Electrostatic Powder Painting Equipment Cascadium

Service Instructions
BYE-134
Electrostatic Powder Painting Equipment
Cascadium BFX-1005 Plus
OPERATION
DESCRIPTION
Equipment is a complete unit for powder coating and has
five basic components (Fig. 1).
CAUTION: The operator should not wear gloves or any
other element that isolates the hand from the spray gun
handle. All personnel next to the spray gun should be
grounded when the equipment is in operation.
Electrical
Cable
Automatic
Gun
THE BFX-1005 EQUIPMENT WITH THE BFP-838 GUN IS
NOT RECOMMENDED FOR USE WITH METALLIC POWDER.
CASCADIUM
Electrical
Pneumatic
Control
Powder
Pump
CONTROL ADJUSTMENTS (fig. 5)
POWDER FLOW
The powder flow of the spray gun being used is controlled
through the powder outflow adjustment knob (POWDER
FLOW RATE), on the electrical pneumatic control panel.
AIR DOSING
The mixture of air and powder is performed through an air
dosage adjustment knob at the control panel.
Fig. 1 – Basic components of the BFX-1005
INSTALLATION
POWER CONNECTION
ATTENTION: Check if the main switch (fig. 5) is off
before connecting the equipment to the power line.
The equipment works with 100 to 240 VAC, 50/60 Hz and
25VA.
Connect the ground wire of the electric pneumatic control
(fig. 5) to the metallic structure of the booth which should
be grounded. Also ground the oven, the conveyor (if any)
and all metallic objects which may conduct electricity and
are next to the booth.
HIGH VOLTAGE
The main switch showing ON turns on the high voltage
supply. The first segment of the voltage indicator (kV) and
of the current indicator (µA) turn on when the power
supply is connected. The working voltage is adjusted with
the voltage adjustment knob at the electrical pneumatic
control panel.
AIR LINE
Connect the air line of the electrical pneumatic control
(fig. 5) to the outlet of the pressure filter regulator which
should be between 80 and 90 psi (5,6 to 6,3 kgf/ cm2).
Consumption is approximately 14 SCFM.
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Service Instructions
BYE-134
CLEANING AND MAINTENANCE OF
THE AUTOMATIC GUN
In order to clean the gun, take out the deflector, release
the barrel cap and take out the diffuser (see fig.2), and
clean these parts with an air jet. Disconnect the hose at
the powder pump entrance, take out the suction tube and
feed the pump with air to blow out the powder in the
powder hose and the internal passages of the gun. The
porous plate inside the powder tank should be cleaned
with a weak air flow.
Tip
Deflector
Diffuser
Barrel
Fig. 2 – Powder gun nozzle
by turning the knob at the control panel counterclockwise.
Change the MANUAL/AUTO switch to MANUAL position
and turn the powder flow adjustment knob to see if it is
controlling the powder flow satisfactorily.
Check if the first segments of the voltmeter and microam
meter are on. In case they do not come on when you turn
the main switch, check the fuse and the line voltage.
The high voltage and output current are indicated in the
voltmeter / microammeter. Change the MANUAL/AUTO
switch to MANUAL position, turn the voltage adjustment
knob to maximum voltage and bring the electrode close to
a grounded object. The high voltage (kV) falls with the
electrode coming close to a grounded point and the
current (A) goes up to maximum.
This first test can determine if the spray gun is generating
high voltage. The lack of high voltage may also be noticed
due to the lack of wrap or powder adherence.
FUNCTIONING DESCRIPTION
The main element of the pneumatic control is a solenoid
valve, connected to the air entry. The outlet of the valve
feeds the injector of the powder pump through a valve
(powder flow rate adjustment) and of the No. 2 hose,
which feeds the powder pump.
The solenoid valve which is normally closed and stopping
the air flow is commanded by a switch activated by the
external control source (such as CLP, supplied by others).
When the MANUAL/AUTO switch is changed to AUTO
position, the switch turns on the electric pneumatic
control giving paint and voltage.
The voltage level is adjusted by means of the voltage
adjustment knob.
OPERATION CHECK
In case the equipment is not working properly, before
making the diagnostic of defects, check if the installation
of the equipment was done according to what is described
in Page 1 in this manual. Also check if the entry pressure
is correct and is the powder is fluidizing correctly.
TROUBLESHOOTING
ATTENTION:
We did not consider defects caused by installation or
operation deficiency in the below described diagnosis.
