Nordson ColorMax 2 User manual

ColorMax®2 Powder Coating System with
Encore®Venturi Feed Center - Color Change Procedure
Color Change Tasks: Cyclone Side Operator
1. Encore®manual guns: Disconnect the powder hose from
the spray gun and connect it to the purge port.
Prodigy®manual guns: Hang up the spray gun so it is
pointing into the booth.
Sure Coat®manual guns: Purge the spray gun, then
disconnect the powder hose and insert the end of the hose
into the booth.
2. Move to the feed center
a. Make sure the damper switch is set to AUTO.
b. Turn OFF the bulk feed pump (if equipped), the reclaim
pump, and the sieve.
c. Disconnect the bulk and reclaim hoses from the sieve and
connect them to the purge ports.
d. At the bulk feed system, remove the siphon hose from the
powder supply and connect it to the purge port.
e. Unclamp the sieve deck and turn the pan chute so it
points toward the back of the feed center.
f. Re-clamp the deck.
g. Turn ON the bulk feed pump (if equipped), reclaim pump,
and color change switch.
NOTE: Lances will move up automatically.
h. Turn OFF the vibratory table (if used).
i. If used, disconnect the fluidizing air tubing from the
hopper.
j. Remove the hopper from the feed center.
k. Blow off the lower parts of the lances and the purge
manifold.
Make sure the other operator is clear of the
spray guns.
l. Turn the purge switch to the GUN PURGE position.
m. Unclamp the sieve.
n. One at a time, remove the deck, screen, and pan and
blow them clean. Remove the gasket from the screen
and clean it.
o. Set the sieve components outside the feed center.
p. Lance assemblies equipped with hose manifolds:
i. When the internal gun purge is done, raise the lances
halfway, unclamp the hose manifold, and blow clean
the manifold and pump outlet nozzles.
ii. Blow down into the nozzles, and up into the lance
ports from the bottom of the lances.
1 of 4
Lances automatically move
down onto the purge manifold,
are clamped in place, and the
internal gun purge begins.
© 2015 Nordson Corporation. All Rights Reserved. 1605545-03
Pan Chute
Purge Port
Fluidizing Tubing
Purge Port
Caution: For all blow-off procedures,
use the grounded blow-off gun and
hose assembly provided by Nordson.

Color Change Tasks: Cyclone Side Operator
q. Lance assemblies not equipped with hose manifolds:
i. When the internal gun purge is done, raise the lances
all the way.
ii. Blow off the bottom of the lances and up into the lance
ports.
r. Blow off the lances, powder hoses, air tubing, sieve
bracket, vibratory table and purge manifold, and inside
ceiling, walls, and floor of the feed center.
s. Turn the purge switch to the PUMP position.
3. Move to the cyclone
Transfer pan must be cleaned while pump purge is cycling
a. Open the transfer pan and blow it clean while the bulk
feed and reclaim pumps are purging.
b. Blow clean the bottom flange of the cyclone.
c. Lock the transfer pan in the open position.
4. Move to the feed center
a. Assemble the sieve with the pan chute pointing toward the
lances.
b. Load a feed hopper or powder box onto the table.
c. Turn the powder source switch to hopper or box.
d. Connect the fluidizing tubing to the hopper (if used).
5. Move to the cyclone
a. Riser cleaning must be completed and riser door closed
before cyclone can be opened
b. Release the latches and swing the lower section into the
cleaning position.
c. Open the cleaning duct slide gate.
6. Move to the feed center
a. Turn the purge switch OFF.
b. Turn the reclaim and bulk feed pumps OFF.
c. Turn the color change switch OFF.
d. Lower the lance into the new powder.
e. Connect the bulk transfer hose to the sieve.
f. If not spraying to waste before production, connect the
reclaim transfer hose to the sieve.
g. At the bulk feed system, insert the pump siphon hose into
the new powder.
h. Turn ON the sieve.
i. Turn ON the vibratory table, if used.
j. Turn ON the reclaim and bulk feed pumps.
