Nordson Encore HD Reference guide

EncorerHD
Manual Powder Spray Gun
Customer Product Manual
Part 1604869-13
Issued 09/19
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/finishing for the latest version
and available local languages.

Part 1604869-13 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
ColorMax, Color-on-Demand, Encore, HDLV, iControl, Prodigy, 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 1604869-13
E2018 Nordson Corporation
Change Record
Revision Date Change
01 01/2014 New release
02 04/2014 New flat spray electrode holder and assembly, new conical nozzle kit and
conical electrode assembly
03 05/2014 Page 7−3, new trigger axle P/N 1605713
Page 7−5, new nozzle P/N’s
04 07/2014 New flat and conical electrode holders
05 09/2014 Re-zero procedure revised
06 12/2014 New powder inlet tube; 3mm and 4mm nozzles to ship with gun
07 10/2015 Revised equipment labels and parts
08 03/16 Added cleaning procedure
09 09/16 Nozzle part number change and positive power supply added
10 03/18 Added 1083205, Deflector to parts list and some callout and
nomenclature changes
11 04/18 Updated system setup images, updated certification label
12 03/18 Changed description for gun labels
13 07/18 Added nLighten LED inspection kit, added XD electrode support, new
reference document links and updated description for part number
1600819. Added power supply resistance test nomenclature changes

Change Record
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Part 1604869-13 E2018 Nordson Corporation

Table of Contents iii
Part 1604869-13
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.............................................
Specifications 2-2...........................................
Equipment Labels 2-2.......................................
Applicator Certification Label 2-2...........................
Setup 3-1..................................................
System Connections 3-1.....................................
Spray Gun Installation 3-2..................................
Operation 4-1..............................................
European Union, ATEX, Special Conditions for Safe Use 4-1......
System Operation 4-2.......................................
Spray Gun Operation 4-2....................................
Changing Presets with the Settings Trigger 4-2...............
Changing Powder Flow with the Settings Trigger 4-3..........
Purging the Spray Gun 4-3................................
Electrode Air Wash Operation 4-4.............................
Daily Operation 4-4.........................................
Initial Startup 4-4.........................................
Startup 4-4..............................................
Standby Button 4-4.......................................
Changing Flat Spray Nozzles 4-5...........................
Converting from Flat Spray Nozzles to Conical Nozzles 4-6....
Changing Deflectors or Conical Nozzles 4-7..................
Installing the Optional Pattern Adjuster Kit 4-8................
Shutdown 4-8...............................................
Maintenance 4-8............................................
Recommended Cleaning Procedure for
Powder Contact Parts 4-9.................................
Maintenance Procedures 4-9...............................

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Part 1604869-13 E2018 Nordson Corporation
Repair 5-1.................................................
Spray Gun Repair 5-1.......................................
Display Module Replacement 5-2...........................
Display Module Removal 5-2............................
Display Module Installation 5-2...........................
Power Supply and Powder Path Replacement 5-4............
Gun Disassembly 5-4...................................
Power Supply Replacement 5-5..........................
Powder Path Removal 5-6..............................
Powder Path Installation 5-6.............................
Gun Re-Assembly 5-8..................................
Cable Replacement 5-9...................................
Cable Removal 5-9.....................................
Cable Installation 5-10...................................
Trigger Switch Replacement 5-10............................
Switch Removal 5-10....................................
Switch Installation 5-11..................................
Troubleshooting 6-1........................................
Spray Gun Power Supply Resistance Test 6-2..................
Electrode Assembly Resistance Test 6-3.......................
Gun Cable Continuity Test 6-4................................
Parts 7-1...................................................
Introduction 7-1.............................................
Reference Documentation 7-1..............................
Spray Gun Parts 7-2........................................
Spray Gun Parts List 7-3..................................
Spray Gun Options 7-4......................................
Miscellaneous Spray Gun Options 7-4.......................
nLightent7-5............................................
Flat Spray Nozzles 7-6....................................
Cross Cut Nozzles 7-6....................................
45-Degree Corner-Spray Nozzle 7-7.........................
45-Degree In-Line Flat-Spray Nozzle 7-7....................
Conical Nozzle, Deflectors and Electrode Assembly Parts 7-8...
Conical Nozzle and Deflectors 7-8........................
Conical Nozzle Kit (shipped with gun) 7-8..................
Conical Electrode Assembly 7-9..........................
XD Electrode Support 7-9..................................
Pattern Adjuster Kit 7-10...................................
Lance Extensions 7-10.....................................
Ion Collector Kit 7-10.......................................
Ion Collector Components for Lance Extensions 7-11..........
Powder Hose and Air Tubing 7-11...........................

Safety 1-1
Part 1604869-13
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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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Part 1604869-13 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
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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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Part 1604869-13 E2018 Nordson Corporation