Nordson Encore HD Customer Product Manual

Manual powder spray system

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Encore

HD Manual

Powder Spray System

Customer Product Manual

Document Number

1605707-08

Issued 12/24

For parts and technical support, call the Industrial Coating

Solutions 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

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Summary of Contents for Nordson Encore HD

Page 1 For parts and technical support, call the Industrial Coating Solutions 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 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 2015. No part of this document may be photocopied,...
Page 3: Table Of Contents
VBF Powder Box Installation ......................Feed Hopper Filling Startup ......................Fluidizing Air Operation ........................Powder Feed Hopper ........................Vibratory Box Feeder ........................Electrode Air Wash Operation ....................... Daily Operation ..........................System Startup ..........................Standby Button ..........................Shutdown ............................1605707-08 ©2024 Nordson Corporation...
Page 4 6-12 Conveyance Air Flow Verification ....................6-12 Parts ............................... Introduction ............................ Reference Documentation ......................Encore HD Manual Powder Spray Systems .................. Encore HD+ Manual Powder Spray Systems ................Mobile System Components ......................Filter/Regulator ..........................Grounding Equipment ........................1605707-08 ©2024 Nordson Corporation...
Page 5: Change Record
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 2/21 Updated safety information Updated specifications. Updated regulator throughout manual and parts list.
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. 1605707-08 © 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. 1605707-08 © 2024 Nordson Corporation...
Page 11: Overview
• Mobile Dolly System with Feed Hopper • Standalone Systems − Single and Dual Configurations • Rail Mount and Wall Mount Systems VBF Mobile Rail/Wall Mount Hopper Mobile Standalone Figure 2-1 Encore HD Manual Powder Systems 1605707-08 © 2024 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 •...
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
Overview Applicator Certification Label 1603105 Controller Certification Label 1606122 Power Unit Certification Label 1606121 1605707-08 © 2024 Nordson Corporation...
Page 17: Installation
• 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) 1605707-08 © 2024 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.) Figure 3-1 Anchoring Stand 1605707-08 © 2024 Nordson Corporation...
Page 19: Hopper Installation For Feed Hopper System
Clamp Stack Vent Hose Ground Cable Ground Plug/Socket 6-mm Fluidizing Air Tubing Hopper Fluidizing Air Fluidizing Pan 10-mm and Barb Fitting and Ground Stud 6-mm Tube Reducer Figure 3-2 Hopper Installation on Mobile System Dolly 1605707-08 © 2024 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. 1605707-08 © 2024 Nordson Corporation...
Page 21: Spray Gun Cable
3. Thread the cable nut onto the receptacle and tighten the nut securely. Net Cable Cable to (To Pump Control Unit) Spray Gun Figure 3-4 Spray Gun Cable Connection to System Controller − Mobile System Shown 1605707-08 © 2024 Nordson Corporation...
Page 22: Air Tubing And Powder Hose
4. For hopper pickup tubes, place barb into push-to-connect fittings on pickup tube. Install the powder hose. Spray Gun Cable HD Hose Adapter 6 mm Blue Pattern Air 8 mm Powder Tubing Hose 4 mm Clear Electrode Air Wash Tubing To Pump Figure 3-5 Spray Gun Connections 1605707-08 © 2024 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) 1605707-08 © 2024 Nordson Corporation...
Page 24: Main System Air And Electrical Connections
The air must be clean and dry. A refrigerant or desiccant-type air drier and air filters are recommended. 10-mm Air Tubing Output to Pump Control Unit 12-mm Air Tubing Supply Air Input Air Filter Figure 3-7 System Air Supply Connection (Shown with Mobile System) 1605707-08 © 2024 Nordson Corporation...
Page 25: Standalone, Rail Mount, And Wall Mount System Air Supply
10-mm Air Tubing Out to Pump Control Unit Figure 3-8 Air Filter Installation − Standalone and Rail/Wall Mount Systems 1. Flow indicator 3. 10-mm dual connector 5. 12-mm elbow connector 2. 10-mm elbow connector 4. Bracket 1605707-08 © 2024 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. 1605707-08 © 2024 Nordson Corporation...