7. Move to the non-cyclone side operator platform
a. Connect the powder hose to the spray gun.
8. Move to the cyclone side operator platform
a. Connect the powder hose to the spray gun and
start spraying the new powder.
9. If spraying to waste before production:
a. Spray until confident all old powder is out of
the system.
b. Move to the feed center, turn OFF the reclaim
pump and sieve.
c. Connect the reclaim hose to the sieve.
d. Turn ON the sieve and reclaim pump.
2 of 4
© 2015 Nordson Corporation. All Rights Reserved. 1605545-03
Cyclone
Flange

ColorMax® 2 Engineered Powder Coating System
With Encore® Venturi Feed Center
Color Change Tasks: Non-Cyclone Side Operator
1. Press the ancillary equipment clean cycle button. The gun movers go to their home position
and the exterior of the automatic spray guns
are blown off.
2. Move to the entry end of the booth
a. Close and latch the booth entry doors.
3. Return to the non-cyclone side operator platform
a. Encore®manual guns: Disconnect the powder hose
from the gun and connect it to the purge port. Remove the
nozzle and electrode holder and blow them clean. Point
the blow gun into the powder inlet and blow out the gun.
Blow off the gun exterior.
Prodigy®manual guns: Blow the gun clean and hang it
up so it is pointing into the booth.
Sure Coat®manual guns: Purge the gun, then
disconnect the powder hose and insert the end of the hose
into the booth. Remove the nozzle and blow it clean. From
the hose inlet, blow out the powder path. Install the nozzle
on the gun then hang it up.
b. Close and latch the operator door.
4. Move to the exit end of the booth – Perform coarse
cleaning
a. Open the operator door and blow off the floor duct while
walking toward the entrance.
b. Blow off the AeroDecks™ and lift them open.
c. Blow off the stainless steel riser door, then exit the booth.
5. Move to the cyclone side operator platform
a. Clean the spray gun and hang it up as described
previously.
b. Close and latch the operator door.
c. Move the booth off-line. (Roll-on/roll-off booth)
6. Move to the exit end of the booth – Perform finish
cleaning
a. Blow off the door and exit opening sills. Open the door and
blow off the entry sills.
b. When the automatic guns closest to the exit end start
purging, enter the booth and blow off the interior of the
booth using a sweeping motion, working from top to
bottom, from exit end to entry end of booth.
c. Clean the ceiling, walls, and floor, blowing the powder
toward the riser inlet.
d. Blow off the automatic gun tips.
e. Blow off the AeroDecks and leave them in the open
position.
f. Blow out the riser inlet while using a sweeping motion.
g. Open the riser door and blow out the interior of the riser.
3 of 4
© 2015 Nordson Corporation. All Rights Reserved. 1605545-03
Purge Port
Caution: For all blow-off procedures,
use the grounded blow-off gun and
hose assembly provided by Nordson.

Color Change Tasks: Non-Cyclone Side Operator
h. Set the AeroDecks in the operating position
and exit the booth.
i. Close and latch the exit door.
7. Move to the cyclone
a. Blow off the lower section of the cyclone. Start
at the flange and blow toward the bottom with
a circular/spiral motion.
b. Blow off the bottom flange and interior of the
cyclone using a circular/spiral motion. Break
air vortex in cyclone by using linear side-to-
side and front-to-back motion inside cyclone.
c. Swing the lower section of the cyclone down
and latch it closed.
d. Swing the transfer pan down and latch it
closed.
e. Close the cleaning duct slide gate.
f. Open the booth doors at the entry end of the
booth (if not already opened).
g. Start spraying new powder.
8. If spraying to waste
a. Spray until confident that all old powder is out of the system.
b. Do not start production until the cyclone side operator has connected the reclaim hose to the sieve.
4 of 4
© 2015 Nordson Corporation. All Rights Reserved 1605545-03
ColorMax, Encore, Prodigy, Sure Coat, Nordson, and the Nordson logo are registered trademarks of Nordson Corporation.
