IPS10A Automatic Integral Power Supply Controller...OBSOLETE IPS10A Automatic Integral Power Supply Controller Customer Product Manual Part 303 816B NORDSON CORPORATION AMHERST, OHIO

OBSOLETE

IPS10A Automatic IntegralPower Supply Controller

Customer Product ManualPart 303 816B

NORDSON CORPORATION � AMHERST, OHIO � USA

OBSOLETE

� 1999 Nordson CorporationAll rights reserved

303 816BIssued 10/99

Manual 9-17

Nordson Corporation welcomes requests for information, comments and inquiries about its products. Generalinformation about Nordson can be found on the Internet using the following address: http://www.nordson.com.

Address all correspondence to:

Nordson CorporationAttn: Customer Service

555 Jackson StreetAmherst, OH 44001

Notice

This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1998. No part ofthis 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

Blue Box, Can Works, Century, CleanSleeve, CleanSpray, Control Coat, Cross-Cut, Easy Coat, Econo-Coat, Excel2000, Flow Sentry, FoamMix, Horizon, Hot Shot, Isocoil, Isocore, Iso-Flo, MEG, Nordson, the Nordson logo,Package of Values, PowderGrid, Pro-Flo, PRX, RBX, Ready Coat, Rhino, SCF, Select Coat, Select Cure, Shur-Lok,

Smart-Coat, System Sentry, Tribomatic, Versa-Coat, Versa-Screen, and Versa-Spray are registered trademarks of Nordson Corporation.

Accu-Jet, Auto-Flo, CanNeck, Clean Coat, CPX, EasyClean, Ink-Dot, OptiMix, PowderGrid, Pulse-Spray, SureCoat, Swirlcoat and Walcom are trademarks of Nordson Corporation.

Viton is a registered trademark of E.I. DuPont de Nemours & Co.

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Table of Contents

1. Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Qualified Personnel 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Intended Use 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Regulations and Approvals 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Personal Safety 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Pressure Fluids 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Fire Safety 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Halogenated Hydrocarbon Solvent Hazards 1-5. . . . . . . . . . . . . . . .

7. Action in the Event of a Malfunction 1-5. . . . . . . . . . . . . . . . . . . . . . . . . .

8. Disposal 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Front Panel Controls 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Rear Panel Connections 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Symbols 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Specifications 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Mounting 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Circuit Board 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Electrical Connections 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Startup 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Adjustments 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrostatic Voltage 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Shutdown 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1Safety

Section 2Description

Section 3Installation

Section 4Operation

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1. Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Daily 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Troubleshooting Charts 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Circuit Board Test Points and Components 6-5. . . . . . . . . . . . . . . . . . .

4. Wiring Diagram 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Electrical Schematic 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Control Module 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Circuit Board 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Introduction 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. IPS10A Controller Parts 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5Maintenance

Section 6Troubleshooting

Section 7Repair

Section 8Parts

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� 1998 Nordson CorporationAll rights reserved Issued 10/98

S1EN–03–[SF–LECAP]–7

Section 1

Safety

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Safety1-0

� 1998 Nordson CorporationAll rights reservedIssued 10/98


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Safety 1-1



Section 1Safety

Read and follow these safety instructions. Task- and equipment-specificwarnings, cautions, and instructions are included in equipmentdocumentation where appropriate.

Make sure all equipment documentation, including these instructions, isaccessible to persons operating or servicing equipment.

Equipment owners are responsible for making sure that Nordsonequipment is installed, operated, and serviced by qualified personnel.Qualified personnel are those employees or contractors who are trainedto safely perform their assigned tasks. They are familiar with all relevantsafety rules and regulations and are physically capable of performingtheir assigned tasks.

Use of Nordson equipment in ways other than those described in thedocumentation supplied with the equipment may result in injury topersons 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

Make sure all equipment is rated and approved for the environment inwhich it is used. Any approvals obtained for Nordson equipment will bevoided if instructions for installation, operation, and service are notfollowed.

1. Introduction

2. Qualified Personnel

3. Intended Use

4. Regulations andApprovals

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Safety1-2



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 areintact and automatic interlocks are operating properly. Do not bypassor disarm any safety devices.

� Keep clear of moving equipment. Before adjusting or servicingmoving equipment, shut off the power supply and wait until theequipment comes to a complete stop. Lock out power and secure theequipment to prevent unexpected movement.

� Relieve (bleed off) hydraulic and pneumatic pressure before adjustingor servicing pressurized systems or components. Disconnect, lockout, and tag switches before servicing electrical equipment.

� While operating manual spray guns, make sure you are grounded.Wear electrically conductive gloves or a grounding strap connected tothe gun handle or other true earth ground. Do not wear or carrymetallic objects such as jewelry or tools.

