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1. ELECTRICAL Prevent serious injury or death Electrical installations must be performed by qualified electricians Installation must conform to all national local and provincial codes and standards www colmetsb com 888 452 6684 COL MET Spray Booths Complete booth assembly and then perform steps 1 5 below to connect electrical service to motor 1 Determine voltage at your facility Col Met does not recommend using 120V single phase on motors above 1HP 2 control panel or motor starter was ordered with this booth confirm that the voltage and phase on the control panel matches the voltage and phase you intend to use 3 Locate the wiring diagram above that matches your voltage phase and HP 4 Some motors may have 2 additional red wires These wires are for an internal thermal overload We do not use these wires and they should be capped off with wire nuts or electrical tape 5 Locate the rotation arrow on the fan and verify belts are rotating in the direction of the arrow If the belts are not rotating in the direction of the arrow reverse the motor 3 4 1 5 Hp 120V Single Phase 3 4 3 Hp 230V Single Phase Wire for Low Voltage Wire for High Voltage To reduce the risk of electric shock the motor is to be grounded per local electrical code To reduce the risk of electric shock the motor is to be grounded per 120VAC local electrical code Hot Incoming 1PH power from control panel2. 20 AMG COPPER ONLY m im M REPLACE FUSE WITH TYPE JAG 3 iw fit TO COMPLY WITH THESE REQUIREMENTS WILL VOID MANUFACTU tameo WS PATENT 1452 176 The Dwyer Timer Board is where the timing can be adjusted for each solenoid You can adjust the amount of time between pulses Time Off in seconds and how long each pulse will last Time on in milliseconds For example if the time off is set for 60 and the time on is set for 150 then the system would perform in the following manner Power is applied to the timer board via the Filters toggle switch on the door of the control panel only active if the fan is in operation The first output of the timer board will send out a 150 millisecond 120vac signal to the first solenoid enclosure The solenoid will open for 150 milliseconds allowing a small amount of air to pass through which allows air to bleed off from the pilot port on the first pulse valve The first pulse valve opens for 150 milliseconds allowing a high volume of compressed air to fire down into the cartridge filter After 150 milliseconds has elapsed the first output of the timer board will turn off which closes the solenoid valve which blocks off the air bleeding out of the pulse valve which closes the pulse valve to prevent air from firing into the cartridge filter The timer board then waits 60 seconds and then the next output of the board will repeat the steps listed above The proces
3. Mecair Pulse Valve Ambient Temperature 20 C 60 C SECTION VII COL MET WARRANTY This Section contains the Warranty for your Col Met Spray Booths powder booth COL MET Spray Booths WARRANTY Col Met Spray Booths has a full one year Warranty on all parts and materials This warranty does not extend to include labor costs for the replacement of parts or materials covered under warranty If a part is believed defective please notify our Customer Service Department A replacement item shall be shipped and regular freight shall be paid by Col Met If Col Met requires the defective part to be returned appropriate return freight costs shall be paid by Col Met IMPORTANT Before returning the defective part s you must first get an RGA Return of Goods Authorization from our Customer Service Department A copy of the RGA document MUST be included with the returned item s The Seller warrants to Buyer that the equipment mentioned herein shall be free from defects of materials or workmanship under normal use and maintenance for a period of one 1 year from date of shipment The liability of Seller under this warranty shall be limited to the repair or replacement at Seller s option of any part or component which may prove to be defective under normal use service and maintenance after Seller in its sole discretion determines same to be defective Said warranty is conditioned upon Buyer giving Seller immediate written notice o
4. motor starter To reverse the motor 12 120VAC Neutral Incoming 1PH power Swap 5 and 8 from control panel motor starter To reverse the motor To reverse the motor ace motor Swap T5 and T8 Swap T5 and T8 5 Hp 230V Single Phase 208 thru 240V Three Phase Wire for High Voltage Wire for Low Voltage To reduce the risk of electric shock the motor is to be grounded per local electrical code T To reduce the risk of electric shock RS the motor is to be grounded per 9 ee electrical code d T 4 1 Incoming 3PH power from control panel motor starter or VFD To reverse the motor Swap L1 and L2 Incoming 1PH power from control panel To reverse the motor motor starter To reverse the motor Swap T5 and T8 Swap 5 and 8 440 thru 480V Three Phase Wire for High Voltage Incoming 3PH power from control panel 12 motor starter or VFD To reverse the motor Swap L1 and L2 To reduce the risk of electric shock the motor is to be grounded per local electrical code www colmetsb com 888 452 6684 COL MET Spray Booths TuBEAXIAL FAN Fan assembly is heavy Fan assembly weight is approximately 50 200 Ibs depending on model Use and adequate lifting device to install fan assembly Prevent serious injury or death Electrical installations must be performed by qualified electricians Installation must conform to all national local and provincial codes and
5. pilot port on the pulse valve then the pulse valve will allow air to fire into the cartridge filter To test this theory turn off the compressed air and then plug the pilot port on the pulse valve that s leaking and then turn the compressed air back on If the pulse valve no longer fires air into the cartridge filter then there is either a leak in the white tubing or the solenoid that controls the valve has failed and is allowing air to pass through it at all times If the valve continues to fire air into the cartridge filter even when the pilot port is plugged then the diaphragm in the pulse valve has failed and will need to be replaced COL MET Spray Booths EXHAUST FILTER INSTALLATION Install one wire grid in each filter cell with prongs facing into booth Exhaust filters will be attached to prongs 13 X 1 2 GASKET ATTACHED TO TOP OF CHAMBER IGNI ENGINE QUEM de he FACTORY INSTALLED FILTER GASKET 12 3 4 X 52 FILTER OPEN TOP END CLOSED BOTTOM END 2 si LITE pr wee epe yr env L x cda FILTER PRESSURE ADJUSTMENT CLAMP IN UNLOCKED POSTION CLAMP IN LOCKED POSTION ARC OF SWING www colmetsb com 888 452 6684 COL MET Spray Booths INTAKE FiLTER INSTALLATION If booth has an intake plenum insert intake filter into filter grid The side marked Air Leaving Side on filter goes toward inside of booth LOOSEN NUT AND TURN 90 TO
6. using a plug style fan with a TEFC type motor Clean air is returned to the plant environment SAFETY AND COMPLIANCE and APPLICABLE CODES WARNING Your safety and the safety of others is a direct result of how you operate this powder booth Make sure you understand all the controls and the operating instructions before beginning BYPASSING SAFETY DEVICES There are several safety devices provided to ensure safe operation of the powder booth DO NOT make any attempt to override these devices PERSONAL SAFETY Consult with your powder material supplier for proper recommendations on respirator types required for applying the powder material supplied Operators should read and follow instructions from the powder companies Material Safety Data Sheets MSDS COMPIANCE TO APPLICABLE CODES This Powder Booth is designed to be in strict accordance with the National Fire Protection Association Standard Number 33 Spray Application Using Flammable Combustible Materials The NFPA Standard Safety Code for the design Construction and Ventilation of Spray Finishing Operations This Powder Booth meets or exceeds the requirements of the Occupational Safety and Health Administration OSHA MATERIAL SPECIFICATIONS The powder booth panels filter racks and product doors if required are constructed of 18 gauge steel conforming to ASTM A527 Lock Forming Quality and are hot dip galvanized per ASTM A525 with G90 coating structural st
