U7698E Flame Detector Customer Product Manual Part 334614E Issued 3/02 NORDSON CORPORATION • AMHERST, OHIO • USA
Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information about Nordson can be found on the Internet using the following address: http://www.nordson.com. Address all correspondence to: Nordson Corporation Attn: Customer Service 555 Jackson Street Amherst, OH 44001 Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 1999.
Table of Contents i Table of Contents Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regulations and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Table of Contents Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Sensor and Electronics Module Replacement . . . . . . . . . . . . . . . .
U7698E Flame Detector 1 U7698E Flame Detector Safety Read and follow these safety instructions. Task- and equipment-specific warnings, cautions, and instructions are included in equipment documentation where appropriate. Make sure all equipment documentation, including these instructions, is accessible to all persons operating or servicing equipment. Qualified Personnel Equipment owners are responsible for making sure that Nordson equipment is installed, operated, and serviced by qualified personnel.
2 U7698E Flame Detector Personal Safety To 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 are intact and automatic interlocks are operating properly. Do not bypass or disarm any safety devices. S Keep clear of moving equipment. Before adjusting or servicing any moving equipment, shut off the power supply and wait until the equipment comes to a complete stop.
U7698E Flame Detector 3 Grounding WARNING: Operating faulty electrostatic equipment is hazardous and can cause electrocution, fire, or explosion. Make resistance checks part of your periodic maintenance program. If you receive even a slight electrical shock or notice static sparking or arcing, shut down all electrical or electrostatic equipment immediately. Do not restart the equipment until the problem has been identified and corrected.
4 U7698E Flame Detector Disposal Dispose of equipment and materials used in operation and servicing according to local codes. Description The model U7698E flame detector installs in a coating system booth and interfaces with the booth and application equipment controls. The flame detector shuts down the booth, application equipment, and conveyor when it detects a fire in the booth. See Figure 1. The flame detector consists of an indicator panel (1) and one or two detector heads (2).
U7698E Flame Detector 5 Indicators, Alarms, Interlocks, and Controls The indicator panel houses the flame detector indicators, alarms, interlocks, and controls. Indicators S POWER ON (green) S DET. HEAD #1 FAULT (amber) S DET.
6 U7698E Flame Detector Detector Heads See Figure 2. A detector head consists of an air shield (1), sensor module (2), electronics module (3), housing (4), and connector board (not shown) mounted in the housing. 1 2 4 ATTENTION 3 1400493A Figure 2 Detector Head Components 1. Air shield 2. Sensor module Part 334614E Manual 34-49 3. Electronics module 4.
U7698E Flame Detector 7 A DIN connector mounted on the electronics module plugs into the connector board in the housing. The detector heads scan the IR spectrum. They use intelligent, real-time signal processing to tell the difference between a real fire and false-alarm radiant energy sources. Each detector head continuously monitors itself via a through-the-lens test. Two clear (white) LEDs on the top of the sensor module light to run the test.
8 U7698E Flame Detector Installation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Mounting See Figure 3. 1. Measure and mark the locations in the booth entrance and exit vestibules (2) for the detector heads (1). 2. Mount the detector heads to the spray booth entrance and exit vestibule walls or floors, using the mounting brackets (7) and screws, flat washers, lock washers, and nuts (8). 3.
U7698E Flame Detector 9 6 1 5 4 3 2 1 7 8 2 1400494A Figure 3 Detector Head Installation 1. Detector heads 2. Booth vestibules 3. Spray guns E 2002 Nordson Corporation 4. Centerlines 5. Conveyor 6. Hangers and workpieces Manual 34-49 7. Mounting bracket 8.
10 U7698E Flame Detector Pneumatic Connections See Figure 4. Install a 0.7-bar (10-psi) fixed-pressure regulator for each detector head. 1. Install the regulator(s) (4) on the booth as close as practical to the detector head (2). 2. Install 6-mm air tubing (5) between the regulator input port(s) and the system air supply. 3. Install 6-mm air tubing (3) between the regulator output port(s) and the air shield input port(s). 1 2 3 4 5 1400495A Figure 4 Detector Head Pneumatic Connections 1.
