Nordson Encore HD Customer Product Manual
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Nordson Encore HD Customer Product Manual

Pump control unit and power supply
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Encore
HD Pump Control Unit and
Power Supply
Customer Product Manual
Part 1606783-06
Issued 6/19
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
and available local languages.
NORDSON CORPORATION • AMHERST, OHIO • USA

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  • 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 and available local languages. 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 2015. No part of this document may be inquiries about its products. General information about Nordson can be...

  • Page 3: Table Of Contents

    Standalone, Rail Mount, and Wall Mount System Air Supply ..3-11 Encore HD Powder Pump Hose ......
  • Page 4 ........Part 1606783−06 E 2019 Nordson Corporation...
  • Page 5 10/15 New release 03/16 Updated gaskets. 1/18 Updated for new Encore HD pump information. 11/18 Replacing part number 1606690 with 1615026 6/19 Update part lists for pump control, panel assembly, manifold assembly, pump, spare parts, powder hose and air tubing.
  • Page 6 Change Record Part 1606783−06 E 2019 Nordson Corporation...

  • Page 7: Safety

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

  • Page 8: Personal Safety

    Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use only replacement parts that are designed for use with original equipment. Contact your Nordson representative for parts information and advice. Part 1606783−06 E 2019 Nordson Corporation...

  • Page 9: Grounding

    Disconnect and lock out electrical power. Close pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the equipment. Disposal Dispose of equipment and materials used in operation and servicing according to local codes. Part 1606783−06 E 2019 Nordson Corporation...
  • Page 10 Safety Part 1606783−06 E 2019 Nordson Corporation...

  • Page 11: Description

    Introduction See Figure 2-1. This manual covers the Encore HD pump control unit, which is used to supply power and to operate Encore HD manual powder spray systems. The pump control unit comes equipped with a Encore HD powder feed pump.

  • Page 12: Specifications

    Description Specifications Model: Encore HD Controller Power Unit Input Rating: 100−240 VAC, 50/60 Hz, 125 VA Output Rating: 24 VDC, 2.5 A Input Air: 6.0−7.6 bar (87−110 psi), <5μ particulates, dew point <10 _C (50 _F) Max Relative Humidity: 95% non-Condensing...
  • Page 13 Encore HD Controller Power Unit Dimensions 179 mm 296 mm (7.0 in.) (11.6 in.) 370 mm 375 mm (14.5 in.) (14.8 in.) 304 mm (11.9 in.) 217 mm (8.6 in.) Figure 2-3 Encore HD+, XD Controller Power Unit Dimensions Part 1606783−06 E 2019 Nordson Corporation...

  • Page 14: Pump Control Unit Certification Label

    (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 2-4 Encore Pump dimensions Pump Control Unit Certification Label 1606121_02 Part 1606783−06 E 2019 Nordson Corporation...

  • Page 15: Encore Hd Pump

    Description Encore HD Pump See Figure 2-1. The Encore HD (High-Density powder, Low-Velocity air) powder feed pump transports precise amounts of powder from a feed source to a powder spray gun. The design of the pump and the small diameter powder tubing used allow powder to be purged quickly and thoroughly for fast color changes.

  • Page 16: Hd Pump Components

    Connect the inlet and outlet fittings to the pinch valves on either half of the pump. Inlet Fitting Connects to the tubing leading from the power source Outlet Fitting Connects to the tubing leading to the powder spray gun Part 1606783−06 E 2019 Nordson Corporation...
  • Page 17 Description Encore HD Pump Encore HD+, XD Pump Figure 2-2 Encore Pump Components Part 1606783−06 E 2019 Nordson Corporation...

  • Page 18: Theory Of Operation

    Theory of Operation Pumping The Encore HD pump consists of two halves that function identically. The halves alternately draw powder in and dispense powder out of the pump; while one half is drawing powder in, the other half is dispensing powder out.
  • Page 19 Powder Powder Powder Powder Left Side Drawing In Left Side Dispensing Right Side Dispensing Right Side Drawing In Figure 2-3 Operation of Pump (Shown as rear, right view of the pump) Part 1606783−06 E 2019 Nordson Corporation...

  • Page 20: Purging

    After the delivery side is purged, the delivery pinch valves close and the suction pinch valves open. The suction side is purged in the same way as the delivery side. Part 1606783−06 E 2019 Nordson Corporation...
  • Page 21 2-11 Description Stage 1 Stage 2 Soft Purge to Soft Purge to Spray Gun Feed Source Powder Powder Powder Stage 3 To Spray Gun and Feed Source Hard Purge Powder Figure 2-4 Purging Operation Part 1606783−06 E 2019 Nordson Corporation...