7. PANEL W VFD DRIVE The following contains a description of the LPB RPB RPC and EZ Pass Thru Powder Booth Control Panel Control Panel NEMA 12 Enclosure w Definitions 1 Turn power on at Main Disconnect Blue power light will be illuminated 2 Turn Lights on using green light on button 3 Turn fan on using green fan on button 4 Turn Filter Pulse Control switch to on position This will pulse filter cartridges in a pre determined sequence 5 Check Magnehelic Gauge to assure booth is running within proper parameters Low end at 25 of water column high end not to exceed 3 5 water column If the reading exceeds 3 5 of water column adjust pulse timer down from a 2 minute interval to a 1 minute interval 6 Filter alarm light only indicates a pressure drop which indicates a filter missing or a hole in the cartridge filter 7 Adjust Variable Frequency Drive to assure a minimum of 100 FPM lineal face velocity in booth openings Control Panel NEMA 12 Enclosure Interior w Definitions Control Panel NEMA 12 Enclosure Interior w Definitions pu Lighting seg VF Star Control Panel NEMA 12 Enclosure Interior Showing Electrical Schematic and UL Sticker Electrical schematic shown inside the NEMA 12 door enclosure 2 UL Listed label shown inside the NEMA 12 door enclosure OPTIMIZING YOUR COLLECTOR S PERFORMANCE Outlined below are some basic collector operating parameters for pulse
8. PROCEDURE COL MET Spray Booths INSTALLATION GENERAL This manual is a guide for installing a variety of spray booths The assembly drawings enclosed are specific for the booth you have purchased This drawing is an exploded isometric drawing showing the relationship of each panel or part to the next one A packing list of all components is provided and must be used in addition to the drawing to identify all components All DAMAGES MUST be reported within 24 hours of receipt and a freight claim filed with the carrier PRELIMINARY COL MET booths are manufactured in accordance with NFPA 33 UFC 45 and NEC 516 However local codes and regulations may apply to the installation and use of this product All permits and approvals be obtained prior to installation and use of the spray booth 1 2 3 4 Uncrate and inventory all spray booth components to ensure all of the parts are accounted for Each component is numbered on the exploded view The floor surface of the booth must be non combustible material of such character as to facilitate the safe cleaning and removal of residues The floor surface must be flat and level Mark the dimensional outline of booth on floor Follow the step by step instructions provided PLANNING AHEAD Clearances between other work areas and combustible storage areas must be held as follows minimum clearance at all sides and sealed entry ways i e door ways e minimum clearance at
9. REMOVE FILTER FINAL FILTER UNLOCKED POSITION LOCKED POSITION www colmetsb com 888 452 6684 5 D SECTION IV GENERAL LIGHTING FIXTURE Prevent serious injury or death Electrical installations must be performed by qualified electricians Installation must conform to all national local and provincial codes and standards Place light fixture into booth panel center in opening and mark locations for mounting holes Install light fixture in panel from outside of booth as shown in drawing Caulk perimeter of light fixture lens frame with appropriate caulking The fixture is provided with an interlock switch that has a normally open contact which opens when the fixture lens is removed from fixture The switch is to be wired to disable spray equipment used in spray booth ALL COMPONENTS MUST BE ELECTRICALLY BONDED AND GROUNDED TO PREVENT STATIC DISCHARGE TEMP RATING 60 DEG C T 8 OR T 5 FLOURESANT LIGHT TUBE T 8 OR T 5 FLOURESANT LIGHT TUBE T 8 OR T 5 FLOURESANT LIGHT TUBE T 8 OR T 5 FLOURESANT LIGHT TUBE Blue 16 THHN Stranded Proximity Switch RED RED INTERLOCK SWITCH BE WIRED IN SUCH A WAY THAT IT DISABLES THE PAINT SPRAY EQUIPMENT WHEN THE LIGHT IS ACCESSED FROM IMPORTANT NORMALLY OPEN MAGNETIC SWITCHES ARE INTENDED TO BE USED TO ACTIVATE A RELAY WHICH DISABLES THE PAINT SPRAYING EQUI
10. Timer Controls 4 Cartridge Filters 5 Final Filters 6 Magnehelic Gauge IV General Lighting Components 1 Fluorescent Light Fixtures General Installation Procedures 1 Installation General 2 Installation Tools Needed 3 Planning Ahead 4 Light Installation 5 Three Stage Exhaust Filter Installation 6 Intake Filter Installation If Required 7 Fan Information TABLE OF CONTENTS Continued SECTION DESCRIPTION VI General Maintenance Procedures 1 General Instructions 2 Fans and Motors 3 Routine Fan Maintenance 4 Excessive Vibration 5 High Motor Temperature 6 High Bearing Temperature 7 Lubrication 8 Cautions 9 Environmental Limitations of Booth Components VII Warranty s VIII NFPA 33 2011 Edition Chapter 10 SECTION 1 GENERAL DESCRIPTION This Section contains literature which describes your Col Met Spray Booths powder spray booth in general terms Subsequent chapters of this manual provide more detailed descriptions of the individual booths and their operating components as well as maintenance procedures This description covers a family of Col Met Spray Booths powder booths The following booth types are covered herein e Industrial Spray to Waste Batch Powder Booths e PB Recovery Cartridge Style Powder Booths RPB e and EZ Pass Thru Powder Booths EPB The powder booth itself consists of four major components powder application area collection extraction chamber exhaus
11. Use adequate lifting devices to raise move and install booth components Prevent serious injury or death Electrical installations must be performed by qualified electricians Installation must conform to all national local and provincial codes and standards OPERATIONAL HAZARDS Prevent serious injury or death Do not operate machine with guards and or covers open or removed Prevent serious injury or death Only trained and qualified personnel may operate booth Prevent serious injury or death Never operate spray booth while under the influence of drugs alcohol or while feeling ill Prevent serious injury or death Always wear personal protective equipment PPE appropriate for job Read Material Safety Data Sheet for products used in spray booth www colmetsb com 888 452 6684 COL MET Spray Booths Shock hazard Only a qualified electrician may open electrical control cabinet Disconnect and lockout tagout all power sources before adjusting repairing or cleaning booth MAINTENANCE HAZARDS Fire HAZARD Prevent serious injury or death Disconnect and lockout tagout all power sources before adjusting repairing or cleaning booth Prevent serious injury or death Service maintenance and adjustments must be performed by trained and qualified personnel Burn hazard Do not touch hot parts Allow to cool before servicing Prevent serious injury or death Al
12. d entretien avant l installation ou l entretien de cet quipment This heater must be installed in accordance with the manufacturer s instructions and local codes In the absence of local codes follow the National Fuel Gas Code ANSI Z223 1 NFPA 54 of the CAN CSA B149 installation code Cet a rotherme doit tre install en accord avec les instructions du fabricant et les r gulations locaux S il n y a pas des r gulations locaux l installation doit tre en accord avec le Code National de Gaz de Carburant ANSI 2223 1 54 ou le Code d installation CAN CSA B149 P N 01010431 RevA To protect you and others against death or serious injury all applicable labels shown must be on the booth and must be legible If any of these labels are missing or cannot be read contact your Col Met for replacement labels www colmetsb com 888 452 6684 TABLE OF CONTENTS SECTION DESCRIPTION l General Description 1 Compliance to Applicable Codes 2 Proper Grounding Procedures I PB Spray to Waste Powder Booth 1 Exhaust Filters 2 Final Filters 3 Manometer 4 Air Solenoid Valve 5 Exhaust Fans 6 Powder Exhaust Filter Proving Assembly 7 Optional Control Panel lll Lab Powder Booth w roller caster base Batch Powder Booth w non rollaway collector module EZ Pass Thru Powder Booth w roll away collector module 1 Control Panel w variable frequency drive 2 Collector Pulse Valves 3 Collector
