Nordson Encore LT Automatic Reference guide

EncorerLT Automatic
Powder Spray Controllers
Customer Product Manual
Part 1604858-01
Issued 11/13
NORDSON CORPORATION •AMHERST, OHIO •USA
For parts and technical support, call the
Finishing Customer Support Center at [phone].
Check http://emanuals.nordson.com/finishing for the latest version.
This document is subject to change without notice.

Part 1604858-01 E2013 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 2011. 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, 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 10/2013 Replaces 1107712

Change Record
ii
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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.............................................
Controller Components 2-2................................
Triggering 2-3............................................
Single/Dual Gun Controller 2-3...........................
Multi-Gun Controller 2-3................................
Interlock Keyswitch 2-3....................................
Specifications 2-4...........................................
Special Conditions for Safe Use 2-4.........................
Controller Dimensions and Weights 2-5......................
Controller Certification Labels 2-6...........................
Single Gun Controller Label 2-6..........................
Dual Gun Controller Label 2-6...........................
Multi-Gun (4−8 Guns) Controller Label 2-7.................
Multi-Gun (4−8 Guns) Controller with Axis Controller Label 2-7

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System Setup 3-1..........................................
System Diagrams 3-1.......................................
Single/Dual Gun System Diagram 3-1.......................
Multi-Gun System Diagram 3-2.............................
Single/Dual Controller Mounting 3-3...........................
Dual Controller Optional Wall Mounting Kit 3-3...............
Multi-Gun Controller Mounting 3-4............................
System Connections 3-5.....................................
Single/Dual Controller Connections 3-5......................
Remote Connections for Single/Dual Controllers 3-5..........
Multi-Gun Controller Connections 3-6.......................
Remote Connections for Multi-Gun Controllers 3-8............
Remote Trigger 3-8.....................................
Conveyor Interlock 3-8..................................
System Air Supply 3-9....................................
System Ground 3-9.......................................
Gun Connections 3-9.....................................
Pump Connections 3-10....................................
Controller Configuration 3-10..................................
Power Up Sequence 3-10..................................
Controller Automatic/Manual Configuration 3-10...............
Entering Configuration Mode 3-11...........................
Function Settings 3-11.....................................
Controller Triggering 3-12...................................
Continuous 3-12........................................
External 3-12...........................................
External Signals 3-12....................................
External Triggering Examples 3-13.........................
Operation 4-1..............................................
Controller Interface 4-1......................................
Low Power Mode 4-1.....................................
Gun Triggering 4-1.......................................
Displays and LEDs 4-2....................................
Electrostatic Settings 4-2....................................
Select ChargerMode 4-2.................................
Custom Electrostatic Mode 4-3.............................
Classic Electrostatic Mode 4-3.............................
Classic Standard (STD) Mode 4-3........................
Classic AFC Mode 4-4..................................
Encore LT PE Mode 4-4...................................
Powder Flow Settings 4-4....................................
Smart Flow Mode Settings 4-5.............................
Classic Flow Mode Settings 4-6............................
Daily Operation 4-7.........................................
Startup 4-7..............................................
Interface Messages 4-8...................................
Shutdown 4-8............................................
Maintenance 4-8............................................
Recommended Cleaning Procedure for Powder
Contact Parts 4-8........................................
Troubleshooting 5-1........................................
Controller Faults 5-1........................................
General Troubleshooting Chart 5-2............................

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Parts 6-1...................................................
Introduction 6-1.............................................
Controller Part Numbers 6-1..................................
Single Controller Parts 6-2...................................
Single Controller Parts List 6-3.............................
Single Controller Rear Panel Parts 6-4......................
Single Controller Rear Panel Sub-Assembly Parts List 6-5.....
Dual Controller Parts 6-6....................................
Dual Controller Parts 6-7..................................
Dual and Multi-Gun Rear Panel Sub-Assembly 6-8..............
Dual and Multi-Gun Rear Panel Sub-Assembly Parts List 6-9...
Multi-Gun Controller Parts 6-10................................
Front Panel Parts 6-10.....................................
Multi-Gun Controller Front Panel Parts List 6-11...............
Multi-Gun Controller Rear Panel Parts 6-12...................
Multi-Gun Controller Rear Panel Parts List 6-13...............
System Parts and Options 6-14................................
Powder Hose and Air Tubing 6-14...........................
System Options 6-14......................................
Wiring Diagrams 7-1........................................

