esb-100 electrostatic shaping baremanuals.nordson.com/finishing/files/cont-liq/108161_03.pdf ·...

ESB-100 Electrostatic Shaping Bar

Customer Product ManualPart 108161-03

Issued 07/19

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

and available local languages.

CAPPROVED

USFM

Part 108161-03 � 2019 Nordson Corporation

tents

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specific Conditions of Use 6. . . . . . . . . . . . . . . . . . .Installation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrostatic Cable Installation 8. . . . . . . . . . . . . . .Power Supply 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mounting 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking Resistance 10. . . . . . . . . . . . . . . . . . . . . . .

Repair 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rebuilding the Extension 11. . . . . . . . . . . . . . . . . . . .

Disassembly 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .Assembly 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Using the Illustrated Parts List 12. . . . . . . . . . . . . . .Shaping Bar Assembly 13. . . . . . . . . . . . . . . . . . . . . .Service Kit 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional Mounting Kit 15. . . . . . . . . . . . . . . . . . . . . . .Electrostatic Cable 15. . . . . . . . . . . . . . . . . . . . . . . . .

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 1991. 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 108161-03� 2019 Nordson Corporation

Change RecordRevision Date Change

02 05/16 Reformatted into short manual format.

03 07/19 Released ATEX labels

Change Recordii


ESB-100 Electrostatic Shaping Bar 1


ESB-100 Electrostatic Shaping Bar

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.

ESB-100 Electrostatic Shaping Bar2


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 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.

� 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 SDS 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 SDSfor 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 SDS 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.



Introduction The Nordson model ESB-100 electrostatic shaping bar is designed to beused in conjunction with an electrostatic spray device, such as a rotaryatomizer. It provides increased control of the path of charged coatingmaterial particles, repelling like-charged particles of coating material awayfrom the bar, and also imparts an electrostatic charge to any unchargedparticles that travel through the bar’s corona, so they become attracted tothe workpiece.

When used in a flat panel coating application, where both sides are beingcoated, the bar can be mounted so that wrap is nearly eliminated, reducingexcess buildup along the edges of the panels.

The ESB-100 shaping bar is used with the Nordson model XPS 115electrostatic power supply and the standard rotary atomizer electrostaticcable. Both the electrostatic cable and the power supply must bepurchased separately.



Description See Figure 1. The shaping bar is T-shaped and manufactured of anonconductive material. The extension assembly (4) contains a replaceableresistor and a jumper. The resistance of the extension assembly serves tolimit amperages to a safe level.

The shaping bar (2) has a series of electrodes (1) installed along its length.High voltage from the power unit travels through the cable, extension, andbar, emitting a corona around each electrode.

1604001A

127.00 cm(50.0 in.)

81.92 cm(32.25 in.)

2

1

3 4

5

Figure 1 ESB-100 Electrostatic Shaping Bar

1. Electrodes2. Shaping bar

3. Shaping bar body4. Extension assembly

5. Cable adapter

Specific Conditions of UseThe RA-20 (HV Cable-Fed) applicator and ESB-100 electronic shaping barshall only be used with the associated XPS 115 controller and associatedhigh voltage cable assemblies.

The user/installer shall take note that the certificate only covers theapplication of the XPS 115 controller as associated apparatus used withCategory 2 equipment, if it functions as Category 3 equipment, then thisapplication is covered by the manufacturer’s declaration and the marking isapplied at the manufacturer’s discretion.



The maximum electrostatic voltage for XPS 115 power supplies is 115 kV.

1611967

Figure 2 Safety Label



Installation WARNING: Allow only qualified personnel to perform the following tasks.Observe and follow the safety instructions in this document and all otherrelated documentation.

The following section explains the installation procedures for the ESB-100electrostatic shaping bar.

Assembly Use the following procedure to assemble the electrostatic shaping bar.

1. See Figure 1. The shaping bar is shipped partially assembled in ashipping tube. Remove the components from the tube, remove theplastic shipping caps from the ends of the extension assembly (4).

2. Apply 3−4 cc of dielectric grease into the shaping bar body (3).

3. Install the extension assembly onto the shaping bar body as shown inFigure 1.

Electrostatic Cable Installation

WARNING: Dielectric grease must be applied each time the shaping bar isdisassembled or the electrostatic cable is removed. Failure to observe thiswarning could lead to internal arcing, carbon tracking, and equipmentfailure.

