Nordson X9800 User manual

X9800 Flame Detector
Customer Product Manual
Document Number 1609500-02
Issued 1/24
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at [phone] or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version.
NORDSON CORPORATION • AMHERST, OHIO • USA

© 2024 Nordson Corporation
1609500-02
Contact Us
Nordson Corporation welcomes requests for information, comments, and
inquiries about its products. General information about Nordson can be found on
the Internet using the following address:
http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 2016. No part of this document may be photocopied,
reproduced, or translated to another language without the prior written consent of
Nordson Corporation. The information contained in this publication is subject to
change without notice.
Trademarks
Nordson and the Nordson logo are registered trademarks of Nordson
Corporation. All other trademarks are the property of their respective owners.
Table of Contents
Safety............................................................................................ 1
Introduction................................................................................... 1
Qualified Personnel...................................................................... 1
Intended Use................................................................................ 1
Regulations and Approvals........................................................... 1
Personal Safety............................................................................ 2
Fire Safety.................................................................................... 2
Grounding..................................................................................... 3
Action in the Event of a Malfunction............................................. 3
Disposal........................................................................................ 3
Description................................................................................... 4
Flame Detection System Components......................................... 4
Flame Detector Heads ................................................................. 5
Theory of Operation....................................................................... 6
Flame Detection.......................................................................... 6
Faults .......................................................................................... 6
Specifications ............................................................................... 6
Detector Head Terminal Block Connections................................ 6
Electrical Power and Temperature Rating................................... 6
Installation.................................................................................... 7
Mounting Equipment .................................................................... 7
Excel Booth Vestibule Mount ...................................................... 7
Colormax Booth Mount ............................................................... 8
Pneumatic Regulator Installation (if applicable).......................... 9
Flame Detector Head Connections........................................... 10
Wiring Diagrams......................................................................... 11
AC-Powered Control Panel....................................................... 11
AC-Powered Control Panel with Field Connector
Box Wiring Diagram .................................................................. 12
Operation.................................................................................... 13
Through-the-Lens Test ............................................................... 13
Detector Head Test Procedure ................................................... 13
Automatic Optical Integrity Test................................................. 13
Magnet Optical Integrity Test..................................................... 13
Maintenance............................................................................... 14
Daily ........................................................................................... 14
Periodically................................................................................. 14
Troubleshooting ........................................................................ 15
Parts............................................................................................ 16
Using the Illustrated Parts List.................................................... 16
X9800 Flame Detector Head...................................................... 17
Universal Mounting Kit ............................................................... 17
Optional Air Supply Parts ........................................................... 18

iChange Record
© 2024 Nordson Corporation 1609500-02
Change Record
Revision Date Change
01 04/16 Release
02 08/23 Removed DC power panel data

© 2024 Nordson Corporation
1609500-02
ii Change Record

1X9800 Flame Detector
© 2024 Nordson Corporation 1609500-02
Safety
Introduction
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.
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
Regulations and Approvals
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.
All phases of equipment installation must comply with all federal, state, and local codes.

2X9800 Flame Detector
© 2024 Nordson Corporation
1609500-02
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 offthe 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 (SDS) 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.
• Ground all conductive equipment. Use only grounded air and fluid hoses. Check
equipment and workpiece grounding devices regularly. Resistance to ground must not
exceed one megohm.
• Shut down all equipment immediately if you notice static sparking or arcing. Do not
restart the equipment until the cause has been identified and corrected.
• Do not smoke, weld, grind, or use open flames where flammable materials are being
used or stored. Do not heat materials to temperatures above those recommended
by the manufacturer. Make sure heat monitoring and limiting devices are working
properly.
• Provide adequate ventilation to prevent dangerous concentrations of volatile particles
or vapors. Refer to local codes or your material SDS for guidance.
• Do not disconnect live electrical circuits when working with flammable materials. Shut
offpower at a disconnect switch first to prevent sparking.
• Know where emergency stop buttons, shutoffvalves, and fire extinguishers are
located. If a fire starts in a spray booth, immediately shut offthe spray system and
exhaust fans.
• Shut offelectrostatic power and ground the charging system before adjusting,
cleaning, or repairing electrostatic equipment.
• 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.

3X9800 Flame Detector
© 2024 Nordson Corporation 1609500-02
Grounding
WARNING: Operating faulty electrostatic equipment is hazardous and can cause elec-
trocution, 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 equip-
ment until the problem has been identified and corrected.
Grounding inside and around the booth openings must comply with NFPA requirements
for Class II, Division 1 or 2 Hazardous Locations. Refer to NFPA 33, NFPA 70 (NEC
articles 500, 502, and 516), and NFPA 77, latest conditions.
• 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-offnozzles. 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 offelectrostatic 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 offthe system immediately
and perform the following steps:
• Disconnect and lock out system electrical power. Close hydraulic and pneumatic
shutoffvalves and relieve pressures.
• Identify the reason for the malfunction and correct it before restarting the system.
Disposal
Dispose of equipment and materials used in operation and servicing according to local
codes.

