Water Base Painting and Drying Spray Booth and Double Fan Preparation Station

Water Base Painting and Drying Spray Booth – For Technical Information please Click

MAIN BOOTH

Side walls are made of 1 mm galvanized sheet with 40 mm glasswool insulation. In order to provide an ergonomic view and longer life, outside surface of the panels are painted with import (electro) static powder paint. Our products have the illumination system which had been designed in order to optimise the color control during the painting phase. Through the reflectors placed with an angular manner, an equal light distribution is provided in the booth. Furthermore electronic balast is used, so energy saving is provided. There is a hanger system with rails hanged on the ceiling, which enables parts painting beside the automobile.

Ceiling, consisting of sheet panels which have special insulation support, is suitable for walk on during the maintenance and repair services. With the aim of cleaning input air, high performance long life filter items, made of non flammable material, are placed under the ceiling.

There is a 3- leaf door system in front of the spray booth for vehicle entry, and a door for personel entry and exit. Door items have observation windows made of safety glass.

Base is consist of steel construction which enables installation of whole system on a concrete floor. Galvanized grates and metal system, which is able to carry 650 Kg wheel load and minimize the dust aeration, placed on steel construction.

At the spray booths with fixed air speed, in the case that air speed and flow inside the booth are not checked, with the contamination of filters, booth inside air speed, flow and pressure generates the following unfavourable cases:

- Causes earlier replacement of the filters.

- High pressure or vacuum may occur in the spray booth.

- Insufficient air entry into the booth causes painted surfaces to get dusty.

- During drying, heat is generated in the heating unit which is at the outside of booth, than carried into the booth by air circulation. In cases of insufficient air and consequently heat is carried into the booth, energy losses arise.

CEILING

Plenum is made of galvanized sheet of 1 mm thickness. Right and left sides, front and back parts of plenum are painted with electrostatic powder paint and there are insulated ceiling panels at the top of plenum. Ceiling filter frames are placed at the bottom part of planum.

Plenum provides cleaning of the inlet air through the filters, and delivery into the booth.

During the application with water base paints, extracted to the plenum by 4 fans and delivered to the booth by air jet nozzles. In front of the suction inlet part of nozzle fans pre filters exist.

Plenums are made of galvanized sheet with 1 mm thickness. Right, left, front and back sides are painted with electrostatic powder paint. There are ceiling panels with insulation at the top part of plenums. Ceiling filters are made of EU5 standard non flammable material.

WALLS

Side and back walls of the spray booth are consist of galvanized sheet with the thickness of 1 mm. There is glasswool insulation of 50 mm inside the walls.

Inside of the spray booth walls are painted with white, and outside are painted with blue electrostatic powder paint. Panels that forms the walls are fitted each other with H profiles, therefore assembly and dismantling operations are considerably easy.

DOORS

There is a 3- leaf door system in front of the spray booth for vehicle entry. Additionally there is a door for personel entry at the side. Personel door may be at right, left or back of the spray booth, according to the position of the units, for the most useful mode.

Illumination equipments are placed at the side of the spray booth, with an angle of 55 0 between walls and plenum. Covers of illumination equipments are placed in front of them with gaskets. These covers are portable, and flourescents can be replaced easily.

Each flourescent has the power of 40 watt. Lighting is provided through electronic ballasts. Electronic ballasts lengthen the life of flourescents as well as providing 30% saving from energy

Grates have the carrying capacity of 650 kg per Wheel. Grates are made of sheet profiles, and placed over the basement. Easily movable grates have the dimensions of 600 x 670 mm and weight of 12 kg. Grates are covered with nickel cadmium, against corrosion and paint particules and for a good view.

Floor has the form of a basement with a height of 400 mm.

surface of the basement is totaly covered with grates. Filters, placed under the grates -where the wheels come on- holds the paint particules. Under the grates of other parts, there are special plates to hold the dust. there are two 400 mm ramps in front of the spray booth, on the front basement for vehicle entry.

If spray booth installation area has an excavation, ramps are not used for vehicle entry. In the case of excavation, it must has a depth equal to the height of basement from the floor level.

