Nordson ColorMax Customer Product Manual
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Nordson ColorMax Customer Product Manual

Nordson ColorMax Customer Product Manual

Powder coating system
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ColorMaxr Engineered
Powder Coating System
Customer Product Manual
Part 1108061-02
Issued 06/15
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.
NORDSON CORPORATION • AMHERST, OHIO • USA

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  • Page 1 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. NORDSON CORPORATION • AMHERST, OHIO • USA...
  • Page 2 Contact Us Notice This is a Nordson Corporation publication which is protected by copyright. Nordson Corporation welcomes requests for information, comments, and Original copyright date 2011. No part of this document may be inquiries about its products. General information about Nordson can be...
  • Page 3 Change Record Change Record Revision Date Change 06/15 Clear powder tubing option added. Part 1108061-02 E 2015 Nordson Corporation...
  • Page 4 Change Record Part 1108061-02 E 2015 Nordson Corporation...

  • Page 5: Table Of Contents

    ..........Part 1108061-02 E 2015 Nordson Corporation...
  • Page 6 ......... . . Afterfilter Fluidizing Plate Replacement ..... Part 1108061-02 E 2015 Nordson Corporation...
  • Page 7 ........8-11 Part 1108061-02 E 2015 Nordson Corporation...
  • Page 8 Table of Contents Part 1108061-02 E 2015 Nordson Corporation...

  • Page 9: Safety

    Regulations and Approvals Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed. All phases of equipment installation must comply with all federal, state, and local codes.

  • Page 10: Personal Safety

    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. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 11: Grounding

    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. Part 1108061-02 E 2015 Nordson Corporation...
  • Page 12 Safety Part 1108061-02 E 2015 Nordson Corporation...

  • Page 13: Description

    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.

  • Page 14: Main Components

    Description Main Components System Components Table 2-1 ColorMax Engineered System − Typical Components Item Component Function After Filter Filters unusable powder from the air before returning the air to the spray area. Houses the exhaust fan and motor, cartridge filters, and final filters. Refer to the Afterfilter manual for more information.

  • Page 15: Canopy And Base Assembly Components

    Allow access to the canopy interior for the manual gun operators. Part doors Close when performing color change cleaning to contain powder within the booth. Duct door Allows operator access to the floor duct for cleaning. Part 1108061-02 E 2015 Nordson Corporation...
  • Page 16 Description Entry End Exit End Figure 2-2 Colormax Engineered System Canopy and Base Assemblies (shown without exhaust duct) Part 1108061-02 E 2015 Nordson Corporation...

  • Page 17: Ducts And Cyclone System Components

    Collects the powder that falls out of the air stream and fluidizes it for transfer to the feed center. Transfer Pump Transports reclaimed powder from the transfer pan to the powder feed center. Afterfilter Figure 2-3 Colormax Engineered System Booth Duct and Cyclone Operation Part 1108061-02 E 2015 Nordson Corporation...

  • Page 18: Afterfilter Components

    Differential Pressure Measures the pressure drop across the final filters. If the final Switch/Gauge filters start clogging, the air pressure inside the housing will rise and trip the switch, shutting down the entire system. Part 1108061-02 E 2015 Nordson Corporation...
  • Page 19 Description Figure 2-4 After Filter Operation Part 1108061-02 E 2015 Nordson Corporation...

  • Page 20: After Filter Operation

    The final filter differential pressure switch (15) monitors the pressure drop across the final filters. At 2.5-in. wc, a red warning light on the system control panel lights. At 3-in. wc, the entire system shuts down. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 21: Powder Feed Center Components

    Control Panel Houses the operator controls, electrical panel, and pneumatic controls for feed center operation. Refer to Powder Feed Center Control Panel on page 2-13 for more information. Part 1108061-02 E 2015 Nordson Corporation...
  • Page 22 2-10 Description Powder Feed Center Components (contd) Figure 2-5 Powder Feed Center Part 1108061-02 E 2015 Nordson Corporation...

