EPS-8 and EPS-9 Electrostatic Power Supplies Customer Product Manual Part For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) 433-9319 or contact your local Nordson representative. This document is subject to change without notice. Check http://emanuals.nordson.com for the latest version. C FM US APPROVED NORDSON CORPORATION AMHERST, OHIO USA
Contact Us Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information about Nordson can be found on the Internet using the following address: http://www.nordson.com. Address all correspondence to: Nordson Corporation Attn: Customer Service 555 Jackson Street Amherst, OH 44001 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date XXXX. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of Nordson Corporation. The information contained in this publication is subject to change without notice. Trademarks Nordson and the Nordson logo are registered trademarks of Nordson Corporation. Part 2001 Nordson Corporation
Table of Contents i Table of Contents Safety 1. Introduction.............................................. 1-1 2. Safety Symbols........................................... 1-1 3. Qualified Personnel....................................... 1-3 4. Intended Use............................................. 1-3 5. Installation............................................... 1-4 6. Operation................................................ 1-5 7. Less-Obvious Dangers.................................... 1-7 8. Action in the Event of a System or Component Malfunction..... 1-8 9. Maintenance and Repair................................... 1-8 10. Material and Solvent Precautions........................... 1-10 11. Disposal................................................ 1-13 12. Safety Labels........................................... 1-15 Description 1. Introduction.............................................. 2-1 2. Components............................................. 2-2 3. Features................................................. 2-5 4. Specifications............................................ 2-5 Installation 1. Installing the Power Supply................................. 3-1 2. Setting the Voltage........................................ 3-3 3. Making Terminal Block Connections A I and 1 4.............. 3-3 4. Using Terminal Block Connections for PLC Interface........... 3-7 5. Installing the Electrostatic Cable........................... 3-10 6. Using the Microammeter.................................. 3-11 Operation 1. Operating the EPS8/9..................................... 4-1 2001 Nordson Corporation
ii Table of Contents Troubleshooting 1. Introduction.............................................. 5-1 Troubleshooting Electrical Problems....................... 5-2 Input Voltage Calibration................................. 5-6 2. Wiring Diagrams.......................................... 5-8 Repair 1. Disassembling the Power Supply............................ 6-1 2. Removing the Multiplier Assembly........................... 6-2 3. Installing the Multiplier Assembly............................ 6-4 4. Assembling the Power Supply.............................. 6-7 5. Testing the Display........................................ 6-7 Parts 1. Introduction.............................................. 7-1 Using the Illustrated Parts List............................ 7-1 EPS8 Standard Parts................................... 7-2 EPS9 Standard Parts................................... 7-6 Cable Cleaning Kit..................................... 7-10 2001 Nordson Corporation
Section 1 Safety 2001 Nordson Corporation Issued 11/95 A1EN 03 [SF LIQD] 3
1-0 Safety A1EN 03 [SF LIQD] 3 Issued 11/95 2001 Nordson Corporation
Safety 1-1 Section 1 Safety 1. Introduction This section contains general safety instructions for using your Nordson equipment. Task- and equipment-specific warnings are included in other sections of this manual where appropriate. Note all warnings and follow all instructions carefully. Failure to do so may result in personal injury, death, or property damage. To use this equipment safely, read and become familiar with the general safety instructions provided in this section of the manual before installing, operating, maintaining, or repairing this equipment. read and carefully follow the instructions given throughout this manual for performing specific tasks and working with specific equipment. store this manual within easy reach of personnel installing, operating, maintaining, or repairing this equipment. follow all applicable safety procedures required by your company, industry standards, and government or other regulatory agencies. Refer to the National Fire Protection Association (NFPA) standard 33 and to federal, state, regulatory agency, and local codes for rules and regulations covering installation and operation of spray systems. obtain and read Material Safety Data Sheets (MSDS) for all materials used. 2. Safety Symbols Become familiar with the safety symbols presented in this section. These symbols will alert you to safety hazards and conditions that may result in personal injury, death, or property and equipment damage. WARNING: Failure to observe this warning may result in personal injury, death, or equipment damage. 2001 Nordson Corporation Issued 11/95 A1EN 03 [SF LIQD] 3
1-2 Safety 2. Safety Symbols (contd.) WARNING: Risk of electrical shock. Failure to observe this warning may result in personal injury, death, or equipment damage. WARNING: Disconnect equipment from line voltage. Failure to observe this warning may result in personal injury, death, or equipment damage. WARNING: Risk of explosion or fire. Fire, open flames, and smoking prohibited. WARNING: Wear protective clothing, safety goggles, and approved respiratory protection. Failure to observe may result in serious injury. WARNING: Hot! Risk of burns. Wear heat-protective clothing, safety goggles with side shields and/or heat-protective gloves depending on the symbol shown. WARNING: System or material pressurized. Relieve pressure. Failure to observe this warning may result in serious injury or death. WARNING: Injection. Do not point this device at yourself or other personnel. Failure to observe this warning may result in serious injury or death. A1EN 03 [SF LIQD] 3 Issued 11/95 2001 Nordson Corporation
