Nordson ColorMax 2 Reference guide

ColorMaxr2 Powder Coating
System with EncorerFeed Center
Customer Product Manual
Part 1605397-04
Issued 02/20
NORDSON CORPORATION AMHERST, OHIO USA
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at [phone] or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.

Part 1605397-04 2015 Nordson Corporation
Contact Us
Nordson Corporation welcomes requests for information, comments, and
inquiries about its products. General information about Nordson can be
found on the Internet using the following address:
http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 2014. No part of this document may be
photocopied, reproduced, or translated to another language without the
prior written consent of Nordson Corporation. The information contained
in this publication is subject to change without notice.
Trademarks
ColorMax, iControl, Nordson, and the Nordson logo are registered
trademarks of Nordson Corporation.
AeroDeck and AeroWash are trademarks of Nordson Corporation.

Change Record i
Part 1605397-04
2015 Nordson Corporation
Change Record
Revision Date Change
02 04/15 Replaced part number 1058969 with part number 1606403. Changed
screen 8 from 20.00 minutes to 10.00 minutes.
03 05/15 Added slidegate assembly parts.
04 10/15 Replaced part number 1008803 with part number 1607911. Added part
number 176299 (12-valve pilot solenoid).

Change Record
ii
Part 1605397-04 2015 Nordson Corporation

Table of Contents iii
Part 1605397-04
2015 Nordson Corporation
Table of Contents
Safety 1-1..................................................
Introduction 1-1.............................................
Qualified Personnel 1-1......................................
Intended Use 1-1............................................
Regulations and Approvals 1-1................................
Personal Safety 1-2.........................................
Fire Safety 1-2..............................................
Grounding 1-3..............................................
Action in the Event of a Malfunction 1-4........................
Disposal 1-4................................................
Description 2-1.............................................
Introduction 2-1.............................................
System Components 2-2....................................
Booth 2-4...............................................
Reclaim System 2-6......................................
Feed Center 2-8..........................................
Automatic Gun Movers/Gun Blow-Off 2-10....................
Afterfilter 2-11.............................................
Afterfilter Operation 2-11.................................
Control Panels 2-13...........................................
Encore Venturi Feed Center Control Panel 2-13................
Main Electrical Control Panel 2-15............................
Typical System Options 2-16...................................
Roll-On/Roll-Off System 2-16................................
Operation 3-1..............................................
Introduction 3-1.............................................
Typical Operating Settings 3-2................................
Operating Air Pressures 3-2................................
Timer Board Settings 3-2...................................
Booth Control Functions 3-3...............................
Changing Function Values 3-6...........................
Startup 3-7.................................................
Ancillary Equipment Clean Function 3-9.....................
Color Change Procedures 3-9..............................
Powder Level Sensor Operation 3-10........................
Booth Moving 3-10...........................................
Shutdown 3-11...............................................

Table of Contents
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Part 1605397-04 2015 Nordson Corporation
Maintenance 4-1...........................................
Initial Canopy Conditioning 4-1...............................
Daily Maintenance 4-2.......................................
System Cleaning 4-2......................................
Daily Equipment Maintenance 4-2...........................
Weekly Maintenance 4-4.....................................
Monthly Maintenance 4-4.....................................
Booth Canopy Conditioning 4-5...............................
Cyclone Cleaning 4-6.......................................
HDLV Transfer Pump and Transfer Pan Maintenance 4-7........
Transfer Pan Cleaning 4-8.................................
Disassembly 4-8.......................................
Cleaning 4-8..........................................
Assembly 4-8..........................................
Emptying the Afterfilter Waste Hoppers 4-10.....................
Maintenance Check List 4-11..................................
Troubleshooting 5-1........................................
Common Problems 5-1......................................
Reversing Motor Direction 5-6.................................
Repair 6-1.................................................
Introduction 6-1.............................................
Cartridge Filter Replacement 6-1..............................
Filter Removal 6-1........................................
Filter Installation 6-2.......................................
Seasoning the Cartridge Filters 6-4..........................
Final Filter Replacement 6-5.................................
Pulse Valve Replacement 6-6................................
Preparation 6-6...........................................
Parts 7-1...................................................
Introduction 7-1.............................................
Afterfilter Parts 7-2..........................................
Gun Blow-Off Parts 7-4......................................
Miscellaneous Parts 7-4......................................
System Diagram 8-1........................................

