Nordson 1082648A Reference guide

RediCoat by Nordson®
Hopper and VBF Dolly Systems
Customer Product Manual
Part 1082648A
Issued 10/07
This document is subject to change without notice.
Nordson Corporation • Amherst, Ohio • USA

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Table of Contents
Safety..........................................................................................................................................................................3
Qualified Personnel..............................................................................................................................................3
Intended Use........................................................................................................................................................3
Regulations and Approvals ..................................................................................................................................3
Personal Safety....................................................................................................................................................4
Fire Safety............................................................................................................................................................4
Grounding ............................................................................................................................................................5
Action in the Event of a Malfunction ....................................................................................................................5
Disposal ...............................................................................................................................................................5
System Descriptions...................................................................................................................................................6
Hopper System Description .................................................................................................................................6
Hopper System Specifications ......................................................................................................................7
VBF System Description ......................................................................................................................................8
VBF System Specifications ...........................................................................................................................9
Control Unit Rear Panel Connections................................................................................................................10
Operation Description ........................................................................................................................................11
Grounding....................................................................................................................................................11
Operation..................................................................................................................................................................11
Startup................................................................................................................................................................11
System Connection Diagrams ...........................................................................................................................13
VBF System Switch Box Wiring .........................................................................................................................14
Shutdown ...........................................................................................................................................................14
Changing Powder ..............................................................................................................................................15
Maintenance .............................................................................................................................................................15
Nozzle Cleaning.................................................................................................................................................15
Troubleshooting........................................................................................................................................................16
Hopper System Packing List ....................................................................................................................................17
VBF System Packing List .........................................................................................................................................17
Parts Lists.................................................................................................................................................................18
Spray Gun Parts ................................................................................................................................................18
Control Unit Parts...............................................................................................................................................19
Powder Pump Parts ...........................................................................................................................................20
Hopper Parts......................................................................................................................................................21
VBF Pickup Tube Parts......................................................................................................................................22
VBF Vibrator Motor and Switch Kits ..................................................................................................................23
Air and Powder Tubing ......................................................................................................................................23

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RediCoat Dolly Systems
Safety
Read and follow these safety instructions. Task– and equipment–specific
warnings, cautions, and instructions are included in equipment
documentation where appropriate.
Make sure all equipment documentation, including these instructions, is
accessible to all persons operating or servicing equipment.
Qualified Personnel
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.
Intended Use
Use of Nordson equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to persons
or damage to property.
Some examples of unintended use of equipment include
• using incompatible materials
• making unauthorized modifications
• removing or bypassing safety guards or interlocks
• using incompatible or damaged parts
• using unapproved auxiliary equipment
• operating equipment in excess of maximum ratings

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Personal Safety
To prevent injury follow these instructions.
• Do not operate or service equipment unless you are qualified.
• Do not operate equipment unless safety guards, doors, or covers are
intact and automatic interlocks are operating properly. Do not bypass or
disarm any safety devices.
• Keep clear of moving equipment. Before adjusting or servicing any
moving equipment, shut off the power supply and wait until the
equipment comes to a complete stop. Lock out power and secure the
equipment to prevent unexpected movement.
• Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
• Obtain and read Material Safety Data Sheets (MSDS) for all materials
used. Follow the manufacturer’s instructions for safe handling and use
of materials, and use recommended personal protection devices.
• To prevent injury, be aware of less–obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces, sharp
edges, energized electrical circuits, and moving parts that cannot be
enclosed or otherwise guarded for practical reasons.
Fire Safety
To avoid a fire or explosion, follow these instructions.
• Do not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
• Provide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material MSDS
for guidance.
• Do not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
• Know where emergency stop buttons, shutoff valves, and fire
extinguishers are located. If a fire starts in a spray booth, immediately
shut off the spray system and exhaust fans.
• Clean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
• Use only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.

