Nordson Encore HD Reference guide

EncorerHD Manual Powder Spray
System
Customer Product Manual
Part 1605707-04
Issued 07/18
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
and available local languages.

Part 1605707-04 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 2015. 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, iFlow, 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 1605707-04
E2018 Nordson Corporation
Change Record
Revision Date Change
01 10/15 New release
02 02/18 Added mobile system components to manual.
03 04/18 Added illustrations showing the Encore HD pump.
04 07/18 Added HD, HD+, and HDXD System part numbers, added nLighten
information

Change Record
ii
Part 1605707-04 E2018 Nordson Corporation

Table of Contents iii
Part 1605707-04
E2018 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.............................................
Introduction 2-1.............................................
Mobile System Components 2-2............................
Standalone and Rail/Wall System Components 2-3...........
Specifications 2-4...........................................
Mobile System with VBF 2-4...............................
Mobile System with 50 lb. Feed Hopper 2-4..................
Applicator Certification Label 2-5...........................
Controller Certification Label 2-5............................
Power Unit Certification Label 2-5..........................
Installation 3-1.............................................
Required Installation Tools 3-1................................
Standalone System 3-2......................................
Anchoring Stand 3-2......................................
Hopper Installation for Feed Hopper System 3-3................
Setup Common to All Manual Systems 3-4.....................
Controller Connections 3-4................................
Spray Gun Connections 3-4...............................
Spray Gun Cable 3-5...................................
Air Tubing and Powder Hose 3-6.........................
Bundling Tubing and Cable 3-7..........................
Main System Air and Electrical Connections 3-8..............
Main System Air Supply 3-8.............................
Standalone, Rail Mount, and Wall Mount
System Air Supply 3-9..................................
Main Electrical Connection 3-10...........................
System Ground 3-10.......................................
Mobile Systems 3-10....................................
Standalone and Rail/Wall Mount Systems 3-10..............

Table of Contents
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Part 1605707-04 E2018 Nordson Corporation
Operation 4-1..............................................
European Union, ATEX, Special Conditions for Safe Use 4-1......
VBF Powder Box Installation 4-2..............................
Feed Hopper Filling Startup 4-3...............................
Fluidizing Air Operation 4-4..................................
Powder Feed Hopper 4-4..................................
Vibratory Box Feeder 4-4..................................
Electrode Air Wash Operation 4-5.............................
Daily Operation 4-6.........................................
Initial Startup 4-6.........................................
System Startup 4-6.......................................
Standby Button 4-7.......................................
Shutdown 4-7...............................................
Maintenance 5-1...........................................
Recommended Cleaning Procedure
for Powder Contact Parts 5-1................................
Maintenance Procedures 5-2.................................
Troubleshooting 6-1........................................
Help Code Troubleshooting 6-1...............................
Viewing Help Codes 6-1...................................
Clearing Help Codes 6-1..................................
Help Code Troubleshooting Chart 6-2.......................
General Troubleshooting Chart 6-7............................
Re-Zero Procedure 6-12......................................
Conveyance Air Flow Verification 6-12..........................
Parts 7-1...................................................
Introduction 7-1.............................................
Reference Documentation 7-1..............................
Encore HD Manual Powder Spray Systems 7-2.................
Encore HD+ Manual Powder Spray Systems 7-2................
Encore HDXD Manual Powder Spray Systems 7-2...............
Mobile System Components 7-3............................
Grounding Equipment 7-4....................................

Safety 1-1
Part 1605707-04
E2018 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 1605707-04 E2018 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 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
Part 1605707-04
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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
1-4
Part 1605707-04 E2018 Nordson Corporation

Description 2-1
Part 1605707-04
E2018 Nordson Corporation
Section 2
Description
Introduction
See Figure 2-1. This manual covers all versions of the EncorerHD manual
powder spray systems:
SMobile Dolly System with Vibratory Box Feeder (VBF)
SMobile Dolly System with Feed Hopper
SStandalone Systems −Single and Dual Configurations
SRail Mount and Wall Mount Systems
Vibratory Box Feeder Feed Hopper Standalone Rail/Wall Mount
Figure 2-1 Encore HD Manual Powder Systems

