Nordson Encore HD Product Manual
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Nordson Encore HD Product Manual

Manual powder spray system controller
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Encore
HD and XT Manual Powder
Spray System Controller
Customer Product Manual
Part 1604870-05
Issued 04/18
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
and available local languages.
NORDSON CORPORATION • AMHERST, OHIO • USA

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  • Page 1 Issued 04/18 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 and available local languages.
  • 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 2014. No part of this document may be inquiries about its products. General information about Nordson can be...
  • Page 3 Change Record Change Record Revision Date Change 01/14 New release 09/14 Re-zero procedure revised 01/15 New equipment labels 10/15 Revised illustrations and content 04/18 Revised some illustrations for new pump. Updated Certification Label. Part 1604870-05 E 2018 Nordson Corporation...
  • Page 4 Change Record Part 1604870-05 E 2018 Nordson Corporation...

  • Page 5: Table Of Contents

    Controller Connections ....... . Part 1604870-05 E 2018 Nordson Corporation...
  • Page 6 ........Part 1604870-05 E 2018 Nordson Corporation...

  • Page 7: 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 8: 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 1604870-05 E 2018 Nordson Corporation...

  • Page 9: 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 1604870-05 E 2018 Nordson Corporation...
  • Page 10 Safety Part 1604870-05 E 2018 Nordson Corporation...

  • Page 11: Description

    Figure 2-1 Encore HD/XT Manual Powder Spray System Controller The system controller is used with the Encore HD with HDLV technology and the Encore XT with venturi technology. The Encore HD and XT controller may be used in the following systems:...

  • Page 12: Specifications

    Description Specifications Model: Encore HD and XT Interface Controller Input voltage rating 24 VDC, 2.75 A Output voltage rating +/− 19 VAC, 1A Input air 6.0−7.6 bar (87−110 psi), <5μ particulates, dew point <10 _C (50 _F) Maximum relative humidity...

  • Page 13: System Setup

    3. Install the universal mounting bracket (3) to the controller rail mount bracket (2). Figure 3-1 Controller Rail Mount Installation (Bottom to Top Orientation) 1. Product stand arm 3. Universal mounting bracket 4. Encore HD controller 2. Controller rail mount bracket Part 1604870-05 E 2018 Nordson Corporation...

  • Page 14: System Connections

    System Diagram WARNING: This diagram does not show system grounds. All conductive equipment in the spray area must be connected to a true earth ground. Use the grounding block supplied with the Nordson system. Powder Spray Gun 4 mm in...

  • Page 15: Controller Connections

    Standard System − One 3 meter (10 ft) Cable Optional Cable Configuration To Interface Module To Power Unit Nipple Sockets Pins Sockets Pins Figure 3-4 Encore Controller Interconnect Cable Connection Part 1604870-05 E 2018 Nordson Corporation...
  • Page 16 System Setup Part 1604870-05 E 2018 Nordson Corporation...

  • Page 17: Operation

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

  • Page 18: Initial Startup

    Table 4-1 Function Settings Function Function Function Default Number Name Values HDLV Mode Gun Type 00=Encore XT/HD, 02=Robot Fluidizing 00=Hopper, 01=Box, 02=Disable Pump Type 00=Venturi, 01=HDLV, 02=COD Control Type 00=Local, 01=External Gun Number 1−4 Part 1604870-05 E 2018 Nordson Corporation...

  • Page 19: Standby Button

    When the controller interface is off, the spray gun cannot be triggered and the spray gun interface is disabled. To shut off controller power, use the power switch on the pump control unit. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 20: Factory Set Presets

    Powder Flow % kV Setting μA Setting Setting Icons Pattern Air Flow Setting Function/Help Display Help Button Rotary Knob Standby Button Nordson Button (Configuration) View Button Enter Button Color Change Button Figure 4-2 Controller Interface Part 1604870-05 E 2018 Nordson Corporation...

  • Page 21: Changing A Factory Configured Preset Or Setpoint Value

    4. To change a preset value, first choose the desired preset by using the Rotary Knob. Once the preset is selected, change the electrostatic and powder flow settings to the desired values. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 22: Electrostatic Settings

    Mode 3 Figure 4-5 Select Charge Mode NOTE: If the operator tries to adjust kV or μA values while a Select Charge mode is selected, the controller will switch to Custom or Classic mode. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 23: Custom Mode

    Refer to View B. When the gun is triggered the actual kV and μA outputs are displayed. View A View B Custom Mode − Gun Triggered Custom Mode − Preset Setpoints Figure 4-6 Custom Mode − Electrostatic Displays Part 1604870-05 E 2018 Nordson Corporation...