  • Page 23: Control Panels

    Provides controls for all system functions and settings. Refer to the Setup and Touch Screen Operation sections of this manual for screens, settings, and functions. MAIN SYSTEM PANEL EMERGENCY STOP SYSTEM SYSTEM START SYSTEM STOP Figure 2-6 Main System Panel Part 1108061-02 E 2015 Nordson Corporation...

  • Page 24: Afterfilter Control Panel

    1−15, according to the settings on the timer board in the Pulse Timer Junction Box on the side of the pulse valve compartment. E−STOP FLUIDIZE TRANSFER START PUMP EXHAUST MOTOR FLUIDIZE TRANSFER Filter Clean STOP PUMP Timer Figure 2-7 Afterfilter Control Panel Part 1108061-02 E 2015 Nordson Corporation...

  • Page 25: Powder Feed Center Control Panel

    10. Color Change Indicator Light (Green) Off: Disable Blinking: In cycle On: Complete 11. Color Change Enable Switch Left: Off Right: On 12. Purge Control Switch Left: Internal Gun Purge Center: Off Right: Pump Purge Part 1108061-02 E 2015 Nordson Corporation...

  • Page 26: Typical System Options

    2-14 Description Typical System Options Refer to the manuals shipped with optional equipment for more information, or contact your Nordson Corporation representative. Table 2-9 Typical System Options Equipment Description Air Dryer Removes moisture from the system air supply. Most systems use regenerative-desiccant or refrigerated air dryers.

  • Page 27: Setup

    WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Introduction This section provides setup instructions for your Nordson representative. The menus and screens used for setup are password protected. New System Preparation Canopy Conditioning Before starting up the powder coating system for the first time, perform the Initial Canopy Conditioning procedure in Maintenance.

  • Page 28: Setup

    Nordson Representatives: Security and Setup Menu. Refer to Nordson Screens and Functions on page . These screens and functions are only accessible by Nordson representatives. If you attempt to open them without being logged in to the system, the following message will appear: Figure 3-2 Security Access Pop-Up −...

  • Page 29: Logging In

    Setup Logging In To access the Nordson Screens and Functions, touch the Security button on the Main Menu. The Security pop-up appears: Figure 3-3 Security Pop-Up − Nordson Screens and Functions 1. Touch the LOGIN button to open the Log-In pop-up: Figure 3-4 Log-In Pop-Up −...

  • Page 30: Setup Menu

    Setup Menu − Nordson Screens and Functions System Setup Touch the System Setup button on the Setup Menu to open the System Setup screen and make the following settings: Figure 3-7 System Setup Screen − Nordson Screens and Functions Part 1108061-02 E 2015 Nordson Corporation...

  • Page 31: Blow-Off Setup

    4. Booth Size: Select the correct booth size. Touch the Return button to return to the Setup Menu. Touch the Main Menu button to exit the Nordson Screens and Functions. Blow-off Setup Touch the Blowoff Setup button on the Setup Menu to open the Blowoff...
  • Page 32 This screen shows the steps configured for the 9 meter booth example on the preceding page. Figure 3-9 Floor Blowoff Setup Screens − Nordson Screens and Functions Part 1108061-02 E 2015 Nordson Corporation...

  • Page 33: Special Functions Setup

    6. Alarm ACK: Touch to acknowledge and silence the current alarm. 7. Alarm Log: Touch to open the Alarm Log screen. Refer to page for information on this screen. 8. Main Menu: Touch to exit the Nordson Screens and Functions. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 34: Blowoff Output Tests

    7.5 and 9 meter booths (floor blowoff outputs 5−8). Figure 3-11 Blowoff Output Test Screen − Nordson Screens and Functions Alarm Acknowledge/Clear See Figure 3-12. If an alarm is generated by a system device, an alarm pop-up appears on the screen.

