Nordson ColorMax 2 Customer Product Manual

ColorMaxr 2 Powder Coating

System with Encorer Feed Center

Customer Product Manual

Part 1605397-04

Issued 02/20

NORDSON CORPORATION  AMHERST, OHIO  USA

For parts and technical support, call the Industrial Coating

Systems Customer Support Center at (800) 433-9319 or

contact your local Nordson representative.

This document is subject to change without notice.

Check http://emanuals.nordson.com for the latest version.

Part 1605397-04  2015 Nordson Corporation

Contact Us

Nordson Corporation welcomes requests for information, comments, and

inquiries about its products. General information about Nordson can be

found on the Internet using the following address:

http://www.nordson.com.

Address all correspondence to:

Nordson Corporation

Attn: Customer Service

555 Jackson Street

Amherst, OH 44001

Notice

This is a Nordson Corporation publication which is protected by copyright.

Original copyright date 2014. No part of this document may be

photocopied, reproduced, or translated to another language without the

prior written consent of Nordson Corporation. The information contained

in this publication is subject to change without notice.

Trademarks

ColorMax, iControl, Nordson, and the Nordson logo are registered

trademarks of Nordson Corporation.

AeroDeck and AeroWash are trademarks of Nordson Corporation.

Change Record i

Part 1605397-04

 2015 Nordson Corporation

Change Record

Revision Date Change

02 04/15 Replaced part number 1058969 with part number 1606403. Changed

screen 8 from 20.00 minutes to 10.00 minutes.

03 05/15 Added slidegate assembly parts.

04 10/15 Replaced part number 1008803 with part number 1607911. Added part

number 176299 (12-valve pilot solenoid).

Change Record

ii

Part 1605397-04  2015 Nordson Corporation

Table of Contents iii

Part 1605397-04

 2015 Nordson Corporation

Table of Contents

Safety 1-1..................................................

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

Qualified Personnel 1-1......................................

Intended Use 1-1............................................

Regulations and Approvals 1-1................................

Personal Safety 1-2.........................................

Fire Safety 1-2..............................................

Grounding 1-3..............................................

Action in the Event of a Malfunction 1-4........................

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

Description 2-1.............................................

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

System Components 2-2....................................

Booth 2-4...............................................

Reclaim System 2-6......................................

Feed Center 2-8..........................................

Automatic Gun Movers/Gun Blow-Off 2-10....................

Afterfilter 2-11.............................................

Afterfilter Operation 2-11.................................

Control Panels 2-13...........................................

Encore Venturi Feed Center Control Panel 2-13................

Main Electrical Control Panel 2-15............................

Typical System Options 2-16...................................

Roll-On/Roll-Off System 2-16................................

Operation 3-1..............................................

Introduction 3-1.............................................

Typical Operating Settings 3-2................................

Operating Air Pressures 3-2................................

Timer Board Settings 3-2...................................

Booth Control Functions 3-3...............................

Changing Function Values 3-6...........................

Startup 3-7.................................................

Ancillary Equipment Clean Function 3-9.....................

Color Change Procedures 3-9..............................

Powder Level Sensor Operation 3-10........................

Booth Moving 3-10...........................................

Shutdown 3-11...............................................

Table of Contents

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Part 1605397-04  2015 Nordson Corporation

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

Initial Canopy Conditioning 4-1...............................

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

System Cleaning 4-2......................................

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

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

Monthly Maintenance 4-4.....................................

Booth Canopy Conditioning 4-5...............................

Cyclone Cleaning 4-6.......................................

HDLV Transfer Pump and Transfer Pan Maintenance 4-7........

Transfer Pan Cleaning 4-8.................................

Disassembly 4-8.......................................

Cleaning 4-8..........................................

Assembly 4-8..........................................

Emptying the Afterfilter Waste Hoppers 4-10.....................

Maintenance Check List 4-11..................................

Troubleshooting 5-1........................................

Common Problems 5-1......................................

Reversing Motor Direction 5-6.................................

Repair 6-1.................................................

Introduction 6-1.............................................