Therefore, the reading of this manual from the beginning
and the Checking Operation described on this page is
important to validate the diagnosis. The reading of the
Functioning Description can also help in the diagnosis.
DEFECT
Powder does
not come out
PROBABLE CAUSE
1. Defective Powder Pump.
2. Defective pneumatic control.
3. Defective Module 3.
4. Defective Module 4.
To determine which of the four causes is most probable,
take out hose (2) which feed the powder pump and
change the MANUAL/AUTO switch to MANUAL position.
If air comes out of the hose, the probable cause is the
pump.
Disassemble the pump, clean it and check the condition
Also check the operation: close completely the dosing air
2/10
Service Instructions
BYE-134
of the adaptor (ref. 5 powder pump, page 11). Replace
defective parts.
If air does not come out of the powder pump feeding
hose, first check the MANUAL/AUTO switch. Disconnect
the switch from control panel and with a wire or any
electric conductive material connect the two screws that
fasten the switch. The solenoid valve should open and air
should come out of the powder pump feeding hose (which
was disconnected from the pump). If this occurs, the
defect is probably in this switch (see exploded view of
electro-pneumatic control at page 7).
If the air does not come out through the powder pump
feeding hose, the defect may be in Module 3, Module 4, in
the electric cable or in the electrical pneumatic control.
Perform a continuity test on the electric cable and, if there
is no cutout, the problem is in Module 3, Module 4 or in
the electrical pneumatic control.
Check if Modules 3 and 4 are functioning as described in
the section Checking the Modules (page 4).
If the modules 3 and 4 are functioning properly, the defect
should be in the solenoid valve. Turn the main switch OFF,
and disconnect the solenoid of the motherboard and
check the continuity of the solenoid valve coils, through
the connector pins of the harnesses removed from the
motherboard. The resistance should be 80 to 120 ohm, if
not, replace the defective coil(s). If the coils are OK, revise
or replace the solenoid valve.
Other problems may occur with the electro-pneumatic
control. If so, talk to DeVilbiss technical assistance or your
distributor.
DEFECT
Little powder comes out
PROBABLE CAUSE
1. BFT-164 Venturi tube of the
powder pump is worn out.
2. Powder pump and suction
tube partially obstructed.
3. Damp powder.
Disassemble and clean powder pump and suction tube.
Replace Venturi tube, if necessary.
DEFECT
There is no wrap or
powder adherence to
the object being painted
or wrap is deficient
PROBABLE CAUSE
1. There is no high voltage or
voltage is low.
2. The object being
painted is not grounded.
Do the Operation Check (page 2). Further to this check,
change the MANUAL/AUTO switch to MANUAL position
and bring a grounded object a few millimeters from the
electrode of the gun. (To make it easy to observe the high
voltage shut the powder flow adjustment). You should see
a blue spark between the electrode and the grounded
object which proves the high voltage presence.
There being high voltage check the grounding of the part.
In case there is no high voltage, the defect should be in
the electrical pneumatic control, in the gun or in the
electric cable of the gun.
Check modules 1, 2, 3, 4 of the motherboard, the gun and
the electric cable of the gun, according to procedures
described in the next sections.
CHECKING MODULES (see fig. 3)
CAUTION: The line voltage is present in the terminals of
Module 1, in the harnesses of the wiring. There can be
danger of electric shocks and short-circuits. This job
should be done by specialized personnel in order to avoid
accidents and fire.
MODULE 1 (fig. 3) Turn the main switch to ON use a
multimeter and check the voltage between terminals AC/L
and AC/N (fig. 3) of the module terminal bar. The voltage
should equal the one in the line (100-240VCA).
If there is no voltage, check the fuse, the installation and
the main switch. Substitute the fuse or switch, if
necessary, or correct the installation.
There being alternate voltage in terminals L and N (fig. 3),
check the voltage between terminals -V and +V (fig. 3) of
module 1, with the main switch ON should be -12 and
+12V. . If there is no voltage, the module is defective and
should be replaced.
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Service Instructions
BYE-134
If Module 1, the main switch and the fuse are not
defective, check the motherboard where the outlets of
modules 2, 3 and 4 are installed.
