1084167 IPS-20 Manual Electrostatic System Controller · KVKV uAA KV AFCAFC AFCAFC KVKV 3 7 2 4 6 1 5 IPS − 20 Electrostatic System Controller Figure 1 Front Panel. IPS-20 Manual

IPS-20 Manual ElectrostaticSystem Controller

Customer Product ManualPart 1084167-03

Issued 6/19

NORDSON CORPORATION • AMHERST, OHIO • USA

This document is subject to change without notice.

CAPPROVED

USFM

Check http://emanuals.nordson.com for the latest version.

For parts and technical support, call theIndustrial Coating Systems Customer Support Center at (800) 433-9319

Part 1084167-03 � 2019 Nordson Corporation

Table of ContentsSafety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Qualified Personnel 1. . . . . . . . . . . . . . . . . . . . . . . . .Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regulations and Approvals 1. . . . . . . . . . . . . . . . . .Personal Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

High-Pressure Fluids 2. . . . . . . . . . . . . . . . . . . . .Fire Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Halogenated Hydrocarbon Solvent Hazards 4.Action in the Event of a Malfunction 4. . . . . . . . . . .Disposal 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Supply Quality 5. . . . . . . . . . . . . . . . . . . . . . .Control Modes 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Front Panel Controls 6. . . . . . . . . . . . . . . . . . . . . . . .Rear Panel Connections 7. . . . . . . . . . . . . . . . . . . . .Symbols 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Connections 9. . . . . . . . . . . . . . . . . . . . . .Atomizing Air Connection to Manual Spray Gun 9Gun Type Configuration 10. . . . . . . . . . . . . . . . . . . . .

Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Recording Current Output on Initial Startup 11. . . .Startup 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrostatic Voltage 12. . . . . . . . . . . . . . . . . . . . . .

Shutdown 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Chart 14. . . . . . . . . . . . . . . . . . . . . .Circuit Board Jumper Settings 16. . . . . . . . . . . . . . .Wiring Diagram 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Circuit Board and Power Supply Replacement 18.Air Flow Switch Replacement 18. . . . . . . . . . . . . . . .

Parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contact UsNordson Corporation welcomes requests for information, comments, andinquiries about its products. General information about Nordson can befound on the Internet using the following address:http://www.nordson.com.Address all correspondence to:

Nordson CorporationAttn: Customer Service555 Jackson StreetAmherst, OH 44001

NoticeThis is a Nordson Corporation publication which is protected by copyright.Original copyright date 2008. No part of this document may bephotocopied, reproduced, or translated to another language without theprior written consent of Nordson Corporation. The information containedin this publication is subject to change without notice.

Trademarks

Kinetix, Nordson, and the Nordson logo are registered trademarks ofNordson Corporation.

IPS-20 Manual Electrostatic System Controller 1

Part 1084167-03� 2019 Nordson Corporation

IPS-20 Manual Electrostatic SystemController

Safety Read 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 persons operating or servicing equipment.

Qualified Personnel Equipment owners are responsible for making sure that Nordson equipmentis installed, operated, and serviced by qualified personnel. Qualifiedpersonnel are those employees or contractors who are trained to safelyperform their assigned tasks. They are familiar with all relevant safety rulesand regulations and are physically capable of performing their assignedtasks.

Intended Use Use of Nordson equipment in ways other than those described in thedocumentation supplied with the equipment may result in injury to personsor 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 whichit is used. Any approvals obtained for Nordson equipment will be voided ifinstructions for installation, operation, and service are not followed.

IPS-20 Manual Electrostatic System Controller2


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 areintact and automatic interlocks are operating properly. Do not bypass ordisarm any safety devices.

� Keep clear of moving equipment. Before adjusting or servicing movingequipment, shut off the power supply and wait until the equipmentcomes to a complete stop. Lock out power and secure the equipment toprevent unexpected movement.

� Relieve (bleed off) hydraulic and pneumatic pressure before adjusting orservicing 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 tothe gun handle or other true earth ground. Do not wear or carry metallicobjects such as jewelry or tools.

� If you receive even a slight electrical shock, shut down all electrical orelectrostatic equipment immediately. Do not restart the equipment untilthe problem has been identified and corrected.