Cartridge Filter Replacement 6-1..............................

Filter Removal 6-1........................................

Filter Installation 6-2.......................................

Seasoning the Cartridge Filters 6-4..........................

Final Filter Replacement 6-5.................................

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

Preparation 6-6...........................................

Parts 7-1...................................................

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

Afterfilter Parts 7-2..........................................

Gun Blow-Off Parts 7-4......................................

Miscellaneous Parts 7-4......................................

System Diagram 8-1........................................

Safety 1-1

Part 1605397-04

 2015 Nordson Corporation

Section 1

Safety

Introduction

Read and follow these safety instructions. Task- and equipment-specific

warnings, cautions, and instructions are included in equipment

documentation where appropriate.

Make sure all equipment documentation, including these instructions, is

accessible to all persons operating or servicing equipment.

Qualified Personnel

Equipment owners are responsible for making sure that Nordson equipment

is installed, operated, and serviced by qualified personnel. Qualified

personnel are those employees or contractors who are trained to safely

perform their assigned tasks. They are familiar with all relevant safety rules

and regulations and are physically capable of performing their assigned

tasks.

Intended Use

Use of Nordson equipment in ways other than those described in the

documentation supplied with the equipment may result in injury to persons

or damage to property.

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

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.

Safety

1-2

Part 1605397-04  2015 Nordson Corporation

All phases of equipment installation must comply with all federal, state, and

local codes.

Personal Safety

To prevent injury follow these instructions.

Do not operate or service equipment unless you are qualified.

Do not operate equipment unless safety guards, doors, or covers are

intact and automatic interlocks are operating properly. Do not bypass or

disarm any safety devices.

Keep clear of moving equipment. Before adjusting or servicing any

moving equipment, shut off the power supply and wait until the

equipment comes to a complete stop. Lock out power and secure the

equipment to prevent unexpected movement.

Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or

servicing pressurized systems or components. Disconnect, lock out,

and tag switches before servicing electrical equipment.

Obtain and read Material Safety Data Sheets (MSDS) for all materials

used. Follow the manufacturer’s instructions for safe handling and use

of materials, and use recommended personal protection devices.

To prevent injury, be aware of less-obvious dangers in the workplace

that often cannot be completely eliminated, such as hot surfaces, sharp

edges, energized electrical circuits, and moving parts that cannot be

enclosed or otherwise guarded for practical reasons.

Fire Safety

To avoid a fire or explosion, follow these instructions.

Do not smoke, weld, grind, or use open flames where flammable

materials are being used or stored.

Provide adequate ventilation to prevent dangerous concentrations of

volatile materials or vapors. Refer to local codes or your material MSDS

for guidance.

Do not disconnect live electrical circuits while working with flammable

materials. Shut off power at a disconnect switch first to prevent

sparking.

Safety 1-3

Part 1605397-04

 2015 Nordson Corporation

Know where emergency stop buttons, shutoff valves, and fire

extinguishers are located. If a fire starts in a spray booth, immediately

shut off the spray system and exhaust fans.

Clean, maintain, test, and repair equipment according to the instructions

in your equipment documentation.

Use only replacement parts that are designed for use with original

equipment. Contact your Nordson representative for parts information

and advice.

Grounding

WARNING: Operating faulty electrostatic equipment is hazardous and can

cause electrocution, fire, or explosion. Make resistance checks part of your

periodic maintenance program. If you receive even a slight electrical shock

or notice static sparking or arcing, shut down all electrical or electrostatic

equipment immediately. Do not restart the equipment until the problem has

been identified and corrected.

All work conducted inside the spray booth or within 1 m (3 ft) of booth

openings is considered within a Class 2, Division 1 or 2 Hazardous location

and must comply with NFPA 33, NFPA 70 (NEC articles 500, 502, and 516),

and NFPA 77, latest conditions.

All electrically conductive objects in the spray areas shall be electrically

connected to ground with a resistance of not more than 1 megohm as

measured with an instrument that applies at least 500 volts to the circuit

being evaluated.