YELLOW
LED 2.1
MODULE 1
MODULE 3
MODULE 2
RED
LED 3.2
-V
BLUE
GREEN
LED 3.3
GREEN
LED M5
+V
WHITE
LED 3.1
AMARELO
RED
LED M4
MOTHERBOARD
GREEN
LED M3
RED
LED 4.3
GREEN
LED 4.4
MODULE 4
YELLOW 5V
LED M1
GREEN 12V
LED M2
GREEN
LED 4.2
YELLOW
LED 4.1
Fig. 3 – Illustration diagram of electrical pneumatic control
MOTHERBOARD
Turning on the on/off switch on the electrical pneumatic
control panel the M1 (yellow) and M2 (green) leds will
turn on indicating that the motherboard is on with the 5V
and 12V voltages. If these two leds do not turn on check if
the unit's plug is connected to an outlet with 100 to
240VAC voltage. If it is properly connected, the problem
may be in the entry fuse, next to the power connecting
cable in the unit's cabinet.
In case current is correct it is possible that the problem is
with Module 1 which is the key control which feeds the
whole equipment. If only one of the leds M1 or M2 is on,
the problem may be in Module 1 or in the connecting
cable of Module 1 to the motherboard. With normal
operation and the M1 and M2 leds on, when adjusting the
voltage of the potentiometer of the equipment's panel,
LEDs M3 (green) and M4 (yellow) will light with a variable
shine depending of the level of adjusted voltage. When
triggering the gun, LED M5 will also show a variable shine
depending on the voltage adjustment in the
potentiometer in the panel, increasing the shine when the
potentiometer
is turned to increase the voltage. LED M5's shine will also
decrease when the outlet voltage of the gun increases,
with a consequent loss of high voltage. If LEDs M3 and M4
are on and LED M5 does not light in the described
conditions, it is possible there is a defect in module 2 or
the motherboard.
Replacement of Module 2 may define the cause.
MODULE 2. Module 2 has only LED 2.1 (yellow) which
shows if the module is being fed at 12 V.
MODULE 3. Leds LED 3.1 (yellow) and LED 3.2 (red) will
turn on when the on/off switch if turned on. When the
MANUAL/AUTO switch is on MANUAL position then the
Stage I the LED 3.3 (green) turns on and LED 3.2 (red) turn
off. If abnormal behavior is observed the module should
be replaced.
MODULE 4. When turning on the equipment, LED 4.1
(yellow) turns on. When the MANUAL/AUTO switch is on
MANUAL position, and Stage II is selected at the gun, LED
4.2 and 4.4 (green) turn on and LED 4.3 (red) turns on for
half a second each time the trigger is depressed. If Stage I
is selected at the gun, LED 4.2 (green) turns on and LED
4.3 (red) as in Stage II turns on for half a second each time
the MANUAL/AUTO switch is changed to MANUAL
position. If abnormal behavior is observed, the module
should be replaced.
CHECKING THE POWER CABLE
Release the connectors and remove the two extremities of
the cable. With a multimeter, check the continuity
between same number pins of the connectors in the two
extremities. If there is an interruption, replace the cable.
Also check the isolation between the pins of a same
connector (fig. 4). The pins are isolated.
Fig.4 – Electric cable connector
CHECKING THE GUN
The high voltage is generated in the gun barrel. If
motherboard, the modules 1, 2, 3, 4 and the electric cable
are not defective and the gun is not generating high
tension, the defect is probably in the gun barrel (see
exploded of powder gun).
The best way to confirm the defect is to replace the gun
with a new one. If the new gun generates high voltage, the
defective gun barrel must be replaced.
4/10
Service Instructions
BYE-134
REPLACING THE ELECTRIC CABLE
REPLACING THE GUN BARREL
Release the connectors and remove the cable.
Main switch ON/OFF
(MANUAL/AUTO)
Remove the two screws that hold the barrel to the gun
body with a hexagonal 1/8” wrench and a 5/8" hex
wrench take out the powder entry tube, and pull the
barrel forward. Install a new barrel and put back the
screws and the powder entry tube.
Voltmeter /
Microamperimeter
Voltage
adjustment
Powder flow
adjustment
Power cable
Compressed
air inlet
Ground wire
Automatic gun
CASCADIUM
Filter
regulator
(NOT INCLUDED)
Electrical cable
Compressed
air supply
Powder
Pump
Supply hose Nº3
(dosing)
Supply hose Nº2
(to powder pump)
Fig. 5 – Schematics of an installation of electrostatic painting outilift
5/10
Service Instructions
BYE-134
REPLACING THE MODULES
Disconnect the voltage from the line before replacing any
module.
