Nordson Encore HD Color-on-Demand Product Manual
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Nordson Encore HD Color-on-Demand Product Manual

Nordson Encore HD Color-on-Demand Product Manual

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Encore
HD Color-on-Demand
System
Customer Product Manual
Part 1612313−03
Issued 12/18
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 for the latest version.
NORDSON CORPORATION • AMHERST, OHIO • USA

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Summary of Contents for Nordson Encore HD Color-on-Demand

  • Page 1 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 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 2018. 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 1/18 Released. 7/18 Added system numbers to add nLighten option. Part 1612313−02 E 2018 Nordson Corporation...
  • Page 4 Change Record Part 1612313−02 E 2018 Nordson Corporation...

  • Page 5: Table Of Contents

    ..... . 3-13 Remote Color Selection and Color Change Start Option ..3-14 Part 1612313−02 E 2018 Nordson Corporation...
  • Page 6 ........Part 1612313−02 E 2018 Nordson Corporation...
  • Page 7 ........Part 1612313−02 E 2018 Nordson Corporation...

  • Page 9: 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 10: 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 1612313−02 E 2018 Nordson Corporation...

  • Page 11: 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 1612313−02 E 2018 Nordson Corporation...
  • Page 12 Safety Part 1612313−02 E 2018 Nordson Corporation...

  • Page 13: Description

    Upon receipt, inspect the shipping materials and components for visible damage. Report any visible damage immediately to the shipper and to your Nordson representative. The Encore HD Color-on-Demand system consists of the components shown in Figure 2-1.
  • Page 14 Color Change Manifolds Pump Panel (Three per spray gun) (One per system) HD+ Pump (One per spray gun) System Pump Stand System Pump Stand (Rear view − cover removed) (Front view) Figure 2-1 System Components Part 1612313−02 E 2018 Nordson Corporation...

  • Page 15: Pump Control Panel

    6−57 l/min (0.2−4.0 scfm) Total Consumption 85−170 l/min (3−6 scfm) Operating Air Pressures Pinch Valves 2.4−2.75 bar (35−40 psi) Flow Control 5.9 bar (85 psi) (to air cap/pump assist) Vacuum Generator 3.5 bar (50 psi) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 16 Pump Control Panel PD7796 Figure 2-2 Manual Color-on-Demand System Panels NOTE: On the inside of the pump cabinet, Pump 1 is referred to as Pump A and Pump 2 is referred to as Pump B. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 17: Pump Control Panel Components

    24. Pump 2 16. Flow control valve 7. Line filter 25. Adapter plate 17. Air filter 8. Power switch 26. Pump 2 control manifold 18. Air supply ball valve 9. Contact block 10. Vacuum generator mufflers Part 1612313−02 E 2018 Nordson Corporation...

  • Page 18: Hd+ Pump Manifold Components

    Turns the airflow through the vacuum generator on or off. Works on the Venturi principle to generate the negative air Vacuum Generator pressure required to draw powder into the fluidizing tubes. Figure 2-4 Pump Manifold Components Part 1612313−02 E 2018 Nordson Corporation...

  • Page 19: Solenoid And Flow Control Valve Functions

    Right Side Delivery Pinch Valve Left Side Fluidizing Tube Vacuum Air (Bottom of Manifold) Left Side Suction Pinch Valve Pattern Air Flow Control Right Side Suction Pinch Valve Pump Air Flow Control Right Side Fluidizing Tube Part 1612313−02 E 2018 Nordson Corporation...

  • Page 20: Color-On−Demand Color Control Panel

    Foot Pedal Manifold Pressure Switch Purge Valves Solenoid Valves Spray Gun A Spray Gun B System Pressure Switch Pump Control Boards PD7796 Figure 2-6 System Control Panels (Dual Spray Gun System) Part 1612313−02 E 2018 Nordson Corporation...

  • Page 21: Color Change Manifold

    Both spray gun controllers must be set for the Gun No: 1 network address. Refer to the Encore HD Manual Powder Spray System Controller manual for a description of the color change cycle and settings. Part 1612313−02 E 2018 Nordson Corporation...
  • Page 22 Bladders Color 9 Color 8 Color 6 Color 7 Color 4 Color 5 Color 3 Color 2 Color 1 Manifold (End View) Suction Line to Pump Figure 2-7 Color Change Manifold and Dump Valve Part 1612313−02 E 2018 Nordson Corporation...

  • Page 23: Installation

    2. Secure the straps to the forks of a forklift or a crane hook. 3. Lift the stand off the pallet and move it to the chosen location. 4. Bolt the stand securely to the floor with the lag bolts included in the installation kit. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 24: Controller Installation

    Connect the ground strap to the controller ground stud and clamp it to a true earth ground. Figure 3-1 Controller Rail Mount Installation 1. Product stand arm 3. Universal mounting bracket 4. Encore HD controller 2. Controller rail mount bracket Part 1612313−02 E 2018 Nordson Corporation...

  • Page 25: Connection Diagram (Rear View Of System)

    Installation Connection Diagram (Rear View of System) Figure 3-2 System Diagram (Dual Spray Gun System Shown) Part 1612313−02 E 2018 Nordson Corporation...

  • Page 26: System Power, Ground, And Spray Gun Controller Connections

    15-m (50-ft) 6-m (20-ft) 15-m (50-ft) Spray Gun Cable Network/Power Cable Spray Gun Cable Network/Power Cable Optional Spray Gun Cable Extensions 4-m: 1073027 6-m: 1083912 Figure 3-3 System Power, Ground, and Gun Controller Connections Part 1612313−02 E 2018 Nordson Corporation...

  • Page 27: System Air Supply And Spray Gun Air Connections

    6-mm OD Blue Air Tubing 6-mm OD Blue Air Tubing Pump Panel Air Supply 6.2−7.6 bar (90−110 psi) (12-mm tubing x 1/2-in. NPT fitting provided) Figure 3-4 System Air Supply and Gun Air Connections Part 1612313−02 E 2018 Nordson Corporation...

  • Page 28: Encore Hd Powder Spray Gun Installation

    Figure 3-5 Spray Gun Connections 1. Quick disconnect 3. Hose adapter 5. Powder inlet tube 2. Barbed fitting 4. O-rings 6. Spray gun cable Part 1612313−02 E 2018 Nordson Corporation...

  • Page 29: Color-On-Demand Controller And Foot Switch Connections

    Connect 6-mm tubing from the FOOTSWITCH A & B fitting to the IN fitting on the switch, and from the OUT fitting to the SWA RTN or SWB RTN ports on the tubing manifolds. Part 1612313−02 E 2018 Nordson Corporation...
  • Page 30 Connectors IN OUT IN OUT Remove footswitch bottom cover to install connectors Color Change Color Change Foot Switch Foot Switch Spray Gun 1 Spray Gun 2 Figure 3-6 Color-on-Demand Controller and Foot Switch Connections Part 1612313−02 E 2018 Nordson Corporation...

