Nordson Encore XT Customer Product Manual
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Nordson Encore XT Customer Product Manual

Manual powder spray systems
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Encore
XT
Manual Powder Spray Systems
Customer Product Manual
Part 1603227-12
Issued 09/16
For parts and technical support, call the
Industrial Coating Systems Customer Support Center
at (800) 433-9319 or contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com/finishing for the latest version.
NORDSON CORPORATION  AMHERST, OHIO  USA

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  • Page 1 Issued 09/16 For parts and technical support, call the Industrial Coating Systems Customer Support Center at (800) 433-9319 or contact your local Nordson representative. This document is subject to change without notice. Check http://emanuals.nordson.com/finishing for the latest version. NORDSON CORPORATION  AMHERST, OHIO  USA...
  • Page 2 Contact Us Notice This is a Nordson Corporation publication which is protected by copyright. Nordson Corporation welcomes requests for information, comments, and Original copyright date 2013. No part of this document may be inquiries about its products. General information about Nordson can be...
  • Page 3 New powder inlet tube; 3- and 4-mm flat spray nozzles ship with gun 01/16 Revised equipment labels 03/16 Added cleaning procedure 04/16 Updated safety labels 05/16 Added trigger kit 09/16 Nozzle and lance extension part number change Part 1603227-12 E 2016 Nordson Corporation...
  • Page 4 Change Record Part 1603227-12 E 2016 Nordson Corporation...

  • Page 5: Table Of Contents

    ......Power Unit and Gun Interface Controllers Certification Label ......Part 1603227-12 E 2016 Nordson Corporation...
  • Page 6 Wall / Rail Mount Systems ......3-14 Part 1603227-12 E 2016 Nordson Corporation...
  • Page 7 ..4-23 Setting the Number of Presets ......4-23 Part 1603227-12 E 2016 Nordson Corporation...
  • Page 8 Vibrator Motor Replacement ......6-18 Part 1603227-12 E 2016 Nordson Corporation...
  • Page 9 ......... . 7-18 Coupling and Pump Adapter Kit ......7-18 Part 1603227-12 E 2016 Nordson Corporation...
  • Page 10 Table of Contents Part 1603227-12 E 2016 Nordson Corporation...

  • Page 11: Safety

    Regulations and Approvals Make sure all equipment is rated and approved for the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if instructions for installation, operation, and service are not followed. All phases of equipment installation must comply with all federal, state, and local codes.

  • Page 12: Personal Safety

    Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 13: Grounding

    Disconnect and lock out electrical power. Close pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the equipment. Disposal Dispose of equipment and materials used in operation and servicing according to local codes. Part 1603227-12 E 2016 Nordson Corporation...
  • Page 14 Safety Part 1603227-12 E 2016 Nordson Corporation...

  • Page 15: Description

    Rail-mount system Wall-mount system Interface Module Spray Gun and Cable Interconnect Cable Mobile System with Mobile System with Hopper Power Unit Vibratory Box Feeder Figure 2-1 Encore XT Mobile Manual Powder Systems − Main Components Part 1603227-12 E 2016 Nordson Corporation...

  • Page 16: Mobile System Components

    Description Mobile System Components Mobile systems include: Encore XT manual controller Encore XT manual spray gun Encore Generation II powder feed pump Encore pump pickup tube One of the following, based on system version: Vibratory table and motor − fluidizes a 25- or 50-lb (11.3- or 22.7-kg) box of powder 50-lb (22.7 kg) Encore round feed hopper −...

  • Page 17: Specifications

    620 (24.4) L x 511.5 (20.1) W Weight: 54.4 kg (120 lbs) Mobile System with 25 lb. Feed Hopper Height: 1078 mm (42.5 in.) Wheel Base: 620 (24.4) L x 511.5 (20.1) W Weight: 53 kg (117 lbs) Part 1603227-12 E 2016 Nordson Corporation...