  • Page 35: Alarm Log

    This screen allows the operator to view past and present alarms and acknowledge alarms. Touching the Alarm Ack button silences the alarm but does not remove it from the log. Figure 3-13 Alarm Log − Operator Screens and Functions Part 1108061-02 E 2015 Nordson Corporation...
  • Page 36 3-10 Setup Part 1108061-02 E 2015 Nordson Corporation...

  • Page 37: Operation

    Follow the safety instructions in this document and all other related documentation. Introduction The ColorMax Engineered Powder Coating System is operated with the controls on the Main System Panel, the Afterfilter Control Panel, and the Spectrum Feed Center Panel. Operators should use this section and the Spectrum Powder Feed Center manual (part number 1103292) to operate the ColorMax Engineered Powder Coating System.

  • Page 38: System Start/Stop Pushbuttons

    See Figure 4-1. The Main Menu appears on the Main System Panel touch screen when you start up the system. Touching the buttons at the bottom of the menu allows access to system controls, setup, and alarm functions. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 39: Screen Access

    Nordson Representatives: Security and Setup Menu. Refer to the Setup section in this manual for screens and functions. The Setup Menu is only accessible by Nordson representatives. If you attempt to open it without being logged in to the system, the following...

  • Page 40: System Control Screen

    Start/Stop Status message reads INT OPEN and the system motors cannot be started. Color Change Status Messages: Indicate the progress of the color change process. When the feed center operator turns ON the Color Change switch, the Color Change Active message appears. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 41: Manual Motor Control

    Start/Stop − Starts and stops the exhauster (fan motor in the afterfilter). NOTE: These buttons will not appear on the screen if the Remote AF Exhauster Start/Stop function is not enabled by your Nordson representative. If these buttons are not present, the exhauster must be started and stopped from the afterfilter control panel.

  • Page 42: Color Change Status

    6. Guns Purge Done To GNMV: Signal sent to the gun mover control panel indicating that the gun purge is complete. Positioners then move to the full in position and the gun blow off starts, blowing off the full length of the guns. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 43: Alarm Acknowledge/Clear

    If the cause of the alarm has not been corrected, the alarm will re-occur. Clearing the alarm does not remove it from the Alarm Log. Figure 4-7 Main Menu with Alarm Pop-Up − Operator Screens and Functions Part 1108061-02 E 2015 Nordson Corporation...

  • Page 44: Alarms

    This screen allows the operator to view past and present alarms and acknowledge alarms. Touching the Alarm Ack button silences the alarm but does not remove it from the log. Figure 4-8 Alarm Log − Operator Screens and Functions Part 1108061-02 E 2015 Nordson Corporation...

  • Page 45: Typical Operating Settings

    On Time (Duration) 0.07 seconds Off Time (Delay) 90 seconds Typical Blow-off Settings Table 4-12 Typical Blow-off Settings Timer Setting Floor Blow-off Delay 5 seconds Floor Blow-off Pulse Duration 0.25 seconds Gun Blow-off ON Duration Part 1108061-02 E 2015 Nordson Corporation...

  • Page 46: Startup

    Control Panel and turn the Exhaust Motor ON, then press the VFD Start button. E−STOP FLUIDIZE TRANSFER START PUMP EXHAUST MOTOR Filter Clean FLUIDIZE TRANSFER Timer PUMP STOP Figure 4-9 System Controls − Operator Screens and Functions Part 1108061-02 E 2015 Nordson Corporation...
  • Page 47 NOTE: It is important that the inside surface of the canopy is not touched by bare hands. Skin oils and other contaminants will affect the ability of the canopy to shed powder. Operators should wear cotton gloves when working with the canopy. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 48: Feed Center Controls

    Off: Disable Blinking: In cycle On: Complete 11. Color Change Enable Switch Left: Off Right: On 12. Purge Control Switch Left: Internal Gun Purge Center: Off Right: Pump Purge Figure 4-10 Feed Center Controls Part 1108061-02 E 2015 Nordson Corporation...