  • Page 31: Ethernet Cable Termination

    4. Cut the foil, clear wrapper, and pull string on the cable. Figure 3-8 Ethernet Cable Termination, Steps 3−4 5. Trim back the four twisted pair wires to approximately 2.25 in. 2.25 in Figure 3-9 Ethernet Cable Termination, Step 5 Part 1612313−02 E 2018 Nordson Corporation...
  • Page 32 Use Type T568B cables. Use T568-B wiring scheme. Rear-Connect Module (End View) Brown Green White/Brown White/Green Orange Blue White/Blue White/Orange Shield Cover Retention Cap Module Bezel Bezel Shield Adapter Figure 3-10 Ethernet Cable Connection to Termination Module Part 1612313−02 E 2018 Nordson Corporation...
  • Page 33 13. Attach the termination module ground wires to the cabinet ground stud. Termination Ethernet Modules Cable B Ethernet Cable A Cabinet Ground Crossover Cables (3 ft) Figure 3-11 Ethernet Cable Termination Inside Color Control Panel Part 1612313−02 E 2018 Nordson Corporation...

  • Page 34: Delivery Tubing Installation

    1 m (3 ft) Minimum Loop Diameter Manual Spray Gun #2 Manual Spray Gun #1 Pump Panel (Bottom View) Factory-Installed Factory-Installed Suction Tubing Suction Tubing Color Change Manifolds (Bottom View) Figure 3-8 Delivery Tubing Installation Part 1612313−02 E 2018 Nordson Corporation...

  • Page 35: Suction And Dump Tubing Installation

    Adapters Vent Hoppers Vent Hoppers into Booth into Booth Color 2 Powder Feed Hopper Color 1 Powder Feed Hopper (Not included with system) (Not included with system) Figure 3-9 Suction and Dump Tubing Installation Part 1612313−02 E 2018 Nordson Corporation...

  • Page 36: Remote Color Selection And Color Change Start Option

    Bit 5 = Most Significant Bit RS2: Remote Start signal 24 V, 25 mA, sourcing (high true) Set the color selection bits first, then strobe the Remote Start bit. Figure 3-10 Remote Color Selection and Color Change Start Connections Part 1612313−02 E 2018 Nordson Corporation...

  • Page 37: Operation

    Operation Section 4 Operation WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 38: Pump Control Panel Setup And Operation

    5. Perform the Configuration procedure on page 4-7. Figure 4-1 Pump and Manifold Installation 1. Mounting screws (2) 3. Pump panel wall 5. Manifold 2. Pump 4. Manifold mounting bracket 6. Manifold mounting screws (2) Part 1612313−02 E 2018 Nordson Corporation...

  • Page 39: Pump Control Board

    Pump 2 Pump Air Flow Control Valve JTAG Programming/Debug/Connector Pump 1 Solenoid I/O Harness Pump 2 Solenoid I/O Harness DC Power In Purge Connector CAN Out Connector CAN In Connector CAN Network Termination Header Part 1612313−02 E 2018 Nordson Corporation...

  • Page 40: Switches And Indicators

    Not Used Suction 1 − Solenoid 3 Not Used Pressure 1 − Solenoid 2 Not Used Delivery 1 − Solenoid 1 Pull up resistor for CCS Vacuum − Solenoid 7 Color Change Status (CCS) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 41 Figure 4-2 Control Board and Manifold Connections Note: The control board is shipped with air tubing labeled from 4−1 installed in the XDCR fittings. Connect the tubing to the appropriate fittings on the manifolds as illustrated. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 42: Control Board Configuration

    3 of the CAN BUS TERM terminals. Move the jumper to pins 1 and 2. As-shipped position (for dual spray gun system) CAN BUS TERM Position for Color-on-Demand single or dual spray gun system CAN BUS TERM Figure 4-4 CAN BUS TERM Jumper Settings Part 1612313−02 E 2018 Nordson Corporation...

  • Page 43: Configuration Procedure

    If replacing a control board or manifold, use this procedure to configure the system.>>> 5 <<< Select and hold the Nordson button for five seconds. The Function/Help display lights to show the function numbers and values. Use the functions to configure the controller for the appropriate application.>>>...

  • Page 44: Air And Powder Tubing Connections

    Pump 1 Flow Air Supply 3.45 bar (50 psi) 4-mm Clear 3 − 4 Pressure Transducer 10-mm Blue Vacuum Generator Vent Top of Manifold Bottom of Manifold Figure 4-6 Powder and Air Tubing Connections Part 1612313−02 E 2018 Nordson Corporation...
  • Page 45 Colors are selected and color changes are initiated by the operator, using the color controller touch screen and the foot switch, or by a remote signal from a customer process controller. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 46: Color-On-Demand Controller Setup And Operation

    Valve Counters Test Service Screen* Outputs 1−20 Outputs 21−40 Inputs 1−16 System Clock Software Version Screen Contrast * Service Screen is for use by Nordson technical service representatives. Figure 4-7 Color-on-Demand Controller Screen Map Part 1612313−02 E 2018 Nordson Corporation...

  • Page 47: Color Change Without Suction Line Purge

    The color change PLC remains powered up until the system power switch is turned off. Figure 4-8 Splash Screen Select the Splash screen to open the Main screen. Figure 4-9 Main Screen Choose the desired button size by selecting Small Buttons or Big Buttons. Part 1612313−02 E 2018 Nordson Corporation...
  • Page 48 Current color. When the color change cycle is complete and the new color is loaded, the Current color and Next color will be the same. COMPLETE appears at the bottom of the screen. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 49: Button Labeling

    To create a label for a color or the system name, select the label button. A keyboard screen appears. Enter a 6-character label for the color, or a 12-character label for the system. Figure 4-13 Button Label Screen (1 of 2) Select Main to return to the Main screen. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 50: System Cleaning

    Process will flash on screen while system is cleaning the suction line. When the system is done purging, the suction line the screen will revert back to the Main screen with the word COMPLETE showing at the bottom of the screen. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 51: Valve Counters

    Note that the WARNING BLADDER MAINTENANCE message will appear at the set count if enabled from the Service Screen. Refer to page 5-6 for more information on this screen. Figure 4-16 Valve Counter Screen Part 1612313−02 E 2018 Nordson Corporation...

  • Page 52: System Clock

    This information may be requested if calling for technical support. Screen Brightness After selecting the Software Version option, select the arrow buttons to adjust the brightness of the display screen. Figure 4-17 Test Screen Part 1612313−02 E 2018 Nordson Corporation...

  • Page 53: Troubleshooting

    Follow the safety instructions in this document and all other related documentation. These troubleshooting procedures cover only the most common problems. If a problem cannot be solved with the following information, contact a local Nordson representative for help. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 54: Pump Control Panel

    Refer to Flow Control Valve changes Cleaning on page 6-2 for instructions. If the problem persists, replace the pattern air flow control valve. Refer to Flow Control Valve Replacement on page 6-3 for instructions. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 55: Color-On-Demand Controller And Control Panel

    Refer to System Cleaning on page 4-14. On either of the Output screens, select the Test button to toggle the test mode ON or OFF, then select an output button to turn the device on and off. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 56: Inputs

    PLC: BIT 4 BIT 1 = Least Significant Bit BIT 3 BIT 5 = Most Significant Bit BIT 2 BIT 1 Set the color selection bits first, then strobe RS2. 15, 16 Spares Part 1612313−02 E 2018 Nordson Corporation...

