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

Nordson Encore HD Customer Product Manual

Automatic powder spray guns
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Encore
r
HD Automatic
Powder Spray Guns
Customer Product Manual
Part 1602018-13
Issued 2/19
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.
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. NORDSON CORPORATION  AMHERST, OHIO  USA...
  • Page 2 Notice Nordson Corporation welcomes requests for information, comments, and This is a Nordson Corporation publication which is protected by copyright. inquiries about its products. General information about Nordson can be Original copyright date 2013. No part of this document may be...
  • Page 3 Page 2-2 - Added ISO standard for air quality in Specifications Page 7-3 - Removed callout 10 and added callout 8 on Figure 7- 10 Page 8-3 - Added part numbers for 1- and 2-packaged spray guns Part 1602018-13 E 2019 Nordson Corporation...
  • Page 4 Change Record Part 1602018-13 E 2019 Nordson Corporation...

  • Page 5: Table Of Contents

    ........Part 1602018-13 E 2019 Nordson Corporation...
  • Page 6 Bar-Mount Spray Gun Parts List ..... . External Diffuser for Encore HD Automatic Spray Guns ..

  • 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 1602018-13 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 1602018-13 E 2019 Nordson Corporation...
  • Page 10 Safety Part 1602018-13 E 2019 Nordson Corporation...

  • Page 11: Description

    The spray guns are used with the Nordson Encore HD iControl system, which provides electrostatic voltage control, electrode air-wash air, atomizing air, and HDLV pump control.

  • Page 12: Specifications

    100 KV, 100 A Air Quality: ISO8573- 1:2010 Class 1.2.1 Max Relative Humidity: 95% non-Condensing Ambient Temperature Rating: +15 to +40 _C (59- 104 _F) Hazardous Location Rating for Applicator: Zone 21 or Class II, Division 1 Part 1602018-13 E 2019 Nordson Corporation...

  • Page 13: Applicator Certification Label

    Special Conditions for Safe Use To meet ATEX requirements for the European Union: The Encore HD powder electrostatic automatic applicators shall only be used with associated Encore HD iControl controllers over the ambient temperature range of +15 _C to +40 _C.

  • Page 14: Dimensions And Weights

    (to end of tube mount) 6- ft Tube Mount Spray Gun Weight: 2.40 kg (5.29 lb) 200.73 cm (79.027 in) 185.58 cm (73.062 in) (to end of tube mount) Figure 2-2 Spray Gun Dimensions and Weights Part 1602018-13 E 2019 Nordson Corporation...

  • Page 15: Installation

    6. M8 x 30 screws 9. T-slot nuts 2. Clamp 7. Support plate 10. T-slot extrusion (not included in kit) 3. Clamping screw -16 x 1-in. screws 11. Clamping handle 4. Mounting sleeve 12. Pivot handle Part 1602018-13 E 2019 Nordson Corporation...

  • Page 16: Bar-Mount Spray Guns

    Figure 3-2 Bar-Mount Spray Gun Mounting 1. Button screws 5. Rotate handle 9. Adjusting rod 2. Tilt bracket 6. Clamp handle 10. Ball 3. Bar-mount adapter 7. Clamp 11. Set screw 4. Tilt knob 8. Locking body Part 1602018-13 E 2019 Nordson Corporation...

  • Page 17: Spray Gun Connections

    Spray Gun Spray Gun 10014163 Figure 3-3 Spray Gun Connections 1. Retainer nut 3. Barbed fitting (4-mm tubing) 5. Spray gun cable receptacle 2. Hose connector 4. Tubing union (4-mm) 6. Tubing union (6-mm) Part 1602018-13 E 2019 Nordson Corporation...

  • Page 18: Ion Collector Installation

    Figure 3-4 Ion Collector Installation - Bar-Mount Spray Gun 1. Collector rod 3. Multi-point tip 4. M3 x 8 pan screw 2. M5 x 8 set screw Note: For clarity, some parts are not shown. Part 1602018-13 E 2019 Nordson Corporation...

  • Page 19: Tube-Mount Spray Gun

    1. Collector rod 4. M10 x 10 set screw 6. Multi-point tip 2. Post 5. Ion collector mounting hole 7. M3 x 8 pan screw 3. Socket-head screw Note: For clarity, some parts are not shown. Part 1602018-13 E 2019 Nordson Corporation...

