X9800 Flame Detector Head - Nordson · 2020. 9. 25. · X9800 Flame Detector 3 2016 Nordson...

X9800 Flame Detector

Customer Product ManualPart 1609500-01

Issued 04/16

NORDSON CORPORATION AMHERST, OHIO USA

For parts and technical support, call the Industrial CoatingSystems 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.

Part 1609500-01 � 2016 Nordson Corporation

tents

Table of ContentsSafety 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 BoxWiring Diagram 12. . . . . . . . . . . . . . . . . . . . . . . . . .DC-Powered Control Panel 13. . . . . . . . . . . . . . . .DC-Powered Controls with Integration into SystemControl Panel 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Through-the-Lens Test 15. . . . . . . . . . . . . . . . . . . . . .Detector Head Test Procedure 15. . . . . . . . . . . . . . .

Automatic Optical Integrity Test 15. . . . . . . . . . . .Magnet Optical Integrity Test 15. . . . . . . . . . . . . .

Maintenance 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Daily 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Periodically 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parts 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the Illustrated Parts List 18. . . . . . . . . . . . . . .X9800 Flame Detector Head 19. . . . . . . . . . . . . . . . .

Universal Mounting Kit 19. . . . . . . . . . . . . . . . . . .Air Supply Parts Option 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 2016. 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

Nordson and the Nordson logo are registered trademarks of NordsonCorporation.

All other trademarks are the property of their respective owners.

Change Record i

Part 1609500-01� 2016 Nordson Corporation

Change RecordRevision Date Change

01 04/16 Release

Change Recordii


X9800 Flame Detector 1


X9800 Flame Detector

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 all 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.

All phases of equipment installation must comply with all federal, state, andlocal codes.

X9800 Flame Detector2


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 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.

� Relieve (bleed off) hydraulic and pneumatic pressure before adjusting orservicing pressurized systems or components. Disconnect, lock out,and tag switches before servicing electrical equipment.

� Obtain and read Safety Data Sheets (SDS) for all materials used.Follow the manufacturer’s instructions for safe handling and use ofmaterials, and use recommended personal protection devices.

� 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.

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

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

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

� Do not disconnect live electrical circuits while 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.

� 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.



Grounding

WARNING: Operating faulty electrostatic equipment is hazardous and cancause electrocution, fire, or explosion. Make resistance checks part of yourperiodic maintenance program. If you receive even a slight electrical shockor notice static sparking or arcing, shut down all electrical or electrostaticequipment immediately. Do not restart the equipment until the problem hasbeen identified and corrected.

Grounding inside and around the booth openings must comply with NFPArequirements for Class II Division 1 or 2 Hazardous Locations. Refer toNFPA 33, NFPA 70 (NEC articles 500, 502, and 516), and NFPA 77, latestconditions.

� All electrically conductive objects in the spray areas shall be electricallyconnected to ground with a resistance of not more than 1 megohm asmeasured with an instrument that applies at least 500 volts to the circuitbeing evaluated.

� Equipment to be grounded includes, but is not limited to, the floor of thespray area, operator platforms, hoppers, photoeye supports, andblow-off nozzles. Personnel working in the spray area must begrounded.

� 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 mustwear shoes with conductive soles or use a ground strap to maintain aconnection to ground when working with or around electrostaticequipment.

� Operators must maintain skin-to-handle contact between their hand andthe gun handle to prevent shocks while operating manual electrostaticspray guns. If gloves must be worn, cut away the palm or fingers, wearelectrically conductive gloves, or wear a grounding strap connected tothe gun handle or other true earth ground.

� Shut off electrostatic power supplies and ground gun electrodes beforemaking adjustments or cleaning powder spray guns.

� Connect all disconnected equipment, ground cables, and wires afterservicing equipment.

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 electrical power. Close pneumatic shutoffvalves and relieve pressures.

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

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



Description

Flame Detection System Components The flame detection system is installed in a coating system booth andinterfaces with the booth and the application system controls. The flamedetector shuts down the booth, application equipment, and the conveyorwhen it detects a flame in the booth.

See Figure 1. The flame detection system consists of one or two detectorheads and an indicator panel. The detector circuit is available as either a120/230 Vac, 24 Vdc, NEMA12 panel, or as a control board and operatorcontrols that can be integrated into a booth control panel.

