Nordson Encore Select HD Customer Product Manual

Robot gun

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Encore

Select HD

Robot Gun

Customer Product Manual

Document Number

1620445-03

Issued 01/22

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 Nordson Corporation welcomes requests for information, comments, and inqui- This is a Nordson Corporation publication which is protected by copyright. ries about its products. General information about Nordson can be found on the Original copyright date 2020. No part of this document may be photocopied,...
Page 3: Table Of Contents
Recommended Cleaning Procedure for Powder Contact Parts ........... Maintenance Procedures......................Repair ............................. Spray Gun Repair .......................... Power Supply and Powder Path Replacement................Spray Gun Disassembly ......................Power Supply Replacement ......................Powder Path Removal ......................... Powder Path Installation......................Spray Gun Re-Assembly ......................1620445-03 ©2022 Nordson Corporation...
Page 4 Conical Nozzle and Deflectors ....................Conical Nozzle Kit ........................Conical Nozzle, Deflectors and Electrode Assembly Parts (contd) ..........Conical Electrode Assembly ......................XD Electrode Support ........................Pattern Adjuster Kit ........................Ion Collector Kit ..........................Dual Spray Gun System Components..................7-10 1620445-03 ©2022 Nordson Corporation...
Page 5 Change Record Change Record Revision Date Change 11/20 Initial Release 02/21 Updated spray gun markings and safety information. Updated approvals information, corrected reference text, and updated power supply 01/22 test image. 1620445-03 ©2022 Nordson Corporation...
Page 7: Safety
Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment may result in injury to persons or damage to property. Some examples of unintended use of equipment include: •...
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. 1620445-03 © 2022 Nordson Corporation...
Page 9: Grounding
• Disconnect and lock out system electrical power. Close hydraulic and pneumatic shutoff valves and relieve pressures. • Identify the reason for the malfunction and correct it before restarting the system. Disposal Dispose of equipment and materials used in operation and servicing according to local codes. 1620445-03 © 2022 Nordson Corporation...
Page 11: Overview
See Figure 2-1. This manual details the Encore Select HD Robot Spray Gun. ® The Encore Select HD Robot Spray Gun should be used with the Encore HD manual controller or Encore Enhance Controller, which provides electrostatic voltage control, electrode air-wash air, and powder pump air.
Page 12: Specifications
186.5 [.255] C.G. [.709] 2X M5X0.8 - 6H ↓ 8.0 18.0 [2.126] Encore Select HD Robot Spray Gun 54.0 Weight: [1.07 lb] 486 g Figure 2-2 Encore Select HD Robot Spray Gun Dimensions and Weights 1620445-03 © 2022 Nordson Corporation...
Page 13: Equipment Markings
Figure 2-4 Encore Select HD Serial Number European Union, EX, Special Conditions for Safe Use 1. The Encore Select HD Robot Spray Gun shall only be used with the associated Encore XT/HD interface control unit and Encore HD controller power unit, or the Encore Enhance controls, over the ambient temperature range of +15 °C...
Page 15: System Connections
4 mm Input 6 mm Pattern Air 4 mm Air Wash 6 mm Input Powder Hose Input Gun Cable Powder Hose Manual System Controller Network/Power Interconnect Pump Control Unit Figure 3-1 System Diagram (Common System Equipment Shown) 1620445-03 © 2022 Nordson Corporation...
