Nordson Encore LT Parts list manual

1
Nordson Corporation
EncorerLT Manual Powder Spray Systems
OPERATOR CARD P/N 1604859-01
WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions
in this document and all other related documentation.
Controller Interface
Trigger LED
Smart Flow LED
Flow Air Output (Classic)
Flow Air % Output (Smart Flow)
Atomizing Air Output (Classic)
Total Flow Output (Smart Flow)
Select Charge Mode Settings
KV/μA Setting/Output
STD/AFC
Mode Toggle
Enable/Disable
Pressing the Enable/Disable button for three
seconds puts the controller to sleep (low power
mode). The displays and LEDs turn off. To wake the
controller press the button again.
The system goes to sleep automatically if no activity
is detected for approximately 15 minutes. Pulling the
gun trigger, pressing the purge switch, or pressing a
button on the controller interface wakes the controller.
When the gun is triggered the Trigger LED
is lit, and actual kV/μA outputs are displayed. When
not triggered the kV/μA setpoint is displayed. The two
air flow displays always show the setpoints.
The Smart Flow LED lights when the
controller is configured for Smart Flow mode. Refer to
Powder Flow Setting for an explanation.
Controller Configuration
During power up or wake up from disable, press and
hold the +and −buttons on the kV/uA panel for 1
second. When the kV/μA panel displays F −1 for
function 1 the controller is in configuration mode.
To change functions, press the Plus or Minus buttons
on the kV/μA panel. To change function values press
the Plus or Minus buttons on the Flow Air panel. To
save your settings and exit Configuration Mode,
press the Enable/Disable button.
Function No. Name Settings Default
1Gun Type 0 = Encore 0
2 Fluidizing 0 = Hopper, 1 = Box, 3 = Disable 0
3Electrostatic Control 0 = Custom, 1 = Classic, 2 = PE 0
4Powder Flow Control 0 = Smart, 1 = Classic 0
5Cable Length 0 = 6 meters, 1 = 12 meters, 2 = 18 meters 0
6Vibratory Box Delay on, 0−90 seconds 30

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Electrostatic Settings
Select ChargerMode
The Select Charge modes are non-adjustable
electrostatic settings. The LEDs above the Select
Charge mode buttons indicate the selected mode.
The Select Charge Modes and electrostatic setpoints
are:
Re-Coat: 100 kV, 15 μA
Metallics: 50 kV, 50 μA
Deep Recesses: 100 kV, 60 μA
Re-Coat Metallics Recesses
NOTE: If you press the STD/AFC selection button
while using a Select Charge mode, the controller
switches to STD or AFC mode. Pressing the +or −
keys have no effect in Select Charge Mode.
Custom Electrostatic Mode
Custom Mode is the default electrostatic mode. In
Custom mode, both kV and μA can be adjusted
independently. Both the STD and AFC LEDs light
when this mode is configured.
Use the View button to toggle the display
between kV and uA.
Use the +and −buttons to select the desired
setpoint. The longer a button is pressed the faster the
units change.
SThe valid STD (kV) range is 0 or 25−100 kV.
SThe valid AFC (μA) range is 5−100 μA.
Classic Electrostatic Mode
Classic Mode is the optional electrostatic mode. The
controller must be configured to use this mode. Refer
to your system manual.
In Classic mode you can choose to control kV (STD)
output or μA (AFC) output, but not both at the same
time. AFC allows you to set a top limit for current
output. As current output increases, kV output
decreases.
Press the STD/AFC button to toggle between
STD and AFC mode.
Press the View button to toggle the display
between kV and μA.
Press the +or −buttons to select the desired
setpoint. The longer a button is pressed the faster the
units change. Valid ranges for kV and μA are the
same as in Custom Mode.
Encore LT PE Mode
To configure the controller for the Encore PE system,
set function number 3 (Electrostatic Control) to
setting 2 (Encore PE).
When the controller function number 3 is set to PE,
the electrostatic settings will allow the user to control
both kV and μA (custom mode) and they will be able
to control the μA setting to values less than 3.0μA in
0.1μA increments.
Powder Flow Settings
Smart Flow Mode −This is the factory default mode.
In this mode, you set the Total Flow rate and the Flow
Air %. If you decrease the flow air %, the flow air
pressure decreases, but the atomizing air pressure
increases, so that the result is that the powder
velocity remains the same. The Smart Flow LED
lights when the controller is configured for Smart
Flow mode.
Classic Flow Mode −This is the standard method of
setting powder flow and velocity, by setting flow and
atomizing air percentages separately and balancing
them manually for optimum results. When the
controller is configured for Classic Flow mode, the
Smart Flow LED is off.

