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Customer Product Manual Part 1604857-04 Issued 06/14 For parts and technical support, call the Finishing Customer Support Center at (800) 433-9319. This document is subject to change without notice. Check http://emanuals.nordson.com/finishing for the latest version. NORDSON CORPORATION AMHERST, OHIO USA...
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...
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New flat spray electrode holder and assembly, new conical nozzle kit and conical electrode assembly 05/14 Page 7−3, new trigger axle P/N 1605713 Page 7−5, new nozzle P/N’s 06/14 New flat and conical electrode holders Part 1604857-04 E 2014 Nordson Corporation...
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Change Record Part 1604857-04 E 2014 Nordson Corporation...
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.
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 1604857-04 E 2014 Nordson Corporation...
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 1604857-04 E 2014 Nordson Corporation...
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Safety Part 1604857-04 E 2014 Nordson Corporation...
Description Section 2 Description Introduction See Figure 2-1. This manual covers all versions of the Encore LT Manual Powder Spray System: Mobile system with vibratory box feeder Mobile system with feed hopper Rail-mount system Wall-mount system Mobile System with Hopper...
Description Mobile System Components Mobile systems include: Encore LT manual controller Encore LT 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 box of powder 50-lb Encore round feed hopper −...
598.5 mm (23.5 in.) Weight: 46.7 kg (103 lbs) Mobile System with 50Lb. Feed Hopper Height: 995 mm (35.2 in.) Length: 812 mm (32 in.) Wheel Base: 598.5 mm (23.5 in.) Weight: 50.4 kg (111 lbs) Part 1604857-04 E 2014 Nordson Corporation...
Powder Spray Gun Certification Labels Controller Certification Label ENCORE LT EN 50050 FM11ATEX0057X (2) 3 D Ex tc IIIC T60C Dc T = +15 to +40C NORDSON CORP. AMHERST, OH, USA Vn=100−250Vac 7n=50−60Hz Pn=100VA OUTPUT: V = +19V Io = +1.0A (peak) (peak) WARNING −...
3. Use the bus-bar grounding kit to connect the controller ground stud to the booth base, as described in the grounding kit instructions. Dished Washer Figure 3-2 Wall-Mount Bracket Installation Part 1604857-04 E 2014 Nordson Corporation...
Hopper** Relay VBF Power Cord* Board Line AC Power Cord Filter Powder Box* Dolly or Booth VIibrator Motor* Ground * VBF System ** Hopper System Figure 3-3 Encore LT Manual Powder System Block Diagram Part 1604857-04 E 2014 Nordson Corporation...
(GRN/YEL) (BROWN) (BLUE) Figure 3-4 Encore LT Gun Controller Connections 1. Electrostatic ground (to cart or booth) 5. Air supply (blue, 10mm) 9. Fluidizing air (blue, 6mm, to pickup tube or hopper) 2. Vibrator motor power cord 6.
3. See Figure 3-6. Install the collar (1) on the pickup tube (2) as shown. Tighten the socket-head screw to secure the collar. Figure 3-6 Collar Installation on Pickup Tube 1. Collar 3. Pickup tube 2. M5 socket head screw (black) 4. Pump mount Part 1604857-04 E 2014 Nordson Corporation...
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10. Secure the tubing to the arm with blue Nordson Velcro straps (5). Part 1604857-04...
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System Setup Create Service Loop Here Figure 3-8 Encore LT Gun Pickup Tube and Pump Installation 1. Bulkhead union 4. Blue 8-mm atomizing tubing* 7. Powder hose 2. 6-mm black fluidizing air tubing* 5. Velcro straps 9. Blue 6-mm fluidizing tubing 3.
(3). NOTE: The pump is equipped with quick-connect couplings that allow you to quickly disconnect the air tubing when cleaning or repairing the pump. Pull back on the knurled coupling rings to uncouple them. Part 1604857-04 E 2014 Nordson Corporation...
System Setup Figure 3-9 Encore LT Mobile System with Hopper − Hopper and Pump Installation 1. Vent hose 5. Pump mount 9. Blue fluidizing air tubing 2. Powder hose 6. Black flow-rate air tubing 10. Ground wire 3. Hose clamp 7.
5. Install the Encore pump into the pump adapter with a slight twisting motion. 2. Replace With Encore Adapter 1. Remove Existing Adapter Hopper Pump Pickup Tube Coupling Assembly Pump Adapter Adapter Installation Coupling Installation Figure 3-10 Pump Mounting Part 1604857-04 E 2014 Nordson Corporation...
