QADS Quality Air Drying System Installation and Owners Manual

QADS Quality Air Drying System Installation and Owners Manual USA PATENT NUMBER: 6192604B1 INTERNATIONAL PATENT APPLIED FOR ETL REFRENCE NUMBER: 3049801 11-30-09

Table of Contents Table of Contents... 3 Warnings... 5 Isolation/Disconnects... 5 Explosion Hazard... 5 Operating conditions... 5 System Description... 7 System Components... 8 QAD Towers... 8 Supply Fans... 9 Controls... 10 QADs Retro (On Bake)... 10 QADs Standard... 11 System Operation... 12 What is the existing gas modulating system control?... 12 QADS on Bake... 12 Remote / No Heat Terminal... 12 Doors & S/N (Static Neutralization) Terminal... 12 System Specifications and Requirements... 14 Electrical requirements... 14 Do s and Don ts... 15 Do s... 15 Prepare and Mask Correctly... 15 Check the Control Panel if fitted... 15 Set the nozzles correctly... 15 Clean the Towers... 16 Don ts... 16 Leave the Vehicle Dirty... 16 Paint with the QAD Doors open... 16 Point the nozzles down or up... 16 Enter the booth whilst the QAD s are on... 16 Common Problems... 17 Service schedule for QAD / SN system ver.1.1... 18 Daily... 18 Weekly Maintenance... 18 Monthly... 18 6 Months... 18 Annually... 18 Warranty... 19 Warranty Registration Card... 20 QAD Tower Dimensions... 21 QADS Typical Installation... 22 Pneumatic Piping Layout... 23 QADS PIPING ARRANGEMENT... 24 Door Air Cylinder Adjustment Detail... 25 Air Solenoid Valve Assembly... 27 3

Air Solenoid Valve Disassembled... 27 Blower Exploded View... 28 Duct Box Assembly View... 29 Important Static Neutralisation Maintenance Instructions... 30 Static Elimination Bar (910) Manual... 31 Static Ionization Equipment Trouble Shooting... 45 Wiring Diagrams... 46 QADS Standard... 46 QADS Standard Control Panel Cover... 47 QADS Standard Control Panel Cover Inside... 47 QADS Standard Control Panel Inside... 48 QADS Retro or ON Bake... 49 QADS Retro Control Panel Cover... 50 QADS Retro Control Panel Cover Inside... 50 QADS Retro Control Panel Inside... 50 QADS Retro Control Panel Inside... 51 QADs Retro Field Wiring Diagram Examples... 52 QADS Retro 4-20 Milliamp... 52 QADS Retro On-Off... 53 QADS Retro 0-24 VDC... 54 QADS Retro 0-5VDC... 55 QADS Retro 0-10VDC... 56 QADs Blower and Ducting Examples... 57 QADs Blowers Mounted at the Rear of the Booth Intake Plenum... 57 QADS Mounted on the Side of the Booth Intake Plenum... 58 QADS Blowers Mounted at the Top of the Booth Intake Plenum... 59 Mechanical Retro Fitting... 60 Installations that require mounting the QADS blowers on the side of the booth due to lack of space above the booth... 65 QADS Manual Tower and Explosion Proof Interior On-Off Switch... 69 QADS Exterior Duct Covers... 70 QADS Interior Duct Covers... 71 QADS 6" T, Y and W Duct... 72 Qualified QAD System Operators... 73 Control PanelsPacking Exploded View... 75 Packing Exploded View... 76 Contact Information... 77 4

