Nordson 100 PLUS 104 360B User manual

100 PLUStMaster
Control Unit
Part 104 360B
NORDSON CORPORATION DAMHERST, OHIO DUSA
Previous
Generation

1997 Nordson Corporation
All rights reserved
104 360B
Issued 2/97
Manual 33-5
Nordson Corporation welcomes requests for information, comments and inquiries about its products.
Address all correspondence to
Nordson Corporation
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1990. 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
Blue Box, ChromaFlex, CleanSleeve, CleanSpray, Control Coat, Cross-Cut, Easy Coat, Econo-Coat, Excel 2000,
Flow Sentry, Isocoil, Isocore, Iso-Flo, Nordson, the Nordson logo, PRX, Pro-Flo, RBX, Ready-Coat, Rhino, Select
Coat, Select Cure, Shur-Lok, Smart Spray, System Sentry, Thread Coat, Tribomatic, and Versa-Spray are
registered trademarks of Nordson Corporation.
100 PLUS, CPX, CanWorks, Excel 2000, PowderGrid, Pulse Spray, SCF, Versa-Coat, Versa Screen, Package of
Values, and Swirl Coat are trademarks of Nordson Corporation.
Viton is a registered trademark of E.I. DuPont de Nemours & Co.
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Table of Contents
i
E1997 Nordson Corporation
All rights reserved 104 360B
Issued 2/97 Manual 33-5
Table of Contents
1. Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Safety Symbols 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Qualified Personnel 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Intended Use 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Installation 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Operation 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Less-Obvious Dangers 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Action in the Event of a System or Component Malfunction 1-7. . . . .
9. Maintenance and Repair 1-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. Disposal 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Introduction 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Theory of Operation 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Introduction 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Installation 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Unit Cables 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Input Power to Master Control 3-6. . . . . . . . . . . . . . . . . . . . . .
Pneumatics 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrostatic Cable 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet Grounds and Optional Interlocks 3-8. . . . . . . . . . . . . . . . . .
3. Options 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Multiple Master Control Units 3-9. . . . . . . . . . . . . . . . . . . .
Auxiliary 12–24 Vdc Power Supply 3-10. . . . . . . . . . . . . . . . . . . . . . .
Safety
Description
Installation
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Table of Contents
ii
E1997 Nordson Corporation
All rights reserved
104 360B
Issued 2/97
Manual 33-5
1. Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial System Startup 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Daily Startup 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Startup 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
During Operation 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Maintenance 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Introduction 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Troubleshooting Chart 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Electrical Schematic 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Removing Modules 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Repair 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distribution Module 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power/Logic Module 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Installing the Modules 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Introduction 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Illustrated Parts List 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Master Control Unit 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Power/Logic Module 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Power Distribution Module 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Pipe Rack I/O Module 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Optional Parts 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100 PLUS Mounting Kit 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet Parts 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation
T
roubleshooting
Repair
Parts
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Table of Contents
iii
E1997 Nordson Corporation
All rights reserved 104 360B
Issued 2/97 Manual 33-5
Dimensions 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inputs 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outputs 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Voltage 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Power 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Control Dimensions 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications
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Table of Contents
iv
E1997 Nordson Corporation
All rights reserved
104 360B
Issued 2/97
Manual 33-5
Previous
Generation

E1995 Nordson Corporation
All rights reserved Issued 11/95 33–5s1
Section 1
Safety
Previous
Generation

Safety
1-0
E1995 Nordson Corporation
All rights reserved
Issued 11/95
33–5s1
Previous
Generation