2. Thread the cable nut onto the receptacle and tighten the nut securely. 3. Secure the cable strain relief to the rear panel with one of the existing panel screws. Mobile System Rail/Wall Mount System Strain Relief Figure 3-11 Gun Cable Connection and Strain Relief Mounting Part 1604857-04 E 2014 Nordson Corporation...
The flow control valve can be located anywhere desired. Use a tubing cutter to make sure the tube ends are square. Air Wash Connector Flow Control Valve To Gun 4-mm Tubing Figure 3-13 Flow Control Valve and Air Wash Tubing Connection Part 1604857-04 E 2014 Nordson Corporation...
5. Note the orientation of the flow indicator (5) on the top of the filter. Cut 10-mm blue air tubing to the required lengths to connect the air supply to the filter and the filter to the controller, then connect the tubing. Part 1604857-04 E 2014 Nordson Corporation...
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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 1604857-04 E 2014 Nordson Corporation...
Rail Mount Systems: Locate the ESD grounding block kit. Follow the kit instructions to install the grounding block to the grounded spray booth base. Connect the flat braided ground cable from the controller ground stud to the grounding block. Part 1604857-04 E 2014 Nordson Corporation...
Adjust the delay as required for your application. Exiting Configuration Mode To accept all function values and exit Configuration Mode, press the Enable/Disable button. The controller can now be operated normally. Part 1604857-04 E 2014 Nordson Corporation...
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3-18 System Setup Part 1604857-04 E 2014 Nordson Corporation...
European Union, ATEX, Special Conditions for Safe Use 1. The Encore LT Controllers and Mobile Powder Systems shall be used over the ambient temperature range of +15_C to +40_C with the Encore LT Powder Electrostatic Manual Applicators.
The electrostatic setpoints for the Select Charge Modes are: Re-Coat 100 kV, 15 A Metallics 50 kV, 50 A Deep Recesses 100 kV, 60 A NOTE: Pressing the + or − keys have no effect when a Select Charge mode is selected. Part 1604857-04 E 2014 Nordson Corporation...
A. Press the + or − buttons to select the desired kV setpoint. The longer a button is pressed the faster the units change. The valid STD range is 0 or 25−100 kV. Part 1604857-04 E 2014 Nordson Corporation...
Since the air flow values are continuously monitored and adjusted, a slight high frequency pulsation in the air lines is normal. Part 1604857-04 E 2014 Nordson Corporation...
At 7 bar (100 psi) supply pressure: Total Flow Flow Air Flow Air Pressure Atomizing Air Pressure Setting % Setting % bar (psi) bar (psi) 1.7 (25) 1.7 (25) 0.86 (12.5) 2.6 (37.5) Part 1604857-04 E 2014 Nordson Corporation...
At 7 bar (100 psi) supply pressure: Flow Atomizing Flow Air Pressure Atomizing Air Pressure Setting % Setting % bar (psi) bar (psi) 1.7 (25) 1.7 (25) 2.7 (40) 0.689 (10) Part 1604857-04 E 2014 Nordson Corporation...
4. Make sure the spray gun is not triggered, then turn on controller power. The displays and icons on the controller interface should light. Part 1604857-04 E 2014 Nordson Corporation...
NOTE: The vibrator table can hold a maximum 25 kg (50 lb) box of powder. 1. See Figure 4-6. Lift the pickup tube up and swing the tube bracket down and under the pickup tube end to hold it in place on the arm. Part 1604857-04 E 2014 Nordson Corporation...
Enable/Disable button 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 page 3-16. Part 1604857-04 E 2014 Nordson Corporation...
6. Press the Enable/Disable button to wake up the controller. NOTE: To clean nozzles, use the Recommended Cleaning Procedure for Powder Contact Parts on page 4-13. Nozzle Nut Flat Spray Nozzle Electrode Assembly Figure 4-7 Changing a Flat Spray Nozzle Part 1604857-04 E 2014 Nordson Corporation...
8. Press the Enable/Disable button to wake up the controller. NOTE: To clean nozzles, use the Recommended Cleaning Procedure for Powder Contact Parts on page 4-13. Conical Electrode Holder Electrode Assembly Deflector Nozzle Nozzle Nut Figure 4-8 Changing a Conical Nozzle Part 1604857-04 E 2014 Nordson Corporation...