13. jet collectors using elements with Non Woven Spun Bond all finishes or Conventional Felted Media e Pressure 50 PSI 80 PSI e Frequency off time 20 seconds e Duration on time Maximum 200 milliseconds Reservoir Requires an unrestricted air supply at least the diameter of the blowpipes and needs to be big enough for valve s demand Ideal conditions will leave the reservoir at 85 of the operating PSI after firing Cleaning Air Needs to be clean and dry which could be accomplished with Pulse Frequency Pulse Sequence Hopper Changing Filters an air dryer In line traps separators can catch a lot of problems in the air supply prior to getting to the collector Frequency should be adjusted to balance the collector s delta P and should be monitored frequently during the first seven days after start up Pulsing frequency can never be any faster than the reservoir recovery to operating PSI Needs to be staggered to maximize the distance between the newly cleaned row and the next row to be pulsed Should not be used for storage Evacuation equipment rotary valves screw conveyors etc should be sized to unload hopper before accumulation occurs Units with slide gates should be left open and equipped with drum adapters To change your filters push the red handle and the filter will drop about an inch Install the new filter then pull the red handle and the filter will lift up into position Be careful not to crush
14. weigh 50 500 Ibs Use adequate lifting devices to raise move and install booth components NOTICE Prevent equipment damage Spray booth roof will not support a person Do not attempt to stand or walk on spray booth roof Refer to exploded view drawings included with your spray booth 1 Starting with exhaust chamber at either rear corner bolt one corner panel and one rear wall corner panel together Bolt opposite rear sidewall panel to rear wall panel Bolt all rear wall panels in place Bolt tie channel along top edge of rear wall panels Place exhaust fan panel above side and rear wall panels and bolt in place Insert filter filler panels between sidewall roof panels and exhaust chamber Bolt in place Oa E CHAMBER SIDE PANEL FILTER FILLER PANEL BOOTH SIDE PANEL 7 Following exploded view drawings continue alternately assembling wall panels and roof panels to each other until you reach front end of booth Finish off roof section by attaching fire curtain if needed If booth has front doors no fire curtain is needed 8 Verify walls are plumb and booth is square and on floor layout marks Tighten all mounting hardware 9 Anchor floor channel to floor at a minimum of every 12 inches 10 Caulk all panel joints inside the booth with the caulk provided Do not use a silicone caulk www colmetsb com 888 452 6684 COL MET Spray Booths 11 If booth is supplied with a personnel door or
15. ASTE BATCH POWDER BOOTH This Section contains information pertaining to the installation and operation of the PB Spray to Waste Batch Powder Booth Ulf NV eS SS RET emm Se EN TRIN Dat in PB Spray to Waste Batch Powder Booth 1 This section contains information regarding the installation and operation of Three Stage Filtration System Pre Filter Primary Pocket Filters and Final Filters Manometer Air Solenoid Valve Exhaust Fan s Powder Exhaust Filter Proving Assembly Optional Control Panel THREE STAGE EXHAUST FILTER SYSTEM PB Spray To Waste Powder Booth Three Stage Filter Arrangement ird Stage HEPA Style inal Filters Second Stage Pocket Filters EXHAUST FILTER MANOMETER This section contains literature pertaining to the installation operation and maintenance of the above component Your Col Met Spray Booths Inc industrial powder booth is provided with an exhaust filter manometer This device is used to measure the pressure drop across the three 3 stage exhaust filters as an indication of the condition of the three 3 stage filter system Product Specification Dwyer Mark II model No 25 inclined vertical manometer Manometer Installation amp Set Up Guide The manometer is used as a gauge to let you know when your exhaust filters need to be changed Exhaust filters typically have a static rating of 5 inches of water Some booths are set up to use additiona
16. An access door on the belt tube is standard Propeller Die cast aluminum construction Unique BackSwept profile with airfoil cross section e Adjustable pitch blades with factory set blade angles Uses split taper lock bushing for superior holding power on shaft Generates low wake turbulence for low noise emis sion 6 Bladed BSA Propeller 2009 Aerovent Bulletin illustrations cover the general appearance of products at the time of publication and we reserve the right to make changes in design and construction at any time without notice Aerovent Bulletin 159 Dimensional Data BELT GUARD E B F HOLES ONLY SIZE 12 HOLES ARE 7 50 STRADDLING CENTER LINE A ID 1 0 DIA B C C DIA O D Dimensions shown are in inches unless otherwise indicated R33867 Dimensions are not to be used for construction Typical Specifications Model BTABD Arrangement 9 Belt Driven Fans where indicated on drawings and schedules shall be Model BTABD Arrangement 9 V belt driven axial flow type as manufactured by Aerovent Minneapolis Minnesota and shall be of the size and capacity as indicated in the fan schedules Model BTABD fans have been tested in an AMCA registered laboratory in accordance with AMCA 210 and AMCA 300 test codes for both air and sound
17. COL MET SI Es POWDER BOOTH INSTALLATION MANUAL CARTRIDGE COLLECTOR COL MET Spray Booths SAFETY SAFETY ALERT SvmBoL AND SIGNAL Worps Before assembling operating or servicing the sprav booth vou must read understand and follow the instructions and safety warnings in this manual Your spray booth may not be equipped with some of the optional equipment described in this manual NEVER ALLOW ANYONE TO OPERATE THIS EQUIPMENT WITHOUT PROPER TRAINING The safety information in this manual is denoted by the safety alert symbol A The level of risk is indicated by the following signal words DANGER DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE NOTICE Indicates a situation that could result in damage to the equipment or other property ASSEMBLY HAZARDS Prevent serious injury or death Overriding a safety system may result in unsafe equipment which may result in serious injury or death Do not override safety devices Blade hazard Keep hands clear of rotating parts Follow lockout procedure before servicing www colmetsb com 888 452 6684 COL MET Spray Booths Prevent serious injury or death
18. In addition each unit shall be factory run tested and final trim balanced prior to shipment CONSTRUCTION Fan casings shall be welded of ASTM A 1011 low carbon commercial quality 12 gauge hot roled steel in sizes through 20 diameter 10 gauge hot rolled steel from 24 diameter through 28 diameter and 7 gauge hot rolled steel on sizes greater than 30 in diameter Inlet and outlet flanges shall be integrally rolled mechanically from fan casing sheet steel to insure concentricity and alignment Accuracy and uniformity of the fan casing shall be insured through the use of welding jigs and fixtures The motor base plate shall be fabricated of minimum s steel plate and welded to the exterior of the fan casing PROPELLERS Propellers shall be constructed of non sparking die cast aluminum hubs and blades Fan blade pitch angle shall be preset at the factory Propellers shall be secured to the fan shaft with a taper lock bushing SHAFT amp BEARINGS All fans shall be supplied with a shaft of AISI C 1045 steel material that has been properly turned ground and polished for accuracy The shaft shall be supported by a matched set of non relubricable bearings that are housed in a cast aluminum monoblock All fan bearings are to have an L 10 minimum life as defined by AFBMA of at least 60 000 hours DRIVES Fan drives shall include cast iron sheaves and non static conducting belts Fans equipped with motors up to and including five horsepowe
19. PMENT DUE TO THE LOW ELECTRICAL CAPACITY OF THE SWITCH SOLID STATE RELAYS ARE RECOMMENDED IT IS BEST TO USE A SEPARATE POWER SUPPLY FOR RELAY OPERATION OTHER THAN LIGHTING POWER SUPPLY THE MAGNETIC SWITCH IS RATED 10 WATTS AT A MAXIMUM OF 300 VOLTS AND A CARRYING CURRENT OF 1 5 AMPS THE MAGNETIC SWITCH IS NOT DESIGNED FOR DIRECT CONNECTION TO LIGHTING POWER SUPPLY OR TO CONTROL LIGHT FIXTURE INSIDE THE PAINT SPRAY B WIRING SCHEMATIC 168 COL MET Spray Booths 5012 BALLAST SEED SWITCH 1 8 DOTH CONDUIT HUB 18 5 16 UNC 18 HEAD BDLT LENSE ASSEMBLY 5 16 UNC 18 HEX FLANGE NUT PAINT SPRAY BOOTH WALL PANEL FIXTURE ENCLOSURE LENS FRAME GLASS AND GASKET LENS FRAME FIXTURE FASTNER FASTNER CAULK SEAM BOOTH WALL PANEL MOUNTING DETAIL CAUTION WHEN TIGHTENING LENS FRAME FASTENERS TIGHTEN USING HAND OLS ONLY TIGHTEN UNTIL SIDES OF META ENS FRAME MAKES CONTACT WITH FIXTURE ENCLOSURE OVER TIGHTENING WILL CAUSE LENS FRAME TO WARP AND WILL BREAK DOWN VAPUR SEAL DF LENS www colmetsb com 888 452 6684 SECTION V GENERAL INSTALLATIONS
