Electrostatic Flux Coating System

Electrostatic Flux CoatingSystem

Customer Product ManualPart 229 809B

NORDSON CORPORATION � AMHERST, OHIO � USA

� 2000 Nordson CorporationAll rights reserved

229 809BIssued 7/00

Manual 38-15

Nordson Corporation welcomes requests for information, comments and inquiries about its products. Generalinformation about Nordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service

555 Jackson StreetAmherst, OH 44001

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1997. No part ofthis 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, Excel2000, 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, SureCoat, Swirlcoat and Walcom are trademarks of Nordson Corporation.

Table of Contents i


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Table of Contents

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 1-4. . . . . . . . . . . . . . . . . . . . . . . . . .

8. Disposal 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. System Operation 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Operation 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. System Components and Functions 2-5. . . . . . . . . . . . . . . . . . . . . . . . .

4. Specifications 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. New System Startup 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan Motor Rotation Check 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sieve Motor Rotation Check 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Settings 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gun Adjustments 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vent-Assist Air Pressure Adjustment 3-4. . . . . . . . . . . . . . . . . . . . . .

Feed-Hopper Level Sensor Calibration 3-4. . . . . . . . . . . . . . . . . . . .

2. Daily Startup and Shutdown Procedures 3-6. . . . . . . . . . . . . . . . . . . . .

Daily Startup 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutdown 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. System Settings 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1Safety

Section 2Description

Section 3Operation

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1. Daily Maintenance 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enclosure Cleaning 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily Equipment Maintenance 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Weekly Maintenance 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Periodic Maintenance 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Maintenance Check List 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Troubleshooting Chart 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Final Filter Replacement 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Cartridge Filter Replacement 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Collector Fluidizing Plate Replacement 6-6. . . . . . . . . . . . . . . . . . . . . . .

4. Feed Hopper Fluidizing Plate Replacement 6-8. . . . . . . . . . . . . . . . . . .

Removal 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Reclaim Hopper Fluidizing Plate Replacement 6-11. . . . . . . . . . . . . . .

Removal 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Pulse Valve Replacement 6-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Motor and Fan Replacement 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan Replacement 6-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Replacement 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Final Filters and Mounting Hardware 7-2. . . . . . . . . . . . . . . . . . . . . . . . .

3. Cartridge Filters and Mounting Hardware 7-3. . . . . . . . . . . . . . . . . . . . .

4. Pulse Valves and Solenoids 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Collector Fluidizing Plate and Hardware 7-7. . . . . . . . . . . . . . . . . . . . . .

6. Fan and Fan Drive 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4Maintenance

Section 5Troubleshooting

Section 6Repair

Section 7Parts

� 2000 Nordson CorporationAll rights reserved Issued 7/00

S1EN−03−[SF−Powder]−6

Section 1

Safety

Safety1-0

� 2000 Nordson CorporationAll rights reservedIssued 7/00


Safety 1-1



Section 1Safety

Read and follow these safety instructions. Task- and equipment-specificwarnings, cautions, and instructions are included in equipmentdocumentation where appropriate.

Make sure all equipment documentation, including these instructions, isaccessible to all persons operating or servicing equipment.

Equipment owners are responsible for making sure that Nordsonequipment is installed, operated, and serviced by qualified personnel.Qualified personnel are those employees or contractors who are trainedto safely perform their assigned tasks. They are familiar with all relevantsafety rules and regulations and are physically capable of performingtheir assigned tasks.

Use of Nordson equipment in ways other than those described in thedocumentation supplied with the equipment may result in injury topersons 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

Make sure all equipment is rated and approved for the environment inwhich it is used. Any approvals obtained for Nordson equipment will bevoided if instructions for installation, operation, and service are notfollowed.

All phases of equipment installation must comply with all Federal, State,and Local codes.

1. Introduction

2. Qualified Personnel

3. Intended Use

4. Regulations andApprovals

Safety1-2



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 areintact and automatic interlocks are operating properly. Do not bypassor disarm any safety devices.

� Keep clear of moving equipment. Before adjusting or servicing anymoving equipment, shut off the power supply and wait until theequipment comes to a complete stop. Lock out power and secure theequipment to prevent unexpected movement.

� Relieve (bleed off) hydraulic and pneumatic pressure before adjustingor servicing pressurized systems or components. Disconnect, lockout, and tag switches before servicing electrical equipment.

� Obtain and read Material Safety Data Sheets (MSDS) for all materialsused. Follow the manufacturer’s instructions for safe handling anduse of materials, and use recommended personal protection devices.

� To prevent injury, be aware of less-obvious dangers in the workplacethat often cannot be completely eliminated, such as hot surfaces,sharp edges, energized electrical circuits, and moving parts thatcannot be enclosed or otherwise guarded for practical reasons.

To avoid a fire or explosion, follow these instructions.

� Do not smoke, weld, grind, or use open flames where flammablematerials are being used or stored.

� Provide adequate ventilation to prevent dangerous concentrations ofvolatile materials or vapors. Refer to local codes or your materialMSDS for guidance.

� Do not disconnect live electrical circuits while working with flammablematerials. Shut off power at a disconnect switch first to preventsparking.

5. Personal Safety

6. Fire Safety

Safety 1-3



� Know where emergency stop buttons, shutoff valves, and fireextinguishers 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 theinstructions in your equipment documentation.

� Use only replacement parts that are designed for use with originalequipment. Contact your Nordson representative for partsinformation and advice.

All work conducted inside the spray booth or within 1 m (3 ft) of boothopenings is considered within a Class 2, Division 1 or 2 Hazardouslocation 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 beelectrically connected to ground with a resistance of not more than 1megohm as measured with an instrument that applies at least 500volts to the circuit being evaluated.

� Equipment to be grounded includes, but is not limited to, the floor ofthe spray area, operator’s platform, hoppers, photoeye supports, andmetal blow-off nozzles. Personnel working in the spray area must begrounded.

� There is a possible ignition potential from the charged human body.Personnel standing on a painted surface, such as the operatorplatform, or wearing non-conductive shoes, are not grounded.Personnel must wear shoes with conductive soles or use a groundstrap to maintain a connection to ground when working with or aroundelectrostatic equipment.

� Operators must maintain skin-to-metal contact between their handand the gun handle to prevent shocks while operating manualelectrostatic spray guns. If gloves must be worn, cut away the palmor fingers, wear electrically conductive gloves, or wear a groundingstrap connected to the gun handle or other true earth ground.

7. Grounding

Safety1-4



� Shut off electrostatic power supplies and ground gun electrodesbefore making adjustments or cleaning powder spray guns.

� Connect all disconnected equipment, ground cables, and wires afterservicing equipment.

WARNING: Operating faulty electrostatic equipment ishazardous and can cause electrocution, fire, or explosion.Make resistance checks part of your periodic maintenanceprogram. If you receive even a slight electrical shock or noticestatic sparking or arcing, shut down all electrical or electrostaticequipment immediately. Do not restart the equipment until theproblem has been identified and corrected.

If a system or any equipment in a system malfunctions, shut off thesystem immediately and perform the following steps:

� Disconnect and lock out electrical power. Close pneumatic shutoffvalves and relieve pressures.

� Identify the reason for the malfunction and correct it before restartingthe equipment.

Dispose of equipment and materials used in operation and servicingaccording to local codes.