Page 27: Operation
European Union, EX, Special Conditions for Safe Use 1. The Encore XT/HD Interface Control Unit and the Encore HD Controller Power Unit, or the Encore XT/HD Interface Control Unit and the Encore HD Hybrid Controller Power Unit, or a Mobile Powder System, shall only be used over the ambient temperature range of +15°C to +40°C with the Encore HD Powder Electrostatic...
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 Tube Catch Pickup Tube Figure 4-1 Pickup Tube Bracket Use 1605707-08 © 2024 Nordson Corporation...
Page 29: Feed Hopper Filling Startup
NOTE: See page 4-4 for recommended pressure at startup. Hose Vent Clamp Stack Rubber Plug Vent Hose Recommended 1/2 full for startup Out to Powder Booth Figure 4-3 Powder Feed Hopper Startup 1605707-08 © 2024 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. 1605707-08 © 2024 Nordson Corporation...
Page 31: Electrode Air Wash Operation
(11/2 turns 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 1605707-08 © 2024 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. 1605707-08 © 2024 Nordson Corporation...
Page 33: Standby Button
3. Turn off the system air supply and relieve the system air pressure. 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. 1605707-08 © 2024 Nordson Corporation...
Page 35: Maintenance
Refer to the individual component manuals for more information, and for spare parts. 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 36: Maintenance Procedures
Check the system air filter/regulator. Drain the filter and change the filter element as needed. (Periodically) Daily: Make sure the system is securely connected to a true earth ground before spraying powder. System Grounds Periodically: Check all system ground connections. 1605707-08 © 2024 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 No Gun Number Setup for more information on gun numbers. Reset the fault (press the Nordson key to open the fault EEPROM Read Failed 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... 1605707-08 © 2024 Nordson Corporation...
Page 40 If air is not leaking, plug the 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. 1605707-08 © 2024 Nordson Corporation...
Page 41 System controller is configured for External Mode, and cannot detect the Prodigy PLC Gateway heartbeat. Check CAN Robot Heartbeat Missing cable. Make sure Gateway is configured properly. Refer to the Prodigy PLC Gateway manual. Continued... 1605707-08 © 2024 Nordson Corporation...
Page 42 Check J12-3 for loose harness connection. Purge Valve 9 Fault Check Valve 8 for loose connection. Check J12-2 for loose harness connection. Purge Pinch Pressure Select Valve 8 Fault Check Valve 8 for loose connection. 1605707-08 © 2024 Nordson Corporation...
Page 43: General Troubleshooting Chart
Remove the electrode assembly and clean it. Remove powder assembly or powder path path if necessary and clean it. Electrode air wash flow Adjust the needle valve at the power unit to decrease the too high electrode air wash flow. Continued... 1605707-08 © 2024 Nordson Corporation...
Page 44 Remove bowl and drain water/dirt. Replace filter element if contamination of flow necessary. Clean system, replace components if necessary. controller Flow valve plugged (H24 Refer to Proportional Valve Cleaning or H25) in the pump control unit manual. 1605707-08 © 2024 Nordson Corporation...
Page 45 Perform the Gun Cable Continuity Test as described in your spray is spraying gun manual. Damaged gun cable If an open or short is found, replace the cable. Continued... 1605707-08 © 2024 Nordson Corporation...
Page 46 Presets with no set values for flow rate and electrostatics are available automatically skipped. Loose or defective Check for a loose trigger switch connection. The trigger switch is trigger switch plugged into the gun display module. 1605707-08 © 2024 Nordson Corporation...
Page 47 Change powder flow to a non-zero number. triggered ON, kV OK Check the gauge on the filter regulator and make sure the air is Input air turned OFF turned ON. Check for Help Codes and follow the procedures 1605707-08 © 2024 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...