� Obtain and read Material Safety Data Sheets (MSDS) for all materialsused. Follow the manufacturer’s instructions for safe handling and useof 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 workplacethat often cannot be completely eliminated, such as hot surfaces, sharpedges, energized electrical circuits, and moving parts that cannot beenclosed or otherwise guarded for practical reasons.

High-Pressure Fluids High-pressure fluids, unless they are safely contained, are extremelyhazardous. Always relieve fluid pressure before adjusting or servicing highpressure equipment. A jet of high-pressure fluid can cut like a knife andcause serious bodily injury, amputation, or death. Fluids penetrating theskin can also cause toxic poisoning.

If you suffer a fluid injection injury, seek medical care immediately. Ifpossible, provide a copy of the MSDS for the injected fluid to the health careprovider.



The National Spray Equipment Manufacturers Association has created awallet card that you should carry when you are operating high-pressurespray equipment. These cards are supplied with your equipment. Thefollowing is the text of this card:

WARNING: Any injury caused by high pressure liquid can be serious. Ifyou 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 theinjury surgically as soon as possible. Do not delay treatment to researchtoxicity. Toxicity is a concern with some exotic coatings injected directly intothe bloodstream.

Consultation with a plastic surgeon or a reconstructive hand surgeon maybe advisable.

The seriousness of the wound depends on where the injury is on the body,whether the substance hit something on its way in and deflected causingmore damage, and many other variables including skin microflora residingin the paint or gun which are blasted into the wound. If the injected paintcontains acrylic latex and titanium dioxide that damage the tissue’sresistance to infection, bacterial growth will flourish. The treatment thatdoctors recommend for an injection injury to the hand includes immediatedecompression of the closed vascular compartments of the hand to releasethe underlying tissue distended by the injected paint, judicious wounddebridement, and immediate antibiotic treatment.

Fire Safety To avoid a fire or explosion, follow these instructions.

� Ground all conductive equipment. Use only grounded air and fluidhoses. 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 orarcing. Do not restart the equipment until the cause has been identifiedand corrected.

� Do not smoke, weld, grind, or use open flames where flammablematerials are being used or stored.

� Do not heat materials to temperatures above those recommended bythe manufacturer. Make sure heat monitoring and limiting devices areworking properly.



Fire Safety (contd)

� Provide adequate ventilation to prevent dangerous concentrations ofvolatile particles or vapors. Refer to local codes or your material MSDSfor guidance.

� Do not disconnect live electrical circuits when working with flammablematerials. Shut off power at a disconnect switch first to preventsparking.

� Know where emergency stop buttons, shutoff valves, and fireextinguishers are located. If a fire starts in a spray booth, immediatelyshut off the spray system and exhaust fans.

� Shut off electrostatic power and ground the charging system beforeadjusting, cleaning, or repairing electrostatic equipment.

� Clean, maintain, test, and repair equipment according to the instructionsin your equipment documentation.

� Use only replacement parts that are designed for use with originalequipment. Contact your Nordson representative for parts informationand advice.

Halogenated Hydrocarbon Solvent Hazards Do not use halogenated hydrocarbon solvents in a pressurized system thatcontains aluminum components. Under pressure, these solvents can reactwith aluminum and explode, causing injury, death, or property damage.Halogenated hydrocarbon solvents contain one or more of the followingelements:

Element Symbol Prefix

Fluorine F “Fluoro-”

Chlorine Cl “Chloro-”

Bromine Br “Bromo-”

Iodine I “Iodo-”

Check your material MSDS or contact your material supplier for moreinformation. If you must use halogenated hydrocarbon solvents, contactyour Nordson representative for information about compatible Nordsoncomponents.

Action in the Event of a Malfunction If a system or any equipment in a system malfunctions, shut off the systemimmediately and perform the following steps:

� Disconnect and lock out system electrical power. Close hydraulic andpneumatic shutoff valves and relieve pressures.

� Identify the reason for the malfunction and correct it before restarting thesystem.

Disposal Dispose of equipment and materials used in operation and servicingaccording to local codes.



