Nordson Encore HD Color-on-Demand, Product Manual

Page 1: ...DSON CORPORATION AMHERST OHIO USA 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...

Page 2: ...otice This is a Nordson Corporation publication which is protected by copyright Original copyright date 2018 No part of this document may be photocopied reproduced or translated to another language wi...

Page 3: ...Change Record i Part 1612313 02 2018 Nordson Corporation Change Record Revision Date Change 01 1 18 Released 02 7 18 Added system numbers to add nLighten option...

Page 4: ...Change Record ii Part 1612313 02 2018 Nordson Corporation...

Page 5: ...Control Valve Functions 2 7 Color on Demand Color Control Panel 2 8 Color Change Manifold 2 9 Installation 3 1 Specifications 3 1 System Pump Stand Installation 3 1 Controller Installation 3 2 Pump S...

Page 6: ...ge without Suction Line Purge 4 11 Button Labeling 4 13 System Cleaning 4 14 Color Change with Suction Line Purge 4 14 Valve Counters 4 15 System Clock 4 16 Software Version 4 16 Screen Brightness 4 1...

Page 7: ...ay Gun System 7 2 Pump Panel Replacement Parts 7 3 Manifold Parts 7 5 Manifold 7 5 Air and Powder Tubing 7 7 PCA Replacement Parts 7 8 PCA Replacement Kit 7 8 Color on Demand Controller and Control Pa...

Page 8: ......

Page 9: ...ules and regulations and are physically capable of performing their assigned tasks Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equip...

Page 10: ...devices To prevent injury be aware of less obvious dangers in the workplace that often cannot be completely eliminated such as hot surfaces sharp edges energized electrical circuits and moving parts...

Page 11: ...unded There is a possible ignition potential from the charged human body Personnel standing on a painted surface such as an operator platform or wearing non conductive shoes are not grounded Personnel...

Page 12: ...Safety 1 4 Part 1612313 02 2018 Nordson Corporation...

Page 13: ...shipping Upon receipt inspect the shipping materials and components for visible damage Report any visible damage immediately to the shipper and to your Nordson representative The Encore HD Color on De...

Page 14: ...and Controller One per spray gun Color Change Panel One per system HD Pump One per spray gun Pump Panel One per system Color Change Manifolds Three per spray gun Dump Valve One per spray gun System Pu...

Page 15: ...supply WARNING Allow only qualified personnel to perform the following tasks Follow the safety instructions in this document and all other related documentation Manifold Specifications Output Maximum...

Page 16: ...on PD7796 Color on Demand Color Control Panel Encore HD Pump 2 Pump Control Panel Encore HD Pump 1 Figure 2 2 Manual Color on Demand System Panels NOTE On the inside of the pump cabinet Pump 1 is refe...

Page 17: ...2 Pump 1 purge valve 3 Pump 1 control manifold 4 Pump 1 5 Pressure switch 6 24 Vdc power supply 7 Line filter 8 Power switch 9 Contact block 10 Vacuum generator mufflers 11 Fuse time delay 3 15 A 12...

Page 18: ...m Description Function 1 Solenoid Valves Control the air flow to the pump during operation NOTE Refer to Solenoid and Control Valve Functions on page 2 7 to identify each valve s specific function 2 P...

Page 19: ...pump and manifold 1 7 8 9 1 2 3 4 6 5 1 2 3 4 5 6 Figure 2 5 Solenoid and Flow Control Valve Functions Item Function Item Function 1 Left Side Delivery Pinch Valve 6 Right Side Delivery Pinch Valve 2...

Page 20: ...ee Figure 2 6 Air and power are supplied to the color control panel from the pump control panel PD7796 PLC Manifold Purge Valves Foot Pedal Pressure Switch Solenoid Valves System Pressure Switch Spray...

Page 21: ...sure switch which signals the PLC to initiate a color change Color Change Manifold See Figure 2 7 The color change manifold consists of 3 valve blocks with 10 ports in the side of each block and ports...

Page 22: ...17 Color 15 Color 13 Color 11 Color 9 Color 7 Color 5 Color 3 Color 1 Color 18 Color 16 Color 14 Color 12 Color 10 Color 8 Color 6 Color 4 Color 2 Suction Line to Pump Dump Manifolds A B Manifold End...

Page 23: ...change manifolds and cover System Pump Stand Installation The system pump stand must be located as close to the powder feed hoppers as possible since the maximum suction tubing length is 3 m 9 8 ft fr...

Page 24: ...em Controller manual for more information Pump Stand Mounting The panel stand is shipped with a controller support arm It can be bolted to the side of the stand with the included M8 x 30 bolts and was...

Page 25: ...Installation 3 3 Part 1612313 02 2018 Nordson Corporation Connection Diagram Rear View of System Figure 3 2 System Diagram Dual Spray Gun System Shown...

Page 26: ...Hz 1 275 VA MAX 15 A Breaker Max 15 m 50 ft Network Power Cable 6 m 20 ft Spray Gun Cable 15 m 50 ft Network Power Cable 6 m 20 ft Spray Gun Cable Brown L1 hot Blue L2 neutral Green Yellow GND NET PW...

Page 27: ...Supply and Spray Gun Air Connections Manual Spray Gun 2 Pump Panel 6 mm OD Blue Air Tubing Manual Spray Gun 1 6 mm OD Blue Air Tubing Air Supply 6 2 7 6 bar 90 110 psi 12 mm tubing x 1 2 in NPT fitti...

Page 28: ...onnect the other end to the spray gun air fitting on the power unit or pump panel 3 Seat the O rings 4 onto the barbed hose adapter 3 Push the barbed end of the hose adapter into the end of the powder...

Page 29: ...thernet cable into the socket as shown 4 Pull the cut end of the cable through the provided in conduit connector and conduit to the color panel and route it inside the panel 5 Connect the cable leads...

Page 30: ...e Color Change Foot Switch Spray Gun 1 Color Change Foot Switch Spray Gun 2 6 mm Tube x NPT Connectors 6 mm Tube x NPT Connectors 6 mm Blue Tubing SWB RTN Power Cable Ground Ground Ethernet Cable Term...

Page 31: ...ethernet cable Figure 3 7 Ethernet Cable Termination Step 1 2 Route the cut end of the ethernet cable into the color panel 3 Trim back the cable jacket about 8 in 4 Cut the foil clear wrapper and pul...

Page 32: ...e to the termination module as possible 8 Install the retention caps on the termination module 9 Crimp a ground lug to the shield wire 10 Assemble the ethernet termination case as shown For rear conne...

Page 33: ...enclosure 12 Connect the 1 m 3 ft long crossover cables from the termination modules to the PLCs 13 Attach the termination module ground wires to the cabinet ground stud A B A B Crossover Cables 3 ft...

Page 34: ...n floor Manual Spray Gun 2 Pump Panel Bottom View Manual Spray Gun 1 Factory Installed Suction Tubing Color Change Manifolds Bottom View Factory Installed Suction Tubing Use tubing cutter to cut tube...

Page 35: ...or 21 Color 19 Color 17 Color 15 Color 13 Color 11 Color 9 Color 7 Color 5 Color 3 Color 1 P1 Purge Air Factory Installed Color Change Manifold Color 2 Powder Feed Hopper Not included with system Vent...

Page 36: ...AE SCCA RM1A RS2A BIT5A SW1A RS1A MD3A MD4A C26AE C25AE SPARE4A MD2A SPARE2A SPARE3A SPARE1A CCDA P2AE BIT3A C28AE C27AE BIT1A BIT4A CCSA CVBA DOCA BIT2A PS1A I O MD1A USR TXD RXD ERROR LINK ON Bits 1...