Page 50: Encore Hd Manual Powder Spray Systems
Encore HD Single Stand Alone 1613904 Encore HD Dual Stand Alone 1613903 Encore HD Rail/Wall Mount Encore HD+ Manual Powder Spray Systems Contact your Nordson representative to order HD+ Systems With nLighten System Description — Encore HD+ 115 V VBF Mobile —...
Page 51: Mobile System Components
If the motor model number is MVE20, then a 2.0 µF capacitor (1083021) is acceptable. 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 1605707-08 © 2024 Nordson Corporation...
Page 52: Filter/Regulator
B. Only included on dual standalone system. C. Filter/regulator mounting hardware for standalone systems. D. Filter/regulator mounting hardware for VBF, hopper, and rail/wall mount systems. NS: Not Shown AR: As Required Grounding Equipment Part Description 1067694 KIT, grounding block 1605707-08 © 2024 Nordson Corporation...
Page 53: Eu Declaration Of Conformity
Description: These are electrostatic, powder spray systems, including applicator, control cables and associated controllers. The Encore XT Manual system uses venturi style pump technology for supplying powder to the spray gun. While the Encore HD Manual system uses high density pump technology for supplying powder to the spray gun.
Page 54 Description: These are electrostatic, powder spray systems, including applicator, control cables and associated controllers. The Encore XT Manual system uses venturi style pump technology for supplying powder to the spray gun. While the Encore HD Manual system uses high density pump technology for supplying powder to the spray gun.
Page 55 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 56 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 found on Original copyright date 2017. No part of this document may be photocopied,...
Page 57: Change Record
10/23 Removed P/N 1620004 & P/N 768181, Added P/N 7035356 per tubing consolidation 04/24 Updating parts and service kits. Removed HD+ references. Updated lower Y-block. 08/24 Updated parts section for clarification on kits and available parts. 1605708-11 ©2024 Nordson Corporation...
Page 59: Safety
• Obtain and read Material Safety Data Sheets (SDS) Use of Nordson equipment in ways other than those for all materials used. Follow the manufacturer’s described in the documentation supplied with the instructions for safe handling and use of materials, and equipment may result in injury to persons or damage to use recommended personal protection devices.
Page 60: Fire Safety
• Use only replacement parts that are designed for use with original equipment. Contact your Nordson Action in the Event of a Malfunction representative for parts information and advice. If a system or any equipment in a system malfunctions,...
Page 61: Description
Encore® HD/XD Pump Description Pump See Figure 1. The Encore HD and XD powder feed pump transports precise amounts of powder from a feed source to a powder spray gun. Encore HD Encore XD Figure 1 Encore HD/XD Pump Features and Benefits •...
Page 62: Pump Components
Inlet Fitting Connects to the tubing leading from the power source Outlet Fitting Connects to the tubing leading to the powder spray gun Encore HD Pump Encore XD Pump Figure 2 Encore HD/XD Pump Components 1605708-11 © 2024 Nordson Corporation...
Page 63: Theory Of Operation
Encore® HD/XD Pump Theory of Operation Pumping The Encore HD/XD 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 Left half drawing powder in, the other half is dispensing powder out.
Page 64: 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. Powder Figure 5 Purging Operation 1605708-11 © 2024 Nordson Corporation...
Page 65: Pump Port Functions
Position 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 6 Pump Port Functions 1605708-11 © 2024 Nordson Corporation...
Page 66: Operation
Refer to the Operation section of the applicable and notify you that it is time to replace the fluidizing tubes. controller manual for specific instructions. Correct vacuum reading is (9-14 in. Hg). 1605708-11 © 2024 Nordson Corporation...
Page 67: Specifications
7.40 in (25 mm) 9.13 in (188 mm) 9.34 in (232 mm) (237 mm) 11.10 in (282 mm) 2.89 in (74 mm) 2.89 in (74 mm) Encore HD Encore XD Figure 7 Encore Pump Dimensions 1605708-11 © 2024 Nordson Corporation...
Page 68: Installation
Tubing Flexible Tubing Figure 8 Powder Tubing Installation Antistatic 8.2 mm OD/5.6 mm ID Tubing Refer to the Encore HD Antistatic Tubing Grounding Kit instruction sheet (1620023). Only used with Encore HD Antistatic Tubing Grounding Kit. 1605708-11 © 2024 Nordson Corporation...