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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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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 (MSDS) 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 MSDS
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.

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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 1604858-01
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Section 2
Description
Introduction
See Figure 2-1. This manual covers all versions of the Encore LT Automatic
Powder Spray Controllers:
SSingle Gun Controller
SDual Gun Controller
SMulti-Gun Controller
SMulti-Gun Controller with Axis Controller
The Dual Gun Controller controls two Encore Automatic Powder Spray
Guns. An optional wall mounting kit that accommodates one or two gun
controllers is available for the Dual Gun Controller.
The Multi-Gun Controller can control from 4 to 8 automatic guns. Optional
Encore Axis Controllers can be installed in a multi-gun controller enclosure,
or as a standalone unit. The Axis controllers control the operation of in/out
positioners and reciprocators. Axis controllers are covered in manual
1600005.
NOTE: Multi-Gun Controllers with Axis Controllers and standalone Axis
Controllers must be installed in a non-hazardous area.
Dual Gun Controller
Multi-Gun Controller
Gun Controllers
Axis Controllers
(Optional)
Single Gun Controller
Figure 2-1 Encore LT Automatic Controllers

Description
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Controller Components
All automatic controllers have the following components:
SGun controllers
SRear panels with power supply and manifold(s)
Multi-gun controllers also include a I/O board, power distribution terminal
blocks, air distribution manifold and pressure gauge, interlock keyswitch,
trigger all switch, and power switch.
Dual Automatic Controller
Multi-Gun
Controller
2
3
4
5
1
6
Figure 2-2 Encore LT Automatic Controllers
10. Gun controllers
11. Power switch (multi-gun only)
12. Trigger All switch (multi-gun only)
13. Keyswitch (multi-gun only)
14. Air supply pressure gauge
(multi-gun only)
15. Axis controllers (optional)

Description 2-3
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Triggering
Single/Dual Gun Controller
Each gun controlled by a single or dual gun controller can be locally
triggered with the Enable/Disable buttons on the gun controller keypads, or
remotely triggered by a PLC or other switching device.
Multi-Gun Controller
Multi-gun controllers are normally triggered remotely by a PLC or other
switching device. The Trigger All switch on the front panel triggers all guns
manually.
Interlock Keyswitch
The Interlock keyswitch (multi-gun controller only) has three positions:
Ready: Normal operation. Guns can be triggered, as long as the conveyor
is running. This prevents powder waste and hazardous operating situations.
Bypass: Allows you to trigger the guns on and off without running the
conveyor. Use the Bypass position to set up and test spray gun settings.
Lockout: Guns cannot be triggered. If Axis Controllers are installed in the
multi-gun controller, the in/out positioners and oscillators or reciprocators
cannot be moved. Use this position when working inside the booth.
CONVEYOR
BYPASS
READY
LOCKOUT
Figure 2-3 Interlock Keyswitch

