RediCoat by Nordson Hopper and VBF Dolly Systems Customer Product Manual Part 1082648A Issued 10/07 This document is subject to change without notice. Nordson Corporation Amherst, Ohio USA
2 Table of Contents Safety...3 Qualified Personnel...3 Intended Use...3 Regulations and Approvals...3 Personal Safety...4 Fire Safety...4 Grounding...5 Action in the Event of a Malfunction...5 Disposal...5 System Descriptions...6 Hopper System Description...6 Hopper System Specifications...7 VBF System Description...8 VBF System Specifications...9 Control Unit Rear Panel Connections...10 Operation Description...11 Grounding...11 Operation...11 Startup...11 System Connection Diagrams...13 VBF System Switch Box Wiring...14 Shutdown...14 Changing Powder...15 Maintenance...15 Nozzle Cleaning...15 Troubleshooting...16 Hopper System Packing List...17 VBF System Packing List...17 Parts Lists...18 Spray Gun Parts...18 Control Unit Parts...19 Powder Pump Parts...20 Hopper Parts...21 VBF Pickup Tube Parts...22 VBF Vibrator Motor and Switch Kits...23 Air and Powder Tubing...23
3 Safety Read and follow these safety instructions. Task and equipment specific warnings, cautions, and instructions are included in equipment documentation where appropriate. Make sure all equipment documentation, including these instructions, is accessible to all persons operating or servicing equipment. Qualified Personnel Intended Use Equipment owners are responsible for making sure that Nordson equipment is installed, operated, and serviced by qualified personnel. Qualified personnel are those employees or contractors who are trained to safely perform their assigned tasks. They are familiar with all relevant safety rules and regulations and are physically capable of performing their assigned tasks. Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment may result in injury to persons or damage to property. Some examples of unintended use of equipment include using incompatible materials making unauthorized modifications removing or bypassing safety guards or interlocks using incompatible or damaged parts using unapproved auxiliary equipment operating equipment in excess of maximum ratings
4 Personal Safety Fire Safety To prevent injury follow these instructions. Do not operate or service equipment unless you are qualified. Do not operate equipment unless safety guards, doors, or covers are intact and automatic interlocks are operating properly. Do not bypass or disarm any safety devices. Keep clear of moving equipment. Before adjusting or servicing any moving equipment, shut off the power supply and wait until the equipment comes to a complete stop. Lock out power and secure the equipment to prevent unexpected movement. Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or servicing pressurized systems or components. Disconnect, lock out, and tag switches before servicing electrical equipment. Obtain and read Material Safety Data Sheets (MSDS) for all materials used. Follow the manufacturer s instructions for safe handling and use of materials, and use recommended personal protection devices. To prevent injury, be aware of less obvious dangers in the workplace that often cannot be completely eliminated, such as hot surfaces, sharp edges, energized electrical circuits, and moving parts that cannot be enclosed or otherwise guarded for practical reasons. To avoid a fire or explosion, follow these instructions. Do not smoke, weld, grind, or use open flames where flammable materials are being used or stored. Provide adequate ventilation to prevent dangerous concentrations of volatile materials or vapors. Refer to local codes or your material MSDS for guidance. Do not disconnect live electrical circuits while working with flammable materials. Shut off power at a disconnect switch first to prevent sparking. Know where emergency stop buttons, shutoff valves, and fire extinguishers are located. If a fire starts in a spray booth, immediately shut off the spray system and exhaust fans. Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice.
5 Grounding Action in the Event of a Malfunction WARNING: Operating faulty electrostatic equipment is hazardous and can cause electrocution, fire, or explosion. Make resistance checks part of your periodic maintenance program. If you receive even a slight electrical shock or notice static sparking or arcing, shut down all electrical or electrostatic equipment immediately. Do not restart the equipment until the problem has been identified and corrected. All electrically conductive objects in the spray areas shall be electrically connected to ground with a resistance of not more than 1 megohm as measured with an instrument that applies at least 500 volts to the circuit being evaluated. Equipment to be grounded includes, but is not limited to, the floor of the spray area, operator platforms, hoppers, photoeye supports, and blow off nozzles. Personnel working in the spray area must be grounded. There is a possible ignition potential from the charged human body. Personnel standing on a painted surface, such as an operator platform, or wearing non conductive shoes, are not grounded. Personnel must wear shoes with conductive soles or use a ground strap to maintain a connection to ground when working with or around electrostatic equipment. Operators must maintain skin to handle contact between their hand and the gun handle to prevent shocks while operating manual electrostatic spray guns. If gloves must be worn, cut away the palm or fingers, wear electrically conductive gloves, or wear a grounding strap connected to the gun handle or other true earth ground. Shut off electrostatic power supplies and ground gun electrodes before making adjustments or cleaning powder spray guns. Connect all disconnected equipment, ground cables, and wires after servicing equipment. If a system or any equipment in a system malfunctions, shut off the system immediately and perform the following steps: Disconnect and lock out electrical power. Close pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the equipment. Disposal Dispose of equipment and materials used in operation and servicing according to local codes.
