DOWNDRAFT

SPRAY BOOTHS Custom Express

DD Series

CUSTOMER: TWF

GLOBAL MODEL #: DDI-10159-RF-S

GLOBAL SALES #: 45922A

12731 NORWAY ROAD PO BOX 250 OSSEO, WI 54758

PHONE: 715.597.3168 / 800.848.8738 FAX: 715.597.2193

~ READ AND KEEP THIS MANUAL FOR FUTURE REFERENCE ~

ALL PERSONNEL OPERATING THE EQUIPMENT CONTAINED IN THIS MANUAL SHOULD REVIEW AND UNDERSTAND ALL INSTRUCTIONS BEFORE USE.

OPERATION AND MAINTENANCE MANUAL

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Table of Contents Introduction…………………………2 Warranty…………………………….3 Safety………………………………..4 Installation…………………………..5 Operation…………………………..11 Maintenance Guide………………...12 Troubleshooting Guide………….…13 Customer Service…………………..14 Notes Page…………………………15

Abbreviation List The following is a list of abbreviations that may be used in this document and the words that they represent. AC Alternating Current DC Direct Current in. Inch/Inches ft. Foot/Feet Hz Hertz psi Pounds per Square Inch cfm Cubic Feet per Minute hp Horsepower

Introduction: A Message for the Purchaser

The management and employees at Global would like to thank you for selecting our product for you industry. Our product conforms to Occupational Safety and Health Administration (O.S.H.A) and National Fire Prevention Association (N.F.P.A.) regulations for your safety. We at Global understand the importance of a quality system and strive to manufacture the best product on the market. The DD Series Downdraft Spray Booth maximizes transfer efficiency by providing uniform distributed air intake and exhaust. Top-quality finishes are ensured by controlling and promptly exhausting any occurring over spray. The DD Series Downdraft Spray Booth provides full uniform air distribution throughout the entire booth and is designed for maximum overall performance and personnel safety. The DD Series Downdraft Spray Booth is constructed of 18-gauge galvanized sheet steel. Panels are pre-punched, companion flanged, and bolted on 6-inch (152) centers for easy fit and fast assembly. The panels have exterior flanges that provide a smooth interior surface. The booth is rigidly reinforced with formed stiffeners. All booths are shipped complete with heavy-duty, exhaust fans, a totally enclosed fan-cooled motor, man access door(s), product doors, manometer, fluorescent light fixtures, intake and exhaust filters with grids, all necessary hardware, and assembly drawings.

IMPORTANT! This manual contains statements relative to worker safety. Read this manual thoroughly and comply as directed. Operate this equipment in accordance with the guidelines set forth in this Installation and Operation Manual. It is impossible to list all potential hazards of this equipment. Instruct all personnel involved with this equipment in the safe conduct and operation of the system. We recommend that only qualified personnel operate and maintain this equipment.

NOTE: All dimensions in ( ) are in millimeters unless otherwise indicated.

SECTION 1 – GENERAL INFORMATION

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GLOBAL LIMITED WARRANTY

GLOBAL (the Sellers) warrants to the original end-user buyer (the buyer) that the equipment manufactured by, and purchased from, the Seller (the Equipment), if properly installed in accordance with the Seller’s Service Manual, operated, and maintained, and used under normal conditions, shall be free from defects in workmanship and materials for a period of one (1) year from the date the Equipment is shipped from the facilities of the Seller. The obligation of the Seller, and the Buyer’s SOLE AND EXCLUSIVE REMEDY hereunder, shall be limited to one of the following, at the Seller’s option: (01) The repair or replacement of defective parts or components (collectively, the Parts) of the Equipment; provided, however, the Buyer shall be

responsible for the payment of all labor costs associated with any such repair or replacement. (02) In the event the Seller is unable to repair or replace the defective Parts, the Buyer shall be entitled to a refund of the cost of the Parts. The Seller shall have no obligation under this Limited Warranty for ordinary wear and tear of the Equipment; if installation of the Equipment does not comply with local, state and federal requirements or laws; or if the Equipment is modified by any other person or organization. The Seller makes no warranty of any kind whatsoever with respect to Parts, which are manufactured or supplied by other persons or organizations (an OEM); provided, however, the Seller shall reasonably assist the Buyer in connection with warranties, if any, provided by an OEM.

WARRANTY PERFORMANCE PROCEDURES

In the event the Buyer believes the Seller may be responsible for the performance of any warranty obligation, the Buyer must immediately send written notice of a claimed defect, and must immediately refrain from any further use of the affected Equipment. No attempted repair of the claimed defect may be made without the prior written consent of the Seller. Before any Parts can be returned to the Seller, the Buyer must contact the Seller and request a Return Authorization. Upon the Buyer’s receipt of the Return Authorization form, the Parts may be shipped, freight prepaid, to the facility designated on the Return Authorization. All Parts returned for repair, replacement, or refund (a refund may be made in the form of a credit to the Buyer’s account), must be accompanied by the Return Authorization. All returned parts are subject to a twenty percent (20%) handling charge. Parts manufactured or supplied by an OEM are subject to the warranties, if any provided by such OEM’s; and repair or replacement of such Parts are subject to the approval of the OEM. The Buyer shall be responsible for the payment of any handling or restocking charges associated with OEM Parts.

DISCLAIMERS OF WARRANTIES

THE WARRANTIES CONTAINED HEREIN ARE EXPRESSLY IN LIEU OF ANY OTHER EXPRESSED OR IMPLIED WARRANTIES, OR ANY OTHER OBLIGATION ON THE PART OF THE SELLER, INCLUDING WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY MODELS, DRAWINGS, PLANS, SPECIFICATIONS, AFFIRMATION OF FACT, PROMISES, OROTHER COMMUNICATIONS BY THE SELLER WITH THE REFERENCE TO THE EQUIPMENT OR THE PERFORMANCE OF THE EQUIPMENT ARE SOLELY FOR THE CONVENIENCE OF THE BUYER AND SHALL NOT IN ANY WAY MODIFY THE EXPRESSED WARRANTIES AND DISCLAIMERS SET FORTH HEREIN. THE BUYER ACKNOWLDGES IT IS PURCHASING THE EQUIMENT SOLELY ON THE BASIS OF THE COMMITEMENTS FOR THE SELLER AS EXPRESSLY SET FORTH HEREIN. NO AGENTS OR OTHER PARTIES ARE AUTHORIZED TO MAKE ANY WARRANTIES ON BEHALF OF THE COMPANY OR TO ASSUME FOR THE COMPANY ANY OTHER LIABILITY OR OBLIGATION IN CONNECTION WITH THE EQUIPMENT.