Page 69: Pump To Cabinet, Panel, Or Housing
3. Secure the pump hand tight to the cabinet wall with the replace both upper Y block and custom O-ring. pump mounting hardware (2). 4. Tighten all hardware securely. Figure 10 Pump Mounting to Cabinet Figure 11 Pump Ground Check 1605708-11 © 2024 Nordson Corporation...
Page 70: Maintenance
Each Time the Pump Is NOTE: Torque screw to 25-30 in.-lb (2.8- Disassembled Lower Y Block 3.4 N●m) for assembly. Gasket Inspect the gasket for damage. Replace if necessary. 1605708-11 © 2024 Nordson Corporation...
Page 71: Troubleshooting
These troubleshooting procedures cover only the most common problems that you may encounter. If you cannot solve the problem with the information given here, call the Nordson Finishing Customer Support Center at (800) 433-9319 or contact your local Nordson representative for help.
Page 72 The delivery tubing must be 60 ft from the pump to the spray gun. not to specification. Problem with pump or Perform Vacuum Check procedure in Troubleshooting section. pump control manifold. (Requires 0-30 in. Hg vacuum gauge.) Continued... 1605708-11 © 2024 Nordson Corporation...
Page 73 2. Remove the vacuum generator vent hose at the bottom of the cabinet (inside). Trigger the spray gun on. Check for exhaust and increase the powder flow. 3. Check for proper direction of the check valve. 1605708-11 © 2024 Nordson Corporation...
Page 74: Vacuum Check
Suction Check finger over the fitting as shown in Figure 12. procedure. 4. Trigger the spray gun and watch the vacuum gauge or feel for the vacuum. Figure 12 Vacuum Check Options 1605708-11 © 2024 Nordson Corporation...
Page 75 9-14 in. HG Vacuum < 8 in. HG Gauge Reading Cycles Vacuum Side 1 Side 2 Side 1 Side 2 9-14 in. HG < 8 in. HG Vacuum Gauge Reading Cycles Figure 13 Vacuum Readings 1605708-11 © 2024 Nordson Corporation...
Page 76: Delivery Check
See Pump is bad, requires repair in the Troubleshooting 2. Trigger the gun and observe the powder flow. table. • If the problem remains, the pump control manifold is bad. See Pump is bad, requires repair in the Troubleshooting. Figure 14 Tubing Connections 1605708-11 © 2024 Nordson Corporation...
Page 77: Repair
2. See Figure 16. Loosen the fluidizing tube access plug and pull the fluidizing tube straight out of the pump Retrofit Pump body. Retrofit Pump Standard Pump Standard Pump Figure 18 Reinstalling the Purge Air Tubing Figure 16 Loosening the Fluidizing Tubes 1605708-11 © 2024 Nordson Corporation...
Page 78: Pump Disassembly
Refer to Replacing Pump Gasket in the Figure 19 Retrofit Pump Disassemble Preparation Repair section if replacement is needed. Figure 20 Standard Pump Disassemble Preparation 1605708-11 © 2024 Nordson Corporation...
Page 79 Encore® HD/XD Pump Figure 21 Pump Disassembly (Encore HD Shown) 1. Fitting caps (2) 9. Purge manifold (1) 16. Filter discs (4) 2. O-Rings (2) 10. Manifold gasket (1) 17. Pinch valve chamber block (1) 3. Check valves (2) 11. Block seal (1) 18.
Page 80: Pump Assembly
(16). Then, once that is complete, assemble the complete access plugs (15) and additional O-rings onto the fluidizing tubes (16). Figure 23 Assemble the Pinch Valve Housing Figure 25 Assemble Fittings to Fluidizing Tubes 1605708-11 © 2024 Nordson Corporation...
Page 81: Replacing Pump Gasket
CAUTION: Ensure gasket is not covering any of the port holes on pump. A second gasket is Figure 28 Replacing Pump Gasket provided with pumps as an additional spare. 1605708-11 © 2024 Nordson Corporation...
