Nordson Encore HD User manual

EncorerHD and XT Manual Powder
Spray System Controller
Customer Product Manual
Part 1604870-05
Issued 04/18
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/finishing for the latest version
and available local languages.

Part 1604870-05 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
Encore, iControl, Prodigy, Color-on-Demand, ColorMax, Select Charge,
Nordson, and the Nordson logo are registered trademarks of Nordson
Corporation.
All other trademarks are the property of their respective owners.

Change Record i
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Change Record
Revision Date Change
01 01/14 New release
02 09/14 Re-zero procedure revised
03 01/15 New equipment labels
04 10/15 Revised illustrations and content
05 04/18 Revised some illustrations for new pump. Updated Certification Label.

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.............................................
Introduction 2-1.............................................
Specifications 2-2...........................................
Equipment Label 2-2........................................
Controller Certification Label 2-2............................
System Setup 3-1..........................................
Rail Mount Installation 3-1....................................
System Connections 3-2.....................................
System Diagram 3-2......................................
Controller Connections 3-3................................

Table of Contents
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Operation 4-1..............................................
European Union, ATEX, Special Conditions for Safe Use 4-1......
Daily Operation 4-1.........................................
Initial Startup 4-2.........................................
Startup 4-2..............................................
Standby Button 4-3.......................................
Factory Set Presets 4-4...................................
Using the Controller Interface 4-4.............................
Interface Components 4-4.................................
Changing a Factory Configured Preset or Setpoint Value 4-5...
Presets 4-5..............................................
Programming or Changing a Preset 4-5...................
Electrostatic Settings 4-6..................................
Select Charger Mode 4-6...............................
Custom Mode 4-7......................................
Classic Mode 4-8......................................
Help Codes 4-10..........................................
Assist Air Setting, Fast Flow Setting, and Software Versions 4-11
Powder Flow Settings 4-12.................................
HD Powder Flow Settings 4-12............................
XT Powder Flow Settings 4-13............................
Color Change Purge 4-17...................................
HDLV System Purge 4-17................................
Color-on-Demand (COD) System Purge 4-19...............
Controller Configuration 4-20...................................
Opening the Function Menu and Setting Preferences 4-20......
Saving and Loading Preset and Function Settings 4-25.........
Setting the Number of Presets 4-25..........................
HD System Shutdown 4-26....................................
XT System Shutdown 4-26....................................
Maintenance 4-27............................................
Troubleshooting 5-1........................................
Help Code Troubleshooting 5-1...............................
Viewing Help Codes 5-1...................................
Clearing Help Codes 5-1..................................
Help Code Troubleshooting Chart 5-2.......................
General Troubleshooting Chart 5-8............................
Re-Zero Procedure 5-13......................................
Conveyance Air Flow Verification for HD 5-13....................
Controller Interconnect Cable Test 5-14.........................
Wiring Diagram 5-15.........................................
Repair 6-1.................................................
Interface Module Repair 6-1..................................
Parts 7-1...................................................
Introduction 7-1.............................................
Controller Parts 7-2.........................................
Controller Exploded View 7-2..............................
Controller Parts List 7-3...................................
Rail Mount Exploded View 7-4..............................
Rail Mount Parts List 7-4..................................

Safety 1-1
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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 1604870-05 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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Description 2-1
Part 1604870-05
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Section 2
Description
Introduction
See Figure 2-1. This manual covers the EncorerHD and XT manual
powder spray system controller.
Figure 2-1 Encore HD/XT Manual Powder Spray System Controller
The system controller is used with the Encore HD with HDLV technology
and the Encore XT with venturi technology. The Encore HD and XT
controller may be used in the following systems:
SEncore HD and XT Wall Mount Systems
SEncore HD and XT Mobile Systems
SEncore HD and XT Rail Mount Systems
SEncore HD and XT Single and Dual Stand Alone
SEncore HD Color-on-DemandrSystems
SColorMaxrPowder Coating Systems
SProdigyrto Encore Upgrade Systems

