Nordson IPS10A User manual

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

OBSOLETE
E1999 Nordson Corporation
All rights reserved
303 816B
Issued 10/99
Manual 9-17
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 1998. 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, Can Works, Century, CleanSleeve, CleanSpray, Control Coat, Cross-Cut, Easy Coat, Econo-Coat, Excel
2000, Flow Sentry, FoamMix, Horizon, Hot Shot, Isocoil, Isocore, Iso-Flo, MEG, Nordson, the Nordson logo,
Package ofValues, 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, Sure
Coat, Swirlcoat and Walcom are trademarks of Nordson Corporation.
Viton is a registered trademark of E.I. DuPont de Nemours & Co.

OBSOLETE
Table of Contents
i
E1999 Nordson Corporation
All rights reserved 303 816B
Issued 10/99 Manual 9-17
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 1
Safety
Section 2
Description
Section 3
Installation
Section 4
Operation

OBSOLETE
Table of Contents
ii
E1999 Nordson Corporation
All rights reserved
303 816B
Issued 10/99
Manual 9-17
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 5
Maintenance
Section 6
Troubleshooting
Section 7
Repair
Section 8
Parts

OBSOLETE
E1998 Nordson Corporation
All rights reserved Issued 10/98 S1EN–03–[SF–LECAP]–7
Section 1
Safety

OBSOLETE
Safety
1-0
E1998 Nordson Corporation
All rights reserved
Issued 10/98
S1EN–03–[SF–LECAP]–7

OBSOLETE
Safety
1-1
E1998 Nordson Corporation
All rights reserved Issued 10/98 S1EN–03–[SF–LECAP]–7
Section 1
Safety
Read and follow these safety instructions. Task- and equipment-specific
warnings, cautions, and instructions are included in equipment
documentation where appropriate.
Make sure all equipment documentation, including these instructions, is
accessible to persons operating or servicing equipment.
Equipment owners are responsible for making sure that Nordson
equipment is installed, operated, and serviced by qualified personnel.
Qualified personnel are those employees or contractors who are trained
to safely perform their assigned tasks. They are familiar with all relevant
safety rules and regulations and are physically capable of performing
their assigned tasks.
Use of Nordson equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to
persons or damage to property.
Some examples of unintended use of equipment include
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards or interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating equipment in excess of maximum ratings
Make sure all equipment is rated and approved for the environment in
which it is used. Any approvals obtained for Nordson equipment will be
voided if instructions for installation, operation, and service are not
followed.
1. Introduction
2. Qualified Personnel
3. Intended Use
4. Regulations and
Approvals

OBSOLETE
Safety
1-2
E1998 Nordson Corporation
All rights reserved
Issued 10/98
S1EN–03–[SF–LECAP]–7
To prevent injury follow these instructions.
SDo not operate or service equipment unless you are qualified.
SDo not operate equipment unless safety guards, doors, or covers are
intact and automatic interlocks are operating properly. Do not bypass
or disarm any safety devices.
SKeep clear of moving equipment. Before adjusting or servicing
moving equipment, shut off the power supply and wait until the
equipment comes to a complete stop. Lock out power and secure the
equipment to prevent unexpected movement.
SRelieve (bleed off) hydraulic and pneumatic pressure before adjusting
or servicing pressurized systems or components. Disconnect, lock
out, and tag switches before servicing electrical equipment.
SWhile operating manual spray guns, make sure you are grounded.
Wear electrically conductive gloves or a grounding strap connected to
the gun handle or other true earth ground. Do not wear or carry
metallic objects such as jewelry or tools.
SIf you receive even a slight electrical shock, shut down all electrical or
electrostatic equipment immediately. Do not restart the equipment
until the problem has been identified and corrected.
SObtain and read Material Safety Data Sheets (MSDS) for all materials
used. Follow the manufacturer’s instructions for safe handling and
use of materials, and use recommended personal protection devices.
SMake sure the spray area is adequately ventilated.
STo prevent injury, be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces,
sharp edges, energized electrical circuits, and moving parts that
cannot be enclosed or otherwise guarded for practical reasons.
5. Personal Safety