Warnings Read this document carefully before operating the equipment. Failure to follow these instructions carefully may result in a fire hazard or explosion risk, causing property damage, personal injury or death. Do not make the equipment operational until you have read and understood all details contained herein. Retain these instructions with the equipment for future reference. Ensure that all relevant safety precautions are followed. Local regulations have jurisdiction over any statement detailed herein and must be applied by the operator / service technician. Code compliance is the sole responsibility of the operator / service technician. This manual only pertains to the installation, operation and maintenance of the Junair QAD System not to the spray booth. The QAD System installer must provide personnel training after commissioning, so that the employees can be assessed for competence. Employees will be classified as Qualified to Operate and Not-Qualified after training. Names of Qualified Operators shall be listed on the last page of this book. Only competent, trained and qualified person should operate or maintain this equipment. Isolation/Disconnects Ensure that all isolation devices are clearly marked with a suitable notice, so that the equipment is not started during the service or maintenance process. The operator must be familiar with the points of electrical and fuel isolation in case of emergency. The electrical isolator for the QAD tm System is on the QAD tm control panel. The spray booth isolator should be on the spray booth main operating control panel. The gas isolation valve is normally fitted before the gas train adjacent to the burner. Familiarise yourself with the position of these isolators before operating the equipment. Explosion Hazard NFPA 33 details the zoning for explosion risk. During the spraying operation the interior of the spray booth cabin is a class 1 division 1 zone. The equipment has been designed to exclude all ignition sources. Do not take into the cabin any item that may generate an ignition source during the spraying or flash off process. DO NOT SMOKE in or around the spray booth oven. Operating conditions The equipment is designed to operate in an ambient air temperature of 41 to 104 deg. F (5 to 40 deg C). Water/Moisture Electrical components should be kept dry and not subject to moisture. 5

Higher Panel Temperature The QADs tm on bake function delivers more of the spray booths heat energy to the vehicle in a shorter time period. The bake temperatures should be set with this in mind. Over baking vehicles / components at high temperature or for an extended time period could result in damage. Do not bake for over 30 minutes or at above 176 deg. F. Junair recommend that only the weekly and monthly maintenance items are attended to by the operators responsible for the equipment. In the event of equipment failure or for any additional information please contact the relevant person detailed on the contact page. A specialist company with competent, qualified and experienced technicians should be used to carry out all service and repair work. North American standards that apply to the QAD tm System are: NFPA 33 (2000 edition) Spray application using flammable or combustible materials. NFPA 86 (1999 edition) Ovens and furnaces. Warning Labels Description The warning labels displayed on a Junair QAD tm System are detailed below. Installations in Canada have an additional French translation. Sited on the main control and burner control panel. Warning all personnel that there are high voltage cables within the control panels. 6

System Description Airflow from the QAD tm System is designed to disrupt the air moving over a painted surface. During the flash off cycle, disruption of the air movement speeds up the removal of solvent or water from the coating. During the bake cycle the auxiliary air movement speeds up the increase in panel temperature, thus shortening the bake process. Direction of the auxiliary air movement system is key to the efficiency of the flash off and bake cycles performance. Each tower has 8 adjustable nozzles to cover all painted surfaces. Nozzle Adjusting Tool with Bracket Tek screw adjusting tool bracket at eye level to interior booth panel for easy access 7

The QAD System can be installed into any spray booth. Generally one QAD tower is fitted into each corner but more can be added onto sidewalls of large booths. There is a door on each tower to cover the air nozzles from overspray. Whilst the doors are closed there is a slight airflow through the nozzles. This positive pressure of the door cavity reduces the risk of overspray contamination. The doors are pneumatically operated through the control panel. Each tower has 2 columns of four air nozzles. Airflow is horizontal / upwards pointing not at floor to further reduce the possibility of paint contamination. Two high-pressure centrifugal fans take pre heated, filtered plenum air and deliver it to the cabin through a system of steel ductwork connecting to the four QAD tm towers. System Efficiency For retrofit equipment the temperature rise is dependant on the efficiency of the heating System. During the winter months in some areas temperature rise may not reach the required set point. System Components QAD Towers The cross section of a QAD tower is detailed below. The 4 towers fit unobtrusively into each corner of the spray booth cabin. The speed of the door opening and closing can be adjusted on the bottom of the L airline fittings on the bottom of the air cylinders. 8

Supply Fans The 2 supply air fan units are normally mounted on the roof of the spray booth Fresh Air Plenum. If necessary the supply fans can be wall or remote mounted depending on installation conditions. See pages 56-58 for examples 9

Controls There are two versions of controls available for QADs. QADs Retro (On Bake) The purpose of the QADS Retro system is to provide turbulent heated airflow during the Flash-Off cycle onto the painted surface of the vehicle to facilitate drying. 10

QADs Standard The Standard control panel will turn the QADs on and off with a timed flash-off cycle (No audible alarm). The original pre-existing control panel controls the paint booth s temperature at all times. 11