3. Turn off the system air supply and relieve the system air pressure. 4. If shutting down for the night or a longer period of time, disconnect power to the controller. 5. Perform the Daily Maintenance procedures on page 4-13. Part 1604857-04 E 2014 Nordson Corporation...
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.
Refer to Parts for the replacement filter element part number. (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 1604857-04 E 2014 Nordson Corporation...
These troubleshooting procedures cover only the most common problems. If you cannot solve a problem with the information given here, contact your contact Nordson technical support at (800) 433−9319 or your local Nordson representative for help. Controller Faults...
Replace worn parts. Plugged electrode assembly or Remove and clean the electrode powder path assembly. Remove and clean the spray gun powder path (inlet tube, elbow, and outlet tube) if necessary. Continued... Part 1604857-04 E 2014 Nordson Corporation...
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Orifice size is .25−.3 mm. Clean with an appropriate tool. Continued... Part 1604857-04 E 2014 Nordson Corporation...
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Clean as necessary with compressed air. Flow and atomizing air tubing Check flow and atomizing air tubing connections reversed routing and switch if incorrect. Continued... Part 1604857-04 E 2014 Nordson Corporation...
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The cable should be inserted past the white line marked towards the end of the cable. Push the black bar back into the white connector to secure. Part 1604857-04 E 2014 Nordson Corporation...
The resistance should be 19−21 megohms. If the resistance is out of this range replace the electrode assembly. 19−21 Megohms Figure 5-11 Electrode Assembly Resistance Test Part 1604857-04 E 2014 Nordson Corporation...
Removing the Power Supply from the Gun Body 3. Slide the new power supply into the upper cavity of the gun body, guiding the gun body ribs between the raised grooves on the top of the power supply. Part 1604857-04 E 2014 Nordson Corporation...
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 1604857-04 E 2014 Nordson Corporation...
Power Supply Trigger VIEW A Ground VIEW B VIEW C Figure 6-6 Cable Replacement 12. M3 x 20 screws 16. M3 x 6 screw 27. Handle base 15. Ground pad 17. Lock washer 30. E-ring Part 1604857-04 E 2014 Nordson Corporation...
4. Remove the spray trigger (20), actuator (21, not shown), and purge trigger (19) from the handle. Gusset Figure 6-7 Removing the Axle and Triggers from the Handle Part 1604857-04 E 2014 Nordson Corporation...
(25) and through the slot in the trigger recess. 2. Peel off the small piece of tape holding the ribbon cable against switch. Figure 6-9 Installing the Trigger Switch − Steps 1 and 2 Part 1604857-04 E 2014 Nordson Corporation...
9. Connect the trigger switch connector to the round cable connector, then tuck the connectors back up to the handle. 10. Re-install the ground cover as described in Cable Installation steps 5−7 on page 6-6. Part 1604857-04 E 2014 Nordson Corporation...
Refer to Section 5, Troubleshooting, for the controller electrical schematic and harness connections. Refer to Section 7, Parts for repair kits. Figure 6-12 Controller Front Panel 1. Bezel 2. Keypad 3. Main control board Part 1604857-04 E 2014 Nordson Corporation...
1. Manifold assembly 4. Line filter 7. Air wash air solenoid valve 2. Relay board 5. Fluidizing air solenoid valve 8. Flow-rate air regulator 3. Power supply 6. Purge air solenoid valve 9. Atomizing air regulator Part 1604857-04 E 2014 Nordson Corporation...
115V MOTOR 230V MOTOR L1 F M1 M2 M3 M1 M2 M3 M1 M2 M3 Jumper JP1 for 115V Motor VBF POWER CORD WIRING Remove Jumper for 230V Motor Figure 6-14 Vibrator Motor Connections Part 1604857-04 E 2014 Nordson Corporation...
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6-12 Repair Part 1604857-04 E 2014 Nordson Corporation...
Support Center at (800) 433-9319 or contact your local Nordson representative. This section covers parts for the Encore LT spray gun, controller, system components and parts, powder and air tubing, and options. Refer to the following manuals for additional information and optional equipment.
Parts Spray Gun Parts Illustration Figure 7-1 Exploded View of Encore LT Manual Spray Gun and Accessories Part 1604857-04 E 2014 Nordson Corporation...