Page 82: Parts
To order parts, call the Nordson Industrial Coating Systems Customer Support Center at (800) 433-9319 or contact your local Nordson representative. See Figure 29 and the following parts lists. Figure 29 Encore HD and XD Standard Parts (shown with manual system pumps) 1605708-11 © 2024 Nordson Corporation...
Page 83: Pump For Manual Systems
Pump for Automatic Systems Part Description Quantity Note 1612248 PUMP, Encore HD retrofit assembly 1612250 PUMP, Encore XD retrofit assembly Kits for Both Manual and Automatic System Pumps See Figure 29 and the following parts list. Pump Service Kits Item...
Page 84: Kits For Both Manual And Automatic System Pumps Continued
SCREW, socket M5, shoulder, stainless steel, HD pump 1620035 SCREW, socket, M5, shoulder, blue, stainless steel, XD pump NOTE: A. If removing screw, replace lower conductive gasket (18). UA: Unavailable for purchase through Nordson. Contact local distributor or local source. 1605708-11 © 2024 Nordson Corporation...
Page 85: Kits For Manual System Pumps
• O-RING, -013, 0.437 x 0.562 x 0.063 in., silicone, 70 Duro Check Valve Kit Item Description Quantity Note 1625733 - KIT, check valve, HD/XD pump — • VALVE ASSEMBLY, check, Encore HD • O-RING, -012, 0.375 x 0.500 x 0.063 in., silicone, 70 Duro 1605708-11 © 2024 Nordson Corporation...
Page 86: Kits For Automatic System Pumps
Figure 30 Retrofit Fluid Tube and Plug Kit Item Description Quantity Note 1610812 - PLUG, retrofit, fluid tube, Encore HD — • CONNECTOR, 10 mm T x 3/8 uni • CHECK VALVE ASSEMBLY, pump • PLUG, retro, fluid tube access, Encore HD •...
Page 87: Manifold Kit
1616440 - KIT, Encore to Prodigy manifold — • ADAPTER, Encore, HD pump to Prodigy manifold • GASKET, adapter, Encore HD pump to Prodigy 1625737 - KIT, adapter gasket, 8 pack, HD/XD pump — • GASKET, adapter, Encore HD pump to Prodigy...
Page 88: Kits For Automatic System Pumps Continued
See Figure 32 and the following parts list. Item Description Quantity Note 1621252 - KIT, ground, pump controller, Encore HD — • JUMPER, ground, 72 in. • LUG, ground, dual tap • SCREW, socket set, 1/4-20 x 0.50, flat zinc •...
Page 89: Air And Powder Tubing Part Numbers
NOTE: A. Barbed fitting required. B. Optional powder hose to use in place of the standard polyolefin. C. Encore HD antistatic tubing for eliminating turbo-charging. Must be used with Encore pump grounding kits 1620013 and 1621252. D. For purge air.
Page 91: Eu Declaration Of Conformity
Description: These pumps allow for low velocity air / high density powder and are used to deliver powder coating material to the applicator. These pumps are labeled for use in a Zone 22 area. The Encore HD is the standard Model. The Encore HD+ has higher flow then the standard. The Encore XD is for high abrasive powders and powder which have tendency to impact fuse.
Page 92 Description: These pumps allow for low velocity air / high density powder and are used to deliver powder coating material to the applicator. These pumps are labeled for use in a Zone 22 area. The Encore HD is the standard Model. The Encore HD+ has higher flow then the standard. The Encore XD is for high abrasive powders and powder which have tendency to impact fuse.
Page 93 For parts and technical support, call the Industrial Coating Solutions 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 DR., AMHERST, OHIO 44001 • USA...
Page 94 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 found on Original copyright date 2014. No part of this document may be photocopied,...
Page 95 Conical Nozzle, Deflectors and Electrode Assembly Parts (contd) ..........Conical Electrode Assembly ......................XD Electrode Support........................Pattern Adjuster Kit ........................Lance Extensions ......................... Ion Collector Kit ..........................Ion Collector Components for Lance Extensions ................. Powder Hose and Air Tubing ......................1604869-18 © 2024 Nordson Corporation...
