Encore 1102771A Reference guide

EncorerMobile Powder Spray
System with Feed Hopper
Customer Product Manual
Part 1102771A
Issued 6/10
NORDSON CORPORATION AMHERST, OHIO USA
For parts and technical support, call the
Finishing Customer Support Center at [phone].
Check http://emanuals.nordson.com/finishing for the latest version.
This document is subject to change without notice.
C
APPROVED
US
FM

Part 1102771A E2010 Nordson Corporation
Contact Us
Nordson Corporation welcomes requests for information, comments, and
inquiries about its products. General information about Nordson can be
found on the Internet using the following address:
http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
555 Jackson Street
Amherst, OH 44001
Notice
This is a Nordson Corporation publication which is protected by copyright.
Original copyright date 2009. No part of this document may be
photocopied, reproduced, or translated to another language without the
prior written consent of Nordson Corporation. The information contained
in this publication is subject to change without notice.
Trademarks
Encore, iFlow, Nordson, and the Nordson logo are registered trademarks
of Nordson Corporation.

Table of Contents i
Part 1102771A
E2010 Nordson Corporation
Table of Contents
Safety 1-1..................................................
Introduction 1-1.............................................
Qualified Personnel 1-1......................................
Intended Use 1-1...........................................
Regulations 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...............................................
System Setup 2-1..........................................
Introduction 2-1.............................................
Specifications 2-2........................................
Applicator Certification Label 2-2.........................
Power Unit and Gun Interface Controllers
Certification Label 2-2..................................
System Connections 2-3.....................................
System Diagram 2-3......................................
Controller Connections 2-3................................
Hopper Installation 2-5......................................
Pump Installation 2-6........................................
Pump Mounting 2-6.......................................
Pump Connections 2-7....................................
Spray Gun Connections 2-8..................................
Gun Cable 2-8...........................................
Spray Gun Air Tubing Connections 2-9......................
Spray Gun Powder Tubing Connection 2-10...................
Bundling Tubing and Cable 2-10.............................
System Air and Electrical Connections 2-11.....................
System Air Supply 2-11....................................
Electrical Connections 2-12.................................
System Ground 2-12.......................................

Table of Contents
ii
Part 1102771A E2010 Nordson Corporation
Operation 3-1..............................................
European Union, ATEX, Special Conditions for Safe Use 3-1.....
Daily Operation 3-1.........................................
Startup 3-1..............................................
Factory Set Presets 3-2...................................
Spray Gun Operation 3-3..................................
Changing Presets with the Settings Trigger 3-3.............
Changing Powder Flow with the Settings Trigger 3-3........
Purging the Gun 3-3....................................
Standby Button 3-4.......................................
Electrode Air Wash Operation 3-4..........................
Changing Flat Spray Nozzles 3-4...........................
Changing Deflectors or Conical Nozzles 3-5..................
Installing the Optional Pattern Adjuster Kit 3-6................
Shutdown 3-6...............................................
Maintenance 3-7............................................
Using the Controller Interface 3-8.............................
Help Codes 3-9.............................................
Maintenance Timer, Configuration, and Versions 3-9.............
Preset Setup 3-10...........................................
Selecting Presets 3-10.....................................
Electrostatic Settings 3-10....................................
Select Charger Mode 3-10..................................
Custom Mode 3-11........................................
Classic Mode 3-11.........................................
Classic Standard (STD) Mode 3-11........................
Classic AFC Mode 3-12..................................
Powder Flow Settings 3-13....................................
Smart Flow Mode Settings 3-13.............................
Setting Smart Flow Setpoints 3-14.........................
Smart Flow Settings -- Metric Units 3-15....................
Smart Flow Settings -- English Units 3-16...................
Classic Flow Mode Settings 3-17............................
Controller Configuration 3-17..................................
Opening the Function Menu and Making Settings 3-17.........
Vibratory Box Feeder On Continuously 3-18...................
Saving and Loading Preset and Function Settings 3-19.........
Setting the Number of Presets 3-19..........................
Troubleshooting 4-1........................................
Help Code Troubleshooting 4-1...............................
Viewing Help Codes 4-1...................................
Clearing Help Codes 4-1..................................
Help Code Troubleshooting Chart 4-2.......................
General Troubleshooting Chart 4-5............................
Re-Zero Procedure 4-9....................................
Spray Gun Power Supply Resistance Test 4-10..................
Electrode Assembly Resistance Test 4-10.......................
Gun Cable Continuity Test 4-11................................
Controller Interconnect Cable Test 4-11.........................
System Wiring Diagrams 4-12.................................