  • Page 18: Equipment Labels

    Equipment Labels Applicator Certification Label 1088008_03 Spray Gun Interface Controller Certification Label ELECTROSTATIC HAND−HELD POWDER SPRAY EQUIPMENT TYPE ENCORE NORDSON CORPORATION, AMHERST, OHIO U.S.A. EN 50 050 FM14ATEX0052X Ta: +15_C TO + 40_C INTERFACE INPUT: Vo=24VDC INTERFACE OUTPUT: Vo=19VAC Io=1A...
  • Page 19 Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Î Part 1603227-12 E 2016 Nordson Corporation...
  • Page 20 Description Part 1603227-12 E 2016 Nordson Corporation...

  • Page 21: System Setup

    (Connections to right or left) 5/16 M4 x 12 Cap Screws Nuts M4 Lockwashers M5 Lockwashers M5 x 12 Cap Screws Controller Mounted Vertical (Connections up or down) Figure 3-1 Controller Wall Mounting Brackets Part 1603227-12 E 2016 Nordson Corporation...

  • Page 22: Controller Rail Mount

    12−14 x 0.5 in. Sheet Metal Screws with Washer Rail Bracket M8 x 40 Cap Screws M8 Jam Nuts Rail Bracket M5 Lockwashers Orientation Options M5 x 12 Cap Screws Figure 3-2 Controller Rail Mounting Brackets Part 1603227-12 E 2016 Nordson Corporation...

  • Page 23: Interconnect Cable Connection

    Standard System − One 3 meter (10 ft) Cable Optional Cable Configuration To Interface Module Nipple To Power Unit NORDSON NORDSON Sockets Sockets Pins Pins Figure 3-3 Controller Interconnect Cable Connections Part 1603227-12 E 2016 Nordson Corporation...

  • Page 24: System Connections

    Chassis Powder Box* Ground * Relay disabled when controller VIibrator Motor* .configured for hopper system ** Filter/Regulator − Mobile systems Filter only − Wall/Rail-mount systems Figure 3-4 Encore XT Manual Powder System Block Diagram Part 1603227-12 E 2016 Nordson Corporation...

  • Page 25: Controller Connections

    (15 ft) (Manual System) or Auxiliary Vibrator Motor Power Cord Fluidizing Air INTERFACE MODULE Check Valve (8-mm, reduced to 6-mm) Ground Network/Power Interconnect Gun Cable Cable (to Gun) Figure 3-5 Encore XT Controller Connections Part 1603227-12 E 2016 Nordson Corporation...

  • Page 26: Vbf System Setup

    1A. Tube holder 4. 6-mm conductive black fluidizing air tubing 8. 8-mm black flow air tubing 2. Pickup tube catch 5. Powder pump 9. Powder hose 3. Pickup tube assembly 6. Quick-connect fittings Part 1603227-12 E 2016 Nordson Corporation...

  • Page 27: Hopper And Wall/Rail Mount System Setup

    Vent Hose Vent Stack Ground Stud Fluidizing Air Ground Fitting Plug/Socket Hopper Reducer Fluidizing Air Fluidizing Ground Tubing Cable Figure 3-7 Hopper Installation on Mobile System dolly Part 1603227-12 E 2016 Nordson Corporation...

  • Page 28: Wall/Rail Mount System Hopper Installation

    System Setup Wall/Rail Mount System Hopper Installation If connecting fluidizing air to a Nordson feed hopper, use the 10-mm stem x 8-mm tube reducer fitting shipped with the controller to connect the 8-mm tubing supplied with the system to the hopper fluidizing air fitting.

  • Page 29: Pump Connections

    Pull back on the knurled coupling rings to disconnect them. Blue 8-mm Tubing (Atomizing AIr Quick-Disconnect Couplings Throat Holder Black 8-mm Tubing Powder Hose (Flow Air) Figure 3-9 Pump Connections Part 1603227-12 E 2016 Nordson Corporation...

  • Page 30: Wall/Rail Mount Power Unit Connections

    3. Thread the cable nut onto the receptacle and tighten the nut securely. Net Cable (To Power Unit) Cable Figure 3-11 Gun Cable Connection to Interface Module − Mobile Systems Part 1603227-12 E 2016 Nordson Corporation...