Page 16: Spray Gun Installation
4. Connect the gun cable to the gun cable receptacle (3). 5. Route the powder hose, gun cable, and air tubing to the system controller. Take care to not kink, bind, or deform the powder tubing. Figure 3-2 Spray Gun Connections 1620445-03 © 2022 Nordson Corporation...
Page 17: Dual Spray Gun System Connections
Power iFlow Module Power Power Figure 3-3 Connections for 2 Spray Gun Robot Systems 1. Encore Select HD Robot spray gun 4. Encore robot cable 7. Encore HD pump control unit 2. Encore controller interface 5. Controller interface cable 8. Network cable 3.
Page 18: Encore Controller Interface Configuration Settings
2. See Figure 3-4. The address switch SW2 must be set to the spray gun number that it is supplying. 3. If the Encore HD pump control unit (7) is connected to the Nordson CAN network on the drop, then the network terminator on JP1 must be removed on each of the pump control units.
Page 19 Setup Network Terminator JP1 Addressing Switch SW2 Figure 3-4 iFlow Module PCA 1620445-03 © 2022 Nordson Corporation...
Page 21 Spray gun triggering and positioning are provided by the Robot controller, or a PLC supplied by either Nordson or the customer. Refer to the appropriate system, controller, and control panel manuals for information and instructions regarding system components.
Page 22: Daily 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. 1620445-03 © 2022 Nordson Corporation...
Page 23: Electrode Air Wash Operation
5. Screw the nozzle nut (3) onto the spray gun body clockwise until finger-tight. NOTE: To clean nozzles, use the Recommended Cleaning Procedure for Powder Contact Parts on page 4-7. Figure 4-1 Changing a Flat Spray Nozzle 1620445-03 © 2022 Nordson Corporation...
Page 24: Converting From Flat Spray Nozzles To Optional Conical Nozzles
Screw the nozzle nut onto the spray gun body clockwise until finger-tight. Install a deflector on the electrode assembly. Do not bend the electrode wire. Conical Spray Nozzle Deflector Figure 4-2 Converting from a Flat Spray Nozzle to a Conical Spray Nozzle 1620445-03 © 2022 Nordson Corporation...
Page 25: Changing Optional Deflectors Or Conical Nozzles
6. Screw the nozzle nut (3) onto the spray gun body clockwise until finger-tight. 7. Install a new deflector (4) on the electrode assembly. Do not bend the electrode wire. Figure 4-3 Changing a Conical Nozzle 1620445-03 © 2022 Nordson Corporation...
Page 26: Installing The Optional Pattern Adjuster Kit
3. Install the integral conical nozzle (1) onto the electrode assembly and screw the nozzle nut clockwise until finger-tight. 4. Install a 16, 19, or 26-mm deflector (2) onto the electrode holder. Figure 4-4 Pattern Adjuster Kit Installation 1620445-03 © 2022 Nordson Corporation...
Page 27: Shutdown
Failure to observe this warning may result in personal injury. Recommended Cleaning Procedure for Powder Contact Parts Nordson Corporation recommends using an ultrasonic cleaning machine and Oakite BetaSolv emulsion cleaner to clean spray gun nozzles and powder path parts.
Page 28: Maintenance Procedures
4. Blow off the spray gun and wipe it down with a clean cloth. Daily: Make sure the system is securely connected to a true earth ground before spraying powder. System Grounds Weekly: All grounds should be inspected weekly at minumum. 1620445-03 © 2022 Nordson Corporation...
Page 29: Repair
14. Screw (handle to spray gun 21D. Ground terminal (J1) body) 4. Outlet tube assembly 15. Lower body 22. Ground screw/lock washer 6. Power supply/body kit 16. Inlet tube/hose adapter kit 7. Filter assembly 18. Gun base 1620445-03 © 2022 Nordson Corporation...