Table of Contents iii
Part 1102771A
E2010 Nordson Corporation
Repair 5-1.................................................
Spray Gun Repair 5-1.......................................
Display Module Replacement 5-1...........................
Display Module Removal 5-1............................
Display Module Installation 5-1...........................
Power Supply Replacement 5-3............................
Power Supply Removal 5-3..............................
Power Supply Installation 5-3............................
Trigger Switch, Gun Cable, and Handle Replacement 5-4......
Gun Disassembly 5-5...................................
Gun Re-assembly 5-8..................................
Interface Module Repair 5-12..................................
Power Unit Repair 5-13.......................................
Removing the Sub Panel 5-13..............................
Sub Panel Components 5-14................................
Regulator Replacement 5-14................................
iFlow Module Repair 5-15...................................
Testing iFlow Modules 5-15...............................
Flow to Pressure Chart 5-17..............................
Solenoid Valve Replacement 5-17.........................
Proportional Valve Cleaning 5-17..........................
Proportional Valve Replacement 5-19......................
Parts 6-1...................................................
Introduction 6-1.............................................
System Part Numbers 6-1...................................
Spray Gun Parts 6-2........................................
Spray Gun Options 6-5......................................
Miscellaneous Spray Gun Options 6-5.......................
Flat Spray Nozzles 6-5....................................
Conical Nozzle and Deflectors 6-6..........................
Optional Cross Cut Nozzles 6-6............................
Optional Pattern Adjuster Kit 6-7...........................
Controller Parts 6-8.........................................
Interface Parts Exploded View 6-8..........................
Interface Parts List 6-9....................................
Power Unit Parts Exploded View 6-10........................
Power Unit Parts List 6-11..................................
iFlow Module Parts 6-12....................................
System Components and Parts 6-13...........................
Powder Hose and Air Tubing 6-13...........................
Options 6-14..............................................
Pump Parts 6-14..........................................
Pump Adapter Kit 6-14.....................................

Table of Contents
iv
Part 1102771A E2010 Nordson Corporation

Safety 1-1
Part 1102771A
E2010 Nordson Corporation
Section 1
Safety
Introduction
Read and follow these safety instructions. Task- and equipment-specific
warnings, cautions, and instructions are included in equipment
documentation where appropriate.
Make sure all equipment documentation, including these instructions, is
accessible to all persons operating or servicing equipment.
Qualified Personnel
Equipment owners are responsible for making sure that Nordson equipment
is installed, operated, and serviced by qualified personnel. Qualified
personnel are those employees or contractors who are trained to safely
perform their assigned tasks. They are familiar with all relevant safety rules
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 may result in injury to persons
or damage to property.
Some examples of unintended use of equipment include
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards or interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating equipment in excess of maximum ratings
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which
it is used. Any approvals obtained for Nordson equipment will be voided if
instructions for installation, operation, and service are not followed.
All phases of equipment installation must comply with all federal, state, and
local codes.

Safety
1-2
Part 1102771A E2010 Nordson Corporation
Personal Safety
To prevent injury follow these instructions.
SDo not operate or service equipment unless you are qualified.
SDo not operate equipment unless safety guards, doors, or covers are
intact and automatic interlocks are operating properly. Do not bypass or
disarm any safety devices.
SKeep clear of moving equipment. Before adjusting or servicing any
moving equipment, shut off the power supply and wait until the
equipment comes to a complete stop. Lock out power and secure the
equipment to prevent unexpected movement.
SRelieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
SObtain and read Material Safety Data Sheets (MSDS) for all materials
used. Follow the manufacturer’s instructions for safe handling and use
of materials, and use recommended personal protection devices.
STo 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 that cannot be
enclosed or otherwise guarded for practical reasons.
Fire Safety
To avoid a fire or explosion, follow these instructions.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SProvide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material MSDS
for guidance.
SDo not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
SKnow where emergency stop buttons, shutoff valves, and fire
extinguishers are located. If a fire starts in a spray booth, immediately
shut off the spray system and exhaust fans.
SClean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
SUse only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.

