Nordson Encore HD Reference guide

EncorerHD Pump Module
Customer Product Manual
Part 1613941-01
Issued 03/19
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.

Part 1613941−01 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 2019. 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, Nordson and the Nordson logo are registered trademarks of
Nordson Corporation.
All other trademarks are the property of their respective owners.

Change Record i
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Change Record
Revision Date Change
01 03/19 New release

Change Record
ii
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Table of Contents iii
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Table of Contents
Safety 1.................................................
Qualified Personnel 1...................................
Intended Use 1.........................................
Regulations and Approvals 1.............................
Personal Safety 2.......................................
Fire Safety 2...........................................
Grounding 3...........................................
Action in the Event of a Malfunction 3.....................
Disposal 3.............................................
Description 4............................................
Introduction 4..........................................
Specifications 5.........................................
Installation 7............................................
Standard Pump Module Mount 7..........................
Connections 8..........................................
Installing and Removing the Muffler 8......................
System Ground 8.......................................
Manifold Solenoid Valve Functions 9......................
Manifold Wiring Diagram 10...............................
Maintenance and Repair 11.................................
Troubleshooting 12.......................................
Parts 13..................................................
Using the Illustrated Parts List 13..........................
Pump Module Assembly 14................................
Pump Module Unit 15....................................
Pump Module Manifold 16.................................

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EncorerHD Pump Module
Safety
Read and follow these safety instructions. Task-specific 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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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.

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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. If the malfunction cannot be identified, unplug the unit and
replace with spare unit if available.
Disposal
Dispose of equipment and materials used in operation and servicing
according to local codes.

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Description
Introduction
See Figure 1. This manual covers the EncoreRHD pump module, which
can be used with Encore HD manual powder spray systems and automatic
powder spray systems.
The pump module comes equipped with an Encore HD, HD+ or an XD
powder feed pump. The unit contains the pneumatic circuit, which controls
the pump.
Encore HD Encore HD+
(Encore XD Not Shown)
Figure 1 Encore HD Pump Modules

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Specifications
Model: Encore HD Pump Module
Input Rating: 24 Vdc, 0.5 A
Output Rating: 24 Vdc, 0.5 A
Input Air: 6.0-7.6 bar (87-110 psi)
Max Relative Humidity: 95% non-Condensing
Ambient Temperature Rating: +15_to +40_C
(59_to 104_F)
Dust Ingress Protection: IP6X
Total Consumption 85-170 l/min (3-6 scfm)
Weight (Encore HD Module) 8.2 kg (18 lb)
Weight (Encore HD+, XD Module) 9.1 kg (20 lb)
Sound Level 80 dBA maximum
HD Pump Module with HD Pump Dimensions, See Figure 2
HD Pump Module with HD+ or XD Pump Dimensions, See Figure 3
Model: Encore HD, HD+, XD Pump
For further pump specifications, see Encore HD Pump manual

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319.77 mm
(12.59 in)
285.0 mm
(11.22 in)
160.2 mm
(6.31 in)
125.1 mm
(4.93 in)
310.3 mm
(12.21 in) 290.3 mm
(11.4 in)
220.5 mm
(8.68 in)
225.7 mm
(8.89 in)
207.7 mm
(8.18 in) 227.7 mm
(8.96 in)
184.9 mm
(7.28 in)
266.0 mm
(10.47 in)
100.0 mm
(3.94 in)
Figure 2 Encore HD Pump Module
328.2 mm
(12.92 in)
285.0 mm
(11.22 in)
266.0 mm
(10.47 in)
160.2 mm
(6.31 in)
100.0 mm
(3.94 in)
125.1 mm
(4.93 in)
226.2 mm
(8.91 in)
207.7 mm
(8.18 in)
227.7 mm
(8.96 in)
220.5 mm
(8.68 in)
225.77 mm
(8.89 in)
290.3 mm
(11.43 in)
310.3 mm
(12.59 in)
Figure 3Encore HD+, XD Pump Module Dimensions

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Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Standard Pump Module Mount
Pump Module with Built-In
Mounting Flange
100 mm
(3.94 in)
160.2 mm
(6.31 in)
266.0 mm
(10.47 in)
Figure 4 Standard Pump Module Mount

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Connections
7
6
5
4
Quick Disconnect
3
1
2
Figure 5 Pump Module Points of Connection
1. Purge air (output)
2. Atomizing air (input)
3. Exhaust muffler and connector
4. Ground connection
5. HD control cable connection (input)
6. Main air (input)
7. Flow air (input)
Installing and Removing the Muffler
See Figure 5. The muffler is a quick connect device. To install, press into the
connector. To remove, press in to the connector and pull out.
System Ground
WARNING: All conductive system components in the spray area must be
connected to a true earth ground. Failure to observe this warning could
result in an electrostatic discharge strong enough to cause a fire or
explosion.

