OPERATION INSTRUCTIONS
I. Brief Introduction
This equipment provides a clean and healthy working environment for automobile manufacture and maintenance industry.
The product has the features of easy operation, safety and reliability, energy-saving, high-efficient, convenient maintenance, and others. Computerized control system can make the booth enter into programmed state through easy operation. The pressure safety protection device ensures a constant pressure in the booth. The super-high temperature protection function can forcibly turn off the heating system when the temperature sensor in the booth malfunctions so as to prevent accidents caused by over-high temperature. The product is consisted of framework structure, so it is easy for installation and maintenance.
The product can also be used in dresses drying and food drying industries.
II. Technical parameters
| name |
Technical parameters |
| Booth's outside dimension mm |
7020×5220×3300mm(L×W×H) |
| Booth's inside dimension mm |
6900×3900×2650mm(L×W×H) |
| Door width mm |
3000 |
| Door height mm |
2450 |
| Air volume of forced fan C.F.M |
15582 |
| Full load indoors air speed m/s |
0.3 |
| Indoors ventilation times /h |
315 |
| Highest working temperature ºC |
60 |
| Heating-up time min (ambient temperature 20ºC) |
5-8min |
| Illuminance Lux |
≥800 |
| Air filtration efficiency |
≥99% |
| Max. Painting quantity kg/h |
3.7 |
| Noise dB(A) |
≤80 |
| TSP value mg/m3 |
≤1.2 |
| Total power kw |
43HP |
(II) Brief introduction of working principle
Normal temperature spraying: Turn on the control power, and turn the spraying switch to normal temperature spraying. Place the baking switch on "OFF" position. Open the lighting power. Air inlet system starts to work. The damper of inner circulation closes. At this time, under the function of air-forced fan, the outer fresh air is filtered by the prefilter device. Then the cleaner air containing the dust with the diameter less than 10um is forced into the fan base, then into the air-forced fan, into the heat exchanger, and into the plenum in the top of the booth. After being filtered by the secondary filter, 98% of dust in the air will be removed away. Thus, the air is clean enough for spraying. The air flows downward at the speed of 0.3m/s to take the paint mist and solvent produced in spraying away in order to ensure the operator's health and to achieve a perfect painting surface. Air containing the paint mist and solvents is delivered into the outer atmosphere after it is filtered by the filter device in the exhaust opening.
Air flow: air-inlet opening→prefilter→air forced fan→plenum→intake secondary filter→spray booth→floor grid glass fiber filter felt→exhaust secondary filter→(exhaust fan)→exhaust duct→atmosphere (Refer to the figure of "air purification flow in normal temperature spraying")
Heating-up spraying: When the ambient temperature is lower than 20ºC(usually lower than 10ºC), firstly set the temperature needed to be reached, then turn on the control power. Turn the spraying switch to the position of heating up spraying. Place the baking switch on "OFF" position. The spraying temperature in the booth is adjusted automatically to keep a constant temperature in the booth. Open the lighting power. Air inlet fan (exhaust fan) and burner start to work. The damper of inner circulation closes. Air in this process is hot air. Its principle is same as that in normal temperature spraying.
Air flow: air-inlet opening→prefilter→air forced fan→heat exchanger ( air is heated to meet the spraying needs) →plenum→intake secondary filter→spray booth→floor grid glass fiber filter felt→exhaust secondary filter→(exhaust fan)→exhaust duct→atmosphere (Refer to the figure of "air purification flow in heating up spraying")
Working principle of baking: Between the spraying stage and baking stage, there is an alternative process for paint and solvents' volatilization. This process can be called as a flashing off stage which is optional. Before baking, firstly set the baking temperature and baking time. Close the lighting switch. Place the spraying switch in the middle position. Turn on the baking switch to begin baking and finish the baking automatically. One air inlet fan continues working. (The exhaust fan stops working.) The burner ignites automatically. The heat resource is automatically controlled according to the temperature set by the temperature controller to keep a constant temperature in the booth. At this time, the outer fresh air (only 15% is outer fresh air) is prefiltered and led into the fan base, then into the heated air system to be heated, and then into the plenum in the top of the booth. After being filtered by the secondary filter, one proportion of heated air is sent into the outer atmosphere after it is filtered by the exhaust filter device. And another proportion of heated air is filtered by two layers to glass fiber filter felt, then is led into the secondary heated air circulation damper, into the fan, and into the heated air system again to be heated. By so, the energy can be saved, and the heating rate can be improved. The reheated air is then sent into the plenum and is purified to be comparatively clean hot air by the secondary filter to heat the surface of the vehicle. Air containing little phene enters into the outer atmosphere after it is filtered by the filter device in exhaust opening.