  • Page 20: Adjusting The Ion Collector Rod

    6. If the desired improvement in the surface finish has not been obtained, loosen the set screw and slide the rod forward approximately 1-in. Tighten the set screw. 7. Repeat steps 5 and 6 until the desired improvement in surface finish is obtained. Part 1602018-13 E 2019 Nordson Corporation...

  • Page 21: Operation

    Automatic and manual control of electrostatic output, air-wash air flow, and pump air flow, are provided by the Nordson iControl system or the Encore LT automatic controllers. Spray gun triggering and positioning are provided by the iControl system, a Nordson axis controller, or a PLC supplied either by Nordson or the customer.

  • Page 22: Changing Flat Spray Nozzles

    NOTE: The tapered electrode holder of the electrode assembly has been designed for optimized cleaning during color changes on systems using flat spray nozzles. This tapered electrode holder will not accept conical deflectors. Figure 4-1 Flat Spray Nozzle Removal and Installation Part 1602018-13 E 2019 Nordson Corporation...

  • Page 23: Changing Optional Deflectors Or Conical Nozzles

    6. Install a new deflector on the electrode assembly, being careful not to bend the electrode. Figure 4-2 Changing Optional Deflectors and Conical Nozzles Part 1602018-13 E 2019 Nordson Corporation...
  • Page 24 Operation Part 1602018-13 E 2019 Nordson Corporation...

  • Page 25: Maintenance

    (4, 6) out from the front of the spray gun body. 5. Disconnect the powder feed hose (8) from the Encore HD automatic diffuser (7).
  • Page 26 Figure 5-1 Maintenance - Bar-Mount Spray Gun Shown without Pivot Mount 1. Nozzle nut 4. Seal 7. Automatic diffuser 2. Nozzle 5. Front powder tube 8. Powder feed hose 3. Electrode assembly 6. Front powder tube seal Part 1602018-13 E 2019 Nordson Corporation...

  • Page 27: Troubleshooting

    These troubleshooting procedures cover only the most common problems. If you cannot solve a problem with the information given here, contact your local Nordson representative for help. NOTE: iFlow modules are used in the iControl controller to control pump air flow.
  • Page 28 Resistance Test on page 6-4. shows kV output), but Damaged spray gun cable Perform the Spray Gun Cable powder is spraying Continuity Test on page 6-5. If an open or shorted connection is found, replace the cable. Continued... Part 1602018-13 E 2019 Nordson Corporation...
  • Page 29 Check the alarm screen for Refer to your controller manual for messages. troubleshooting procedures. No powder flow when Input air turned OFF Check the iControl console air spray gun is triggered supply. ON, kV OK Part 1602018-13 E 2019 Nordson Corporation...

  • Page 30: Power Supply Resistance Test

    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 6-2 Power Supply Resistance Test Part 1602018-13 E 2019 Nordson Corporation...

  • Page 31: Electrode Assembly Resistance Test

    J2- 4 (BLACK) WIRING DIAGRAM J3- 1 (BROWN) J2- 3 (BLUE) J3- 2 (BLUE) J2- 1 (BROWN) J3- 3 (WHITE) J2- 2 (WHITE) J3 (FACE VIEW) J2 (FACE VIEW) Figure 6-4 Spray Gun Receptacle Harness Part 1602018-13 E 2019 Nordson Corporation...

  • Page 32: Spray Gun Extension Cable

    3 (BLACK) 6 (GREEN) 5 (BLANK) NO PIN 1097540 52.0 FEET 6.00 IN (16M) 324 OHM  1% GUN END (J2) POWER UNIT END (J1) (FACE VIEW) (FACE VIEW) Figure 6-6 Spray Gun Cable Part 1602018-13 E 2019 Nordson Corporation...

  • Page 33: Repair

    6. Install the hose connector onto the end of the powder tube and tighten the retainer nut to secure the hose connector. Figure 7-7 Powder Wear Parts Replacement 1. Nozzle nut 3. Electrode assembly 5. Powder tube 2. Nozzle 4. Seal 26. Automatic diffuser Part 1602018-13 E 2019 Nordson Corporation...