CONSEQUENTIAL DAMAGES

The Seller shall not be liable for any incidental or consequential damages arising from the use of the equipment by the Buyer, the breach of any warranties, the failure to deliver, delay in delivery, delay on nonconforming condition, or for any other breach of contract or duty between the Seller and the Buyer.

LIMITATION OF ACTIONS

Any action resulting from the breach of any warranty contained herein by the Seller must be commenced within one (1) year after the cause of action accrues. In no event shall the Seller’s total liability for any or all breaches of any warranty exceed the actual purchase price paid by the Buyer for the Equipment.

P.O. Box 250 • 12731 Norway Road

Osseo, Wisconsin 54758-0250 Phone: 717-597-3168

Toll Free: 800-848-8738 Fax: 715-597-2193

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• The product must be installed and serviced only by

a trained, qualified service technician. • All personnel who will operate, service, inspect or

otherwise handle this product must read and understand the safe operating practices, safety precautions and warning messages in this documentation.

• Disconnect and lock out the main electrical service before installing, adjusting or servicing the product.

• A qualified electrician should complete electrical installation. Installation must meet all applicable national, state, and local electrical codes.

• Ensure that all electrical components are grounded to a central ground.

• Become familiar with all controls. • Safety signs, panels, and labels that are normally

affixed to the product must be replaced immediately if illegible or missing.

• New or replacement equipment components that are installed during repair or maintenance must include all safety signs, panels, and labels as specified by the manufacturer. These must be affixed to the new or replacement equipment as specified by the manufacturer.

• Some spray activities may require the use of respiratory protection. Consult the Material Safety Data Sheet (MSDS) for information on the appropriate respiratory protection to be worn.

SAFETY HAZARD! Failure to observe these safety practices can result in personal injury or death.

General Safety Notes Operation and servicing of the product must be performed properly by qualified personnel who observe the warnings in all documentation provided with the product and the notes on the product. Follow all general standards for installation and safety for work on installations. Follow all good practices for the proper use of lifting tackle and lifting equipment. The use of protective equipment such as safety goggles and protective footwear must be considered. If any pumps or compressors are included as part of this installation, they must be connected in compliance with data in the documentation provided.

Covers Guards and covers which prevent contact with electrically energized or moving parts, or are required to direct the flow of air for effective cooling, must not be removed or left open during operation.

Sound Pressure Levels Sound pressure levels in excess of 85 decibels may cause damage to health. Where applicable, suitable protective measures, such as wearing earplugs, must be taken.

Safety Precautions

Installation • Follow all local electric, safety, N.F.P.A., O.S.H.A,

and National Electric Code (N.E.C.) regulations. • Install the booth in compliance with the standards of

the N.F.P.A. • Do not use the spray booth until turning the exhaust

fan on. Check to see that the fan is operating correctly before entering the booth.

• Check local codes to see if a booth interlock is required. (A booth interlock prevents the operation of spray devices unless the booth fan is operating.)

• Check local codes to see if sprinklers are required for the booth.

Operation • Use an O.S.H.A.-approved paint respirator when

spraying in the booth. • When the manometer indicates that the filter pads need

replacing, do not operate the spray booth. • Treat used arrestor filter pads and any other paint-

contaminated items as a flammable product and dispose of properly.

• Properly duct the exhaust air from the fan away from the working environment to the outdoors. Properly duct the booth before operating.

• Isolate the outdoor vent from air-conditioning intakes, windows, and any other equipment that may re-circulate exhaust indoors.

• Do not use arrestor filter pads alternately for different types of coating materials where the combination of materials may be conducive to spontaneous combustion.

• Do not overfill and permit fluid to collect in the flexible plastic connecting loop in the back of the manometer. This could cause a serious reading error.

• If the manometer is subject to overfilling, check to ensure that the fluid has not passed into the plastic connecting loop.

SECTION 2 – SAFETY

SAFETY HAZARD! There are inherent hazards associated with the operation and service of this equipment. For your personal safety, observe the following safety practices.

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Installation Guidelines

SECTION 3 - INSTALLATION

IMPORTANT! State and local codes vary widely. Install all spray booth exhaust ductwork, electrical, gas, water connections, etc., to conform to the code that has jurisdiction and/or the project specifications. Read the following guidelines to avoid any complications while assembling this spray booth.

1. Find the miscellaneous box by locating the yellow sticker attached to it. The assembly drawings that are inside this box will contain the information needed to ascertain the location of the various components required to assemble this booth.

2. To avoid confusion during installation, only open the crates containing the components that will be assembled first.

3. Install the booth on a smooth and level surface. 4. Ensure that there is sufficient overhead clearance

for the exhaust unit, exhaust ductwork, ceiling lights, and light brackets. Refer to the supplied assembly drawings for the correct dimensions.

5. Ensure that there is sufficient side clearance for the proper orientation of the man access door.

IMPORTANT! Refer to the included assembly drawings for reference to the pit. Correctly center the downdraft spray booth over the pit.

6. Ensure that there is sufficient clearance in front of

the booth for the proper operation of the front product entry doors.

7. The floor must be level. If it is not, use shims underneath the spray booth to avoid any misalignment.

8. During installation, panels must be perpendicular to the floor. The sides of the booth must be parallel to each other.

9. Typically, the inside of the booth will be smooth. Unless otherwise instructed, install all panel flanges to the outside.