NOTE: The field wiring connector adapter box connects to the AC controlpanel and is available as an option to primarily support XL-3000 legacysystems.

Control Panel, Flame Detection, 24 Vdc

Flame Detector Panel Integration Kit Field Wiring Connector Adapter Kit

Front View Side View

Flame Detector Head

Control Panel, Flame Detection, AC Power

Figure 1 Flame Detection System Components



Flame Detector HeadsSee Figure 2.

The detector heads simultaneously scan IR spectrum and the visiblespectrum. They use intelligent, real-time signal processing to tell thedifference 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 reflectionfrom the reflective plate. If the test fails, the detector head goes into faultmode and the amber fault indicator light is turned on.

Each detector head has a status LED, visible through the lens. Thedetector head lens is continuously cleaned by low-pressure air flowing fromthe air shield.

X9800 MODEL

Figure 2 X9800 Flame Detector Head



Theory of Operation

Flame DetectionIf a flame is detected inside the booth, interlock relays in the indicator panelopen and shut down the exhaust fan, application equipment, and conveyor.The red FLAME DETECTED indicator light is turned on and the flame alarmsounds.

FaultsThe FAULT DETECTED indicator light and the fault alarm alert theoperators of problems with the detector heads. There are two fault modes:

Fault: A fault occurs when one detector head loses power, fails athrough-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 andonly one is in fault. If only one detector head is used, any fault is treated asa major fault.

Major Fault: A major fault occurs when both detector heads lose power, faila through-the-lens test, or have microprocessor/sensor malfunctions. Bothfault indicators light and the fault alarm sounds. If only one detector head isconnected, then any fault is a major fault. A major fault shuts down thebooth and application equipment. The conveyor will continue to run. Theconveyor 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 RatingItem Specification

Detector Head Input Voltage 24 Vdc, 120 mA

Temperature Rating -40 �C to +75 �C, (-40 �F to +185 �F)



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

Mounting Equipment

Excel Booth Vestibule Mount See Figure 3.

1. Measure and mark the locations in the booth entrance and exitvestibules (2) for the detector heads (1).

2. Mount one detector head to the floor of each vestibule diagonally asshown below, using the included brackets and screws, washers, lockwashers, and nuts.

NOTE: Mounting brackets will need to be oriented differently dependingon 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 unobstructedview of the spray guns (3), conveyor (5), hangers, and workpieces (6).

4. Mount the indicator panel in an appropriate location, close to or on thebooth electrical panel, or on an operator platform, using the mountingholes on the panel flanges.

1

4 23

5

6

1

Figure 3 Flame Sensors and Light Test Source Excel Booth Installation Top View

1. Detector heads2. Booth vestibules

3. Spray guns4. Centerlines

5. Conveyor6. Hangers and workpieces



Colormax Booth Mount See Figure 4.

1. Measure and mark the locations at the top of the booth entrance (2) tomount the detector heads (1).

2. Mount the detector heads to the top corners of the booth entry wall asshown below. Orient the bracket appropriately using the includedbrackets and screws, washers, lock washers, and nuts.

NOTE: Mounting brackets will need to be oriented differently dependingon 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 unobstructedview of the spray guns (3), conveyor (5), hangers, and workpieces (6).

4. Mount the indicator panel in an appropriate location, close to or on thebooth electrical panel, or on an operator platform, using the mountingholes on the panel flanges.

4

2

3

5

6

1

1

Figure 4 Flame Sensors and Light Test Source Colormax Booth Installation Top View

1. Detector heads2. Booth entrance

3. Spray guns4. Centerlines

5. Conveyor6. Hangers and workpieces



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 detectorhead (2).

2. Connect 6-mm air tubing (3) from the air supply to the regulator andfrom the regulator to the detector head air shield.

1 2

3

4

Figure 5 Detector Head Pneumatic Connections

1. Vestibule2. Detector head

3. 6 mm air tubing 4. Regulator



Flame Detector Head Connections

WARNING: All electrical connections must be made according to local ornational electrical codes. Use properly sized wire and approved conduitand fittings. Failure to observe this warning could result in property damageor 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 shieldedcable, 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 12minimum) and install in the open port.

4. Pull the cable (8) and ground wire (3) through the conduit (6), thenconnect the conduit to the fitting (5).

5. Connect the cable wires (8) to the terminal block (9) on the bottom of themicroprocessor/ 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 cablewires to the control panel as shown in Figures 7, 8, 9, or 10.

