Nordson XPS 60 Power Supply Owner's manual

XPS 60 Power Supply

Customer Product Manual

Document Number 1606291-04

Issued 04/23

For parts and technical support, call the Industrial Coating

Systems Customer Support Center at (800) 433-9319 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

1606291-04

Contact Us

Nordson Corporation welcomes requests for information, comments, and inqui-

ries 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 2015. 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

Iso-Flo, Trilogy, Nordson, and the Nordson logo are registered trademarks of

Nordson Corporation. All other trademarks are the property of their respective

owners.

i

Table of Contents

Safety ............................................................................................................................................. 1-1

Introduction ................................................................................................................................... 1-1

Qualied Personnel ...................................................................................................................... 1-1

Intended Use ................................................................................................................................ 1-1

Regulations and Approvals ........................................................................................................... 1-1

Personal Safety ............................................................................................................................ 1-2

High-Pressure Fluids ................................................................................................................... 1-3

Fire Safety .................................................................................................................................... 1-4

Halogenated Hydrocarbon Solvent Hazards ............................................................................... 1-4

Action in the Event of a Malfunction ............................................................................................. 1-5

Disposal ........................................................................................................................................ 1-5

Special Conditions for Safe Use .................................................................................................... 3-2

Safety Labels ................................................................................................................................ 3-2

System Diagram ............................................................................................................................ 4-1

Mounting the Power Supply ........................................................................................................... 4-2

AC Power Connections .................................................................................................................. 4-4

Relay Terminals ............................................................................................................................. 4-5

Installing Interlock Relay ................................................................................................................ 4-5

Relay Connections ......................................................................................................................... 4-6

Digital Inputs and Outputs ............................................................................................................. 4-6

Digital Inputs and Outputs (contd) ................................................................................................. 4-8

Trigger Signal ................................................................................................................................ 4-9

Analog Inputs and Outputs .......................................................................................................... 4-10

Analog Inputs and Outputs (contd) .............................................................................................. 4-12

Installing the Electrostatic Cable.................................................................................................. 4-13

Operation ....................................................................................................................................... 5-1

Controller Interface ........................................................................................................................ 5-1

Startup ........................................................................................................................................... 5-2

Displays and LEDs ........................................................................................................................ 5-2

Menu .............................................................................................................................................. 5-2

Menu Functions ............................................................................................................................. 5-3

STD and AFC Mode ....................................................................................................................... 5-4

STD Mode .................................................................................................................................... 5-4

AFC Mode .................................................................................................................................... 5-4

Custom Mode ................................................................................................................................ 5-5

Remote Mode ................................................................................................................................ 5-5

Faults ............................................................................................................................................. 5-6

Troubleshooting ............................................................................................................................ 6-1

Troubleshooting Electrical Problems ............................................................................................. 6-1

Common Problems ........................................................................................................................ 6-2

Repair ............................................................................................................................................. 7-1

Disassembling the Power Supply .................................................................................................. 7-1

Disassembling the Power Supply (contd) ...................................................................................... 7-2

Removing the Multiplier ................................................................................................................. 7-3

Installing the Multiplier Assembly ................................................................................................... 7-4

Replacing the PCA......................................................................................................................... 7-5

Replacing the Keypad.................................................................................................................... 7-6

Assembling the Power Supply ....................................................................................................... 7-7

Multiplier Calibration Procedure..................................................................................................... 7-8

Parts ............................................................................................................................................... 8-1

Introduction .................................................................................................................................... 8-1

XPS 60 Power Supply ................................................................................................................... 8-1

Wiring Diagrams ........................................................................................................................... 9-1

Appendix ...................................................................................................................................... 10-1

1606291-04

ii Table of Contents

i

Change Record

Revision Date Change

01 10/15 Initial Release

02 07/16 Added approval labels. Updated cable cleaning instructions and Appendix.

03 07/19 Updated approval labels.

04 04/23 Updated safety data and added UK compliance.

1606291-04

ii Change Record

1-1

Safety

Section 1

Safety

Introduction

Read and follow these safety instructions. Task- and equipment-specic 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.

