Fixed Reclaim System Manual P/N 779163 --English-- Keep for Future Reference Nordson China Sourcing - Shanghai
Trademarks AccuJet, Aquaguard, Asymtek, Automotive, Autotech, Blue Box, CF, Can Works, Century, Clean Coat, CleanSleeve, CleanSpray, COLORMAX, Compumelt, Control Coat, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EPREG, ETI, Excel 2000, Flex-O-Coat, Flexi-Spray, Flow Sentry, Fluidshooter, FoamMelt, FoamMix, Helix, Horizon, Hose Mole, Hot Shot, Hot Stitch, Isocoil, Isocore, Iso-Flo, KB30, Little Squirt, Magnastatic, MEG, Meltex, MicroSet, Millenium, Mini Squirt, Moist-Cure, MultiScan, Nordson, OmniScan, Opticoat, Package of Values, PluraFoam, Porous Coat, Powderware, Pro-Flo, ProLink, PRX, Rhino, S.design stylized, SC5, SCF, Select Coat, Select Cure, Slautterback, Smart-Coat, Spray Squirt, Spraymelt, Super Squirt, Sure-Bond, Sure Coat, System Sentry, Tela-Therm, Trends, Tribomatic, UniScan, UpTime, Versa-Coat, Versa-Screen, Versa- Spray, Watermark, When you expect more are registered trademarks- - of Nordson Corporation. ATS, Auto-Flo, AutoScan, BetterBook, Chameleon, CanNeck, Check Mate, CPX, Control Weave, Controlled Fiberization, EasyClean, Ebraid, Eclipse, Equi=Bead, Fillmaster, FlexiCoat, Gluie, Ink-Dot, JR, Maxima, MicroFin, Minimeter, Mountaingate, Multifil, OptiMix, Pattern View, PluraMix, Primarc, Prism, Pro-Meter, Pro-Stream, Process Sentry, PurTech, Pulse Spray, Saturn, Seal Sentry, Select Charge, Select Series, Sensomatic, Shaftshield, Spectral, Spectrum, Sure Brand, Sure Coat, Swirl Coat, Vista, Walcom, 2 Rings (Design) are trademarks - - of Nordson Corporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners rights.
Table of Contents I Table of Contents Congratulations on the Purchase of Your Nordson Product Your Safety is Important to Nordson 0-1 Manufacturer of Equipment 0-1 Nordson Asia Sales Offices 0-2 Section 1 Safety 1. Introduction 1-1 2. Qualified Personnel 1-1 3. Intended Use 1-1 4. Regulations and Approvals 1-1 5. Personal Safety 1-2 6. Fire Safety 1-3 7. Action in the Event of a Malfunction 1-3 8. Disposal 1-3 1. Intended Use 2-1 Section 2 Equipment Familiarisation 2. Features 2-2 Section 3 Operating Instructions 1. Start-Up 3-1 2. Shut-Down and Routing Maintenance 3-1
Table of Contents I Section 4 Control Panel Guide 1. Operation of Fan Starter Control 5-1 2. Fan Starter Controls Consist of 5-1 Section5 Electrical Requirements Electrical Requirement 5-1 Section 6 System Air Flow Requirements Compressed Air Requirements (Maximum) 6-1 Section7 Maintenance Procedures Tasks To Be Performed 7-1 Section 8 Colour Change Procedure Colour Change Procedure 8-1 Section 9 Troubleshooting 1. Troubleshooting Guide 9-1 2. Cartridge Filter Troubleshooting 9-3 Section 10 Commissioning Report Commissioning Report 10-1 Section 11 Powder System Audit Cartridge Filter Troubleshooting 11-1
Introduction 0-1 Congratulations on the Purchase of Your Nordson Product Nordson equipment is engineered and manufactured in accordance with strict specifications, using high quality components and state-of-the-art technologies that assure reliable, long term performance. Your Product was thoroughly tested for proper operation prior to shipment. Before unpacking and installing your new equipment, please read this manual. It is your guide to safe installation, productive operation and effective maintenance. We recommend that you keep the manual available for future reference. Your Safety is Important to Nordson Carefully read the Safety section. Your product is designed for safe operation when used according to the published instructions. Potential hazards exist when operating instructions are not followed. Manufacturer of Equipment Nordson China, China Sourcing Operation 828 Xin Jin Qiao Road Pudong New District Shanghai 201206 China Telephone: 86-21-58568855 Fax: 86-21-58565777 For a list of local Nordson organizations, see Nordson international.