Fresh Air Unit

This unit delivers the filtered fresh air to the spray booth and throws the used air out during the painting, and during the drying it delivers the air that is heated upto 60 ˚C to the booth and circulates the used air by mixing it with 10% fresh air (via pneumatic damper) and re-heating.

Heating of the air is provided by a burner with the capacity of 200.000 kcal/h and an exchanger made of 304 quality stainless steel sheet. It takes approximately 15 minutes to raise the air temperature of the first starting up to 60 ˚C, depending on the weather conditions.

Delivery or circulation of the air heated or not heated is provided by two industrial type fans each having the capacity of 24.000 m³/h. Air delivered to the booth after filtered from a pre-filter in this unit. Additionally output air is controlled by a damper located in the output air channel.

In the case of water base paints used, in addition to these two industrial type fans toher 4 fans included too. These fans blow air with a total force of 10.000m³/h, through the nozzles inside of the spray booth. This extra blowed air during the drying, provides water base paint to dry in a very short time. Thereby, water base paint is dryied in accordance with its chemical structure, and saving from fuel, energy and time is provided too.

SPRAY BOOTH OPERATIONAL PRINCIPLE

Solvent Base Paint Application

If solvent base paint will be used in painting process, solvent base paint obtion must be selected at the digital screen. So, solvent base paint will be applied in the booth.

Spray Booth has four operational phase.

1- Painting Time

2- Flash-off Time

3- Drying Time

4- Cooling Time

These phases are commanded through Command Panel.

PAINTING TIME

When the booth is started it begins to operate with painting position. In this case pneumatic damper in the heating unit is closed. Heating unit takes 100% of circulation air from outside. Air passing through pre-filter pass from exchanger cell and delivered to the plenum under fixed temperature of 20 0C.

Compressed air enters the spray booth with a homogeneous flow, through the ceiling filters via plenum. Vertical air speed is aproximately 0.25 m/s.

Polluted air is derived out. Air, which is polluted by paint particules derived out after it had been purified with floor filter (paint stop) at first and than exhaust filter in the exhaust unit.

FLASH-OFF TIME

This process is the phase which provides the derivation of solvent formed in the booth after painting and it continues for 4 minutes. During this period by circulating the fresh air taken from outside, complete purification of the air is provided. At the end of this period pneumatic damper in the heating unit opened and spray booth proceed to drying position after the temperature reached to the baking set temperature.

DRYING TIME

In this phase aproximately 80% of circulated air is re-delivered to the booth at 60 0C through the plenum. Becouse 20% of the air inside the booth is derived out, solvent which is generated during drying is derived out with this air. It is suggested to dry auto repair paints below 60 0C. If you wish to change booth inside temperature, temperature set could be changed through digital screen of kontrol panel.

COOLING TIME

after the drying process which continue approximately 30 minutes is completed control panel shuts the burner off. Pneumatic damper closes and exhaust unit starts operation again. In the cooling phase fresh air taken from outside of the booth is circulated. At the end of 4 minutes system will stop itself automatically by the command panel.

Application with Water Base Paint

If water base paint will be used in painting process, water base paint obtion must be selected at the digital screen. So, water base paint will be applied in the booth.

Spray Booth has six operational phase

1- Pre-painting Time (this phase will be repeated)

2- Pre-Drying Time (this phase will be repeated)

3- Final Painting Time

4- Flash-off Time

5- Final Drying Time

6- Cooling Time

These articles are adjusted by the electronic card system of kontrol panel.

PRE-PAINTING TIME

When the booth is started it begins to operate with painting position. In this phase pneumatic damper in the heating unit is closed. Heating unit does not take air from booth inside, it takes 100% outside air filtered by pre-filter. Air temperature in painting phase is 20 °C. Pre-painting which is the first coat of painting process will be executed.

Compressed air in the plenum which is filtered through ceiling filter, supplied to the booth inside equally through all ceiling section. Air speed in the spray booth is approximately 0.25 m\sn.

Air that is polluted with spray paint, derived out by the suction of exhaust unit from booth inside towards floor (paint stop) filters. Polluted air filtered again in the cassette filters in exhaust unit.

