Dry Filter Continuous Pipe Coater System

Transcription

1 Dry Filter Continuous Pipe Coater System Customer Product Manual Issued 1/14 For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) or contact your local Nordson representative. This document is subject to change without notice. Check for the latest version. NORDSON CORPORATION AMHERST, OHIO USA

2 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: Address all correspondence to: Nordson Corporation Attn: Customer Service 555 Jackson Street Amherst, OH Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 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 PermaFlo, Nordson and the Nordson logo are registered trademarks of Nordson Corporation. All other trademarks are the property of their respective owners.

3 Table of Contents i Table of Contents Safety... 1 Qualified Personnel... 1 Intended Use... 1 Regulations and Approvals... 1 Personal Safety... 2 High-Pressure Fluids... 2 Fire Safety... 3 Halogenated Hydrocarbon Solvent Hazards... 4 Action in the Event of a Malfunction... 4 Disposal... 4 Description... 5 Introduction... 5 Operation... 5 System Components... 5 Hydraulic Control Panel... 5 Coater Cabinet and Integral Dry Filter Exhaust System... 7 Specifications... 9 Space Requirements Cabinet Capacities Installation Coater Cabinet Installation Hydraulic System Setup Operation Initial Start Up Flush Pump and Filter Systems Flush Spray Ring Pressure Check Initial Coating Load Daily Start Up Shutdown Procedures Maintenance Daily Maintenance Weekly Maintenance Periodic Maintenance Troubleshooting PermaFlo Pumps Common Problems Preventing Air Valve Freezing NH4 Heaters Solvent Wash Spray Guns Repair Parts Optional Equipment Spray Ring Lift Assembly Russel Finex Filter Other Available Options... 32

4 ii Table of Contents

5 Dry Filter Continuous Pipe Coater System 1 Dry Filter Continuous Pipe Coater System Safety 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 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.

6 2 Dry Filter Continuous Pipe Coater System 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 moving equipment, shut off the power supply and wait until the equipment comes to a complete stop. Lock out power and secure the equipment to prevent unexpected movement. Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or servicing pressurized systems or components. Disconnect, lock out, and tag switches before servicing electrical equipment. While operating manual spray guns, make sure you are grounded. Wear electrically conductive gloves or a grounding strap connected to the gun handle or other true earth ground. Do not wear or carry metallic objects such as jewelry or tools. If you receive even a slight electrical shock, shut down all electrical or electrostatic equipment immediately. Do not restart the equipment until the problem has been identified and corrected. Obtain and read Material Safety Data Sheets (MSDS) for all materials used. Follow the manufacturer s instructions for safe handling and use of materials, and use recommended personal protection devices. Make sure the spray area is adequately ventilated. 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. High-Pressure Fluids High-pressure fluids, unless they are safely contained, are extremely hazardous. Always relieve fluid pressure before adjusting or servicing high pressure equipment. A jet of high-pressure fluid can cut like a knife and cause serious bodily injury, amputation, or death. Fluids penetrating the skin can also cause toxic poisoning. If you suffer a fluid injection injury, seek medical care immediately. If possible, provide a copy of the MSDS for the injected fluid to the health care provider.

7 Dry Filter Continuous Pipe Coater System 3 The National Spray Equipment Manufacturers Association has created a wallet card that you should carry when you are operating high-pressure spray equipment. These cards are supplied with the purchase of spray guns. The following is the text of this card: WARNING: Any injury caused by high pressure liquid can be serious. If you are injured or even suspect an injury: Go to an emergency room immediately. Tell the doctor that you suspect an injection injury. Show him this card Tell him what kind of material you were spraying MEDICAL ALERT AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN Injection in the skin is a serious traumatic injury. It is important to treat the injury surgically as soon as possible. Do not delay treatment to research toxicity. Toxicity is a concern with some exotic coatings injected directly into the bloodstream. Consultation with a plastic surgeon or a reconstructive hand surgeon may be advisable. The seriousness of the wound depends on where the injury is on the body, whether the substance hit something on its way in and deflected causing more damage, and many other variables including skin microflora residing in the paint or gun which are blasted into the wound. If the injected paint contains acrylic latex and titanium dioxide that damage the tissue s resistance to infection, bacterial growth will flourish. The treatment that doctors recommend for an injection injury to the hand includes immediate decompression of the closed vascular compartments of the hand to release the underlying tissue distended by the injected paint, judicious wound debridement, and immediate antibiotic treatment. Fire Safety To avoid a fire or explosion, follow these instructions. Ground all conductive equipment. Use only grounded air and fluid hoses. Check equipment and workpiece grounding devices regularly. Resistance to ground must not exceed one megohm. Shut down all equipment immediately if you notice static sparking or arcing. Do not restart the equipment until the cause has been identified and corrected. Do not smoke, weld, grind, or use open flames where flammable materials are being used or stored. Do not heat materials to temperatures above those recommended by the manufacturer. Make sure heat monitoring and limiting devices are working properly.