Introduction 0-2 Nordson Asia For your nearest Nordson office contact. The Nordson offices below for detail information. Contact Nordson Phone Fax China (North) Nordson China 86-21-5854 2345 86-21 5854 9150 China (South) Solar Pike 86-20-8544 0092 86-20-8552 0707 Hong Kong Nordson Application Equipment 852-2687 2828 852-2687 4748 Taiwan Nordson Da 8862 8209 7066 8862 8209 7022 Korea Nordson Sang San 82-347-766 8321 82-347-7668320 Philippines Thailand Indonesia Vietnam Nordson South East Asia 65-778 2511 65-778 3151 Australia Nordson Australia 61-2-9838 7144 61-2-9838 7394 New Zealand Nordson New Zealand 61-2-9838 7144 Malaysia Nordson Malaysia 603-5637 6281 603-5635 2977 Japan Nordson Japan 81-3-5762 2700 81-3-5762 2701 India Nordson India 91-80-783 4915 to 783 4920 91-80-783 4922 South America Latin America Nordson PSD 1-440-988 9411 1-440-985 3710 Nordson America USA 1-440-988 9411 1-440-985 1417
Section 1 Safety
Safety 1-1 Section 1 Safety 1. Introduction Read and follow these safety instructions. Task and equipment specific warning, 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 or performing their assigned tasks. 3. Intended Use Use of Nordson equipment in ways other than described in the documentation supplied with the equipment may result in injury to persons or damage to property. some example of unintended use equipment include using incompatible materials making unauthorized modifications removing or bypassing safety guards or interlocks using incompatible or damaged parts 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. Warning: When using the gun mover for liquid paint application, it must be equipped with an E.X.E. (explosion proof) motor. The motor gland, wiring and plug must meet local electrical regulations for a CLASS 1 ZONE 1 environment.
Safety 1-2 5. Personal Safety To prevent 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 services. 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. While operating manual electrostatic spray guns, make sure you are grounded. Wear electrically conductive gloves or a grounding strap connected to the gun handle or other true earth ground. Do not wear or carry metallic objects such as jewelry or tools. If you receive even a slight electrical shock, shut down all electrical or electrostatic equipment immediately. Do not restart the equipment until the problem has been identified and corrected. 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.
Safety 1-3 6. Fire Safety To avoid a fire or explosion, follow these instructions. Ground all conductive equipment in the spray area. Clerk equipment and workpiece grounding devices regularly. Resistance to ground must not exceed one mega-ohm. Shut down all equipment immediately if you notice static sparking or arcing. Do not restart the equipment until the cause has been identified and corrected. 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. Shut off electrostatic power and ground the charging system before adjusting, cleaning, or repairing electrostatic equipment. 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. 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. 8. Disposal Dispose of equipment and materials used in operation and servicing according to local codes.
Section 2 Equipment Familiarisation
Section 3 Operating Instructions
Operating Instructions 3-1 Section 3 Operating Instruction 1. Start-Up 1. Turn on compressor or ensure compressed air supply to refrigerant drier. 2. Turn on electrical supply to refrigerant drier either locally or at main booth control panel isolator. 3. Turn the main isolator on the control panel to "on". Push the green "start" button to activate the extraction fan and turn the pulsing (where used) to "on". Turn "on" the booth lights (where used). N.B. After approximately 15 minutes from item 2, compressed air will be passed to booth. 4. With compressed air available start loading conveyor with work or if work present at start of booth, turn power packs on and start oscillators/reciprocators immediately. 2. Shut-Down and Routine Maintenance 1. Turn "off" power packs. Turn "off" the pulsing switch (where used). 2. Remove powder delivery hoses from powder pumps and blow through with compressed air. 3. Clean powder pump by removing and cleaning with compressed air. Refit. 4. Clean nozzles, antenna and sleeves on guns. Note: Ensure gun alignment is not altered. 5. Push red button to "stop" main extraction fan. 6. Turn off compressed air and shut down air dryer. 7. Drain oscillator oil collectors and refill oscillator oiler. 8. Turn off booth lights and main isolator. 9. Cartridge filters: check for seating and tighten if necessary at least once a month.
