Nordson Encore Customer Product Manual

Automatic powder spray gun

Hide thumbs Also See for Encore:

Customer product manual (139 pages)

Installation, troubleshooting, repair (97 pages)

Product manual (67 pages)

Table Of Contents

Table of Contents

Quick Links

Download this manual

Encore

Automatic Powder

Spray Gun

Customer Product Manual

D ocument Number 1625071-01

– English –

Issued 08/24

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 • 100 NORDSON DRIVE, AMHERST, OHIO 44001 • USA

Table of Contents

Need help?

Do you have a question about the Encore and is the answer not in the manual?

Questions and answers

Summary of Contents for Nordson Encore

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 • 100 NORDSON DRIVE, AMHERST, OHIO 44001 • USA...
Page 2 – Original document – Trademarks Encore, iControl, iFlow, HDLV, Nordson and the Nordson logo are registered trademarks of Nordson Corporation. All other trademarks are the property of their respective owners. 1625071-01 © 2024 Nordson Corporation...
Page 3: Table Of Contents
Electrode Assembly Resistance Test ..................... Cable Continuity Tests ........................Spray Gun Cable .......................... Repair ............................. Base Gun Repair ........................... Base Gun Disassembly ........................ Base Gun Assembly ........................Kit Repair ............................Tube-Mount Disassembly ......................Bar-Mount Gun Disassembly ......................1625071-01 ©2024 Nordson Corporation...
Page 4 Parts .............................. Using the Illustrated Parts List ...................... Base Spray Gun ..........................Tube-Mounting Applicator ......................Bar-Mounting Applicator ........................ HD Diffuser for Encore Automatic Applicator ................. Options ............................Cables ............................Flat Spray Nozzles ......................... Cross-Cut Nozzles ......................... 45-Degree Corner-Spray Nozzle ....................
Page 5 Change Record Change Record Revision Date Change 08/24 Initial Release of combined Encore HD and Encore Automatic Gun manuals 1625071-01 ©2024 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. 1625071-01 © 2024 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. 1625071-01 © 2024 Nordson Corporation...
Page 11: Description
A standard, base gun can be combined with either a bar- mount kit or a tube-mount kit to create two distinct spray gun configurations. Either of the two configurations can also be combined with the Encore HD diffuser kit to create an HD style spray gun.
Page 12: Specifications
• 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 1625071-01 © 2024 Nordson Corporation...
Page 13: Applicator Certification Label
Special Conditions for Safe Use To meet EX requirements: • The Encore HD powder electrostatic automatic applicators shall only be used with associated Encore LT, Encore HD iControl, or Encore Engage controllers over the ambient temperature range of +15 °C (59 °F) to +40 °C (104 °F).
Page 14: Dimensions And Weights
155.91 cm (61.38 in) 183.06 cm (72.07 in) 6 ft 2.00 kg (4.40 lb) 185.91 cm (73.19 in) 213.06 cm (83.88 in) 8 ft 2.55 kg (5.62 lb) 245.91 cm (96.81 in) 273.06 cm (107.50 in) 1625071-01 © 2024 Nordson Corporation...
Page 15: Installation
2. Clamp 6. M8 x 30 screws 10. T-slot extrusion (not included in kit) 3. Clamping screw 7. Support plate 11. Clamping handle 4. Mounting sleeve 8. 3/8-16 x 1 in. screws 12. Pivot handle 1625071-01 © 2024 Nordson Corporation...