Page 37: ...Part 1612313 02 2018 Nordson Corporation Section 4 Operation WARNING Allow only qualified personnel to perform the following tasks Follow the safety instructions in this document and all other related...

Page 38: ...t the manifold onto the appropriate mounting bracket 4 against the pump panel wall 3 Secure the manifold with the mounting screws 6 but do not tighten the screws 3 Secure the pump to the pump panel an...

Page 39: ...ack of this manual Item Description XD CR1 Pump 1 Pattern Air Pressure Transducer In Out XD CR2 Pump 1 Flow Air Pressure Transducer In Out XD CR 3 Pump 2 Pattern Air Pressure Transducer In Out XD CR4...

Page 40: ...on PB2 Reset Switch DS1 Power Indicator DS2 Fault Indicator P1 and P2 Pinouts Pin P1 Function P2 Function 1 24 Vdc Not Used 2 24 Vdc Not Used 3 24 Vdc Not Used 4 24 Vdc Not Used 5 24 Vdc Not Used 6 24...

Page 41: ...J1 P1 1 2 3 4 2 1 4 3 XDCR2 XDCR1 J5 P4 P5 P6 W1 P3 PB1 PB2 SW1 SW2 DS1 DS2 6 5 8 7 Figure 4 2 Control Board and Manifold Connections Note The control board is shipped with air tubing labeled from 4...

Page 42: ...PEN 2 OPEN 3 OPEN 4 CLOSED For Color on Demand System For Standard Manual Spray Gun System Figure 4 3 SW1 and SW2 Settings Network Termination See Figure 4 4 The control board is shipped with a jumper...

Page 43: ...nction value blinks To change the function value rotate the knob Select the Enter button to save the change and exit the value so that rotating the knob now scrolls through the function numbers Functi...

Page 44: ...Blue Pump Assist Pattern Air Flow Control 5 9 bar 85 psi B 8 mm Clear Powder Suction from Feed Source H 6 mm Blue Spray Gun Pattern Air Flow Control to spray gun C 8 mm Clear Powder Delivery to Spray...

Page 45: ...from 0 100 equivalent to a percent of flow which corresponds to a predefined pump cycle rate Increasing the flow rate setting increases the cycle rate decreasing the flow rate setting decreases the c...

Page 46: ...Buttons 1 14 Main Splash Screen Small Buttons Setup Button Labels 1 14 Valve Counters Test Outputs 1 20 Outputs 21 40 Inputs 1 16 Software Version Screen Contrast Button Labels 15 28 System Clock Purg...

Page 47: ...creen appears NOTE Note that the controller power switch only turns the controller on and off The color change PLC remains powered up until the system power switch is turned off Figure 4 8 Splash Scre...

Page 48: ...then select a color or press the foot pedal then select the desired color button After starting a color change with the foot pedal or Start button there are approximately 11 seconds with factory defau...

Page 49: ...1 to 14 plus the label button for the system name The system name appears in yellow at the bottom left of the color buttons screens Select the More button to go to the button label screen for colors 1...

Page 50: ...NOTE To perform this procedure the Hopper Purge function must be enabled See the Service Screen section on page 5 6 to enable and disable the function Remove the suction line to be purged from the fe...

Page 51: ...l is 30 000 cycles When this count is reached disassemble the color change manifolds and install new bladders Replacing the bladders before they fail will prevent color contamination and expensive uns...

Page 52: ...on Software Version See Figure 4 17 Go to the Test screen then select Software Version This screen displays software version information This information may be requested if calling for technical supp...

Page 53: ...lified 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...

Page 54: ...7 to determine which solenoid valve controls the affected pinch valve Defective pump check valve Replace the check valves 3 Reduced powder input loss of suction from feed source Blockage in the powde...

Page 55: ...enoid valves and air tubing are all coded on the labels for easy traceability For example when color 1 is selected for spray gun1 the LEDs for C1AE on both the PLC and solenoid should light Refer to t...

Page 56: ...Start 1 Signal from foot pedal pressure switch 3 CCS Color Change Status signal from pump control board 4 CVB Color Valve Back purge signal from pump control board 5 PS1 Air pressure switch prevents c...

Page 57: ...adder Figure 5 3 Outputs 1 20 Screen Figure 5 4 Outputs 21 40 Screen Output Channel Code Function 1 SCC Start Color Change signal to the pump control boards 2 RM1 Remote Monitor 1 3 CCD Not Used 4 P2E...

Page 58: ...be done from the Valve Counter screen Dump Valve Counter Preset Allows the counter to be reset if accidentally reset from the Valve Counter screen Warning Count Set When this value is exceeded by the...

Page 59: ...d valves Field replacement of other parts is not possible due to the need to calibrate the manifold at the factory using equipment not available in the field Preparation NOTE Tag all air tubing and wi...

Page 60: ...emove the flow control valve from the manifold CAUTION The valve parts are very small Be careful not to lose any parts Do not mix the springs from one valve with those from another The valves are indi...

Page 61: ...ver Solenoid Valve Replacement See Figure 6 1 To remove the solenoid valves remove the two screws 11 in the valve body and lift the solenoid valve 12 off the manifold Make sure the gasket furnished wi...

Page 62: ...e circuit board replacement kit comes with detailed removal installation and calibration instructions Follow the instructions carefully to avoid damaging the circuit board Color on Demand Controller a...

Page 63: ...t the cover off the manifold 8 Remove the filter discs 15 valve bladders 13 and bladder supports 14 from the manifold 12 9 Remove the bladder supports 14 from the valve bladders 13 10 Blow out the man...

Page 64: ...9 10 12 11 16 8 8 8 9 9 9 Figure 6 2 Manifold Exploded View 1 Elbow fitting 2 Socket screw 3 Screw 4 Nut 5 Lock washer 6 Flat washer 7 Ground jumper 8 Side lock knob 9 O ring 10 Fasteners 11 Module br...

Page 65: ...hrough the valve body 5 Put the UP end of the new pinch valve in the tool The UP end of the pinch valve fits into the smaller counterbore in the valve body 5 6 Pinch the UP end of the pinch valve 4 th...

Page 66: ...Repair 6 8 Part 1612313 02 2018 Nordson Corporation...

Page 67: ...The Description column gives the part name as well as its dimensions and other characteristics when appropriate Indentions show the relationships between assemblies subassemblies and parts If you orde...

Page 68: ...al single Encore HD 1604125 1604125 CONTROL UNIT interface Encore XT 1 1603160 1603160 SPRAY GUN assembly manual Encore HD 1 CONTROLLER COD single pump Encore HD 1 1605276 1605276 KIT ship with spray...

Page 69: ...7 1 Pump Panel Replacement Parts Dual Pump System Shown Item Part Description Quantity Note 1 303132 VALVE 3 4 in I O air operated AR A 2 MANIFOLD ASSEMBLY HDLV pump control AR A B 3 1610978 PUMP ASS...

Page 70: ...964 SWITCH pressure AR 16 1606840 ADAPTER NS 1604832 HARNESS SET single air wash AR NS 1604833 HARNESS SET dual air wash AR NOTE A Quantities for AR items vary depending on number of spray guns in sys...

Page 71: ...5 Part 1612313 02 2018 Nordson Corporation Manifold Parts Manifold See Figure 7 2 and refer to the following parts list 1 2 3 4 5 6 7 8 11 9 10 12 13 14 15 8 15 3 16 17 18 15 8 11 Figure 7 2 Manifold...