Use the following procedure to install the shaping bar’s electrostatic cable.

1. See Figure 1. Make sure that both ends of the electrostatic cable areclean and dry.

2. Using one of the applicators provided with the shaping bar, inject 5−6 ccof dielectric grease into the cable adapter (5).

3. Push the end of the cable (without the brass tag) into the cable adapteruntil it bottoms out. Thread the cable nut onto the cable adapter.Tighten the cable nut securely and wipe up any dielectric greasedisplaced by the cable.

4. See Figure 3. Route the electrostatic cable (2) between the bar and thepower supply so that the cable will be protected from damage. Do notbend the cable around a radius of less than 15.25 cm (6 in.).

NOTE: If the bar is mounted on a reciprocator or oscillator, do not tie thecable to machine members where the cable must move or stretch. Protectthe cable from abrasion and excessive flexing.



Power Supply The XPS 115 power supply must be mounted outside the spray areaaccording to the National Fire Protection Association publication NFPA-33.Refer to the XPS 115 customer product manual for power supply installationinformation.

Fill the XPS 115 electrostatic cable well with dielectric oil. Insert the end ofthe electrostatic cable (with the brass tag) into the power supply cable welland secure it with the cable nut. Wipe up any oil displaced by the cable.

Mounting See Figure 3. The shaping bar (4) is usually mounted either above or belowthe rotary atomizer (5) and approximately 2.54−5.08 cm (1−2 in.) behind thecup or spray nozzle. Position the shaping bar so that it does not becomecoated, yet is close enough to influence the spray pattern.

Mount the shaping bar so that the electrodes are arranged to obtain thedesired effect. Experimenting with several mounting positions may benecessary to obtain the desired results.

The optional mounting fixture (3) can be used with a48.25-mm (1.90-in.) OD mounting bar (1) to mount the electrostatic shapingbar. Refer to the Parts section for ordering information.

1604002A

1

2

3 4

5

2.54−5.08 cm(1−2 in.)

Figure 3 Installing the Electrostatic Shaping Bar

1. Mounting bar2. Electrostatic cable

3. Optional mounting fixture4. Shaping bar

5. Rotary atomizer



Maintenance Preventive maintenance is limited to cleaning the exterior of the shaping barand checking the electrical resistance of the bar from the electrodes to theend of the electrostatic cable.

Cleaning Use a nontoxic, nonconductive solvent to clean the exterior of the shapingbar. Be careful not to damage the electrodes.

Checking Resistance Check the electrical resistance using the following guidelines:

� Check the resistance from the electrodes on the shaping bar to the endof the electrostatic cable using a megohm meter. Resistance should be906 megohms, ± 15%. If the reading is out of this tolerance zone,rebuild the extension. Refer to the Repair section for more information.

� Resistance of the electrostatic cable (end to end) should be 180−270megohms.



Repair This section explains common repair procedures for the ESB-100electrostatic shaping bar.

Rebuilding the Extension Rebuilding the extension involves removing and replacing the electrostaticcable jumper and resistor. Refer to the Parts section for service kit orderinginformation.

See Figure 4. Use the following procedures to rebuild the shaping bar’sextension.

Disassembly 1. Loosen the jam nut (9) and unscrew the extension (8) from the shaping

bar body (4).

2. Use a wooden dowel to push the resistor (5) and jumper (7) out of theextension. Discard the resistor and jumper.

3. Remove the cable adapter (6) from the extension.

4. Clean the inside and outside of the extension and shaping bar body.Remove all traces of grease and check the interior for damage.Replace the extension if burn-through has occurred.

Assembly 1. Install the jumper (7) into the extension (8).

2. Install the cable adapter (6) onto the extension.

3. Apply 3−4 cc of dielectric grease into the shaping bar body (4).

4. Apply 2−3 cc of dielectric grease into the end of the extension thatthreads into the shaping bar body.

5. Coat the new resistor (5) with dielectric grease.

6. Install the resistor into the end of the extension that threads onto theshaping bar body.

7. Carefully thread the extension into the shaping bar body, lining up theresistor with its hole in the shaping bar body.