Description
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Specifications
Model Input Rating Output Rating
ENCORE Applicator +/−19 VAC, 1 A 100 kV, 100 μA
Single Gun Controller 100−250 VAC, 50/60 Hz,1 phase
2.5 A, 100 VA max
N/A
Dual Gun Controller 100−250 VAC, 50/60 Hz,1 phase
2.5 A, 125 VA max
N/A
Multi-Gun Controller 100−250 VAC, 50/60 Hz,1 phase
6.3 A, 275 VA max
N/A
SInput Air: 4.0−7.6 bar (58−110 psi), <5μparticulates, dew point <10 _C
(50 _F)
SMax Relative Humidity: 95% non-Condensing
SAmbient Temperature Rating (Encore System): +15 to +40 _C
(59−104 _F)
SHazardous Location Rating for Applicator: Zone 21 or Class II, Division 1
SHazardous Location Rating for Controllers (without Axis Controllers):
Zone 22 or Class II, Division 2
SDust Ingress Protection: IP6X
Special Conditions for Safe Use
To meet ATEX requirements for the European Union:
SThe Encore LT Controllers shall be used over the ambient temperature
range of +15 _C to +40 _C (59−104 _F) with the Encore Powder
Electrostatic Automatic Applicators.
SThe equipment must be installed and used in accordance with Standard
EN50177.
SThe Encore LT Automatic Controller can be installed in a non-hazardous
area or in a hazardous area defined as a Zone 22.
SThe Encore LT Automatic Controller with Axis Controller must be
installed in a non-hazardous area.
SCaution should be taken where cleaning plastic surfaces of the Encore
LT Controller. There is a potential for static electricity build up on these
components.

Description 2-5
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Controller Dimensions and Weights
221.5
[8.720]
442
[17.402]
368
[14.502]
15
[0.59]
2X M5 THREAD
BOTH SIDES
245
[9.646]
30
[1.18]
75 196 196
598 [23.5]
1835
[72.25]
500
[19.7]
544
[21.4]
6 x ∅10.0
Mounting
Holes
478
[18.8]
34
[1.3]
Dual Controller Multi-Gun Controller
4X M5 THREAD
(TYP. TOP & BOTTOM)
Single Controller
75
[2.953]
200
[7.87]
75
[2.963]
63
[2.46]
40
[1.57]
212
[8.34]
312
[12.30]
7
[1.27]
198
[7.79] 168
[6.61]
Weight = 11.7 kgs (25.8 lbs) Weight = 121.6 kgs (268 lbs)
Maximum when fully populated
Weight = 6.2 kgs (13.6 lbs)
Figure 2-4 Controller Dimensions (mm, [in.])

Description
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Controller Certification Labels
Single Gun Controller Label
ENCORE LT
Ex tc IIIC T60°C Dc
T = +15 to +40°C
A
NORDSON CORP. AMHERST, OH, USA
Vn=100−250Vac 7n=50−60Hz Pn=100VA
OUTPUT: Vo (peak)= +19V Io (peak)= +1.0A
WARNING −POTENTIAL ELECTROSTATIC CHARGING
HAZARD, SEE INSTRUCTION MANUAL.
EN50177 FM11ATEX0057X
(2) 3 D
Dual Gun Controller Label
ENCORE LT
Ex tc IIIC T60°C Dc
T = +15 to +40°C
A
NORDSON CORP. AMHERST, OH, USA
Vn=100−250Vac 7n=50−60Hz Pn=125VA
OUTPUT: Vo (peak)= +19V Io (peak)= +1.0A
WARNING −POTENTIAL ELECTROSTATIC CHARGING
HAZARD, SEE INSTRUCTION MANUAL.
EN50177 FM11ATEX0057X
(2) 3 D

Description 2-7
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Multi-Gun (4−8 Guns) Controller Label
ENCORE LT
Ex tc IIIC T60°C Dc
T = +15 to +40°C
A
NORDSON CORP. AMHERST, OH, USA
Vn=100−250Vac 7n=50−60Hz Pn=275VA
OUTPUT: Vo (peak)= +19V Io (peak)= +1.0A
WARNING −POTENTIAL ELECTROSTATIC CHARGING
HAZARD, SEE INSTRUCTION MANUAL.
EN50177 FM11ATEX0057X
(2) 3 D
Multi-Gun (4−8 Guns) Controller with Axis Controller
Label
ENCORE LT
T = +15 to +40°C
A
NORDSON CORP. AMHERST, OH, USA
Vn=100−250Vac 7n=50−60Hz Pn=275VA
OUTPUT: Vo (peak)= +19V Io (peak)= +1.0A
EN50177 FM11ATEX0057X
(2) D
THE CONTROLLER MUST BE LOCATED
IN A NON-EXPLOSIVE ZONE.

Description
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