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

Manual powder spray system
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Encorer HD Manual Powder Spray
System
Customer Product Manual
Part 1605707-04
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 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 Change Record Revision Date Change 10/15 New release 02/18 Added mobile system components to manual. 04/18 Added illustrations showing the Encore HD pump. 07/18 Added HD, HD+, and HDXD System part numbers, added nLighten information Part 1605707-04 E 2018 Nordson Corporation...
  • Page 4 Change Record Part 1605707-04 E 2018 Nordson Corporation...

  • Page 5: Table Of Contents

    ........3-10 Standalone and Rail/Wall Mount Systems ....3-10 Part 1605707-04 E 2018 Nordson Corporation...
  • Page 6 ......Encore HD Manual Powder Spray Systems ....

  • 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 1605707-04 E 2018 Nordson Corporation...

  • Page 9: Grounding

    Disconnect and lock out electrical power. Close pneumatic shutoff valves and relieve pressures. Identify the reason for the malfunction and correct it before restarting the equipment. Disposal Dispose of equipment and materials used in operation and servicing according to local codes. Part 1605707-04 E 2018 Nordson Corporation...
  • Page 10 Safety Part 1605707-04 E 2018 Nordson Corporation...

  • Page 11: Description

    Mobile Dolly System with Feed Hopper Standalone Systems − Single and Dual Configurations Rail Mount and Wall Mount Systems Vibratory Box Feeder Feed Hopper Standalone Rail/Wall Mount Figure 2-1 Encore HD Manual Powder Systems Part 1605707-04 E 2018 Nordson Corporation...

  • Page 12: Mobile System Components

    Mobile System Components See Figure 2-2. Mobile Systems include: Encore HD manual system controller Encore HD manual spray gun and cable Encore HD powder feed pump Encore HD pump control unit Encore pump pickup tube One of the following, based on system version: Vibratory table and motor −...

  • Page 13: Standalone And Rail/Wall System Components

    See Figure 2-2. Standalone and Rail/Wall Systems include: Encore HD manual system controller Encore HD manual spray gun and cable Encore HD powder feed pump Encore HD pump control unit Pump adapter kit and coupling for use on HR/NHR feed hoppers NOTE: Hoppers are sold separately.

  • Page 14: Specifications

    Input Rating Output Rating Encore HD Applicator +/− 19 VAC, 1 A 100 KV, 100 μA Encore HD Interface Control Unit 24 VDC, 2.0 A +/− 19 VAC, 1A Encore HD Controller Power Unit 100−240 VAC, 50/60 Hz, 125 VA 24 VDC, 2.5 A...

  • Page 15: Applicator Certification Label

    Description Applicator Certification Label For Electrostatic Finishing Applications Class II Spray Material 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...
  • Page 16 Description Part 1605707-04 E 2018 Nordson Corporation...

  • Page 17: Installation

    Follow the safety instructions in this document and all other related documentation. Required Installation Tools Flathead screw driver Scissors Tube cutters Wrench Pliers Drill Masonry drill bit included in anchoring kit (Standalone systems only) Tapcon screws included in anchoring kit (Standalone systems only) Part 1605707-04 E 2018 Nordson Corporation...

  • Page 18: Standalone System

    2. Anchor the stand to floor or platform using Tapcon screws supplied with kit. 4 x ∅ 0.250 Mounting Holes 355.6 mm 317.5 mm (14.0 in (12.5 in 317.5 mm (12.5 in 355.6 mm (14.0 in 10013908 Figure 3-1 Anchoring Stand Part 1605707-04 E 2018 Nordson Corporation...

  • Page 19: Hopper Installation For Feed Hopper System

    Hose Clamp Stack Vent Hose Ground Cable Ground Plug/Socket 6-mm Fluidizing AirTubing Hopper Fluidizing Fluidizing Air 10-mm and Barb Fitting and 6-mm Tube Reducer Ground Stud Figure 3-2 Hopper Installation on Mobile System Dolly Part 1605707-04 E 2018 Nordson Corporation...

  • Page 20: Setup Common To All Manual Systems

    Spray Gun Connections Unpack the spray gun. Uncoil the spray gun cable and the included clear 4-mm and blue 6-mm air tubing. Connect the gun cable and air tubing as described in the following procedures. Part 1605707-04 E 2018 Nordson Corporation...

  • Page 21: Spray Gun Cable

    3. Thread the cable nut onto the receptacle and tighten the nut securely. Cable to Net Cable Spray Gun (To Pump Contol Unit) Figure 3-4 Spray Gun Cable Connection to System Controller − Mobile System Shown Part 1605707-04 E 2018 Nordson Corporation...

  • Page 22: Air Tubing And Powder Hose

    Install the powder hose. Spray Gun Cable HD Hose Adapter 6 mm Blue Pattern Air Tubing 8 mm Powder Hose 4 mm Clear Electrode Air Wash Tubing To Pump Figure 3-5 Spray Gun Connections Part 1605707-04 E 2018 Nordson Corporation...

  • Page 23: Bundling Tubing And Cable

    See Figure 3-6. Use the sections of black spiral wrap supplied with the system to bundle together the spray gun cable, air tubing, and powder hose. Black Spiral Wrap Adjustable Cable Ties Figure 3-6 Bundling Tubing (Shown with Mobile System) Part 1605707-04 E 2018 Nordson Corporation...