Description The IPS-20 manual electrostatic system spray gun controller provideselectrostatic control, dc power, and monitoring functions for manual liquidspray guns.

The controller provides low-voltage dc to the spray gun voltage multiplier.The air flow switch in the controller turns on the voltage output to the spraygun multiplier when the spray gun is triggered. The multiplier then producesthe electrostatic voltage used to charge the paint as it is sprayed.

Specifications Enclosure Meets IP54 requirements

Electrical

Input 85−250 Vac at 50−60 Hz, 40 VA

Output 7−21 Vdc

Short circuit output current 500 mA

Pneumatic

Minimum input pressure 0.7 bar (10 psi)

Maximum input pressure 6.9 bar (100 psi)

ISA S82.1 Pollution Degree 2Over Voltage Category 2

Air Supply Quality Air must be clean and dry. Use a regenerative desiccant or refrigerated airdryer capable of producing 3.4 �C (38 �F) or lower dew point at 6.9 bar (100psi) and a filter system with prefilters and coalescent type filters, capable ofremoving oil, water and dirt in the submicron range.

Control Modes Push buttons on the controller’s front panel allow the operator to choosebetween two different control modes and to set output levels.

� In the kV mode, voltage output is controlled by the + and − keys.

� In the Automatic Feedback Current (AFC) mode, maximum currentoutput is controlled by the + and − keys. The AFC mode also providesoptimum kV output and electric field strength for coating parts withinterior corners and deep recesses at close range or recoating coatedand cured parts.



Front Panel Controls

Table 1 Front Panel

Item Description Function

1 Power Switch Turns on or off power to the control unit.

2 kV / μA Display Indicators Indicate which unit of measure (kV or μA) is currentlybeing displayed on the digital display.

3 Digital Display Display depends on current operating state:

When Control Unit Is Powered On: Momentarilydisplays the last saved kV or μA set point.

When Gun Is Not Triggered: Displays − − −.

When Gun Is Triggered: Displays the actual kV or μAoutput of the spray gun.

4 Setpoint Adjust Keys Increase or decrease the kV or μA set point.

5 kV / AFC Mode Indicators Indicate the currently selected operating mode.

6 kV / AFC Mode Key Toggles the operating mode between kV and AFC.

7 View Key Switches the unit of measure (kV or μA) being displayedon the digital display

KVKV uuAA

KVKVAFCAFC

AFCAFC

KVKV

3

7

2 4

6

51

IPS − 20Electrostatic System Controller

Figure 1 Front Panel



Rear Panel Connections

Table 2 Rear Panel

Item Description Function

1 2 Amp, 250 Vac Fuses Protect the control unit from electrical surges

2 POWER INPUT Cable Connects the system to an AC power source

3 GUN OUTPUT Receptacle Connects the spray gun to the control unit

4 Air Out Connection Atomizing air supply OUT from flow switch, 1/4 in. NPT

5 Air In Connection Atomizing air supply IN to flow switch, 1/4 in. NPT

6 Ground Stud Connects the control unit to a true earth ground

NORDSON CORPORATION, AMHERST, OHIO

PART NO. XXXXXXXY

SERIAL NO. XXYYX00000

MODEL

OUTPUT INPUT

250VACF2 2A

250VACF1 2A

Non−Hazardous AreaSeparate only in a

WARNING

GUN POWER

1

63

2

AIRIN OUT

5 4

Figure 2 Controller Rear Panel

SymbolsThese symbols are used on the front and rear panels.

ON VIEW GROUNDOFF MODE

KV

AFC

Figure 3 Symbols



Installation WARNING: Allow only qualified personnel to perform the following tasks.Follow the safety instructions in this document and all other relateddocumentation.

MountingSee Figure 4. Two M6 x .5 threaded inserts are available on each side ofthe cabinet for mounting with the optional mounting bracket kit. In addition,four M6 x .5 threaded inserts are available on the top of the cabinet.

The optional mounting bracket kit allows the controller to be mounted on ashelf or wall. The kit includes two threaded knobs. Use the front threadedholes on the side of the cabinet if the bracket is oriented under the cabinet.

