Nordson HORIZON 200 User manual

Horizonr200/400
Powder Coating System
Customer Product Manual
Part 106913−04
Issued 6/18
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 106913−04 E2018 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 1996. 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
Horizon, Nordson, the Nordson logo, Sure Coat, Tribomatic, and
Versa-Spray are registered trademarks of Nordson Corporation.

Change Record i
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Change Record
Revision Date Change
04 06/18 Added part numbers for Horizon 200 components.

Change Record
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Table of Contents iii
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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.............................................
Introduction 2-1.............................................
System Configuration 2-1..................................
System Operation 2-2........................................
Powder Application 2-2....................................
Powder Recovery and Reclaim 2-2..........................
Non-Reclaim Systems 2-2.................................
System Equipment 2-4.......................................
Recovery and Reclaim Equipment 2-4.......................
System Controls 2-5.......................................
Application Equipment 2-5.................................
Typical System Options 2-7................................
System Electrical and Pneumatic Controls 2-9..................
Motor Starter Panel 2-9...................................
System Pneumatic Panel 2-12..............................
Rotary Sieve Pneumatic Panel 2-13.............................
Operation 3-1..............................................
New System Startup 3-1.....................................
Transfer Pump and Pulse Valve Timer Settings 3-1...........
Seal Checks 3-2.........................................
Air Pressure and Air Flow Settings 3-3......................
Rotary Sieve Settings 3-5.................................
Final Startup Steps 3-5....................................
Fan Damper Adjustment 3-6...............................
Feed Hopper Level Sensor Calibration 3-6...................
Vent-Assist Air Pressure Adjustment 3-8.....................
Daily Startup and Shutdown Procedures 3-8....................
Startup 3-8...............................................
Shutdown 3-9............................................
Changing Colors 3-9.........................................
Color Change: Reclaim-to-Reclaim 3-9......................
Old Color Removal 3-9.................................
New Color Installation 3-10................................
Color Change: Reclaim-to-Non-Reclaim 3-12..................
New Color Module/Feed Hopper Assembly 3-12.............
New Color Module with Portable Feed Hopper 3-14..........
Startup after Color Change 3-15.............................

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New Cartridge Filter Seasoning 4-1..........................
Introduction 4-1.............................................
Seasoning with a Manual Operated Fan Damper 4-1............
Seasoning with a Manual AMS System 4-2.....................
Seasoning with an Automatic AMS System 4-2..................
Seasoning Without a Fan Damper or AMS System 4-3...........
Maintenance 5-1...........................................
Daily Maintenance 5-1.......................................
Cleaning 5-1.............................................
Daily Equipment Maintenance 5-2...........................
Weekly Maintenance 5-4.....................................
Periodic Maintenance 5-5....................................
Maintenance Check List 5-6..................................
Troubleshooting 6-1........................................
Introduction 6-1.............................................
Troubleshooting Procedures 6-2..............................
Reversing Motor Direction 6-8.................................
Exhaust Fan Motor 6-8....................................
Sieve Motor 6-8...........................................
Schematics 6-9.............................................
Pneumatic Schematic 6-9.................................
Electrical Schematic 6-10...................................
Repair 7-1.................................................
Introduction 7-1.............................................
Final Filter Replacement 7-1.................................
Cartridge Filter Replacement 7-3..............................
Cartridge Filter Removal 7-3................................
Cartridge FIlter Installation 7-3.............................
Color Module Fluidizing Plate Replacement 7-6..................
Preparation 7-6..........................................
Fluidizing Plate Replacement 7-6...........................
Feed Hopper Fluidizing Plate Replacement 7-8..................
Preparation 7-8...........................................
Fluidizing Plate Replacement 7-8...........................
Vibratory Sieve Repair 7-10....................................
Pulse Valve Replacement 7-10.................................
Fan and Fan Drive Repair 7-12.................................
V-Belt Replacement 7-14.....................................
Sheave Replacement 7-16....................................
Sheave Removal 7-16.....................................
Sheave Installation 7-16....................................
Motor Replacement 7-19......................................
Motor Removal 7-19.......................................
Motor Installation 7-19.....................................
Fan Replacement 7-21.......................................
Fan Removal 7-21.........................................
Fan Installation 7-21.......................................
Fan Shaft and Bearing Replacement 7-23.......................
Bearing Types 7-23........................................
Fan Shaft and Bearing Removal 7-23........................
Fan Shaft and Bearing Installation 7-24
.......................
Old-Style Bearing and Fan Shaft Adjustment 7-25...........
New-Style Bearing and Fan Shaft Adjustment 7-26..........