  • Page 31: Air Tubing And Powder Hose

    Purge Air Tubing Powder Hose Figure 3-12 Gun Connections Bundling Tubing and Cable Use the sections of black spiral wrap supplied with the system to bundle together the spray gun cable, air tubing, and powder hose. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 32: System Air And Electrical Connections

    The air must be clean and dry. A refrigerant or desiccant-type air drier and air filters are recommended. 10-mm Air Tubing Air Filter/ Regulator Figure 3-13 System Air Supply Connection Part 1603227-12 E 2016 Nordson Corporation...

  • Page 33: Wall / Rail Mount System Air Supply

    Figure 3-14 Air Filter Installation − Wall and Rail Mount Systems 1. 10-mm air tubing (blue) 4. Bracket 6. Release latch 2. 10-mm tube x 1/2 male connectors 5. Flow indicator 7. Customer-supplied fasteners 3. M5 screws Part 1603227-12 E 2016 Nordson Corporation...

  • Page 34: Electrical Connections

    Use the ESD ground bus bar kit included with the system to connect the power unit ground stud to the grounded spray booth or a true earth ground. Refer to the instructions included with the kit. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 35: Operation

    European Union, ATEX, Special Conditions for Safe Use 1. The Encore XT manual applicator shall only be used with the associated Encore XT/HD interface control unit and Encore XT controller power unit, over the ambient temperature range of +15 _C to +40 _C.

  • Page 36: Feed Hopper Filling

    Do not overfill, as the powder volume will increase when fluidizing air is turned on. Make sure the vent hose is connected to the powder booth, so that vented fine powder dust does not contaminate the spray room. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 37: Spray Gun Operation

    Purging the Spray Gun 1. See Figure 4-3. Point the gun into the booth and release the spray trigger. 2. Press the Purge button. The purge will continue as long as you press the purge button. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 38: Fluidizing Air Operation

    Standby or turn off controller power. To configure the system for a vibratory box feeder, change the VBF delay time, or set the vibrator motor to continuous operation, refer to Controller Configuration on page 4-21. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 39: Electrode Air Wash Operation

    Powder Box Installation on page 4-1 for instructions. 4. See Figure 4-5. Make sure the spray gun is not triggered, then turn on controller power. The displays and icons on the controller interface and gun interface should light. Part 1603227-12 E 2016 Nordson Corporation...
  • Page 40 NOTE: If using Total Flow mode, the total air setpoint must be greater to zero or you will not be able to set % Flow Air and the gun will not spray powder. Refer to page 4-17 for more information. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 41: Standby Button

    Max kV, 150 g/min (20 lb/hr) Max kV, 300 g/min (40 lb/hr) Select Charge 3 (deep recess), 150 g/min (20 lb/hr) 100* * Select Charge Mode settings are factory set and cannot be changed. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 42: Changing Flat Spray Nozzles

    Follow the instructions in the conical nozzle kit shipped with the gun for this conversion. 1. Purge the spray gun and turn off the interface in order to prevent accidentally triggering the gun on. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 43: Installing The Optional Pattern Adjuster Kit

    4. Install a 16, 19, or 26-mm deflector onto the electrode holder. Pattern Adjuster Kit Deflector Electrode Assembly Conical Electrode Holder Figure 4-8 Pattern Adjuster Kit Installation Part 1603227-12 E 2016 Nordson Corporation...

  • Page 44: Shutdown

    Failure to observe this warning may result in personal injury. Recommended Cleaning Procedure for Powder Contact Parts Nordson Corporation recommends using an ultrasonic cleaning machine and Oakiter BetaSolv emulsion cleaner to clean spray gun nozzles and powder path parts.

