Nordson Encore HD Parts list manual

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Nordson Corporation
OPERATOR’S CARD
P/N 1604871-01
EncorerHD Manual Powder Spray System with
ProdigyrPump Cabinet
WARNING: Allow only qualified personnel to
perform the following tasks. Follow the
safety instructions in this document and all
other related documentation.
Refer to component operator manuals for more
information on safety, setup, operation,
troubleshooting, repair and parts.
System Diagram
Pump 1Pump 2
Pump Control
Panel
Gun 1Gun 2
Gun 1
Controller
Gun 2
Controller
Fluidizing Air
Regulator
Fluidizing Air
Powder
Hopper
Pump
Adapters
System Air
Power
Switch
System
Power
Figure 1 System Diagram (Two-Gun System Shown)

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Controller Interface
When power is activated at the pump cabinet, the
controller is turned on. To shut off controller power,
use the power switch on the pump cabinet.
Use the controller interface to make preset settings,
view help codes, monitor system operation, and to
configure the controller.
Use the Standby button shown in Figure 2 to shut off
the interface and disable the spray gun during breaks
in production. When the controller interface is off the
spray gun cannot be triggered, and the spray gun
interface is disabled.
Gun Triggered On Indicator
Select Charge
Modes
kV Setting
Function/Help Display
Current Preset Number
% of Flow
Rotary Knob
Standby Button
Nordson Button
(Configuration)
Setting Button LEDs
Preset Select
Setting Icons
Pattern Air Flow Setting
A Setting
Help Button
View Button Enter Button
Color Change Button
Figure 2 Controller Interface
The Setpoint icons light to indicate the configured or
selected setpoints.
Setpoints include Select Charge, kV, mA, % of Flow
and Pattern Air flow rates.
To select a Preset or change a Preset setpoint, press
the Preset Select button or a Setpoint button. The
button LED lights to indicate that it is selected.
Use the Rotary Knob to change the selected
setpoint: clockwise to increase, counter-clockwise to
decrease. The setpoints reset to the minimum if
increased past their maximum.
Selecting a Setpoint to Change Changing a Setpoint
Figure 3 Selecting and Changing Setpoints
Help Codes
The Help icon in the Function/Help display lights if a
problem occurs.
To display the Help codes, press the Help
button. The controller retains the last 5 codes in
memory. Rotate the knob to scroll through the codes.
The display blanks if there is no activity for 5
seconds.
To clear the Help codes, scroll through them
until CLr is displayed, then press the Enter button.
The Help icon stays lit until the controller clears the
codes.

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Assist Air Setting, Fast Flow Setting, and
Software Versions
The View button allows the user access to
adjust Assist Air and Fast Flow preset values, and to
view software versions.
Press the View button consecutively to display, in
order, the following functions: Assist Air Setting (AA),
Fast Flow Setting (FF), Gun Controller Software
Version (GC), Gun Display Module Software Version
(Gd), Flow Module Software Version (FL), and
Hardware Version for Main Control Board (Hd).
Assist Air Setting
Assist air is the air flow that pushes the powder out of
the pump to the gun. This screen allows you to
increase or decrease the assist air flow by a
percentage of the total flow for each preset, to
optimize pump and spray performance.
Assist air can be adjusted from +50% to −50% in
1% increments.
To set the assist air rate:
1. Press the View button until AA is displayed.
2. Turn the rotary knob to increase or decrease the
value.
3. Press Enter to save.
Figure 4 Assist Air Settings>>> 1 <<<
Fast Flow Setting
The Fast Flow setting allows you to specify Fast Flow
or Normal Flow for each preset. Normal is the
default, and is the setting used for most powders.
Use a Fast Flow setting when using powders that are
hard to fluidize and that may tend to clump.
When set to Normal, the pump cycle rate varies with
the powder flow setting. When Fast Flow is enabled,
the pump cycles at a continuous fast cycle rate.
NOTE: Fast Flow should be used only when working
with difficult powders, as it will decrease the life of the
pump pinch valves.
To set the Fast Flow setting:
1. Press the View button until FF is displayed.
2. Turn the rotary knob to toggle between 0for
Normal and Ffor Fast Flow.
3. Press Enter to save.
Figure 5 Fast Flow Settings>>> 2 <<<
Spray Settings
For the following spray settings, when the gun is not
triggered the setpoints are displayed. When the gun
is triggered the actual outputs are displayed.
Custom Mode −
Preset Setpoints
Custom Mode −
Gun Triggered
Figure 6 Custom Mode Displays
Classic Mode
To use Classic mode, the controller must be
configured for it. In Classic mode you can choose to
control kV (STD) output or A (AFC) output, but not
both at the same time.
Classic Standard (STD) Mode
Use the Standard mode to set kV. In Standard mode
you cannot set A.
1. To set the kV setpoint, press the kV button. The
button LED lights to show that kV is selected.

