Nordson Encore HD Color-on-Demand User manual

EncorerHD Color-on-Demandr
System
Customer Product Manual
Part 1612313−03
Issued 12/18
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 1612313−02 2018 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 2018. 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, Prodigy, Color-on-Demand, Nordson, and the Nordson logo are
registered trademarks of Nordson Corporation.
nLighten is a trademark of Nordson Corporation.
All other trademarks are the property of their respective owners.

Change Record i
Part 1612313−02
2018 Nordson Corporation
Change Record
Revision Date Change
01 1/18 Released.
02 7/18 Added system numbers to add nLighten option.

Change Record
ii
Part 1612313−02 2018 Nordson Corporation

Table of Contents iii
Part 1612313−02
2018 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.............................................
System Components 2-1....................................
Pump Control Panel 2-3...................................
Manifold Specifications 2-3...............................
Pump Control Panel Components 2-5.....................
HD+ Pump Manifold Components 2-6.....................
Solenoid and Flow Control Valve Functions 2-7............
Color-on−Demand Color Control Panel 2-8...................
Color Change Manifold 2-9..............................
Installation 3-1.............................................
Specifications 3-1...........................................
System Pump Stand Installation 3-1...........................
Controller Installation 3-2....................................
Pump Stand Mounting 3-2.................................
Grounding 3-2...........................................
Connection Diagram (Rear View of System) 3-3................
System Power, Ground, and Spray Gun Controller Connections 3-4
System Air Supply and Spray Gun Air Connections 3-5..........
Encore HD Powder Spray Gun Installation 3-6..................
Color-on-Demand Controller and Foot Switch Connections 3-7....
Ethernet Cable Termination 3-9...............................
Delivery Tubing Installation 3-12...............................
Suction and Dump Tubing Installation 3-13......................
Remote Color Selection and Color Change Start Option 3-14......

Table of Contents
iv
Part 1612313−02 2018 Nordson Corporation
Operation 4-1..............................................
Pump Control Panel Setup and Operation 4-2..................
Manifold and Pump Installation 4-2..........................
Pump Control Board 4-3...................................
Electrical and Pneumatic Connections 4-3.................
Switches and Indicators 4-4.............................
P1 and P2 Pinouts 4-4..................................
Control Board Configuration 4-6..........................
Network Termination 4-6................................
Configuration Procedure 4-7.............................
Air and Powder Tubing Connections 4-8.....................
Operation 4-9............................................
Color-on-Demand Controller Setup and Operation 4-10...........
Screen Map 4-10..........................................
Color Change without Suction Line Purge 4-11................
Button Labeling 4-13.......................................
System Cleaning 4-14......................................
Color Change with Suction Line Purge 4-14...................
Valve Counters 4-15.......................................
System Clock 4-16........................................
Software Version 4-16......................................
Screen Brightness 4-16..................................
Troubleshooting 5-1........................................
Pump Control Panel 5-2.....................................
Color-on-Demand Controller and Control Panel 5-3..............
Inputs 5-4...............................................
Outputs 5-5..............................................
Powder Flow 5-6.........................................
Service Screen 5-6.......................................
Repair 6-1.................................................
Pump Control Panel Repair 6-1...............................
Preparation 6-1..........................................
Flow Control Valve Cleaning 6-2............................
Flow Control Valve Replacement 6-3........................
Solenoid Valve Replacement 6-3...........................
Manifold Installation 6-3...................................
Circuit Board Replacement 6-4.............................
Color-on-Demand Controller and Control Panel Repair 6-4.......
Manifold Repair 6-5.......................................
Repair Procedure 6-5...................................
Dump Valve Repair 6-7....................................