Page 30: Power Supply And Powder Path Replacement
The air wash tubing from the filter assembly (7) will prevent a complete separation; leave it connected unless it must be replaced. Figure 5-2 Spray Gun Body Disassembly 1620445-03 © 2022 Nordson Corporation...
Page 31: 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 spring contact inside the gun body. 5. Route the power supply harness connector through the top hole in the bulkhead. 1620445-03 © 2022 Nordson Corporation...
Page 32: Powder Path Removal
2. Install the inlet tube assembly (16) into the lower body (15), then install the end of the tube into the gun base (18). 3. Install the elbow (13) onto the inlet tube assembly, with the end oriented toward the front of the spray gun as shown. Figure 5-4 Powder Path Replacement 1620445-03 © 2022 Nordson Corporation...
Page 33: Spray Gun Re-Assembly
7. Install the nozzle (2) on the electrode assembly, making sure the keys in the electrode assembly slide into the slots on the nozzle. 8. Install the nozzle nut (1) over the nozzle and rotate clockwise to secure. 1620445-03 © 2022 Nordson Corporation...
Page 35: 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. General Troubleshooting Chart...
Page 36 6-4. 5. No kV output from the spray gun (interface Perform the Power Supply Resistance Test on page Spray gun power supply open shows kV output), but 6-4. powder is spraying Continued... 1620445-03 © 2022 Nordson Corporation...
Page 37 Check the alarm screen for Refer to your controller manual for troubleshooting flow OK messages. procedures. 10. No powder flow when spray gun is triggered Input air turned OFF Check the controller console air supply. ON, kV OK 1620445-03 © 2022 Nordson Corporation...
Page 38: Spray Gun Power Supply Resistance Test
Measurements should also be taken at room temperature 22 °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 (BLACK) (RED) Figure 6-1 Power Supply Resistance Test 1620445-03 © 2022 Nordson Corporation...
Page 39: Electrode Assembly Resistance Test
FEEDBACK WHITE COMMON BLACK CHASSIS GND CABLE GND J2-4 (BLACK) J2-1 WIRING DIAGRAM J3-1 (BROWN) (BROWN) J2-3 (BLUE) J3-2 (BLUE) J2-2 J3-3 (WHITE) (WHITE) J3 (FACE VIEW) J2 (FACE VIEW) Figure 6-3 Gun Receptacle Harness 1620445-03 © 2022 Nordson Corporation...
Page 40: Gun Extension Cable
(22 GA) GRN CHASSIS GND J2-4 µA J1-6 SPIRAL WRAPPED POWER UNIT END (J1) SHIELD (FACE VIEW 1 (RED) WIRING DIAGRAM 2 (WHITE) µA NORDSON 4 (GREEN) 3 (BLACK) COMMON GUN END (J2) (FACE VIEW) Figure 6-5 Gun Cable 1620445-03 © 2022 Nordson Corporation...
Page 41: Parts
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 Select HD Robot powder spray gun. Reference Documentation For additional information related to other components in the system, reference the...
Page 42: Spray Gun Parts
7-2 Parts Spray Gun Parts See Figure 7-1 and the parts list on the following pages. DSP_10020134 Figure 7-1 Encore HD Select Robot Spray Gun and Accessories Parts 1620445-03 © 2022 Nordson Corporation...
Page 43: Spray Gun Parts List
B. For flat spray nozzle use only. See Spray Gun Options for kits to convert for conical nozzle and deflector use. C. Application specific: Order part number 1609053 if a positive powder supply is needed. The positive power supply is sold separately from the gun body. 1620445-03 © 2022 Nordson Corporation...
Page 44: Powder Hose And Air Tubing
These cables connect the spray gun to the spray gun controller. Part Description 1605436 CABLE, robot, auto, Encore, 8 m 1620523 CABLE, robot, auto, Encore, 20 m 1601344 CABLE, extension, Encore, 4 m 1620466 CABLE, extension Encore, 10 m 1620445-03 © 2022 Nordson Corporation...