  • Page 49: Color Change Procedure

    Color Change Procedure A separate illustrated Color Change guide, part number 1108059, can be ordered from your Nordson Representative. NOTE: Whenever it becomes difficult to blow powder off the canopy surface, perform the Booth Canopy Conditioning procedure on page 5-5.

  • Page 50: Color Change Procedure

    When the gun blow-off is complete, blow off the Turn the sieve OFF. duct door sills at the exit end of the booth. Open the duct door and blow off the door sill and the Aerodeck seams and hinges. Continued... Part 1108061-02 E 2015 Nordson Corporation...
  • Page 51 Turn ON the Vibratory Table if using a powder box. Turn ON and adjust the feed hopper or lance fluidizing air. Turn ON the Virgin Transfer Pump, if used. Turn on the spray guns and start production. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 52: Shutdown

    8. If you will be shutting down the system for maintenance, repair, or an extended period of time, turn the disconnect switches on the powder feed center, system, and afterfilter control panels to the off position. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 53: Maintenance

    7. Repeat step 5 two more times, for a total of three rinse cycles, then allow the canopy to completely dry before resuming spray operations. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 54: Daily Maintenance

    3. Remove any powder residue from the canopy using an air-powered vacuum with a soft brush attachment. Wipe down all surfaces with a damp, lint-free cotton cloths (do not use tack cloths). 4. Clean the floor around the booth. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 55: Daily Equipment Maintenance

    Maintenance Daily Equipment Maintenance Establish a daily maintenance schedule for your Colormax Engineered powder coating system equipment. Table 5-1 Daily Equipment Maintenance Equipment Procedure Flame Detector Check the detector sensors every four hours and clean the lenses, if System necessary. Make sure the detector system is operating properly.

  • Page 56: Weekly Maintenance

    Maintenance Weekly Maintenance Use the following guidelines to establish a weekly maintenance schedule for your Colormax Engineered powder coating system. Table 5-2 Weekly Maintenance Equipment Procedure After Filter Waste Empty the afterfilter waste hoppers as frequently as is required, or monthly.

  • Page 57: Booth Canopy Conditioning

    4. With the exhaust fan running, dump 1−2 cups of cyclone cleaning media into the cyclone inlet duct. 5. Let media clean the cyclones for approximately one hour. This duration can be reduced or increased as needed. 6. Shut down the exhaust fan. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 58: Emptying Afterfilter Waste Hopper

    (30 psi). Increase the transfer pump air pressure if desired. 7. When the transfer pump is not drawing any more powder out of the waste hopper, turn off the transfer pumps and fluidizing air. Part 1108061-02 E 2015 Nordson Corporation...
  • Page 59 Maintenance Figure 5-1 Emptying the Afterfilter Waste Hopper 1. Vent hose 3. 55-gallon drum 5. Transfer hoses 2. Waste lid 4. Transfer pumps Part 1108061-02 E 2015 Nordson Corporation...

  • Page 60: Maintenance Check List

    Or as required. Continuously monitor the workpiece clearance. **** Frequency varies depending on application. Check more frequently if spraying to waste often. Every 6 Lubrication months Roll-on/roll-off wheel bearings (optional equipment) Fan and motor bearings Part 1108061-02 E 2015 Nordson Corporation...