Safety 1-3
Part 1102771A
E2010 Nordson Corporation
Grounding
WARNING: Operating faulty electrostatic equipment is hazardous and can
cause electrocution, fire, or explosion. Make resistance checks part of your
periodic maintenance program. If you receive even a slight electrical shock
or notice static sparking or arcing, shut down all electrical or electrostatic
equipment immediately. Do not restart the equipment until the problem has
been identified and corrected.
Grounding inside and around the booth openings must comply with NFPA
requirements 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.
SAll electrically conductive objects in the spray areas shall be electrically
connected to ground with a resistance of not more than 1 megohm as
measured with an instrument that applies at least 500 volts to the circuit
being evaluated.
SEquipment to be grounded includes, but is not limited to, the floor of the
spray area, operator platforms, hoppers, photoeye supports, and
blow-off nozzles. Personnel working in the spray area must be
grounded.
SThere 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 must
wear shoes with conductive soles or use a ground strap to maintain a
connection to ground when working with or around electrostatic
equipment.
SOperators must maintain skin-to-handle contact between their hand and
the gun handle to prevent shocks while operating manual electrostatic
spray guns. If gloves must be worn, cut away the palm or fingers, wear
electrically conductive gloves, or wear a grounding strap connected to
the gun handle or other true earth ground.
SShut off electrostatic power supplies and ground gun electrodes before
making adjustments or cleaning powder spray guns.
SConnect all disconnected equipment, ground cables, and wires after
servicing equipment.
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
SDisconnect and lock out electrical power. Close pneumatic shutoff
valves and relieve pressures.
SIdentify the reason for the malfunction and correct it before restarting the
equipment.
Disposal
Dispose of equipment and materials used in operation and servicing
according to local codes.

Safety
1-4
Part 1102771A E2010 Nordson Corporation

System Setup 2-1
Part 1102771A
E2010 Nordson Corporation
Section 2
System Setup
Introduction
See Figure 2-1. The Encore Mobile Powder Spray System is a complete
manual powder spray system mounted on a sturdy four-wheel cart. The
system includes a manual spray gun, two-piece controller, powder pump
and pick-up tube, 25- or 50-lb (11.3- or 22.7-kg) powder feed hopper, and all
powder and air tubing required for operation.
Follow the procedures in this section to prepare the system for operation.
4
2
1
6
5
3
Figure 2-1 Encore Mobile Powder Spray System with Powder Feed Hopper
1. Encore spray gun
2. Powder feed hopper
3. Cart tower
4. Encore powder feed pump
5. Fluidizing air regulator
6. Spray gun controller
Note: Power unit portion of controller is installed in rear of cart tower.

System Setup
2-2
Part 1102771A E2010 Nordson Corporation
Specifications
Model Input Rating Output Rating
ENCORE Applicator +/-- 19 VAC, 1 A 100 KV, 100 A
ENCORE Interface Control Unit 24 VDC, 2.75 A +/-- 19 VAC, 1A
ENCORE Controller Power Unit 100--240 VAC, 50/60 Hz, 85 VA 24 VDC, 2.75 A
SInput Air: 6.0--7.6 bar (87--110 psi), <5particulates, dew point <10 _C
(50 _F)
SMax Relative Humidity: 95% non-Condensing
SAmbient Temperature Rating (Encore System): +15 to +40 _C
(59--104 _F)
SHazardous Location Rating for Applicator: Zone 21 or Class II, Division 1
SHazardous Location Rating for Controls: Zone 22 or Class II, Division 2
SDust Ingress Protection: IP6X
SHopper Capacity: 11.3 or 22.7 kg (25 or 50 lb)
Applicator Certification Label
CUS
APPROVED
Power Unit and Gun Interface Controllers Certification
Label
ELECTROSTATIC HAND--HELD POWDER
SPRAY EQUIPMENT TYPE ENCORE
NORDSON CORPORATION, AMHERST, OHIO U.S.A.
DO NOT OPEN WHEN EXPLOSIVE ATMOSPHERE IS PRESENT
INTERFACE OUTPUT: Vo=19VAC Io=1A
PWR UNIT OUTPUT: Vo=24VDC Io=2.75A
Vn=100--240 VAC, fn = 50/60 Hz
SIRA08ATEX5010XEN 50 050
Pn=85 VA
Ex tD A22 IP6X
Ta: +15_CTO+40_C
T60_C
1180 II 3 (2) D
r