Page 16 12. Push the end cap into the back of the mounting tube until bottomed. 13. Install the lock washer (16), saddle washer (15) and the M5 screw (17), into the grounding plate through the mounting hole. Torque the screw to 40 in-lb (4.5 N●m). 1625071-01 © 2024 Nordson Corporation...
Page 17 20. VT hose connector retainer nut 5. Barbed fitting (air wash) 13. Hose hanger 21. Gun cable 6. HD diffuser (with retainer nut) 14. End cap 7. HD hose connector 15. Saddle washer 8. Tubing union 16. Lock washer 1625071-01 © 2024 Nordson Corporation...
Page 18: Tube-Mounting Hardware Kit
Figure 3-3 Tube-Mounting Hardware Kit 1. Saddle washer 2. Lock washer 3. M5 x 12 screw 1625071-01 © 2024 Nordson Corporation...
Page 19: Bar-Mount Spray Guns
(11) attached to the HD diffuser. 5. Connect the clear, 4-mm electrode air-wash tube (7) to the small barbed fitting (5) on the gun body. 6. Attach the gun cable (8) to the gun harness receptacle (4). 1625071-01 © 2024 Nordson Corporation...
Page 20 4. Gun harness receptacle 10. HD hose connector 16. VT hose connector retainer nut 5. Barbed fitting (air wash) 11. Tubing union 17. M3 x 30 screw 6. Bar-mount adapter 12. 8-mm powder feed hose 1625071-01 © 2024 Nordson Corporation...
Page 21 Figure 3-5 Bar-Mount Spray Gun Mounting 1. Button screws 5. Rotate handle 9. Gun bar 2. Tilt bracket 6. Clamp handle 10. Set screw 3. Bar-mount adapter 7. Clamp 4. Tilt knob 8. Locking body 1625071-01 © 2024 Nordson Corporation...
Page 22: Ion Collector Kit
Figure 3-6 Ion Collector Installation - Tube-Mount Spray Gun (for clarity, some parts are not shown) 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. M5 X 10 Screw 1625071-01 © 2024 Nordson Corporation...
Page 23: Bar-Mount Spray Gun Installation
2. Attach the multi-point tip (3) to the collector rod using the M3 x 8 screw (4). Figure 3-7 Ion Collector Installation - Bar-Mount Spray Gun (for clarity, some parts are not shown) 1. M5 x 8 set screw 3. Multi-point tip 4. M3 x 8 pan screw 2. Collector rod 1625071-01 © 2024 Nordson Corporation...
Page 24: 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. 1625071-01 © 2024 Nordson Corporation...
Page 25: Operation
Automatic and manual control of electrostatic output, air-wash air flow, and pump air flow, are provided by the Nordson iControl system, Encore Engage, 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 26: Changing Flat Spray Nozzles
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 1625071-01 © 2024 Nordson Corporation...
Page 27: Changing Optional Deflectors Or Conical Nozzles
5. Screw the nozzle nut onto the spray gun body until the face of the nozzle nut bottoms against the shoulder of the spray gun body. 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 1625071-01 © 2024 Nordson Corporation...
Page 29: Maintenance
6. Clean all parts removed with a low-pressure blow gun. Wipe the parts with a clean, dry cloth. 7. Carefully remove any fused powder with a wooden or plastic dowel or similar tool. Do not use tools that will scratch the plastic. Powder will build up and impact-fuse on scratches. 1625071-01 © 2024 Nordson Corporation...
Page 30 Figure 5-1 Maintenance - Bar-Mount Spray Gun Shown without Pivot Mount (shown with HD diffuser) 1. Nozzle nut 4. Seal 6. HD diffuser 2. Nozzle 5. Powder outlet tube 7. Powder feed hose 3. Electrode assembly 1625071-01 © 2024 Nordson Corporation...
Page 31: Troubleshooting
Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. 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: Refer to the applicable controller manual for problems related to iFlow modules.