� If you receive even a slight electrical shock, shut down all electrical orelectrostatic equipment immediately. Do not restart the equipmentuntil the problem has been identified and corrected.

� Obtain and read Material Safety Data Sheets (MSDS) for all materialsused. Follow the manufacturer’s instructions for safe handling anduse of materials, and use recommended personal protection devices.

� Make sure the spray area is adequately ventilated.

� To prevent injury, be aware of less-obvious dangers in the workplacethat often cannot be completely eliminated, such as hot surfaces,sharp edges, energized electrical circuits, and moving parts thatcannot be enclosed or otherwise guarded for practical reasons.

5. Personal Safety

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Safety 1-3



High-pressure fluids, unless they are safely contained, are extremelyhazardous. Always relieve fluid pressure before adjusting or servicinghigh pressure equipment. A jet of high-pressure fluid can cut like a knifeand cause serious bodily injury, amputation, or death. Fluids penetratingthe skin can also cause toxic poisoning.

If you suffer a fluid injection injury, seek medical care immediately. Ifpossible, provide a copy of the MSDS for the injected fluid to the healthcare provider.

The National Spray Equipment Manufacturers Association has created awallet card that you should carry when you are operating high-pressurespray equipment. These cards are supplied with your equipment. Thefollowing is the text of this card:

WARNING: Any injury caused by high pressure liquid can beserious. If you are injured or even suspect an injury:

� Go to an emergency room immediately.� Tell the doctor that you suspect an injection injury.� Show him this card.� Tell him what kind of material you were spraying.

MEDICAL ALERT–AIRLESS SPRAY WOUNDS: NOTE TO PHYSICIAN

Injection in the skin is a serious traumatic injury. It is important to treatthe injury surgically as soon as possible. Do not delay treatment toresearch toxicity. Toxicity is a concern with some exotic coatings injecteddirectly into the bloodstream.

Consultation with a plastic surgeon or a reconstructive hand surgeon maybe advisable.

The seriousness of the wound depends on where the injury is on thebody, whether the substance hit something on its way in and deflectedcausing more damage, and many other variables including skinmicroflora residing in the paint or gun which are blasted into the wound.If the injected paint contains acrylic latex and titanium dioxide thatdamage the tissue’s resistance to infection, bacterial growth will flourish.The treatment that doctors recommend for an injection injury to the handincludes immediate decompression of the closed vascular compartmentsof the hand to release the underlying tissue distended by the injectedpaint, judicious wound depravement, and immediate antibiotic treatment.

High-Pressure Fluids

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Safety1-4



To avoid a fire or explosion, follow these instructions.

� Ground all conductive equipment in the spray area. Use onlygrounded air and fluid hoses. Check equipment and workpiecegrounding devices regularly. Resistance to ground must not exceedone megohm.

� Shut down all equipment immediately if you notice static sparking orarcing. Do not restart the equipment until the cause has beenidentified and corrected.

� Do not smoke, weld, grind, or use open flames where flammablematerials are being used or stored.

� Do not heat materials to temperatures above those recommended bythe manufacturer. Make sure heat monitoring and limiting devices areworking properly.

� Provide adequate ventilation to prevent dangerous concentrations ofvolatile particles or vapors. Refer to local codes or your materialMSDS for guidance.

� Do not disconnect live electrical circuits while working with flammablematerials. Shut off power at a disconnect switch first to preventsparking.

� Know where emergency stop buttons, shutoff valves, and fireextinguishers are located. If a fire starts in a spray booth,immediately shut off the spray system and exhaust fans.

� Shut off electrostatic power and ground the charging system beforeadjusting, cleaning, or repairing electrostatic equipment.

� Clean, maintain, test, and repair equipment according to theinstructions in your equipment documentation.

� Use only replacement parts that are designed for use with originalequipment. Contact your Nordson representative for partsinformation and advice.

6. Fire Safety

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Safety 1-5



Do not use halogenated hydrocarbon solvents in a pressurized systemthat contains aluminum components. Under pressure, these solventscan react with aluminum and explode, causing injury, death, or propertydamage. Halogenated hydrocarbon solvents contain one or more of thefollowing elements:

Element Symbol Prefix

Fluorine F “Fluoro-”

Chlorine Cl “Chloro-”

Bromine Br “Bromo-”

Iodine I “Iodo-”

Check your material MSDS or contact your material supplier for moreinformation. If you must use halogenated hydrocarbon solvents, contactyour Nordson representative for information about compatible Nordsoncomponents.

If a system or any equipment in a system malfunctions, shut off thesystem immediately and perform the following steps:

� Disconnect and lock out system electrical power. Close hydraulic andpneumatic shutoff valves and relieve pressures.

� Identify the reason for the malfunction and correct it before restartingthe system.

