Versa-Spray IPS Demonstration Unit
Versa-Sprayr IPSDemonstration UnitCustomer Product ManualPart 108 210CNORDSON CORPORATION D AMHERST, OHIO D USA
Nordson Corporation welcomes requests for information, comments and inquiries about its products.Address all correspondence toNordson Corporation555 Jackson StreetAmherst, OH 44001NoticeThis is a Nordson Corporation publication which is protected by copyright. Original copyright date 1991. No part ofthis document may be photocopied, reproduced, or translated to another language without the prior written consentof Nordson Corporation. The information contained in this publication is subject to change without notice.Trademarks100 Plus, 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-Sprayare registered trademarks of Nordson Corporation.CPX, CanWorks, Excel 2000, PowderGrid, Pulse Spray, SCF, Versa-Coat, Versa Screen, Package of Values, andSwirl Coat are trademarks of Nordson Corporation.Manual 38-8108 210CIssued 3/99E 1999 Nordson CorporationAll rights reserved
Table of ContentsiTable of Contents1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Regulations and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Action in the Event of a Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . 4Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63. Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Operating Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10MicroAmpere Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Electrostatic Powder Coating Variables . . . . . . . . . . . . . . . . . . . 105. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127. Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Using the Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Other Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22E 1999 Nordson CorporationAll rights reserved108210CIssued 3/99Manual 38-8
iiTable of ContentsManual 38–8108210CIssued 3/99E 1999 Nordson CorporationAll rights reserved
Versa-Sprayr IPS Demonstration Unit1Versa-Spray IPS Demonstration Unit1. SafetyRead and follow these safety instructions. Task- and equipment-specificwarnings, cautions, and instructions are included in equipmentdocumentation where appropriate.Make sure all equipment documentation, including these instructions, isaccessible to all persons operating or servicing equipment.Qualified PersonnelEquipment owners are responsible for making sure that Nordsonequipment is installed, operated, and serviced by qualified personnel.Qualified personnel are those employees or contractors who are trainedto safely perform their assigned tasks. They are familiar with all relevantsafety rules and regulations and are physically capable of performingtheir assigned tasks.Intended UseUse of Nordson equipment in ways other than those described in thedocumentation supplied with the equipment may result in injury topersons or damage to property.Some examples of unintended use of equipment includeSSSSSSRegulations and ApprovalsE 1999 Nordson CorporationAll rights reservedusing incompatible materialsmaking unauthorized modificationsremoving or bypassing safety guards or interlocksusing incompatible or damaged partsusing unapproved auxiliary equipmentoperating equipment in excess of maximum ratingsMake sure all equipment is rated and approved for the environment inwhich it is used. Any approvals obtained for Nordson equipment will bevoided if instructions for installation, operation, and service are notfollowed.108 210CIssued 3/99Manual 38-8
2Versa-Sprayr IPS Demonstration UnitPersonal SafetyTo prevent injury follow these instructions.S Do not operate or service equipment unless you are qualified.S Do not operate equipment unless safety guards, doors, or covers areintact and automatic interlocks are operating properly. Do not bypassor disarm any safety devices.S Keep clear of moving equipment. Before adjusting or servicing anymoving equipment, shut off the power supply and wait until theequipment comes to a complete stop. Lock out power and secure theequipment to prevent unexpected movement.S Relieve (bleed off) hydraulic and pneumatic pressure before adjustingor servicing pressurized systems or components. Disconnect, lockout, and tag switches before servicing electrical equipment.S While operating manual electrostatic spray guns, make sure you aregrounded. Wear electrically conductive gloves or a grounding strapconnected to the gun handle or other true earth ground. Do not wearor carry metallic objects such as jewelry or tools.S If you receive even a slight electrical shock, shut down all electrical orelectrostatic equipment immediately. Do not restart the equipmentuntil the problem has been identified and corrected.S Obtain and read Material Safety Data Sheets (MSDS) for all materialsused. Follow the manufacturer’s instructions for safe handling anduse of materials, and use recommended personal protection devices.S To prevent injury, be aware of less-obvious dangers in the workplacethat often cannot be completely eliminated, such as hot surfaces,sharp edges, energized electrical circuits, and moving parts thatcannot be enclosed or otherwise guarded for practical reasons.Manual 38-8108 210CIssued 3/99E 1999 Nordson CorporationAll rights reserved