  • Page 45: Maintenance Procedures

    Check the system air filter/regulator. Drain the filter and change the filter element as Filter needed. (Periodically) System Daily: Make sure the system is securely connected to a true earth ground before Grounds spraying powder. Periodically: Check all system ground connections. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 46: Using The Controller Interface

    Use the Rotary Knob to change the selected setpoint: clockwise to increase, counter-clockwise to decrease. The setpoints reset to the minimum if increased past their maximum. Selecting a Setpoint to Change Changing a Setpoint Figure 4-10 Selecting and Changing Setpoints Part 1603227-12 E 2016 Nordson Corporation...

  • Page 47: Help Codes

    The Help icon lights if the maintenance timer is set and runs out. To reset the maintenance timer, press the View button. The Timer icon lights when the maintenance hours are displayed. While they are displayed, press the Enter button. Figure 4-12 Displaying Maintenance Hours Part 1603227-12 E 2016 Nordson Corporation...

  • Page 48: Presets

    Mode 3 Figure 4-14 Select Charge Mode NOTE: If the operator tries to adjust kV or A values while a Select Charge mode is selected, the controller will switch to Custom or Classic mode. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 49: Custom Mode

    When the gun is triggered the actual KV and A outputs are displayed. Custom Mode − Gun Triggered Custom Mode − Preset Setpoints Figure 4-15 Custom Mode − Preset Setpoints and Gun Triggered Displays Part 1603227-12 E 2016 Nordson Corporation...

  • Page 50: Classic Mode

    NOTE: The default A range is 10−50 A. The limits of the range can be adjusted. Refer to Controller Configuration on page 4-21. When the gun is not triggered the A setpoint is displayed. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 51: Powder Flow Settings

    Total Flow R: 2.55−10.2 M /HR, minimum 0.17 M /HR increments, or 1.5−6.0 SCFM, minimum 0.1 SCFM increments. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 52: Setting Smart Flow Setpoints

    When the spray gun is triggered the displays show actual flows. Flow Air % Total Flow Air in M /HR or SCFM Figure 4-20 Smart Flow Mode − Flow Air % or Total Flow  Part 1603227-12 E 2016 Nordson Corporation...

  • Page 53: Smart Flow Settings − Metric Units

    6.37 6.79 7.22 7.64 8.07 8.49 8.92 9.34 9.77 10.19 5.95 6.80 7.22 7.65 8.07 8.50 8.92 9.35 9.77 10.20 0.85 1.27 1.70 2.12 2.55 2.97 3.40 3.82 4.25 4.67 5.10 5.52 5.95 Flow Part 1603227-12 E 2016 Nordson Corporation...

  • Page 54: Smart Flow Settings − English Units

    4.00 4.25 4.50 4.75 5.00 5.25 5.50 5.75 6.00 3.50 4.00 4.25 4.50 4.75 5.00 5.25 5.50 5.75 6.00 0.50 0.75 1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25 3.50 SCFM Flow Part 1603227-12 E 2016 Nordson Corporation...

  • Page 55: Classic Flow Mode Settings

    When the spray gun is triggered the actual flows are displayed. Controller Configuration Opening the Function Menu and Making Settings Press and hold the Nordson button for 5 seconds. The Function/Help display lights to show the Function numbers and values. Use the Functions to configure the controller for your application.
  • Page 56 Total Hours View Only − Save/Restore/Reset 00=System Save, 01=System Restore, 02=Factory Reset Gun Display Brightness 00=Low, 01=Medium, 02=Maximum Number of Presets 01−20 presets NOTE: Refer to Section 4, Troubleshooting for the Zero Reset procedure. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 57: Vibratory Box Feeder On Continuously

    3. Set F06 to F06−On. The default setting is F06−30. To set it to On, rotate the knob counterclockwise to decrement the numbers past 0 to 4. Press Enter to set the value to On, then press the Nordson button to exit the Functions menu.
  • Page 58 4-24 Operation Part 1603227-12 E 2016 Nordson Corporation...

  • Page 59: Troubleshooting

    These troubleshooting procedures cover only the most common problems. If you cannot solve a problem with the information given here, contact Nordson technical support at (800) 433−9319 or your local Nordson representative for help. Help Code Troubleshooting The Help icon in the Function/Help display lights if a problem occurs that the controller can sense.