10. At corners where an assembly angle is used, place the nuts on the inside of the panel flanges.

11. When assembling the booth, install all the bolts to hold each panel in position. Ensure that the bolt heads are on the inside of the booth. Hand-tighten the nuts - do not over-tighten them. Completely assemble each section.

12. Ensure that the booth is level and square. 13. Tighten all bolts. 14. Caulk all connecting joints and interior seams to

ensure a dust-tight seal.

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INSTALLATION

Pit NOTE: Global does not provide material for the construction of the pit. It is up to the customer to arrange for the actual construction of the pit.

1. Verify that the dimensions of the pit correspond to the provided site drawings.

2. Install the roll media and grating. Refer to Figure 1.

NOTE: Check the inside working dimensions of the booth. Properly center the booth on the pit. Use the pit as a reference to the booth dimensions during installation.

Beam Assembly 1. Connect 2 horizontal I-beams to 2 vertical columns.

Refer to Figure 2. 2. Repeat this procedure for another set of beams and

columns.

Bay Booth Assembly 1. Using a temporary brace, stand the columns upright. 2. Attach a bottom panel to each column on each side of

the booth. Refer to Figure 3. 3. Working form bottom to top, install the next panel by

sliding it down from the top of bay to the bottom panel. Refer to the included assembly drawings for the correct panel sequence.

4. Repeat steps 1 through 4 for every additional bay. Do not anchor the columns to the floor at this time.

IMPORTANT! Do not anchor the columns to the floor at this time.

Man Access Door(s) Assembly 1. Determine the location of the man access door(s) by

referring to the included assembly drawings.

NOTE: The man access door is shipped with the doorframe and the P-Seal already in place.

2. Connect the man access door to the doorframe by inserting the hinge pins in the hinge. (The door will be either left or right hinged.) Ensure that the door opens out from the booth. Refer to Figure 4.

3. Attach the safety door latch to the man access door. Refer to Figure 5.

4. Properly adjust the man access door inside the doorframe.

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Top Filter and Light Assembly 1. Spread the crossbeams apart slightly at the center of

the beams. Place the 2 outside panels between the beams. Refer to Figure 6.

2. Slide each panel to the outside edge of the bay. 3. Repeat step 2 for each component referring to the

included assembly drawings for the correct sequence.

Intake Plenum Assembly 1. Slide the side plenum panels down from the top so

that they sit on top of the bay booth wall. 2. Spread the crossbeams apart slightly at the center of

the beams. Place the 2 outside panels between the beams. Refer to Figure 7.

3. Slide each panel to the outside edge of the bay. 4. Repeat step 2 for each component referring to the

included assembly drawings for the correct sequence. 5. Install the perforated plates and baffles if the booth

requires them. Refer to Figure 8 and the included assembly drawings for locations.

End Wall Assembly 1. Install the end walls, panels, and door structure

(jambs and header). 2. Square the entire booth. Tighten all bolts.

Product Door Wall Assembly 1. Hang the doors. Refer to Figure 9.

IMPORTANT! Proper door alignment is critical to the operation of the booth. Ensure that there is equal space around the doors. Move the bottom of the doorjamb to the left or right until the doors are sealed and plumb.

2. Properly seal the doors at the center seal and at the top by moving the bottom of the doorjamb front to back.

a. After properly aligning the doors on both axes, anchor the booth to the floor.

b. Anchor the doorjambs using 2 anchors (obtained locally) per doorjamb.

3. Align the product door before anchoring. Move the doorframe in or out until the door seals on all sides. After aligning the doorframe, anchor the doorframe to floor. Oil the hinge pins.

4. Attach the door handles to the product doors. 5. Attach the safety door latch to the product door.

Refer to Figure 9. NOTE: The size and type of door determines the number of safety door latches on the product doors. Refer to the included assembly drawings for the correct number of latches.

INSTALLATION

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Bi-Fold Doors (Optional) For booths having bi-fold doors, refer to Figure 10.

1. Install and align the bi-fold doors using procedures set forth in the Product Door Assembly section of this manual.

2. After installing and aligning the bi-fold doors, anchor the door guide to the floor.

Anchoring Booth 1. Place a level on the side columns and move them in

or out at the bottom until they are plumb. 2. Re-check the working width and adjust accordingly.

Anchor the columns. 3. After anchoring the columns, anchor the panel

flanges using anchor studs – 1 every 3 feet (914). IMPORTANT! Failing to properly anchor the booth to the floor may result in structural damage.

Exhaust Fan Assembly 1. Assemble the exhaust fan onto the pit plate. Refer to

Figure 12. 2. Install the motor on the motor support base. 3. Assemble the V-belts to the pulleys. 4. Mount the belt or motor guard.

NOTE: The direction of the fan blade rotation is indicated on the outside of the exhaust fan housing.

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Lighting

Inside Access Lights

1. Refer to the fluorescent light installation drawing. 2. Install cage nuts into light fixture as shown in detail on the light drawing. 3. When installing the light fixture (box part):

a. Start with rolled edge facing away. b. Slide lighting fixture box inward and upward so that the 2 flanges on the top of the light fixture are on either

side of the light panel. c. Then straighten the light fixture box and slide it down so that the 2 bottom flanges are on either side of the

light panel. 4. The light cover is attached using 8 (6mm x 20mm) cap head screws. These are located under the ballast cover.)

Miscellaneous Assembly

Manometer Assembly

1. Install the manometer to the exterior sidewall of the exhaust plenum at a convenient height.

2. Drill holes for tubing. Run the supplied tubing from the manometer to the filter bank. Place the tube from the low side of the filter bank. Refer to Figure 15.

Manometer Setup

1. Fill the manometer with fluid as per manufacturer’s instructions.

2. Turn the fan off. Adjust the manometer until the gauge displays 0.

3. Install clean filters in the booth. a. Observe the rise in the manometer reading. b. Mark this reading with the supplied green

arrow. c. Add .30 from this reading and mark it with the

supplied red arrow. This is the dirty filter mark for fiberglass paint arrest filter. Adjust the differential setting for other style of filters per manufacturer’s recommendations.