7. Grounding (contd)

8. Action in the Event of aMalfunction

9. Disposal


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Section 2

Description

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Description 2-1


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Section 2Description

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 detectionsystems are covered by separate manuals. For information on systemcomponents not covered by the manuals furnished with your system,contact your Nordson Corporation representative.

See Figure 2-1. A porous fluidizing plate in the feed hopper (20) plenumdiffuses low-pressure compressed air into the powdered flux supply. Theair 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 witha high velocity stream of air. This air conveys the flux through the feedhoses (18) to the spray guns. The guns electrostatically charge the fluxand spray it on the workpieces passing through the booth.

The exhaust fan (1) pulls air into the booth enclosure (17) and throughthe cartridge filters (4). The oversprayed flux suspended in the air flowcollects on the outside of the cartridge filters. The final filters (2) removeany remaining flux from the air. On a signal from a timer, the pulsevalves (3) release large volumes of air through the center of the cartridgefilters, blowing off the accumulated flux. The flux falls into the bottom ofthe collector (5), where it is fluidized. The reclaimed flux is then pumpedby transfer pumps (6) through large-diameter transfer hoses (7) to anaccumulator (15) mounted on a rotary sieve (13).

The rotary sieve screens the flux. Particles too large to pass through thescreen are discharged into a scrap container (11). The screened fluxfalls into the reclaim hopper (12), where it is stored and fluidized. A loadchute on the reclaim hopper allows new flux to be added when systemsupplies run low. Flux is pumped by transfer pumps (10) through largediameter transfer hoses (8) to the feed hopper accumulator (21) on asignal from a level sensor. Conveying air, fluidizing air, and dust arevented into the collector through vent hoses (9, 22).

1. Introduction

2. System Operation

Description2-2


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3815001A

1

2

3

4

5

6910

11

12

13

15

16

17

18 19

20

2122

78

Clean air

Vent air and dust

Powder

14

14

Fig. 2-1 System Operation

1. Exhaust fan2. Final filters3. Pulse valves4. Cartridge filters5. Collector6. Transfer pumps7. Transfer hoses8. Transfer hoses

9. Vent hose10. Transfer pumps11. Scrap container12. Reclaim hopper13. Rotary sieve14. Agitators15. Accumulator

16. Spray gun17. Enclosure18. Feed hose19. Feed pumps20. Feed hopper21. Accumulator22. Vent hose

2. System Operation (contd)

Description 2-3


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See Figure 2-2. The feed pump (1) has three air inlets in the pump bodyand an in-line inlet fitting installed at the outlet. When a spray gun istriggered, flow-rate air (A), atomizing air (B) and pulse air (C, C1) areturned on. Flow-rate air draws the powdered flux into the pump andconveys 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 itsvelocity.

When the spray gun is turned off, flow-rate, atomizing, and pulse air areturned off and reverse air (D, D1) is turned on. Reverse air prevents theflux 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 solenoidvalves that control air flow, all air lines are equipped with one-way checkvalves (3).

Pump Operation

Description2-4


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3815002A

C AB DC1 D1

AB

1

2

3

Fig. 2-2 Feed and Transfer Pump Operation

1. Feed pump 2. Transfer pump 3. Check valves

Pump Operation (contd)

Description 2-5


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See Table 2-1 for a description of major system components. Thenumbers in the Item columns are references to Figure 2-3.

Table 2-1 Containment and Recovery System Components and FunctionsItem 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 pneumaticequipment.

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 sprayroom.

4 Accumulators Provides a connection point for multiple transfer hoses. Collects powdered fluxpumped from the collector to the reclaim hopper and from the reclaim hopper to thefeed 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 airthrough the cartridge filters and pushes it through the final filters. The air flowcontains 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 pressuregauge

Monitors the pressure drop across the cartridge filters. A high reading indicates filterclogging.

11 Vent-assist plate Provides a connection point for hopper and accumulator vent hoses.

12 Versa-Screenworkstation

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 reclaimhopper 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 systempanel

Houses the controls for the fire detection system. Sensors monitor the system andshut 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 thesystem 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 powerto the gun control units. A pilot valve and pneumatic manifold in the cabinetdistributes compressed air to the gun control units.

3. System Components andFunctions

Description2-6


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3815003A

21 3

5

7

8

9

10

11

13

12

17

19

5

16

15

18

14

20

21

22

23

6

4

4

Fig. 2-3 System Components

3. System Components andFunctions (contd)

Description 2-7


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Overall Base Dimensions:

Height 2.6 m (8.5 ft)Width 2.4 m (8.0 ft)Length 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 m3/min (2500 cfm)Air flow at 6-in. w.c. 56 m3/min (2000 cfm)

System Equipment Capacities:

Spray guns six (automatic only)Cartridge filters four, 66.0 cm (26 in.)Pulse valves fourFinal filters two, 61.0 x 50.8 cm (24 x 20 in.)

4. Specifications

Description2-8


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Section 3

Operation

Operation3-0


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Operation 3-1


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Section 3Operation

WARNING: Allow only qualified personnel to perform thefollowing tasks. Follow the safety instructions in this documentand all other related documentation.

Use these procedures to prepare your Nordson flux coating system forproduction. Your Nordson representative will help you set up yourapplication equipment and adjust your system control settings before youstart production.

Start the exhaust fan (refer to Daily Startup) and make sure the fan ispulling 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 theelectrical panel before opening the panel door. Failure toobserve 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 thecorrect direction.

Make sure the sieve motor is rotating in the direction indicated by thearrow 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 Checkprocedure, reversing the sieve motor starter (M120) wires instead.

NOTE: The settings given in this procedure are suggested initial startupsettings. Make adjustments as needed for optimum performance. All thesettings listed here are included in the System Settings chart at the endof this section, along with space for you to write in your adjusted settings.Copy this chart and post it on your system.

1. New System Startup

Fan Motor Rotation Check

Sieve Motor Rotation Check

System Settings

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WARNING: Shut off power at a disconnect ahead of theelectrical panel before opening the panel door. Failure toobserve this warning could result in serious injury or death.

1. Open the electrical panel door. Set the transfer-pump delay timer to60 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) 15 secondsDuration (ON) 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 to6.9 bar (100 psi).

6. Turn on the exhaust fan (refer to Daily Startup).

WARNING: Wear an approved respirator or dust mask andgoggles when handling powders. Avoid getting powders onyour 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 LevelSensor 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 10−15 minutes for the flux to fluidize before spraying.

10. Set the reclaim and feed hopper vent-assist pump air pressure to0.7 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 collectormodule, adjust the pressure. You should see the surface of the fluxboil gently.

12. At the rotary sieve control panel, make the following settings:

Seal air pressure 1.7 bar (25 psi)Flowmeters 100 SCFH

System Settings (contd)

Operation 3-3


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13. Set the accumulator vent-assist air pressure. Refer to AccumulatorVent-Assist Air Pressure Adjustment in this section.

14. Set the transfer-pump selector switch to AUTO. This will allow thelevel sensors to control the transfer pumps. Set the transfer pump airpressures:

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 toaccess the pulse valve air controls. Set the pulse valve regulatorto 3.4−4.1 bar (50−60 psi). Watch the pressure gauge. Thepressure will drop when the valves open.

b. Adjust the gate valve so the air pressure returns to 3.4−4.1 bar(50−60 psi) just before the next pulse. This adjustment willprevent the powder pumps from being deprived of air duringpulses.