11 12 13 14 15 16 17 18 19

3

2 5

1

6

8

9

7

4

Figure 6 Detector Head Electrical Connection

1. Housing2. Plug3. Ground wire

4. Bulkhead5. Conduit fitting6. Conduit

7. Housing lid8. Cable9. Terminal block



Wiring Diagrams NOTE: Connections must be made so that power is supplied to theindicator panel as long as the booth electrical power is turned on. Supplyservice must be provided from a disconnect switched source.

AC-Powered Control PanelMake connections according to Figure 7. Supply 120−240 Vac, 1 phase,50/60 Hz, 2 amp electrical service with ground to the indicator panel fromthe 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.

S/N

MADE IN USA

R1

+24VDC

PCA

1604

467

B

1 5 9

13

4 8 12

14

1 5 9

13

4 8 12

14

3

7

11

13

4

8

12

14

12

4

8

10

2

6

9

1

5

7 8 95 6431 2

56

73

42

18

910

123

56

73

42

15

67

34

21

LED1FU104

1.0A TD

1 5 9

13

4 8 12

14

1 5 9

13

4 8 12

14

NO

RD

SON

CR

105

CR

123

CR

109

CR

116

CR

120

JPW

R

JEXT

JDH

2JD

H1

JFP

+24VDC

DCCOM GND

PE

PCB

1604

466

BFL

AME

DET

ECTO

R

-V +V

L N

DC ON

ÎÎÎÎÎ

PWS102FUSES: 2A TD

S505R-2 or equal

L1 -

FU

101

L2 -

FU

102

- -

- -

- -

- -

PE/G

ND

1

2

3

4

5

6

7

JDH

1

1

2

3

4

5

6

7

8

9

JEXT

1

2

3

4

5

6

7

JDH

2

10

PE/GND10401200104010901060DCCOM

DET

ECTO

R H

EAD

#1PE/GND

10401200104011601130DCCOM

DET

ECTO

R H

EAD

#2

PE/GND

--

12531250

129112901292127112701272

BOO

THIN

T'LK

CO

NVE

YOR

INTE

RLO

CK

250V

AC 5

A M

AX

= O

K=

FLAM

E D

ET

1

2

3

4

6

7

BLKWHTREDGRNORGBLUSHIELD


BLK

WHT

RED

GRN

ORG

BLU

1

2

3

4

6

7

BLK

WHT

RED

GRN

ORG

BLU

PE12501253

127112701272

129112901292

GND

GND

GRN/YEL

120−240 VAC 1PH

50/60HZ 2A

INTERCONNECTLABEL

DETECTOR HEAD #2

DETECTOR HEAD #1

GREEN/YELLOWGROUND CABLE (TYP)

MULTICONDUCTOR CABLE (TYP)

MAY ALSO BETERMINATED FROMDETECTOR HEAD TOSYSTEM GROUNDBLOCK

CABLE OPTIONTRAY RATED

BLK

YEL

RED

BRN

ORG

BLU

GRN/YEL

GRN/YEL

FLAME SYSTEM INTERLOCK

(CUSTOMER USE)

BOOTH INTERLOCK

CONVEYOR INTERLOCK

76

43

21

FLAM

E FAU

LTVD

C

76

43

21

FLAM

E FAU

LTVD

C

Figure 7 Installation Wiring Diagram − Flame Detection Control Panel, AC Power, Indicator Panel



AC-Powered Control Panel with Field Connector BoxWiring Diagram

Make connections according to Figure 8.