Qualied Personnel

Equipment owners are responsible for making sure that Nordson equipment is installed,

operated, and serviced by qualied personnel. Qualied 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 modications

• 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.

1606291-04

1-2 Safety

Personal Safety

To prevent injury follow these instructions.

• Do not operate or service equipment unless you are qualied.

• 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 moving equipment,

shut o 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 o) hydraulic and pneumatic pressure before adjusting or servicing

pressurized systems or components. Disconnect, lock out, and tag switches before

servicing electrical equipment.

• While 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.

• If 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

identied and corrected.

• Obtain and read 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.

• Make sure the spray area is adequately ventilated. 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.

1-3

Safety

High-Pressure Fluids

High-pressure uids, unless they are safely contained, are extremely hazardous. Always

relieve uid pressure before adjusting or servicing high pressure equipment. A jet of

high-pressure uid can cut like a knife and cause serious bodily injury, amputation, or

death. Fluids penetrating the skin can also cause toxic poisoning.

If you suer a uid injection injury, seek medical care immediately. If possible, provide a

copy of the SDS for the injected uid 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:

• Go to an emergency room immediately.

• Tell the doctor that you suspect an injection injury.

• Show them this card

• Tell them what kind of material you were spraying

MEDICAL ALERT — AIRLESS SPRAY 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 deected causing more damage, and many

other variables including skin microora 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 ourish. 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 debridement, and immediate antibiotic

treatment.

1606291-04

1-4 Safety

Fire Safety

To avoid a re or explosion, follow these instructions.

• Ground all conductive equipment. Use only grounded air and uid 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 identied and corrected.

• Do not smoke, weld, grind, or use open ames where ammable 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 ammable materials. Shut

o power at a disconnect switch rst to prevent sparking.

• Know where emergency stop buttons, shuto valves, and re extinguishers are

located. If a re starts in a spray booth, immediately shut o the spray system and

exhaust fans.

• Shut o electrostatic 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.

Halogenated Hydrocarbon Solvent Hazards

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 Prex

Fluorine F “Fluoro-”

Chlorine Cl “Chloro-”

Bromine Br “Bromo-”

Iodine I “Iodo-”

Check your material SDS 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.

1-5

Safety

Action in the Event of a Malfunction

If a system or any equipment in a system malfunctions, shut o the system immediately

and perform the following steps:

• Disconnect and lock out system electrical power. Close hydraulic and pneumatic

shuto valves 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.

2-1

Description

Section 2

Description

The XPS 60 power supply is a regulated electrostatic power supply designed for use

with air or airless electrostatic spray equipment and with Iso-Flo® systems. The XPS 60

produces a maximum variable output voltage of 60 kV for the application of waterborne

paints. The power supply is used with the following:

• Trilogy® manual waterborne low pressure air spray/HVLP applicators

• Trilogy automatic waterborne applicators

The XPS 60 oers the following design features:

• Variable output voltage at low amperage, which allows a safe but highly ecient eld

of attraction between the coating material and the workpiece

• Digital displays for monitoring kV and μA setpoints and output

• LEDs to help you troubleshoot digital inputs

• Programmable logic control (PLC) compatible inputs are available for some functions

• Standard, AFC, and custom electrostatic modes

• Analog inputs and outputs for closed loop control on the y

See Figure 2-1 for a list of main components.

1606291-04

2-2 Description

1

2

3

5

4

6

7

8

9

13

12

11

10

Top View

10013878/10013978

Figure 2-1 XPS 60 Power Supply Main Component

1. Keypad/Display

2. Bezel

3. Power switch (see note A)

4. HC cable well

5. PCA

6. Ribbon cable

7. Upper terminal block assembly

8. PCA to multiplier cable

9. Multiplier

10. Lower terminal block assembly

11. Enclosure earth ground

12. AC line in

13. Analog/digital signal in (see note B)

NOTE: A. The power switch (3) is for 24 Vdc to the PCA (5) only.

