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.
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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.......................................

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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.................................

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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.....................................

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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.

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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.

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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
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Part 1102771A E2010 Nordson Corporation