Safety 1-3 2. Safety Symbols (contd.) CAUTION: Failure to observe may result in equipment damage. CAUTION: Hot surface. Failure to observe may result in burns. 3. Qualified Personnel Qualified personnel is defined here as individuals who thoroughly understand the equipment and its safe operation, maintenance, and repair. Qualified personnel are physically capable of performing the required tasks, familiar with all relevant safety rules and regulations, and have been trained to safely install, operate, maintain, and repair the equipment. It is the responsibility of the company operating this equipment to see that its personnel meet these requirements. 4. Intended Use WARNING: Use of this equipment in ways other than described in this manual may result in personal injury, death, or property and equipment damage. Use this equipment only as described in this manual. Nordson Corporation cannot be responsible for injuries or damages resulting from nonstandard, unintended applications of its equipment. This equipment is designed and intended only for the purpose described in this manual. Uses not described in this manual are considered unintended uses and may result in serious personal injury, death, or property damage. Unintended uses may result from taking the following actions: making changes to equipment that have not been recommended or described in this manual or using parts that are not genuine Nordson replacement parts failing to make sure that auxiliary equipment complies with approval agency requirements, local codes, and all applicable safety standards using materials or auxiliary equipment that are inappropriate or incompatible with your Nordson equipment allowing unqualified personnel to perform any task 2001 Nordson Corporation Issued 11/95 A1EN 03 [SF LIQD] 3
1-4 Safety 5. Installation Read the installation section of all system component manuals before installing your Nordson equipment. A thorough understanding of system components and their requirements will help you to install this equipment safely and efficiently. WARNING: Failure to follow these safety procedures can result in personal injury or death. Allow only qualified personnel to install Nordson equipment. Use only approved equipment. Using unapproved equipment in an approved system may void agency approvals. Make sure all equipment is rated and approved for the environment in which you are using it. Follow all instructions for installing components and accessories. Install all electrical, pneumatic, gas, and hydraulic connections to local code. Install locking, manual, shutoff valves in the air supply lines to the system. This allows you to relieve air pressure and lock out the pneumatic system before undertaking maintenance and repairs. Install a locking disconnect switch or breaker in the service line ahead of any electrical equipment. Use only electrical wire of sufficient gauge and insulation to handle the rated current demand. All wiring must meet local codes. Ground all electrically conductive equipment. Ungrounded conductive equipment can store a static charge which could ignite a fire or cause an explosion if a hot spark is discharged. Route electrical wiring, electrostatic cables, and air hoses and tubing along a protected path. Make sure they will not be damaged. Do not bend electrostatic cables around a radius of less than 6 in. (152 mm). Install safety interlocks and approved, fast-acting fire detection systems. These shut down the spray system and any flammable liquid supply if a ventilation or electrical problem occurs, a fire is detected, or other emergency situation develops. A1EN 03 [SF LIQD] 3 Issued 11/95 2001 Nordson Corporation
Safety 1-5 5. Installation (contd.) Make sure the spray area floor is conductive to ground and that the operator s platform is grounded. Use only designated lifting points or lugs to lift and move heavy equipment. Always balance and block loads when lifting to prevent shifting. Lifting devices must be inspected, certified, and rated for a greater weight than the equipment being lifted. Do not use unapproved fluid hoses. Solvents may cause them to deteriorate rapidly which may allow flammable or pressurized material to escape. Protect components from damage, wear, and harsh environmental conditions. Allow ample room for maintenance, material supply container drop-off and loading, panel accessibility, and cover removal. Protect equipment with safety devices as specified by applicable safety regulations. If safety devices must be removed for installation, install them immediately after the work is completed and check them for proper functioning. 6. Operation Only qualified personnel, physically capable of operating the equipment and with no impairments to their judgement or reaction times, should operate this equipment. Read all component manuals before operating this equipment. A thorough understanding of system components and their operation will help you operate the system safely and efficiently. Use this equipment only in the environments for which it is rated. Do not operate this equipment in humid, flammable, or explosive environments unless it has been rated for safe operation in these environments. Before starting this equipment, check all safety interlocks, fire-detection systems, and protective devices such as panels and covers. Make sure all devices are fully functional. Do not operate the system if these devices are not working properly. Do not deactivate or bypass automatic safety interlocks, locked-out electrical disconnects, or pneumatic valves. 2001 Nordson Corporation Issued 11/95 A1EN 03 [SF LIQD] 3
