away from the vestibules or openings. Reverse the rotation of the motor. Refer to the Fan Motor Rotation Check procedure in the Operation section. Continued on next page

50 5-8 Troubleshooting

51 Section 6 Repair

52 6-0 Repair

53 Repair 6-1 Section 6 Repair WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. 1. Final Filter Replacement WARNING: Before performing this procedure, shut off electrical power at the system electrical panel. Lock and tag the switch. Failure to observe this warning could result in personal injury or death. 1. See Figure 6-1. Unscrew and remove the knobs (3) and brackets (2) securing the final filters (1) to the fan section. The filters will stay in place. 2. Remove the old filters and discard them. 3. Check the interior of the fan section. If you see large amounts of flux inside, it is leaking through the cartridge filters or mounting plate. Fix the leak before starting the system. 4. Remove the new filters from their cartons. Inspect the filter housings, gaskets, and media for damage. NOTE: Do not use damaged filters. 5. Insert the new filters into the openings. 6. Install the brackets over the threaded studs. Thread the knobs onto the studs. 7. Tighten the knobs to compress the filter gaskets slightly. Do not overtighten the knobs. 8. Restore system electrical power. Start the exhaust fan and check for leaks around the filter gaskets.

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