Section 4 Control Panel Guide
Control Panel Guide 4-1 Section 4 Control Panel Guide a) INTRODUCTION Fan Starter Control - This panel provides the basic control functions for operation of the booth. b) INSTALLATION The control is normally fitted to the side of the reclaim section. The provision of a mains electricity supply to the isolator incoming terminals situated inside the panel, other minor associated wiring, and of a main compressed air supply to either the control entry bulkhead fitting or to the supply point on the ring main is the responsibility of the customer. Standard booth electrical requirements are given in the following pages. Compressed air requirements will be notified by Nordson personnel but may also be estimated from the compressed air utility requirements stated in this section. Some larger panels may be supplied free-standing. Bolting down is the responsibility of the customer. c) COMPRESSED AIR DRYER A refrigerator type compressed air dryer together with a coalescing type micro filter for removing oil from the air supply is vital to the operation of any powder booth. A compressed air dryer, together with a coalescing filter and a timer/solenoid air valve, to be fitted in a suitable location are normally supplied and the services connected by the customer. Some installations will have the compressed air conditioning equipment supplied, fitted and site wired by Nordson Australia Pty Ltd personnel and this will be agreed during negotiations. Depending upon the degree of automation agreed upon, the dryer and booth may be interlocked to prevent the operation of the booth without a supply of conditioned air, or the correct operation and start sequence may be specified in the operating instructions. With either manual or automatic control of the dryer it should be impossible to spray powder into the booth without a conditioned air supply. 1. Operation of the Fan Starter Control Main Functions The main isolator disconnects the 3 phases input to the control panel. Green push button energises the extraction fan motor contactor and pulse sequence timer board. Red push button performs the opposite function of the green push button and deactivates the circuits. (Additional remote emergency stop buttons may be wired in parallel by the customer.)
Control Panel Guide 4-2 Auxiliary Functions 1. Cartridge Cleaning: The time interval between and the duration of each cleaning pulse are selected by the miniature potentiometers mounted on the sequence control printed circuit board, one potentiometer for each timing function, which are clearly marked. Typical timer settings are 9-45 seconds between pulses and 40 milli-seconds for the duration time of the pulse. As 40 milli-seconds requires the use of sophisticated timing equipment to set up on the timing card, experience has equated this to a short sharp "bang" from the powder collector. In each case the set times are dependent upon the powder loading and cartridge cleaning pressure with good cleaning being the object. Some versions are fitted with a programmable type timer board it is preset at the time of manufacture and should not be adjusted at any time. Well cleaned cartridges are normally indicated by differential pressure readings of approximately 0.7 Kpa (2.8 inches water gauge). Readings between approximately 0.25 and 0.75 Kpa would be acceptable for typical installations newly installed and these will rise during the life of the cartridge, progressively up to about 1.1 Kpa (4.4 inches water gauge), and then more rapidly until the maximum differential pressure is reached. (Some installations with high powder loading may run at more than 0.75 Kpa (3 inches water gauge). 2. Powder Recovery - Bulk Feeder Powder Supply: Oversprayed powder collects in the hopper of the recovery section and is pumped out pneumatically. This powder returns to the powder delivery guns to be re-used. To maintain a minimum supply of powder to the fans from the module recovery hopper a Bulk Feeder powder supply can be connected. Looking from the rear of the collector module, the Bulk Feeder inlet is located on the left side at the bottom above the sieve screen level. The level control probe in the supply hopper will sense when more powder is required. The probes will energise a solenoid valve via a dual channel relay in the level control enclosure to supply refrigerated air to the Bulk Feeder pump and activate the vibrator. It is important to check the operation of the Bulk Feeder at every start up of the system along with level of powder in the recovery/supply hopper. 2. Fan Starter Controls Consist of: a) Main Isolator b) Stop button c) Start button d) Filter cleaning on/off switch e) Magnetic gauge
Section 5 Electrical Requirements
Electrical Requirements 5-1 Section 5 Electrical Requirements ELECTRICAL REQUIREMENTS NOTE: Can be supplied to other voltages. BOOTH / MODULE SIZE MAIN SUPPLY FAN MOTOR LOAD 2 Cartridge Module 415-3 - 50 3 phase neutral and earth 1.5 Kw 4 Carriage Module 415-3 - 50 3 phase neutral and earth 3.0 Kw 6 Cartridge Module 415-3 - 50 3 phase neutral and earth 8 Cartridge Module 415-3 - 50 3 phase neutral and earth 10 Cartridge Module 415-3 - 50 3 phase neutral and earth 12 Cartridge Module 415-3 - 50 3 phase neutral and earth 4.0 Kw 5.5 Kw 7.5 Kw 11.0 Kw These electrical requirements are for installations with average Versa power pack loading. Special installations may have larger requirements due to - Eg. Memory and Detection systems, Versa consoles to replace Versa power pack. Any non-standard electrical requirements will be notified by Nordson representatives before the system is installed.