8 4 Dry Filter Continuous Pipe Coater System Fire Safety (contd) Provide adequate ventilation to prevent dangerous concentrations of volatile particles or vapors. Refer to local codes or your material MSDS for guidance. Do not disconnect live electrical circuits when working with flammable materials. Shut off power at a disconnect switch first to prevent sparking. Know where emergency stop buttons, shutoff valves, and fire extinguishers are located. If a fire starts in a spray booth, immediately shut off the spray system and exhaust fans. Shut off electrostatic power and ground the charging system before adjusting, cleaning, or repairing electrostatic equipment. Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice. Halogenated Hydrocarbon Solvent Hazards Do not use halogenated hydrocarbon solvents in a pressurized system that contains aluminum components. Under pressure, these solvents can react with aluminum and explode, causing injury, death, or property damage. Halogenated hydrocarbon solvents contain one or more of the following elements: Element Symbol Prefix Fluorine F Fluoro- Chlorine Cl Chloro- Bromine Br Bromo- Iodine I Iodo- Check your material MSDS or contact your material supplier for more information. If you must use halogenated hydrocarbon solvents, contact your Nordson representative for information about compatible Nordson components. 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 system electrical power. Close hydraulic and pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the system. Disposal Dispose of equipment and materials used in operation and servicing according to local codes.

9 Dry Filter Continuous Pipe Coater System 5 Description Introduction This manual covers the Nordson Dry Filter Continuous Coater System. It includes a description of the major system components and their operation, general troubleshooting procedures, and general maintenance procedures. Continuous 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 continuous coating systems are engineered for the application, Nordson Corporation provides separate manuals for each component or sub system, such as heaters, pumps and controllers. Refer to these manuals for more information on the operation and maintenance of these components. The Dry Filter Continuous Coater System coats the surface of products continuously with uniform coverage, and is designed for high production speeds. The system is a compact, integrated finishing system which requires minimal floor space and adapts easily to in-line production methods. High volumes of product are easily coated, and over-spray material is captured and routed back through the self-contained system for reuse. The system consists of a circulating, heated, airless spray system connected to a custom-designed spray cabinet through which a product is conveyed. Spray nozzles inside the cabinet are positioned to provide consistent, uniform coverage of the product as it passes through the coater. Over-sprayed material not deposited on the product is recovered in the coater cabinet and returned to be resprayed. Operation Product enters the coater via a customer-supplied conveyor system. Inside the coater cabinet, spray nozzles are positioned to apply coating material at line speeds of 25 to 1,000 feet (7.6 to 305 meters) per minute, depending on the application. Coating material that is not applied to the product falls to the bottom of the continuous coater where it is collected in a sump. The material passes through a strainer, then a pump returns the material to the main material supply. System Components Hydraulic Control Panel See Figure 1. The control panel contains the Nordson coating supply pump, heaters, high pressure filters, valves and necessary hardware, providing a center of operation. Coating material temperature, filtration, and supply to the coater cabinet is facilitated by this control panel.

10 6 Dry Filter Continuous Pipe Coater System The hydraulic control station contains the fluid circuitry of the continuous coater. It siphons coating material from the supply source through a PermaFlo pump, where fluid pressures from 300 to 3,000 psi (21 to 211 kg/cm2) are developed. Coating material flows from the pump through heaters which stabilize the material temperature. This reduces and stabilizes viscosity, improving atomization and deposition. The material is then filtered and routed to the spray nozzles contained in the coater cabinet Figure 1 Hydraulic Control Panel Components (Configurations May Vary) 1. Heaters 2. Magnetic filter 3. Step down filter assembly 4. PermaFlo pump 5. Air motor accessory group

11 Dry Filter Continuous Pipe Coater System 7 Coater Cabinet and Integral Dry Filter Exhaust System See Figure 3. Order the coater cabinet in mild or stainless steel construction, depending on the coating materials being used. The cabinet contains entry and exit ports dimensioned for product size. An access hatch opening provides a means for installing and adjusting a spray ring and spray nozzles. In instances with space limitations a guillotine-style lift raises the spray ring out of the cabinet for regular maintenance and nozzle access. The internal cabinet contains the spray ring and spray nozzles. In some cabinets, customer-supplied support rollers are installed within the cabinet to assist in supporting and conveying the sprayed product. A scavenger pump mounted on the cabinet exterior returns excess paint or solvent to the original coating supply container for reuse. Attached to the coater cabinet at the entrance and exit is an integral dry filter exhaust system utilizing standard size disposable filter media. When connected to the customer-supplied exhaust fan and ducting, the system creates a draft at the entry and exit port of the cabinet to prevent the escape of material fumes and particles. Spray Ring Lift Assembly Figure 2 Nordson Dry Filter Continuous Coater Cabinet (Rear View Shown with Optional Spray Ring Lift Assembly)

12 8 Dry Filter Continuous Pipe Coater System Front View 5 Back View 8 7 8X Top View Side View Figure 3 Continuous Coater Cabinet Components (PC2 Model Shown) 1. Integral dry filter exhaust system 2. Solvent wash guns 3. Access hatch 4. Scavenger pump 5. Y strainer 6. Lift (Optional) 7. Strainer 8. Sump 9. Spray ring 10. Spray nozzles 11. Entry / exit port