1-6 Safety 6. Operation (contd.) Know where EMERGENCY STOP buttons, shutoff valves, and fire extinguishers are located. Make sure they work. If a component malfunctions, shut down and lock out the equipment immediately. Before operating, make sure all conductive equipment, objects being sprayed, and fluid containers are connected to a true earth ground. Never operate equipment with a known malfunction or leak. Never point handguns or applicator nozzles at yourself or other persons. Never touch exposed electrical connections on equipment while the power is ON. Do not operate the equipment at pressures higher than the rated maximum working pressure of any component in the system. Shut off moving equipment before taking measurements or inspecting workpieces. Know the pinch points, temperatures, pressures, and material composition for all equipment that you are working with. Recognize potential hazards associated with these and exercise appropriate caution. Wear shoes with conductive soles, such as leather, or use grounding straps to maintain a connection to ground when working with or around electrostatic equipment. Do not wear or carry metallic objects (jewelry or tools) while working with or around electrostatic equipment. Ungrounded metal can store a static charge and cause harmful shocks. Maintain skin-to-metal contact between your hand and the gun handle to prevent shocks while operating manual electrostatic spray guns. If wearing gloves, cut away the palm or fingers. Shut off electrostatic power supplies and ground gun electrodes before making adjustments to powder spray guns. If you notice electrical arcing in a spray area, shut down the system immediately. An arc can cause a fire or explosion. Keep parts of the body or loose clothing away from rotating parts. Remove personal jewelry and cover or tie back long hair. A1EN 03 [SF LIQD] 3 Issued 11/95 2001 Nordson Corporation
Safety 1-7 6. Operation (contd.) Wear National Institute of Occupational Safety and Health (NIOSH) approved respirators while operating spray equipment and when performing maintenance and cleaning tasks. Wear eye protection when operating spray equipment. Wear gloves and protective clothing to protect your skin from materials. Keep paint pumps, pressure pots, and containers of flammable coating materials or solvents far enough away from spray booths to prevent their inclusion in a booth fire. Do not smoke in the spray area. A lit cigarette could ignite a fire or cause an explosion. Treat all high-pressure fittings and hoses as if they could leak. High-pressure compressed air can be injected under the skin and cause serious injury or death. Do not use materials that will corrode the equipment. Do not attempt to operate electrical equipment if standing water is present. Wash exposed skin frequently with soap and water, especially before eating or drinking. Do not use solvents to remove coating materials from your skin. 7. Less-Obvious Dangers Operators should also be aware of less-obvious dangers in the workplace that often cannot be completely eliminated: exposed surfaces on the equipment which may be hot or have sharp edges and cannot be practically safeguarded electrical equipment which may remain energized after the equipment has been shut off vapors and materials which may cause allergic reactions or other health problems automatic hydraulic, pneumatic equipment, or mechanical parts that may move without warning unguarded, moving mechanical assemblies 2001 Nordson Corporation Issued 11/95 A1EN 03 [SF LIQD] 3
1-8 Safety 8. Action in the Event of a System or Component Malfunction Do not operate a system that contains malfunctioning components. If a component malfunctions, turn the system OFF immediately. Disconnect and lock out electrical power. Close and lock out hydraulic and pneumatic shutoff valves and relieve pressures. Allow only qualified personnel to make repairs. Repair or replace the malfunctioning component according to instructions provided in its manual. 9. Maintenance and Repair Allow only qualified personnel to perform maintenance, troubleshooting, and repair tasks. Only persons who are properly trained and familiar with Nordson equipment are permitted to service this equipment. Always wear appropriate protective clothing and use safety devices when working on this equipment. Follow the recommended maintenance procedures in your equipment manuals. Do not service or adjust any equipment unless another person trained in first aid and CPR is present. Disconnect, lock out, and tag electrical power at a disconnect or breaker in the service line ahead of electrical equipment before servicing. Relieve air and fluid pressures before servicing equipment. Follow the specific instructions in this manual. Use only genuine Nordson replacement parts. Using unapproved parts or making unapproved modifications to equipment may void agency approvals and create safety hazards. WARNING: Note the flash point of the cleaning solvent used. Only use controlled methods and equipment, such as temperature-controlled or explosion-protected heaters, to heat cleaning solvent. Observe explosion-prevention regulations and follow applicable safety instructions. Refer to the MSDS before using solvents to clean this equipment. The MSDS will provide use, storage, and disposal information about the solvent. Read this information carefully and follow instructions. A1EN 03 [SF LIQD] 3 Issued 11/95 2001 Nordson Corporation
Safety 1-9 9. Maintenance and Repair (contd.) Never use an open flame to clean the unit or components of the unit. Do not store flammable materials in the spray area or room. Keep paint pumps, pressure pots, and containers of flammable coating materials or solvents far enough away from spray booths to prevent their inclusion in a booth fire. If a fire or explosion occurs, flammable materials in the area will increase the chances and the extent of personal injuries and property damage. Make sure that the room where you are working is sufficiently ventilated. Avoid breathing vapors over prolonged periods of time. Check interlock systems periodically to ensure their effectiveness. WARNING: Operating faulty or electrostatic equipment is hazardous and can cause electrocution, fire, or explosion. Make resistance checks part of your periodic maintenance program. Check all ground connections periodically with a megohm meter. Resistance to ground must not exceed one megohm. If sparks or arcing occur, shut down the system immediately. Connect all disconnected equipment ground cables and wires after servicing the equipment. Ground all conductive equipment. WARNING: Service lines connected to panel disconnect switches will still be energized unless power is shut off at another disconnect ahead of the panel. Make sure the power is off before servicing. Wait 5 minutes for capacitors to discharge after shutting off the electrical power. Turn off the electrostatic power supply and ground the gun electrode before adjusting or cleaning the nozzles, fluid tips, or air caps. If a power on test is required, perform the test carefully and then shut off and lock out power as soon as the test is over. Never troubleshoot the power supply without first disconnecting all external power supplies and discharging the high-voltage capacitors with an insulated screwdriver. Ground electrodes and electrostatic cable ends before touching them. 2001 Nordson Corporation Issued 11/95 A1EN 03 [SF LIQD] 3