Section 6 System Air Flow Requirements
System Air Flow Requirements 6-1 Section 6 System Air Flow Requirements COMPRESSED AIR REQUIREMENTS (MAXIMUM) AIR FLOW Powder Pump to Manual or Automatic gun Feeder Hopper Fluidising Air AH - 2.5 AH23 AH120, AH80 REQUIREMENTS 10 scfm ea. gun 1 scfm ea. Hopper 3 scfm ea. Hopper 20 scfm ea. Hopper Powder Pump to the sieve, from the Collector Hopper. 12 scfm ea. Transfer Pump Recovery Unit Cartridge Pulsing Fluidised Reclaim Hopper 4 scfm/1000 cfm of collector capacity - 410 Kpa 30 scfm per Hopper NOTE: All pneumatic functions are controlled from the Air Service Manifold.
Section 7 System Clean-Up Steps
System Clean-Up Steps 7-1 Section 7 System Clean-Up Steps Tasks To Be Performed With System ON 1. Squeegee down booth On Collector Hoppers On Bulk Hopper With System OFF 1. Clean all Transfer Pumps 2. Clean Sieve Screens 3. Clean Feeder and/or Bulk Hopper Vents (if applicable). 4. Clean Bulk Hopper Cyclone (if applicable). With System ON 1. Check hopper base and fluidising tile for small parts or foreign items. 2. Complete remainder of booth clean-up. Turn Off All Fluidising Air and Transfer Pumps 1. Clean guns/hoses and pumps 2. Clean outside of booth (walls, hoses, oscillator, etc.) 3. Check gun voltages 4. Clean up detectors 5. Mop paint room
Section 8 Colour Change Procedure
Colour Change Procedure 8-1 Section 8 Colour Change Procedure COLOUR CHANGE PROCEDURE Fixed Reclaim sections are themselves not easily colour changeable and are virtually exclusively used in spray to waste or single colour applications. However, they may be used in conjunction with a booth that may require cleaning in between colours. Should the Fixed Reclaim section ever require to be colour changeable, it is necessary for a set of filter cartridges be kept for each colour used which must be swapped over at colour change time. 1. Clean out spray guns and hoses by disconnecting at pump and blowing clean with air line. Note: Booth extraction fan should be running during this operation (Booth on line). 2. Strip gun and clean internal parts with air line. 3. Roll booth to off line position. (Roll-on/Roll-off arrangement only.) 4. Ensure fan is running and proceed to clean down thoroughly all booth walls and roof, pushing powder into reclaim section. Turn "off" pulse to reduce noise inside booth (where used). The following sequence is suggested for cleaning: Brush or squeegee excess powder from booth. Vacuum booth down. Wipe down with damp, lint-free cloth or chamois. 5. When clean, press the red button to stop the extraction fan.