4X9800 Flame Detector
© 2024 Nordson Corporation
1609500-02
Description
Flame Detection System Components
The flame detection system is installed in a coating system booth and interfaces with
the booth and the application system controls. The flame detector shuts down the booth,
application equipment, and the conveyor when it detects a flame in the booth.
See Figure 1. The flame detection system consists of one or two detector heads and an
indicator panel. The detector circuit is available as either a 120/230 Vac NEMA12 panel
or as a control board and operator controls that can be integrated into a booth control
panel.
NOTE: The field wiring connector adapter box connects to the AC control panel and is
available as an option to primarily support XL-3000 legacy systems.
Flame Detector Head
Flame Detector Integration Kit
Flame Detection AC-Power Control Panel
Field Wiring Connector Adapter Kit
Figure 1 Flame Detection System Components

5X9800 Flame Detector
© 2024 Nordson Corporation 1609500-02
Flame Detector Heads
See Figure 2.
The detector heads simultaneously scan IR spectrum and the visible spectrum. They
use intelligent, real-time signal processing to tell the difference between a real flame and
false-alarm radiant energy sources.
Each detector head continuously monitors itself via a through-the-lens test. The detector
head shines a light through the lens and looks for a reflection from the reflective plate. If
the test fails, the detector head goes into fault mode and the amber fault indicator light is
turned on.
Each detector head has a status LED, visible through the lens. The detector head lens is
continuously cleaned by low-pressure air flowing from the air shield.
Figure 2 FX9800 Flame Detector

6X9800 Flame Detector
© 2024 Nordson Corporation
1609500-02
Theory of Operation
Flame Detection
If a flame is detected inside the booth, interlock relays in the indicator panel open and
shut down the exhaust fan, application equipment, and conveyor. The red FLAME
DETECTED indicator light is turned on and the flame alarm sounds.
Faults
The FAULT DETECTED indicator light and the fault alarm alert the operators of problems
with the detector heads. There are two fault modes:
Fault: A fault occurs when one detector head loses power, fails a through-the-lens test,
or has a microprocessor/sensor module malfunction. The fault indicator for that detector
head lights and the fault alarm sounds. No interlocked equipment is shut down if two
detector heads are used and only one is in fault. If only one detector head is used, any
fault is treated as a major fault.
Major Fault: A major fault occurs when both detector heads lose power, fail a through-
the-lens test, or have microprocessor/sensor malfunctions. Both fault indicators light and
the fault alarm sounds. If only one detector head is connected, then any fault is a major
fault. A major fault shuts down the booth and application equipment. The conveyor will
continue to run. The conveyor is shut down only if a flame is detected.
Specifications
Detector Head Terminal Block Connections
X9800 Model Pin Function
1 DC Common
2 +24 Vdc
3 Fault Relay (N.O.)
4 Fault Relay (COM)
6 Fire Relay (N.O.)
7 Fire Relay (COM)
Electrical Power and Temperature Rating
Item Specification
Detector Head Input Voltage 24 Vdc, 120 mA
Temperature Rating -40 °C to +75 °C
(-40 °F to +167 °F)

7X9800 Flame Detector
© 2024 Nordson Corporation 1609500-02
Installation
WARNING: Allow only qualified personnel to perform the following tasks. Follow the
safety instructions in this document and all other related documentation.
Mounting Equipment
Excel Booth Vestibule Mount
See Figure 3.
1. Measure and mark the locations in the booth entrance and exit vestibules (2) for the
detector heads (1).
2. Mount one detector head to the floor of each vestibule diagonally as shown below,
using the included brackets and screws, washers, lock washers, and nuts.
NOTE: Mounting brackets will need to be oriented differently depending on the
detector head being used.
NOTE: Each detector head has a 90-degree cone-shaped field of view.
3. Align the detector head center lines (4) so they have an unobstructed view of the
spray guns (3), conveyor (5), hangers, and workpieces (6).
4. Mount the indicator panel in an appropriate location, close to or on the booth electrical
panel, or on an operator platform, using the mounting holes on the panel flanges.
1
5
4
3
2
6
1
Figure 3 Excel Booth Flame Sensors and Light Test Source Installation (Top View)
1. Detector heads
2. Booth vestibules
3. Spray gun
4. Centerlines
5. Conveyor
6. Hangers and workpieces