6 System Descriptions Hopper System Description Powder Pump Flow Rate Air kv Output Display and Adjustment Powder Pump Atomizing Air Spray Gun Rinsing Air Control Unit Spray Gun Grounding Knob Gun Bracket Powder Pump Ventilation Hose Connector Fluidizing Air Needle Valve Pump Adapter and Pickup Tube Hopper Fluidizing Air Fitting Figure 1 - Hopper System Components
7 Hopper System Specifications Electrical Input voltage (single-phase): 115 Vac ±5%, 60Hz or 220 Vac ±5%, 50Hz Output voltage (spray gun): 0 90 kv Output current (spray gun): 0 100 µa Solenoid valve voltage: 24 Vdc Pneumatic Input air pressure: 8 bar Compressed air quality: water <1.3 g/m 3, oil <0.01 g/m 3 Other Gun cable and powder hose: Spray gun weight: Hopper powder capacity: Machine weight: 5 m 555 g 16 kg 40 kg
8 VBF System Description Powder Pump Flow Rate Air Electrostatic Output Display and Adjustment Powder Pump Atomizing Air Spray Gun Rinsing Air Control Unit Spray Gun Grounding Knob Gun Bracket Powder Pump Fluidizing Air Needle Valve Pickup Tube Powder Box (customer supplied) Pickup Tube Bracket Pickup Tube Fluidizing Air Fitting Vibrator Table Figure 2 - VBF System Components
9 VBF System Specifications Electrical Input voltage (single-phase): 115 Vac ±5%, 60Hz or 220 Vac ±5%, 50Hz Vibrator voltage (single-phase): 115 Vac ±5%, 60Hz or 220 Vac ±5%, 50Hz Output voltage (spray gun): 0 90 kv Output current (spray gun): 0 100 µa Solenoid valve voltage: 24 Vdc Pneumatic Input air pressure: 8 bar Compressed air quality: water <1.3 g/m 3, oil <0.01g/m 3 Other Gun cable and powder hose: Spray gun weight: Vibrator table load capacity: 5 m 555 g 25 Kg
10 Control Unit Rear Panel Connections Gun Cable Air Supply Inlet (8 mm) Flow Rate Air Outlet (8 mm) Atomizing Air Outlet (8 mm) Rinsing Air Outlet (4 mm) Control Unit Ground Fuse (0.5 A) Power Cable Power Switch Figure 3 - Control Unit Rear Panel
11 Operation Description The powder pump creates a vacuum in the pickup tube which pulls the fluidized powder from the box or hopper and then forces the powder through the powder hose to the spray gun. The electrostatic voltage and the pump are adjusted by the voltage control knob and air regulators on the control unit. The fluidizing air pressure is adjusted by the needle valve mounted on the control unit support column. The electrostatic voltage (up to 90KV) applied to the spray gun electrode generates an electric field that charges the sprayed powder. The charged powder is distributed as a cloud and attracted to the grounded workpieces. The powder that does not stick to the workpieces can be collected, sieved, and re-used. Effective recycling could save 20% of the powder coatings, and decrease cleaning time. Operation Startup Grounding Each component of the system should be connected to the ground stud on the control unit column with the included ground wires. The included ground cable with clamp should also be connected to the ground stud, and to a true earth ground, such as the powder spray booth. Not properly grounding both the RediCoat system and the workpieces may cause the following coating problems: poor powder coverage rough powder coat powder being attracted back to the spray gun, coating the spray gun and operator The electrical resistance between the workpieces and the ground must not be more than 1 MΩ. Test the resistance regularly will a megohm meter. Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. See Figures 4, 5, and 6 for system connections. 1. Locate the dolly system on a level surface. 2. For hopper systems, install the hopper on the dolly and connect the ground cable from the hopper to the ground knob. 3. Install the pickup tube and pump. Connect the ground clamp to the nut on the flow rate air fitting on the pump. 4. Connect blue 6 mm tubing to the needle valve outlet and the fitting on the pickup tube, or the fitting at the bottom of the hopper.