Section 9 Troubleshooting
Troubleshooting Guide 9-1 Section 9 Troubleshooting Guide 1. Troubleshooting Guide SYMPTOM FAULT CORRECTIVE ACTION No extract air. Fan not running. (See also sieve faults) Emergency stop open. Supply fuse blown. Motor power phase fuse. Close emergency stop. Check for short circuit and replace fuse. Check for motor faults and replace fuse blown or overload or reset overloads. Check overloads. Open setting against motor running current. Fan runs but cartridges won t clean. (Cartridge clean facility turned on or clean poorly). No output from sequence control card. Output from PCB, cartridges not pulsing. If all output affected, check fuse on PCB If one or more outputs, but not all affected, check trial firing by changing faulty output to unused output if available, or by exchanging connections with functioning output, replace faulty board. Check cleaning rate - ie. Position of potentiometer - increase delay between pulses. Check pressure gauge on recovery module 420 Kpa required. Check to see if cartridge reverse jet is passing air continuously - if so shut system down and replace valve. Check and replace faulty solenoid valve(s) as necessary
Troubleshooting Guide 9-2 SYMPTOM FAULT CORRECTIVE ACTION Powder not returning from recovery hoppers No air to transfer pump or fluidised bed. Air to transfer pump, fluidised but not transferring. Check regulator(s) and gauges(s) supplying recovery equipment. Typical operating pressures should be 60-100 Kpa fluidising and 140 Kpa hoppers, transfer pump. Check nylon hoses for kinking or blockage. Remove air supply. Check transfer pump, spigot into recovery hopper and transfer hose for blockage or obstruction. Remove blockage (blow through with low pressure compressed air) and refit equipment and hoses. Extract fan running but no powder from the guns. Powder pack mains, local to pack or on main panel (where isolator incorporated) but not on. Pack switches on but no powder from the gun. Turn pack(s) on. Turn control panel off at isolator. Check fuse in feed to packs. Check compressed air to pack. Check powder pump for blockage. Check compressed air to powder pump. Check powder delivery hose for blockage. Check hopper for sufficient powder. Check powder flow rate and atomising air settings on pack. Atomising air typically 30-40 psi. Flow rate typically 50-70 psi. Sieve not running. Sieve unplugged Plug in sieve (gyratory only) Fan running, sieve not running but turned on. Magnetic switch on inspection door of rotary sieve not made. Sieve fuses blown or over-load tripped. Close door securely - restart system. Shut down system. Check for faults. Replace fuses in sieve supply, or reset overload.
Troubleshooting Guide 9-3 2. Cartridge Filter Troubleshooting Short Filter Life no dust pass through 1. Moisture Problems Wavey pleats. Total plug-pleat bridging (see below) Remove moisture. Remember moisture source may not be in collector area such as air lines. Filter appears to be affected by moisture but none can be found. Check paint for wax content. 2. Collector Design Problem Total plug-pleat bridging. Check to see if deflector shield from booth to collector has been installed. Deflector must extend below cartridges to allow reverse pulse to work. 3. Reverse Pulse Pressure Problem Total plug-pleat bridging. Check reverse pulse pressure to see that it is in approximately 350-410 Kpa. More or less is not normally better. Dust Pass Through 1. Seal Problems Check sealing gasket to be sure it is clean and properly installed. It is important that you do not skimp on adhesive in field retrofits. This is one area where more is better! On models which use the old configuration with centre post bolts be sure new post seal is installed and sealed with RTV if necessary. Be sure nut has not been over torque. Be sure that tube sheet and surrounding area where gasket will be seating has been cleaned. Filter looks to be operating fine but dust is coming out of final filters or final filters are clogging up prematurely. Have powder analysed - it may be too fine to be caught by filters.
Troubleshooting Guide 9-4 2. Damage Problems Visually check cartridges for damage. 3. Construction Problems Check all piping and seams on system. Pay particular attention to joints between booth and collector. Inspect joint between tube sheet and venturi for gaps and leaks. Cartridge Maintenance When new cartridges have been installed, a re-tightening check should be made after eight (8) hours of operation. Cartridge media can fail for a number of reasons: 1. Pleat failure due to normal wear. 2. Pleat failure from using a high pressure blow gun to clean the exterior/interior of the cartridge. 3. Defective media. 4. Damage during shipment ie. dented or bent. 5. The powder has very fine particles which pass through the media. 6. Certain media disintegrates if it is contaminated with oil or water. 7. Expanded metal support has punctured the media.
Troubleshooting Guide 9-5 General Maintenance Make regular inspection checks on: 1. Condition of fluidising tile - replace if damaged or shows signs of blocked pores. 2. Condition of sieve material - holes or blocked areas. Replace if faulty. 3. Sieve vibrator operation. 4. Diaphragm valve operation - see attached data sheet. 5. Possible leakage of powder from collection section to clean air (fan section). If powder is present in or after the clean air section, then checks must be carried out to find source. (a) (b) A break or hole has appeared in the cartridge support plate (partition between the two sections) - possibly where it is sealed around cabinet housing. One (or more) of the cartridges is not sealing to plate due to fault in the gasket, not fully tightened, or distortion in the tube plate. (See cartridge replacement.) Cartridge Replacement While having someone else support the cartridge, remove the top nut and associated hardware and remove the cartridge. Clean the tube plate to provide a positive sealing surface. Remove the hanger from the cartridge by removing the single nut, washer and rubber washer. Re-fit to new cartridge. Install the new cartridge in the reverse order of removal. PLEASE REFER TO DRAWINGS/DIAGRAMS AND COMPONENT BROCHURES AT THE END OF THIS MANUAL.