  • Page 22: Pump Control Manifold Components

    High Pinch Valve Regulates the high pinch valve 80 psi pressure Low Pinch Valve Regulates the low pinch valve 37 psi pressure Vacuum Generator Regulator Regulates the supply from the 80 psi vacuum generator Part 1606783−06 E 2019 Nordson Corporation...
  • Page 23 2-13 Description Figure 2-5 Pump Control Manifold Part 1606783−06 E 2019 Nordson Corporation...
  • Page 24 2-14 Description Part 1606783−06 E 2019 Nordson Corporation...

  • Page 25: Installation

    Wall Mount Configuration Rail Mount Configuration Figure 3-1 Controller with Mounting Brackets NOTE: Filter ordered separately. Less than 5 micron filtration before point of use is recommended. Part 1606783−06 E 2019 Nordson Corporation...
  • Page 26 Fasteners shown are provided with the controller. Make sure to provide clearance for the connections to both the power unit and the interface module. Figure 3-2 Pump Control Unit Wall Mounting Brackets 1. Pump control unit 2. Wall mount bracket 3. Rail mount bracket Part 1606783−06 E 2019 Nordson Corporation...

  • Page 27: Interconnect Cable Connection

    Interconnect Cable Connection See Figure 3-3. Connect the gray, 3 meter (10 ft) interconnect cable to the net/auxiliary receptacles on Encore HD system controller to the pump control unit. NOTE: The interconnect cable shipped with the system is 3 meters (10 ft) long.

  • Page 28: System Connections

    For additional information, see the Wiring Diagrams section. Encore HD Manual Powder Spray Gun Hopper Pump Vacuum Pinch Hi/Lo Pump Manifold Purge Encore HD Flow Module Figure 3-4 Encore HD Pump Control Unit Pneumatic Diagram Part 1606783−06 E 2019 Nordson Corporation...
  • Page 29 System Controller Pump Manifold Pump Purge Valve Pinch Hi/Low Valve Blue LED Encore HD Flow Module AC Power Relay/ Power Supply Filter Fuses VBF Motor Figure 3-5 Encore HD Pump Control Unit Electrical Diagram Part 1606783−06 E 2019 Nordson Corporation...

  • Page 30: Pump Control Unit Connections

    Installation Pump Control Unit Connections The Encore HD spray gun is controlled by the system controller and pump control unit connected by a network/power cable. The pump control unit houses a 24Vdc power supply, circuit board, and iFlowr air controller and valves used to control the Encore HD pump.

  • Page 31: Spray Gun Connections

    3. Thread the cable nut onto the receptacle and tighten the nut securely. Net Cable Cable to (To Pump Contol Unit) Spray Gun Figure 3-7 Spray Gun Cable Connection to System Controller − Mobile System Shown Part 1606783−06 E 2019 Nordson Corporation...

  • Page 32: Air Tubing And Powder Tube

    4-mm Clear Electrode Air Wash Tubing HD Tube Adapter Spray Gun Cable 8 mm Powder Hose 6-mm Blue Pattern Air Tubing Figure 3-8 Spray Gun Connections Part 1606783−06 E 2019 Nordson Corporation...

  • Page 33: Bundling Tubing And Cable

    Spiral wrap is used to protect the tubing from the swivel castors. For Standalone and Rail/Wall systems: The tubing must be coiled in a 3 ft diameter in a horizontal orientation. Part 1606783−06 E 2019 Nordson Corporation...

  • Page 34: Main System Air And Electrical Connections

    10-mm Air Tubing 10-mm Air Tubing Main Supply Air Input Output to Pump Control Unit Air Filter Figure 3-10 System Air Supply Connection (Shown with Mobile System) Part 1606783−06 E 2019 Nordson Corporation...

  • Page 35: Standalone, Rail Mount, And Wall Mount System Air Supply

    Air Filter Installation − Standalone and Rail/Wall 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 1606783−06 E 2019 Nordson Corporation...

  • Page 36: Encore Hd Powder Pump Hose

    3. Push the flexible powder tubing (4) over the barbed ending of the adapter (2). Poly Tubing Flexible Tubing Figure 3-12 Encore HD Pump Tubing Installation 1. Lower Y block 3. Poly tubing 2. Barbed tubing adapter 4. Flexible tubing Part 1606783−06...