Description
2-2
Part 1604870-05 E2018 Nordson Corporation
Specifications
Model: Encore HD and XT Interface Controller
Input voltage rating 24 VDC, 2.75 A
Output voltage rating +/−19 VAC, 1A
Input air 6.0−7.6 bar (87−110 psi), <5μparticulates, dew point
<10 _C (50 _F)
Maximum relative humidity 95% non-condensing
Ambient temperature rating +15 to +40 _C (59−104 _F)
Hazardous location rating Zone 22 or Class II, Division 2
Enclosure rating IP6X, Dust ingress protection
Equipment Label
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
FM14ATEX0052X
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

System Setup 3-1
Part 1604870-05
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Section 3
System Setup
Rail Mount Installation
See Figure 3-1. Use the hardware shipped with the mounting kit to mount
the controller to the pump cabinet stand as described below. Tighten all
hardware securely.
NOTE: Bracket can be oriented top to bottom or bottom to top. Pictured
below is the most common system orientation (bottom to top).
1. Install the controller rail mount bracket (2) to the arm on the product
stand (1).
2. Install the controller (4) to the universal mounting bracket (3).
3. Install the universal mounting bracket (3) to the controller rail mount
bracket (2).
1
2
3
4
Figure 3-1 Controller Rail Mount Installation (Bottom to Top Orientation)
1. Product stand arm
2. Controller rail mount bracket
3. Universal mounting bracket 4. Encore HD controller

System Setup
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System Connections
System Diagram
WARNING: This diagram does not show system grounds. All conductive
equipment in the spray area must be connected to a true earth ground. Use
the grounding block supplied with the Nordson system.
4 mm in
6 mm Purge Air 4 mm Clean Air Wash
Gun Cable
Network/Power
Interconnect
Delivery Powder
Hose
6 mm in
Delivery in
Powder Spray Gun
Pump Control Unit
Manual System
Controller
Figure 3-2 Typical HD System Diagram
Pump Control
Unit
Manual
System Controller
Powder Spray Gun
Powder Feed
Pump
Gun Cable
Delivery
Powder
Hose
Network/Power Interconnect
Atomizing
Flow Air
6 mm Purge Air
4 mm Clear Air Wash
4 mm in
6 mm in
Delivery in
Figure 3-3 Typical XT System Diagram

System Setup 3-3
Part 1604870-05
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Controller Connections
The system controller contains the displays and controls used to make
controller function settings and spray settings.
See Figure 3-4. Use the network/power interconnect cable to connect the
controller to the pump cabinet.
1. Securely attach the socket end of the interconnect cable to the
NET/PWR plug (1) in the back of the controller.
2. Securely attach the pin ends of the interconnect cable to the NET/PWR
1 plug (2) in the top of the pump cabinet.
3. Repeat steps 1 and 2 to attach a second controller to the NET/PWR 2
plug at the top of the pump stand for a dual-gun system.
Pins
Sockets SocketsPins
Nipple To Power Unit
To Interface Module
Standard System −One 3 meter (10 ft) Cable
Optional Cable Configuration
2
1
Figure 3-4 Encore Controller Interconnect Cable Connection

System Setup
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Operation 4-1
Part 1604870-05
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Section 4
Operation
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
WARNING: This equipment can be dangerous unless it is used in
accordance with the rules laid down in this manual.
WARNING: All electrically conductive equipment in the spray area must be
grounded. Ungrounded or poorly grounded equipment can store an
electrostatic charge which can give personnel a severe shock or arc and
cause a fire or explosion.
European Union, ATEX, Special Conditions for Safe Use
1. The Encore XT manual applicator or the Encore HD manual applicator
shall only be used with the Encore XT and HD interface controller and
the Encore XT controller power unit or the Encore HD controller power
unit over the ambient temperature range of +15 _C to +40 _C.
2. Equipment may only be used in areas of low impact risk.
3. Caution should be taken when cleaning plastic surfaces of the Encore
controller and interface. There is a potential for static electricity build up
on these components.
Daily Operation
WARNING: All conductive equipment in the spray area must be connected
to a true earth ground. Failure to observe this warning may result in a
severe shock.
NOTE: The controller is shipped with a default configuration that will allow
you to start spraying powder as soon as you finish setting up the system.
Refer to Controller Configuration on page 4-20 to reference a list of the
defaults and preset change instructions.