  • Page 34: Tube-Mount Spray Gun Repair

    9. Disconnect the extension cable (19) from the receptacle harness (15). 10. Disconnect the clear 4-mm air tubing (18) from the barbed fitting (13). 11. If you are replacing the extension cable, remove the cable receptacle (20). If not, you can leave them connected. Part 1602018-13 E 2019 Nordson Corporation...
  • Page 35 Figure 7-10 Tube-Mount Spray Gun Disassembly 3 of 5 6A. Filter assembly tubing 11. Power supply harness 15. Receptacle harness 8. Bulkhead 14. Rear spray gun body 17. Socket-head screws 17A. Lock washers Part 1602018-13 E 2019 Nordson Corporation...
  • Page 36 NOTE: When reassembling, secure the ring-tongue ground terminal to the rear spray gun body with the screw (12) and lock washer (12A) and torque the screw to 2.5 NSm (22 inch-lbs). Part 1602018-13 E 2019 Nordson Corporation...

  • Page 37: Tube-Mount Spray Gun Assembly

    7. Connect the clear 4-mm tubing (18) to the barbed fitting on the rear body assembly. 8. Orient the mounting tube (22) with the ion collector hole facing towards the front of the spray gun. Part 1602018-13 E 2019 Nordson Corporation...

  • Page 38: Bar-Mount Spray Gun Repair

    3. Carefully pull the rear body assembly far enough off the bulkhead (8) to disconnect the power supply harness (11) from the receptacle harness (15); and the filter assembly tubing (10) from the barbed fitting inside the rear body assembly. Part 1602018-13 E 2019 Nordson Corporation...
  • Page 39 * Install with Loctite 222 Groove Figure 7-14 Bar-Mount Spray Gun Disassembly 2 of 3 Clear 4-mm tubing 8. Bulkhead 10. Allen nuts 6A. Filter assembly tubing 9. Screw plate 11. Powder supply 7. Gasket Part 1602018-13 E 2019 Nordson Corporation...
  • Page 40 Figure 7-15 Bar-Mount Gun Disassembly 3 of 3 12. Screw 14. Rear body 16. Bar mount adapter 12A. Lockwasher 15. Receptacle and harness 18. Quad ring 13. Barbed fitting and lockwasher 15A. Receptacle nut Part 1602018-13 E 2019 Nordson Corporation...

  • Page 41: Bar-Mount Gun Assembly

    (17) and lock washers (17A). 5. Install the powder tube, electrode assembly, nozzle, nozzle nut, and hose connector as described in Powder Wear Parts Replacement on page 7-1. Part 1602018-13 E 2019 Nordson Corporation...
  • Page 42 7-10 Repair Part 1602018-13 E 2019 Nordson Corporation...

  • Page 43: 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 44: Tube-Mount Spray Gun Parts

    Parts Tube-Mount Spray Gun Parts Figure 8-17 Tube-Mount Spray Gun Parts Part 1602018-13 E 2019 Nordson Corporation...

  • Page 45: Standard 5-Ft Tube-Mount Spray Gun Parts List

    Description Quantity Note 1606970 GUN, auto, tube mount, Encore HD, 5 ft 1614275 GUN, auto, tube mount, Encore HD, 5 ft PVC, 2-pack 1614276 GUN, auto, tube mount, Encore HD, 5 ft PVC, 1-pack 1081638 NUT, nozzle, handgun, Encore 1081658...
  • Page 46 E: The type of material used for the tube mount determines the type of spray gun. F: Application Specific: Order part number 1609053 if a positive power supply is needed. The positive power supply is sold separately from the gun body. AR: As Required NS: Not Shown Part 1602018-13 E 2019 Nordson Corporation...

  • Page 47: Bar-Mount Spray Gun Parts

    Parts Bar-Mount Spray Gun Parts Figure 8-18 Bar-Mount Spray Gun Parts Part 1602018-13 E 2019 Nordson Corporation...

  • Page 48: Bar-Mount Spray Gun Parts List

    NOTE: Cables for the bar-mount spray gun are optional. Refer to Options, Cables, on page 9-2 for available cables. Item Part Description Quantity Note 1606969 GUN, auto, bar mount, Encore HD 1081638 NUT, nozzle, handgun, Encore 1081658 NOZZLE, flat spray, 4 mm, Encore 1604824 ELECTRODE ASSEMBLY, Encore, flat spray 1106078...
  • Page 49 C: For flat spray nozzle use only. Refer to the Options section for assemblies and parts for use with conical nozzles and deflectors. NS: Not Shown Part 1602018-13 E 2019 Nordson Corporation...

