RTT Powder Booths Installation Manual

The RTT SmartConnect App provides the ability to remotely view oven status when the control panel is connected to an active internet connection. SmartConnect provides the ability to monitor temperature, process time remaining, elapsed time, system faults or burner status remotely.

INSTA L LATION MANUAL POWDER BOOTHS Class 4

>> 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 ' s powder booths.

888-452-6684 www.rttsolutions.com Revised August 2020

RTT Finishing Solutions 2975 Discovery Blvd. Rockwall, TX 75032 Toll-Free 888-452-6684 Email sales@rttsolutions.com www.rttsolutions.com

Contents

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

General Description 1.1 General Description

This s ection 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.

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.

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

2.1.1 Assembly Hazards

WARNING

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.

WARNING

Blade hazard. Keep hands clear of rotating parts. Follow lockout procedure before servicing.

WARNING

Prevent serious injury or death. Use adequate lifting devices to raise, move and install booth components.

WARNING

Prevent serious injury or death. Electrical installations must be performed by qualified electricians. Installation must conform to all national, local, and provincial codes and standards.

2.1.2 Operational Hazards

WARNING

Prevent serious injury or death. Do not operate machine with guards and/or covers open or removed.

WARNING

Prevent serious injury or death. Only trained and qualified personnel may operate booth.

WARNING

Prevent serious injury or death. Never operate spray booth while under the influence of drugs, alcohol or while feeling ill.

WARNING

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

Shock hazard. Only a qualified electrician may open electrical control cabinet. Disconnect and lockout / tagout all power sources before adjusting, repairing, or cleaning booth.

2.1.3 Maintenance Hazards

WARNING

Prevent serious injury or death. Disconnect and lockout / tagout all power sources before adjusting, repairing, or cleaning booth.

WARNING

Prevent serious injury or death. Service, maintenance and adjustments must be performed by trained and qualified personnel.

WARNING

Burn hazard. Do not touch hot parts. Allow to cool before servicing.

WARNING

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.

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.

WARNING

Explosion and fire hazard. No smoking or open flame within 50 feet of spray booth.

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 FI R E EXTINGUISHERS MUST BE LOCATED IN OR AROUND YOUR PAINT MIX ROOM PER NFPA 10.

DANGER

2.2 Safety Decals

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.

Printed in the USA

DANGER

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

Printed in the USA

WARNING

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.

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 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. 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, modification, 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. P/N 01010431 Rev A

Printed in the USA

DANGER

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.

Imprimé aux É.-U.

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 c omponents will not be aff 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 immediat ely aft 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.

10.5.3 Waste containers for flammable liquids shall be constructed of conductive materials and shall be bonded and grounded. 10.5.4 Waste containers for flammable liquids shall be handled and stored in accordance with Chapter 8. 10.6 Clothing. Employeesʼ clothing contaminated with sprayed material shall not be left on the p emises overnight unless kept in metal lockers. 10.7 Cleaning Operations. 10.7.1 Scope. This section shall apply to the use of flammable or combustible liquids for the flushing and cleaning of equipment. 10.7.2 Liquids. Class I and Class II liquids used in cleaning operations shall be in original shipping containers or in listed safety containers. 10.7.3 Location. Cleaning operations using flammable or combustible liquids shall be conducted inside a spray area with ventilating equipment operating or in ventilated areas that meet the requirements of Chapter 7. Such areas shall also meet the electrical area classification requirements of 6.5.5. 10.7.4 Equipment. Equipment using flammable or combustible liquids shall meet the requirements of 6.5.5 and shall be bonded and grounded. 10.7.5 Manual Cleaning. Individual manual cleaning operations shall be limited to not more than 4 L (1 gal) of flammable or combustible liquid for each cleaning operator. 10.7.6 Liquid Storage. Flammable and combustible liquids shall be handled and stored in accordance with Chapter 8. Containers used for handling, storage, or recovery of Class I liquids shall be constructed of conductive 10.8.1.1 Section 10.8 shall apply to solvent distillation units having distillation chambers or still pots that do not exceed 227 L (60 gal) capacity and are used to recycle Class I, Class II, and Class lIlA liquids. [30:19.6.1.1] 10.8.1.2 This section shall not apply to research, testing, or experimental processes; to distillation processes carried out in petroleum refineries, chemical plants, or distilleries; or to distillation equipment used in dry cleaning operations. [30:19.6.1.2] 10.8.2 Equipment. Solvent distillation units shall be approved or shall be listed in accordance with ANSI/UL 2208, Standard for Solvent Distillation Units. [30:19.6.3] 10.8.3 Solvents. Solvent distillation units shall only be used to distill liquids for which they have been investigated and that are listed on the unitʼs marking or contained within the manufacturerʼs literature. [30:19.6.3] 10.8.3.1 Unstable or reactive liquids or material shall not be processed unless they have been specifically listed on the systems markings or contained within the manufacturerʼs literature. [30:19.6.3.1] materials and shall be bonded and grounded. 10.8 Solvent Distillation Units (Solvent Recyclers). 10.8.1 Scope.