Use the rear threaded holes on the side of the cabinet if the bracket isoriented to the rear of the cabinet, as it would be for a wall-mount. Thisprovides clearance for the gun cable and air tubing bend radius.

124.5 mm(4.90 in.)

63.5 mm(2.50 in.)

25.4 mm(1.0 in.)

190 mm(7.48 in.)

180 mm(7.087 in.)

(331 mm(13.03 in.)

255 mm(10.04 in.)

Side-MountHoles

(M6 x .5)Top-Mount Holes

(M6 x .5)

Shelf Mount Wall Mount

Knobs in FrontSide-Mount Holes Bracket Bracket

Knobs in RearSide-Mount Holes

131 mm(5.16 in.)

Optional Mounting Bracket Kit

Dimensions

Figure 4 Controller Mounting



Electrical Connections

WARNING: Install a locking disconnect switch or breaker in the service lineahead of the controller so power can be shut off during installation or repair.

CAUTION: Equipment damage may occur if the control unit is connected toany line voltage other than that stated on the I.D. plate.

Input voltage must be 85−250 Vac nominal, 1 ∅, 50−60 Hz.

1. Connect the unterminated end of the POWER INPUT cord (1) to apower supply according to the following table:

Function Wire Color

L (L1-hot) Brown

N (L2-neutral) Blue

PE (Ground) Green/Yellow

2. Connect the ground strap furnished with the controller to the cabinetground stud (3). Secure the clamp to a true earth ground.

WARNING: All electrically conductive equipment in the spray area must begrounded. Ungrounded or poorly grounded equipment can store anelectrostatic charge which can give personnel a severe shock, or arc andcause a fire or explosion.

3. Connect the spray gun cable to the GUN OUTPUT receptacle (2).

OUTPUT INPUT

250VACF2 2A

250VACF1 2A

Non−Hazardous AreaSeparate only in a

WARNING

GUN POWER

32

1

AIRIN OUT

5 4

Figure 5 Control Unit Rear Panel

1. Power cord2. Gun cable receptacle

3. Cabinet ground stud4. Atomizing air outlet

5. Supply air input

Atomizing Air Connection to Manual Spray Gun Connect a supply of clean, dry air to the IN port on the controller. Connect agrounded air hose from the OUT port on the controller to the spray gun.Both ports are 1/4 in. NPT.



Gun Type Configuration Use this procedure to set the type of spray gun connected to the controller.This only needs to be done when the controller is first installed or the circuitboard is replaced.

1. See Figure 6. Make sure that the power switch (1) is in the off position.

2. While holding down the kV/AFC key (4), turn the power switch to the ONposition. A code will appear, identifying the currently selected gun type.

3. Use the +/− keys (3) to select the appropriate gun type code:

Spray Gun Code

Not Used on this system

C-1

C-2

C-3

C-4

Kinetix automatic and manual spray guns C-5

Not Used on this system

C-6

C-7

C-8

4. Press the kV/AFC key to save the gun type and begin operation.

KVKV uuAA

KVKVAFCAFC

AFC

KV

321

5 43

Figure 6 Controller Operation

1. Power switch2. Digital display3. +/− Keys

4. KV/AFC Mode Key5. View key



Operation WARNING: Allow only qualified personnel to perform the following tasks.Follow the safety instructions in this document and all other relateddocumentation.

WARNING: This equipment can be dangerous unless it is used inaccordance with the rules laid down in this manual.

WARNING: All electrically conductive equipment in the spray area must begrounded. Ungrounded or poorly grounded equipment can store anelectrostatic charge which can give personnel a severe shock, or arc andcause a fire or explosion.

Before operating a Nordson liquid spray system, read the systemcomponent manuals and familiarize yourself with the functions andoperation of each component. A thorough understanding of systemoperation will help you obtain desired results and diagnose problems.

Recording Current Output on Initial Startup When a spray gun is first put into service, set the mode switch to kV. Setthe kV to the maximum setting and trigger the spray gun. Press the Viewbutton to view the μA output and record the μA output with no parts in frontof the spray gun.

Monitor the output daily, under the same conditions, with the same kVsetting. A significant increase in μA output indicates a probable short in thespray gun resistor. A significant decrease indicates a failing resistor orvoltage multiplier.