  • Page 57: Outputs

    Purge 2 solenoid: Manifold purge air inlet actuation air 5−32 C28E−C1E Color 28 to 1 solenoids Dump 1 solenoid: Manifold dump outlet actuation air Dump 2 solenoid: Dump valve actuation air Purge 1 Solenoid 36−40 SPR1−6 Spares Part 1612313−02 E 2018 Nordson Corporation...

  • Page 58: Powder Flow

    If the pinch valve has failed, powder will be visible in the body cavity around the pinch valve. Service Screen The Service screen is used by Nordson technical service representatives.>>> 9 <<< Dump Valve Counter Reset: Resets the counter. Can also be done from the Valve Counter screen.

  • Page 59: Repair

    2. Shut off system power and air pressure. Relieve the system air pressure. 3. Tag the pump manifold air tubing, then disconnect the tubing from the manifold. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 60: Flow Control Valve Cleaning

    (12). 9. Install the coil (2) on the stem, with the coil wiring pointing away from the solenoid valves (12). Secure the coil with the nut (1). Part 1612313−02 E 2018 Nordson Corporation...

  • Page 61: Flow Control Valve Replacement

    Figure 6-1 Manifold Repair 1. Nut 5. Spring 9. Orifice 2. Coil 6. Cartridge 10. Long screws (2) 3. Short screws (2) 7. Valve body 11. Screws (2) 4. Valve stem 8. O-rings (2) 12. Solenoid valve Part 1612313−02 E 2018 Nordson Corporation...

  • Page 62: Circuit Board Replacement

    Repair of the Color-on-Demand controller and color control panel is limited to replacement of components. Refer to to the foldouts in the back for pneumatic and electrical diagrams. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 63: Manifold Repair

    18. Slide the lock knobs (8), then the O-rings (9), on the powder tubing. 19. Insert the tubing into the manifold ports until it bottoms out, then screw the lock knobs into the ports until tight. Part 1612313−02 E 2018 Nordson Corporation...
  • Page 64 2. Socket screw 8. Side lock knob 13. Valve bladder 3. Screw 9. O-ring 14. Bladder support 4. Nut 10. Fasteners 15. Filter disc 5. Lock washer 11. Module bracket 16. Cover 6. Flat washer Part 1612313−02 E 2018 Nordson Corporation...

  • Page 65: Dump Valve Repair

    UP end of pinch valve Figure 6-3 Dump Valve Cross-Section View 1. 12-mm fitting 3. Cap 5. Valve body 2. Socket head screw 4. Pinch valve 6. 8-mm fitting Part 1612313−02 E 2018 Nordson Corporation...
  • Page 66 Repair Part 1612313−02 E 2018 Nordson Corporation...

  • Page 67: Parts

    A dash (—) is used when the part number applies to all parts in the illustration. The number in the Part column is the Nordson Corporation part number. A series of dashes in this column (- - - - - -) means the part cannot be ordered separately.

  • Page 68: System Manuals

    S CONTROLLER, COD, dual pump, Encore HD 1605276 1605276 S KIT, ship-with, spray system 1067148 1067148 S KIT, ship-with, Color-on-Demand system 1101491 1101491 S KIT, controller interface 1611977 −−−−−−− S KIT, nLighten, LED, Encore Part 1612313−02 E 2018 Nordson Corporation...

  • Page 69: Pump Panel Replacement Parts

    1610978 PUMP ASSEMBLY, hi-flow, Encore HD 1043906 POWER SUPPLY, 24, 5, 12 Vdc, 60 W 334805 FILTER, line, RFI, power, 10A 334806 SWITCH, round, 2 position, 90 degree 288806 CONTACT BLOCK, 2 N.O. contacts Part 1612313−02 E 2018 Nordson Corporation...
  • Page 70 D: If using an old harness with three positions, use the supplied adapter. If using a new a harness with two positions, the supplied adapter can be discarded. AR: As Required NS: Not Shown Part 1612313−02 E 2018 Nordson Corporation...

  • Page 71: Manifold Parts

    Parts Manifold Parts Manifold See Figure 7-2 and refer to the following parts list. Figure 7-2 Manifold Parts Part 1612313−02 E 2018 Nordson Corporation...
  • Page 72 NOTE A: These are not serviceable parts. Do not remove these from the manifold. B: If using an old harness with three positions, use the supplied adapter. If using a new harness with two positions, the supplied adapter can be discarded. AR: As Required Part 1612313−02 E 2018 Nordson Corporation...

  • Page 73: Air And Powder Tubing

    8-mm Clear polyethylene 900742 6-mm Blue polyurethane 173101 8-mm Clear polyethylene 900617 4-mm Clear polyurethane 1, 8 900740 10-mm Blue polyurethane Top of Manifold Bottom of Manifold Figure 7-3 Air and Powder Tubing Part Numbers Part 1612313−02 E 2018 Nordson Corporation...

  • Page 74: Pca Replacement Parts

    Parts PCA Replacement Parts PCA Replacement Kit See Figure 7-4 and refer to the following parts list. Part Description Note 1101498 KIT, PCA, replacement, pump control Figure 7-4 PCA Replacement Kit Part 1612313−02 E 2018 Nordson Corporation...

  • Page 75: Color-On-Demand Controller And Control Panel Parts

    S CLAMP, ground w/wire −−−−−− S BRACKET, base, manual control interface −−−−−− S BRACKET, post, manual control −−−−−− S BRACKET, mounting, U, manual control NOTE A: See Figure 7-5 and accompanying parts list for serviceable parts. Part 1612313−02 E 2018 Nordson Corporation...
  • Page 76 Parts 7-10 Figure 7-5 Controller Kit Parts Part 1612313−02 E 2018 Nordson Corporation...

  • Page 77: Controller Parts

    S RECEPTACLE, net, controller interface, Encore 1082759 1082709 S RECEPTACLE, gun, Encore HD 982286 S SCREW, flat, slotted, M5 x 10, zinc NOTE A: Receptacles include harnesses. B: Items 2 and 3 are sold together as kit 1604025. Part 1612313−02 E 2018 Nordson Corporation...
  • Page 78 Parts 7-12 Figure 7-6 Controller Parts Part 1612313−02 E 2018 Nordson Corporation...

  • Page 79: Color Change Control Panel Parts

    NOTE A: Select appropriate control unit for your system. Parts break down on following pages. C: One required per spray gun. D: 31 N.O. valves and 1 N.C. valve required per spray gun. E: Order in increments of 1 ft. AR: As Required NS: Not Shown Part 1612313−02 E 2018 Nordson Corporation...
  • Page 80 Parts 7-14 Spray Gun A Spray Gun B Figure 7-7 Color Control Panel Parts Part 1612313−02 E 2018 Nordson Corporation...
  • Page 81 NOTE A: Two required for dual control unit, one for single. B: Four required for dual control unit, two for single. C: Ten required for dual control unit, five for single. D: Installation by a qualified Nordson service representative is recommended for these parts. AR: As Required Part 1612313−02...
  • Page 82 Parts 7-16 Figure 7-8 Control Unit (PLC) Parts Part 1612313−02 E 2018 Nordson Corporation...