Operation
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Part 1604870-05 E2018 Nordson Corporation
Initial Startup
With no parts in front of the gun and the fluidizing and flow rate set to 0%,
trigger the gun and record the μA output. Monitor the μA output daily, under
the same conditions. A significant increase in μA output indicates a
probable short in the gun resistor. A significant decrease indicates a
resistor or voltage multiplier requiring service.
Startup
Standby
Button
Controller
Interface
Function / Help
Display
Color Change
Figure 4-1 System Controls −Mobile System Shown
The following controller functions must be set up before operation:
Table 4-1 Function Settings
Function
Number
Function
Name
Function
Values
Default
HDLV Mode
F00 Gun Type 00=Encore XT/HD, 02=Robot 00
F01 Fluidizing 00=Hopper, 01=Box, 02=Disable 02
F18 Pump Type 00=Venturi, 01=HDLV, 02=COD 00
F19 Control Type 00=Local, 01=External 00
F20 Gun Number 1−4 00

Operation 4-3
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When power is activated at the pump cabinet, the controller is turned on.
Upon startup, the function/help display screen will quickly scroll through
various function settings, displaying the following information:
Table 4-2 Startup Display
Screen Code Description
Encore Controller Type
XT Controller Type
HDLV
or
Venturi
or
COD
System Type
Loc
or
Ext
Local or External Control
Gun −1, −2, …Gun Number, 1 −4
GC −X.XX Gun Controller, Software Version
Gd −X.XX Gun Display Module, Software Version
FL −X.XX Flow Module, Software Version
Select the desired preset and start production. Refer to Presets on page
4-5 for preset programming instructions.
The controller interface displays actual output when the gun is spraying, and
the current preset setpoints when the gun is off.
Standby Button
Use the Standby button shown in Figure 4-1 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.
To shut off controller power, use the power switch on the pump control unit.

Operation
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Part 1604870-05 E2018 Nordson Corporation
Factory Set Presets
Presets are programmed electrostatic and powder flow setpoints for a
particular part or application. Up to 20 presets can be programmed.
The system is shipped with presets 1−3 already programmed. See Table
4-3 and 4-4 for default preset values for the both the HD and XT systems.
Refer to Presets on page 4-5 for programming instructions.
Table 4-3 HD System Factory Set Presets
Preset Electrostatics, Powder Flow kV mA %
1Max kV, 150 g/min (20 lb/hr) 100 30 35 0.7
2Max kV, 300 g/min (40 lb/hr) 100 30 80 1.0
3Select Charge 3 (deep recess), 150 g/min (20 lb/hr) 100* 60* 35 0.7
* Select Charge Mode settings are factory set and cannot be changed.
Table 4-4 XT System Factory Set Presets
Preset Electrostatics, Powder Flow kV mA % 
1Max kV, 150 g/min (20 lb/hr) 100 30 45 3.0
2Max kV, 300 g/min (40 lb/hr) 100 30 75 3.0
3Select Charge 3 (deep recess), 150 g/min (20 lb/hr) 100* 60* 45 3.0
* Select Charge Mode settings are factory set and cannot be changed.
Using the Controller Interface
Interface Components
Use the controller interface to make preset settings, view help codes,
monitor system operation, and configure the controller. See Figure 4-2.
Gun Triggered On Indicator
Select Charge
Modes
kV Setting
Function/Help Display
Current Preset Number
Powder Flow %
Rotary Knob
Standby Button
Nordson Button
(Configuration)
Setting Button LEDs
Preset Select
Setting Icons
Pattern Air Flow Setting
μA Setting
Help Button
View Button Enter Button
Color Change Button
Figure 4-2 Controller Interface