Versa-Sprayr IPS Demonstration UnitFire Safety3To avoid a fire or explosion, follow these instructions.S Ground all conductive equipment in the spray area. Checkequipment and workpiece grounding devices regularly. Resistance toground must not exceed one megohm.S Shut down all equipment immediately if you notice static sparking orarcing. Do not restart the equipment until the cause has beenidentified and corrected.S Do not smoke, weld, grind, or use open flames where flammablematerials are being used or stored.S Provide adequate ventilation to prevent dangerous concentrations ofvolatile materials or vapors. Refer to local codes or your materialMSDS for guidance.S Do not disconnect live electrical circuits while working with flammablematerials. Shut off power at a disconnect switch first to preventsparking.S Know where emergency stop buttons, shutoff valves, and fireextinguishers are located. If a fire starts in a spray booth,immediately shut off the spray system and exhaust fans.S Shut off electrostatic power and ground the charging system beforeadjusting, cleaning, or repairing electrostatic equipment.S Clean, maintain, test, and repair equipment according to theinstructions in your equipment documentation.S Use only replacement parts that are designed for use with originalequipment. Contact your Nordson representative for partsinformation and advice.E 1999 Nordson CorporationAll rights reserved108 210CIssued 3/99Manual 38-8
4Versa-Sprayr IPS Demonstration UnitAction in the Event of aMalfunctionIf a system or any equipment in a system malfunctions, shut off thesystem immediately and perform the following steps:S Disconnect and lock out electrical power. Close pneumatic shutoffvalves and relieve pressures.S Identify the reason for the malfunction and correct it before restartingthe equipment.DisposalDispose of equipment and materials used in operation and servicingaccording to local codes.2. DescriptionSee Figure 1. The Versa-Spray IPS demo unit is a portable,self-contained unit used for electrostatic powder coating demonstrations.It can be set up and operating in minutes. All components necessary tospray powder are included. External connections are provided forelectrical power and compressed air.3808001AFig. 1 Versa-Spray IPS Demonstration UnitManual 38-8108 210CIssued 3/99E 1999 Nordson CorporationAll rights reserved
Versa-Sprayr IPS Demonstration UnitComponents5Components of the sytem includeS Case with removable hinged lidS Control panel mounted in caseS Versa-Spray Integral Power Supply (IPS) manual spray gun withconical nozzle and 4 meter power/control cableS Flat spray nozzle kitS Miniature powder feed hopper with 3.9 lb capacity, pump mounting,and pickup tubeS 100 Plus low-flow powder feed pumpS Low-flow powder feed tubing (10 ft)S High-flow powder feed tubing (6 ft) for venting hopper into boothS1/ -in.4flow rate, atomizing, and fluidizing polyurethane air tubingS3/ -in.8air inlet tubing with 3/8-in. tube by 1/4-in. NPT fittingS Hopper and control panel ground cablesS Power cordRequirementsAir: 7 bar (100 psi) maximum, 4 bar (60 psi) minimum.Use prefilters and coalescent type filters with automatic drains, and arefrigerated or regenerative desiccant air dryer capable of producing adewpoint of 3.4 C (38 F) at 7 bar (100 psi).Power: 100, 120, 230, 240 Vac, single phase, 50–60 Hz.E 1999 Nordson CorporationAll rights reserved108 210CIssued 3/99Manual 38-8
6Versa-Spray IPS Demonstration UnitWARNING: Allow only qualified personnel to perform thefollowing tasks. Observe and follow the safety instructions inthis document and all other related documentation.3. SetupSee Figure 2 for control panel symbols and Figure 3 for the location ofthe control panel fittings and connections.NOTE: The case must remain outside the Class II, Division 2 zone whileconnected to electrical power.41526373808002AFig. 2 Control Panel Symbols1.2.3.4.Manual 38-8GroundFluidizing airFlow-rate airAtomizing air108 210CIssued 3/995. High voltage6. Off7. On1999 Nordson CorporationAll rights reserved