System Operation The pre-existing heater control panel controls the booth temperature in the Spray and Bake Modes. The QADS system is inactive during Spray Mode. The QADS Retro panel takes control of the spray booth temperature during Flash Off. Flash Off is started by pressing the System On button on the QADS control panel. What is the existing gas modulating system control? The control voltage of the existing gas modulation system you are working with must be determined in order to correctly interface with the QADS RETRO (On Bake) control panel. (See field wiring diagram examples on pages 51-55). Change Over Relay Connection The control voltage for the existing burner gas-modulating valve needs to be re-routed through the Changeover Relay. When the Flash Off (System On) button is pushed the QADS temperature controller will take over control of the pre-existing gas modulating system. In Flash Off the relay is activated. The heater control panel s modulating voltage is interrupted and the QADS control panel modulating voltage is routed to the modulating valve to control booth temperature. QADS on Bake Two ice cube Relays are provided (one 110vac and one 24vac) along with a relay base. You will need to find a 110vac or 24vac voltage source that is energized when the preexisting heater control system comes on in the bake mode. The voltage source must be continuous in order to keep the QADS on during the entire bake cycle. This voltage source along with a neutral wire is connected to the relay coil. Two wires need to be run from the QADS control panel to the pre existing heater control panel where the relay has been installed and then connected to a set of normally open contacts on that relay. The other end of the wires will be connected to terminals 4 and 1 inside the QADS Retro control box. Once this has been completed the QADS will turn on when the preexisting heater bake mode is switched on. Remote / No Heat Terminal A normally open momentary switch (Customer supplied) can be connected to this input. Pressing the button will turn on the QADS blower motors. Booth temperature is controlled by the heater control panel. QADS stay active for the pre-programmed time period of the Smart Relay in the QADS control panel. This feature is use to manually activate the QADS either from the Quads control panel or from an auxiliary location. Doors & S/N (Static Neutralization) Terminal Pneumatic cylinders open the QADS doors when the system is activated. The air solenoid valve that controls airflow to the cylinders needs to be connected to the Doors & S/N (static neutralization) terminal. There will be 24VAC on this terminal when activated. When the static neutralization option is installed, the static neutralization system will also be activated by this terminal. 12

Determining Modulating Signal The first step is to find out what kind of operating signal is sent from the heater control panel to the modulating valve. This signal will have to be interrupter in Flash Off. The QADS temperature controller signal needs to be routed to the modulating valve during Flash Off. The QADS temperature controller has two output options. Terminal 1 and 2 will put out 4-20mA Terminal 14 and 15 is a relay contact that closes when the set point temperature is lower than the process temperature. If the modulating valve is made by Maxitrol you need to use a Maxitrol signal converter (SC10C-B6S1). This will convert the 4-20mA signal to the required 0-24VDC signal. QADS Temperature Controller Programming Parameters Please refer to the programming leaflet for menu structure and button functions. Initial Setting Mode Set Input Type: J Set Temperature Unit: F Set Control Mode: On/Off Alarm 1 Mode Setting: 3 Optional Static Neutralization (QADs tm SN) The Static Neutralization (SN) bars fitted to the QAD tm towers ionize the airflow directed at the vehicle, greatly reducing the static charge. A vehicle carries a high static charge, particularly plastic components such as bumpers. Static electricity in the form of electro static attraction or repulsion generates dust contamination and other paint defects. The 910 bar is fitted between the two columns of nozzles. It is a shockless static eliminator. 13

Electrical requirements System Specifications and Requirements A 24V AC power supply to power the QAD control panel is included in the package. A filter regulator is fitted to provide filtered compressed air at the correct operating pressure to the pneumatic cylinders. Maximum inlet pressure to filter regulator Maximum outlet pressure (operating pressure) Flow rate less than 0.222 CFM per door operation 145 lb/sq in. 44 lb/sq in. Solenoid valve coil is 24V 60Hz Filtration The paint finishing industry accepts that particles greater than 14 microns will be responsible for visible defects in the paint finish. The filter media used in QADs tm is designed to remove all particles greater than 10 microns to provide a good margin of safety. We recommend that input filter material is changed every 1000 working hours or every 12 months whichever is the earlier. Compressed air is required to operate the QAD tm doors. An isolating solenoid valve is also required where the SN system has been installed. The maximum inlet pressure is 145 lb/sq inch. SN System Two ice cube Relays are provided (one 110vac and one 24vac) along with a relay base to turn on the SN system. The compressed air isolating solenoid valve voltage must be 14