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Filter Assembly 1. Install the furnished 20 x 20 inch (508x508) inlet air

filters by pushing 1 filter into each filter frame. Refer to Figure 16.

2. Ensure that the logo faces the inside of the booth on intake filters.

3. Install the exhaust roll media in the pit. Refer to Figure 1.

IMPORTANT! Use the included caulk to ensure a dust-tight seal by caulking all connecting joints and interior seams after installation.

Deluxe Control Panel (Optional) This control panel houses a main disconnect switch, control/lighting transformer, motor starter(s) with fuse and overload protection per NEC requirements, push buttons, selector switches, and operating pilot lights. All standard units are factory wired for 480 volt 3-phase 60 hertz unless otherwise requested at the time of purchase. Mount the control panel either on the exterior paint booth wall or the adjacent wall. DO NOT mount the panel inside the booth enclosure. The electric motor requires wiring to the main control panel. IMPORTANT! Install the optional deluxe control panel following N.F.P.A. 33 and N.F.P.A. 70 guidelines. Ensure that the installation also complies with all local codes.

Air Make-Up Unit For installation instructions on the air make-up unit, refer to the assembly drawings. IMPORTANT: The temperature control is set at the remote control panel or the deluxe control panel. The set point temperature is the discharge air temperature, NOT the booth temperature. The booth temperature will run slightly lower due to heat losses in ductwork and the booth.

Warning Stickers Referring to Figure 17, attach the warning stickers to the booth.

Fan Tub Size

Motor Size

Size/Description Vendor Part # JBI Part #

Fan Tub 30" TAB-30 206-530

Drive 1VL44 x 7/8 350066 213-302

Driven 561B 351894 213-417

Bushing SDS x 1.25 351941 213-447

Motor 2 hp TEFC 3 Ph. 145Fr. 303005 234-007

Belt AP58 345181 211-214

JBI Model HP RPM Fan Tub Drive Driven Bushing Motor Belt

TAB-30-021T3 2 985 - 1308 206-530 213-302 213-449 213-447 234-007 211-214

Prop Dia. Model HP RPM Free Air .25" .375" .5" .75"

30" TAB-30-021T3 2 985 - 1308 9809 - 13045 8111 - 11805 7080 - 11141 5439 - 10460 *5934 - 8761

* ---- This represents the lowest possible cfm at a particular static pressure due to instability of the fan curve.

The drive sheave cannot be set below a certain RPM for these ranges.

Model RPM turns open Free Air .25" .375" .5" .75"

985 5 9809 8111 7080 5439 *

1017 4 1/2 10108 8463 7511 6175 *

1050 4 10456 8870 8001 6806 *

1082 3 1/2 10755 9216 8380 7335 *

1114 3 11104 9617 8817 7850 *

Tab-30-021T3 1147 2 1/2 11402 9957 9188 8285 *

1179 2 11751 10352 9616 8786 5934

1211 1 1/2 12050 10689 9977 9208 6760

1243 1 12398 11081 10387 9650 7597

Revised -4/25/01 1276 1/2 12697 11416 10736 10026 8139

1308 0 13045 11805 11141 10460 8761

CFM

TAB-30-021T3Fan Data Sheet

Type (motor)

Phase (motor)

Fan Tub Size

Motor Size

Size/Description Vendor Part # JBI Part #

Fan Tub 36" TAB-36 206-536

Drive 2VP56 x 1-1/8 351827 213-304

Driven 642B 351840 213-456

Bushing SDS x 1.5 351942 213-467

Motor 5 hp. TEFC 3 Ph. 184 fr. 303010 234-009

Belt AP69 345238 211-245

JBI Model HP RPM Fan Tub Drive Driven Bushing Motor Belt

TAB-36-050T3 5 1197 - 1478 206-536 213-304 213-456 213-467 234-009 211-245 (2)

Prop Dia. Model HP RPM Free Air .25" .375" .5" .75" 1"

36" TAB-36-050T3 5 1197 - 1478 18558 - 22907 16709 - 21440 15731 - 20660 14656 - 19872 11754 - 18175 *10350 - 16062

Model RPM turns open Free Air .25" .375" .5" .75" 1"

1197 5 18558 16709 15731 14656 11754 *

1225 4 1/2 19024 17223 16273 15247 12586 *

1253 4 19490 17736 16810 15834 13386 *

1281 3 1/2 19878 18162 17256 16319 13971 10350

1309 3 20267 18586 17700 16799 14550 11219

Tab-36-050T3 1338 2 1/2 20733 19093 18229 17349 15237 12246

1366 2 21198 19599 18756 17896 15917 13155

1394 1 1/2 21664 20103 19279 18439 16578 13994

1422 1 22053 20522 19712 18889 17081 14684

Revised - 4/25/01 1450 1/2 22519 21023 20230 19426 17680 15477

1478 0 22907 21440 20660 19872 18175 16062

* ---- This represents the lowest possible cfm at a particular static pressure due to instability of the fan curve.The drive sheave cannot be set below a certain RPM for these ranges.

Fan Data Sheet

TAB-36-050T3Phase (motor)

Type (motor)

CFM

T 800-848-8738 www.globalfinishing.com

4 FT. 4 TUBE LAMPPART NUMBER- LFM-4-120/277 -LFM-4-347

Finishing Solutions

FEATURESl ETL & CANADA LISTED ETL-Cl CLASS 1, DIVISION 2, GROUPS A, B, C, Dl INTERLOCK SAFETY SWITCH

l ENCLOSED & GASKETED

l TWIST-IN LAMP HOLDERS

l INSIDE ACCESS ONLY

l CORNER ENCLOSURE (OPTIONAL) PART NUMBER - CLS101l ALLOWS EASY RETROFITS

l TEMPLATE FOR INSTALLATION INTO EXISTING PANELS

l DESIGNED SPECIFICALLY FOR SPRAYBOOTHS

l ENERGY EFFICIENT T-8, 32 WATT ELECTRONIC BALLASTS

l DUAL VOLTAGE 120/277 VOLT, 50/60 HZ OR SINGLE 347 VOLT 60 HZ

Energy Efficient, Color Corrective Lamps

T 800-848-8738 F 715-597-2193 www.globalfinishing.com info@globalfinishing.com

Finishing Solutions

Wiring Notes:1. All Wire is 18 gauge.2. The magnetic microswitches are a safety

feature and are wired into the control circuit.The switches are used to disable theoperation of the spray gun*, should any ofthe light fixture covers not be closed properly.