1-10 Safety 9. Maintenance and Repair (contd.) Do not attempt to service electrical equipment if there is standing water present. Do not service electrical equipment in a high-humidity environment. Use tools with insulated handles when working with electrical equipment. Keep high-voltage connection points clean and insulated with dielectric grease or oil. Do not attempt to service a moving piece of equipment. Shut off the equipment and lock out power. Secure equipment to prevent uncontrolled movement. 10. Material and Solvent Precautions WARNING: Hot! Risk of burns. Wear heat-protective clothing, eye protection with side shields and/or heat-protective gloves. Heated materials may cause severe burns on contact. Remember that some materials, even solid materials, may retain heat for some time. If you are burned by a heated material, immediately cool the affected skin with lots of cool, clean water. Do not try to remove hot, melted material from the skin. Seek immediate medical attention. High-pressure fluids, unless they are safely contained, are extremely hazardous. A jet of high-pressure fluid can act like a knife or needle, penetrate skin and muscle, and inject itself into your body. Injected fluids can cause toxic poisoning. Do not treat an injection injury as minor. Seek medical care immediately. Inform the medical staff at the hospital that you have an injection injury and identify the fluid that was injected. If possible, give the doctor copies of the MSDS for the injected fluid and for any additives, such as solvents, that are in the injected fluid. Also, Nordson recommends that you carry a National Safety Equipment Manufacturers Association (NSEMA) wallet card to give to emergency medical staff in the event of an injection injury. These cards are supplied with the equipment. Additional cards are available free from Nordson Corporation. A1EN 03 [SF LIQD] 3 Issued 11/95 2001 Nordson Corporation
Safety 1-11 10. Material and Solvent Precautions (contd.) WARNING: Injection hazard. Do not go near a known leak in a hose or fitting, and stay clear of all spray nozzles or orifices. Do not point an applicator at yourself or other personnel. The high-pressure fluid stream can penetrate skin and inject fluid into the body causing serious injury or death. To prevent an injection injury, take some basic safety precautions when operating your equipment. Always handle spray applicators carefully. Do not point a pressurized gun at yourself or other personnel. Never place hands, fingers, or other parts of your body directly over a spray nozzle or in front of a leak in a high-pressure system. Never back-flush the nozzles. Blocking a nozzle causes the high-pressure fluid to reverse direction and can lead to an injection injury. Always relieve system pressure before servicing equipment. Trigger all applicators and bleed off system pressure. Halogenated hydrocarbon solvents can cause an explosion when used with aluminum components in a pressurized fluid pumping system (pumps, heaters, filters, valves, spray guns, and tanks). The explosion could cause serious bodily injury, death, or substantial property damage. No available stabilizers will prevent this violent reaction from happening. WARNING: Never use halogenated hydrocarbon solvents to clean aluminum parts or to flush any system. Cleaning agents, coatings and paints, or adhesives may contain halogenated hydrocarbon solvents. Obtain and read the MSDS for each material and solvent being used. Use nonhalogenated solvents. Contact your solvent supplier to determine whether your existing materials and solvents contain halogenated hydrocarbons or to obtain a suitable, nonhalogenated hydrocarbon solvent for cleaning and flushing your system. 2001 Nordson Corporation Issued 11/95 A1EN 03 [SF LIQD] 3
1-12 Safety 10. Material and Solvent Precautions (contd.) See Table 1-1. Check the labels on your solvent containers. Halogenated hydrocarbon solvents can be recognized if any of the following elements are listed in the name of the product or as an ingredient: Element Symbol Prefix Flourine F Flouro- Chlorine Cl Chloro- Bromine Br Bromo- Iodine I Iodo- If you are now using halogenated hydrocarbon solvents in pressurized systems with aluminum components, perform the following steps: Pump the system empty, shut off the pumps, and relieve the system pressure. Disassemble and inspect the system components. Replace any damaged or corroded parts. Thoroughly clean all noncorroded parts with nonhalogenated hydrocarbon. Contact your coatings, solvent, or adhesive supplier for a nonhalogenated solvent to thoroughly flush the entire system before operating it. If you must continue to use halogenated hydrocarbon solvents, consult your Nordson representative about compatible Nordson components. A1EN 03 [SF LIQD] 3 Issued 11/95 2001 Nordson Corporation
Safety 1-13 10. Material and Solvent Precautions (contd.) Table 1-1 Solvents Containing Halogenated Fluids Chlorinated Solvents Iodinated Solvents Brominated Solvents Fluorocarbon Solvents Carbon Tetrachloride Ethyl Iodide Ethylene Dibromide Dichlorofluoromethane Chloroform Methyl Iodide Methyl Bromide Trichlorofluoromethane Ethylene Dichloride N-butyl Iodide Methylene Chlorobromide Freon Methylene Chloride Propyl Iodide 1-1-1 Trichloroethane Monochlorobenzene Orthodichlorobenzene Perchloroethylene Trichloroethylene 11. Disposal Dispose of equipment and materials used in operation and cleaning according to your local regulations. 2001 Nordson Corporation Issued 11/95 A1EN 03 [SF LIQD] 3
1-14 Safety A1EN 03 [SF LIQD] 3 Issued 11/95 2001 Nordson Corporation