Dispose of equipment and materials used in operation and servicingaccording to local codes.

Halogenated HydrocarbonSolvent Hazards

7. Action in the Event of aMalfunction

8. Disposal

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Section 2

Description

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Section 2Description

See Figure 2-1. The IPS10A integral power supply controller provideselectrostatic control, dc power, and monitoring functions for rotaryatomizers.

The controller provides low-voltage dc to the rotary atomizer voltagemultiplier. The multiplier produces the electrostatic voltage used tocharge the paint as it is sprayed.

0917001A

Fig. 2-1 IPS10A Integral Power Supply Controller

1. Introduction

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A push-pull rotary switch and potentiometer (kV/AFC switch) allows theoperator to choose between two different control modes and to set outputlevels. In the kV mode, voltage output is controlled by the potentiometersetting.

In the Automatic Feedback Current (AFC) mode, maximum currentoutput is controlled by the potentiometer setting. The AFC mode alsoprovides optimum kV output and electric field strength for coating partswith interior corners and deep recesses at close range or recoatingcoated and cured parts.

See Figure 2-2 and refer to Table 2-1 for a description of front panelcontrols and functions.

MODE

��

AFC AFC4

5 67

8

91001

2

3

kV%kV

µAkV

0917002A

1 2 3 6 7 84 5

Fig. 2-2 Front Panel Controls

1. Introduction (contd)

2. Front Panel Controls

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Table 2-1 Front Panel Controls

Item Component Function

1 Power switch Turns the control unit on. If switch S5 on the circuit board isset to continuous, the power switch will activate the rotaryatomizer (if the kV potentiometer is turned on). Switch S5should be set to External Trigger for the IPS10A.

2 Power LED (Green) Lights when the control unit power switch is turned on.

3 High Voltage LED (Green) Lights when a trigger signal is sent from the PLC or otherexternal triggering device and indicates that high voltage hasbeen turned on.

4 kV LED (Amber) Lights when the kV/AFC switch is set to kV mode and turnedon.

5 AFC LED (Amber) Lights when the kV/AFC switch is set in the AFC mode andturned on.

6 Digital display Displays the percentage of kV output, µA output, andmultiplier polarity (positive or negative) in both kV and AFCmodes. The kV/µA switch changes the display from %kV toµA.

As parts go by the rotary atomizer, both kV and µA outputwill fluctuate. µA output increases when the rotary atomizeris moved closer to a grounded part. The kV outputdecreases as µA output increases. If the unit is in AFCmode, µA output will not increase past the maximum currentset point. Part shape and paint flow rates also affectmicroampere output.

7 kV/µA switch Changes the output display from %kV to µA.

8 kV/AFC switch/potentiometer Changes voltage control modes and sets output levels.Pushing the knob in puts the unit in kV mode. Pulling theknob out puts the unit in AFC mode. Turning the switch toposition 1 turns on the electrostatic voltage. Rotating theswitch clockwise increases the voltage output when in kV orincreases the maximum current set point when in AFCmode.

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See Figure 2-3 and refer to Table 2-2 for rear panel connections.

0917003A

1 2 3

Fig. 2-3 Rear Panel Connections

Table 2-2 Rear Panel Connections

Item Component Function

1 Output receptacle 6-pin receptacle for the rotary atomizer.

2 Power cable receptacle 6-pin receptacle for the power cord.

3 Cabinet ground stud Ground wire connection.

NOTE: The IPS10A controller must be connected to a true earth ground.

3. Rear Panel Connections

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See Figure 2-4. The IPS10A integral power supply controller uses thesesymbols to identify the power switch, the ground connection on the rearpanel, and above the green high voltage indicator light on the front panel.

0917004B

ON HIGH VOLTAGE GROUNDOFF

Fig. 2-4 Symbols

Enclosure Meets IP54 and Class II, Division II requirements

ElectricalInput 120 or 240 Vac ± 10% at 50/60 HzOutput 7–21 VdcShort circuit output current 300 mAMaximum output current 500 mA

4. Symbols

5. Specifications

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Section 3

Installation

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Section 3Installation

WARNING: Allow only qualified personnel to perform thefollowing tasks. Follow the safety instructions in this documentand all other related documentation.

This section provides IPS10A integral power supply installationprocedures. The section also describes the circuit board power cord andrear panel connections.

See Figure 3-1. Use four M6 x 1 fasteners (two on each side) to mountthe cabinet in a secure location.

1. See Figure 3-1. Loosen the captive screws (2) and slide the controlmodule (1) out of the cabinet.

2. Unplug the ground wire (3) from the circuit board if necessary.

1. Introduction

2. Mounting

3. Circuit Board

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41

2 3

0917005A

Fig. 3-1 Removing the Control Module

1. Control module2. Captive screws

3. Ground wire4. Circuit board

3. See Figure 3-2. Set up the control unit for your application using thejumper blocks and switches. Refer to Table 3-1 for jumper block andswitch settings.

