Nordson Encore HD Reference guide

EncorerHD Automatic
Powder Spray Guns
Customer Product Manual
Part 1602018-13
Issued 2/19
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 1602018-13 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 2013. 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, iControl, iFlow, HDLV, Nordson, and the Nordson logo are
registered trademarks of Nordson Corporation.

Change Record i
Part 1602018-13
E2019 Nordson Corporation
Change Record
Revision Date Change
03 1/14 Page 45 & 48 - Added Electrode assembly, flat spray
Page 54 - Added conical nozzle kit and conical electrode assembly
04 6/14 New socket-head screws, spacers and grounding harness; new angled
spray extensions; new nozzle P/N’s
05 7/14 New flat and conical electrode holders
06 5/16 Released only (no changes)
07 8/16 Added power supply kits and spray gun part numbers
08 9/16 Nozzle part number change and ion collector plug added
09 1/18 Released external diffuser
10 2/18 1612462 was 1003572
11 2/18 Added fitting 1106373 to external diffuser kit
12 7/18 XD electrode support, updated spray gun dimensions and updated power
supply resistance test nomenclature, added system numbers
13 2/19 Page 2-2 - Added ISO standard for air quality in Specifications
Page 7-3 - Removed callout 10 and added callout 8 on Figure 7- 10
Page 8-3 - Added part numbers for 1- and 2-packaged spray guns

Change Record
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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.............................................
Specifications 2-2...........................................
Applicator Certification Label 2-3............................
Serial Number Label 2-3...................................
Special Conditions for Safe Use 2-3.........................
Dimensions and Weights 2-4...............................
Installation 3-1.............................................
Tube-Mount Spray Guns 3-1.................................
Bar-Mount Spray Guns 3-2...................................
Spray Gun Connections 3-3..................................
Ion Collector Installation 3-4..................................
Bar-Mount Spray Gun 3-4.................................
Tube-Mount Spray Gun 3-5................................
Adjusting the Ion Collector Rod 3-6..........................
Operation 4-1..............................................
Changing Flat Spray Nozzles 4-2.............................
Changing Optional Deflectors or Conical Nozzles 4-3............
Maintenance 5-1...........................................
Daily Maintenance 5-1.......................................
Troubleshooting 6-1........................................
General Troubleshooting Chart 6-1............................
Power Supply Resistance Test 6-4............................
Electrode Assembly Resistance Test 6-5.......................
Cable Continuity Tests 6-5...................................
Spray Gun Receptacle Harness 6-5........................
Spray Gun Extension Cable 6-6............................
Spray Gun Cable 6-6.....................................

Table of Contents
iv
Part 1602018-13 E2019 Nordson Corporation
Repair 7-1.................................................
Powder Wear Parts Replacement 7-1.......................
Tube-Mount Spray Gun Repair 7-2.........................
Tube-Mount Spray Gun Disassembly 7-2..................
Tube-Mount Spray Gun Assembly 7-5....................
Bar-Mount Spray Gun Repair 7-6...........................
Bar-Mount Spray Gun Disassembly 7-6...................
Bar-Mount Gun Assembly 7-9...........................
Parts 8-1...................................................
Introduction 8-1.............................................
Using the Illustrated Parts List 8-1..........................
Tube-Mount Spray Gun Parts 8-2...........................
Standard 5-ft Tube-Mount Spray Gun Parts List 8-3.........
Bar-Mount Spray Gun Parts 8-5............................
Bar-Mount Spray Gun Parts List 8-6......................
External Diffuser for Encore HD Automatic Spray Guns 8-8.....
Options 9-1................................................
Optional 6-ft Tube Mount Spray Gun 9-1.......................
Hose Hanger 9-1............................................
Cables 9-2.................................................
Flat Spray Nozzles 9-2.......................................
Cross-Cut Nozzles 9-2......................................
45-Degree Corner-Spray Nozzle 9-3...........................
45-Degree In-Line Flat-Spray Nozzle 9-4.......................
Conical Nozzle, Deflectors, and Electrode Assembly 9-4..........
Conical Nozzle and Deflectors 9-4...........................
Conical Nozzle Kit 9-5.....................................
Conical Electrode Assembly 9-5............................
XD Electrode Support 9-5..................................
Encore Angled Spray Extensions 9-6..........................
Tube-Mount Spray Gun Mounting Assemblies 9-7...............
Standard Mount Assembly 9-7.............................
Pivot Mount Assembly 9-7.................................
Extrusion Mounting Assembly 9-8..........................
Spray Gun Bar for Bar-Mount Spray Guns 9-9..................
Ion Collector Kit 9-10.........................................

