MANUAL Std Multi Clone Booth

MITSUBA SYSTEMS (INDIA) PVT. LTD.

STD MULTICLONE BOOTH SYSTEM

INSTRUCTION AND MAINTENANCE

MANUAL

STD MULTICLONE POWDER SPRAY

CUM RECOVERY BOOTH SYSTEM

MITSUBA SYSTEMS (INDIA) PVT. LTD. SAFETY

SAFETY

1. Introduction

READ THIS CAREFULLY BEFORE OPERATING ANY EQUPMENTS. 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.

2. Qualified Personnel

Equipment owners are responsible for making sure that Mitsuba Systems’ 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 safely rules and regulations and are capable of performing their assigned tasks.

3. Intended Use Use of Mitsuba Systems’ 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

• using incompatible materials

• making unauthorized modifications

• removing or bypassing safety guards or interlocks

• using incompatible or damaged parts

• using unapproved auxiliary equipment

• operating equipment in excess of maximum ratings

4. Regulations and Approvals Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Mitsuba Systems equipment will be voided if it instructions for installation, operation, and service are not followed. The equipment shall be considered dangerous if not operated according to the standards EN 50050, EN 50053 Part 2, EN 60079-0 and EN 1953. The Equipment is CE certified under EN1953 and the Powder Spray Guns are ATEX certified under Certificate No. FTZU 07 ATEX 0165


5. Personal Safety

WARNING

• Do not operate or service equipment unless you are Qualified.

• Do 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.

• Keep 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.

• Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or servicing pressurized systems or components. Disconnected, lock out, and tag switches before servicing electrical equipment.

• While operating manual electrostatic spray guns, make sure you are grounded. Wear electrically conductive gloves or a grounding strap connected to the gun handle or other true earth ground. Do not wear or carry metallic objects such as tools.

• If you receive even a slight electrical shock, shut down all electrical or electrostatic equipment immediately. Do not restart the equipment until the problem has been identified and corrected.

• Follow the manufacturer’s instructions for safe handling and use of materials, and use recommended personal protection devices.

To 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. Care to be taken to especially avoid any repetitive strain injury due to any recoil forces while operating the trigger of the gun.


6. Fire Safety

TO AVOID A FIRE OR EXPLOSION, FOLLOW THESE INSTRUCTIONS.

WARNING

• Ground all conductive equipment in the spray area. Check equipment and work piece grounding devices regularly. Resistance to ground must not exceed one mega ohm.

• Shut down all equipment immediately if you notice static sparking or arcing. Do not restart the equipment until the cause has been identified and corrected

• Do not smoke, weld, grind, or use open flames where flammable materials are being used or stored.

• Provide adequate ventilation to prevent dangerous concentrations of volatile materials or vapors. Refer to local codes for guidance.

• Do not disconnect live electrical circuits while working with flammable materials. Shut off power at disconnect switch first to prevent sparking.

• Know 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.

• Shut off electrostatic power and ground the charging system before adjusting, cleaning, or repairing electrostatic equipment.

• Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation.

Use only replacement parts that are designed for use with original equipment. Contact your local Mitsuba Systems representative for parts information and advice.


7. 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:

• Disconnect and lock out electrical power. Close pneumatic shutoff valves and relieve pressure.

• Identify the reason for the malfunction and correct it before restarting the equipment.

8. Disposal

Dispose of equipment and materials used in operation and servicing according to local codes that govern your area.

• According to EN 50050: Additional information

-in the potentially explosive atmospheres produced by the spraying process, only appropriate explosion-protected electrical apparatus shall be used: -hand-held equipment shall be used only by instructed personnel, -it shall be ensured that excess coating material (overspray) will be safely collected; -any other information required for proper use of the equipment: see 7.1 of EN 1953.

-the note:” This equipment can be dangerous it is used in accordance with the instruction laid down in this manner”.


9. Caution List – for Operating Safety of the Equipment

• Your system can take normal voltage fluctuations. For extreme & constant fluctuations, it is advisable to install a voltage stabilizer and spike suppressor. This will ensure peak performance over long periods.