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Parts 8-1...................................................
Introduction 8-1.............................................
System Electrical Panel 8-2..................................
Horizon 400 Parts 8-6........................................
Base Parts 8-6...........................................
Pulse Valves and Air Manifold Parts 8-8......................
Pulse Valve Solenoids and Air Volume Control Parts 8-9.......
Fan and Fan Drive Parts 8-10...............................
Belt/Bushing/Sheave/Motor/Mounting Plate Parts 8-12..........
Fan Damper Parts 8-12.....................................
Final Filters and Mounting Parts 8-14.........................
Color Module Parts 8-15....................................
Color Module Fluidizing Plates, Direct Vent, and Vent Stub Parts ......
8-17
Cartridge Filters 8-17.....................................
Vent Options 8-17.......................................
Horizon 200 Parts 8-19........................................
Base Parts 8-19...........................................
Fan and Fan Drive 8-20.....................................
Color Module 8-21.........................................
Cart-Mounted Feed Hoppers and Sieves 8-22....................
Hopper with Vibratory Sieve 8-22.............................
Hopper with 10-Port Cyclone 8-22............................
Hopper with Nordson
230/460 V Rotary Sieve 8-23................................
Feed Hopper with AZO Sieve 8-24...........................
Feed Hopper with Nordson NRPS-100 Rotary Sieve 8-25.......
Specifications 9-1..........................................
Dimensions and Capacities 9-1................................
Operating Environment 9-1...................................
Utilities 9-2.................................................
Normal Design Standards 9-2.................................

Safety 1-1
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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

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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 Safety Data Sheets (SDS) 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 SDS
for guidance.
SDo not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.

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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
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.
SAll 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.
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.

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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
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Section 2
Description
Introduction
This manual covers Horizon 200 and 400 powder coating systems. It
includes booth operation, maintenance, troubleshooting, repair procedures,
and lists of serviceable parts. Other components of your system are
covered in separate manuals.
System Configuration
This manual covers a basic, manually operated powder coating system. The
illustrations show a Horizon 400 system. The Horizon 200 system is
smaller, but has the same basic components. Additionally, your system may
have optional equipment not described in this manual, such as the
Smart-Coat system or other advanced control systems.
Systems are either permanently located under the conveyor, or mounted on
casters and rails (roll-on/roll-off system). Roll-on/roll-off systems can be
moved off-line for powder changes or maintenance.
Figure 2-1 illustrates the operation of the typical system. Figures 2-2
through 2-5 show the equipment and controls used in a typical system. You
should also review the engineering drawings (plan views and schematics)
furnished with your system.

Description
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System Operation
See Figure 2-1.
Powder Application
A porous fluidizing plate in the bottom of the feed hopper (8) diffuses
low-pressure compressed air into the powder supply. The air fluidizes the
powder, so it can be pumped to the spray guns. A vent duct connects the
hopper to the color module (10).
The powder pumps (7) draw the powder out of the hopper, mix it with a
high-velocity stream of air, and force it through the feed hoses (9) to the
powder spray guns (2). The guns electrostatically charge the powder and
spray it onto the workpieces (3) passing through the enclosure (1). The
charged powder sticks to the grounded workpieces.
Powder Recovery and Reclaim
The exhaust fan (16) pulls spray-room air through the enclosure and into
the color module through an opening in the base floor. A skirt seal prevents
powder from escaping from the gap between the base floor and the color
module. The air flows through the cartridge filters (13), into the fan
compartment, through the final filters (17), and back into the spray room.
The standard, manual fan damper (15) (Horizon 400 only) controls the
volume of air flowing through the booth.
The oversprayed powder suspended in the air collects on the external
surfaces of the cartridge filters. At timed intervals, the pulse valves (14)
force large volumes of air through the center of the cartridge filters, blowing
off the collected powder. The powder falls into the color module hoppers,
where it is fluidized.
The transfer pumps (12) pump the fluidized powder in the color module
hoppers through the transfer hoses (11) to the accumulator (5) on top of the
sieve (6). The powder flows from the accumulator into the sieve screen.
The screened powder falls into the feed hopper. The sieve discharges
particles and clumps too large to pass through the screen into a scrap
container. The vent hose (4) connecting the accumulator to the color
module helps maintain a neutral air pressure in the accumulator and sieve.
Non-Reclaim Systems
You can convert your Horizon system from reclaim to non-reclaim by
installing a color module for the new powder and connecting the transfer
hoses to a scrap drum instead of an accumulator and sieve. You can then
use a standard feed hopper attached to the color module, or a portable feed
hopper, to supply the new powder to the spray guns.

Description 2-3
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Air Flow
Powder Flow
12 3
8
10
7
911
16 131517 14 12
5
6
4
Figure 2-1 System Operation
1. Enclosure
2. Spray guns
3. Workpiece
4. Vent hose
5. Accumulator
6. Sieve
7. Powder pumps
8. Feed hopper
9. Feed hoses
10. Color module
11. Transfer hoses
12. Transfer pumps
13. Cartridge filters
14. Pulse valves
15. Fan damper
16. Exhaust fan
17. Final filters

