This section provides an overview of the RTT Powder Booth manual, including important safety information, system operation, and receiving procedures. It explains the booth's main components, how the airflow and filtration system works to maintain a clean powder application environment, and identifies the supported booth models. It also outlines inspection requirements upon delivery, reporting procedures for shipping damage or missing parts, and emphasizes that unauthorized equipment modifications may void the warranty and create safety risks.
Certified Installation & Maintenance Manual
RTT Finishing Solutions 2975 Discovery Blvd, Rockwall, TX 75032 www.rttsolutions.com 888-452-6684
Contents 1. Introduction.............................................................................................................5 1.1 Introduction ............................................................................................................................. 5 1.2 Receiving, Unpacking, And Reporting Missing Items.............................................................. 5 1.3 Back-Charges For Material And Labor.................................................................................... 6 2. Safety ........................................................................................................................7 2.1 Safety Alert Symbol And Signal Words .................................................................................... 7 2.1.1 Assembly Hazards .......................................................................................................... 7 2.1.2 Operational Hazards....................................................................................................... 8 2.1.3 Maintenance Hazards..................................................................................................... 9 2.1.4 Fire Hazard .................................................................................................................... 10 2.2 Safety Decals ..........................................................................................................................11 2.3 NFPA 33 ................................................................................................................................. 12 3. COMPONENT DESCRIPTION................................................................................15 3.1 PB-Spray To Waste Batch Powder Booth .............................................................................. 15 3.2 EZ Pass Thru Powder Booth.................................................................................................. 16 3.3 Cartridge Filter Powder Booth................................................................................................ 17 3.4 Compliance To Applicable Codes........................................................................................... 18 3.5 Material Specifications ........................................................................................................... 18 3.6 General Description ............................................................................................................... 18 3.6.1 Paint Area ...................................................................................................................... 18 3.6.2 Exhaust Fan And Chambers.......................................................................................... 18 3.6.3 Product Doors (Optional) ............................................................................................... 18 3.6.4 Door Latch (Optional) .................................................................................................... 18 3.6.5 Door Limit Switch (Optional) .......................................................................................... 19 3.7 Exhaust Filter Manometer ...................................................................................................... 19 3.8 Air Solenoid Valve .................................................................................................................. 19 3.9 Powder Exhaust Filter Proving Assembly .............................................................................. 19 4. Installation..............................................................................................................20 4.1 General .................................................................................................................................. 20 4.2 Preliminary...................................................................................................................................20 4.3 Planning Ahead ...................................................................................................................... 20 4.4 Proper Booth Grounding For PB – Spray To Waste Batch Powder Booth............................. 20 4.5 Booth Assembly ..................................................................................................................... 21 4.6 Lights......................................................................................................................................22 4.7 Manometer ............................................................................................................................. 24 4.8 Exhaust Filter Installation ....................................................................................................... 27 4.8.1 Cartridge Filter Powder Booth ....................................................................................... 27 4.9 Intake Filter Installation .......................................................................................................... 28 4.9.1 Cartridge Filter Powder Booth ....................................................................................... 28 4.10 Motor Installation.................................................................................................................. 29 4.10.1 Mounting ...................................................................................................................... 29 4.10.2 Install Sheaves And Fan Belts ..................................................................................... 29 4.10.3 Electrical ...................................................................................................................... 29 4.11 Tubeaxial Fan....................................................................................................................... 31 4.12 Exhaust Duct Installation (Optional)..................................................................................... 32
4.13 Product Door (Optional) ....................................................................................................... 32 4.14 Access Door Limit Switch Installation (Optional).................................................................. 34 4.15 Product Door Limit Switch Installation (Optional)................................................................. 35 4.16 Solenoid Wiring Diagram ..................................................................................................... 36 4.17 Checklist...............................................................................................................................37 4.18 Optimizing Collector Performance ....................................................................................... 37 5.Maintenan ce ...........................................................................................................39 5.1 Maintenance Interval Cart ...................................................................................................... 39 5.2 Daily ....................................................................................................................................... 40 5.2.1 Inspect Filters ................................................................................................................ 40 5.2.2 Filter Maintenance ......................................................................................................... 40 5.2.3 Determine Filter Condition ............................................................................................. 40 5.3 Every Two Months.................................................................................................................. 40 5.3.1 Lubricate Door Latches..................................................................................................40 5.4 Every Six Months ................................................................................................................... 41 5.4.1 Check Fan Belts ............................................................................................................ 41 5.5 Every Year.............................................................................................................................. 41 5.5.1 Inspect Motor ................................................................................................................. 41 5.5.2 Inspect Fan Wheel......................................................................................................... 41 5.5.3 Inspect And Clean Air Solenoid Valve............................................................................ 42 6 Warranty ..................................................................................................................43 6.1 Returning Items For Credit.................................................................................................... 43 6.2 Back Charges For Material And Labor .................................................................................. 44
1. Introductioni RiiUiARiiim 1.1 I ntroductIon
Thank you for purchasing a RTT Spray Booth, powder booth.