Safety 1-15 12. Safety Labels Table 1-2 contains the text of the safety label on this equipment. The safety label is provided to help you operate and maintain your equipment safely. See Figure 1-1 for the location of the safety label. Table 1-2 Safety Labels Item Part Description 1. - - - - - - WARNING: Electrical discharge can be dangerous. Turn off this unit. Ground gun electrode and remove gun from spray area before performing any servicing or cleaning. 2. 140 475 CAUTION: Input voltage on this unit can be adjusted for 115 Volts or 230 Volts. Failure to adjust this unit to proper input line voltage can cause damage to this unit. 3. 184 258 WARNING: Do not locate this unit in an area classified as hazardous. Install, operate, and service in accordance with all applicable safety codes and Nordson instruction manual. If you have questions concerning this electrostatic spray equipment, call (440) 985-4000, and ask to speak with the Liquid Systems Group Technical Service Department. Nordson Corporation, Amherst, OH, 44001, U.S.A. 1 2 3 Fig. 1-1 Safety label locations 1. Front panel label 2. Inside cabinet label 3. Warning tag 0913001A 2001 Nordson Corporation
1-16 Safety 2001 Nordson Corporation
Section 2 Description 2001 Nordson Corporation
2-0 Description 2001 Nordson Corporation
Description 2-1 Section 2 Description 1. Introduction The Nordson Electrostatic Power Supply (EPS8 or EPS9) is a regulated, solid state, electrostatic power supply. This power supply is designed for use with air or airless electrostatic spray equipment. The EPS8 is designed for use with manual systems and produces a maximum variable output voltage of 76 kv. The EPS9 is designed for use with automatic systems and produces a maximum variable output voltage of 115 kv. 2001 Nordson Corporation
2-2 Description 2. Components The following chart lists the major components of the EPS8 and EPS9. See Figures 2-1 and 2-2. Component Main circuit board Current limiter board (optional) Multiplier Voltage select switch Fuse Terminal blocks Digital display board Potentiometer knob Display selector switch ON/OFF toggle switch Intrinsic safety barrier (optional for EPS8) Function Creates and controls voltage for the multiplier and generates the signal for the digital display. Limits the amount of current that you can use. You can adjust this limit. Creates and controls the main output voltage of the power supply. Allows you to connect the power supply to: 120 Vac or 240 Vac service 100 Vac or 200 Vac service Limits the input current to the power supply and disconnects the power if a fault occurs inside the power supply. Interconnect the power supply circuit. Displays the kv setting of the power supply or the current draw in microamperes (μa). Adjusts the kv setting of the power supply. Enables you to select either the kv setting or the current draw in microamperes at the front panel. Also enables you to remotely change the display using a normally-open (NO) switch. Turns the main power ON and OFF. Provides explosion protection by limiting electrical and thermal energy below a level required to ignite a specific hazardous mixture. 2001 Nordson Corporation
Description 2-3 1 6 5 2 3 4 11 12 7 8 9 10 Fig. 2-1 EPS8 (front and inside views) 1. kv indicator 2. μa indicator 3. Display selector switch 4. Adjustment potentiometer 5. ON/OFF switch 6. kv ON light 0913002A 7. Multiplier 8. Fuse holder 9. Voltage selector switch 10. Main circuit board 11. Intrinsic safety barrier 12. Optional current limiter board 2001 Nordson Corporation
2-4 Description 2. Components (contd.) 6 5 1 2 3 4 11 7 8 9 10 Fig. 2-2 EPS9 (front and inside views) 1. kv indicator 2. μa indicator 3. Display selector switch 4. Adjustment potentiometer 5. ON/OFF switch 6. kv ON light 7. Current limiter board 8. Fuse holder 9. Voltage selector switch 10. Multiplier 11. Main circuit board 0913003A 2001 Nordson Corporation
Description 2-5 3. Features The EPS8 and EPS9 offer the following design features: Variable output voltage at low amperage, which allows a safe but highly efficient field of attraction between the coating material and the workpiece. Digital display for monitoring kv output setting or output current. Optional current limiter to automatically shut down the output if the output current exceeds a set amount. LEDs to help you troubleshoot the power supply. Programmable logic control (PLC) is also available for some functions. 4. Specifications Specification Input voltage Operating Requirements 120/240 Vac, 10%, 50/60 Hz 100/200 Vac, 10%, 50/60 Hz Input current protection Variable output voltage (open circuit) Output current (EPS8) (short circuit) Output current (EPS9) (short circuit) Display accuracy Automatic shutdown current adjustment Operating temperature range 0.75-amp fuses EPS8: 30,000 76,000 Vdc, 3 kv EPS9: 30,000 115,000 Vdc, 3 kv 150 μa, maximum 170 μa, maximum 2 counts 10 150 μa 0 +60 C (32 +140 F) Cabinet dimensions (H x W x D) 355.6 x 304.88 x 152.4 mm (14.0 x 12.0 x 6.0 in.) Door Unit weight Hinged at left-hand side 13.15 kg (29.0 lb) 2001 Nordson Corporation
2-6 Description 2001 Nordson Corporation
Section 3 Installation 2001 Nordson Corporation
3-0 Installation 2001 Nordson Corporation
Installation 3-1 Section 3 Installation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. 1. Installing the Power Supply WARNING: This equipment can be dangerous unless it is used in accordance with the rules laid down in this manual. WARNING: Electrical discharge can be dangerous. Do not install the power supply in an area classified as hazardous (refer to NFPA-33 publication for specifications). Ground the electrostatic power supply, all sprayed objects, fluid containers, and other electrically conductive objects located within 6 meters (19.7 ft) of the spray area. Keep spray area, conveyors, and hangers clean. CAUTION: Do not install the power supply on a reciprocator or in an area where excessive vibration occurs. Do not place the power unit where timers or signal devices are closely located. These devices can affect the electrical operation of the electrostatic power supply. Mount the power supply in an accessible area for ease of operation and maintenance. See Figure 3-1 for mounting dimensions. Perform the following steps to mount the power supply: 1. To install the unit near the spray booth, allow at least a 1.5 m (5 ft) radius outside the booth opening area. 2. Observe the mounting dimensions for the power supply. 3. Remove the eight screws (2) from the front panel door, and then open the door. 4. See Figures 5-1, 5-2, or 5-3 in the Troubleshooting section and make wiring connections. 2001 Nordson Corporation
3-2 Installation 1. Installing the Power Supply (contd.) 5. Secure the power supply to the installation site using the four mounting screws (1). 6. Close the front panel door and secure it with the eight retaining screws (2). 1 7.9 mm (0.312 in.) 2 374.7 mm (14.75 in.) 254 mm (10 in.) 0913004A Fig. 3-1 Power supply mounting dimensions 1. Mounting screws 2. Retaining screws (8) for front panel 2001 Nordson Corporation