10.8.4 Location [30:19.6.4] 10.8.4.1 Solvent distillation units shall only be used in locations in accordinance with their approval or listing. 10.8.4.2 Solvent distillation units shall not be used in basements. 10.8.4.3 Solvent distillation units shall be located away from potential sources of ignition, as indicated on the unitʼs marking. 10.8.5 Liquid Storage. Distilled liquids and liquids awaiting distillation shall be stored in accordance with Chapter 6 of NFPA 30. 10.9 Spontaneous Ignition Hazards. The same spray booth shall not be alternately used f or diff erent types of coating materials if the combination of the materials is conducive to spontaneous ignition, unless all deposits of the first-used coating material are removed from the booth and exhaust ducts prior to spraying with the second coating material. 10.10 Chlorinated Solvents. Coating materials containing chlorinated solvents shall not be used with spray application apparatus or fluid-handling equipment if the chlorinated solvent will come into contact with aluminum within a piping system, pump, enclosed container, or any enclosure that is capable of being pressurized by the potential reaction. This shall apply even if the container or system has been constructed with pressure relief devices. 10.11 Smoking. Signs stating NO SMOKING OR OPEN FLAMES in large letters on contrasting color background shall be conspicuously posted at all spray areas and paint storage rooms. 10.12 Hot Work. Welding, cutting, and other spark producing operations shall not be permitted in or adjacent to spray areas until a written permit authorizing such work has been issued. The permit shall be issued by a person in authority following his or her inspection of the area to ensure that precautions have been taken and will be followed until the job is completed.

3. Spray to Waste Batch Powder Booth 3.1 Three-Stage Filter System (Pre-Filter, Primary Pocket Filters an d Final Filters)

3.2 Manometer The manometer is used as a gauge to let you know when your exhaust filters need to be changed. Exhaust filters typically have a static rating of .5 inches of water. Some booths are set up to use additional filters or optional filters that have a higher static rating than the standard .5 inches of water. Check your filter spec sheet to find the exact rating of the filter, but for this guide we will use the standard .5 inches of water column. Step 1 - Locate the Manometer The manometer needs to be located where it can be read daily by the paint department. Locate it on the booth where there are no obstructions such as shelving or walls to interfere with viewing the manometer. Remember, without the manometer, you will have no idea how clogged your exhaust filters are, and therefore , no idea if the booth is performing correctly. The manometer needs to be installed close to the exhaust filter wall to keep the tubing length to a minimum. Excess tubing length will reduce the accuracy of the manometer. There will be a high port and a low port on the top of the manometer. The high port will need to connect to the work chamber, and the low port will need to connect to the chamber on the suction side of the filter grid.

Low Pressure Port (Back Side of Filters)

High Pressure Port (Front Side of Filters)

Filter Grid Wall

Step 2 - Install the Hose Barbs Drill a hole in the booth wall just large enough for the plastic hose barb to fit through (approx. 13/32). Then install the washer and nut on the back side. Be careful not to over tighten or you may strip the plastic threads.

Inside Wall of Booth

Plastic Hose Bart

Washer and Nut

Step 3 - Mount the Manometer Mount the manometer on the wall of the booth and ensure it is level using the included bubble level at the bottom of the manometer. If the manometer is not level, it will not be accurate.

