Nordson Encore User manual

© 2021 Nordson Corporation 1608259-03
Installation Guide
Part Number 1608259-03
© 2021 Nordson Corporation
Original Copyright Date 2015 Issued: 05/2021
Encore™ HD Mobile
Powder Coating
System
Follow the safety, operation, and maintenance instructions in the product manual.
Refer to the Encore HD manual 1605707 for additional information.
ENCORE HD MOBILE SYSTEM COMPONENTS
Components Required For
Installation
Preassembled Mobile System
Encore® HD Spray Gun with Cable
4-mm Clear Air Tubing
6-mm Blue Air Tubing
8-mm Powder Hose
12-mm Blue Air Tubing
Tube Cutters
Barbed Fitting (Pickup Tube)
Spiral Wrapping
Tools Required for Installation
Scissors
Tube Cutters (included)
Screwdriver
Pliers
Wrench
Optional Components
Rail Mount Bracket
Grounding Block
Adapter

© 2021 Nordson Corporation
1608259-03
2Encore™ HD Mobile Powder Coating System
INSTALLATION PROCEDURES
1
Install the spray gun cable on the manual system.
1. Connect the spray gun cable to the connector on the back of the controller.
View 1 View 2
2
Install the 4-mm clear and 6-mm blue tubing to the top of the pump control
unit.
1. Feed the tubing through the front opening at the top of the tower.
2. Connect the tubing to the appropriate tting on the top of the unit.
3
Install the tubing from the pump control unit to the spray gun.
Tool Required: tube cutters
1. Measure the tubing the same length as the spray gun cable (typically
6 m).
2. Cut all the tubing straight across to create a 90-degree angle.
3. Push the tubing into the connections located at the bottom of the
spray gun.
4-mm Clear Tubing
6-mm Blue Tubing

© 2021 Nordson Corporation 1608259-03
3
Encore™ HD Mobile Powder Coating System
4
Install the powder tubing from the spray gun to the pump.
Tool Required: scissors
1. Connect the powder tubing from the pump to the spray gun adapter.
2. Dress out the air tubing, powder hose, and spray gun adapter using a cut piece of black spiral wrapping (step not
shown).
NOTE:Do not pinch powder tubing.
Tubing is Factory
Installed
5
Connect the powder tubing from the pump to the pickup tube.
Tool Required: scissors
1. Connect the end of the powder tubing to the front-right (suction side) barbed tting on the pump.
2. Route the tubing through the tower to the top of the pickup tube.
3. Connect the tubing to the barbed tting on the top of the pickup tube.
4. Dress out the pickup tubing using a cut piece of black spiral wrapping.
Suction
Side
Delivery
Side
Barbed
Fitting Barbed
Fitting
INSTALLATION PROCEDURES CONT...

© 2021 Nordson Corporation
1608259-03
4Encore™ HD Mobile Powder Coating System
© 2021 Nordson Corporation
1608259-03
4Encore™ HD Mobile Powder Coating System
Issued 05/21
Original copyright date 2015. Encore, Nordson, and the Nordson logo are registered trademarks of Nordson Corporation.
All other trademarks are the property of their respective owners.
INSTALLATION PROCEDURES CONT...
6
HOPPER VERSION ONLY
Connect the vent hose to the hopper using the
provided hose clamp.
Tool Required: screwdriver
7
Connect the ground cable attached to the pump control unit ground stud to
a true earth ground.
8
Connect the main air and input power to begin
operation. Green/Yellow = Ground/Earthing
Brown = L1/Hot
Blue = L2/Neutral

© 2021 Nordson Corporation 1608259-03
Installation Guide
Part Number 1608259-03
© 2021 Nordson Corporation
Original Copyright Date 2015 Issued: 05/2021
Encore™ HD Mobile
Quick Tips
POSSIBLE SITUATION: INCONSISTENT DELIVERY TO THE SPRAY GUN
Verify that the suction line is as short as possible (12 feet long or less).
Verify that the hose is routed correctly and horizontally. Utilize the clips
beneath the mobile system.
Tighten all connections to eliminate potential air leaks.
Check and adjust the assist air up or down as necessary. Refer to the
system manual for specications.
Check for proper uidization. Proper uidization should resemble a “low
simmer” or laterally-moving powder with no bubbles. Fluidization can
appear di󰀨erently depending on the type of powder used.
NOTE:If proper uidization is di󰀩cult to achieve, there may be an issue
with the material. For a potential temporary resolution, set the pump
control to fast-ow mode.
If the situation continues, see the system manual to perform a vacuum test on
the pump. Consult Nordson technical support if the situation continues.
POSSIBLE SITUATION: INCONSISTENT SPRAY PATTERN
Verify that the nozzle and the electrode assembly “bridge” are parallel to each other.
INCORRECT CORRECT
Check if the electrode air wash is too high. Adjust the needle valve on the pump control unit.
Check if the pattern air is too high or low. Adjust the pattern air on the system controller.
If the situation continues, consult the system manual or Nordson technical support.
Follow the safety, operation, and maintenance instructions in the product manual.
Refer to the Encore HD manual 1605707 for additional information.