S SCREW, Philips head, M3 x 20, zinc 1088506 S KIT, body assembly, handgun, Encore 1088558 S FILTER ASSEMBLY, handgun 1106871 S HANDLE, ground pad, handgun, Encore LT/XT 983520 S WASHER, lock, internal, M3, zinc 982427 S MACHINE SCREW, pan head, recessed, M3 x 6, zinc...
NOTE A: This pattern adjuster kit is only for use with a lance extension. See page 7-8 for the standard pattern adjuster kit. B: Refer to the instruction sheet 1102764 shipped with the kit for instructions. NS: Not Shown Part 1604857-04 E 2014 Nordson Corporation...
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 1604857-04 E 2014 Nordson Corporation...
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 1604857-04 E 2014 Nordson Corporation...
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 1604857-04 E 2014 Nordson Corporation...
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 1604857-04 E 2014 Nordson Corporation...
7-10 Parts Controller Parts Front Panel and Internal Cabinet Ground Parts Illustration Rear Panel Assembly See Figures 7-11 and 7-12 for parts Figure 7-10 Controller Parts Part 1604857-04 E 2014 Nordson Corporation...
Quantity Note − 1107552 CONTROLLER ASSY, manual, Encore LT, packaged 1108279 S KIT, PCA, control, Encore LT 1108312 S PANEL, keypad, Encore LT/auto controller, packaged 982916 S SCREW, flat, socket, M5 x 10, black 982636 S SCREW, button, socket, M5 x 12, zinc...
7-12 Parts Rear Panel Parts Illustration Manifold Assembly See Figure 7-12 (this screw only) Figure 7-11 Rear Panel Parts Part 1604857-04 E 2014 Nordson Corporation...
972808 S CONNECTOR, strain relief, 1/2 in. NPT 984192 S NUT, lock, 1/2 in. NPT, nylon 117549 S GASKET, panel, rear, Encore LT controller 982824 S SCREW, pan head, recessed, M3 x 8, with lockwasher, black 1107696 S FILTER, line, RFI power, 3A, with 0.250 QD...
1/8 unithread 1604486 S VALVE, flow control, 6 mm x 1/8 R 1108313 S MUFFLER, exhaust, 1/8 R 1107593 S GASKET, manifold, controller, Encore LT 1107597 S REGULATOR, electro-pneumatic 1099281 S VALVE, solenoid, 3 port, 24V, 0.35W Part 1604857-04...
1093708 GROMMET, 0.719 ID x 1.281 OD x 0.093 GR 134575 WIRE, ground (with ground clamp) 1107895 KIT, VBF pickup tube arm assembly, Encore LT 1107903 S KIT, pickup tube collar, Encore LT 1107913 KIT, rail mount, Encore LT 1600437...
C: For mobile systems only. To install the tray, remove the 2 top screws from the controller tower, install the #10 dished lock washer in the kit on one screw, then use the screws to install the tray. Part 1604857-04 E 2014 Nordson Corporation...
7-17 Parts Optional Transportable Manual System This system consists of an Encore LT manual powder spray system packed into a case for transportation. The following parts list consists of replacements for the components in the system. Part Description Quantity Note...
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7-18 Parts Part 1604857-04 E 2014 Nordson Corporation...
Wiring Diagram Section 8 Wiring Diagram Part 1604857-04 E 2014 Nordson Corporation...
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Wiring Diagram Part 1604857-04 E 2014 Nordson Corporation...
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230V MOTOR M1 M2 M3 M1 M2 M3 A.C. POWER HARNESS NO.1 (GROUND JUMPER 2) 15 FT (4.6M) POWER CORD CONTROLLER CABINET NO.4 VBF POWER CORD WIRING Figure 8-1 Encore LT Manual Controller Wiring Diagram Part 1604857-04 E 2014 Nordson Corporation...
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DECLARATION of CONFORMITY PRODUCT: Encore LT Automatic and Manual Powder Spray Systems Models: Encore Automatic Applicator and Encore LT Automatic Controllers Encore LT Manual Applicator with Encore LT Manual Controller Description: The automatic electrostatic powder spray system includes applicator, control cable, and associated controllers.
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ZONE REV DESCRIPTION CHK RELEASE NO. DATE PRELIMINARY 07APR11 CABLE P/N WAS 1102625 PE602493 13APR11 RELEASED PE602493 03AUG11...
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ZONE REV DESCRIPTION CHK RELEASE NO. DATE (SEE SHEET 1 FOR REVISION HISTORY.)
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