Section 10 Commissioning Report
Commissioning Report 10-1 Section 10 Commissioning Report PRODUCT: COMMISSIONING REPORT GUNS: Atomising Flow rate Nozzle C = Cone Nozzle F = Flat Oscillator Stroke Length Up pressure Down Pressure GUN ONE GUN TWO GUN THREE GUN FOUR GUN FIVE GUN SIX CONTROLS: INSTRUMENT FUNCTION ACTUAL SETTING RECOMMENDED SETTING *PS1 Final filter DP 10 Mbar *PS2 Cartridge filter DP 10 Mbar *T2 Slugging relay timer 10 sec *T1 Dual hopper recycle / As needed timer Magnahelic Cartridge DP / 0.6-1.1 Kpa Pulse timer Cartridge cleaning / Frequently dependent upon number of cartridges. Duration of 40ms. PRESSURE REGULATOR SETTINGS: INSTRUMENT FUNCTION ACTUAL SETTING RECOMMENDED SETTING R1 Fluidising 60-100 Kpa R3 Pulsing 415 Kpa R7 Module Pump-out 40 Kpa Check for correct seating of all cartridge filters and tighten to approximately 7nm (5ft-lb). Check for correct seating of all cartridge filters and tighten if necessary.
Section 11 Powder System Audit
Powder System Audit 11-1 Section 11 Powder System Audit CUSTOMER: AUDITOR: DATE: / /. PART ONE - GENERAL POWDER SYSTEM AUDIT A. B. C. Record pressure drop across filter. Pulse / blowdown cycle (time between) Pulse / blowdown cycle duration Kpa Sec Sec PART TWO - BOOTH NO. ITEM YES NO COMMENT 1. Any evidence of exterior powder leakage. If yes where? 2. Is pulse air pressure 415Kpa 3. Any evidence of cartridge / filter leakage? If yes, describe. 4. Are all the cartridges sealed tight? 5. Is the fan operation normal? Check for correct direction of rotation 6. Is the differential pressure switch operational? (If fitted) 7. Is the final filter in good condition? If no, describe. 8. Is the manometer function normal? N/A 9. Is the powder level control functional/ (if fitted) 10. Do system powder pumps function properly? 11. Is collector & blower securely mounted? 12. Is the tubing neat, well supported and free of damage or wear? 13. 14. Is collector & other recovery system components electrically grounded? Are ground straps intact and undamaged?... Ohms to building ground
Powder System Audit 11-2 UV DETECTION SYSTEM (IF FITTED) NO. ITEM YES NO COMMENT 1. Has UV Check # 1 been done? VDC Pulse to VDC. Every... Sec 2. Has UV check # 2 been done? Any How many?... bulbs replaced? 3. Has UV check # 3 been done? Set at level... 4. Has UV check # 4 been done? VDC to Ground 5. Has UV check # 5 been done? 6. Are air shields at detector properly located and functional? 7. B to Ground 8. C to Ground 9. 15 to 1 10. A to D1 11. A to D2 12. A to D3 13. A to D4 MINI - CYCLONE/SIEVE Operating PSI... 1. 2. 3. 4. 5. 6. NO. ITEM YES NO COMMENT Evidence of external leakage of powder from this equipment? If yes, describe. Does sieve vibrate properly? If no, describe. Are mini-cyclone, sieve & stand secured together and to the floor? Is tubing neatly dressed, supported and free from damage or wear? Is system connected to building ground? If grounding straps are used, are they intact and undamaged?... Ohms to building ground.