* air line solenoid valve is required

(Part Number ss9902)

Dual Voltage Lighting Ballast

ICN-4P32-SC120V/0.94A277V/0.41A50/60Hz4 x 32W = 128W Total

Single Voltage Lighting Ballast

347 VoltGEL-4P324 Tube0.31A60Hz4 x 32W = 128W Total

4 Ft. 4 Tube LampPART NUMBER- LFM-4-120/277 -LFM-4-347

P.O. Box 250, Osseo, WI 54758 USA50 Wood St. Barrie, ON L4N 2T1 Canada, in Canada please call toll free: 888-712-5777All designs, specifications and components are subject to change at the manufacturer's sole discretion at any time without notice. Data published herein is informational in nature and shall not be construed to warrant suitability of the unit for any particular purpose as performance may vary with the conditions encountered.

Dimensions

Hermetic Proximity Sensor (Interlock Switch)Side View(without face plate)

SOLENOID VALVE TROUBLESHOOTING

Pulse valve malfunctions are usually caused by diaphragm failure or dirt and/or moisture getting into thevalve body. These problems can be identified by disassembling the valve and inspecting it. Before checkingvalves, verify that tubing and fittings between diaphragm (pulse) valves are not leaking, and that the tubing isconnected to the inlet port on the solenoid valve.

Prior to servicing the diaphragm valve, the solenoid pilot valve needs to be checked for proper operation. Ifmalfunctioning, refer to the steps below:

If the solenoid valve will not open:

1. Confirm adequate electrical connection.2. Check continuity of coil. If a metallic click is heard when the coil is energized, the coil is not the source of the

problem.3. Depressurize the system. Check solenoid valve for dirt or wear - clean or replace.

If the solenoid valve will not close:

I. Disconnect the electrical source to ensure the coil is not continuously energized.2. Depressurize the system. Check solenoid valve for dirt or wear - clean or replace.

If the pulse valves and solenoid valves are all in operatiniq order, the next step is to inspect the cleaningsvstem controller, followina the procedure listed below:

1. Check power supply to the timer board to ensure it is correct.2. If present, check the fuse on the timer board. Replace if it is blown.3. Turn power on and observe output signals to ensure each output is supplying a signal. Look for any outputs

that may be supplying a continuous signal. If no signal, replace board.4. If the timer board is working properly, p w e ; y p echeck the wiring between the timer and the solenoids for any

discontinuity and/or short circuits.5. If the signal is controlled by a signal from a pressure switch, check to ensure that the jumper between terminals

on the timer board used to tie in the pressure switch has been removed. Also check the pressure switch itselfto ensure that its air lines are not plugged. Its signaling capability can be checked by manually adjusting thedifferential pressure set points to a position that causes the relays in the switch pressure to activate.

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Dwyer Mark II series molded manometers are of the inclined and inclined-vertical types. The curved inclined-vertical tube of the Model 25 gage provides higher ranges with more easily read increments at low readings. The Model 25 is excellent for general purpose work. The Model 40 inclined gage provides linear calibration and excellent resolution throughout its range. The Model 40 is ideally suited for air velocity and air filter gage applications. Both gage types are capable of pressure measurements above and below atmospheric as well as differential pressure measurements. Construction - Mark II manometers are economically prices, compact and available in both stationary and portable configurations. Portable stand is standard on Model 40, available as optional A-612 stand for Model 25. Construction is simple with virtually indestructible molded white styrene-acrylonitrile housing, indicating tube and fluid wells, molded ABS knobs and zero adjust plunger, shock mounted glass level vial and leak proof "O" ring seals. Moderate overpressures are accommodated by an overflow tank incorporated in the Model 25. Greater protection is provided by float operated overflow traps in the Model 40. Scales are lithograph printed on aluminum and epoxy coated. Installation - Mark II manometers can be mounted on any vertical surface with the two mounting screws provided. A built-in spirit level simplifies leveling before mounting screws are tightened. Simply fill the reservoir, adjust fluid level to zero, connect the tubing, and the gage is ready for operation. Accessories - Included with each Mark II manometer are two tubing connectors for 1/8" pipe or sheet metal ducts, two mounting screws, ¾ oz. Bottle of indicating fluid, red and green pointer flags and complete instructions. The Model 25 also includes 8' of flexible double column plastic tubing.

Portable operation of the Model 25 is made possible by the use of the optional A-612 portable stand. A short piece of tubing can be slipped over the Model 25 pressure connections to contain the gage oil in transit. The Model 40 contains two 4 ½' lengths of clear plastic tubing, a plastic swing-out stand and leveling screw for portable operation. It also features convenient rapid shutoff pressure connections and integral overpressure safety traps. OEM Specials - All Dwyer Mark II molded plastic manometers can be supplied on OEM quantities with your name or special graphics and scales.

Fig. 13-1, Mark II Model No. 25 Inclined-vertical manometer.

(shown with optional A-612 portable stand)

Fig. 13-2, Mark II Model No. 40-1 Inclined manometer

MODEL CHART Model Range Fluid Used

25 0-3 in w.c. Red oil, .826 s.g.

26 0-7 in w.c. Blue oil, 1.91 s.g.

27* 0-7000 fpm Red oil, .826 s.g.

28* 0-10,500 fpm Blue oil, 1.91 s.g.

MM-80 0-80 mm w.c. Red oil, .826 s.g.