Safety 1-1
Part 1602018-13
E2019 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
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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Part 1602018-13 E2019 Nordson Corporation
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 (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.

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
connectedtogroundwitharesistanceofnotmorethan1megohmas
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
1-4
Part 1602018-13 E2019 Nordson Corporation

Description 2-1
Part 1602018-13
E2019 Nordson Corporation
Section 2
Description
EncorerHD automatic electrostatic powder spray guns are available in
tube-mount or bar-mount versions. The 156.2 cm (5.1-ft) tube-mount spray
gun is standard; an optional 186.7 cm (6.1-ft) tube-mount spray gun is
available. The bar-mount spray gun includes a swivel mount that fits into
the end of the optional spray gun bar.
The spray guns are equipped with a 100 kV integral voltage multiplier and
electrode air-wash to prevent powder from collecting on the electrode. The
spraygunshaveastraight-throughpowderpathtominimizeimpactfusion
and a quick-disconnect powder hose connector for quick color change.
The spray guns are used with the Nordson Encore HD iControlrsystem,
which provides electrostatic voltage control, electrode air-wash air,
atomizing air, and HDLVrpump control.
Flat spray nozzles with 2.5- and 4-mm slots are shipped with the spray
guns. Optional equipment includes:
S8-, 12-, and 16-meter (26-, 39-, 52-ft) control cables, and a 4-meter
cable extension
SStandard, pivoting, and fixed extrusion spray gun mounts for tube-mount
spray guns
SSpray gun bar with 4-foot (121-cm) bar and clamp for 25-mm (1-in.)
mounting bars
SAngled spray extensions
SIon collector kit
SA variety of flat, conical, and cross-cut nozzles

Description
2-2
Part 1602018-13 E2019 Nordson Corporation
10014163/10015551
Bar-Mount Spray Gun
Tube-Mount Spray Gun
Figure 2-1 Bar-Mount and Tube-Mount Spray Guns
Specifications
Input Rating Output Rating
+/- 19 VAC, +/- 1 A (Peak) 100 KV, 100 A
SAir Quality: ISO8573- 1:2010 Class 1.2.1
SMax Relative Humidity: 95% non-Condensing
SAmbient Temperature Rating: +15 to +40 _C(59-104_F)
SHazardous Location Rating for Applicator: Zone 21 or Class II, Division 1

Description 2-3
Part 1602018-13
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Applicator Certification Label
Serial Number Label
NOTE: The spray gun serial number contains the location, year, and month
it was manufactured. The serial number starts with “AA10A”. The “AA”
means the product was built in Amherst, Ohio, the “10” meaning the year
2010. The “A” means the month of January, “B” would be February, and so
on.
Special Conditions for Safe Use
To meet ATEX requirements for the European Union:
SThe Encore HD powder electrostatic automatic applicators shall only be
used with associated Encore HD iControl controllers over the ambient
temperature range of +15 _Cto+40_C.
SThe equipment must be installed and used in accordance with Standard
EN50177.