Powder System Audit 11-3 HOPPER - RECYCLE NO. ITEM YES NO COMMENT 1. Is there any evidence of powder leaks from this device? If yes, describe. 2. Is negative pressure evidence inside hopper? 3. Is fluidising function normal 60 to 100 Kpa? 4. If used, is float control operation normal? If not, describe. 5. Is hopper properly vented? 6. Is tubing heat, supported & free from damage or wear? 7. Is hopper connected to building ground?... Ohms to building ground. BOOTH NO. ITEM YES NO COMMENT 1. Is illumination suitable? If not, describe. 2. Is powder overspray being captured efficiently? 3. Is air velocity through each spray enclosure opening greater than 60 FPM? If no, record velocity. 4. Note the required frequency of...hours cleaning 5. List the total air flow (CFM) through Avg. FPM x total the booth opening in sq. Ft. = CFM 6. List worst condition powder/air - Oz Ft³ concentration for this booth Powder lbs/hr x 16 x No. Of guns. 7. Is system connected to building ground? 8. Is booth location 900mm from combustible construction? 9. Are sprinklers provided for fire control?...oz/ft³...60 x cfm... Ohms to building ground
Powder System Audit 11-4 GUNS & POWDER SUPPLY NO. ITEM YES NO COMMENT 1. Any evidence of damage or excessive wear? If yes, describe. 2. Can spray pattern be adjusted properly? 3. Is handgun triggering reliable? 4. Is there evidence of powder leakage into the gun resistor cavity? 5. Does reciprocator or oscillator function properly? 6. Do all switches function properly? 7. Do pilot lights function properly? 8. Does the overcurrent protection circuit trip and reset properly? 9. Does exhaust monitor interlock function reliably? (If fitted) 10. Does the fire alarm interlock function properly? (If fitted) 11. Does the conveyor interlock function reliably? (If fitted) 12. Has dielectric grease been installed in each gun? INFORMATION ON POWDER BEING USED 1. Manufacturer: 2. Specification Number: 3. Colour: 4. Shipping container size: 5. Any moisture problems: Yes No If yes: Explain:
Powder System Audit 11-5 GUN AND POWDER SUPPLY INFORMATION NO. ITEM 1 2 3 4 5 6 1. Ejector pressure - PSI 2. Diffuser pressure - PSI 3. Gun output voltage at KV setting 4. Gun output voltage at KV setting 5. Gun output voltage at KV setting 6. Power pack output voltage at KV setting 7. Power pack output at KV setting. GENERAL INFORMATION - SPRAY ROOM & SURROUNDING AREA NO. ITEM YES NO COMMENT 1. Is wiring installed in a business-like manner and enclosed in proper circuit? 2. Is an electrical disc. Lock-out provided on main power input? 3. Are dust tight approved enclosures used in all classified areas? 4. Is conveyor rail firmly connected to building... Ohms to building ground. ground? 5. Is work piece adequately grounded to the... Ohms to building ground. conveyor? 6. Are conveyor hooks clean? 7. Is conveyor provided with a single start station? If no, explain. 8. Is area housekeeping vacuum cleaner on hand? 9. Is an industrial vacuum cleaner on hand? 10. Are instruction manuals for all equipment on hand and easily accessible? 11. Are operators & supervisors adequately trained to safely operate the equipment? Date of school... 12. Any obvious ignition sources within two (2) meters of the spray booth. 13. Any flammable liquids or materials stored in the area? 14. Adequate emergency exit from area? 15. Are fire control sprinklers installed? 16. Is a fire alarm system installed? 17. Is the fire alarm tested routinely 18. Are lights within six (6) meters of the spray room guarded? 19. Is make-up air adequate?
Powder System Audit 11-6 GENERAL INFORMATION - SPRAY ROOM & SURROUNDING AREA GENERAL INFORMATION NO. ITEM YES NO COMMENT 1. Are routine safety checks conducted? 2. Are no smoking signs posted in powder coating area? 3. Is no smoking ban enforced? 4. Is warning tag number 600-001 posted? 5. Have operating personnel attended a Nordson powder school? How many?... 6. Have regional Customer Service Representatives been trained? AIR DRYER NO. ITEM YES NO COMMENT 1. Is unit properly sized? CFM rating... Suction pressure gauge... 2. Does condensation drain function properly? 3. Does coalescent filter operate? 4. Is the correct size piping used for the system? 5. Is air prefilter operational? 6. Has a time delay lockout been installed? OVERALL COMMENT: AUDIT APPROVAL BY CUSTOMER Approval By: Nordson Representative: Nordson Regional Representative: Date Completed: Title Title Title
Section 12 Drawings
Drawings 12-1