Page 72: ...0 mm tube plastic 1 10 972283 CONNECTOR male with internal hex 10 mm tube x 1 4 in universal 1 11 1098501 KIT flow control valve pump control 2 12 328524 CONNECTOR male with internal hex 6 mm tube x M...

Page 73: ...lue polyurethane F 900740 10 mm Blue polyurethane B 173101 8 mm Clear polyethylene G 900740 10 mm Blue polyurethane C 173101 8 mm Clear polyethylene H 900742 6 mm Blue polyurethane D 173101 8 mm Clear...

Page 74: ...13 02 2018 Nordson Corporation PCA Replacement Parts PCA Replacement Kit See Figure 7 4 and refer to the following parts list Part Description Note 1101498 KIT PCA replacement pump control Figure 7 4...

Page 75: ...hange III 1 A 2 129592 KNOB clamping M6 x 12 mm long 2 3 129590 SPACER cabinet friction 2 4 982649 SCREW hex machine M10 x 22 mm 1 5 983405 WASHER lock split M10 steel zinc 1 6 288828 KIT bracket moun...

Page 76: ...Parts 7 10 Part 1612313 02 2018 Nordson Corporation 2 7 4 5 8 9 1 10 11 3 6 12 Figure 7 5 Controller Kit Parts...

Page 77: ...ed M4 x 10 zinc 8 6 982636 SCREW button socket M5 x 12 zinc 2 7 983127 WASHER lock internal M5 zinc 2 8 984526 NUT lock 1 2 in conduit 2 9 939122 SEAL conduit fitting 1 2 in blue 2 10 1082734 ENCLOSUR...

Page 78: ...Parts 7 12 Part 1612313 02 2018 Nordson Corporation 1 2 3 17 6 7 14 13 12 11 5 4 11 12 13 14 9 8 16 15 10 Figure 7 6 Controller Parts...

Page 79: ...30 psi AR B 5 1068324 VALVE solenoid 3 port 24V N O w o leads AR C 6 1068325 VALVE solenoid 3 port 24V N C w o leads AR C NS 173101 TUBING polyethylene 8 mm x 6 mm natural AR D NS 900742 TUBING polyur...

Page 80: ...Parts 7 14 Part 1612313 02 2018 Nordson Corporation 1 2 3 4 5 6 5 5 6 5 Spray Gun A Spray Gun B Figure 7 7 Color Control Panel Parts...

Page 81: ...n III AR A D 2 1064193 MODULE 8 channel digital input Wago 750 430 AR B D 3 1064195 MODULE 8 channel digital output Wago 750 530 AR C D 4 1064191 MODULE end carrier Wago 750 600 1 5 1064192 POWER SUPP...

Page 82: ...Parts 7 16 Part 1612313 02 2018 Nordson Corporation 3 2 1 4 5 3 2 1 4 Figure 7 8 Control Unit PLC Parts...

Page 83: ...ty Note 1094892 MANIFOLD module Color on Demand assembly 1 972126 CONNECTOR male elbow 6 mm tube x 1 8 in unithread 10 2 981225 SCREW socket head 1 4 20 x 0 625 in 16 3 1045837 SCREW pan head M5 x 12...

Page 84: ...Parts 7 18 Part 1612313 02 2018 Nordson Corporation 1 2 5 4 6 3 7 10 11 12 8 9 15 16 13 14 4 17 8A 8 8A 8 8A 8 8A 9 9 9 Figure 7 9 Color Change Manifold Parts...

Page 85: ...M6 x 14 zinc 8 3 CAP dump valve Color on Demand 2 4 1066626 VALVE pinch HDLV pump 1 A 5 1074028 BODY dump valve Color on Demand 1 6 972126 CONNECTOR male elbow 6 mm x 1 8 in unithread 1 7 971121 CONN...

Page 86: ...Parts 7 20 Part 1612313 02 2018 Nordson Corporation This page intentionally left blank...

Page 87: ...System Diagrams 8 1 Part 1612313 02 2018 Nordson Corporation Section 8 System Diagrams...

Page 88: ...System Diagrams 8 2 Part 1612313 02 2018 Nordson Corporation...

Page 89: ...BRN 24VDC BLUE BLUE BRN GRN YEL GRN YEL BRN BLUE 1 FLOW ACTUATOR HARNESSES INLCUDED WITH PUMP CONTROL MANIFOLD PUMP CONTROL HARNESS 356MM SEE TABLE TO HDLV PUMP CONTROL MANIFOLD 1 SOLENOIDS 1 7 1 6 4...

Page 90: ...M COLOR CHANGE MANIFOLDS B SEE 1064953 140 ELECTRODE AIR WASH MANIFOLD 34 12 FROM COLOR CHANGE MANIFOLDS A SEE 1064953 SEE PUMP PUMP CONTROL BOARD DETAILS SHEET 2 1 2 4 3 6 5 8 7 PINCH SELECT MANIFOLD...

Page 91: ...MP CONTROL BOARD 8 7 6 5 4 3 2 1 BOTTOM VIEW 3 4 2 1 PUMP MANIFOLD 1 PUMP CONTROL BOARD A DETAIL V 1 3 4 2 A PUMP MANIFOLD PUMP CONTROL BOARD B DETAIL B PUMP CONTROL BOARD Y BOTTOM VIEW 7 8 5 6 6 8 7...

Page 92: ...N ROCKER SWITCH FROM ETHERNET INSULATION DISPLACEMENT CONNECTOR PART OF COLOR CHANGE CONTROLLER GREEN YELLOW GREEN YELLOW RED YELLOW GREEN YELLOW YELLOW 50 STRAIGHT CONDUIT CONNECTOR TO BACK PLATE GRO...

Page 93: ...C20BE C19BE C6BE C7BE C8BE C5BE C1BE C2BE C4BE C3BE C16BE D1BE C24AE C23AE C21AE C22AE C20AE C19AE C18AE C17AE C16AE L N C8AP D1AP P1AP M C13AP C5AP H C14AP C6AP C15AP C7AP C12AP C4AP C11AP C3AP C9AP...

Page 94: ...T T S R V W W TO PUMP 1 SEE 1066932 TO DUMP Q P1A X A U TO PUMP 2 SEE 1066932 U R W R S W S T V TO DUMP COLOR CHANGE DISTRIBUTION MANIFOLD B D2 T X Q C19BP C27BP C3BP C11BP C18BP C16BP C17BP C1BP C9BP...

Page 95: ...COLOR CHANGE DISTRIBUTION MANIFOLD CONTACT BLOCK DETAIL A A B COLOR CHANGE DISTRIBUTION MANIFOLD SEE SCHEMATICS COMMUNICATION HARNESS COMMUNICATION HARNESS PRESSURE SWITCH HARNESS FOOT SWITCH HARNESS...

Page 96: ...PATT A SOL 1 8 1 BLUE WHITE 24VDC RED BLACK BLUE WHITE BLUE WHITE CVB BLUE CVB WHITE CABLE 3A DOC WHITE DOC BLUE CABLE 4A COMMUNICATION HARNESS WHITE BLUE CABLE 1B TO PLC B SEE SCHEMATIC TO PLC A SEE...

Page 97: ...GRAY TB3A GRAY TB2A D2AE BLACK D1AE BLACK C28AE BLACK C27AE BLACK C26AE BLACK C25AE BLACK C24AE BLACK C23AE BLACK C22AE BLACK C21AE BLACK C20AE BLACK C19AE BLACK C18AE BLACK C17AE BLACK C16AE BLACK C1...