Read and understand this manual before using your booth and follow all of the safety instructions. Keep this manual with your booth at all times.
This manual explains the assembly and routine maintenance of the RTT powder booth.
This manual covers a family of RTT Spray Booths, powder booths. The following booths are covered:
• Industrial Spray to Waste Batch Powder Booths • (PB) Recovery Cartridge Style Powder Booths (RPB and RPC) • EZ Pass Thru Powder Booths (EPB)
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. The text contained in this manual is for current production models. Some instructions and maintenance procedures may not apply to your specific unit. Equipment modifications from original design and specifications are strictly prohibited. Modifications may compromise safe operation of the booth, subjecting users to serious injury or death and may void any remaining warranty. This Operator’s Manual does not replace, nor does its use release the operator from observing all safety or operating limitations as well as any applicable federal, state, provincial or local regulations.
1.2 r eceIvIng , u npackIng , a nd r eportIng M IssIng I teMs
When receiving and unloading equipment check for damage. Note on Bill of Lading “FREIGHT DAMAGE.” Notify the RTT customer service department immediately of any damage. Unpack all items and verify on packing list within ten (10) days of receipt. Notify RTT customer service department of missing items and discrepancies immediately. RTT will not pay for overnight freight on shorted items. If overnight freight is necessary, the buyer shall be accountable for freight costs.
For quality control, RTT's Shipping Department photographs all items as they are packed.
Per company policy, two independent checks are performed to verify each item against the packing list. If RTT determines that the reported shortage was checked off in our records, replacement parts will be shipped AND invoiced accordingly.
Items that can be shipped UPS usually take from one to three days to receive, depending on distance. Items too large for UPS will ship via common freight. This shipping method typically takes from one to five days to reach the destination. During the warranty period, RTT Powder application Booths will repair or replace, free of charge, any parts that RTT Powder application Booths has verified to be defective in materials or workmanship. If inspection of the equipment does not disclose any defect in workmanship of material, repairs will be made at a reasonable charge, which will include the costs of labor, materials and transportation. 1.3 B ack -c harges F or M aterIal a nd l aBor RTT Powder application Booths shall not be held responsible for any Back-Charges incurred for materials or labor without prior written consent. Should a problem arise, please notify RTT immediately. Once the issue is investigated, should costs be incurred, an amount shall be agreed on by both parties before-hand. Do NOT attempt modifications or repairs without prior consent as this may void further warranty repairs or credit. RTT will not accept back-charges associated with late delivery.
Please address warranty repairs to:
RTT Engineered Solutions 2975 Discovery Blvd. Rockwall, TX 75032 Attention: Customer Service
For all electrical and gas control service issues please direct to:
RTT Engineered Solutions 2975 Discovery Blvd. Rockwall, TX 75032 Attention: Controls Engineering Manager
2. SafetySfASmbASiAAYAUUAAAAAAUAUAmbHAAF 2.1 s aFety a lert s yMBol a nd s Ignal W ords
Before assembling, operating or servicing the powder application booth, you must read, understand and follow the instructions and safety warnings in this manual. Your powder application 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 DaNGER - Indicates a hazardous situation, which, if not avoided, WILL result in death or serious injury. ^ WaRNING WaRNING - Indicates a hazardous situation, which, if not avoided, could result in death or serious injury. ^ CauTION CauTION - Indicates a hazardous situation, which, if not avoided, could result in minor or moderate injury. NOTICE NOTICE - Indicates a situation that could result in damage to the equipment or other property.