BOOTHINTERLOCK

S/N

MADE IN USA

R1

+24VDC

PCA

1604

467

B

1 5 9

13

4 8 12

14

1 5 9

13

4 8 12

14

3

7

11

1314

12

4

8

10

2

6

9

1

5

7 8 95 6431 2

56

73

42

18

910

123

56

73

42

15

67

34

21

LED1

FU104

1.0A TD

1 5 9

13

4 8 12

14

1 5 9

13

4 8 12

14

NO

RD

SON

CR

105

CR

123

CR

109

CR

116

CR

120

JPW

R

JEXT

JDH

2JD

H1

JFP

+24

VDC

DC

COM GND

PE

PCB

1604

466

BFL

AME

DET

ECTO

R

-V +V

L N

DC ON

ÇÇÇÇÇÇÇÇÇÇ

PWS102FUSES: 2A TD

S505R-2 or equal

L1 -

FU

101

L2 -

FU

102

- -

- -

- -

- -

PE/G

ND

1

2

3

4

5

6

7

JDH

1

1

2

3

4

5

6

7

8

9

JEXT

1

2

3

4

5

6

7

JDH

2

10

PE/GND10401200104010901060DCCOM

DET

ECTO

R H

EAD

#1

PE/GND10401200104011601130DCCOM

DET

ECTO

R H

EAD

#2

PE/GND

--

12531250

129112901292127112701272

BOO

THIN

T'LK

CO

NVE

YOR

INTE

RLO

CK

250V

AC 5

A M

AX

= O

K=

FLAM

E D

ET

120VAC

1

2

3

4

6

7

WHT/BLKWHT/BRNWHT/REDWHT/ORGWHT/YELPURGRY

BLKBRNREDORGYELBLUGRN

BLK

WHT

RED

GRN

ORG

BLU

1

2

3

4

6

7

BLK

WHT

RED

GRN

ORG

BLU

PE12501253

127112701272

CONVEYORINTERLOCK

129112901292

FLAME SYS.INTERLOCK

(CUSTOMER USE)

INTERCONNECTLABEL

BLK

WH

T

RED

GR

N

OR

G

BLU

SHLD

1 2 3 4 5 6 SH

BLK

WH

T

RED

GR

N

OR

G

BLU

SHLD

1 2 3 4 5 6 PE1 2 3 4 5

DET HEAD #2DET HEAD #1CONNECTOR CONNECTOR CONNECTORBL

K

BRN

RED

OR

G

YEL

BLU

GR

N

WH

/BK

WH

/BR

WH

/RD

WH

/OR

WH

/YL

PUR

GR

Y

RED

WH

T

GR

N/Y

LW

GNDGRN/YEL

WH

TR

EDG

R/Y

WBL

KO

RG

GNDGRN/YEL

AC POWER120VAC 60HZ

(1)

(2)

(3)

(4)

(5)

L2/N

L1

GND

RLY CNT 1

RLY CNT 2

120V POWER

INPUT

BOOTH INTLK

CONTACT

GREEN/YELLOWGROUND CABLE (TYP)

MULTICONDUCTORCABLE (TYP)

DETECTOR HEAD #2

DETECTOR HEAD #1CABLE OPTIONTRAY RATED

BLK

YEL

RED

BRN

ORG

BLU

GRN/YEL

FIELD WIRINGCONNECTOR BOX

76

43

21

FLAM

EFA

ULT

VDC

76

43

21

FLAM

EFA

ULT

VDC

Figure 8 Installation Wiring Diagram − AC-Powered Control Panel with Field Connector Adapter Box



DC-Powered Control PanelMake connections according to Figure 9.

S/N

MADE IN USA

R1

+24VDC

PCA

1604

467

B

1 5 9

13

4 8 12

14

1 5 9

13

4 8 12

14

3

7

11

13

4

8

12

14

12

4

8

10

2

6

9

1

5

7 8 95 6431 2

56

73

42

18

910

123

56

73

42

15

67

34

21

LED1FU104

1.0A TD

1 5 9

13

4 8 12

14

1 5 9

13

4 8 12

14

NO

RD

SON

CR

105

CR

123

CR

109

CR

116

CR

120

JPW

R

JEXT

JDH

2JD

H1

JFP

+24VDC

DCCOM GND

PE

PCB

1604

466

BFL

AME

DET

ECTO

R

1234567

JDH

1

123456789

JEXT

1234567

JDH

2

10

PE/GND10401200104010901060DCCOM

DET

ECTO

R H

EAD

#1

PE/GND10401200104011601130DCCOM

DET

ECTO

R H

EAD

#2

PE/GND

--

12531250

129112901292127112701272

BOO

THIN

T'LK

CO

NVE

YOR

INTE

RLO

CK

250V

AC 5

A M

AX

= O

K=

FLAM

E D

ET

1

2

3

4

6

7



BLK

RED

WHT

GRN

ORG

BLU

1

2

3

4

6

7

BLK

RED

WHT

GRN

ORG

BLU

PE12501253

127112701272

129112901292

GND

GNDGRN/YEL

GRN/YEL

+24 C PE

CONVEYORINTERLOCK

FLAME SYSTEM INTERLOCK

BOOTH INTERLOCK

(CUSTOMER USE)