  • Page 83: Ship-With Kit Parts

    NOTE A: Available in packages of 12. Order 1065983: KIT, Color-on-Demand, O-ring, 12-pack B: Available in packages of 10 bladders and 10 filter discs. Order 1065982: KIT, Color-on-Demand, bladder, 10-pack C: Internal O-ring for lock knob. Part 1612313−02 E 2018 Nordson Corporation...
  • Page 84 Parts 7-18 Figure 7-9 Color Change Manifold Parts Part 1612313−02 E 2018 Nordson Corporation...

  • Page 85: Dump Valve Parts

    -in. NPT NOTE A: To replace, order 1066626: KIT, dump valve, pinch valve, 4-pack. Use insertion tool shipped with pump pinch valve kit to install. UP end of pinch valve Figure 7-10 Dump Valve Parts Part 1612313−02 E 2018 Nordson Corporation...
  • Page 86 Parts 7-20 This page intentionally left blank. Part 1612313−02 E 2018 Nordson Corporation...

  • Page 87: System Diagrams

    System Diagrams Section 8 System Diagrams Part 1612313−02 E 2018 Nordson Corporation...
  • Page 88 System Diagrams Part 1612313−02 E 2018 Nordson Corporation...
  • Page 89 NET/PWR 2 NET/PWR 1 Î Î Î (FOR SINGLE (NETWORK (NETWORK AND DUAL CABLE) CABLE) GUN SYSTEMS) JUMPER PINS 1 & 2 ELECTRODE AIR WASH MANIFOLD ASSEMBLY Figure 8-6 Pump Control Panel Wiring Diagram Part 1612313−02 E 2018 Nordson Corporation...
  • Page 90 MANIFOLD DETAIL MANIFOLD (CONFIGURATION FOR 1 PUMP CONTROLLER) (CONFIGURATION FOR 1 PUMP CONTROLLER) VENT GUN 1 GUN 2 EXHAUST EXHAUST PINCH SELECT MANIFOLD Figure 8-7 Pump Control Panel Pneumatic Diagram (Sheet 1 of 2) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 91 PUMP/MANIFOLD (BOTTOM VIEW) (BOTTOM VIEW) PUMP CONTROL BOARD − PUMP CONTROL BOARD − PUMP CONTROL PUMP CONTROL BOARD ”B” DETAIL BOARD ”A” DETAIL Figure 8-8 Pump Control Panel Pneumatic Diagram (Sheet 2 of 2) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 92 (ENCLOSURE GROUND) .50 STRAIGHT RECEPTACLE 6 PIN CONDUIT CONNECTOR ROCKER SWITCH GROUND WIRE FROM ETHERNET INSULATION DISPLACEMENT CONNECTOR TO BACK PLATE (PART OF COLOR CHANGE GROUND STUD CONTROLLER) Figure 8-9 Color-on-Demand Controller Wiring Diagram Part 1612313−02 E 2018 Nordson Corporation...
  • Page 93 Encore HD Color-on-Demand System Figure 8-10 Color Change Control Panel Internal Pneumatic Diagram (Dual Unit Shown) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 94 Encore HD Color-on-Demand System Figure 8-11 Color Change Control Panel External Pneumatic Diagram (Dual Unit Shown) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 95 BLUE SUB PANEL GREEN/YELLLOW SUPPLY (INSIDE PUMP (SEE SCHEMATICS) ENCLOSURE BOTTOM) PURGE PILOT MANIFOLD NC (WHITE) PRESSURE SWITCH HARNESS COM (BLUE) Figure 8-12 Color Change System Wiring Diagram (Dual Unit, Sheet 1 of 2) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 96 LABEL “2” (C.O.D. ENCLOSURE) (C.O.D. ENCLOSURE) (PUMP CTRL ENCLOSURE) (C.O.D. ENCLOSURE) PINCH SELECT PURGE PILOT MANIFOLD MANIFOLD (PART OF PUMP CONTROLLER PANEL) Figure 8-13 Color Change System Wiring Diagram (Dual Unit, Sheet 2 of 2) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 97 USE 8 POS. (BLUE) D2AE (BLACK) JUMPER P1AE (BLACK) BRAIDED JUMPER BRAIDED JUMPER ENCLOSURE ENCLOSURE STUD STUD BRAIDED JUMPER 1080 1080 1070 1120 1070 Figure 8-14 Color-on-Demand Control Panel Schematic (Dual Unit, Sheet 1 of 10) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 98 COLOR CHANGE 3,IN5 SELECT & STROBE BIT2A VIA ”AUX. 1” 7,IN6 BIT1A LSB 4,IN7 COLOR CHG W/SUCTION LINE PURGE 8,IN8 SPARE 4 750− Figure 8-15 Color-on-Demand Control Panel Schematic (Dual Unit, Sheet 2 of 10) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 99 C2AE (BLACK) C2AE C2AE (RED) VALVE VALVE 8,OUT8 8,OUT8 C17AE (BLACK) C17AE C17AE (RED) C1AE (BLACK) C1AE C1AE (RED) VALVE VALVE 750− 750− Figure 8-16 Color-on-Demand Control Panel Schematic (Dual Unit, Sheet 3 of 10) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 100 OUTPUT 36 SPARE 2 3,OUT5 OUTPUT 37 SPARE 3 7,OUT6 OUTPUT 38 SPARE 4 4,OUT7 OUTPUT 39 SPARE 5 8,OUT8 VFD HIGH SPEED 750− 750− Figure 8-17 Color-on-Demand Control Panel Schematic (Dual Unit, Sheet 4 of 10) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 101 C25BE (BLACK) (BLUE) C26BE (BLACK) C27BE (BLACK) TB12B C28BE (BLACK) D1BE (BLACK) USE 8 POS. (BLUE) D2BE (BLACK) JUMPER P1BE (BLACK) 1080 1070 Figure 8-18 Color-on-Demand Control Panel Schematic (Dual Unit, Sheet 5 of 10) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 102 COLOR CHANGE 3,IN5 SELECT & STROBE BIT2B VIA ”AUX. 1” 7,IN6 BIT1B LSB 4,IN7 COLOR CHG W/SUCTION LINE PURGE 8,IN8 SPARE 4 750− Figure 8-19 Color-on-Demand Control Panel Schematic (Dual Unit, Sheet 6 of 10) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 103 C2BE (BLACK) C2BE C2BE (RED) VALVE VALVE 8,OUT8 8,OUT8 C17BE (BLACK) C17BE C17BE (RED) C1BE (BLACK) C1BE C1BE (RED) VALVE VALVE 750− 750− Figure 8-20 Color-on-Demand Control Panel Schematic (Dual Unit, Sheet 7 of 10) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 104 OUTPUT 36 SPARE 2 3,OUT5 OUTPUT 37 SPARE 3 7,OUT6 OUTPUT 38 SPARE 4 4,OUT7 OUTPUT 39 SPARE 5 8,OUT8 VFD HIGH SPEED 750− 750− Figure 8-21 Color-on-Demand Control Panel Schematic (Dual Unit, Sheet 8 of 10) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 105 750−430 750−530 750−530 750−530 750−530 750−530 750−600 TB3B −V TB1A TB2B TB2A TB1B TB3A TB4A DIN RAIL JUMPER JUMPER TB5A POWER SUPPLY Figure 8-22 Color-on-Demand Control Panel Schematic (Dual Unit, Sheet 9 of 10) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 106 MD2A MD3A MD5A MD6A MD8A MD1B MD2B MD3B MD4B MD5B MD6B LINK LINK LINK TXD/RXD TXD/RXD TXD/RXD TXD/RXD ERROR ERROR ERROR ERROR Figure 8-23 Color-on-Demand Control Panel Schematic (Dual Unit, Sheet 10 of 10) Part 1612313−02 E 2018 Nordson Corporation...
  • Page 107 The product specified conforms to the directive and standards described above. _______________________________________ Date: 24Jan2018 Vance Wilson Engineering Manager Industrial Coating Systems Amherst, Ohio, USA Nordson Authorized Representative in the EU Contact: Operations Manager Industrial Coating Systems Nordson Deutschland GmbH Heinrich-Hertz-StraBe 42-44 D-40699 Erkrath Nordson Corporation ...
  • Page 108 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 109 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 110 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 111 Change Record Part 1604870-05 E 2018 Nordson Corporation...
  • Page 112 Controller Connections ....... . Part 1604870-05 E 2018 Nordson Corporation...
  • Page 113 ........Part 1604870-05 E 2018 Nordson Corporation...