routed through one of the normally closed contacts of this relay in order to make sure the air is off when the SN system is on. Bar operating voltage 7 kv Maximum temperature 185 deg F Power unit electrical input 110/120V 60Hz 3A Do s Do s and Don ts Prepare and Mask Correctly The QADs system utilizes accelerated air drawn from the plenum that creates controlled turbulence over the vehicle thus speeding up the drying of all basecoats and clear coats. It is recommended to use static controlled plastic sheeting that is secured at each corner of the unit being painted to stop the masking billowing and causing poor air flow over the vehicle. Keep the masking film tight thus replicating the shape of the vehicle as much as possible. Check the Control Panel if fitted If your QADs system is fitted with an automatic temperature raising function [mainly for drying waterborne base coats] make sure it is set to 35C, this will reduce the humidity and thus speed up the release of water solvents from the film and speed up drying. Set the nozzles correctly Normally the nozzles should be set up and left, however if many off car parts require painting and drying then adjustment might be required. Generally the nozzles are set like the diagrams below Front End plus Panels 15

Rear End plus Panels NB, when painting a single vehicle in the booth make sure the vehicle is in the center of the booth. Clean the Towers Cleanliness and good housekeeping are essential to produce a clean job. Daily clean the QAD s nozzles and Doors with a tack cloth. Don ts Leave the Vehicle Dirty Make sure that the vehicle is clean prior to masking, and if masking has been applied outside the booth make sure it is blown off prior to tack ragging of the part and or parts to be painted. Paint with the QAD Doors open Make sure that all QAD doors are closed prior to the application of any paint film, failure to do so may result in overspray landing on the nozzles and possibly causing dirt issues in the final paint film. Point the nozzles down or up The QAD nozzles should always be horizontal to the booth floor, pointing down with result in dust and dirt being blown off the floor and may cause dirt in the final paint film. Pointing the nozzles up may result in slow drying of the paint film. Enter the booth whilst the QAD s are on Dust or contamination from operative s overalls can be blown onto the paint film and may cause dust and dirt in the final paint film. Use the QAD s to flash off Clears Never use the QAD s to flash off clears this will cause skinning of the paint film and may lead to gloss drop, adhesion issues or solvent popping/ 16

Common Problems When using the QADs the following issues may arise Solvent popping in Clear coats Solvent popping is normally caused by; Over application of clears Using too fast a hardener / thinner combination Too fast a heat rise in the booth Too high a heat on bake The panels are too close to the QAD nozzles Failure to follow the flash off times as set by the paint company To resolve these issue make sure that Clears are applied to manufacturers recommendations Use a medium to slow hardener thinner combination Slow down the heat rise in the booth Reduce the bake temperature (Energy Saving!) Move the panels further away from the QAD s nozzles, typically they should be no closer than 3ft from the QAD tower Follow manufacturers flash off times. Slow drying of water borne base coat colors Slow drying is normally caused by Nozzles being placed wrongly Temperature in the booth being too low Panels being placed wrongly Over application of the base coat To resolve these issues make sure that The nozzles are set as diagrams above Raise the temperature of the booth during flash off, this will reduce the humidity [moisture content] in the booth and speed up this process. Make sure that the painted surface of the panel is on the outside thus allowing the air from the QAD nozzles to strike the paint film, air cannot travel through metal. Apply as per manufactures instructions. 17