20. all non sealed entry ways i e the open face of spray booth or a silhouette openings 10 ft minimum clearance must be held between the exhaust stack of the booth and the intake of another apparatus NFPA 33 dictates a minimum discharge clearance of 3 ft from the nearest combustible material however stack height requirements vary with individual states and can be up to 175 times the building s roof height from grade e 10 ft minimum clearance must be held between the intake of this booth and the exhaust of any other apparatus Permits are not included It is the responsibility of the end user to acquire all permits to install a booth A FIRE SUPRESSION SYSTEM IS NOT INCLUDED WITH THE BOOTH BUT IT IS REQUIRED Generally this is supplied and installed by a licensed local installer Electrical installation must be performed by a licensed electrician familiar with national local electrical codes and regulations in your location www colmetsb com 888 452 6684 COL MET Spray Booths BoorH AssEMBLY When assembling booth leave bolts finger tight until each section is assembled All flanges should face outward Install bolts from inside so nut is outside booth Use a drift pin to align panel holes when two or more panels are difficult to align by hand Lay out all floor channel for exhaust chamber and walls As you attach wall panels together they will also bolt to the floor channel Prevent serious injury or death Most booth components
21. ay to equal 0 then press the Select button and the Down Time Cycles LED will light up 9 Use the Up or Down button to adjust the number on the display to equal 0 then press the Select button The Process LED should light up and it will immediately start pulsing the valves to the new settings you have entered Use the following guide to change the speed of your fan Note The maximum speed setting is based on the CFM rating of your collector Some collectors will only accept a maximum setting of F43 00 while other collectors will accept up to F54 00 or even F60 00 If you try to set a speed higher than what the collector is capable of the drive will simply flash several times and then go back to the previous setting Setting the collector too high can cause the powder to be pulled away from the parts which will waste powder Your powder supplier can help you decide on an optimal speed to run the fan so that you get sufficient air flow in the booth but no so much that it s pulling the powder away from the parts 1 Push the Fans Start Button on the control panel The fan should start spinning 2 Press the Enter button on the Yaskawa V1000 mounted next to the control panel The first digit on the display should be flashing 3 Use the or V arrows to change the digit higher or lower Use the Reset button to move over one space to change the second digit Once you get to the speed you want press the Enter button an
22. ble charge which will include the costs of labor materials and transportation RETURNING ITEMS For CREDIT Col Met Spray Booths will take back any standard stocked items returned and issue a credit less a 15 handling and restocking fee Customer is responsible for all Freight Charges and the item MUST be returned in its original condition If the item is damaged in transit you will not receive credit Col Met will mark the Bill of Lading Damaged and send you pictures of the damaged item For custom or non stock special order items you must contact our Customer Service Department to determine is the item may be returned Any restocking charges shall be determined on a case by case basis www colmetsb com 888 452 6684 COL MET Spray Booths If an item needs to be returned Col Met will issue you an RGA Return Goods Authorization form Please ensure that a copy is sent back with returned item s Without an RGA the product may be lost or returned to stock with no credit issued Please note that in some cases the freight may be more than the item is worth when credit is received Back CHARGES For MATERIAL AND LABOR Col Met Spray Booths shall not be held responsible for any Back Charges incurred for materials or labor without prior written consent Should a problem arise please notify Col Met immediately Once the issue is investigated should costs be incurred an amount shall be agreed on by both parties before hand Do NOT attempt modifi
23. cations or repairs without prior consent as this may void further warranty repairs or credit Col Met will not accept back charges associated with late delivery Please address warranty repairs to Col Met Spray Booths 1635 Innovation Drive Rockwall TX 75032 Attention Customer Service For all electrical and gas control service issues please direct to Col Met Spray Booths 1635 Innovation Drive Rockwall TX 75032 Attention Controls Engineering Manager www colmetsb com 888 452 6684 SECTION VIII NFPA 33 CHAPTER 10 2011 EDITION OPERATIONS AND MAINTENANCE COL MET Spray Booths NEPA 33 Reprinted with permission from NFPA 33 2011 Standard for Spray Application Using Flammable or Combustible Materials Copyright 2010 National Fire Protection Association Quincy MA This reprinted material is not the complete and official position of the NFPA on the referenced subject which is represented only by the standard in its entirety The following is section 10 from NFPA 33 10 1 General Maintenance procedures shall be established to ensure that all spray application apparatus and processes are operated and maintained in accordance with the manufacturers specifications and the requirements of this standard Maintenance shall be the responsibility of the users of the apparatus and processes 10 1 1 Spray application operations shall not be conducted outside predetermined spray areas 10 1 2 Inspection of extinguishing systems
24. d the display will flash End and the fan will change speed Press the ESC button to make the drive stop flashing Note The maximum speed varies depending on the CFM rating of your collector If you select a speed that is too high the display will simply flash and will not accept your speed setting Try a lower speed These are general operating parameters These recommendations are good starting points but every collector and application has unique operating conditions Understanding The Pulse Down System 60 to 80 PSI compressed air is plumbed into the manifold on the collector Compressed air feeds from the manifold to each pulse valve Compressed air feeds from the pilot port on each pulse valve to the solenoid enclosure The pulse valve acts like a high volume switch for compressed air Compressed air is fed into the inlet of the valve and some of the air bleeds off through the pilot port on the top where it feeds over to the solenoid enclosure The solenoid enclosure is where the air stops which is what keeps the pulse valve closed As long as air is not allowed to continuously bleed out of the pilot port on top then the pulse valve will remain closed When air is allowed to bleed out of the pilot port on top then the pulse valve will open until the pilot port is blocked off and pressure is allowed to rebuild High Volume Compressed Air Inlet Some of the compressed air bleeds out of the pilot port to t
25. eel conforms to ASTM A36 SAFETY Local fire codes prohibit smoking in the vicinity of powder coating operations Consult your local fire marshal for posting of No Smoking signs Improperly maintained equipment could cause sparks which could ignite the powder cloud FOR YOUR SAFETY Beware of poor electrical wiring that could cause sparks DO NOT store flammable liquids adjacent to or inside the powder booth Read all refinishing product labels and instructions FIRE PROTECTION An approved fire detection suppression system must be installed on the powder coating booth to comply with NFPA 33 Section 9 and all applicable state and local others PROPER GROUNDING The powder booth must be properly grounded to a positive earth ground Powder booth installation should include 5 8 diameter rod by 8 0 in length driven into the ground leaving 8 of protruding above the floor see picture The booth and all booth components MUST be grounded to this rod including all powder application equipment PROPER BOOTH GROUNDING e 5 8 diameter x 8 0 long copper rod e Grounding rod installed through hole in the floor leaving at least 8 of rod above floor as close to booth as installation will allow e Booth parts hangers application equipment must be grounded to this rod Failure to properly ground all booth components could possibly cause static discharge which could result in a fire SECTION II SPRAY to W