12 5. Connect 8 mm blue tubing from the air manifold outlet fitting to the control unit inlet fitting. 6. Connect the spray gun and pump to the powder control unit: a. Connect blue 8 mm tubing from the pump flow rate air connection at the rear of the pump to the flow rate air fitting on the control unit. b. Connect red 8 mm tubing from the pump atomizing air connection at the top of the pump to the atomizing air fitting on the control unit. c. Connect the gun cable to the receptacles on the control unit and gun handle. d. Connect the blue 6 mm air tubing bundled with the gun cable and powder tubing to the rinsing air fitting on the control unit and to the rinsing air connection on the gun handle. e. Connect the powder tubing to the gun handle and pump. 7. Make sure the fluidizing air needle valve is closed. Supply compressed air to the control unit at 8 bar. The supply line should have a ball valve installed so you can turn the air supply on or off. 8. Connect the power cord to an electrical receptacle supplying the correct voltage. 9. Install a 25 kg box of powder on the vibrator table and insert the pickup tube into the powder, or fill the hopper 2/3 full of powder. 10. Turn the kv adjustment knob clockwise until it clicks on. Leave kv adjusted to zero. NOTE: The kv knob must be turned to the on position before you turn on power. If the knob is turned off the controller will open the solenoid valves and pump powder through the gun. 11. Press the control unit power switch until it lights. 12. VBF systems: Turn the vibrator motor switch to the ON position. 13. Adjust the needle valve until the powder is gently boiling in the hopper or just around the pickup tube. Too much air will cause the powder to erupt out of the hopper or box. 14. Set the flow rate air pressure to about 1 kg/cm 2 and the atomizing air pressure to about 0.3 kg/cm 2. 15. Point the spray gun into the spray booth and trigger the gun. Adjust the output voltage (kv) to 90. 16. Start coating workpieces and adjust the voltage and air pressure as needed to obtain the desired results.
13 System Connection Diagrams 8 2 1 Compressed Air (6-8 bar) 3 6 Power Plug System Ground Cable with Clamp (3.2 m) 9 5 3 10 7 4 1. Red 8 mm tubing with ferrule end 2. Blue 8-mm tubing with ferrule end 3. Blue 6-mm tubing 4. Gun cable 5. Powder tubing 6. Controller ground cable (0.5 m) 7. Ventilation hose (to spray booth) 8. Blue 8 mm tubing 9. Pump ground cable with clamp (1.8m) 10. Hopper ground cable (1.0 m) Figure 4 - Hopper System Diagram 7 2 1 Compressed Air (6-8 bar) 3 6 System Ground Cable with Clamp (3.2m) Power Plug 8 3 1. Red 8-mm tubing w/ferrule end 2. Blue 8-mm tubing w/ferrule end 3. Blue 6-mm tubing 4. Gun cable 5. Powder tubing 6. Controller ground cable (0.5m) 7. Blue 8 mm tubing 8. Pump ground cable with clamp (1.8m) 5 4 Figure 5 - VBF System Diagram
14 VBF System Switch Box Wiring To Control Unit Switch Box BROWN BLUE BLUE BROWN GRN/YEL GRN/YEL GRN/YEL BROWN BLACK Capacitor Cover GRN/YEL GRN/YEL BLACK BLACK BROWN BROWN BLUE C=450V 1.5 µf To Motor 110V (220V) Power Figure 6 - VBF System Switch Box Wiring Shutdown 1. Turn off the vibrator motor, if used. 2. Press the main power switch until the switch light turns off. 3. Shut off the compressed air supply to the system. NOTE: Shut off the air supply at a valve in the supply line to the system to avoid having to re-adjust the fluidizing air needle valve the next time you start up the system.
