Nordson ColorMax3 User manual

ColorMax3t
Customer Product Manual
P/N 7135457_E
Issued 05/17
NORDSON GmbH ERKRATH GERMANY
For parts and technical support, call your nearest Finishing Customer Support Centre.
Find your nearest centre at www.nordson.com/directory
This document is available on the Internet at http://emanuals.nordson.com/finishing

Part 7135457- E E2017 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 GmbH
Heinrich Hertz Strasse 42
40699 Erkrath,
Germany
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 2007. 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
Nordson and the Nordson logo are registered trademarks of Nordson
Corporation.
Designations and trademarks stated in this document may be brands that,
when used by third parties for their own purposes, could lead to violation
of the owners’ rights.

Change Record i
Part 7135457- E
E2017 Nordson Corporation
Change Record
Revision Date Change
01 18/05/2017 Pneumatic & Electrical diagrams updated

Change Record
ii
Part 7135457- E E2017 Nordson Corporation

Table of Contents iii
Part 7135457- E
E2017 Nordson Corporation
Table of Contents
Safety 1-1..................................................
Introduction 1-1.............................................
Qualified Personnel 1-1......................................
Intended Use 1-1............................................
Regulations and Approvals 1-2................................
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.............................................
Intended Use 2-1............................................
Description of Components 2-1................................
Installation 3-1.............................................
Transport 3-1...............................................
Unpacking 3-1..............................................
Storage 3-1.................................................
Preparing for Installation 3-1..................................
Electrical Connection 3-2.....................................
Pneumatic Connection 3-2....................................
Disassembly 3-2............................................
Disposal 3-2................................................
Booth Conditioning Procedure 3-3.............................
Recommended Cleaning Solvent 3-4...........................
Operation 4-1..............................................
Daily Operation 4-1..........................................
Start Up Procedure 4-1......................................
Color Change Procedure 4-2..................................
Maintenance 5-1...........................................
Daily Maintenance 5-1.......................................
Troubleshooting 6-1........................................
Important Hints for Troubleshooting 6-1........................
Table of Troubleshooting 6-2..................................
Parts 7-1...................................................
Introduction 7-1.............................................
Using the Illustrated Parts List 7-1..........................
Pneumatic & Electrical Diagrams 8-1........................

O-1Introduction
E2012 Nordson Corporation
All rights reserved NI_EN_O-0211
Nordson International
http://www.nordson.com/Directory
Country Phone Fax
Europe
Austria 43-1-707 5521 43-1-707 5517
Belgium 31-13-511 8700 31-13-511 3995
Czech Republic 4205-4159 2411 4205-4124 4971
Denmark Hot Melt 45-43-66 0123 45-43-64 1101
Finishing 45-43-200 300 45-43-430 359
Finland 358-9-530 8080 358-9-530 80850
France 33-1-6412 1400 33-1-6412 1401
Germany Erkrath 49-211-92050 49-211-254 658
Lüneburg 49-4131-8940 49-4131-894 149
Nordson UV 49-211-9205528 49-211-9252148
EFD 49-6238 920972 49-6238 920973
Italy 39-02-216684-400 39-02-26926699
Netherlands 31-13-511 8700 31-13-511 3995
Norway Hot Melt 47-23 03 6160 47-23 68 3636
Poland 48-22-836 4495 48-22-836 7042
Portugal 351-22-961 9400 351-22-961 9409
Russia 7-812-718 62 63 7-812-718 62 63
Slovak Republic 4205-4159 2411 4205-4124 4971
Spain 34-96-313 2090 34-96-313 2244
Sweden 46-40- 680 1700 46-40-932 882
Switzerland 41-61-411 3838 41-61-411 3818
United Kingdom Hot Melt 44-1844-26 4500 44-1844-21 5358
Industrial
Coating
Systems
44-161-498 1500 44-161-498 1501
Distributors in Eastern & Southern Europe
DED, Germany 49-211-92050 49-211-254 658

O-2 Introduction
E2012 Nordson Corporation
All rights reserved
NI_EN_O-0211
Outside Europe / Hors d’Europe / Fuera de Europa
SFor your nearest Nordson office outside Europe, contact the Nordson offices
below for detailed information.
SPour toutes informations sur représentations de Nordson dans votre pays,
veuillez contacter l’un de bureaux ci-dessous.
SPara obtener la dirección de la oficina correspondiente, por favor diríjase a unas
de las oficinas principales que siguen abajo.
Contact Nordson Phone Fax
Africa / Middle East
DED, Germany 49-211-92050 49-211-254 658
Asia / Australia / Latin America
Pacific South Division, USA 1-440-685-4797 -
Japan
Japan 81-3-5762 2700 81-3-5762 2701
North America
Canada 1-905-475 6730 1-905-475 8821
USA Hot Melt 1-770-497 3400 1-770-497 3500
Finishing 1-880-433 9319 1-888-229 4580
Nordson UV 1-440-985 4592 1-440-985 4593