System Setup 2-3
Part 1102771A
E2010 Nordson Corporation
System Connections
System Diagram
NOTE: This diagram does not show system grounds. The system and its
components must all be connected to a true earth ground.
Purge Air
Input Air
Reg
85 PSI
Switch
Fuses
Relay*
Power
Supply
AC Power Cord
Fluidizing Air
Main Control
iFlow Module
CAN/+24V
Air Wash Air
Atomizing Air
Flow-Rate Air
Gun cable
80
20
psi
BAR
10
0
6
7
100
40
23
60
5
4
Fluidizing Air
Gauge and Regulator
6mm black
4mm clear
8mm blue
8mm black
6mm blue
Power Unit
Interface
Module
Hopper
Pump
Spray Gun
Powder hose
6mm blue
Board
* Relay disabled when controller
configured for hopper system
10mm
Filter/Regulator
10mm
Encore Controller
Figure 2-2 Encore Manual Powder System Block Diagram
Controller Connections
The Encore Spray Gun Controller is a two piece unit, consisting of a
interface module and a power unit, connected by a network/power
interconnect cable.
The power unit houses a 24Vdc power supply, circuit board, and iFlowrair
control manifold.
The interface module houses the operator interface panel, which contains
the displays and controls used to make controller function settings and
spray settings, and the spray gun driver board.

System Setup
2-4
Part 1102771A E2010 Nordson Corporation
L1
L2
GND
System Power Switch
Fluidizing Air
Check Valve
(8 mm, reduced to 6-mm)
VBF Power
(Cap if not used)
Net
(Manual System)
or Auxiliary
Purge Air (6 mm)
Air Supply
(10 mm)
Electrode Air Wash
(4 mm)
Electrode Air Wash
Needle Valve
Atomizing Air
(8 mm)
Flow Air
(8 mm)
Ground
Power Cord
(15 ft)
Gun Cable
(to Gun)
Ground
Network/Power
Interconnect
Cable
POWER UNIT
INTERFACE MODULE
(Brown)
(Blue)
(Green/Yellow)
Figure 2-3 Encore Gun Controller Connections

System Setup 2-5
Part 1102771A
E2010 Nordson Corporation
Hopper Installation
1. Unclamp the hopper lid and remove the vent hose and hose clamps.
2. Place the hopper on the cart platform so that the bottom of the fluidizing
pan fits into the cutout in the cart platform.
3. Connect the 10-mm stem x 6-mm tube reducer to the 10-mm elbow
fitting on the fluidizing pan.
4. Connect the 6-mm blue fluidizing air tubing to the reducer.
5. Connect the ring-tong terminal on the 1-ft green/yellow ground cable
shipped with the system to the ground stud on the side of the fluidizing
pan, then plug the cable into the grounding socket on the cart base.
6. Install the hose clamp over the end of the vent hose and connect the
hose to the vent stack on the lid. Tighten the clamp to secure the hose.
NOTE: Before turning on the controller interface, route the other end of the
vent hose into the spray booth. This prevents the very fine powder particles
in the vented fluidizing air from contaminating the spray room.
Fluidizing
Air
Tubing
Vent Stack
Ground
Plug/Socket
Hopper
Fluidizing
Pan
Vent Hose
Ground
Cable
Fluidizing Air
Fitting
Ground Stud
Reducer
Figure 2-4 Hopper Installation