15 Changing Powder When changing powder colors or type, clean the following components thoroughly with a blow gun, vacuum cleaner, and clean, dry cloths: Spray gun (remove nozzles and clean separately) Powder pump (remove venturi throat and clean separately) Powder hose Pickup tube and pump adapter Hopper, if used Maintenance Clean the system regularly with compressed air, vacuum cleaner, and clean, dry cloths. 1. Shut off the control unit and disconnect the system air supply and electrical power. 2. Disconnect the air lines and powder hose from the spray gun and pump. Blow out the spray gun, pump, and hose with compressed air. 3. Empty the powder hopper and clean it thoroughly. Vacuum the fluidizing plate in the bottom and inspect it for contamination. If it is discolored, check the air supply for water or oil contamination. Replace the plate if it contaminated. NOTE: Never use solvents or other cleaning agents to clean any components of the system. Nozzle Cleaning See Figure 6. 1. Remove the deflector. 2. Unscrew the nozzle nut and remove the nozzle. 3. Pull the electrode support out of the nozzle. 4. Inspect all parts and replace them if worn or damaged. NOTE: The conical nozzle electrode support is longer than the flat spray nozzle electrode support. Nozzle Deflector (Conical Nozzle) Electrode Support Long: conical Short: flat Nozzle Nut Figure 6 - Nozzle Cleaning
16 Troubleshooting Problem Possible Cause Correction Switch light off, control unit off Switch off Fuse blown Press switch to turn on control unit. Replace fuse (0.5 amp) Powder spray uneven or puffing Powder escaping from box or hopper No powder spray when gun triggered Atomizing air pressure too low Powder hose worn Supply air pressure unstable Fluidizing air pressure too high Powder supply low Blockage in spray gun Blockage in powder hose Blockage in powder pump Blockage in pickup tube Increase atomizing air pressure. Replace powder hose. Install air regulator on supply line to regulate pressure if necessary. Adjust needle valve to decrease air pressure. Replace box or refill hopper. Remove powder hose and blow out spray gun with compressed air. Clean nozzle. Disconnect powder hose from spray gun and pump. Blow out hose with compressed air. Disconnect powder hose and air tubing from pump. Remove venturi throat and blow out throat and pump. Remove pickup tube and clean.
17 Hopper System Packing List VBF System Packing List Component Quantity Control unit 1 Dolly 1 Spray gun 1 Conical nozzle 1 Flat spray nozzle 1 Deflectors (small, medium, large) 6 Conical nozzle electrode support (long) 2 Flat spray nozzle electrode support (short) 2 Ground cable with clamp 1 Power cable 1 Spray gun cable 1 Powder hose 1 8-mm air tubing 4 6-mm air tubing 1 Powder pump 1 Pickup tube 1 Stainless steel hopper 1 Casters 4 Spray gun bracket 1 Component Quantity Control unit 1 Dolly 1 Spray gun 1 Conical nozzle 1 Flat spray nozzle 1 Deflectors (small, medium, large) 6 Conical nozzle electrode support (long) 2 Flat spray nozzle electrode support (short) 2 Ground cable with clamp 1 Power cable, including vibrator switch box 1 Spray gun cable 1 Powder hose 1 8-mm air tubing 4 6-mm air tubing 1 Powder pump 1 Pickup tube 1 Pickup tube bracket 1 Vibrator table, including vibrator motor 1 Casters 4 Spray gun bracket 1
18 Parts Lists Spray Gun Parts 10 2 1 11 9 12 13 6, 6A 19 19 17 20 7 15 8 20 14 5 4 16 3 Figure 7 Spray Gun Parts Item Part Description Quantity Note - 1081822 Handgun, Manual RDC 1 1 1081898 Sleeve, threaded, RDC 1 2 1081899 Body, gun, RDC 1 3 - - - - - - - Deflector, plate, 18 mm, RDC 1 A 4 - - - - - - - Deflector, plate, 25 mm, RDC 1 A 5 - - - - - - - Deflector, plate, 33 mm, RDC 1 A 6 1081904 Holder, electrode, RDC, flat jet nozzle (short) 1 D 6A 1083149 Holder, electrode, RDC, round jet nozzle (long) 1 E 7 - - - - - - - Nozzle, round jet, RDC 1 B 8 - - - - - - - Nozzle, flat jet, RDC 1 B 9 1081907 Tube, horizontal, RDC 1 10 1081908 Cascade, high voltage, RDC 1 11 1081909 Plate, end, with hook, RDC 1 12 1081910 Screw, manual gun, RDC 2 13 1081911 Handle, manual gun, RDC 1 14 1081912 Tube, vertical, RDC 1 15 1081913 Connector, rinsing air, RDC 1 16 1081914 Cable, gun, complete with 5 m cable, RDC 1 17 1081916 Connection part, RDC 1 18 1081917 Plate, grounding, RDC 1 19 1081918 Trigger, complete, RDC 1 20 - - - - - - - O-ring, 12 mm x 1 mm, RDC 6 C Note A: These parts included in 1082309 Kit, gun deflector plates, 18, 25, 33 mm, RDC. Note B: These parts included in 1082311 Kit, gun nozzles, flat jet, round jet, RDC. Note C: These parts included in 1082312 Kit, gun O-ring, 12 x 1 mm, RDC. Note D: Use only with flat jet nozzle. Note E: Use only with round jet nozzle.