AeroDeck is a trademark of Nordson Corporation.
Nordson Corporation •Amherst, Ohio USA
Issued 06/15

ColorMax®2 Powder Coating System with
Encore®Venturi Feed Center - Color Change Procedure
Color Change Tasks: Cyclone Side Operator Color Change Tasks: Non-Cyclone Side Operator
1. Encore®manual guns: Disconnect the powder hose from the
spray gun and connect it to the purge port.
Prodigy®manual guns: Hang up the spray gun so it is pointing into
the booth.
Sure Coat®manual guns: Purge the spray gun, then disconnect
the powder hose and insert the end of the hose into the booth.
2. Move to the feed center
a. Make sure the damper switch is set to AUTO.
b. Turn OFF the bulk feed pump (if equipped), the reclaim pump,
and the sieve.
c. Disconnect the bulk and reclaim hoses from the sieve and
connect them to the purge ports.
d. At the bulk feed system, remove the siphon hose from the
powder supply and connect it to the purge port.
e. Unclamp the sieve deck and turn the pan chute so it points
toward the back of the feed center.
f. Re-clamp the deck.
g. Turn ON the bulk feed pump (if equipped), reclaim pump, and
color change switch.
NOTE: Lances will move up automatically.
h. Turn OFF the vibratory table (if used).
i. If used, disconnect the fluidizing air tubing from the hopper.
j. Remove the hopper from the feed center.
k. Blow off the lower parts of the lances and the purge manifold.
Make sure the other operator is clear of the
spray guns.
l. Turn the purge switch to the GUN PURGE position.
m. Unclamp the sieve.
n. One at a time, remove the deck, screen, and pan and blow
them clean. Remove the gasket from the screen and clean it.
o. Set the sieve components outside the feed center.
p. Lance assemblies equipped with hose manifolds:
i. When the internal gun purge is done, raise the lances
halfway, unclamp the hose manifold, and blow clean the
manifold and pump outlet nozzles.
ii. Blow down into the nozzles, and up into the lance ports
from the bottom of the lances.
1 of 2
Lances automatically move down onto
the purge manifold, are clamped in
place, and the internal gun purge
begins.
© 2015 Nordson Corporation. All Rights Reserved.
Pan Chute
Purge Port
Fluidizing Tubing
Purge Port
1. Press the ancillary equipment clean cycle button. The gun movers go to their home position and the exterior of
the automatic spray guns are blown off.
2. Move to the entry end of the booth
a. Close and latch the booth entry doors.
3. Return to the non-cyclone side operator platform
a. Encore®manual guns: Disconnect the powder
hose from the gun and connect it to the purge port.
Remove the nozzle and electrode holder and blow
them clean. Point the blow gun into the powder inlet
and blow out the gun. Blow off the gun exterior.
Prodigy®manual guns: Blow the gun clean and
hang it up so it is pointing into the booth.
Sure Coat®manual guns: Purge the gun, then
disconnect the powder hose and insert the end of the
hose into the booth. Remove the nozzle and blow it
clean. From the hose inlet, blow out the powder path.
Install the nozzle on the gun then hang it up.
b. Close and latch the operator door.
4. Move to the exit end of the booth – Perform Coarse
Cleaning
a. Open the operator door and blow off the floor duct
while walking toward the entrance.
b. Blow off the AeroDecks™ and lift them open.
c. Blow off the stainless steel riser door, then exit the
booth.
5. Move to the cyclone side operator platform
a. Clean the spray gun and hang it up as described
previously.
b. Close and latch the operator door.
c. Move the booth off-line. (Roll-on/roll-off booth)
a. Make sure all operators are clear of the
spray guns.
6. Move to the exit end of the booth – Perform Finish
Cleaning
a. Blow off the door and exit opening sills. Open the
door and blow off the entry sills.
Purge Port
Disclaimer: Due to the different number of tasks and explanations required for each
operator, the tasks cannot line up exactly on paper. Exact coordination is approximate.