  • Page 114: 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 115: 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 116: 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 117 Safety Part 1604870-05 E 2018 Nordson Corporation...

  • Page 118: Description

    Encore HD and XT Wall Mount Systems Encore HD and XT Mobile Systems Encore HD and XT Rail Mount Systems Encore HD and XT Single and Dual Stand Alone Encore HD Color-on-Demand Systems ColorMax Powder Coating Systems Prodigy...

  • Page 119: Specifications

    IP6X, Dust ingress protection Equipment Label Controller Certification Label ELECTROSTATIC HAND−HELD POWDER SPRAY EQUIPMENT TYPE ENCORE ® NORDSON CORPORATION, AMHERST , OHIO U.S.A. EN 50050−2 FM14ATEX0052X Ta: +15°C TO +40°C INPUT : Vo=24VDC OUTPUT : Vo=±19VAC Io=1A FOR: ADMISSIBLE COMBINATIONS OF DEVICES, SEE INSTRUCTION MANUAL.

  • Page 120: 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 121: 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 122: 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 123 System Setup Part 1604870-05 E 2018 Nordson Corporation...

  • Page 124: Operation

    NOTE: The controller is shipped with a default configuration that will allow you to start spraying powder as soon as you finish setting up the system. Refer to Controller Configuration on page 4-20 to reference a list of the defaults and preset change instructions. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 125: 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 126: 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 127: 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 128: 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 129: 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 130: 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 131: 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 132 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 133: 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 134: 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 135: 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 136: 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 137 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 138 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 139 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 140: 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 141 (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 142: 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 143: 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 144 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 145 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 146 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 147 (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 148 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 149: 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 150: 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 151 Operation 4-28 Part 1604870-05 E 2018 Nordson Corporation...

  • Page 152: 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 153: 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 154 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 155 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 156 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 157 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 158 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 159: 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 160 − 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 161 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 162 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 163 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 164: 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 165: 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 166: 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 167 Troubleshooting 5-16 Part 1604870-05 E 2018 Nordson Corporation...

  • Page 168: 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 169 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 170: 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 HD and XT system controller.

  • Page 171: Controller Parts

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

  • Page 172: Controller Parts List

    S RECEPTACLE, net, controller interface, Encore 1082709 S RECEPTACLE, gun, Encore HD 982286 S SCREW, flat, slotted, M5 x 10, zinc NOTE A: Receptacles include harnesses. B: Items 2 and 3 are sold together as kit 1604025. Part 1604870-05 E 2018 Nordson Corporation...

  • Page 173: 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...
  • Page 174 Issued 07/18 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 175 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 176 03/18 Changed description for gun labels 07/18 Added nLighten LED inspection kit, added XD electrode support, new reference document links and updated description for part number 1600819. Added power supply resistance test nomenclature changes Part 1604869-13 E 2018 Nordson Corporation...
  • Page 177 Change Record Part 1604869-13 E 2018 Nordson Corporation...
  • Page 178 ....... . . Maintenance Procedures ....... Part 1604869-13 E 2018 Nordson Corporation...
  • Page 179 7-11 Powder Hose and Air Tubing ......7-11 Part 1604869-13 E 2018 Nordson Corporation...

  • Page 180: 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 181: 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 1604869-13 E 2018 Nordson Corporation...

  • Page 182: 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 1604869-13 E 2018 Nordson Corporation...
  • Page 183 Safety Part 1604869-13 E 2018 Nordson Corporation...

  • Page 184: Description

    Flat spray nozzles with 3-mm and 4-mm slots are shipped with the gun, as well as a conical nozzle kit that contains a conical nozzle, a 26-mm deflector and a conical electrode holder. Use the conical nozzle kit to convert from flat spray to conical spray applications. Part 1604869-13 E 2018 Nordson Corporation...

  • Page 185: Specifications

    FOR USE WITH ENCORE HD MANUAL CONTROLS APPROVED OR ENCORE HD HYBRID MANUAL CONTROLS WHEN CONFIGURED IN ACCORDANCE WITH 1084547 FM14ATEX0051X EN 50050-2 Ex tb IIIB T65 C Db II 2 D 1180 1603105−02 Part 1604869-13 E 2018 Nordson Corporation...

  • Page 186: Setup

    Delivery In 6 mm Pattern Air 4 mm Clear Air Wash 6 mm In Gun Cable Delivery Powder Manual Hose System Controller Network/Power Interconnect Pump Control Unit Figure 3-1 System Diagram (Common System Equipment Shown) Part 1604869-13 E 2018 Nordson Corporation...

  • Page 187: Spray Gun Installation

    Figure 3-2 Spray Gun Connections 1. Quick disconnect 3. Barbed hose adapter 5. Powder inlet tube 2. Barbed fitting 4. O-rings 6. Gun cable Part 1604869-13 E 2018 Nordson Corporation...

  • Page 188: Operation

    2. Equipment may only be used in areas of low impact risk. 3. Caution should be taken when cleaning plastic surfaces of the Encore controller and interface. There is a potential for static electricity build up on these components. Part 1604869-13 E 2018 Nordson Corporation...

  • Page 189: System Operation

    NOTE: Unprogrammed preset numbers (presets where all setpoints are zero) are automatically skipped. Refer to your controller manual for preset programming instructions. 4. Press the spray trigger. The system sprays with the new preset. See controller configuration F08 for more settings. Part 1604869-13 E 2018 Nordson Corporation...

  • Page 190: Changing Powder Flow With The Settings Trigger

    The purge length and frequency required will depend on the application. NOTE: The purge air only cleans the spray gun powder path. Refer to the system controller manual for additional HDLV purge information. Part 1604869-13 E 2018 Nordson Corporation...