  • Page 37: Pump Adapter Installation

    3-13 Pump Adapter Installation See Figure 3-13. The pump adapter allows you to connect the Encore HD pump to your powder source. Install the tubing onto the barbed hose adapter. Then, plug the barbed hose adapter into the pump adapter.

  • Page 38: Electrical Connections

    Use the ESD ground bus bar kit included with the system to connect the power unit ground stud to the grounded spray booth or a true earth ground. Refer to the instructions included with the kit. Part 1606783−06 E 2019 Nordson Corporation...

  • Page 39: Operation

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

  • Page 40: Maintenance

    Every Six Months Y Block Gasket NOTE: Replace the Y block gasket each time the pump is Each Time You disassembled. Disassemble the Pump Lower Y Block Inspect the gasket for damage. Gasket Replace if necessary. Part 1606783−06 E 2019 Nordson Corporation...

  • Page 41: 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 1606783−06...

  • Page 42: Pump Troubleshooting

    If the exhaust muffler appears to be plugged, replace it. Defective pump air flow Clean the pump air flow control valve. control valve Refer to either the pump panel or control manifold manual for more information. Part 1606783−06 E 2019 Nordson Corporation...

  • Page 43: Pump Port Functions

    Function Right Side Suction Pinch Valve Right Side Delivery Pinch Valve Right Side Fluidizing Tube Left Side Fluidizing Tube Left Side Delivery Pinch Valve Left Side Suction Pinch Valve Figure 5-15 Pump Port Functions Part 1606783−06 E 2019 Nordson Corporation...

  • Page 44: Manifold Troubleshooting

    Refer to iFlow Module Repair changes on page 6-4 for instructions. If the problem persists, replace the pattern air flow control valve. Refer to iFlow Module Repair on page 6-4 for instructions. Part 1606783−06 E 2019 Nordson Corporation...

  • Page 45: Solenoid And Flow Control Valve Functions

    Right Side Delivery Pinch Valve Vacuum Generator Right Side Fluidizing Tube High Pinch Valve (80 psi) Left Side Fluidizing Tube Low Pinch Valve (37 psi) Left Side Delivery Tube Vacuum Generator Regulator (80 psi) Part 1606783−06 E 2019 Nordson Corporation...

  • Page 46: 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 47: Repair

    CAUTION: Electrostatic sensitive device. To avoid damaging the controller circuit boards, wear a grounding wrist strap and use proper grounding techniques when making repairs. Refer to the Wiring Diagram section for the pump control unit electrical schematic and harness connections. Part 1606783−06 E 2019 Nordson Corporation...

  • Page 48: Removing Panel Assembly

    External Enclosure Ground Internal Enclosure Ground Figure 6-18 Sub-Panel Removal 1. Enclosure 3. Panel Assembly 2. Screws Part 1606783−06 E 2019 Nordson Corporation...

  • Page 49: Sub-Panel Components

    2. Set the regulator to 85 psi. 3. Remove the gauge and replace the plug in the regulator fitting. 4. Push the regulator knob to lock the setting. Fittings 10014746 Figure 6-19 Regulator Adjustment Part 1606783−06 E 2019 Nordson Corporation...

  • Page 50: Iflow Module Repair

    4. Decrease the assist air to −50% and trigger the pump ON. The monometer should read 1.0−3.0 psi (0.1−0.2 bar). Pattern Air Use the flow verification tool (1039881) with its instructions and connect to the pattern air output. Part 1606783−06 E 2019 Nordson Corporation...

  • Page 51: Solenoid Valve Replacement

    See Figure 6-20. If cleaning the proportional valve does not correct the flow problem then replace the valve. Before installing a new valve, remove the protective cover from the bottom of the valve body. Be careful to not lose the O-rings under the cover. Part 1606783−06 E 2019 Nordson Corporation...
  • Page 52 7. Direction of flow arrow 11. Valve body 3. Coil−proportional valve (2) 8. Stem 12. Orifice 4. Long screws−valve to manifold (2) 9. Spring 13. Solenoid valves 5. Short screws−valve stem to body (2) Part 1606783−06 E 2019 Nordson Corporation...

  • Page 53: Vibrator Motor Replacement

    Check the ID plate on the power unit. Replacement motors include the power cable. Refer to the Power Unit Wiring Diagram in the Troubleshooting section of this manual for internal VBF wiring. Part 1606783−06 E 2019 Nordson Corporation...

