Nordson Encore HD Powder Spray System with Prodigy... Reference guide

EncorerHD Powder Spray System
with ProdigyrColor-on-Demandr
Customer Product Manual
Part 1605396-04
Issued 05/18
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 1605396-04 E2018 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 2014. 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.
All other trademarks are the property of their respective owners.

Change Record i
Part 1605396-04
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Change Record
Revision Date Change
04 05/18 Added power supply cover kit to part list.

Change Record
ii
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Table of Contents iii
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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 2-2...................................
Manifold Specifications 2-3..............................
Pump Control Panel Components 2-5.....................
HDLV Pump Manifold Components 2-6...................
Color-on−Demand Color Control Panel 2-7...................
Color Change Manifold 2-8..............................
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) 3-4..............
System Power, Ground, and Gun Controller Connections 3-5...
System Air Supply and Gun Air Connections 3-6..............
Encore HD Powder Spray Gun Installation 3-7................
Color-on-Demand Controller and Foot Switch Connections 3-8.
Ethernet Cable Termination 3-10.............................
Delivery Tubing Installation 3-13.............................
Suction and Dump Tubing Installation 3-14....................
Remote Color Selection and Color Change Start Option 3-15....

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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 4-7.....................
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...................................
Solenoid and Flow Control Valve Functions 5-3............
Color-on-Demand Controller and Control Panel 5-3...........
Inputs 5-4.............................................
Outputs 5-5...........................................
Powder Flow 5-7.......................................
Service Screen 5-7.....................................
Repair 6-1.................................................
Pump Control Panel Repair 6-1...............................
Preparation 6-1..........................................
Flow Control Valve Cleaning 6-2............................
Flow Control Valve Replacement 6-2........................
Solenoid Valve Replacement 6-3...........................
Manifold Installation 6-3...................................
Color-on-Demand Controller and Control Panel Repair 6-4.......
Manifold Repair 6-4.......................................
Repair Procedure 6-4...................................
Dump Valve Repair 6-7....................................

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Parts 7-1...................................................
Introduction 7-1.............................................
Reference Documentation 7-1..............................
Using the Illustrated Parts List 7-2..........................
Single Gun System 7-3....................................
Dual Gun System 7-3.....................................
Pump Panel Replacement Parts 7-4........................
Manifold Air and Powder Tubing Part Numbers 7-6.........
Color-on-Demand Controller and Control Panel Parts 7-7......
Controller Kit Parts 7-7..................................
Controller Parts 7-8....................................
Color Change Control Panel Parts 7-10....................
Control Unit (PLC) Parts 7-12.............................
Ship-With Kit Parts 7-14.................................
Color Change Manifold Parts 7-14.........................
Dump Valve Parts 7-16..................................
System Diagrams 8-1.......................................

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Safety 1-1
Part 1605396-04
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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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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.

Safety 1-3
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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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Description 2-1
Part 1605396-04
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Section 2
Description
System Components
The Encore HD Powder Spray System with Prodigy Color-on-Demand 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 Powder Spray System with Prodigy Color-on-Demand
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
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Encore HD Gun Controller
(1 per Gun)
Color-on-Demand Controller
(1 per Gun)
Color Change Panel
(One per System)
HDLV Pump
(1 per Gun)
Pump Panel
(One per System) Color Change
Manifolds
(3 per Gun)
Dump Valve
(1 per Gun)
System Pump Stand
(Front)
System Pump Stand
(Rear, w/Cover Removed)
Encore HD
Manual Spray Gun
Figure 2-1 System Components
Pump Control Panel
The pump panel is the central electrical and pneumatic enclosure for the
Color-on-Demand system. The pump panel houses the Prodigy HDLVr
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.

Description 2-3
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Manifold Specifications
Output (Maximum) 23.5 kg (52 lb)
per hour
Air Consumption
Conveying Air 21−35 l/min
(0.75−1.25 scfm)
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 1605396-04 E2018 Nordson Corporation
Pump
Control
Panel
Color-on-Demand
Color Control
Panel
HDLV
Pump 1
HDLV
Pump 2
Figure 2-2 Manual Color-on-Demand System Panels

Description 2-5
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Pump Control Panel Components
22 1
21 2
3
20
15
16
18
17
4
5
6
8
9
11
10
12
12
13
14
19
7
23
24
24
s
25 25
Figure 2-3 Pump Control Panel Components (Dual Pump System Shown)
1. Pump 2 purge valve
2. Pump 1 control manifold
3. Pump 1
4. 24 VDC power supply
5. Line filter
6. Power switch
7. Contact block
8. Fuse, time delay, 3.15 A
9. Purge pilot manifold/solenoids
10. Pinch select manifold/solenoids
11. Pump control board
12. Vacuum generator mufflers
13. Air filter
14. Air supply ball valve
15. Pinch low regulator/gauge
16. Pinch high regulator/gauge
17. Flow control regulator/gauge
18. Vacuum regulator/gauge
19. Purge regulator/gauge
20. Pump 2
21. Pump 2 control manifold
22. Pump 1 purge valve
23. Electrode air wash manifold
assembly
24. Pressure switch
25. Flow control valve

Description
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NOTE: One pump control board (11) controls one pump. If the system has
two pumps, then there are two control boards stacked on top of each other.
For wiring and pneumatic diagrams, refer to the foldouts in the back of this
manual.
For pump repair and parts, refer to manual 1081195.
HDLV Pump Manifold Components
The Prodigy High-Density powder, Low-Volume air (HDLV) 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 5-3 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
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Color-on−Demand Color Control Panel
See Figure 2-5. Air and power are supplied to the color control panel from
the pump control panel.
Gun A
Gun B
Manifold
Purge
Valves
PLC
Footpedal
Pressure
Switch
Solenoid
Valves
System
Pressure
Switch
Pump
Control
Boards
Figure 2-5 System Control Panels (Dual Gun System)

Description
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The color control panel houses the PLC and solenoid valves that control the
color change system. The PLC also interfaces with the pump control
boards in the pump control panel to signal a color change start.
The Color-on-Demand controller provides the operator interface for the
color change controls. The controller communicates with the color control
panel through an Ethernet cable.
Power is supplied to the COD controller from the color control panel through
a separate power cable.
Other major components of the color control panel include the manifold
purge valves, which provide manifold purge air during the color change
cycle; the system pressure switch, which senses system air pressure and
prevents a color change from starting if the air pressure drops below 70 psi;
and the foot pedal pressure switches. When the operator steps on the foot
pedal, it sends a signal to the pressure switch, which signals the PLC to
initiate a color change.
Color Change Manifold
See Figure 2-6. The color change manifold consists of 3 valve blocks with
10 ports in the side of each block and ports at each end. Of the 30 side
ports, 28 are powder inlet valves and one is a purge air inlet valve. A
separate external dump valve is connected to the top outlet on the top
block.
The manifold valve bladders are inflated to close the side ports and deflated
to open them. The currently selected powder flows around the valve
bladder and out the suction line to the HDLV pump. During a color change,
air is exhausted from the Dump 2 valve, allowing them to open so that
purge air can push the remaining powder in the suction lines and manifold
out through the dump lines to the booth.
Color change cycle settings are made from the Manual Gun Controller
interface (Tools>Purge). These settings determine the pump soft purge,
pulse purge, and new color pre-load timing.
Both gun controllers must be set for the “Gun No: 1” network address.
Refer to the Encore HD Manual Powder Spray System Controller manual
(part number1604869) for a description of the color change cycle and
settings.