  • Page 60: Help Code Troubleshooting Chart

    Refer to the controller wiring diagrams in this section. Check the wiring harness connection to J7 and the proportional valve solenoid. Check the solenoid operation. Replace the valve if the solenoid is not working. Continued.. Part 1603227-12 E 2016 Nordson Corporation...
  • Page 61 If the fault reoccurs, check for a bad trigger switch. EEPROM Data Version Software version has been changed. This code appears after Changed a software update. Clear the fault. It should not reappear. Continued.. Part 1603227-12 E 2016 Nordson Corporation...
  • Page 62 If the A display reads 0 with the gun triggered on and close to a part, check the gun cable or the gun power supply. When the gun is triggered on and kV is set >0, the A display should always read >0. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 63: General Troubleshooting Chart

    Remove powder path if necessary and clean it. Electrode air wash flow too high Adjust the needle valve at the power unit to decrease the electrode air wash flow. Continued... Part 1603227-12 E 2016 Nordson Corporation...
  • Page 64 Perform the Gun Cable Continuity Test on page 5-11. NOTE: It may be possible to use the settings trigger as the spray trigger until repairs are made. Set Function F08 to F08−05. Refer to page 4-22. Continued... Part 1603227-12 E 2016 Nordson Corporation...
  • Page 65 Check powder inlet tube, elbow, and electrode support for impact fusion or debris. Clean as necessary with compressed air. Flow and atomizing air tubing Check flow and atomizing air tubing reversed routing and correct if incorrect. Continued.. Part 1603227-12 E 2016 Nordson Corporation...
  • Page 66 17. Gun flow % does not Total air set to zero If the total air is set to zero the flow increment, always 0 percent cannot be adjusted. Change the total flow to a non-zero number. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 67: Re-Zero Procedure

    1. At the power unit, disconnect the flow and atomizing air tubing and install 8-mm plugs in the output fittings. 2. Press the Nordson button for 5 seconds to display the controller functions. F00−00 is displayed. 3. Rotate the knob until F10−00 is displayed.

  • Page 68: Spray Gun Power Supply Resistance Test

    The resistance should be 19−21 megohms. If the resistance is out of this range replace the electrode assembly. 19−21 Megohms Figure 5-3 Electrode Assembly Resistance Test Part 1603227-12 E 2016 Nordson Corporation...

  • Page 69: Gun Cable Continuity Test

    CAN + WHITE J1−2 P1−2 V− BLACK J1−3 P1−3 2 CAN + J1−4 P1−4 4 V+ 4 V+ SHIELD/DRAIN BARE 2 CAN + J1−5 P1−5 3 V− 3 V− Figure 5-5 Controller Interconnect Cable Wiring Part 1603227-12 E 2016 Nordson Corporation...

  • Page 70: System Wiring Diagrams

    (BLACK) DC COM (RED) +24VDC (RED) +24VDC 3 (WHITE) DC COM (GREEN) 4 (GREEN) +24VDC 5 (GRAY) DRAIN 1 (RED) CAN− 2 (BLACK) CAN+ (GREEN W/YELLOW) (GREEN W/YELLOW) Figure 5-6 Power Unit Wiring Diagram Part 1603227-12 E 2016 Nordson Corporation...
  • Page 71 5 (YELLOW) FEEDBACK (WHITE) CAN+ (GREEN) CHASSIS (BLUE) CAN− (BLACK) DC COM 3 (BLACK) DC COM 4 (WHITE) CAN+ 5 (BLUE) CAN− 1 (GREEN) CHASSIS 2 (RED) +24VDC Figure 5-7 Controller Interface Wiring Diagram Part 1603227-12 E 2016 Nordson Corporation...
  • Page 72 5-14 Troubleshooting Part 1603227-12 E 2016 Nordson Corporation...