Table of Contents v
Part 1612313−02
2018 Nordson Corporation
Parts 7-1...................................................
Introduction 7-1.............................................
Using the Illustrated Parts List 7-1..........................
System Manuals 7-2........................................
Reference Documentation 7-2..............................
System Numbers 7-2........................................
Single Spray Gun System 7-2..............................
Dual Spray Gun System 7-2...............................
Pump Panel Replacement Parts 7-3...........................
Manifold Parts 7-5...........................................
Manifold 7-5..............................................
Air and Powder Tubing 7-7................................
PCA Replacement Parts 7-8..................................
PCA Replacement Kit 7-8..................................
Color-on-Demand Controller and Control Panel Parts 7-9........
Controller Kit Parts 7-9....................................
Controller Parts 7-11.......................................
Color Change Control Panel Parts 7-13.......................
Control Unit (PLC) Parts 7-15...............................
Ship-With Kit Parts 7-17....................................
Color Change Manifold Parts 7-17............................
Dump Valve Parts 7-19.....................................
System Diagrams 8-1.......................................

Safety 1-1
Part 1612313−02
2018 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
using incompatible materials
making unauthorized modifications
removing or bypassing safety guards or interlocks
using incompatible or damaged parts
using unapproved auxiliary equipment
operating 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 1612313−02 2018 Nordson Corporation
Personal Safety
To prevent injury follow these instructions.
Do not operate or service equipment unless you are qualified.
Do 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.
Keep 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.
Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out,
and tag switches before servicing electrical equipment.
Obtain 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.
To 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.
Do not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
Provide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material MSDS
for guidance.
Do not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent
sparking.
Know 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.
Clean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
Use only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.

Safety 1-3
Part 1612313−02
2018 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.
All 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.
Equipment 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.
There 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.
Operators 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.
Shut off electrostatic power supplies and ground gun electrodes before
making adjustments or cleaning powder spray guns.
Connect 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:
Disconnect and lock out electrical power. Close pneumatic shutoff
valves and relieve pressures.
Identify 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 1612313−02 2018 Nordson Corporation

Description 2-1
Part 1612313−02
2018 Nordson Corporation
Section 2
Description
System Components
The EncoreHD Color-on-DemandSystem has been carefully tested,
inspected, and packaged prior to shipping. Upon receipt, inspect the
shipping materials and components for visible damage. Report any visible
damage immediately to the shipper and to your Nordson representative.
The Encore HD Color-on-Demand system consists of the components
shown in Figure 2-1.
The system pump stand is shipped bolted to a pallet. The spray guns,
controllers, and installation kits are shipped on a separate pallet.

Description
2-2
Part 1612313−02 2018 Nordson Corporation
Encore HD Spray Gun Controller
(One per spray gun)
Color-on-Demand Controller
(One per spray gun)
Color Change Panel
(One per system)
HD+ Pump
(One per spray gun)
Pump Panel
(One per system)
Color Change Manifolds
(Three per spray gun)
Dump Valve
(One per spray gun)
System Pump Stand
(Front view)
System Pump Stand
(Rear view −cover removed)
Encore HD
Manual Spray Gun
Figure 2-1 System Components

Description 2-3
Part 1612313−02
2018 Nordson Corporation
Pump Control Panel
The pump panel is the central electrical and pneumatic enclosure for the
Color-on-Demand system. The pump panel houses the Encore HD+ pump
(high-flow pumps), pump manifolds and control boards, air filter and
pneumatic controls, and DC power supply.
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Manifold Specifications
Output (Maximum) 23.5 kg (52 lb) per hour
Air Consumption
Conveying Air 21−35 l/min (0.75−1.25 scfm)
Spray Gun Pattern Air 6−57 l/min (0.2−4.0 scfm)
Total Consumption 85−170 l/min (3−6 scfm)
Operating Air Pressures
Pinch Valves 2.4−2.75 bar (35−40 psi)
Flow Control
(to air cap/pump assist) 5.9 bar (85 psi)
Vacuum Generator 3.5 bar (50 psi)

Description
2-4
Part 1612313−02 2018 Nordson Corporation
PD7796
Color-on-Demand
Color Control Panel
Encore HD+
Pump 2
Pump Control Panel
Encore HD+
Pump 1
Figure 2-2 Manual Color-on-Demand System Panels
NOTE: On the inside of the pump cabinet, Pump 1 is referred to as
Pump A and Pump 2 is referred to as Pump B.