4. Slide the control module into the cabinet. Tighten the captive screws.

3. Circuit Board (contd)

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S/N

P/N

7 8

16

10 11 12

18 17

9

15 14 13

3318007A

J4

S4

S5

120/240

EUR

JAPAN

115V

TRIGGER

CONTINUOUS

J1–1

Fig. 3-2 Jumper Block and Switch Settings

1. Power cord receptacle (J1)2. Input voltage jumper (J4)

3. Trigger switch (S5) 4. Voltage range switch (S4)

Table 3-1 Jumper Block and Switch Settings

Jumper Block J4— Install the jumper to match input voltage.

Top

Middle

Bottom

120/240 V nominal input power (USA)

110/220 V nominal input power (Europe)

100/200 V nominal input power (Japan)

Switch S4—Set switch to input voltage range.

Top

Bottom

100/115/120 Vac

200/230/240 Vac

Switch S5—Set this switch to the correct position for your application.

External Trigger

Continuous

External trigger. (High voltage is turned on via an external switch).

Internal trigger. (The power switch turns on high voltage, if the kV/AFC switch is turned on.This setting should not be used with the IPS10A controller).

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WARNING: Install a locking disconnect switch or breaker in theservice line ahead of the equipment so power can be shut offduring installation or repair.

CAUTION: Equipment damage may occur if the control unit isconnected to any line voltage other than that stated on the I.D.plate.

Input voltage must be 100–240 Vac nominal, 1 ∅ , 50/60 Hz. Switchesand jumpers must be set appropriately. The control unit is shipped withan input voltage set to 230 Vac.

1. See Figure 3-3. Connect the power cord to the POWER INPUTreceptacle (2) on the rear panel.

2. Connect the unterminated end of the cord to the main power supplyaccording to Table 3-2.

Table 3-2 Power Cord Plug Connections

Function Wire Color

L (L1—hot) Brown

N (L2—neutral) Blue

PE (Ground) Green/Yellow

Trigger White

NOTE: Internally, the power cord receptacle wires are connected to afive-position plug that mates with receptacle J1 on the circuit board.

Table 3-3 Power Connections to Circuit Board (Reference only)

J1 Pin No. Wire Color

1 Brown

2 Blue

3 Green/Yellow

4 Black (open)

5 White

4. Electrical Connections

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WARNING: All electrically conductive equipment in the sprayarea must be grounded. Ungrounded or poorly groundedequipment can store an electrostatic charge which can givepersonnel a severe shock, or arc and cause a fire or explosion.

3. Connect the ground strap supplied with the controller to the cabinetground stud (3). Secure the clamp to an earth ground.

4. Connect the rotary atomizer cable to the power output receptacle (1).

0917003A

1 2 3

Fig. 3-3 Rear Panel Connections

1. Power output receptacle2. Power input receptacle

3. Cabinet ground stud

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Section 4

Operation

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Section 4Operation


WARNING: This equipment can be dangerous unless it is usedin accordance with the rules laid down in this manual.

WARNING: All electrically conductive equipment in the sprayarea must be grounded. Ungrounded or poorly groundedequipment can store an electrostatic charge which can givepersonnel a severe shock, or arc and cause a fire or explosion.

Before operating a Nordson liquid spray system, read the systemcomponent manual and familiarize yourself with the operatingcharacteristics of each component. A thorough understanding of thesystem operation will help you obtain desired results and diagnoseproblems.

NOTE: When a rotary atomizer is first put into service, set the kV/AFCswitch to the kV mode, turn the switch to the maximum setting, andrecord the µA output with no parts in front of the gun. Monitor the outputdaily, under the same conditions. A significant increase in µA outputindicates a probable short in the rotary atomizer resistor. A significantdecrease indicates a failing resistor or voltage multiplier.

1. Turn on the control unit power switch. The power LED lights up.

2. Turn the kV potentiometer switch on. Push the kV/AFC switch in toput the unit in kV mode or pull it out to put the unit in AFC mode.Refer to the Description section for more information. If the switch isset for the kV mode, rotate it fully clockwise for maximum voltage. Ifthe switch is set for the AFC mode, rotate it to position 4. Thisposition represents approximately 40 µA.

1. Introduction

2. Startup

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3. Trigger the rotary atomizer. The high voltage LED will light up,indicating that high voltage has been turned on.

4. Coat a part and adjust the kV output or AFC settings to achieve thedesired result.

WARNING: Turn off the electrostatic voltage and ground therotary atomizer electrode before making adjustments to therotary atomizer or nozzle.