26. es filter loading in the powder booth requiring that the filters be monitored An automated signal will alert the operator while shutting down powder spray operations in the event of filter failure This is an NFPA 33 Code 15 8 2 Powder Exhaust Filter Proving Assembly FILTER ALARM 9 sre Powder Exhaust Filter Proving Assembly Open OPTIONAL POWDER BOOTH CONTROL PANEL Your Col Met Spray Booths powder booth may be equipped with an optional pre wired electrical control panel Refer to the electrical control drawings for the electrical schematic and component Bill of Material Also shown on this drawing is the wiring required at the time of installation No spare parts are provided with this control panel This panel and its associated wiring must be installed under the supervision of a licensed electrician The cabinet that houses the controls is either NEMA 1 or NEMA 12 rated It is not suitable for Class I Division II area Refer to Chapter 6 in the NFPA 33 Standard and consult with the local authority having jurisdiction for the definition of this area for your powder booth COL MET SDS 2 DO CII SECTION CARTRIDGE POWDER BOOTHS POWDER BOOTH WITH COLLECTOR MODULE CARTRIDGE COLLECTOR GENERAL COL MET POWDER BOOTH PICTURES EZ Pass Thru Powder Booth RPC Collector Showing Final Filters and Control Panel CONTROL
27. f an alleged defect and refraining from the attempted repair of alleged defects without prior written consent of Seller The Seller makes no warranty whatsoever with respect to accessories or components not supplied by Seller For any components purchased by Seller for use on or in conjunction with the equipment which is the subject of this contract the Seller extends to the Buyer only the same warranty granted to Seller by the component vendor or manufacturer THIS LIMITED WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR PARTICULAR PURPOSE AND OF ANY NON CONTRACTUAL LIABILITIES INCLUDING PRODUCT LIABILITIES BASED ON NEGLIGENCE OR STRICT LIABILITY EVERY FORM OF LIABILITY FOR DIRECT SPECIAL OR CONSEQUENTIAL DAMAGES OR LOSS IS EXPRESSLY EXCLUDED AND DENIED IN NO CASE SHALL COL MET SPRAY BOOTHS LIABILITY ON THIS WARRANTY EXCEED THE AMOUNT OF THE PURCHASE PRICE The performance and safety of the equipment mentioned herein is contingent upon proper installation the use of suitable process materials and operation and maintenance by properly trained personnel During the warranty period Col Met Spray Booths will repair or replace free of charge any parts that Col Met Spray Booths has verified to be defective in materials or workmanship If inspection of the equipment does not disclose any defect in workmanship of material repairs will be made at a reasona
28. front filter doors apply foam gasket to perimeter of all door openings Attach door hardware and adjust latches Level door with doors off then attach doors to hinges DOOR STOP HOLO DOWN STRIP FOAM TAPE DOOR SWEEP i DOOR CHANNEL END VIEW HOLE FOR ANCHOR BOLT DOOR SWEEP a HOLD DOWN STRIP dd n Ed DOOR LATCH DOOR SWEEP HOLD DOWN DOOR DOON SWEER PRODUCT DOOR DOOR SWEEP DETAIL DOOR LATCH DOOR FRAME AND SEAL DETAIL BASE DETAIL www colmetsb com 888 452 6684 COL MET Spray Booths MOTOR INSTALLATION Couplings drive belts chains or other mounted devices must be in proper alignment balanced and secure for safe motor operation MOUNTING This motor must be securelv mounted Sufficient ventilation must be provided to insure proper operation INSTALL SHEAVES AND FAN BELTS 1 The fan sheave A and motor sheave B must be in axial alignment Shafts must be parallel in both vertical A and horizontal planes EN 2 The sheaves must be in radial alignment When LE sheaves are of equal width align with a straightedge C When sheaves are of unequal width align center of sheaves C 3 Check fan belts for proper tension and for signs of wear Belt should have a slight sag at bottom of sheaves Belt D is properly adjusted Belt E is too B loose Belt F is too tight aoe gm
29. he solenoid enclosure Compressed air is vented out of this port only when the solenoid is open Power Inlet Compressed Air inlet Compressed Air Outlet The solenoid enclosure has 1 solenoid for each of the pulse valves to be operated Each solenoid acts like an electrical switch for compressed air The solenoid is closed when it does not have power applied to it meaning that no compressed air is allowed to pass though until power is applied to the electrical coil of the solenoid As long as the solenoid stays closed the system remains pressurized which keeps each pulse valve closed When power is applied to the coil of the solenoid a small amount of compressed air is allowed to pass through This small amount of air is all that is needed for the pulse valve to open and allow a larger amount of compressed air to fire down into the cartridge filter As long as the solenoid stays on allowing air to escape the pulse valve will continue to fire air into the cartridge filter DWYER INSTRUMENTS gt MICHIGAN CITY IN STATUS HicH umr RUN amp LOW iD Aes ALARM HIGH ALARM RESET LOW ALARM CYCLE DE MANUAL OVERRIDE DOWN TIME CYCLES Mif AUTO ALARM RESET INDUSTRIAL CONTROL EQUIPMENT LON USTED 5288 mns INSTRUMENTS me CIGAN CITY IN 46360 MODEL DCT1022 INPUT RATING 108 TO 240 1 MAX LOND AMBIEN dic TMS UNIT MUST BE ENCLOSED USE MEC
30. interrupteur de verrouillage peut tre requis pour d brancher le courant lectrique de cet appareil L appareil doit tre connect une source de courant reli e la terre Le non respect de ces instructions peut entrainer de la mort ou des chocs lectriques Imprim aux U A DANGER Severe Injury Hazard Do not enter equipment while in operation Equipment may start automatically Do not operate with door open Installation operation and service must be done by a trained technician only Failure to follow these instructions can result in death or injury Printed in USA A DANGER Risque de Blessures Graves Ne pas entrer dans cet appareil pendant l op ration Cet apparell peut d marrer automatiquement tout moment Ne pas op rer l apparell avec la porte ouverte L installation l op ration et l entretien doit tre effectu s par un installateur prouv Le non respect de ces instructions peut entrainer de la mort ou des blessures Imprim aux U A WARNING Improper installation adjustment alleration service or maintenance can result in death injury or property damage Read the Installation Operation and Service Manual thoroughly before installing or servicing this equipment Installation modification reglage ou maintenance incorrectes peuvent provoquer de la mort des blessures ou des d g ts mat riels Liser attentivement le manuel d installation d operations et
31. l filters or optional filters that have a higher static rating than the standard 5 inches of water Check your filter spec sheet to find the exact rating of the filter but for this guide we will use the standard 5 inches of water column Step 1 Locate the Manometer The manometer needs to be located where it can be read daily by the paint department Locate it on the booth where there are no obstructions such as shelving or walls to interfere with viewing the manometer Remember without the manometer you will have no idea how clogged your exhaust filters are and therefore no idea if the booth is performing correctly The manometer needs to be installed close to the exhaust filter wall to keep the tubing length to a minimum Excess tubing length will reduce the accuracy of the manometer There will be a high port and a low port on the top of the manometer The high port will need to connect to the work chamber and the low port will need to connect to the chamber on the suction side of the filter grid Low Pressure Port Filter Grid Wall High Pressure Port Back Side of Filters Front Side of Filters Step 2 Install the Hose Barbs Drill a hole in the booth wall just large enough for the plastic hose barb to fit through approx 13 32 Then install the washer and nut on the back side Be careful not to over tighten or you may strip the plastic threads Inside Wall of Booth Washer and Nut Plastic Hose Barb Step 3 Mo
32. lenoid valve for the purpose of insuring that pressurized air is only available to the powder application equipment if the powder booth is operating properly The function of this valve is to interrupt the supply of compressed air to the powder application equipment under certain conditions This is done to prevent powder coating from occurring when the powder booth is not operating as designed or if any booth doors are open if equipped The air solenoid valve is electrically interlocked with the powder booth exhaust fan s If the optional switches are purchased it is also interlocked with the product and personnel doors if equipped If the fan is not operating or if a door if equipped is open for longer than a few seconds the air solenoid valve will shut off the flow of pressurized air to the powder application equipment The unit should be installed down stream of any regulators and filters and upstream of the powder application equipment It should be located as close as possible to the fitting to which the powder application equipment connects in order to insure rapid loss of supply pressure COL MET Spray Booths SOLENOID WiRING DIAGRAM L1 of Customer provided 3 Phase power L2 of Customer provided 3 Phase power L3 of Customer provided 3 Phase power 120VAC Hot Wire provided by customer 120VAC Neutral Wire pr