  • Page 61: Troubleshooting

    Refer also to the Spectrum Powder Feed Center and iControl Console Hardware manuals, and all other equipment manuals as needed for more troubleshooting procedures. Common Problems Use the following tables to correct common problems with the Colormax powder coating system. Problem Page Spray guns are surging or spitting;...
  • Page 62 Hose should be no longer than 7.6 m (25 ft) with a maximum 2.7-m (9-ft) vertical rise. Severe tribo-charging in powder Contact your Nordson representative feed hose for a suitable hose material. Contact your powder supplier. Obstruction in spray gun Clean the spray gun.
  • Page 63 Replace the cartridges if the gaskets or filter media are damaged. Replace clogged final filters. Leaks in afterfilter housing Locate and seal any leaks with RTV allowing powder to bypass filters sealant. Continued... Part 1108061-02 E 2015 Nordson Corporation...
  • Page 64 Fuse(s) blown Check the fuses in the main control panel. Replace the blown fuse(s). If the fuses continue to blow, fix the electrical problem. Electrical failure Trace the circuits and correct the problem. Continued... Part 1108061-02 E 2015 Nordson Corporation...
  • Page 65 Booth openings too large Close or decrease the size of the openings. Workpieces too large for booth Contact your Nordson Corporation representative. Fan rotation backward Reverse the rotation of the motor. Refer to the Reversing Motor Direction procedure in this section.

  • Page 66: Alarm Messages

    Use the following chart to identify and correct system alarms that appear on the main system panel touch screen. NOTE: Variable frequency drives (VFDs) are programmed by Nordson application engineers. If the problem appears to be caused by a VFD, contact your Nordson representative for help.

  • Page 67: Reversing Motor Direction

    (L1, L2, or L3) connected to the live side of the fan motor circuit breaker (CB1). Close the panel door. 5. Turn the disconnect switches to the on position. Start the fan and check the rotation direction. Part 1108061-02 E 2015 Nordson Corporation...
  • Page 68 Troubleshooting Part 1108061-02 E 2015 Nordson Corporation...

  • Page 69: Repair

    Follow the safety instructions in this document and all other related documentation. Introduction This section covers basic repair procedures for the Colormax Engineered powder coating system. Repair procedures for the feed center and other system components can be found in their own manuals.

  • Page 70: Cartridge Filter Installation

    This will compress the filter gasket (11) and seal the cartridge against the mounting plate. 9. When all filters have been replaced, inspect the access door gaskets for damage. Replace any damaged gaskets. Install the access doors. Part 1108061-02 E 2015 Nordson Corporation...
  • Page 71 Cartridge Filter Replacement − Aftterfilter with access doors removed 1. Pulse valve compartment 5. Flat washer 9. Centering bracket 2. Filter compartment 6. Mounting bracket 10. Cartridge filter 3. Hex nut 7. Mounting plate 11. Gasket 4. Lock washer 8. Draw rod Part 1108061-02 E 2015 Nordson Corporation...

  • Page 72: Cartridge Filter Seasoning

    7. Close the cyclone access doors and transfer pan. 8. Record the average air velocity across the booth part openings using a hand-held velometer. 9. Record the cartridge filter and final filter static pressure. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 73: Final Filter Replacement

    7. Install the final filter brackets and clamping knobs. 8. Tighten the clamping knobs to compress the final filters evenly on all four sides. Figure 7-2 Final Filter Replacement 1. Clamping knobs 3. Final filters 4. Fan housing 2. Final filter brackets Part 1108061-02 E 2015 Nordson Corporation...

  • Page 74: Pulse Valve Replacement

    8. Screw the new pulse valve assembly onto the nipple. Make sure that the pulse valve nozzle points straight down into the cartridge filter. 9. Connect the wiring to the pulse valve. Figure 7-3 Pulse Valve Replacement 1. Nipple 3. Nozzle 2. Pulse valve Part 1108061-02 E 2015 Nordson Corporation...

  • Page 75: Afterfilter Fluidizing Plate Replacement

    C-clamp screws with a torque wrench to 2.8 NSm (25 in.-lb) in a criss-cross pattern. This prevents flange distortion and fluidizing plate damage. Figure 7-4 Fluidizing Plate Replacement 1. Plenum 3. Gasket 4. Fluidizing plate 2. C-clamp kits Part 1108061-02 E 2015 Nordson Corporation...
  • Page 76 Repair Part 1108061-02 E 2015 Nordson Corporation...