Obtaining a high-quality finish and maximum transfer efficiency(percentage of paint sprayed that adheres to the part) requiresexperimentation and experience. Settings for electrostatic voltage affectoverall coating performance. In most applications, the settings shouldproduce a soft spray pattern that directs as much of the paint as possibleonto the part with a minimum of overspray. These settings will allow themaximum amount of charged paint to be attracted to the grounded part.

Lowering the voltage is a common method for trying to improve thecoverage of deep recess and interior corners of parts. However, loweringthe voltage may also reduce your overall transfer efficiency. Paintvelocity, direction, and pattern shape can be just as important aselectrostatic voltage in coating these areas.

Use the AFC mode with coated parts that have already been cured butrequire additional recoating and curing, and with coated parts with deeprecesses. In this mode, the AFC switch/potentiometer lets you set afeedback current threshold. Voltage is automatically set to the maximum.If the current threshold is reached the voltage is automatically adjusted tomaintain the required coverage. A suggested starting point is position 4on the kV/AFC switch dial, which corresponds to approximately 40 µA.Adjustments can then be made to optimize performance for different partconfigurations and application parameters.

When the device-to-part distances changes, the AFC circuitry maintainsthe optimum combination of voltage and current.

Turn the controller power switch off to turn off the dc power to thecontroller and rotary atomizer.

2. Startup (contd)

3. Adjustments

Electrostatic Voltage

4. Shutdown

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Section 5

Maintenance

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Section 5Maintenance


This section provides preventive maintenance procedures. Refer to theRepair section for complete disassembly and rebuilding procedures.

1. With no parts in front of the rotary atomizer, compare the rotaryatomizer’s µA output in kV mode with the output and kV settingrecorded at initial startup.

NOTE: Significant differences may mean that the rotary atomizer resistoror multiplier is failing.

2. Check all ground connections, including part grounds.

NOTE: Ungrounded or poorly grounded parts will not attract chargedpaint. This affects transfer efficiency, electrostatic wrap, and the qualityof the finish. Ungrounded equipment and parts may also accumulate acharge that could arc and cause a fire or an explosion.

3. Check power and cable connections.

1. Introduction

2. Daily

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Section 6

Troubleshooting

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Section 6Troubleshooting


This section contains troubleshooting procedures. These procedurescover only the most common problems that you may encounter. If youcannot solve the problem with the information given here, contact yourlocal Nordson representative for help.

Problem Page

1. All LEDs off, no display 6-2

2. No power or no high voltage LED’s 6-2

3. kV mode LED off, AFC mode LED off, display on 6-2

4. kV mode LED off, AFC mode LED off, display on 6-2

5. Display off, kV mode or AFC mode LED on 6-2

6. Display off, kV mode or AFC mode LED on 6-3

7. No kV out, kV mode or AFC mode LED off, display off,LED on high voltage

6-3

8. Low kV output 6-3

9. Display reads 0 µA output, device spraying normally 6-4

10. Display reads 100% kV, but reads 0 µA output, loss ofwrap/transfer efficiency

6-4

11. Loss of wrap, poor transfer efficiency 6-4

12. Poor surface finish, catering, starring, or orange peel 6-4

Components designations, such as SW1 and U3, may be given introubleshooting procedures. These identify components on the circuitboard. Refer to the illustrations at the end of this section when atroubleshooting problem involves a circuit board.

1. Introduction

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WARNING: Electrical power must be on to check voltages.Perform these procedures carefully, using insulated tools.Touching energized electrical components could be fatal.

Problem Possible Cause Corrective Action

1. All LEDs off, no display No input power Make sure power is supplied to thecontrol unit.

Power switch (S1) off or open Make sure switch S1 is operatingproperly.

Blown F1 fuse; C2 shorted Correct the overload or short andreplace fuse F1. If fuse F1 continues toblow, replace circuit board.

S4 not set properly Make sure switch S4 is set correctly.

J4 jumper loose or missing Make sure the jumper is locatedcorrectly on jumper block J4.

2. No power or no highvoltage LEDs

Regulator U3 failed; no power or highvoltage LED

Replace the circuit board.

3. kV mode LED off, AFCmode LED off, displayon

LED D5 or D7 failed Replace the circuit board.

S2 failed Replace the circuit board.

4. Display off, kV mode orAFC mode LED on

Q4 failed Replace the circuit board.

U6 failed Replace the circuit board.

5. High voltage LED off,power LED on, kV modeor AFC mode LED on

Diode D6 shorted Replace the circuit board.

Q1 failed; TP-8 to ground is greaterthan 1 V

Replace the circuit board.

2. Troubleshooting Charts

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6. No kV out; kV mode orAFC mode LED on; highvoltage LED off; displayreads 00

No trigger signal—possible cabledamage

Disconnect the power cable from thecontrol unit. Check for continuity acrossplug pins 5 and ground. Replace thecable if no continuity is detected.