Page 97 Updated safety information 05/21 Update input air specifications, labels, and air tubing part. Converted to new formatting. 01/22 Updated approvals information and power supply resistence test figure. 12/23 Updated range for resistence test. 11/24 Updated manufacturing address. 1604869-18 © 2024 Nordson Corporation...
Page 99: 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 100: 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. 1604869-18 © 2024 Nordson Corporation...
Page 101: 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. 1604869-18 © 2024 Nordson Corporation...
Page 102: Description
See Figure 1. This manual covers the Encore® HD manual powder spray gun with 6 meter power cable and tubing. The Encore HD manual powder spray gun should be used with the Encore HD manual controller, which provides electrostatic voltage control, electrode air-wash air, and powder pump air.
Page 103: Specifications
Encore® HD Manual Powder Spray Gun Optional equipment is available for the Encore HD manual spray gun including the following: • Additional flat, conical and cross-cut nozzles options • 6-meter cable extension • 150 and 300-mm lance extensions • Pattern adjuster for use with lance extensions •...
Page 104: Setup
Delivery In 6 mm In 4 mm Clear Air Wash 6 mm Pattern Air Gun Cable Delivery Powder Manual Hose System Controller Network/Power Interconnect Pump Control Unit Figure 2 System Diagram (Common System Equipment Shown) 1604869-18 © 2024 Nordson Corporation...
Page 105: Spray Gun Installation
(5) in the bottom of the spray gun handle. 4. Connect the gun cable (6) to the gun connection on the back of the Encore HD manual system controller.
Page 106: Operation
European Union, EX, 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 Encore HD controller power unit, over the ambient temperature range of +15 °C to +40 °C.
Page 107: System Operation
Encore® HD Manual Powder Spray Gun System Operation This manual includes information on the Encore HD Manual Powder Spray Gun. Refer to appropriate system, controller and control panel manuals for information on system components. Spray Gun Operation The spray gun interface and settings trigger allow you to change the preset or the powder flow settings, or purge the gun as needed, without using the controller interface.
Page 108: Changing Powder Flow With The Settings Trigger
The purge length and frequency required will depend on the application. NOTE: The purge air only cleans the spray gun powder path. Refer to the system controller manual for additional HDLV purge information. 1604869-18 © 2024 Nordson Corporation...
Page 109: Electrode Air Wash Operation
Standby Button Use the Standby button on the Encore HD controller to shut off the interface and disable the spray gun during breaks in production. When the controller interface is off the spray gun cannot be triggered, and the spray gun interface is disabled.
Page 110: Changing Flat Spray Nozzles
To clean nozzles, use the Recommended Cleaning Procedure for Powder Contact Parts on page 16. Flat Spray Nozzle Nut Flat Spray Nozzle Electrode Assembly Figure 5 Changing a Flat Spray Nozzle Electrode Assembly Bridge Figure 6 Correct Nozzle Orientation 1604869-18 © 2024 Nordson Corporation...
Page 111: Converting From Flat Spray Nozzles To Conical Nozzles
Contact Parts on page 16. Electrode Flat Spray Nozzle Flat Spray Nozzle Nut Electrode Holder Conical Spray Nozzle Conical Spray Deflector Electrode Holder Figure 7 Converting from a Flat Spray Nozzle to a Conical Spray Nozzle 1604869-18 © 2024 Nordson Corporation...
Page 112: Changing Deflectors Or Conical Nozzles
6. Screw the nozzle nut onto the gun body clockwise until finger-tight. 7. Install a new deflector on the electrode assembly. Do not bend the electrode wire. Nozzle Deflector Conical Electrode Conical Electrode Nozzle Nut Assembly Holder Figure 8 Changing a Conical Nozzle 1604869-18 © 2024 Nordson Corporation...