  • Page 77: Parts

    Parts Section 8 Parts To order parts, call the Nordson Finishing Customer Support Center at (800) 433-9319 or your local Nordson representative. Afterfilters, Fan Motors, and Fans See Figure 8-1. Item Part Description Quantity Note − 1106103 AFTERFILTER, 9000, 380/415V, 60Hz...

  • Page 78: Afterfilter Parts

    C: Used on 9000 and 11250 CFM afterfilter. D: Used on 15750 CFM afterfilter. E: Refer to Transfer Pump parts list for repair parts. F: Waste container, must be vented to afterfilter and grounded. AR: As Required NS: Not Shown Part 1108061-02 E 2015 Nordson Corporation...
  • Page 79 Parts Figure 8-1 Afterfilter Parts Part 1108061-02 E 2015 Nordson Corporation...

  • Page 80: Transfer Pump Parts

    CAP, pipe, 1 in. BSPT, black, class 150 1100285 REGULATOR, air, 1 in., 0.05−12 bar 1099424 VALVE, air, global PFC main interlock NOTE A: Quantity required depends on booth length and configuration. AR: As Required Part 1108061-02 E 2015 Nordson Corporation...
  • Page 81 Parts Figure 8-2 Base Parts Part 1108061-02 E 2015 Nordson Corporation...

  • Page 82: Gun Blow-Off Parts

    OSCILLATOR, 500C, electromechanical, 380−3−50 Hz, EXE motor 780473 OSCILLATOR, 500C HD, electromechanical, 200−3−50 Hz, TEFC motor 780474 OSCILLATOR, 500C HD, electromechanical, 200−3−60 Hz, TEFC motor 780192 OSCILLATOR, 500C HD, electromechanical, 380−3−50 Hz, TEFC motor Part 1108061-02 E 2015 Nordson Corporation...

  • Page 83: Standard Powder Feed Tubing

    There is a minimum order quantity for this tubing. The tubing is sold in increments equal to the minimum order quantity. Part Description Note Min. Order Qty (ft) 768176 Anti-static powder tubing, 11 mm (0.43 in.) 768178 Anti-static powder tubing, 12.7 mm (0.50 in.) Part 1108061-02 E 2015 Nordson Corporation...

  • Page 84: Anti-Static Powder Transfer Tubing

    900619 Polyurethane, 8 mm OD, black 900593 Polyethylene, 10 mm OD, blue (fluidize/input) 900740 Polyurethane, 10 mm OD, blue (fluidize/input) 900613 Polyethylene, 12 mm OD, blue 900600 Soft Nylon, 16 mm OD, black — Part 1108061-02 E 2015 Nordson Corporation...

  • Page 85: Measurement Equipment

    Coupling, spring lock, 10 mm 972875 Coupling, connector body, 10 mm 972876 Coupling, insert, 10 mm 972871 Coupling, connector body, 1/2 in. x 12 mm 972873 Coupling, insert w/ring, 1/2 in. x 12 mm Part 1108061-02 E 2015 Nordson Corporation...

  • Page 86: Fittings And Connectors

    NOTE A: For through-hole applications, as in sheet metal panel, where hex version connector may not work. B: New style SMC ten-tube connector fittings. C: Used in Sure Coat manual control unit for flow and atomizing air. Part 1108061-02 E 2015 Nordson Corporation...

  • Page 87: Miscellaneous Parts

    247658 Dielectric grease, 10 cc applicator (box of 12) 245733 Dielectric grease, 3 cc applicator (box of 12) 1018784 ColorMax, cyclone cleaning media, 50 lb drum 1053608 Pump, throat wear gauge 301841 Velcro strap, small, 25 x 3 cm 301866...
  • Page 88 8-12 Parts Part 1108061-02 E 2015 Nordson Corporation...

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