13 Dry Filter Continuous Pipe Coater System 9 1 2, 3, 4 5 Figure 4 1. Nozzle holder 2. Nozzle Spray Ring Assembly 3. Strainer 4. Nozzle retaining nut 5. Fluid inlet Specifications NOTE: Specifications are typical. Outcome will vary depending on the system being used, the product being coated, line speeds, and available plant area. Table 1 Continuous Coater Specifications Description Minimum Maximum Pressure 400 psi (27.6 bar) 3000 psi (206.8 bar) Flow rate 0.5 gallons (1.9 liters) per minute 2 gallons (7.6 liters) per minute Line speed 25 ft (7.6 meters) per minute 1000 ft (304.8 meters) per minute Temperature range Ambient 180F (82.2C)

14 10 Dry Filter Continuous Pipe Coater System Space Requirements Continuous coaters are available with your choice of 5 cabinet sizes to accommodate a wide range of materials. See Table 2. Table 2 Continuous Coater Typical Space Requirements Nordson Model Approximate Length Approximate Width PC1-DF 100 in. (254.0 cm) 60 in (152.4 cm) PC2-DF 120 in. (304.8 cm) 60 in (152.4 cm) PC3-DF 140 in. (355.6 cm) 70 in (177.8 cm) PC4-DF 164 in. (416.6 cm) 80 in (203.2 cm) PC5-DF 164 in. (416.6 cm) 90 in (228.6 cm) Cabinet Capacities See Table 3. Table 3 Continuous Coater Cabinet Size Options Nordson Model Minimum Capacity (Pipe Diameter) Maximum Capacity (Pipe Diameter) PC1-DF 0.5 in. (1.27 cm) in ( cm) PC2-DF 0.5 in. (1.27 cm) in ( cm) PC3-DF 2 in. (5.08 cm) 16 in (40.64 cm) PC4-DF 2 in. (5.08 cm) 20 in (50.8 cm) PC5-DF 2 in. (5.08 cm) 24 in (60.96 cm) NOTE: Customized systems available upon request.

15 Dry Filter Continuous Pipe Coater System 11 Installation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: If flammable liquids are to be sprayed, establish and mark off an appropriate floor area surrounding the equipment as a hazardous area. NOTE: During the initial construction of the continuous coater system, Nordson Engineering and customer personnel will have established the location and parameters concerning equipment installation. The following procedures are meant to assist with the final installation and initial start-up of the system. Coater Cabinet Installation Refer to system drawings supplied by your Nordson Representative. Refer to the National Fire Protection Association publication NFPA33 for standards on the installation and operation of this spray system and to federal, state, and local codes governing installation and operation of these systems. 1. Install coater cabinet and control panel in position. Make sure that all components are level. 2. Centralize and align coater cabinet with conveyor and fasten equipment to floor securely. 3. In some instances support rollers or chain drive mechanisms are incorporated in line with the coater cabinet. These mechanisms must be connected to the main conveyor system. NOTE: When support rollers are designed in the system, make certain that the surface speed of the rollers matches the speed of both the supply and take-away conveyors. 4. Check and remove any dirt or packing material from the coater cabinet. 5. Install exhaust filters to their respective frames in the upper chamber of the coater cabinet. 6. Install a fan exhaust system containing a blast gate arrangement which is connected to the coater exhaust outlet. Hydraulic System Setup See Figure Install all siphon and drain-off hoses to their respective selector valve connections. Refer to Figure 5 for siphon/drain-off hose diagram. 2. Tighten all hydraulic fittings which may have loosened during shipment. 3. Connect all fluid pressure and return lines to coater cabinet and control panel.

16 12 Dry Filter Continuous Pipe Coater System WARNING: Make certain that electrical installation and maintenance is performed only by qualified personnel in accordance with all applicable codes. 4. Install all electrical connections to heaters. Refer to individual manuals for proper installation. 5. Install electrical connections to automatic viscosity control, if used. Refer to individual manual for proper installation. WARNING: Make certain that all paint, solvent, air and water lines are protected from damage by location, or by installation of suitable guards. WARNING: Make certain that all pumps, heaters, coater cabinet, control panel, conveyor and coating material supply containers are adequately grounded. 6. Add solvent chamber fluid to the Nordson pumps to the level indicated on the filler cups. Refer to the pump operator manual for more information. 7. Fill the air line lubricator with vitalizer oil to the prescribed level. FILTERS PAINT RETURN SOLVENT RETURN DRAIN VALVES PLUG E RETURN 1 3 WAY 2 VALVE P NORDSON CONTINUOUS COATER AIR SUPPLY FILTER IN FILTERS MAG FIL SCAVENGER PUMP FIL VAL MODEL 815 PUMP ACCUMULATOR 3 WAY 1 2 VALVE P DRAIN VALVES FILTER OUT 3 WAY 1 2 VALVE P TO CLEANOUT GUN 1 TO CLEANOUT GUN 2 SUPPLY VALVE SPRAY RING CIRCUIT A 4 NOZZLES SPRAY RING CIRCUIT B 6 NOZZLES SPRAY RING CIRCUIT C 8 NOZZLES DIVERTER VALVE FROM PAINT SUPPLY 1 SIPHON 3 WAY VALVE P 2 FROM SOLVENT SUPPLY CIRCULATION VALVE DRAIN VALVE AIR SUPPLY FIL LUB VAL TO SCAVENGER PUMP SOL DIVERTER SOL PAINT PUMP SOL SCAVENGER PUMP MAIN ELECTRICAL ENCLOSURE TO BLOW GUN Figure 5 Fluid and Pneumatic System Diagram