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 toManual 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 90−100a 40

NOTE: These are suggested starting pressures. To fine-tune your filmbuild, watch the guns spray while adjusting the flow-rate and atomizingair pressures on the gun control panels. Flow-rate air pressure iscontrolled by the left regulator, while atomizing air pressure is controlledby the right regulator.

Gun Adjustments

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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.

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 itdeflates, decrease the vent-assist air pressure.

NOTE: Depending on the sieve used, the vent-assist air pressureregulator is located either on the sieve pneumatic panel or on the systempneumatic panel.

The level sensor is a capacitive proximity switch. For it to functionproperly, you must calibrate it. Perform this procedure when you start upa new system or replace a sensor.

1. See Figure 3-1. Insert the level sensor into the plastic mounting wellin the side of the feed hopper until it bottoms out, then pull it backabout 3.175 mm (0.125 in.). Tighten the plastic screws on the side ofthe 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). Thepowder level should rise above the top of the mounting well as thepowder fluidizes. Add powder to the hopper if it does not.

5. Shut off the fluidizing air. The mounting well should now be coatedwith a film of powder.

Gun Adjustments (contd)

Vent-Assist Air PressureAdjustment

Feed-Hopper Level SensorCalibration

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229 809BIssued 7/00

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6. 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 thepotentiometer counterclockwise until it lights, then clockwise until itgoes off.

7. Increase the fluidizing pressure until the powder level rises above themounting well. The LED should be off.

8. Turn the potentiometer counterclockwise. Count the number of turnsyou make until the LED lights.

9. Turn the potentiometer clockwise for 1/2 the number of turns youcounted in step 8. The LED will go off. The sensor is now set in themidpoint of its sensitivity range.

NOTE: Replacement sensors are shipped configured as normally closed(N.C.) switches.

3815015A

1

23

3.175 mm

N.O.

N.C.

L1(Vac)+ (Vdc)

1 3

2 4

L2(Vac)− (Vdc)

4

(0.125 in.)

Fig. 3-1 Level Sensor Installation and Configuration

1. Cover2. Potentiometer

3. LED4. Jumper wire

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Use these procedures for routine operation of your system.

1. Walk around the booth. Make sure the transfer, feed, and vent hosesare connected correctly, and that all equipment ground connectionsare secure.

WARNING: An ungrounded or poorly grounded workpiece,conveyor, or equipment ground can cause electrical arcing. Ifarcing is observed, shut down the system immediately. Correctthe cause before restarting the system. Failure to observe thiswarning could result in a fire or explosion, causing propertydamage, 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 guncontrol cabinet, if not already on.

4. Push the SYSTEM START button on the electrical panel. Thisenergizes the system.

5. Make sure the flame detector(s) and relay/indicator panel arefunctioning 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 systemdevices. 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).

2. Daily Startup andShutdown Procedures

Daily Startup

Operation 3-7


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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 moversare not in the Home position, you will not be able to selectAutomatic 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 thesystem in Automatic mode, the guns will start spraying automaticallyas 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 whileadjusting the flow-rate and atomizing air pressures on the gun controlpanels. Flow-rate air pressure is controlled by the left regulator, whileatomizing air pressure is controlled by the right regulator.

9. Measure the air flow velocity at the enclosure entry and exitvestibules with a velometer. The velocity should be 30.5−36.6 m/min(100−120 ft/min). Make sure the sprayed flux is not being pulled fromthe guns and workpieces, and that the flux is not escaping from theenclosure openings.

NOTE: Keep the air dryer running continuously. This will preventmoisture from accumulating in the compressed air system.

1. Start the transfer pumps and sieves. Pump the reclaimed flux fromthe collector module back into the reclaim hopper.

2. Turn off the spray-gun master control unit.

3. Perform the daily maintenance procedures described in theMaintenance section. Perform daily maintenance procedures forother system equipment as described in their manuals.

4. Turn off the exhaust fan. Shut off the system electrical power andcompressed air supply.

Shutdown

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EquipmentRecommendedInitial Settings Final Setting Changes

Primary Air Pressure (plant supply) 6.9 bar (100 psi)

Collector Module

Fluidizing 2.1 bar (30 psi)

Transfer pump flow rate 1.7 bar (25 psi)

Transfer pump pulse 0.7 bar (10 psi)

Feed Hopper


Vent-assist 0.7 bar (10 psi)

Reclaim Hopper


Vent-assist pump 0.7 bar (10 psi)

Transfer pump flow rate 1.7 bar (25 psi)

Transfer pump pulse 0.7 bar (10 psi)

Pulse Manifold

Air pressure 3.4−4.1 bar (50−60 psi)

Rotary Sieve

Flowmeter #1 100 SCFH

Flowmeter #2 100 SCFH

Seal air pressure 1.7 bar (25 psi)

Vent-assist air pressure 2.8 bar (40 psi)

Pulse Timer

Delay (OFF) time 15.0 sec.

Duration (ON) time 0.07 sec.

Filter Pressure Drop Maximum Readings

Cartridge filters 4−6-in. w.c.

Final filters 2-in. w.c.

Spray guns

#1 Flow-rate 0.8 bar (12 psi)

Atomizing 1.7 bar (25 psi)

Pulse 1.4 bar (20 psi)

Reverse 1.7 bar (25 psi)

Voltage 90−100 kV

AFC 40 A

3. System Settings

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EquipmentRecommendedInitial Settings Final Settings Changes

Spray guns (contd)





Voltage 90−100 kV

AFC 40 A





Voltage 90−100 kV

AFC 40 A





Voltage 90−100 kV

AFC 40 A





Voltage 90−100 kV

AFC 40 A





Voltage 90−100 kV

AFC 40 A

Operation3-10


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Manual 38-15

Section 4

Maintenance

Maintenance4-0


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Maintenance 4-1


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Section 4Maintenance


Perform these procedures daily to keep your system clean andfunctioning properly.

WARNING: Wear an approved respirator and safety glasses orgoggles when handling flux, operating the system, orperforming maintenance or cleaning operations.

1. Turn off the automatic-gun master-control unit.

2. Turn on the exhaust fan (refer to Daily Startup in the Operationsection). Set the motor speed to 10.

3. 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 fluxinto the collector hopper.

5. Remove the remaining residue from the enclosure with anair-powered vacuum and a soft brush attachment. Wipe down allsurfaces 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.

1. Daily Maintenance

Enclosure Cleaning

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Equipment Procedure

Filters 1. Check the final filter differential pressure gauge. It should read between1- and 2-in. w.c. A pressure greater than 2-in. w.c. will shut down the systemautomatically. Make sure no flux is leaking from around the filter gasket orface.

2. Check the cartridge filter differential pressure gauge. It should read between4- and 6-in. w.c. A reading higher than 6-in. w.c. indicates that the filters areclogged and should be replaced. Check the pulse valve timing.

Rotary Sieve 1. Empty the scrap container.

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 accumulatorvent-assist air pressure. Refer to your AZO sieve manual for moreinformation.

Feed and Transfer Pumps 1. Disconnect the hoses from the pumps. Blow out the hoses with compressedair.

2. Place a small container under the pumps to catch spilled flux. Depress thespring clips on the pumps and pull them off the adapters.

3. Disassemble the pumps. Clean the parts with a low-pressure air gun and aclean cloth. Replace any worn or damaged parts.