Equipment to be grounded includes, but is not limited to, the floor of the

spray area, operator platforms, hoppers, photoeye supports, and

blow-off nozzles. Personnel working in the spray area must be

grounded.

There is a possible ignition potential from the charged human body.

Personnel standing on a painted surface, such as an operator platform,

or wearing non-conductive shoes, are not grounded. Personnel must

wear shoes with conductive soles or use a ground strap to maintain a

connection to ground when working with or around electrostatic

equipment.

Operators must maintain skin-to-handle contact between their hand and

the gun handle to prevent shocks while operating manual electrostatic

spray guns. If gloves must be worn, cut away the palm or fingers, wear

electrically conductive gloves, or wear a grounding strap connected to

the gun handle or other true earth ground.

Shut off electrostatic power supplies and ground gun electrodes before

making adjustments or cleaning powder spray guns.

Connect all disconnected equipment, ground cables, and wires after

servicing equipment.

Safety

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Part 1605397-04  2015 Nordson Corporation

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.

Disposal

Dispose of equipment and materials used in operation and servicing

according to local codes.

Description 2-1

Part 1605397-04

 2015 Nordson Corporation

Section 2

Description

Introduction

This manual covers ColorMax 2 Engineered Powder Coating Systems

equipped with Encore Feed Centers. It includes a description of the major

system components and their operation; basic daily operation and general

troubleshooting procedures; booth and afterfilter maintenance and repair

procedures; and part numbers for normal wear items.

Because powder coating systems are customized to meet customer

requirements, your system may have controls and equipment not described

in this manual or located in different positions. Your Nordson representative

can provide you with additional information and training to supplement this

manual.

Because powder coating systems are engineered for the application,

Nordson Corporation provides separate manuals for each component or

sub-system, such as the feed center, automatic guns, automatic gun

controllers, manual spray systems, powder pumps, fire detection systems,

and gun movers. Refer to these manuals for more information on the

operation and maintenance of these components.

Description

2-2

Part 1605397-04  2015 Nordson Corporation

System Components

Figure 2-1 shows a typical fully equipped ColorMax system.

Item Component Function

1 Booth Consists of canopy and base. Contains the oversprayed

powder within the system. Refer to page 2-4 for more

information.

2Reclaim System Consists of the cyclone assembly, banjo, duct work, and

afterfilter (not shown here). The cyclones separate the

oversprayed powder from the air flowing through the

booth. The reclaimed powder is pumped back to the

feed center. Refer to page 2-6 for more information.

3Encore Feed Center Consists of an enclosure, sieve, and powder lances and

pumps, and purge manifolds. Conditions virgin and

reclaimed powder, fluidizes the powder, and pumps it to

the spray guns. Refer to page 2-8 for more information.

4Utility Deck Provides a platform for the major components of the

system, and houses wiring and air hoses and tubing,

valves and regulators, powder hoses, and gun cables.

Shipped pre-plumbed and wired for quick system

installation.

5Main Electrical Control Panel Houses the system operator controls, PLC, and Variable

Frequency Drives (VFDs) for the gun movers. Refer to

page 2-15 for more information.

6Gun Movers and Gun Blow-Off Optional equipment. The spray guns can be mounted on

fixed stands, oscillators, or reciprocators. These devices

can be mounted on automatic or manual positioners.

Refer to page 2-10 for more information.

7Powder Application Equipment Optional equipment. Typically consists of automatic and

manual spray guns and controllers. The Nordson

iControl 2 system controls both the automatic spray

guns and automatic gun movers (positioners and

reciprocators).

Refer to the manuals supplied with your system

components for information on setup and operation.

Not

Shown

Afterfilter Houses the system exhaust fan, along with cartridge

filters that separate the waste powder from the air flow,

and final filters that clean the air before returning it to

spray room. Refer to page 2-11 for more information.

Not

Shown

iControl 2 Controls gun triggering and spraying, and gun movers

such as in/out positioners and reciprocators.

The system uses signals from conveyor encoders, photo

eyes, light curtains, and proximity sensors to identify and

track the movement of parts through the spray booth,

and to control the spray guns and gun movers.