OBSOLETE
Safety
1-3
E1998 Nordson Corporation
All rights reserved Issued 10/98 S1EN–03–[SF–LECAP]–7
High-pressure fluids, unless they are safely contained, are extremely
hazardous. Always relieve fluid pressure before adjusting or servicing
high pressure equipment. A jet of high-pressure fluid can cut like a knife
and cause serious bodily injury, amputation, or death. Fluids penetrating
the skin can also cause toxic poisoning.
If you suffer a fluid injection injury, seek medical care immediately. If
possible, provide a copy of the MSDS for the injected fluid to the health
care provider.
The National Spray Equipment Manufacturers Association has created a
wallet card that you should carry when you are operating high-pressure
spray equipment. These cards are supplied with your equipment. The
following is the text of this card:
WARNING: Any injury caused by high pressure liquid can be
serious. If you are injured or even suspect an injury:
SGo to an emergency room immediately.
STell the doctor that you suspect an injection injury.
SShow him this card.
STell him what kind of material you were spraying.
MEDICAL ALERT–AIRLESSSPRAY WOUNDS: NOTE TO PHYSICIAN
Injection in the skin is a serious traumatic injury. It is important to treat
the injury surgically as soon as possible. Do not delay treatment to
research toxicity. Toxicity is a concern with some exotic coatings injected
directly into the bloodstream.
Consultation with a plastic surgeon or a reconstructive hand surgeon may
be advisable.
The seriousness of the wound depends on where the injury is on the
body, whether the substance hit something on its way in and deflected
causing more damage, and many other variables including skin
microflora residing in the paint or gun which are blasted into the wound.
If the injected paint contains acrylic latex and titanium dioxide that
damage the tissue’s resistance to infection, bacterial growth will flourish.
The treatment that doctors recommend for an injection injury to the hand
includes immediate decompression of the closed vascular compartments
of the hand to release the underlying tissue distended by the injected
paint, judicious wound depravement, and immediate antibiotic treatment.
High-Pressure Fluids

OBSOLETE
Safety
1-4
E1998 Nordson Corporation
All rights reserved
Issued 10/98
S1EN–03–[SF–LECAP]–7
To avoid a fire or explosion, follow these instructions.
SGround all conductive equipment in the spray area. Use only
grounded air and fluid hoses. Check equipment and workpiece
grounding devices regularly. Resistance to ground must not exceed
one megohm.
SShut down all equipment immediately if you notice static sparking or
arcing. Do not restart the equipment until the cause has been
identified and corrected.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SDo not heat materials to temperatures above those recommended by
the manufacturer. Make sure heat monitoring and limiting devices are
working properly.
SProvide adequate ventilation to prevent dangerous concentrations of
volatile particles or vapors. Refer to local codes or your material
MSDS for guidance.
SDo not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
SKnow where emergency stop buttons, shutoff valves, and fire
extinguishers are located. If a fire starts in a spray booth,
immediately shut off the spray system and exhaust fans.
SShut off electrostatic power and ground the charging system before
adjusting, cleaning, or repairing electrostatic equipment.
SClean, maintain, test, and repair equipment according to the
instructions in your equipment documentation.
SUse only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts
information and advice.
6. Fire Safety

OBSOLETE
Safety
1-5
E1998 Nordson Corporation
All rights reserved Issued 10/98 S1EN–03–[SF–LECAP]–7
Do not use halogenated hydrocarbon solvents in a pressurized system
that contains aluminum components. Under pressure, these solvents
can react with aluminum and explode, causing injury, death, or property
damage. Halogenated hydrocarbon solvents contain one or more of the
following 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 more
information. If you must use halogenated hydrocarbon solvents, contact
your Nordson representative for information about compatible Nordson
components.
If a system or any equipment in a system malfunctions, shut off the
system immediately and perform the following steps:
SDisconnect and lock out system electrical power. Close hydraulic and
pneumatic shutoff valves and relieve pressures.
SIdentify the reason for the malfunction and correct it before restarting
the system.
Dispose of equipment and materials used in operation and servicing
according to local codes.
Halogenated Hydrocarbon
Solvent Hazards
7. Action in the Event of a
Malfunction
8. Disposal

OBSOLETE
Safety
1-6
E1998 Nordson Corporation
All rights reserved
Issued 10/98
S1EN–03–[SF–LECAP]–7

OBSOLETE
E1999 Nordson Corporation
All rights reserved 303 816B
Issued 10/99 Manual 9-17
Section 2
Description