Top Mounting Hole

Bubble Level

Bottom Mounting Hole (Slotted to easily adjust level)

Step 4 - Fill the Manometer Turn the “Zero Set” knob counter clockwise until it stops, then turn the knob clockwise 3 full turns. This will place the adjustment knob in the middle of its travel range. Remove the fill plug at the top of the manometer and slowly fill with the red fluid. You will not need the entire bottle. Stop filling as soon as you can see the red fluid enter the clear tube at the bottom of the manometer. Then use the “Zero Set” adjustment knob to get the red fluid to sit on the 0 mark. If you overfill the gauge, remove the excess fluid by inserting a pipe cleaner through the fill port to blot up excess oil. Once the red fluid is set on zero, replace the fill cap.

Step 5 - Create Your Baseline Measurement IMPORTANT: All of the filters in the booth need to be installed and new in order to get an accurate baseline. If the filters have already been used , you will need to remove them and install new , clean filters. With the new clean filters installed, turn on your exhaust fan. If your exhaust fan is connected to a VFD to control the speed of the fan, make sure it is set to run at full speed. You will notice the red fluid should move up the scale and then settle at a number.

The number will be diff erent from booth to booth, but that does not matter . T his is just a baseline setting. Wherever the red fluid stops is where you will place your Green arrow. In this example, the red fluid stopped at .25 inches of water column. So because we know our filters are rated for .5 inches of water column, and we know that with clean filters the fan is drawing .25 inches of water column, we simply add the two numbers together to tell us where the filters will pack out. .25 inches of water + .5 inches of water = .75 inches of water total Step 6 - Set Your Change Filter Arrow Now that the baseline is set, measure up the scale .5 inches of water to allow for your filters to pack out and that is where you will place the Red arrow.

End Pressure (Change Filters)

Starting Pressure (Fan on with Clean Filters)

At this point, your manometer is set up and ready to use. You should never need to move the arrows once they are placed. Always check the manometer before turning the fan on to ensure the red fluid is sitting on the 0 mark. If the fluid is not on 0, simply turn the “Zero Set” knob to adjust the fluid to zero before starting the fan.

3.3 Air Solenoid Valve This section contains literature pertaining to the installation, operation and maintenance of the above component. As a built in safety feature, your RTT powder booth is provided with a two-way solenoid valve for the purpose of ensuring that pressurized air is only available to the powder application equipment if the powder booth is operating properly. The function of this valve is to interrupt the supply of compressed air to the powder application equipment under certain conditions. This is done to prevent powder coating from occurring when the powder booth is not operating as designed or if any booth doors are open (if equipped). The air solenoid valve is electrically interlocked with the powder booth exhaust fan(s). If the optional switches are purchased, it is also interlocked with the product and personnel doors (if equipped). If the fan is not operating, or if a door (if equipped) is open for longer than a few seconds, the air solenoid valve will shut off the flow of p r essurized air to the powder application equipment. The unit should be installed down stream of any regulators and filters and upstream of the powder application equipment. It should be located as close as possible to the fitting to which the powder application equipment connects in order to insure rapid loss of supply pressure.

L1 of Customer provided 3 Phase power L2 of Customer provided 3 Phase power L3 of Customer provided 3 Phase power 120VAC Hot Wire provided by customer 120 VAC Nuetral Wire provided by customer Ground Wire provided by customer