17 Dry Filter Continuous Pipe Coater System 13 Operation Initial Start Up Flush Pump and Filter Systems 1. Place required amount of solvent for proper flushing into a solvent drum. The solvent must be compatible with the coating material to be used. 2. Place the pump siphon rod in the coating material supply drum. 3. Place siphon and drain-off rods in the solvent drum. 4. Place filter IN and OUT valve controls to the A position. NOTE: System will not operate unless both controls are in the same position. 5. Place siphon valve and return valve controls to the SOLVENT position. 6. Shut off the coating supply main ball valve located on the control panel which feeds the coating material to the coater cabinet spray ring and hand gun manifold. NOTE: This valve is located below the A designation of the filter OUT valve control. WARNING: Do not turn heaters on until system installation is complete and initial start up and flush have been performed. 7. Check that the circulation valve is closed on the coating supply pump. NOTE: Close the circulation valve finger tight. Over-tightening can cause carbide seat and stem damage or breakage. WARNING: Make certain that ventilation (exhaust) system is operating to remove solvent vapors. 8. Turn on the main air supply to the coating supply pump and pressurize the pump to approximately 20 PSI (1.41 kg/cm 2 ) for moderate stroke action. 9. Slowly open the drain valve control at the supply pump circulation valve to purge the air from the pump system. 10. Close the drain valve and circulate the material for 5 minutes. 11. Switch filter IN and filter OUT valve controls to the B position. 12. Slowly open the drain valve control at the supply pump circulation valve to purge the air from the pump system. 13. Close the drain valve and circulate the material for 5 minutes. 14. Switch the siphon valve control to PAINT position, and continue to purge the system air through the pump drain- off valve. 15. When solvent begins to flow from the drain-off and all air has been purged from the system, close drain-off valve and increase pump pressure to 80 PSI (5.62 kg/cm 2 ). Check for leaks.

18 14 Dry Filter Continuous Pipe Coater System NOTE: When the above steps have been followed and the circulation valve and drain-off valve controls are closed the pump should stop. 16. Slowly rotate the supply pump circulation valve control counter-clockwise until the pump strokes at a rate of 8 to 10 strokes per minute. 17. While the system is operating, check all hoses and fittings for leaks. Also check the spray ring and nozzles for leakage. NOTE: If solvent is leaking from the spray ring nozzles check the fluid control manifold on the coater cabinet to insure the ball valves are in the closed position. 18. Reduce pump pressure to 20 PSI (1.41 kg/cm 2 ). 19. Start the scavenger pump, located on the coater cabinet. Adjust the pressure until the pump strokes adequately to remove any residual material. NOTE: Insure that the ball valves at the manifold on the coater cabinet which supply fluid to the hand gun and the spray nozzles are closed securely. Flush Spray Ring 1. Remove the spray nozzles from the spray ring. 2. Position the spray ring in the cabinet and close the access hatch opening. 3. Open the spray ring manifold at the coater cabinet releasing solvent through the spray ring nozzle blocks. Pump solvent though the system for a minimum of 30 minutes. 4. After the 30-minute flush operation above, close the spray ring manifold valve at the coater cabinet and install the spray nozzles to the spray ring. Open the spray ring manifold and allow the fluid to spray through the nozzles for approximately 10 minutes. 5. Close the spray ring manifold valve, shut off the pump air pressure, and open the pump drain-off valve. 6. Shut off the scavenger pump pressure and the water supply tank pump. 7. Alternate between A and B filter settings to relieve pressure from both sides. 8. Position a container under the high pressure filter drain pipes at the control panel. 9. Slowly open the filter drain valve to relieve pressure. 10. Remove the filter screens. Inspect, clean, then reinstall the screens. 11. Close all filter drain valves.

19 Dry Filter Continuous Pipe Coater System 15 Pressure Check 1. Check that the circulation valve is closed on the coating supply pump. NOTE: Close the circulation valve finger tight. Over-tightening can cause carbide seat and stem damage or breakage. 2. Place siphon rod in the coating material drum. 3. Turn on the main air supply to the coating supply pump and pressurize the pump to approximately 20 PSI (1.41 kg/cm 2 ) for moderate stroke action. 4. Slowly open the drain valve control at the supply pump circulation valve to purge the air from the pump system. 5. Switch filter IN and filter OUT valve controls to the B position. 6. Switch the siphon valve control to PAINT position, and continue to purge the system air through the pump drain- off valve. 7. When solvent begins to flow from the drain-off and all air has been purged from the system, close drain-off valve and increase pump pressure to 80 PSI (5.62 kg/cm 2 ). NOTE: When the above steps have been followed and the circulation valve and drain-off valve controls are closed the pump should stop. 8. Slowly rotate the supply pump circulation valve control counter-clockwise until the pump strokes at a rate of 8 to 10 strokes per minute. 9. Turn the spray ring manifold control to the open position and check that the spray ring nozzles are spraying adequately. 10. Turn the heaters on and adjust the thermostat for 120 F (37.8 C). See NH-4 heater manual for additional operation instructions. 11. Circulate the material for 30 minutes, allowing the temperature to stabilize. 12. When the 30-minute operational period is complete, turn off heaters and allow a 15-minute cool-off period while the system is still operating. 13. Shut off the pumps and open the drain valves to relieve hydraulic pressure. NOTE: After the above steps have been followed and the system filter screens indicate all contamination has been removed, continue with initial start-up procedure. 14. Close the pump circulation valve finger tight. 15. Close the spray ring manifold valve, leaving the pump drain valves open. 16. Remove the siphon rods from the solvent container. 17. Shut off the scavenger pump. 18. Open the ball valve at the bottom of the coater cabinet and drain out any remaining solvent. 19. Remove the Y inline filter located at the scavenger pump siphon inlet and clean all contamination from the filter element. Reinstall the element and tighten. 20. Close the ball valve on the coater cabinet drain.