Air flow: air-inlet opening→prefilter→fan→plenum→intake secondary filter→spray booth→floor grid glass fiber filter felt→exhaust secondary filter→(exhaust fan)→exhaust duct→atmosphere (Refer to the figure of "air purification flow in baking")
IV. Operation methods:
(I) Explanations to control cabinet's face panel
1.Temperature controller (spray) 2. Temperature controller (bake) 3. Timer 4. Time accumulator 5. Baking indicator lamp 6. Lighting indicator lamp 7. Over temperature indicator lamp 8. Over temperature warner 9. Lighting switches 10. Baking switch 11. Load switch 12. Emergency stop button 13. Spraying switch 14. Stop button 15. Start-up button 16. Power indicator lamp 17. Normal temperature spraying indicator lamp 18. Heating up spraying indicator lamp
(III) Face panel drawing before turning on the equipment
(IV) Turn on the equipment
- clockwise place it into the position as shown in the picture
- after rotation clockwise, it will pup-up automatically
- Press down this button, the power indicator light will be lighted on
(V).Normal temperature spraying
- Rotate it to the right to the position of normal temperature spraying
- Rotate this switch to the right to turn on the lighting system. The indicator lamp is lighted on.
- This temperature controller works.
- The time accumulator works to accumulate working time.
(VI) Heating up spraying
(When the PV temperature is lower than the SV temperature)
- Rotate is to the left to the heating up spraying.
- Rotate this switch to the right to turn on the lighting system. The indicator lamp is lighted on.
- This temperature controller works to adjust or reduce or improve the SV temperature settings.
- The time accumulator works to accumulate working time
- Baking
Rotate this to the right to baking stage.
- Place this switch in the middle.
- Rotate this lighting switch to the left to turn off the lighting system. The lamp is off. (Or, don't rotate this switch, the lighting system will turn off automatically.)
- This temperature controller works to adjust or reduce or improve SV temperature settings. (Factory setting is 140 ºF.)
- Set baking time (refer to the following operation instructions for timer)
- The time accumulator works to accumulate working time.
- Firstly enters into flashing off stage. The air forced fan and exhaust fan work. 3 minutes later, only one air forced fan works. Enter into baking stage automatically.
- The baking finishes. The air forced fan and the exhaust fan work to reduce down the temperature in the booth. 8 minutes later, the equipment stops automatically.
(VIII) Turn off the equipment
- Rotate the baking switch to the left to the position as shown in the picture.
- Press down the stop button. The power indicator lamp turns off.
- Rotate the load switch to the left to OFF position.
(IX) Emergency stop
- When the temperature is higher than the mechanical temperature controller's setting value (230), the over temperature Warner will work, and the over temperature indicator lamp will be light on.
- Press down this button to cut off the system's power.
(X) Spraying:
A. Cautions when automobile enters into spray booth and cautions during spraying:
- Interior of the booth and area within 1 meter outside the booth must be kept clean without any combustible or explosive goods.
- The automobile must be prepared well for spraying.
- Before spraying, let the fan to run for some time (about 5-6 minutes).
- During spraying process, the spray gun held by the operator must not be higher than his breathing zone.
B Operation order:
- When the ambient temperature is lower than 68F (usually lower than 50F), set the heating up spraying temperature value. Suggest the temperature is set at 68F; when the ambient temperature is higher than 68F, this step can be omitted.
- Switch on the start-up power.
- Turn on the spray switch (rotate to left for normal temperature spraying, to right for heating up spraying).