• The control panel should be serviced and opened by qualified personnel only. Care to be taken of any hot surfaces within the panel while opening it and five minutes after opening panel given enough time for the components to cool down making them safe to touch and service.

• Ensure that all the nuts and bolts of the booth system are tight to prevent any loss of recovery efficiency. Similarly the clamps at the collector bin have to be kept absolutely tight.

• Clean the booth and recovery module insides by the use of compressed air only. DO NOT USE any liquid cleaners.

• Do not block or reduce the area of exhaust air outlet, this may create backpressure in turn giving less suction at the mouth of the booth.

• Do not change the wiring connection of the motor; ensure that it is running in the direction as shown on the Blower.

• During color change keep the booth in running condition and blow Air

through all the openings of the booth. Ensure that each and every clone is cleaned thoroughly to avoid contamination.

• The Powder Spray cum recovery booth system must be grounded solid and separate from other system earths. This means that this Earth must not be looped to Main Earth via the powder spray system, Oven etc., but it should be connected to Main Earth separately.

• Maintain polarity of the Phase, Neutral and Earth at the Mains Power Inlet.


10. Basic Safety Care for Automatic and Manual Booth Systems

CAUTION • Properly ground all equipments within 5m of the powder spray area to an

earth ground.

• The floor of the powder spray area must be electro statically conductive.

• Powder should be removed from the skin with soap and water only. DO NOT USE SOLVENTS.

• Do not tape the trigger in ‘ON’ position.

• Before cleaning or maintaining the booth, make sure that the main power supply to the control panel of the booth is switched off. Disconnect if necessary.

• The electronic control unit is designed to cut out the mains voltage system in case of overloads. This is a safety precaution in-built into the system. In case the system has cut-out (the booth blower motor has overloaded), investigate the cause of the overload and switch off the system and restart.

• A ground cable must be connected to the ground terminal of the booth control panel. This cable must have proper metallic connection with the coating booth, recovery unit, conveyor & jigs.

• All ground connection must be checked daily or at least weekly.

MITSUBA SYSTEMS (INDIA) PVT. LTD. TECHNICAL DATA

TECHNICAL DATA

Electrical Data

System Control Panel

Input Voltage 440/415V Three phase AC

Frequency 50 Hz.

Connected loads Depends on supply (Refer to Supply Invoice)

Safety class IP 54

Temperature Range +2 °C to +50 °C

Nominal Output Voltage to Blower Motor

440/415V Three phase AC

Nominal Output Voltage for Booth Lighting

230/220V Single phase AC

Mechanical Data

Booth dimensions Refer to supply dimension drawings

MITSUBA SYSTEMS (INDIA) PVT. LTD. FUNCTIONAL DESCRIPTION

FUNCTIONAL DESCRIPTION

Rotary clone Recovery Booth without optional After Filter Module

The equipment consists of a booth body, recovery modules, powder collector bin, blower with motor and control panel

The blower with motor is fitted onto the recovery module. It sucks the air out of the clone inner area. This in turn results in suction of air through the booth body spray openings, through the clone central section at the recovery and into the clones. The powder over sprayed at the booth shall now mix with this sucked air and this powder-air mix is sucked into the clones by the suction action of the blower. The design of the clones makes the powder-air mixture to spiral into a high velocity cyclone. At the plenum of the cyclone, the powder gets separated from the powder-air mixture and falls into the powder collector bin. The separated air is now sucked into the blower. It then impinges onto the optional after filter module and exhausts it at its outlet. The precise design and correct connection of the various parts of the booth account for the very high separation efficiency offered by these booths.

MITSUBA SYSTEMS (INDIA) PVT. LTD. FUNCTIONAL DESCRIPTION

2. Functional Description – with optional After Filter module

The equipment consists of a booth body, recovery module/s, Optional after filter module, powder collector bin, blower with motor and control panel

The blower with motor is fitted onto the optional after filter module. This after filter module is in turn fit with the recovery module. The blower sucks the air out of the after filters and in turn through the clone inner area. This in turn results in suction of air through the booth body spray openings, through the clone central section at the recovery and into the clones. The powder over sprayed at the booth shall now mix with this sucked air and this powder-air mix is sucked into the clones by the suction action of the blower. The design of the clones makes the powder-air mixture to spiral into a high velocity cyclone. At the plenum of the cyclone, the powder gets separated from the powder-air mixture and falls into the powder collector bin. The separated air is now sucked into the blower. This separated air may contain some minute amount of very fine powder. This separated air then impinges onto the optional after filter module and exhausts it at the blower’s outlet. The precise design and correct connection of the various parts of the booth account for the very high separation efficiency offered by these booths.