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Manifold Solenoid Valve Functions
Figure 6 identifies the flow control valve functions from the manifold on the
pump module. The table below defines the function of each position
identified.
Position Description Function Set Points
(psi−static)
1Right Side Suction Pinch Valve Open and closes pinch valve −−−
2Right Side Delivery Pinch Valve Open and closes pinch valve −−−
3Right Side Fluidizing Tube Alternates negative and positive
air pressure to the pump chamber −−−
4Left Side Fluidizing Tube Alternates negative and positive
air pressure to the pump chamber −−−
5Left Side Delivery Pinch Valve Open and close pinch valve −−−
6Left Side Suction Pinch Valve Open and close pinch valve −−−
7Vacuum Generator Valve Open and closes valve −−−
8Diffuser Purge Air Valve Open and closes valve −−−
9Main Purge Air Valve Open and closes valve −−−
10 Low Pinch Regulator Regulates the low pinch valve
pressure 35 psi
11 High Pinch Regulator Regulates the high pinch valve
pressure 85 psi
Not
Shown
Vacuum Generator (integrated) Works on the venturi principal to
generate the negative air pressure
required to draw powder into the
tubes
−−−
8
9
10
11
7
6
5
4321
1
25
6
7
4
3
3
Figure 6 Pump Module Functions

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Manifold Wiring Diagram
10017618
12
34
5
6
7
89
10
R+
R+R+
R+
R+R+
R+R+
R+
R+
TOP
J28 J2A
4
5
6
7
10
1
2
3
8
9
J1
TO LED IN
UPPER ASSY
Figure 7 Manifold Wiring Diagram
1. Right side suction pinch valve
2. Right side delivery pinch valve
3. Right side fluidizing tube
4. Left side fluidizing tube
5. Left side delivery tube
6. Left side suction pinch valve
7. Vacuum generator valve
8. Diffuser purge air valve
9. Main purge air valve
10. LED blue light indicator

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Maintenance and Repair
NOTE: For pump maintenance or repair, refer to Encore HD Pump manual.
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
WARNING: Before making repairs to the pump module, 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
warning could result in personal injury.
To maintain, troubleshoot, and repair any aspect of the pump, please refer
to the Encore HD Pump manual.
The pump module contains no parts that will need regular maintenance.
For any repair needed to the pump module, contact Nordson Technical
Support at [phone] or your local Nordson representative for further
assistance.

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Troubleshooting
The troubleshooting procedures below cover only the most common
problems. If you cannot solve a problem with the information given here,
contact Nordson technical support at [phone] or your local Nordson
representative for help.
Problem Possible Cause Corrective Action
1. Reduced powder
output (pinch valves
are opening and
closing)
Blockage in the powder tubing to
the spray gun
Check the tubing for blockages.
Purge the pump and spray gun.
Defective pump check valve Replace the check valves. See
Encore HD Pump manual for further
instruction.
2. Reduced powder
output (pinch valves
are not opening and
closing)
Defective pinch valve Replace the pinch valves and filter
discs on pump. See Encore HD
Pump manual for further instruction.
Defective solenoid valve Replace the solenoid valve. Refer to
Manifold and Solenoid Valve
Functions on page 9 to determine
which solenoid valve controls the
affected pinch valve.
Defective pump check valve Replace the check valves. See
Encore HD Pump manual for further
instruction.
3. Reduced powder
input (loss of suction
from feed source)
Blockage in the powder tubing
from the feed source
Check the tubing for blockages.
Purge the pump and spray gun.
Loss of vacuum in the pump Check the pump module exhaust
muffler. If the exhaust muffler
appears blocked, replace it.
See Installation, Connections to see
illustration of installation.
4. No powder flow Defective pump module, cable end
or board
Take apart housing to expose top of
manifold, plug the module into the
controller. Check blue LED light on
manifold and additional blue LED on
outside that indicates pump or gun
down.
If any LED is not lit up, check the
wiring connection.
If all wiring connections are good and
valve(s) are not lit, check cable for
continuity.
If cable continuity is good, replace
valves that are not lit.

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Parts
To order parts, call the Nordson Industrial Coating Systems Customer
Support Center at [phone] or contact your local Nordson
representative.
Using the Illustrated Parts List
Numbers in the Item column correspond to numbers that identify parts in
illustrations following each parts list. The code NS (not shown) indicates
that a listed part is not illustrated. A dash (—) is used when the part number
applies to all parts in the illustration.
The number in the Part column is the Nordson Corporation part number. A
series of dashes in this column (−−−−−−) means the part cannot be ordered
separately.
The Description column gives the part name, as well as its dimensions and
other characteristics when appropriate. Indentions show the relationships
between assemblies, sub−assemblies, and parts.
SIf you order the assembly, items 1 and 2 will be included.
SIf you order item 1, item 2 will be included.
SIf you order item 2, you will receive item 2 only.
The number in the Quantity column is the quantity required per unit,
assembly, or sub−assembly. The code AR (As Required) is used if the part
number is a bulk item ordered in quantities or if the quantity per assembly
depends on the product version or model.
Letters in the Note column refer to notes at the end of each parts list. Notes
contain important information about usage and ordering. Special attention
should be given to notes.
Item Part Description Quantity Note
— 0000000 Assembly 1
1 000000 SSubassembly 2 A
2 000000 SS Part 1

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Pump Module Assembly
Encore HD Encore HD+
(Encore XD Not Shown)
Figure 8 Encore HD Pump Modules
Item Part Description Quantity Note
— 1613916 PUMP MODULE ASSEMBLY, Encore HD, pkg 1
— 1613943 PUMP MODULE ASSEMBLY, Encore HD+, pkg 1
— 1613944 PUMP MODULE ASSEMBLY, Encore XD, pkg 1
NS 1610819 SWRENCH, t-handle, hex drive, 4 mm 1
NS 1614455 SWRENCH, t-handle, hex drive, 3 mm 1
NS: Not Shown