Nordson ColorMax Parts list manual

1
Nordson Corporation
OPERATOR’S CARD
P/N 1015049B
ColormaxtPowder Coating System
Color Change Process
Safety
WARNING: Allow only qualified personnel to
perform the following tasks. Follow the
safety instructions in this document and all
other related documentation.
Introduction
Types of Color Changes
There are two basic types of color changes:
Color Change
Type Definition
Similar Shade When changing from either
Sa light powder to another
light powder, or
Sa dark powder to another
dark powder
Different Shade When changing from either
Sa light powder to a dark
powder, or
Sa dark powder to a light
powder
The color change process varies slightly depending
on which type of color change you are performing.
The time it takes to perform a different shade color
change will depend on how many spray guns are in
your system.
Conditions for an Effective Color Change
In order for the color change process to be effective,
the following conditions must be met:
SKeep spare sieve screens, Sure Max reclaim
receiver filters, and powder supply containers on
hand to allow quick replacement during color
change and thorough cleaning while the system is
coating parts.
SOperate the system in spray-to-reclaim mode
during normal operation.
SKeep the area around the booth clean to avoid
cross-contamination of powder.
SCondition the booth interior at least once each
week.

2
Color Change Menu Navigation
Figure 1 illustrates how to access the menus necessary to perform a color change.
1400091A
AUTO
AUTO
AUTO
AUTO
Figure 1 Color Change Menu Navigation

3
Color Change
To perform a color change in the shortest time
possible, two operators must be present. A single
operator could perform the entire process, but it
would take longer. The operators are responsible for
cleaning the following items:
SOperator A: Interior of the booth canopy and
cyclones
SOperator B: Powder feed center
The two operators’ tasks should be performed at the
same time. Unless otherwise noted, do not move on
to the next procedure until both operators’ tasks have
been completed.
Use the following procedures to perform a color
change in the Colormax booth. Perform all of the
applicable steps in each procedure.
NOTE: When a procedure affects both operators, it
is shown straddling both operator’s columns in the
following table.
Tasks
Procedure Operator A
See Figure 2 Operator B See Figure 3
1Close the booth doors and, if applicable, move the booth offline.
2From the Auto Menu, touch the COLOR MENU button to access the Color Change Control
menu. Touch the INITIATE, B-OFF Start button. The system automatically performs the
following tasks:
NOTE: Perform procedure 3 while the system is performing these tasks.
NOTE: The INITIATE, B-OFF Stop button interrupts the gun blow-off cycle.
SOscillators (if used) stop and the spray guns move in to the fully extended position.
SFeed center’s sieve, fluidizing air, and vibrating table stop, and the lance assembly raises.
SIn/out gun positioners retract (one at a time) and powder is blown off the spray guns.
When the gun blow-off cycle is complete, the COLOR CHANGE CYCLE DONE indicator
flashes.
31. Disengage the coupling connecting the
reclaim conveyor line (9) to the reclaim
port (8).
2. Open the transfer pan (5) and blow out all
powder remaining in the pan.
3. Send three cleaning sponges through the
reclaim conveyor line.
NOTE: Do not close the transfer pan at this
time.
1. Unclamp the underpan (3) and turn it
counterclockwise until the chute is directly
over the chute on the back wall of the
powder feed center.
NOTE: If you are using the optional fluidizing
hopper, disconnect the air tubing before
removing the hopper from the feed center.
2. Remove the powder source from the feed
center.
Continued...

4
Color Change (contd)
Tasks
Procedure Operator A
See Figure 2 Operator B See Figure 3
4Touch the GUN PURGE Start button. The system automatically performs the following tasks:
NOTE: Perform procedure 5 while the system is performing these tasks.
NOTE: The GUN PURGE Stop button interrupts the gun purge cycle.
SLance assembly lowers onto the purge manifold.
SPurge manifold sends pulses of air through the lances, pumps, feed hoses, and spray guns.
SLance assembly raises and the sieve restarts.
When the gun purge cycle is complete, the COLOR CHANGE CYCLE DONE indicator flashes.
Continued...
1400127A
1
2
9
6
4
5
3
7
8
Figure 2 Operator A Color Change Tasks
1. AeroDeck
2. Vertical inlet duct
3. Cyclone access doors
4. Scrap receiver
5. Transfer pan
6. Scrap port
7. Scrap conveyor line
8. Reclaim port
9. Reclaim conveyor line

5
Tasks
Procedure Operator A
See Figure 2 Operator B See Figure 3
5Blow off all door seams from the outside of the
booth. Blow powder off the lance assembly.
61. Turn the LOCKOUT keyswitch on the
system control panel to the LOCKED
position. This locks out in/out gun
positioner and oscillator operation.
2. While on the outside of the booth, go to the
cyclone end of the booth and blow powder
off the AeroDeck (1).
3. Enter the booth and close all the doors.
4. Working from the operator opening end of
the booth toward the cyclones, blow off the
ceiling, walls, and doors.
5. Blow off the AeroDeck, lift it from its
operating position, and set it aside.
6. Open the access doors to the cyclone
vertical inlet duct (2) and blow out the
interior of the vertical inlet duct.
7. Close the vertical inlet duct access doors.
8. Set the AeroDeck in its operating position
and exit the booth.
1. Touch the Sure Max System Enabled
button. This causes the following things to
happen:
SThe sieve and Sure Max powder
transfer system are disabled and the
Sure Max System Disabled button
appears.
SThe reclaim receiver discharge door
opens.
SThe reclaim filter is pulsed 3 times
(10 seconds total).
2. Disconnect the amplifier hose and pulse air
tubing from the top of the reclaim filter
assembly (6).
3. Disengage the coupling connecting the
reclaim conveyor line to the reclaim
receiver (5).
4. Rotate the reclaim receiver so that it is at a
45_angle.
5. Remove the reclaim filter assembly.
Remove the filter element and place it in its
dedicated plastic container.
6. Remove the three cleaning sponges from
the reclaim receiver and place them in their
dedicated plastic container.
7. Rotate the reclaim receiver so that the
small opening is facing the operator, then
blow as much powder out of the receiver
as possible. Rotate the reclaim receiver so
that the large opening is facing the
operator, then blow out any powder
remaining in the receiver. Continued...