MITSUBA SYSTEMS (INDIA) PVT. LTD. ASSEMBLY, INSTALLATION & SETUP

ASSEMBLY, INSTALLATION & SETUP

WARNING: Allow only qualified personnel to perform the following Tasks. Follow the safety instructions in this document and all other related documentation.

WARNING: All electrically conductive equipment in the spray area must be grounded. Ungrounded or poorly grounded equipment can Store an electrostatic charge which can give personnel a severe Shock or arc and cause a fire or explosion.

1. Assembly & Installation (Detachable Booth System)




1. Assembly & Installation

• Open the packing of all the components of the booth cum recovery system from their respective boxes. The main components being the assembled booth body, Booth removable duct, Connection duct between booth to recovery, recovery module, powder collector bin, booth control panel, jig and blower with motor.

• Place the booth body in the desired position.

• Assemble the recovery module to the booth body by connecting the Duct.

• Connect the powder collector bin to the lid using the side clamps.

• Mount the blower with motor onto the top of the recovery section. Utilize the bolts provided and ensure that the blower to recovery module connection is air tight.

• Connect the three phase supply to the booth control panel as per the wiring diagram.

• Connect the three phase supply to the blower motor from the booth control panel as per the wiring diagram.

• Connect the booth lighting to the booth control panel as per the wiring diagram.

• Connect gun plug to panel. Connect mains inlet cable to panel. Confirm phase, Neutral + Earth polarity are correct on the mains plug.

• Connect a proper earth to the jig installed into the booth.

• Confirm that earth connection is given to a proper ground. This is very IMPORTANT.

• Put an air relief hose from the powder hopper into the powder spray booth if you have a relief vent with the system.


2. Commencement of Operations

• Ensure proper earthing to the equipment.

• Switch on the three phase supply to the booth control panel.

• Ensure that all the three phases are operative by observing the 3 phase indicator lights on the booth control panel.

• Switch on the booth light using the light switch on the booth control panel. Ensure that the light switches on correctly.

• For a first time operation, start the motor of the blower and quickly shut it off. Observe the direction of rotation of the motor fan blades and ensure that they are moving in the correct direction as indicated by the arrow on the motor/blower. If it is moving in the opposite direction, this can hamper operations. Switch off. Disconnect power and switch the red and yellow phases of the motor connection. Now repeat the above procedure to ensure correct direction of rotation of the blower/motor.

• Now switch on the blower of the booth using the green push button on the booth control panel. This push button shall now illuminate to indicate that the blower motor has been switched on. To stop the motor the red push button has to be pushed.

• This starts the suction inside the booth and powder can now be sprayed onto the workpiece kept inside the booth.

The equipment is ready for operation.

MITSUBA SYSTEMS (INDIA) PVT. LTD. COLOUR CHANGE & MAINTENANCE SCHEDULE

COLOUR CHANGE & MAINTENANCE SCHEDULE

1. Colour Change

It is important to note that a black and white powder mix in powder coating does not give gray. It gives a black finish with white spots and vice versa. So the Colour change operation is very critical.

PROCEDURE

1. Stop powder spray into the booth.

2. Start the blower motor of the booth.

3. Use compressed air to blow the powder from the spray openings towards the suction area of the booth. Systematically blow the powder towards the suction area of the booth so that all the residual powder is cleaned from the booth area.

4. Now open the port doors of the recovery module. Blow compressed

air and each clone thoroughly.

5. Now detach the clamps holding the powder collector bin at the bottom of the recovery module. Remove the powder collector bin but keep the lid of the bin attached to the clones via the bellows.