- Turn on the lighting switch (rotate to right).
- After spraying is finished, turn off the spraying switch. (Place the knob switch in middle position.)
(XI) Baking
A. Cautions
Before baking, firstly set the baking temperature (already set at 140F when leaving factory) and baking time. Place the spray knob switch in the middle position. Turn off the lighting switch.
B. Operation order
- Set the temperature value needed for baking;
- Set the needed baking time;
- Turn on the control power switch;
- Turn on the baking switch. The booth enters into programmed condition automatically.
- When the temperature reaches to the set value, cut off the heating source. When the baking temperature is lower than the lower limit of the set value, the equipment will turn on the heating source automatically so as to ensure a constant temperature in the booth.
When the set baking time reaches, the booth will automatically turn off the heating resource. The fan still runs to cool down the heat exchanger for about 5min. then the baking finishes.
- If it is needed to stop the equipment during baking, then cut off the baking switch. The control system enters into misoperation protection stage automatically. Cut off the burner's power to stop heating up. The fan stops after 5 minutes.
V. Installation and debugging of electrical appliances
(I) Installation
- Firstly check to see if there is any obvious damage on exterior of control cabinet and on elements on panels. Then check to see if the elements and thrums in the cabinet are loose or fallen out.
- Determine the control cabinet's installation position. Take the left lower corner of the control cabinet as zero line). Ground clearance is 1200mm.
- Determine the routing of air inlet fan, exhaust fan, burner, and lighting wires. And use wiring channel to lay these wires.
- Install the connection wires between control cabinet and each load strictly according to electrical appliances' performance norms.
- The sectional area of burner's and lighting wires must ≥16AWG.
The sectional area of fan's (10HP) wire must ≥10AWG.
The sectional area of control cabinet's air-inlet wire must ≥6AWG.
- Wires threading through walls must be protected with protecting bush and must be away from heat resources. Wires that are close to rotating machinery must be locked and fixed.
- Cases of fans, control cabinet, mechanical temperature meter (vertically installed onto the heated air opening), and lamp house must be connected with booth body to form a protective earthling net and must be connected onto null line. (It would be better to bury earth plate under the ground.)
- The electrical appliances must be installed under the guidance of professional electricians and engineers according to wiring diagram and performance norms.
(II) Debugging
- Visually inspect and test by hand the flexibility of machinery's transmission.
- Check the insulation of electrical appliances:
Fan's main circuit to ground ≥2 megohm
Lighting circuit to ground≥1 megohm
Burner circuit to ground≥1 megohm
Control circuit ≥1 megohm
- Visually inspect whether the breaker and main brake are agree with the wiring diagram.
- Put on power to confirm the fan rotate forwardly. Otherwise the motor may be burnt.
- Adjustment to normal temperature spraying
Turn on the control power, Connect the control circuit and spray knob switch (SA41 is connected), time accumulator runs, temperature controller displays the ambient temperature. Normal temperature spraying indicator light (HL3) lights. Electric actuator (SM) runs. Damper closes. Air inlet fan and exhaust fan start up at reduced pressure. Contactor KM2, KM1 close, air inlet fan starts up at reduced pressure.12 seconds later, KM3 and KM4 close. KM2 is released. Change to run under the motor's rated voltage.
Contactors KM6 and KM5 close, exhaust fan starts up at reduced pressure.6 seconds later, KM7 and KM8 close. KM6 is released. Change to run under the motor's rated voltage.
- Adjustment of heating up spraying
If the ambient temperature is low, the temperature in the booth must be raised in order to ensure perfect spraying quality. Use burner to heat.
Set heating up spraying temperature (usually at 68F). At this time turn on the heating up spraying knob switch (SA42). The heating up spraying indicator light (HL2) lights. The temperature controller takes part in the system control to control the burner's operation state automatically. Others are as same as those in normal temperature spraying.
- Adjustment of baking state
Firstly set the baking time and baking temperature (already set at 140F when leaving factory). Place the spray knob in the middle position. Turn off the lighting knob switch (SA6). Turn on the baking knob switch (SA5).