8X9800 Flame Detector
© 2024 Nordson Corporation
1609500-02
Colormax Booth Mount
See Figure 4.
1. Measure and mark the locations at the top of the booth entrance (2) to mount the
detector heads (1).
2. Mount the detector heads to the top corners of the booth entry wall as shown below.
Orient the bracket appropriately using the included brackets and screws, washers,
lock washers, and nuts.
NOTE: Mounting brackets will need to be oriented differently depending on the
detector head being used.
NOTE: Each detector head has a 90-degree cone-shaped field of view.
3. Align the detector head center lines (4) so they have an unobstructed view of the
spray guns (3), conveyor (5), hangers, and workpieces (6).
4. Mount the indicator panel in an appropriate location, close to or on the booth electrical
panel, or on an operator platform, using the mounting holes on the panel flanges.
1
5
4
3
2
6
1
Figure 4 Colormax Booth Flame Sensors and Light Source Installation (Top View)
1. Detector heads
2. Booth entrance
3. Spray gun
4. Centerlines
5. Conveyor
6. Hangers and workpieces

9X9800 Flame Detector
© 2024 Nordson Corporation 1609500-02
Pneumatic Regulator Installation (if applicable)
See Figure 5.
Install a 1.0 bar (15 psi) fixed-pressure regulator for each detector head.
1. Install the regulator (4) on the booth as close as practical to the detector head (2).
2. Connect 6-mm air tubing (3) from the air supply to the regulator and from the regulator
to the detector head air shield.
2
1
3
4
Figure 5 Flame Detector Head Pneumatic Connections
1. Vestibule
2. Detector head
3. 6 mm air tubing
4. Regulator

10 X9800 Flame Detector
© 2024 Nordson Corporation
1609500-02
Flame Detector Head Connections
WARNING: All electrical connections must be made according to local or national
electrical codes. Use properly sized wire and approved conduit and fittings. Failure to
observe this warning could result in property damage or personal injury.
NOTE: Use copper conductors for all field wiring to the indicator panel. See Figure 6.
Connect the detector heads to the indicator panel with six-wire shielded cable, ground
wire, flexible or rigid conduit, and liquid-tight conduit fittings (Type 12 minimum rating).
1. Unscrew the housing lid (7) from the housing (1).
2. If installed, remove one of the plugs (2) from the housing (1) ports.
3. Screw the bulkhead (4) on the liquid−tight conduit fitting (5) (Type 12 minimum) and
install in the open port.
4. Pull the cable (8) and ground wire (3) through the conduit (6), then connect the
conduit to the fitting (5).
5. Connect the cable wires (8) to the terminal block (9) on the bottom of the
microprocessor/ sensor module. See Wiring Diagrams Figures 7, 8, 9, or 10 for
connections.
6. Connect the ground wire (3) to the green ground stud in the housing (1).
7. Screw the housing lid (7) on the housing (1).
8. Install plugs (2) in the lower housing as required.
9. Refer to the appropriate system wiring diagram and connect the cable wires to the
control panel as shown in Figures 7, 8, 9, or 10.
1
5
6
7
9
2
4
3
8
Figure 6 Flame Detector Electrical Connections
1. Housing
2. Plug
3. Ground wire
4. Bulkhead
5. Conduit fitting
6. Conduit
7. Housing lid
8. Cable
9. Terminal block

11X9800 Flame Detector
© 2024 Nordson Corporation 1609500-02
Wiring Diagrams
NOTE: Connections must be made so that power is supplied to the indicator panel as
long as the booth electrical power is turned on. Supply service must be provided from a
disconnect switched source.
AC-Powered Control Panel
Make connections according to Figure 7. Supply 120−240 Vac, 1 phase, 50/60 Hz, 2 amp
electrical service with ground to the indicator panel from the booth electrical panel. Use
three-wire cable, flexible or rigid conduit, and liquid-tight conduit fittings.
NOTE: If a field wiring connector box is added, refer to Figure 8.
Interconnect
Cable
TRAY RATED
CABLE OPTION
Figure 7 Wiring Diagram for AC-Powered Control Panel

12 X9800 Flame Detector
© 2024 Nordson Corporation
1609500-02
AC-Powered Control Panel
with Field Connector Box Wiring Diagram
Make connections according to Figure 8.
Interconnect
Cable
FIELD WIRING
CONNECTOR BOX
Figure 8 Wiring Diagram for AC-Powered Control Panel with Field Connection Box