Where it is CRITICAL for operators to coordinate tasks, it is noted in the procedure.
Caution: For all blow-off procedures,
use the grounded blow-off gun and
hose assembly provided by Nordson.
1605545-03

Color Change Tasks: Cyclone Side Operator
q. Lance assemblies not equipped with hose manifolds:
i. When the internal gun purge is done, raise the
lances all the way.
ii. Blow off the bottom of the lances and up into
the lance ports.
r. Blow off the lances, powder hoses, air tubing, sieve
bracket, vibratory table and purge manifold, and
inside ceiling, walls, and floor of the feed center.
s. Turn the purge switch to the PUMP position.
3. Move to the cyclone
a. Open the transfer pan and blow it clean while the
bulk feed and reclaim pumps are purging.
b. Blow clean the bottom flange of the cyclone.
c. Lock the transfer pan in the open position.
4. Move to the feed center
a. Assemble the sieve with the pan chute pointing
toward the lances.
b. Load a feed hopper or powder box onto the table.
c. Turn the powder source switch to hopper or box.
d. Connect the fluidizing tubing to the hopper (if used).
e. Turn the purge switch OFF.
f. Turn the reclaim and bulk feed pumps OFF.
g. Turn the color change switch OFF.
5. Move to the cyclone
a. Release the latches and swing the lower section into
the cleaning position.
b. Open the cleaning duct slide gate.
6. Move to the feed center
a. Lower the lance into the new powder.
b. Connect the bulk transfer hose to the sieve.
c. If not spraying to waste before production, connect
the reclaim transfer hose to the sieve.
d. At the bulk feed system, insert the pump siphon
hose into the new powder.
e. Turn ON the sieve.
f. Turn ON the vibratory table, if used.
g. Turn ON the reclaim and bulk feed pumps.
7. Move to the non-cyclone side operator platform
a. Connect the powder hose to the spray gun.
8. Move to the cyclone side operator platform
a. Connect the powder hose to the spray gun and start
spraying the new powder.
9. If spraying to waste before production:
a. Spray until confident all old powder is out of the
system.
b. Move to the feed center, turn OFF the reclaim pump
and sieve.
c. Connect the reclaim hose to the sieve.
d. Turn ON the sieve and reclaim pump.
2 of 2
© 2015 Nordson Corporation. All Rights Reserved.
Cyclone
Flange
Color Change Tasks: Non-Cyclone Side Operator
b. When the automatic guns closest to the
exit end start purging, enter the booth
and blow off the interior of the booth
using a sweeping motion, working from
top to bottom, from exit end to entry end
of booth.
c. Clean the ceiling, walls, and floor,
blowing the powder toward the riser
inlet.
d. Blow off the automatic gun tips.
e. Blow off the AeroDecks and leave them
in the open position.
f. Blow out the riser inlet while using a
sweeping motion.
g. Open the riser door and blow out the
interior of the riser.
h. Set the AeroDecks in the operating
position and exit the booth.
i. Close and latch the exit door.
7. Move to the cyclone
a. Blow off the lower section of the
cyclone. Start at the flange and blow
toward the bottom with a circular/spiral
motion.
b. Blow off the bottom flange and interior
of the cyclone using circular/spiral
motion. Break air vortex in cyclone by
using linear side-to-side and front-to-
back motion inside cyclone.
c. Swing the lower section of the cyclone
down and latch it closed.
d. Swing the transfer pan down and latch it
closed.
e. Close the cleaning duct slide gate.
f. Open the booth doors at the entry end
of the booth (if not already opened).
g. Start spraying new powder.
8. If spraying to waste
a. Spray until confident that all old powder is out of the system.
b. Do not start production until the cyclone side operator has connected the reclaim hose to the sieve.
Riser cleaning must be completed and riser door closed
before lower cyclone can be opened
Transfer pan must be cleaned while pump purge is cycling
1605545-03