  • Page 50: External Diffuser For Encore Hd Automatic Spray Guns

    Parts External Diffuser for Encore HD Automatic Spray Guns See Figure 8-19. This external diffuser is shipped with Encore HD automatic spray guns. Figure 8-19 Encore HD External Diffuser Item Part Description Quantity Note — 1609990 KIT, diffuser, external, Encore HD, auto, packaged...

  • Page 51: Options

    Item Part Description Quantity Note 1606971 GUN, auto, tube mount, Encore HD, 6 ft 1602675 S TUBE, powder, tube mount, auto, Encore, 6 ft 1097536 S CABLE, extension, auto, Encore, 1496 mm 1602676 S TUBE, clamp, 6 ft...

  • Page 52: Cables

    Options Cables These cables connect the spray gun to the spray gun controller (Encore HD iControl integrated control unit). Part Description Note 1097537 CABLE, auto, Encore, 8 m (26.25 ft) 1097539 CABLE, auto, Encore, 12 m (39.4 ft) 1097540 CABLE, auto, Encore, 16 m (52.5 ft) 1601344 CABLE, extension, Encore, 4 m (13.1 ft)

  • Page 53: 45-Degree Corner-Spray Nozzle

    Spray Pattern Wide fan pattern perpendicular to the spray gun axis Slot Type Angled, cross slot Application Flanges and recesses Part Description Note 1102872 NOZZLE, corner spray, Encore Figure 9-4 45-Degree Corner Spray Nozzle Part 1602018-13 E 2019 Nordson Corporation...

  • Page 54: 45-Degree In-Line Flat-Spray Nozzle

    Conical Nozzle and Deflectors 1083201 1083205 1083206 1083207 16-mm Deflector 19-mm Deflector 26-mm Deflector 38-mm Deflector 1082060 Conical Nozzle All deflectors include a 1098306 O-ring, Viton, 3mm x 1.1mm wide Figure 9-6 Conical Nozzle and Deflectors Part 1602018-13 E 2019 Nordson Corporation...

  • Page 55: Conical Nozzle Kit

    The XD (extended duty) Electrode Support provides 2 to 3 times longer wear life than that of the standard duty electrode support. 1613834 1613835 XD Flat Spray Electrode Support XD Conical Spray Electrode Support Figure 9-9 Conical Spray and Flat Spray Electrode Supports Part 1602018-13 E 2019 Nordson Corporation...

  • Page 56: Encore Angled Spray Extensions

    90-Degree Extension Extension Extension Figure 9-10 Angled Spray Extensions Item Part Description Note — 1605703 EXTENSION, spray, 45 degree, Encore — 1605614 EXTENSION, spray, 60 degree, Encore — 1604084 EXTENSION, spray, 90 degree, Encore Part 1602018-13 E 2019 Nordson Corporation...

  • Page 57: Tube-Mount Spray Gun Mounting Assemblies

    - 16 x 2.75 in. - - - - - - S MOUNT, clamp, automatic gun - - - - - - S MOUNT, sleeve, automatic gun 981561 S SCREW, socket, - 16 x 1.00 in., zinc Part 1602018-13 E 2019 Nordson Corporation...

  • Page 58: Extrusion Mounting Assembly

    S MOUNT, sleeve, with screws, automatic 981561 S S SCREW, socket, - 16 x 1.00 in., zinc 981528 S SCREW, socket, M8 x 30, zinc 1016458 S PLATE, attachment, support, gun bar 1016533 S NUT, T-slot, steel, M8 Part 1602018-13 E 2019 Nordson Corporation...

  • Page 59: Spray Gun Bar For Bar-Mount Spray Guns

    248669 S BODY, adjust mounting 248957 S HANDLE, adjust, - 16 x 1.77 in. 249074 S HANDLE, adjust, - 16 x 2.75 in. 983061 S WASHER, flat, 0.406 x 0.812 x 0.065 in., zinc Part 1602018-13 E 2019 Nordson Corporation...

  • Page 60: Ion Collector Kit

    9-10 Options Ion Collector Kit The ion collector kit is optional. It can be used on either Encore HD automatic spray gun model. Figure 9-14 Ion Collector Kit NOTE: For clarity, some parts are not shown. Item Part Description Quantity...
  • Page 61 Product: Encore HD Automatic Powder Spray System This Declaration is issued under the sole responsibility of the manufacture. Models: Encore HD Automatic Applicator and Encore HD iControl 2 Description: This high density, automatic electrostatic powder spray system includes applicator, control cable and associated controllers.

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