Page 45: Spray Gun Options (Contd)
3 mm Flat Spray 1081657 1620198 4 mm Flat Spray 1081658 1620199 1620200 6 mm Flat Spray 1081659 60-Degree Cross-Cut 1082184 1620201 90-Degree Cross-Cut 1082185 1620202 2.5 mm Castle 1082186 1620203 Figure 7-2 Optional Nozzles 1620445-03 © 2022 Nordson Corporation...
Page 46: 45-Degree Corner-Spray Nozzle
Slot Type Three angled slots in-line with spray gun axis Application Top and bottom coating; typically no in/out part positioning Part Description Note 1102871 NOZZLE, 45 degree, corner spray, Encore Figure 7-4 45-Degree Flat Spray Nozzle 1620445-03 © 2022 Nordson Corporation...
Page 47: Conical Nozzle, Deflectors, And Electrode Assembly Parts
• DEFLECTOR, 26 mm 1082060 • NOZZLE, conical 1605861 • ELECTRODE HOLDER, conical NOTE: A. The conical nozzle requires a different style electrode holder than what is used in the flat spray nozzle electrode assembly. 1620445-03 © 2022 Nordson Corporation...
Page 48: Conical Nozzle, Deflectors And Electrode Assembly Parts (Contd)
XD Electrode Support The XD (extended duty) Electrode Support provides 2 to 3 times longer wear life than that of the standard duty electrode support. Figure 7-8 Conical Spray and Flat Spray Electrode Supports 1620445-03 © 2022 Nordson Corporation...
Page 49: Pattern Adjuster Kit
This kit installs on the standard length spray gun. Refer to the instruction sheet shipped with the spray gun for installation instructions and repair parts. Part Description Note 1603854 KIT, ion collector assembly, manual, Encore (std length spray gun) 1620445-03 © 2022 Nordson Corporation...
Page 50: Dual Spray Gun System Components
Figure 7-10 Connections for 2 Spray Gun Robot Systems Item Part Description Note 1620076 Encore Select HD Robot spray gun 1604125 • Encore XT/HD controller interface 1614566 • Encore Enhance controller interface 1101422 • Control unit, ProdigyR Gen III, PLC gateway 1605436 •...
Page 51 1084547 NOTICE THIS DRAWING IS NORDSON PROPERTY,CONTAINS PROPRIETARY INFORMATION AND MUST BE RETURNED UPON REQUEST. DO NOT CIRCULATE, REPRODUCE OR DIVULGE TO OTHER PARTIES WITHOUT WRITTEN CONSENT OF NORDSON. ENCORE XT/HD INTERFACE CONTROL UNIT ENCORE XT CONTROLLER POWER UNIT ENCORE HD CONTROLLER...
Page 52 1084547 NOTICE THIS DRAWING IS NORDSON PROPERTY,CONTAINS PROPRIETARY INFORMATION AND MUST BE RETURNED UPON REQUEST. DO NOT CIRCULATE, REPRODUCE OR DIVULGE TO OTHER PARTIES WITHOUT WRITTEN CONSENT OF NORDSON. CONTROLLER INTERFACE CABLE 115V VIBRATOR MOTOR 1604511 230V VIBRATOR MOTOR 1080950 1080718-10 FT.
Page 54 - Ex tb IIIB T60ºC / Ex II 2 D / 2mJ = (Encore XT and HD Applicators) - Ex tc IIIB T60ºC / EX II (2) 3 D = (Controllers) - Ex II 2 D / 2mJ = (Encore Auto Applicator and Encore Select HD Robot Applicator) Certificates: - FM14ATEX0051X = Encore XT/HD Manual Appl.
Page 55 - Ex tb IIIB T60ºC / Ex II 2 D / 2mJ = (Encore XT and HD Applicators) - Ex tc IIIB T60ºC / EX II (2) 3 D = (Controllers) - Ex II 2 D / 2mJ = (Encore Select HD Robot Applicator) Certificates: - FM21UKEX0129X = Encore XT/HD Manual App &...
Page 56 Jeremy Krone 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-Straße 42-44 D-40699 Erkrath Nordson Corporation • 555 Jackson St, Amherst, Ohio 44001. USA DOC14048-03...
Page 57 - Ex tc IIIB T60ºC Dc / Ex II (2) 3 D = (Enhance Manual Interface Controller) - Ex II (2) D = (Enhance Stack Controller) – Located in Unclassified Location (Zone) - Ex II 2 D / 2mJ = (Encore Auto Applicator, Encore HD Auto Applicator and Encore Select HD Robot Appl) Certificates:...

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