GREEN/YELLOWGROUND CABLE (TYP) MULTICONDUCTOR

CABLE (TYP)

DETECTOR HEAD #2

DETECTOR HEAD #1

INTERCONNECTLABEL


BLK

YEL

RED

BRN

ORG

BLU

GRN/YEL

76

43

21

FLAM

E FAU

LTVD

C

76

43

21

FLAM

E FAU

LTVD

C

Figure 9 Installation Wiring Diagram − 24Vdc Powered Control Panel



DC-Powered Controls with Integration into SystemControl PanelMake connections according to Figure 10.

924924

+24VDCMAIN 24V COM

10011001

+24VDCMAIN

24V COM

+24VDC

7 8 95 6431 2

56

73

42

18

910

123

56

73

42

15

67

34

21

FU104

1.0A TD

CR

105

CR

123

CR

109

CR

116

CR

120

JPW

R

JEXT

JDH

2JD

H1

JFP

+24VDC

DCCOM GND

PE

PCA 1604467 B

NORDSONFLAME DETECTOR

G

LT944

SS946

R

LT941

LT936

A

FLAME DETECTION SYS POWER

FLAME DETECTED

AUDIBLE ALARM

DETECTOR HEAD #2

ALB939

FAULT

DETECTOR HEAD #1FAULT

DETECTOR HD RESETDET 1 DET 2

X

X

DC COMMON

718

718BOOTH INTERLOCK

JEXT (2), JEXT (3)

CONVEYOR INTERLOCK A

JEXT(8) JEXT(7) JEXT(9)

CLOSED WHEN NORMAL

NORMAL STATE SHOWN

NO FAULTS

CONVEYOR INTERLOCK B

JEXT(5) JEXT(4) JEXT(6)

NORMAL STATE SHOWN

NO FAULTS

FLAME BOARD OUTPUTS

OPEN WHEN FAULT DETECTED

INTERLOCKCUSTOMER CONVEYOR

INTERLOCKBOOTH

7165

7167

9300

9290

FLAME DETECTOR #1

PE/GND

FIRE OUTPUT (2)FAULT OUTPUT (1)FAULT OUTPUT (2)VDCDC COM

FIRE OUTPUT (1)

SHIELDPE/GND

64321

7

FLAME DETECTOR #2

PE/GND

FIRE OUTPUT (2)FAULT OUTPUT (1)FAULT OUTPUT (2)VDCDC COM

FIRE OUTPUT (1)

SHIELDPE/GND

64321

7GRN/YEL

ORANGEGREEN

REDWHITEBLACK

BLUE

GRN/YEL

ORANGEGREEN

REDWHITEBLACK

BLUE

A


BLK

YEL

RED

BRN

ORG

BLU

GRN/YEL

9291

LT938

Figure 10 Reference Drawing for Flame Detector Panel Kit − Integration into System Control Panel



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

Through-the-Lens TestThe detector heads automatically perform periodic through-the-lens tests tocheck 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 acalibrated performance test that is automatically performed once per minuteto verify complete detector operation capabilities. No testing with anexternal test lamp is required. The detector automatically performs thesame test that a maintenance person with a test lamp would perform.However, a successful Automatic Optical Integrity test does not produce analarm condition.

Magnet Optical Integrity Test The Magnetic Optical Integrity test procedure is the approved externaloptical test method for the X9800 flame detector head to verify end-to-endfunction. 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 thedetector.

2. Hold magnet in place for 6 seconds. This will activate the IR emitter onthe unit.

3. If the resulting signal meets the test criteria, the indicating LED willchange to red. If the test criteria is not met, no alarm is produced and afault is generated.



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

WARNING: Keep the detector head lenses clean. Dirty lenses can preventthe detector heads from detecting a flame in the booth. Failure to observethis warning could result in property damage or personal injury.

NOTE: Keeping the lenses clean will prevent nuisance fault alarms orshutdowns. A dirty lens can cause a through-the-lens test to fail, triggeringa fault. If only one detector head is installed, a fault will shut down thecoating system during production.