Control Panel

Booth Door Limit Switch #1 Booth Door Limit Switch #1

Booth Exhaust Fan

Booth Light Fixture

#4 #5

#1 #2

Compressed Air Line

Air Com- pressor

Paint Gun

3.4 Exhaust Fans This section contains literature pertaining to the installation, operation and maintenance of the above component. Your RTT powder booth is equipped with a Aerovent tubeaxial fan for exhausting air from the powder booth. This type of fan was designed specifically for use in applications such as powder booths where the fan drive motor must be located out of the air stream. The fan blades are constructed of non-sparking aluminum for added safety. The fan and drive motor have been sized for the specific air flow of your booth, in accordance with all applicable environmental and safety requirements. Belt Driven Tubeaxial Fans The Aerovent model BTABD is a belt driven tubeaxial fan that is designed specifically for reliable and cost eff ective air movement in paint spray booth applications. Model BTABD exhaust fans are designed for applications requiring either a horizontal or a vertical airflow direction. > Sizes and Performance > Arrangement 9 – belt driven > Available in sizes from 12" to 42" diameter > Capacity from 1,295 to 36,131 CFM > Static pressures to 1.25" w.g. Construction Features > Aluminum non-sparking propeller dynamically balanced for quiet, vibration-free operation > Continuously welded, heavy-gauge, corrosion resistant, enamel coated steel housing with pre- punched inlet and outlet flanges > OSHA belt guards are standard > No-relubricable "sealed for life" ball bearings in mono-block housing to ensure reliable bearing performance > Designed f or continuous duty Housing Housings are heavy-gauge, hot-rolled steel construction, continuously welded and ground smooth to assure efficient airflow th r ough the housing. Inlet and outlet flanges are integrally rolled and punched to allow attachment to ductwork or accessories as necessary. When an inlet bell is required, the housing is formed with a bell shaped inlet instead of the inlet flange, eliminating the need for and the expense of a separate inlet bell. Drive Isolated from Airstream The shaft and b e aring assembly is mounted within an inner cylinder isolated from the airstream. The v-belt drive assembly is enclosed in an aerodynamically designed belt tube which maximizes fan efficien c y, minimizes air blockage and reduces noise generation. An access door on the belt tube is standard.

Propeller

> Die Cast aluminum construction > Unique BackSwept profile with airfoil cross section > Adjustable pitch blades with factory set blade angles > S plit t aper lock bushing for superior holding power on shaft > Generates low wake turbulence for low noise emission

Dimensional Data

Belt Guard

Airflow

('E') 'F' Holes (Only size 12 holes are straddling center line)

'A' ID. I.D. 'B' DIA. B.C. 'C' DIA. O.D.

Max. 7.50"

'D'

Max. Mtr Frame

Size

12 12.25 13.88 14.88 12.00 8 14 14.25 15.88 16.88 12.00 8 16 16.25 17.88 19.00 12.00 8 18 18.25 19.88 21.00 12.00 8 24 24.25 25.88 27.13 15.50 8 30 30.38 31.88 33.25 15.50 8 34 34.38 35.75 37.38 15.50 8 36 36.38 37.88 39.38 15.50 16 42 42.50 43.75 45.50 15.50 16 Dimensions shown are in inches unless otherwise indicated. Dimensions are not to be used for construction.

.44 .44 .44 .44 .56 .56 .56 .56 .56

145T 145T 145T 145T 184T 184T 184T 184T 215T

R33867

Typical Specifications Model BTABD, Arrangement 9 – Belt Driven

Fans, where indicated on drawings and schedules, shall be Model BTABD, Arrangement 9, V-belt driven, axial flow type as manufactured by Aerovent, Minneapolis, Minnesota, and shall be of the size and capacity as indicated in the fan schedules. Model BTABD fans have been tested in an AMCA registered laboratory in accordance with AMCA 210 and AMCA 300 test codes for both air and sound. In addition each unit shall be factory run tested and final trim balanced prior to shipment. CONSTRUCTION — Fan casings shall be welded of ASTM A-1011 low carbon, commercial quality 12-gauge hot rolled steel in sizes through 20" diameter, 10-gauge hot rolled steel from 24" diameter thruough 28" diameter, and 7-gauge hot rolled steel on sizes greater than 30" in diameter. Inlet and outlet flanges shall be integrally rolled mechanically from fan casing sheet steel to insure concentricity and alignment. Accuracy and uniformity of the fan casing shall be insured through the use of welding jigs and fixtures. The motor base plate shall be fabricat ed of minimum 3∕16" st eel plate and welded to the exterior of the fnan casing. PROPELLERS — Propellers shall be constructed of non-sparking, die cast aluminum hubs and blades. Fan blade pitch angle shall be preset at the factory. Propellers shall be secured to the fan shaft with a t aper lock bushing. SHAFT & BEARINGS — All fans shall be supplied with a shaft of AISI -1045 steel material that has been properly turned, ground, and polished for accuracy . The shaft shall be supported by a matched set of non- relubricable bearings that are housed in a cast aluminum monoblock. All fan bearings are to have an L-10 minimum life as defined by AFBMA of at least 60,000 hours. DRIVES — Fan drives shall include cast iron sheaves and non-static conducting belts. Fans equipped with motors up to and including five horsepower will be furnished with a variable pitch type drive sheave to allow for minor speed adjustment of the fan propeller during system balance. Fans equipped with larger motors will be furnished with a fixed drive sheave. A belt guard is to be provided to afford personnel safe t y and general traffic protection. MOTORS — Fan motors shall be manufactured in accordance with current applicable standards of IEEE and NEMA. They shall be foot-mounted, NEMA standard, TEFC or ODP, continuous duty, ball bearing with class “B” insulation. BALANCING — The propeller assembly shall be statically and dynamically balanced in accordance with ANSI/ AMCA 204-05 “Balance Quality and Vibration Levels for Fans” to Fan Application Category BV-3, Balance Quality Grade G6.3. In addition, belt driven fan propellers shall be balanced on the fan shaft after final assembly in the fan casing, in the manufacturing facility to the following peak velocity values, filter-in, at the fan t es t speed:

Fan Application Category Rigidly Mounted (In/Sec)

Flexibly Mounted (In/Sec)

BV-3

0.15

0.20

Final test room vibration levels in the axial, vertical, and horizontal planes shall be recorded and a written copy shall be available upon request.

FINISH — The f an housing, aft er fabrication, shall be cleaned and chemically pretreated by a phosphatizing process and shall be painted inside and out with two coats of air dry enamel.

3.4 Powder Exhaust Filter Proving Assembly

This assembly addresses filter loading in the powder booth requiring that the filters be monitored. An automated signal will alert the operator while shutting down powder spray operations in the event of filter failure.

This is an NFPA 33 Code 15.8.2

Powder Exhaust Filter Proving Assembly

Powder Exhaust Filter Proving Assembly (Open)

3.6 Optional Powder Booth Control Panel

Your RTT powder booth may be equipped with an optional pre-wired electrical control panel. Refer to the electrical control drawings for the electrical schematic and component Bill of Material. Also shown on this drawing is the wiring required at the time of installation. No spare parts are provided with this control panel. This panel and its associated wiring must be installed under the supervision of a licensed electrician. The cabinet that houses the controls is either NEMA 1 or NEMA 12 rated. It is not suitable for Class I, Division II area. Refer to Chapter 6 in the NFPA 33 Standard and consult with the local authority having jurisdiction for the definition of this area for your powder booth.

4. Lab, Batch and Pass Through Powder Booths Photos

Cartridge Batch Powder Booth

Cartridge Collector

Lab Powder Booth

Pass Through Powder Booth

RPC Collector Showing Final Filters and Control

4.1 Control Panel with VFD Drive

The following contains a description of the LPB, RPB, RPC and EZ Pass Thru Powder Booth Control Panel.

Main Disconnect

Variable Frequency Drive

Control Panel (Nema 12) Enclosure with Definitions

Magnahelic

1. Turn power on at Main Disconnect (Blue power light will be illuminated). 2. Turn Lights on using green light on button. 3. Turn fan on using green fan on button.

4. Turn Filter Pulse Control switch to on position. This will pulse filter cartridges in a pre-determined sequence. 5. Check Magnehelic Gauge to assure booth is running within proper parameters. Low end at .25” of water column, high end not to exceed 3.5” water column. If the reading exceeds 3.5” of water column adjust pulse timer down from a 2 minute interval to a 1 minute interval. 6. Filter alarm light only indicates a pressure drop which indicates a filter missing or a hole in the cartridge filter. 7. Adjust Variable Frequency Drive to assure a minimum of 100 FPM lineal face velocity in booth openings.

Control Panel (Nema 12) Enclosure Interior with Definitions

Control Panel (Nema 12) Enclosure Interior Showing Electrical Schematic and UL Sticker

1. Electrical schematic shown inside the NEMA 12 door enclosure. 2. UL Listed label shown inside the NEMA 12 door enclosure.