System Setup
2-6
Part 1102771A E2010 Nordson Corporation
Pump Installation
Pump Mounting
CAUTION: Pump adapter O-rings are conductive silicone, to provide a
ground connection between the pump body and the pickup tube or hopper
lid. Do not replace these O-rings with non-conductive O-rings.
The system is shipped with pump adapter for the Encore pump. The
hopper is shipped with a pump adapter used for other types of pumps. To
mount the pump on the hopper:
1. See Figure 2-5. Pull the pickup tube assembly out of the pump mount.
2. Unscrew the adapter from the pickup tube.
3. Screw the new adapter onto the pickup tube.
4. Re-install the pickup tube assembly into the pump mount then install the
pump into the new adapter with a slight twisting motion.
Pickup Tube
Remove
This
Adapter
Replace
With This
Adapter
Figure 2-5 Pump Mounting

System Setup 2-7
Part 1102771A
E2010 Nordson Corporation
Pump Connections
1. Plug the blue atomizing air and black flow-rate air tubing into the pump
tube fittings as shown in Figure 2-6.
2. Push the powder feed hose onto the barbed throat holder.
Quick-Disconnect Coupling
Blue 8-mm Tubing (Atomizing AIr)
Black 8-mm Tubing
(Flow-Rate Air)
Throat Holder
Powder Hose
Figure 2-6 Pump Connections
NOTE: The pump is equipped with quick-connect couplings that allow you
to quickly disconnect the air tubing when cleaning or repairing the pump.
Pull back on the knurled coupling rings to disconnect them.

System Setup
2-8
Part 1102771A E2010 Nordson Corporation
Spray Gun Connections
Unpack the spray gun. Uncoil the spray gun cable and the included 4-mm
clear and 6-mm black air tubing. Make the following connections:
Gun Cable
SeeFigure2-7.
1. Feed the spray gun cable into the back of the tower and up through the
top front. This will allow you to bundle the cable with the purge and
electrode air wash tubing.
2. Connect the cable to the interface module receptacle. The cable plug
and receptacle are keyed.
3. Thread the cable nut onto the receptacle and tighten the nut securely.
Net Cable
(To Power Unit)
Gun Cable
Figure 2-7 Connecting the Gun Cable to the Controller Interface Module

System Setup 2-9
Part 1102771A
E2010 Nordson Corporation
Spray Gun Air Tubing Connections
See Figures 2-8 and 2-9.
Clear 4-mm and black 6-mm air tubing is shipped with the spray gun.
1. Connect the 6-mm black air tubing to the quick-disconnect fitting in the
gun handle.
2. Connect the 4-mm clear electrode air wash tubing to the barbed fitting in
the gun handle.
4-mm Clear
Electrode Air Wash
Tubing
6-mm Black
Purge Air Tubing
Figure 2-8 Connecting Purge and Air Wash Tubing to the Spray Gun
3. Route the air tubing around the cart to the rear of the tower.
4. Connect the 4-mm clear electrode air wash tubing to the electrode air
wash quick-disconnect fitting.
5. Connect the 6-mm black purge air tubing to the purge air
quick-disconnect fitting.
4-mm Clear
Electrode Air
Wash Tubing
6-mm Black
Purge Air Tubing
Figure 2-9 Connecting Purge and Air Wash Tubing to the Controller

System Setup
2-10
Part 1102771A E2010 Nordson Corporation
Spray Gun Powder Tubing Connection
See Figure 2-10.
Push the barbed hose adapter into the end of the powder feed hose, then
plug the adapter into the receptacle in the bottom of the spray gun handle.
Make sure the adapter clips snap into the groove in the receptacle.
(To quickly remove the hose adapter and hose from the gun, press in on the
bottom ends of the clips to release them from the groove.)
Powder Tubing
11-mm or 1/2in.
to Pump
Barbed Hose
Adapter
Press IN on
clips when
installing or
removing
adapter
Make sure clips
are seated in
groove
Figure 2-10 Connecting the Powder Tubing to the Spray Gun
Bundling Tubing and Cable
Use the sections of black spiral wrap supplied with the system to bundle
together the spray gun cable, air tubing, and powder feed tubing.