B. Item 13 is part of a ship with kit, and requires eld installation.

2-3

Description

3-1

Specications

Section 3

Specications

Model: XPS 60

Ambient temperature rating 0° to +40° C (32° to +104° F)

Dust ingress protection Constructed to meet IP54

Input current protection fuse 2A-1/4 W

Input voltage 100-240 Vac, 50/60 Hz, 1 phase 65 VA max

Maximum relative humidity 95% non-condensing

Output current (short circuit) 100 μA

Output voltage 60 kV max

Weight 27.1 lb (12.3 kg)

1606291-04

3-2 Specications

Special Conditions for Safe Use

The installation, operation, maintenance, and repair of the system equipment shall be in

accordance with the safety Instructions and user’s manual supplied by the manufacturer.

The power supply/control unit type XPS 60 and the Iso-Flo unit shall be installed only in a

safe area.

Safety Labels

Figure 3-1 contains the text of the safety label on this equipment. The safety label is

provided to help you operate and maintain your equipment safely. See Figure 3-2 for the

location of safety labels.

Table 3-1 Safety Labels

Item Part Description

1. 242867 WARNING: Electrical discharge can be dangerous. Turn o this unit. Ground gun electrode and

remove gun from spray area before performing any servicing or cleaning.

2. 140475

WARNING: 

• This unit is factory set for 240 Vac. For use with 120 Vac, see manual

• Refer to the Installation section to change the voltage interlock relay.

3. 229901

WARNING: Do not locate this unit in an area classied as hazardous. Install, operate, and

service in accordance with all applicable safety codes and Nordson instruction manual.

NOTE: If you have questions concerning this electrostatic spray equipment, call (440) 985-4000, and

ask to speak with the Liquid Systems Group Technical Service Department.

Nordson Corporation, Amherst, OH, 44001, U.S.A.

1609470

Figure 3-1 XPS 60 EU Approval Label

3-3

Specications

10013878/10013978

2

3

1

Top View

Figure 3-2 Safety Labels

1606291-04

3-4 Specications

170.0 mm

(6.69 in.)

Ø7.9mm

(0.313 in.)

374.7 mm

(14.75 in.)

254.0 mm

(10.0 in.)

336.0 mm

(13.23 in.)

32.0 mm

(1.26 in.)

10013878

Weight: 27.1 lb (12.3 kg)

Figure 3-3 XPS Power Supply Dimensions and Weight

1606291-04

4-1 Installation

Section 4

Installation

WARNING: Allow only qualied personnel to perform the following tasks. Follow the

safety instructions in this document and all other related documentation.

System Diagram

Fluid Tubing To Coating

Material Supply

High Voltage Cable 8m

1092080

Figure 4-1 XPS Power Supply with Dispense Applicator and Iso-Flo HD

1606291-04

4-2 Installation

Mounting the Power Supply

WARNING: This equipment can be dangerous unless it is used in accordance with the

rules laid down in this manual.

WARNING: Electrical discharge can be dangerous. Do not install the power supply in an

area classied as hazardous (refer to NFPA-33 publication or local regulations as

applicable for specications). Ground the electrostatic power supply, all sprayed objects,

uid containers, and other electrically conductive objects located within 6 meters (19.7 ft)

of the spray area. Keep spray area, conveyors, and hangers clean.

CAUTION: Do not install the power supply on a reciprocator or in an area where

excessive vibration occurs.

Mount the power supply in an accessible area for ease of operation and maintenance.

See Figure 4-2 for mounting dimensions.

Perform the following steps to mount the power supply:

1. To install the unit near the spray booth, allow at least a 1.5 m (5 ft) radius outside the

booth opening area.

2. Observe the mounting dimensions for the power supply.

3. Loosen the two screws (2) and remove the latches (3) from the front door, and then

open the door.

4. See Wiring Diagrams section to make wiring connections.

5. Secure the power supply to the installation site using the four mounting holes (1).

NOTE: Mounting hardware is supplied by customer.

6. Close the front door and secure it with the two screws and latches.

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Nordson XPS 60 Power Supply Owner's manual

Nordson XPS 60 Power Supply Owner's manual

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