  • Page 73: Repair

    9. Display module 20.Cable assembly 29. Settings/purge trigger 10. Hook 20A. Power supply connector (J2) 30. Screw (handle to gun body) Note: Ground terminal (20C) must always be connected to the ground screw (16). Part 1603227-12 E 2016 Nordson Corporation...

  • Page 74: Display Module Replacement

    6. Gently fold the trigger switch ribbon cable and display module cable into the gun, and install the display module onto the gun. 7. Slide the hook (10) onto the display module, then install the bezel (11). 8. Install and tighten the screws (12). Part 1603227-12 E 2016 Nordson Corporation...

  • Page 75: Power Supply And Powder Path Replacement

    The air wash tubing will prevent a complete separation; leave it connected unless it must be replaced. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 76: Power Supply Replacement

    4. Press on the end of the power supply to ensure that the power supply contact tip is firmly seated against the brass contact inside the gun body. 5. Route the power supply harness connector through the top hole in the bulkhead. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 77: Powder Path Replacement

    O-rings are undamaged. Figure 6-5 Powder Path Replacement 4. Outlet tube 14. Air wash tubing 22. M3 x 20 screws 5. Elbow 18. Ground pad 25. Inlet tube 13. Gun body 21. Handle base 26. Handle Part 1603227-12 E 2016 Nordson Corporation...

  • Page 78: Powder Path Installation

    6. Install the nozzle (2) on the electrode assembly, making sure the keys in the electrode assembly slide into the slots on the nozzle. 7. Install the nozzle nut (1) over the nozzle and rotate clockwise to secure. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 79: Cable Replacement

    VIEW A VIEW B Figure 6-7 Cable Replacement 12. M3 x 35 screw 17. Lock washer 19. Retaining ring 16. M3 x 6 screw 18. Ground pad 21. Handle base 22. M3 x 20 screws Part 1603227-12 E 2016 Nordson Corporation...

  • Page 80: Cable Installation

    6. Remove the spray trigger (27), actuator (28), and purge trigger (29) from the handle. 7. Use a tool to pry and pull the trigger switch (14) off the handle, then pull it up and out of the handle. Gusset Figure 6-8 Trigger Switch Replacement Part 1603227-12 E 2016 Nordson Corporation...

  • Page 81: Switch Installation

    7. Feed the trigger switch ribbon cable through the bottom of the bulkhead and connect the ribbon cable connector to the display module as described in Display Module Installation on page 6-2. 8. Re-assemble the gun as described in Gun Re-assembly on page 6-6. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 82: Interface Module Repair

    Refer to Section 7, Parts for repair kits. External Enclosure Ground Internal Enclosure Ground Connect to 2A, J6 Figure 6-10 Interface Module Assembly 1. Bezel 2A. Main Control Board 2C. Keypad Panel 2. Keypad/PCB Assembly 2B. Main Display Board 3. Enclosure Part 1603227-12 E 2016 Nordson Corporation...

  • Page 83: Power Unit Repair

    Refer to Section 5, Troubleshooting, for the power unit electrical schematic and harness connections. Removing the Sub-Panel External Enclosure Ground Internal Enclosure Gound Figure 6-11 Sub-Panel Removal 1. Enclosure 2. Sub-Panel 3. Power Switch Guard Part 1603227-12 E 2016 Nordson Corporation...

  • Page 84: Sub-Panel Components

    Install the plugs and connectors from the old regulator in the new regulator. 1. See Figure 6-13. Pull the sub-panel (7) far enough out of the power unit cabinet to access the regulator. Part 1603227-12 E 2016 Nordson Corporation...
  • Page 85 Figure 6-13 Regulator Adjustment 1. Orifice assembly 4. Air wash fitting 6. Air fitting plugs 2. 4-mm clear tubing 5. Regulator 7. Sub-panel 3. Manometer Part 1603227-12 E 2016 Nordson Corporation...