Description
2-4
Part 1602018-13 E2019 Nordson Corporation
Dimensions and Weights
(to end of tube mount)
4.9 cm
(1.929 in)
9.62 cm
(3.787 in)
6.7 cm
(2.637 in)
36.23 cm (14.263 in)
39.68 cm (15.621 in)
46.69 cm (18.383 in)
1.01 cm
(.398 in)
4.9 cm
(1.929 in)
5.79 cm
(2.280 in)
16.91 cm
(6.659 in)
7.56 cm
(2.978 in)
8.9 cm
(3.504 in)
(to Pivot Center)
(to end of tube mount)
170.46 cm (67.112 in)
155.58 cm (61.251 in)
200.73 cm (79.027 in)
185.58 cm (73.062 in)
6- ft Tube Mount Spray Gun
Weight: 2.40 kg (5.29 lb)
5- ft Tube- Mount Spray Gun
Weight: 2.05 kg (4.51 lb)
Bar- Mount Spray Gun
Weight: 682 grams (1.50 lb)
Figure 2-2 Spray Gun Dimensions and Weights

Installation 3-1
Part 1602018-13
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Section 3
Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Tube-Mount Spray Guns
Tube-mount spray gun mounting assemblies are optional. Refer to page
9-7 for assembly part numbers.
See Figure 3-1. Mount the tube-mount spray gun on a fixed spray gun
stand, oscillator, or reciprocator using one of the mounting assemblies
shown below.
3
1
2
4
5
11
3
1
2
4
5
11
12
Standard Tube Mount Pivoting Tube Mount
T-Slot Extrusion Mount 3
4
7
8
6
9
10
5
Figure 3-1 Tube-Mount Spray Gun Mounting Assemblies
1. Mounting bar 25.4-mm (1-in.)
2. Clamp
3. Clamping screw
4. Mounting sleeve
6. M8 x 30 screws
7. Support plate
8. 3/8-16 x 1-in. screws
9. T-slot nuts
10. T-slot extrusion (not included
in kit)
11. Clamping handle
12. Pivot handle

Installation
3-2
Part 1602018-13 E2019 Nordson Corporation
Bar-Mount Spray Guns
The spray gun bar is optional. Refer to page 9-9 in the Options section for
the spray gun bar part number.
See Figure 3-2. Install the spray gun bar-mount adapter (3) into the end of
the adjusting rod (9) and secure it by tightening the set screw (11) with a
4-mm hex key.
STo move the spray gun tip from side to side, loosen the right button
screw (1).
STo tilt the spray gun tip up or down, loosen the tilt knob (4).
STo rotate the adjusting bar on the locking body (8) axis or in the locking
body, loosen the rotate handle (5).
To mount the spray gun on a fixed spray gun stand, oscillator, or
reciprocator, position the clamp (7) on a 1-in. mounting bar and tighten the
clamp handle (6).
56
9
7
1
2
4
11
10
3
8
Figure 3-2 Bar-Mount Spray Gun Mounting
1. Button screws
2. Tilt bracket
3. Bar-mount adapter
4. Tilt knob
5. Rotate handle
6. Clamp handle
7. Clamp
8. Locking body
9. Adjusting rod
10. Ball
11. Set screw

Installation 3-3
Part 1602018-13
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Spray Gun Connections
SeeFigure3-3.
1. Connect the powder feed hose to the hose connector (2). The
connector can be disconnected from the spray gun by unscrewing the
retainer nut (1) and pulling back away from the spray gun.
2. Connect 4-mm clear electrode air-wash tubing to the barbed fitting (3)
(bar-mount spray gun) or tubing union (4) (tube-mount spray gun).
3. Connect the 6-mm blue atomizing tubing to the tubing union (6).
4. Connect the spray gun cable to the receptacle (5) and tighten the cable
nut securely.
10014163
1
2
3
5
61
6
2
5
4
Bar-Mount
Spray Gun Tube-Mount
Spray Gun
Figure 3-3 Spray Gun Connections
1. Retainer nut
2. Hose connector
3. Barbed fitting (4-mm tubing)
4. Tubing union (4-mm)
5. Spray gun cable receptacle
6. Tubing union (6-mm)