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2. Turn the rotary knob to increase or decrease the
kV setpoint. The setpoint is automatically saved if
it does not change for 3 seconds, or when any
button is pressed.
STD Mode −
kV Setpoint
STD Mode −
Gun Triggered
Figure 7 STD Mode Displays
Classic AFC Mode
Use the AFC mode to set A output limits. In AFC
mode you cannot adjust kV; it is automatically set to
100 kV.
1. To set A, press the mAbutton. The button LED
lights to show that A is selected.
Presets
Presets are programmed electrostatic and powder
flow setpoints that allow the operator to quickly
change spray settings simply by changing the preset
number.
The controller can store 20 presets. Presets 1, 2,
and 3 are programmed at the factory for the most
common applications and can be adjusted as
needed. Presets 4−17 can be programmed as
needed.
Selecting or Changing a Preset
1. Press the Preset button. The button LED lights.
2. Turn the rotary knob. The preset number
increases from 1 to 20 then resets to 1.
3. With the desired preset selected, begin
production. All preset electrostatic and powder
flow values will be used.
4. To change a preset’s values, first choose the
desired preset by using the rotary knob. Once
the preset is selected, change the electrostatic
and powder flow settings to the desired values.
5. The preset number will begin blinking, indicating a
change has been made. To save the new
settings, press the Enter button. The preset
number will stop blinking, indicating the values
have been saved.
6. To begin production without saving the new
settings, do not press Enter. The new values will
be used for the current job, but the preset will
keep the original values for future use.
The setpoints for the selected preset are displayed
when the gun is not triggered.
Preset Button
Figure 8 Preset Select
Electrostatic Settings
Electrostatic output can be in Select Charge mode,
Custom mode, or Classic mode.>>> 3 <<<
Select ChargerMode
The Select Charge modes are non-adjustable
electrostatic settings. The LEDs above the Select
Charge mode buttons indicate the selected mode.
The Select Charge modes and factory settings are:
Mode 1 Re-Coat 100 kV, 15 A
Mode 2 Metallics 50 kV, 50 A
Mode 3 Deep Recesses 100 kV, 60 A
Mode 1 Mode 2 Mode 3
Figure 9 Select Charge Mode
NOTE: If the operator tries to adjust kV or A values
while a Select Charge mode is selected, the
controller will switch to Custom or Classic mode.
Custom Mode
Custom mode is the factory default mode. In Custom
mode, both kV and A can be adjusted
independently. In Custom mode the STD and AFC
icons are not displayed.