4. Check the pump adapters and pickup tubes. If they are clogged with flux, usea wooden dowel or plastic rod to clean them out, working from the inside of thehopper.

Fan Section 1. Remove the final filters and inspect the fan compartment. Vacuum out anyflux.

2. Inspect the pulse-valve compartment. Vacuum out any flux. If significantamounts of flux have accumulated in the fan or pulse-valve compartment, thecartridge filters may be leaking. Refer to the Troubleshooting and Repairsections for instructions.

Daily Equipment Maintenance

Maintenance 4-3


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Equipment Procedure

Spray Guns Disassemble and clean the guns according to the instructions in their manuals.

Fire Detection System Check the detector sensors every four hours and clean the lenses, if necessary.Make sure air is being supplied to the sensors. Make sure the detector system isoperating properly.

Compressed Air Supplyand Air Dryer

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 ofcontamination. 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 fromaccumulating in the compressed air system.

Refer to your air dryer manual for maintenance procedures and schedules.

Gun Movers Each shift, make sure the gun movers are stroking smoothly and at the properspeed. Make repairs and adjustments if necessary. Lubricate the gun movers asdescribed in their manuals.

Accumulators and VentHoses

Vacuum out the accumulators and blow the flux out of the vent hoses withcompressed air.

Workpiece and ConveyorGrounds

WARNING: An ungrounded or poorly grounded workpiece or conveyorcan cause electrical arcing. If arcing is observed, shut down thesystem 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. Theresistance between the workpieces and ground, must be less than1 megohm. You will get better transfer efficiency and workpiececoverage at 500 ohms or less. Clean or strip workpiece hangersregularly.

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Manual 38-15

Equipment Procedure

Booth Clean the booth enclosure interior as described in Enclosure Cleaning, and theexterior, all attached equipment, and the spray room.

Spray Guns Perform resistance checks on the spray guns and cables as described in the gunmanuals.

Reclaim and Feed Hoppers Remove the flux from the hoppers. Vacuum the interiors. Check the fluidizingplates. If the plates are stained, the air supply could be contaminated by oil ormoisture. Check the air dryer and air filters. Replace the fluidizing plates if theyare contaminated. Lubricate the hopper casters with a lithium grease.

Collector Start the exhaust fan and activate the pulse valves to blow off as much flux aspossible off the cartridge filters. Do not vacuum the cartridge filters. Remove thecartridge filters and inspect the filter media and gaskets. Replace the filters ifthey are damaged.

Pump the flux out of the collector. Vacuum the interior. Check the fluidizingplate. 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 iscontaminated.

Equipment Procedure

Electrical Connections Check all terminal blocks, and junction boxes for loose wires. Tighten any looseconnections and inspect all wiring for damaged insulation. Replace the wiring ifthe insulation is damaged.

Air Dryer Check the air dryer operation. Refer to your air dryer manual for maintenanceprocedures and schedules.

Gaskets Inspect all gaskets and seals for damage. Replace them if they are damaged.

Bearings Every six months, lubricate the motor bearings with two shots of lithium orpolyurea grease from a grease gun.

AZO Rotary Sieve Lubricate the AZO rotary-sieve lip seals every three months with a white lithiumgrease. Refer to your sieve manual for more information.

2. Weekly Maintenance

3. Periodic Maintenance

Maintenance 4-5


229 809BIssued 7/00

Manual 38-15

ActivityEachShift 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.

4. Maintenance Check List

Maintenance4-6


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Manual 38-15

Section 5

Troubleshooting

Troubleshooting5-0


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Troubleshooting 5-1


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Manual 38-15

Section 5Troubleshooting


This section contains troubleshooting procedures. These procedurescover only the most common problems that you may encounter. If youcannot solve the problem with the information given here, contact yourlocal Nordson representative for help.

Problem Page

1. Guns are surging or spitting; flux flow is inadequate orintermittent

5-2

2. Problems with coating uniformity, edge coverage, filmbuild, wrap, or penetration into recesses

5-3

3. Flux not transferring between collector, reclaim hopper,and feed hopper

5-3

4. Flux not fluidizing, or clouds of flux erupting from surface 5-4

5. Final filters clogged, flux in fan compartment 5-5

6. Cartridge filters clogged 5-5

7. System shuts down or will not start 5-6

8. Sieve not screening flux 5-7

9. Sieve scrap bucket filling up with flux 5-7

10. Flux escaping from booth openings 5-7

1. Introduction

Troubleshooting5-2


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Manual 38-15

Problem Possible Cause Corrective Action

1. Guns are surging orspitting; flux flow isinadequate or intermittent

Flux in feed hopper inadequatelyfluidized

Adjust the fluidizing air pressure. Theflux should be gently boiling. Refer toproblem 4 for more troubleshootingprocedures.

Low flux level in feed hopper Add flux to the feed hopper. Refer toproblem 3 for more troubleshootingprocedures.

Feed pump venturi nozzles or throatsworn; adapter O-rings leaking; pumpor pickup tube clogged

Clean the pump and pickup tube.Replace any worn parts. Replace theadapter O-rings, if they are damaged.

Obstruction in feed hose Disconnect the feed hose from thepump. Blow the flux out of the hose withcompressed air. Make sure the hose isclear. Eliminate kinks or severe bendsin the hose. The hose should be nolonger than 7.6 m (25 ft) with amaximum 2.7-m (9-ft) vertical rise.

Severe tribo-charging in feed hose Contact your Nordson Corporationrepresentative for a suitable hosematerial.

Obstruction in gun Unclog the gun. To do this, put the gunsin Manual mode (refer to GunAdjustments in the Operation section)and increase the flow-rate air pressureto 2.8 bar (40 psi) or higher until the gunclears. Return the pressure setting tonormal. If this does not work, open thesolenoid panel and increase the airpressure on the purge air regulator(middle regulator) until the gun clears. Ifthe gun is still clogged, stop production,shut down the system, and manuallyclean the gun. If you are using conicalnozzles, make sure there is a 3-mm(0.125-in.) or larger gap between thedeflector and the nozzle.

Flow-rate or atomizing air pressureincorrect

Refer to the Operation section forrecommended air pressures and ratios.

Continued on next page

2. Troubleshooting Chart

Troubleshooting 5-3


229 809BIssued 7/00

Manual 38-15


2. Problems with coatinguniformity, edgecoverage, film build,wrap, or penetration intorecesses

Poor workpiece grounding Resistance from workpiece to groundmust be less than 1 megohm. For bestresults, resistance should not be morethan 500 ohms. Clean the workpiecehangers if necessary. Check theconveyor ground.

Gun placement incorrect Position the guns 25.4−35.6 cm(10−14 in.) from the workpieces.Stagger the guns 30.5-cm (12-in.) apartvertically and 38.1-cm (15-in.) aparthorizontally to avoid fan pattern andelectrostatic field overlap. Contact yourNordson Corporation representative foradvice.

Feed pump flow-rate and atomizingair pressure incorrect

Refer to the Operation section for therecommended air pressures and ratios.

Electrostatic voltage (kV) or AFCsetting incorrect for workpieces beingcoated

Adjust the voltage to 90−100 kV forlarge flat surfaces and 60−75 kV forrecesses. Never set the voltage below60 kV. Refer to the Operation sectionfor the recommended voltage and AFCsettings.