Page 98: ...CABLE 4A 1 1 223 PS1 BLACK 1080 1070 143 143 TB1A 1030 GND GREEN YELLOW 1070 24COM BLACK 1080 24VDC RED BLACK RED 24V 750 842 _ 0V _ WAGO I O SYSTEM BUS CONTROLLER MD1A ETHERNET FIELD PS2A FOOT SWITC...

Page 99: ...C19AE BLACK C18AE BLACK C17AE BLACK C22AE VALVE C21AE VALVE C20AE VALVE C19AE VALVE C18AE VALVE C17AE VALVE C22AE RED C21AE RED C20AE RED C19AE RED C18AE RED C17AE RED MD6A 8 PT SOURCE OUTPUT POS 4 C1...

Page 100: ...1 428 427 426 425 422 424 423 MD8A 8 PT SOURCE OUTPUT POS 6 1 OUT1 5 OUT2 6 OUT4 3 OUT5 2 OUT3 7 OUT6 4 OUT7 8 OUT8 750 530 D1AE BLACK D2AE BLACK D1AE VALVE D2AE VALVE D1AE RED D2AE RED OUTPUT 36 SPAR...

Page 101: ...BLACK C27BE BLACK C26BE BLACK C25BE BLACK C24BE BLACK C23BE BLACK C22BE BLACK C21BE BLACK C20BE BLACK C19BE BLACK C18BE BLACK C17BE BLACK C16BE BLACK C15BE BLACK C14BE BLACK C13BE BLACK C12BE BLACK C1...

Page 102: ...PUMP CABLE 2B CABLE 3B CABLE 4B 623 PS1 BLACK 1080 1070 543 543 TB1B 24V 750 842 _ 0V _ WAGO I O SYSTEM BUS CONTROLLER MD1B ETHERNET FIELD PS2B FOOT SWITCH B PRESSURE SWITCH RS1B WHITE 2 2 INPUT 7 SP...

Page 103: ...C19BE BLACK C18BE BLACK C17BE BLACK C22BE VALVE C21BE VALVE C20BE VALVE C19BE VALVE C18BE VALVE C17BE VALVE C22BE RED C21BE RED C20BE RED C19BE RED C18BE RED C17BE RED MD6B 8 PT SOURCE OUTPUT POS 4 C1...

Page 104: ...1 828 827 826 825 822 824 823 MD8B 8 PT SOURCE OUTPUT POS 6 1 OUT1 5 OUT2 6 OUT4 3 OUT5 2 OUT3 7 OUT6 4 OUT7 8 OUT8 750 530 D1BE BLACK D2BE BLACK D1BE VALVE D2BE VALVE D1BE RED D2BE RED OUTPUT 36 SPAR...

Page 105: ...2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 4 3 2 1 1 2 3 4 4 3 2 1 1 2 3 4 4 3 2 1 1 2 3 4 4 3 2 1 1 2 3 4 4 3 2 1 1 2 3 4 WAGO I O SYSTEM 750 842 WAGO I O SYSTEM 750 842 750 430 750 430 75...

Page 106: ...O ERROR ERROR TXD RXD TXD RXD LINK ON PLC A LED DEFINITIONS PLC A LED DEFINITIONS PLC B LED DEFINITIONS PS1A CCSA SW1A RS1A CVBA DOCA RS2A BIT4A BIT2A BIT1A BIT3A BIT5A RM1A SCCA CCDA P2AE C27AE C28A...

Page 107: ...EN55011 2009 NFPA79 2015 EN60204 2006 EN61000 6 2 2005 EN61000 6 3 2007 Principles This product has been manufactured according to good engineering practice The product specified conforms to the dire...

Page 108: ...RATION AMHERST OHIO USA 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 subjec...

Page 109: ...H 44001 Notice This is a Nordson Corporation publication which is protected by copyright Original copyright date 2014 No part of this document may be photocopied reproduced or translated to another la...

Page 110: ...poration Change Record Revision Date Change 01 01 14 New release 02 09 14 Re zero procedure revised 03 01 15 New equipment labels 04 10 15 Revised illustrations and content 05 04 18 Revised some illus...

Page 111: ...Change Record ii Part 1604870 05 E 2018 Nordson Corporation...

Page 112: ...egulations and Approvals 1 1 Personal Safety 1 2 Fire Safety 1 2 Grounding 1 3 Action in the Event of a Malfunction 1 3 Disposal 1 3 Description 2 1 Introduction 2 1 Specifications 2 2 Equipment Label...

Page 113: ...Settings 4 13 Color Change Purge 4 17 HDLV System Purge 4 17 Color on Demand COD System Purge 4 19 Controller Configuration 4 20 Opening the Function Menu and Setting Preferences 4 20 Saving and Load...

Page 114: ...and regulations and are physically capable of performing their assigned tasks Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment...

Page 115: ...ces S To prevent injury be aware of less obvious dangers in the workplace that often cannot be completely eliminated such as hot surfaces sharp edges energized electrical circuits and moving parts tha...

Page 116: ...ed S There is a possible ignition potential from the charged human body Personnel standing on a painted surface such as an operator platform or wearing non conductive shoes are not grounded Personnel...

Page 117: ...Safety 1 4 Part 1604870 05 E 2018 Nordson Corporation...

Page 118: ...r The system controller is used with the Encore HD with HDLV technology and the Encore XT with venturi technology The Encore HD and XT controller may be used in the following systems S Encore HD and X...

Page 119: ...e rating 15 to 40 _C 59 104 _F Hazardous location rating Zone 22 or Class II Division 2 Enclosure rating IP6X Dust ingress protection Equipment Label Controller Certification Label ELECTROSTATIC HAND...

Page 120: ...o bottom or bottom to top Pictured below is the most common system orientation bottom to top 1 Install the controller rail mount bracket 2 to the arm on the product stand 1 2 Install the controller 4...

Page 121: ...system 4 mm in 6 mm Purge Air 4 mm Clean Air Wash Gun Cable Network Power Interconnect Delivery Powder Hose 6 mm in Delivery in Powder Spray Gun Pump Control Unit Manual System Controller Figure 3 2 T...

Page 122: ...socket end of the interconnect cable to the NET PWR plug 1 in the back of the controller 2 Securely attach the pin ends of the interconnect cable to the NET PWR 1 plug 2 in the top of the pump cabinet...

Page 123: ...System Setup 3 4 Part 1604870 05 E 2018 Nordson Corporation...

Page 124: ...D manual applicator shall only be used with the Encore XT and HD interface controller and the Encore XT controller power unit or the Encore HD controller power unit over the ambient temperature range...

Page 125: ...ase indicates a resistor or voltage multiplier requiring service Startup Standby Button Controller Interface Function Help Display Color Change Figure 4 1 System Controls Mobile System Shown The follo...

Page 126: ...troller Software Version Gd X XX Gun Display Module Software Version FL X XX Flow Module Software Version Select the desired preset and start production Refer to Presets on page 4 5 for preset program...

Page 127: ...s are factory set and cannot be changed Table 4 4 XT System Factory Set Presets Preset Electrostatics Powder Flow kV mA 1 Max kV 150 g min 20 lb hr 100 30 45 3 0 2 Max kV 300 g min 40 lb hr 100 30 75...

Page 128: ...gure 4 3 Selecting and Changing Setpoint Values Presets See Figure 4 4 The preset select button allows the operator to quickly change spray settings simply by changing the preset number The operator c...

