RTT Powder Booths User manual

Installation Manual
Powder Booths
Class 4
Follow Us:
>> Batch Powder Booths
>> Cartridge Batch Powder Booths
>> Pass Through Powder Booths
>> Lab Powder Booths
This Installation Manual reviews an introduction,
safety, component description, installation,
maintenance and warranties of RTT'spowder booths.
888-452-6684
www.rttsolutions.com
Revised August 2020
RTT Engineered Solutions
2975 Discovery Blvd. Rockwall, TX 75032 Toll-Free 888-452-6684 Email [email protected] www.rttsolutions.com
1

1. General Description .................................................. 2
1.1 General Description ..................................................................2
1.2 Compliance to Applicable Codes ........................................... 2
1.3 Proper Grounding Procedures.................................................3
2. Safety ..................................................................... 4
2.1 Safety Alert Symbol and Signal Words................................... 4
2.1.1 Assembly Hazards................................................................... 5
2.1.2 Operational Hazards ..............................................................6
2.1.3 Maintenance Hazards ............................................................7
2.1.4 Fire Hazard ...............................................................................7
2.2 Safety Decals...............................................................................8
2.3 NFPA 33 .......................................................................................9
3. Spray to Waste Powder Booth...................................12
3.1 Three-Stage Filter System ......................................................12
3.2 Manometer................................................................................12
3.3 Air Solenoid Valve ....................................................................16
3.4 Exhaust Fans .............................................................................17
3.5 Powder Exhaust Filter Proving Assembly ...........................20
3.6 Optional Control Panel ...........................................................20
4. Lab, Batch, and Pass Through Powder Booths............21
4.1 Control Panel with Variable Frequency Drive.....................22
4.2 Optimizing Your Collector's Performance ...........................24
4.3 Understanding the Pulse Down System ..............................26
4.4 Troubleshooting Pulse Problems .........................................30
4.5 Exhaust Filter Installation .......................................................33
4.6 Intake Filter Installation ..........................................................34
5. General Lighting Components ..................................35
5.1 Light Fixtures.............................................................................35
6. General Installation Procedures................................36
6.1 Installation General .................................................................36
6.2 Booth Assembly........................................................................37
6.3 Motor Installation.....................................................................39
6.4 Electrical ....................................................................................40
6.6 Tubeaxial Fan............................................................................42
7. General Maintenance Procedures..............................43
7.1 General Instructions ................................................................43
7.2 Fans and Motors.......................................................................43
7.3 Routine Fan Maintenance.......................................................43
7.4 Excessive Fan Vibration...........................................................44
7.5 High Motor Temperature ........................................................44
7.6 High Bearing Temperature.....................................................44
7.7 Lubrication ................................................................................44
7.8 Cautions.....................................................................................44
7.9 Environmental Limitations of Booth Components...........44
7. Warranty ................................................................46
Contents
1

General Description
1.1 General Description
This section contains literature which describes your RTT powder spray booth in general terms. Subsequent
chapters of this manual provide more detailed descriptions of the individual booths and their operating
components, as well as maintenance procedures.
This description covers a family of RTT powder booths. The following booth types are covered herein:
>> Batch Powder Booths (PB)
>> Cartridge Batch Powder Booths (RPB)
>> Pass Through Powder Booths (EPB)
>> Lab Powder Booths
The powder booth itself consists of four major components: powder application area, collection/extraction
chamber, exhaust fan and chamber, and in some cases product doors. A brief description is provided for these
and other related items.
The parts to be powder coated are placed in the powder application area, through the booth opening or
product doors (if so equipped). Air flows through the booth opening(s) to the exhaust filters. Exhaust filters will
vary based on the style of booth purchased. The booth exhaust is routed the exhaust plenum(s) at the exit of the
booth. The exhaust fan then routes the exhaust out through the Final Filters and discharges clean contaminate
free air back into the powder coating room.
Exhaust Fan and Chambers
The Spray to Waste Industrial Batch Powder exhaust chamber is located as shown in the mechanical drawing
package which is included in this manual. Powder laden air is drawn through a three stage filtration system (pre
filter, primary filter and final filter) by a tubeaxial fan which is powered by an ODP motor. Filters clean the air of
powder allowing it to return into the plant environment. The fan is made of spark resistant material and the
motor is located out of the air stream. The exhaust chamber(s) operate(s) under a negative pressure to induce
the required airflow through the exhaust filters.
The Recovery Powder Booth exhaust is located as shown in the mechanical drawing package which is included
with this manual. Powder laden air is drawn through a two stage filtration system (primary cartridge filter and
final HEPA filter) using a plug style fan with a TEFC type motor. Clean air is returned to the plant environment.
1.2 Compliance to Applicable Codes
Warning: Your safety and the safety of others is a direct result of how you operate this powder booth. Make sure
you understand all the controls and the operating instructions before beginning.
Bypassing Safety Devices There are several safety devices provided to ensure safe operation of the powder
booth. DO NOT make any attempt to override these devices.
2