Safety 1-1
Part 7135457- E
E2017 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
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards or interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating equipment in excess of maximum ratings

Safety
1-2
Part 7135457- E E2017 Nordson Corporation
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.
All phases of equipment installation must comply with all federal, state, and
local codes.
Personal Safety
To prevent injury follow these instructions.
SDo not operate or service equipment unless you are qualified.
SDo 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.
SKeep 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.
SRelieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
SObtain 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.
STo 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.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SProvide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material MSDS
for guidance.
SDo 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 7135457- E
E2017 Nordson Corporation
SKnow 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.
SClean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
SUse 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
Grounding inside and around the booth openings must comply with
European Union harmonized norm requirements for Zone 20, Zone
21, or Zone 22, which ever Zone is applicable.
Refer to EN12981 and EN50177.
SAll electrically conductive objects in the spray areas shall be electrically
connectedtogroundwitharesistanceofnotmorethan1megohmas
measured with an instrument that applies at least 500 volts to the circuit
being evaluated.
SEquipment 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.
SThere 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.
SOperators 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.
SShut off electrostatic power supplies and ground gun electrodes before
making adjustments or cleaning powder spray guns.
SConnect all disconnected equipment, ground cables, and wires after
servicing equipment.

Safety
1-4
Part 7135457- E E2017 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:
SDisconnect and lock out electrical power. Close pneumatic shutoff
valves and relieve pressures.
SIdentify 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.

Description 2-1
Part 7135457- E
E2017 Nordson Corporation
Section 2
Description
Intended Use
The Nordson ColorMax3Booth System is designed primarily as fast and
easy clean booth.
Description of Components
Figure 2 Typical ColorMax3Booth System

Description
2-2
Part 7135457- E E2017 Nordson Corporation
The Nordson ColorMax3booth system forms part of a family of powder
booths based on proven Nordson booth technology. The booth system
offers an economical easy clean alternative to other due to the method of
construction.
Theboothstructureismadeupofacombination of stainless steel platform,
Apogeebooth floor and PVC, which allows the powder to be blown and
wiped away easily with a non-abrasive material.
Figure 2-1 ColorMax3Operation Mode
1. Application equipment, gun
movers, guns
2. Booth control panels
3. Stainless steel platform
4. Hinged door
5. Apogeefloor with
AeroWashTsystem
6. Central single duct extract

Installation 3-1
Part 7135457- E
E2017 Nordson Corporation
Section 3
Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Transport
Transport the unit so as to avoid damage. Use suitable packaging materials.
Protect the unit from humidity, large temperature fluctuations
(condensation), dust and vibrations.
Unpacking
Unpack the unit carefully to avoid damage. Inspect for any damage caused
during transport. Save packing materials for possible later use, or otherwise
dispose of properly according to local regulations.
Storage
Use suitable packaging materials. Protect the unit from humidity, large
temperature fluctuations (condensation), dust and vibrations.
Preparing for Installation
NOTE: Booths are generally delivered flat pack for on- site assembly.
NOTE: Installation of the booth should not be undertaken without the
presence of a Nordson representative or a suitably qualified person.
1. Choose a level site on which to install the ColorMax Booth, away from
drafts or any other airborne contaminates.
2. Seal concrete floors with a suitable material to avoid dust. Other floor
surfaces should be of a type that is easy to keep clean.

Installation
3-2
Part 7135457- E E2017 Nordson Corporation
Electrical Connection
WARNING: Risk of electrical shock. Disconnect and lock out input power to
equipment before servicing. Failure to observe this warning may result in
personal injury or death.
A single supply cable is required to the booth control panel. The supply
should be fed from a suitable disconnect device. Introduce the cable into the
panel using an IP6X cable gland. Ensure that all the electrical wires are
suitably sized for the fan motor loading and adequate fuse/circuit protection
is provided at the source of supply. Consult electrical schematic drawings
for on site conditions and refer to engineering design.
Pneumatic Connection
WARNING: The air supply pressure should be set to 4 bar (maximum) and
shouldonlybemodifiedbyaNordsontechnician.
Connect the air supply to the booth pneumatic panel and ensure that the air
supply is of the required quality. Also check that the air has been discharged
from the system via the tank inlet filter to ensure that any material left in the
line during installation does not enter the system.
Disassembly
To disassemble the unit, turn the unit off and remove the air and power
supplies.
Disposal
Dispose of properly according to local regulations.