Wrong nozzles being used Use flat spray nozzles for large,regular-shaped workpieces. Use conicalnozzles for deep recesses and mostmanual touch-up.

Flux feed problems Refer to problem 1 for moretroubleshooting procedures.

3. Flux not transferringbetween collector,reclaim hopper, and feedhopper

Transfer pump air pressure too low Increase the air pressure.

Transfer pump venturi nozzle cloggedor throat worn

Clean the pump and replace worn parts.

Transfer hose plugged Blow the flux out of the hose withcompressed air.

Sieve screens clogged, or motorrunning in wrong direction

Clean the sieve screens. Refer to theSieve Motor Rotation Check procedurein the Operation section.


Troubleshooting5-4


229 809BIssued 7/00

Manual 38-15


3. Flux not transferringbetween collector,reclaim hopper, and feedhopper (contd)

Accumulator plugged Clean out the inlet ports. Clean theaccumulator interior.

Accumulator vent-assist air pressuretoo high

Reduce the vent-assist air pressure.

Transfer pump delay too long, levelsensor sensitivity adjusted incorrectly,or sensor failed

Decrease the transfer pump delay.Calibrate the level sensor as describedin the Operation section. Replace thelevel sensor if the problem continues.

Flux in collector not fluidized. Deephole in flux around pickup tube

Increase the fluidizing pressure. If theproblem continues, go to the next cause.

Flux damp or contaminated; cannotbe fluidized or pumped

Refer to problem 4 for moretroubleshooting procedures.

4. Flux not fluidizing, orclouds of flux eruptingfrom surface

Fluidizing pressure too low or high Check the flux in the hoppers. Increasethe fluidizing air pressure until the flux isgently boiling. Decrease the pressure ifclouds of flux are erupting from thesurface.

Moist or oil-contaminated flux Open the drain valve at the air-supplydrop leg and check the air supply forwater or oil. Check the filters,separators, and air dryer.

Replace the flux in the hoppers, then goto the next cause.

Air leaking from fluidizing pan gasketinstead of diffusing through fluidizingplate, or contaminated air pluggingpores in fluidizing plates

Check for air leaks around the fluidizingpan gaskets. If leaks are found, removethe pan and replace the gasket.

If fluidizing air pressure increases ordecreases abruptly, remove the flux fromthe hoppers and inspect the fluidizingplates for stains, discoloration, orpolished surfaces. Replace thefluidizing plates if they are contaminatedor plugged.


2. Troubleshooting Chart(contd)

Troubleshooting 5-5


229 809BIssued 7/00

Manual 38-15


4. Flux not fluidizing, orclouds of flux eruptingfrom surface (contd)

Transfer pumps or hoses areplugged, or fluidizing plate is cracked

Clean the transfer pumps and replaceworn parts. Blow the flux out of thetransfer hoses with compressed air.Make sure the hoses are clear.

Check the fluidizing plates and replaceany plate that is cracked.

Incorrect ratio of reclaimed-to-newflux

Change the transfer-pump air pressureto increase or decrease the transferrate. Add new flux to hopper. The fluxsupply should be no more than 3 partsreclaim-to-1 part new flux.

Uneven distribution of flux in hopper Increase the fluidizing pressure. Checkthe flux and the fluidizing plate forcontamination as previously described.

5. Final filters clogged, fluxin fan compartment

Leaking cartridge filter gaskets, orhole in filter media

Make sure the gaskets are sealingcorrectly. If you can slip a 0.381 mm(0.015 in.) feeler gauge between thegasket and the sealing surface, tightenthe tension screws to compress thegaskets. Refer to the Repair section forinstructions.

If the gaskets continue to leak, removethe cartridges. Clean and inspect thegaskets, sealing surfaces, and filtermedia. Replace the cartridges if thegaskets or filter media are damaged.Refer to the Repair section. Replaceclogged final filters.

Leak in cartridge filter mounting plate Locate and seal any leaks with RTVsealant.

6. Cartridge filters clogged Pulse air pressure inadequate Increase the pulse air pressure orvolume. 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. Replacecontaminated flux and fix the source ofcontamination.


Troubleshooting5-6


229 809BIssued 7/00

Manual 38-15


6. Cartridge filters clogged(contd)

Pulse valves out of position Position the valves so they are pointingstraight down. The nozzles must directthe pulse air through the center of thefilters.

Timer board settings incorrect Adjust the timer board settings asdescribed in the Operation section.

Pulse valve or solenoid valvesclogged or malfunctioning

Open the pulse-valve timer panel. If youdo not hear a pulse each time a LEDlights, the solenoid valve or the pulsevalve connected to that LED may beclogged or failed. Check the wiring tothe solenoid valve before opening thesolenoid box and replacing the solenoidvalve.

Flux level in collector too high Pump out excess flux.

7. System shuts down orwill not start

Fire detection system detects a flameor spark, or is malfunctioning

Check for a fire inside the enclosure orcollector. Check the workpiece andconveyor grounds. Make sure thesensors are aimed properly.

Follow the troubleshooting procedures inthe flame detector system manual.

Final filters clogged Locate the source of flux leakage andcorrect the problem. Refer to problem 5for more troubleshooting procedures.

Final filter pressure switch failed Replace the switch.

Air dryer not operating, or interlocknot activated

Start the air dryer. Follow thetroubleshooting procedures in the dryermanual. Check the interlock circuit.

Fuse(s) blown Check the fuses in the system electricalpanel. Replace the blown fuse(s). If thefuses continue to blow, fix the electricalproblem.

Electrical failure Trace the circuits and correct theproblem.


2. Troubleshooting Chart(contd)

Troubleshooting 5-7


229 809BIssued 7/00

Manual 38-15


8. Sieve not screening flux Screen clogged or damaged Clean or replace screen.

9. Sieve scrap bucket fillingup with flux

Scrap bucket lid not sealed Lid must be airtight. Tighten lid. Checkscrap hose connections.

Screen clogged Clean or replace screen.

Hopper or accumulator vents cloggedor hose kinked

Clean vents, checks hoses.

Vent-assist air pressure too low Increase vent-assist air pressure. Referto Vent-Assist Air Pressure Adjustmentin the Operation section.

10. Flux escaping frombooth openings

Cartridge filters clogged If the differential pressure gauge showsmore than 6-in. w.c., refer to problem 6.

Cross drafts interfering with exhaustfan draw

Check for cross drafts at all enclosureopenings. Eliminate or divert drafts.

Workpieces entering booth are toohot

Cool the workpieces before movingthem into the booth. The workpiecetemperature should not exceed 49 �C(120 �F).

Spray gun output exceeds boothcontainment capability

Reduce the flux flow and/or the numberof the guns.

Booth openings too large Close or decrease the size of theopenings.

Fan section slide dampers open Close the slide damper on the side ofthe fan section.

Workpieces too large for booth Contact your Nordson Corporationrepresentative.

Guns too close to entrance and exitvestibules or openings

Move the guns farther away from thevestibules or openings.

Fan rotation backward Reverse the rotation of the motor. Referto the Fan Motor Rotation Checkprocedure in the Operation section.


Troubleshooting5-8


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Manual 38-15

Section 6

Repair

Repair6-0


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Manual 38-15

Repair 6-1


229 809BIssued 7/00

Manual 38-15

Section 6Repair


WARNING: Before performing this procedure, shut offelectrical power at the system electrical panel. Lock and tag theswitch. Failure to observe this warning could result in personalinjury 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 inplace.

