Nordson Encore HD Reference guide

EncorerHD Pump Control Unit and
Power Supply
Customer Product Manual
Part 1606783-06
Issued 6/19
NORDSON CORPORATION •AMHERST, OHIO •USA
For parts and technical support, call the Industrial Coating
Systems Customer Support Center at [phone] or
contact your local Nordson representative.
This document is subject to change without notice.
Check http://emanuals.nordson.com for the latest version
and available local languages.

Part 1606783−06 E2019 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 2015. 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.
All other trademarks are the property of their respective owners.

Table of Contents i
Part 1606783−06
E2019 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...............................................
Description 2-1.............................................
Introduction 2-1.............................................
Specifications 2-2...........................................
Pump Control Unit Certification Label 2-4....................
Encore HD Pump 2-5.......................................
HD Pump Components 2-6................................
Theory of Operation 2-8...................................
Pumping 2-8..........................................
Purging 2-10...........................................
Pump Control Manifold Components 2-12.....................
Installation 3-1.............................................
Wall/Rail Mount Systems 3-1.................................
Pump Control Unit Mount 3-1..............................
Interconnect Cable Connection 3-3.........................
System Connections 3-4.....................................
System Diagram 3-4......................................
Pump Control Unit Connections 3-6.........................
Spray Gun Connections 3-7...............................
Spray Gun Cable 3-7...................................
Air Tubing and Powder Tube 3-8.........................
Bundling Tubing and Cable 3-9..........................
Main System Air and Electrical Connections 3-10..............
Main System Air Supply 3-10.............................
Standalone, Rail Mount, and Wall Mount System Air Supply ........
3-11
Encore HD Powder Pump Hose 3-12.........................
Standard 8-mm OD Poly Tubing 3-12......................
Flexible 8-mm OD Tubing 3-12............................
Pump Adapter Installation 3-13..............................
Electrical Connections 3-14.................................
System Ground 3-14.........................................
Mobile Systems 3-14.......................................
Wall / Rail Mount Systems 3-14.............................

Table of Contents
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Part 1606783−06 E2019 Nordson Corporation
Operation 4-1..............................................
European Union, ATEX, Special Conditions for Safe Use 4-1......
Maintenance 4-2............................................
Troubleshooting 5-1........................................
Pump Troubleshooting 5-2...................................
Pump Port Functions 5-3..................................
Manifold Troubleshooting 5-4.................................
Solenoid and Flow Control Valve Functions 5-5...............
Re-Zero Procedure 5-6......................................
Controller Interconnect Cable Test 5-6.........................
Repair 6-1.................................................
Removing Panel Assembly 6-2............................
Sub-Panel Components 6-3................................
Regulator Adjustment 6-3.................................
iFlow Module Repair 6-4...................................
Testing iFlow Modules 6-4...............................
Solenoid Valve Replacement 6-5.........................
Proportional Valve Cleaning 6-5..........................
Proportional Valve Replacement 6-5......................
Vibrator Motor Replacement 6-7............................
Fluidizing Tube Replacement 6-8...........................
Pump Disassembly 6-10....................................
Pump Assembly 6-12......................................
Pinch Valve Replacement 6-15..............................
Pinch Valve Removal 6-15................................
Pinch Valve Installation 6-16..............................
Parts 7-1...................................................
Introduction 7-1.............................................
Using the Illustrated Parts List 7-1..........................
Pump Control Unit 7-2.......................................
Panel Assembly 7-4......................................
iFlow Module 7-6.........................................
Manifold Assembly 7-7....................................
Pump 7-9................................................
Spare Parts 7-11........................................
Wall/Rail Mount System 7-12................................
Powder Hose and Air Tubing 7-12...........................
Miscellaneous Options 7-13.................................
Wiring Diagrams 8-1........................................

Change Record i
Part 1606783−06
E2019 Nordson Corporation
Change Record
Revision Date Change
01 10/15 New release
02 03/16 Updated gaskets.
04 1/18 Updated for new Encore HD pump information.
05 11/18 Replacing part number 1606690 with 1615026
06 6/19 Update part lists for pump control, panel assembly, manifold assembly,
pump, spare parts, powder hose and air tubing.