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Grounding
WARNING: Operating faulty electrostatic equipment is hazardous
and can cause electrocution, fire, or explosion. Make resistance checks
part of your periodic maintenance program. If you receive even a slight
electrical shock or notice static sparking or arcing, shut down all electrical or
electrostatic equipment immediately. Do not restart the equipment until the
problem has been identified and corrected.
• All electrically conductive objects in the spray areas shall be electrically
connected to ground with a resistance of not more than 1 megohm as
measured with an instrument that applies at least 500 volts to the circuit
being evaluated.
• Equipment to be grounded includes, but is not limited to, the floor of the
spray area, operator platforms, hoppers, photoeye supports, and blow–
off nozzles. Personnel working in the spray area must be grounded.
• There is a possible ignition potential from the charged human body.
Personnel standing on a painted surface, such as an operator platform,
or wearing non–conductive shoes, are not grounded. Personnel must
wear shoes with conductive soles or use a ground strap to maintain a
connection to ground when working with or around electrostatic
equipment.
• Operators must maintain skin–to–handle contact between their hand
and the gun handle to prevent shocks while operating manual
electrostatic spray guns. If gloves must be worn, cut away the palm or
fingers, wear electrically conductive gloves, or wear a grounding strap
connected to the gun handle or other true earth ground.
• Shut off electrostatic power supplies and ground gun electrodes before
making adjustments or cleaning powder spray guns.
• Connect all disconnected equipment, ground cables, and wires after
servicing equipment.
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
• Disconnect and lock out electrical power. Close pneumatic shutoff
valves and relieve pressures.
• Identify the reason for the malfunction and correct it before restarting the
equipment.
Disposal
Dispose of equipment and materials used in operation and servicing
according to local codes.

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System Descriptions
Hopper System Description
Figure 1 - Hopper System Components
Control Uni
t
Powder Pum
p
Pump Adapter
and Pickup
Tube
Hoppe
r
Spray Gun
Fluidizing Air
Needle Valve
Grounding Knob
kV Output Displa
y
and Adjustmen
t
Powder Pump Flow Rate Air
Powder Pump Atomizing Air
Spray Gun Rinsing Air
Gun Bracket
Fluidizing Air
Fitting
Ventilation Hose
Connecto
r

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Hopper System Specifications
Electrical
Input voltage (single-phase): 115 Vac ±5%, 60Hz
or 220 Vac ±5%, 50Hz
Output voltage (spray gun): 0−90 kV
Output current (spray gun): 0−100 µA
Solenoid valve voltage: 24 Vdc
Pneumatic
Input air pressure: 8 bar
Compressed air quality: water <1.3 g/m3, oil <0.01 g/m3
Other
Gun cable and powder hose: 5 m
Spray gun weight: ≤555 g
Hopper powder capacity: 16 kg
Machine weight: 40 kg

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VBF System Description
Figure 2 - VBF System Components
Vibrator Table
Control Uni
t
Powder Pump
Pickup Tube
Spray Gun
Fluidizing Air
Needle Valve
Grounding Knob
Electrostatic Outpu
t
Display and Adjustmen
t
Powder Pump Flow Rate Air
Powder Pump Atomizing Air
Spray Gun Rinsing Air
Gun Bracket
Powder Bo
x
(custome
r
supplied)
Pickup Tube
Bracket
Pickup Tube
Fluidizing Air
Fitting

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VBF System Specifications
Electrical
Input voltage (single-phase): 115 Vac ±5%, 60Hz
or 220 Vac ±5%, 50Hz
Vibrator voltage (single-phase): 115 Vac ±5%, 60Hz
or 220 Vac ±5%, 50Hz
Output voltage (spray gun): 0−90 kV
Output current (spray gun): 0−100 µA
Solenoid valve voltage: 24 Vdc
Pneumatic
Input air pressure: 8 bar
Compressed air quality: water <1.3 g/m3, oil <0.01g/m3
Other
Gun cable and powder hose: 5 m
Spray gun weight: ≤555 g
Vibrator table load capacity: 25 Kg

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Control Unit Rear Panel Connections
Figure 3 - Control Unit Rear Panel
A
ir Supply Inle
t
(8 mm)
Flow Rate Air Outle
t
(8 mm)
A
tomizing Air Outle
t
(8 mm)
Rinsing Air Outle
t
(4 mm)
Powe
r
Switch
Control Unit Ground
Powe
r
Cable
Fuse
(0.5 A)
Gun Cable