2. Remove the old filters and discard them.

3. Check the interior of the fan section. If you see large amounts of fluxinside, it is leaking through the cartridge filters or mounting plate. Fixthe 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 ontothe studs.

7. Tighten the knobs to compress the filter gaskets slightly. Do notovertighten the knobs.

8. Restore system electrical power. Start the exhaust fan and check forleaks around the filter gaskets.

1. Final Filter Replacement

Repair6-2


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Manual 38-15

3815004A

1

2

3

Fig. 6-1 Final Filter Replacement

1. Final filters 2. Brackets 3. Knobs

1. Final Filter Replacement(contd)

Repair 6-3


229 809BIssued 7/00

Manual 38-15

Two people are needed to remove and replace the cartridge filters. Oneperson removes and installs the mounting hardware from the top of themounting plate, while the other person holds the filters.

WARNING: Before performing this procedure, shut offelectrical power at the system electrical panel. Lock and tag theswitch. Failure to observe this warning could result in personalinjury or death.

1. See Figure 6-2. Manually pulse the filters to remove all excess flux.Remove the baffle (9).

2. Remove the pulse valve compartment and filter compartment accessplates (1).

3. Reach down into the center of the filters (8) and grasp the draw rodT-handle (6). Have another person hold the filters up against themounting plate (10). This will prevent them from falling into thecollector and damaging the fluidizing plate when the mountinghardware is removed.

4. Remove the nuts (2), lock washers (3), flat washers (4), and filtermounts (5) from the draw rods. Save the removed parts.

5. Remove the cartridge filters from the collector.

6. Unscrew the draw rods from the cartridge filter bosses and removethe filter centering brackets (7) and draw rods from the cartridgefilters. Save the draw rods and centering brackets for reuse.

NOTE: Do not use any cartridge filters other than those specified foryour system. Using unapproved cartridge filters could seriously affect theoperation and performance of your system, as well as void any agencyapprovals. Do not use damaged filters.

Carefully inspect the new cartridge filters for

� cuts or other damage to the rubber gaskets� bent or dented end caps� holes or other damage to the filter media

2. Cartridge FilterReplacement

Removal

Installation

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229 809BIssued 7/00

Manual 38-15

1. See Figure 6-2. Thoroughly clean the sealing surfaces on theunderside of the mounting plate (10). Dirty surfaces will prevent thecartridge filter gaskets from sealing properly and allow flux to leak intothe fan section.

2. Insert the threaded end of the draw rods (6) through the centeringbrackets (7).

3. Install the draw rods and centering brackets into the new cartridgefilters (8). Screw the draw rods into the filter bosses and tighten themby hand.

4. Center the cartridge filters under the filter openings in the mountingplate. Hold the cartridge filters up against the mounting plate.

5. Use the draw rod T-handles to pull the cartridge filters up against thefilter mounting plate. Install the filter mounts (5) on the draw rods,making sure the slots slip over the T-handles.

6. Install the flat washers (4), lock washers (3), and nuts (2) on the drawrods.

7. Slip the tabs on the filter mount arms into the locating slots in themounting plate.

CAUTION: Do not overtighten the nuts, or you may damagethe cartridge filters.

8. Tighten the nuts until the filter mounts and centering brackets aretouching. This will compress the filter gaskets (11) and seal thecartridges against the mounting plate.

9. Re-install the pulse valve compartment and filter compartment accessplates. Make sure the plate gaskets are not damaged.

Installation (contd)

Repair 6-5


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3815005A

2

3

4

5

6

7

8

4

7

6

8

11

9

10

234

1

Fig. 6-2 Cartridge Filter Replacement

1. Access plates2. Nuts3. Lock washers4. Flat washers

5. Filter mount6. Draw rod7. Centering bracket8. Cartridge filters

9. Baffle10. Mounting plate11. Filter gaskets

Repair6-6


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Manual 38-15

Replacement is needed only if the plate is contaminated or damaged.

1. Start the transfer pumps and pump as much as possible of the flux inthe collector to the reclaim hopper. If the flux is contaminated, pumpit into a scrap bucket.

2. Vacuum any remaining flux out of the collector.

3. Use a forklift or jacks to raise the collector several inches off the floor.Install safe, solid support blocks under the collector legs to hold it up.This will give you enough clearance to remove the collector plenum.

4. See Figure 6-3. Unscrew the clamping-channel screws (5) about6.35−9.53 mm (0.250−0.375 in.) to clear the gasket (3). Support theplenum (6) and remove the clamping channels (4).

5. Slide the plenum out from under the collector (1).

6. Discard the old fluidizing plate (2).

7. Clean the plenum and collector flange.

8. Make sure the gasket is correctly installed on the new fluidizing plate.

9. Line up the gasket with the plenum flange. Slide the plenum underthe collector.

10. Hold the plenum up against the collector flange and line up the gasketwith the collector flange.

11. Install the clamping channels over the plenum and collector flange.Tighten the clamping-channel screws to 2.82 Nm (25 in.-lbs) in acriss-cross pattern. This will prevent flange distortion and fluidizingplate damage.

12. Lower the collector to the floor.

3. Collector Fluidizing PlateReplacement

Repair 6-7


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3815006A

1

2

3

4

5

6

23 1

4

56

Fig. 6-3 Collector Fluidizing Plate Replacement

1. Collector2. Fluidizing plate

3. Gasket4. Clamping channels

5. Screws6. Plenum

Repair6-8


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Manual 38-15


1. Pump as much flux as you can from the hopper. Shut off and relievesystem air pressure.

2. See Figure 6-4. Depress the spring clips on the pump bodies andpull the feed pumps off the adapters (9).

3. Disconnect the transfer hoses and vent hose from the accumulator,and the vent hoses and air tubing from the vent-assist pumps andagitator motor.

4. Disconnect the ground wire from the hopper.

5. Unclamp the lid and lift it off the hopper body (1). Vacuum anyremaining flux out of the body.

6. Release the clamps (11) holding the plenum (10) and hopper bodytogether.

7. Lift the body off the plenum. Clean the bottom edge of the body.

8. Unscrew the adapters. The pickup tubes (7) may remain threadedinto the adapters, or into the plate mounts (4).

9. Lift the fluidizing plate (3) off the plenum. Unscrew the nuts (6) andremove the plate mounts, gaskets (5), pickup tubes, and pumpmounts (8).

10. Clean the plenum and the parts removed in steps 8 and 9.

4. Feed Hopper FluidizingPlate Replacement

Removal

Repair 6-9


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Manual 38-15

1. See Figure 6-4. Re-install the pump mounts (8) and gaskets (5) onthe plenum (10) with the nuts (6).

2. Screw the pickup tubes (7) into the plate mounts (4).

3. Install the plate mounts, gaskets, and nuts on the new fluidizingplate (3).

4. Make sure the gasket (2) is installed correctly on the new fluidizingplate.

5. Install the fluidizing plate into the plenum, making sure the ends of thepickup tubes fit into the pump mounts. Do not damage the pickuptube threads.

6. Install the pump adapters (9) into the pump mounts. Screw theadapters onto the pickup tubes. Tighten the adapters by hand.