Installation 3-3 2. Setting the Voltage CAUTION: Verify that the main power source voltage corresponds with the voltage rating indicated on the voltage selector switch. If you connect 230-volt power with the selector switch set at 115 volts, immediate fuse failure and power supply damage can occur. Nordson Corporation ships the power supply with the selector switch set to the 230-volt position. If you require 115-volt power, move the selector switch to the 115-volt position. NOTE: If you connect 115-volt power with the selector switch set at 230 volts, reduced electrostatic efficiency and loss of wrap can occur. 3. Making Terminal Block Connections A I and 1 4 See Figure 3-2 and make the following connections on TB3 and TB4: 1. Remove any packing materials from inside the power supply. 2. Install liquid-tight, one-half-inch conduit at the EPS8 or EPS9 and connect it using only the Nordson-supplied conduit connector. 3. Install 18 22 gauge wire that meets local electrical codes through the conduit and connect the main power supply leads to terminals A, B, and C on terminal block TB4, as follows: a. Connect ground wire (1) to TB4-A. b. Connect wire L1 (2) to TB4-B. c. Connect wire L2 (3) to TB4-C. 4. Connect a ground wire (12 gauge or larger) from the ground stud on the power supply to a true earth ground. 5. Install the wires through the factory-supplied suppressor (4) for the power wiring (L1, L2, and ground wires): a. Open the suppressor (4). b. Install wires L1 (2), L2 (3), and ground (1) through the suppressor. c. Tightly close the suppressor, without pinching the wires. 2001 Nordson Corporation
3-4 Installation 3. Making Terminal Block Connections A I and 1 4 (contd.) TB3 TB4 4 Fig. 3-2 1. Ground wire 2. Power wire L1 EPS8 and EPS9 terminal block connections 3. Power wire L2 4. Suppressor 123 0913005B 2001 Nordson Corporation
Installation 3-5 6. Make the following optional connections to terminal block TB4, as required: CAUTION: When connecting terminals F, G, H, or I, voltage must not exceed 250 volts AC and the current must not exceed 10 amperes, otherwise, equipment damage can occur. NOTE: Terminals J, K, and L have no connections (NC). To: Interrupt power to EPS unit if interlock switch opens Provide contact closure on a power supply equipped with a current limiter board, when high voltage is ON Provide contact closure on a power supply equipped with a current limiter board, when current limit is exceeded Connect these terminals: As follows: D, E (interlock terminals) 1. Remove factory-installed jumper. 2. Connect customer-supplied interlock switch to terminals. F, G (high voltage ON) Connect warning device to terminals. See CAUTION above. H, I (alarm circuit) Connect warning device to terminals. See CAUTION above. NOTE: Do not make the following trigger connections when you use the EPS8 with a manual C-1 hand gun; a switch in that C-1 hand gun provides the trigger signal. 7. Perform step 7a, 7b, or 7c to make one of the required trigger connections: a. To use an air flow switch for contact closure when you actuate the gun, see Figure 3-3 and use the installation instructions that accompany the air flow switch (1) to install the switch on the power supply. Connect the air flow switch wires to TB3-1 (5) and TB3-2 (4). Connect the air inlet line (3) to an air pressure source. Connect the air outlet line (2) to your air spray gun. b. See Figure 3-2. To use an electromechanical relay for contact closure when you actuate the gun, connect the relay contacts to TB3-1 and to TB3-2. c. See Figure 3-2. To use a programmable logic controller (PLC) or another 24 Vdc source, connect +V to TB3-10 and connect V to TB3-11. For more information, refer to Using Terminal Block Connections for PLC Interface in this section. 2001 Nordson Corporation
3-6 Installation 3. Making Terminal Block Connections A I and 1 4 (contd.) 5 4 1 2 3 0913006A Fig. 3-3 Air flow switch installed on EPS8 1. Air flow switch 2. Air outlet ( 1 / 4 -in. NPT) 3. Air inlet ( 1 / 4 -in. NPT) 4. TB3-2, Common 5. TB3-1, Trigger 2001 Nordson Corporation
Installation 3-7 8. If your EPS8 or EPS9 uses an optional current limiter board, see Figure 3-2 and use TB3-3 to reset the current limiter board by either turning the power OFF for at least 10 seconds and then ON again, or by briefly grounding TB3-3. NOTE: Current limit is factory-set to 100 microamps and is adjustable up to 150 microamps. 9. To remotely select kv or microamps to show on the front panel display, use TB3-4. Set the toggle switch on the front panel to kv. Ground TB3-4 to remotely change the displayed reading from kv to microamps. 4. Using Terminal Block Connections for PLC Interface You can use a digital programmable logic controller (PLC) or other digital device to remotely operate the EPS8 or EPS9 using 12 24 Vdc logic. See Figure 3-2 to make these optional terminal block connections at TB3: CAUTION: When connecting terminals 5 through 8, do not exceed 24 Vdc maximum, otherwise, equipment damage can occur. NOTE: Terminals 5 through 11 are electrically isolated from the rest of the circuit. Terminals 5 through 8 allow you to use a PLC to remotely trigger and adjust the EPS8 or EPS9. These terminals provide the binary pattern that the EPS uses to correctly set the voltage. The following digital pattern corresponds to the kv settings shown in Table 3-1. Terminal 5 = bit 8 Terminal 6 = bit 4 Terminal 7 = bit 2 Terminal 8 = bit 1 2001 Nordson Corporation
3-8 Installation 4. Using Terminal Block Connections for PLC Interface (contd.) Table 3-1 Voltage Settings Channels EPS9 115 kv max EPS8 76 kv max 8 4 2 1 kv kv 0 0 0 0 25 31 0 0 0 1 31 34 0 0 1 0 37 37 0 0 1 1 43 40 0 1 0 0 49 43 0 1 0 1 55 46 0 1 1 0 61 49 0 1 1 1 67 52 1 0 0 0 73 55 1 0 0 1 79 58 1 0 1 0 85 61 1 0 1 1 91 64 1 1 0 0 97 67 1 1 0 1 103 70 1 1 1 0 109 73 1 1 1 1 115 76 NOTE: 1 = 24 Vdc 0 = 0 Vdc 2001 Nordson Corporation