  • Page 191: Electrode Air Wash Operation

    When the controller interface is off the spray gun cannot be triggered, and the spray gun interface is disabled. To turn off controller power, shut system power off at power unit or control panel. Part 1604869-13 E 2018 Nordson Corporation...

  • Page 192: Changing Flat Spray Nozzles

    NOTE: To clean nozzles, use the Recommended Cleaning Procedure for Powder Contact Parts on page 4-9. Nozzle Nut Flat Spray Electrode Assembly Flat Spray Nozzle Figure 4-4 Changing a Flat Spray Nozzle Electrode Assembly Bridge Figure 4-5 Correct Nozzle Orientation Part 1604869-13 E 2018 Nordson Corporation...

  • Page 193: Converting From Flat Spray Nozzles To Conical Nozzles

    Powder Contact Parts on page 4-9. Electrode Flat Spray Nozzle Flat Spray Electrode Holder Nozzle Nut Conical Spray Nozzle Conical-Spray Electrode Holder Deflector Figure 4-6 Converting from a Flat Spray Nozzle to a Conical Spray Nozzle Part 1604869-13 E 2018 Nordson Corporation...

  • Page 194: Changing Deflectors Or Conical Nozzles

    6. Screw the nozzle nut onto the gun body clockwise until finger-tight. 7. Install a new deflector on the electrode assembly. Do not bend the electrode wire. Deflector Conical Electrode Nozzle Nut Conical Electrode Holder Nozzle Assembly Figure 4-7 Changing a Conical Nozzle Part 1604869-13 E 2018 Nordson Corporation...

  • Page 195: Installing The Optional Pattern Adjuster Kit

    WARNING: Before performing the following tasks, turn off the controller and disconnect system power. Relieve system air pressure and disconnect the system from its input air supply. Failure to observe this warning may result in personal injury. Part 1604869-13 E 2018 Nordson Corporation...

  • Page 196: Recommended Cleaning Procedure For Powder Contact Parts

    Operation 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. NOTE: Do not immerse the electrode assembly in solvent. It cannot be disassembled;...
  • Page 197 Operation 4-10 Part 1604869-13 E 2018 Nordson Corporation...

  • Page 198: Repair

    7. Filter assembly 19. Cable assembly 28. Settings/purge trigger 10. Display module 19B. Power supply connector (J2) 29. Screw (handle to gun body) Note: Ground terminal (19D) must always be connected to the ground screw (16). Part 1604869-13 E 2018 Nordson Corporation...

  • Page 199: 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 (11) onto the display module, then install the bezel (12). 8. Install and tighten the screws (13). Part 1604869-13 E 2018 Nordson Corporation...
  • Page 200 (new switch) Display Module and Cable J3 Connectors Adhesive Switch Support Pad Header Figure 5-2 Display Module Replacement 10. Display module 12. Bezel A. Ground wire connector 11. Hook 13. M3 x 35 screws Part 1604869-13 E 2018 Nordson Corporation...

  • Page 201: Power Supply And Powder Path Replacement

    The air wash tubing will prevent a complete separation; leave it connected unless it must be replaced. Figure 5-3 Removing the Gun Body from the Handle Part 1604869-13 E 2018 Nordson Corporation...

  • Page 202: 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 1604869-13 E 2018 Nordson Corporation...

  • Page 203: Powder Path Removal

    NOTE: To verify proper installation, place a flashlight inside the bottom of the inlet adapter and verify the internal connections by looking through the outlet tube from the front of the powder spray gun. Part 1604869-13 E 2018 Nordson Corporation...
  • Page 204 Figure 5-5 Powder Path Replacement 4. Outlet tube kit 7. Filter assembly 21. M3 x 20 screws 5. Elbow 17. Ground pad 24. Inlet tube/hose adapter kit 6B. Gun body 20. Handle base 25. Handle Part 1604869-13 E 2018 Nordson Corporation...

  • Page 205: Gun Re-Assembly

    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 1604869-13 E 2018 Nordson Corporation...

  • Page 206: Cable Replacement

    VIEW A VIEW B Figure 5-7 Cable Replacement 13. M3 x 35 screw 16. M3 x 6 screw 18. Retaining ring 15. Lock washer 17. Ground pad 20. Handle base 21. M3 x 20 screws Part 1604869-13 E 2018 Nordson Corporation...

  • Page 207: Cable Installation

    5. Remove the spray trigger (27), actuator (26), and purge trigger (28) from the handle. 6. Use a tool to pry and pull the trigger switch (14) off the handle, then pull it up and out of the handle. Part 1604869-13 E 2018 Nordson Corporation...

  • Page 208: Switch Installation

    6. 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 5-2. 7. Re-assemble the gun as described in Gun Re-assembly on page 5-8. Part 1604869-13 E 2018 Nordson Corporation...
  • Page 209 Repair 5-12 Part 1604869-13 E 2018 Nordson Corporation...

  • Page 210: 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. Part 1604869-13...

  • Page 211: Spray Gun Power Supply Resistance Test

    C or 72 F. Allow time for the multiplier to cool to room temperature for repeatable results. 225-335 Megohms at 500 VDC J2−3 (YELLOW) J2−1 (RED) FEEDBACK J2−2 (BLACK) COMMON Figure 6-9 Power Supply Resistance Test Part 1604869-13 E 2018 Nordson Corporation...

  • Page 212: Electrode Assembly 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 6-10 Electrode Assembly Resistance Test Part 1604869-13 E 2018 Nordson Corporation...

  • Page 213: Gun Cable Continuity Test

    (BLUE) J3−3 AND BLUE) (ORANGE) J3−1 J1−1 (WHITE) J1−3 (ORANGE) (RED) J2−1 J2−3 J1−6 (RED) J1−4 (YELLOW) J2−2 (GREEN) (WHITE) (BLACK) J1−5 J2 (FACE VIEW) (YELLOW) POWER SUPPLY CONNECTOR Figure 6-11 Gun Cable Wiring Part 1604869-13 E 2018 Nordson Corporation...

  • Page 214: 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 parts and options for the Encore HD manual powder spray gun.

  • Page 215: Spray Gun Parts

    Parts Spray Gun Parts See Figure 7-1 and the parts list on the following pages. 24, 24C, 24D Figure 7-1 Encore HD Manual Spray Gun and Accessories Parts Part 1604869-13 E 2018 Nordson Corporation...

  • Page 216: Spray Gun Parts List

    S HANDLE, handgun, Encore HD/XT 1106892 S ACTUATOR, switch, trigger, Encore HD 1606999 S KIT, service, Encore trigger axle/trigger 1081540 S TRIGGER, setting, handgun 1088601 S SCREW, flat head, recess, M5x 10, nylon Continued... Part 1604869-13 E 2018 Nordson Corporation...
  • Page 217 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 1604869-13 E 2018 Nordson Corporation...

  • Page 218: Nlightent

    LED inspection kit that helps powder coaters improve quality by effectively illuminating hard to see surface areas. Any imperfection or missed area is quickly identified and corrected. Find out more at: nordsoncoating.com/nLighten. 1611977 nLighten Figure 7-2 LED Inspection Kit Part 1604869-13 E 2018 Nordson Corporation...