Page 129: ...ot triggered Preset Button Figure 4 4 Preset Select Electrostatic Settings Electrostatic output can be set to Select Charger mode preconfigured Custom mode or Classic mode Refer to the Controller Conf...

Page 130: ...is pressed 3 To set or change the A setpoint press the mA button The button LED lights to indicate that A is selected 4 Turn the Rotary Knob to increase or decrease the A setpoint The setpoint is aut...

Page 131: ...s NFC mode allows the user to adjust the kV setting in increments of 1 kV below the value of 25 kV For example the user can set the kV settings from 25 24 23 22 through 0 Classic Mode Classic Mode all...

Page 132: ...Electrostatic Displays Adjust mA Classic Mode AFC NOTE Use the AFC mode to adjust and set A output limits kV cannot be adjusted in AFC mode kV setting is automatically set to 100 kV 1 To adjust A pre...

Page 133: ...Function Help display lights if a problem occurs Display Codes Clear Codes Figure 4 9 Displaying and Clearing Help Codes To display the Help codes press the Help button The controller retains the last...

Page 134: ...e Version View only Gd X XX Gun Display Module Software Version View only FL X XX Flow Module Software Version View only Hd X XX Hardware Version for Main Control Board View only To adjust the Assist...

Page 135: ...low is not affected by the pattern air setting The pattern air will change the delivery velocity as the powder exits the gun as well as change the atomization of the powder cloud S Powder flow output...

Page 136: ...tomizing air icons are lit NOTE Refer to Controller Configuration on page 4 20 for a list of the mode defaults and configuration instructions Flow Air Atomizing Air Flow Air Total Air Figure 4 11 Powd...

Page 137: ...low Air increases powder flow Increase flow no change in velocity Max Flow Increase velocity no change in flow 50 Flow Air Setpoint 3 00 Total Flow Setpoint Max Velocity Figure 4 12 Reading the Smart...

Page 138: ...2 57 5 95 60 6 37 63 6 80 65 7 22 67 7 65 68 8 07 70 8 50 1 9 2 97 22 3 82 30 4 24 36 4 67 42 5 09 46 5 52 50 5 94 53 6 37 56 6 79 59 7 22 61 7 64 63 8 07 65 8 49 67 8 92 2 3 3 40 20 4 25 27 4 67 33 5...

Page 139: ...0 54 3 25 57 3 50 60 3 75 63 4 00 65 4 25 67 4 50 68 4 75 70 5 00 28 1 75 22 2 25 30 2 50 36 2 75 42 3 00 46 3 25 50 3 50 53 3 75 56 4 00 59 4 25 61 4 50 63 4 75 65 5 00 67 5 25 34 2 00 20 2 50 27 2 7...

Page 140: ...is triggered the actual flows are displayed Flow Atomizing Figure 4 14 Classic Mode Flow Air or Atomizing Air Flow Setpoints Color Change Purge NOTE Before starting the purge cycle make sure the guns...

Page 141: ...owder Cycle 2 Pulse Purge Purge air is directed in pulses from the pump to the powder supply Siphon Pulses then from the pump to the spray gun Gun Pulses Pulse On sets duration of each pulse Pulse Off...

Page 142: ...the system for production The color change cycle is started by the operator or by a remote signal to the Color On Demand controller The operator starts the color change by selecting a new color and to...

Page 143: ...he function numbers are in the form F00 00 Function Number Function Value To scroll through the function numbers rotate the knob To select the displayed function number press the Enter button When the...

Page 144: ...assic Choose custom or classic feedback control mode See page 4 6 for more information 00 F04 Powder Flow Control 00 Smart 01 Classic Choose smart or classic mode See page 4 12 for more information N...

Page 145: ...ormal 01 Reset Refer to page 5 13 for the Zero Reset procedure 00 F11 Gun Display Errors 00 Flashing 01 Disable Enable or disable gun display errors Display will flash when an error occurs if enabled...

Page 146: ...ring initial setup 00 F21 Maintenance Timer Pump 00 View Timer 01 Set Timer 000 Disable through 999 02 Reset 00 01 Sets a timer for when pump maintenance is due 00 is view only 01 allows you to choose...

Page 147: ...s directed through the pump and siphon tubing back to the powder supply Soft Siphon then through the pump and delivery tubing to the spray gun Soft Gun This clears the pump powder tubing and gun of po...

Page 148: ...0 to 0 500 0 Saving and Loading Preset and Function Settings To save the current preset and function settings set F15 to F15 00 and press Enter All current preset and function settings are saved to me...

Page 149: ...y gun and interface 4 Turn off the system air supply and relieve the system air pressure at the pump cabinet 5 If shutting down for the night or a longer period of time shut off system power 6 Perform...

Page 150: ...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...

Page 151: ...Operation 4 28 Part 1604870 05 E 2018 Nordson Corporation...

Page 152: ...n 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 H...

Page 153: ...roller Configuration section on page 4 20 Check the DIP switch setting on the pump controller Check the interface interconnect cable Make sure the cable connections are secure and the cable is not dam...

Page 154: ...un triggered ON Check for blockage in proportional valve Check for oil water contamination Perform the Conveyance Air Flow Verification for HD procedure on page 5 13 Check for water and or oil contami...

Page 155: ...low is higher than setpoint System unable to turn it down Check if input pressure is less than 110 psi 7 6 bar Check if internal regulator is set to 85 psi 5 7 bar with the spray gun triggered ON Chec...

Page 156: ...If the help code persists re zero the module as described on page 5 13 Refer to the Repair section in the Encore XT Manual Powder Spray Systems manual for procedures using the iFlow Air Flow Verifica...

Page 157: ...US Communication Fault Gun Cable Perform Gun Cable Continuity Tests in the spray gun manual to check J3 connection If an open or short is found replace the cable If the gun cable is okay replace the g...

Page 158: ...loose harness connection Check Valve 6 for loose connection H49 Delivery Tube A Valve 3 Fault Check J11 3 for loose harness connection Check Valve 3 for loose connection H50 Delivery Tube B Valve 4 Fa...

Page 159: ...sure Increase the pattern air Improper fluidization of powder in hopper Increase the fluidizing air pressure If the problem persists remove the powder from the hopper Clean or replace the fluidizing p...

Page 160: ...bag VBF units blocking pick up tube Vibratory box feeder disabled VBF units only Set the Custom Function F01 for a box feeder F01 01 See the Controller Configuration section on page 4 20 Low supply a...

Page 161: ...when gun triggered but powder is spraying NOTE Before checking possible causes check the help code on the controller and perform the corrective actions recommended in this section Damaged gun cable P...

Page 162: ...module membrane switch is defective Replace display module If display module shows PU Check the purge air tubing and solenoid valve on the iFlow manifold Perform the Gun Cable Continuity Test as descr...

Page 163: ...tom Function F01 for a box feeder F01 01 Refer to the Controller Configuration section on page 4 20 for more information Check for loose cable on pump control unit 14 Fluidizing Air is on all the time...

Page 164: ...e controller functions F00 00 is displayed 3 Rotate the knob until F10 00 is displayed 4 Press the Enter button then rotate the knob to display F10 01 5 Press the Enter button The system controller wi...

Page 165: ...r Interconnect Cable Test CAN CAN V V SHIELD DRAIN J1 1 J1 2 J1 3 J1 4 J1 5 BLUE WHITE BLACK RED BARE 5 Drain 1 CAN 2 CAN 3 V 4 V P1 3 P1 5 P1 4 P1 1 P1 2 5 Drain 4 V 1 CAN 2 CAN 3 V Pump Cabinet End...