Description
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System Equipment
A typical system includes the equipment described below. Your system may
have different equipment, or the equipment may be installed in locations
different from those shown in the illustrations.
Recovery and Reclaim Equipment
Item numbers in Table 2-1 correspond to callouts in Figure 2-2.
Table 2-1 Recovery and Reclaim Equipment
Item Equipment Description
1Booth enclosure
(canopy)
Contains the sprayed powder within the booth. It has a
conveyor slot in the roof, exit and entry vestibules at each end,
and slots and openings in the sides for automatic and manual
spray guns.
7Booth base Supports the enclosure and houses the exhaust fan, motor,
fan damper, cartridge filter pulse valves and air manifold, and
final filters. A covered tray running around the top edge of the
base houses the system wiring and pneumatic plumbing.
10 Transfer pumps Pump the reclaimed powder from the color module hoppers to
the accumulator. A three-position switch on the system
electrical panel controls pump operation.
14 Color module Houses the cartridge filters, fluidizing plates and pans, and
transfer pumps. Oversprayed powder accumulates in hoppers
in the bottom of the module. A baffle plate covers the
cartridge filters. A steel mesh grill covers the top of the
module. A D-gasket seals the joint between the color module
and the fan compartment.
15 Sieve Screens the reclaimed powder. Discards powder particles and
clumps too large to pass through the sieve screen. Electrically
driven rotary sieves or air-powered vibratory sieves are
available.
16 Accumulator Collects the reclaimed powder pumped from the color module
by the transfer pumps. The accumulator provides multiple
inlet connections for the transfer hoses. It is vented into the
color module.

Description 2-5
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System Controls
Item numbers in Table 2-2 correspond to callouts in Figure 2-2.
Table 2-2 System Controls
Item Equipment Description
2Motor starter panel Houses motor starters and overload protectors, transformers,
interlock relays, differential-pressure switches, pulse valve
timers, and basic system controls and indicator lights. An
optional programmable controller can be installed in the panel.
3Flame detector
indicator/relay panel
Provides visible and audible fault and fire alarms and process
shutdown relays. If a detector senses a flame, the interlock
relays shut down the conveyor, booth exhaust fan,
compressed air and electrical power to the spray guns.
ANSI/NFPA-33 standards require flame detectors in all
systems equipped with automatic spray guns.
5Pneumatic panel Houses air-pressure regulators and gauges for the color
module, differential pressure switch gauges, feed hoppers,
transfer pumps, and other pneumatic equipment.
6Fan damper control Opens and closes the fan damper louvers to control air flow
through the enclosure. (Used only on Horizon 400.)
8Pulse air controls Regulate the pulse air pressure and volume. Controls include
a regulator, pressure gauge, and gate valve.
11 Feed-hopper level
sensor
Monitors the level of powder in the feed hopper. Turns on the
transfer pumps when the level of powder falls below the
sensor.
17 Flame detectors Monitor the enclosure (booth) interior for flames. The
detectors use IR sensing technology and provide
through-the-lens self test to check for powder build-up.
Application Equipment
Item numbers in Table 2-3 correspond to callouts in Figure 2-2.
Table 2-3 Application Equipment
Item Equipment Description
4Gun control units Control air pressure to the powder pumps. Generate
(cable-fed units) and control electrostatic voltage. Each spray
gun requires a control unit. An equipment cabinet houses the
automatic gun control units, a master control unit, and air
supply controls.
9Automatic spray guns Charge powder particles electrostatically and spray them
toward the grounded workpieces. The operator uses a
manual spray gun for touch-up work.
12 Feed hopper Stores and fluidizes the powder supply for automatic and
manual spray guns.
13 Powder pumps Pump powder out of the feed hopper to the spray guns. Each
spray gun requires a pump.

Description
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Application Equipment (contd)
1
2
4
3
5
6
8
9101112
13
14
15
16
17
7
Figure 2-2 System Components
1. Booth enclosure
2. Motor starter panel
3. Flame detector indicator/relay
panel
4. Gun control units
5. Pneumatic panel
6. Fan damper control
7. Booth base
8. Pulse air controls
9. Automatic spray guns
10. Transfer pumps
11. Feed hopper level sensor
12. Feed hopper
13. Powder pumps
14. Color module
15. Sieve
16. Accumulator
17. Flame detectors

Description 2-7
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Typical System Options
Options include those described below. Contact your Nordson Corporation
representative for further information on these and other options.
Item numbers in Table 2-4 correspond to callouts in Figure 2-3.
Table 2-4 Typical System Options
Item Equipment Description
1Air dryer Removes moisture from the system air supply. Most systems
use regenerative-desiccant or refrigerated air dryers.
2Gun movers Use oscillators or reciprocators to move automatic spray guns
in a repetitive pattern for better workpiece coverage. Gun
movers may also be equipped to move the spray guns toward
and away from the workpieces.
3Powder drum unloaders Transfer powder from shipping drums to feed hoppers or color
modules.
4Color change
equipment
Consists of additional color modules, feed hoppers, sieves and
accumulators. These contain different powders for quick
changes.
—Roll on/roll-off
equipment
Move the booth and attached equipment on and off the
conveyor line. Manual and powered equipment movers are
available.
—Advanced automation
systems
Identify and track parts on the conveyor line; control
automatic-gun movement, triggering, air pressure, and
voltage. Also gather data on system operation and generate
reports.
—Airflow Management
System
Automatically controls air flow through the booth, using a
variable-speed motor control and pressure sensors.

Description
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Typical System Options (contd)
1
2
3
4
Figure 2-3 Typical System Options
1. Air dryer
2. Gun movers
3. Powder drum unloaders 4. Color change equipment