Change Record
ii
Part 1606783−06 E2019 Nordson Corporation

Safety 1-1
Part 1606783−06
E2019 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
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Part 1606783−06 E2019 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 Safety Data Sheets (SDS) 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 SDS
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 1606783−06
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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
1-4
Part 1606783−06 E2019 Nordson Corporation

Description 2-1
Part 1606783−06
E2019 Nordson Corporation
Section 2
Description
Introduction
See Figure 2-1. This manual covers the EncoreRHD pump control unit,
which is used to supply power and to operate Encore HD manual powder
spray systems.
The pump control unit comes equipped with a Encore HD powder feed
pump. The unit contains the pneumatic circuit, which controls all pump,
color change, and vibratory box feed (VBF) functions.
Encore HD Encore HD+, XD
Figure 2-1 Encore HD Pump Control Unit

Description
2-2
Part 1606783−06 E2019 Nordson Corporation
Specifications
Model: Encore HD Controller Power Unit
Input Rating: 100−240 VAC, 50/60 Hz, 125 VA
Output Rating: 24 VDC, 2.5 A
Input Air: 6.0−7.6 bar (87−110 psi),
<5μparticulates,
dew point <10 _C (50 _F)
Max Relative Humidity: 95% non-Condensing
Ambient Temperature Rating: +15 to +40 _C
(59−104 _F)
Hazardous Location Rating for
Controls:
Zone 22 or Class II, Division 2
Dust Ingress Protection: IP6X
Dimensions −See Figure 2-2 and -3.
Model: Encore HD, HD+, XD Pump
Maximum Output HD: 80 lb/hour (600 g/min.)
Maximum Output HD+, XD: 100 lb/hour (750 g/min.)
Air Consumption
Conveying Air: 12.5−31 l/min
(0.438−1.1 scfm)
Gun Pattern Air 6−57 l/min (0.2−2.0 scfm)
Total Consumption 85−170 l/min (3−6 scfm)
Operating Air Pressures
Pinch Valves: 35 psi (2.4 bar) Do Not Adjust
Flow Control (to pattern air/pump
assist):
85 psi (5.9 bar) Do Not Adjust
Vacuum Generator: 50 psi (3.5 bar) Do Not Adjust
Powder Tubing
Size: 8 mm OD x 6 mm ID
Length: Output: 20 m (60 ft)
Input 1−3 m (3.5−12 ft)
Dimensions −See Figure 2-4.

Description 2-3
Part 1606783−06
E2019 Nordson Corporation
179 mm
(7.0 in.) 296 mm
(11.6 in.)
318 mm
(12.9 in.)
375 mm
(14.8 in.)
304 mm
(11.9 in.)
217 mm
(8.6 in.)
Figure 2-2 Encore HD Controller Power Unit Dimensions
304 mm
(11.9 in.)
375 mm
(14.8 in.)
179 mm
(7.0 in.) 296 mm
(11.6 in.)
217 mm
(8.6 in.)
370 mm
(14.5 in.)
Figure 2-3 Encore HD+, XD Controller Power Unit Dimensions

Description
2-4
Part 1606783−06 E2019 Nordson Corporation
70mm
(2.75 in.)
189mm
(7.44 in)
25mm
(0.97 in.)
233mm
(9.19 in.)
79mm
(3.10 in.)
79mm
(3.10 in.)
282mm
(11.10 in.)
70mm
(2.75 in.)
74mm
(2.89 in.)
79mm
(3.11 in.)
77mm
(3.03 in.)
237mm
(9.34 in.)
Encore HD Encore HD+ and XD
(HD+ Stamped on Encore HD+)
Figure 2-4 Encore Pump dimensions
Pump Control Unit Certification Label
1606121_02

Description 2-5
Part 1606783−06
E2019 Nordson Corporation
Encore HD Pump
See Figure 2-1. The Encore HD (High-Density powder, Low-Velocity air)
powder feed pump transports precise amounts of powder from a feed
source to a powder spray gun.
The design of the pump and the small diameter powder tubing used allow
powder to be purged quickly and thoroughly for fast color changes.
The pump is more efficient than traditional venturi-style pumps in that a very
little amount of air is used to operate the pump and carry the powder to the
spray gun.
The standard-flow pump is designed to deliver approximately 550 grams/
minute (72 lb/hour). For applications requiring higher flow rates, install a
high flow pump for additional capacity up to 750 grams/minute (100
lb/hour). Refer to Parts section for kit part number.
NOTE: The total powder output may vary depending on fluidized density
and powder specific gravity.
Encore HD+ Encore HD Encore XD
Figure 2-1 Encore HD Pump