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Operation Description
The powder pump creates a vacuum in the pickup tube which pulls the
fluidized powder from the box or hopper and then forces the powder through
the powder hose to the spray gun.
The electrostatic voltage and the pump are adjusted by the voltage control
knob and air regulators on the control unit. The fluidizing air pressure is
adjusted by the needle valve mounted on the control unit support column.
The electrostatic voltage (up to 90KV) applied to the spray gun electrode
generates an electric field that charges the sprayed powder. The charged
powder is distributed as a cloud and attracted to the grounded workpieces.
The powder that does not stick to the workpieces can be collected, sieved,
and re-used. Effective recycling could save 20% of the powder coatings,
and decrease cleaning time.
Grounding
Each component of the system should be connected to the ground stud on
the control unit column with the included ground wires. The included ground
cable with clamp should also be connected to the ground stud, and to a true
earth ground, such as the powder spray booth.
Not properly grounding both the RediCoat system and the workpieces may
cause the following coating problems:
• poor powder coverage
• rough powder coat
• powder being attracted back to the spray gun, coating the spray gun and
operator
The electrical resistance between the workpieces and the ground must not
be more than 1 MΩ. Test the resistance regularly will a megohm meter.
Operation
Startup
Allow only qualified personnel to perform the following tasks. Follow
the safety instructions in this document and all other related documentation.
See Figures 4, 5, and 6 for system connections.
1. Locate the dolly system on a level surface.
2. For hopper systems, install the hopper on the dolly and connect the
ground cable from the hopper to the ground knob.
3. Install the pickup tube and pump. Connect the ground clamp to the nut
on the flow rate air fitting on the pump.
4. Connect blue 6 mm tubing to the needle valve outlet and the fitting on
the pickup tube, or the fitting at the bottom of the hopper.

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5. Connect 8 mm blue tubing from the air manifold outlet fitting to the
control unit inlet fitting.
6. Connect the spray gun and pump to the powder control unit:
a. Connect blue 8 mm tubing from the pump flow rate air connection at
the rear of the pump to the flow rate air fitting on the control unit.
b. Connect red 8 mm tubing from the pump atomizing air connection at
the top of the pump to the atomizing air fitting on the control unit.
c. Connect the gun cable to the receptacles on the control unit and gun
handle.
d. Connect the blue 6 mm air tubing bundled with the gun cable and
powder tubing to the rinsing air fitting on the control unit and to the
rinsing air connection on the gun handle.
e. Connect the powder tubing to the gun handle and pump.
7. Make sure the fluidizing air needle valve is closed. Supply compressed
air to the control unit at 8 bar. The supply line should have a ball valve
installed so you can turn the air supply on or off.
8. Connect the power cord to an electrical receptacle supplying the correct
voltage.
9. Install a 25 kg box of powder on the vibrator table and insert the pickup
tube into the powder, or fill the hopper 2/3 full of powder.
10. Turn the kV adjustment knob clockwise until it clicks on. Leave kV
adjusted to zero.
NOTE: The kV knob must be turned to the on position before you turn
on power. If the knob is turned off the controller will open the solenoid
valves and pump powder through the gun.
11. Press the control unit power switch until it lights.
12. VBF systems: Turn the vibrator motor switch to the ON position.
13. Adjust the needle valve until the powder is gently boiling in the hopper or
just around the pickup tube. Too much air will cause the powder to erupt
out of the hopper or box.
14. Set the flow rate air pressure to about 1 kg/cm2and the atomizing air
pressure to about 0.3 kg/cm2.
15. Point the spray gun into the spray booth and trigger the gun. Adjust the
output voltage (kV) to 90.
16. Start coating workpieces and adjust the voltage and air pressure as
needed to obtain the desired results.