2.1.1 a sseMBly h azards
^ WaRNING
Shock hazard. all parts and components must electrically bonded and properly grounded to prevent static buildup and discharge.
^ WaRNING
^ 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 o peratIonal h azards
^ 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 powder application 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 powder application 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 M aIntenance h azards
^ 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 powder application booth.
2.1.4 F Ire h azard No smoking or open flame in or near powder application booth. Local fire codes prohibit smoking in the vicinity of spray powder application 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 powder application booth. An approved fire protection system must be installed on your powder application booth to comply with NFPA 33, Section 7. Portable fire extinguishers must be located in or around your powder application room per NFPA 10.
DANGER
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 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 e ectués par un installateur éprouvé. Le non-respect de ces instructions peut entraîner de la mort ou des blessures.
DANGER
Imprimé aux É.-U.
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. 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/CSA- B149 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. P/N 01010431 Rev A ^ WaRNING 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.
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.
Printed in 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.
Reprinted with permission from NFPA 33-2011, 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 NFPA on the referenced subject, which is represented only by the standard in its entirety. The following is section 15 from NFPA 33:
Chapter 15 Powder Coating
15.1* Scope. This chapter shall apply to processes in which combustible dry powders are applied.
15.2 General. The installation and use of powder coating application apparatus shall comply with the requirements of this chapter and also shall comply with the applicable requirements of all other chapters. 15.3 Applicability. Section 15.4 through Section 15.10 are general and shall apply to all methods of powder coating application.
Section 15.11 through Section 15.13 shall apply to the specific method indicated therein.
15.4 Location. Powder coating operations shall be confined to enclosures that are located in accordance with Chapter 4.
15.5 Protection. Powder coating operations shall be protected in accordance with Chapter 9.
15.6 Enclosures. Powder shall be confined by conducting coating operations within one of the following: (1) A completely enclosed, ventilated room of noncombustible or limited-combustible construction with smooth surfaces designed to prevent accumulation of powder and to facilitate cleaning (2) A ventilated spray booth meeting the requirements of Section 5.1 through Section 5.5, and having enclosed, ventilated containers (tanks, bins, etc.)
15.7 Electrical and Other Sources of Ignition.
15.7.1 Electrical utilization equipment and other sources of ignition shall meet both the requirements of Chapter 6 of this standard and Articles 500, 502, 504, and 516 of NFPA 70, National Electrical Code, as applicable. 15.7.2 Where the object or material being coated is preheated in an oven, the controls shall be set so that the surface temperature of the object or material does not come within 28°C (50°F) of the autoignition temperature of the powder used. 15.7.3 All electrically conductive objects in the spray area, except those objects required by the process to be at high voltage, shall be electrically connected to ground with a resistance of not more than 1 megohm (106 ohms), as measured with an instrument that applies at least 500 volts to the circuit being evaluated. This requirement shall also apply to any personnel who enter the area.
15.8 Ventilation, Dust Collection, and Explosion Protection. See Annex C.
15.8.1* Ductwork. Where non-deposited, air-suspended powder (powder overspray) is conveyed by ductwork to a recovery system, sufficient airflow shall be provided in the ductwork to maintain the powder concentration in the ductwork at not more than 50 percent of the minimum explosive concentration (MEC) of the powder in use. Exhaust equipment shall bear an identification plate stating the ventilation rate for which it was designed. Exception: Where, by design, the coating operation is conducted at an exhaust duct concentration above 50 percent of the MEC, listed explosion suppression equipment shall be provided. 15.8.1.1 The manufacturer of the powders being used shall provide the MEC of those powders for the purposes of proper design of the exhaust system.