20 16 Dry Filter Continuous Pipe Coater System NOTE: Discard all solvent used during this initial start-up and flush operation. DO NOT use this solvent as a coating material reducer. Initial Coating Load 1. Place the supply pump drain-off rod in a scrap material supply drum. NOTE: Some system installations incorporate an automatic viscosity control mechanism. This control is an accessory which is mounted to the coating material supply container. During operation, the control continuously measures and adjusts coating material viscosity automatically by adding solvent to the recycling coating supply. 2. Check the viscosity of the coating material and correct if necessary. 3. Place the siphon and return valve controls to the PAINT position. 4. Place the filter IN and OUT valve controls to the A position. 5. Check that the circulation valve is closed on the coating supply pump. NOTE: Close the circulation valve finger tight. Over-tightening can cause carbide seat and stem damage or breakage. 6. Turn on the main air supply to the coating supply pump and pressurize the pump to approximately 20 PSI (1.41 kg/cm 2 ) for moderate stroke action. 7. Slowly open the drain valve control at the supply pump circulation valve to purge the air from the pump system. 8. Switch filter IN and filter OUT valve controls to the B position. 9. Switch the siphon valve control to PAINT position, and continue to purge the system air through the pump drain- off valve. 10. When coating material begins to flow from the drain-off and all air has been purged from the system, close drain-off valve and increase pump pressure to 80 PSI (5.62 kg/cm 2 ). NOTE: When the above steps have been followed and the circulation valve and drain-off valve controls are closed the pump should stop. 11. Slowly rotate the supply pump circulation valve control counter-clockwise until the pump strokes at a rate of 8 to 10 strokes per minute. 12. Open the drain-off rod and purge the solvent from the system until the coating material runs freely. Close the drain rod. 13. Change the filter valve controls to the B position to purge the system of solvent that may be trapped in the filter assemblies. 14. Close the supply pump drain-off valve and adjust the supply pump pressure to operating pressure. 15. Open the supply pump circulation valve and adjust to an 8-10 strokes per minute stroke rate. 16. Turn the heaters on to control the material viscosity.

21 Dry Filter Continuous Pipe Coater System 17 NOTE: Heater temperature settings should not exceed 10 F ( 12.2 C) above the seasonal high ambient temperature for the area. Temperatures higher than 120 F (49 C) generally cause excessive solvent loss in the coater cabinet. 17. When the coating material has attained operating temperature open the spray ring ball valve. 18. Start the scavenger pump. 19. Check that the pump pressure, viscosity, temperature and exhaust system are adjusted properly. 20. Open the spray ring ball valve and check the nozzle operation. 21. With the system operating run a test product through the coater. 22. Make necessary nozzle adjustments. Check system components and make adjustments as necessary. Daily Start Up NOTE: Before starting the system observe system components for loose fittings or closed drain-off valves. Check main air line water separator, vitalizer oiler, solvent chamber fluid in pumps, water supply tank level, coating material supply and viscosity. Also check that all equipment electrical grounds are intact and undamaged. 1. Turn on the main air line. 2. Pressurize the supply pump to 20 PSI (1.41 kg/cm 2 ) air pressure. 3. Switch the filter IN and OUT valve controls to the A position. 4. Set the siphon and return valve controls to the PAINT position. 5. Place the siphon rod in the container of solvent. 6. Start the scavenger pump. 7. Open the drain-off valve at the supply pump and pump all solvent in the system back into the solvent container. 8. While the system is still pumping, alternate the filter valve controls from A to B positions to purge solvent from both filter banks. 9. Open the spray ring ball valve at the coater cabinet. 10. When paint appears at the drain-off rod, close the drain valve. 11. Turn on the heaters. 12. Adjust the pump to proper pump pressure and adjust the circulation rate to 8 to 10 strokes per minute. 13. Open the spay ring ball valve and observe that all nozzles are spraying. NOTE: Periodically check the coating material viscosity to insure the material is within the proper spray range. Shutdown Procedures The following procedure is to be used as a basis and can be modified as system operating experience is developed.