Description
2-6
Part 1606783−06 E2019 Nordson Corporation
HD Pump Components
See Figure 2-2.
Item Description Function
1Purge Air Fittings and
Check Valves
Route high pressure purge air through the pump. Check valves
prevent powder contamination of the purge valves.
2Fluidizing Tubes Porous cylinders that draw powder into the pump when a
vacuum is applied, and force powder out of the pump when air
pressure is applied.
3Purge Manifold Contains the fluidizing tubes, check valves, and air passages.
4Upper Y Block Interface 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.
5Pinch Valves Open and close to allow powder to be drawn in or dispensed out
of the fluidizing tubes.
6Pinch Valve Body Houses the pinch valves. Made from clear plastic to easily
inspect the pinch valves for wear and tear.
7Lower Y Block Connect the inlet and outlet fittings to the pinch valves on either
half of the pump.
8Inlet Fitting Connects to the tubing leading from the power source
9Outlet Fitting Connects to the tubing leading to the powder spray gun

Description 2-7
Part 1606783−06
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1
5
3
9
4
8
2
7
6
Encore HD Pump
1
2
3
4
7
9
Encore HD+, XD Pump
5
6
8
Figure 2-2 Encore Pump Components

Description
2-8
Part 1606783−06 E2019 Nordson Corporation
Theory of Operation
Pumping
The Encore HD pump consists of two halves that function identically. The
halves alternately draw powder in and dispense powder out of the pump;
while one half is drawing powder in, the other half is dispensing powder out.
Left Half Drawing Powder In
See Figure 2-3 View A.
The left suction pinch valve is open, while the left delivery pinch valve is
closed. Negative air pressure is applied to the left porous fluidizing tube,
which draws powder in the inlet fitting, up the left side of the inlet
manifold wear block, through the left suction pinch valve, and into the left
fluidizing tube.
After the negative air pressure has been on for the specified time, the
fluidizing tube’s negative air pressure shuts off and the left suction pinch
valve closes.
Right Half Dispensing Powder Out
See Figure 2-3 View B.
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 out of the fluidizing tube,
down the right delivery pinch valve, down the right side of the outlet
manifold wear block, out the delivery fitting, and out to the tubing that
leads to the powder spray gun.
As the sides complete these processes, they alternate. In the example
explained above, the left half would now dispense powder out while the right
half would draw powder in.
As each half dispenses powder out, the powder in the tubing blends
together, resulting in a consistent flow of powder from the spray gun.

Description 2-9
Part 1606783−06
E2019 Nordson Corporation
View A View B
Left Side Drawing In
Right Side Dispensing
Left Side Dispensing
Right Side Drawing In
L R
R
L
Left half
suction
valve
open
Right half
delivery
valve
open
Air
Powder
Out
Powder
In
Air
Powder
Out
Powder
In
L
R
RL
Right half
suction
valve
open
Left half
delivery
valve
open
Figure 2-3 Operation of Pump (Shown as rear, right view of the pump)

Description
2-10
Part 1606783−06 E2019 Nordson Corporation
Purging
See Figure 2-4. When the operator initiates a color change, the pump goes
through a three-stage purge process.
Stage 1:Soft Purge to Spray Gun
The suction pinch valves close, while the delivery pinch valves remain open.
Pump assist air pressure turns on, starting at a low pressure and building up
to maximum pump assist pressure. The air dispenses powder out of both
fluidizing tubes, through the powder delivery tubing and spray gun and out
into the booth.
Stage 2: Soft Purge to Feed Source
The suction pinch valves are open, while the delivery pinch valves close.
Pump assist air pressure turns on, starting at a low pressure 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.
Stage 3: Hard Purge to Spray Gun and Feed Source
The delivery pinch valves open. Pump assist air pressure turns on at
maximum pressure, while pulses of line air pressure are sent down the
purge air fittings at the tops of the fluidizing tubes. The pulses of air remove
any powder that remains in the pump, spray gun, and suction and delivery
tubing.
After the delivery side is purged, the delivery pinch valves close and the
suction pinch valves open. The suction side is purged in the same way as
the delivery side.