33. losure There should be air pressure feeding though the white tubes into each solenoid When the solenoid is energized by the Dwyer timer board the air pressure is allowed to pass though the solenoid which allows the main pulse down valve to fire air into the filter If some of the filter pulse but some do not pulse then there could be a problem with the solenoid associated with the pulse valve that s not pulsing It could be clogged or it may have failed 120vac must be present here for the solenoid to open and allow the pulse valve to fire Check for loose wiring or any discoloring of the solenoid which could indicate it has failed To test the solenoid to see if it is bad first turn off the power to the main control panel Disconnect the wires leading to the suspect solenoid and use a volt meter set on Ohms to measure between the two terminals on the solenoid If the volt meter does not show a reading at all then the coil is open meaning the solenoid will need to be replaced If the volt meter does show a reading then the coil is ok and the problem is somewhere else possibly a loose wire between the solenoid and the Dwyer timer board Place volt meter probes between these two terminals Check the white tubing between the pilot port on the pulse valve and the solenoid Sometimes these tubes can come loose during shipping or over time develop a leak which allows the compressed air to escape the system If the air is leaking out of the
34. lters shall be discarded and replaced 10 4 2 At the close of the day s operation all discarded overspray collector filters residue scrapings and debris contaminated with residue shall be removed immediately to a designated storage location placed in a noncombustible container with a tight fitting lid or placed in a water filled metal container 10 5 Waste Containers 10 5 1 Approved waste containers shall be provided wherever rags or waste are impregnated with sprayed material and all such rags or waste shall be deposited therein immediately after use The contents of waste containers shall be placed in a designated storage location 10 5 2 Waste containers containing flammable liquids shall be located in ventilated areas that meet the requirements of Chapter 7 Such areas shall also meellhe electrical area c1assificalion requirements of 6 5 5 www colmetsb com 888 452 6684 COL MET Spray Booths 10 5 3 Waste containers for flammable liquids shall be constructed of conductive materials and shall be bonded and grounded 10 5 4 Waste containers for flammable liquids shall be handled and stored in accordance with Chapter 8 10 6 Clothing Employees clothing contaminated with sprayed material shall not be left on the premises overnight unless kept in metal lockers 10 7 Cleaning Operations 10 7 1 Scope This section shall apply to the use of flammable or combustible liquids for the flushing and cleaning of equipment 10 7 2 Liquid
35. material 10 10 Chlorinated Solvents Coating materials containing chlorinated solvents shall not be used with spray application apparatus or fluid handling equipment if the chlorinated solvent will come into contact with aluminum within a piping system pump enclosed container or any enclosure that is capable of being pressurized by the potential reaction This shall apply even if the container or system has been constructed with pressure relief devices 10 11 Smoking Signs stating NO SMOKING OR OPEN FLAMES in large letters on contrasting color background shall be conspicuously posted at all spray areas and paint storage rooms 10 12 Hot Work Welding cutting and other spark producing operations shall not be permitted in or adjacent to spray areas until a written permit authorizing such work has been issued The permit shall be issued by a person in authority following his or her inspection of the area to ensure that precautions have been taken and will be followed until the job is completed www colmetsb com 888 452 6684
36. move up the scale and then settle at a number The number will be different from booth to booth but that does not matter this is just a baseline setting Wherever the red fluid stops is where you will place your Green arrow In this example the red fluid stopped at 25 inches of water column So because we know our filters are rated for 5 inches of water column and we know that with clean filters the fan is drawing 25 inches of water column we simply add the two numbers together to tell us where the filters will pack out 25 inches of water 5 inches of water 75 inches of water total Step 6 Set your Change Filter arrow Now that the baseline is set measure up the scale 5 inches of water to allow for your filters to pack out and that is where you will place the Red arrow Starting Pressure End Pressure Fan On With Clean Filters Change Filters At this point your manometer is set up and ready to use You should never need to move the arrows once they are placed Always check the manometer before turning the fan on to ensure the red fluid is sitting on the O mark If the fluid is not on O simply turn the Zero Set knob to adjust the fluid to zero before starting the fan AIR SOLENOID VALVE This section contains literature pertaining to the installation operation and maintenance of the above component As a built in safety feature your Col Met Spray Booths powder booth is provided with a two way so
37. ncluded with this manual High Motor Temperature Check to make sure that the cooling air to the motor has not been blocked or diverted by dirty guards or similar obstacles Check the input power for high amperage or excessive amperage draws An increase in power requirements may indicate that some major changes in the powder system may have occurred High Bearing Temperatures This condition 15 usually caused by improper lubrication either over or under In every case if the cause of the trouble is not easily determined only experienced personnel should examine the equipment before it put back into service Lubrication The manufacture of fans and motors used in the powder booth applications may be different based on the type of powder booth purchased Due to this variance in these fans or motors refer to the manufactures literature and instruction for instruction in proper lubrication intervals and procedures Caution Lubricate fans and motors only when they are at a standstill Use only clean grease Remove and replace drain plugs only when the motors are at a standstill DO NOT mix different types of grease ENVIROMENTAL LIMITATIONS OF POWDER BOOTH COMPONENTS Tubeaxial Fans Maximum Air Temperature 200 Maximum Air Temperature 20 F Air Solenoid Valve Maximum Air Temperature 150 F Maximum air temperature 32 F Control Panel NEMA 12 Ballast Minimum Air Temperature 50
38. ovided by customer Ground Wire provided by customer Control Panel Booth Door 4o 93 me 46 Limit Switch 1 Booth Door Booth Limit switch 14 Exhaust 2 sg wx L 8 a 2 TE sslis gt gt gt gt 412 Booth Booth Booth Light Light Light Fixture Fixture Fixture 3 4 5 l l l MG S Paint Compressor Gun www colmetsb com 888 452 6684 EXHAUST FANS This section contains literature pertaining to the installation operation and maintenance of the above component Your Col Met Spray Booths powder booth is equipped with a Aerovent tubeaxial fan for exhausting air from the powder booth This type of fan was designed specifically for use in applications such as powder booths where the fan drive motor must be located out of the air stream The fan blades are constructed of non sparking aluminum for added safety The fan and drive motor have been sized for the specific air flow of your booth in accordance with all applicable environmental and safety requirements Belt Driven Tubeaxial Fans The Aerovent model BTABD is a belt driven tubeaxial fan that is designed specifically for reliable and cost effective air movement in paint spray booth applica Model BTABD tions Model BTABD exhaust fans are designed for ede applications requiring either a horizontal or a ver