22 18 Dry Filter Continuous Pipe Coater System NOTE: When the continuous coater system is to be operated constantly, the following procedure must be performed once a day, ideally every 24 hours. 1. Turn off heaters and allow pumping system to continue operating for at least 15 minutes. 2. Drain the coater cabinet sump area of paint. 3. Switch the siphon valve control to the SOLVENT position and pressurize the supply pump to 20 PSI (1.41 kg/cm 2 ). 4. Open the supply pump drain-off valve to push the coating material through the system. When solvent begins to flow, close the drain-off valve. 5. Circulate solvent for 5 minutes. 6. Switch filter IN and OUT valve controls to the B position and pump one additional gallon of solvent. 7. Open the drain-off valve and purge the material from the B side filters. 8. Close the drain valve and allow solvent to circulate through the system for a minimum of 5 minutes. 9. Pressurize the supply pump to 40 PSI (2.81 kg/cm 2 ), open the spray ring ball valve and allow to spray about 2 minutes or 100 strokes of the supply pump, whichever is longer. Shut off the spray ring ball valve. 10. Switch the RETURN valve control to the SOLVENT position and place the solvent drain-off rod into a 5 gallon (18.9 liter) container. Start the scavenger pump and allow approximately 4 gallons (15.1 liters) of solvent to flow into the 5 gallon (18.9 liter) container. 11. Turn off the scavenger pump, return the solvent drain-off rod to the solvent supply and restart the scavenger pump. 12. Open the spray ring ball valve and allow the solvent to spray through the nozzles for approximately 10 minutes. 13. Turn off the spray ring ball valve and open the hand gun ball valve. After the coater cabinet is nearly void of fog, wash down any remaining residue using the manual spray gun. WARNING: Make certain that the ventilation system is on so that solvent fumes may be exhausted. 14. When the system is clean, close the manual spray gun ball valve and shut of the supply pump. 15. When the coater cabinet is void of all solvent, shut off the scavenger pump. 16. When flush operation is complete, shut off the pump pressure and open the drain valve to relieve pressure. 17. Switch filter IN and OUT valve controls to the A position to relieve system pressure, then switch back to B position. 18. Open the filter drain valves and drain solvent into the waste container. 19. Remove the filter screens and clean. Reinstall the screens and tighten the filter housings.

23 Dry Filter Continuous Pipe Coater System Close the filter drain valve and the pump drain valve. 21. Remove the inline filter at the scavenger pump Y. Clean and reinstall. 22. Change filter media. This may be necessary occasionally during operation. Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Daily Maintenance Perform these procedures daily to keep your system clean and functioning properly. 1. Adjust pump packing. See the pump operator manual for more information. 2. Check the solvent chamber fluid in the pumps and fill to the appropriate level. See operator manual for more information. 3. Inspect and clean the high pressure fluid filters. 4. Inspect and clean the spray nozzles. Check for and clear any clogs. 5. Inspect and adjust spray nozzles for correct orientation. 6. Inspect the Y strainer and clean any debris present. 7. Inspect the vestibule filters and replace daily or after each shift. 8. Verify film thickness and adjust as necessary. 9. Check for any leakage or seepage of material. 10. Keep equipment and general area clean and free of dirt, debris and excess material.

24 20 Dry Filter Continuous Pipe Coater System Weekly Maintenance NOTE: The following procedures are to be performed weekly or after each 40 hours of operation. 1. Open the sump valve at the coater cabinet and drain the cabinet. 2. Clean the interior of the booth with a manual spray gun using a coating-compatible cleaner. Check and clean the coater cabinet of all contamination. 3. Clean all surface buildup in and around system. 4. Flush the pumping system with a coating-compatible cleaner. 5. Flush the Russell Finex filter, if applicable. 6. Remove spray ring nozzles and clean. 7. Inspect the spray ring lift assembly function, if applicable. Check the bearings and air cylinder. 8. If the coater is equipped with internal rollers, lubricate the roller bearings and the drive mechanism. 9. Clean and lubricate the coater cabinet access door hinges and latch. 10. Inspect the final exhaust filter and replace as needed. 11. Clean the material return filter and adjust as needed. 12. Check for any leakage or seepage of material. Periodic Maintenance Perform these procedures on a monthly basis or as needed. 1. Clean vestibule filter racks. 2. Check all electrical connections and grounds.

25 Dry Filter Continuous Pipe Coater System 21 Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. These troubleshooting procedures cover only the most common problems. If you cannot solve a problem with the information given here, refer to the component operator manual or contact your local Nordson representative for help. PermaFlo Pumps Common Problems No. Problem Page 1. Pump fails to start or stops while operating and fails to 22 restart 2. Pump double strokes at one end of stroke and will not 23 change direction 3. Excessive or constant air leakage from air motor or air 23 valve 4. Pump strokes irregularly when spray device is 23 triggered 5. Pump operates but flow is restricted, or pump surges Pump fails to siphon coating material Pump continues to operate even after drain and 25 circulation valves are closed and spray devices are shut off 8. Pump does not stroke when circulation valve opened Solvent cup overflows often Fading or narrowing spray pattern Spray pattern has tails of unatomized coating material at the outer edges 26