Description 2-5
Part 1612313−02
2018 Nordson Corporation
Pump Control Panel Components
NOTE: One pump control board (13) controls one pump. If the system has
two pumps, there are two control boards stacked on top of each other.
PD7978
2
3
4
7
6
5
10
13
15
17
18
23
22
21
20
19
24
26
1
8
9
14
16
5
25
11
12
Figure 2-3 Pump Control Panel Components (Dual Pump System Shown)
1. Pump 2 purge valve
2. Pump 1 purge valve
3. Pump 1 control manifold
4. Pump 1
5. Pressure switch
6. 24 Vdc power supply
7. Line filter
8. Power switch
9. Contact block
10. Vacuum generator mufflers
11. Fuse, time delay, 3.15 A
12. Purge pilot manifold/solenoids
13. Pump control board
14. Electrode air wash manifold
assembly
15. Pinch select manifold/solenoids
16. Flow control valve
17. Air filter
18. Air supply ball valve
19. Pinch low regulator/gauge
20. Pinch high regulator/gauge
21. Flow control regulator/gauge
22. Vacuum regulator/gauge
23. Purge regulator/gauge
24. Pump 2
25. Adapter plate
26. Pump 2 control manifold

Description
2-6
Part 1612313−02 2018 Nordson Corporation
Pump Control Panel Components (contd)
For wiring and pneumatic diagrams, refer to the foldouts in the back of this
manual.
For pump repair and parts, refer to the Encore HD Pump manual.
HD+ Pump Manifold Components
The Encore HD+ powder feed pump transports precise amounts of powder
from a feed source to a powder spray gun. The pump manifold controls the
pump air and vacuum flow. The pump control board controls all manifold
functions.
Table 2-1 Manifold Components
Item Description Function
1Solenoid Valves
Control the air flow to the pump during operation.
NOTE: Refer to Solenoid and Control Valve Functions on
page 2-7 to identify each valve’s specific function.
2Pattern Air Flow Control
Valve
Regulates the air pressure to the spray gun’s nozzle, which
shapes the powder spray pattern.
3Pump Air Flow Control Valve Regulates the positive air pressure to the fluidizing tubes,
which dispenses the powder out of the tubes.
4Vacuum Air Solenoid Turns the airflow through the vacuum generator on or off.
5Vacuum Generator Works on the Venturi principle to generate the negative air
pressure required to draw powder into the fluidizing tubes.
23
4
5
1
Figure 2-4 Pump Manifold Components

Description 2-7
Part 1612313−02
2018 Nordson Corporation
Solenoid and Flow Control Valve Functions
Figure 2-5 identifies the solenoid and flow control valve functions and the
corresponding ports on the pump and manifold.>>> 1 <<<
7
8
9
1
23
4
6
5
123456
Figure 2-5 Solenoid and Flow Control Valve Functions
Item Function Item Function
1Left Side Delivery Pinch Valve 6Right Side Delivery Pinch Valve
2Left Side Fluidizing Tube 7Vacuum Air (Bottom of Manifold)
3Left Side Suction Pinch Valve 8Pattern Air Flow Control
4Right Side Suction Pinch Valve 9Pump Air Flow Control
5Right Side Fluidizing Tube

Description
2-8
Part 1612313−02 2018 Nordson Corporation
Color-on−Demand Color Control Panel
See Figure 2-6. Air and power are supplied to the color control panel from
the pump control panel.
PD7796
PLC
Manifold
Purge Valves
Foot Pedal
Pressure Switch
Solenoid
Valves
System
Pressure Switch
Spray
Gun A
Spray
Gun B
Pump
Control Boards
Figure 2-6 System Control Panels (Dual Spray Gun System)