  • Page 54: Fluidizing Tube Replacement

    Figure 6-21 Removing the purge air tubing. 2. Loosen the fluidizing tube access plug and pull the fluidizing tube straight out of the pump body. Retrofit Pump Standard Pump Figure 6-22 Loosening the fluidizing tubes Part 1606783−06 E 2019 Nordson Corporation...
  • Page 55 Figure 6-23 Replacing the Access Plugs to the Fluidizing Tubes. 4. Install the fluidizing tube assemblies into the pump body. Tighten the access plugs, then reconnect the purge air tubing. Retrofit Pump Standard Pump Figure 6-24 Reinstalling the Purge Air Tubing. Part 1606783−06 E 2019 Nordson Corporation...

  • Page 56: Pump Disassembly

    Discard the Y block gasket (19). NOTE: Refer to Pinch Valve Replacement on page 6-15 for instructions on removing the pinch valves from the pinch valve body. Retrofit Pump Standard Pump Figure 6-25 Disassembly Preparation Part 1606783−06 E 2019 Nordson Corporation...
  • Page 57 6-11 Repair Figure 6-26 Pump Disassembly (Encore HD Shown) 1. Fitting caps (2) 9. Purge manifold 17. Filter discs (4) 2. O-rings (2) 10. Manifold gasket 18. Pinch valve block 19. Y block gasket 3. Check valves (2) 11. Block seal 4.

  • Page 58: Pump Assembly

    2. Assemble pinch valves (5), filter discs (6), and O-rings (7) into pinch valve housing (8). Refer to Pinch Valve Replacement on Page 6-15 for assembly procedure. Figure 6-28 Assemble the Pinch Valve Housing Part 1606783−06 E 2019 Nordson Corporation...
  • Page 59 (17) and additional O-rings onto the fluidizing tubes (18) Figure 6-30 Assemble Fittings to Fluidizing Tubes 5. After the pump is assembled, completely tighten the long screw to fit all components together securely. Part 1606783−06 E 2019 Nordson Corporation...
  • Page 60 7. Mount the pump to the cabinet before assembling the feed tubing to the ports in the bottom of the pump. Refer to Installation on page 3-12 for more information. PolyTubing Flex Tubing Figure 6-32 Assemble Tubing into Lower Y Block Part 1606783−06 E 2019 Nordson Corporation...

  • Page 61: Pinch Valve Replacement

    3. Cut the flange off with scissors, then pull the rest of the pinch valve out of the top of the pinch valve body. Figure 6-34 Pinch Valve Removal Part 1606783−06 E 2019 Nordson Corporation...

  • Page 62: Pinch Valve Installation

    Figure 6-35 Inserting Pinch Valve into Insertion Tool 2. Drag the valve through the chamber and check the alignment of the pinch valve in the housing. Pinch Valve position Figure 6-36 Pull Insertion Tube through Chamber Part 1606783−06 E 2019 Nordson Corporation...
  • Page 63 Pull and twist the pinch valve to align the ribs with the grooves as necessary. Check rib on valve matches groove on pinch valve chamber Figure 6-38 Checking Rib and Groove Alignment Part 1606783−06 E 2019 Nordson Corporation...
  • Page 64 6-18 Repair Your notes Part 1606783−06 E 2019 Nordson Corporation...

  • Page 65: 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 66: Pump Control Unit

    Item Part Description Quantity Note — 1605584 PUMP CONTROL UNIT, 115 V, Encore HD — 1605586 PUMP CONTROL UNIT, 230 V, Encore HD - - - - - - S PANEL, controller, power/pneumatic 1045837 S SCREW, pan, recessed, M5 x 12, with internal lock...
  • Page 67 Parts 17,18,19,20 5, 15, 16 7, 8, 24 17,18,19,20,26 10013427 Figure 7-1 Pump Control Unit Part 1606783−06 E 2019 Nordson Corporation...

  • Page 68: Panel Assembly

    - - - - - - S PUMP ASSEMBLY, Encore HD 1027585 S VALVE, solenoid, 3−way, sub base 1605442 S MODULE, digital air flow, manual system, Encore HD 1604082 S VALVE, solenoid, 3−port, 24 vdc, ¼ NPTF 1100310 S REGULATOR, NPT, 7−125 psi, pneumatic...
  • Page 69 S CONNECTOR, male, elbow, 6 mm T x 972313 S TEE, union, 8 mm tube x 8 mm tube, pl 1604804 S MANIFOLD ASSEMBLY, pump control, Encore HD 1605754 S FILTER, line, with terminals, Encore HD 984702 S NUT, hex, M5, brass 983021 S WASHER, flat, E, 0.203 x 0.406 x 0.040, br...