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1. To set or change kV, press the kV button. The
button LED lights to show that kV is selected.
2. Turn the rotary knob to increase or decrease the
kV setpoint. The setpoint is automatically saved if
it does not change for 3 seconds, or when any
button is pressed.
3. To set or change the A setpoint, press the mA
button. The button LED lights to indicate that A
is selected.
4. Turn the rotary knob to increase or decrease the
A setpoint. The setpoint is automatically saved
if it does not change for 3 seconds, or when any
button is pressed.
NOTE: The default A range is 10−50 A. The limits
of the range can be adjusted.
SWhen the gun is not triggered the kV and A
setpoints are displayed.
SWhen the gun is triggered the actual kV and A
outputs are displayed.
Custom Mode −
Preset Setpoints
Custom Mode −
Gun Triggered
Figure 10 Custom Mode Displays
Classic Mode
To use Classic mode, the controller must be
configured for it. In Classic mode you can choose to
control kV (STD) output or A (AFC) output, but not
both at the same time.
Classic Standard (STD) Mode
Use the Standard mode to set kV. In Standard mode
you cannot set A.
1. To set the kV setpoint, press the kV button. The
button LED lights to show that kV is selected.
2. Turn the rotary knob to increase or decrease the
kV setpoint. The setpoint is automatically saved if
it does not change for 3 seconds, or when any
button is pressed.
STD Mode −
kV Setpoint STD Mode −
Gun Triggered
Figure 11 STD Mode Displays
Classic AFC Mode
Use the AFC mode to set A output limits. In AFC
mode you cannot adjust kV, it is automatically set to
100 kV.
1. To set A, press the mAbutton. The button LED
lights to show that A is selected.
2. Turn the rotary knob to increase or decrease the
A setpoint. The setpoint is automatically saved
if it does not change for 3 seconds, or when any
button is pressed.
The default A range is 10−50 A. The limits of the
range can be adjusted.
For example, the user can set the A settings from 5,
4, 3.0, 2.9, 2.8, ..... through 0.1.
AFC Mode −Gun TriggeredAFC Mode −A Setpoint
Figure 12 AFC Mode Displays
Powder Flow Setting
Powder flow rate and pattern air ranges are:
Powder flow rate from 0−100%
Pattern air from 0−3.50 in 0.05 increments
To set flow rate or pattern air:
1. Press the Flow or Pattern button. The green
LED on the selected button lights.

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2. Turn the knob to increase or decrease the
setpoints. The setpoint is automatically saved if it
does not change for 3 seconds or when any
button is pressed.
Flow Button
Pattern Icon
Percent Flow Icon
Pattern Button
Figure 13 Flow Rate and Pattern Setpoints

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Purge Operation
HDLV System Purge
Press the Color Change button on the controller and
then press Enter o.
The Purge Cycle operates as follows:
1. Soft Purge −Assist air is directed through the
pump and siphon tubing back to the powder
supply (Soft Siphon), then through the pump and
delivery tubing to the spray gun (Soft Gun). This
clears the pump, tubing, and gun of powder.
2. Pulse Purge −Purge air is directed in pulses
from the pump to the powder supply (Siphon
Pulses), then from the pump to the spray gun
(Gun Pulses). Pulse On sets the duration of each
pulse, Pulse Off sets the time between pulses.
NOTE: Make sure the guns are aimed into the booth
before starting a purge.
See functions F26 through F31 for settings.
Color-on-Demand (COD) System Purge
Press the Color Change button on the controller and
then press Enter o.
The COD Purge Cycle operates as follows:
1. Manifold Purge −The dump valve opens. The
pump speeds up to 100% of flow to pump the
remaining powder out of the manifolds.
2. Soft Purge −Assist air is directed through the
pump and siphon tubing back to the powder
supply (Soft Siphon), then through the pump and
delivery tubing to the spray gun (Soft Gun). This
clears the pump, powder tubing, and gun of
powder.
3. Pulse Purge −Purge air is directed in pulses
from the pump to the powder supply (Siphon
Pulses), then from the pump to the spray gun
(Gun Pulses). Pulse On sets the duration of each
pulse, Pulse Off sets the time between pulses.
4. Powder Pre-Load −The new color powder is
pumped to the spray gun for the set time at 100%
of flow to load the system for production.
The Color Change cycle is started by the operator or
by a remote signal to the Color-On-Demand
controller. The operator starts the color change by
selecting a new color and touching the Start button
on the touch screen, or by pressing a foot pedal, then
selecting a new color before the powder pre-load
begins.
Powder type, humidity, tubing length and other
variables can change the effectiveness of these
settings. You may have to adjust these settings to
avoid color cross-contamination and maintain
performance.
See functions F26 through F33 for settings.