8. Apply 5−6 cc of dielectric grease into the end of the cable adapter (6).

9. Install the electrostatic cable into the cable adapter and wipe away anydielectric grease that is forced out of the cable adapter.



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



Shaping Bar Assembly See Figure 4.

Item Part Description Quantity Note— 134620 Bar, shaping, electrostatic, ESB-100 1

1 134619 � Bar, shaping 1

2 941176 � � O-ring, silicone, 0.813 x 1.000 x 0.094in.

1

3 941162 � � O-ring, silicone, 0.750 x 0.937 x 0.094in.

1

4 134542 � � Body, bar, shaping 1

5 307999 � Resistor, 30 kV, 5 W, 665 megohm, 10% 1

6 246153 � Adapter, cable 1

7 134544 � Jumper, 0.38 x 31.5 in. 1

8 134547 � Extension, shaping bar 1

9 134545 � Nut, jam, 1-16, nylon 1

10 940163 � O-ring, silicone, 0.625 x 0.750 x 0.063 in. 1

NS 247639 � Applicator, dielectric grease 2

NS: Not Shown

Service Kit See Figure 4.

Item Part Description Quantity Note— 134750 Service kit, shaping bar 1



5 307999 � Resistor, 30 kV, 5 W, 665 megohm, 10% 1

7 134544 � Jumper, 0.38 x 31.5 in. 1


NS 247639 � Applicator, dielectric grease 2

NS: Not Shown



1604003A

1

23

4

5

109

8

6

7

Figure 4 Rebuilding the Electrostatic Shaping Bar



Optional Mounting Kit See Figure 5.

Item Part Description Quantity Note— 134749 Kit, installation, shaping bar 1

1 - - - - - - � Fixture, 1.5 crossover 1

2 134829 � Spacer, mounting 2

1604004A

1

2

Figure 5 Electrostatic Shaping Bar Mounting Kit

Electrostatic Cable

Item Part Description Quantity NoteNS 117473 Cable, high voltage, 16 meter 1

NS: Not Shown



This page intentionally left blank.

EU DECLARATION of Conformity

Product: RA-20, ESB-100, XPS-115

Models: RA-20 – High Voltage Cable Fed Liquid Electrostatic Rotary Atomizer ESB-100 – Electrostatic Shaping Bar XPS-115 – High Voltage Power Supply / Controller

Description: The RA-20 & the ESB-100 are both used with the XPS-115 controller. The XPS-115 controller has a high

voltage cable which supplies 115KV Max to the RA-20 or the ESB-100. The RA-20 liquid electrostatic rotary atomizer is used for applying liquid coatings to a sub straight. The ESB-100 is used to shape the liquid coating pattern from the RA-20 and in most cases decrease the height of the spray pattern to help eliminate coating of the spray booth ceiling.

Applicable Directives: 2006/42/EC - Machinery Directive 2014/30/EU - EMC Directive 2014/34/EU - ATEX Directive

Standards Used for Compliance: EN/ISO12100 (2010) EN50050-1 (2013) EN61000-6-3 (2007) EN60204-1 (2018) EN50176 (2009) EN61000-6-2 (2005) EN1953 (2013) EN55011 (2016)

Type of Protection: - Ex II 2 G / 0.24mJ = ESB-100 & RA-20- ESB-100 & RA20 are energy level Type: A-L per EN50176 thus tested to EN50050-1.- EX II (2) G = XPS-115 High Voltage Power Supply / Controller

ATEX Product Certificates: - Sira 17ATEX5276X, Sira (Hawarden, UK)

ATEX Quality System Certificate - 1180 SGS Baseefa (Buxton, Derbyshire, UK)

___________________ Date: 19June2019 Hallie Smith - Petee Engineering Manager Industrial Coating Systems Amherst, Ohio, USA

Nordson Authorized Representative in the EU Person authorized to compile the relevant technical documentation. Contact: Operations Manager

Industrial Coating Systems Nordson Deutschland GmbH Heinrich-Hertz-StraBe 42-44 D-40699 Erkrath

Nordson Corporation Westlake, Ohio DOC 13033-01

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