Personal Safety Consult with your powder/material supplier for proper recommendations on respirator types
required for applying the powder/material supplied. Operators should read and follow instructions from the
powder companies Material Safety Data Sheets (MSDS).
All parts and components must be electrically bonded and properly grounded to prevent static buildup
and discharge.
Compliance to Applicable Codes This Powder Booth is designed to be in strict accordance with the National
Fire Protection Association Standard Number 33, “Spray Application Using Flammable Combustible Materials.
The NFPA Standard Safety Code for the design, Construction and Ventilation of Spray Finishing Operations.” This
Powder Booth meets or exceeds the requirements of the Occupational Safety and Health Administration (OSHA).
Material Specifications The powder booth panels, filter racks and product doors (if required) are constructed
of 18 gauge steel, conforming to ASTM A527 “Lock Forming Quality” and are hot dip galvanized per ASTM A525
with G90 coating.
All structural steel conforms to ASTM A36.
Safety Local fire codes prohibit smoking in the vicinity of powder coating operations. Consult your local fire
marshal for posting of “No Smoking” signs.
Improperly maintained equipment could cause sparks which could ignite the powder cloud.
For Your Safety Beware of poor electrical wiring that could cause sparks. DO NOT store flammable liquids
adjacent to or inside the powder booth. Read all refinishing product labels and instructions.
Fire Protection An approved fire detection/suppression system must be installed on the powder coating booth
to comply with NFPA 33, Section 9 and all applicable state and local codes. NOTE: Fire detection/suppression
system supplied by others.
1.3 Proper Grounding Procedures
The powder booth must be properly grounded to a positive earth ground. Powder booth installation should
include a 5/8” diameter rod by 8ʼ-0” in length driven into the ground leaving 8” of protruding above the floor (see
picture). The booth and all booth components MUST be grounded to this rod including all powder application
equipment.
PROPER BOOTH GROUNDING:
>> 5/8” diameter x 8ʼ-0” long copper rod.
>> Grounding rod installed through hole in the floor
leaving at least 8” of rod above floor as close to
booth as installation will allow.
>> Booth, parts hangers, application equipment must
be grounded to this rod.
Failure to properly ground all booth components could
possibly cause static discharge which could result in a fire.
3