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Configuration
Opening the Function Menu and
Selecting Settings
Press and hold the Nordson button
for 5 seconds. The Function/Help display lights to
show the function numbers and values. Use the
functions to configure the controller for your
application.>>> 4 <<<
Use the rotary knob to scroll through the function
numbers. To select the displayed function number,
press the Enter button. The function numbers are in
the form F00−00 (function number−value).
When the function is selected, the function value
blinks. To change the function value, rotate the knob.
Press the Enter button to save the change and exit
the value, so that rotating the knob now scrolls
through the function numbers again.
Function 01, Value 00 Function 01, Value 01
Figure 14 Displaying and Changing Functions>>> 5 <<<

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Table 1 Function Settings
Function Number Function Name
F00 Gun Type
F01 Fluidizing
F02 Display Units
F03 Electrostatic Control
F04 Powder Flow Control
F05 Keypad Lockout
F06 Vibratory Box Delay Off
F07 Maintenance Timer, Gun
F08 Setting Trigger Function
F09 Help Codes
F10 Zero Reset (Flow)
F11 Gun Display Errors
F12 A Lower Limit
F13 A Upper Limit
F14 Total Hours
F15 Save/Restore/Reset
F16 Gun Display Brightness
F17 Number of Presets
F18 Pump Type
Function Number Function Name
F19 Control Type
F20 Gun Number
F21 Maintenance Timer, Pump
F22 Purge
F25 Pattern Air Delay
F26 Soft Siphon
F27 Soft Gun
F28 Pulse ON
F29 Pulse OFF
F30 Siphon Pulses
F31 Gun Pulses
F32 Powder Pre−Load
F33 Manifold Purge
F34 Conveyance Air
Constant A
F35 Conveyance Air
Constant C
F36 Pattern Air Constant A
F37 Pattern Air Constant C

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Spray Gun Operation
The spray gun interface and settings trigger allow you
to change the preset or the powder flow settings, or
purge the gun, without using the controller interface.
Mode Button
Preset Mode Icon Flow Mode Icon
Purge Button
Display
Spray Gun Interface
Figure 15 Gun Interface Controls
Increase/On
Decrease/Off
Settings Trigger
Spray Trigger
Figure 16 Gun Trigger Controls
Shutdown
For HDLV system shutdown, complete the following
steps:
1. Press the Color Change button to start cleaning
the system of residual powder.
2. Purge the spray gun by pressing the Purge
button on the back of the spray gun until no more
powder is blown from the gun.
3. Press the Standby button to turn off the spray
gun and interface.
4. Turn off the system air supply and relieve the
system air pressure at the pump cabinet.
5. If shutting down for the night, or for a longer
period of time, shut off the system power.
6. Perform the daily maintenance procedures.
Maintenance
Clean the spray gun nozzle, gun powder path, pump
nozzle and pump throat in an ultrasonic cleaning
machine using OakiteRBetaSolv or an equivalent
emulsion cleaning solution. Rinse with clean water
and dry before re-installing.
Do not immerse the spray gun electrode assembly in
the cleaning solution or the rinse water. Remove all
O-rings before cleaning. Do not allow the O-rings to
come in contact with the cleaning solution.
Daily maintenance for the controller should include
blowing off the interface module with a blow gun.
Wipe any residual powder off the controller with a
clean cloth.

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Periodically check all system ground connections.
Issued 1/14
Original copyright date 2014. Prodigy, Encore, HDLV, Nordson, and the Nordson logo are registered trademarks of Nordson Corporation.