Refer to the operator manual for more information.

Description 2-3

Part 1605397-04

 2015 Nordson Corporation

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Figure 2-1 ColorMax 2 System Components

Description

2-4

Part 1605397-04  2015 Nordson Corporation

Booth

Figure 2-2 shows the exterior and interior components of a typical ColorMax

powder spray booth.

Item Component Function

1Conveyor slot and air knife The conveyor slot allows the part hangers to pass

completely through the canopy. Compressed air flowing

from the air knife prevents sprayed powder from

escaping from the conveyor slot.

2Fire detector heads Continuously monitor the interior of the booth. If an

electrical spark or flame is detected, the fire detection

system shuts down the entire system. The system

controller is typically mounted on the side of the main

electrical control panel, or close to it.

3 Canopy Contains the powder within the booth. Can be made

from Nordson Apogee panels or polypropylene. The

canopy requires periodic conditioning and should not be

touched with bare hands to preserve its ability to shed

powder.

4 Base Provides the platform for the canopy and includes the

floor duct through which the air flows on its way to the

cyclones.

5Manual spray gun operator doors Provides access to the booth for the manual spray gun

operators.

6Operator platforms Provide operators with access to the booth. Manual gun

controllers are typically mounted on the platform railings.

7Booth doors Provide a way to close off the end of the booth and

prevent powder from escaping when blowing off the

interior of the booth during color changes and routine

cleaning.

8Vertical riser door Provides access to the riser that routes the air flowing

through the booth into the cyclone for cleaning and

inspection.

9AeroDeckAct as dampers to prevent the air flowing into the riser

inlet from drawing the powder sprayed by the automatic

guns away from the parts moving through the booth. Air

is pulsed across the AeroDecks by the air knife running

down the center of the decks to keep powder from

accumulating on top of them.

10 Floor blow-offs Blow the powder off the floor and into the floor duct to

prevent accumulations. The blow-offs are pulsed in a

repetitive pattern, one section at a time, to keep air

consumption to a minimum.

11 Gun blow-off manifolds Distribute the gun blow-off air to the blow-off nozzles.

12 Gun blow-off nozzles Blow off the exterior of the guns as they are retracted

from the booth during the color change sequence. There

are 4 nozzles for each gun.

Description 2-5

Part 1605397-04

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8

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Figure 2-2 Booth Components

Description

2-6

Part 1605397-04  2015 Nordson Corporation

Reclaim System

Figure 2-3 shows the components of a typical ColorMax reclaim system.

Item Component Function

1Dual cyclone Reclaims usable powder from the air flowing through

them. Inside the cyclones, the air swirls around and

slows so the larger and heavier powder particles fall to

the bottom, into the transfer pan. The fine powder dust

stays suspended in the air flow and is carried through the

ductwork to the afterfilter.

2Lower section of cyclone Allows the interior of the cyclones to be cleaned

thoroughly during color changes. The lower section is

hinged so that it swings up and mates with a cleaning

port that is connected to the afterfilter ductwork.

3Transfer pan Collects and fluidizes the reclaimed powder so the

transfer pump can pump it back to the feed center to be

sieved and re-used. It contains a porous membrane that

diffuses low pressure compressed air into the powder to

fluidize it The transfer pan is hinged so it can be opened

and cleaned thoroughly during color changes.

4Transfer pump Pumps the reclaimed powder back to the feed center.

The pump is a Nordson High Capacity HDLV pump with

purge capability.

5Cyclone cleaning port Mates with the lower cyclone section when it is swung

open. The port maintains an air flow through the lower

section while the operator cleans the interior. The port

duct is connected to the afterfilter duct work so that

waste powder flows directly to the afterfilter.

6Slide gate Allows air to be pulled through the lower cyclone section

and cleaning port when open. Close when not cleaning

the lower section.

7Banjo and afterfilter duct Conveys air and waste powder to the afterfilter from the

cyclone. A pneumatically operated slide gate in the duct

closes if a fire is detected in the booth to prevent it from

spreading to the afterfilter.