2. Safety
2.1 Safety Alert Symbol And Signal Words
Before assembling, operating or servicing the spray booth, you must read, understand and follow the
instructions and safety warnings in this manual. Your spray booth may not be equipped with some of the
optional equipment described in this manual.
NEVER ALLOW ANYONE TO OPERATE THIS EQUIPMENT WITHOUT PROPER TRAINING!
The safety information in this manual is denoted by the safety alert symbol:
The level of risk is indicated by the following signal words:
DANGER - Indicates a hazardous situation, which, if not
avoided, WILL result in death or serious injury.
DANGER
WARNING - Indicates a hazardous situation, which, if not
avoided, could result in death or serious injury.
WARNING
CAUTION - Indicates a hazardous situation, which, if not
avoided, could result in minor or moderate injury.
CAUTION
NOTICE - Indicates a situation that could result in damage
to the equipment or other property.
NOTICE
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2.1.1 Assembly Hazards
Prevent serious injury or death.
Overriding a safety system may result in unsafe
equipment, which may result in serious injury or death.
Do not override safety devices.
Blade hazard. Keep hands clear of rotating parts.
Follow lockout procedure before servicing.
Prevent serious injury or death.
Use adequate lifting devices to raise, move and install
booth components.
Prevent serious injury or death.
Electrical installations must be performed by qualied
electricians.
Installation must conform to all national, local, and
provincial codes and standards.
WARNING
WARNING
WARNING
WARNING
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2.1.2 Operational Hazards
Prevent serious injury or death.
Do not operate machine with guards and/or covers open
or removed.
Prevent serious injury or death.
Only trained and qualied personnel may operate booth.
Prevent serious injury or death.
Never operate spray booth while under the inuence of
drugs, alcohol or while feeling ill.
Prevent serious injury or death.
Always wear personal protective equipment (PPE)
appropriate for job.
Read Material Safety Data Sheet for products used in
spray booth.
Shock hazard.
Only a qualied electrician may open electrical control
cabinet.
Disconnect and lockout / tagout all power sources
before adjusting, repairing, or cleaning booth.
WARNING
WARNING
WARNING
WARNING
WARNING
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2.1.3 Maintenance Hazards
2.1.4 Fire Hazard
No smoking or open flame in or near spray booth. Local fire codes prohibit smoking in the vicinity of spray
painting operations.
Prevent serious injury or death.
Disconnect and lockout / tagout all power sources
before adjusting, repairing, or cleaning booth.
Prevent serious injury or death.
Service, maintenance and adjustments must be
performed by trained and qualied personnel.
Burn hazard. Do not touch hot parts.
Allow to cool before servicing.
Explosion and re hazard.
No smoking or open ame within 50 feet of spray booth.
Prevent serious injury or death.
Always wear personal protective equipment (PPE)
appropriate for job.
Read Material Safety Data Sheet for products used in
spray booth.
WARNING
WARNING
WARNING
WARNING
WARNING
7

Do not store flammable liquids adjacent to or inside spray booth. Read all product labels and instructions.
Do not use any electric powered airless spray rigs, pressure washers or similar equipment when applying a low
flash point solvent or peel coating. Run spray booth exhaust fan to purge dangerous vapors that could ignite or
explode while cleaning or performing maintenance inside spray booth.
AN APPROVED FIRE PROTECTION SYSTEM MUST BE INSTALLED ON YOUR SPRAY BOOTH TO COMPLY
WITH NFPA 33, SECTION 9. PORTABLE FIRE EXTINGUISHERS MUST BE LOCATED IN OR AROUND YOUR
PAINT MIX ROOM PER NFPA 10.
2.2 Safety Decals
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may
be required to disconnect electric from
equipment.
Equipment must be properly grounded.
Failure to follow these instructions can result
in death or electrical shock.
Risque de Choc Electrique
Débrancher le courant avant l’entretien.
Plus qu’un interrupteur de verrouillage peut
être requis pour débrancher le courant
électrique de cet appareil.
L’appareil doit être connecté à une source de
courant reliée à la terre.
Le non-respect de ces instructions peut
entraîner de la mort ou des chocs électriques.
DANGER
DANGER
Printed in the USA
Imprimé aux É.-U.
Severe Injury Hazard
Do not enter equipment while in operation.
Equipment may start automatically.
Do not operate with door open.
Installation, operation and service must be done by a trained
technician only.
Failure to follow these instructions can result in death or injury.
Risque de Blessures Graves
Ne pas entrer dans cet appareil pendant l’opération.
Cet apparell peut démarrer automatiquement à tout moment.
Ne pas opérer l’apparell avec la porte ouverte.
L’installation, l’opération et l’entretien doit être eectués par un
installateur éprouvé.
Le non-respect de ces instructions peut entraîner de la mort ou des
blessures.
DANGER
DANGER
Printed in the USA
Printed in the USA
To protect you and others against death or serious injury, all
applicable labels shown must be on the booth and must be legible.
If any of these labels are missing or cannot be read, contact your
RTT for replacement labels.
WARNING
Improper installation, adjustment, alleration, service or maintenance can result in death, injury
or property damage. Read the Installation, Operation and Service Manual thoroughly before
installing or servicing this equipment.
Installation, modication, reglage ou maintenance incorrectes peuvent provoquer de la mort, des
blessures ou des dégâts matériels. Liser attentivement le manuel d’installation, d’operations et
d’entretien avant l’installation ou l’entretien de cet équipment.
This heater must be installed in accordance with the manufacturer’s instructions and local
codes. In the absence of local codes, follow the National Fuel Gas Code, ANSI Z223.1 / NFPA
54 of the CAN/CSAB149 installation code.
Cet aérotherme doit être installé en accord avec les instructions du fabricant et les régulations
locaux. S’il n’y a pas des régulations locaux, l’installation doit être en accord avec le Code
National de Gaz de Carburant, ANSI Z223.1 / NFPA 54 ou le Code d’installation, CAN/
CSA-B149.
WARNING
P/N 01010431 Rev A
8