15.8.2 Air exhausted from the recovery system of a powder operation shall not be recirculated unless the concentration of particulate matter in the exhaust air has been reduced to a level that is considered safe for personnel occupational exposure and suitable equipment continuously monitors the filtration system to signal the operator and to automatically shut down the operation in the event the filtration system fails to maintain the air in this condition. 15.8.3* Enclosures. Enclosures either shall be listed for the specific application or shall be designed to resist the destructive effects of an internal deflagration. Any enclosure that is not so listed and is effectively tight, such as a spray booth, dust collector, powder recovery device, or other enclosure, shall be provided with one of the following: (1) Deflagration venting (2) A deflagration suppression system that meets the requirements of NFPA 69, Standard on Explosion Prevention Systems 15.8.4 Ventilation for fluidized beds and electrostatic fluidized beds shall be designed to effectively prevent escape of nondeposited powder from the enclosure. 15.8.5 The ventilation system shall confine air-suspended powder to the booth and the recovery system at all times.
15.9 Drying, Curing, and Fusing Equipment.
15.9.1 The temperature of the object or material being coated shall be maintained at least 28°C (50°F) below the autoignition temperature of the powder. 15.9.2 Drying, curing, and fusing equipment shall meet all applicable requirements of NFPA 86, Standard for Ovens and Furnaces.
15.10 Operation and Maintenance.
15.10.1 The area surrounding the spray area, including horizontal surfaces such as ledges, beams, pipes, hoods, and booth floors, shall be maintained to prevent the accumulation of powder. 15.10.2 Surfaces shall be cleaned in a manner that does not scatter powder or create dust clouds. Vacuum sweeping equipment, where used, shall be of a type approved for use in hazardous locations. 15.10.3 Means shall be provided to prevent tramp metal or spark-producing material from being introduced into the powders being applied. 15.10.4 Signs stating NO SMOKING OR OPEN FLAMES in large letters on contrasting color background shall be conspicuously posted at all powder coating areas and powder storage rooms. 15.11 Automated Electrostatic Powder Spraying Equipment. The provisions of Chapter 11 and other sections of Chapter 15 shall apply to fixed electrostatic equipment, except that electrical equipment not covered therein shall comply with Section 15.7. 15.12 Handheld Electrostatic Powder Spraying Equipment. The provisions of Chapter 12 and other sections of Chapter 15 shall apply to electrostatic hand guns where used in powder coating, except that the high-voltage circuits shall be designed so as not to produce a spark capable of igniting any powder–air mixtures likely to be encountered instead of the vapor–air mixtures referred to and except that electrical equipment not covered therein shall comply with Section 15.7.
15.13 Electrostatic Fluidized Beds.
15.13.1 The high-voltage circuits shall be designed so that any discharge produced when the charging electrodes of the bed are approached or contacted by a grounded object cannot produce a spark that is capable of igniting the most hazardous powder–air mixture likely to be encountered and so that they cannot result in a shock hazard. 15.13.2 Transformers, power packs, control apparatus, and all other electrical portions of the equipment, with the exception of the charging electrodes and their connections to the power supply, shall be located outside the area classified as hazardous or otherwise shall conform to the requirements of Section 15.7. 15.13.3 All electrically conductive objects within the powder coating area, except those objects required by the process to be at high voltage, shall be electrically connected to ground with a resistance of not more than 106 ohms (1 megohm). This requirement shall also apply to any personnel who might enter the area. The powder coating equipment shall carry a prominent, permanently installed warning regarding the necessity for grounding these objects. 15.13.4 Highly resistive objects (i.e., surface conductivity between 108 and 1011 ohms per square) that exhibit a surface voltage below 2500 volts, as measured using a nonloading kilovoltmeter and when subjected to coronal current not less than that expected in the application process shall be considered adequately grounded. 15.13.5 Objects or material being coated shall be maintained in electrical contact [less than 106 ohms (1 megohm)] with the conveyor or other support to ensure grounding. Hangers shall be cleaned to ensure effective contact. Areas of contact shall be sharp points or knife edges where possible. 15.13.6 The electrical equipment and compressed air supplies shall be interlocked with the ventilation system so that the equipment cannot be operated unless the ventilation fans are in operation.