Startup1. Turn on the power switch.

2. Select the desired mode, kV or AFC, by pressing the mode key. Referto the Description section for more information on these modes.

If the mode is set for kV, hold the + key until the maximum kV isdisplayed.

If the mode is set for AFC use the + and − keys to select 40 μA.

3. Trigger the spray gun. The display will show the actual output.

4. Coat a part and adjust the kV output or AFC settings to achieve thedesired result.



Adjustments

WARNING: Turn off the electrostatic voltage and ground the spray gunelectrode before making adjustments to the spray gun or nozzle.

Obtaining a high-quality finish and maximum transfer efficiency (percentageof paint sprayed that adheres to the part) requires experimentation andexperience. Settings for electrostatic voltage affect overall coatingperformance. In most applications, the settings should produce a soft spraypattern that directs as much of the paint as possible onto the part with aminimum of overspray. These settings will allow the maximum amount ofcharged paint to be attracted to the grounded part.

Electrostatic VoltageLowering the voltage is a common method for trying to improve thecoverage of deep recess and interior corners of parts. However, loweringthe voltage may also reduce your overall transfer efficiency. Paint velocity,direction, and pattern shape can be just as important as electrostaticvoltage in coating these areas.

Use the AFC mode with coated parts that have already been cured butrequire additional recoating and curing, and with coated parts with deeprecesses. In this mode, the AFC setpoint lets you set a feedback currentthreshold. Voltage is automatically set to the maximum. If the currentthreshold is reached the voltage is automatically adjusted to maintain therequired coverage. A suggested starting point is approximately 40 μA.Adjustments can then be made to optimize performance for different partconfigurations and application parameters.

When the gun-to-part distance changes, the AFC circuitry maintains theoptimum combination of voltage and current.

ShutdownTurn off the power switch. This will turn off the DC power to the spray gun,shutting off the electrostatic voltage.



Maintenance WARNING: Allow only qualified personnel to perform the following tasks.Follow the safety instructions in this document and all other relateddocumentation.

WARNING: An ungrounded or poorly grounded workpiece, hanger orconveyor can cause electrostatic arcing. If arcing is observed, shut downthe system immediately. Correct the cause before resuming operations.Failure to observe this warning could result in a fire or explosion, causingproperty damage and possible personal injury or death.

The following preventive maintenance procedures should be performedperiodically, according to your maintenance schedule. Refer to the Repairsection for disassembly and rebuild procedures.

1. Set the kV output to maximum. Trigger the spray gun with no parts infront of it. Press the View button to display μA and compare the outputwith the output and kV setting recorded at initial startup.

A significant increase in μA output indicates a probable short in thespray gun resistor. A significant decrease indicates a failing resistor orvoltage multiplier.

2. Check all ground connections, including conveyor and part grounds.Ungrounded or poorly grounded parts will not attract charged paint.This affects transfer efficiency, electrostatic wrap, and the quality of thefinish. Measure the resistance between the part and the ground with astandard ohmmeter.

3. Check power and spray gun cable connections.

4. Check the air supply filters and air dryer, if used. Drain filters andchange elements regularly.

Refer to your spray system and component manuals for additionalmaintenance information.



Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks.Follow the safety instructions in this document and all other relateddocumentation.

These procedures cover only the most common problems that you mayencounter. If you cannot solve the problem with the information given here,contact your local Nordson representative for help.

Troubleshooting Chart

WARNING: Electrical power must be on to check voltages. Perform theseprocedures carefully, using insulated tools. Touching energized electricalcomponents could be fatal.

Refer also to the circuit board drawing on page 16 and wiring diagram onpage 17.

Problem Possible Cause Corrective Action

1. All LEDs off, nodisplay

No input power Make sure power is supplied to thecontrol unit.

Blown fuse. Correct the overload or short andreplace fuse F1 or F2.

Fuse on power supply blown Check the power supply fuse andreplace if necessary.

2. There is no displayand the LEDs are Onor the Display and theLEDs are off

Faulty circuit board Replace the circuit board.

3. No kV out when spraygun is triggered

Bad gun cable Check gun cable for damage. Checkcontinuity of cable. Replace thecable if no continuity is detected.