OBSOLETE
Description
2-0
E1999 Nordson Corporation
All rights reserved
303 816B
Issued 10/99
Manual 9-17

OBSOLETE
Description
2-1
E1999 Nordson Corporation
All rights reserved 303 816B
Issued 10/99 Manual 9-17
Section 2
Description
See Figure 2-1. The IPS10A integral power supply controller provides
electrostatic control, dc power, and monitoring functions for rotary
atomizers.
The controller provides low-voltage dc to the rotary atomizer voltage
multiplier. The multiplier produces the electrostatic voltage used to
charge the paint as it is sprayed.
0917001A
Fig. 2-1 IPS10A Integral Power Supply Controller
1. Introduction

OBSOLETE
Description
2-2
E1999 Nordson Corporation
All rights reserved
303 816B
Issued 10/99
Manual 9-17
A push-pull rotary switch and potentiometer (kV/AFC switch) allows the
operator to choose between two different control modes and to set output
levels. In the kV mode, voltage output is controlled by the potentiometer
setting.
In the Automatic Feedback Current (AFC) mode, maximum current
output is controlled by the potentiometer setting. The AFC mode also
provides optimum kV output and electric field strength for coating parts
with interior corners and deep recesses at close range or recoating
coated and cured parts.
See Figure 2-2 and refer to Table 2-1 for a description of front panel
controls and functions.
MODE

AFC AFC 456
7
8
9
10
0
1
2
3
kV
%kV
µA
kV
0917002A
1 2 3 6 7 84 5
Fig. 2-2 Front Panel Controls
1. Introduction (contd)
2. Front Panel Controls

OBSOLETE
Description
2-3
E1999 Nordson Corporation
All rights reserved 303 816B
Issued 10/99 Manual 9-17
Table 2-1 Front Panel Controls
Item Component Function
1Power switch Turns the control unit on. If switch S5 on the circuit board is
set to continuous, the power switch will activate the rotary
atomizer (if the kV potentiometer is turned on). Switch S5
should be set to External Trigger for the IPS10A.
2Power LED (Green) Lights when the control unit power switch is turned on.
3High Voltage LED (Green) Lights when a trigger signal is sent from the PLC or other
external triggering device and indicates that high voltage has
been turned on.
4kV LED (Amber) Lights when the kV/AFC switch is set to kV mode and turned
on.
5AFC LED (Amber) Lights when the kV/AFC switch is set in the AFC mode and
turned on.
6Digital display Displays the percentage of kV output, µA output, and
multiplier polarity (positive or negative) in both kV and AFC
modes. The kV/µA switch changes the display from %kV to
µA.
As parts go by the rotary atomizer, both kV and µA output
will fluctuate. µA output increases when the rotary atomizer
is moved closer to a grounded part. The kV output
decreases as µA output increases. If the unit is in AFC
mode, µA output will not increase past the maximum current
set point. Part shape and paint flow rates also affect
microampere output.
7 kV/µA switch Changes the output display from %kV to µA.
8kV/AFC switch/potentiometer Changes voltage control modes and sets output levels.
Pushing the knob in puts the unit in kV mode. Pulling the
knob out puts the unit in AFC mode. Turning the switch to
position 1 turns on the electrostatic voltage. Rotating the
switch clockwise increases the voltage output when in kV or
increases the maximum current set point when in AFC
mode.

OBSOLETE
Description
2-4
E1999 Nordson Corporation
All rights reserved
303 816B
Issued 10/99
Manual 9-17
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
1Output receptacle 6-pin receptacle for the rotary atomizer.
2Power cable receptacle 6-pin receptacle for the power cord.
3Cabinet ground stud Ground wire connection.
NOTE: The IPS10A controller must be connected to a true earth ground.
3. Rear Panel Connections

OBSOLETE
Description
2-5
E1999 Nordson Corporation
All rights reserved 303 816B
Issued 10/99 Manual 9-17
See Figure 2-4. The IPS10A integral power supply controller uses these
symbols to identify the power switch, the ground connection on the rear
panel, 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
Electrical
Input 120 or 240 Vac ±10% at 50/60 Hz
Output 7–21 Vdc
Short circuit output current 300 mA
Maximum output current 500 mA
4. Symbols
5. Specifications

OBSOLETE
Description
2-6
E1999 Nordson Corporation
All rights reserved
303 816B
Issued 10/99
Manual 9-17