39. r will be furnished with a variable pitch type drive sheave to allow for minor speed adjustment of the fan propeller during system balance Fans equipped with larger motors will be furnished with a fixed drive sheave A belt guard is to be provided to afford personnel safety and general traffic protection MOTORS Fan motors shall be manufactured in accordance with current applicable standards of IEEE and NEMA They shall be foot mounted NEMA standard TEFC or ODP continuous duty ball bearing with class insulation BALANCING The propeller assembly shall be statically and dynamically balanced in accordance with ANSI AMCA 204 05 Balance Quality and Vibration Levels for Fans to Fan Application Category BV 3 Balance Quality Grade G6 3 In addition belt driven fan propellers shall be balanced on the fan shaft after final assembly in the fan casing in the manufacturing facility to the following peak velocity values filter in at the fan test speed Fan Application Category Rigidly Mounted In Sec Flexibly Mounted In Sec BV 3 0 15 0 20 Final test room vibration levels in the axial vertical and horizontal planes shall be recorded and a written copy shall be available upon request FINISH The fan housing after fabrication shall be cleaned and chemically pretreated by a phosphatizing process and shall be painted inside and out with two coats of air dry enamel POWDER EXHAUST FILTER PROVING ASSEMBLY This assembly address
40. s Class and Class II liquids used in cleaning operations shall be in original shipping containers or in listed safety containers 10 7 3 Location Cleaning operations using flammable or combustible liquids shall be conducted inside a spray area with ventilating equipment operating or in ventilated areas that meet the requirements of Chapter 7 Such areas shall also meet the electrical area classification requirements of 6 5 5 10 7 4 Equipment Equipment using flammable or combustible liquids shall meet the requirements of 6 5 5 and shall be bonded and grounded 10 7 5 Manual Cleaning Individual manual cleaning operations shall be limited to not more than 4 L 1 gal of flammable or combustible liquid for each cleaning operator 10 7 6 Liquid Storage Flammable and combustible liquids shall be handled and stored in accordance with Chapter 8 Containers used for handling storage or recovery of Class liquids shall be constructed of conductive materials and shall be bonded and grounded 10 8 Solvent Distillation Units Solvent Recyclers 10 8 1 Scope 10 8 1 1 Section 10 8 shall apply to solvent distillation units having distillation chambers or still pots that do not exceed 230 L 60 gal capacity and are used to recycle Class Class II and Class IIIA liquids 30 7 11 1 1 10 8 1 2 This section shall not apply to research testing or experimental processes to distillation processes carried out in petroleum refineries chemical plant
41. s or distilleries or to distillation equipment used in dry cleaning operations 30 7 11 1 2 10 8 2 Equipment Solvent distillation units shall be approved or shall be listed in accordance with ANSI UL 2208 Standard for Solvent Distillation Units 30 7 11 2 10 8 3 Solvents Solvent distillation units shall only be used to distill liquids for which they have been investigated and which are indicated on the unit s marking 01 instruction manual Unstable 01 reactive liquids or materials shall not be processed unless they have been specifically indicated on the system s markings or in the instruction manual 30 7 11 3 10 8 4 Location Solvent distillation units shall only be used in locations in accordance with their approval or listing They shall not be used in basements They shall be located away from potential sources of ignition as indicated on the unit s marking 30 7 11 4 10 8 5 Liquid Storage Distilled liquids and liquids awaiting distillation shall be stored in accordance with Chapter 6 of NFPA 30 Flammable and Combustible Liquids Code www colmetsb com 888 452 6684 COL MET Spray Booths 10 9 Spontaneous Ignition Hazards The same spray booth shall not be alternately used for different types of coating materials if the combination of the materials is conducive to spontaneous ignition unless all deposits of the first used coating material are removed from the booth and exhaust ducts prior to spraying with the second coating
42. s repeats until the last output is reached and then starts back at the beginning Troubleshooting Pulse Problems Check the incoming air pressure to the manifold The system requires air pressure at all times to pulse The air pressure should be between 60 and 80 PSI If the pressure is too low all of the valves may release air at the same time Air inlet Install plug at opposite side of manifold Air Manifold Check the Dwyer timer board Ensure there is 120VAC at terminals L1 and L2 at the bottom of the board There should be a solid red LED on the left side of the board and a flashing red LED on the right side of the board The red LED above each number at the bottom of the board should start flashing one at a time every 60 to 120 seconds as soon as the board is powered up This flash indicates that the board is outputting 120VAC at that terminal which feeds the solenoid enclosure located at the High Limit and Com should top of the collector be connected together Comm e n om be As soon as power is applied to the board on terminal Power On Indicator Should 11 amp L2 illuminate Red as soon as power is applied to the board on terminal L1 amp L2 120VAC to power the board LED above each number will flash in sequence once every 60 to 120 seconds or however long the Time Off has been set during programming When this LED flashes you should also hear the pulse air fire into the filter Check the solenoid enc
43. shall be conducted to ensure thatthe performance of the extinguishing system components will not be affected by overspray and residues 10 2 Combustible Deposits 10 2 1 All spray areas shall be kept free of excessive accumulation of deposits of combustible residues 10 2 2 Combustible coverings thin paper plastic and strippable coatings shall be permitted to be used to facilitate cleaning operations in spray areas 10 2 2 1 Where plastic covering is used it shall be of a static dissipative nature or shall have a maximum breakdown voltage of 4 kV to prevent accumulation of a hazardous static electric charge 10 2 3 If residue accumulates to excess in booths duct or duct discharge points or other spray areas all spraying operations shall be discontinued until conditions have been corrected 10 3 High Pressure Hose Lines High pressure hose lines that convey flammable or combustible coating material in airless spray application operations shall be inspected frequently and shall be repaired or replaced as necessary Hose lines and equipment shall be located so that in the event of a leak or rupture coating material will not be discharged into any space having a source of ignition 10 4 Maintenance Procedures 10 4 1 Maintenance procedures shall be established to ensure that overspray collector filters are replaced before excessive restriction to airflow occurs Overspray collectors shall be inspected after each period of use and clogged fi
44. standards The fan and motor assembly will bolt to exhaust roof panel CHECKLIST Check the following items prior to start up Motors wired for proper voltage All fans and motors turn freely Lubricate all bearings Check installation of exhaust fan for proper airflow direction Generally airflow is out of booth Listen for excessive or unusual noise when booth is operating With booth operating open any door for 30 seconds and see if spray gun will shut down This will verify proper safety operation of the booth DOF PO ASSEMBLY HAZARDS www colmetsb com 888 452 6684 SECTION VI GENERAL MAINTENANCE PROCEDURES This Section contains booth maintenance procedures and techniques which will extend the life of your Col Met Spray Booths powder booth and its components and make booth operation a smooth routine occurrence General Instructions Operational maintenance and repair instructions for the various mechanical components of your Col Met Spray Booths powder booth are described in the manufactures data incorporated in this manual Please review the applicable safety precautions before performing any maintenance work on the booth s components SAFETY FIRST Fan and Motor Periodically check the fan belts for proper tension and signs of wear If equipped normally on PB Style Booth only If the booth fails to function properly during normal operation or if a component fails to come on line during booth s