6. Use compressed air and blow clean the bottom side of the powder

collector bin lid and the bottom of the clones.

7. Remove residual powder from the powder collector bin and clean the bin thoroughly.

8. Re-fit the bin, close all the ports opened and generally tighten any

parts that had been loosened / removed for cleaning.

9. Restart spraying the new colour.

CAUTION

1. DO NOT use ANY liquid cleaners to clean the powder in the

booth.


2. Basic Safety Care for Automatic and Manual Booth Systems

WARNING

1. Properly ground all equipments within 5m of the powder spray area to an earth ground.

2. The floor of the powder spray area must be electrostatically conductive.

3. Powder should be removed from the skin with soap and water only. DO

NOT USE SOLVENTS.

4. Before cleaning or maintaining the booth, make sure that the main power supply to the control panel of the booth is switched off. Disconnect if necessary.

5. A ground cable must be connected to the ground terminal of the booth control panel. This cable must have proper metallic connection with the coating booth, recovery unit, conveyor & jigs.

6. All ground connection must be checked daily or at least weekly.


3. Servicing & Routine Maintenance

1. Blow air and clean the powder at the booth body every day at least.

2. Blow air and clean the clones at every colour change. Also if no colour change is effected, clean the clones at least once a week.

3. Check and replace if necessary, the gasket at the powder collector

hopper at least once a month.

4. Check and replace if necessary, all booth and recovery module gaskets at least once in six months.

5. Check and tighten all electrical connections at least once in six

months.

6. Check direction of rotation of the blower at least once a year to make sure it is running correctly.

7. Once a year the equipment should be overhauled by a trained

maintenance engineer.

MITSUBA SYSTEMS (INDIA) PVT. LTD. TROUBLESHOOTING

TROUBLE-SHOOTING

Introduction This section contains troubleshooting procedures. These procedures cover only the most Common problems that you may encounter.

If you cannot solve the problem with the Information given here, contact your Mitsuba System representative. Note that the Mitsuba System is not responsible for any damages done to the system while handling or trouble-shooting the equipment.

FAULT CAUSE REMEDY

BOOTH SUCTION NOT

NO MAINS INPUT RECTIFY SITUATION

NOT PRESENT / MOTOR NOT WORKING

CHECK IF MOTOR OVERLOADED

CHECK CAUSE AND RESET OVERLOAD AND RE-START

MCB IN CONTROL PANEL IS TRIPPED / NOT SWITCHED ON

CHECK CAUSE AND RE-START

MOTOR BURNT / DEFECTIVE

CHECK WITH MEGGER AND RE-WIND / REPLACE IF NECESSARY

BOOTH SUCTION LESS

CHECK FOR LOOSE CLAMPS / BOLTS AT THE GASKETED JUNCTIONS

RECTIFY LOOSE CONNECTION

BLOWER MOTOR DIRECTION REVERSE

CHECK AND RECTIFY BY SWITCHING 2 PHASES OF THE MOTOR CONNECTIONS

BLOWER OUTLET IS NOT FREE AND RESTICTED

REMOVE RESTRICTIONS SUCH AS LESSER AREA DUCT ETC.

POWDER COLLECTOR BIN NOT FIT CORRECTLY

TIGHTEN CLAMPS AND RE-FIT COLLECTOR BIN

MORE POWDER COMING OUT OF THE EXHAUST END

BLOWER MOTOR DIRECTION REVERSE

CHECK AND RECTIFY BY SWITCHING 2 PHASES OF THE MOTOR CONNECTIONS

OF THE BLOWER

POWDER COLLECTOR BIN NOT FIT CORRECTLY / NOT FIT AT ALL

TIGHTEN CLAMPS / RE-FIT COLLECTOR BIN

MITSUBA SYSTEMS (INDIA) PVT. LTD.

WIRING DIAGRAM

WIRING DIAGRAM

BOOTH PANEL

WIRING DIAGRAM OF

BOOTH PANELN.T.S.

ISHO 18/09/03

MNP 18/09/03

ABS 18/09/03

1 NO

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MANUAL Std Multi Clone Booth