Page 32 Powder buildup on the air-wash tubing, and check for flow at the output fitting electrode air-wash electrode tip when the spray gun is triggered on. Refer to your controller flow manual for more troubleshooting information. Continued... 1625071-01 © 2024 Nordson Corporation...
Page 33 Adjust the controller regulator to 5.86 bar (85 psi). Refer to pressure regulator set the iFlow Air Flow Verification Kit instruction sheet. too low iFlow module flow valve or Encore LT Refer to your controller manual. flow valve plugged 7. Low powder flow Air tubing kinked or Check flow and atomizing air tubing for kinks.
Page 34: 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 1625071-01 © 2024 Nordson Corporation...
Page 35: Electrode Assembly Resistance Test
243 OHM ± 1% 3 (BLACK) 5 (BLANK) NO PIN 6 (GREEN) GUN END (J2) 1097540 52.0 FT 6.00 IN (16M) 324 OHM ± 1% (FACE VIEW) POWER UNIT END (J1) (FACE VIEW) Figure 6-3 Spray Gun Cable 1625071-01 © 2024 Nordson Corporation...
Page 37: Repair
11. To disassemble the rear body assembly, remove the screw (9), lock washer (10) and barbed fitting (11) from inside the rear spray gun body (17). A 3-mm hex key and 1/4- in. deep-well socket are required. 1625071-01 © 2024 Nordson Corporation...
Page 38 8. Hex nuts 14. Grounding plate 3. Power supply 9. Screw 15. Quad Ring 4. Power supply harness 10. Lockwasher 16. Receptacle nut 5. Gasket 11. Barbed fitting and lockwasher 6. Bulkhead 12. Rear gun body 1625071-01 © 2024 Nordson Corporation...
Page 39: Base Gun Assembly
10. Place the grounding plate (14) onto the rear gun body. Install the lock washers (18) over the M3 screws (19) then thread the screws into the grounding plate. Torque the M3 screws with a 2 mm hex key to 4.9 in-lb (0.5 N●m). 1625071-01 © 2024 Nordson Corporation...
Page 40 1. Filter assembly tubing 13. Receptacle harness 18. Washer 4. Power supply harness 14. Grounding plate 19. M3 screws 6. Bulkhead 16. Receptacle nut 20. Front gun body 8. Hex nuts 17. Rear gun body 1625071-01 © 2024 Nordson Corporation...
Page 42: Kit Repair
(8) attached to the HD diffuser. 7. Feed the cable, tubing, and hose through the mounting tube then through the end cap (14). NOTE: Assembly is in the reverse order of disassembly. Refer to Installation section for specific instructions. 1625071-01 © 2024 Nordson Corporation...
Page 43 20. VT hose connector retainer nut 5. Barbed fitting (air wash) 13. Hose hanger 21. Gun cable 6. HD diffuser (with retainer nut) 14. End cap 7. HD hose connector 15. Saddle washer 8. Tubing union 16. Lock washer 1625071-01 © 2024 Nordson Corporation...
Page 44: Bar-Mount Gun Disassembly
M3 screws (17) with lock washers on the back of the bar mount adapter with a 2 mm hex key. NOTE: Assembly is in the reverse order of disassembly. Refer to installation section for specific instructions. 1625071-01 © 2024 Nordson Corporation...
Page 45 4. Gun harness receptacle 10. HD hose connector 16. VT hose connector retainer nut 5. Barbed fitting (air wash) 11. Tubing union 17. M3 x 30 screw 6. Bar-mount adapter 12. 8-mm powder feed hose 1625071-01 © 2024 Nordson Corporation...
Page 46: 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 48 B. For flat spray nozzle use only. Refer to the Options section for assemblies/parts for use with conical nozzles and deflectors. C. For use with 11 mm and 12.7 mm hose. UA: Unavailable for purchase through Nordson. Contact local distributor or local source. 1625071-01 © 2024 Nordson Corporation...
Page 49: Tube-Mounting Applicator
8-4 Parts Tube-Mounting Applicator Figure 8-2 Tube-Mount Spray Gun Parts 1625071-01 © 2024 Nordson Corporation...