3. COMPONENT DESCRIPTI ON 3.1 pB-s pray t o W aste B atch p oWder B ooth
Item Qty
Part Number
Description
1 2 3 4 5 6 7
Third Stage HEPA Style Final Filters
Second Stage Pocket Filters
Motor
Manometer Light Fixture Support Steel
Tubeaxial Fan First Stage Filter Blanket (Not Shown)
3.2 ez p ass t hru p oWder B ooth
1
2
3
4
Item Qty
Part Number
Description Cartridge Filter Support Steel Light Fixture Diaphragm Valve
1 2 3 4
3.3 c artrIdge F Ilter p oWder B ooth
Item Qty
Part Number
Description
1 2 3 4 5
Tubeaxial Fan and Motor
Powder Final Filters
Collector Control Panel
Diaphragm Valve Cartridge Filter
3.4 c oMplIance t o a pplIcaBle c odes
This Powder Application 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 application booth meets or exceeds the requirements of the Occupational Safety and Health Administration (OSHA). 3.5 M aterIal s pecIFIcatIons The powder booth panels, filter racks and product doors are constructed of 18- gauge steel, conforming to ASTM A527 “Lock Forming Quality” and are hot dipped galvanized per ASTM A525. All structural steel conforms to ASTM A36. 3.6 g eneral d escrIptIon The powder application booth 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. 3.6.1 p oWder a rea The powder area is the actual “booth” part of the spray powder booth. Parts are placed in this area, through 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 3.6.2 e xhaust F an a nd c haMBers 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 tube axial 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. 3.6.3 p roduct d oors (o ptIonal ) The product doors can be filtered or solid and may be either overhead doors, bi-fold doors, or tri-fold doors. Some industrial powder application booths have an open front in lieu of product doors. Overhead doors are equipped with an intrinsically safe pneumatic safety edge. There are two 3-button controls to operate each door. Doors can be manually operated also. 3.6.4 d oor l atch (o ptIonal ) Door latches secure doors in closed position and hold contact against foam rubber seal. Latches are pressure relief latches that allow doors to open in case of explosion. This feature also allows for ease of booth operator egress from powder application booth by applying moderate pressure to the door from inside booth.
3.6.5 d oor l IMIt s WItch (o ptIonal ) Optional micro switch to indicate when a door is open on the booth. If a door is in the open position, micro switch contact is opened which breaks the circuit for the powder air solenoid. 3.7 e xhaust F Ilter M anoMeter
Manometer is used to measure pressure drop across exhaust filters to indicate the condition of the filters.
3.8 a Ir s olenoId v alve The function of this valve is to interrupt the supply of compressed air to powder application equipment under certain conditions. This is done to prevent powder coating from occurring when powder booth is not operating as designed or if any booth doors are open (if equipped). Air solenoid valve is electrically interlocked with powder booth exhaust fan(s). If the optional switches are purchased, it is also interlocked with product and personnel doors (if equipped). If fan is not operating, or if a door (if equipped) is open for longer than a few seconds, air solenoid valve will shut off flow of pressurized air to powder application equipment. The unit should be installed down stream of any regulators and filters and upstream of powder application equipment. It should be located as close as possible to fitting to which the powder application equipment connects in order to insure rapid loss of supply pressure. 3.9 p oWder e xhaust F Ilter p rovIng a sseMBly This assembly addresses filter loading in powder booth requiring filters be monitored. An automated signal will alert operator while shutting down powder spray operations in the event of filter failure. This is an NFPA 33 Code 15.8.2
4. I NSTaLLaTION 4.1 g eneral
This manual is a guide for installing a variety of powder booths. The assembly drawings enclosed are specific for the booth you have purchased. This drawing is an exploded isometric drawing showing the relationship of each panel or part to the next one. A packing list of all components is provided and must be used in addition to the drawing to identify all components.
All DAMAGES MUST be reported within 24 hours of receipt and a freight claim filed with the carrier.