MODULE 1. Disconnect the connectors and remove the
module from the plastic fixers.
MODULE 2. Remove the module.
MODULE 3. Remove the module.
MODULE 4. Remove the module.
MOTHERBOARD. Disconnect the connectors and remove
the board from the plastic fixers.
MODULE 2
MODULE 3
MOTHERBOARD
MODULE 1
MODULE 4
Module 3
Electrical cable
Automatic gun
Solenoid valve
Powder hose
Powder pump
Filter
regulator
Powder
adjustment
valve
Fluidized powder
(NOT INCLUDED)
Fluidization powder source
(NOT INCLUDED)
Fig. 6 – Illustration diagram of the electrical pneumatic control
6/10
Service Instructions
BYE-134
BGA-????: ELECTRO-PNEUMATIC FONT
4
25
3
5
7
1
13
6
10
2
9
1
8
11
18
24
19
17
23
20
19
15
14
21
12
19
22
29
22
16
23
24
19
15
26
19
14
18
29
7/10
Service Instructions
BYE-134
PARTS LIST ELECTRICAL PNEUMATIC CONTROL
REFERENCE
DeVILBISS CODE
DESCRIPTION
QUANTITY
1
BSS-6103
Switch
2
2
BGA-0420
Microammeter
1
3
BSS-11201
Module 1
1
4
BGA-0422
Connector
1
5
BGA-0421
Harness
1
6
BGA-0418
Module 3
1
7
BGA-0417
Module 2
1
8
BGA-0428
Module 4
1
9
BGA-0605
Motherboard
1
10
BGA-0424
Microammeter Harness
1
11
BGA-0426
Potentiometer
1
Flow orifice
1
12
13
BGA-0427
Module 1 Harness
1
14
BFC-0528
Adapter
2
15
K-8119
Hoses
1
16
BFC-0753
Valve
1
17
BFC-0754
Valve
1
18
BFC-0175
Screw
2
19
BSS-602014-K5
O Ring Kit
1
20
BFC-0548
Manifold with restraint
2
21
BSH-0100
Adapter
1
22
BGA-0423
Solenoid Valve
1
23
BSS-602013-K5
O Ring Kit
1
24
BFC-0527
Adapter
2
25
BSS-006326-K5
Fuse Assembly
1
26
BFC-0177
2 Stage Manifold
1
27
H-1766
14” NPS x 1/8” NPT
1
28
BFC-0561
Hose Nº1
1
29
BFC-0562
Hose Nº2
1
30
BFC-0563
Hose Nº3
1
8/10
Service Instructions
BYE-134
BFP-0833 POWDER GUN
1
8
2
6
4
13
7
5
10
9
3
TABLE 1
Pattern
Code
Round
NFP-0601
Elliptical
BFP-0603
1
11
14
9
15
16
REFERENCE
DeVILBISS CODE
DESCRIPTION
QUANTITY
1
BFP-0777
Barrel
1
2
See Table 1
Deflector Assemply
1
3
K-8111
Replacement Kit
1
4
BFP-0345
Tip
1
5
BFP-0598
Electrode Support
1
6
BFP- 0347
Deflector pusher
1
7
BFP-0588
Deflector
1
8
BFP-0333
Powder tube
1
Body
1
9
10
BFP-0594
Command Assembly
1
11
BGA-0411
Barrel Harness
1
13
BGA-0412
Harness
1
14
BFP-0591
Powder Entry Tube
1
15
BFP-0584
Electrode Assembly
1
16
BFP-0350
Elliptical Pattern Tip
1
9/10
Service Instructions
BYE-???
BFP-0847: POWDER PUMP ASSEMBLY
BFP-0867: CABLE ASSEMBLY
9
1
3
1
1
2
2
REFERENCE
5
4
8
DeV. CODE DESCRIPTION
7
QTY
1
BFP-0???
Power cable
1
2
BFP-0???
Powder hose
Assemply
1
6
REFERENCE
DeV. CODE
DESCRIPTION
QTY
1
BFT-0523
Retaining
2
2
BFT-0416
Injector
1
3
BFT-0164
Venturi Tube
1
4
BFT-0415
Adapter Support
1
5
BFT-0181
Pump Ring
1
6
BFT-0540
Suction Tube
1
7
BSS602013-K5
“O” Ring
1
8
BSS-602018-K5
“O” Ring
1
9
BSS602017-K5
“O” Ring
1
10/10