Installation 3-9 Dip switches 2 and 3 on the main circuit board, SW1-5 (2), allow the PLC to control the power supply. Refer to Table 3-2 and see Figure 3-4. NOTE: The remaining dip switches on the main circuit board are for factory settings only. Table 3-2 Dip Switch Settings Dip Switch PLC Control Front Panel Control 2 closed (down) open (up) 3 open (up) closed (down) J4 1 2 3 4 5 6 R29 A1 1 R40 R19 C18 C2 C8 CR13 R81 R37 R38 R35 R49 R20 R36 R32 U12 V2 R34 CR15 R18 R33 CR3 C14 C16 U9 U14 R9 R8 SW1 5 J1 24 CR14 CR16 R77 U4 R54 R57 R55 R4 Q5 R69 54321 CR5 R10 R22 R24 CR2 R23 CR1 R46 R11 U15 C7 R17 R56 C11 C5 C25 C6 J2 R1 R13 R59 R83 R39 U10 V1 R12 CR6 C10 C15 C4 C13 J5 R74 CR9 C3 R60 R15 C17 CR7 Q6 R75 R43 CR10 R67 R66 R68 R72 Q1 U13 R14 R73 CR8 C20 C9 R7 U5 U8 CR12 R70 C24 C19 C21 1 R76 R58 U2 C22 C23 R62 Q7 R82 R65 R63 C1 R71 U6 C12 R61 R53 R64 R51 R79 Q3 U11 R52 R80 R78 U7 U3 3 2 1 0913007A Fig. 3-4 Main circuit board 1. HV transformer connector (J2) 2. Dip switch panel (SW1-5) 3. Q5 Transistor 2001 Nordson Corporation
3-10 Installation 4. Using Terminal Block Connections for PLC Interface (contd.) TB3-9, -10, and -11 provide the controls shown in Table 3-3. Terminal TB3-9, Strobe Table 3-3 TB3-9, -10, -11 Connections Control Enables the EPS8 or EPS9 to read the bit pattern and set the output voltage when the strobe voltage goes to 24 volts. TB3-10, Trigger Enables the PLC to trigger the EPS8 or EPS 9 using the logic 1 (24 Vdc) signal. Use this terminal instead of creating a short at TB3-1 and TB3-2. TB3-11, Common Provides a ground terminal for the PLC unit. This terminal connection is independent of TB3-2 (ground for the EPS) and is a required connection for the digital interface to operate correctly. NOTE: TB3-12 is not connected (NC). 5. Installing the Electrostatic Cable Perform the following steps to install the electrostatic cable: 1. Use the cable cleaning kit to remove any contamination from both ends of the electrostatic cable. Refer to the Parts section for kit ordering information. 2. Cut the tip from the vial of high-voltage dielectric oil. 3. See Figure 5-2. Pour the dielectric oil into the high-voltage well of the multiplier. NOTE: Dielectric oil does not contain PCBs. 4. Slowly install the high-voltage cable into the multiplier well. Wipe away any oil that overflows the well. 5. Secure the cable with the connecting nut and attach the cable strain relief onto the side of the power supply cabinet. 6. Refer to the instructions in your gun manual and install the gun end of the electrostatic cable to the spray gun. Tighten the connecting nut. 2001 Nordson Corporation
Installation 3-11 6. Using the Microammeter The electrostatic power supply uses a microammeter for monitoring output current. The microammeter is also useful for monitoring the operating condition of the power supply. To test the microammeter, do the following: 1. After installing the spray device and cable to the power supply, turn on the power supply using the power ON/OFF switch at the front panel. See Figures 2-1 or 2-2. 2. Set the kv/μa switch on the front panel to microamps (μa). See Figures 2-1 or 2-2. 3. Trigger the EPS8 or EPS9. 4. Observe the microammeter. If you are far from any grounded object, the microammeter should read approximately 20 80 microamps. 5. Slowly move the gun electrode closer to ground; the microammeter reading increases. The power supply should respond as follows: a. If you installed the current limiter and adjusted it correctly, you should be able to almost touch a grounded object before the output voltage turns off. The current reading at that point will be 100 150 microamps. b. If you did not install a current limiter in your power supply, the EPS8 or EPS9 will not automatically turn off when the gun electrode approaches ground. 2001 Nordson Corporation
3-12 Installation 2001 Nordson Corporation
Section 4 Operation 2001 Nordson Corporation
4-0 Operation 2001 Nordson Corporation
Operation 4-1 Section 4 Operation 1. Operating the EPS8/9 See Figures 2-1 or 2-2. The following instructions explain the daily operation for your power supply. The following steps describe daily operation of your EPS8 or EPS9. Routine daily maintenance is not required. 1. Place the EPS8 or EPS9 power ON/OFF switch (5) to ON. 2. Set kv to the required setting using the potentiometer (4). 3. If you use an EPS8 (manual spray system), hold the spray gun in your bare hand to ensure that you are grounded. 4. Pressurize the fluid system. 5. Trigger the gun to begin spraying. 2001 Nordson Corporation
4-2 Operation 2001 Nordson Corporation
Section 5 Troubleshooting 2001 Nordson Corporation
5-0 Troubleshooting 2001 Nordson Corporation
Troubleshooting 5-1 Section 5 Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. 1. Introduction This section contains troubleshooting procedures. These procedures cover only the most common problems that you may encounter. If you cannot solve the problem with the information given here, contact your local Nordson representative for help. Problem 1. No output voltage at nozzle; loss of wrap with power ON, and kv ON lamp illuminated Page 2. Front panel lamps do not illuminate 5-4 3. Power ON lamp illuminated and the kv lamp is not 5-4 4. Power ON and kv lamps illuminated, but kv does not shut off 5. Spray device does not power off 5-4 6. All front panel LEDs and lamps extinguished 5-5 7. LEDs and lamps operate correctly, with no kv output, and kv ON lamp is extinguished 8. LEDs and lamps operate correctly, with no kv output, and kv ON lamp is illuminated 9. kv indicator remains on even if power supply is not triggered 10. kv output weak or erratic 5-6 11. Potentiometer operating incorrectly 5-6 5-3 5-4 5-5 5-6 5-6 2001 Nordson Corporation
5-2 Troubleshooting Troubleshooting Electrical Problems As you begin to spray, notice the microammeter on the electrostatic power supply. A normal operating reading is approximately 20 80 microamps. Use the operating current as a guide for troubleshooting. For example, if the current reading starts to increase, the flow or conductivity of the coating material might have increased, or moist or dirty air has entered the system. A decrease in the current might indicate that the power supply voltage has increased, or there is a poor path to ground in the system. WARNING: When checking the power supply with the spray device and electrostatic cable removed, see Figure 3-2 and install a jumper wire between TB3-1 and TB3-2 to energize the high-voltage circuit. After completing the test, remove the jumper. NOTE: Keep the ball of the kv meter as far away as possible from any grounded object. The following table provides troubleshooting procedures for correcting electrical problems. If multiple causes exist, the table lists those problems in the order of importance. 2001 Nordson Corporation