Description 2-7

Part 1605397-04

 2015 Nordson Corporation

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7

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3

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Figure 2-3 Common Reclaim Components

Description

2-8

Part 1605397-04  2015 Nordson Corporation

Feed Center

Figure 2-4 shows the components of the Encore Feed Center. Refer to the

feed center manual for additional information and parts lists.

Item Component Function

1Operator control panel Houses electrical and pneumatic controls for the feed

center and system.

2Lance purge regulator Adjusts the lance purge air pressure.

3Fluidizing air regulator Adjusts the fluidizing air for the hopper or lance.

4Blow gun Used to blow off the components of the feed center.

5Level sensors Detect powder levels in hopper or box. When powder

level falls below end of sensor, either an alarm is

activated or the virgin powder transfer pump is turned on

to add more powder to the system, depending on the

system configuration.

6Powder lances Function as pickup tubes so that the pumps mounted on

top of the lances can draw powder out of the hopper or

box and deliver it to the spray guns. The lances are

mounted on the lift assembly. The lances shown are

equipped with optional fluidizing bars for use with powder

boxes and optional hose manifolds.

7Powder hopper (optional) Contains and fluidizes the power supply. A porous

membrane in the bottom diffuses low pressure

compressed air into the powder so that it behaves like a

fluid.

8Vibrating table (vibrator motor is

optional)

Supports the powder hopper or box, vibrates to fluidize

the powder supply. Normally turned on only when

powder boxes are used instead of hoppers.

9In-line powder pumps Pump the powder out to the spray guns.

10 Sieve Vibrates to screen reclaimed and virgin powder before

delivering it to the powder hopper or box. Can be fitted

with a ultrasonic screen for higher throughput if needed.

11 Lift assembly Consists of a carriage, vertical slide, and pneumatic

cylinder. The lances are mounted on the carriage. The

cylinder moves the lances up and down. Proximity

switches on the cylinder are positioned to stop the lances

at different positions depending on the powder source

selected by the operator.

12 Disconnect switch Turns on and off power to the feed center controls.

Not

Shown

Purge manifold and clamping

cylinder

Located below the vibrating table. During a color

change, the lances are lowered onto the purge manifold,

where they are clamped in place before the lance and

gun purge starts.

Not

Shown

Duct damper Located on top of the exhaust duct transition. Opened

and closed with a pneumatic cylinder. Controlled by a

switch on the operator panel. In Auto mode, when a

color change is initiated, the damper is automatically

opened to contain the powder within the feed center.

When the color change is complete, the damper is

partially closed since full flow is not required during

normal operation. The operator can also open the

damper manually as desired.

Description 2-9

Part 1605397-04

 2015 Nordson Corporation

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Figure 2-4 Encore Feed Center Components (shown with optional hose manifolds on lances)

Description

2-10

Part 1605397-04  2015 Nordson Corporation

Automatic Gun Movers/Gun Blow-Off

NOTE: Gun movers are optional. If they are not used, then the spray guns

are mounted on fixed stands.

Component Description

Positioners Move the spray guns into or out of the canopy. The positioners can be

manually operated or electrically driven automatic devices. Automatic

positioner movement is controlled by the Nordson iControl system or Axis

Controller. During production, the positioners maintain the set gun-to-part

distance settings, following the contours of the parts. Positioners move the

guns horizontally. Applications may require vertical positioners.

Oscillators or

Reciprocators

Move the spray guns in repetitive or variable patterns for thorough part

coverage; position spray guns between blow-off nozzles during color changes.

Gun Blow-Off System Blow powder off the spray guns as they are retracted out of the booth during

the first part of a color change sequence. The nozzles are supplied with air by

manifolds located in the booth base.

Positioner

Oscillator

(or Reciprocator)

Automatic Guns

Blowoff Manifolds

and Nozzles

Figure 2-5 View of Positioner and Oscillator with Gun Blow-Off System

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Nordson ColorMax 2 Customer Product Manual

Nordson ColorMax 2 Customer Product Manual

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