7. Install the feed pumps on the adapters.

8. Install the hopper body (1) on the fluidizing plate. Clamp the plenumand body together.

9. Install the lid and accumulator on the hopper body and clamp themtogether.

10. Reconnect the hoses, tubing, and ground wire.

Installation

Repair6-10


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Manual 38-15

3815007A

1

2 3

4

5

6

7

6

8

9

10

11

5

Fig. 6-4 Feed Hopper Fluidizing Plate Replacement

1. Hopper body2. Gasket3. Fluidizing plate4. Plate mount

5. Gasket6. Nuts7. Pickup tube8. Pump mount

9. Adapter10. Plenum11. Clamps


Repair 6-11


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Manual 38-15


1. Pump as much flux as you can from the hopper. Shut off and relievethe system air pressure.

2. See Figure 6-4. Depress the spring clips on the pump bodies andpull the transfer pumps off the adapters (9).

3. Disconnect the vent hoses and air tubing from the vent-assist pumpsand agitator. Disconnect the rubber boot from the hopper lid andsieve outlet.

4. Disconnect the ground wire from the hopper.

5. Unclamp the lid and lift it off the hopper body (1). Vacuum anyremaining flux out of the body.

6. Release the clamps (11) holding the plenum (10) and hopper bodytogether.

7. Lift the hopper body off the plenum. Clean the bottom edge of thebody.

8. Unscrew the adapters. The pickup tubes (7) may remain threadedinto the adapters, or into the plate mounts (4).

9. Lift the fluidizing plate (3) off the plenum. Unscrew the nuts (6) andremove the plate mounts, gaskets (6), pickup tubes, and pumpmounts (8).

10. Clean the plenum and the parts removed in steps 8 and 9.

1. Re-install the pump mounts and gaskets on the plenum with the nuts.

2. Screw the pickup tubes into the plate mounts.

3. Install the plate mounts, gaskets, and nuts on the new fluidizing plate.

4. See Figure 6-4. Make sure the gasket (2) is installed correctly on thenew fluidizing plate (3).

5. Install the fluidizing plate into the plenum, making sure the ends of thepickup tubes fit into the pump mounts. Do not damage the pickuptube threads.

5. Reclaim HopperFluidizing PlateReplacement

Removal

Installation

Repair6-12


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Manual 38-15

6. Install the pump adapters into the pump mounts. Screw the adaptersonto the pickup tubes. Tighten the adapters by hand.

7. Install the transfer pumps on the adapters.

8. Install the hopper body on the fluidizing plate. Clamp the plenum andbody together.

9. Install the lid on the hopper body and clamp them together.

10. Reconnect the hoses, tubing, rubber boot, and ground wire.

NOTE: To avoid connecting the valves to the wrong solenoids, removeand replace one valve at a time. Incorrect connections will cause thevalves to open in the wrong order.

See Figure 6-6 for pulse valve and solenoid connections.

WARNING: Shut off the system compressed-air supply andrelieve the system air pressure. Shut off electrical power at adisconnect switch ahead of the system electrical panel. Lockand tag the disconnect switch.

1. See Figure 6-5. Remove the access plate (6).

2. Disconnect the pilot air tubing (1) from the tube fitting (2).

3. Unscrew the pulse valve (3) from the manifold (4).

4. Remove the tube fitting and nozzle (5) from the old valve. WrapPTFE tape around the threads of the tube fitting and nozzle. Installthe fitting and nozzle into the new valve.

5. Wrap PTFE tape around the threads of the manifold nipple. Screwthe new valve onto the nipple. Position the valve so the finaladjustment will tighten the threads and form an air-tight seal.

6. Adjust the valve so the nozzle is vertically plumb.

7. Connect the pilot air tubing to the valve fitting.


6. Pulse Valve Replacement

Repair 6-13


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Manual 38-15

3815008A

1

23

4

5

4

5

2

3

6

Fig. 6-5 Pulse Valve Replacement

1. Pilot air tubing2. Tube fitting

3. Pulse valve4. Manifold

5. Nozzle6. Access plate

Repair6-14


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Manual 38-15

3815009A

4 3 2 1

1234

L1 L2 C 1 2 3 41

2

35

4

7

6

Fig. 6-6 Pulse Valve Air Lines and Wiring

1. 14-ga white jumper to all solenoids2. 14-ga white wire (common)

3. 14-ga red wire (positive)4. Timer board

5. Solenoid enclosures6. Pulse valves

6. Pulse Valve Replacement(contd)

Repair 6-15


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Manual 38-15

WARNING: Shut off electrical power at the system electricalpanel. Lock and tag the disconnect switch. Failure to observethis warning could result in injury or death.

1. See Figure 6-7. Remove the access plate (5).

2. Remove the screws (9), lock and flat washers (7, 8), and inletcone (6) from the fan section.

3. Hold up the fan (4). Reach through the fan blades and loosen the setscrews in the hub.

4. Remove the fan and key from the motor shaft.

5. Install the new fan on the shaft, line up the keyways, and install thekey.

6. Tighten the fan-hub set screws to hold the fan in place.

7. Install the inlet cone using the washers and screws removed instep 2. Do not tighten the screws.

8. Loosen the fan-hub set screws and adjust the position of the fan onthe shaft so the bottom edge of the fan sits 3.18−6.35 mm(0.125−0.250 in.) inside the cone. Tighten the fan-hub set screws.

9. Adjust the inlet cone so the gap between the fan and the cone is thesame all the way around. Use your finger to check the gap.

10. Tighten the inlet cone screws and recheck the gap. Rotate the fanand make sure it does not rub against the cone.

11. Start the fan motor and make sure the fan does not rub against theinlet cone.

7. Motor and FanReplacement

Fan Replacement

Repair6-16


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Manual 38-15

3815010B

3.18 − 6.35 mm

(0.125 − 0.250 in.)

1

2

3

4

5

7

8

9

6

1011

12

15

13

14

16

10

17

Fig. 6-7 Fan and Motor Replacement

1. Motor junction box2. Conduit3. Support4. Fan5. Access plate6. Inlet cone

7. Flat washers8. Lock washers9. Screws

10. Flat washers11. Lock washers12. Nuts

13. Screws14. Lock washers15. Flat washers16. Screws17. Motor

Fan Replacement (contd)

Repair 6-17


229 809BIssued 7/00

Manual 38-15

WARNING: Use approved, tested lifting equipment of adequatecapacity. Failure to observe this warning could result inproperty damage, injury, or death.

1. Remove the final filters.

2. See Figure 6-7. Remove the cover from the motor junction box (1).Tag and disconnect the wiring from the motor leads. Disconnect theconduit (2) from the junction box.

3. Remove the inlet cone (6) and fan (4), as described in the FanReplacement procedure.

4. Remove the screws (16), flat and lock washers (10, 11), and nuts (12)from the support (3). Maneuver the motor and support to one of thefilter openings.

5. Lift the motor and guide it out of the fan section. Move the motor to aclean work area.

6. Remove the screws (13), flat and lock washers (14, 15), andmotor (17) from the support.

7. Install the new motor on the support with the screws and washersremoved in step 6.

8. Lift the motor and support and guide them into the fan section.Secure the mount in its original position with the screws, washers,and nuts removed in step 4.

9. Re-install the fan and inlet cone as described in Fan Replacement.

10. Remove the cover from the motor junction box. Connect the conduitto the motor junction box and the wiring to the motor leads. Re-installthe cover.