© 2021 Nordson Corporation
1608259-03
6Encore™ HD Mobile Powder Coating System
© 2021 Nordson Corporation
1608259-03
6Encore™ HD Mobile Powder Coating System
Issued 05/21
Original copyright date 2015. Encore, Nordson, and the Nordson logo are registered trademarks of Nordson Corporation.
All other trademarks are the property of their respective owners.
MAINTENANCE CHECKS
Cleaning and Maintenance
At the end of each shift, perform a color change and inspect the nozzle and electrode assembly for signs of wear
or impact fusion.
1
Remove the suction line from the pickup tube and point it towards the powder collector.
2
Point the spray gun towards the powder collector.
3
Press the color change button on the controller and press enter.
4
Once the color change is complete, remove the nozzle and inspect for wear or impact fusion.
5
Inspect the pinch valves by looking at the clear block on the pump. If powder is present around the pinch valves,
pump maintenance is required.
Shutdown
After performing the cleaning and maintenance of the pump, the system can be shut down by pressing the
standby button on the system controller.

© 2021 Nordson Corporation 1608259-03
Installation Guide
Part Number 1608259-03
© 2021 Nordson Corporation
Original Copyright Date 2015 Issued: 05/2021
Encore™ HD System
Controller and Spray
Gun Operation
SYSTEM CONTROLLER AND SPRAY GUN DISPLAY
Preset Mode
Icon
Display
Mode
Button
Flow Mode
Icon
Purge
Button
Select Charge
Modes
kV Settings
µA Settings
Function/Help
Display
Help Button
Nordson Button
(Conguration)
View Button Color Change Button Enter Button
Rotary Knob
Pattern Air
Flow Setting
Standby
Button
Setting Icons
Powder Flow %
Preset Select
Setting Button LEDs
Current Preset Number
Gun Triggered On Indicator
Frequently Used Buttons
Standby: Shuts o󰀨 controller interface and spray
gun during operation
Enter: Activates selected function or setting.
Help: Light will display if a problem occurs. Rotate
knob to scroll through the last ve codes. CLR +
Enter will clear the codes.
View: Displays assist air setting (AA), fast-ow
setting (FF), gun controller software (GC), gun
display module software (DD), ow module
software (FL)and hardware version for the main
control board (HD).
Rotary Knob: Adjusts displayed values up or down.
Selecting
a Setpoint
Changing
a Setpoint
Frequently Used Settings
Assist Air
Fast Flow
kV Voltage
µA Control
Powder
Flow %
Pattern Air
Flow
Presets
Follow the safety, operation, and maintenance instructions in the product manual.
Refer to the Encore HD manual 1605707 for additional information.

© 2021 Nordson Corporation
1608259-03
8Encore™ HD Mobile Powder Coating System
© 2021 Nordson Corporation
1608259-03
8Encore™ HD Mobile Powder Coating System
Issued 05/21
Original copyright date 2015. Encore, Nordson, and the Nordson logo are registered trademarks of Nordson Corporation.
All other trademarks are the property of their respective owners.
SYSTEM CONTROLLER FUNCTION CODES AND VALVES
Code Function Name Function Value Code Function Name Function Value
F00 Gun Type 00= Encore XT/HD
02= Robot
F18 Pump Type 00= Venturi
01= HDLV
02= COD
F01 Fluidizing 00= Hopper
01= Box
02= Disable
F19 Control Type 00= Local
01= External
F02 Display Units 00= SCFM
01= M3/HR
F20 Gun Number *See manual for additional values
F21 Maintenance Timer,
Pump
00= View
01= Set
02= Reset
*See manual for additional values
F03 Electrostatic Control 00= Custom
01= Classic
F04 Powder Flow Control
F22 Purge *See manual for additional values
F05 Keypad Lockout 00= Unlocked
04= Reset Password
*See manual for additional values
F25 Pattern Air Delay 0.00-5.00
F26 Soft Siphon 1-10 Sec
F06 Vibratory Box Delay O󰀨 00-90 Seconds F27 Soft Gun 1-10 Sec
F07 Maintenance Timer,
Gun
*See manual for additional values F28 Pulse ON 0.1-0.95 Sec
F08 Setting Trigger Func-
tion
*See manual for additional values F29 Pulse OFF 0.1-0.95 Sec
F09 Help Codes 00= Enable
01= Disable
F30 Siphon Pulses 1-99
F31 Gun Pulses 1-99
F10 Zero Reset (Flow) *See manual for additional values F32 Powder Pre-Load *See manual for additional values
F11 Gun Display Errors 00= Flash
01= O󰀨
F33 Manifold Purge 0-10 Sec
F12 uA Lower Limit *See manual for additional values F34 Conveyance Air
Constant A
*Constant should match sticker
onmanifold
F13 uA Upper Limit *See manual for additional values
F35 Conveyance Air
Constant C
*Constant should match sticker
onmanifold
F14 Total Hours 00= Gun Total Hours
01= Pump Total Hours
F36 Pattern Air Constant A *Constant should match sticker
onmanifold
F15 Save/Restore/Reset 00= Save
01= Restore
02= Reset
F37 Pattern Air Constant C *Constant should match sticker
onmanifold
F16 Gun Display Brightness 00= Low
01= Medium
02= Maximum
F17 Number of Presets *See manual for additional values