Controller air flow switch notactivating

Check air flow switch wiring andmake sure connections are good.

Check air flow switch operation. Airpressure should close switch andcomplete circuit. Replace switch ifnecessary.

4. Spray gun will nottrigger. − − − flashingon display

Gun trigger shorted at power on This condition occurs if the spray gunis triggered on at power up.

5. Keypad not working Circuit board is not configuredproperly

Make sure JP1 is set to the defaultsetting. Refer to Circuit BoardConfiguration for more information.

Continued...



Problem Possible Cause Corrective Action

6. Loss of wrap, poortransfer efficiency

Poorly grounded part Measure the resistance between thepart and ground with a standardohmmeter. Clean the conveyor andpart hangers if the resistance isgreater than one megohm. For bestresults, the resistance should be 500ohms or less.

Spray gun resistor or multiplierfailed

Check the gun resistor and multiplierwith an ohmmeter.

Moisture in air causing kV to leakto ground

Check the air dryer and filters.

Paint conductivity is too low Contact the paint manufacturer.



Circuit Board Jumper Settings Jumpers JP1, JP2, and JP3 must be set as shown for the IPS-20 Controller.

IPS-20 Control Unit(No Jumper)

CONTROL UNIT TYPEJP1

1

IPS SPRAY GUNSJUmper JP3

IPS

TR

IBO

JP2

JP3

GUN TYPE(JP2, JP3)

(Default is IPS)

Figure 7 Circuit Board Jumper Settings



Wiring Diagram

DECREASE SETPOINTCOMMON

INCREASE SETPOINTMODE SELECT

KEYPADLABEL

FOIL GROUND TAB

(GR

EE

N W

/YE

LLO

W)

JUM

PE

R

(GRN W/YEL)

JUMPER

(GR

EE

N W

/YE

LLO

W)

POWER HARNESS

1074846

(BLUE)

(BROWN)

PO

WE

R H

AR

NE

SS

COVERCABINET

CONTROLLER

GND

GNDNO.22

SWITCH2

3

(BROWN)(BLUE)

5

6

LINE FILTER

(BROWN) (BROWN)

(GRN W/YEL)

(BLUE) (BLUE)

(BLUE)

(BLUE)

(BROWN)F1

FUSE

(BROWN)

F2

&FUSE HOLDER

1GNDNO.1

N/C 7

DC COM (GREEN)TRIGGER (WHITE)

+VDC OUT (RED)CURRENT FEEDBACK (YELLOW)

N/C

(FRONT VIEW)RECEPTACLE

GUN (BLU

E)

24V

CO

M

7

(BLA

CK

) +

24V

DC

(RE

D)

+5V

DC

(BR

OW

N)

DC

CO

M

(BR

OW

N)

DC

CO

M(G

RE

Y)

+5V

DC

(OR

AN

GE

) +

12V

DC

(RED) +5VDC(BLUE) 24V COM

(BROWN) DC COM

(BLACK) +24VDC

(GRAY) +5VDC

(ORANGE) +12VDC

56 34 12J5 (POWER)

6

43

5

21

J2 (GUN)(KEYPAD) J4

21

J1 (SOLENOID)

SK1L (3)

N (1)

SK2 DC POWER SUPPLY

56

34

12

234

1

PRINTED CIRCUIT BOARD

J6

(WHITE)

(GREEN) J2−2

(RED) J2−4

(YELLOW) J2−3

5

(BLACK) N/C

4

32

16

(GRAY) J2−6

(BROWN)

POWERINPUT

(GREEN)

(GRAY)

(GRAY)

(WHITE)

(WH

ITE

)

288803

NOT USED

AIR FLOW SWITCH

(RED)

(WHITE)

Figure 8 Wiring Diagram



Repair WARNING: Disconnect and lock out electrical power before performing thefollowing tasks. Failure to observe this warning could result in personalinjury or death.

Circuit Board and Power Supply Replacement

CAUTION: Electrostatic sensitive device. To avoid damaging the circuitboard, wear a grounding wrist strap and use proper grounding techniques.