Page 166: ...HASSIS 24VDC DC COM CAN CAN 1 ORANGE 6 GREEN 5 YELLOW 12VDC GROUND FEEDBACK 4 WHITE 3 RED LIN OSC 2 BLACK DC COM J6 J7 J2 J3 1 2 BLACK DC COM RED OSC WHITE LIN YELLOW FEEDBACK ORANGE 12VDC NET RECEPTA...

Page 167: ...Troubleshooting 5 16 Part 1604870 05 E 2018 Nordson Corporation...

Page 168: ...r disconnect ahead of the controller before opening the controller enclosures Failure to observe this warning could result in a severe electrical shock and personal injury CAUTION Electrostatic sensit...

Page 169: ...n Corporation 1 2 3 2A 2B 2C Connect to 2A J6 Internal Enclosure Ground External Enclosure Ground J6 Figure 6 1 Interface Module Assembly 1 Bezel 2 Keypad PCB Assembly 2A Main Control Board 2B Main Di...

Page 170: ...ment Encore HD Mobile Powder Spray System 1605707 Encore HD Manual System Spray Gun 1604869 Encore HD Pump Control Unit and Power Supply 1606783 Encore XT Manual Powder Spray Systems 1603227 ColorMax...

Page 171: ...Parts 7 2 Part 1604870 05 E 2018 Nordson Corporation Controller Parts Controller Exploded View 1 2 3 17 6 7 14 13 12 11 5 4 11 12 13 14 9 8 16 15 10 Figure 7 1 Controller Parts...

Page 172: ...982636 S SCREW button socket M5 x 12 zinc 2 7 983127 S WASHER lock internal M5 zinc 2 8 984526 S NUT lock 1 2 in conduit 2 9 939122 S SEAL conduit fitting 1 2 in blue 2 10 1082734 S ENCLOSURE control...

Page 173: ...re 7 2 Item Part Description Quantity Note 1 1604881 BRACKET controller rail mount 1 2 336281 NUT hex serrated 0 5 16 18 2 3 1091006 NUT hex flanged serrated M8 2 4 1103115 SCREW hex serrated M8 x 16m...

Page 174: ...ERST OHIO USA 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 chang...

Page 175: ...is a Nordson Corporation publication which is protected by copyright Original copyright date 2014 No part of this document may be photocopied reproduced or translated to another language without the...

Page 176: ...powder inlet tube 3mm and 4mm nozzles to ship with gun 07 10 2015 Revised equipment labels and parts 08 03 16 Added cleaning procedure 09 09 16 Nozzle part number change and positive power supply add...

Page 177: ...Change Record ii Part 1604869 13 E 2018 Nordson Corporation...

Page 178: ...on 3 2 Operation 4 1 European Union ATEX Special Conditions for Safe Use 4 1 System Operation 4 2 Spray Gun Operation 4 2 Changing Presets with the Settings Trigger 4 2 Changing Powder Flow with the S...

Page 179: ...Supply Resistance Test 6 2 Electrode Assembly Resistance Test 6 3 Gun Cable Continuity Test 6 4 Parts 7 1 Introduction 7 1 Reference Documentation 7 1 Spray Gun Parts 7 2 Spray Gun Parts List 7 3 Spra...

Page 180: ...and regulations and are physically capable of performing their assigned tasks Intended Use Use of Nordson equipment in ways other than those described in the documentation supplied with the equipment...

Page 181: ...ces S To prevent injury be aware of less obvious dangers in the workplace that often cannot be completely eliminated such as hot surfaces sharp edges energized electrical circuits and moving parts tha...

Page 182: ...ed S There is a possible ignition potential from the charged human body Personnel standing on a painted surface such as an operator platform or wearing non conductive shoes are not grounded Personnel...

Page 183: ...Safety 1 4 Part 1604869 13 E 2018 Nordson Corporation...

Page 184: ...mp air It is compatible with the following systems S Encore HD Mobile Systems S Encore HD Manual Wall or Rail Mount Systems S Encore Single and Dual Stand Alone S Encore Color on Demandr Systems S Col...

Page 185: ...plicator Input Rating 19 VAC 1 A Output Rating 100 KV 100 A Input Air 6 0 7 6 bar 87 110 psi 5 particulates dew point 10 _C 50 _F Max Relative Humidity 95 non Condensing Ambient Temperature Rating 15...

Page 186: ...grounds All conductive equipment in the spray area must be connected to a true earth ground Powder Spray Gun Pump Control Unit Manual System Controller Gun Cable 6 mm Pattern Air Delivery 4 mm Clear A...

Page 187: ...ontrol fitting on top of the pump control unit 3 Seat the O rings 4 onto the barbed hose adapter 3 Push the barbed end of the hose adapter into the end of the powder hose then plug the adapter into th...

Page 188: ...rounded or poorly grounded equipment can store an electrostatic charge which can give personnel a severe shock or arc and cause a fire or explosion European Union ATEX Special Conditions for Safe Use...

Page 189: ...e Off Spray Gun Interface Settings Trigger Spray Trigger Figure 4 3 Gun Controls Changing Presets with the Settings Trigger 1 See Figure 4 3 Release the spray trigger Presets cannot be changed while t...

Page 190: ...3 Point the gun into the booth and release the spray trigger 2 Press and hold the Purge button The purge will continue as long as you hold the Purge button NOTE If the settings trigger is configured f...

Page 191: ...the gun trigger the gun and record the A output Monitor the A output daily under the same conditions A significant increase in A output indicates a probable short in the gun resistor A significant dec...

Page 192: ...n off the interface in order to prevent accidentally triggering the gun on 2 See Figure 4 4 Unscrew the nozzle nut counterclockwise 3 Pull the flat spray nozzle off the electrode assembly NOTE Re inst...

Page 193: ...er and the nozzle See Figure 4 6 A Unscrew the nozzle nut counterclockwise and remove it Pull the flat spray nozzle off the electrode assembly B Remove the tapered flat spray electrode holder Do not b...

Page 194: ...e to prevent accidentally triggering the gun on 2 Gently pull the deflector off the electrode holder If only changing the deflector install the new one on the electrode holder being careful not to ben...

Page 195: ...ctrode holder Deflector Conical Electrode Assembly Pattern Adjuster Kit Conical Electrode Holder Figure 4 8 Pattern Adjuster Kit Installation Shutdown 1 Purge the spray gun by pressing the Purge butto...

Page 196: ...mpact fusion 4 Rinse all parts in clean water and dry before re assembling the spray gun Inspect the O rings and replace any that are damaged NOTE Do not use sharp or hard tools that will scratch or g...

Page 197: ...Operation 4 10 Part 1604869 13 E 2018 Nordson Corporation...

Page 198: ...w of Spray Gun item numbers in this section match item numbers in parts list 1 Nozzle nut 2 Nozzle flat spray 3 Electrode assembly flat spray 4 Outlet tube kit 5 Elbow 6 Power supply body kit 7 Filter...

Page 199: ...carefully clean the trigger switch header mounting surface and surrounding area with isopropyl alcohol Allow the surface to dry completely before proceeding 2 If you are installing a new trigger swit...

Page 200: ...orporation 12 13 10 11 Adhesive Support Pad Switch Header Remove 2 liners new switch 13 Display Module and Cable J3 Connectors A Figure 5 2 Display Module Replacement 10 Display module 11 Hook 12 Beze...