Page 50 See Figure 8-2. Item Part Description Quantity Note — 1625163 KIT, Tube, mount, auto, Encore, 5 ft — 1625164 KIT, Tube, mount, auto, Encore, 6 ft — 1625165 KIT, Tube, mount, auto, Encore, 8 ft - - - - - - •...
Page 51: Bar-Mounting Applicator
8-6 Parts Bar-Mounting Applicator Figure 8-3 Bar-Mount Spray Gun Parts 1625071-01 © 2024 Nordson Corporation...
Page 52 • WASHER, flat, 0.34 x 0.74 x 0.06 in., nylon • SCREW, button, socket, M5 x 10 - - - - - - • KNOB, T-handle NS: Not Shown UA: Unavailable for purchase through Nordson. Contact local distributor or local source. 1625071-01 © 2024 Nordson Corporation...
Page 53: Hd Diffuser For Encore Automatic Applicator
NOTE: A. This fitting is used for installations with 10 mm tubing coming from the pump cabinet or feed center. These installations need to reduce down to 8 mm tube for the last 3 meters prior to gun/diffuser connection. UA: Unavailable for purchase through Nordson. Contact local distributor or local source. NS: Not Shown 1625071-01 ©...
Page 54: Options
Options Section 9 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)
Page 55: 45-Degree Corner-Spray Nozzle
See Figure 9-3. 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 9-3 45-Degree Corner Spray Nozzle 1625071-01 © 2024 Nordson Corporation...
Page 56: 45-Degree In-Line Flat-Spray Nozzle
Part Description Note 1102871 NOZZLE, 45-degree, flat spray, Encore Figure 9-4 45-Degree Flat Spray Nozzle Conical Nozzle, Deflectors, and Electrode Assembly See Figure 9-5. The conical nozzle and deflectors must be used with the conical electrode holder. These parts are optional and must be ordered separately.
Page 57: Conical Nozzle Kit
Conical Nozzle Kit Figure 9-6 Conical Nozzle Kit Item Part Description Quantity Note — 1604828 KIT, conical nozzle, Encore 1083206 • DEFLECTOR, 26mm 1082060 • NOZZLE, conical 1605861 • ELECTRODE HOLDER, conical Conical Electrode Assembly Figure 9-7 Conical Electrode Assembly...
Page 58: Encore Angled Spray Extensions
Options Encore Angled Spray Extensions See Figure 9-9. Encore angled spray extensions are available in 45, 60, and 90 degree versions. They are designed to be used on Encore automatic powder spray guns, allowing powder to be sprayed at varying angles to the spray gun mounting orientation.
Page 59: Tube-Mount Spray Gun Mounting Assemblies
• MOUNT, clamp, automatic gun - - - - - - • MOUNT, sleeve, automatic gun • SCREW, socket, 3/8- 16 x 1.00 in., zinc UA: Unavailable for purchase through Nordson. Contact local distributor or local source. Pivot Mount Assembly Item Part...
Page 60: Extrusion Mounting Assembly
SCREW, socket, 3/8- 16 x 1.00 in., zinc • SCREW, socket, M8 x 30, zinc 1016458 • PLATE, attachment, support, gun bar 1016533 • NUT, T-slot, steel, M8 UA: Unavailable for purchase through Nordson. Contact local distributor or local source. 1625071-01 © 2024 Nordson Corporation...
Page 61: Spray Gun Bar For Bar-Mount Spray Guns
• HANDLE, adjust, 3/8- 16 x 1.77 in. 249074 • HANDLE, adjust, 3/8- 16 x 2.75 in. • WASHER, flat, 0.406 x 0.812 x 0.065 in., zinc UA: Unavailable for purchase through Nordson. Contact local distributor or local source. 1625071-01 © 2024 Nordson Corporation...
Page 62: Ion Collector Kit
• SCREW, set, nylon tip, M5 x 8, black - - - - - - • TIP, ion collector, multi-point • SCREW, pan, rec, M3 x 8, zinc UA: Unavailable for purchase through Nordson. Contact local distributor or local source. 1625071-01 © 2024 Nordson Corporation...
Page 64 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.
Page 65 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.

Nordson Encore Customer Product Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Nordson Encore

Summary of Contents for Nordson Encore

Table of Contents