MM-180 0-180 mm w.c. Blue oil, 1.91 s.g.

M-700Pa 10-0-700 Pa Red oil, .826 s.g.

*Require Pitot Tube at additional cost. See Flow and Velocity section.

SPECIFICATIONS Accuracy: ± 3% full scale Maximum internal working pressure: 10 psi (70 kPa) Maximum Working temperature: 140°F (60°C) MODEL CHART

Model Range Fluid Used 40-1 .1-0-1.0 in. w.c. Red oil, .826 s.g.

40-25 mm 0-26 mm w.c. Red oil, .826 s.g.

40-250 Pa 10-0-250 Pa Red oil, .826 s.g.

41-2 .2-0-2.4 in. w.c. Blue oil, 1.91 s.g.

41-60 mm 0-60 mm w.c. Blue oil, 1.91 s.g.

41-600 Pa 0-180 mm w.c. Blue oil, 1.91 s.g.

40-1-AV* 0-1.1 in. w.c. & 0-4200 fpm Red oil, .826 s.g.

40-250 Pa-AV* 0-260 Pa & 0-21 mps Red oil, .826 s.g.

41 -2-AV* 0-2.5 in w.c. & 0-6300 fpm Blue oil, 1.91 s.g.

*Require Pitot Tube at additional cost. See Flow and Velocity section.

SPECIFICATIONS Accuracy: ± 3% full scale Maximum internal working pressure: 15 psi (100kPa) Maximum working temperature: 130°F (54°C)

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SECTION 4 – OPERATION

SAFETY HAZARD! Some spray activities may require the use of respiratory protection. Consult the MSDS for information on the appropriate respiratory protection to be worn.

IMPORTANT! Equipment owners and operators should read and understand all operation and maintenance information. Keep this manual on file for future reference.

Operation

Standard Booth (With optional control panel)

1. Turn the power on at the main breaker / disconnect. (The black handle on the face of the control panel.)

2. Turn the lights on by switching the “LIGHTS OFF/ON” to the “ON” position.

3. Momentarily depress “SYSTEM START” to enter the booth start-up- sequence and operation.

4. The “EXHAUST ON” light will illuminate after the “SYSTEM START” button is pushed.

5. Pushing the “SYSTEM STOP” button momentarily will shut the booth down at any time that the system is energized.

.

Operation

Pressurized Booth (With optional control panel)

1. Turn the power on at the main breaker / disconnect. (The black handle on the face of the control panel.)

2. Turn the lights on by switching the “LIGHTS OFF/ON” to the “ON” position.

3. Momentarily depress “SYSTEM START” to enter the booth start-up sequence and operation.

4. The following lights will illuminate in sequence after the “SYSTEM START” button is pushed.

a. “SYSTEM ENERGIZED” Light

NOTE! On systems that feature an air make-up unit with an intake or discharge damper section, there will be a delay of 1-1/2 minutes before the next 2 lights illuminate.

b. “EXHAUST ON” Light(s) c. “AMU BLOWER ON” Light

5. Turn the switch labeled “BURNER OFF/ON” to the desired position. The air make-up burner will modulate to achieve the desired discharge air temperature – as set by the remote set point dials. A minimum of 10 degrees Fahrenheit (5.6 degrees Celsius) temperature rise is always present. When this is in the “ON” position, a pilot light labeled “AMU BURNER ON” will illuminate once a flame is present.

6. The “AMU FLAME FAILURE” light will illuminate when the burner fails to ignite. The system will not operate with a flame failure.

7. Pushing the “SYSTEM STOP” button momentarily will shut the booth down at any time that the system is energized.

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Ductwork

Do not allow over spray to accumulate on the inside of the duct walls. When over spray accumulates, remove it as soon as possible to prevent a possible fire hazard.

Interior Booth Walls Do not allow over spray to accumulate on the inside of the paint booth walls. When over spray accumulates, remove it as soon as possible to prevent a possible fire hazard. Use a non-ferrous, non-sparking scraper to eliminate any possibilities of igniting combustible material. Do not leave piles of paint sweepings in the booth as it creates a possible fire hazard. To aid in booth clean up, use a pre-coating, clear peel coat, or flame resistant paper. Consult the factory for details.

Maintenance Schedule After initial start-up, service the exhaust unit every six months.

Exhaust Units Check the exhaust units for the following:

• Loose belts • Noisy bearings • Misaligned pulley or sheave • Paint build-up on the fan blade

NOTE: Use any standard bearing grease lubricant on the grease fittings where applicable.

Air Make-Up Units Check the air make-up unit for the following:

• Movement in the blower shaft • Loose lock rings on blower shaft bearings • Misaligned pulley or sheave • Bad or loose bearings • Loose belts • Clean the burner assembly • Check to see if there is adequate lubrication

NOTE: Use any standard bearing grease lubricant on the grease fittings.

SECTION 5 -MAINTENANCE GUIDE

Maintenance The frequency of many of the following maintenance checks depends upon the amount and kind of material being sprayed. Perform these maintenance checks at regular intervals to reduce fire hazards, to maintain booth efficiency, to prevent freshly painted objects from becoming blemished, and to hinder booth rust.

Exhaust Fan and Motor

Regularly check the belt tension on the exhaust fan and motor. Bearings in the exhaust fan and motor may wear unnecessarily when belts are too tight. Do not allow over spray to accumulate on the exhaust fan blade. When over spray accumulates, remove it as soon as possible to keep the blade in balance. Remove the blade and clean when necessary. Do not hammer or step on the blade because it is made of aluminum. Some exhaust fan units are equipped with sealed-for-life bearings that require no grease. Consult the included operation and maintenance manual for details.

Intake Filters Replace the intake filters every 2 to 6 months, depending upon the environment that the spray booth operates, and how frequently the booth is in operation. Verify that the intake filters need replacing by taking a visual manometer reading across the intake filter bank.