  • Page 70: Iflow Module

    1099288 S VALVE, solenoid, 3-way, w/connector 1027547 S VALVE, proportional, solenoid, sub-base 1602319 S PCA, Encore HD flow node, 1 channel 972277 S CONNECTOR, male, elbow, 8 mm T x 972399 S CONNECTOR, male, with/int hex, 6 mm T x...

  • Page 71: Manifold Assembly

    Description Quantity Note — 1604804 MANIFOLD ASSEMBLY, pump control, Encore HD 1604080 S GASKET, pump control manifold, Encore HD 1074535 S CONNECTOR, male, 90 elbow, 10 mm T x 1603927 S CONNECTOR, male elbow, 8 mm x 1605530 S CONNECTOR, male, elbow, 6 mm T x RPT.
  • Page 72 Parts 1604804 Figure 7-5 Manifold Assembly Parts Part 1606783−06 E 2019 Nordson Corporation...

  • Page 73: Pump

    Parts Pump See Figure 7-6. Figure 7-6 Encore HD, HD+ and XD Standard Parts Part 1606783−06 E 2019 Nordson Corporation...
  • Page 74 B: If the purge lines enter the top of the pump, use Check Valve Kit 1078161 (Includes 2 check valves). C: Use gasket 1613013 instead of 1612795 on applications with the Encore HD pump module. D: Replace the gasket each time the pump is disassembled.

  • Page 75: Spare Parts

    HD+, XD Pump 1612218 1093557 Includes the following 8 Pinch Valves 8 O−Rings 10 Filter Discs 2 Gaskets Check Valve Barbed Tubing Adapter Service Kit (Retrofit) for Flexible Tubing 1078161 1078006 Check Valve Service Kit 1605570 Part 1606783−06 E 2019 Nordson Corporation...

  • Page 76: Wall/Rail Mount System

    Do not replace with non-conductive tubing. F: Standard powder hose delivered with system. G: Optional powder hose to use in place of the standard polyolefin. Part 1606783−06 E 2019 Nordson Corporation...

  • Page 77: Miscellaneous Options

    7-13 Parts Miscellaneous Options Part Description Quantity Note 1091429 KIT, input air, Encore HD manual systems 972841 S CONNECTOR, male, 10 mm tube x in. unithread 971102 S CONNECTOR, male, 10 mm tube x in. unithread 973500 S COUPLING, pipe, hydraulic, in., steel, zinc...
  • Page 78 7-14 Parts Your notes Part 1606783−06 E 2019 Nordson Corporation...

  • Page 79: Wiring Diagrams

    Wiring Diagrams Section 8 Wiring Diagrams Description Part Number Encore HD Power/Pneumatic 10013427 Controller Assembly Part 1606783−06 E 2019 Nordson Corporation...
  • Page 80 Wiring Diagrams Part 1606783−06 E 2019 Nordson Corporation...
  • Page 81 TO BACK OF HOUSING REMOVE JUMPER FOR 230V APPLICATION DETAIL E SCALE 1 : 1 AIR IN FRONT PANEL SET TO 85 PSI BOTTOM VIEW MANIFOLD REF DWG,PWR/PNEU CTRLR ASSY,ENCORE HD DESCRIPTION 10013427 NUMBER REVISION SHEET AIR IN FRONT PANEL...
  • Page 82 BLACK DC COMM FILTER BLACK DC COMM BROWN BROWN RED + 24VDC RED + 24VDC NETWORK (GREEN/YELLOW) JUMPER 120v VBF ONLY WHITE BLACK (GREEN/YELLOW) GREEN VBF RECEPTACLE REF DWG,PWR/PNEU CTRLR ASSY,ENCORE HD DESCRIPTION 10013427 NUMBER REVISION SHEET INSIDE TOP OF HOUSING...
  • Page 83 The Encore XT Manual system uses venturi style pump technology for supplying power to the spray gun. While the Encore HD Manual system uses high density pump technology for supplying power to the spray gun. The Encore Auto Gun is listed with Manual XT controls for single auto gun applications and could be mounted to a gun stand or on a robot.

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