4.2 p relIMInary RTT booths are manufactured in accordance with NFPA 33, UFC 45 and NEC 516. However, local codes and regulations may apply to the installation and use of this product. All permits and approvals be obtained prior to installation and use of the powder application booth. 1. Uncrate and inventory all spray powder booth components to ensure all of the parts are accounted for. Each component is numbered on the exploded view. 2. The floor surface of the booth must be non-combustible material of such character as to facilitate the safe cleaning and removal of residues. The floor surface must be flat and level. 1. Clearances between other work areas and combustible storage areas must be held as follows: • 3 ft. minimum clearance at all sides and sealed entry ways (i.e., door ways). • 5 ft. minimum clearance at all non-sealed entry ways (i.e., the open face of powder application booth or a silhouette openings). • 10 ft. minimum clearance must be held between the exhaust stack of the booth and the intake of another apparatus. NFPA 33 dictates a minimum discharge clearance of 5 ft. from the nearest combustible material; however, stack height requirements vary with individual states and can be up to 1½ times the building’s roof height from grade. • 10 ft. minimum clearance must be held between the intake of this booth and the exhaust of any other apparatus. 2. Permits are not included. It is the responsibility of the end user to acquire all permits to install a booth. 3. A fire suppression system is not included with the booth. Generally this is supplied and installed by a licensed local installer. 4. Electrical installation must be performed by a licensed electrician familiar with national, local electrical codes and regulations in your location. 4.4 p roper B ooth g roundIng F or pB – s pray t o W aste B atch p oWder B ooth 3. Mark the dimensional outline of booth on floor. 4. Follow the step-by-step instructions provided. 4.3 p lannIng a head
Install 5/8 inch by 8 foot long copper rod in floor as close to booth as possible, leaving 8 inches of rod above floor.
Booth, parts hangers and application equipment must be grounded to this rod. failure to properly ground all booth components could cause static discharge which could result in a fire.
4.5 B ooth a sseMBly When assembling booth, leave bolts finger tight until each section is assembled. All flanges should face outward. Install bolts from inside so nut is outside booth. Use a drift pin to align panel holes when two or more panels are difficult to align by hand. Lay out all floor channel for exhaust chamber and walls. As you attach wall panels together, they will also bolt to the floor channel. ^ WaRNING Prevent serious injury or death. Most booth components weigh 50-500 lbs. use adequate lifting devices to raise, move and install booth components.
NOTICE
Prevent equipment damage. Powder application booth roof will not support a person. Do not attempt to stand or walk on powder application booth roof.
Refer to exploded view drawings included with your powder application booth. 1. Starting with exhaust chamber at either rear corner, bolt one corner panel and one rear wall corner panel together. 2. Bolt opposite rear sidewall panel to rear wall panel. 3. Bolt all rear wall panels in place. 4. Bolt tie channel along top edge of rear wall panels. 5. Place exhaust fan panel above side and rear wall panels and bolt in place. 6. Insert filter filler panels between sidewall, roof panels and exhaust chamber. Bolt in place.
CHAMBER SIDE PANEL
FILTER FILLER PANEL
BOOTH SIDE PANEL
7. Following exploded view drawings, continue alternately assembling wall panels and roof panels to each other until you reach front end of booth. Finish off roof section by attaching fire curtain if needed. If booth has front doors, no fire curtain is needed. 8. Verify walls are plumb and booth is square and on floor layout marks. Tighten all mounting hardware.
9. Anchor floor channel to floor at a minimum of every 12 inches. 10. Caulk all panel joints inside the booth with the caulk provided. Do not use a silicone caulk. 11. If booth is supplied with a personnel door or front filter doors, apply foam gasket to perimeter of all door openings. Attach door hardware and adjust latches. Level door with doors off, then attach doors to hinges.
4.6 l Ights
^ 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.
1. Place light fixture into booth panel, center in opening, and mark locations for mounting holes. 2. Install light fixture in panel from outside of booth as shown in drawing. When mounting fixture horizontally, make sure that ballast locates to the bottom of fixture. 3. Caulk perimeter of light fixture lens frame with appropriate caulking. 4. The fixture is provided with an interlock switch that has a normally open contact, which opens when the fixture lens is removed from fixture. The switch is to be wired to disable powder application equipment used in spray booth.
4.7 M anoMeter
Locate manometer on booth where it can be read daily by paint department.