13X9800 Flame Detector
© 2024 Nordson Corporation 1609500-02
Operation
WARNING: Allow only qualified personnel to perform the following tasks. Follow the
safety instructions in this document and all other related documentation.
Through-the-Lens Test
The detector heads automatically perform periodic through-the-lens tests to check their
operation. If a test fails, the detector head goes into fault mode. Refer to Troubleshooting
for diagnostic and correction procedures.
Detector Head Test Procedure
Automatic Optical Integrity Test
The X9800 includes the Automatic Optical Integrity (oi) feature which is a calibrated
performance test that is automatically performed once per minute to verify complete
detector operation capabilities. No testing with an external test lamp is required. The
detector automatically performs the same test that a maintenance person with a test lamp
would perform. However, a successful Automatic Optical Integrity test does not produce
an alarm condition.
Magnet Optical Integrity Test
The Magnetic Optical Integrity test procedure is the approved external optical test method
for the X9800 flame detector head to verify end-to-end function. This test replaces the
need of a traditional external test lamp.
1. Place a magnet at the location marked “MAG OI” on the outside of the detector.
2. Hold magnet in place for 6 seconds. This will activate the IR emitter on the unit.
3. If the resulting signal meets the test criteria, the indicating LED will change to red. If
the test criteria is not met, no alarm is produced and a fault is generated.

14 X9800 Flame Detector
© 2024 Nordson Corporation
1609500-02
Maintenance
WARNING: Allow only qualified personnel to perform the following tasks. Follow the
safety instructions in this document and all other related documentation.
WARNING: Keep the detector head lenses clean. Dirty lenses can prevent the detector
heads from detecting a flame in the booth. Failure to observe this warning could result in
property damage or personal injury.
NOTE: Keeping the lenses clean will prevent nuisance fault alarms or shutdowns. A
dirty lens can cause a through-the-lens test to fail, triggering a fault. If only one detector
head is installed, a fault will shut down the coating system during production.
Daily
Check the detector head lenses daily. If they are dirty, clean them with an approved low-
pressure air gun or an oil- and silicone-free cloth. If necessary, dampen the cloth with
ethyl alcohol. Do not use a silicone-based product such as commercial window cleaner to
clean the detector head lenses.
NOTE: If the detector head lenses are covered with powder overspray, check the air
supply to the air shields. Air should be supplied at 1.0 bar (15 psi). Make sure the air
shield orifices are not clogged.
Periodically
Check all electrical connections periodically. Tighten any loose terminals. Replace any
wiring that has worn or damaged insulation. Make sure conduit fittings are tight.

15X9800 Flame Detector
© 2024 Nordson Corporation 1609500-02
Troubleshooting
WARNING: Allow only qualified personnel to perform the following tasks. Follow the
safety instructions in this document and all other related documentation.
WARNING: Hazardous voltages are present inside the indicator panel when booth
power is on. Do not touch exposed terminals or wiring when checking voltages. Use
insulated tools. Failure to observe could result in severe shock and personal injury.
These troubleshooting procedures cover only the most common problems. If you
cannot solve a problem with the information given here, contact your local Nordson
representative for help.
Problem Possible Cause Corrective Action
1. Detector Fault Through-the-lens
test failed
If the status LED on the detector head is yellow, the detector lens
is obstructed. Make sure the detector lens is clean and clear of
powder. If powder is accumulating on the lenses, check the air
supply to the air shields. Reset the detector head to clear the
fault.
Detector head lost power Check the status LED on the detector head. When operating
normally, the LED should be green. If the LED is off, check the
wiring between the indicator panel and the detector. There should
be 24 Vdc between pins 1 and 2 at the detector.
• If 24 Vdc is present, call a technical service representative.
Detector head may need to be replaced.
• If 24 Vdc is not present, make sure green POWER ON
indicator on the indicator panel is lit.
If the indicator panel has power, repair or replace the wiring
between controller and detector.
Microprocessor/sensor
module failed
No LED indication on the detector head and 24 Vdc power
present at pins 1 and 2. Replace the detector head or contact
your technical service representative.

16 X9800 Flame Detector
© 2024 Nordson Corporation
1609500-02
Parts
To order parts, call the Nordson Industrial Coating Systems Customer Support Center at
[phone] or contact your local Nordson representative.
Using the Illustrated Parts List
Numbers in the Item column correspond to numbers that identify parts in illustrations
following each parts list. The code NS (not shown) indicates that a listed part is not
illustrated. A dash (—) is used when the part number applies to all parts in the illustration.
The number in the Part column is the Nordson Corporation part number. A series of
dashes in this column (−−−−−−) means the part cannot be ordered separately.
The Description column gives the part name, as well as its dimensions and other
characteristics when appropriate. Indentions show the relationships between assemblies,
subassemblies, and parts.
• 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 the part number is a bulk item
ordered in quantities or if the quantity per assembly 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. Special attention should be given
to notes.
Item Part Description Quantity Note
—0000000 Assembly 1
1000000 • Subassembly 2 A
2 000000 • • Part 1