Safety
1-1
E1995 Nordson Corporation
All rights reserved Issued 11/95 33–5s1
Section 1
Safety
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,
Sread and become familiar with the general safety instructions
provided in this section of the manual before installing, operating,
maintaining, or repairing this equipment.
Sread and carefully follow the instructions given throughout this manual
for performing specific tasks and working with specific equipment.
Sstore this manual within easy reach of personnel installing, operating,
maintaining, or repairing this equipment.
Sfollow 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 powder spray
systems.
Sobtain and read Material Safety Data Sheets (MSDS) for all materials
used.
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.
1. Introduction
2. Safety Symbols
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Safety
1-2
E1995 Nordson Corporation
All rights reserved
Issued 11/95
33–5s1
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: System or material pressurized. Relieve pressure.
Failure to observe this warning may result in serious injury or
death.
CAUTION: Failure to observe may result in equipment
damage.
“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 the
equipment to see that its personnel meet these requirements.
2. Safety Symbols (contd.)
3. Qualified Personnel
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Safety
1-3
E1995 Nordson Corporation
All rights reserved Issued 11/95 33–5s1
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:
Smaking changes to equipment that have not been recommended or
described in this manual or using parts that are not genuine Nordson
replacement parts
Sfailing to make sure that auxiliary equipment complies with approval
agency requirements, local codes, and all applicable safety standards
Susing materials or auxiliary equipment that are inappropriate or
incompatible with your Nordson equipment
Sallowing unqualified personnel to perform any task
Read the installation section of all system component manuals before
installing your equipment. A thorough understanding of system
components and their requirements will help you install the system safely
and efficiently.
SAllow only qualified personnel to install Nordson and auxiliary
equipment.
SUse only approved equipment. Using unapproved equipment in an
approved system may void agency approvals.
SMake sure all equipment is rated and approved for the environment in
which you are using it.
SFollow all instructions for installing components and accessories.
SInstall all electrical, pneumatic, gas, and hydraulic connections to
local code.
4. Intended Use
5. Installation
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Safety
1-4
E1995 Nordson Corporation
All rights reserved
Issued 11/95
33–5s1
SInstall 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.
SInstall a locking disconnect switch or breaker in the service line ahead
of any electrical equipment.
SUse only electrical wire of sufficient gauge and insulation to handle
the rated current demand. All wiring must meet local codes.
SGround all electrically conductive equipment within 10 feet (3 meters)
of the spray area. Ungrounded conductive equipment can store a
static charge which could ignite a fire or cause an explosion if a hot
spark is discharged.
SRoute electrical wiring, electrostatic cables, and air hoses and tubing
along a protected path. Make sure they will not be damaged by
moving equipment. Do not bend electrostatic cables around a radius
of less than 6 in. (152 mm).
SInstall safety interlocks and approved, fast-acting fire detection
systems. These shut down the spray system if the booth exhaust fan
fails, a fire is detected, or other emergency situation develops.
SMake sure the spray area floor is conductive to ground and that the
operator’s platform is grounded.
SUse 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.
SProtect components from damage, wear, and harsh environmental
conditions.
SAllow ample room for maintenance, material supply container drop-off
and loading, panel accessibility, and cover removal.
SIf safety devices must be removed for installation, install them
immediately after the work is completed and check them for proper
functioning.
5. Installation (contd.)
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Safety
1-5
E1995 Nordson Corporation
All rights reserved Issued 11/95 33–5s1
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 a powder spray system.
A thorough understanding of all components and their operation will help
you operate the system safely and efficiently.
SUse 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.
SBefore 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 or locked-out electrical
disconnects or pneumatic valves.
SKnow 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.
SBefore operating, make sure all conductive equipment in the spray
area is connected to a true earth ground.
SNever operate equipment with a known malfunction or leak.
SDo not attempt to operate electrical equipment if standing water is
present.
SNever touch exposed electrical connections on equipment while the
power is ON.
SDo not operate the equipment at pressures higher than the rated
maximum working pressure of any component in the system.
SKnow the pinch points, temperatures, and pressures for all equipment
that you are working with. Recognize potential hazards associated
with these and exercise appropriate caution.
SWear shoes with conductive soles, such as leather, or use grounding
straps to maintain a connection to ground when working with or
around electrostatic equipment.
6. Operation
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Safety
1-6
E1995 Nordson Corporation
All rights reserved
Issued 11/95
33–5s1
SDo 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.
SMaintain 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.