Install close to exhaust filter wall to keep tubing length to a minimum. Excess tubing length will reduce accuracy of manometer. High port will connect to work chamber, and low port will connect to chamber on suction side of filter grid.
1. Drill hole in booth wall just large enough for plastic hose barb to fit through (approx. 13/32). Install washer and nut on back side. Do not over tighten.
2. Mount manometer on booth wall and ensure it is level using bubble level on manometer. Manometer must be level or it will not be accurate. Bottom mounting hole is slotted for easy level adjusting.
3. Turn “Zero Set” knob counter clockwise until it stops, then turn knob clockwise 3 full turns. This will place the adjustment knob in the middle of its travel range. Remove fill plug at top of manometer and slowly fill with red fluid. You will not need entire bottle. Stop filling as soon as red fluid enters clear tube at bottom of manometer. Turn “Zero Set” adjustment knob to set red fluid on 0 mark. If gauge overfilled, remove excess fluid by inserting a pipe cleaner through fill port to blot up excess oil. Once red fluid is set on zero, replace fill cap.
Complete booth assembly and then perform steps 4-6 to set manometer.
IMPORTANT: All filters in booth must be installed and new to get an accurate baseline.
4. Turn on exhaust fan. If exhaust fan is connected to a VFD to control speed of fan, make sure it is set to run at full speed. Red fluid should move up scale and settle at a number. Number will be different from booth to booth, but that does not matter, this is just a baseline setting. 5. Wherever the red fluid stops is where you will place the 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
6. Now that baseline is set, measure up the scale .5 inches of water. That is where you will place the red arrow.
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, turn “Zero Set” knob to adjust fluid to zero before starting fan.
4.8 e xhaust F Ilter I nstallatIon
4.8.1 c artrIdge F Ilter p oWder B ooth
4.9 I ntake F Ilter I nstallatIon
4.9.1 c artrIdge F Ilter p oWder B ooth
4.10 M otor I nstallatIon
Couplings, drive belts, chains or other mounted devices must be in proper alignment, balanced and secure for safe motor operation. 4.10.1 M ountIng This motor must be securely mounted. Sufficient ventilation must be provided to insure proper operation. 4.10.2 I nstall s heaves a nd F an B elts
1. The fan sheave (A) and motor sheave (B) must be in axial alignment. Shafts must be parallel in both vertical and horizontal planes. 2.
A
The sheaves must be in radial alignment. When sheaves are of equal width, align with a straightedge (C). When sheaves are of unequal width, align center of sheaves. Check fan belts for proper tension and for signs of wear. Belt should have a slight sag at bottom of sheaves. Belt (D) is properly adjusted. Belt (E) is too loose. Belt (F) is too tight.
3.
C
B
F
D E
4.10.3 e lectrIcal
^ 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.
Complete booth assembly and then perform steps 1-5 below to connect electrical service to motor. 1. Determine voltage at your facility. RTT does not recommend using 120V single phase on motors above 1HP. 2. If a control panel or motor starter was ordered with this booth, confirm that the voltage and phase on the control panel matches the voltage and phase you intend to use. 3. Locate the wiring diagram above that matches your voltage, phase, and HP. 4. Some motors may have 2 additional red wires. These wires are for an internal thermal overload. We do not use these wires and they should be capped off with wire nuts or electrical tape. 5. Locate the rotation arrow on the fan and verify belts are rotating in the direction of the arrow. If the belts are not rotating in the direction of the arrow, reverse the motor.
3/4 - 1.5 Hp 120V Single Phase (Wire for "Low Voltage")
3/4 - 3 Hp 230V Single Phase (Wire for "High Voltage")
To reduce the risk of electric shock, the motor is to be grounded per local electrical code.
T5
T1
T3
T3
To reduce the risk of electric shock, the motor is to be grounded per local electrical code.
T2
T5
L1 120VAC Hot
T2
T1
To reverse the motor Swap 5 and 8 Incoming 1PH power from control panel, motor starter.
L1
T4
T4
L2 120VAC Neutral
T8
T8
L2
To reverse the motor Swap 5 and 8 Incoming 1PH power from control panel, motor starter.