Page 113: Installing The Optional Pattern Adjuster Kit
Before performing the following tasks, turn off the controller and disconnect system power. Relieve system air pressure and disconnect the system from its input air supply. Failure to observe this warning may result in personal injury. 1604869-18 © 2024 Nordson Corporation...
Page 114: Recommended Cleaning Procedure For Powder Contact Parts
16 Encore® HD Manual Powder Spray Gun 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. NOTE: Do not immerse the electrode assembly in solvent. It cannot be disassembled;...
Page 115: Repair
7. Filter assembly 19. Cable assembly 28. Setting/purge trigger 10. Display module 19B. Power supply connector (J2) 29. Screw (handle to gun body) NOTE: Ground terminal (19D) must always be connected to the ground screw (16). 1604869-18 © 2024 Nordson Corporation...
Page 116: Display Module Replacement
6. Gently fold the trigger switch ribbon cable and display module cable into the gun, and install the display module onto the gun. 7. Slide the hook (11) onto the display module, then install the bezel (12). 8. Install and tighten the screws (13). 1604869-18 © 2024 Nordson Corporation...
Page 117 Remove 2 liners (new switch) Display Module and Switch Adhesive Cable J3 Connectors Header Support Pad Figure 11 Display Module Replacement 10. Display module 12. Bezel A. Ground wire connector 11. Hook 13. M3 x 35 screws 1604869-18 © 2024 Nordson Corporation...
Page 118: Power Supply And Powder Path Replacement
The air wash tubing will prevent a complete separation; leave it connected unless it must be replaced. Figure 12 Removing the Gun Body from the Handle 1604869-18 © 2024 Nordson Corporation...
Page 119: 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 brass contact inside the gun body. 5. Route the power supply harness connector through the top hole in the bulkhead. 1604869-18 © 2024 Nordson Corporation...
Page 120: Powder Path Removal
NOTE: To verify proper installation, place a flashlight inside the bottom of the inlet adapter and verify the internal connections by looking through the outlet tube from the front of the powder spray gun. 1604869-18 © 2024 Nordson Corporation...
Page 121 Figure 14 Powder Path Replacement 4. Outlet tube kit 7. Filter assembly 21. M3 x 20 screws 5. Elbow 17. Ground pad 24. Inlet tube/hose adapter kit 6. B - Gun body 20. Handle base 25. Handle 1604869-18 © 2024 Nordson Corporation...
Page 122: Gun Re-Assembly
6. Install the nozzle (2) on the electrode assembly, making sure the keys in the electrode assembly slide into the slots on the nozzle. 7. Install the nozzle nut (1) over the nozzle and rotate clockwise to secure. 1604869-18 © 2024 Nordson Corporation...
Page 123: Cable Replacement
View C View B Figure 16 Cable Replacement 13. M3 x 35 screw 17. Ground pad 21. M3 x 20 screws 15. Lock washer 18. Retaining ring 16. M3 x 6 screw 20. Handle base 1604869-18 © 2024 Nordson Corporation...
Page 124: Cable Installation
5. Remove the spray trigger (27), actuator (26), and purge trigger (28) from the handle. 6. Use a tool to pry and pull the trigger switch (14) off the handle, then pull it up and out of the handle. 1604869-18 © 2024 Nordson Corporation...
Page 125: Switch Installation
6. Feed the trigger switch ribbon cable through the bottom of the bulkhead and connect the ribbon cable connector to the display module as described in Display Module Installation on page 18. 7. Re-assemble the gun as described in Gun Re-Assembly on page 24. 1604869-18 © 2024 Nordson Corporation...
Page 126 28 Encore® HD Manual Powder Spray Gun This page intentionally left blank. 1604869-18 © 2024 Nordson Corporation...
Page 127: 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. 1604869-18...
Page 128: 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 18 Power Supply Resistance Test 1604869-18 © 2024 Nordson Corporation...
Page 129: Electrode Assembly Resistance Test
The resistance should be 19−23 megohms. If the resistance is out of this range replace the electrode assembly. 19-23 Megohms Figure 19 Electrode Assembly Resistance Test 1604869-18 © 2024 Nordson Corporation...