SKeep parts of the body or loose clothing away from moving
equipment or parts. Remove personal jewelry and cover or tie back
long hair.
SWear National Institute of Occupational Safety and Health (NIOSH)
approved respirators, safety glasses or goggles, and gloves, and
while handling powder containers, filling hoppers, operating spray
equipment, and performing maintenance or cleaning tasks. Avoid
getting powder coatings on your skin.
SNever point manual guns at yourself or other persons.
SDo not smoke in the spray area. A lit cigarette could ignite a fire or
cause an explosion.
SIf you notice electrical arcing in a spray area, shut down the system
immediately. An arc can cause a fire or explosion.
SShut off electrostatic power supplies and ground gun electrodes
before making adjustments to powder spray guns.
SShut off moving equipment before taking measurements or inspecting
workpieces.
SWash exposed skin frequently with soap and water, especially before
eating or drinking. Do not use solvents to remove coating materials
from your skin.
SDo not use high-pressure compressed air to blow powder off your
skin or clothes. High-pressure compressed air can be injected under
the skin and cause serious injury or death. Treat all high-pressure
fittings and hoses as if they could leak and cause injury.
6. Operation (contd.)
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Safety
1-7
E1995 Nordson Corporation
All rights reserved Issued 11/95 33–5s1
Operators should also be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated:
Sexposed surfaces on the equipment which may be hot or have sharp
edges and cannot be practically safeguarded
Selectrical equipment which may remain energized for a period of time
after the equipment has been shut off
Svapors and materials which may cause allergic reactions or other
health problems
Sautomatic hydraulic, pneumatic, or mechanical equipment or parts
that may move without warning
Sunguarded, moving mechanical assemblies
Do not operate a system that contains malfunctioning components. If a
component malfunctions, turn the system OFF immediately.
SDisconnect and lock out electrical power. Close and lock out
hydraulic and pneumatic shutoff valves and relieve pressures.
SAllow only qualified personnel to make repairs. Repair or replace the
malfunctioning component.
Allow only qualified personnel to perform maintenance, troubleshooting,
and repair tasks.
SAlways wear appropriate protective devices and use safety devices
when working on this equipment.
SFollow the recommended maintenance procedures in your equipment
manuals.
SDo not service or adjust any equipment unless another person trained
in first aid and CPR is present.
SUse only genuine Nordson replacement parts. Using unapproved
parts or making unapproved modifications to equipment may void
agency approvals and create safety hazards.
7. Less-Obvious Dangers
8. Action in the Event of a
System or Component
Malfunction
9. Maintenance and Repair
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Safety
1-8
E1995 Nordson Corporation
All rights reserved
Issued 11/95
33–5s1
SDisconnect, lock out, and tag electrical power at a disconnect or
breaker in the service line ahead of electrical equipment before
servicing.
SDo not attempt to service electrical equipment if there is standing
water present. Do not service electrical equipment in a high-humidity
environment.
SUse tools with insulated handles when working with electrical
equipment.
SDo not attempt to service a moving piece of equipment. Shut off the
equipment and lock out power. Secure equipment to prevent
uncontrolled movement.
SRelieve air pressures before servicing equipment. Follow the specific
instructions in this manual.
SMake sure that the room where you are working is sufficiently
ventilated.
SIf 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.
SConnect all disconnected equipment ground cables and wires after
servicing the equipment. Ground all conductive equipment.
SService lines connected to panel disconnect switches may still be
energized unless they are disconnected. Make sure the power is off
before servicing. Wait 5 minutes for capacitors to discharge after
shutting off the electrical power.
STurn off the electrostatic power supply and ground the gun electrode
before adjusting or cleaning.
SKeep high-voltage connection points clean and insulated with
dielectric grease or oil.
SCheck all ground connections periodically with a standard ohmmeter.
Resistance to ground must not exceed one megohm. If arcing
occurs, shut down the system immediately.
9. Maintenance and Repair
(contd.)
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Safety
1-9
E1995 Nordson Corporation
All rights reserved Issued 11/95 33–5s1
SCheck interlock systems periodically to ensure their effectiveness.
WARNING: Operating faulty electrostatic equipment is
hazardous and can cause electrocution, fire, or explosion.
Make resistance checks part of your periodic maintenance
program.
SDo not store flammable materials in the spray area or room. Keep
containers of flammable materials 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.
SPractice good housekeeping procedures. Do not allow dust or
powder coatings to accumulate in the spray area or booth or on
electrical equipment. Read this information carefully and follow
instructions.
Dispose of equipment and materials used in operation and cleaning
according to your local regulations.
9. Maintenance and Repair
(contd.)
10. Disposal
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Safety
1-10
E1995 Nordson Corporation
All rights reserved
Issued 11/95
33–5s1
Previous
Generation

E1997 Nordson Corporation
All rights reserved 104 360B
Issued 2/97 Manual 33-5
Section 2
Description
Previous
Generation

Description
2-0
E1997 Nordson Corporation
All rights reserved
104 360B
Issued 2/97
Manual 33-5
Previous
Generation