Page 201: ...small screwdriver into the recess in the J2 gun cable power supply connectors to release the catch and disconnect them 4 See Figure 5 3 Remove the black nylon screw 29 from the gun body 5 Grasp the h...

Page 202: ...k to the bulkhead with pressure sensitive adhesive 6A 29 9 8 6B Figure 5 4 Removing the Power Supply from the Gun Body 3 Slide the new power supply into the upper cavity of the gun body guiding the gu...

Page 203: ...interiors are worn or coated with impact fused powder If re using the tubes make sure the O rings are undamaged Powder Path Installation 1 See Figure 5 5 Install the outlet tube 4 into the gun body 6B...

Page 204: ...018 Nordson Corporation 17 7 24 6B 4 21 20 5 25 17 Figure 5 5 Powder Path Replacement 4 Outlet tube kit 5 Elbow 6B Gun body 7 Filter assembly 17 Ground pad 20 Handle base 21 M3 x 20 screws 24 Inlet tu...

Page 205: ...elbow then push on the tube to seat it in the elbow 3 Connect the power supply harness to the gun cable then tuck both through the bottom hole in the bulkhead into the gun body 4 See Figure 5 2 Instal...

Page 206: ...6 See Figure 5 7 View B Remove the M3 x 8 screw lock washer 16 15 and ground terminal from the ground pad 7 Remove the retaining ring 18 from the cable 8 See Figure 5 7 View C Pull the cable connector...

Page 207: ...st the handle and ground pad and tighten securely the two M3 x 20 screws 21 in the base 7 Re install the M3 x 35 screw 13 in the bottom of the display module Trigger Switch Replacement Switch Removal...

Page 208: ...your finger up and down on the switch to ensure it is securely adhered to the handle 4 Install the purge trigger 28 into the spray trigger 27 with the gusset oriented upward as shown Do not install t...

Page 209: ...Repair 5 12 Part 1604869 13 E 2018 Nordson Corporation...

Page 210: ...repairs to the controller or spray gun shut off system power and disconnect the power cord Shut off the compressed air supply to the system and relieve the system pressure Failure to observe this war...

Page 211: ...nce falls outside this range replace the power supply NOTE There are multiple variables that can affect the Meg Ohm readings of your meter temperature and measurement voltage If the Meg Ohm meter outp...

Page 212: ...megohm meter to measure the resistance of the electrode assembly from the contact ring on the back to the antenna wire in the front The resistance should be 19 21 megohms If the resistance is out of...

Page 213: ...J1 2 J1 3 J1 4 J1 5 J1 6 FEEDBACK GND BRAIDED SHIELD GRN WHT CABLE GND GRN BLK RED J2 2 J2 1 RED BLK ORG BLU WHT J3 1 J3 2 YEL J3 3 12V ORG J2 3 FEEDBACK YEL BLU J1 1 ORANGE J1 3 RED J1 6 GREEN J1 5 Y...

Page 214: ...nd options for the Encore HD manual powder spray gun Reference Documentation For additional information related to other components in the system reference the following documentation Document Title D...

Page 215: ...Gun Parts See Figure 7 1 and the parts list on the following pages 1 32 32A 34 33 31 3A 3B 3 4 4A 4B 5 2 6 6 7 8 9 4 4 4 4 17 15 16 18 19 19A 24B 24 24 24C 24D 21 20 24A 22 23 25 26 27 28 29 30 14 Fi...

Page 216: ...W pan head recessed M3 x 35 BZN 2 14 1101872 S KIT trigger switch Encore HD 1 NS 1085631 S S SUPPORT adhesive handgun Encore 1 15 983520 S WASHER lock internal M3 zinc 1 16 982427 S MACHINE SCREW pan...

Page 217: ...r to the following pages for optional nozzles B This O ring is a component of all deflectors C Order in increments of one foot or one meter D Also available in wear resistant material Refer to Spray G...

Page 218: ...Lighten is an 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 Fin...

Page 219: ...with the spray gun All other flat spray nozzles are optional 1081656 2 5 mm Flat Spray 1081657 3 mm Flat Spray 1081658 4 mm Flat Spray 1081659 6 mm Flat Spray Figure 7 3 Flat Spray Nozzles Cross Cut N...

Page 220: ...cription Note 1102872 NOZZLE corner spray Encore Figure 7 5 45 Degree Corner Spray Nozzle 45 Degree In Line Flat Spray Nozzle See Figure 7 6 Spray Pattern Narrow fan pattern in line with spray gun axi...

Page 221: ...083201 16 mm Deflector 1083205 19 mm Deflector 1083206 26 mm Deflector 1083207 38 mm Deflector All deflectors include a 1098306 O ring Viton 3 mm x 1 1 mm wide Figure 7 7 Conical Nozzle and Deflectors...

Page 222: ...2 1106078 S ELECTRODE 1 3 1605861 S ELECTRODE HOLDER Conical 1 A NOTE A The conical nozzle requires a different style electrode holder than what is used in the flat spray nozzle electrode assembly XD...

Page 223: ...he instruction sheet shipped with the lance extensions for installation instructions and repair parts NOTE A conical electrode holder is required for use with conical deflectors and lance extensions S...

Page 224: ...F 1606695 Clear powder hose 6 mm ID x 8 mm OD polyurethane by 500 ft C F 900617 Air tubing polyurethane 4 mm clear electrode air wash A 900742 Air tubing polyurethane 6 mm blue pattern air A 1096789...

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Page 226: ...RDSON CORPORATION AMHERST OHIO USA For parts and technical support call the Finishing Customer Support Center at 800 433 9319 Check http emanuals nordson com finishing for the latest version This docu...

Page 227: ...assembly 19 Pump Assembly 21 Pinch Valve Replacement 23 Pinch Valve Removal 23 Pinch Valve Installation 23 Parts 26 Pump 26 Spare Parts 28 Air and Powder Tubing Part Numbers 29 Contact Us Nordson Corp...

Page 228: ...Change Record i Part 1605708 02 E 2018 Nordson Corporation Change Record Revision Date Change 01 11 17 New publication 02 3 18 Added CE mark and new DOC14045 01 02 12 18 1093557 was 1903557...

Page 229: ...Change Record ii Part 1605708 02 E 2018 Nordson Corporation...

Page 230: ...aged parts S using unapproved auxiliary equipment S operating equipment in excess of maximum ratings Regulations and Approvals Make sure all equipment is rated and approved for the environment in whic...

Page 231: ...rements for Class II Division 1 or 2 Hazardous Locations Refer to NFPA 33 NFPA 70 NEC articles 500 502 and 516 and NFPA 77 latest conditions S All electrically conductive objects in the spray areas sh...

Page 232: ...valves molded Y blocks and standard porous tubes S High flow pump HD is the same as a standard pump except for high flow spacing block and high flow porous tubes S Extreme duty pump XD is the same as...

Page 233: ...face between the pinch valves and the porous tubes consists of two Y shaped passages that join the inlet and outlet branches of either half of the pump 5 Pinch Valves Open and close to allow powder to...

Page 234: ...Out See Figure 4 The right suction pinch valve is closed while the right delivery pinch valve is open Positive air pressure is applied to the right porous fluidizing tube which dispenses the powder o...

Page 235: ...ure and building up to maximum pump assist pressure The air dispenses powder out of both fluidizing tubes through the powder suction tubing and back into the powder feed source Stages 3 and 4 Hard Pur...