26 22 Dry Filter Continuous Pipe Coater System Problem Possible Cause Corrective Action 1. Pump fails to start or stops while operating and fails to restart No compressed air supply, or air pressure too low Blockage in fluid system Air fittings are loose Spool in air valve stuck in middle position Three-way air valve damaged or sticking Air supply contaminated Air valve damaged Check the air supply at the drop-leg drain valve. Make sure the air regulator is working correctly. Check for flow from each component and hose, working from the spray device to the pump, as follows: 1. Shut off the air to the pump and relieve the hydraulic pressure. 2. Break the connection. 3. Turn on the air to the pump. If the pump starts, the blockage is in the component or hose after the broken connection. Make sure all hose connections to the air valve are tight. Set the input air to 40 psi. Open and close the input air ball valve to give the air valve quick bursts of air. If the pump does not start, turn off the air and remove the cap from the top of the air valve. Push the spool down further into the air valve. Replace the cap, turn on the air and start the pump. If the pump stalls at the top of the stroke, clean and inspect the three-way valve in the lower cylinder head. Replace the valve if damaged. If the pump stalls at the bottom of the stroke, clean and inspect the three-way air valve in the upper cylinder head. Replace the valve if damaged. Clean and inspect both air pilot actuators. Replace them if damaged. Check air filtration system. Rebuild air valve. Continued...

27 Dry Filter Continuous Pipe Coater System 23 Problem 2. Pump double strokes at one end of stroke and will not change direction 3. Excessive or constant air leakage from air motor or air valve 4. Pump strokes irregularly when spray device is triggered Possible Cause Three-way air valve damaged or sticking Worn U-cup seal in underside of lower cylinder head O-rings sealing air valve to cylinder heads leaking O-rings sealing cylinder to cylinder heads leaking. Air valve seals worn Air piston seal worn or damaged Air in hydraulic system Coating material temperature too high, causing cavitation Worn or clogged ball check valve Worn packings Corrective Action If the pump double strokes at the top of the stroke, clean and inspect the three-way valve in the lower cylinder head. Replace the valve if damaged. If the pump double strokes at the bottom of the stroke, clean and inspect the three-way valve in the upper cylinder head. Replace the valve if damaged. Clean and inspect both air pilot actuators. Replace them if damaged. Stop the pump during an upstroke and check for air leaking around the connecting rod. Replace the U-cup seal if it is leaking. Check for air leaking at the air valve-to-cylinder head joint. Replace the O-rings if they are leaking. Check for air leaking around the cylinder heads. Replace the O-rings if they are leaking. Replace the seals. Replace the air piston. Purge the air from the hydraulic system. Refer to Pump and System Flushing in Operation. Add defoaming agents to coating material. As coating material temperature is increased, vacuum created by pump siphon can cause solvents to boil and cause cavitation. Lower heater thermostat setting. Flush the pump and system with a compatible cleaning solution. If the problem continues, rebuild the ball check valves. Replace the packings. Continued...

28 24 Dry Filter Continuous Pipe Coater System Problem 5. Pump operates but flow is restricted, or pump surges 6. Pump fails to siphon coating material Possible Cause Corrective Action Air motor or air valve leak Refer to problem 3. Volume of supply air is inadequate Check for a restriction in the air lines, regulator or filter. Make sure the air lines are the correct size. Blockage in hydraulic system Refer to problem 1. Coating material too viscous Check the material viscosity. Add solvent to the material to lower the viscosity. Drain valve leaking Check for flow from the valve when it is closed. Output from spray devices exceeds pump capacity Blocked siphon strainer screen, rod, or hose Air leak in siphon system Coating material too viscous Siphon hose too long, hose ID too small, or strainer screen too fine for coating material Reduce the spray device nozzle or fluid tip size. Reduce the number of spray devices connected to the pump. Reduce the circulation rate. Check and clean the hose, rod, and strainer. Check the siphon hose for leaks. Break apart all connections in the siphon system. Remove old sealant from the fitting threads and wrap them with PTFE tape before reconnecting them. Check the material viscosity. Add solvent to the material to lower the viscosity. Use a correctly sized siphon hose. Check the strainer screen. If the strainer screen is clogged with pigment, use a coarser mesh screen or a strainer without a screen. Contact your Nordson representative for advice. Continued...

29 Dry Filter Continuous Pipe Coater System 25 Problem 7. Pump continues to operate even after drain and circulation valves are closed and spray devices are turned off 8. Pump does not stroke when circulation valve is opened 9. Solvent chamber overflows often Possible Cause Coating material supply low, pump siphoning air Leaking drain valve Leaking circulation valve Leaking ball check valve Clogged circulation valve, or blockage in system No compressed air supply, or air pressure is too low Upper packings worn Corrective Action Fill the supply container. Rebuild or replace the drain valve. Check for a damaged or worn circulation valve as follows: 1. Shut off the pump air supply. 2. Open the drain valve to relieve the hydraulic pressure. 3. Close the drain valve. 4. Immerse the siphon rod in coating material. 5. Disconnect the return hose from the circulation valve. 6. Connect an air hose to the circulation valve in place of the return hose. 7. Apply compressed air to the circulation valve. If air bubbles from the siphon rod, replace the circulation valve needle and seat. Rebuild the ball check valves. Open the circulation valve fully, then close it partially. If the problem continues, flush the system with a compatible cleaning solution. Refer to problem 1. Check the air supply at the drop-leg drain valve. Make sure the regulator is working correctly. Shut off pump, relieve hydraulic pressure, and tighten solvent cup 1 / 8 to 1 / 4 turn. If leaking continues, replace the packings. Upper and lower packings should be replaced at the same time. Continued...