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Smart Flow Mode
The Smart Flow LED lights when the
controller is configured for Smart Flow mode.
sets the powder flow rate (Flow Air %).
sets the powder velocity (Total Flow).
Setting values for both are 0−99%.
Press the +and −buttons to select the desired
setpoint. The longer a button is pressed the faster the
units change.
Set Total Flow first to obtain the desired pattern size
and velocity, then set Flow Air % for the desired
powder flow.
NOTE: If either Total Flow or Flow Air are set to 0%
then the controller cannot output any air when
triggered and no powder is pumped.
Classic Flow Mode
To use Classic Flow mode, the controller must be
configured for it. Refer to your system manual for
configuration settings.
sets the flow air pressure as a percentage
of maximum pressure.
sets the atomizing air pressure as a
percentage of maximum pressure.
Setting values for both are 0−99% of maximum air
pressure. Press the +and −buttons to select the
desired setpoint. The longer a button is pressed the
faster the units change.
System Operation
NOTE: Allow powder in the feed hopper to fluidize
for several minutes before spraying powder.
Spraying Powder: Point the spray gun into the booth
and pull the spray trigger.
Purging the Gun: Release the spray trigger and
press down on the purge trigger. Pump air and
electrostatic voltage turn off and Pappears on the
displays.
Electrode air wash air turns on and off automatically
as the gun is triggered. The air flow prevents powder
from collecting on the electrode.
Purge Trigger
Spray Trigger
The box feeder vibrator motor turns on when the
gun is triggered on. When the gun is turned off the
vibrator motor stays on for a set period of time (0−90
seconds, factory default is 30) to prevent rapid on-off
cycling of the motor during production.
Fluidizing air for box feeders turns on when the gun
is triggered. Feed hopper fluidizing air turns on when
the controller is turned on and remains on until the
power is turned off. Adjust the fluidizing air flow with
the needle valve on the rear panel of the controller.
The powder should boil gently.
Fluidizing Air
Purge Air
Electrode Air
Wash Air
Flow-Rate Air
Atomizing Air
CONTROLLER
REAR PANEL
AIR CONNECTIONS
Maintenance
Clean the spray gun nozzle and powder path, and
pump nozzle and venturi throat, in an ultrasonic
cleaning machine, using OakiterBetaSolv or an
equivalent emulsion cleaning solution. Rinse with
clean water and dry before re-installing.
Do not immerse the spray gun electrode assembly in
the cleaning solution or rinse. Remove all O-rings
before cleaning. Do not allow the O-rings to come in
contact with the cleaning solution. Refer to your
system manual for more information.

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Troubleshooting
Refer to your system manual for more troubleshooting procedures, resistance checks, and continuity checks.
Problem Possible Cause Corrective Action
1. Gun not spraying powder,
Trigger LED blinking
Gun triggered while controller powering
up or waking up, or shorted trigger
switch or cable
Release the spray trigger. Press the
Disable/Enable button to put the controller
to sleep, then press it again to wake it up.
Check the cable and trigger switch.
2. Powder not charging,
kV/mA display blinking
Gun is shorted Check gun cable and power supply. Refer
to your system manual.
3. Uneven pattern, unsteady
or inadequate powder
flow
Blockage in spray gun, powder feed
hose, or pump
Purge the gun. Check the feed hose and
pump.
Nozzle, deflector, or electrode
assembly worn
Remove, clean, and replace as necessary.
Low pump air pressure Increase pump air setpoints.
Low fluidizing air pressure Increase air pressure.
Damp powder Check powder supply.
4. Voids in powder pattern Worn nozzle or deflector Remove and replace if necessary.
Plugged electrode assembly or powder
path in gun
Remove and clean.
5. Low powder flow or
surging
Low supply air pressure Input air must be greater than 4.1 bar (60
psi).
Pump throat worn Check and replace if necessary.
Pickup tube blocked Check and clean if necessary.
Fluidizing air not adjusted correctly Check and adjust.
Powder hose plugged, kinked, or ID too
small for length
Check hose. If longer than 20 ft, use 1/2
in. ID hose.
Regulator on controller manifold
plugged or malfunctioning
Remove tubing at controller and check air
flow. Replace regulator if necessary.
6. Loss of wrap, poor
transfer efficiency
Low electrostatic voltage Increase voltage setpoint.
Poor electrode connection Remove and clean. Check electrode and
gun power supply.
Poorly grounded parts Check part grounds. Resistance to ground
should be less than 1 mΩ.
7. Powder build up on
electrode
Insufficient air wash air Remove air wash connector from rear
panel. Check orifice for blockage and
clean if necessary.
8. No kV output from gun Damaged gun cable or gun power
supply
Check cable and power supply.
9. No kV and powder output
from gun or no purge air
Malfunctioning trigger switch or cable Check Trigger LED. Check trigger switch
and cable.
10. More than one key on the
keypad quits working
when pressed
Flex connection from the keypad to the
main board is not seated properly
Loosen and re-seat the flex circuit on the
main board, making sure the ribbon cable
is fully inserted into the J8 connector. See
operator’s manual for more information.
Issued 11/13
Original copyright date 2011. Encore, Nordson, and the Nordson logo are registered trademarks of Nordson Corporation.