  • Page 24: Classic Mode

    1. To adjust the kV setpoint, press the kV button. The button LED lights to show that kV is selected. 2. Turn the Rotary Knob to increase or decrease the kV setpoint. The setpoint automatically saves in 3 seconds or when any button is pressed. Part 1604870-05 E 2018 Nordson Corporation...
  • Page 25 3 seconds, or when any button is pressed. NOTE: The default μA range is 10−50 μA. The limits of the range can be adjusted. Refer to Controller Configuration on page 4-20. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 26: Help Codes

    To clear the Help codes, scroll through them until CLr is displayed, then press the Enter button. The Help icon stays lit until the controller clears the codes. Refer to Section 5, Troubleshooting, for help code troubleshooting, general system troubleshooting, and controller wiring diagram. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 27: Assist Air Setting, Fast Flow Setting, And Software Versions

    NOTE: Adjustments to Assist Air and Fast Flow preset values only affect the preset you are currently viewing. A user can program as many as 20 presets, and each preset must be adjusted individually where required. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 28: Powder Flow Settings

    When the spray gun is triggered the actual flows are displayed. Flow Button Flow Icon Pattern Button Pattern Icon Figure 4-10 Flow or Pattern Setpoints NOTE: Increasing pattern air will not increase powder flow output. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 29: Xt 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 1604870-05 E 2018 Nordson Corporation...
  • Page 30 When the spray gun is triggered the displays show actual flows. Flow Air % Total Flow Air in M /HR or SCFM Figure 4-13 Smart Flow Mode − Flow Air % or Total Flow ∑ Part 1604870-05 E 2018 Nordson Corporation...
  • Page 31 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 1604870-05 E 2018 Nordson Corporation...
  • Page 32 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 1604870-05 E 2018 Nordson Corporation...

  • Page 33: Color Change Purge

    DUAL - Both guns (two gun systems) are purged. DISABLED - Color Change key is disabled. Automatically selected if the Gun Type is set to HDLV-COD or EXTNAL-COD REMOTE - Purging is controlled by the iControl system. Part 1604870-05 E 2018 Nordson Corporation...
  • Page 34 (F30) SIPHON PULSES: 1−99 pulses, default is 7. (F31) GUN PULSES: 1−99 pulses, default is 13. NOTE: Refer to functions F22 through F33 in the Controller Configuration section on page 4-20 for more information. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 35: Color-On-Demand (Cod) System Purge

    (F31) GUN PULSES: 1−99 pulses, default is 18. (F32) POWDER PRE-LOAD: 0−99 seconds, default is 4. NOTE: To return to the factory defaults, manually reset F15 to 02. Refer to the Controller Configuration section on page 4-20 for more information. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 36: Controller Configuration

    4-20 Controller Configuration Opening the Function Menu and Setting Preferences 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 37 00−90 Seconds Sets the number of On=Continuous seconds the vibratory Operation box continues to operate after the gun trigger is released. Choose from 0 to 90 seconds, or choose ON for continuous operation. Continued... Part 1604870-05 E 2018 Nordson Corporation...
  • Page 38 Gun Display Brightness 00=Low Sets brightness for gun 01=Medium display. 02=Maximum Number of Presets 01−20 Presets Choose from 1 to 20 presets. See page 4-5 for more information. Continued... Part 1604870-05 E 2018 Nordson Corporation...
  • Page 39 0.00 - 5.00 Seconds in Sets the number of 0.00 0.25 Increments seconds the pattern air continues to operate after the gun trigger is released. Choose from 0 to 5 seconds in 0.25 increments. Continued... Part 1604870-05 E 2018 Nordson Corporation...
  • Page 40 (Gun Pulses). Powder Pre−Load 1−99 The new color powder is pumped to the spray gun for the set time at 100% of flow to load the system for production. Continued... Part 1604870-05 E 2018 Nordson Corporation...

  • Page 41: Saving And Loading Preset And Function Settings

    NOTE: If you configure F19=01 External (Robot Gateway), then there are only 10 presets. NOTE: If the function is set to F17−01, then only 1 preset will be available for use. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 42: Hd System Shutdown

    4. If shutting down for the night or a longer period of time, move the power unit switch to the OFF position to shut off system power. 5. Perform the Maintenance procedures on page 4-27. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 43: Maintenance

    Daily maintenance for the controller should include blowing off the interface module with a blow gun. Wipe any residual powder off the controller with a clean cloth. Periodically check all system ground connections. Part 1604870-05 E 2018 Nordson Corporation...
  • Page 44 Operation 4-28 Part 1604870-05 E 2018 Nordson Corporation...