Description
2-2
Part 1605707-04 E2018 Nordson Corporation
Mobile System Components
See Figure 2-2.
Mobile Systems include:
SEncore HD manual system controller
SEncore HD manual spray gun and cable
SEncore HD powder feed pump
SEncore HD pump control unit
SEncore pump pickup tube
SOne of the following, based on system version:
SVibratory table and motor −up to 50 lb (25.0 kg) box of powder
S50 lb (25.0 kg) Encore round feed hopper −fluidizes powder with
low-pressure compressed air
SFactory installed powder hose oriented under the base of the dolly.
NOTE: The powder hose should always be oriented in a 3 m diameter,
horizontal to the ground.
S8-mm powder hose, 4-mm air tubing, spiral wrap, Velcrorstraps, barbed
fitting
SAir filter
SAccessories for future use:
SBracket
SGrounding block
SAdapter
The components are mounted on a sturdy wheeled dolly.

Description 2-3
Part 1605707-04
E2018 Nordson Corporation
Standalone and Rail/Wall System Components
See Figure 2-2.
Standalone and Rail/Wall Systems include:
SEncore HD manual system controller
SEncore HD manual spray gun and cable
SEncore HD powder feed pump
SEncore HD pump control unit
SPump adapter kit and coupling for use on HR/NHR feed hoppers
NOTE: Hoppers are sold separately.
SStand included with standalone systems
SRail/Wall mount brackets for rail/wall systems
SGrounding kit
S8-mm powder hose, 4-mm air tubing, spiral wrap, Velcro straps
SAir filter kit included with standalone only.
NOTE: Order separately for rail/wall systems.
Encore HD
Powder Spray Gun
Encore HD Manual
System Controller
Pump Control Unit
with Powder Feed Pump
Figure 2-2 Common System Components (NOTE: Not all system configuration components shown)

Description
2-4
Part 1605707-04 E2018 Nordson Corporation
Specifications
Model Input Rating Output Rating
Encore HD Applicator +/−19 VAC, 1 A 100 KV, 100 μA
Encore HD Interface Control Unit 24 VDC, 2.0 A +/−19 VAC, 1A
Encore HD Controller Power Unit 100−240 VAC, 50/60 Hz, 125 VA 24 VDC, 2.5 A
Vibratory Motor 50 Hz 230 VAC, +/−10% NA
Vibratory Motor 60 Hz 115 VAC, +/−10% NA
Input Air: 6.0−7.6 bar (87−110 psi), <5μparticulates, dew point <10 _C (50 _F)
Max Relative Humidity: 95% non-condensing
Ambient Temperature Rating: +15 to +40 _C (59−104 _F)
Hazardous Location Rating
for Applicator:
Zone 21 or Class II, Division 1
Hazardous Location Rating
for Controls:
Zone 22 or Class II, Division 2
Dust Ingress Protection: IP6X
Vibrator Table Capacity: 25 kg (50 lb) box of powder
Hopper Capacity: 11.3 or 22.7 kg (25 or 50 lb)
Mobile System with VBF
Height: 1078 mm (42.5 in.)
Wheel Base: 620 (24.4) L x 511.5 (20.1) W
Weight: 50.8 kg (112 lbs)
Mobile System with 50 lb. Feed Hopper
Height: 1078 mm (42.5 in.)
Wheel Base: 620 (24.4) L x 511.5 (20.1) W
Weight: 54.4 kg (120 lbs)

Description 2-5
Part 1605707-04
E2018 Nordson Corporation
Applicator Certification Label
1180 II 2 D
EN 50050-2
O
Ex tb IIIB T65 C Db
FM14ATEX0051X 2mJ
FM
CUS
APPROVED
For Electrostatic Finishing Applications
Class II Spray Material
FOR USE WITH ENCORE HD MANUAL CONTROLS
OR ENCORE HD HYBRID MANUAL CONTROLS WHEN
CONFIGURED IN ACCORDANCE WITH 1084547
1603105−02
Controller Certification Label
ELECTROSTATIC HAND−HELD POWDER
SPRAY EQUIPMENT TYPE ENCORE
NORDSON CORPORATION, AMHERST , OHIO U.S.A.
DO NOT OPEN WHEN EXPLOSIVE ATMOSPHERE IS PRESENT
INPUT: Vo = 24VDC
FM14A TEX0052X
Ta: +15°CTO +40°C
EN 50050−2
1180 II (2)3 D
Ex tc IIIB T60°C Dc
OUTPUT : Vo=±19VAC Io=1A
FOR: ADMISSIBLE COMBINATIONS OF DEVICES, SEE INSTRUCTION MANUAL
IP6X
®
1606122−02
Power Unit Certification Label
ELECTROSTATIC HAND−HELD POWDER
SPRAY EQUIPMENT TYPE ENCORE
NORDSON CORPORATION, AMHERST , OHIO U.S.A.
DO NOT OPEN WHEN EXPLOSIVE ATMOSPHERE IS PRESENT
PWR UNIT OUTPUT: Vo=24VDC Io=2.5A
Vn=100−240 VAC, fn = 50/60 Hz
FM14ATEX0052X
Ta: +15°CTO +40°C
EN 50050−2
Pn=125 V A
1180 II (2)3 D
Ex tc IIIB T60°C Dc
FOR:ADMISSIBLE COMBINATIONS OF DEVICES, SEE INSTRUCTION MANUAL
IP6X
®
1606121−02