Exhaust Filters Replace the exhaust filter when the accumulation of paint over spray hinders the airflow of the booth. The manometer will indicate that it is time to replace the filters. Check the filter manufacturer’s recommendations for filter final resistance rating. Immediately remove all arrestor filter pads from the booth. Discard arrestor filter pads to a safe, well-detached location, or place in a water-filled metal container to prevent a possible fire hazard. Disposal varies depending on the type of paint that is being captured. Consult local authorities for storage and disposal requirements.

Manometer Check the fluid level in the manometer periodically and adjust as needed. Clean the manometer with a soft damp cloth.

Lighting When a tube burns out, open the access panel of the light fixture to remove the burned-out tube. A heavy-duty pressure lock telescopic lamp holder holds the light fixture in place. Place one end of the tube in the end of the spring-loaded holder and push in. Slide the other end into the opposite end holder. To aid in clean up, use a clear plastic film or a clear peel coat over the light glass. Consult factory for details.

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Use the decision table below to troubleshoot products that are not operating properly.

Symptom Probable Cause Remedy The filter is dirty. Change filters as necessary.

There are obstructions in front of the filters. Remove any obstructions.

Increase the speed of the fan, if possible. The filters in use do not match the design

specifications. Change the filters to match the design specifications.

The fan blades are dirty. Clean the fan blades.

There isn't enough airflow in booth.

The fan is not turning fast enough. Adjust the fan sheaves so they are closer together. Check the amp draw after adjusting. Re-adjust the

fan sheaves as necessary.

The gas pressure is low. Check the gas pressure to the air make-up unit.

The temperature selector setting is incorrect. Adjust the temperature to represent the exit air temperature of the air make-up unit.

The booth is not operating at the correct temperature.

The fan is rotating too quickly. Adjust fan sheaves so that the sheaves are farther

apart.

There is too much airflow. The filters are not properly seated.

Ensure that all filters are in place.

The booth has too much negative pressure.

The airflow of the booth is not balanced.

Open the variable-pitch pulley to slow the exhaust sheave down or speed up the air make-up sheave. Check the amp draw after adjusting. Re-adjust the

fan sheaves as necessary.

The booth has too much positive pressure. The airflow of the booth is not balanced.

Close the variable-pitch pulley to speed up the exhaust sheave or slow down the air make-up

sheave. Check the amp draw after adjusting. Re-adjust the fan sheaves as necessary.

The motor is running too fast.

Compare the recommended amperage draw on the motor identification tag with the draw of the

motor while the motor is running. If the amperage draw of the motor is reading higher than

recommended, slow the motor down by adjusting the variable-pitched pulleys.

The belt alignment and tension may be incorrect. Loosen and line-up the pulleys by adjusting the motor base.

The ductwork is inappropriately applied. Check the static pressure of the ductwork configuration and adjust as necessary.

The exhaust fan motor overloads.

The filters are dirty. Replace the filter pads as necessary.

The fluid level is low. Check the fluid level and add fluid as necessary. The manometer is not functioning properly.

There are obstructions in the hoses. Clear any obstructions in the hoses.

Check for loose connections. A light is not functioning properly.

The wiring of the light may not be 120 or 277 volts AC.

Change the wiring as necessary.

Section 6 – Troubleshooting Guide

= Call for a consultation

SPARE PARTS LIST

Part Number

TAB-36-50T3 FAN, 36", 5 HP TEFC, 3 PHASE

TAB-20-21T3 FAN, 30", 2 HP TEFC, 3 PHASE

LFMK4-120277-NP LIGHT INSIDE ACCESS NO PIGTAIL

217-012 20 X 20 X 1 FILTER PANEL TACKY STD

242-001 MANOMETER STD 0-3 IN WATER COLUMN

217-031 60W X 2 MEDIA POLYESTER 50FT LG

242-124 VALVE SOLENOID 3-WAY,N.C UL .75 FPT

206-536 FAN, TUBE AXIAL, 36" LMD

234-009 MOTOR 5HP 3PH TEFC 184T FRAME

213-304 SHEAVE, DRIVE, 2VP56 X 1-1/8

213-456 SHEAVE, DRIVEN, 642B

213-467 BUSHING, SDS X 1.5

211-245 V-BELT, A69

206-530 FAN, TUBE AXIAL, 30" LMD

213-302 SHEAVE, DRIVE, 1VL44 X 7/8

234-007 MOTOR 2.0 HP 3PH TEFC 145T FRAME

213-449 SHEAVE, DRIVEN, 561B

213-447 BUSHING, SDSX1-1.25

211-214 V-BELT, A58

254-017 STICKER- NO AIR ROTATION

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Contacting Customer Service When contacting our Customer Service department it is important to know all pertinent information before ordering. Please have the following information at hand when placing the order:

• Model Number of the booth: found on the ID plate on the booth located either by the man door or on the fire curtain.

• Serial Number of the booth: found on the ID plate on the booth located either by the man door or on the fire curtain.

• Part Number, Description and Quantity of the parts being ordered. • Purchase Order Number • Manner in which the items will be shipped: For example, UPS, FedEx, truck, air, etc. • Complete Shipping and Billing Address

If there are any questions or problems with the spray booth, please contact Customer Service.

• Phone: 1.800.848.8738 • Fax: 715.597.2193 • Email: techservices@globalfinishing.com

Ordering Service or Replacement Parts To order service or replacement parts, contact our Small Parts Department.

• Phone: 1.800.848.8738 • Fax: 715.597.2193 • Email: smallparts@globalfinishing.com

NOTE: Current price and delivery will be quoted at the time the order is placed. All prices are quoted F.O.B. Osseo, Wisconsin.

Returning Parts To return or exchange any items, contact Global Finishing Solutions and request a Return Goods Authorization form. All items intended to be returned for credit or exchange must be accompanied by this form. Upon receipt of the Return Goods Authorization form, the items are subject to a 20% handling charge. Special non-stock items can be accepted only with the approval of our suppliers and are subject to any additional handling and restocking charges.