Page 130: Gun Cable Continuity Test
(BLUE) (BLACK J3-3 J3-1 AND BLUE) (ORANGE) J1-1 (WHITE) J1-3 (ORANGE) (RED) J2-3 J2-1 (YELLOW) (RED) J2-2 J1-6 J1-4 (GREEN) (BLACK) (WHITE) J2 (FACE VIEW) J1-5 POWER SUPPLY CONNECTOR (YELLOW) Figure 20 Gun Cable Wiring 1604869-18 © 2024 Nordson Corporation...
Page 131: 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 HD manual powder spray gun. Reference Documentation For additional information related to other components in the system, reference the...
Page 132: Spray Gun Parts
34 Encore® HD Manual Powder Spray Gun Spray Gun Parts See Figure 21 and the parts list on the following pages. 24, 24C, 24D Figure 21 Encore HD Manual Spray Gun and Accessories Parts 1604869-18 © 2024 Nordson Corporation...
Page 133 • CHECK VALVE, male, M5 x 6 mm 1081616 • FITTING, bulkhead, barb, dual, 10−32 x 4 mm 1608282 • KIT, inlet tube and hose adapter, Encore HD, Gen 2 1084773 • • O-RING, silicone, 18 mm ID x 2 mm wide 1081785 •...
Page 134: Spray Gun Options
• O-RING, silicone, 0.468 x 0.568 x 0.05 in. 941113 • O-RING, silicone, 0.438 x 0.625 x 0.094 in. 1096696 ELBOW, powder tube, Encore, impact resistant 1085168 CABLE, 6-wire, shielded, handgun, 6 meter extension NS: Not Shown 1604869-18 © 2024 Nordson Corporation...
Page 135: Nlighten
LED inspection kit that helps powder coaters improve quality by effectively illuminating hard to see surface areas. Any imperfection or missed area is quickly identified and corrected. Find out more at: nordsoncoating.com/nLighten. 1611977 nLighten Figure 22 LED Inspection Kit 1604869-18 © 2024 Nordson Corporation...
Page 136: Flat Spray Nozzles
3 mm Flat Spray 1081658 1081659 4 mm Flat Spray 6 mm Flat Spray Figure 23 Flat Spray Nozzles Cross Cut Nozzles 1082184 1082185 1082186 90 Degree Cross-cut 2.5 mm Castle 60 Degree Cross-cut Figure 24 Cross-cut Nozzles 1604869-18 © 2024 Nordson Corporation...
Page 137: 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, flat spray, Encore Figure 26 45-Degree Flat Spray Nozzle 1604869-18 © 2024 Nordson Corporation...
Page 138: 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. 1604869-18 © 2024 Nordson Corporation...
Page 139: Conical Nozzle, Deflectors And Electrode Assembly Parts (Contd)
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 30 Conical Spray and Flat Spray Electrode Supports 1604869-18 © 2024 Nordson Corporation...
Page 140: Pattern Adjuster Kit
EXTENSION, lance, 150 mm, Encore HD 1604970 EXTENSION, lance, 300 mm, Encore HD NOTE: A. If a longer lance extension is required, contact your Nordson representative. Ion Collector Kit This kit installs on the standard length gun. Refer to the instruction sheet shipped with the spray gun for installation instructions and repair parts.
Page 141: Ion Collector Components For Lance Extensions
Do not replace with non-conductive tubing. E. Standard powder hose delivered with system. F. Optional powder hose to use in place of the standard polyolefin. 1604869-18 © 2024 Nordson Corporation...
Page 143 Description: These are electrostatic, powder spray systems, including applicator, control cables and associated controllers. The Encore XT Manual system uses venturi style pump technology for supplying powder to the spray gun. While the Encore HD Manual system uses high density pump technology for supplying powder to the spray gun.
Page 144 Description: These are electrostatic, powder spray systems, including applicator, control cables and associated controllers. The Encore XT Manual system uses venturi style pump technology for supplying powder to the spray gun. While the Encore HD Manual system uses high density pump technology for supplying powder to the spray gun.

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