DailyCheck the detector head lenses daily. If they are dirty, clean them with anapproved low-pressure air gun or an oil- and silicone-free cloth. Ifnecessary, dampen the cloth with ethyl alcohol. Do not use asilicone-based product such as commercial window cleaner to clean thedetector 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.

PeriodicallyCheck all electrical connections periodically. Tighten any loose terminals.Replace any wiring that has worn or damaged insulation. Make sureconduit fittings are tight.



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

WARNING: Hazardous voltages are present inside the indicator panelwhen booth power is on. Do not touch exposed terminals or wiring whenchecking voltages. Use insulated tools. Failure to observe could result insevere 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 yourlocal Nordson representative for help.

Problem Possible Cause Corrective Action

Detector Fault Through-the- lens testfailed

If the status LED on the detector head is yellow,the detector lens is obstructed. Make sure thedetector lens is clean and clear of powder. Ifpowder is accumulating on the lenses, check theair supply to the air shields. Reset the detectorhead to clear the fault.

Detector head lostpower

Check the status LED on the detector head. Whenoperating normally, the LED should be green. Ifthe LED is off, check the wiring between theindicator panel and the detector. There should be24 Vdc between pins 1 and 2 at the detector.

� If 24 Vdc is present, call a technical servicerepresentative. Detector head may need to bereplaced.

� If 24 Vdc is not present, make sure green POWERON indicator on the indicator panel is lit.

If the indicator panel has power, repair or replace thewiring between controller and detector.

Microprocessor/sensormodule failed

No LED indication on the detector head and 24Vdc power present at pins 1 and 2. Replace thedetector head or contact your technical servicerepresentative.



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

Using the Illustrated Parts List Numbers in the Item column correspond to numbers that identify parts inillustrations following each parts list. The code NS (not shown) indicatesthat a listed part is not illustrated. A dash (—) is used when the part numberapplies to all parts in the illustration.

The number in the Part column is the Nordson Corporation part number. Aseries of dashes in this column (−−−−−−) means the part cannot be orderedseparately.

The Description column gives the part name, as well as its dimensions andother characteristics when appropriate. Indentions show the relationshipsbetween 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 partnumber is a bulk item ordered in quantities or if the quantity per assemblydepends on the product version or model.

Letters in the Note column refer to notes at the end of each parts list. Notescontain important information about usage and ordering. Special attentionshould be given to notes.

Item Part Description Quantity Note— 0000000 Assembly 11 000000 � Subassembly 2 A2 000000 � � Part 1



X9800 Flame Detector HeadSee Figure 11 and the following parts list.

2

1

Figure 11 Detector Head Parts

Item Part Description Quantity Note1 1609231 SHIELD, air, X9800 12 1609504 DETECTOR, flame, X9800 1

Universal Mounting Kit

Item Part Description Quantity Note− 1609232 KIT, mounting brackets, fire detector, UNI 1



Air Supply Parts OptionSee the following parts list.

Part Description Note249467 REGULATOR, in-line air900730 TUBING, polyurethane, 0.250 x 0.040 in. A900742 TUBING, polyurethane, 6/4 mm, blue A

NOTE A: Order tubing in 1-foot increments.

SafetyQualified PersonnelIntended UseRegulations and ApprovalsPersonal SafetyFire SafetyGroundingAction in the Event of a MalfunctionDisposal

DescriptionFlame Detection System ComponentsFlame Detector HeadsTheory of OperationFlame DetectionFaults

SpecificationsDetector Head Terminal Block ConnectionsElectrical Power and Temperature Rating

InstallationMounting EquipmentExcel Booth Vestibule MountColormax Booth Mount

Pneumatic Regulator Installation (if applicable)Flame Detector Head ConnectionsWiring DiagramsAC‐Powered Control PanelAC‐Powered Control Panel with Field Connector Box Wiring DiagramDC‐Powered Control PanelDC‐Powered Controls with Integration into System Control Panel

OperationThrough‐the‐Lens TestDetector Head Test ProcedureAutomatic Optical Integrity TestMagnet Optical Integrity Test

MaintenanceDailyPeriodically

TroubleshootingPartsUsing the Illustrated Parts ListX9800 Flame Detector HeadUniversal Mounting Kit

Air Supply Parts Option

X9800 Flame Detector Head - Nordson · 2020. 9. 25. · X9800 Flame Detector 3 2016 Nordson...

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