With the water base paint applications, there will be painting in several phases, after pre-drying phases second or third painting (coat) will be executed.

PRE-DRYING TIME

When the temperature reaches to the set value, pneumatic damper in the fresh air unit opens and spray booth will be started at pre-drying position.

After the booth inside temperature reached to pre-drying set value, air jet nozzle motors will run and air with more speed will delivered to booth inside. Through these nozzles there will be moreair speed, therefore water will depart from paint and through air jet nozzles water will be evaporated. For each nozzle there are 4 pre-filter cassettes at fan entries for air filtering.

In this phase, 80% of air taken from booth inside and heated up to 40 °C. Then delivered to the booth inside through plenum. Additionally this system provides heat saving.

During the drying, water in the booth in the conformation of water base paint derived out and in order to keep fresh air 20%, booth continues to take 20% fresh air from outside. In this process aproximately 40 °C hot air delivered to the plenum.

Paint companies suggest 40 °C for water base paints, in the pre drying phase for repair paint of automobile. If your paint supplier suggests a different temperature, temperature set value may be changed, however booth temperature set value must never be set over 80 C.

If changing booth inside temperature is necessary, temperature set could be changed via digital screen of control panel.

Pre-drying phase takes 15 minutes under 40 °C and afterwards it will be completed automatically. Exhaust unit does not operate during pre-drying phase. At the end of drying phase exhaust unit fan will run and final painting process will be re-started.

If water base paint requires second pre-drying phase, after painting phase you have to select the pre-drying obtion again via digital screen of control panel.

FINAL PAINTING TIME

When final painting phase begin operating air jet nozzle motors will be stopped automatically. Spray booth begin to operate in painting process again. In this phase pneumatic damper in heating unit closes. Heating unit does not take air from booth inside, it takes 100% outside air filtered by pre-filter. Air temperature in painting phase is 20 °C. Final painting which is the second coat of painting process will be executed.

Air in the plenum which is filtered through ceiling filter, supplied to the booth inside equally through all ceiling section. Air speed in the spray booth is approximately 0.25 m\sn.

Air that is polluted with spray paint, derived out by the suction of exhaust unit from booth inside towards floor (paint stop) filters. Polluted air filtered again in the cassette filters in exhaust unit.

FLASH-OFF TIME

In this process, which takes 4 minutes is the purification time for purifying booth inside. When painting phase completed, spray booth continues deriving out air and takes fresh air from outside for 4 minutes. When flash-off phase completed, pneumatic damper in the fresh air unit will open and spray booth will proceed to drying position.

Spray booth will proceed with all of these phases automatically through electronic card of kontrol panel.

FINAL DRYING TIME

When temperature reached to set value, spray booth proceeds with final drying phase.

After the booth inside temperature reached to final drying set value, drying time will begin and air jet nozzle motors will run. Air with more speed through these nozzles, will be delivered to booth inside.

In this phase, 80% of air taken from booth inside and heated up to 60 °C. Then delivered to the booth inside through plenum. Additionally this system provides heat saving.

During the drying, water in the booth in the conformation of water base paint derived out and in order to keep fresh air 20%, booth continues to take 20% fresh air from outside. In this process aproximately 60 °C hot air delivered to the plenum.

Paint companies suggest 60 °C for water base paints, in the final drying phase for repair paint of automobile.

If you wish to change booth inside temperature, temperature set could be changed via digital screen of control panel.

Final drying phase takes 15 minutes under 60 °C and afterwards it will be completed automatically.

Exhaust unit does not operate during final drying phase. At the end of drying phase exhaust unit fan will run and cooling process will be automatically proceeded.

COOLING TIME

After the final drying process completed control panel shuts the burner off. Meantime pneumatic air damper will be closed and exhaust unit will begin to operate. Cooling is executed by delivering the air which is taken 100% from outside, to the booth inside.

At the end of 4 minutes, cooling time will be completed and fresh air and exhaust fans will be stopped automatically by electronic card of the control panel.

Copyright © FIRAT