  • Page 86: Iflow Module Repair

    Check the output pressure at different flow settings. If the manometer reading is within the acceptable range then the digital flow module is working correctly. If the reading is not within the acceptable range refer to the Troubleshooting procedures in Section 4, Troubleshooting. Part 1603227-12 E 2016 Nordson Corporation...
  • Page 87 2.0 (29) 2.2 (32) 5.05 (3.00) 2.3 (33) 2.5 (36) 5.50 (3.25) 2.5 (37) 2.8 (40) 5.95 (3.50) 2.8 (41) 3.0 (44) 6.35 (3.75) 3.0 (45) 3.3 (48) 6.80 (4.00) 3.4 (49) 3.6 (52) Part 1603227-12 E 2016 Nordson Corporation...

  • Page 88: Solenoid Valve Replacement

    The valves are calibrated for different springs. 3. Remove the valve stem (8) from the valve body (11). 4. Remove the valve cartridge (10) and spring (9) from the stem. Part 1603227-12 E 2016 Nordson Corporation...
  • Page 89 7. Direction of flow arrow 11. Valve body 3. Coil−proportional valve (2) 8. Stem 12. Orifice 4. Long screws−valve to manifold (2) 9. Spring 13. Solenoid valves 5. Short screws−valve stem to body (2) Part 1603227-12 E 2016 Nordson Corporation...

  • Page 90: Proportional Valve Replacement

    Check the ID plate on the power unit. Replacement motors include the power cable. Refer to the Power Unit Wiring Diagram in the Troubleshooting section of this manual for internal VBF wiring. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 91: Parts

    Parts Section 7 Parts Introduction To order parts, call the Nordson Industrial Coating Systems Customer Support Center at (800) 433-9319 or contact your local Nordson representative. This section covers components, parts and options for the Encore LT spray gun, controller, and systems.

  • Page 92: Spray Gun Parts

    Parts Spray Gun Parts See Figure 7-1 and the parts list on the following pages. Spray Gun Parts Illustration Figure 7-1 Exploded View of Encore XT Manual Spray Gun and Accessories Part 1603227-12 E 2016 Nordson Corporation...

  • Page 93: Spray Gun Parts List

    M3 x 6, zinc 1106871 S HANDLE, ground pad, handgun, Encore LT/XT 1081777 S RETAINING RING, external, 10 mm 1600745 S CABLE ASSY, handgun, 6 meter, Encore XT 940129 S S O-RING, silicone, conductive, 0.375 x 0.50in. 1087762 S BASE, handle, handgun 760580...

  • Page 94: Spray Gun Options

    S O-RING, silicone, 0.468 x 0.568 x 0.05 in. 941113 S O-RING, silicone, 0.438 x 0.625 x 0.094 in. 1096696 ELBOW, powder tube, Encore, impact resistant 1085168 CABLE, 6-wire, shielded, handgun, 6 meter extension NS: Not Shown Part 1603227-12 E 2016 Nordson Corporation...

  • Page 95: Flat Spray Nozzles

    3 mm Flat Spray 1081658 1081659 6 mm Flat Spray 4 mm Flat Spray Figure 7-2 Flat Spray Nozzles Cross-Cut Nozzles 1082184 1082185 1082186 60 Degree Cross-cut 90 Degree Cross-cut 2.5 mm Castle Figure 7-3 Cross-cut Nozzles Part 1603227-12 E 2016 Nordson Corporation...

  • Page 96: 45-Degree Corner-Spray Nozzle

    Three angled slots in-line with spray gun axis Application Top and bottom coating; typically no in/out part positioning Part Description Note 1102871 NOZZLE, 45 degree, flat spray, Encore Figure 7-5 45-Degree Flat Spray Nozzle Part 1603227-12 E 2016 Nordson Corporation...

  • Page 97: Conical Nozzle, Deflectors And Electrode Assembly Parts

    S ELECTRODE HOLDER, Conical 1605861 Conical Electrode Assembly Figure 7-8 Conical Electrode Assembly Item Part Description Quantity Note — 1106076 ELECTRODE ASSEMBLY, conical, Encore −−−−−− S ELECTRODE SUPPORT 1106078 S ELECTRODE S ELECTRODE HOLDER, Conical 1605861 Part 1603227-12 E 2016 Nordson Corporation...