Description
2-6
Part 1605707-04 E2018 Nordson Corporation

Installation 3-1
Part 1605707-04
E2018 Nordson Corporation
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.
Required Installation Tools
SFlathead screw driver
SScissors
STube cutters
SWrench
SPliers
SDrill
SMasonry drill bit included in anchoring kit (Standalone systems only)
STapconrscrews included in anchoring kit (Standalone systems only)

Installation
3-2
Part 1605707-04 E2018 Nordson Corporation
Standalone System
Anchoring Stand
NOTE: Masonary bit and Tapcon screws provided with anchoring kit.
1. See Figure 3-1 Using masonary bit, drill holes in platform or floor using
the dimensions shown.
2. Anchor the stand to floor or platform using Tapcon screws supplied with
kit.
317.5 mm
(12.5 in)
355.6 mm
(14.0 in)
317.5 mm
(12.5 in)
355.6 mm
(14.0 in)
4 x ∅0.250
Mounting
Holes
10013908
Figure 3-1 Anchoring Stand

Installation 3-3
Part 1605707-04
E2018 Nordson Corporation
Hopper Installation for Feed Hopper System
1. See Figure 3-2. Unclamp the hopper lid and remove the vent hose and
hose clamps.
2. Place the hopper on the dolly platform so that the bottom of the fluidizing
pan fits into the cutout in the dolly platform.
3. Connect the 10-mm stem x 6-mm tube reducer to the 10-mm elbow
fitting on the fluidizing pan.
4. Connect the 6-mm blue fluidizing air tubing to the reducer.
5. Connect the ring-tong terminal on the 1-ft green/yellow ground cable
shipped with the system to the ground stud on the side of the fluidizing
pan, then plug the cable into the grounding socket on the dolly base.
6. Install the hose clamp over the end of the vent hose and connect the
hose to the vent stack on the lid. Tighten the clamp to secure the hose.
7. Route the suction line from the pump to the pickup tube from the hopper.
NOTE: Before turning on the controller interface, route the other end of the
vent hose to a vent stub on a color module or into the spray booth. This
prevents the very fine powder particles in the vented fluidizing air from
contaminating the spray room.
NOTE: On VBF mobile systems, all pneumatic connections are factory
installed.
6-mm Fluidizing
AirTubing
Vent
Stack
Ground
Plug/Socket
Vent
Hose
Ground
Cable
Fluidizing Air
10-mm and Barb Fitting and
6-mm Tube Reducer Ground Stud
Hopper
Fluidizing
Pan
Hose Clamp
Figure 3-2 Hopper Installation on Mobile System Dolly

Installation
3-4
Part 1605707-04 E2018 Nordson Corporation
Setup Common to All Manual Systems
Controller Connections
See Figures 3-3 and 3-4.The controls for the system consist of a two piece
unit connected by a network/power cable.
SPump control unit: houses a 24Vdc power supply, circuit board, and
iFlowrair control manifold.
SSpray System Controller: houses the controller interface panel, which
contains the displays and controls used to make controller function
settings and spray settings.
Connect the gray 3 m (10 ft) network cable to the net/auxiliary receptacles
on the system controller and pump control unit. See the Spray Gun
Connections section for additional information on the gun cable installation.
Gun cable
Network Cable
Figure 3-3 Controller Connections
Spray Gun Connections
Unpack the spray gun. Uncoil the spray gun cable and the included clear
4-mm and blue 6-mm air tubing. Connect the gun cable and air tubing as
described in the following procedures.