U7698E Flame Detector 11 Electrical Connections WARNING: All electrical connections must be made according to local or national electrical codes. Use properly sized wire and approved conduit and fittings. Failure to observe this warning could result in property damage or personal injury. Detector Heads Connect the detector heads to the indicator panel with 7-wire shielded cable, flexible or rigid conduit, and liquid-tight conduit fittings. See Figure 5. 1.
12 U7698E Flame Detector Detector Heads (contd) 9 1 2 3 4 5 6 7 8 9 10 11 12 on off 1 ATTENTION 3 8 7 5 4 6 2 1400496A Figure 5 Detector Head Electrical Connection 1. Upper housing 2. Terminal block 3. Electronics module 4. Lower housing 5. Cable 6. Conduit 7. Conduit fitting (3/4-in. NPT) 8. Plug 9. Configuration switches Interlocks NOTE: All interlock relays are rated for 120–240 Vac, 10A. Connect interlock wiring as shown in Figure 6. 1.
U7698E Flame Detector 13 Power Supply See Figure 6. Supply 120–240 Vac, 1phase, 50/60 Hz, 2A electrical service to the indicator panel from the booth electrical panel, using 3-wire cable, flexible or rigid conduit, and liquid-tight conduit fittings. Connections must be made so that power is supplied to the indicator panel as long as the booth electrical power is turned on.
14 U7698E Flame Detector Operation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Startup Turn on power to the powder coating system. S The green POWER ON indicator on the indicator panel will light. S The FAULT indicators will light then shut off if there are no faults. S The red FIRE DETECTED indicator will stay off.
U7698E Flame Detector 15 Major Fault Mode The system goes into major fault mode when faults are detected in both detector heads, preventing the detection of a fire. WARNING: Immediately correct any condition that causes a fault or major fault. Do not operate the coating system with the flame detector shut down or bypassed, or with a malfunctioning flame detector component. In major fault mode, S both amber DET. HEAD FAULT indicators light. S the FAULT DETECTED alarm turns on (continuous tone).
16 U7698E Flame Detector Optional Test Lamp An optional test lamp can be used to test the ability of the flame detector to detect and warn of a fire in the spray booth. The test lamp produces light with the same frequencies as the light produced by a fire. The test lamp must be placed very close to the detector and waved back and forth slightly to initiate a response. Refer to Parts for the part number. Maintenance WARNING: Allow only qualified personnel to perform the following tasks.
U7698E Flame Detector 17 Troubleshooting WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. This section contains troubleshooting procedures. These procedures cover only the most common problems that you may encounter. If you cannot solve the problem with the information given here, contact your local Nordson representative for help.
18 U7698E Flame Detector Troubleshooting Chart Use the following chart to isolate and correct problems with the flame detector. Problem 1. Detector fault Possible Cause Corrective Action Through-the-lens test failed Make sure the detector lens is clean. If powder is accumulating on the lenses, check the air supply to the air shields. Reset the detector head if the fault continues. Detector head lost power, or sensor or electronics module malfunctioned Check the red detector head LEDs.
U7698E Flame Detector 19 Electrical Schematic See Figure 7. L1 L2 100 101 PE 120–240VAC, 1PH, 50/60HZ, 2A SUPPLY FU101 1010 FU101 1011 2A 2A PWS102 102 L +24VDC POWER SUPPLY 30W, 1.3A OUTPUT N INPUT 50/60 Hz .68A 100–240VAC 1.3A 103 OUTPUT 24VDC V+ 104 V– 1040 DCCOM CR105 105 106 107 108 (14) RESET DET. #1 DET. #2 X SS106 TO LINE 113 1060 BOOTH INTERLOCK RELAY BUFFER 125 POWER ”ON” DETECTOR HEAD RESET 1040 DET.