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System Connection Diagrams
Figure 4 - Hopper System Diagram
Figure 5 - VBF System Diagram
Compressed Ai
r
(6-8 bar)
Power Plug
System Ground
Cable with Clamp
(3.2 m)
Power Plug
System Ground
Cable with Clamp
(3.2m)
Compressed Ai
r
(6-8 bar)
8
1. Red 8 mm tubing with ferrule end
2. Blue 8-mm tubing with ferrule end
3. Blue 6-mm tubing
4. Gun cable
5. Powder tubing
6. Controller ground cable (0.5 m)
7. Ventilation hose (to spray booth)
8. Blue 8 mm tubing
9. Pump ground cable with clamp (1.8m)
10. Hopper ground cable (1.0 m)
1
2
3
3
4
5
6
9
1. Red 8-mm tubing w/ferrule end
2. Blue 8-mm tubing w/ferrule end
3. Blue 6-mm tubing
4. Gun cable
5. Powder tubing
6. Controller ground cable (0.5m)
7. Blue 8 mm tubing
8. Pump ground cable with clamp (1.8m)
7
2
1
3
5
3
4
8
10
6
7

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VBF System Switch Box Wiring
BLUE
BLUE BLUE
BROWN
BROWN
BROWN
BROWN
BROWN
BLACK
BLACK
BLACK
GRN/YEL
GRN/YEL
GRN/YEL
GRN/YEL
GRN/YEL
To
C
ontrol Unit
To Motor
110V
(220V)
P
o
w
e
r
C=450V 1.5 µF
Capacitor Cover
Switch Box
Figure 6 - VBF System Switch Box Wiring
Shutdown
1. Turn off the vibrator motor, if used.
2. Press the main power switch until the switch light turns off.
3. Shut off the compressed air supply to the system.
NOTE: Shut off the air supply at a valve in the supply line to the system to
avoid having to re-adjust the fluidizing air needle valve the next time you
start up the system.

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Changing Powder
When changing powder colors or type, clean the following components
thoroughly with a blow gun, vacuum cleaner, and clean, dry cloths:
• Spray gun (remove nozzles and clean separately)
• Powder pump (remove venturi throat and clean separately)
• Powder hose
• Pickup tube and pump adapter
• Hopper, if used
Maintenance
Clean the system regularly with compressed air, vacuum cleaner, and
clean, dry cloths.
1. Shut off the control unit and disconnect the system air supply and
electrical power.
2. Disconnect the air lines and powder hose from the spray gun and pump.
Blow out the spray gun, pump, and hose with compressed air.
3. Empty the powder hopper and clean it thoroughly. Vacuum the fluidizing
plate in the bottom and inspect it for contamination. If it is discolored,
check the air supply for water or oil contamination. Replace the plate if it
contaminated.
NOTE: Never use solvents or other cleaning agents to clean any
components of the system.
Nozzle Cleaning
See Figure 6.
1. Remove the deflector.
2. Unscrew the nozzle nut and remove the nozzle.
3. Pull the electrode support out of the nozzle.
4. Inspect all parts and replace them if worn or damaged.
NOTE: The conical nozzle electrode support is longer than the flat spray
nozzle electrode support.
Figure 6 - Nozzle Cleaning
Deflecto
r
(Conical Nozzle)
Nozzle Nut
Electrode
Support
Long: conical
Short: flat
Nozzle

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Troubleshooting
Problem Possible Cause Correction
Switch off Press switch to turn on control unit.Switch light off, control
unit off
Fuse blown Replace fuse (0.5 amp)
Atomizing air pressure too low Increase atomizing air pressure.
Powder hose worn Replace powder hose.
Powder spray uneven
or puffing
Supply air pressure unstable Install air regulator on supply line to regulate
pressure if necessary.
Powder escaping from
box or hopper
Fluidizing air pressure too high Adjust needle valve to decrease air pressure.
Powder supply low Replace box or refill hopper.
Blockage in spray gun Remove powder hose and blow out spray gun
with compressed air. Clean nozzle.
Blockage in powder hose Disconnect powder hose from spray gun and
pump. Blow out hose with compressed air.
Blockage in powder pump Disconnect powder hose and air tubing from
pump. Remove venturi throat and blow out
throat and pump.
No powder spray when
gun triggered
Blockage in pickup tube Remove pickup tube and clean.

