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

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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
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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