Page 236: ...re 7 The Encore High Density powder Low Volume air HD powder feed pump transports precise amounts of powder from a feed source to a powder spray gun The pump control manifold controls the air flow in...

Page 237: ...Pump operation is controlled by specifying a set point from 0 100 which translates to a percent of flow at the spray gun controller At the pump each set point results in a predefined cycle rate Increa...

Page 238: ...l min 3 6 scfm Operating Air Pressures Pinch Valves 35 psi 2 4 bar Flow Control to pattern air pump assist 85 psi 5 9 bar Vacuum Generator 50 psi 3 5 bar Powder Tubing Size 8 mm OD x 6 mm ID Length Ou...

Page 239: ...bing Flexible Tubing 2 1 3 4 Figure 9 Powder Tubing Installations 1 Lower Y block 2 Barbed tubing adapter 3 Poly tubing 4 Flexible tubing Pump to Cabinet or Panel WARNING Allow only qualified personne...

Page 240: ...ocedure Daily Visual Inspection Pinch Valves Inspect the pinch valve body for signs of powder leakage If powder is seen in the pinch valve body or there are stress cracks in the pinch valves replace t...

Page 241: ...ctive pump check valve Replace the check valves 2 Reduced powder output pinch valves are not opening and closing Defective pinch valve Replace the pinch valves and filter discs Defective solenoid valv...

Page 242: ...ing 6 Air leaking around end cap Multiplier gasket worn Replace the multiplier gasket 7 Powder tubing too stiff Spiral wrap too close to the spray gun Remove any spiral wrap that is within 24 in of th...

Page 243: ...p adapter 8 mm tube fitting loose Tighten the 8 mm tube fitting Pump mount O rings worn Replace the pump mount O rings Refer to your pickup tube instruction sheet or hopper manual for part numbers Pic...

Page 244: ...el less vacuum on one side of pump than the other proceed to Delivery Check procedure S For low vacuum readings less than 8 in Hg on one side of pump or you feel less vacuum on one side of pump than t...

Page 245: ...e the vacuum gauge The correct vacuum reading ranges from 9 14 in Hg If the problem is in the delivery tubing or spray gun 1 Clean or replace the delivery tubing 2 Check the spray gun lock nut O ring...

Page 246: ...troller test mode on by toggling the test mode button The test mode button pressurizes all the air lines to the COD manifold pinch valves If any of the pinch valves are leaking bubbles will appear in...

Page 247: ...pump then relieve the system air pressure and disconnect the purge air tubing Retrofit Pump Standard Pump Figure 12 Removing the purge air tubing 2 Loosen the fluidizing tube access plug and pull the...

Page 248: ...he top of the retrofit pump 1 where applicable 2 See Figure 17 Disconnect the inlet 2 and outlet powder tubing 3 from the bottom of the pump 3 Remove the cabinet mounting hardware securing the pump to...

Page 249: ...itting Caps 2 2 O rings 2 3 Check Valves 2 4 O rings 2 5 Access Plugs 2 6 O rings 2 7 Fluidizing Tubes 2 8 O rings 2 9 Purge Manifold 10 Manifold Gasket 11 Block Seal 12 Upper Y Block 13 Lock Washers...

Page 250: ...h valve housing 8 Refer to Pinch Valve Replacement on Page 23 for assembly procedure 5 7 6 8 Figure 20 Assemble the Pinch Valve Housing 3 Assemble gasket 10 over lower Y block 11 then thread long scre...

Page 251: ...ure 23 Fasten Fluidizing Tubes into Manifold 6 After the pump is assembled completely tighten the long screw to fit all components together completely 7 Mount the pump to the cabinet before assembling...

Page 252: ...kit when you replace the pinch valves Refer to Step 2 of the Pump Assembly procedure Pinch Valve Removal 1 Place the pinch valve body in a padded vise 2 Grasp the bottom flange of a pinch valve with...

Page 253: ...inside the valve body Continue pulling on the insertion tool until the pinch valve pops through the valve body and the tool comes loose Figure 29 Pulling Pinch Valve into Valve Body 4 Pull the pinch...

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Page 255: ...on Corporation Parts Pump To order parts call the Nordson Finishing Customer Support Center at 800 433 9319 or contact your local Nordson representative 9 10 11 6 15 8 7 13 14 1 2 4 5 3 3 4 5 7 12 13...

Page 256: ...Y 1 5 1605568 1605568 1611092 S BLOCK lower Y 1 6 1612795 1612795 1612795 S GASKET manifold 1 7 1057258 1903557 1903557 S KIT fluidizing tube 1 A 8 1605570 1605570 1605570 S KIT check valve 1 A B 9 S...

Page 257: ...217 Includes the following 8 Pinch Valves 8 O Rings 8 Filter Discs Gasket Amber Pinch Valve Kit Extreme Duty Pump 1612218 Includes the following 8 Pinch Valves 8 O Rings 8 Filter Discs Gasket Check Va...

Page 258: ...ethane 6 900740 10 mm Blue Polyurethane 2 173101 8 mm Clear Polyethylene 7 900740 10 mm Blue Polyurethane 3 173101 8 mm Clear Polyethylene 8 900742 6 mm Blue Polyurethane 4 173101 8 mm Clear Polyethyl...

Page 259: ...Encorer HD Pump 30 Part 1605708 02 E 2018 Nordson Corporation This page intentionally left blank...

Page 260: ...1 Nordson Corporation OPERATOR S CARD P N 1605548 01 Encorer HD Powder Spray System with Prodigyr Color on Demandr Figure 1 System Diagram Two Gun System Shown...

Page 261: ...s pointing into the booth Select a new color and touch the START button or touch the START button first then select the new color Color Change with the Foot Pedal Point the gun into the booth or hang...

Page 262: ...creen appears Enter a 6 character label for the color or a 12 character label for the system The labels are retained in memory when the controller is turned off Figure 6 Color Controller Button Label...

Page 263: ...Button Figure 8 Controller Interface The Setpoint icons light to indicate the configured or selected setpoints Setpoints include Select Charge kV mA of Flow and Pattern Air flow rates To select a Pre...

Page 264: ...tting when using powders that are hard to fluidize and that may tend to clump When set to Normal the pump cycle rate varies with the powder flow setting When Fast Flow is enabled the pump cycles at a...

Page 265: ...in blinking indicating a change has been made To save the new settings press the Enter button The preset number will stop blinking indicating the values have been saved 6 To begin production without s...

Page 266: ...ode you cannot set A 1 To set the kV setpoint press the kV button The button LED lights to show that kV is selected 2 Turn the rotary knob to increase or decrease the kV setpoint The setpoint is autom...

Page 267: ...cle operates as follows 1 Manifold Purge The dump valve opens The pump speeds up to 100 of flow to pump the remaining powder out of the manifolds 2 Soft Purge Assist air is directed through the pump a...

Page 268: ...Value 00 Function 01 Value 01 Figure 20 Displaying and Changing Functions Table 1 Function Settings Function Number Function Name F00 Gun Type F01 Fluidizing F02 Display Units F03 Electrostatic Contr...

Page 269: ...es 21 and 22 Press the Mode button until the Flow Mode icon is lit 2 Push the settings trigger up or down to change the flow setpoint This can be done without releasing the spray trigger The powder fl...

Page 270: ...e 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 To turn off controller power shut system power of...

Page 271: ...12 Issued 03 14 Original copyright date 2014 Encore Prodigy Color on Demand Nordson and the Nordson logo are registered trademarks of Nordson Corporation...