Installation
3-4
Part 1602018-13 E2019 Nordson Corporation
Ion Collector Installation
The ion collector can improve the smoothness and appearance of cured
powder coatings. It collects ions emitted from the spray gun’s charging
electrode instead of allowing them to deposit on the part. This reduces the
rate of charge buildup in the powder deposited on the part, which may
reduce defects in the cured coating such as pinholing and orange peel.
Refertopage9-10intheOptions section for part numbers.
The ion collector kit can be used on both the bar-mount and tube-mount
spray guns. After installing the ion collector, adjust the collector rod position
for best results as described on page 3-6.
Bar-Mount Spray Gun
1. See Figure 3-4. Insert the collector rod (1) into the grounding plate and
secureitwiththeM5x8setscrew(2)includedintheioncollectorkit.
2. Attach the multi-point tip (3) to thecollectorrodusingtheM3x8
screw (4).
1
2
34
Figure 3-4 Ion Collector Installation - Bar-Mount Spray Gun
1. Collector rod
2. M5 x 8 set screw
3. Multi-point tip 4. M3 x 8 pan screw
Note: For clarity, some parts are not shown.

Installation 3-5
Part 1602018-13
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Tube-Mount Spray Gun
NOTE: The mounting hole must remain plugged for optimal performance.
If the ion collector is removed, replace it with the appropriate plug. The
mounting plug part number is listed in the Parts section of this manual.
NOTE: The ion collector mounting hole must be installed towards the front
of the spray gun as shown in Figure 3-5. If the ion collector hole is installed
towards the far rear, it must be reversed to allow access to the grounding
plate in the rear body assembly. If necessary, perform Steps 1- 7 of the
tube-mount disassembly procedure on page 7-2 to remove the tube, then
turn it around and reassemble the spray gun.
1. See Figure 3-5. Remove the plug from the mounting hole (5) if
applicable.
2. Secure the post (2) to the grounding plate with the socket-head
screw (3).
3. Insert the collector rod (1) into the post and secure it with the M10 x 10
nylon-tipped set screw (4).
4. Attach the multi-point tip (6) to the collector rod with the M3 x 8
screw (7).
1
7
2
3
4
5
6
Figure 3-5 Ion Collector Installation - Tube-Mount Spray Gun
1. Collector rod
2. Post
3. Socket-head screw
4. M10 x 10 set screw
5. Ion collector mounting hole
6. Multi-point tip
7. M3 x 8 pan screw
Note: For clarity, some parts are not shown.

Installation
3-6
Part 1602018-13 E2019 Nordson Corporation
Adjusting the Ion Collector Rod
The ion collector rod should be mounted so that the tip at the end of the rod
is the optimum distance from the tip of the electrode for the application.
SIf the tip at the end of the rod is too far away from the tip of the
electrode, the ion collector will not collect any ions or improve the
appearance of the cured coating.
SIf the tip of the end of the rod is too close to the tip of the electrode,
powder particles may not be charged efficiently and the powder transfer
efficiency may be reduced.
Use this procedure to position the end of the ion collector rod.
1. Remove the rod and multi-point tip from the post, then coat several test
parts. Note the current (A) shown on the control unit display when
coating the parts. Cure the coatings.
2. Install the rod into the post and the multi-point tip on the spray gun.
3. Loosen the M10 x 10 set screw for the tube-mount or the M5 x 8 set
screw for the bar-mount, and move the multi-point tip far away from the
front end of the spray gun.
4. Turn on the electrostatic voltage and spray powder on a test part in front
of the spray gun. Slide the rod forward until the current shown on the
control unit display is 5 to 7 A higher than that displayed without an ion
collector. Tighten the set screw.
5. Cure the coating on the test parts. Compare the surface finish on these
parts with the finish on the parts coated in step 1 (before the ion
collector kit was installed).
6. If the desired improvement in the surface finish has not been obtained,
loosen the set screw and slide the rod forward approximately 1-in.
Tighten the set screw.
7. Repeat steps 5 and 6 until the desired improvement in surface finish is
obtained.