6
Color Change (contd)
1400092A
1
2
3
4
5
8
7
6
9
Figure 3 Operator B Color Change Tasks
1. Sieve deck
2. Sieve screen
3. Sieve underpan
4. Sieve
5. Reclaim receiver
6. Reclaim filter assembly
7. Lance assembly
8. Feed hose manifold
9. Vacuum diverter handle

7
Tasks
Procedure Operator A
See Figure 2 Operator B See Figure 3
71. Remove the plug from the scrap port (6),
blow off the plug, and set it aside.
2. Blow out any powder remaining in the
transfer pan (5), being careful not to get
any powder into the reclaim conveyor
line (9).
3. Install the plug into the reclaim port (8).
4. Open the cyclone access doors (3).
5. Blow off all interior surfaces of the
cyclones.
6. Depending on whether the system will be
operating in either spray-to-reclaim or
spray-to-waste mode, follow one of these
procedures:
Spray-to-Reclaim Mode Operation:
a. Close and latch the cyclone access
doors (3).
b. Close and latch the transfer pan (5).
c. Install the scrap conveyor line (7) onto
the scrap port (6).
Spray-to-Waste Mode Operation:
Leave the cyclone access doors (3) and
transfer pan (5) open.
NOTE: Each color must have a dedicated
reclaim filter element. Using a filter element
for multiple colors will result in cross
contamination.
1. Install the appropriate color-specific
reclaim filter element and install the
reclaim filter assembly (6) into the reclaim
receiver (5).
2. Rotate the reclaim receiver so that it is in
the upright position.
3. Connect the amplifier hose, pulse air
tubing, and reclaim conveyor line to the
reclaim receiver.
4. Touch the Sure Max Door Close button to
close the reclaim receiver discharge door.
NOTE: If your system has the optional
Vibrasonic sieve screen, unplug the Vibrasonic
transducer cable from its support bracket and
use caution when cleaning around the screen’s
Vibrasonic transducer.
5. Remove the sieve deck (1) and screen (2).
SSimilar Shade Color Change: Blow
off the sieve screen.
SDifferent Shade Color Change: Set
the sieve screen aside and clean it
later. Install a clean sieve screen.
6. Blow off the sieve deck and underpan (3).
Turn the underpan clockwise until the
chute is directed toward the lance
assembly (7).
7. Install the appropriate sieve screen and the
sieve deck, and connect the Vibrasonic
transducer cable (if applicable).
8. Touch the Sure Max Disabled button to
enable the Sure Max powder transfer
system. Turn the vacuum diverter handle
to the fully counterclockwise position.
SSimilar Shade Color Change: Install the
powder source into the feed center and
connect the fluidizing air tubing (if
applicable).
SDifferent Shade Color Change: Do not
install a new powder source until the end of
procedure 8. Continued...

8
Color Change (contd)
Tasks
Procedure Operator A
See Figure 2 Operator B See Figure 3
NOTE: Perform procedure 8 only if you are performing a different shade color change. If you are performing
a similar shade color change, proceed to procedure 9.
8Remove the powder feed hose from each
spray gun and install the other feed hose. 1. Remove the feed hose manifold (8) from
the lance assembly (7).
2. Blow down into the powder pumps on the
lance assembly to clear away any
remaining powder.
3. Install the other feed hose manifold.
4. Install the new powder source into the feed
center and connect the fluidizing air tubing
(if applicable).
91. Turn the LOCKOUT keyswitch on the system control panel to the NORMAL position.
2. Touch the Auto Menu button to return to the Auto Menu.
3. Touch the FINISH COLOR CHANGE Press to Finish button. The spray guns move back
into the booth and begin oscillating (if applicable).
4. Touch either the Select Box or Select Hopper button to lower the lance assembly to the
appropriate location.
5. If you want to operate the booth in spray-to-reclaim mode, touch the Spray to Waste button.
The button’s text changes to Spray to Reclaim to indicate the currently selected operating
mode.
After a few minutes, the powder in the feed source will fluidize and the system will be ready for
operation.
NOTE: Spray approximately 0.5 kg (one lb) of powder to waste before performing
procedure 10. The amount of time that it takes to spray 0.5 kg (one lb) of powder will vary
depending on the components in your system. Spraying the powder to waste seasons the ducts
and cyclones to allow for more effective powder reclaim.
10 Spray-to-Reclaim Mode Operation Only:
1. Disconnect the scrap conveyor line (7)
from the scrap port (6).
2. Remove the plug from the reclaim port (8)
and set it aside.
3. Install the plug into the scrap port.
4. Install the reclaim conveyor line (9) and
coupling onto the reclaim port.
Spray-to-Reclaim Mode Operation Only:
Turn the vacuum diverter handle (9) to the fully
clockwise position.
Issued 2/02
Original copyright date 2001. Nordson and the Nordson logo are registered trademarks of Nordson Corporation.
Vibrasonic is a registered trademark of Russell Finex Limited Corporation.