Connections at circuit boardconnector J3 or OUTPUT receptaclebad

Check the connections at J3 connectorand the receptacle.

Fuse F2 blown Check fuse F2 and replace it, if it isblown.

U1 or U2 chip failed Replace the U1 chip. If this does not fixthe problem, replace the U2 chip. If thisstill does not fix the problem, replace thecircuit board.

S5 failed Move S5 to the CONTINUOUS position.Turn on the controller. If the kV is notavailable, replace the circuit board.

7. No kV out, kV mode orAFC mode LED off,display off, LED on highvoltage

kV/AFC switch (S2) off Turn the kV/AFC switch and set it to thedesired level.

U1, Q2, or U3 failed Replace the U1 chip. If this does not fixthe problem, replace the circuit board.

8. Low kV output kV/AFC switch (S2) not adjustedproperly

Increase the AFC current set point orthe kV output.

Low input voltage—TP-1 less than24 Vdc

Make sure S4 and J4 are set correctlyfor the input Voltage.

U1 chip failed Check from TP-2 to ground for 21 Vdcwith a Voltmeter. If this voltage is notpresent, replace U1 chip.

Rotary atomizer resistor, cable, ormultiplier failed

Check the resistor and multiplier with amegohmmeter. Check the cablecontinuity.

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9. Display reads 0 µAoutput, device sprayingnormally

Rotary atomizer cable feedbackcircuit open, or loose or dirty cableconnection

Check connections at the J3 connectoron the circuit board, the device OUTPUTreceptacle, and at the device multiplier.Check the cable continuity. Replace thecable if no continuity is detected.

Feedback resistor open Replace the rotary atomizer multiplier.Refer to the rotary atomizer manual forinstructions.

kV/µA switch (S3) failed Replace the circuit board.

10. Display reads 100% kV,but reads 0 µA output;loss of wrap/transferefficiency

Loose or dirty device cableconnections, or cable damaged

Check connections at J3, receptacle,and rotary atomizer. Check the rotaryatomizer cable continuity and replace ifnecessary.

Multiplier failed Replace the multiplier.

11. Loss of wrap, poortransfer efficiency

Poorly grounded part Measure the resistance between thepart and ground with a standardohmmeter.

Clean the conveyor and part hangers ifthe resistance is greater than onemegohm. For best results, theresistance should be 500 ohms or less.

Rotary atomizer resistor or multiplierfailed

Check the rotary atomizer resistor andmultiplier with an ohmmeter.

Moisture in air causing kV to leak toground

Check the air dryer and filters.

12. Poor surface finish—catering, starring, ororange peel

Excess surface charge on part Set the kV/AFC switch in the AFC mode,position 4. Adjust for the bestcombination of surface finish andtransfer efficiency. Increase the settingto improve paint transfer efficiency.Decrease the setting to improve surfacefinish.

Poorly grounded part Measure the resistance between thepart and ground with a standardohmmeter. Clean the conveyor and parthangers if the resistance is greater thanone megohm. For best results, theresistance should be 500 ohms or less.

Paint conductivity is too low Contact the paint manufacturer.

2. Troubleshooting Charts(contd)

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See Figure 6-1. This figure calls out jumpers (J1 through J4), switches(S1 through S5), fuses (F1 and F2) and test points (TP1 through TP11).

S/N

P/N

7 8

16

10 11 12

18 17

9

15 14 13

3318008A

S1 TP1 F1 S4 J4 J1

J2

J3

F2

TP8

TP11TP10S5TP2U1U2S2 TP9

S3

Fig. 6-1 Circuit Board Test Points and Components

3. Circuit Board Test Pointsand Components

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See Figure 6-2.

0917006A

J1

1 2 3 4 5

J2 J3

1 2 1 2 3 4 5

Brown

Blue

Green/yellow

Black

Yellow

Red

Green

White

Red

Yellow

Black

Gray

White

Green

Green/yellow Green/yellow

Cabinetground

Component panelground

Cabinet

Circuit Board

1

2

34

5

Spray DeviceReceptacle (Output)

PowerCable(Input)

Dust-tightReceptacle

6

White

Fig. 6-2 Wiring Diagram

4. Wiring Diagram

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See Figure 6-3.