Versa-Spray IPS Demonstration Unit71. Open the case and remove the hopper, power cord, 3/8-in. blue inputair tubing, 1/4-in. black poly tubing (marked F), and ground cable.2. Remove the hopper lid. Remove the powder feed tubing, 1/4-in. bluepoly tubing (two 10 ft pieces, marked H and A), suction tube, andground cable.3. Fasten the ground cable ring terminal to the control panel groundstud. Clamp the cable to a true earth ground (cold water pipe orgrounded booth).4. Connect the blue 1/4-in. tubing (marked H) to the fluidizing air quickdisconnect fitting on the control panel. Connect the other end of thetubing to the quick disconnect fitting on the side of the hopper.7 BAR (100 PSI) MAXPOWERINPUT120/240 VAC50/60 HZ, 1 1 AMPGUNOUTPUTVERSA-SPRAY3808003AFig. 3 Control Panel1999 Nordson CorporationAll rights reserved108 210CIssued 3/99Manual 38-8
8Versa-Spray IPS Demonstration Unit3. Setup (contd.)5. Connect the input air tubing to the quick disconnect connector in thecenter of the control panel. Use the 1/4-in. NPT by 3/8-in. tube fittingto connect the tubing to the compressed air supply.6. Plug the power cord into the control panel. Secure the cord to theconnector with the cord nut.NOTE: The factory default power setting is 120 Vac, 60 Hz. Refer toFigure 5 for circuit board switch settings, if using a different powersupply.7. Screw the pickup tube into the pump mount from the underside of thehopper lid. Install the lid on the hopper. Secure the lid with the knob.8. Remove the case lid by sliding it to the left, off the hinge pins.Remove the inner lid and take out the handgun and cable assembly,spiral cut tubing, and low-flow powder pump.9. See Figure 4. Unwind the gun cable. Plug the cable into the gunoutput receptacle on the control panel. Secure the cable to thereceptacle with the cable nut.10. Remove the red cap from the powder inlet connector. Remove theconnector and replace it with the low-flow connector from the kit.1233808004AFig. 4 Powder Gun Installation1. Nozzle2. Inlet connectorManual 38-8108 210CIssued 3/993. Cable1999 Nordson CorporationAll rights reserved
Versa-Spray IPS Demonstration Unit911. Install the pump on the pump mounting on the hopper lid.NOTE: The pump mounting O-rings are electrically conductive toprovide a ground between the pump body and the hopper. Do notreplace them with non-conductive O-rings.12. Connect the low-flow powder feed tubing to the pump outlet and theinlet connector on the gun.13. Connect the black 1/4-in. air tubing to the quick disconnect fitting onthe control panel marked F and to the powder pump fitting marked F.Connect the blue 1/4-in. air tubing to the quick disconnect fitting onthe control panel and to the pump fitting marked A.14. Remove the red cap from the gun nozzle. The conical nozzle can bereplaced with the flat spray nozzle, if desired.15. Connect the 1.2-m (4-ft) length of high flow powder feed tubing to thehopper vent connection. Route the end of the tubing inside the booth,or connect it to a vent stub.16. Plug the power cord into an appropriate power receptacle.17. Turn the pressure regulator knobs counterclockwise to zero pressure.Pull up on the knobs to unlock, push down to lock. Supply air to theunit.4. OperationWARNING: Allow only qualified personnel to perform thefollowing tasks. Observe and follow the safety instructions inthis document and all other related documentation.WARNING: Before turning on the electrostatic voltage, makesure all conductive objects in the spray area are grounded.Electrical sparks discharged from ungrounded conductiveobjects may start fires or cause explosions.WARNING: Breathing airborne dusts, including finishingpowders, can be hazardous to your health. Use appropriaterespiratory protection.NOTE: The case must remain outside the Class II, Division 2 zone whileconnected to electrical power.1. Fill the hopper half full of clean, dry, powder. Do not overfill. Thepowder will expand to fill the hopper when fluidizing air is turned on.1999 Nordson CorporationAll rights reserved108 210CIssued 3/99Manual 38-8