1. Turn off the control unit and disconnect it from its input power source.

2. Remove the control unit cover.

3. See Figure 9. Disconnect the wiring harnesses (1) from the circuitboard (2) or power supply, depending on the component being replaced.

4. Remove the four screws (3) and washers (4) securing the circuit boardor power supply to the control unit then remove the component.

5. If you are replacing the circuit board, make sure the jumpers at JP1 andJP3 are set correctly for the IPS-20 controller. Refer to Figure 7 onpage 16.

6. Secure the new component to the control unit using the screws andwashers you removed in step 5.

7. Connect the wiring harnesses to the component.

8. Install the cover and connect power to the controller.

9. Perform the Gun Type Configuration to set the type of spray gunconnected to the controller.

Air Flow Switch Replacement If you replace the air flow switch, make sure you connect the air tubingcorrectly, from the IN port on the rear panel to the IN port on the switch, andfrom the OUT port on the switch to the OUT port on the rear panel.

Refer to the Wiring Diagram on page 17 for electrical connections.



1

1

1

2 1

1

34

5

1

34

1

1

6

INOUT

INOUT

Figure 9 Circuit Board and Power Supply Replacement

1. Wiring harness2. Circuit board

3. Screws (4)4. Washers (4)

5. Power supply6. Air flow switch



Parts To order parts, call the Nordson Industrial Coating Systems CustomerSupport Center at (800) 433-9319 or contact your local Nordsonrepresentative.

See Figure 10.

Item Part Description Quantity Note— 1083263 CONTROLLER, manual, IPS-20 1

1 322404 � SWITCH, rocker, DPST, dust-tight 1

2 1068603 � KIT, PCB, controller, manual, Vantage 1 A

3 288803 � POWER SUPPLY, 24, 5, 12 Vdc, 40 W 1

4 984192 � NUT, lock, 1/2-in. NPT, nylon 1

5 1611323 � CONNECTOR, strain relief, 1/2 -in. NPT 1 C

6 334800 � PLUG, 1/2-in. pipe, 1-in. hex 2

7 939122 � SEAL, conduit fitting, 1/2-in. blue 2

8 984526 � NUT, lock, 1/2-in.conduit 2

9 984702 � NUT, hex, M5, brass 4

10 983401 � WASHER, lock, M, split, M5, steel, zinc 10

11 983264 � WASHER, flat, M, reg, M5, stainless steel 18

12 933469 � LUG, 90 double, 0.250 in., 0.438 in. 1

13 240674 � TAG, ground 3

14 131477 � FUSE, 2.00 amp, fast acting 250V, 5 x 2 2 A

15 288804 � FUSE HOLDER, ,panel, mount 5 x 20 2 A

16 1005671 � GASKET, controller cabinet cover 1

17 126336 � SCREW, pan, slotted, M5 x 12 steel 8

18 1605370 � SWITCH, magnetic, air flow, w/o nipple 1

19 972183 � ELBOW, male, 3/8 in. tube x 1/4 in. NPT 3

20 971177 � CONNECTOR, male, 3/8 in. tube x 1/4 in. NPT 1

21 1042060 � GASKET, manifold, pneumatic, output 1

22 1611324 � O-ring, Buna-N, 0.75 in. ID, 0.07 W 1 C

NS 1084166 KIT, wall mount, IPS-20 1 B

NOTE A: Recommended spare part. Keep this part in inventory to avoid unplanned downtime.

B: Optional kit, not included with controller. Must be ordered separately.

C: For models before 2012, item 5 is part number 972808, and item 22 is not used.



1

1

2

3

1

6

13

Detail C

11 9 11 9 11 10 9

SeeDetail C

4

5 78

1415

16See

Detail B11

10

Side ViewCutaway

Detail B9

11

10

13

Detail A

9

10 11 12

11 13

Foil GroundTab fromKeypad Label

18

19

20

21

See Detail B

INOUT

INOUT

22

Figure 10 Controller Parts



Documents

1084167 IPS-20 Manual Electrostatic System Controller · KVKV uAA KV AFCAFC AFCAFC KVKV 3 7 2 4 6 1 5 IPS − 20 Electrostatic System Controller Figure 1 Front Panel. IPS-20 Manual