Service schedule for QAD / SN system ver.1.1 Daily Before using the equipment check that the QAD tm nozzles are adjusted correctly. The QAD tm nozzles should be adjusted, using the bar provided, as per the diagram in the drawing section of this manual. None of the QAD tm nozzles should be directed towards the floor. This can cause paint contamination. Weekly Maintenance The QAD tm filter tubes should be changed at the same time as the intake filter. Report and record damage and/or faults occurred the previous week. The QAD tm System should be serviced every 750 hours. Total system run time should be documented and reviewed weekly. Qualified service company should be contacted for service appointment at about 700 hours of use. Drain the water filter bowl on the QAD air pressure regulator. Monthly 1. QAD nozzle wiped down and cleaned, all residues removed. Operator / Service company. 2. SN emitter brushed down with nylon brush (toothbrush). Operator / Service company. 3. SN emitters tested with supplied volt stick tester. Operator / Service company. 4. System functionality tested. Operator / Service company. 6 Months 1. QAD nozzle wiped down and cleaned, all residues removed. Operator / Service company. 2. SN emitter brushed down with nylon brush (toothbrush). Operator / Service company. 3. SN emitters tested with supplied volt stick tester. Operator / Service company. 4. System functionality tested. Operator / Service company. 5. QAD door pneumatic rams stripped down and cleaned. Service company. 6. Temperature controller calibrated, certificate acquired. Service company. 7. Approved QAD filter socks fitted, residues remove from duct. Service company. Annually 1. QAD nozzle wiped down and cleaned, all residues removed. Operator / Service company. 2. SN emitter brushed down with nylon brush (toothbrush). Operator / Service company. 3. SN emitters tested with supplied volt stick tester. Operator / Service company. 4. System functionality tested. Operator / Service company. 5. QAD door pneumatic rams stripped down and cleaned. Service company. 6. Temperature controller calibrated, certificate acquired. Service company. 7. Approved QAD filter socks fitted, residues remove from duct. Service company. 8. QAD fans stripped down, impellers checked / cleaned. Service company. 9. Ductwork checked for leaks, resealed if necessary. Service company. 10. Nozzle velocity checked against manufacturer recommendations. Service company. 18

Warranty Junair US, Incorporated, hereinafter "Seller," units are warranted to the original end user, hereinafter called Purchaser against defects in workmanship or materials under normal usage for a period of one year, from shipping date of the system. This limited warranty applies only to the original Purchaser, who acquired the parts or unit from Seller s distributor. Purchaser is responsible for shipping costs of the replacement parts from Seller facility at 1427 N. Linden Avenue Rialto, CA 92376 to Purchaser facility. Purchaser shall obtain a Return Merchandise Authorization (RMA) number from Seller before returning any parts or complete units to Seller. Purchaser agrees to write the RMA number on the outside of the package. Seller will pay for the shipping cost of the returned part(s) back from Purchaser s facility to Seller s facility by issuing a call tag. Seller will charge a Good Part Testing Charge if the returned part(s) functions as intended during Seller s test. The Good Part Testing Charge is sixty-five dollars ($65) an hour with a thirty (30) minute minimum charge. This limited warranty shall not apply to: A. Equipment that is not installed and fired up by a licensed and qualified heater contractor in accordance with "Seller's" installation instructions, or, B. Equipment that is not installed in accordance with all Local, State and/or Federal laws or regulations, or, C. Equipment that has been altered in any way, from it's original factory configuration. D. Equipment which s warranty card is not completely filled out and/or not returned to Seller within 30 days of the completed installation. E. Any labor costs Purchaser incurs in the process of removing a defective part and installing the replacement part. F. Damage caused by acts of God, such as Lightning, Earthquakes, Tornadoes and Storms of any kind. G. Any part or component, which has been abused or failed as a result of poor maintenance, installation or neglect. This limited warranty gives Purchaser specific legal rights, which vary from state to state. To the extent allowable under law, "Seller's" liability for consequential and incidental damages is expressly disclaimed. "Seller's" liability in all events is limited to, and shall not exceed, the original purchase price. In the event of a dispute, the controversy will be adjudicated in the competent Court of San Bernardino County, State of California. 19

Warranty Registration Card 20

QAD Tower Dimensions 21

QADS Typical Installation 22

Pneumatic Piping Layout Tees Red Hose Tees Tees Tees 23

QADS PIPING ARRANGEMENT All the tubing should be kept as short and equal as possible to ensure the correct operation of the qads. If tubing is cut at different lengths it will make the opening and shutting of the qad doors difficult to synchronize. Tubing should be as neat as possible and tied together at regular intervals and then tied to the fixed section of the booth, where possible grommets should be used were tubing passes through any sheet metal panels or ducting to prevent damaging the tubing, this also makes it easier to replace when necessary. Qads are manufactured with 6m of tubing inserted through them, this should be enough tubing to reach the centre of most booths which is the ideal position to make the connections that link them together, (see diagram) Tubing should never be pulled or cut so short that the tubing kinks. If this occurs the tubing must be replaced. Standing or walking on the tubing must be avoided at all times. Any 90 bends needed in the pipe work must be achieved by using the natural curve of the tube or by a push in elbow fitting if required. Qad tails that run through the qads must never be pulled tort, ideally a 100mm should remain inside the qads so that a new connection can be made if required to the pneumatic ram at the base of the qad. Slack in the tubing must be left to allow the ram to pivot or the doors will not operate correctly. 24