  • Page 24: Main System Air And Electrical Connections

    10-mm 10-mm Air Tubing Air Tubing Supply Air Output to Input Pump Control Unit Air Filter Figure 3-7 System Air Supply Connection (Shown with Mobile System) Part 1605707-04 E 2018 Nordson Corporation...

  • Page 25: 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 1605707-04 E 2018 Nordson Corporation...

  • Page 26: Main Electrical Connection

    Use the ESD ground bus bar kit included with the system to connect the pump control unit ground stud to the grounded spray booth or a true earth ground. Refer to the instructions included with the kit. Part 1605707-04 E 2018 Nordson Corporation...

  • Page 27: Operation

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

  • Page 28: Vbf Powder Box Installation

    NOTE: See page 4-4 for recommended pressure at startup. Fluidizing Air Supply and Ground Connection Pickup Tube Arm Pickup Tube Tube Catch Figure 4-1 Pickup Tube Bracket Use Part 1605707-04 E 2018 Nordson Corporation...

  • Page 29: Feed Hopper Filling Startup

    NOTE: See page 4-4 for recommended pressure at startup. Vent Hose Stack Clamp Rubber plug Vent Hose Recommended ½ full for startup Out to Powder Booth Figure 4-3 Powder Feed Hopper Startup Part 1605707-04 E 2018 Nordson Corporation...

  • Page 30: Fluidizing Air Operation

    To configure the system for a vibratory box feeder, change the VBF delay time, or set the vibrator motor to continuous operation, refer to Controller Configuration in the system controller operator manual. NOTE: Over or under fluidization is a common cause of inconsistent delivery. Part 1605707-04 E 2018 Nordson Corporation...

  • Page 31: Electrode Air Wash Operation

    CCW from fully closed position), but can be adjusted if needed. NOTE: Excessive electrode air wash will create a void in the center of the spray pattern. Electrode Air Wash Needle Valve Figure 4-4 Electrode Air Wash Valve Location Part 1605707-04 E 2018 Nordson Corporation...

  • Page 32: Daily Operation

    Refer to Controller Configuration in the system controller operator manual for information on changing the motor function setting. 6. Select the desired preset and start production. Refer to Presets in the system controller operator manual for preset programming instructions. Part 1605707-04 E 2018 Nordson Corporation...

  • Page 33: Standby Button

    4. If shutting down for the night or a longer period of time, turn off the power disconnect to the unit. 5. Perform the appropriate maintenance steps listed in Maintenance Procedures on page 5-2. Part 1605707-04 E 2018 Nordson Corporation...
  • Page 34 Operation Part 1605707-04 E 2018 Nordson Corporation...

  • Page 35: Maintenance

    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 36: Maintenance Procedures

    Check the system air filter/regulator. Drain the filter and change the filter element as Filter needed. (Periodically) System Daily: Make sure the system is securely connected to a true earth ground before Grounds spraying powder. Periodically: Check all system ground connections. Part 1605707-04 E 2018 Nordson Corporation...

  • Page 37: Troubleshooting

    Failure to observe this warning could result in personal injury. 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 system controller can sense.

  • Page 38: Help Code Troubleshooting Chart

    Gun cannot be set to 0, must be a number from 1−4. Refer to Setup for more information on 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.
  • Page 39 Use the flow verification tool (1039881) with its instructions and connect to the pattern air output. 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 1605707-04 E 2018 Nordson Corporation...
  • Page 40 6 mm pattern port and perform the Re-Zero Procedure on page 6-12. Use the flow verification tool 1039881. 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 1605707-04 E 2018 Nordson Corporation...
  • Page 41 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 1605707-04 E 2018 Nordson Corporation...
  • Page 42 Purge Valve 9 Fault Check J12-3 for loose harness connection. Check Valve 8 for loose connection. Purge Pinch Pressure Select Check J12-2 for loose harness connection. Valve 8 Fault Check Valve 8 for loose connection. Part 1605707-04 E 2018 Nordson Corporation...

  • Page 43: General Troubleshooting Chart

    Remove powder path if necessary and clean it. Electrode air wash flow too high Adjust the needle valve at the power unit to decrease the electrode air wash flow. Continued... Part 1605707-04 E 2018 Nordson Corporation...
  • Page 44 − 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 1605707-04 E 2018 Nordson Corporation...
  • Page 45 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 1605707-04 E 2018 Nordson Corporation...
  • Page 46 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 1605707-04 E 2018 Nordson Corporation...
  • Page 47 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 1605707-04 E 2018 Nordson Corporation...

  • Page 48: 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 49: 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. Reference Documentation For additional information related to other components in the system, reference the following documentation:...

  • Page 50: Encore Hd Manual Powder Spray Systems

    Parts Encore HD Manual Powder Spray Systems With nLightent Standard System System Description Option 1613900 1605588 Encore HD 115 V VBF Mobile 1613901 1605589 Encore HD 230 V VBF Mobile 1613899 1605587 Encore HD 50 lb Hopper Mobile 1613902 1605590...

  • Page 51: Mobile System Components

    C: Installed in power unit fluidizing air output fitting. D: Plugs unused port in system air filter/regulator output fitting. E: Conductive fitting. Do not replace this fitting with a non−conductive fitting. NS: Not Shown Part 1605707-04 E 2018 Nordson Corporation...

  • Page 52: Grounding Equipment

    Parts Grounding Equipment Part Description 1067694 KIT, grounding block Part 1605707-04 E 2018 Nordson Corporation...

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