The electric actuator (SM) runs. The damper rotates from close position to open position. While baking, the hot air circuit circulates in the booth.
Time accumulator runs for timing. The baking indicator light (HL4) lights on. The exhaust fan stops working. The air inlet fan starts at reduced pressure.
During baking process, if the air inlet fan has some troubles, the burner will shut down, and the exhaust fan will operate automatically to cool the heat exchanger. The mechanical temperature controller supervises the temperature in the booth.
The burner's operation stage is controlled through the temperature controller on the face panel that can adjust the baking temperature automatically. As soon as the whole baking process is programmed, it will enter into programmed control stage to finish baking.
- Switch on the lighting power. The contactor KM4 closes. All the fluorescent lamps must be lighted.
- The setting of the mechanical temperature controller must be at 230F. When the KM9 is closed, manually simulate super-temperature. Rotate the finger clockwise to over 230F, KM9 must cut off immediately.
- Adjustment of the temperature controller (already set at 68F, 140F when leaving factory)
For concrete adjustment methods, refer to its operation manual.
- Adjustment of electric actuator
Loosen the fixed screw of electric actuator and damper's rotor shaft. In spraying stage, cut off the damper. At this time, the electric actuator must in the max. corner position. Lock the rotor shaft and test again the baking stage. The damper must be in the opening position.
12. Adjustment of wind pressure switch
The wind pressure switch is installed horizontally on the heated air opening. (Joints have been left when leaving factory). Before leaving factory, the wind pressure switch is set at 50Pa. When the fan reverses or the wind pressure doesn't reach the set value, the heating up system cannot run. It is used to check the pressure in the booth's plenum.
VI. Troubleshooting of common failures
1.At the very beginning of fan's start-up, the breaker trips.
Check: Motor's breaker setting →fan's main loop earth insulation→ insulation between phase conductors (disconnect load) →phase conductor's earth insulation.
2. Abnormal sound is heard after the fan is started-up. And the breaker trips.
Check: If the motor overload setting is too small→if the main electricity power loses phase →the temperature of the outer case of the fan is too high (judge whether is seriously overloaded)
3. The burner cannot be ignited:
VII.Cautions
- Cautions for maintenance:
- Only use the parts provided by manufacturer.
- For all the daily maintenance and timely care, the main switch of the power must be cut off. And hang a warning card of "Notice: No electricity power in repair".
- Every 4-6 months check to see if the bolts on the fan's bearing base, on the fan's base and on other connection parts are tightened enough.
- Check and change roof filters, air inlet filters, floor grid filters, and exhaust filters at regular intervals according to the records of time accumulator and maintenance.
- Clean the lamps and walls at regular intervals. (once every two months)
- Clean and maintain the filter parts of compressed air system.
Do the following maintenance at least once a year
- Check and clean all the air pipes.
- Check the tightness of each electrical appliance's wiring terminal and whether they are separated correctly. Check to see if all the earthing resistance of high-power equipment and electrical appliances are conforming to related national norms.
- Check to see if all the sealing parts are sealed properly.
- Lubricate each moving part at regular intervals.
- Check to see if the oil tank is oil leaked at regular intervals. Maintain and clean the oil tank once a season.
- Check to see if all the meters and instruments are working normally at regular intervals, to see if all the safety devices are working reliably.
(II) Cautions in usage:
- No inflammable or explosive objects can be stored in the booth.
- Clean the booth after operation every time.
- Use a dust cleaner to clean the floor grid and indoors ground once a week.
- The electricity power's voltage can not be lower or higher 10% of the rated voltage.
- The booth can only be used under the environment without any explosive dangers or fires. No smoking in the booth.
- The manufacturer will take no responsibility for any damages caused by improper changes to the equipment without the manufacturer's approval.
- The manufacturer will take no responsibility for any removal or changes of the safety devices without the manufacturer's approval.
- Solvent of low boiling point cannot be used for cleaning the wall panels in the booth.
- The booth must be supervised in operation. After operation, all the switches must return to their original positions.
- Only those professional persons who well-know the equipment can operate the equipment.
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