0917007A

J1

1Brown

Blue

Green/yellow

Black

Yellow

Red

Gray

Green/yellow

Cabinetground

Componentpanel ground

Circuit board

Powercable

2

3

4

5

4

2

3

1

5

Brown

Blue

Green/yellow

Black

White

Line

Neutral

Ground

Alarm

External Trigger

J2

1

2

Ground

+21 Vdc

Feedback

White

Green

Red

Black

Blue or Yellow

Black Black

Yellow

Red +21 Vdc

Feedback

Common

J3

1

2

3

4

5

1

2

3

4

5

6

Multiplier

L1

L2

Ground

Cabinet

Trigger

Trigger

Fig. 6-3 Electrical Schematic

5. Electrical Schematic

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Section 7

Repair

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Section 7Repair


This section describes repair procedures for the IPS10A automaticintegral power supply controller. No special tools are required.

WARNING: Disconnect and lock out electrical power beforeperforming the following tasks. Failure to observe this warningcould result in personal injury or death.

See Figure 7-1. The control module must be removed from the cabinetto replace or repair internal components. Use these procedures toremove and install the control module.

1. Unplug the power cable and disconnect the rotary atomizer.

2. Loosen the captive screws (1) securing the control module to thecabinet.

3. Slide the control module from the cabinet and disconnect the groundwire (2) from the module.

NOTE: Check all electrical connections before installing the module inthe cabinet.

1. Introduction

2. Control Module

Removal

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1. Connect the ground wire (2) to the module.

2. Make sure the front and rear panel gaskets (not shown) areundamaged and correctly positioned. Slide the control module intothe cabinet.

3. Tighten the captive screws (1) securing the control module to thecabinet.

4. Connect the rotary atomizer cable to the power output receptacle andthe power cable to the power input receptacle as described in theInstallation section.

5. Connect the cabinet ground wire to a true earth ground.

0917008A

31

2

1

Fig. 7-1 Removing the Control Module from the Cabinet

1. Captive screws2. Ground wire

3. Circuit board

Installation

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See Figure 7-2.

1. Remove the control module from the cabinet.

2. Disconnect the plug connectors J1 and J3 on the circuit board. (SeeFigure 6-1 for connector locations, if necessary).

3. Remove the dust-cover nuts (1) securing the power and kV/µA toggleswitches (2) to the front panel.

4. Remove the cap (4) and knob (5) from the kV/AFC switch (7).

5. Remove the nut (6) securing the kV/AFC switch to the front panel.

6. Remove the three screws and washers (not shown), securing thecircuit board (See Figure 7-1, (3)) to the control module. Remove thecircuit board from the module.

3318015A

1 2

3

4 5 6 7 8

Fig. 7-2 Circuit Board Replacement

1. Dust-cover nut2. Toggle switch3. Front panel4. Cap

5. Knob6. Nut7. kV/AFC switch8. O-ring

3. Circuit Board

Removal

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CAUTION: Do not over-tighten the screws or you will damagethe circuit board.

1. Make sure the O-ring for the kV/AFC switch (See Figure 7-2, (8)) is inplace before installing the circuit board into the module.

2. Install a new circuit board into the module.

3. Install the three screws and washers (not shown).

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Section 8

Parts

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Section 8Parts

To order parts, call the Nordson Customer Service Center or your localNordson representative. Use this five-column parts list, and theaccompanying illustration, to describe and locate parts correctly.

Numbers in the Item column correspond to numbers that identify parts inillustrations following each parts list. The code NS (not shown) indicatesthat a listed part is not illustrated. A dash (—) is used when the partnumber applies to all parts in the illustration.

The six-digit number in the Part column is the Nordson Corporation partnumber. A series of dashes in this column (- - - - - -) means the partcannot be ordered separately.

The Description column gives the part name, as well as its dimensionsand other characteristics when appropriate. Indentions show therelationships between assemblies, subassemblies, and parts.

Item Part Description Quantity Note

— 000 000 Assembly 1

1 000 000 � Subassembly 2 A

2 000 000 � � Part 1

� If you order the assembly, items 1 and 2 will be included.� If you order item 1, item 2 will be included.� If you order item 2, you will receive item 2 only.

The number in the Quantity column is the quantity required per unit,assembly, or subassembly. The code AR (As Required) is used if thepart number is a bulk item ordered in quantities or if the quantity perassembly depends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list.Notes contain important information about usage and ordering. Specialattention should be given to notes.

1. Introduction

Using the Illustrated PartsList

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See Figures 8-1, 8-2, and 8-3.