20 U7698E Flame Detector Electrical Schematic (contd) FROM LINE 119 FROM LINE 119 CR120 1040 120 1200 (14) TO LINE 110 DETECTOR HEAD #1 1200 1040 121 TO LINE 117 DETECTOR HEAD #2 LT121 (13) FIRE DETECTED R 122 CR109 (4) (12) 123 1230* CR116 (4) (12) *1231 ABU122 (14) (13) CR123 124 CR105 CR120 CR123 1250 (5) (9) 1251 (4) (12) 1252 (1) (9) 1253 125 FIRE DETECTED BUFFER RELAY 125, 127, 127, 129, 129 ABU124 FIRE DETECTED ALARM BUZZER DUAL DETECTOR FAULT BUFFER RELAY 125 FAULT DETECT
U7698E Flame Detector 21 Repair WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. WARNING: Disconnect and lock out electrical power before servicing. Sensor and Electronics Module Replacement Removing the Old Sensor and Electronics Modules See Figure 8. 1. Turn off power to the detector heads by turning off power to the system. 2. Disconnect the air tubing (1) from the air fitting (2). 3.
22 U7698E Flame Detector Installing the New Sensor and Electronics Modules 1. Set the configuration switches. See Figure 5 for settings. 2. See Figure 8. Plug the electronics module (10) DIN connector into the socket on the connector board in the upper housing (8). Secure in place by tightening the mounting screws. NOTE: Apply molybdenum disulfide grease to the lower housing and sensor housing threads to prevent galling or binding. 3. Screw the lower housing (11) into the upper housing. 4.
U7698E Flame Detector 23 Parts To order parts, call the Nordson Customer Service Center or your local Nordson representative. Use this five-column parts list, and the accompanying illustration, to describe and locate parts correctly. Using the Illustrated Parts List Numbers in the Item column correspond to numbers that identify parts in illustrations following each parts list. The code NS (not shown) indicates that a listed part is not illustrated.
24 U7698E Flame Detector Detector Head See Figure 9.
U7698E Flame Detector 25 Indicator Panel See Figure 10. Item — 1 2 3 4 5 6 Part 307445 341361 332222 332223 939267 332227 332226 Description Quantity 1 1 1 4 2 Panel, indicator S Power supply, 24 V S Relay, control, 3-pole S Relay, control, 2-pole S Fuse, fast-acting, 250 V, 2 A, 0.25 x 1.25 in.
26 U7698E Flame Detector Options Options must be ordered separately. Test Lamp See Figure 11. Part 341566 Description Note Lamp, test, U7698E 1400503A Figure 11 Test Lamp Air Supply Parts Use these parts to supply air to the air shields. Part 249467 900730 900742 Part 334614E Description Note Regulator, fixed, 10 psi Tubing, 0.25 x 0.040 in.
U7698E Flame Detector 27 Specifications This section includes specifications for the Nordson U7698E flame detector. Detector Head Terminal Block Connections Table 1 Detector Head Terminal Block Connections Function Pin 1 +24 Vdc 2 dc Common 6 Fire Relay (N.O.) 7 Fire Relay (Com) 9 Fault Relay (N.O.) 10 Fault Relay (Com) Configuration Switch Settings See Figure 12.
28 U7698E Flame Detector Interlock Relay Contact Conditions Table 2 Interlock Relay Contact Conditions Condition Interlock Booth Conveyor Customer U Use Terminal No Power Normal Operation Fault Major Fault Fire Alarm 1250– 1253 1272– 1271 1271– 1270 1292– 1291 1291– 1290 d D D d d D D D D d d d d d D D D D D d d d d d D D = Closed contact d = Open contact NOTE: All relays are rated at 120–240 Vac, 10A. Weight and Dimensions Indicator Panel Height: 304.8 mm (12 in.