11. Turn on the system electrical power and start the exhaust fan. Makesure the fan rotates in the direction shown by the yellow arrow next tothe fan opening on the underside of the fan section. The fan must notrub against the inlet cone.

Motor Replacement

Repair6-18


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Manual 38-15


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Manual 38-15

Section 7

Parts

Parts7-0


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Manual 38-15

Parts 7-1


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Manual 38-15

Section 7Parts

To order parts, call the Nordson Customer Service Center or your localNordson representative. Use this five-column parts list, and theaccompanying illustration, to describe and locate parts correctly.

Numbers in the Item column correspond to numbers that identify parts inillustrations following each parts list. The code NS (not shown) indicatesthat a listed part is not illustrated. A dash (—) is used when the partnumber applies to all parts in the illustration.

The six-digit number in the Part column is the Nordson Corporation partnumber. A series of dashes in this column (- - - - - -) means the partcannot be ordered separately.

The Description column gives the part name, as well as its dimensionsand other characteristics when appropriate. Indentions show therelationships between assemblies, subassemblies, and parts.

Item Part Description Quantity Note

— 000 000 Assembly 1

1 000 000 � Subassembly 2 A

2 000 000 � � Part 1

� If you order the assembly, items 1 and 2 will be included.� If you order item 1, item 2 will be included.� If you order item 2, you will receive item 2 only.

The number in the Quantity column is the quantity required per unit,assembly, or subassembly. The code AR (As Required) is used if thepart number is a bulk item ordered in quantities or if the quantity perassembly depends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list.Notes contain important information about usage and ordering. Specialattention should be given to notes.

1. Introduction

Using the Illustrated PartsList

Parts7-2


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Manual 38-15

See Figure 7-1.


1 156 995 Filter, final, 24 x 20 in., internal 2

2 176 366 Clamp, final filter, 18.50 x 2.75 in. 4

3 176 367 Knob, final filter 8

3815004A

1

2

3

Fig. 7-1 Final Filters and Mounting Hardware

2. Final Filters andMounting Hardware

Parts 7-3


229 809BIssued 7/00

Manual 38-15

See Figure 7-2.


1 984 178 Nut, hex, regular, 5/8-11 unc-2b, zinc-plated steel 4

2 983 440 Washer, lock, e, split, 5/8 in., nickel-plated steel 4

3 983 090 Washer, flat, e, 0.656 x 1.312 x 0.095 in., zinc 4

4 174 720 Mount, filter cartridge, Excel 4

5 174 723 Rod, filter mount, 36 in., Excel 4

6 174 722 Bracket, filter, centering, Excel 4

7 158 661 Cartridge, filter, 26 in., PowderGrid, center-mount 4

8 - - - - - - Baffle 1

3. Cartridge Filters andMounting Hardware

Parts7-4


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Manual 38-15

3815011A

2

3

4

5

6

78

1

Fig. 7-2 Cartridge Filters and Mounting Hardware

3. Cartridge Filters andMounting Hardware (contd)

Parts 7-5


229 809BIssued 7/00

Manual 38-15

See Figure 7-3.


1 - - - - - - Connector, straight, 3/4 in. flexible conduit AR

2 - - - - - - Conduit, metal, flexible, 3/4 in. AR

3 - - - - - - Elbow, 90�, female, conduit, 3/4 in. AR

4 - - - - - - Washer, sealing, conduit, 3/4 in. AR

5 - - - - - - Nipple, close, 3/4 in. NPT AR

6 - - - - - - Enclosure, pulse valve solenoid AR

NS 601 364 � Valve, solenoid, 1/8 in. NPT 4

7 981 315 Screw, hex head, 5/16-18 x 1 in., cap, zinc 6


9 983 527 Washer, flat, 0.344 x 1.125 x 0.063 in., zinc 10

10 - - - - - - Manifold, pulse 1

11 165 726 Nozzle, cartridge pulse 4

12 972 126 Fitting, elbow, 6 mm tube x 1/8 unithread 4

13 174 824 Valve, pulse, 1 in. NPT internal, cast tube 4

NS 183 944 Kit, repair, pulse valve 1

14 984 150 Nut, lock 4

15 - - - - - - Fitting, barbed, swivel, 3/4 in. hose x 3/4 in. NPT 1

16 339 234 Hose, black, 3/4 in. AR

17 178 971 Fitting, brass, barbed, 3/4 in. hose x 3/4 in. NPT 2

18 - - - - - - Elbow, 3/4 in. NPT 1

19 176 301 Control, air volume 1

20 900 742 Tubing, 6 mm, blue, polyurethane AR

21 - - - - - - Panel, manifold access 1

AR: As Required

NS: Not Shown

4. Pulse Valves andSolenoids

Parts7-6


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Manual 38-15

3815012A

1

2

1

3

4

56

7

89

109

148

9

7

21

98

7

17

16

15

20

11

12

13

1719

5

18

Fig. 7-3 Pulse Valves and Solenoids

4. Pulse Valves andSolenoids (contd)

Parts 7-7


229 809BIssued 7/00

Manual 38-15

See Figure 7-4.


1 176 330 Gasket, fluidizing plate, 31.5 x 41.5 in. 1

2 176 312 Plate, fluidizing, 33.0 x 43.0 x 0.5 in. 1

3 - - - - - - Kit, C-clamp 1

4 - - - - - - Assembly, fluidizing pan 1

3815013A

2

1

3

4

Fig. 7-4 Collector Fluidizing Plate and Hardware

5. Collector Fluidizing Plateand Hardware

Parts7-8


229 809BIssued 7/00

Manual 38-15

See Figure 7-5.


1 174 760 Motor, 3 horsepower 1

2 - - - - - - Nipple, close, 3/4 in. NPT AR

3 - - - - - - Washer, sealing, conduit, 3/4 in. AR

4 - - - - - - Elbow, 90�, conduit, 3/4 in. AR

5 - - - - - - Connector, straight, conduit, 3/4 in. AR

6 - - - - - - Conduit, metal, flexible, 3/4 in. AR

7 983 007 Washer, flat, e, 0.531 x 1.000 x 0.063 in., zinc AR

8 983 180 Washer, lock, e, split, 1/2 in., nickel-plated steel AR

9 981 611 Screw, hex head, 1/2-13 x 1 in., cap, zinc AR

10 - - - - - - Support, bearing, fan 1

11 174 735 Wheel, fan 1

12 - - - - - - Cone, inlet 1

13 981 315 Screw, hex head, 5/16-18 x 1 in., cap, zinc AR

14 983 150 Washer, lock, e, split, 5/16 in., nickel-plated steel AR

15 983 527 Washer, flat, 0.344 x 1.125 x 0.063 in., zinc AR

16 983 255 Washer, flat, 0.406 x 1.250 x 0.100 in., zinc 8

17 981 426 Screw, hex head, 3/8-16 x 1.5 in., cap, zinc 4


19 984 152 Nut, hex, regular, 3/8-16 in., steel, plain 4

AR: As Required

6. Fan and Fan Drive

Parts 7-9


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Manual 38-15

3815014A

1

2

3

11

15

14

13

12

1618

19

7

9

8

17

16

17

45

65

10

Fig. 7-5 Fan and Fan Drive

Parts7-10


229 809BIssued 7/00

Manual 38-15

Electrostatic Flux Coating System

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Transcript of Electrostatic Flux Coating System