  • Page 98: Pattern Adjuster Kit

    26-mm conical nozzle deflectors listed on the preceding pages. Refer to the instruction sheet shipped with the pattern adjuster for installation instructions and repair parts. Part Description Note 1100012 KIT, pattern adjuster, Encore lance extension. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 99: Ion Collector Kit

    ROD, ion collector, 15 in. — 189484 ROD, ion collector, 21 in. — 1603939 BRACKET, lance extension, ion collector, Encore A, B NOTE A: Use for 150-mm lance extension. B: Use for 300-mm lance extension. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 100: Controller Parts

    7-10 Parts Controller Parts Interface Exploded View Interconnect Cable Refer to System Components and Parts, page 7-15 Figure 7-10 Interface Parts Part 1603227-12 E 2016 Nordson Corporation...

  • Page 101: Interface Parts List

    240674 S TAG, ground 939122 S SEAL, conduit fitting, in., blue 984526 S NUT, lock, in. conduit 1082709 S RECEPTACLE, gun, Encore 1082759 S RECEPTACLE, net, controller interface, Encore NOTE A: Receptacles include harnesses. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 102: Power Unit Exploded View

    7-12 Parts Power Unit Exploded View Interconnect Cable Refer to System Components and Parts, page 7-15 Figure 7-11 Power Unit Parts Part 1603227-12 E 2016 Nordson Corporation...

  • Page 103: Power Unit Parts List

    G: Only use this capacitor with the 115V power unit (1600468) using a vibrator motor with the model number MVE21M. If the vibrator motor model number is MVE20, then a 2.0 F capacitor (1083021) is acceptable. AR: As Required NS: Not Shown Part 1603227-12 E 2016 Nordson Corporation...

  • Page 104: Iflow Module Exploded View And Parts List

    972399 S CONNECTOR, male, w/internal hex, 6 mm tube x in. unithread 972125 S CONNECTOR, male, elbow, 10 mm tube x in. unithread 1082612 S VALVE, flow control, 4 mm x ⅛ uni Part 1603227-12 E 2016 Nordson Corporation...

  • Page 105: System Components And Parts

    If the motor model number is MVE20, then a 2.0 F capacitor (1083021) is acceptable. G: Refer to pump manual 1095927 for repair kits. NS: Not Shown Figure 7-13 Miscellaneous Mobile System Parts Part 1603227-12 E 2016 Nordson Corporation...

  • Page 106: Wall/Rail Mount System Parts

    C: This tubing is used on VBF systems to provide fluidizing air from the bulkhead union to the pickup tube. It is conductive and grounds the pickup tube to the cart body. Do not replace with non-conductive tubing. D: Minimum order quantity is 25 ft. E: Minimum order quantity is 100 ft. Part 1603227-12 E 2016 Nordson Corporation...

  • Page 107: Miscellaneous Options

    Elements are not interchangeable. Cup Gun See Figure 7-14. See the Encore Cup Gun instruction sheet for spare parts information. Part Description Quantity Note 1100777 KIT, cup gun, Encore Figure 7-14 Cup Gun Kit Part 1603227-12 E 2016 Nordson Corporation...

  • Page 108: Pump Parts

    Each Encore pump is shipped with a manual containing installation, repair, and parts information. Encore pump manuals can also be downloaded from the internet in PDF format from http://emanuals.nordson.com. Coupling and Pump Adapter Kit Wall and rail mount systems, and mobile systems with feed hoppers are shipped with an Encore pump adapter kit for use with the Encore Powder Pump.

  • Page 109: Declaration Of Conformity

    Type of Protection: - Ambient Temperature: +15ºC to +40ºC - Ex tb IIIB T60ºC / Ex II 2 D / 2mJ = (Encore XT and HD Applicators) - Ex tc IIIB T60ºC / EX II (2) 3 D = (Controllers)

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