Item Part Part Description Quantity Note

— 297 136 Power unit, IPS10A, packaged,standalone

1

— 310 210 Power unit, IPS10A, packaged, rackmount

1 A

1 - - - - - - - - - - - - � Module, electric, IPS10A 1 D

2 981 387 981 387 � � Screw, captive, M5 x 25 mm,stainless steel

4 B

3 983 038 983 038 � � Washer, flat, 0.203 x 0.309 x 0.04in., nylon

4 B

4 297 129 297 129 � � Panel, bezel, IPS10A 1 B

5 - - - - - - - - - - - - � � � Gasket, panel, bezel 1 B

6 940 073 940 073 � � O ring, Viton, 0.145 ID x 0.070 in.,brass

4 B

7 129 583 129 583 � � Gasket, bezel 1 B

8 940 121 940 121 � � O ring, Viton, 0.364 ID x 0.070 in.,brass

1 B

9 173 121 173 121 � � Seal, 1/8 in. shaft, rotary 1 B

10 173 099 173 099 � � Knob, collet, 21 mm, 1/8 in. shaft 1 B

11 173 100 173 100 � � Cap, flat, 21 mm, white line 1 B

12 170 695 170 695 � � Boot, switch, waterproof 2 B

13 - - - - - - - - - - - - � � Rod, support 2 C

14 129 600 129 600 � � Gasket, rear panel 1 C

15 982 096 982 096 � � Screw, pan, slotted, M4 x 8, zinc 3 C

16 983 416 983 416 � � Washer, lock, M, int, M4 steel, zinc 3 C

17 982 139 982 139 � � Screw, flat, slotted, M4 x 8, zinc 5 C

NOTE A: This controller does not come with an enclosure. The controller must be mounted in acustomer-supplied rack.

B: See Figure 8-1.

C: See Figure 8-2.

D: See Figure 8-3.

NS: Not Shown

Continued on next page

2. IPS10A Controller Parts

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Item Part Part Description Quantity Note

18 171 031 171 031 � � Circuit board, Versa-Spray II 1 C

NS 939 098 939 098 � � � Fuse, 1 A, 250 V, fast acting 1

NS 939 991 939 991 � � � Fuse, 50 mA, 250 V, fast acting 1

19 171 017 171 017 � � � Service kit, IC, Versa-Spray (U1,U2 chips)

1 C

20 163 443 163 443 � � Jumper, ground, cable, 15.0 in. 1 C

21 240 674 240 674 � � Tag, ground 1 C

22 933 469 933 469 � � Lug, 90, double, 0.250, 0.438 in. 1 C

23 983 021 983 021 � � Washer, flat, e, 0.203 x 0.406 x0.040 in., brass

1 C

24 984 702 984 702 � � Nut, hex, M5, brass 1 C

25 983 401 983 401 � � Washer, lock,M, SPT, M5, steel,zinc

1 C

26 933 343 933 343 � � Connector, plug, 5 position 1 C

NS 130 629 130 629 � � Cable, power, 5 wire, 6.5 ft, female 1

27 130 625 130 625 � � Receptacle, input, 5 wire, male 1 C

28 939 122 939 122 � � Seal, conduit fitting, 1/2 2 C

29 984 526 984 526 � � Nut, lock, 1/2 conduit 2 C

30 130 627 130 627 � � Receptacle, input, 6 wire, female 1 C

31 933 162 933 162 � � Terminal, push on, 0.250 in., 22-18 1 C

32 240 674 � Tag ground 2 D

33 983 021 � Washer, flat, e, 0.203 x 0.406 x0.040 in., brass

2 D

34 983 401 � Washer, lock, M,SPT, M5, steel, zinc 2 D

35 984 702 � Nut, hex, M5, brass 2 D

36 140 165 � Gasket, filler, panel, front 1 D

NS 240 976 � Clamp, ground with wire 1

NOTE C: See Figure 8-2.

D: See Figure 8-3.

NS: Not Shown

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0917010A

9

2 3 5 4 6 7

81011

12

Fig. 8-1 IPS10A Parts

2. IPS10A Controller Parts(contd)

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0917011A

15

13 14

17

16

18

20

2122232425

27282926

30

31

19


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0917009A

36

1

32

33

34

35


2. IPS10A Controller Parts(contd)

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DECLARATION of CONFORMITY

PRODUCT:

IPS-10A Controller used with IPS RA-20 or RA–20R

APPLICABLE DIRECTIVES:

98/37/EEC (Machinery)

2006/95/EEC (Low Voltage Directive)

2004/108/EEC (ElectroMagnetic Compatibility Directive)

STANDARDS USED TO VERIFY COMPLIANCE:

EN12100 EN55011

EN60204 EN50050

EN61000–6–2 EN50176

FM7260

PRINCIPLES:

This product has been manufactured according to good engineering practice.

The product specified conforms to the directive and standards described above.

CERTIFICATIONS:

Factory Mutual Certified

DNV ISO9001:2000

Date: 15 October 2007

Joseph SchroederEngineering ManagerFinishing Product Development

Nordson Corporation � Westlake, Ohio DOC13003B02

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Documents

IPS10A Automatic Integral Power Supply Controller...OBSOLETE IPS10A Automatic Integral Power Supply Controller Customer Product Manual Part 303 816B NORDSON CORPORATION AMHERST, OHIO