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20 Control Unit Parts 9 4 8 5 6 7 3 2 1 Figure 8 - Control Unit Parts Item Part Description Quantity Note - 1081825 Control unit, 110V, RDC 1-1081826 Control unit, 220V, RDC 1 1 1081940 Valve, pressure reducing, RDC 3 2 1081928 Knob, control, RDC 1 3 1081941 Regulator, 0-90 psi, 0-6 bar, RDC 3 4 1081946 Switch, power, RDC 1 5 1081951 Transformer, 110V, control unit, RDC 1 A 5 1081950 Transformer, 220V, control unit, RDC 1 A 6 1081948 PCB, control unit, RDC 1 7 1081949 Potentiometer, control unit, RDC 1 8 1081944 Solenoid valve, 24 Vdc, RDC 1 9 1081947 Fuse, 0.5 A, RDC 1 NOTE A: Order correct transformer for your system. Refer to identification plate on rear panel.
21 Powder Pump Parts 3 2 1 Figure 9 - Pump Parts Item Part Description Quantity Note - 1081827 Pump, gun and dolly system, RDC 1 1 - - - - - - - Connector, pump, powder hose, RDC 1 A 2 - - - - - - - O-ring, 20.5 mm x 2 mm, RDC 1 A 3 - - - - - - - O-ring, 15 mm x 2.5 mm, RDC 1 A Note A: These parts included in 1082313 Kit, pump, O-rings, hose connector, RDC.
22 Hopper Parts 2 3 4 1 5 6 7 Figure 10 - Hopper Parts Item Part Description Quantity Note - 1081834 Hopper, assembly, RDC 1 1 1081992 Latch, hopper, RDC 6 2 1081994 Tube, pickup, hopper, RDC 1 3 1081995 Connector, pump, hopper, RDC 1 4 1081996 Tube, ventilation, hopper, RDC 1 5 1081997 Seal, foam, 5 mm x 10 mm, RDC 1 6 1081998 Seal, foam, 6 mm x 6 mm, RDC 1 7 1081999 Fluidizer, one-piece, hopper, RDC 1
23 VBF Pickup Tube Parts 1 2 3 4 5 6 7 Item Part Description Quantity Note - 1082314 Kit, pickup tube assembly, RDC 1 1 - - - - - - Adapter, pump, vibratory box feeder 1 2 - - - - - - Elbow, M5 x 6, RDC 1 3 1081823 O-ring, 15 x 1.7 mm, RDC 1 A 4 - - - - - - Tube, pickup, outer, fluidizing, RDC 1 5 1081881 Tube, pickup, fluidizing box feeder, RDC 1 A 6 1081885 Insert, fluidizing disc, box feeder, RDC 1 7 - - - - - - Adapter, insert, fluidizing, RDC 1 Note A: These parts are included in 1082316 Kit, O-ring and pickup tube, RDC
24 VBF Vibrator Motor and Switch Parts Item Part Description Quantity Note - 1082608 Kit, switch, vibratory mechanism, RDC 1-1081896 Motor, VBF, 110V, RDC 1 A - 1081897 Motor, VBF, 220V, RDC 1 A Note A: Order correct motor for your system. Air Manifold Kit This kit contains the fluidizing air needle valve and the air inlet and outlet fittings. It is installed on the control unit support bracket. Item Part Description Quantity Note - 1083166 Kit, manifold, air supply 1 Air and Powder Tubing Item Part Description Usage - 900742 Tubing, polyurethane, 6/4 mm, blue Rinsing air, fluidizing air - 900618 Tubing, polyurethane, 8 mm OD, blue Supply air - 1083562 Tubing, 8 x 6 mm, 1.2 m, w/ferrule end, red Atomizing air 1083563 Tubing, 8 x 6 mm, 1.2 m, w/ferrule end, blue Flow rate air - 900648 Tubing, powder, 11 mm, 0.44 in. ID, blue Powder - 900650 Tubing, powder, 12.7 mm, 0.5 in. ID, blue Ventilation
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