Section 7 – Customer Service

PARTS & SUPPLIES SERVICES All standard and custom products as designed and built by GLOBAL. All parts are retained on file for immediate reference, replacement, and availability when required. * PRICING ON ALL ITEMS

GLOBAL price sheets provide pricing on all standard parts: Call Small Parts Department for immediate service. Toll Free 1-800-848-8738. (Minimum $50.00 Billing)

* AVAILABILITY / SERVICE

Critical operational parts for productions and customer safety will be shipped overnight when possible by contacting GLOBAL Customer Service.

Standard parts allow 30 days for delivery. Contact Small Parts Department.

* VENDOR

All components are supplied by GLOBAL. * OPERATION & MAINTENANCE MANUALS

GLOBAL includes an electronic copy of the Operation & Maintenance Manual with each job. There will be a charge for additional electronic or printed manuals.

* SUPPLIER TO STOCK

For replacement parts or supplies contact the Small Parts Department: 1-800-848-8738

TECHNICAL SERVICE

Global Finishing Solutions supplies on-going technical support for our customers.

For “TECHNICAL SERVICE” or “SMALL PARTS”:

GLOBAL Phone: (800) 848-8738 or (715) 597-3168

GLOBAL Fax: (715) 597-2193

You can reach a technical service representative during regular business hours by calling either (800) 848-8738 or (715) 597-3168 and asking for “Technical Service”. If you prefer to send a fax at (715) 597-2193, or leave a message on the voice mail system, someone will get back to you as soon as possible. If you need replacement parts please call and ask for the “Small Parts” department.

GLOBAL LIMITED WARRANTY

GLOBAL? (the Sellers) warrants to the original end-user buyer (the buyer) that the equipment manufactured by, and purchased from, the Seller (the Equipment), if properly installed in accordance with the Seller’s Service Manual, operated, and maintained, and used under normal conditions, shall be free from defects in workmanship and materials for a period of one (1) year from the date the Equipment is shipped from the facilities of the Seller. The obligation of the Seller, and the Buyer’s SOLE AND EXCLUSIVE REMEDY hereunder, shall be limited to one of the following, at the Seller’s option: (01) The repair or replacement of defective parts or components (collectively, the Parts) of the Equipment; provided, however,

the Buyer shall be responsible for the payment of all labor costs associated with any such repair or replacement. (02) In the event the Seller is unable to repair or replace the defective Parts, the Buyer shall be entitled to a refund of the cost

of the Parts. The Seller shall have no obligation under this Limited Warranty for ordinary wear and tear of the Equipment; if installation of the Equipment does not comply with local, state and federal requirements or laws; or if the Equipment is modified by any other person or organization. The Seller makes no warranty of any kind whatsoever with respect to Parts, which are manufactured or supplied by other persons or organizations (an OEM); provided, however, the Seller shall reasonably assist the Buyer in connection with warranties, if any, provided by an OEM.

WARRANTY PERFORMANCE PROCEDURES

In the event the Buyer believes the Seller may be responsible for the performance of any warranty obligation, the Buyer must immediately send written notice of a claimed defect, and must immediately refrain from any further use of the affected Equipment. No attempted repair of the claimed defect may be made without the prior written consent of the Seller. Before any Parts can be returned to the Seller, the Buyer must contact the Seller and request a Return Authorization. Upon the Buyer’s receipt of the Return Authorization form, the Parts may be shipped, freight prepaid, to the facility designated on the Return Authorization. All Parts returned for repair, replacement, or refund (a refund may be made in the form of a credit to the Buyer’s account), must be accompanied by the Return Authorization. All returned parts are subject to a twenty percent (20%) handling charge. Parts manufactured or supplied by an OEM are subject to the warranties, if any provided by such OEM’s; and repair or replacement of such Parts are subject to the approval of the OEM. The Buyer shall be responsible for the payment of any handling or restocking charges associated with OEM Parts.

DISCLAIMERS OF WARRANTIES

THE WARRANTIES CONTAINED HEREIN ARE EXPRESSLY IN LIEU OF ANY OTHER EXPRESSED OR IMPLIED WARRANTIES, OR ANY OTHER OBLIGATION ON THE PART OF THE SELLER, INCLUDING WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ANY MODELS, DRAWINGS, PLANS, SPECIFICATIONS, AFFIRMATION OF FACT, PROMISES, OROTHER COMMUNICATIONS BY THE SELLER WITH THE REFERENCE TO THE EQUIPMENT OR THE PERFORMANCE OF THE EQUIPMENT ARE SOLELY FOR THE CONVENIENCE OF THE BUYER AND SHALL NOT IN ANY WAY MODIFY THE EXPRESSED WARRANTIES AND DISCLAIMERS SET FORTH HEREIN. THE BUYER ACKNOWLDGES IT IS PURCHASING THE EQUIMENT SOLELY ON THE BASIS OF THE COMMITEMENTS FOR THE SELLER AS EXPRESSLY SET FORTH HEREIN. NO AGENTS OR OTHER PARTIES ARE AUTHORIZED TO MAKE ANY WARRANTIES ON BEHALF OF THE COMPANY OR TO ASSUME FOR THE COMPANY ANY OTHER LIABILITY OR OBLIGATION IN CONNECTION WITH THE EQUIPMENT.

CONSEQUENTIAL DAMAGES

The Seller shall not be liable for any incidental or consequential damages arising from the use of the equipment by the Buyer, the breach of any warranties, the failure to deliver, delay in delivery, delay on nonconforming condition, or for any other breach of contract or duty between the Seller and the Buyer.

LIMITATION OF ACTIONS

Any action resulting from the breach of any warranty contained herein by the Seller must be commenced within one (1) year after the cause of action accrues. In no event shall the Seller’s total liability for any or all breaches of any warranty exceed the actual purchase price paid by the Buyer for the Equipment.

P.O. Box 250 ? 12731 Norway Road

Osseo, Wisconsin 54758-0250 Phone: 717-597-3168

Toll Free: 800-848-8738 Fax: 715-597-2193

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NOTES: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ ________________________________________________