2.3 NFPA 33 Standards for Spray Application
Reprinted with permission from NFPA 33-2016, Standard for Spray Application Using Flammable or Combustible
Materials, Copyright © 2010, National Fire Protection Association, Quincy, MA. This reprinted material is not the
complete and official position of the NF A on the referenced subject, which is represented only by the standard
in its entirety. The following is section 10 from NFPA 33:
10.1 General. Maintenance procedures shall be established to ensure that all spray application apparatus
and processes are operated and maintained in accordance with the manufacturers specifications and the
requirements of this standard. Maintenance shall be the responsibility of the users of the apparatus and
processes.
10.1.1 Spray application operations shall not be conducted outside predetermined spray areas.
10.1.2 Inspection of extinguishing systems shall be conducted to ensure that the performance of the
extinguishing system components will not be aected by overspray and residues.
10.2 Combustible Deposits.
10.2.1 All spray areas shall be kept free of excessive accumulation of deposits of combustible residues.
10.2.2 Combustible coverings (thin paper, plastic) and strippable coatings shall be permitted to be used to
facilitate cleaning operations in spray areas.
10.2.2.1 Where plastic covering is used, it shall be of a static dissipative nature or shall have a maximum
breakdown voltage of 4 kV to prevent accumulation of a hazardous static electric charge.
10.2.3 If residue accumulates to excess in booths, duct or duct discharge points, or other spray areas, all
spraying operations shall be discontinued until conditions have been corrected.
10.3 High-Pressure Hose Lines. High-pressure hose lines that convey flammable or combustible coating
material in “airless” spray application operations shall be inspected daily and shall be repaired or replaced as
necessary. Hose lines and equipment shall be located so that, in the event of a leak or rupture, coating material
will not be discharged into any space having a source of ignition.
10.4 Maintenance Procedures
10.4.1 Overspray collectors shall be inspected daily and clogged filters shall be discarded and replaced.
Maintenance procedures shall be established to ensure that overspray collector filters are replaced before
restriction to airflow is reduced below the minimum established by Section 7.2.
10.4.2 At the close of the dayʼs operation, all discarded overspray collector filters, residue scrapings, and
debris contaminated with residue shall be removed immediately to a designated storage location, placed in a
noncombustible container with a tight-fitting lid, or placed in a water-filled metal container.
10.5 Waste Containers.
10.5.1 Approved waste containers shall be provided wherever rags or waste are impregnated with sprayed
material, and all such rags or waste shall be deposited therein immediately aer use. The contents of waste
containers shall be placed in a designated storage location.
10.5.2 Waste containers containing flammable liquids shall be located in ventilated areas that meet the
requirements of Chapter 7. Such areas shall also meet the electrical area classification requirements of 6.5.5.
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