Troubleshooting 5-3 Problem Possible Cause Corrective Action 1. No output voltage at nozzle; loss of wrap with power ON, and kv ON lamp illuminated Poor ground to conveyor or coated part Poor ground to power supply Spray device resistor failed Needle resistor failed Power supply malfunctioned Spray device extension and nozzle are contaminated Air supply contains water or contaminates Voltage is arcing within extension Electrostatic cable failed Clean conveyor, hooks, and part. Provide true earth ground to power supply. Remove resistor from spray device and use a megohm meter to measure resistance. Resistance should read 75 megohms 10%; if it does not, replace the resistor. Remove needle from spray device. Use a megohm meter to measure resistance. Resistance should measure 12 megohms 10%; if it does not, replace needle. Use kv meter to verify high-voltage output of power supply. Output should measure 72 kv 80 kv for EPS8, or 109 kv 121 kv for EPS9. Disassemble and clean spray device extension and nozzle. Check main air supply for contaminates. Replace extension. Remove the cable from the spray device. Use a kv meter to check kv at spray device end of the cable. Use a megohm meter to measure cable resistance. Depending on your spray device, the cable should read roughly 200 megohms 10%. Refer to your spray device s manual for specific megohm vlaues. If the electrostatic cable does not meet the required values, replace the cable. 2001 Nordson Corporation
5-4 Troubleshooting Troubleshooting Electrical Problems (contd) Problem Possible Cause Corrective Action 2. Front panel lamps do not illuminate 3. Power ON lamp illuminated and the kv lamp is not 4. Power ON and kv lamps illuminated, but kv does not shut off 5. Spray device does not power off Output voltage missing or incorrect Power supply not triggered Current limiter LED illuminated (current limiter tripped) Defective transistor Q5 Air flow switch fixed in ON position Trigger switch on spray device requires repair Verify the following: 1. Energized circuit breaker or fuse ahead of power supply. 2. Fuses installed and closed. If a fuse is open, install a new fuse. 3. ON/OFF switch set to ON. 4. Interlock jumper installed on TB4-D and TB4-E. Short TB3-1 and TB3-2. If kv lamp illuminates, verify contact closure from trigger circuit. If kv lamp does not illuminate, replace transistor Q5 on main circuit board. Set ON/OFF switch to OFF, and then to ON to restore the output voltage. Do the following to adjust the current limiter: 1. Turn the current limiter control counter-clockwise. 2. Verify that the spray device electrode is 0.125 cm ( 1 / 8 in.) from a true earth ground. 3. Install jumper at TB3-1 and TB3-2 to trigger power supply. Remove jumper after testing. 4. Turn the current limiter control clockwise until red lamp on current limiter board illuminates. See Figure 3-4. Replace transistor Q5 on main circuit board. Verify that air flow switch operates correctly. Refer to service manual for spray device repair procedures. 2001 Nordson Corporation
Troubleshooting 5-5 Problem Possible Cause Corrective Action 6. All front panel LEDs and lamps extinguished 7. LEDs and lamps operate correctly, with no kv output, and kv ON lamp is extinguished Incorrect line voltage EPS8: Defective trigger switch PLC signal missing Defective air flow switch EPS9: Defective contact closure device PLC signal missing Verify that ON/OFF switch set to ON. Verify that fuse at power transformer is not open. If fuse is open, replace it. Verify input power at TB4-B and TB4-C for correct voltage. Set 120/240 voltage switch at top of transformer to correct input voltage. Calibrate the input voltage. Refer to Input voltage calibration in this section. If the existing input voltage settings do not match the values given in Tables 5-1 and 5-2, replace the transformer. Verify trigger circuit as follows: 1. Use length of wire to short TB3-1 and TB3-2. 2. If kv ON lamp illuminates, check trigger circuit of gun and cable. Refer to gun instruction manual. 3. EPS8 only: If kv ON lamp illuminates, check fuse for intrinsic safety barrier inside cabinet. Replace fuse if open. 4. If power supply uses a current limiter board and kv ON lamp does not illuminate, remove current limiter board, and then trigger circuit again. If power supply functions correctly, adjust or replace current limiter board. 5. See Figure 3-4. Replace transistor Q5 on main circuit board, or replace main circuit board. 2001 Nordson Corporation
5-6 Troubleshooting Troubleshooting Electrical Problems (contd) Problem Possible Cause Corrective Action 8. LEDs and lamps operate correctly, with no kv output, and kv ON lamp is illuminated 9. kv indicator remains on even if power supply is not triggered 10. kv output weak or erratic 11. Potentiometer operating incorrectly Defective multiplier assembly or main circuit board Defective transistor Q5 on main circuit board Defective or damaged multiplier Incorrect dip switch settings Damaged ribbon cable connecting display board to main circuit board Incorrectly installed ribbon cable Incorrectly wired or defective potentiometer Damaged or defective main circuit board Replace multiplier assembly or main circuit board. See Figure 3-4. Replace transistor Q5 on main circuit board. Replace multiplier. Verify correct dip switch settings on main circuit board. Check for damaged ribbon cable connecting display board to main circuit board. Replace cable, if damaged. Correctly and firmly seat ribbon cable connectors. Check for damaged potentiometer wiring, or replace potentiometer. Replace main circuit board. Input Voltage Calibration WARNING: Disconnect equipment from line voltage before servicing. Use this procedure to test and calibrate the input voltage. 1. Disconnect and lock out the main power source. 2. Remove the main circuit board (See Figure 2-1, (10) or Figure 2-2, (11)) and turn on the main electrostatic power supply. 3. Connect the electrostatic power supply to a power source following these considerations: Connect 100/200 Vac units to a 100 Vac source Connect 120/240 Vac units to a 120 Vac source 4. Set the internal voltage select switch (See Figure 2-1, (9) or Figure 2-2, (9)) to 120. 5. Measure the Vac on TB1-3, TB1-4, and TB1-5 according to the values given in Table 5-1. 2001 Nordson Corporation