30 26 Dry Filter Continuous Pipe Coater System Problem 10. Spray pattern fades or narrows 11. Spray pattern has tails of unatomized coating material at the outer edges Possible Cause Corrective Action Compressed air pressure is too Make sure the air pressure regulator low is working correctly. The pump air motor requires at least 1.38 bar (20 psi) air pressure to operate. Increase the air pressure. Check for a restriction in the air supply line. Blockage in hydraulic system Refer to problem 1. Nozzles or fluid tips too large, or too many spray devices connected to system Spray device nozzle plugging Circulation valve opened too far Low hydraulic pressure or partial blockage in system Material too viscous Damaged nozzle or fluid tip Reduce the nozzle or fluid tip size, or the number of spray devices connected to the pump. Remove the fluid filter screen and inspect it. If the screen is damaged, replace it. If the screen is undamaged, replace it with one with a smaller mesh size. Close the circulation valve completely, then reopen until pump is stroking 5 to 10 strokes per minute with guns turned off. Increase the air pressure. Flush the system with a compatible cleaning solution. Refer to problem 1. Add solvent or heat to the coating material to lower the viscosity. Replace the nozzle or fluid tip. Preventing Air Valve Freezing As compressed air is exhausted from the air valve, it expands rapidly and cools the air valve. The PermaFlo air motor exhaust paths have been designed to minimize blockage due to freezing. A coating of frost on the muffler surfaces is typically the result of moisture in the air. If the valve does get cold enough for water vapor to condense and freeze on or in the mufflers and interfere with the operation of the valve, try one of the following actions: Run the pump at no more than 8 10 strokes per minute. If you are operating the pump at high speed in a humid environment, lubricate the compressed air with a glycol-based antifreeze fluid. Do not use an antileak-type antifreeze fluid. Install an air dryer to remove moisture from the air supply.

31 Dry Filter Continuous Pipe Coater System 27 NH4 Heaters Problem Possible Cause Corrective Action 1. Insufficient heat Faulty thermometer Lightly tap the thermometer to make sure it is not giving an erratic reading. If an erratic reading still exists, replace the thermometer. Demand is exceeding the capacity of the heater Coating material is baked on the inside of the fluid passage body 2. No heat output Thermostat failed in the on position causing the heat limiter to open an electrical circuit to the heater cartridge Heater cartridge failed Make sure the heating capacity is not being exceeded. A single heater has the capacity to raise the temperature of most organic solvent type coating materials 56 C (100 F) at a flow rate of 45 l/hr (12 gph). A temperature rise greater than 56 C (100 F) would proportionately decrease the capacity of the heater. For stainless steel heaters: Flush the heater with a compatible solvent. If the heat output is not sufficient after flushing it out, replace the fluid reservoir. For all other heaters: Disassemble the heater and clean the fluid passage body. Refer to the Repair section or the Disassembly Tool Kit section for more information. Replace the thermostat and heat limiter. Refer to the Repair section for more information. Refer to the Repair section for more information. Disconnect the heater cartridge leads 2 and L2 from the terminal block. Check for continuity between the heater cartridge leads 2 and L2. If continuity is not present, replace the heater cartridge.

32 28 Dry Filter Continuous Pipe Coater System Solvent Wash Spray Guns Problem Possible Cause Corrective Action 1. Gun leaks around nozzle Dirty or damaged nylon washer Relieve system fluid pressure. Remove the nozzle and clean or replace the nylon washer. 2. Gun leaks around barrel nut 3. Gun leaks through the weep hole in the gun body directly behind the fittings Dirty or damaged metal sealing surfaces Worn packing cartridge Relieve system fluid pressure. Remove the barrel nut and clean or replace the barrel. Replace the packing cartridge and seals. Refer to Parts for the seal kit and packing cartridge part numbers. 4. Gun spits Dirty or worn ball tip or seat Relieve system fluid pressure. Clean or replace the ball tip and seat. 5. On/Off cycle response is poor or non-existent Long trigger air lines Air trapped in fluid system Air piston worn or out of adjustment Mount the solenoid valve on or as close as possible to the gun. Purge the air from the fluid system. Adjust or replace the air piston assembly. Low pressure to the air solenoid Increase the air pressure to bar (40 60 psi). Long trigger air lines High fluid pressure Mount the solenoid on or as close as possible to the gun. Reduce the fluid pressure at the pump. The maximum pressure allowed is 117 bar (1700 psi).

33 Dry Filter Continuous Pipe Coater System 29 Repair Refer to the component operator manuals for repair information. For additional help, call the Nordson Industrial Coatings Customer Support Center at (800) , or contact your local Nordson representative. Parts For information on parts, refer to the component operator manuals. To order parts, call the Nordson Industrial Coating Systems Customer Support Center at (800) or contact your local Nordson representative.