45. t fan and chamber and in some cases product doors A brief description is provided for these and other related items The parts to be powder coated are placed in the powder application area through the booth opening or product doors if so equipped Air flows through the booth opening s to the exhaust filters Exhaust filters will vary based on the style of booth purchased The booth exhaust is routed the exhaust plenum s at the exit of the booth The exhaust fan then routes the exhaust out through the Final Filters and discharges clean contaminate free air back into the powder coating room Exhaust Fan and Chambers The Spray to Waste Industrial Batch Powder exhaust chamber is located as shown in the mechanical drawing package which is included in this manual Powder laden air is drawn through a three stage filtration system pre filter primary filter and final filter by a tube axial fan which is powered by an ODP motor Filters clean the air of powder allowing it to return into the plant environment The fan is made of spark resistant material and the motor is located out of the air stream The exhaust chamber s operate s under a negative pressure to induce the required airflow through the exhaust filters The Recovery Powder Booth exhaust is located as shown in the mechanical drawing package which is included with this manual Powder laden air is drawn through a two stage filtration system primary cartridge filter and final HEPA filter
46. tart up then troubleshooting will be required to identify the problem It is necessary for the person troubleshooting the booth be familiar with the control system logic A good preventative maintenance program will keep your booth on line and reduce unnecessary downtime The manufactures data sheets included in this manual contain specific information regarding repair of their components Routine Fan Maintenance Do not attempt to do any maintenance on a fan unless the electrical supply is properly disconnected If the powder booth is not supplied with a control panel with a disconnect then it will be necessary to pull the fuses at the control panel and lock control panel to assure power can not be turned on during maintenance or repairs Under normal circumstances handling clean air the system will require cleaning about once a year However the fan and all components should be checked in regular maintenance intervals as required by usage A regular inspection of the rotating assembly should be made to detect any indication of weakening of the fan and motor because of corrosion erosion or metal fatigue Excessive Fan Vibration Check for material buildup on the fan wheel and clean as necessary Check for bent broken or cracked fan blades which may cause fan imbalance Never allow a fan to operate 1f the amplitude of the vibration exceeds safe limits Contact the fan manufacture for your fan style for this information if not i
47. the new filter by putting too much tension on the clamp If the new filter doesn t seem to fit you can adjust the metal plate the filter sits on by loosening the nuts on the all thread and then moving the plate up or down Use the following guide to program the Dwyer Timer Board 1 Control panel power indicator light should be illuminated blue 2 Press fan start button and allow the fan to come up to speed 3 Turn on the Filters toggle switch This will turn on the Dwyer Timer Board 4 Once the timer board is on push the Select button on the timer Last Output LED will light up 5 Use the Up or Down button to adjust the number on the display to equal the total number of pulse valve you have on your collector then press the Select button and the Time Off LED will light up 6 Use the Up or Down button to adjust the number on the display to equal the amount of time between pulses Col Met pre sets this number to 120 but it can be lowered based on the amount of time needed to re pressurize the air manifold feeding the pulse valves 7 Press the select button and the Time On LED will light up This is the amount of time the pulse valve will remain on in milliseconds Use the Up or Down button to adjust the number on the display NEVER ADJUST THIS TIME TO MORE THAN 200 8 Press the Select button and then the Cycle Delay LED will light up Use the Up or Down button to adjust the number on the displ
48. tical airflow direction Sizes and Performance Arrangement 9 belt driven Available in sizes from 12 to 42 diameter Capacity from 1 295 to 36 131 CFM Static pressures to 1 25 w g Construction Features e Aluminum non sparking propeller dynamically bal anced for quiet vibration free operation Continuously welded heavy gauge corrosion resis tant enamel coated steel housing with pre punched inlet and outlet flanges OSHA belt guards are standard Non relubricable sealed for life ball bearings in mono block housing to ensure reliable bearing per formance Designed for continuous duty Aerodynamic belt tube with standard access door Housing Housings are heavy gauge hot rolled steel construc tion continuously welded and ground smooth to assure efficient airflow through the housing Inlet and outlet flanges are integrally rolled and punched to allow attachment to ductwork or accessories as nec essary When an inlet bell is required the housing is formed with a bell shaped inlet instead of the inlet flange eliminating the need for and the expense of a separate inlet bell Drive Isolated from Airstream Maintenance free bearing assembly The shaft and bearing assembly is mounted within an inner cylinder isolated from the airstream The v belt drive assembly is enclosed in an aerodynamically designed belt tube which maximizes fan efficiency minimizes air blockage and reduces noise generation
49. unt the Manometer Mount the manometer on the wall of the booth and ensure it is level using the included bubble level at the bottom of the manometer If the manometer is not level it will not be accurate Top Mounting Hole Bottom Mounting Hole Bubble Level Slotted to easily adjust level Step 4 Fill the Manometer Turn the Zero Set knob counter clockwise until it stops then turn the knob clockwise 3 full turns This will place the adjustment knob in the middle of its travel range Remove the fill plug at the top of the manometer and slowly fill with the red fluid You will not need the entire bottle Stop filling as soon as you can see the red fluid enter the clear tube at the bottom of the manometer Then use the Zero Set adjustment knob to get the red fluid to sit on the O mark If you overfill the gauge remove the excess fluid by inserting a pipe cleaner through the fill port to blot up excess oil Once the red fluid is set on zero replace the fill cap Step 5 Create your baseline measurement IMPORTANT of the filters in the booth need to be installed and new in order to get an accurate baseline If the filters have already been used you will need to remove them and install new clean filters With the new clean filters installed turn on your exhaust fan If your exhaust fan is connected to a VFD to control the speed of the fan make sure it is set to run at full speed You will notice the red fluid should
50. ways wear personal protective equipment PPE appropriate for job Read Material Safety Data Sheet for products used in spray booth No smoking or open flame in or near spray booth Local fire codes prohibit smoking in the vicinity of spray painting operations www colmetsb com Explosion and fire hazard No smoking or open flame within 50 feet of spray booth 888 452 6684 COL MET Spray Booths Do not store flammable liquids adjacent to or inside spray booth Read all product labels and instructions Do not use any electric powered airless spray rigs pressure washers or similar equipment when applying a low flash point solvent or peel coating Run spray booth exhaust fan to purge dangerous vapors that could ignite or explode while cleaning or performing maintenance inside spray booth AN APPROVED FIRE PROTECTION SYSTEM MUST BE INSTALLED ON YOUR SPRAY BOOTH TO COMPLY WITH NFPA 33 SECTION 9 PORTABLE FILE EXTINGUISHERS MUST BE LOCATED IN OR AROUND YOUR PAINT MIX ROOM PER NFPA 10 SAFETV DECALS NO SMOKING OR PEN FLAMES DANGER Electrical Shock Hazard Disconnect electric before service More than one disconnect switch may be required td disconnect electric from equipment Equipment must be properly grounded Failure to follow these instructions can result in death or electrical shock DANGER Risque de Choc Electrique Printed in USA D brancher le courant avant l entretien Plus qu un
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