4.2 Optimizing Your Collector's Performance

Outlined below are some basic collector operating parameters for pulse jet collectors using elements with Non Woven Spun Bond (all finishes) or Conventional Felted Media:

> > >

50 PSI - 80 PSI 20 seconds* Maximum 200 milliseconds

Pressure

Frequency (off time) Duration (on time)

Reservoir:

Requires an unrestricted air supply at least the diameter of the blowpipes and needs to be big enough for valveʼs demand. Ideal conditions will leave the reservoir at 85% of the operating P SI aft er firing. Needs to be clean and dry, which could be accomplished with an air dryer. In-line traps/ separators can catch a lot of problems in the air supply prior to getting to the collector.

Cleaning Air:

*Pulse Frequency: Frequency should be adjusted to balance the collector's delta P and should be monitored frequently during the first se ven days aft er start up. Pulsing frequency can never be any faster than the reservoir recovery to operating PSI.

Pulse Sequence:

Needs to be staggered to maximize the distance between the newly cleaned row and the next row to be pulsed. Should not be used for storage. Evacuation equipment (rotary valves, screw conveyors, etc.) should be sized to unload hopper before accumulation occurs. Units with slide gates should be left open and equipped with drum adap ers. To change your filters, push the red handle and the filter will drop about an inch. Install the new filter, then pull the red handle and the filter will lift up in o position. Be careful not to crush the new filter by putting too much tension on the clamp. If the new filter doesnʼt seem to fit, you can adjust the metal plate the filter sits on by loosening the nuts on the all-thread and then moving the plate up or down.

Hopper:

Changing Filters :

Use the following guide to program the Dwyer Timer Board:

1. Control panel power indicator light should be illuminated blue. 2. Press fan start button and allow the fan to come up to speed. 3. Turn on the “Filters” toggle switch. This will turn on the Dwyer Timer Board. 4. Once the timer board is on push the “Select” button on the timer, “Last Output” LED will light up. 5. Use the “Up” or “Down” button to adjust the number on the display to equal the total number of pulse valve you have on your collector, then press the “Select” button and the “Time Off” LED will light up.

6. Use the “Up” or “Down” button to adjust the number on the display to equal the amount of time between pulses. RTT pre-sets this number to 120, but it can be lowered based on the amount of time needed to re-pressurize the air manifold feeding the pulse valves. 7. Press the “select” button and the “Time On” LED will light up. This is the amount of time the pulse valve will remain on in milliseconds. Use the “Up” or “Down” button to adjust the number on the display. NEVER ADJUST THIS TIME TO MORE THAN 200. 8. Press the “Select” button and then the “Cycle Delay” LED will light up. Use the “Up” or “Down” button to adjust the number on the display to equal 0, then press the “Select” button and the “Down Time Cycles” LED will light up. 9. Use the “Up” or “Down” button to adjust the number on the display to equal 0, then press the “Select” button. The “Process” LED should light up and it will immediately start pulsing the valves to the new settings you have entered.

Use the following guide to change the speed of your fan:

Note: The maximum speed setting is based on the CFM rating of your collector. Some collectors will only accept a maximum setting of F43.00 while other collectors will accept up to F54.00 or even F60.00. If you try to set a speed higher than what the collector is capable of, the drive will simply flash several times, and then go back to the previous setting. Setting the collector too high can cause the powder to be pulled away from the parts which will waste powder. Your powder supplier can help you decide on an optimal speed to run the fan so that you get sufficient ai r -flow in the booth, but no so much that itʼs pulling the powder away from the parts. 1. Push the “Fans Start” Button on the control panel. The fan should start spinning. 2. Press the “Enter” button on the Yaskawa V1000 mounted next to the control panel. The first digit on the display should be flashing. 3. Use the “/\” or “\/” arrows to change the digit higher or lower. Use the “Reset” button to move over one space to change the second digit. Once you get to the speed you want, press the “Enter” button and the display will flash “End” and the fan will change speed. Press the “ESC” button to make the drive stop flashing. Note: The maximum speed varies depending on the CFM rating of your collector. If you select a speed that is too high, the display will simply flash and will not accept your speed setting. Try a lower speed. These are general operating parameters. These recommendations are good starting points, but every collector and application has unique operating conditions.