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Hopper System Packing List
Component Quantity
Control unit 1
Dolly 1
Spray gun 1
Conical nozzle 1
Flat spray nozzle 1
Deflectors (small, medium, large) 6
Conical nozzle electrode support (long) 2
Flat spray nozzle electrode support (short) 2
Ground cable with clamp 1
Power cable 1
Spray gun cable 1
Powder hose 1
8-mm air tubing 4
6-mm air tubing 1
Powder pump 1
Pickup tube 1
Stainless steel hopper 1
Casters 4
Spray gun bracket 1
VBF System Packing List
Component Quantity
Control unit 1
Dolly 1
Spray gun 1
Conical nozzle 1
Flat spray nozzle 1
Deflectors (small, medium, large) 6
Conical nozzle electrode support (long) 2
Flat spray nozzle electrode support (short) 2
Ground cable with clamp 1
Power cable, including vibrator switch box 1
Spray gun cable 1
Powder hose 1
8-mm air tubing 4
6-mm air tubing 1
Powder pump 1
Pickup tube 1
Pickup tube bracket 1
Vibrator table, including vibrator motor 1
Casters 4
Spray gun bracket 1

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Parts Lists
Spray Gun Parts
Figure 7 Spray Gun Parts
Item Part Description Quantity Note
- 1081822 Handgun, Manual RDC 1
1 1081898 • Sleeve, threaded, RDC 1
2 1081899 • Body, gun, RDC 1
3 - - - - - - - • Deflector, plate, 18 mm, RDC 1 A
4 - - - - - - - • Deflector, plate, 25 mm, RDC 1 A
5 - - - - - - - • Deflector, plate, 33 mm, RDC 1 A
6 1081904 • Holder, electrode, RDC, flat jet nozzle (short) 1 D
6A 1083149 • Holder, electrode, RDC, round jet nozzle (long) 1 E
7 - - - - - - - • Nozzle, round jet, RDC 1 B
8 - - - - - - - • Nozzle, flat jet, RDC 1 B
9 1081907 • Tube, horizontal, RDC 1
10 1081908 • Cascade, high voltage, RDC 1
11 1081909 • Plate, end, with hook, RDC 1
12 1081910 • Screw, manual gun, RDC 2
13 1081911 • Handle, manual gun, RDC 1
14 1081912 • Tube, vertical, RDC 1
15 1081913 • Connector, rinsing air, RDC 1
16 1081914 • Cable, gun, complete with 5 m cable, RDC 1
17 1081916 • Connection part, RDC 1
18 1081917 • Plate, grounding, RDC 1
19 1081918 • Trigger, complete, RDC 1
20 - - - - - - - • O-ring, 12 mm x 1 mm, RDC 6 C
Note A: These parts included in 1082309 Kit, gun deflector plates, 18, 25, 33 mm, RDC.
Note B: These parts included in 1082311 Kit, gun nozzles, flat jet, round jet, RDC.
Note C: These parts included in 1082312 Kit, gun O-ring, 12 x 1 mm, RDC.
Note D: Use only with flat jet nozzle.
Note E: Use only with round jet nozzle.
1
6, 6A
7
8
5
4
3
16
20
17
9
19
14
20
15
19
13
12
11
10
2

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Control Unit Parts
Figure 8 - Control Unit Parts
Item Part Description Quantity Note
- 1081825 Control unit, 110V, RDC 1
- 1081826 Control unit, 220V, RDC 1
1 1081940 • Valve, pressure reducing, RDC 3
2 1081928 • Knob, control, RDC 1
3 1081941 • Regulator, 0-90 psi, 0-6 bar, RDC 3
4 1081946 • Switch, power, RDC 1
5 1081951 • Transformer, 110V, control unit, RDC 1 A
5 1081950 • Transformer, 220V, control unit, RDC 1 A
6 1081948 • PCB, control unit, RDC 1
7 1081949 • Potentiometer, control unit, RDC 1
8 1081944 • Solenoid valve, 24 Vdc, RDC 1
9 1081947 • Fuse, 0.5 A, RDC 1
NOTE A: Order correct transformer for your system. Refer to identification plate on rear panel.
6
7
2
5
1
3
8
4
9