  • Page 219: Flat Spray Nozzles

    1081658 1081659 6 mm Flat Spray 4 mm Flat Spray Figure 7-3 Flat Spray Nozzles Cross Cut Nozzles 1082184 1082185 1082186 60 Degree Cross-cut 90 Degree Cross-cut 2.5 mm Castle Figure 7-4 Cross-cut Nozzles Part 1604869-13 E 2018 Nordson Corporation...

  • Page 220: 45-Degree Corner-Spray Nozzle

    Three angled slots in-line with spray gun axis Slot Type Top and bottom coating; typically no in/out part positioning Application Part Description Note 1102871 NOZZLE, 45 degree, flat spray, Encore Figure 7-6 45-Degree Flat Spray Nozzle Part 1604869-13 E 2018 Nordson Corporation...

  • Page 221: Conical Nozzle, Deflectors And Electrode Assembly Parts

    S DEFLECTOR, 26 mm 1082060 S NOZZLE, conical S ELECTRODE HOLDER, conical 1605861 NOTE A: The conical nozzle requires a different style electrode holder than what is used in the flat spray nozzle electrode assembly. Part 1604869-13 E 2018 Nordson Corporation...

  • Page 222: Conical Electrode Assembly

    The XD (extended duty) Electrode Support provides 2 to 3 times longer wear life than that of the standard duty electrode support. 1613835 1613834 XD Conical Spray Electrode Support XD Flat Spray Electrode Support Figure 7-10 Conical Spray and Flat Spray Electrode Supports Part 1604869-13 E 2018 Nordson Corporation...

  • Page 223: Pattern Adjuster Kit

    EXTENSION, lance, 150 mm, Encore HD 1604970 EXTENSION, lance, 300 mm, Encore HD NOTE A: If a longer lance extension is required, contact your Nordson representative. Ion Collector Kit This kit installs on the standard length gun. Refer to the instruction sheet shipped with the spray gun for installation instructions and repair parts.

  • Page 224: Ion Collector Components For Lance Extensions

    Do not replace with non-conductive tubing. E: Standard powder hose delivered with system. F: Optional powder hose to use in place of the standard polyolefin. Part 1604869-13 E 2018 Nordson Corporation...
  • Page 225 Parts 7-12 This page intentionally left blank. Part 1604869-13 E 2018 Nordson Corporation...
  • Page 226 Issued 12/18 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 and available local languages. NORDSON CORPORATION • AMHERST, OHIO • USA...
  • Page 227 ....... 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 2017. No part of this document may be inquiries about its products.
  • Page 228 Change Record Change Record Revision Date Change 11/17 New publication 3/18 Added CE mark and new DOC14045-01. 12/18 1093557 was 1903557. Part 1605708−02 E 2018 Nordson Corporation...
  • Page 229 Change Record Part 1605708−02 E 2018 Nordson Corporation...

  • Page 230: Safety

    Make sure all equipment is rated and approved for documentation where appropriate. the environment in which it is used. Any approvals obtained for Nordson equipment will be voided if Make sure all equipment documentation, including instructions for installation, operation, and service these instructions, are accessible to all persons are not followed.

  • Page 231: Fire Safety

    Use only replacement parts that are designed ground gun electrodes before making for use with original equipment. Contact your adjustments or cleaning powder spray guns. Nordson representative for parts information Connect all disconnected equipment, ground and advice. cables, and wires after servicing equipment.

  • Page 232: Description

    Extreme duty pump (XD) is the same as a Improved gasket design high flow pump except for machine tivar Y Centralized wear parts blocks and high temperature pinch valves Higher powder output Over torque protection Part 1605708−02 E 2018 Nordson Corporation...

  • Page 233: Pump Components

    Inlet Fitting Connects to the tubing leading from the power source Outlet Fitting Connects to the tubing leading to the powder spray gun Encore HD Pump Encore HD+, XD Pump Figure 2 Encore Pump Components Part 1605708−02 E 2018 Nordson Corporation...

  • Page 234: Theory Of Operation

    As each half dispenses powder out, the powder in the tubing blends together, resulting in a consistent Right half suction flow of powder from the spray gun. valve open Powder Powder Figure 4 Left Side Dispensing, Right Side Drawing In Part 1605708−02 E 2018 Nordson Corporation...

  • Page 235: Purging

    After the delivery side is purged, the delivery pinch Powder valves close and the suction pinch valves open. The suction side is purged in the same way as the delivery side. Figure 5 Purging Operation Part 1605708−02 E 2018 Nordson Corporation...

  • Page 236: Pump Port Functions

    Right Side Suction Pinch Valve Right Side Delivery Pinch Valve Right Side Fluidizing Tube Figure 7 Encore HD Pump Manifold with Port Functions Left Side Fluidizing Tube Left Side Delivery Pinch Valve Left Side Suction Pinch Valve Part 1605708−02 E 2018 Nordson Corporation...

  • Page 237: Operation

    The spray gun controller will generate a fault to Encore Manual Spray Gun Controller manual for indicate this condition and notify you that it is time specific instructions. to replace the fluidizing tubes. Correct vacuum reading is (9−14 in. Hg). Part 1605708−02 E 2018 Nordson Corporation...

  • Page 238: Specifications

    189mm (7.44 in) 233mm 237mm (9.19 in.) (9.34 in.) 282mm (11.10 in.) 79mm (3.10 in.) 74mm (2.89 in.) Encore HD Encore HD+ and XD (HD+ Stamped on Encore HD+) Figure 8 Encore Pump dimensions Part 1605708−02 E 2018 Nordson Corporation...

  • Page 239: Installation Pump Tubing Installation

    1. Pump Flexible Tubing 2. Pump mounting hardware 3. Panel or cabinet wall Figure 9 Powder Tubing Installations 4. Manifold 1. Lower Y block 2. Barbed tubing adapter 3. Poly tubing 4. Flexible tubing Part 1605708−02 E 2018 Nordson Corporation...

  • Page 240: Maintenance

    Y-block for signs of wear or impact fusion. Clean these parts in an ultrasonic cleaner if necessary. Every Six Months Each Time You Disassemble the Pump Lower Y Block Inspect the gasket for damage. Gasket Replace if necessary. Part 1605708−02 E 2018 Nordson Corporation...

  • Page 241: Troubleshooting

    These troubleshooting procedures cover only the most common problems that you may encounter. If you cannot solve the problem with the information given here, call the Nordson Finishing Customer Support Center at (800) 433-9319 or contact your local Nordson representative for help.
  • Page 242 Increase or decrease the fluidizing air incorrect pressure. The powder should be gently boiling. Powder damp or Check the air driers and filter/separators. contaminated Check the powder in the feed hoppers and make sure it flows easily. Continued... Part 1605708−02 E 2018 Nordson Corporation...
  • Page 243 The delivery tubing must be arranged arrangement in a 3-ft. coil and be parallel to the ground. Delivery tubing length is not to The delivery tubing must be 60 ft. specification from the pump to the spray gun. Continued... Part 1605708−02 E 2018 Nordson Corporation...
  • Page 244 If the discs are even slightly raised, the gasket will leak, causing the pump to malfunction. Pinch valve leaking Replace the pinch valves and filter disks. Lower Y-block plugged Remove and clean the lower Y-blocks. Part 1605708−02 E 2018 Nordson Corporation...