  • Page 45: 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 46: Help Code Troubleshooting Chart

    Startup section on page 4-2 for more information on setting up gun numbers. EEPROM Read Failed Reset the fault (press the Nordson key to open the fault screen). This fault will sometimes occur when the software is upgraded. Gun Open Trigger the gun and check the display.
  • Page 47 Refer to the Repair section in the Encore XT Manual Powder Spray Systems manual for procedures using the iFlow Air Flow Verification Kit (1039881) to check the operation of the iFlow module proportional valves and the output of the precision air pressure regulator. Continued... Part 1604870-05 E 2018 Nordson Corporation...
  • Page 48 Perform the Conveyance Air Flow Verification for HD procedure on page 5-13. Check for water and/or oil contamination in the transducer filters by removing the board from the flow manifold. Replace filters with 1604436. Continued... Part 1604870-05 E 2018 Nordson Corporation...
  • Page 49 5-13. Check for water and/or oil contamination in the transducer filters by removing the board from the flow manifold. Replace filters with 1604436. Atomizing Air Flow High Fault See H25 (XT) (XT) Continued... Part 1604870-05 E 2018 Nordson Corporation...
  • Page 50 Robot Heartbeat Missing System controller is configured for External Mode, and cannot detect the Prodigy PLC Gateway heartbeat. Check CAN cable. Make sure Gateway is configured properly. Refer to the Prodigy PLC Gateway manual. Continued... Part 1604870-05 E 2018 Nordson Corporation...
  • Page 51 Purge Valve 9 Fault Check J12-3 for loose harness connection. Check Valve 9 for loose connection. Purge Pinch Pressure Select Check J12-2 for loose harness connection. Valve 8 Fault Check Valve 8 for loose connection. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 52: General Troubleshooting Chart

    Air tubing kinked or plugged (H24 Check pattern air tubing for kinks. or H25) Fluidizing air too high If fluidizing air is set too high the ratio of powder to air will be be too low. Continued... Part 1604870-05 E 2018 Nordson Corporation...
  • Page 53 − water contamination of Replace filter element if necessary. flow controller Clean system, replace components if necessary. Flow valve plugged (H24 or H25) Refer to Proportional Valve Cleaning in the pump control unit manual. Continued... Part 1604870-05 E 2018 Nordson Corporation...
  • Page 54 Resistance Test as described in your spraying spray gun manual. Damaged gun cable Perform the Gun Cable Continuity Test as described in your spray gun manual. If an open or short is found, replace the cable. Continued... Part 1604870-05 E 2018 Nordson Corporation...
  • Page 55 Presets with no set values for flow rate and electrostatics are automatically skipped. Loose or defective trigger switch Check for a loose trigger switch connection. The trigger switch is plugged into the gun display module. Continued... Part 1604870-05 E 2018 Nordson Corporation...
  • Page 56 ON, kV OK Input air turned OFF Check the gauge on the filter regulator and make sure the air is turned ON. Check for Help Codes and follow the procedures Part 1604870-05 E 2018 Nordson Corporation...

  • Page 57: Re-Zero Procedure

    1. At the pump control panel, disconnect the 6 mm pattern 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 58: Controller Interconnect Cable Test

    CAN + 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 5-2 Controller Interconnect Cable Wiring Part 1604870-05 E 2018 Nordson Corporation...

  • Page 59: Wiring Diagram

    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 5-3 Controller Interface Wiring Diagram Part 1604870-05 E 2018 Nordson Corporation...
  • Page 60 Troubleshooting 5-16 Part 1604870-05 E 2018 Nordson Corporation...

  • Page 61: Repair

    See Figure 6-1 for a view of the interface module assembly and repair parts. Refer to Section 5, Troubleshooting, for the interface electrical schematic and harness connections. Refer to Section 7, Parts for repair kits. Part 1604870-05 E 2018 Nordson Corporation...
  • Page 62 Repair External Enclosure Ground Internal Enclosure Ground Connect to 2A, J6 Figure 6-1 Interface Module Assembly 1. Bezel 2A. Main Control Board 2C. Keypad Panel 2. Keypad/PCB Assembly 2B. Main Display Board 3. Enclosure Part 1604870-05 E 2018 Nordson Corporation...

  • Page 63: Parts

    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 HD and XT system controller. Refer to the following manuals for additional information and optional equipment.

  • Page 64: Controller Parts

    Parts Controller Parts Controller Exploded View Figure 7-1 Controller Parts Part 1604870-05 E 2018 Nordson Corporation...

  • Page 65: Controller Parts List

    − 1604125 CONTROL UNIT, interface, Encore HD/XT 1604855 S PANEL, keypad, Encore HD controller 1085084 S PCA, main controller display, Encore HD 1601341 S PCA, main control, Encore HD 983403 S WASHER, lock, split, M4, steel, zinc 982308 S SCREW, pan head, recessed, M4 x 10, zinc...

  • Page 66: Rail Mount Exploded View

    SCREW, hex, serrated, M8 x 16mm, zinc 982448 SCREW, skt, cap, M4 x 12mm 1084121 WASHER, lock, dished #8 983403 WASHER, lock, M4 981346 SCREW, hex, 0.5/16 − 8 x 2.500 1082732 BRACKET, universal mount Part 1604870-05 E 2018 Nordson Corporation...

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