Door Air Cylinder Adjustment Detail 25

Air Solenoid Valve Assembly Air Solenoid Valve Disassembled 27

Blower Exploded View 28

Duct Box Assembly View 29

Important Static Neutralization Maintenance Instructions These important maintenance requirements must be followed to ensure long term reliability of the Static Neutralization system. Keep in mind it is in your best interest to maintain this system as the replacement parts are expensive. 1. With the power off, you must clean the Static Neutralization Bars once a week with a small brush and rubbing alcohol to remove any dirt or overspray from the entire exposed surface of the bars. Cleaning weekly will ensure easy cleaning and prevent a dangerous build up of overspray that could cause arcing which will lead to total failure of the Static Neutralization Bars. 2. The transformer for the Static Neutralization Bars is usually installed on the roof of the paint booth which is normally a place that collects a lot of dust and dirt in the average body shop. The transformer puts out high voltage and low amperage which attracts the dust and dirt and will cause the transformer to fail if not cleaned regularly. The power to the system must be off. Remove the cover of the transformer and remove any dirt and dust with rubbing alcohol. Replace the cover and repeat this procedure for the outside of the transformer as well. This should be done every two weeks to one month depending on the amount of dust produced in your shop. 30

Static Elimination Bar (910) Manual 31

Static Elimination Power Supply (904) Manual 39

QADS Retro or ON Bake 43

Static Ionization Equipment Trouble Shooting 45

Wiring Diagrams QADS Standard 46

QADS Standard Control Panel Cover QADS Standard Control Panel Cover Inside 47

QADS Standard Control Panel Inside 48

QADS Retro or ON Bake 49

QADS Retro Control Panel Cover QADS Retro Control Panel Cover Inside 50

QADS Retro Control Panel Inside 51

QADS Retro 4-20 Milliamp QADs Retro Field Wiring Diagram Examples 52

QADS Retro On-Off 53

QADS Retro 0-24 VDC 54

QADS Retro 0-5VDC 55

QADS Retro 0-10VDC 56

QADs Blower and Ducting Examples QADs Blowers Mounted at the Rear of the Booth Intake Plenum Optional 6" T duct 57

QADS Mounted on the Side of the Booth Intake Plenum Optional 6" T duct 58

QADS Blowers Mounted at the Top of the Booth Intake Plenum 59

Mechanical Retro Fitting 4" duct runs up the corner of the booth penetrating the gable section of the booth ceiling and then expands into a 6" duct 60

6" Straight Ducting from each corner Joins into a 6" Y-Duct that is attached to the blower with a 6" universal coupling 61

QADS motor and blower mounted on top of the paint booth fresh air plenum 62

Installations that require mounting the QADS blowers on the side of the booth due to lack of space above the booth 65

4" duct exits the boot on the side 4" duct expands to a 6" duct that goes back towards the middle of the booth to the QADS blower mounted on the side of the fresh air plenum 66

68 In this case there is a mixing room attached to the booth. The duct exited the booth through the Mixing Room

QADS Manual Tower and Explosion Proof Interior On-Off Switch Explosion Proof On-Off remote control for the interior of the Paint Booth 69

QADS Exterior Duct Covers 70

QADS Interior Duct Covers 71

QADS 6" T, Y and W Duct 72

Qualified QAD System Operators Name Date Instructor 73

Control Panels 75

Packing Exploded View 76

Contact Information Junair US Technical Support 1427 N. Linden Ave. Rialto, CA 92376 Phone.: 1-800-535-8196 1-909-419-7011 Fax.: 1-909-419-7020 Copyright This specification is meant for your own use only and must not be forwarded to third parties without our written consent. The contents of the specification may not be published. The policy of Spraytech/Junair is one of continuous improvement. The right is reserved to alter the design or any structural details of the products at any time without giving notice. The information within this specification was established to our best ability great care has been taken to ensure its accuracy. Spraytech/Junair accept no liability for loss consequential or otherwise arising from the use of this information. 77