  • Page 245: Delivery Check

    Figure 11 on page 17. If the problem remains, the pump control 2. Trigger the gun and observe the powder manifold is bad. See Pump is bad, requires flow. repair in the Troubleshooting table. Part 1605708−02 E 2018 Nordson Corporation...

  • Page 246: Bubble Test For Color-On-Demand (Cod) System

    The test any that are worn out. mode button pressurizes all the air lines to the COD manifold pinch valves. If any of the pinch valves are leaking, bubbles will appear in the water. Part 1605708−02 E 2018 Nordson Corporation...

  • Page 247: Repair

    2. Loosen the fluidizing tube access plug and pull the fluidizing tube straight out of the pump body. Retrofit Pump Retrofit Pump Standard Pump Standard Pump Figure 13 Loosening the fluidizing tubes Figure 15 Reinstalling the purge air tubing. Part 1605708−02 E 2018 Nordson Corporation...

  • Page 248: Pump Disassembly

    Figure 16 Retrofit Pump Disassemble Preparation NOTE: Refer to the Pinch Valve Replacement Instructions, page 23 to remove pinch valves from pinch valve chamber. Figure 17 Standard Pump Disassemble Preparation Part 1605708−02 E 2018 Nordson Corporation...
  • Page 249 21. Lock Washer 6. O-rings (2) 14. Screws M5 x 25 (6) 22. Hose Barbs (2) 7. Fluidizing Tubes (2) 15. Pinch Valves (4) 23. Screws M5 x 85 8. O−rings (2) 16. O-rings (2) Part 1605708−02 E 2018 Nordson Corporation...

  • Page 250: Pump Assembly

    (17) and additional O−rings onto the fluidizing tubes (18) Figure 20 Assemble the Pinch Valve Housing Figure 22 Assemble Fittings to Fluidizing Tubes Part 1605708−02 E 2018 Nordson Corporation...
  • Page 251 Refer to Installation on page 10 for more information. PolyTubing Flex Tubing Figure 23 Fasten Fluidizing Tubes into Manifold Figure 24 Assemble Tubing into Lower Y Block Part 1605708−02 E 2018 Nordson Corporation...

  • Page 252: Pinch Valve Replacement

    Align the pinch valve point to the center of the pinch valve housing. Pinch Valve position Figure 27 Inserting Pinch Valve into Insertion Tool Part 1605708−02 E 2018 Nordson Corporation...
  • Page 253 Continue pulling on the insertion tool until the pinch valve pops through the valve body and the tool comes loose. Figure 29 Pulling Pinch Valve into Valve Body Part 1605708−02 E 2018 Nordson Corporation...
  • Page 254 Encore HD Pump This page intentionally left blank. Part 1605708−02 E 2018 Nordson Corporation...

  • Page 255: Parts Pump

    Encore HD Pump Parts Pump To order parts, call the Nordson Finishing Customer Support Center at (800) 433-9319 or contact your local Nordson representative. Figure 31 Encore HD, HD+ and XD Standard Parts Part 1605708−02 E 2018 Nordson Corporation...
  • Page 256 NOTE A: These parts are available in service kits listed on page 28. B: If your purge lines enter the top of the pump, then use Check Valve Kit p/n 1078161 (Includes 2 check valves). Part 1605708−02 E 2018 Nordson Corporation...

  • Page 257: Spare Parts

    Fluidizing Tube Kit HD+, XD Pump Amber Pinch Valve Kit 1093557 Extreme Duty Pump 1612218 Includes the following 8 Pinch Valves 8 O−Rings 8 Filter Discs Gasket Barbed Tubing Adapter for Flexible Tubing 1078006 Part 1605708−02 E 2018 Nordson Corporation...

  • Page 258: Air And Powder Tubing Part Numbers

    6 mm Blue Polyurethane 173101 8 mm Clear Polyethylene 900617 4 mm Clear Polyurethane 900740 10 mm Blue Polyethylene Top of Manifold Pump Tubing Bottom of Manifold Figure 32 Air and Powder Tubing Part Numbers Part 1605708−02 E 2018 Nordson Corporation...
  • Page 259 Encore HD Pump This page intentionally left blank. Part 1605708−02 E 2018 Nordson Corporation...
  • Page 260 Nordson Corporation OPERATOR’S CARD P/N 1605548-01 Encorer HD Powder Spray System with Prodigyr Color-on-Demandr Figure 1 System Diagram (Two-Gun System Shown)
  • Page 261 WARNING: Allow only qualified personnel to Refer to component operator manuals for more perform the following tasks. Follow the information on safety, setup, operation, troubleshooting, repair and parts. safety instructions in this document and all other related documentation. Quick Start 1.
  • Page 262 System Cleaning Point the gun into the booth, or hang it so it is pointing into the booth. Go to the Main screen, then press PURGE, then CLEAN, then START. NOTE: If for some reason your system loses air pressure during production, cross-contamination may occur.
  • Page 263 Setting Setting Icons μA Setting Pattern Air Flow Setting Function/Help Display Help Button Rotary Knob Nordson Button (Configuration) Standby Button View Button Enter Button Color Change Button Figure 8 Controller Interface The Setpoint icons light to indicate the configured or Help Codes selected setpoints.
  • Page 264 Assist Air Setting, Fast Flow Setting, and Software Versions The View button allows the user access to Figure 10 Assist Air Settings adjust Assist Air and Fast Flow preset values, and to Fast Flow Setting view software versions. The Fast Flow setting allows you to specify Fast Flow or Normal Flow for each preset.
  • Page 265 6. To begin production without saving the new settings, do not press Enter. The new values will be used for the current job, but the preset will keep the original values for future use. The setpoints for the selected preset are displayed when the gun is not triggered.
  • Page 266 2. Turn the rotary knob to increase or decrease the kV setpoint. The setpoint is automatically saved if it does not change for 3 seconds, or when any button is pressed. 3. To set or change the μA setpoint, press the mA button.
  • Page 267 2. Turn the knob to increase or decrease the setpoints. The setpoint is automatically saved if it Percent Flow Icon does not change for 3 seconds or when any Flow Button button is pressed. Pattern Button Pattern Icon Figure 19 Flow Rate and Pattern Setpoints Purge Operation HDLV System Purge 2.
  • Page 268 Press the Enter button to save the change and exit the value, so that rotating the knob now scrolls through the function numbers again. 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 269 Spray Gun Operation The spray gun interface and settings trigger allow you Changing Powder Flow with the Settings to change the preset or the powder flow settings, or Trigger purge the gun, without using the controller interface. 1. See Figures 21 and 22. Press the Mode button Preset Mode Icon Flow Mode Icon until the Flow Mode icon is lit.
  • Page 270 Electrode Air Wash Operation Electrode air wash air continually washes the spray Refer to your controller manual for instructions on gun electrode to prevent powder from collecting on it. adjusting electrode air wash flow. Electrode air wash air turns on and off automatically when the spray gun is triggered on and off.
  • Page 271 Issued 03/14 Original copyright date 2014. Encore, Prodigy, Color-on-Demand, Nordson and the Nordson logo are registered trademarks of Nordson Corporation.

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