Safety 1-1
Part 1605397-04
2015 Nordson Corporation
Section 1
Safety
Introduction
Read and follow these safety instructions. Task- and equipment-specific
warnings, cautions, and instructions are included in equipment
documentation where appropriate.
Make sure all equipment documentation, including these instructions, is
accessible to all persons operating or servicing equipment.
Qualified Personnel
Equipment owners are responsible for making sure that Nordson equipment
is installed, operated, and serviced by qualified personnel. Qualified
personnel are those employees or contractors who are trained to safely
perform their assigned tasks. They are familiar with all relevant safety rules
and regulations and are physically capable of performing their assigned
tasks.
Intended Use
Use of Nordson equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to persons
or damage to property.
Some examples of unintended use of equipment include
using incompatible materials
making unauthorized modifications
removing or bypassing safety guards or interlocks
using incompatible or damaged parts
using unapproved auxiliary equipment
operating equipment in excess of maximum ratings
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which
it is used. Any approvals obtained for Nordson equipment will be voided if
instructions for installation, operation, and service are not followed.

Safety
1-2
Part 1605397-04 2015 Nordson Corporation
All phases of equipment installation must comply with all federal, state, and
local codes.
Personal Safety
To prevent injury follow these instructions.
Do not operate or service equipment unless you are qualified.
Do not operate equipment unless safety guards, doors, or covers are
intact and automatic interlocks are operating properly. Do not bypass or
disarm any safety devices.
Keep clear of moving equipment. Before adjusting or servicing any
moving equipment, shut off the power supply and wait until the
equipment comes to a complete stop. Lock out power and secure the
equipment to prevent unexpected movement.
Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
Obtain and read Material Safety Data Sheets (MSDS) for all materials
used. Follow the manufacturer’s instructions for safe handling and use
of materials, and use recommended personal protection devices.
To prevent injury, be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces, sharp
edges, energized electrical circuits, and moving parts that cannot be
enclosed or otherwise guarded for practical reasons.
Fire Safety
To avoid a fire or explosion, follow these instructions.
Do not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
Provide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material MSDS
for guidance.
Do not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.

Safety 1-3
Part 1605397-04
2015 Nordson Corporation
Know where emergency stop buttons, shutoff valves, and fire
extinguishers are located. If a fire starts in a spray booth, immediately
shut off the spray system and exhaust fans.
Clean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
Use only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.
Grounding
WARNING: Operating faulty electrostatic equipment is hazardous and can
cause electrocution, fire, or explosion. Make resistance checks part of your
periodic maintenance program. If you receive even a slight electrical shock
or notice static sparking or arcing, shut down all electrical or electrostatic
equipment immediately. Do not restart the equipment until the problem has
been identified and corrected.
All work conducted inside the spray booth or within 1 m (3 ft) of booth
openings is considered within a Class 2, Division 1 or 2 Hazardous location
and must comply with NFPA 33, NFPA 70 (NEC articles 500, 502, and 516),
and NFPA 77, latest conditions.
All electrically conductive objects in the spray areas shall be electrically
connected to ground with a resistance of not more than 1 megohm as
measured with an instrument that applies at least 500 volts to the circuit
being evaluated.
Equipment to be grounded includes, but is not limited to, the floor of the
spray area, operator platforms, hoppers, photoeye supports, and
blow-off nozzles. Personnel working in the spray area must be
grounded.
There is a possible ignition potential from the charged human body.
Personnel standing on a painted surface, such as an operator platform,
or wearing non-conductive shoes, are not grounded. Personnel must
wear shoes with conductive soles or use a ground strap to maintain a
connection to ground when working with or around electrostatic
equipment.
Operators must maintain skin-to-handle contact between their hand and
the gun handle to prevent shocks while operating manual electrostatic
spray guns. If gloves must be worn, cut away the palm or fingers, wear
electrically conductive gloves, or wear a grounding strap connected to
the gun handle or other true earth ground.
Shut off electrostatic power supplies and ground gun electrodes before
making adjustments or cleaning powder spray guns.
Connect all disconnected equipment, ground cables, and wires after
servicing equipment.

Safety
1-4
Part 1605397-04 2015 Nordson Corporation
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
Disconnect and lock out electrical power. Close pneumatic shutoff
valves and relieve pressures.
Identify the reason for the malfunction and correct it before restarting the
equipment.
Disposal
Dispose of equipment and materials used in operation and servicing
according to local codes.