Installation 3-3
Part 7135457- E
E2017 Nordson Corporation
Booth Conditioning Procedure
1. Remove any installation materials inside the booth.
2. Switch on booth extraction system by pressing Fan start on the booth
control panel.
3. Switch off Recycle mode on the booth control panel. the Recycle system
operates in the spray to waste mode.
4. With all doors closed, use the blow lance to blow internal booth faces
free of dust.
5. Dampen a sponge with water and wipe clean internal booth faces,
Apogeefloor and internal cyclone access area. A drop of detergent
may be used for the first wash. Repeat the wash with water only.
6. Whilst allowing the booth to dry, wipe the exterior of the booth. The blow
lance may be used to decrease the drying time.
CAUTION: Use a sharp solvent (see reference below) and apply to the
internal parts of the booth, base deflector and internal cyclone access area
withcleanlintfreewipers.
SUse eye protection, mask and gloves
SPolish dry
SWipe one square metre and blow with air lance and proceed until
complete
SIt is important not to touch the faces wiped with bare hands.
7. Allow to dry.
8. Spray powder to waste for 5 minutes, solvent clean any areas which
preferentially collect powder.
9. Clean cyclone and recycle in the normal way.
10. The system is now ready for use.

Installation
3-4
Part 7135457- E E2017 Nordson Corporation
Recommended Cleaning Solvent
Listed below is the composition of solvent we recommend for the initial set
up and for maintenance cleaning.
SDistillate: 5%
SButylacetate: 17%
SCellesolve-Acetate: 5%
SAcetone: 20%
SBenzene 80/110: 15%
SXylol: 38%
The nearest standard solvent available to the above is cellulose thinners.

Operation 4-1
Part 7135457- E
E2017 Nordson Corporation
Section 4
Operation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Daily Operation
The majority of systems are installed with a Powder Feed Centre. If a
Powder Feed Centre is not present, please ignore the steps where it is
mentioned.
In order to successfully colour change the booth and application system
follow the procedure outlined below.
Start Up Procedure
1. Put a box of powder onto the vibrator table in the Powder Feed Centre.
2. Start booth extraction by pressing Fan start on the booth control panel.
3. Put Powder Feed Centre into run mode. Refer to Powder Feed Centre
manuals.
4. Ensure the dip legs enter the powder and do not catch on the bag.
5. Put the transfer hoses into the waste holsters at the back of the Powder
Feed Centre.
6. Start the gun movers on the application control panel. Refer to
application control manuals.
7. Turn on the recycle mode by pressing Recycle on on the booth control
panel.
8. Start spraying powder and run production. Refer to Powder Feed Centre
manuals.
9. After approx. 2 minutes of recycled powder being returned back through
the recycle hose, move the hose into the sieve holster.

Operation
4-2
Part 7135457- E E2017 Nordson Corporation
Color Change Procedure
1. Leave the guns spraying until products pass the spray guns.
Figure 4-1 ColorMax3in
operation
2. Wait until the products are outside of the booth.
3. Turn the spray guns off on the application control panel. Refer to Gun
control manuals.
Figure 4-2 Preparation for
color change
4. Put Powder Feed Centre into clean mode. Refer to Powder Feed Centre
manuals.
5. Withdraw the guns so that just the nozzles are left inside the booth.
6. Close the booth doors.
7. Start the gun purge process. Refer to Powder Feed Centre manuals.
8. Blow off the exterior of the dip legs and fluid assist. Refer to Powder
Feed Centre manuals.
9. Start the pump purge sequence. Refer to Powder Feed Centre manuals.
Figure 4-3 Spray guns in purge
position

Operation 4-3
Part 7135457- E
E2017 Nordson Corporation
10. Blow off the outside of the guns (may be manual or automatic depending
on your system).
11. After the pulsing has finished, manually clean the back of the gun
nozzle.
12. Clean the walls and roof of the booth with the blow lance taking care not
to scratch any surface and do not touch the booth walls.
13. Clean the booth base using the blow lance taking care not to scratch.
Figure 4-4 Manual booth
14. Open the duct door and clean, also clean inside the duct and the inlet to
the cyclone.
15. If required, when most of the powder has been blown away wipe the
inside of the booth with a damp cloth, ensure the cloth is damp only.
Figure 4-5 Open duct door