10Versa-Spray IPS Demonstration Unit4. Operation (contd.)2. Adjust the fluidizing air pressure to 0.35–0.55 bar (5–8 psi). Allowpowder to fluidize for a few minutes, then remove the hopper lid andmake sure that the powder is properly fluidized before beginning tospray. The surface should be boiling slightly, and there should be noclumps of powder in the hopper. The hopper has a restrictor, locatedafter the fluidzing air connector, that allows the gauge to give areading at this low pressure.3. Turn on the control panel power switch. The power, kV, and air LEDswill light.4. Turn the kV potentiometer switch on and adjust it to 80 kV. Thedisplay normally shows kV output. Pressing the kV/uA switch willchange the readout to microamps.5. Adjust the flow-rate and atomizing air pressure to 2.7 bar (40 psi).6. Make sure the booth exhaust fan is on.7. Aim the gun into the booth and press the trigger. While coating aworkpiece, adjust the flow rate and the atomizing air pressures andkV until you obtain the desired results.Operating NotesPowder coating performance is affected by a number of variables. Usethe following suggestions to tune your system.MicroAmpere ReadingThe microampere (µA) reading will fluctuate as work pieces go by thegun tip. The closer a work piece is to the gun tip, the greater will be theµA reading. µA readings are affected by gun tip-to-workpiece distance,geometry of the workpiece, and powder flow rates.Record the µA reading when you first put the unit into service. Monitorthe µA readings periodically. If the µA output increases significantly,check the resistance of your gun resistor with an ohmmeter.Electrostatic Powder Coating VariablesVoltage: As the electrostatic voltage is lowered the deposition rate willdecrease. Use lower voltages to coat recessed areas. Increasing thevoltage will increase the deposition rate up to a point, after which theelectrostatic charge on the powder already deposited will tend to repelany additional powder.Manual 38-8108 210CIssued 3/991999 Nordson CorporationAll rights reserved
Versa-Spray IPS Demonstration Unit11Flow-Rate Air Pressure: Increasing the flow-rate air pressure willincrease the powder velocity and deposition rate. Increasing the velocitymay help in coating recessed areas by partially defeating the electrostaticattraction of the powder to projections around the recess (called theFaraday Cage Effect). However, high flow-rate air pressure can cause aloss of wrap, a decrease in powder economy, and increased wear ofpowder contact parts.Atomizing Air Pressure: Increasing atomizing air pressure willdecrease the density of the powder cloud and lower deposition rates.Decreasing the pressure will increase the powder-to-air ratio, providingbetter coverage. Too low a pressure can result in powder clogging thepump venturi throat or gun passages. Too high a pressure can causerapid wear of powder contact parts.5. MaintenanceWARNING: Allow only qualified personnel to perform thefollowing tasks. Observe and follow the safety instructions inthis document and all other related documentation.NOTE: When cleaning parts that come in contact with powder, do notuse any tools that may scratch the part surfaces. Powder will build up onscratches and cause impact fusion.1. Empty the hopper and blow it out with compressed air. Vacuum outany remaining powder. Clean the hopper with a clean dry cloth.2. Disconnect the powder feed tubing from the gun and pump. Placethe end of the tubing into the booth. Make sure the exhaust fans areon. Blow out the tubing with compressed air.NOTE: Do not blow out the feed tubing while it is connected to thepump. Blowing powder backwards into the pump will clog atomizingair passageways and the valves in the control panel.3. Disassemble the gun’s powder path. Clean the parts withcompressed air, then wipe them clean with a soft dry cloth. Ifnecessary, use a cloth dampened with isoprophyl alcohol. Do notsoak the gun parts in alcohol or use any other solvents to clean them.Replace any worn or damaged parts.4. Remove the pump from the hopper lid. Clean the hopper lid.Disassemble the pump and clean the parts with compressed air and aclean dry cloth. Replace any worn or damaged parts.1999 Nordson CorporationAll rights reserved108 210CIssued 3/99Manual 38-8
12Versa-Spray IPS Demonstration UnitWARNING: Allow only qualified personnel to perform thefollowing tasks. Observe and follow the safety instructions inthis document and all other related documentation.6. TroubleshootingAny fault may have a number of reasons for occurring. Check allpossible causes for any given fault. Obvious causes of malfunction suchas broken wires, or missing fasteners should be corrected immediately.The letter/number designations (S1, U3 etc.) given in the troubleshootingprocedures refer to components
See Figure 1. The Versa-Spray IPS demo unit is a portable, self-contained unit used for electrostatic powder coating demonstrations. It can be set up and operating in minutes. All components necessary to spray powder are included. External connections are provided for electrical power and compressed air. 3808001A Fig. 1 Versa-Spray IPS .
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