4.3 Understanding the Pulse Down System

60 to 80 PSI compressed air is plumbed into the manifold on the collector.

Compressed air feeds from the manifold to each pulse valve.

#1 High Volume

Compressed Air Inlet

Some of the compressed air bleeds out of the pilot port to the solenoid enclosure

Compressed air feeds from the pilot port on each pulse valve to the solenoid enclosure.

Compressed air is vented out of this port only when the solenoid is open.

The pulse valve acts like a high volume switch for compressed air. Compressed air is fed into the inlet of the valve and some of the air bleeds off th r ough the pilot port on the top where it feeds over to the solenoid enclosure. The solenoid enclosure is where the air stops, which is what keeps the pulse valve closed. As long as air is not allowed to continuously bleed out of the pilot port on top, then the pulse valve will remain closed. When air is allowed to bleed out of the pilot port on top, then the pulse valve will open until the pilot port is blocked off and p r essure is allowed to rebuild.

Compressed Air Inlet

Compressed Air Outlet

Power Inlet

The solenoid enclosure has 1 solenoid for each of the pulse valves to be operated. Each solenoid acts like an electrical switch for compressed air. The solenoid is closed when it does not have power applied to it, meaning that no compressed air is allowed to pass though until power is applied to the electrical coil of the solenoid. As long as the solenoid stays closed, the system remains pressurized which keeps each pulse valve closed. When power is applied to the coil of the solenoid, a small amount of compressed air is allowed to pass through. This small amount of air is all that is needed for the pulse valve to open and allow a larger amount of compressed air to fire down into the cartridge filter. As long as the solenoid stays on allowing air to escape, the pulse valve will continue to fire air into the cartridge filter.

The Dwyer Timer Board is where the timing can be adjusted for each solenoid. You can adjust the amount of time between pulses (Time Off in se c onds) and how long each pulse will last (Time on in milliseconds). For example, if the time off is s e t for 60 and the time on is set for 150, then the system would perform in the following manner: Power is applied to the timer board via the “Filters” toggle switch on the door of the control panel. (only active if the fan is in operation). The first output of the timer board will send out a 150 millisecond 120vac signal to the first solenoid enclosure. The solenoid will open for 150 milliseconds allowing a small amount of air to pass through which allows air to bleed off f r om the pilot port on the first pulse valve. The first pulse valve opens for 150 milliseconds allowing a high volume of compressed air to fire down into the cartridge filter. A ft er 150 milliseconds has elapsed, the first output of the timer board will t urn off , clos ing the solenoid valve, which blocks off the air bleeding out of the pulse v alve, then closes the pulse valve to prevent air from firing into the cartridge filter. The timer board then waits 60 seconds and then the next output of the board will repeat the steps listed above. The process repeats until the last output is reached, and then starts back at the beginning.

4.4 Troubleshooting Pulse Problems

No Filters Are Pulsing

Check the incoming air pressure to the manifold. The system requires air pressure to pulse at all times. The air pressure should be between 60 and 80 PSI. If the pressure is too low, all of the valves may release air at the same time.

Air inlet. Install plug at opposite side of manifold.

Air manifold

Check the Dwyer timer board. Ensure there is 120VAC at terminals L1 and L2 at the bottom of the board. There should be a solid red LED on the left side of the b o ard and a flashing red LED on the right side of the board. The red LED above each number at the bottom of the board should start flashing one at a time every 60 to 120 seconds as soon as the board is powered up. This flash indicates that the board is outputting 120VAC at that terminal , which feeds the solenoid enclosure located at the top of the collector.

Comm LED should be flashing as soon as power is applied to the board on terminal L1 & L2 .

High Limit and Com should be connected together.

Power On Indicator. Should illuminate Red as soon as power is applied to the board on terminal L1 & L2 .

120VAC to power the board .

LED above each number will flash in sequence once every 60 to 120 seconds, or however long the “Time Off ” has been set during programming. When this LED flashes, you should also hear the pulse air fire into the filter .

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