To reverse the motor Swap T5 and T8
To reverse the motor Swap T5 and T8
5 Hp 230V Single Phase (Wire for "High Voltage")
208 thru 240V Three Phase (Wire for "Low Voltage")
To reduce the risk of electric shock, the motor is to be grounded per local electrical code.
To reduce the risk of electric shock, the motor is to be grounded per local electrical code.
T1
L1
T8
T7
T2
T1
T8
L1
T4
L2
T5
To reverse the motor Swap L1 and L2 Incoming 3PH power from control panel, motor starter, or VFD.
T3
T5
T4
T9
T6
L2
To reverse the motor Swap 5 and 8 Incoming 1PH power from control panel, motor starter.
L3
To reverse the motor Swap T5 and T8
440 thru 480V Three Phase (Wire for "High Voltage")
L1
T1
To reverse the motor Swap L1 and L2 Incoming 3PH power from control panel, motor starter, or VFD.
T2
L2
T3
T4
L3
T7
T5
T9
T6
To reduce the risk of electric shock, the motor is to be grounded per local electrical code.
T8
4.11 t uBeaxIal F an
^ WaRNING
fan assembly is heavy. fan assembly weight is approximately 50 - 200 lbs., depending on model. use and adequate lifting device to install fan assembly.
^ 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.
The fan and motor assembly will bolt to exhaust roof panel.
Use the following guide to change speed of fan: Note: The maximum speed setting is based on CFM rating of 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. Setting a speed higher than what the collector is capable of, will cause the drive to simply flash several times, and then go back to previous setting. Setting the collector too high can cause the powder to be pulled away from parts which will waste powder. Powder supplier can help to decide on an optimal speed to run the fan so that there is sufficient air-flow in the booth, but no so much that it’s pulling powder away from parts. 1. Push “Fans Start” Button on control panel. The fan should start spinning. 2. Press “Enter” button on Yaskawa V1000 mounted next to control panel. The first digit on display should be flashing. 3. Use “/\” or “\/” arrows to change digit higher or lower. Use “Reset” button to move over one space to change second digit. Once to speed desired, press “Enter” button and display will flash “End” and fan will change speed. Press “ESC” button to make drive stop flashing. Note: The maximum speed varies depending on CFM rating of your collector. If a speed that is too high is selected, the display will simply flash and will not accept 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.
4.12 e xhaust d uct I nstallatIon (o ptIonal )
If equipped with optional exhaust ductwork, it is recommended to have this professionally installed. To assemble the ductwork: 1. Bolt pipe with connecting ring to the exhaust fan. 2. Remaining ductwork is crimped on one end to interlock with the next section. 3. Your ARV(automatic damper) will be mounted on top. 4. Storm collar will attach to duct above flashing to make it weather proof. Where more than 25 ft. of piping is required, static pressure (resistance) is increased and the air flow may be hindered when using the standard exhaust unit recommended for use with the booth. Where a piping arrangement of an unusual nature is necessary or where two or more elbows are used, a similar condition may exist. Therefore, if either of these situations arises, contact the RTT for recommendations. Exhaust piping, including the canopy (if used), should extend a minimum of 6’ ft. above the highest point of building. There should be an access door just above exhaust unit and another just below each elbow.
4.13 p roduct d oor (o ptIonal )
E
E
C C D D
C C D D
A A B B
A A B B
C C D D
C C D D
A A B B
A A B B
E
E
Side of door with 2 x 4 in. tube is the hinge side. Before installing door, verify both door channels and top door stop installed properly and squared. Verify dimension between channels and floor to door stop with door drawing.
Install Left Door 1. Place spacers between door and floor. Door is manufactured to have a 1 in. clearance at bottom, 1/2 in. clearance on top and 3/8 in. clearance on sides. 2. Put hinges in place per dimension (E) on door drawing. Install screw in center of slots A and C on all hinges. Do not tighten screws at this time. 3. Adjust the door in all directions. Assure the door closes completely, then tighten screws. 4. Install screws in center of slots B and D. 5. Remove spacers. 6. Repeat steps 1-5 to install right door.
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